Air Return Panning: Replacing The Old With New

Return air duct panning is an important aspect of HVAC systems, facilitating the circulation of air by carrying it back to the furnace or air handler. While traditional methods employ sheet metal or corrugated aluminium panels, modern alternatives like Reflectix® RAP offer advantages in terms of cost, flexibility, and ease of installation. When replacing existing air return panning, considerations include the sizing of cold air returns, the use of dampers for better airflow control, and potential issues like dust accumulation and unpredictable interstitial air movement. Understanding these factors is crucial before undertaking installation or replacement work.

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Understand the function of return ducts

Return ducts are an essential component of your HVAC system's air distribution network. They play a vital role in maintaining your comfort and ensuring the HVAC system works efficiently.

Return ducts carry the air back to the furnace or air handler, where it is warmed or cooled again before being circulated back out through the supply vents. This circulation ensures the air in your home remains properly ventilated. Without return ducts, the air in your home would become stagnant, leading to higher energy costs and reduced system efficiency.

The return duct is responsible for applying negative pressure to the system, housing the filter. This negative pressure allows the air to be filtered before it is recirculated, ensuring clean air is distributed throughout your home. The filter removes dust and debris particles, enhancing the quality of the air you breathe.

While some systems may require a return duct in each room, modern duct systems usually have one or two returns serving the entire structure. It is important to avoid installing return ducts in bathrooms or kitchens, as these spaces often contain moisture and odours that could be circulated throughout the system. Instead, it is recommended to centralise the return duct near the thermostat, allowing for optimal temperature monitoring and control.

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Choose the right material

When replacing existing air return panning, it is important to choose the right material to ensure the efficiency and longevity of your HVAC system. The most common materials used for air return duct panning are sheet metal, foil-faced cardboard, and bubble insulation.

Sheet metal, such as galvanized steel, is a durable option that can be purchased in sections of round metal ducts or sheets. However, it tends to be the most expensive and labor-intensive solution, requiring more material to install. Sheet metal is also available in thinner varieties, which can be fastened directly to the bottom of floor joists to create a return-air pathway.

Foil-faced cardboard products like Thermopan are more user-friendly and cost-effective than sheet metal. However, they lack flexibility and require more effort to create a sealed return. Additionally, foil-faced cardboard is susceptible to damage from excess moisture.

Bubble insulation, such as EcoFoil, is a flexible and cost-effective alternative to sheet metal and foil-faced cardboard. It comes in pre-cut widths that fit easily between floor joists and can be sealed with reflective tape to create an airtight barrier. EcoFoil is also waterproof and resists the growth of mold and fungi.

Other materials that can be used for air return duct panning include Reflectix® RAP (Corrugated Sheet), fiberglass duct board, and flexible duct. It is important to note that some materials, such as building cavity spaces, are not recommended due to difficulties in creating an airtight seal and potential fire safety concerns.

When choosing the right material for your air return panning, consider factors such as cost, ease of installation, durability, and the ability to create an airtight seal. Additionally, ensure that the material you choose meets local building code requirements and is suitable for your specific HVAC system and space constraints.

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Install the ductwork

Installing ductwork for your HVAC system can be a challenging task, and it is always recommended to seek professional help. However, if you are confident and have the right tools, installing ductwork can be a rewarding DIY project. Here is a step-by-step guide to help you through the process:

Plan the Layout:

Before starting the installation, it is crucial to plan the layout and path of the ducts. Mark the locations of the supply and return vents, ensuring you avoid putting them in kitchens or bathrooms, as moisture and odors can circulate through the ductwork.

Choose the Right Materials:

Select the appropriate material for your ductwork. You can use sheet metal, which is durable but expensive and labor-intensive. Alternatively, foil-faced cardboard products like Thermopan are user-friendly but require proper sealing to prevent air leakage. EcoFoil's Radiant Barrier Bubble Insulation is another option that fits between or underneath floor joists.

Measure and Cut:

Accurately measure the airflow needs in cubic feet to determine the size of the vents. Cut holes in the panning perpendicular to the joists, ensuring they are slightly smaller than the vents to allow secure attachment to the wall. Measure and cut the straight, rectangular ducting to the required length before installing each corner piece.

Connect the ductwork to your HVAC system, ensuring proper alignment and efficient airflow. Install the return air duct at a 90-degree angle to the joists and secure it tightly to the bottom of the ceiling joists using S-slips and drive cleats. Continue this process for each corner until all pieces connect seamlessly.

Seal and Insulate:

Ensure airtight seals at all joints and connections to prevent air leakage. You can use aluminum tape or UL181-approved aluminum tape for sealing. Insulate the ductwork to optimize energy efficiency and prevent heat loss. Consider using fiberglass duct wrap or products like EcoFoil, which is waterproof and resists mold growth.

Remember to always consult local building codes and regulations before starting any ductwork installation project.

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Seal the seams

Sealing the seams of your air return panning is a crucial step in ensuring the efficiency of your HVAC system. Here are some detailed instructions to help you seal the seams effectively:

Firstly, it's important to understand the materials used for air return panning. Traditionally, sheet metal has been used for panning, but this is not the only option. Foil-faced cardboard products like Thermopan are user-friendly, but they require more effort to create a sealed return and are susceptible to moisture damage. A recommended option is to use bubble insulation products, such as EcoFoil, which offer flexibility and ease of installation.

When using bubble insulation, sealing the seams is straightforward. After installing the insulation to the bottom of the floor joists, use reflective tape to seal the seams. This tape will ensure an airtight seal, enhancing the performance of your HVAC system.

For those using foil-faced cardboard products, sealing the seams requires a bit more effort. While you can use staples to attach the material to the floor joists, sealing the seams might require additional methods. You can use steel staples, sheet metal screws, or roofing nails for a secure hold. After ensuring a tight fit, seal the seams with foil tape, such as InfraStop® Foil Tape, to create an effective barrier.

It is important to note that building cavities are not recommended for supply or return ducts due to the challenge of properly sealing them. However, if you choose to use building cavities, ensure that all seams, gaps, and holes are sealed with caulk or foam to prevent air leakage.

By following these instructions and choosing the appropriate materials, you can effectively seal the seams of your air return panning, contributing to a well-functioning HVAC system and a more comfortable indoor environment.

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Avoid common issues

When replacing existing air return panning, there are several issues to be aware of and avoid. Firstly, it is important to note that panned studs and joists have been criticised for pulling in dust and contaminants, as well as moisture into the wall cavity, which can cause rot in the framing. While some HVAC contractors may disagree, it is important to be aware of this potential issue.

Secondly, using floor joists as return ducts by panning can cause leakage due to negative pressure in the cavity. This will draw air from outside into the cavity through the construction joints of the rim area at the end of the joist cavity. This can lead to increased energy usage and reduced efficiency of the HVAC system. To avoid this, ensure that the panning is properly sealed to prevent outside air leakage paths.

Additionally, when installing return ducts, it is advisable to avoid placing them in bathrooms or kitchens as this can cause the system to circulate cooking odours and moisture, leading to discomfort and potential issues with mould or deterioration of building materials. Instead, it is recommended to centralise the thermostat and return duct to draw circulation and temperature readings from every part of the home.

Furthermore, it is important to consider fire safety when replacing air return panning. While using building cavities as return-air pathways is not a fire hazard in itself, it can encourage a fire to spread throughout the building. Ensure that any materials used meet the flame- and smoke-spread criteria and do not use combustible materials in return air plenums.

Lastly, sizing is an important consideration when replacing air return panning. The size of the ducting will depend on the amount of air you want to move through it. It is recommended to seek advice from an HVAC expert to determine the appropriate size for your specific needs.

Frequently asked questions