Problem

Fixing leaky HVAC ductwork and envelopes in buildings can be an expensive, labor-intensive process. Yet doing so can save significant amounts of energy. According to the Department of Energy, homes and buildings consume 40% of the nation’s energy, but an average of 30% of this energy is wasted. A considerable fraction of this wasted energy is due to air lost from small leaks in heating and cooling ductwork, as well as in the building envelope separating the interior and exterior of every structure. Even after a new heating and air conditioning system is installed, 10-30% of thermal cooling and heating is often lost to duct leakage. 

Solution

Lawrence Berkeley National Lab (Berkeley Lab) scientist Dr. Mark Modera, PhD student Remi Carrie, and engineer Duo Wang developed a novel duct sealing technology in the 1990s. It was based on research funded in part by the DOE’s Office of Energy Efficiency and Renewable Energy (EERE) and other sponsors. It uses airborne adhesive particles to seal leaks from inside of pressurized ducts, reaching previously unfixable leaks at lower cost and minimal disruption, while reducing utility bills and energy consumption in government buildings, healthcare and educational facilities, residences, and hospitality/hotel facilities. 

To commercialize this innovation, Dr. Modera’s startup company Aeroseal licensed the system in 1997 for sealing ducts in residential buildings, and then licensed a further Berkeley Lab development that facilitated sealing commercial buildings in 2003. This technique has been proven to seal from 70 to 90% of duct leaks with a guaranteed life span of 10 years.

In 2001, the company was bought by Carrier Corporation. After working at Carrier until 2008, Dr. Modera became a professor at University of California at Davis. In 2010, Amit Gupta recognized the potential of the technology and joined forces with Dr. Modera to spin out Aeroseal from Carrier as a standalone company. Amit became the CEO in 2010, bringing management and marketing expertise, while Dr. Modera became the Chief Scientific Advisor. 

As a professor at UC Davis, Dr. Modera built upon the original air sealing innovation, creating a way to seal building envelopes. That technology was licensed to Aeroseal, turning into the AeroBarrier product in 2016. This advanced technology extended sealing capability beyond ducts to entire building envelopes—including walls, ceilings, and floors—significantly enhancing overall building performance and becoming another key solution for energy efficiency in buildings.

Recognition and Impact

Aeroseal’s pioneering technologies have garnered significant recognition and validation. For instance, in 2023, the company was recognized in the Inc. 5000, Inc. Magazine’s annual list of the fastest-growing private companies in America. 

Today, Aeroseal, headquartered in Dayton, Ohio, operates globally, having sealed over 300,000 homes and more than 500 million square feet of commercial space. Its technology has been adopted by prestigious organizations including Pfizer Pharmaceuticals, Hyundai Motor Company, Hilton Hotels, as well as numerous education, healthcare, military, and government facilities.

Aeroseal is continuing its growth trajectory. In 2023, it completed a $67 million Series B funding round led by Breakthrough Energy Ventures, which will facilitate the company’s further expansion into new markets and applications, such as gas pipeline sealing.