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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The most common culprits are high-resistance filters, dirty or aging ductwork, unbalanced systems, or outdated fans.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:

  1. Increased energy use due to pressure drop

  2. 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.

Exploring the Differences Between Mechanical and Natural Ventilation

  • Writer: Jennifer Crowley
    Jennifer Crowley
  • Jul 31, 2023
  • 3 min read

Updated: Jul 9, 2024

Four rooftop ventilation units emerging from a building roof
In practice, most buildings utilize a combination of both natural and mechanical ventilation systems to balance the pros and cons and achieve optimal Indoor Air Quality (IAQ) and thermal comfort.

Mechanical and Natural ventilation are two different methods for introducing fresh air into a building or space. Both have their own benefits and drawbacks, and the appropriate choice will depend on the specific needs of the space being ventilated.


Mechanical ventilation involves using mechanical means, such as fans and ductwork, to bring fresh air into a space. This type of ventilation is often used in buildings with no windows or spaces where natural ventilation is insufficient. One advantage of mechanical ventilation is that it can be precisely controlled, allowing for precise regulation of temperature, humidity, and air quality. It is also a good option for spaces that need to be kept at a specific temperature or humidity level, such as hospitals or laboratories.


However, mechanical ventilation can be expensive to install and maintain and requires a reliable power source. It can also be noisy, which may be a concern in certain settings.


On the other hand, natural ventilation relies on the movement of air through open windows, doors, or vents to bring fresh air into a space. This type of ventilation is often used in residential buildings and other spaces where windows and doors can be opened to allow air circulation. One advantage of natural ventilation is that it is generally less expensive to install and maintain than mechanical ventilation. It is also typically quieter than mechanical ventilation, as it does not involve mechanical fans or other equipment.


However, natural ventilation is less precise than mechanical ventilation and may not be suitable for spaces that require a specific temperature or humidity level. It is also not ideal for areas that do not have windows or other openings that can be used to bring in fresh air.


Natural ventilation and mechanical ventilation are both methods of controlling the airflow within a building, but they have some key differences in terms of their benefits and drawbacks.

Pros of natural ventilation:

  1. Energy efficient: Natural ventilation systems do not require the use of mechanical equipment, which means they consume less energy and have a lower environmental impact.

  2. Cost-effective: Natural ventilation systems typically have lower upfront costs than mechanical systems and may also have lower maintenance costs over time.

  3. Improved indoor air quality: Natural ventilation helps remove stale indoor air and bring in fresh outdoor air, improving the overall air quality within a building.


Cons of natural ventilation:

  1. Dependent on the weather: The effectiveness of natural ventilation systems can be affected by the weather and may not function as well during periods of high heat, humidity, or low winds.

  2. Limited control: It can be challenging to control and regulate airflow in a natural ventilation system, which can result in uneven temperature and air quality in different parts of a building.

  3. Site and architecture-specific: Natural ventilation might not be suitable for all buildings, especially in urban or high-rise areas or extreme weather conditions, as a well-designed natural ventilation system must be integrated into the architecture and design of the building.


Pros of mechanical ventilation:

  1. Climate independence: Mechanical ventilation systems can operate regardless of weather conditions and provide consistent airflow and temperature control.

  2. Greater control: Mechanical systems can be designed and controlled to provide a specific level of airflow, temperature and humidity, allowing for better indoor environmental quality control.

  3. Suitable for any building type: Mechanical systems can be installed in any building and can be designed to suit the specific needs of the building.


Cons of mechanical ventilation:

  1. Higher energy consumption: Mechanical systems consume energy to power the mechanical equipment needed to circulate air, making them less energy efficient than natural ventilation systems.

  2. Higher upfront costs: Mechanical ventilation systems tend to have higher upfront costs than natural systems and more regular maintenance costs.


In practice, most buildings utilize a combination of both natural and mechanical ventilation systems to balance the pros and cons and achieve optimal Indoor Air Quality (IAQ) and thermal comfort.


In summary, both mechanical ventilation and natural ventilation have their own advantages and drawbacks, and the appropriate choice will depend on the specific needs of the space being ventilated. Mechanical ventilation is generally more precise and can be used to maintain specific temperature and humidity levels, but it is more expensive and requires a reliable power source. Natural ventilation is generally less expensive and quieter, but it is less precise and may not be suitable for certain spaces.

Explore expert insights, stay up to date with industry events, and gain a deeper understanding of the cutting-edge developments that are revolutionizing the indoor air quality landscape within Blade Air's comprehensive Insights Hub.

You can also subscribe to our monthly newsletter below for exclusive early access to Blade's Insights content, uncovering tomorrow's air quality advancements before they hit our Hub.

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