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Aeroseal Duct Sealing Cost: Smart Savings Decoded!

The cost of Aeroseal duct sealing typically ranges from $1,500 to $2,500. Prices may vary based on ductwork size and system complexity.


Aeroseal duct sealing is a cutting-edge solution designed to improve your home's energy efficiency and indoor air quality. By sealing leaks from the inside using a polymer adhesive, Aeroseal can drastically reduce energy losses, leading to lower utility bills and a more comfortable living environment.


This process not only helps in maintaining consistent temperatures throughout your home but also contributes to reducing the entry of pollutants and allergens. Optimizing your HVAC system with Aeroseal duct sealing is considered a smart investment toward prolonged system health and enhanced home comfort.

aeroseal duct sealing cost | Thermo Shield LLC

Introduction: Aeroseal Duct Sealing Cost

Aeroseal duct sealing is a revolutionary method that improves your home's comfort and energy efficiency. This technique seals leaks in air duct systems from the inside out. It represents a forward leap in home energy technology. By fixing leaks hidden in the walls, ceilings, and floors, Aeroseal enhances indoor air quality and reduces energy bills.

Understanding Duct Leakage And Efficiency

Duct leakage is a common problem in many homes, leading to energy loss, uneven heating and cooling, and higher utility bills. Leaks can occur due to age, poor installation, or maintenance. When your ducts leak, they force your HVAC system to work harder. This means more energy consumption and less comfort. Aeroseal seals these leaks, making your system more efficient and your home more eco-friendly.

Brief History Of Aeroseal Technology

Developed at the University of California, Berkeley, with funding from the U.S. Department of Energy, Aeroseal has been changing the way homes handle efficiency since the 1990s. This innovative sealant technology uses a polymer to plug leaks and holes up to 5/8 inches wide, moving through your ducts to find and seal gaps with precision. With its proven results, Aeroseal has won multiple awards for its impact on energy conservation.

The Importance Of Proper Duct Sealing

Proper duct sealing is crucial for any home or building. It stops air from leaking out of your ducts. This means your heating and cooling systems don't work as hard.

Impact On Energy Consumption

Sealed ducts can lower energy bills. They make sure the air goes right where it's needed. When ducts leak, your system uses more energy. That means higher costs.

  • Improved efficiency: Sealed ducts make heating and cooling equipment work better.

  • Less waste: Without leaks, no energy is wasted. This is good for your wallet and the planet.

Benefits Of Indoor Air Quality

Clean air is vital. Leaky ducts pull in dust and pollutants. Sealing them keeps air pure. This is especially important for people with allergies.

  • Fewer allergens: Less dust and pollen means fewer allergy symptoms.

  • Better breathing: Pure air is easier on your lungs.

Longevity And Maintenance Of HVAC Systems

Duct sealing can prolong the life of your HVAC system. It prevents it from working overtime. This means fewer repairs and maintenance.

Without Proper Sealing

With Proper Sealing

More strain on HVAC

Reduced strain on HVAC

Frequent repairs

Fewer repairs needed

Shorter system life

Extended system life

How Aeroseal Works: A Technical Perspective

Understanding the Aeroseal duct sealing process can save on energy costs and enhance home comfort. Here's the technical scoop on how this innovative solution works.

The Science Behind Aeroseal

Aeroseal technology harnesses the power of aerosol physics to seal leaks. It was developed at the University of California, Berkeley, with support from the U.S. Department of Energy. The technology involves injecting a mist of adhesive particles into the ductwork. These particles get suspended in the air and accumulate at the edges of leaks. Through this process, seals form from the inside out, plugging leaks up to 5/8 of an inch wide.

Step-by-step Sealing Process
  1. Pre-assessment: A technician tests the duct system to determine the initial leakage.

  2. System sealing: Small aerosol particles are blown into the duct system. As air escapes the leaks, particles attach and seal them.

  3. Final assessment: After sealing, a test confirms the reduction in leakage. The results are then presented to the property owner.

Safety And Environmental Considerations

Aeroseal is safe for both occupants and the environment. The sealant used for the ductwork is non-toxic and certified by the Occupational Safety and Health Administration (OSHA). It has a low Volatile Organic Compound (VOC) content, making it safe for indoor environments. The UL-tested sealant ensures that air quality remains uncompromised.

Aeroseal Cost Considerations

Understanding the cost of Aeroseal duct sealing involves several factors. It is essential to break down each element to see where your money goes. Homeowners seeking energy efficiency and improved HVAC performance find Aeroseal a valuable investment. Let's explore the cost considerations in detail.

Breaking Down The Costs

Each Aeroseal duct sealing project is unique. Costs vary based on specific needs and the current state of your ductwork. Generally, you will face expenses for materials, labor, and any additional services. These might include initial inspections and post-seal testing.

Factors Influencing The Price Of Aeroseal Duct Sealing

The final price tag for Aeroseal duct sealing doesn't just pull a number out of thin air. It reflects various aspects, such as:

  • Size of Home: Larger homes have more ducts, which raises the cost.

  • Complexity of Ductwork: Complicated duct systems require more time and sealant.

  • Condition of Ducts: Poorly maintained ducts might need repairs before sealing.

  • Accessibility: Hard-to-reach ducts can lead to higher labor charges.

A clear understanding of these factors ensures no surprises on your bill. Homeowners can also consider potential energy savings over time, which can offset the upfront costs of Aeroseal.

Comparing Aeroseal To Traditional Duct Sealing Methods

When choosing a duct sealing method, Aeroseal stands out. It uses advanced technology. Other methods are more manual. Each has its costs and benefits. The right choice depends on your needs.

aeroseal duct sealing cost | thermo

Cost-benefit Analysis

Understanding the cost-effectiveness of Aeroseal versus traditional methods is key. Let's break it down:

  • Initial Costs: Aeroseal may seem higher at first. But it includes all sealing materials.

  • Long-Term Savings: Aeroseal often leads to lower energy bills. This means more savings over time.

Rebates and Incentives: Some energy programs offer rebates. These can reduce Aeroseal costs.

Sealing Method

Initial Cost

Estimated Savings



More over time



Less over time

Performance And Durability Comparisons

Performance is important. So is how long the seal lasts. See how Aeroseal stacks up:




Leak Reduction

Up to 90%



10-year warranty

No warranty

Material Quality

High-tech sealant

Manual materials

Aeroseal often outperforms manual methods. It also comes with a warranty. The chances of seals holding up are high. So you know you're making a smart investment.

Financial Incentives And Rebates

Aeroseal duct sealing improves your home's energy efficiency. This upgrade, while pricier upfront, often qualifies for enticing financial incentives and rebates. Homeowners can significantly lower the overall cost. This section dives into utility rebates and government incentives available for Aeroseal users. Let’s unravel how you can save money.

Utility Rebates

Many local utility companies offer rebates for energy-efficient home improvements. Aeroseal sealing might earn you a rebate, depending on where you live. Here's how:

  • Utility companies list approved upgrades that qualify for rebates.

  • Aeroseal sealing typically falls under these upgrades.

  • The amount saved varies based on utility provider policies.

Contact your utility provider directly to learn about specific Aeroseal rebates.

Government Incentives

The government sometimes offers tax credits for energy-efficient home improvements. Aeroseal duct sealing may be applicable. To check current incentives:

  1. Visit the Database of State Incentives for Renewables & Efficiency (DSIRE).

  2. Search for energy improvement credits in your area.

  3. Review the criteria for qualifying improvements.

How To Qualify For Aeroseal Rebates

To qualify for Aeroseal rebates, follow these steps:

  • Check eligibility: Ensure your project matches rebate criteria.

  • Gather documentation: Some rebates require pre and post-sealing specifications or a Home Energy Assessment.

  • Apply promptly: Submit your rebate application within the specified timeframe. Deadlines are strict.

Assessing The Return On Investment (ROI)

When considering home improvement, evaluating the financial benefits is crucial. Aeroseal duct sealing is no exception. Homeowners often ask about its tangible returns. Does Aeroseal justify the initial investment? Let's crunch some numbers.

Calculating Energy Savings Over Time

Energy efficiency leads to cost savings. Sealed ductwork reduces air leakage. As a result, your HVAC system runs more effectively. This efficient operation translates to lower utility bills.

Here's how savings unfold:

  • Less energy is wasted.

  • The HVAC system uses less power to heat or cool your home.

  • Reduced power usage lowers energy bills.

Over months and years, these savings accumulate. Think about your average monthly energy bill. Even a 20-30% reduction adds up, especially over the system's lifespan.

Estimating Payback Period For Aeroseal

The payback period is the time it takes for savings to cover the initial cost. For Aeroseal, this period can vary. Several factors influence the payback timeframe.

Consider the following steps to estimate:

  1. Determine the Aeroseal service cost.

  2. Subtract any available rebates or incentives.

  3. Calculate monthly energy savings.

  4. Divide the net cost by monthly savings.

This will give you a payback period of months. In many cases, homeowners notice a payback period of a few years. This is often shorter than the lifespan of the ductwork. Investing in Aeroseal can thus be cost-effective in the long term.

Commercial And Industrial Applications



Cost Savings


Improved sterile environments

Up to 40% in energy costs


Balanced classroom temperatures

Reduced HVAC workload by 20%


Consistent production conditions

Minimized system loss

Notable Success: A tech campus cut down HVAC energy use by 50%> through Aeroseal duct sealing.

aeroseal duct sealing cost | duct Sealing

Navigating The Aeroseal Installation Process

Welcome to your comprehensive guide on Aeroseal duct sealing—a cutting-edge solution for enhancing home energy efficiency and indoor air quality. Understanding the process is key to achieving the best results.

Selecting A Qualified Aeroseal Contractor

Begin your Aeroseal journey by selecting a reputable contractor. Research is paramount. Look for:

  • Certified experts with proven experience

  • Positive customer reviews and case studies

  • Transparent pricing and warranty offers

Use BBB ratings and industry certifications to gauge reliability.

What To Expect During The Installation

The installation process is concise and non-invasive:

  1. Technicians perform an initial system inspection

  2. They seal vents and measure leakage

  3. A non-toxic sealant is deployed throughout the ducts

  4. Real-time results demonstrate improvements

Expect the whole process to take a few hours.





Ductwork assessment

30–60 mins


Vent sealing

30 mins


Aeroseal application

1–2 hours


Leakage measurement

15–30 mins

Your home remains clean and safe during installation.

Maintenance And Long-term Considerations

Thinking about Aeroseal duct sealing extends beyond the initial installation. Effective maintenance can ensure your home's air delivery system runs efficiently for years to come. Let's explore how you can maintain sealed ductwork and know when it's time for a reassessment or recoat.

Maintaining Sealed Ductwork

Once sealed, maintaining your ductwork is straightforward but vital for lasting performance. Here are key steps for upkeep:

  • Regular Inspections: Check your ducts annually for any signs of damage or wear.

  • Clean Filters: Replace or clean air filters every 3 months to prevent blockages.

  • Professional Check-ups: Have a licensed HVAC technician inspect your system every couple of years.

Clean ducts contribute to the system's efficiency, saving money on energy bills and repairs.

When To Reassess And Recoat Ducts

Your sealed ductwork won't last forever. Be attentive to signs of aging or damage:

  1. Energy Spike: An unexplained increase in energy use could indicate leaks.

  2. Uneven Temperature: Rooms feeling different from one another might suggest issues.

  3. Visible Damage: Any visible rips or tears in your ductwork need immediate attention.

A typical Aeroseal treatment has a warranty of 10 years. Plan for a reassessment near the end of this period. Recoating may be necessary to ensure continued performance.


Understanding the costs involved in Aeroseal duct sealing is key to making an informed decision. The investment promises enhanced energy efficiency and improved air quality. Factor in your specific needs and consult with professionals for accurate estimates. Prioritize this upgrade for a comfortable, cost-effective home environment.

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