If you’ve ever noticed uneven temperatures in your home, dusty air, or high utility bills, your ductwork could be the silent culprit.
One great solution to this is Aeroseal duct sealing. This is a modern, science-backed solution designed to fix air leaks in your HVAC system from the inside out. This technology has gained attention for its promise to improve energy efficiency, enhance indoor comfort, and reduce monthly energy costs, all without tearing down walls or replacing ducts.
In this article, we’ll explore how Aeroseal duct sealing works, whether it’s safe, if it’s worth the investment, and what kind of results you can expect based on real-world data and homeowner experiences.
What Is Aeroseal Duct Sealing
Aeroseal duct sealing is an innovative technology developed to help homeowners and businesses combat air leakage in ducts. Unlike traditional sealing methods that require manual access to ducts (and often extensive labor), Aeroseal uses an aerosol-based polymer that seals leaks from the inside. The process works even in ducts hidden behind walls or ceilings, making it ideal for both existing homes and new constructions.
These polymers are non-toxic and certified safe, forming a flexible, durable seal that lasts for years. The technology stands out because it combines precision diagnostics with automated sealing, giving homeowners measurable proof of improved duct performance through a digital report at the end of the process.
How Does Aeroseal Duct Sealing Work?
The Aeroseal duct sealing process is both advanced and surprisingly simple from the homeowner’s perspective. Here’s a step-by-step overview:
Preparation and Leak Testing
First, an HVAC technician blocks all air registers and grilles throughout the home. This isolates the duct system for accurate leak testing. The Aeroseal computer system then pressurizes the ducts to measure total air loss and locate leaks.
Aerosol Sealing Process
Once the system is prepared, a specialized machine injects atomized polymer particles into the ductwork. These particles remain suspended in the air and naturally gather around the edges of leaks due to pressure differentials.
Leak Closure
Over 1–2 hours, the particles build up on the edges of cracks and gaps, forming an airtight seal. The process continues until leak levels drop to the desired range, often reducing leakage by up to 90% or more.
Verification and Reporting
After sealing, the system performs a second diagnostic test to measure improvements. Homeowners receive a printed or digital certificate showing before-and-after leakage rates, ensuring transparency and proof of performance.
This closed-loop, computer-controlled process ensures precision and repeatability, making Aeroseal a trusted solution for improving duct performance without demolition or guesswork.
Does Aeroseal Duct Sealing Work?
Yes, and there’s strong data to prove it. Independent studies by the U.S. Department of Energy (DOE) and the Environmental Protection Agency (EPA) have validated Aeroseal’s effectiveness, reporting leak reductions. Real-world examples include a DOE test home in Florida that reduced duct leakage from 280 CFM to just 25 CFM post-sealing, an impressive 91% improvement. Homeowners often describe the difference as “night and day” in terms of comfort and airflow consistency. It is also a great step to take to prepare your HVAC for winter.
Is Aeroseal Duct Sealing Worth It
When it comes to ROI and comfort, Aeroseal is widely considered worth the investment. By reducing air leaks, you effectively maximize every dollar spent on heating and cooling. According to Energy Star, duct leaks can waste up to 30% of conditioned air, meaning a third of your HVAC system’s effort is lost. Aeroseal reverses this inefficiency.
Some of the benefits of Aeroseal duct sealing are:
- Lower utility bills: Typical savings range from 20–40% annually.
- Consistent temperatures: No more hot or cold spots between rooms.
- Cleaner indoor air: Reduces infiltration of dust, mold, and outdoor pollutants for better indoor air quality.
- Enhanced HVAC performance: Systems run smoother, quieter, and last longer.
Compared to manual sealing using mastic or tape, Aeroseal offers comprehensive coverage without accessing hidden ducts, a major advantage in older or multi-story homes. For homeowners planning to stay long-term, Aeroseal often pays for itself within 3–5 years, thanks to reduced energy costs and maintenance savings.
Is Aeroseal Duct Sealing Safe
Absolutely. Aeroseal duct sealing is safe for both your home and your family. The sealing material is a non-toxic, water-based polymer similar to what’s used in medical adhesives and chewing gum. It carries UL and EPA certifications and meets all ASHRAE and LEED standards for indoor air safety.
Key safety facts:
- No harmful off-gassing or fumes
- Odor dissipates within hours
- Safe for HVAC components and electronics
- Proven not to damage ducts, even flexible ones
Aeroseal’s technology has been used in hospitals, schools, and government buildings, a testament to its safety and reliability.
FAQs
How long does Aeroseal duct sealing last?
Aeroseal seals are designed to last over 10 years, with many lasting the lifetime of the duct system.
Does Aeroseal make the system louder?
No. It often makes your HVAC system quieter because airflow becomes smoother and more efficient.
Can Aeroseal be used in older homes?
Yes. It’s ideal for older homes with hard-to-reach or hidden ductwork.
Is maintenance required after Aeroseal?
Minimal. Once sealed, ducts typically need no reapplication unless damaged or modified.
Will Aeroseal affect my air conditioner or furnace?
Not at all. It improves system performance by reducing stress and optimizing airflow.
Should You Try Aeroseal Duct Sealing?
If your home suffers from uneven airflow, rising energy bills, or excessive dust, Aeroseal duct sealing could be the upgrade you need. It’s scientifically proven, environmentally safe, and offers tangible comfort and energy benefits.
For homeowners seeking long-term value, Aeroseal is both safe and worth the investment. It not only reduces energy waste but also enhances indoor comfort, improves air quality, and extends the life of your HVAC system.
Ready to make your home more efficient and comfortable?
Learn more or schedule your professional Aeroseal service today with TIES 360, Florida’s trusted HVAC and Aeroseal experts dedicated to improving your home’s air quality and performance. Contact us today to schedule an inspection!