Cost Comparison: Ductwork Replacement vs AerosealJonathan at Aeroseal
During the floor-to-ceiling renovation of the Gallego Intermediate School in Tucson, Arizona, contractors removed the existing ceiling tiles to find ductwork that was in such bad shape that replacing the entire duct system seemed to be the only option. The building’s HVAC system included 34 individual units, each with its own supply and return ducts, all made of duct board that was literally falling apart at the seams. Some of the ducts were in such disrepair that they made leakage testing impossible. Surely the cost of new ductwork in this scenario would be significant.
After doing an estimate cost to replace ductwork, unfortunately, the Tucson, Arizona-area school district couldn’t afford either the ductwork replacement cost or the time necessary to replace the existing duct system. Beyond the estimated $200,000 dollars it would have cost to replace all of the damaged ductwork in the building, the school was set to open in three months and replacing the ductwork would have taken twice that amount of time.
Project Summary Points
- Building: Gallego Middle School, Sunnyside SD
- Location: Tucson, Arizona
- Consulting Contractor: Kelly Wright & Associates
- Aeroseal: GreenSeal / Div. of Excel Mechanical
- Goal: Repair existing ductwork within time and budget
- Before Aeroseal: 49k CFM of leakage
- After Aeroseal: 8k CFM leakage
- Results: Only two weeks to attain 5% leakage rate at ¼ cost of duct replacement
Faced with an air duct replacement cost that was far too expensive, a consulting engineer on the project suggested they consider Aeroseal, a new duct sealing technology he had seen demoed at a recent industry seminar. The cost of Aeroseal duct sealing was supposedly much lower than the average cost to replace HVAC ductwork. The Aeroseal experts at GreenSeal were called in to share information about the new technology and in just a matter of days, the project started was under way!
Given the poor condition of much of the existing ductwork, the GreenSeal crew began reconnecting and repairing the most dilapidated portions of the ductwork using tape and mastic. Even after this work, testing showed a total system leakage rate of about 49,000 CFM. Then the Aeroseal application began.
It took GreenSeal less than two weeks to Aeroseal all 34 duct systems – both supply and return. The final results showed total leakage down to 8,000 CFM – an 85% reduction and well below the 5% leakage rate they were targeting. The total air duct sealing cost from Aeroseal was a fraction of the estimate for duct replacement cost and best of all, the school opened on time!
“I think a lot of schools in the district could benefit from this technology. The Aeroseal team was able to work in coordination with all the other contractors on the job, ensuring that we maintained our extremely tight schedule. They also assisted us in securing a rebate from the local utility company that helped us stay within budget on the ductwork sealing cost. In the end, this was an ideal solution to a potentially derailing problem. I look forward to assessing energy savings over the next year or two. In the meantime, we have heard nothing but positive feedback regarding the comfort of those using the new school building.”
– Tom Hubbard, Bond Project Manager, Sunnyside School District
“When contractors removed the ceiling tiles, they saw that the existing ductwork was in really bad shape. They wanted to replace all of the ductwork but it was simply out of the budget range – and that’s when one of our engineering consultants suggested we look into using Aeroseal as an alternative. The duct sealing cost proved to be much less expensive than replacing the ductwork and it took only a matter of days to complete the job so the school was able to open as scheduled.”
– Cindy Bova, Energy Project Manager, Sunnyside School District
Rather than burden yourself trying to find the answer to the question “How much does it cost to replace ductwork?” you might consider Aeroseal as an alternative. If you’re looking at how much it costs to replace ductwork, it can be a substantial amount in most cases. The ductwork repair cost of Aeroseal is much lower, however. The lower ductwork cost is due, in part, to the fact that Aeroseal is a much simpler solution to leaky ductwork. Rather than having a team of contractors come in and spend weeks performing messy, costly removal and reinstallation of new ductwork, Aeroseal works with what you already have.
Instead of pulling out all of the old ductwork, Aeroseal professionals will apply the Aeroseal solution from the inside, out. Searching for and filling in leaks and holes wherever they may be, Aeroseal professionals provide your ductwork system with a semi-permanent fix that costs far less than the average total HVAC replacement cost. This will save you money in the short-term as well as the long-term.