Duct sealing

Duct Sealing with Duct Armor

When a duct run has corroded or lost its integrity, cleaning cannot bring it back. Sealing coats the interior to restore a sound surface without tearing out the ductwork.

A round duct interior before and after a protective coating was applied

The short answer

What duct sealing involves

The duct interior is cleaned and prepared, then a coating is applied to the inside surface of the run, forming a continuous lining over the existing metal. It is done in place, through the existing access points, so the ductwork does not have to be dug out or replaced.

It is the right answer for runs that have corroded or deteriorated rather than simply become dirty. An inspection establishes which of those you are looking at.

Interior of a corroded duct plenum before treatment Interior of a duct plenum after a protective coating was applied

When it is the right answer

Cleaning removes debris. Sealing restores the surface.

These are different problems. A dirty duct has material in it that can be taken out. A deteriorated duct has lost the surface it needs to move air cleanly, and no amount of cleaning replaces that.

  • Rust and corrosion visible on the interior of the run
  • Ductwork that has deteriorated with age rather than simply collected dust
  • Runs where replacement would mean opening floors, walls or slab
  • Systems where an inspection has already established the condition

Know exactly what you get

What a sealing project covers

Included

  • Inspection of the run to confirm sealing is the appropriate work
  • Cleaning and preparation of the duct interior before any coating
  • Application of the coating to the interior surface of the run
  • Work carried out in place through existing access points
  • A walkthrough of the finished run before and after

Not included

  • Replacing ductwork, which is a different job for a different trade
  • Sealing exterior joints or wrapping duct from the outside
  • Mould testing, identification or remediation
  • Furnace, air handler or refrigerant work
  • Any run where an inspection shows the duct is beyond restoring
  • Asbestos-containing materials, which need a licensed abatement contractor

How we price it

A custom estimate, because every system is different

  1. Length of run to be treated

    Sealing is priced by the extent of the ductwork being restored, not by property size.

  2. Condition found

    Heavier deterioration means more preparation before any coating goes on.

  3. Access

    The number and position of usable access points changes how the work is staged.

  4. System layout

    Branch count, takeoffs and plenum size all affect the surface being covered.

  5. Preparation required

    A run that needs thorough cleaning first is a longer project than one already clear.

What sealing is, and what it is not

Duct sealing restores the interior surface of ductwork that has deteriorated. The run is cleaned and prepared, then a coating is applied to the inside, forming a continuous lining over the existing metal. Because the work happens in place through existing access points, a system buried in a slab or under a floor can be restored without excavation.

It is not a substitute for cleaning

A duct that is simply dirty needs cleaning, not sealing. Sealing is for runs that have corroded or deteriorated to the point where the surface itself is the problem. An inspection is what tells the two apart, and we will not recommend sealing for a system that only needs a clean.

It is not a repair for structural damage

Runs that are crushed, collapsed or disconnected need mechanical repair or replacement. Coating the inside of a duct that has lost its shape does not restore it, and we will tell you when that is what we have found rather than take the work.

Deciding whether it is worth doing

The honest comparison is against replacement. Where ductwork is accessible and straightforward to replace, replacement may be the better long-term answer and we will say so. Where the run is under a slab, behind finished surfaces, or otherwise expensive to reach, restoring it in place is usually the more sensible option. The inspection gives you both sides of that.

Common questions

Duct sealing questions

How do I know whether I need sealing or cleaning?

An inspection settles it. If the run holds material that can be removed, it needs cleaning. If the interior surface itself has corroded or deteriorated, cleaning will not bring it back and sealing is the conversation. Most systems need one or the other, not both.

Does the ductwork have to come out?

No. The work is done in place through the existing access points, which is the reason it exists as an option. Runs under a slab or behind finished surfaces can be restored without opening the building up.

How long does a project take?

It depends on the length of run being treated, the condition found, and how much preparation is needed first. The inspection gives you a realistic timescale before you commit to anything.

What does it cost?

It is priced by the extent of ductwork being restored rather than by property size, so a specific number needs an inspection. We do not publish a figure because the range between a single deteriorated run and a whole system is very wide.

Is sealing always the right answer?

No. Where ductwork is accessible and straightforward to replace, replacement may be the better long-term choice, and we would rather tell you that than sell you a coating. Sealing earns its place when reaching the duct to replace it would be disruptive or expensive.

What happens to the debris already in the run?

It is cleaned out first. Preparation is part of the work, and nothing is applied over material that should have been removed.

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