The Hidden Cost of Poor Airflow in High-Performance Commercial Buildings

Poor airflow in commercial buildings leads to higher energy bills, reduced indoor air quality, and HVAC wear. Learn how to identify and solv

Ava Montini

Mar 24, 2025

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Why airflow inefficiencies drive up costs, compromise indoor air quality, and create hidden challenges for facility managers

Most commercial and institutional buildings today are designed with performance and efficiency in mind. Energy benchmarks, ESG goals, and occupant well-being are often front and center. But despite those efforts, one critical element of building performance is consistently underdiagnosed: airflow.

Poor airflow can silently affect every corner of your building’s operations — from higher energy consumption and HVAC maintenance costs to reduced indoor air quality (IAQ) and missed sustainability opportunities. It rarely shows up as a red flag on day one, but over time, it chips away at performance in ways that are both measurable and avoidable.

Inefficient Airflow Increases Energy Use — Even in “Efficient” Buildings

In many commercial buildings, HVAC systems account for roughly 30–40% of total energy consumption, according to Natural Resources Canada and ASHRAE. But when airflow is restricted, that percentage can climb significantly.

The most common culprits are high-resistance filters, dirty or aging ductwork, unbalanced systems, or outdated fans. These conditions increase static pressure, which forces HVAC fans to work harder and longer to achieve required airflow levels.

According to a study by the U.S. National Institute of Standards and Technology (NIST), buildings with airflow-related HVAC issues can see energy use increase by up to 30% compared to optimized systems. [1]

Even minor issues can have an outsized impact. A 100,000 sq. ft. office building experiencing elevated fan energy use due to clogged filters or inefficient duct design could face annual utility costs tens of thousands of dollars higher than necessary. For building owners managing multiple sites, that inefficiency compounds quickly.

Airflow and Indoor Air Quality Are Closely Linked

Buildings are dynamic systems, and air quality tends to suffer when airflow is compromised. Insufficient airflow can lead to poor ventilation, uneven air distribution, and pockets of stagnation in rooms or zones. These areas often experience elevated levels of carbon dioxide (CO₂), volatile organic compounds (VOCs), and particulate matter — especially in high-occupancy spaces.

A 2015 study from Harvard’s T.H. Chan School of Public Health found that employees working in well-ventilated buildings performed 61% better on cognitive tasks than those in typical buildings with poor ventilation and air quality. [2]

In schools, researchers have found that students in classrooms with improved ventilation perform better on standardized tests. [3] In healthcare facilities, inadequate air movement can increase the risk of airborne illness transmission.

Common complaints like “stuffy rooms,” temperature inconsistencies, or fatigue can often be traced back to airflow and ventilation issues — even when temperature setpoints and filtration standards are technically being met.

Poor Airflow Wears Down HVAC Systems Faster

Inefficient airflow costs more on your energy bill and accelerates mechanical wear and tear. When fan motors, compressors, and dampers are forced to operate under continuous load, components degrade faster than expected.

This leads to:

More frequent repairs and service calls
Shortened equipment lifespan
Greater downtime and occupant discomfort during peak seasons

A study from the National Air Duct Cleaners Association (NADCA) notes that air distribution restrictions are a key factor in premature HVAC failure and reduced system capacity. [4]

The cost of replacing a rooftop unit, for example, can range from $10,000 to $25,000, depending on building size and complexity — not including indirect costs from temporary system downtime.

Sustainability Targets Can Be Quietly Undermined

Many facilities today are pursuing ESG goals, LEED certification, or local emissions reduction mandates. But airflow inefficiencies can quietly work against those targets by increasing Scope 2 emissions (energy-related emissions) and filter waste.

High-resistance air filters, mainly traditional pleated filters, can contribute to this in two ways:

Increased energy use due to pressure drop
Frequent changeouts, leading to more waste and landfill contribution

According to a 2021 study in Building and Environment, filter pressure drop is one of the most overlooked contributors to unnecessary HVAC energy use — especially when filters are overused or under-maintained. [5]

If a building claims progress in sustainability, it’s important to ensure that filtration and airflow practices align with those claims—both from an energy and waste standpoint.

Missed Opportunities for Incentives and Cost Recovery

One of the lesser-known downsides of inefficient airflow is the lost opportunity to qualify for energy retrofit incentives.

Many utility and government programs across North America offer rebates, grants, or low-interest financing for businesses upgrading HVAC systems, controls, and low-pressure filtration. But to be eligible, buildings often need to demonstrate quantifiable improvements in system performance.

For example, Ontario’s Save on Energy Retrofit Program offers up to 50% of project costs for energy-efficiency upgrades, including those related to ventilation, air handling units, and demand control ventilation systems. [6]

Without data on airflow improvement or energy reduction — or without addressing underlying airflow inefficiencies — buildings may fail to qualify, leaving funding on the table.

Practical Steps to Address Airflow Challenges

The good news is that improving airflow doesn’t require a major capital project. Many impactful changes can be made within existing operations and maintenance cycles.

Here’s where most facilities can start:

Conduct a static pressure and airflow assessment to identify bottlenecks
Replace high-pressure filters with low-pressure, high-efficiency alternatives
Balance and tune your HVAC system, especially if zones have changed due to new usage patterns
Install real-time IAQ monitors to detect issues as they emerge, not after complaints arise
Track filter changeouts and energy use to capture data for future incentive applications

These strategies are already being implemented in facilities across North America — and in most cases, they deliver measurable improvements in energy efficiency, equipment reliability, and occupant satisfaction.

Airflow may not be the most visible part of your building, but it’s one of the most influential. When ignored, it quietly drives up energy costs, reduces system lifespan, and compromises air quality.

For facility managers and business owners focused on performance, sustainability, and operational clarity, airflow should be on the radar — not just as a maintenance metric but as a lever for long-term efficiency and resilience.

Addressing airflow challenges is a straightforward, high-ROI step that supports healthier, more cost-effective, and future-ready buildings.

A Step-by-Step Guide to Retrofitting Old Buildings for Better Air Quality

Jennifer Crowley
Jul 4, 2024
4 min read

Updated: Jul 8, 2024

Old building mechanical room — Retrofitting older buildings for better indoor air quality is a comprehensive process that involves assessment, choosing the right solutions, implementation, and maintenance.

Retrofitting older buildings for better indoor air quality (IAQ) is essential for ensuring the health and well-being of occupants. Over time, buildings accumulate dust, allergens, and other pollutants that can compromise air quality. Additionally, outdated HVAC systems often fail to meet modern standards, leading to inefficient energy use and higher operational costs. Retrofitting these buildings with advanced air quality solutions can dramatically improve IAQ, energy efficiency, and occupant comfort.

Assessment Phase

The first step in retrofitting old buildings for better air quality is to conduct a thorough assessment of the current air quality and HVAC systems. This involves:

Young black male maintenance technician with a clipboard checking off inspecting the HVAC system performance — The first step in retrofitting old buildings for better air quality is to conduct a thorough assessment.

1. Air Quality Testing:

Measure levels of common indoor pollutants such as dust, mold spores, VOCs, and carbon dioxide. Use professional-grade sensors and testing kits to get accurate readings.

2. HVAC System Evaluation:

Inspect the existing HVAC system for inefficiencies, outdated components, and potential areas for improvement. Check for signs of wear and tear, and assess the system’s filtration and ventilation capabilities.

3. Building Inspection:

Look for structural issues that could affect air quality, such as leaks, poor insulation, and areas prone to mold growth. This helps identify underlying problems that need to be addressed during the retrofit.

Retrofitting Old Buildings for Better Air Quality - Choosing the Right Solutions

Once the assessment is complete, the next step is to choose the right retrofit solutions. Blade Air offers a range of advanced products designed to improve IAQ and enhance energy efficiency:

Rear image of a young while male maintenance working changing out a dirty air filter — The right IAQ solutions can improve IAQ, save energy, and create a healthier environment.

These capture ultrafine particles, including viruses and bacteria, far exceeding the capabilities of traditional pleated filters. They ensure cleaner air and better protection against airborne contaminants.

2. HEPA+ Filters:

Ideal for capturing up to 99.97% of airborne particles, including dust, pollen, and mold spores. These filters are especially beneficial for occupants with allergies or respiratory conditions.

3. UV-C Light Technology:

This technology uses ultraviolet light to kill bacteria and viruses in the air. It is an excellent solution for reducing microbial contaminants and improving overall air hygiene.

4. Carbon Filters:

Effective for removing odors and volatile organic compounds (VOCs),

enhancing overall air quality and comfort.

5. HEPA Air Purifiers:

These portable units combine HEPA filtration with activated carbon to provide superior air purification in specific areas, making them perfect for targeted air quality improvements.

Implementation:

The implementation phase involves installing and integrating the chosen air quality solutions. Here’s a step-by-step process:

1. Preparation:

Building Readiness: Ensure the building is ready for retrofit activities. This involves scheduling the retrofit to minimize disruption to occupants. Informing occupants of the upcoming changes can help manage expectations.

Minor Repairs: Address any minor structural repairs identified during the assessment phase. This might include sealing leaks, improving insulation, or fixing areas prone to mold growth.

Cleaning: Perform a thorough cleaning of the HVAC system and areas where new equipment will be installed. Removing accumulated dust and debris ensures a smoother installation process.

Older white male in coveralls removing the cover to the HVAC unit — Ensures proper installation and maintenance training by bringing in a Pro for installation.

2. Installation:

Professional Installation: Blade Air recommends that our expert team install our filtration products for you. This ensures proper installation and allows us to train your team on installation and maintenance procedures.

HEPA Air Purifiers: Place HEPA air purifiers in strategic locations such as high-traffic areas, common rooms, and near HVAC intakes. Ensure you follow the instruction manual and that they are plugged in and functioning correctly.

3. Integration:

System Connection: Connect the new filters and UV-C light systems to the existing HVAC controls. This may involve updating the HVAC control software or adding new control modules.

Testing and Calibration: After installation, conduct thorough testing to ensure all components are working correctly. Calibrate the UV-C light intensity and HEPA air purifier settings to achieve optimal air quality.

Optimization: Adjust the HVAC system settings to account for the new filters and purification devices. Ensure that airflow and ventilation rates are optimized for the enhanced filtration system.

Young bearded male using an air quality monitor to review IAQ output. — Measure airflow rates, filter pressure drops, and UV-C light output to ensure all is within range.

4. Testing:

Initial Performance Check: Perform an initial performance check of the installed systems. Measure airflow rates, filter pressure drops, and UV-C light output to ensure everything is within specified ranges.

Air Quality Testing: Conduct air quality tests to verify the improvement in IAQ. Measure levels of dust, VOCs, mold spores, and other pollutants before and after installation.

System Monitoring: Set up continuous monitoring to track the performance of the new systems over time. This helps in identifying any immediate adjustments needed to maintain optimal IAQ.

5. Training:

Staff Training: Provide comprehensive training sessions for building maintenance staff. Cover topics such as filter replacement schedules, UV-C light maintenance, and operation of HEPA air purifiers.

User Manuals: Supply detailed user manuals and quick reference guides. Ensure that staff have access to resources that help them manage and troubleshoot the new systems.

Ongoing Support: Offer ongoing support through Blade Air’s customer service. Encourage staff to reach out with any questions or concerns during the initial adjustment period.

Maintenance

Maintaining the new air quality systems is crucial for long-term efficiency and performance. Here are some tips:

1. Regular Inspections:

Schedule routine inspections to check the condition of filters, UV-C lights, and other components. Look for signs of wear and replace parts as needed.

2. Filter Replacement:

Follow the manufacturer’s guidelines for replacing filters. Regular replacement ensures optimal filtration and prevents clogging.

3. System Calibration:

Periodically calibrate the smart monitoring systems to ensure accurate air quality readings.

4. Cleaning:

Keep the HVAC system and air quality devices clean. Regular cleaning prevents dust buildup and maintains system efficiency.

5. Data Review:

Regularly review air quality data to identify trends and potential issues. Use this data to make informed decisions about maintenance and system adjustments.

Retrofitting older buildings for better indoor air quality is a comprehensive process that involves assessment, choosing the right solutions, implementation, and maintenance. By following these steps, you can significantly improve IAQ, enhance energy efficiency, and create a healthier environment for occupants.

Blade Air is here to assist you throughout the entire retrofit process, offering advanced products and expert guidance to ensure your retrofit project is a success. Contact us today to learn more about how we can help transform your building’s air quality.