top of page

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

Written by 

Published on

Tags

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The most common culprits are high-resistance filters, dirty or aging ductwork, unbalanced systems, or outdated fans.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

How is Indoor Air Quality Measured?

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

Updated: Jul 10, 2024

Humidity sensor in a mans hand in the foreground, with a blurry male digging in his toolbox in the background
By monitoring air quality, you can stop the negative consequences of indoor air pollutants.

For all the right reasons, improving indoor air quality has become a concern for many. However, when do we know the measures being taken to improve the IAQ are actually working? Or when we need to take further measures?


You can use monitors to check on your building’s air quality to provide a safer and healthier environment. By monitoring air quality, you can also stop the negative consequences of indoor air pollutants. Many methods are used to extract the level of indoor air quality, specifically measuring common symptoms found indoors. This includes; humidity, CO2 and VOCs.


Humidity Sensors

What is Humidity?

Humidity is the concentration of water vapour present in the air. Common sources of excess moisture indoors include the overuse of a humidifier, long showers, running water for other uses, boiling or steaming in cooking, plants, and drying clothes indoors. Also, a tight, energy-efficient building holds more moisture inside.


Humidity Sensor

A humidity sensor is an electronic device that measures the humidity in its environment and converts its findings into a corresponding electrical signal. Humidity sensors vary widely in size and functionality; some humidity sensors can be found in handheld devices (such as smartphones), while others are integrated into larger embedded systems (such as air quality monitoring systems).


Humidity sensors can be divided into two groups, depending on the method used to calculate the humidity. Relative humidity, or RH, is calculated by comparing the live humidity reading at a given temperature to the maximum humidity for air at the same temperature. RH sensors must therefore measure temperature to determine relative humidity. Contrastingly, absolute humidity (AH) is calculated without reference to temperature.


CO2 Sensors

What is CO2?

CO2 is a natural constituent of the air we breathe; it is a colourless, odourless and non-flammable gas produced by metabolic processes (such as respiration) and by the combustion of fossil fuels. This is a result of both external atmospheric CO2 and internal production from the presence of people.


The average outdoor air concentration of CO2 is in the order of 300 to 400 ppm. Indoor levels are usually higher due to the CO2 exhaled by building occupants. Indoor combustion appliances, particularly gas stoves, can also increase CO2 levels.

Chart depicting air quality status based on CO2 levels

CO2 Sensors

A carbon dioxide sensor is a device used to measure carbon dioxide gas concentration in the atmosphere. It is measured using “parts per million” (ppm) and is measured through different technologies, including;

  1. Nondispersive Infrared (NDIR): monitors the absorption of infrared light at a specific wavelength (4.3 μm), a wavelength at which CO2 has very strong absorption. If the infrared light is absorbed, then CO2 is present, whereas non-absorption indicates a lack of CO2.

  2. Photoacoustic Spectroscopy: Subjects a sample to pulses of electromagnetic energy that are tuned specifically to the absorption wavelength of CO2. The CO2 molecules within the sample will absorb and generate pressure waves via the photoacoustic effect with each energy pulse. These pressure waves are then detected with an acoustic detector and converted to a usable CO2 reading through a computer or microprocessor.

  3. Electrochemical Carbon: dioxide sensors measure electrical current to determine how much CO2 is in the air. When CO2 enters the sensor, it chemically reacts within a polymer surface, resulting in an electrical charge. The type and amount of electrical charge are then used to determine how much CO2 is present.


VOC Sensors

What are VOCs?

Volatile organic compounds (VOCs) are emitted as gases from certain solids or liquids. VOCs are emitted by a wide array of products. Examples include: paints and lacquers, paint strippers, cleaning supplies, pesticides, building materials and furnishings, office equipment such as copiers and printers, correction fluids and carbonless copy paper, graphics and craft materials including glues and adhesives, permanent markers, and photographic solutions.


VOC Sensors 

As the name suggests, VOC sensors detect surrounding volatile organic compounds. VOCs typically come from gases that emanate from solid or liquid compounds. This can be residual paint fumes or gases from solvents or fuels. Commonly, people can detect or identify if they’re near VOCs by smell.

There are three main types of sensors used to detect VOC levels in the air:

  1. PIDs (photoionization detectors) break down compounds into positive and negative ions using ultraviolet light to identify VOCs. These sensors can analyze and detect a vast array of chemicals, including methylene chloride.

  2. FIDs (flame ionization detectors) detect hydrocarbons in various industries. A hydrogen flame interacts with hydrocarbons to produce ions. Alerts sound when any changes in ion levels are detected.

  3. MOS (metal oxide semiconductor sensor) sensors use a delicate film to detect compounds in the surrounding atmosphere, such as benzene, ethanol, and toluene. These sensors can operate in low humidity.


Symptoms of Poor Indoor Air Quality

Another easy way to measure indoor air quality is by looking around your home, office or workspace and looking for common signs of poor IAQ. Signs commonly include:

  1. Mould

  2. High Humidity

  3. Odour (stale smell)

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.

Insights Hub

Lorem ipsum dolor sit amet, consec tetur adipiscing elit. Sit quis auctor 

Lorem ipsum dolor sit amet cotetur 

Lorem ipsum dolor sit amet, consec tetur adipiscing elit. Sit quis auctor 

Lorem ipsum dolor sit amet cotetur 

Lorem ipsum dolor sit amet, consec tetur adipiscing elit. Sit quis auctor 

Lorem ipsum dolor sit amet cotetur 

bottom of page