Air leakage testing is becoming a standard requirement across Saudi Arabia as energy codes tighten and sustainability targets move closer to Vision 2030 and Net-Zero 2060. Yet, a large number of residential, commercial, and institutional buildings still fail air leakage tests on their first attempt. This failure is rarely caused by one single issue. Instead, it is usually the result of design gaps, construction practices, and late-stage testing without corrective planning.
This article explains why most Saudi buildings fail air leakage testing and outlines practical, proven ways to fix these issues and achieve compliant, high-performing buildings.
Why Air Leakage Testing Is Becoming Critical in Saudi Arabia
Saudi Arabia’s climate places extreme pressure on buildings. High outdoor temperatures, long cooling seasons, and heavy reliance on HVAC systems mean that uncontrolled air leakage directly translates into higher energy use and operating costs.
Air leakage testing is now essential because it:
Verifies real building performance, not design assumptions
Supports compliance with SBC 601 and SBC 602
Reduces cooling loads and HVAC oversizing
Improves indoor air quality and pressure control
Forms the foundation of Net-Zero-ready buildings
Despite this, many projects still underestimate airtightness until it is too late.
The Most Common Reasons Saudi Buildings Fail Air Leakage Tests
Airtightness Is Addressed Too Late
One of the biggest reasons for failure is timing. Airtightness is often treated as a finishing task rather than a core design requirement. By the time testing is conducted, walls are closed, finishes are installed, and access to leakage paths is limited.
At this stage, fixing leaks becomes expensive, disruptive, and sometimes incomplete.
Poor Coordination Between Trades
Air leakage frequently occurs at interfaces between systems. These include wall-to-roof junctions, façade connections, and service penetrations.
When architects, HVAC contractors, electricians, and plumbers work in isolation, gaps are left behind. Each trade completes its scope, but no one takes responsibility for sealing the complete building envelope.
Unsealed or Poorly Sealed HVAC Ductwork
In many Saudi buildings, duct leakage alone can reach 20 to 40 percent. Energy models often assume low duct leakage, but real-world installations rarely match these assumptions.
Unsealed ducts cause buildings to fail duct leakage testing and increase overall air leakage results, even if the envelope is partially sealed.
Overreliance on Visual Inspection
Many projects rely on visual checks instead of measured testing. Leaks hidden behind walls, above ceilings, or inside shafts remain undetected until blower door or duct leakage tests are performed.
By then, failures are already built into the structure.
Complex Building Designs Without Airtightness Strategy
Modern Saudi buildings often feature large glass façades, complex roof geometries, service risers, and mixed-use layouts. Without a clear airtightness strategy, these designs introduce hundreds of potential leakage points.
Complex buildings require planned airtight layers, not improvised sealing.
How Air Leakage Failures Impact Building Performance
Failing air leakage tests is not just a compliance issue. It directly affects building operation.
Buildings with high leakage experience:
Higher cooling loads and electricity bills
Uneven indoor temperatures and comfort complaints
Poor pressure balance across floors and zones
Increased humidity and mold risk, especially in coastal cities
Shortened HVAC equipment lifespan
These issues persist for the life of the building if not corrected early.
How to Fix Air Leakage Issues Effectively
Start Airtightness Planning at the Design Stage
The most successful projects treat airtightness as a design requirement, not a construction afterthought.
This includes:
Defining a continuous airtight layer in drawings
Detailing sealing requirements at all interfaces
Assigning responsibility for airtightness execution
Including airtightness targets in specifications
Early planning dramatically improves test outcomes.
Conduct Mid-Construction Air Leakage Testing
Waiting until project completion often guarantees failure. Mid-construction blower door testing allows teams to identify and fix major leaks while access is still available.
This approach:
Reduces rework costs
Improves final test results
Keeps projects on schedule
Prevents last-minute compliance risks
Seal HVAC Ductwork as a Priority
Duct sealing delivers fast and measurable improvements. Properly sealed ducts:
Reduce HVAC energy losses
Improve airflow delivery
Support airflow balancing
Lower overall building leakage
Advanced internal duct sealing technologies can seal leaks that are inaccessible using traditional methods, making them ideal for large or occupied buildings.
Use Advanced Envelope Sealing Solutions
Manual sealing methods often miss hidden leakage paths. Advanced envelope sealing solutions use controlled pressure to identify and seal leaks throughout the building.
These systems:
Seal gaps as small as a human hair
Work across complex geometries
Deliver predictable airtightness results
Support re-testing and verification
They are especially effective for retrofits and high-performance projects.
Verify Results with Post-Sealing Testing
Fixes are only successful if they are verified. Re-testing after sealing confirms:
Actual reduction in air leakage
Compliance with SBC requirements
Improved HVAC efficiency
Documented performance improvements
This data is essential for handover, certification, and long-term facility management.
Why Airtightness Is Essential for Net-Zero Buildings
Many Saudi Net-Zero projects fail to meet performance targets because airtightness is underestimated. Renewable energy systems, high-efficiency chillers, and smart controls cannot compensate for uncontrolled air leakage.
Without airtightness:
Cooling loads exceed design values
Renewable systems underperform
Operational costs rise
Sustainability targets are missed
Airtightness is the foundation on which all other efficiency measures depend.
Conclusion
Most Saudi buildings fail air leakage testing not because the goal is unachievable, but because airtightness is addressed too late, poorly coordinated, or inadequately verified. The good news is that these failures are entirely preventable.
By integrating airtightness planning early, sealing ductwork properly, using advanced envelope sealing solutions, and verifying results through testing, buildings can pass air leakage tests with confidence.
In Saudi Arabia’s climate and regulatory environment, airtightness is no longer optional. It is a measurable, fixable, and essential requirement for energy-efficient, compliant, and Net-Zero-ready buildings.
