Condensation on Air Distribution Products

What Is Sweating or condensation?

Sweating presents itself in an air distribution system as moisture that forms on the faces
of lay-in diffusers and T-bar grids adjacent to those diffusers, where this moisture
collects and drips into the areas below.
Why Is It a Problem?
If left unrepaired condensation triggers a destruction process and allows mold and
mildew to grow. If allowed to occur inside the building walls or roof, condensation will
cause deterioration of the structure. While sweating may be a simple annoyance, it may
also be potentially dangerous. Either way, it is a symptom of a larger problem with the
HVAC system, the building construction, or both. Dripping moisture is annoying, but with
smooth flooring, it can create areas that are slipping hazards.
Over time, the accumulation of moisture will contribute to the rusting of the diffuser and
damage to the surrounding ceiling system.The sweating/condensing phenomenon
happens mostly in Asian, Southern states, Coast locations, or any other location where
high levels of humidity are a common occurrence. However, humidity is usually just a
contributing factor in sweating. Sweating is most common in locations where there is
significant traffic between the occupied air conditioned space and the outside
environment where hot and humid air is allowed to get into the air conditioned room. In
those situations, the air conditioning system runs for longer periods of time trying to
maintain a comfortable inside temperature, chilling the metal diffuser. Sweating happens
when the warm, moist room air contacts the chilled diffuser face while the supply air
temperature is below the dew point temperature. Since dew point temperature is the
temperature at which water vapor condenses into water, the result is sweating. The
problem is that the supply air temperature is lower than it should be for the current
conditions of temperature and humidity
Occupant comfort is also affected if condensation comes from high humidity. Humidity
greatly affects the comfort of building occupants, making it almost impossible to work or
relax. Ideally, the relative humidity should be maintained between 50% and 60%. as
suggested by ASHRAE.
Simple items to check that can contribute to sweating are:
Is the air conditioning unit cycling? If so, switch to a constant running option.
Are the returns undersized, restricting return airflow?
Are the filters dirty?
Are the coils on the VAV box dirty?

Since sweating happens when the difference between the room air and the supply airchilled diffuser face is below the dew point temperature, you can decrease the
difference between the room temperature and the supply air temperature (T). This can
be done by adjusting the thermostat to a higher temperature. But, doing this, while still
meeting the spaces load requirements, will also require an increase to the cfm into the
occupied space.
An easier method of preventing sweating is to install an insulation blanket on the back
side of the diffuser. This will insulate the diffuser face from the warmer air in the attic
space and prevent the face from collecting moisture, decreasing the T. With the
temperature differential minimized, sweating will decrease or be eliminated.
Duct approach can also contribute by following these steps.
1.
2.
3.
4.
5.
6.
7.
8.

Supply air to the remainder of the room to ensuring there are no stagnant areas
Locate the return duct where it will optimize the entire airflow pattern.
Prevent air short-circuiting by avoiding supply air diffusers near the return grille.
Properly positioned supply and return grilles and ducting controls the
majority of condensate problems
Insulate all the cold surfaces, including supply ducts, VAV terminals, and
diffusers. In addition, a properly sealed vapor retarder should be included on the
warm side of the insulation to prevent condensation within the insulation.
If possible, use an open ceiling plenum for return air. This results in a conditioned
plenum, which means a lower dew point and less risk of condensation.
During humid weather, maintain positive building pressurization to reduce or
eliminate the infiltration of humid outdoor air.
During startup, slowly ramp the SAT setpoint downward to slowly lower surface
temperatures while lowering the dew point inside the building.

Finally, the supply cold air approach. This will not be discussed since it is a system used
by thermal storage. Some have shown the advantage of system in relation to
condensation and humidity control.