Aeroseal provides automated duct and envelope sealing technology that seals leaks from the inside, improving energy efficiency, building performance, and occupant well-being
Aeroseal
Duct and Envelope Sealing
Automated air sealing for ventilation ducts, windows, and building envelopes
Description
The Aeroseal Duct Sealing and AeroBarrier systems enable building owners to address energy waste — Aersoeal Duct Sealing turns a leaky HVAC distribution system into an efficient one, sealing holes up to 5/8 inch, while AeroBarrier turns a leaky building envelope into an airtight one. Both solutions leverage automated processes and real-time monitoring to ensure sealing results. They may be used to extend the life of existing heating and cooling systems, or to improve the ROI on new heating and cooling systems by ensuring that air is efficiently and properly distributed throughout a building.
Use Cases
Upgrade building envelope
Air seal building/unit
Make HVAC vents more efficient
Seal windows
Regulate indoor building temperature
Key Differentiators
Automated sealing - Aeroseal's Duct Sealing delivers automated, computer-controlled sealing from inside ductwork. AeroBarrier delivers automated envelope sealing. Both allow for faster installation than manual sealing
Non-toxic - Both solutions use patented, non-toxic sealants
Verified performance - Both solutions are monitored in real-time to ensure coverage and effectiveness
Precise - Aeroseal's Duct Sealing process pressurizes duct systems, driving sealant particles directly to leaks to seal them from the inside without coating the entire duct, with no demolition and minimal disruption. AeroBarrier is renowned for its ability to detect and seal even the smallest air leaks.
Cost Savings
These sealing solutions can save home and property owners and residents up to 30% of utility costs while extending the life and efficacy of HVAC equipment.
About
Decarbonization Impacts
Operational Emissions
While energy savings and CO2 reductions will vary significantly by building type (high rise, low rise), fuel type (steam, electric), and solution (ventilation rehabilitation, envelope sealing, or both), any reductions in the amount of energy wasted through air leaks will have a direct implact on carbon emissions as well. In fact, using an example of a New York City building, a recent study in the ASHRAE Journal showed that with pre-seal leakage of 16%, the Aeroseal energy model proved out savings across the categories of:
Reduced fan power
Reduced cooling and heating loads
Lower reheat requirements in VAV (variable air volume) systems.
Reduced peak electrical demand with results suggesting roughly 1% incremental energy savings for each percentage point of leakage sealed — representing substantial energy-saving and carbon-reducing potential for commercial and multifamily buildings; especially where initial leakage is high.
Embodied Carbon
AeroBarrier helps reduce a building’s embodied carbon by improving the overall effectiveness of the insulation system. Because the building envelope is much tighter, builders can often reduce or eliminate high-carbon materials like spray foam, use less traditional insulation, and even specify lower-performance windows — all while maintaining the same energy performance targets. Since AeroBarrier’s sealant itself has very low embodied carbon, it adds virtually no additional eCO₂ impact while enabling meaningful reductions in other, more carbon-intensive materials.
Project + Building Compatibility
Project Type
Both existing building retrofits and new construction
Essential Building Characteristics
Aeroseal's technologies work in a broad range of applications, with any insulation type, in any climate zone. Aeroseal Duct requires ductwork with leakage to seal, while AeroBarrier requires an enclosed space/building envelope where positive pressure and blower door testing can be used.
Ideal Building Characteristics
Any home or duct system with leakage that needs energy savings or envelope performance (all will benefit from our tech).
Minimum Project Size
Aeroseal’s direct sales team primarily targets projects above $100k, though smaller projects may still be considered through local channel partners. For high-rise multifamily ventilation retrofits, projects generally cost around $2k per unit, making a 100-unit building approximately a $200k project depending on scope and building systems.
Ideal Project Size
$100k-$500k high-rise multifamily ventilation retrofits or mid-rise new construction projects, generally involving 20+ stories and 200+ units
NY Contractor Availability
Installation contractors are available nationwide; Aeroseal has a network of certified contractors that are authorized to perform work on their behalf.
Other Screening Criteria
Aeroseal technology can be used in any project where energy savings, improved ventilation, and improved comfort are goals. This technology supports meeting code compliance, PHIUS, LEED, Energy Star, LIHTC, LL97 and other building performance requirements
Example Installations
Installed By
Multiple multi-family buildings in the Northeast including 150 West End Ave in NYC, Jaycee Place in MA, Northgate in NJ, and multiple AvalonBay communities. Aeroseal also works with clients such as Pfizer Pharmaceuticals, the American Dental Association, Steven Winters Associates, Ameresco, Johnson Controls, Beazer Homes, D.R. Horton, PulteGroup, and Disney, and has sealed buildings such as the Met Life Building, The Wynn Hotel, and several structures at Harvard and The Ohio State Universities.
Case Studies
Resident Experience
During Installation
Aeroseal Duct creates no mess and is typically completed in a couple of hours for homeowners. For commercial and high rise duct sealing, there is minimal disruption to residents with no demolition required. AeroBarrier is typically implemented in unoccupied areas, but if done in occupied spaces, would require several hours to days depending on the scope of work, to prep and cover finished surfaces such as counters, flooring, and windows. No demolition is required, and no residue or mess is left behind upon completion.
Post Installation
Improved comfort & indoor air quality
Even temperatures room to room
Reduced odor transfer between units
Less noise traveling through leaky pathways
Cleaner, controlled airflow
HVAC systems that perform as designed
Financing
NY Incentives/Financing Resources
Custom incentives available - contact Aeroseal for further information.
Upfront Costs
Upfront costs are heavily dependent on the scope of work, the building size and type, the fuel type, the goals of the project, and other factors.
Payback Period
The average payback time is 3-10 years for Aeroseal duct sealing for multifamily housing.
Operations, Management, and Maintenance
Ease of Operations
Aeoseal's duct technology and AeroBarrier envelope sealing technology simplify envelope sealing and reduces uncertainty and variability. For one equipment platform, Aeroseal Duct leads to 66% faster prep and teardown. Aeroseal handles the process end to end with verified air tightness results.
Data + Performance
Aeroseal software generates a certificate of completion with before-and-after leakage test results, a graph of progress during the process, and heating and cooling capacity improvement.
Moisture Management
AeroBarrier virtually eliminates condensation and damp building materials in the exterior walls of a building.
Future Proofing
Aeroseal materials will be compliant with stricter building codes in extreme weather circumstances, positioning buildings for a resilient net-zero future.
Specifications
ASHRAE Standard 152, PlanNYC, NFPA, FEMP, USGBC, LEED, Green Guard Gold certified, UL, NFPA 90A, ASTM, DIN EN ISO 846, NGBS Green, NYSERDA approved energy savings
