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

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The most common culprits are high-resistance filters, dirty or aging ductwork, unbalanced systems, or outdated fans.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

Understanding Indoor Air Quality: What’s in the Air We Breathe?

Jennifer Crowley
Jul 31, 2023
3 min read

Updated: Jul 9, 2024

Man's hand holding a magnifying glass in front of a table full of house plants — Poor indoor air quality has been linked to various health problems, including respiratory issues, allergies, and cancer.

The air we breathe plays a vital role in our health and well-being. Yet, while outdoor air pollution has received much attention recently, indoor air quality is just as important and often neglected. This blog post will take a closer look at what’s in the air we breathe, focusing on indoor air.

Common Indoor Air Contaminants

Volatile Organic Compounds (VOCs)

These are chemicals released into the air from products such as paints, cleaning supplies, and personal care products. They can be invisible and have a distinct odour, but only sometimes. However, they can cause eye, nose, and throat irritation, headaches, and in severe cases, long-term health problems.

Particulate Matter (PM)

These tiny particles float in the air and can be inhaled into our lungs. They can come from sources such as tobacco smoke, cooking, and dust. Particulate Matter can be seen as fine dust or smoke but can also be invisible. Inhaling PM can cause respiratory problems and worsen conditions such as asthma and heart disease.

Biological Contaminants

This includes mould, mildew, bacteria, and viruses. These can be visible or invisible and cause allergic reactions and respiratory problems. They can grow in damp or humid areas and are often a result of poor ventilation or water damage.

Carbon Monoxide (CO)

This is a toxic gas produced by burning fuel. It is colourless, odourless, and tasteless, making it difficult to detect. It can cause headaches, dizziness, and in severe cases, death. Carbon monoxide is often a result of improperly ventilated appliances such as stoves, heaters, and fireplaces.

Radon

This naturally occurring radioactive gas is released from the ground and can enter buildings through cracks in the foundation. It’s the second leading cause of lung cancer in the U.S. and is also odourless and tasteless, making it difficult to detect.

Formaldehyde

This toxic chemical is commonly found in building materials and furniture. It can cause eye, nose, and throat irritation, and in severe cases, it can cause cancer. Formaldehyde can be released into the air from products such as particleboard, flooring, and textiles.

Adverse Health Effects of Poor Indoor Air Quality

Breathing in poor-quality indoor air can have a range of negative health effects. Some of these include:

Eye, nose, and throat irritation
Headaches
Allergic reactions
Respiratory problems, including asthma and bronchitis
Dizziness
Long-term health problems, including cardiovascular disease and cancer
Increased risk of lung cancer, especially from radon exposure

According to the Environmental Protection Agency (EPA), indoor air can be up to five times more polluted than outdoor air, and the average person spends 90% of their time indoors. Poor indoor air quality has been linked to various health problems, including respiratory issues, allergies, and cancer. The World Health Organization (WHO) estimates that each year, 3.2 million people die prematurely from illnesses attributable to household air pollution caused by the incomplete combustion of solid fuels and kerosene used for cooking.

Indoor air quality is just as important as outdoor air quality, and understanding what’s in the air we breathe is crucial to our health and well-being. By reducing exposure to common indoor air contaminants such as VOCs, PM, biological pollutants, CO, radon, and formaldehyde, we can significantly improve the air we breathe and protect our health.

Some simple steps to improve indoor air quality include:

Ventilating your home regularly to bring in fresh air
Using natural, non-toxic cleaning products and personal care items
Keeping your home well-maintained and free of moisture and mould
Using air filters to remove particulate matter and other contaminants
Testing your home for radon and taking steps to reduce exposure if necessary

In conclusion, improving indoor air quality and protecting our health is crucial. By understanding what’s in the air we breathe, we can make informed decisions to improve the air we breathe, reduce exposure to harmful contaminants, and promote good health.

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