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Aeroseal Envelope is an interior applied air sealing system that seals all building envelope leaks up to 1/2″.
The waterborne acrylic sealant is applied by pressuring a targeted building area, then spraying the aerosolized sealant into the pressurized space. The sealant is self-guided to the edges of visible and invisible leaks creating a seal not by packing the gap but by accumulating a crossed surface of leaks.
Designed to deposit in leaks and not on vertical surfaces, the sealant is applied within 60-90 minutes. It dries before system cleanup is complete, allowing construction to resume shortly after the process is complete with little to no impact on standard construction schedules.
The system measures the envelope leakage in real-time, enabling the system to dial-in specific requirements for air leakage and guarantee the results.
Aeroseal Envelope may be applied at any time between rough-in and before occupancy. Although, the ideal time to apply Aeroseal Envelope is rough-in or post-drywall. Other factors that affect installation are the build process and climate zone.
No. During application, if a technician has to enter the space while it is being sealed, they wear personal protective equipment (PPE). After the sealing, the area is safe to enter without protective gear within 20 to 30 minutes.
The Aeroseal Envelope Sealant (AeroBarrier X1) is based on waterborne acrylic that has been used as a fluid-applied permeable air barrier for many years. The sealant is GREENGUARD Gold certified and has been tested according to various ASTM standards and NFPA 285 for fire spread, smoke production, adhesion, antifungal properties, tensile strength, etc.
The sealant is low VOC and has no off-gassing.
The entire Aeroseal Envelope process, from setup to completion, takes approximately 4-hours for a typical single-family home. Additional time may be required when targeting reduced envelope leakage levels of Passive House or ZERH.
The cost will depend on the construction phase and targeted air tightness levels.
Once we have your job specifications, we will provide a written quote within 24 hours.
What is the life cycle of the product, or how long does the tight seal last?
Third-party lab testing reveals that Aeroseal Envelope withstands a simulated 50-year durability test with little or no seal degradation. Click here to see the durability test results (PDF file opens in new window).
Aeroseal Envelope seals holes as large as ½” and as tiny as human hair. Aerosol sealing is extremely effective at sealing narrow gaps and small holes that are typically not cost-effective or are missed during manual sealing.
If Aeroseal Envelope is applied at rough-in or right after drywall is installed, very minimal preparation is required. Vertical surfaces like walls and windows require no covering. All designed openings, such as ducts, electrical and plumbing, must be covered before sealing. All finished horizontal surfaces need to be covered.
The Aeroseal Envelope process requires temperature control and pressurizing of the areas to be sealed. The ideal condition is an outdoor temperature of ≥ 40˚F. Sealing can be done below 40˚F but may require additional steps for the preparation.
Yes, the Aeroseal Envelope sealant is GreenGuard Gold Certified, meaning that it’s safe to be used inside a home and meets the stricter certification requirements for use in schools and healthcare facilities.
The area must be aired for 30 minutes after the sealing is complete. This is done by opening doors and windows while running the fan. But work can resume in the space as soon as the sealing equipment is removed and 30 minutes have passed.
The Aeroseal Envelope system uses a standard blower door to measure envelope leakage during the process. The blower door is calibrated to meet ASTM Standard E779, E1554, CGSB-149.10-M86, EN 13829, ATTMA Technical Standard 1, NFPA 2001, RESNET and USACE.
Aeroseal Envelope modifies its blower door by adding a heater onto the fan. This allows the system to achieve optimal room temperature and humidity during sealing, allowing more sealant to be sprayed into the space for a faster, more efficient sealing process.
How large of a space (square footage) can this be used?
Aeroseal Envelope has been used in apartments as small as 500 sq ft and homes over 10,000 sq ft. As long as the space can be pressurized, it can typically be sealed. Additional blower doors can be added to increase the pressure in larger spaces.
Aeroseal Envelope has sealed houses to as low as 0.19 ACH50. But the value is in the system’s ability to allow builders to seal a home as tight as it is designed for. AeroBarrier can meet any IECC, Passive House, LEED, Well Standard, ENERGY STAR or Net Zero requirement.
A too-tight home can be bad if the space isn’t designed for that level of tightness. The popular saying “build tight, ventilate right” applies here and works both ways. Building tight without proper ventilation could cause issues with indoor air quality (IAQ) in the space. On the flip side, a leaky home with proper ventilation could cause the mechanical system to not work as designed. Because Aeroseal Envelope can dial in the desired tightness of the space, it removes the guesswork and ensures that the home is only as tight as the space it is designed for.
Aeroseal Duct sealing is an advanced process that uses a patented, non-toxic aerosol sealant to seal leaks in HVAC ductwork from the inside. The process begins by pressurizing the duct system and introducing aerosolized sealant particles. These particles are carried by airflow to leaks, where they accumulate and seal the openings without coating the entire duct interior. This innovative method improves energy efficiency, indoor air quality, and overall comfort by ensuring conditioned air reaches its intended destination. The system also monitors the sealing progress in real-time to ensure optimal results.
Any! Aeroseal Duct’s versatility gives contractors unmatched flexibility to meet their duct sealing needs with reliable results at any stage of the project. The only prerequisite is that the ductwork is installed in place—having the air handler installed is not required. This advantage allows sealing to be performed even when the ductwork is not easily accessible, providing greater scheduling flexibility while ensuring you and the builder can achieve your duct efficiency goals seamlessly.
The sealant (DuctSeal LT) is non-toxic and has been safely used in hospitals, surgery centers, schools, and government facilities all over the world. Additionally, the sealant has been tested by an independent lab and found to have extremely low concentration of volatile organic compounds (VOC’s). The primary component has no OSHA maximum exposure limit.
With Aeroseal Duct, up to a 5/8” hole can be sealed efficiently. Our technicians may perform manual repairs to plug larger accessible leaks and hasten the overall sealing process.
The cost will depend on the construction phase and on the size of the building. Once we have your job specifications, we will provide a written quote within 24 hours.
The Aeroseal Duct equipment comes standard with the same testing instruments used by code officials across Canada and the United States. Aeroseal integrates a manometer and our software intuitively tracks duct leakage in real time. Upon completion of the seal, a final duct efficiency test is conducted at 25 pascals, as required by code, and a certified copy is made available for your records and to provide all necessary parties.
When the duct work material is hung to manufacturer specifications, Aeroseal is a direct replacement for any traditional duct sealing method and removes the need for hand sealing at all connection points throughout the duct system. This leaves only the cabinet to be hand sealed as needed.
In these situations, we recommend drilling a small, 1/4″ hole, in the ductwork which is easily visible. Sealant will fill the hole just like all the other leaks and the inspector can confirm the presence of sealant. Some inspectors require that they must visually see sealant, despite the tightness of the ducts.
AeroSeal Resources
Learn more about Aeroseal and what it’s a perfect solution for addressing airtightness requirements for commercial and residential construction!
- aeroseal ENVELOPE: Net Zero Made Easy
- aeroseal ENVELOPE: Inflation Reduction Act Incentives for High Performance Homes
- aeroseal ENVELOPE: Multifamily Buildings - Guaranteed Air Sealing Made Easy
- aeroseal ENVELOPE: Single Family Homes - Guaranteed Air Sealing Made Easy
- aeroseal: Guide to Air Sealing - Strategies for Minimizing Air Leaks
Case Studies
Explore case studies demonstrating Aeroseal results for meeting and exceeding airtight residential and commercial construction requirements.
Video Gallery
Explore videos that provide insights into the Aeroseal process and results.
