Duct Sealing with Aeroseal
Duct Sealing with Aeroseal
Seal Commercial Duct Leaks from the Inside with Aeroseal®
Smart Space Atlanta uses advanced Aeroseal technology to eliminate hidden duct leakage, improve airflow, and reduce energy waste delivering reliable performance for even the largest HVAC systems.
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What is Sealing Commercial Duct Systems with Aeroseal?
Sealing commercial duct systems with Aeroseal is a technology-driven method that seals air leakage from within the ductwork without invasive demolition or duct replacement. It is well suited for large, complex HVAC distribution systems commonly found in offices, schools, medical facilities, multifamily buildings, and industrial spaces.
During the process, a computerized system temporarily pressurizes the ductwork while a UL-tested, water-based sealant is introduced into the airflow. Sealant particles remain suspended until they reach leakage points, where escaping air draws them to cracks, seams, and failed joints, progressively sealing openings.
This method is particularly effective for commercial duct systems located above ceilings, inside walls, or within shafts that are difficult or cost-prohibitive to access using conventional manual sealing methods.
Why Aeroseal for Commercial Duct Systems?
Aeroseal provides a fast, non-invasive way to eliminate hidden duct leakage and optimize comfort throughout the entire building.
Energy Efficiency & Cost Savings
Commercial duct sealing reduces distribution losses and HVAC energy demand, with measured leakage reductions commonly ranging from 50-90%, depending on baseline leakage.
Better Air Balance, Comfort, and Indoor Air Quality
Leaks in duct systems cause uneven airflow, pressure imbalances, and temperature variation (hot/cold spots) across zones. Sealing helps stabilize and equalize air distribution.
Reduced infiltration of dust, pollutants, and unwanted air into conditioned air, improving indoor air quality (IAQ).
Equipment Longevity & Maintenance Savings
By reducing duct leakage, the HVAC system operates under more stable airflow and pressure conditions, decreasing run time and mechanical stress on fans, motors, and compressors.
Reduced particulate infiltration and cleaner duct interiors help maintain coil and filter cleanliness, extending maintenance intervals and improving long-term system reliability.
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How the Aeroseal Process Works
Diagnostics & Pretest
What Happens
The existing duct network is assessed. Supply and return registers / diffusers are blocked or isolated so that only leaks remain as airflow paths. The baseline duct leakage is measured (often via duct blaster or other testing equipment).
Purpose
Establishes how much leakage exists, where the distribution is, and sets a benchmark for post-seal validation.
Isolation & Set Up
What Happens
Registers, grills, coils, fans, and other sensitive components are temporarily blocked or sealed so the sealant particles stay within the duct paths. A temporary injection point (port) into the duct is created.
Purpose
Ensures that the sealant does not enter or settle in mechanical equipment or unintended areas.
Pressuization & Aeroseal Injection
What Happens
The duct system is pressurized (i.e. forced air flow through thenetwork). The aerosolized sealant is injected. Because air is leaking out through even small openings, the sealant follows that path, colliding with the edges of leaks and adhering. Over time, particles accumulate and progressively close the gaps.
Purpose
This is the core of the Aeroseal method sealing from the inside outward.
Monitoring & Control
What Happens
A computer control system measures pressure changes, airflow, and leakage in real time. It monitors how the sealing process is proceeding and stops when targeted leakage reduction is achieved.
Purpose
Maintaining control ensures sealing is effective and does not overshoot or under-seal.
Verification & Post Test
What Happens
After sealing, the system is tested again to measure final ductleakage. A report is generated showing before vs after, leakage reduction, and performance metrics.
Purpose
This certification is crucial for validating results and for client confidence.
Clean Up & Return to Service
What Happens
All temporary plugs and seals are removed, ducts are restored to normal operation. Any manual sealing, repairs, or rebalancing as needed are done.
Purpose
The building returns to normal function, but now with more efficient ductwork.
Frequently Asked Questions (FAQs) on Sealing Ducts with Aeroseal
What tyes of commercial buildings is Aeroseal best suited for?
Aeroseal is ideal for offices, schools, medical facilities, multifamily buildings, retail spaces, and light industrial propertiesespecially where ductwork is concealed above ceilings, inside walls, or within shafts.
How Does Aeroseal seal duct leaks without opening walls or ceiling?
The duct system is temporarily pressurized while a UL-tested, water-based sealant is introduced into the airflow. Sealant particles are carried to leakage points, where escaping air draws them to cracks, seams, and failed joints, sealing leaks from the inside without invasive access.
Is the Aeroseal sealant safe for occupants and HVAC equipment?
Yes. The sealant is a UL-tested, water-based polymer formulated for HVAC applications. For systems with higher leakage rates, air scrubbers are used during installation, and work is typically scheduled during non-business hours to minimize occupant exposure.
During installation, the duct system is isolated to protect mechanical equipment. Once cured, the sealant is inert, stable, and does not off-gas during normal HVAC operation.
How long does the Aeroseal process take and will it disrupt building operations?
Most commercial Aeroseal projects are completed within one to two days, depending on system size and complexity. The process is significantly less disruptive than manual duct sealing or replacement and can be coordinated during off-hours to minimize impact on occupants and building operations.
How is duct leakage verified?
Leakage is measured before and after sealing using calibrated airflow and pressure testing equipment. This provides documented, verifiable results suitable for commissioning, retrofit validation, and incentive programs.
See How Much Your Building Can Save
See How Much Your Building Can Save
What People Are Saying
Smart Home Atlanta did an outstanding job with our energy audit, duct sealing, and crawlspace encapsulation. The difference in efficiency, humidity, and air quality has been massive. High-quality work, excellent communication, and very informative throughout the process – highly recommend!
– Joseph W.
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