What Is Aeroseal?
Aeroseal is a patented, non-invasive duct sealing technology that injects a water-based polymer mist into pressurized HVAC ducts. The aerosol particles find and seal leaks from the inside—even leaks hidden behind walls or in ceilings—without requiring demolition. Recognized by the U.S. Department of Energy (DOE) and EPA, Aeroseal is one of the most effective duct sealing methods available.
In older Chicago-area homes, where ducts are often routed through walls, between floors, or in unconditioned attics, traditional sealing (tape or mastic) often misses hidden leaks. These homes can lose 25–40% of conditioned air through duct leaks. Aeroseal targets those hard-to-reach spots and seals them with up to 95% effectiveness, greatly improving efficiency and comfort.
Local Case Studies
DOE Study – Chicago Home
- Duct delivery efficiency before sealing: 67%
- After manual sealing: 83% (~20% heating cost savings)
- Aeroseal typical outcome: ~95% efficiency—with no damage to walls or ceilings
Chicago Retrofit (2015)
- Older home with ducts in walls
- Achieved 95% leak reduction
- Saved ~$600/year on energy
- ROI: ~2 years
Indiana Farmhouse
- Cold-climate, older construction
- Achieved ~34% utility savings (~$678/year) after Aeroseal
- Climate and construction comparable to Chicago
Highland Park Mid-Century Modern (1951)
- Duct efficiency before sealing: ~55%
- Post-sealing: >95% air delivery
- Followed by foam insulation, HVAC downsizing (AC reduced 50%, furnace BTUs cut by ⅓)
- Total ROI: 2 years on Aeroseal as part of a comprehensive upgrade
Benefits
Energy Savings
- Common savings: 20–35% of HVAC energy use
- Midwest/Northeast average: $300–$700+/year
- com cites $300–$400/year average savings
Comfort and Air Quality
- Better room-to-room temperature consistency
- Fewer short cycles and improved humidity control
- Reduced infiltration of dust, allergens, and outdoor air
Hidden Leak Effectiveness
- Seals leaks manual methods can’t reach
- Particularly useful in Chicago-area homes with concealed ductwork
Impact on HVAC System Performance
Improved System Efficiency
- Sealed ducts mean more conditioned air reaches living spaces
- Improved delta-T and airflow reduce equipment wear
- Lower system runtime and fewer cycles
Optimized Equipment Sizing
- Aeroseal can bring airflow into line with Manual D standards
- Makes Manual J sizing more accurate—avoiding oversized systems
- Right-sized systems improve efficiency, reduce short-cycling, and enhance lifespan
Why It’s Crucial in Chicago’s Climate and Housing
Chicago’s cold winters and humid summers make energy loss through leaky ducts a costly problem. Older homes often have ducts:
- Hidden in walls or attics
- Without insulation or sealing (pre-modern code)
- Inaccessible to manual sealing methods
Aeroseal’s inside-out approach solves this problem—without demolition.
Summary for Chicago Homeowners
Why Aeroseal is worth it:
- Leakage reduction: Homes often lose 25–40% of air; Aeroseal routinely seals 80–95% of leaks
- Energy savings: Typical savings of 20–35% annually (~$300–$700+), with ROI in 2–4 years
- Comfort boost: More even heating/cooling, fewer drafts, improved indoor air quality
- Equipment performance: Allows right-sizing of HVAC systems, extending lifespan and cutting install costs
- Low disruption: No wall cutting or duct demolition—most jobs done in a few hours
Even though newer case studies specific to Chicago are limited, results from DOE studies, nearby Midwest homes, and documented regional installs clearly demonstrate Aeroseal’s relevance and effectiveness for the Chicago area.
Final Thoughts
For homeowners in the Chicago area, Aeroseal is one of the most impactful upgrades you can make to an older home’s HVAC system. It tackles a hidden but major cause of inefficiency—duct leakage—using a proven, noninvasive method. Whether you’re aiming for energy savings,
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