Engineers & Energy Consultants

All air ducts leak unless they have been meticulously sealed by hand at every potential leak. There have been many studies on the effects of duct leakage made in USA and Europe.

“Light commercial duct leakage is typically 30% or more”

Florida Solar Energy Centre, California Energy Committee Studies

“On average, 10-20% of air provided by supply fans does not reach the occupied space”

Lawrence Berkeley National Laboratory Studies

For further information see

In previous years Engineers have made allowances to overcome these leaks to provide the correct air quantities and pressure required for the system to operate effectively. In the current era of high efficiency design and equipment, NABERS, Green Star and Commercial Building Disclosure, air leaks in ductwork are an unsustainable loss which must be rectified. Until now there has not been an effective, efficient and affordable way to seal leaks. The Aeroseal process has now changed that.

Energy use of HVAC Fans is a major part of a buildings energy profile.

The use of high efficiency fans, low pressure drop designs and Variable Speed Drives have all contributed to a reduction in energy usage in this area. However until now there has not been an effective way to seal the air leaks in an installed system. This loss of air flow and pressure has caused issues at commissioning of new systems and in chasing better efficiency in existing buildings. Any loss or waste of energy can not be recovered. Aeroseal solves the problem by sealing leaks from the inside out.

New Installations

To positively seal all potential leaks in a new system involves a great deal of care during both manufacture and installation. There is still the potential that there will be an issue on site. The Aeroseal process can be used before commissioning to give the best opportunity to seal the entire system in position from the inside out.

Existing Installations

Existing systems have the dual issues of age, with the breakdown of sealants and movement in joints, as well as a lack of access to the installed duct. To provide the Aeroseal process we must firstly seal Ceiling, Wall & Floor Registers, isolate Fans, Coils and other supplementary equipment including smoke alarms. We then directly seal the entire duct system with a minimum of penetrations, access or preparation. All types of duct can be sealed – rigid, flexible, insulated, metal, masonry, P3 or any other material. There is no need to remove dampers. There is no residue left in the duct. The process in normally carried out outside of business hours to reduce any inconvenience to the occupants.

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 Sealant is a safe effective Vinyl Acetate Polymer:

  • It is similar to what is used as a base for chewing gum, hair spray and water based paints.
  • It remains rubbery and flexible after it has cured.
  • UL723 listed for smoke and flame spread
  • UL181 listed for Mould growth
  • It is certified Low VOC
  • It takes approximately 2 hours to cure
  • There is a 3 year Commercial Application guarantee

The Aeroseal sealing process requires no on-going maintenance. It does not affect service openings or any other maintenance procedures. It will provide the benefits of a well-sealed system for many, many years to come.


HVAC Fans are a major contributor to energy usage

Learn More

Aeroseal Duct Sealing Aust can provide Lunch’n’Learn sessions in your office to show you the full benefits of Aeroseal to your Clients.