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Duct Sealing

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Aeroseal Solutions specializes in providing our customers with a viable option to resolve one of the most common and frustrating issued faced by homeowners today — rooms that are either too hot in the summer or too cold in the winter. There are a few factors that case this phenomenon however the key one is leaky ductwork. On average 20-40% of airflow leaving your furnace or AC never reaches the room as a result of leaks in the ductwork. With the Aeroseal® system we are effectively able to seal all leaks in your ductwork allowing air to reach its intended destination. The result is a highly efficient duct work system that restores comfort to your home, increases air quality and reduces heating costs.

The issue of hot or cold rooms has unfortunately become an accepted problem by home-owners due to the absence of a viable solution. We are able to provide you with the solution you have been looking for. In the image shown below you can see the locations of various leaks throughout your homes duct system. Your system is operating inefficiently due to these leaks resulting in room comfort issues, poor indoor air quality and ultimately higher energy bills.

Think of your furnace as the heart of your HVAC (Heating, Ventilation & Air Conditioning) system and your ductwork as your veins that transport oxygen (air) throughout your body. Ideally you don’t want there to be any leaks in your veins as that will mean that the oxygen your heart is working hard to produce isn’t getting to where it needs to go. This puts added stress on your heart (furnace) to have to work harder to produce enough oxygen to keep your body going.

By sealing your duct system what you are doing is ensuring that the maximum amount of airflow being output by your system is reaching its intended destination. The rooms are typically located the furthest away from your furnace or on runs that were improperly sized are the ones that are always either too hot or too cold. Sealing your entire ductwork with Aeroseal is the most efficient and cost effective way to resolve these types of issues.


As energy prices continue to rise home-owners are becoming more aware and conscientious about their usage patterns. A recent article in the Toronto Star cites that electricity bills are set to double by 2030 under the new energy plan. Whether its the use of smart thermometers or scheduling the usage of high current draw appliances to off-peak hour rates, consumers are taking steps to minimize these high costs. Independent studies have shown that on average you are losing 30-40% of air travelling through your ductwork to leaks. By sealing these leaks your furnace will need to run less frequently and for shorter intervals resulting in lower energy costs for you.

With up to 60% of your annual energy bill going towards heating and cooling it is one of the major costs of owning a home. It comes by no surprise that sealing your ducts has been shown to the best energy efficient upgrade you can have done. It ranks higher than having new windows put in or even insulating walls and attics. It is estimated that more than 30% of heated and cooled air is lost through duct leaks. The Energy Minister of Ontario Bob Chiarelli has actually come out and said that amidst these increases in energy costs it is ultimately up to the home-owner to control their own hydro bill.

Newer high-efficiency furnaces have the ability to operate at varying levels of output to minimize your unit having to be either on at 100% or off at 0 %. These units will definitely save you money based on this principle alone however even if you have a new furnace the weakest link in this system is still the leaky ductwork. No matter how efficient your furnace is it still faces the same problems your old unit did. We have had several customers who have upgraded to high efficiency furnaces to resolve both comfort issues and high energy costs that did not see the results they had been expecting. It was only once they sealed their ductwork that they were able to maximize the benefits of their new furnace and obtain the comfort and savings they had been seeking.

This would be the equivalent of swapping a completely brand new fuel efficient engine into your current vehicle to resolve an issue with fuel leaking. Sure your engine would be functioning more efficiently but you would still be leaking gas thus impacting the savings. Until you resolve the issue of fuel leak (ductwork) you would still be left with an inefficient system that’s costing you more to run than it should.

The process of sealing the ductwork in a residential home will take on average 6-7 hours. The first step is preparing the system and setting up the equipment to run a pre-diagnostic test. The next step is blocking off all the registers with foam inserts so that we can pressurize the ductwork. This test will provide us with an initial  amount of leakage (CFM) in the system. Once this test has been completed we can begin the sealing process.



During the sealing process the sealant  is aerosolized into particles to form a mist that is kept suspended and then pushed continuously throughout the ductwork. Since we have blocked off the registers the only place left for the sealant to escape is via the existing leaks. As air escapes through these leaks the particles adhere to the edges of the leak and start to collide with each other to close off the leak. As time passes more particles collide until the leak is completely sealed. This process continues for each leak until the sealing process comes to an end. Sealing times vary but on average can take between 1-1.5 hours to complete.


Upon completion of the seal a post-diagnostic test is completed which includes the new leakage figure. A chart is also included that plots the decrease in leakage throughout the sealing process. Shown below is an example of the report. Here you can see that we were able to achieve a 98% reduction in duct leakage which will lead to improved airflow that results in a restored feeling of comfort for the home-owner.



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