How Does Aeroseal Duct Sealing Work?
If you’ve ever dealt with stubborn air leaks in your ductwork, you know the drill—find the leak, patch it, and hope you got them all. But what if the leaks are buried inside walls, ceilings, or other places you can’t reach without tearing half the house apart? That’s where Aeroseal Technology comes in, and honestly, it’s pretty fascinating how it works.
The Hidden Problem of Duct Leaks
Most homeowners have no idea how much conditioned air is lost through tiny cracks and gaps in their ducts. We’re talking about leaks you can’t see—microscopic even—spread throughout the system.
In some houses, I’ve seen leakage rates over 30%. That’s 30% of the air you’re paying to heat or cool gone—floating up into the attic, leaking into crawl spaces, or disappearing into wall cavities.
This is exactly the kind of inefficiency Aeroseal Technology was designed to fix.
Step One: Finding the Leaks
Here’s the part that makes people raise an eyebrow—Aeroseal Technology doesn’t “find” leaks by physically looking at them. Instead, it pressurizes your duct system and uses computer software to measure exactly how much air is escaping.
Think of it like a medical test for your HVAC system. You’re not peeking inside the body—you’re running diagnostics to see how well (or poorly) it’s functioning. That data gives you a baseline before the sealing even starts.
Step Two: The Sealing Process (This Is the Cool Part)
Instead of climbing around your attic with duct tape (please, don’t actually do that), Aeroseal Technology seals leaks from the inside.
Here’s how it works:
- The system is blocked off, so air can’t blow out your registers.
- A specialized sealant is aerosolized—basically turned into a fine mist.
- The mist is blown through the ductwork, and as it flows, the tiny particles stick to the edges of any leaks.
- The particles build up bit by bit until the gap is sealed.
The sealant only sticks where there’s a leak—it doesn’t coat the inside of your ducts randomly. And yes, it works on leaks as small as a pinhole and as large as about 5/8 of an inch.
Real-Time Results
One of the reasons I like Aeroseal Technology is that you’re not just guessing whether it worked—you get live results as the process runs. The software tracks leakage levels, and you can watch the numbers drop on the screen as the sealant does its job.
I’ve been in rooms where the leakage went from 200 CFM (cubic feet per minute) to under 20 in less than an hour. That’s not just impressive—it’s money saved on every future utility bill.
How Long Does It Last?
People always ask this. According to field testing, the seals created by Aeroseal Technology can last decades—25 years or more in most cases. The material stays flexible and doesn’t crack or crumble as the ducts expand and contract over time.
Of course, like any system, if someone physically damages the duct later (say, during a renovation), that’s a separate problem. But the actual seal? It’s designed to be permanent for the life of the system.
Is It Safe?
Short answer—yes. The sealant used in Aeroseal Technology is a water-based formula with a low VOC rating. That means it’s safe for use in homes, schools, and even medical facilities. Once it’s dry, there’s no lingering smell or residue in your living space.
I’ve had clients with asthma and allergies use it without issues, which is a big deal when you’re talking about something that’s blown through your entire air system.
My First Time Seeing It in Action
The first time I watched Aeroseal Technology at work, I was skeptical. I kept thinking, “How can a mist possibly fix metal ducts?” But watching that leak reading tick down in real time was a game-changer. The homeowner went from losing over a quarter of their conditioned air to under 5% leakage—just like that.
The kicker? They called me a month later to say their home felt evenly comfortable for the first time. No more hot bedrooms or cold living rooms. That’s when I knew it wasn’t just about saving money—it was about comfort, too.
Why It’s Better Than the Old Way
Traditional leak sealing is… well, messy. You need access to the ducts, which isn’t always possible without cutting into walls or ceilings. And even if you patch the areas you can reach, you’re guessing about the rest.
With Aeroseal Technology, the entire duct network gets treated at once—whether you can see the leaks or not. It’s faster, more thorough, and usually ends up costing less than tearing open drywall to chase down gaps.
Final Thoughts
Aeroseal Technology isn’t just a neat gadget—it’s a real solution for one of the most overlooked problems in home efficiency. It finds the leaks without tearing your home apart, seals them from the inside, and gives you proof it worked before the crew even leaves.
If your energy bills are high, certain rooms are always uncomfortable, or you just want your HVAC system to stop wasting air, this technology is worth a serious look.
Because sometimes, the problem isn’t your AC or furnace—it’s all that conditioned air escaping into places you’ll never see… unless you’ve got a way to seal it up from the inside out.
