VA Hospital Uses Aeroseal to Properly Seal Ductwork






Post Construction Testing Found Building’s ERV System Did Not Meet Specifications – Aeroseal Proved To Be the Ideal Technology To Fix the Problem


Just months after opening the doors to its new Veterans House, the VA medical center of Indianapolis, Indiana discovered that the building’s Energy Recovery Ventilation (ERV) system wasn’t working properly. The diagnosis: intake and exhaust ductwork running throughout the building and through the ERV were full of leaks, making it impossible to balance and adjust airflow. Strict government standards require a leakage rate of 10% or less. Pretesting showed a leakage rate that exceeded 45% in some areas. Faced with this reality, VA administrators were contemplating a massive setback – the prospect of having to empty out the facility, close its doors and begin tearing down walls and ceilings in order to access the ductwork and manually seal the leaks. Lucky for all involved, the project’s construction company did a little Internet research and came across an alternative solution…Aeroseal.

In Brief

Property Owners: Veterans Administration
Engineers: RL Turner Corporation; IndianaScreen Shot 2015-11-09 at 11.19.23 AM
Aeroseal Experts:
Reupert Heating & Air
Type: 3-story temporary housing facility
Goal: Meet ERV specifications
Before Aeroseal: 900+ CFM* of total leakage
After Aeroseal: 63 CFM of total leakage
Results: Reduced average leakage by 93%
*Cubic feet per minute

It took Reupert Heating & Air just three days to aeroseal the building’s entire ductwork – the alternative option would have taken a year or more to complete and hundreds of thousands of dollars more in added demolition and construction costs to accomplish. Aeroseal works from the inside of the duct system to locate and seal leaks, so finding and sealing all of the various holes and gaps throughout the entire duct system could be accomplished without disturbing any of the newly finished construction. The aeroseal technology is safe and highly effective. The work was done over Memorial Day weekend and the building was open for veterans and their families the following day.

Aeroseal was first brought in to seal the exhaust ducts that ran from the bathroom grilles to the ERV. After VA administrators saw how effective and unobtrusive the sealing process was, the scope of the sealing project was expanded to include all four airflow systems.


“Aeroseal proved to be the right solution for the problem. I’ve been in this business for quite a long time and I’ve seen quicky solutions come and go, but this one actually held water…or I should say ‘air’ as the case may be.”

Timothy Flynn, General Engineer, Roudebush VA Medical Center

“I did my research and found that short of tearing down and starting over, there was only one option – Aeroseal. For retrofits and new construction projects like this, it is the ideal solution. The technology prevented a much more expensive and invasive procedure.”

David Petty, RL Turner Corporation

“The before and after reports showed us the results. The VA’s independent contractors then came in and confirmed what we already knew – Aeroseal did the job. And while we were simply looking to reduce leakage and fulfill specification requirements, it doesn’t take a rocket scientist to add up the difference Aeroseal made in system performance and know that it also provided a significant savings for somebody’s checkbook.”

Joe Reupert, Reupert Heating & Air

Aeroseal – The Technology

Developed at Lawrence Berkeley National Laboratory in 1994.

Research for Aeroseal was partially funded by the U.S. Department of Energy.

Aeroseal is the only duct sealant technology that is applied from the inside of the duct system. It is delivered as a non-toxic aerosol mist that seeks out and plugs leaks.

Aeroseal has proven to be 95% effective at sealing air duct leaks.

The Department of Energy proclaimed aeroseal technology to be one of the top 23 most important energy conservation technologies for consumers to come out since the department was first established.

Aeroseal has won several prestigious awards including DOE energy 100 Award, Popular Science – Best of What’s New, This Old House – new technologies and 2012 EBie award for use on an existing building retrofit project.

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