Why Are my Ducts Sweating?

Why your ducts may form condensation, why that’s a problem, and what can be done about it.

Condensation is forming on a supply duct.

Condensation is forming on this cold supply duct because the hot outside air is coming into contact with it.

Why Your Ducts May Form Condensation

Condensation forming on ductwork can occur due to several factors. Here are a few possible reasons:

  1. Temperature difference: When warm air passes through cold ductwork, the temperature difference can cause the moisture present in the air to condense on the surface of the ducts. This is similar to how water droplets form on the outside of a cold glass on a hot day.

  2. High humidity: If the surrounding air has high humidity levels, it increases the likelihood of condensation forming on the ductwork. When warm, moist air comes into contact with cooler duct surfaces, the moisture in the air can condense.

  3. Poor insulation: Inadequate insulation on the ductwork can contribute to condensation. If the ducts are not properly insulated, they can be more susceptible to temperature variations, leading to condensation formation.

  4. Air leaks: Air leaks in the ductwork can introduce warm, humid air into cooler areas, causing condensation to form. These leaks can also result in temperature differentials and create the conditions for moisture condensation.

  5. Improper ventilation: Inadequate airflow or poor ventilation in certain areas can contribute to condensation problems. Insufficient air movement can allow humidity to accumulate around the ductwork, increasing the chances of condensation formation.

Why Is This A Problem?

This can be a huge problem because I’ve only seen this occur in my career within the home’s conditioned space. This means that condensation is dripping off ductwork behind the drywall. This will destroy the drywall and form mold in enough time, which will entail significant drywall removal.

What Can Be Done About It?

The below are solutions to consider when addressing duct sweating/condensation.

  1. Seal outside leaks: Air leaks to the outside can introduce warm, humid air that can interact with the cooler ducts. This is the first thing that should be done.

  2. Insulate the ducts: Properly insulating the ductwork helps prevent temperature differentials between the air inside the ducts and the surrounding environment. Insulation acts as a barrier, reducing the likelihood of condensation forming on the surface of the ducts. Insulation materials such as fiberglass, foam insulation, or reflective insulation can be used.

  3. Seal air leaks: Air leaks in the ductwork can introduce warm, humid air into cooler areas, contributing to condensation. It's important to identify and seal any leaks using appropriate duct sealant or metal tape. This helps maintain consistent temperature and humidity levels inside the ducts, reducing the chances of condensation formation.

  4. Improve ventilation: Enhancing airflow and ventilation in the affected areas can help mitigate condensation. By increasing air movement, you reduce the stagnant air that can contribute to moisture buildup. Ensure that supply and return air vents are unobstructed and appropriately positioned to facilitate better air circulation.

  5. Dehumidify the air: If high humidity is a persistent issue, using a dehumidifier in the affected space can help remove excess moisture from the air. By reducing the humidity levels, you decrease the likelihood of condensation forming on the ductwork.

Ducts sweating can be a difficult problem so let the pros at Smart Energy Pros help you!

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The Residential Data Collection Checklist-2012 IECC Code