How Does Aeroseal Duct Sealing Work?
Aeroseal is designed to seal many small leaks in ductwork from inside the duct system.
Instead of opening walls or ceilings to reach every joint and seam, the process introduces sealant into a prepared duct system. The sealant is carried toward leakage points, where it accumulates around the edges of small openings.
Why Duct Leakage Matters
Duct systems can leak at joints, seams, connections, and other small openings.
On the supply side, leakage can allow heated or cooled air to escape before it reaches the intended rooms.
On the return side, leaks can pull air into the system from areas that were not intended to be part of the return path.
Duct leakage can be one possible contributor to airflow or comfort problems, but it is not the only one. Equipment condition, duct design, balancing, insulation, and HVAC sizing can also affect system performance.
How the Aeroseal Process Works
The Duct System Is Evaluated
The process should begin by determining whether meaningful duct leakage exists and whether the system is appropriate for sealing. Testing and inspection can help identify the condition of the ductwork before work begins.
Major Duct Problems Are Addressed First
Aeroseal is not designed to repair large physical defects. Disconnected ducts, crushed sections, large holes, or severely damaged ductwork generally need direct repair before sealing.
Registers and HVAC Components Are Prepared
Registers and grilles are temporarily sealed so the duct system can be pressurized. The furnace, air conditioner, coil, and other HVAC components are isolated or protected as appropriate for the system.
Aeroseal Equipment Is Connected to the Ductwork
Aeroseal equipment is connected to the duct system, typically near the air-handling equipment. The prepared duct system is then pressurized.
Sealant Is Introduced Into the System
A fine aerosolized sealant is introduced into the ductwork. As air moves through the system, the sealant travels toward small leakage points. Particles collect around the edges of those openings and gradually build a seal.
Duct Leakage Is Measured Again
Testing can be used after the sealing process to measure the remaining leakage. This provides a before-and-after comparison rather than relying only on a visual assumption that the ducts were sealed.
What Types of Leaks Can Aeroseal Address?
Aeroseal is designed primarily for smaller leaks distributed throughout a duct system, such as leakage around joints, seams, and connections.
It can be especially useful when those areas are concealed behind finished walls or ceilings.
It is not intended to replace physical repair when the ductwork has major structural damage.
What Aeroseal Cannot Fix
Aeroseal generally cannot correct disconnected duct sections, crushed ducts, large openings, severely deteriorated ductwork, incorrect duct sizing, poor system balancing, or mechanical HVAC problems.
Those issues need to be evaluated and repaired separately.
Do Air Ducts Need to Be Cleaned Before Aeroseal?
Not automatically.
The condition of the system should be evaluated first.
If significant dust, debris, construction material, or other buildup is present and could interfere with the sealing process, cleaning may be appropriate before Aeroseal is performed.
The preparation should match the condition of the duct system.
Can Aeroseal Help With Uneven Room Temperatures?
Potentially, if meaningful duct leakage is part of the reason a room is not receiving the intended airflow.
But hot or cold rooms can also result from duct design, balancing, insulation, equipment sizing, window exposure, or other building conditions.
Testing is important because it helps separate duct leakage from other possible causes.
Aeroseal in New Construction and Existing Homes
Aeroseal can be used in both existing buildings and some new-construction applications.
In an existing home, the advantage is often the ability to address concealed leakage without opening large sections of finished walls or ceilings.
In new construction, duct leakage testing and sealing may be used as part of quality-control or performance goals when required by the project.
Frequently Asked Questions
What is Aeroseal made to seal?
Does Aeroseal coat the entire inside of the ductwork?
Do walls need to be opened for Aeroseal?
How do you know whether Aeroseal worked?
Is Aeroseal right for every duct system?
Have Questions About Aeroseal Duct Sealing?
Safety King can evaluate duct leakage and system condition to determine whether Aeroseal is appropriate. The goal is to confirm the problem first, prepare the system correctly, and use duct sealing only when the system is a good fit.