As an expert in the HVAC industry with over 20 years of experience, I have seen many homeowners make the mistake of using duct tape to seal their ductwork. While it may seem like a quick and easy solution, the truth is that duct tape is not a good product to use for this purpose. One of the main issues with duct tape is that after the adhesive dries, it becomes very brittle. This means that it can easily crack and peel off, leaving your ducts vulnerable to leaks once again. To properly seal ductwork, you should use 3 to 4 screws at a minimum, which is something that many people overlook when using duct tape. In fact, in my experience, the percentage of adhesive tape used in ducts is close to zero.
This is because there are much better options available for sealing ductwork, such as high-quality HVAC aluminum tape or putty. While putty may be the perfect option for sealing your duct system, it does require careful application and can cause problems if not used correctly. Additionally, it can be difficult to reach all areas of the ducts, making it challenging to fill in important gaps without accidentally getting putty inside the ducts. To determine the most effective product for sealing ductwork, a study was conducted where eight identical finger joints were tested simultaneously using different sealing products. The results showed that adhesive tape, clear plastic tape, aluminum-backed tape, and injected aerosol sealant all had varying levels of success in sealing leaks. If your pipe ducts have insulation around them, you will need to remove the insulation before sealing any leaks and then replace it afterwards. This can be a time-consuming process and may require additional tools or equipment. Another factor to consider is the temperature at which these products are being used.
In a study conducted over three months, various sealing materials were tested under conditions similar to those found in real HVAC systems. The results showed that many adhesive tapes failed due to the high temperatures, making them ineffective for sealing ductwork. When it comes to rigid pipe ducts with insulation, the process is even more complicated. Not only do you have to remove and replace the insulation, but you also have to seal any leaks in the ducts themselves. After understanding the best way to apply each product, you may reconsider whether duct sealing is a project that you should attempt yourself. It requires careful attention to detail and knowledge of the different products available. In response to the almost total failure of current adhesive tapes, experts in the industry believe that there is potential for reformulation of adhesives and construction methods to make them more effective at higher temperatures.
This could lead to better options for sealing ductwork in the future. From reducing energy loss to improving indoor air quality, there are many good reasons to properly seal leaking ducts. However, it is important to use the right products and techniques for this task. Duct tape may seem like a convenient solution, but it is not a reliable or long-term solution for sealing ductwork.