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Duct Armor vs. Aeroseal: Which is Better?

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Brandon Kirk

Brandon Kirk

Brandon Kirk is the owner of Planet Duct-Air Duct Cleaning. As a NADCA Certified Air-Duct Cleaning Specialist, he has extensive experience servicing air ducts in El Paso County and the Southern CO region since 2019.

At Planet Duct, we offer two duct sealing methods to help improve your home’s energy efficiency and air quality—Duct Armor and Aeroseal. Energy Star estimates that 20-30% of conditioned air escapes your home’s ductwork through leaks and holes. Unfortunately, this means that your HVAC system has to work harder to maintain a comfortable temperature in your living area, costing you thousands of dollars in energy bills and wear and tear on your HVAC units. 

Though it can save you money in the long run, duct sealing does require a sizable upfront investment, so naturally, you want to choose the best duct sealant. As a certified Aeroseal and Duct Armor dealer, Planet Duct is here to give you an honest comparison of Duct Armor vs. Aeroseal.

What is Aeroseal?

Aeroseal is a revolutionary technology that seals the air ducts from the inside, using a non-toxic aerosol mist that adheres to leaks and cracks and causes them to seal up. The process is quick, efficient, and entirely safe for all building occupants. 

Aeroseal has been shown to reduce air leakage by up to 90%, which translates to significant energy savings for homeowners and commercial property owners. Furthermore, by sealing up leaks and cracks in your air ducts, you can enjoy improved indoor air quality and enhanced comfort inside your home or office. Overall, it is a highly effective solution to energy waste, high utility bills, and poor indoor air quality.

What is Duct Armor?

Duct Armor is a spray-on rubberized duct lining that encapsulates rust, mold, smoke, and water damage to restore ductwork while sealing any potential leaks. In addition, this layer acts as a protective barrier against external and internal factors that can cause further damage. External factors include weather conditions, rodents, and other environmental hazards, while internal factors can range from aging components to potential mold growth.

Much like Aeroseal, Duct Armor is an effective way to prolong the lifespan of HVAC ductwork and enhance the performance of your HVAC system. You may even notice cleaner, fresher air in your building.

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Comparing Two Duct Sealing Processes

You may already be noticing some critical differences between Aeroseal and Duct Armor, but let’s compare the installation processes for each product. 

Aeroseal Installation

Aeroseal installation takes about 4 hours to complete. Your certified Aeroseal dealer will start by measuring how much air is escaping your ductwork. First, they will completely seal off your system by blocking all vents and registers. Next, they will pressurize the system and generate an air leakage report. Aeroseal solution will then be distributed throughout your ductwork and adhere to all of the holes and cracks. 

Aeroseal’s patented technology will provide you with real-time reports on your system’s performance so that you can see the improvement. There is virtually no cleanup since Aeroseal is so precise, and your HVAC system is safe to use immediately.

Duct Armor Installation

before and after for duct armor

Duct Armor also takes about 3-4 hours to install. Your Duct Armor technician will start with a video inspection of the ductwork to create the best plan for duct restoration. Duct Armor should not be applied to ducts with excess debris or standing water, so the installer may recommend a duct cleaning or drainage repair first.

Then the liquid Duct Armor will be applied non-invasively through your home’s vents. The non-toxic formula will harden, sealing your ducts and protecting them from further damage. Your technician will do a final video inspection, and then your HVAC system is ready.

Pros and Cons of Duct Armor vs. Aeroseal

Aeroseal Pros and Cons


  • Can improve your home’s energy efficiency by up to 90%.
  • Works well for ducts that can’t be accessed externally.
  • Keeps your home’s temperature more consistent.
  • Reduce dust and other contaminants in your air.
  • Precisely measures system leakage to help pinpoint problem areas.


  • More expensive than traditional duct sealing methods.
  • Only seals holes smaller than ⅝ inch.
  • You may not notice a huge difference if your system leaks are minor.
  • Does not fully line ducts, so you’re not protected from future leaks.

Duct Armor Pros and Cons


  • Provides an extra layer of durability to your ductwork.
  • Safely encapsulates asbestos, mold, and other contaminants without requiring you to replace your system.
  • Duct Armor formula is non-toxic, fire-resistant, and mold resistant.
  • Improves indoor air quality and HVAC efficiency.


  • Cannot be used on flex ductwork.
  • More expensive than traditional duct sealing methods.

Can I Seal My Ducts Myself?

Yes! You can seal your ductwork with an adhesive called mastic available at most hardware stores. Mastic allows you to seal holes or cracks smaller than ¼ inch. Larger holes will require a metal patch sealed by mastic and mesh tape. 

You may be wondering why you’d need Aeroseal or Duct Armor if you can repair your own ducts at a much lower cost. Repairing your ducts with mastic or a patch requires you to have external access to your ductwork, and in many homes, this is not the case. 

You also need to know where the leaks are in your ductwork. DIY duct sealing requires a lot of guesswork, whereas a certified Aeroseal technician can find and seal every place where air is escaping from your ducts, so you can be confident that the job is done right. 

In addition, DIY duct sealing will not address your mold, rust, or asbestos problem like Duct Armor. 

Book a Duct Sealing Appointment Today

Duct Armor and Aeroseal are both great products that serve different purposes for homeowners. Generally, if you just want to improve your energy efficiency and indoor air quality, Aeroseal is the right choice for you. If your ductwork is heavily damaged, however, or contains harmful substances like mold, you’ll want to opt for a complete lining like Duct Armor. Contact our duct sealing experts for more information on the differences between Duct Armor and Aeroseal or to book your appointment.