How to use this chart
Pick the friction rate your system is designed to, find your duct diameter in the left column, and read across. The CFM column is what that duct will carry at that friction rate; the velocity beside it is how fast the air is moving to do it, and the flag says whether that velocity is inside the limits ACCA publishes for residential duct.
One thing to settle before you read anything: 0.10 in. w.g. per 100 ft is a default, not a standard. It is the rate almost every published duct chart quietly assumes, and it is the rate this page prints, but Manual D calculates the friction rate for your system from its available static pressure and its total effective length. If your system's rate is 0.07, the 0.10 column is telling you about somebody else's house. Section 4 covers how to get your own number.
Duct CFM chart — round, flex and rectangular at 0.10 in. w.g. per 100 ft
| Duct diameter | Round CFM | Round fpm | Round vs limit | Flex CFM | Flex fpm | Flex vs limit |
|---|---|---|---|---|---|---|
| 4 in | 37 | 424 | OK | 31 | 357 | OK |
| 5 in | 68 | 497 | OK | 57 | 418 | OK |
| 6 in | 111 | 564 | OK | 93 | 474 | OK |
| 7 in | 168 | 628 | OK | 141 | 527 | OK |
| 8 in | 240 | 688 | OK | 201 | 577 | OK |
| 9 in | 329 | 745 | Over rec. | 276 | 625 | Over rec. |
| 10 in | 436 | 800 | Over rec. | 366 | 670 | Over rec. |
| 12 in | 709 | 903 | OVER MAX | 594 | 757 | OVER MAX |
| 14 in | 1,069 | 1,000 | OVER MAX | 895 | 837 | OVER MAX |
| 16 in | 1,525 | 1,092 | OVER MAX | 1,276 | 914 | OVER MAX |
| 18 in | 2,084 | 1,179 | OVER MAX | 1,744 | 987 | OVER MAX |
| 20 in | 2,755 | 1,263 | OVER MAX | 2,305 | 1,056 | OVER MAX |
The flex column is fully extended flex — pulled taut, supported, no sag. That is a laboratory condition, not an attic. Section 5 is what compression does to these numbers, and it is a bigger effect than everything else on this page combined.
The same chart at 0.05 and 0.08 in. w.g. per 100 ft
| Duct diameter | Round CFM @0.05 | fpm | vs limit | Flex CFM @0.05 | fpm | vs limit | Round CFM @0.08 | fpm | vs limit | Flex CFM @0.08 | fpm | vs limit |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 4 in | 25 | 287 | OK | 22 | 247 | OK | 33 | 374 | OK | 28 | 317 | OK |
| 5 in | 46 | 337 | OK | 40 | 290 | OK | 60 | 439 | OK | 51 | 372 | OK |
| 6 in | 75 | 384 | OK | 65 | 330 | OK | 98 | 499 | OK | 83 | 422 | OK |
| 7 in | 114 | 428 | OK | 98 | 367 | OK | 148 | 555 | OK | 125 | 469 | OK |
| 8 in | 164 | 469 | OK | 140 | 402 | OK | 212 | 608 | OK | 179 | 514 | OK |
| 9 in | 225 | 509 | OK | 192 | 436 | OK | 291 | 659 | OK | 246 | 556 | OK |
| 10 in | 298 | 547 | OK | 255 | 468 | OK | 386 | 708 | Over rec. | 326 | 597 | OK |
| 12 in | 486 | 619 | OK | 415 | 529 | OK | 629 | 800 | Over rec. | 530 | 674 | Over rec. |
| 14 in | 734 | 687 | OK | 626 | 586 | OK | 948 | 887 | Over rec. | 798 | 747 | OVER MAX |
| 16 in | 1,048 | 751 | Over rec. | 893 | 640 | Over rec. | 1,352 | 968 | OVER MAX | 1,138 | 815 | OVER MAX |
| 18 in | 1,434 | 812 | Over rec. | 1,222 | 691 | Over rec. | 1,849 | 1,046 | OVER MAX | 1,555 | 880 | OVER MAX |
| 20 in | 1,898 | 870 | Over rec. | 1,615 | 740 | OVER MAX | 2,445 | 1,121 | OVER MAX | 2,056 | 942 | OVER MAX |
Rectangular duct is keyed by its dimensions rather than a diameter, so it has its own table in section 6.
How the CFM in this chart is calculated
Duct friction is the Darcy–Weisbach equation. ASHRAE publishes it in the inch-pound form that returns inches of water directly, as Equation 19 of the “Duct Design” chapter of the ASHRAE Handbook–Fundamentals:
A friction rate is just this equation with L = 100. ASHRAE publishes no separate “per 100 ft” formula, which is worth knowing, because charts routinely quote a per-100-ft figure as though it came from a distinct constant somewhere.
The friction factor f here is the explicit Swamee–Jain approximation to Colebrook–White, which is the same correlation the duct size calculator and the duct sizing chart on this site already use, so all three pages agree with each other on the same physics. It was cross-run against an iterative Colebrook–White solution and against ASHRAE's own explicit Altshul–Tsal approximation (Equations 20 and 21 of the same chapter): the three agree within 0.8 % at every diameter and rate on this page, and Colebrook against Swamee–Jain within 0.35 %.
Standard air is ASHRAE's term for air weighing 0.075 lb/ft³, which approximates dry air at a temperature of 70 °F and a barometric pressure of 29.92 in. Hg
(ASHRAE Terminology). That is what the whole chart is drawn for.
Roughness — why the material changes the answer
Absolute roughness ε is the one input that separates a metal duct from a flex duct of the same size. ASHRAE's “Duct Design” Table 1 sorts duct materials into roughness categories:
| Category | ε, ft (mm) | Materials |
|---|---|---|
| Smooth | 0.0001 (0.03) | Uncoated carbon steel, clean; PVC plastic pipe; aluminum |
| Medium Smooth | 0.0003 (0.09) | Galvanized steel, longitudinal seams, 4 ft joints |
| Average | 0.0005 (0.15) | Galvanized steel, continuously rolled, spiral seams, 10 ft joints; spiral seam with 1–3 ribs |
| Medium Rough | 0.003 (0.9) | Fibrous glass duct, rigid; fibrous glass liner with facing material |
| Rough | 0.01 (3.0) | Fibrous glass liner, spray coated; flexible duct, metallic (0.004–0.007 ft fully extended); flexible duct, all types of fabric and wire (0.0035–0.015 ft fully extended); concrete |
ASHRAE's own friction chart is drawn at the Medium Smooth value: This chart is based on standard air flowing through round galvanized ducts with beaded slip couplings on 48 in. centers, equivalent to an absolute roughness of 0.0003 ft.
Notice the consequence — spiral-seam galvanized duct is an Average material, so it sits slightly outside the envelope the chart itself claims. Very few published duct charts make that distinction, or any distinction at all.
No corrections to Figure 9 are needed for (1) duct materials with a medium smooth roughness factor, (2) temperature variations in the order of ±30 °F from 70 °F, (3) elevations to 1500 ft, and (4) duct pressures from −20 in. of water to +20 in. of water relative to the ambient pressure.Outside those four conditions — a hot attic in Denver, say — the numbers need correcting, and this chart does not correct them for you.
The flex column on this page uses ε = 0.003 ft rather than Table 1's “Rough” 0.01 ft. That is a deliberate choice with a real conflict behind it, and section 5 states the conflict, marks the flex figures for verification, and prints the 0.01 ft alternative so you can see the size of the disagreement rather than taking our word for it.
Independent calibration
A published friction chart read-back gives a check that does not come from our own arithmetic. A PE continuing-education course from CED Engineering reads its friction chart as putting the intersection of the 0.1 in.-wc line and the 1,000 CFM line at a round duct diameter of 13.5 in. The model behind this page gives 13.65 in for the same point — +1.1 %, which is inside the precision of reading a value off a log-log chart at all.
Which friction rate should you use — 0.05, 0.08 or 0.10?
This is the part most duct charts skip, and skipping it is why their numbers disagree by more than half.
Manual D does not prescribe a friction rate. It calculates one. The friction rate is available static pressure divided by total effective length, times 100 — where available static pressure is the blower's total external static pressure less all the component pressure losses, and total effective length is the sum of the longest supply path and the longest return path. Two houses with the same equipment and different duct runs get different friction rates, and the same house gets a different rate when you add a better filter.
ACCA's own blog makes the point in its title: Calculating Friction Rate — It's Not a Constant. It observes that designers usually assume
0.1 iwc/100′, and argues against doing that. A widely cited worked example elsewhere puts it bluntly: if the calculated rate comes out just over 0.07 and you use 0.1 instead, your ducts come out undersized.
So what are the three rates on this page?
- 0.05 — supply trunk or plenum. Component guidance, not a whole-system rate.
- 0.08 — supply run-outs. Same source, same status. (The matching return-duct guidance in that source is 0.02.)
- 0.10 — the traditional single-rate default. Described in the PE course literature as
a very common friction rate for a reasonably well designed system
, and by ACCA as the number people assume when they have not calculated one.
On Manual D's own permitted band the sources disagree and we are not going to pretend otherwise. The lower bound is unanimously 0.06. The upper bound is cited as 0.18 by an ACCA-attributed brochure and two independent write-ups, and as 0.16 by a third. Manual D itself is paywalled; three-to-one favours 0.18, and if your calculated rate lands near either end, that is the point to check a licensed copy rather than a web page.
Flex duct: why it carries less air, and what compression costs you
Two separate penalties sit on flex duct, they come from different places, and a chart that mixes them will be wrong in both directions. This page keeps them apart.
Penalty one: roughness, both ducts taut
At ε = 0.003 ft, fully extended flex carries 84–86 % of the CFM of galvanized steel at the same diameter and the same friction rate. That ratio is essentially flat from 4 in to 20 in, which makes the rule of thumb reliable: taut flex carries roughly one sixth less air than metal of the same size, so going up one nominal size gets it back. At ASHRAE Table 1's “Rough” value of 0.01 ft the ratio falls to 70–73 %.
the maximum stretch case and rigid duct showed agreement within 2%— that is, taut flex measured almost as smooth as metal. Our 0.003 ft sits between that finding and Table 1, and matches the value already used across this site's duct pages. It is a judgement, not a standard, and it is the one number here most likely to move against a licensed ASHRAE copy. The table below shows what the conservative Table 1 reading would give instead.
| Duct diameter | CFM @0.05 | fpm | CFM @0.08 | fpm | CFM @0.10 | fpm |
|---|---|---|---|---|---|---|
| 4 in | 18 | 207 | 23 | 264 | 26 | 296 |
| 5 in | 33 | 244 | 42 | 310 | 47 | 348 |
| 6 in | 55 | 278 | 69 | 354 | 78 | 396 |
| 7 in | 83 | 310 | 105 | 394 | 118 | 442 |
| 8 in | 119 | 340 | 151 | 433 | 169 | 485 |
| 9 in | 163 | 370 | 208 | 470 | 232 | 526 |
| 10 in | 217 | 398 | 276 | 505 | 309 | 566 |
| 12 in | 354 | 451 | 449 | 572 | 503 | 641 |
| 14 in | 535 | 500 | 679 | 635 | 760 | 711 |
| 16 in | 765 | 548 | 970 | 695 | 1,086 | 778 |
| 18 in | 1,047 | 593 | 1,329 | 752 | 1,488 | 842 |
| 20 in | 1,387 | 636 | 1,760 | 807 | 1,970 | 903 |
And the honest framing, because the laboratory result is easy to misread: fully extended, board-supported flex is a laboratory condition. The Air Diffusion Council's installation standard exists precisely because field flex is not that. Taut flex measures nearly as smooth as metal in a lab; the chart derates it because installed flex is not taut — and the next section is what that actually costs.
Penalty two: compression, and the disagreement that matters
ADC publishes a friction-rate multiplier for longitudinal compression, and it is the number a contractor can cite in a submittal:
Install ducts fully extended. Do not install in the compressed state or use excess length as this will noticeably increase friction losses.
When a flexible duct is fully extended, it is said to have no more than 4% longitudinal compression and the published friction rate may be used for duct sizing calculations (0 - 4% = 1 x Friction Rate).
For 15% longitudinal compression the friction rate can increase by a factor of two (15% = 2 x Friction Rate).ADC, Flexible Duct Performance & Installation Standards, 5th Edition
For longitudinal compression of 30% the friction rate can increase as much as four times (30% = 4 x Friction Rate).
Lawrence Berkeley National Laboratory measured the same thing and got a much larger number. Its published finding is that moderate compression in flexible ducts, typical of that often seen in field installations, could increase the pressure drop by a factor of four, while further compression could increase the pressure drop by factors close to ten
— with around 15 % described as the moderate field case and around 30 % as the extreme case, the same two compression levels ADC uses. A separate laboratory programme at Texas A&M, run to the ASHRAE Standard 120 test method, reported the same direction: some configurations show over ten times the pressure loss found in rigid ducts or fully stretched flexible ducts of the same diameter
, and that the existing published design data does not include pressure loss data for flexible ducts that are compressed beyond approximately 4%
.
Turning a friction multiplier into a capacity loss needs the exponent linking pressure drop to flow. It is not 2. Measured off this page's own flex model at 0.08 in./100 ft it runs from about 1.89 at 4 in to about 1.95 at 20 in, so the table below uses n = 1.90 and derates CFM by the friction multiplier raised to −1/1.90.
| Longitudinal compression | ADC friction multiplier | CFM derate (ADC) | LBNL PDCF, 6 in | CFM derate (LBNL, 6 in) |
|---|---|---|---|---|
| 0–4 % (“fully extended”) | 1× | 1.00 | 2.01× | 0.69 |
| 15 % (“typical field install”) | 2× | 0.69 | 4.80× | 0.44 |
| 30 % (“extreme”) | 4× | 0.48 | 8.61× | 0.32 |
Note also that LBNL's own 6 in model returns a pressure-drop factor of 2.01 at just 4 % compression — directly contradicting ADC's “0 − 4 % = 1 × friction rate” at exactly the small end where residential branch runs live.
Fittings: what a bend costs in flex
Compression is not the only thing that eats a flex run's budget. From the same ADC standard, expressed as equivalent length of straight duct:
- A 90-degree bend ≈ 20 lineal feet of flexible duct.
- A gradual 45-degree bend ≈ 10 lineal feet.
- A 180-degree offset ≈ 40 lineal feet.
- Support spacing must hold maximum centreline sag to ½ in per foot of spacing between supports — sag is compression by another name.
A 25 ft flex run with two 90-degree bends is, for pressure purposes, closer to 65 ft. That is why the calculated friction rate in section 4 uses total effective length rather than tape-measure length.
Rectangular duct and equivalent diameter
A rectangular duct is matched to a round one by Huebscher's equivalent diameter, published as Equation 25 of the ASHRAE “Duct Design” chapter, with a and b in inches:
ASHRAE gives the provenance in its own words: Huebscher (1948) developed the relationship between rectangular and round ducts that is used to determine size equivalency based on equal flow, resistance, and length.
The primary is R. G. Huebscher, Friction equivalents for round, square and rectangular ducts, ASHVE Transactions 54, pp. 101–118 (1948).
| Rectangular size | Aspect | De (in) | CFM @0.05 | fpm | CFM @0.08 | fpm | CFM @0.10 | fpm | vs limit @0.10 |
|---|---|---|---|---|---|---|---|---|---|
| 3.25 × 10 in | 3.08:1 | 6.00 | 75 | 334 | 98 | 434 | 111 | 492 | OK |
| 3.25 × 12 in | 3.69:1 | 6.49 | 93 | 345 | 121 | 448 | 137 | 506 | OK |
| 3.25 × 14 in † | 4.31:1 | 6.93 | 111 | 353 | 145 | 458 | 164 | 518 | OK |
| 6 × 6 in | 1.00:1 | 6.56 | 96 | 384 | 125 | 498 | 141 | 563 | OK |
| 8 × 6 in | 1.33:1 | 7.55 | 140 | 421 | 182 | 546 | 206 | 618 | OK |
| 10 × 6 in | 1.67:1 | 8.40 | 187 | 448 | 242 | 581 | 274 | 657 | OK |
| 12 × 6 in | 2.00:1 | 9.14 | 234 | 469 | 304 | 607 | 343 | 686 | OK |
| 14 × 6 in | 2.33:1 | 9.80 | 283 | 485 | 366 | 628 | 414 | 709 | Over rec. |
| 8 × 8 in | 1.00:1 | 8.75 | 208 | 468 | 270 | 607 | 305 | 686 | OK |
| 10 × 8 in | 1.25:1 | 9.76 | 280 | 504 | 362 | 652 | 409 | 736 | Over rec. |
| 12 × 8 in | 1.50:1 | 10.66 | 354 | 531 | 458 | 687 | 517 | 775 | Over rec. |
| 14 × 8 in | 1.75:1 | 11.46 | 430 | 553 | 556 | 714 | 627 | 806 | Over rec. |
| 16 × 8 in | 2.00:1 | 12.19 | 507 | 570 | 655 | 737 | 739 | 832 | Over rec. |
| 18 × 8 in | 2.25:1 | 12.86 | 585 | 585 | 756 | 756 | 853 | 853 | Over rec. |
| 20 × 8 in | 2.50:1 | 13.48 | 664 | 597 | 857 | 771 | 967 | 870 | Over rec. |
| 22 × 8 in | 2.75:1 | 14.06 | 743 | 608 | 959 | 785 | 1,082 | 886 | Over rec. |
| 24 × 8 in | 3.00:1 | 14.61 | 823 | 617 | 1,062 | 797 | 1,198 | 899 | Over rec. |
| 10 × 10 in | 1.00:1 | 10.93 | 379 | 546 | 490 | 706 | 553 | 797 | Over rec. |
| 12 × 10 in | 1.20:1 | 11.96 | 482 | 579 | 623 | 748 | 704 | 844 | Over rec. |
| 14 × 10 in | 1.40:1 | 12.89 | 589 | 606 | 761 | 782 | 858 | 883 | Over rec. |
| 16 × 10 in | 1.60:1 | 13.73 | 697 | 628 | 901 | 810 | 1,016 | 914 | OVER MAX |
| 20 × 10 in | 2.00:1 | 15.23 | 920 | 662 | 1,187 | 854 | 1,339 | 964 | OVER MAX |
| 12 × 12 in | 1.00:1 | 13.12 | 617 | 617 | 797 | 797 | 899 | 899 | Over rec. |
| 16 × 12 in | 1.33:1 | 15.11 | 900 | 675 | 1,161 | 871 | 1,309 | 982 | OVER MAX |
| 20 × 12 in | 1.67:1 | 16.80 | 1,194 | 716 | 1,539 | 923 | 1,735 | 1,041 | OVER MAX |
| 24 × 12 in | 2.00:1 | 18.28 | 1,494 | 747 | 1,926 | 963 | 2,171 | 1,086 | OVER MAX |
† Aspect-ratio validity. ASHRAE publishes no algebraic aspect-ratio limit on Equation 25; it shades a “not recommended” region in its circular-equivalents table, which is a buildability constraint rather than a validity one. The only quantified accuracy statement we could source is from a peer-reviewed conference paper by Hassan (AIVC 2002), reporting a study by Zou (2001): for normal ventilation duct aspect ratios, a/b < 4, the deviations are always less than 1%
for Reynolds numbers between 4,000 and 10⁷. Every row in the table at or below 4:1 is therefore good to about 1 %. The 3.25 × 14 in row is 4.31:1 and sits above that band; it is marked, and its figures should be treated as slightly less certain than the rest.
Velocity limits — when a duct is big enough but too loud
A duct that satisfies the friction rate can still be the wrong duct, because velocity is what you hear. ACCA publishes velocity limits in Manual D Table 3-1; the values below are that table as reproduced by ACCA in its own Table of Useful Air Distribution System Design Information.
| Duct | Supply rec. rigid | Supply rec. flex | Supply max rigid | Supply max flex | Return rec. rigid | Return rec. flex | Return max rigid | Return max flex |
|---|---|---|---|---|---|---|---|---|
| Trunk ducts | 700 | 600 | 900 | 700 | 600 | 600 | 700 | 700 |
| Branch ducts | 600 | 600 | 900 | 700 | 400 | 400 | 700 | 700 |
| Where | Face velocity (fpm) |
|---|---|
| Supply outlet, sized for throw | 700 |
| Return grille | 500 |
| Filter grille | 300 |
Three things in that table contradict what most people assume, and all three are useful:
- Return branch recommended velocity is 400 fpm, not 600. This is probably the most commonly mis-stated number in residential duct design.
- Filter grille face velocity is 300 fpm. That single number is why return filter grilles have to be physically enormous: 1,200 CFM through a filter grille needs four square feet of free area.
- Flex maximum caps at 700 fpm everywhere — supply and return, trunk and branch.
This is not a defect in the physics, and it does not mean the CFM figures are wrong. It means the equal-friction method and the velocity ceiling are two separate constraints, and on large duct at a high friction rate they stop agreeing. A chart that prints the CFM and hides the velocity is showing you a duct that satisfies one constraint and quietly fails the other.
On noise, and what we are not going to claim
There is no authoritative published “above X fpm a duct gets noisy in a house” figure that we could source. The industry encodes the noise limit implicitly, as Manual D's Maximum column. A secondary summary of a paywalled ASHRAE applications chapter does circulate with specific velocity thresholds attached; we are not printing those, because the attribution could not be verified against the standard itself. What is worth carrying is the caveat, which is both citable and true:
PDHonline Course M246, HVAC Ducting: Principles and Fundamentals
Velocity limits are commonly used as a surrogate for limiting duct breakout noise. Many argue it is a poor indicator since noise is more likely to result from turbulence than velocity.
Which matches what people actually experience: a straight run at 900 fpm is often quieter than a sharply turned one at 600.
Why published duct CFM charts disagree
Before you take any duct CFM chart at face value — this one included — it is worth knowing how far apart the published ones are. We transcribed the 10 in round rigid figure from the six duct CFM chart pages that currently rank for these queries, along with whatever basis each one states for its numbers. They are anonymised here because the point is the pattern, not the pages.
| Chart | Basis stated on the page | 10 in round, as published |
|---|---|---|
| Chart A | None stated | 270 CFM |
| Chart B | None stated | 300 CFM (flex table) / 325 CFM (metal table) |
| Chart C | Column headings name a friction-loss figure; no units given, never “per 100 ft” | 300 CFM (lower column) / 420 CFM (0.1 column) |
| Chart D | 700 fpm target velocity; no friction rate at all | 350 CFM |
| Chart E | 0.1 in. w.c. per 100 ft, single straight run, no fittings | 360 CFM |
| Chart F | 0.1 in. w.c. per 100 ft | 300 CFM (one table) / 400 CFM (a second table on the same page) |
| This page | 0.10 in. w.g. per 100 ft; round galvanized, ε = 0.0003 ft; standard air ρ = 0.075 lb/ft³; Darcy–Weisbach with a Swamee–Jain friction factor; velocity 800 fpm, flagged over ACCA recommended | 436 CFM |
The published spread for one ordinary duct size is 270 to 420 CFM — a factor of 1.56. At 20 in the published spread runs from about 1,620 to 2,600 CFM, with three separate pages printing exactly 2,000 while citing three different bases or none. Specific defects in that set, without naming anyone:
- Two of the six state no basis whatever — no friction rate, no velocity, no material, nothing. One of those two is the top-ranking page for the query.
- One contradicts itself on the same page at the same stated rate: its by-diameter table and its quick-reference table give different capacities for a 10 in duct, both labelled 0.1 in./100 ft.
- One publishes a non-monotonic set — its prose rates a 12 in duct below its own 10 in table entry, and its prose and its table disagree about the 8 in figure as well. Its table has three rows in total.
- One is velocity-based, not friction-based. Constant-velocity capacity scales as d²; equal-friction capacity scales as roughly d^2.5. Its numbers are structurally non-comparable to the rest of the set and only converge with them by coincidence near 8–10 in.
- Two of the six give a friction rate with units, properly. Those two are the only ones in the set whose numbers can be checked at all.
Duct CFM chart FAQ
How many CFM in a 6 inch duct?
About 111 CFM in round galvanized steel at a friction rate of 0.10 in. w.g. per 100 ft, at 564 fpm. At 0.08 it is 98 CFM and at 0.05 it is 75 CFM. In fully extended flex the same 6 in duct carries 93 CFM at 0.10. Compressed flex carries far less — at the 15 % compression both ADC and the laboratory literature call a typical field install, that 93 CFM falls to roughly 64 CFM on the trade standard's multiplier, or roughly 41 CFM on the laboratory model.
How many CFM can 8 inch flex duct handle?
About 201 CFM fully extended at 0.10 in. w.g. per 100 ft, at 577 fpm — which is inside ACCA's 600 fpm recommended velocity for flex, so 8 in flex at that rate is a clean size. At 0.08 it is 179 CFM and at 0.05 it is 140 CFM. All three assume the run is pulled taut and supported; the word “handle” does a lot of work in this question, and compression is what usually decides the real answer.
Is flex duct the same as metal duct of the same size?
No. At the same diameter and the same friction rate, fully extended flex carries 84–86 % of the airflow of galvanized steel, and that ratio holds flat from 4 in to 20 in, so in practice flex needs to go up one nominal size to match metal. That is the taut comparison. Installed flex that is compressed 15 % carries between 69 % and 44 % of its own taut rating depending on whose data you use, which is a much bigger penalty than the roughness difference.
What friction rate should I use?
The one your system calculates, which is available static pressure divided by total effective length, times 100. If you have not calculated it, 0.10 in. w.g. per 100 ft is the traditional default and the rate this chart prints, 0.08 is common guidance for supply run-outs and 0.05 for supply trunks. Manual D's own permitted band starts at 0.06 and is commonly cited as reaching 0.18, with one source saying 0.16. None of these is an industry standard rate, whatever other charts call them — and assuming 0.10 when your system actually calculates to 0.07 will undersize the duct.
How many CFM per ton of cooling?
The usual residential design figure is 400 CFM per ton, which puts a 3-ton system at about 1,200 CFM of total supply air. That is an airflow target, not a duct size: 1,200 CFM through a single trunk at 0.10 in./100 ft needs something between a 14 and 16 in round duct, and at 16 in it would be running at 1,092 fpm, well over ACCA's 900 fpm maximum. That is exactly the case for splitting into trunks rather than sizing one large duct. To go the other direction — airflow to size — use the duct sizing chart.
Why is my duct big enough but still noisy?
Because friction rate and velocity are two different constraints and they stop agreeing on large duct. At 0.10 in. w.g. per 100 ft, round duct from 12 in up exceeds ACCA's 900 fpm maximum velocity while still satisfying the friction rate perfectly — a 20 in duct at that rate runs at 1,263 fpm. Flex is over its own 700 fpm ceiling from 12 in up. Velocity is also only a proxy for noise: turbulence from a sharp turn, a crushed takeoff or a boot too close to the register generates more noise than the same air moving straight, which is why a duct that reads fine on a chart can still whistle.
Does this chart work for rectangular duct?
Yes — the rectangular table gives 26 common sizes from 3.25 × 10 to 24 × 12 in at all three friction rates. Each is matched to a round duct by Huebscher equivalent diameter, which means equal friction and equal flow, not equal area. The velocity shown is calculated on the actual rectangular free area, which is the number that exists in your duct; charts that print the round-equivalent velocity instead are printing a number that is not happening anywhere.
Can I trust these numbers for a real design?
They are computed, stated and checkable, which is more than most published charts offer — every equation, constant and roughness value is named above, and the model reproduces an independently published friction-chart read-back to +1.1 %. Two groups of numbers here are explicitly marked verify against standard: the flex roughness value, and the Manual D velocity limits, both of which sit behind paywalled standards we do not hold a licensed copy of. For anything stamped, permitted or paid for, this chart is a sanity check and the licensed standard is the authority.
Sources
- ASHRAE Handbook–Fundamentals, “Duct Design” chapter — Equations 19 (Darcy–Weisbach, I-P form), 20 (Colebrook–White), 21 (Altshul–Tsal) and 25 (Huebscher equivalent diameter); Table 1, Duct Roughness Factors; the validity note at Figure 9.
- ASHRAE Terminology, “standard air” — the 0.075 lb/ft³ definition used for every value here.
- ACCA, Calculating Friction Rate — It's Not a Constant — the friction-rate formula and the argument against assuming 0.1.
- ACCA, Table of Useful Air Distribution System Design Information — Manual D Table 3-1 velocity limits and face velocities, as reproduced by ACCA.
- Air Diffusion Council, Flexible Duct Performance & Installation Standards, 5th Edition — compression friction multipliers, bend equivalent lengths, sag limit.
- Abushakra, Walker & Sherman (Lawrence Berkeley National Laboratory), Compression Effects on Pressure Loss in Flexible HVAC Ducts — the PDCF models and the factor-of-four / factor-of-ten finding.
- Weaver & Culp (Texas A&M Energy Systems Laboratory), Static Pressure Losses in 6, 8, and 10-inch Non-Metallic Flexible Ducts — ASHRAE Standard 120 test method; taut flex within 2 % of rigid; compressed configurations over ten times the loss.
- CED Engineering PE course M06-032, HVAC: How to Size and Design Ducts — standard air density, the friction-chart read-back used for calibration, and the 0.05 / 0.08 / 0.02 component guidance.
- Hassan, AIVC 2002 conference paper — Huebscher (1948) provenance and the Zou (2001) aspect-ratio accuracy statement.
- PDHonline Course M246, HVAC Ducting: Principles and Fundamentals — the velocity-as-noise-surrogate caveat.
- McGill AirFlow, Duct System Design Guide, Ch. 2 — the practical friction-loss band for equal-friction design.
ASHRAE Handbook–Fundamentals Chapter 21 and ACCA Manual D are both paywalled. Every ASHRAE and Manual D figure quoted above comes from a university-hosted chapter copy, a national-laboratory document, ACCA's own blog and brochure, or peer-reviewed papers. Before this page is treated as authoritative, both should be checked against licensed copies.