I teach the following HVAC principle in every class: “Air follows the path of least resistance.” That means if you force it through a high-pressure filter or a narrow return, it will find a new path, usually one that bypasses the very components intended to clean and condition it. The result? Dirty coils, unhappy customers, and systems that under perform from day one.
The Numbers Don’t Lie
Here are some sobering statistics: National Comfort Institute (NCI) discovered that 57% performance is the norm for residential HVAC systems. That means homeowners are getting just over half the heating or cooling they paid for.
Why? Think about this: 42 states adopted codes equivalent to IECC from 2009 to 2018. Twenty-nine states require contractors to use Manual J to size equipment. Yet, only around five percent of HVAC contractors use Manual J. The rest are guessing — or worse, copying what the last guy did.
Builders ask, “How much per ton?” Contractors respond by cranking up the tonnage to make the job profitable.
The result is that most air conditioning systems are 50% oversized and still uncomfortable. It’s a vicious cycle. That is NOT High-Performance HVAC!
Add to that the reality that the median home in America was built in 1984. That means half the housing stock is outdated by energy code standards. And while homes have become tighter and more efficient, HVAC sizing practices haven’t kept up. We’re still applying 1970s rules of thumb to 21st-century homes.
Guessing Isn’t Good Enough Anymore
To quote Henry Ford, “If you think you can, or you think you can’t, you’re right.” Ford’s truism is also valid in the HVAC Industry.
Our training says that some problems are “the way things are.” But they’re not. They’re solvable. You need to learn how.
Years ago, when I was working with Austin Energy, a Texas utility, we did everything by the book. That means we performed Manual J calculations, duct sealing, the whole program.
When I measured performance, we hit 62%. That was with everything done “right.” Imagine what the rest of the industry was and still is delivering.
That’s when I challenged their staff to come out and measure with me. I wanted them to see that following the rules still doesn’t guarantee good performance. You need to exceed them. This means you need to think like a craftsman.
You Can’t Teach What You Don’t Know
I often say that success is a byproduct of craftsmanship. You don’t chase it, you become it. And once you know the truth, you begin to understand the confusion.
I remember reading an article in a trade magazine — back when I was in the weeds trying to sort through bad information from professors who had never touched a furnace.
The article had math that actually worked. That blew me away. I called the magazine, talked to Dominick Guarino, and found someone who could answer my questions. That was my turning point.
You can’t teach what you don’t know. And you won’t learn it unless you admit you need to. That’s why real High-Performance HVAC craftsmanship begins with humility. The most competent techs I know are the ones who admit they’re always learning.
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