How to size ducts
Sizing & LoadCFM per ton, friction rate, and the duct calculator method step by step.
10 min
A CFM per ton calculator in two modes: the airflow a cooling system should move for its tonnage and climate, and the airflow a furnace is actually moving, worked out from the temperature rise across it.
Mode: Cooling target
Pre-filled with a 3-ton system in a dry climate and 1,100 CFM read off a flow hood or the blower table.
1 ton = 12,000 BTU/h.
Airflow per ton
3.0 tons at 400 CFM/ton is 1,200 CFM. Measured 1,100 CFM is 367 CFM/ton: inside the cooling band.
CFM per ton is blower airflow divided by cooling capacity, with a ton being 12,000 BTU/h. The site works to 350 to 400 CFM per ton: 400 in a dry climate, 350 where latent load matters and you want the coil colder so it pulls more water out of the air. A three-ton system at 400 moves 1,200 CFM. The duct sizing guide starts from the same number.
The rule of thumb is a starting point, not the design. On a certified house the design fan airflow is taken from the manufacturer's expanded performance data and written down separately for cooling and heating, and a third-party rater can grade the airflow actually delivered.
Sources: EPA ENERGY STAR, National HVAC Design Report v3.1/3.2/3.3 (Rev. 14), Item 5.2 and Footnote 34 (read 2026-10-18) · EPA ENERGY STAR, National Rater Field Checklist v3.1/3.2/3.3 (Rev. 14), Item 5a.1 (read 2026-10-18)
A furnace puts a known output into the air, so the temperature rise across it tells you how much air there was. The sensible heat equation does it: CFM = BTU/h ÷ (1.08 × ΔT). The 1.08 is standard air folded into one constant: 0.075 lb per cubic foot, times 60 minutes, times a specific heat of 0.24 BTU per pound per °F.
| Rise | Airflow | Per ton, 3-ton coil |
|---|---|---|
| 45 °F | 1,580 CFM | 527 CFM/ton |
| 55 °F | 1,290 CFM | 431 CFM/ton |
| 65 °F | 1,090 CFM | 365 CFM/ton |
Use output, not input: an 80,000 BTU/h input furnace at 96% AFUE puts 76,800 BTU/h into the air. The rise has to land inside the range on the furnace's rating plate. A rise above the range means too little air across the heat exchanger; a rise below it means too much air, or a burner firing short of its rating. The furnace sizing guide walks the same check from the sizing side.
Safety — High rise, repeated limit trips
A furnace that keeps running above its plate rise is overheating its heat exchanger, and the high limit is what stops it. Fix the airflow before it runs another cycle. Anything involving the burner, the gas valve or a suspected crack in the exchanger is a job for a licensed technician.
Low CFM per ton is almost never the blower's fault. It is a loaded filter, a dirty coil, an undersized return or flex duct that was never pulled tight, and each of those shows up as high static pressure. Measure it with the static pressure calculator and read the static pressure guide for what each component should cost. The total has to sit below the limit of the equipment, so turning the blower up to hide a restriction only trades one fault for another. On the cooling side, low airflow drops the coil temperature until it freezes, which is a branch of the AC not cooling decision list.
Sources: DOE Building America Solution Center, Air Conditioning (read 2026-09-04) · EPA ENERGY STAR, National HVAC Design Report v3.1/3.2/3.3 (Rev. 14, revised 2025-01-15), Item 5.4 and Footnote 36 (read 2026-09-04)
The CFM-per-ton total is the trunk. Split it room by room in proportion to each room's share of the cooling load, not its floor area; the Manual J load worksheet gives those shares. Then size each branch for its share. The federal design checklist names ACCA Manual D for that step, with the duct system designed for the equipment actually selected.
Sources: EPA ENERGY STAR, National HVAC Design Report v3.1/3.2/3.3 (Rev. 14, revised 2025-01-15), Item 5.1 (read 2026-09-04)
CFM per ton, friction rate, and the duct calculator method step by step.
10 min
Total external static pressure from supply and return readings, against the rated maximum.
in. w.c. · TESP
Round and rectangular duct sizes from CFM and friction rate, with equivalent diameter.
CFM · in. w.c./100 ft
Friction, bends, support spacing, sag and leakage, and where each belongs.
in sag · ft span
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