How Aeroseal Works

Time-lapse of sealant collecting in gaps and cracks

What is Aeroseal Duct Sealing?

Aeroseal duct sealing is an automated technology for sealing leaks in ductwork in both residential and commercial buildings. Using a patented, non-toxic aerosol sealant, the process pressurizes duct systems, driving sealant particles directly to leaks to seal them from the inside without coating the entire duct.

Our advanced formula is very low tack, ensuring it only deposits where needed and maintains duct integrity.

Monitored in real-time for coverage and effectiveness, this technology improves HVAC efficiency, air quality, and comfort. Suitable for both new constructions and retrofits, it precisely meets any duct sealing requirement.

See how Aeroseal Works:

Aerosealing the ductwork not only solved our critical ventilation issue, but it allowed us to lower fan speeds while increasing HVAC efficiency. There is no doubt that the duct sealing process had a significant impact on reducing energy usage and saving the county money.

Jeff Hatton, Energy Management,
Montgomery County Government, Miami Valley Autopsy Lab.

The Process

Step 1: Prep up the ductwork

All registers are blocked or taped to pressurize the ductwork. Vital components, such as furnaces, coils, smoke detectors, and other sensors, are protected to prevent contact with the sealant. The supply and return duct systems are typically sealed separately.

Step 2: Connect the Aeroseal Equipment

The Aeroseal equipment is connected to the duct system through plastic lay-flat tubing, either via an existing register or an access hole in the ductwork. A pretest is conducted to measure initial leakage, like a Duct Blaster test. These results are used in the post-seal report to verify the seal's effectiveness and estimate the time required for sealing.

Step 3: Seal the Ductwork

The equipment now begins spraying sealant directly into the duct system. Our non-toxic sealant is atomized and sprayed into the lay flat tubing where it’s exposed to heated air, removing moisture from the sealant make it temporarily sticky, allowing it to collect in cracks and gaps in the ductwork. The sealant slowly builds up overtime, collecting onto itself, like the platelets in your blood after a scrap, until the gap is sealed. The entire process is monitored by our proprietary software, making automatic adjustments to pressure and flow rate to optimize effectiveness.

Step 4: Certify the Results

When the target leakage rate is reached, the equipment is turned off, and any access holes are patched. Tape and blockers are removed, and the HVAC system is restored to normal operation. A detailed seal report is generated, comparing the before-and-after leakage rates to confirm effectiveness.

What is Aeroseal Duct Sealing?

The Process

Ready to dive in?