NEW CONSTRUCTION DUCT LEAKAGE TESTING & AEROSEAL • TORONTO & THE GTA
Test the duct system. Correct the defects. Seal the leakage. Verify the result.
DAVESDUCTS works with builders, general contractors, mechanical contractors, project teams and custom-home clients to make duct tightness a measurable part of new-construction quality control. We inspect the installed duct system, identify physical deficiencies, coordinate or complete accessible repairs where appropriate, perform Aeroseal on suitable leakage, and document the before-and-after result.
WHY TEST NEW DUCTWORK?
New construction does not automatically mean a tight duct system.
Forced-air duct systems are assembled from trunks, branches, fittings, takeoffs, boots, transitions, seams and field-made connections. Good sheet-metal workmanship and manual sealing are essential, but visual inspection alone does not tell the project team how much leakage remains in the completed system.
WORKMANSHIP
Build and seal the duct system properly.
Major joints, connections and accessible openings should be mechanically completed and sealed using appropriate construction methods.
TESTING
Measure what was actually installed.
A duct-leakage test establishes an objective baseline after the system has reached the agreed stage of construction.
VERIFICATION
Document the completed result.
Post-seal testing provides measurable information for the builder, mechanical contractor and project record rather than relying only on visual confirmation.
THE DAVESDUCTS BUILDER PROCESS
Aeroseal should be part of a disciplined construction sequence — not a substitute for proper ductwork.
Our process separates physical duct defects from qualifying leakage so the right correction is used for each condition.
01
Inspect
Review accessible ductwork and identify obvious disconnections, incomplete fittings, large openings, damaged sections, blockages and other deficiencies that require physical correction.
02
Test
Prepare the system and establish the initial duct-leakage measurement so the project starts with a documented baseline.
03
Repair & Seal
Correct accessible physical leakage where appropriate and use Aeroseal for suitable smaller leakage throughout the prepared duct system.
04
Verify
Measure the final leakage result and provide applicable before-and-after sealing documentation for the project file.
WHAT AEROSEAL SOLVES
Use Aeroseal for duct leakage. Use physical repairs for construction defects.
Aeroseal is most effective when the duct system has already been installed correctly and major defects have been addressed. It can then target many smaller leakage paths that may be difficult to locate or reach manually.
Good Aeroseal applications
- Small leakage at duct joints and seams.
- Leakage at numerous difficult-to-access connections.
- Residual leakage after conventional manual sealing.
- Projects where measured duct tightness is required or desired.
- Quality-control verification before project turnover.
Repair these conditions physically
- Disconnected duct sections.
- Crushed or damaged ductwork.
- Blocked duct runs.
- Incomplete boots, plenums or transitions.
- Large construction openings or missing components.
IMPORTANT
A tightly sealed duct system can still be poorly designed.
Aeroseal reduces leakage; it does not increase the physical capacity of undersized supply or return ductwork, correct excessive static pressure, rebalance an improperly distributed system or repair an equipment-selection problem. Duct design, airflow and leakage should be treated as separate but related mechanical issues.
MEASURED PROJECT DOCUMENTATION
Turn duct tightness into a documented performance result.
For suitable projects, the value is not simply that sealant was applied. The project team receives measurable information showing the condition before sealing and the result after the sealing process.
BEFORE
Baseline Leakage
Establish the leakage level of the prepared duct system before aerosol sealing begins.
DURING
Sealing Progress
Monitor the sealing process as qualifying leakage is reduced throughout the system.
AFTER
Final Verification
Record the final leakage result and provide applicable project documentation for the builder, mechanical contractor or owner.
PROJECT WORKFLOW
Pre-Seal Test → Physical Corrections → Aeroseal → Post-Seal Test → Project Documentation
This sequence gives the construction team a clear quality-control record while keeping physical repairs and aerosol sealing in their proper roles.
CONSTRUCTION SEQUENCING
Schedule testing while major deficiencies can still be corrected.
The exact stage depends on the project, duct-system configuration and any applicable specification. In general, the system needs to be sufficiently complete for testing while remaining accessible enough to correct major physical deficiencies before finishes make repairs more disruptive.
PLAN EARLY
Coordinate before the sealing date.
Review the drawings, number of systems, anticipated register count, construction schedule and any project-specific leakage target or documentation requirement.
SYSTEM READY
Complete enough to prepare and test.
Relevant supply and return ductwork should be installed to the agreed test stage while major defects can still be reached and corrected.
BEFORE TURNOVER
Leave time for corrective work.
Complete verification early enough that any remaining physical or mechanical deficiencies can be addressed without disrupting occupancy or closeout.
WHO WE WORK WITH
DAVESDUCTS can provide the duct-testing and Aeroseal scope without replacing your existing mechanical contractor.
We can coordinate our work with the project team while the installing mechanical contractor remains responsible for the broader HVAC design, equipment installation and physical construction scope unless otherwise agreed.
Custom Home Builders
Add measurable duct tightness to high-performance and custom-home mechanical quality control.
Production Builders
Develop a repeatable testing and sealing workflow that can be coordinated across multiple homes or phases.
Mechanical / HVAC Contractors
Use DAVESDUCTS as the Aeroseal and duct-leakage-testing specialist while your team retains responsibility for the installed mechanical system.
General Contractors
Coordinate testing and sealing with site access, drywall sequencing, mechanical completion and project closeout.
Architects & Consultants
Coordinate measurable duct-leakage verification where it forms part of the project specification or performance objective.
Custom-Home Owners
Owners building or purchasing a new home can ask whether the duct system was ever pressure-tested and request verification where appropriate.
CUSTOM HOMES & BUILDER PROGRAMS
One-off projects and repeat construction need different workflows.
CUSTOM HOMES
Project-specific duct verification.
For a custom home, we can coordinate the test and sealing scope around the mechanical design, construction stage, system count and any performance objective established for the project.
BUILDER PROGRAMS
A repeatable quality-control process.
For builders completing multiple homes, we can discuss a standardized preparation, testing, sealing and documentation workflow that fits the construction schedule and reduces unnecessary site-by-site reinvention.
WHAT TO SEND DAVESDUCTS
Early project information makes coordination easier.
For builder and contractor inquiries, send the available mechanical information and construction schedule so we can understand the project before proposing the testing and sealing scope.
Mechanical information
- Mechanical or HVAC drawings, if available.
- Number of furnaces, air handlers or separate duct systems.
- Approximate supply and return register count.
- Duct material and general system configuration.
- Equipment schedule, if available.
- Any specified leakage target or testing requirement.
Construction information
- Project address and building type.
- Current construction stage.
- Expected duct-completion date.
- Drywall, insulation and ceiling schedule.
- Site-access or working-hour restrictions.
- Required documentation or inspection deadline.
NEW CONSTRUCTION AEROSEAL FAQ
Common questions from builders, contractors and project teams.
Why use Aeroseal on brand-new ductwork?
New ductwork can still leak at joints, seams, boots, takeoffs and field-fabricated connections. Aeroseal adds measured leakage testing and can seal many smaller openings that may be difficult to identify or reach manually.
Does Aeroseal replace mastic and proper duct installation?
No. Major joints, connections and physical defects should still be constructed and sealed properly. Aeroseal complements good workmanship by testing the completed system, sealing suitable residual leakage and verifying the result.
Can Aeroseal help with a specified duct-leakage target?
Where the system and project are suitable, pre-seal and post-seal measurements can be compared with the applicable project target or requirement. The project specification and test method should be reviewed before work is scheduled.
When should Aeroseal be performed during construction?
The exact stage should be coordinated with DAVESDUCTS. The system generally needs to be sufficiently complete for testing while major physical deficiencies can still be accessed and corrected before finishes make repairs more difficult.
Can Aeroseal repair disconnected ducts or large openings?
No. Disconnections, crushed ducts, blockages and major openings require physical repair. These conditions should be identified and corrected before or separately from the aerosol sealing process.
Does Aeroseal fix undersized ductwork or poor airflow?
No. Aeroseal reduces leakage; it does not increase the physical capacity of undersized supply or return ductwork, correct excessive system resistance or replace proper airflow design and balancing.
Do we receive before-and-after documentation?
For applicable projects, the Aeroseal process provides measured pre-seal and post-seal leakage information and applicable sealing documentation for the project record.
Can DAVESDUCTS work with our existing HVAC contractor?
Yes. DAVESDUCTS can provide the duct-leakage testing and Aeroseal scope while coordinating with the project’s HVAC contractor, builder or general contractor regarding preparation and required physical duct repairs.
Can this be used for both custom homes and production housing?
Yes. The process can be applied to an individual custom home or coordinated as part of a repeatable quality-control program for multiple new homes, subject to project requirements and system suitability.
AEROSEAL FOR BUILDERS • TORONTO & THE GTA
Planning a custom home or residential development?
Talk to DAVESDUCTS about duct-leakage testing, physical deficiency review, Aeroseal sealing and before-and-after verification. Send us the mechanical drawings, number of systems, construction schedule and any project-specific testing requirements so we can plan the scope properly.
