Top Ten Questions Still Asked About Aeroseal

The word about aeroseal technology and the impact of duct leaks on indoor comfort and energy savings is rapidly spreading globally. However, as with any innovation, questions persist about the technology, the process, the cost, and the results. In fact, we've observed that around a dozen questions from homeowners and the professional HVAC community consistently appear on blog posts, Facebook pages, and in emails. Frequently, these questions are followed by speculative answers or misinformation.

The crack team in our Question Processing Department (yes, we actually have one) has compiled a list of the most frequently asked questions about Aeroseal, complete with trustworthy answers.

Feel free to share any additional questions, and we'll promptly provide you with the answers.

Q1: How much money can a homeowner save by aerosealing their ducts?

A: This is probably the most common question for anyone considering aerosealing for their home or building. The answer varies depending on several factors, such as location, utility rates, severity of leakage, HVAC system design, and more. For instance, residents in Kansas City, where the furnace is in use for approximately 2/3rds of the year, would save more compared to someone in a milder city like Portland, Oregon. While the answer may not be entirely satisfying, after years of aerosealing homes, we can provide average savings. Homeowners in the Midwest, Northeast, and Mid-Atlantic regions typically save $300 – $400 a year, while those in the Northwest, Southwest, and South save $600 – $900 a year. The customary disclaimer applies—your mileage may vary.

Q2: How quickly will a homeowner see a return on their aeroseal investment?

A: This question is closely related to the first, and the answer remains similar—it depends. On average, homeowners see a return on investment (ROI) in 2.5 to 5 years, considering all factors. One noteworthy anecdote comes from a homeowner who received praise from his investment counselor. The calculated energy savings from aerosealing his home were deemed the best investment, surpassing any single stock or investment option suggested by the counselor.

Q3: How long will Aeroseal last?

A: Aeroseal comes with a ten-year warranty, but its lifespan is much longer. Accelerated testing at Lawrence Berkeley National Laboratory revealed no signs of deterioration, and it continued to seal well beyond the lifespan of tape and mastic. The durability testing exceeds 40 years, and it complies with all UL standard tests for durability. The strongest warranty in the industry covers contractors for ten years for parts and labor for any Aeroseal seal failure.

Q4: Is it safe?

A: The Aeroseal sealant consists of a vinyl acetate polymer, similar to ingredients found in hairspray and chewing gum. It is nontoxic, certified by the Occupational Safety and Health Administration, and UL approved. Notably, Aeroseal has been used in prestigious medical facilities, including the Mayo Clinic and Nemours Children’s Hospital, with day-to-day operations often remaining uninterrupted during application.

Q5: How many homes have been aerosealed?

A: As of the end of 2013, nearly 100,000 homes have been sealed, with approximately 200 additional homes added weekly.

Q6: Is there an odor?

A: During application, there is a very mild odor similar to Elmer’s glue, which dissipates completely within a few hours.

Q7: Will the ducts be covered with sealant?

A: Aeroseal does not coat the ductwork but remains suspended in the air until it reaches a leak. It then clings to the edge of the hole and other sealant particles until the leak is completely sealed.

Q8: Does Aeroseal seal all leaks?

A: Aeroseal seals leaks as large as 5/8’’, covering the majority of problematic leaks in today’s homes and buildings. While it cannot remedy disconnected ductwork, it alerts professionals to this issue for proper resolution. On average, Aeroseal effectively seals 95% or more of duct system leakage.

Q9: Will Aeroseal seal flex duct? Fiberglass-lined ducts? Fiberboard ducts?

A: Yes, Aeroseal effectively seals flex duct, fiberglass-lined ducts, fiberboard ducts, and even cement and brick passageways.

Q10: Why use Aeroseal instead of manual sealing with tape and mastic?

A: There are several reasons. Manual sealing is impossible for ductwork that is hidden or difficult to access. Aeroseal reaches and seals leaks throughout the entire duct system, providing a real impact on energy savings and HVAC performance. Even meticulously sealed ductwork in new homes can underperform due to leaks, which Aeroseal addresses effectively. Additionally, Aeroseal offers documentation of results, providing a before-and-after analysis through computerized testing. Studies show that Aeroseal is 60% more effective and 30% less expensive than manual sealing. If you have questions about Aeroseal, feel free to let us know. We welcome your comments.