HVAC In the Northeast w/ Leo & Paul Sharkey

Key takeaways

Engineers transitioning to HVAC can leverage their analytical skills for better systems integration and efficiency.
Conducting thorough Manual J calculations is critical, especially for older homes with unique heat load characteristics.
The challenges of HVAC in the Northeast require customized solutions, considering the extreme weather conditions and the variability of older buildings.
Backup heating systems are often necessary in cold climates due to the limitations of heat pumps.
Awareness and education about the implications of HVAC system design and distinguishing qualified contractors are essential for customers.

Summary

Transitioning from Engineering to HVAC

Leo and Paul Sharkey discuss their background as mechanical engineers transitioning to the HVAC field. Their experience in semiconductor engineering and management informs their approach to HVAC HVAC systems. They realized traditional sizing methods, like 'one ton per 400 square feet', were inadequate, particularly in older homes. They emphasize rigorous Manual J calculations, having completed thousands over five years, to ensure efficient system sizing.

Challenges of New England HVAC

Operating in the Northeast presents unique HVAC challenges, especially with older homes dating back to the 1600s and 1700s. The Sharkeys share the difficulties of extreme infiltration and non-linear heat loss characteristics typical of such structures. They explain the importance of understanding heat loads versus cooling loads and address issues like unequal heating in homes with mixed construction.

Heat Pumps in Cold Climates

Leo and Paul analyze the practicalities of heat pump installations amidst cold climate challenges. They discuss critical factors like turndown ratio and the necessity of backup heating systems for reliability. The conversation highlights common pitfalls, including issues with installation and the implications of cold-weather performance.

Ducted vs. Ductless Systems

The discussion contrasts ducted and ductless HVAC systems, analyzing both optimal uses and economic rationales depending on building layout and insulation. They elaborate on how their consulting approach aids in determining the best solution for clients given each unique situation.

Market Incentives and Quality Concerns

A significant topic is the impact of market incentive programs, particularly in Massachusetts, on the quality of installations in the HVAC industry. The Sharkeys express concerns about fly-by-night operators who prioritize rebate eligibility over fulfilling proper service quality and design standards.

Show notes

In this engaging episode of the HVAC School podcast, host Bryan Orr sits down with Leo and Paul Sharkey, a father-son duo of mechanical engineers who made the leap into the HVAC business. Leo and Paul share their remarkable journey of purchasing an HVAC company in September 2020 and quadrupling its revenue within five years. Their engineering backgrounds bring a refreshing, data-driven perspective to an industry that often relies on rules of thumb and outdated practices.

The Sharkeys operate in the challenging Northeast market, where homes can date back to the 1600s and 1700s. They discuss the eye-opening discovery that traditional HVAC sizing methods—like the simplistic "one ton per 400 square feet" rule—fail dramatically in older housing stock. Their commitment to running thousands of Manual J calculations has transformed their approach, often resulting in smaller, more efficient systems than competitors propose. The conversation dives deep into the unique challenges of working with centuries-old New England homes, including extreme infiltration rates, non-linear heat loss curves during harsh winters, and the complications of mixing modern additions with ancient construction.

Beyond sizing, Leo and Paul tackle the practical realities of heat pump installations in cold climates. They explain why turndown ratio is critical, how they handle homes with heat loads that triple their cooling loads, and when backup heating systems are truly necessary. Their consultative approach rejects the "one-size-fits-all" mentality that has flooded the market with incentive-chasing installations. They candidly discuss the problems created by Massachusetts' generous rebate programs, which have attracted fly-by-night operators who prioritize rebate qualifications over proper design and long-term performance.

The episode also explores the balance between ductless and ducted systems, revealing when each approach makes economic and technical sense. The Sharkeys share fascinating case studies, from a 1748 house with the equivalent of a full-size door's worth of air leakage to underground concrete dome homes requiring specialized dehumidification. Their willingness to take on complex projects that other contractors avoid demonstrates how engineering thinking, combined with trade expertise, can solve challenging HVAC problems. This conversation is essential listening for anyone serious about understanding cold climate HVAC design, building science principles, and what it takes to deliver quality comfort solutions in real-world conditions.

Topics Covered

Engineering background transition to HVAC - How mechanical engineering experience in semiconductors and manufacturing informed their HVAC business approach
Manual J calculations and proper sizing - Running 7,000-9,000 Manual J calculations over five years and why they typically specify smaller systems than competitors
Old New England housing challenges - Working with homes from the 1600s-1700s, extreme infiltration rates, and heat loss characteristics of ancient construction
Heat load vs. cooling load imbalances - Managing homes where heat loads can be triple the cooling loads and how this affects system design
Heat pump turndown ratios - Why equipment turndown capability is critical for shoulder seasons and preventing short cycling in cold climates
Cold weather performance and derating - Equipment capacity loss at low ambient temperatures and the importance of proper backup heat sizing
Ductless vs. ducted system economics - When to choose multi-zone ductless over ducted systems based on home layout, infrastructure, and cost
Retrofit complications in mixed construction - Dealing with homes that combine 200-year-old sections with modern additions on the same heating system
Massachusetts incentive programs - How Mass Save rebates (up to $25,000 financing + $10,000 rebates) have impacted market quality and contractor behavior
Installation challenges at low temperatures - Field issues including undersized ductwork, poor equipment placement, defrost cycle complications, and electric backup heat requirements
Building science fundamentals - Blower door testing, weatherization impacts, infiltration effects on heat load, and wind loading considerations
Consultative sales approach - Rejecting one-size-fits-all solutions and customizing system recommendations based on home characteristics and homeowner needs
Backup heating strategies - When and why fuel-based backup systems are necessary, including power outage considerations and client comfort levels
Complex project examples - Case studies including underground concrete dome homes, storage closet air handler installations, and severely under-designed retrofit corrections

Learn more about Leo and Paul's business, Jay Moody HVAC, at https://jaymoodyhvac.com/.

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