Thanks for the info on the past discussion on this product. I should have searched first before I posted
For reference, we have a local HVAC contractor that has been doing this for years. In performing QA on a utility rebate, I questioned the home owner on the work he had done and found that "Dayco" had performed the aeroseal process on his ducts along with replacing the furnace. I remember the duct leakage numbers being well below the rebate target of 10% of conditioned floor area with a cost of about $1,000 or so. Standard duct sealing with mastic and hand contact with the ductwork runs around $400-500 in our area.
Taking into account whether or not ducts are accessable and/ or insulated under a pile of attic insulation may result in the Aeroseal process being the more efficient way to go, especially if you have to re-blow portions of the attic or re-wrap the ducts.
Here is their link.
Just an fyi, there were problems within Carrier when they owned the rights and the project/technology was shelved just as their second generation of machine was hitting the market. Aeroseal was sold and is now back on the market under the Aeroseal name.
We are now a dealer for Aeroseal and could not be more happy with the results we've been getting. The process is labor intensive to get setup (removing register covers, blocking and sealing boots, etc...), but the sealing process works great. We were just called in to help out with a house for one of our Raters (we are a RESNET Rating and Rater Training Provider, and BPI Affilliate), that works on houses for Habitat. One of their homes was going to fail Energy Star because of duct leakage (they had tried to seal the ducts themselves but caught the problem too late after drywall)- we came in and we're able to take total supply leakage from 369 CFM@25 to under 60 and the the cavity ducted returns from over 400 CFM to approximately 44 CFM@25.
In another example - a house with two separate air handlers and duct systems - we were able to reduce the total system leakage (boots, ducts, air handler, etc...) by over 80%. The house was only 6 years old, and the return and supply were metal rectangular trunks with round branch ducts. Both systems had over 400 CFM of supply leakage, and about equal return leakage (not including the boots). Given both systems total flows were only about 1,300 CFM (actual measured flows), that means over 30% was being lost to floor cavities, wall cavities and some to the outside. The home owners saw a 16% reduction in total KWH year over year the first month (with only about 2 weeks of the billing cycle being included after sealing), with the exact same average daily temperature for the month as the year prior.
We'll be putting these examples and more out on our website soon. Check out our website for more information - Priority Energy , but in short - so far we are really happy with the product. We operate in Illinois, Wisconsin, Iowa, Michigan and Indiana.