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If you are building a new home, you have the opportunity
to make sure that the duct system will deliver top-notch comfort
and efficiency by specifying to the builder that you want a leak-free,
insulated duct system. Even better, discuss with your builder
the option of locating the ducts within the conditioned space
and hiding them so that they don't show. It is possible to box
in ductwork installed near the intersection of a wall and the
ceiling, or to use other builders' tricks so that the raw duct
materials will not be visible. This isn't as tough as it might
seem because an energy-efficient duct system in a energy-efficient
home can be less bulky than a standard duct system. This is because
the heating and air conditioning loads are smaller permitting
the use of a smaller furnace and air conditioner which requires
less air flow through the duct system.
When it is possible to reduce the size of the duct system and the central unit, you save on equipment, materials, and installation costs, possibly enough to pay for the cost to hide ducts that are located within the conditioned space. In that case, energy savings will begin immediately. Even if some additional cost is involved, a duct system properly installed inside the conditioned space is energy loss-free and will likely be one of your best investments.
The ductwork should be designed to provide adequate airflow to each area of your home. Too often, contractors rely on rules of thumb, such as a four-inch diameter duct for a bedroom, rather than calculating the optimum size duct to meet the specific heating and cooling needs for a room. Insist that your ducts be designed using industry standards, such as Manual D, published by the Air Conditioning Contractor's Association.
Smooth-walled metal ducts offer the most efficient air-flow and are highly recommended, along with insulation wrap. As discussed earlier, metal duct materials and installation costs do fall in the additional cost category, but the long-term benefits far outweigh those of short-life products or improperly installed products. A properly installed metal duct system can service your home for the life of the home. This is not possible with flex-duct and some other lower cost materials.