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Correctional facility project with Aeroseal

Correctional Facility Energy Savings Achieves $7000/yr with Duct Sealing

When one of the industry’s most respected facility services providers was asked to make energy-efficient upgrades to a correctional facility (prison) in Pennsylvania, it had two key issues in mind. First, the services provider knew that the facility would be occupied during renovation, so limiting disruptions and health risks to the occupants was essential. Secondly, working as an ESCO, the company also knew it had to deliver on promised energy savings or face paying the difference out of its own pocket.

So when it came time to repurpose the existing supply ductwork serving the HVAC system’s VAV terminal boxes, using aeroseal to shore up any duct leaks was a no-brainer. Following inspection and data crunching it was estimated that duct sealing alone would generate energy savings of $7,108 annually.

In Brief

  • Building Type: Correctional Facility
  • Location: Pennsylvania
  • Services Provider: Large energy services company (ESCO)
  • HVAC Subcontractor: PLD Associates
  • Goal: Energy savings with minimal disruption
  • Before Aeroseal: 2,450 CFM of leakage
  • After Aeroseal: 256 CFM of leakage
  • Results: Through duct sealing alone, the ESCO saved its client $7,000+ annually, with an ROI of less than 4 years
Correctional Facility Saves Energy with Duct Sealing

Correctional facility in Pennsylvania uses Aeroseal duct sealing to save energy and money.

Unlike manual duct sealing methods, aeroseal is a computerized sealing process that works from inside the duct system to find and seal leaks. This inside/out approach makes accessing the entire duct system easy and demolition-free. The ESCO had used aeroseal in the past to seal the ductwork in hospitals, laboratories and other highly sensitive environments, so it knew the process itself was safe even for building occupants that can’t leave during the procedure. A call was placed to the Aeroseal duct sealing experts at PLD Associates.

PLD used foam blocks to isolate the area of ductwork to be sealed and then connected the aeroseal system to the duct via a long, flexible tube that ran from the sealing equipment to a temporary access hole cut into the ductwork. Once setup was completed, a switch was flipped and sealant was blown down the tube and into the duct interior. Twenty minutes later, sealing was finished.

In a single afternoon, the ESCO was able to reduce overall leakage by 90%. Post-sealing analysis showed annual energy savings to be 400% more than originally estimated and a return on investment of less than four years – all done without health risks, demolition or any other disruption to normal operations.


“We have used aeroseal in the past and knew it was really the only viable, cost-effective means of shoring up leaks in existing ductwork that is hard to access. We guarantee estimated savings so it’s imperative that we get real results – and we know that there is nothing more effective at finding and eliminating all the leaks than aeroseal.”

ESCO Project Manager

“Aerosealing was by far the easiest way to get the job done. We were able to quickly seal the leaks without having to rip into walls or ceilings. You’ll find that the inmates often look for reasons to complain, but the aeroseal process was so unobtrusive we didn’t hear a single complaint before, during or after it was used.”

Facility Maintenance Supervisor

About Aeroseal Technology

Before/After Aeroseal

Photo: Duct sealing results from applying Aeroseal to residential or commercial ductwork.

  • Developed at Lawrence Berkeley National Laboratory in 1994.
  • Research for aeroseal technology 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.

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