An engineered project built in the 50s and 60s was constructed to last and provide a pretty good delivery air system to the buildings they we controlling. Those systems lasted, and lasted. As a matter of fact there are many of them still running today. There were not as many companies competing so the prices were not driving the market. Most HVAC companies today are owned by past technicians. They know the workings of an HVAC unit, but business, they just haven't the time to learn. When they worked for the big contractors in the 60s they thought they could do it cheaper. So new companys were started until in the 70s competition in the market began bringing down prices. New products were created to be able to put these comfort systems in cheaper; flex duct, fiberglas ductboard, plastic registers, and even some manufactures used thinner metals to reduce prices. Sounds like the new cars of today doesn't it. Well when prices dictate the market and staying in business means getting a job, the quality materials put into the jobs of the 50s and 60s are given up for the cheaper materials and products of today. It's like there is no choice, the lowest price gets the job.
Please don't misunderstand me, most of the new materials like flex duct and ductboard can work and work quite well. But! and I mean But! they must be installed properly to work well. The problem comes in the installation of these new materials. To install them properly means care in sticking with the engineering physics of air flows and structural design. Flex duct is 10 time more resistive to air flows due to the construction of the inner walls just as well as ductboard and insulation liners. So it must be installed in a way to minimize the resistance and sized to compensate. But!..... again this would increase the price to take such time to insure good air flows, so it just isn't being done.
In conclusion, the contractor is getting his job for the low prices with the low quality installation with the low priced materials and makes his small, and I do mean small, profits. The owner of the building gets a project completed with the lowest price and then has to live with the poor preformance and higher electric bills, which he doesn't really know are high, and the probability that the HVAC equipment will fail and have to be replaced in 10 to 20 years from now. When you consider a 30 year note to build this project you have to realize that cheaper means buying it twice when a quality system will last as long as the note and only cost you once. Therefore, which one is truly cheaper.
What can an owner do?........... Well on most projects there is a mechanical engineer who knows the proper designs and can draw up the proper project for you. Get to know him well. Then inspecting of these projects should be done not only by the cities inspectors but by the engineer himself. This will insure the proper installation of the project. Also, just as you would not have a cheaper window installed you should require the best HVAC materials and equipment for the project. It is your building and you can have what you want in it. Don't let others tell you that they have to allow optional equipment or materials to be fair with other manufactures. Competition is necessary to prevent the prices from going up, but don't let the quality go down with the prices.
Residential homes on the other hand do not have mechanical engineers to design your cooling system. Usually one of those low priced contractors design the system with....you guested it...... low prices in mind. Not necessarily because that is what the contractor wants but it's what the builder wants, or, unfortunately, even sometimes it's what you want. The only thing is that no one tells you what's going on so you did not know about what you are getting. So what can you do as a residential home owner? Well it is harder than with commercial but there are a few tips I can give you.
1. Look for a contractor who cares about your needs. He should spend time with you asking what you would like in a comfort system.
2. The SEER (Seasonal Energy Efficiency Ratio) is important. The higher the number the more efficient the unit. But remember the unit is only part of the equation to high efficiency.
3. If there is duct work involved, ask what kinds of measures are taken to ensure high efficiency air flow. You can use your common sense here. Strait is better, smooth inside surface is good, gradual turns with some means to help the air make the turn(long radius or turning veins), and with flex duct it should be stretched to take the wrinkles out inside the flex. Also ask how they determine the sizes of the duct work. A duct calculator or ductculator should be used. Don't let them just tell you a size based on their experience. I have been in the business for 31 years and I still have to go to the ductculator to size it properly.
4. What kind of start up tests do they use? (Most contractors do not have a start up test.)
5. When freon line are needed for "split systems" they should take care to not let contamination into the lines. Nitrogen should be used during any welding or brazing, and filter driers should be installed. Also, the lines should be evacuated before the freon is opened up.
6. The freon charge should also be checked during the start up procedure. The new units come with a charge of freon but it needs to be adjusted for the freon lines installed.
So in conclusion, we at Bowling Service of America are one of very few who are trying to change the quality of our industry to meet the needs for higher efficiency comfort systems. I believe we are in an uphill battle that we most likely cannot win. There are just too many others against us simply saying "We've been doing for many years and it works." Please be carful that you may be paying a low price for a new unit that may work today but over the long run you most likely will be paying much more over the years to come and quite possibly replacing it much too soon.
Michael D. Bowling, C.E.O.,
Bowling Refrigeration, Inc.
References: Home Energy Magazine
