I replaced all the ducts but the trunks in my 1969 home when I replaced the horizontal furnace under the house with a gas pack. I got advice from a friend who was an HVAC contractor. I was surprised to find the trunks and other ducts very clean. I replaced the individual runs with flex primarily for the insulation. I wrapped the trunks with insulation also.
If you believe that the AC's not working or you're getting little or no cold air, check these three things first. Make sure all the registers in the house are wide open. Then be sure the furnace filter is clean. Then go outside and clean off the condenser coils (Photo 2). If several registers were closed or the filter was clogged, the reduced airflow could have caused the evaporator coil to ice up and stop cooling your home. If you've changed the filter and opened all the registers and you're still not getting airflow at the registers, deice the A-coil. Move the thermostat mode switch from “Cooling” to “Off” and move the fan switch from “Auto” to “On.” Let the blower run for at least 30 minutes or until there's good airflow at the registers. Then turn the AC back on to test it. If it works for the next 12 hours, you've solved the problem.
If you are using existing ducting, it will have to be inspected. Proper ducting loses around 2% to 5% of your energy. Old, leaking ducts can lose 50% or more. A contractor will need to have the ducts inspected and replace any parts ahead of time. If you are changing the size of your HVAC system because of significant changes to your home, you might need to replace the ductwork regardless.
Since the 1980s, manufacturers of HVAC equipment have been making an effort to make the systems they manufacture more efficient. This was originally driven by rising energy costs, and has more recently been driven by increased awareness of environmental issues. Additionally, improvements to the HVAC system efficiency can also help increase occupant health and productivity. In the US, the EPA has imposed tighter restrictions over the years. There are several methods for making HVAC systems more efficient.
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