Aeroseal vs. AeroBarrier: Duct Sealing vs. Whole-House Air Sealing

Key Takeaways

1. Two Products from One Company

Aeroseal LLC makes both products, and they share the same core idea. Pressurized air carries a fine sealant mist toward the leaks. As the air squeezes out through a gap, sealant particles stick to the edges and build up until the gap closes.

The difference is what gets pressurized. With Aeroseal duct sealing, only the duct system is pressurized, and the sealant stays inside the ducts. With AeroBarrier, the whole house is pressurized with a blower door, and the sealant is sprayed into the rooms so it finds leaks in the building shell.

2. What Aeroseal Duct Sealing Does

Aeroseal seals your heating and cooling ducts from the inside. Registers are blocked so sealant only builds at the leaks, and the furnace and coil are isolated. A computer tracks leakage live in CFM25, which is cubic feet per minute of leakage at 25 Pascals of pressure.

It reaches joints, seams and boots hidden in walls, floors and ceilings that no one can seal by hand. Holes up to about 5/8 inch close with sealant, and larger gaps are repaired by hand first. Aeroseal describes the sealant as non-toxic and ultra-low VOC (volatile organic compounds).

In MaxSeal’s data from 38 Bay Area systems, average leakage fell from 400 to 54 CFM25, an 86% reduction.

3. What AeroBarrier Does

AeroBarrier is whole-house air sealing. According to Aeroseal, the process works like this:

• A blower door and fan put the house under positive pressure
• A starting test measures air leakage, and a target is entered
• Spray stations placed around the interior release an atomized sealant
• The sealant follows escaping air into cracks up to 1/2 inch and seals them
• Leakage is monitored in real time, and spraying stops when the target is reached
• A report documents the final result

Results are measured in ACH50, the number of times the house’s air volume leaks out per hour at 50 Pascals of pressure. Aeroseal says the sealant is a waterborne acrylic, GREENGUARD Gold certified and ultra-low VOC, and that a typical single-family home takes about four hours from setup to completion.

4. Aeroseal vs. AeroBarrier Side by Side

5. Who Each One Is For

Aeroseal duct sealing fits existing homes where the ducts are leaking. Typical signs include uneven rooms, weak vents, high bills and ducts that run through an attic, crawl space or garage. It’s usually done in one day per system, and Aeroseal recommends occupants not be home during the sealing stage.

AeroBarrier is aimed mainly at builders, energy raters and insulation contractors. Aeroseal positions it as a way to help new homes meet tight envelope targets, including ENERGY STAR, Passive House and IECC code requirements. Aeroseal says it can be applied anywhere from rough-in until before occupancy, with the ideal window right after drywall when prep is minimal.

If you’re building or gutting a home, ask your builder about envelope sealing. If you live in your home and your ducts leak, Aeroseal duct sealing is the one that addresses that.

6. Can AeroBarrier Be Used in an Existing Home?

Aeroseal’s guidance is that if a space can be pressurized, it can typically be sealed. The catch is preparation. Finished horizontal surfaces, such as countertops, floors and sills, must be covered, along with designed openings like ducts, electrical and plumbing. Technicians who enter during sealing wear protective equipment, and the space is aired out afterward.

In an empty building shell, that prep is simple. In a furnished home, it means covering or moving a lot of belongings and finishes. That’s why AeroBarrier is mostly used in new construction and major renovations. If you’re curious about it for an existing home, talk to an AeroBarrier installer about prep and cost for your situation.

7. A Note on Similar Names

When people search for air sealing, they often see similar-sounding names like airseal, homeseal or seal air. Some are unrelated companies or products, and some are simply search variations. If you’re comparing quotes, check that the product named on the quote is Aeroseal, that the contractor is an authorized dealer, and that you’ll get before and after leakage numbers in writing. Our guide to choosing an Aeroseal contractor covers what to ask.

8. How Aeroseal Duct Sealing Works at MaxSeal

Our Typical Aeroseal Process

1. Free consultation. We discuss your comfort problems and look at your system.
2. Baseline test. We measure duct leakage with a calibrated fan and airflow at every register with a flow hood.
3. Hand repairs. Large gaps and disconnected sections are fixed by hand.
4. Sealing. Aeroseal closes the remaining leaks while a computer tracks the drop in leakage.
5. Final test and report. You get before and after numbers and a certificate.

Our standard target is under 50 CFM25, and on request we aim for under 30. See what to expect on seal day.

9. Which One Should You Look Into?

• Rooms too hot or cold, weak vents, dusty house: start with a duct leakage test and consider Aeroseal.
• Building a new home: ask your builder or energy rater about AeroBarrier, and about duct testing too.
• Replacing HVAC equipment: test and seal your ducts first. See Title 24 duct testing.
• Drafty rooms, but ducts test tight: look at envelope air sealing with a qualified contractor.