If your energy bills are creeping up, your home has hot and cold spots, or your indoor air feels stale and dusty, leaky ductwork might be the hidden culprit. You might need duct sealing services.
Many homeowners are unaware that up to 30% of conditioned air can be lost through small cracks and gaps in their duct system — causing their HVAC system to work harder while delivering less comfort and efficiency.
That’s where Aeroseal comes in. This innovative, non-invasive duct sealing technology has changed the way professionals fix duct leaks.
In this blog, we’ll explain Aeroseal, how the process works step by step, why it matters for your home or business, and compare it to traditional air duct sealing methods. If you’re serious about saving energy, improving air quality, and getting more life out of your HVAC system, this is a solution worth understanding.
What is Aeroseal?
Aeroseal is a cutting-edge air duct sealing technology that fixes leaks from the inside of your ductwork without the need for demolition, cutting into walls, or removing ceiling panels. It’s a patented process designed to seal holes, cracks, and gaps in air ducts using a non-toxic, water-based aerosol mist made of polymer particles.
Developed at the Lawrence Berkeley National Laboratory and backed by decades of research, Aeroseal has revolutionized the way residential and commercial properties address inefficient ductwork.
Unlike traditional sealing methods that require manual patching with tape or mastic (which often miss hidden or hard-to-reach leaks), Aeroseal uses advanced pressurization to deliver the sealant exactly where it’s needed.
Once inside the ducts, the aerosolized particles stay suspended in the airflow until they begin sticking to the edges of leaks. These particles build up layer by layer until the holes are completely sealed — typically those as large as ⅝ of an inch.
The result? A dramatic reduction in air leakage, improved HVAC performance, and measurable improvements in energy efficiency and indoor comfort.
Aeroseal is safe, fast, and incredibly effective, making it a smart solution for homeowners and building managers who want to cut energy waste, improve air quality, and extend the life of their heating and cooling systems.
How Aeroseal works (step-by-step)
Aeroseal duct sealing services involve a precise, non-invasive process designed to eliminate air leaks in your duct system from the inside. Here’s how it works, step by step:
1. Preparation and system setup
To begin, your HVAC system must be turned off with temporary foam plugs placed in the supply and return vents throughout your home. This isolates the ductwork, ensuring the sealant only flows through the ducts and not into your living space. Then, a specialized machine is connected to your system, ready to pressurize and seal.
2. Pressurization and leak detection
The Aeroseal system pressurizes your ductwork with air, allowing it to detect and measure how much air is escaping through leaks. A computer-generated test provides a before snapshot, showing exactly how much leakage exists in your system. This gives a baseline to track the results of the sealing process.
3. Sealant injection
Once the leakage is measured, a safe, non-toxic aerosol sealant made of polymer particles is injected into the duct system. These tiny particles remain airborne until they reach a leak. When air tries to escape through a gap or hole, the particles naturally stick to the edges and build up until the leak is completely sealed.
The process does not coat the inside of the ducts — it only seals where leaks are detected. This targeted approach ensures no waste or unnecessary buildup inside your system.
4. Real-time monitoring and completion
Throughout the process, a computer monitors the leakage rate in real time. You can actually watch the leakage drop as the sealant does its job. Most homes see up to 90% reduction in duct leakage in under a few hours.
Once sealing is complete, a final pressurization test is performed to verify the results. You receive a detailed before-and-after report showing the exact improvement in efficiency, airflow, and leakage reduction.
5. Quick dry time and system restart
The sealant dries quickly — usually within 30 minutes — so your HVAC system can be restarted shortly after the process is complete. There’s no mess, no damage to your home, and no need for construction.
Why Aeroseal matters
Leaky ductwork is one of the most common and costly issues in homes and commercial buildings — and most people don’t even realize they have a problem. Here’s how Aeroseal makes a major impact.
Saves energy and lowers bills
When your HVAC system loses air through leaks, it has to run longer and harder to maintain your desired temperature. Aeroseal stops this waste by sealing those hidden gaps from the inside. Once sealed, your system doesn’t have to work overtime, which translates to lower energy use and smaller utility bills.
Improves indoor comfort
Leaky ducts create uneven airflow, leading to rooms that are too hot in the summer or too cold in the winter. By sealing leaks, Aeroseal ensures more balanced airflow and consistent temperatures throughout your home. You’ll notice the difference in every room.
Boosts indoor air quality
Duct leaks allow pollutants — like dust, pollen, insulation particles, mold spores, and even fumes from crawl spaces or attics — to enter the air supply.
Aeroseal creates a tighter, cleaner duct system, helping block these contaminants and improve the air you breathe. For families with asthma, allergies, or respiratory issues, this can make a huge difference.
Extends HVAC system life
When your system runs constantly to make up for lost air, it wears out faster. Sealing your ducts reduces that strain, helping prevent breakdowns and extending the life of expensive equipment like your furnace, AC, or heat pump. That means fewer repairs and longer-lasting performance.
Non-invasive, fast, and long-lasting
Aeroseal is completed in a few hours and doesn’t require cutting into walls or ceilings. It reaches leaks in places that are otherwise inaccessible and offers long-term results, backed by performance reports and satisfaction guarantees.
Aeroseal vs. traditional air duct sealing
When it comes to fixing leaky ductwork, there are two main options: traditional manual sealing or Aeroseal’s high-tech aerosol solution. Both aim to stop air leaks, but the way they work and the results they deliver are very different.
Method of application
Traditional sealing
Manual sealing involves locating accessible leaks and patching them using duct mastic or foil-backed tape. Technicians have to physically reach each section of ductwork, which limits their access — especially in tight spaces like behind walls, in ceilings, or in crawl spaces.
Aeroseal
Aeroseal seals the leak from the inside out using an aerosolized polymer. It’s blown through the pressurized duct system, and particles naturally seek out and seal leaks wherever they occur — even in hard-to-reach areas that manual methods can’t touch.
Accuracy and coverage
Traditional sealing
This method only works on visible or easily reachable parts of the duct system. If leaks exist behind walls or deep in the system, they may be missed. There’s also no precise measurement of how much air leakage has been reduced.
Aeroseal
Aeroseal measures leakage before and after the process with exact numbers, giving you a real-time, data-backed performance report. It seals leaks up to ⅝ of an inch in size and typically reduces air leakage by 90% or more.
Effectiveness over time
Traditional sealing
Over time, manual seals can dry out, shift, or degrade — especially in ducts exposed to temperature swings or vibration. If the job isn’t done perfectly, new leaks may develop.
Aeroseal
The sealant used in Aeroseal is designed to be flexible and long-lasting. It remains effective for years.
Time and disruption
Traditional sealing
Manual sealing can be time-consuming, especially if parts of the system are hard to access. It may involve removing drywall or cutting into ceilings to reach duct joints, creating a bigger mess and more labor costs.
Aeroseal
Aeroseal only takes a few hours and requires no demolition. It’s a non-invasive process that seals the entire system without opening walls or removing ducts.
The verdict
Traditional duct sealing works, but only to a point. It’s limited by what can be seen and reached, and it may miss the real problem areas. Aeroseal offers a faster, cleaner, and more thorough solution that delivers proven results.
If you want maximum efficiency, better comfort, and clean air throughout your home, Aeroseal outperforms traditional sealing in nearly every category.
Trust Duct Brothers with your duct sealing needs!
Don’t let leaky ducts waste your energy or compromise your comfort. Whether you’re dealing with high utility bills, uneven temperatures, or poor indoor air quality, Duct Brothers has the solution. Our expert team specializes in Aeroseal duct sealing services, delivering precise, long-lasting results that traditional methods can’t match.
We’ll inspect your system, identify hidden leaks, and use cutting-edge technology to seal them from the inside. You’ll notice the difference in your home’s comfort, HVAC performance, and monthly energy savings.
Get it done right the first time. Contact Duct Brothers today to schedule your Aeroseal consultation and take the first step toward a cleaner, more efficient, and healthier home.
