Draft:Aeroseal LLC

Research into aerosol-based duct-sealing technology began at Lawrence Berkeley National Laboratory (LBNL) in the 1990s under the direction of Dr. Mark Modera.^[9] Modera founded Aeroseal in 1997 and sold the company to Carrier Corporation in 2001.^[10] In 2010, Amit Gupta, then a senior manager at Carrier, acquired the Aeroseal technology from Carrier and established Aeroseal LLC as an independent company. In 2011, Gupta partnered with Modera and relocated the company from Syracuse, New York, to Miamisburg, Ohio, where its headquarters remain.^[11]

Aeroseal later extended the aerosol-sealing approach to whole-building envelopes through collaborations with the Western Cooling Efficiency Center at the University of California, Davis. The envelope-sealing technology that became AeroBarrier was publicly unveiled in 2015 and was in broader market use by 2018.^[12][13]

In 2021, Aeroseal raised a $22 million Series A funding round led by Breakthrough Energy Ventures, with participation from Energy Impact Partners and Building Ventures.^[14] In 2023, the company raised a $67 million Series B funding round led by Breakthrough Energy Ventures and Climate Investment.^[15]

The company has expanded internationally through partnerships and acquisitions. These include a merger agreement in Canada with AeroBarrier Canada and Construction Evolution Systems.^[16] The company also incorporated AeroBarrier UK and Ireland Ltd in 2023, and acquired Saudi-based Advanced World Trading in 2024, which was rebranded as Aeroseal Arabia.^[17] Technical reports have described the deployment of Aeroseal’s duct-sealing technology across multiple countries, with a Lawrence Berkeley National Laboratory publication stating that the technology is used in 27 countries through its licensing model.^[18]

Aeroseal’s systems use a water-based acrylic polymer delivered as an aerosol while the duct systems or building enclosures are pressurized. Using pressure differentials, the aerosol particles accumulate at leakage sites, sealing gaps from the inside. Unlike conventional duct sealing methods that rely on manual application of mastic or tape at accessible joints, the aerosol process seals leaks throughout the system, including areas that are otherwise inaccessible.^[19]

In practice, the procedure is performed without demolition. The ductwork or building enclosure is isolated, pressurized, and injected with aerosolized sealant, while a computer-controlled system measures pressure and leakage levels in real time.^[20] In addition, Aeroseal’s duct-sealing technology measures duct leakage before and after sealing using duct pressurization testing, and its AeroBarrier envelope-sealing system uses blower-door pressurization with pre- and post-sealing airtightness testing to document results.^[21][22] The U.S. Environmental Protection Agency’s Energy Star program states that sealing and insulating ducts can improve heating and cooling system efficiency by as much as 20% or more, and field studies have reported energy savings in the range of 15–30% from duct sealing and related HVAC efficiency measures.^[23][24]

Aeroseal’s products are used in residential, commercial, and new construction applications, including duct sealing in existing buildings and envelope sealing for new homes and multifamily construction.^[25][26]

In a field demonstration at a Denver Federal Center building (Building 40), the U.S. General Services Administration and Oak Ridge National Laboratory reported more than 50% envelope air-leakage reduction in under seven hours, with modeled energy and HVAC load reductions based on the measured airtightness improvements.^[27] The method has been applied in homes, schools, hospitals, high-rise towers, and federal facilities, and has been evaluated by the U.S. General Services Administration (GSA) through its Green Proving Ground program.^[28] The AeroBarrier product applies the same aerosol-sealing method to building envelopes to achieve specified airtightness targets.^[29]

Aeroseal technology has been used in a range of institutional and commercial projects. At Harvard University’s Girguis Laboratory renovation, duct sealing was used to reduce leakage and improve HVAC performance.^[30] In the King Abdullah Financial District in Riyadh, the technology was applied in high-rise buildings to improve air quality and energy efficiency.^[31] At Memorial Sloan Kettering Cancer Center in New York City, Aeroseal duct sealing was used to address HVAC leakage in a healthcare facility.^[32] A building-envelope sealing demonstration at the Denver Federal Center (Building 40) was conducted in collaboration with the U.S. General Services Administration and Oak Ridge National Laboratory.^[33][34] Aeroseal technology was also included in a U.S. Department of Energy–recognized energy-efficiency retrofit project at Northgate II in Camden, New Jersey.^[35]

Technical literature describes Aeroseal’s duct-sealing method as proprietary. A National Renewable Energy Laboratory report states that the technology was developed jointly by the U.S. government and Aeroseal, and that Aeroseal holds an exclusive license to use it.^[36]

Early patents describing remote aerosol sealing include U.S. Patent No. 5,522,930, Method and device for producing and delivering an aerosol for remote sealing and coating (1996), and U.S. Patent No. 5,980,984, Method for sealing remote leaks in an enclosure using an aerosol (1999), both assigned to the Regents of the University of California.^[37][38]

Public patent records also list later Aeroseal-assigned patents related to sealing process controls, including U.S. Patent No. 11,921,524, Autonomous concentration control systems and methods of controlling concentration of a gas or particle mixture (2024).^[39][40]

Aeroseal is listed as the assignee on publicly available U.S. patent records, including published U.S. patent applications such as U.S. Patent Application US20240419195A1, which relates to sealing system operation and remains pending.^[41]

Buildings account for a significant share of global energy use and related greenhouse gas emissions, commonly estimated at approximately 30–40%.^[42][43] Air leakage in HVAC duct systems can contribute 20–40% of heating and cooling energy loss in typical U.S. homes.^[44] Aeroseal’s duct- and envelope-sealing systems are intended to reduce such leakage, improving building energy performance.

Aeroseal has received industry recognition and awards for its duct and building envelope sealing technologies. The company was named a BloombergNEF Pioneers winner in 2024 in the category of decarbonizing the construction and operation of buildings.^[45][46] Aeroseal has also been included in the Global Cleantech 100 list by Cleantech Group and was named among Time magazine’s America’s Top GreenTech Companies in 2025.^[47][48]

The company’s products have received multiple industry awards. AeroBarrier received Best in Show and Most Innovative Building Product honors at the NAHB International Builders’ Show in 2018.^[49][50] Aeroseal HomeSeal was named Product of the Year at the 2016 AHR Expo Innovation Awards.^[51] AeroBarrier Connect received recognition at the Best of IBSx awards in 2021 and the Architizer A+Product Awards.^[52][53] Additional product and industry awards include recognition from ACHR News, Environment+Energy Leader, BLT Built Design Awards, Products That Count, and the Ohio Success Awards.^{[54][55][56][57]}