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The most common culprits are high-resistance filters, dirty or aging ductwork, unbalanced systems, or outdated fans.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

Retrofitting Indoor Air Quality (IAQ) Systems for Existing Buildings: Overcoming Challenges and Implementing Solutions

Jennifer Crowley
Apr 9, 2024
3 min read

Updated: Jul 8, 2024

Exterior of dilapidated heritage building with broken windows faded facade and ornate design — By prioritizing IAQ initiatives, building owners can create healthier, more productive environments for their occupants while enhancing the overall value of their properties.

As the importance of indoor air quality (IAQ) continues to gain recognition, many building owners and facility managers are seeking ways to enhance IAQ in their existing structures. Retrofitting IAQ systems in older buildings presents unique challenges, but with the right strategies and solutions, it is possible to achieve significant improvements in air quality and occupant comfort.

In this blog post, we'll delve deeper into the challenges associated with retrofitting IAQ systems and explore effective solutions, including a detailed case study of a heritage building that overcame limited space, compatibility issues, and cost concerns.

Challenges of Retrofitting IAQ Systems:

Limited Space: Retrofitting IAQ systems in existing buildings often poses challenges due to limited space for new equipment and ductwork. This can make it difficult to install advanced filtration systems or ventilation upgrades without major renovations.
Compatibility Issues: Existing HVAC systems may not be compatible with modern IAQ technologies, making it challenging to integrate new components seamlessly. Compatibility issues can arise with control systems, airflow configurations, and equipment compatibility.
Cost Concerns: Retrofitting IAQ systems can be costly, especially for older buildings with outdated infrastructure. Building owners may be hesitant to invest in IAQ improvements due to budget constraints or concerns about the return on investment.
Disruption to Occupants: Retrofitting IAQ systems may require temporary disruptions to building operations, causing inconvenience to occupants and potential productivity losses. Minimizing disruption while implementing IAQ upgrades is essential to maintaining tenant satisfaction.

Solutions for Successful Retrofitting:

Comprehensive Assessment: Begin the retrofitting process with a comprehensive assessment of the existing IAQ conditions and HVAC systems. Identify areas for improvement and prioritize upgrades based on their potential impact on air quality and occupant health.
Tailored Solutions: Implement IAQ solutions that are tailored to the specific needs and challenges of each building. This may include installing high-efficiency filtration systems, upgrading ventilation equipment, or integrating air purification technologies.
Strategic Planning: Develop a strategic retrofitting plan that minimizes disruption to building occupants while maximizing the efficiency of IAQ upgrades. Coordinate with tenants and schedule work during off-peak hours to minimize inconvenience.
Investment in Technology: Leverage advanced IAQ technologies and smart building solutions to optimize air quality and energy efficiency. Investing in state-of-the-art filtration systems, sensors, and monitoring tools can provide real-time insights and ensure optimal IAQ performance.
Collaboration with Experts: Partner with IAQ experts, HVAC contractors, and building engineers to develop and implement effective retrofitting strategies. Their expertise and guidance can help you navigate complex challenges and ensure successful IAQ upgrades.

Interior photo of heritage building exposed HVAC system — Begin the retrofitting process with a thorough assessment of existing IAQ conditions & HVAC systems.

Case Study:

In a recent retrofitting project for a heritage building, Blade Air faced numerous challenges including limited space, compatibility issues, and cost concerns. However, by leveraging Blade Air filtration products designed to fit any HVAC system, conducting minor equipment upgrades, and developing a detailed plan, they overcame these hurdles. Blade Air provided assurances that the energy, maintenance, and logistical savings resulting from the IAQ upgrades would balance out the initial investment costs within two years, ultimately saving time and money for the building owner.

Retrofitting IAQ systems for existing buildings presents challenges, but with careful planning, strategic solutions, and collaboration with experts, it is possible to achieve significant improvements in indoor air quality and occupant comfort. By prioritizing IAQ initiatives and investing in modern technologies, building owners can create healthier, more productive environments for their occupants while enhancing the overall value of their properties.

Are you considering retrofitting IAQ systems in your existing building? Contact Blade Air today to learn more about our IAQ solutions and how we can help you achieve your indoor air quality goals.

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