Aeroseal Duct Sealing Review: Is It Worth the Cost in 2025?

Your heating and cooling system pushes 5,000+ cubic feet of air through ducts every hour. Most of those ducts leak. Studies by the U.S. Department of Energy estimate that 15-30% of conditioned air escapes through cracks, holes, and poor connections before it reaches your rooms. Aeroseal is a duct sealing technology that claims to seal these leaks from the inside without opening walls or ceilings. But does it work? Is it worth $1,000-$2,500? And how does it compare to traditional duct sealing? This comprehensive review covers what Aeroseal does, real-world results, pricing, and whether it's a smart investment for your home.

How Aeroseal Duct Sealing Works

Aeroseal uses a patented aerosol process to seal duct leaks from the inside. Here's the process: A specialized machine pressurizes your duct system and releases a non-toxic, water-based polymer sealant as a fine mist into the ducts. The mist flows with the air and reaches leaks throughout the network. When the particles encounter an air leak, they accumulate at the opening and progressively seal it until airflow stops. Unlike tape or mastic (adhesive paste applied manually), Aeroseal reaches leaks in hidden, inaccessible ductwork behind walls and in attics.

Key Takeaway: Aeroseal seals ducts from the inside without cutting walls open, making it ideal for hard-to-reach leaks that traditional sealing can't address.

Aeroseal Process and Timeline

Step-by-Step Procedure

An Aeroseal technician follows this typical process:

1. Blower door test: Measures current air leakage (CFM25 units) to establish baseline. Example: a 2,000 sq ft home might leak 8,000-12,000 CFM25 (CFM at 25 Pascal pressure). This quantifies how much conditioned air escapes.
2. System preparation: Technician seals return air vents and registers with temporary plugs (except one measurement point). Blocks combustion appliance air inlets to prevent draft issues.
3. Pressurization: Aeroseal machine pressurizes ducts to negative or positive pressure (typically 20-30 Pascals) depending on whether supply or return ducts have more leakage.
4. Sealant application: Machine releases polymer particles into pressurized ducts. Process runs 2-4 hours depending on system size and leak severity. Homeowner remains in home (sealant is non-toxic).
5. Verification: Second blower door test confirms duct leakage reduction. Target: 60-80% reduction in leakage. Example outcome: 8,000 CFM25 reduced to 2,000-3,000 CFM25.
6. System restart: Technician removes plugs, restarts HVAC, and verifies all vents flow normally.

Total appointment time: 3-5 hours including setup, testing, and cleanup. Some homeowners report slight smell (polymer odor) that dissipates within 24 hours.

Real-World Performance Results

Aeroseal publishes performance data, but independent field data from energy auditors and utility rebate programs offers real-world perspective:

Key observation: Older homes with more deteriorated ductwork show higher absolute CFM reductions but similar percentage improvements. A 2,200 sq ft house reducing from 6,800 to 1,600 CFM25 prevents approximately 3,000-3,500 CFM of conditioning air from leaking into unconditioned spaces (walls, attics). This translates to measurable energy savings.

Energy Savings: How Much Will You Actually Save?

DOE and utility studies link duct sealing to 15-30% heating/cooling energy savings, but this varies dramatically by climate and existing efficiency:

Scenario 1: Older home, hot climate (Texas)

2,000 sq ft home, 2025 electric rates $0.14/kWh, AC baseline 18 kWh/day (June-September). Current bill $2,520/year for cooling. Aeroseal reduces duct losses by 72% (from 6,000 CFM25 to 1,700 CFM25). This saves approximately 24% of cooling energy = 4.3 kWh/day = $180/month during cooling season. Annual AC savings: $720-$810 depending on season length and setpoints. ROI: $1,500 cost ÷ $765 savings = 1.96 years payback.

Scenario 2: Average home, temperate climate (Ohio)

1,800 sq ft home, $0.13/kWh (mixed gas and electric heating), heating $1,200/year, cooling $600/year. Aeroseal seals at 70% efficiency. Total HVAC energy ~19,000 kWh/year equivalent. Duct sealing saves ~12% = 2,280 kWh equivalent = $296/year. ROI: $1,800 cost ÷ $296 savings = 6.08 years payback.

Scenario 3: Newer, efficient home (Pennsylvania)

2,100 sq ft with modern insulation, new windows, baseline duct leakage only 3,500 CFM25 (relatively tight already). Aeroseal reduction: 70% = 1,050 CFM25 remaining. Energy savings only ~8% of HVAC = $150/year. ROI: $2,000 cost ÷ $150 savings = 13.3 years payback.

Key Takeaway: Aeroseal ROI ranges from 2-15 years depending on existing duct condition, climate, and energy costs. Older, leakier homes in extreme climates break even faster.

Aeroseal Cost vs. Traditional Duct Sealing

Cost breakdown for typical $1,600 Aeroseal project:

• Blower door test (baseline): $150-$200
• Aeroseal application and equipment: $900-$1,100
• Verification blower door test: $150-$200
• Ductwork inspection (if included): $0-$200

Will Your Utility Company Rebate Aeroseal?

Many utility companies offer rebates for duct sealing through energy efficiency programs. In 2025:

Utilities offering Aeroseal rebates:

• ComEd (Illinois): Up to $500 rebate for duct sealing (Aeroseal and manual qualify)
• AEP Ohio: $400-$600 for duct sealing depending on verified energy savings
• PECO (Pennsylvania): $300-$500 for HVAC efficiency upgrades including ductwork
• Xcel Energy (Minnesota/Colorado): Up to $800 for duct sealing
• Duke Energy (Carolinas): Rebate programs vary by region; $200-$400 typical
• Consumers Energy (Michigan): Up to $300 for eligible duct sealing

Real example: A homeowner in Illinois with ComEd pays $1,600 for Aeroseal. ComEd rebate: $500. Net cost: $1,100. Energy savings: $140/year. ROI: 1,100 ÷ 140 = 7.9 years payback (much better than without rebate).

Check your utility rebate: Contact your local utility company or visit their energy efficiency website. Many require pre-approval and use of certified contractors. Aeroseal is commonly on approved contractor lists because it's measurable (blower door door testing verifies results).

Pros and Cons of Aeroseal

Advantages

• Reaches hidden leaks: Unlike manual sealing, Aeroseal reaches leaks inside walls, behind cabinets, and in complex ductwork arrangements. Typical homes have 15-30% of duct surface area inaccessible without opening walls.
• Measurable results: Blower door testing before/after provides proof of effectiveness. Contractors can show you exactly how much leakage was reduced (CFM measurements). Traditional tape/mastic isn't always verified.
• Fast process: Completed in one visit, no wall demolition, minimal cleanup. Homeowners don't need extended access to attics or crawlspaces.
• Utility rebates available: Many utilities recognize Aeroseal and offer rebates because results are measurable and documented.
• Improves HVAC efficiency: Reduces strain on furnace/AC compressors, potentially extending equipment life and improving performance consistency (rooms no longer starved of conditioned air).
• Addresses often-missed problem: Many homeowners seal air leaks in envelope but ignore ductwork leaks (usually hidden). Aeroseal tackles this blind spot.

Disadvantages

• High upfront cost: $1,200-$2,500 is expensive for many homeowners. Even with rebates, net cost remains significant compared to other efficiency upgrades.
• Limited availability: Aeroseal requires specialized equipment and training. Not every HVAC contractor offers it. Geographic availability is limited (major cities and regions with utility rebate programs).
• Requires existing ductwork: If your home uses radiant heating, mini-split heat pumps, or has minimal ducts, Aeroseal doesn't apply. Newer homes with efficient designs may have already tight ductwork, reducing potential savings.
• Slower payback than other upgrades: Compared to air sealing envelope, improving attic insulation, or window replacements, Aeroseal payback often takes 6-10+ years (though dependent on baseline conditions).
• Environmental concerns (minor): The sealant is water-based and non-toxic, but it's an industrial polymer. Some homeowners prefer avoiding new chemicals in their homes, even if approved by EPA.
• Doesn't address undersized ducts: If your existing ductwork is undersized (common in older homes), Aeroseal seals leaks but doesn't solve air delivery problems. Some rooms may remain starved of airflow.
• Temporary nature: Unlike duct replacement, sealed leaks can re-open over decades if ducts age. The polymer remains flexible but isn't permanent (lifespan estimated 15-20+ years).

Aeroseal vs. DIY Duct Sealing

Homeowners sometimes ask: "Can I seal ducts myself?" Answer: Partially. You can access and manually seal visible ductwork leaks using mastic (duct sealant) and foil tape for $100-$200 in materials. However, you cannot reach 70-80% of duct leaks because they're hidden inside walls, between floor joists, and in complex ductwork behind cabinets. DIY sealing typically reduces leakage by only 15-25% because it's incomplete. Aeroseal's advantage is reaching what you can't see or access, achieving 70%+ reduction in leakage.

Best hybrid approach: Have an energy auditor perform a blower door test to identify ductwork leakage. Then hire a professional HVAC technician to manually seal accessible leaks (cheaper step). Finally, if leakage remains >50% of baseline, apply Aeroseal to reach hidden leaks. This combination approach can achieve 80-90% reduction at lower total cost than Aeroseal alone for some homes.

Is Aeroseal Worth It? Decision Tree

Get Aeroseal if:

• Your home has baseline duct leakage >6,000 CFM25 (measured by blower door test) AND your utility offers >$400 rebate
• You live in an extreme climate (hot summers, cold winters) where HVAC costs exceed $1,500/year
• Your home is 35+ years old with original or deteriorated ductwork
• You've already sealed the envelope, improved insulation, and upgraded windows (Aeroseal is next-tier efficiency)
• You plan to stay in your home 10+ years (payback period is long but positive over time)

Skip or delay Aeroseal if:

• Baseline duct leakage is <3,500 CFM25 (your ducts are already fairly tight)
• Your HVAC energy costs are <$600/year (savings won't be meaningful)
• Your home uses radiant heating, heat pumps, or has minimal ductwork
• No utility rebates are available in your area (payback extends to 12+ years)
• You plan to move within 5 years (payback won't recoup investment before you leave)
• Your utility doesn't verify results (harder to justify cost without proof)

Next Steps

Step 1: Schedule a blower door test. Contact a certified energy auditor (BPI or RESNET certified) in your area. Cost: $150-$250. This measures your actual duct leakage in CFM25 and gives you baseline data to decide if Aeroseal makes financial sense. Many auditors use software to estimate energy savings based on your specific home.

Step 2: Check utility rebates. Call your local electric or gas utility and ask if they offer duct sealing rebates for 2025. Ask specifically if Aeroseal contractors are on their approved list. Getting pre-approval can lock in rebate amounts.

Step 3: Get competitive quotes. Contact 2-3 Aeroseal-certified contractors in your region. Reputable contractors will provide written quotes that include baseline and predicted post-sealing CFM measurements, equipment fees, and expected energy savings. Compare total cost after rebates.

Step 4: Combine with other upgrades (optional). If Aeroseal payback is 8+ years without other upgrades, consider pairing it with attic insulation, air sealing, or window replacement. Many utilities offer rebates for these too, and combined projects often qualify for additional incentives that lower total cost.

Related articles: Understanding Your Electricity Bill, AC Cooling Costs, Blower Door Testing