Applications Commercial

Why Aeroseal?

Are you looking for ways to reduce your building’s energy costs, improve indoor air quality (IAQ), fix your ventilation issues and extend equipment life? What is often neglected is the ductwork delivering your air. Unless a duct has been hand sealed across every possible joint there is every chance that there is a myriad of small leaks and possibly some major ones. This leakage wastes fan power, conditioned air and may allow the ingress of unconditioned outside air or air from other sources such as loading docks or waste areas. Aeroseal seals leaks from the inside out. It can reduce leakage by 90%, saving up to 30% of HVAC Energy. It can seal leaks up to 15mm (5/8”) throughout a system regardless of construction, installation & access.


Building problems caused by leaky duct work include:

  • Inadequate air flow to some zones
  • Comfort issues with cold or hot spots
  • Problems Identified by Test and Balance Report
  • High Electricity Bills
  • Increased Cooling or Heating Capacity Needs
  • Unexplained odours or fumes
  • Poor or Inconsistent Exhaust from Toilets, Bathrooms or Laundries
  • Inadequate Moisture Management

But there’s a simple solution to this costly problem. You can reduce your energy and equipment repair costs resulting from compromised ductwork with the most advanced duct sealing in the industry - Aeroseal Certified Duct Diagnostics and Sealing.

We can investigate & seal all types of HVAC Ducts & Systems

Air Conditioning ducts including:

  • Supply Air Ducts and Plenums
  • Return Air Ducts and Plenums
  • Outside & Exhaust Air Ducts

Ventilation Ducts including:

  • Toilet Exhaust Duct
  • Car park Exhaust Duct
  • Battery Room Exhaust Duct
  • Bathroom Exhaust Duct
  • Laundry Exhaust Duct
  • All other Ventilation systems

Aeroseal is the most effective, affordable, and viable method of sealing duct leaks. Just like anywhere else, ducts in commercial buildings leak. Leaking ducts cost you money via:

Increased Energy Consumption

With fan power representing 40-50% of HVAC energy usage, leakage costs can be significant due to the increase in fan speed to compensate for leakage; even 15% leakage can lead to an increase in system fan power of 40%. The performance of variable speed drives on fans is increased when leaks are reduced. If conditioned supply air is lost to the atmosphere it must be replaced with unconditioned outside air which must be heated or cooled & dehumidified to maintain conditions. This adds additional load to the air conditioning plant increasing power usage.

Thermal Loss – Comfort Issues

When supply air escapes, variations in temperature between rooms and floors occur affecting comfort levels in the space. The system is unable to supply sufficient air quantity to the far reaches of the duct run if air is leaking and pressure is lost due to small holes in the duct. This results in tenant comfort issues and complaints of stuffiness in occupied spaces.

Indoor Air Quality Issues

Lack of sufficient air quantity for supplied air, infiltration of outside or contaminated air from unexpected sources such as loading docks and waste areas can all lead to Indoor Air Quality issues. Modern buildings rely on pressurisation from the HVAC system to stop the ingress of outside air and moisture into the buildings. Ventilation systems are designed with sufficient air to remove the build-up of odours and moisture from areas such as Toilets, Bathrooms and Laundries. If this moisture is not removed it may lead to the growth of Mould, Yeast & Bacteria which can be detrimental to the health of occupants.

Equipment Overload

Your system will run longer and harder than specified to compensate for air loss pressure drop, additional loads and temperature fluctuations; this could lead to increased maintenance costs and premature component replacement.

Building Code Issues

Leakage could lead to ventilation building code issues relating to lack of adequate exhaust in Toilets, Bathrooms & Laundries, along with excessive fan power use. This may lead to an increase in moisture build-up causing corrosion and Indoor air quality issues. Are you aware that there is a new Australian Standard for rigid ductwork? AS4254.2:2012 requires that any system supplying more than 3000 l/s is required to be tested for air leaks. This is now incorporated into BCA2013 which essentially this makes it compulsory to comply for new construction. Please click here for more information.

Enhanced Building Pressurization

By sealing air leaks more effective Building Pressurization can be achieved through the increased air flow and pressure. This stops the ingress of outside air and relevant issues, it allows the building to operate as designed.

Airflow safety

For hospitals, laboratories and manufacturing facilities, the unexpected spread of contaminant and biohazards through back drafting could pose a liability. Design air quantities and pressures can only be met by excessive air flows over coming leakage which is a waste of energy and money.

Cleaning of ducts may be required before the Aeroseal process takes place if there is a build-up on the ducts of greater than 3mm.


The computerized duct system inspection performed by Aeroseal Duct Sealing Aust will illustrate not only the building leakage percentage, but also the impact that sealing the leaks can have on your company’s bottom line. Using local electricity rates, estimated system operating hours, and other inputs supplied by your operations personnel, our software closely calculates all the financial parameters of the project including simple payback, benefit-to-cost ratio and a Return on Investment timeframe.