Aerosol Envelope Sealing of New Residences: U.S. Department of Energy (DOE), Energy Efficiency & Renewable Energy (EERE)

Dave Bohac, Curtis Harrington, Lena Burkett (NREL Technical Monitor)

Research output: NRELTechnical Report


This project investigated the use of an aerosol-based sealing method to reduce air leakage of new homes in the United States. The process involves pressurizing the building while dispersing an aerosol sealant “fog” to the building interior. As air escapes the building through leaks in the envelope, the sealant particles are carried to the leaks where they make contact and stick, sealing the leaks. A standard blower door is used to facilitate the sealing process and to provide real-time feedback and a permanent record of the sealing. The technology is thus capable of simultaneously measuring, locating, and sealing leaks in a building automatically. The project team worked directly with builders to identify the best stages for incorporating aerosol sealing from the perspectives of cost, performance, and seamless integration into the construction process. A total of eight builders in Minnesota and California participated in the research, providing homes for testing and feedback on appropriate stages of construction to apply the sealing. The cost of the aerosol sealing and resulting house tightness were compared to similar group of houses that used conventional sealing methods. Aerosol sealing produced tighter houses overall. Researchers also evaluated conventional sealing methods to determine whether they can be eliminated or reduced to improve cost effectiveness.
Original languageAmerican English
Number of pages149
StatePublished - 2020

Bibliographical note

Work performed by the Center for Energy & Environment, Minneapolis, Minnesota, and the University of California, Davis

NREL Publication Number

  • NREL/TP-5500-78112


  • aerosol
  • buildings
  • envelope
  • residential buildings


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