80-1-IsD - Condensation Control On Air Conditioning Ducts

Air Handling Systems
Engineering & Technical Bulletin
80-1-ISD Condensation Control on Air Conditioning Ducts
Condensation of water vapor can occur on ducts going through any location if the dew point temperature of the
ambient air is higher than the operating temperature of the HVAC system. Although this situation could be present in
ducts in any location, particular attention should be given to ducts exposed to outside or unconditioned air, such as
ducts in attics and crawl spaces.
For ducts in conditioned spaces, it is normal HVAC design to maintain a conditioned ambient temperature of 75F and
relative humidity of 50% or below with a supply air or operating temperature in the range of 55F to 60F, thus reducing
by design the need for duct insulation since the dew point temperature of the conditioned space would be equal or
less than 55F.
Under actual conditions, variations in the rate of ventilation, number of people and equipment, could increase the dew
point temperature of the conditioned space above the operating temperature. A typical example would be in a building
with supply ducts going through return air plenums where usage of the conditioned space has been changed to
conference areas instead of regular office work.
Attached are condensation parameters and the calculation procedure to determine the required insulation needed to
prevent condensation.
Also attached is a table from which the ambient dew point temperature can be obtained knowing the dry bulb temperature and relative humidity. The dew point temperature below the line indicates condensation is likely to occur.
Condensation Parameters
1.
Temperature of air in the duct or operating temperature.
2.
Condition of air in the space where ducts are located.
a.
b.
c.
3.
Duct location.
dry bulb temperature

relative humidity
dew point temperature
General Formula to Calculate Minimum Insulation Thickness Required to Prevent Condensation

(TDP - TOP)
tk = kRs

(TADB - TDP)
tk
Insulation thickness (in)
Thermal conductivity
R S
TDP
Dew point temperature (F)
TOP
Operating temperature (F)
TADB
Ambient dry bulb temperature (F)
Btuin
[(hrft
F)]
(hrft F)
Surface temperature resistance [
Btu ]
2
The typical values for:
TOP
55F cooling; 140F heating
RS
1.32 (hrft F) (reflective surface, still air)

2
Btu
By setting tk = 0 and solving the equation for TOP , it has been determined that the minimum condition for which insulation would be required is when TOP is equal to the dew point temperature. Therefore, at standard barometric pressure
and normal cooling operating conditions, insulation would be required when TDP 55F.
Example
For those conditions where the operating temperature is less than or equal to the dew point temperature, the required
insulation can be calculated as follows:
Vapor
Barrier
Surface
Air Flow
Sheet Metal Duct
Microlite XG (Type 75)
Solving for insulation thickness:

(TDP - TOP)
tk = kRS
(TADB - TDP)
= (0.29) (1.32)
= 0.15 inches
(62-55)
(80-62)
Assumptions
TADB
=
80F
Relative
Humidity =
55%
TDP
62F (from table)
TOP
55F
0.29 Microlite XG (Type 75)
RS
1.32
(hrft2F)
Btu
The results show that 0.15 inches of insulation is required in order to avoid condensation. Although this is not very
thick, the point is that without any insulation, this duct will sweat and cause problems, e.g. stained ceilings and wet
floors.
Since water vapor would be free to penetrate fiber glass insulation, a vapor barrier is required in order to prevent
condensation within the insulation and possible damage to the product.
Heating Season
Condensation during the heating season is rare but can occur inside the duct where solar energy is used for heating
or in return ducts going through unconditioned spaces. Also, in dry climates where humidifiers are used in the supply
air, condensation can occur if the duct is exposed to the outside air.
North American Sales Offices,

Insulation Systems
Eastern Region
P.O. Box 158
Defiance, OH 43512
(800) 334-2399
Fax: (419) 784-7866
717 17th St.

Denver, CO 80202
(800) 654-3103
specJM.com
80-1-ISD 10-08 (Replaces 2-07)
Western Region & Canada

P.O. Box 5108
Denver, CO 80217
(800) 368-4431
Fax: (303) 978-4661
The physical and chemical properties of the Air Handling Products

represent typical, average values obtained in accordance with
accepted test methods and are subject to normal manufacturing
variations. They are supplied as a technical service and are
subject to change without notice. Numerical flame spread and
smoke developed ratings are not intended to reflect hazards
presented by these or any other materials under actual fire
conditions. Check with the Regional Sales Office nearest you
to assure current information. All Johns Manville products are
sold subject to Johns Manvilles standard Terms and Conditions
including Limited Warranty and Limitation of Remedy. For a copy
of the Johns Manville standard Terms and Conditions, Limited
Warranty and Limitation of Remedy, and information on other
Johns Manville thermal insulations and systems, call
(800) 654-3103.
Printed on recycled paper.
Copyright 2008 Johns Manville

Printed in USA
40
30
34
38
41
45
48
52
95
100
105
110
115
120
125
63
60
56
52
48
44
32
29
25
21
18
36
13
70
27
10
65
14
11
23
60
90
55
85
-1
50
17
-4
45
-5
20
-7
40
75
-12
35
72
68
64
60
56
52
48
44
40
35
32
28
24
20
16
13
-3
-8
-15
-9
-11
-16
-20
-25
20
-16
-21
80
-20
-24
20
-15
-28
15
25
-31
30
-30
-35
5
10
-25
15
Dry-bulb
temp. F 10
78
74
70
66
62
58
54
49
45
41
37
33
28
25
21
17
13
-4
-8
-12
-16
-21
25
84
79
75
71
67
63
59
54
50
46
42
37
33
29
25
21
17
14
-4
-8
-13
-17
30
35
89
85
80
77
72
68
63
58
54
50
46
41
38
32
28
24
20
16
12
-2
-5
-10
93
88
84
80
76
71
67
62
58
54
49
45
40
35
97
92
88
84
79
75
70
66
61
57
52
48
43
39
34
30
32
25
27
22
18
13
-1
-5
-10
45
23
19
15
11
-3
-7
-12
40
100
96
91
87
82
78
73
69
64
60
55
50
46
42
37
32
28
24
20
15
10
-3
-8
50
104
99
94
90
85
81
76
72
67
62
57
53
49
44
39
34
30
26
22
17
12
-2
-6
55
107
102
97
92
88
84
79
74
69
65
60
55
51
46
41
37
32
28
24
20
15
10
-5
60
109
105
100
95
90
86
82
77
72
111
107
102
98
93
88
84
79
74
69
64
62
67
60
55
50
45
41
36
31
27
23
18
13
-2
70
57
53
48
43
39
34
29
26
22
16
11
-4
65
114
109
105
100
95
91
86
81
76
72
66
62
57
52
47
42
38
33
28
24
19
14
-1
75
117
112
107
102
97
92
88
83
78
74
69
64
59
54
49
44
39
35
30
25
20
15
10
80
119
114
109
104
99
94
90
85
80
75
70
65
60
55
50
45
41
36
32
27
21
16
12
85
121
116
111
106
101
96
91
87
82
77
72
67
62
57
52
47
43
38
33
28
23
18
13
90
123
118
113
108
103
98
93
89
83
78
74
68
63
59
53
49
44
39
34
29
24
19
14
95

Percent relative humidity
-14
Dew-Point Temperature Chart
125
120
115
110
105
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
100

80-1-IsD - Condensation Control On Air Conditioning Ducts

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Air Handling Systems

Engineering & Technical Bulletin

80-1-ISD Condensation Control on Air Conditioning Ducts

Temperature of air in the duct or operating temperature.

Condition of air in the space where ducts are located.

dry bulb temperature

General Formula to Calculate Minimum Insulation Thickness Required to Prevent Condensation

Insulation thickness (in)

Dew point temperature (F)

Operating temperature (F)

Ambient dry bulb temperature (F)

The typical values for:

55F cooling; 140F heating

1.32 (hrft F) (reflective surface, still air)

Solving for insulation thickness:

62F (from table)

0.29 Microlite XG (Type 75)

North American Sales Offices,

717 17th St.

80-1-ISD 10-08 (Replaces 2-07)

Western Region & Canada

The physical and chemical properties of the Air Handling Products

Printed on recycled paper.

Copyright 2008 Johns Manville

Dew-Point Temperature Chart

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