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Air seal a heat pump or air conditioner air handler cabinet at all seams, holes, and junctions

Air seal a heat pump or air conditioner air handler cabinet at all seams, holes, and junctions
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Air seal all holes and seams in the furnace cabinet with mastic, foil tape, or putty

Air seal all holes and seams in the furnace cabinet with mastic, foil tape, or putty
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Air seal and insulate flex ducts

Air seal and insulate flex ducts
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Air seal around all duct shafts and flues installed through ceilings, walls, or flooring to keep conditioned air from leaking into unconditioned space.

Air seal around all duct shafts and flues installed through ceilings, walls, or flooring to keep conditioned air from leaking into unconditioned space.
CAD File:

Air seal at chase walls - plan

Preview Image
Air seal at chase walls - plan
CAD File:

Air seal at duct boot

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Air seal at duct boot
CAD File:

Air seal at duct soffit

Preview Image
Air seal at duct soffit
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Air seal duct boot to ceiling by installing fiberglass mesh tape and mastic over seam

Air seal duct boot to ceiling by installing fiberglass mesh tape and mastic over seam
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All dampers should be completely open in a duct system being tested for air leakage; looking at the actuator from outside the duct is not a reliable way to know damper position, so the pressure downstream of the damper should be measured

All dampers should be completely open in a duct system being tested for air leakage; looking at the actuator from outside the duct is not a reliable way to know damper position, so the pressure downstream of the damper should be measured
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All dampers should be completely open in a duct system being tested for air leakage; this damper is only partially open and should be opened fully prior to testing

All dampers should be completely open in a duct system being tested for air leakage; this damper is only partially open and should be opened fully prior to testing
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All of the ductwork for the efficient (8.5 HSPF, 15 SEER) heat pump is mastic sealed and installed in conditioned space.

All of the ductwork for the efficient (8.5 HSPF, 15 SEER) heat pump is mastic sealed and installed in conditioned space.
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All other supply ducts and all return ducts in unconditioned space have insulation ≥ R-6

All other supply ducts and all return ducts in unconditioned space have insulation ≥ R-6
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An energy recovery ventilator provides filtered fresh air to every room in the house.

An energy recovery ventilator provides filtered fresh air to every room in the house.
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An ENERGY STAR central exhaust ventilation test is performed on a rooftop ERV duct system by an ENERGY STAR MFNC rater

An ENERGY STAR central exhaust ventilation test is performed on a rooftop ERV duct system by an ENERGY STAR MFNC rater.
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An in-line airflow station installed in rigid duct provides a location to measure ventilation airflow

An in-line airflow station installed in rigid duct provides a location to measure ventilation airflow
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Apply a nylon tie on top of the tape.

Apply a nylon tie on top of the tape.
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Apply a robust amount of UL-181 fiber reinforced duct sealant mastic paste to cover well past the edges of the tape.

Apply a robust amount of UL-181 fiber reinforced duct sealant mastic paste to cover well past the edges of the tape.
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Apply a thick layer of UL-181 fiber reinforced duct sealant mastic paste spanning over the polyester film of the flex duct core, the tape, and nylon tie, to the take-off collar.

Apply a thick layer of UL-181 fiber reinforced duct sealant mastic paste spanning over the polyester film of the flex duct core, the tape, and nylon tie, to the take-off collar.
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Assembled section of fiber board duct

Assembled section of fiber board duct
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Back-draft damper still has a piece of tape that prevented it from rattling during shipping

Back-draft damper still has a piece of tape that prevented it from rattling during shipping
Video:

Backdraft Dampers

Case Study:

Baxter Community - High Performance Green Building

Baxter Community - High Performance Green Building
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Because this ICF and spray foamed house is so well insulated, the HVAC system is smaller, the round metal ducts are smaller diameter, and the duct layout is more compact.

Because this ICF and spray foamed house is so well insulated, the HVAC system is smaller, the round metal ducts are smaller diameter, and the duct layout is more compact.
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Bedrooms pressure-balanced and provide 1 sq. in. of free area opening per 1 CFM of supply air or achieve a Rater-measured pressure differential ≤ 3 Pa

Bedrooms pressure-balanced and provide 1 sq. in. of free area opening per 1 CFM of supply air or achieve a Rater-measured pressure differential ≤ 3 Pa