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Ductwork Leakage — The Hidden Energy Drain
Ductwork leakage is the unseen enemy of ventilation efficiency. Even minor leaks across an extensive system can waste thousands of pounds in energy each year.
In commercial and industrial environments, this leads to higher operating costs, reduced airflow, and compromised air quality.
Leaks often occur through poor installation, damaged joints, or natural wear — issues that worsen over time without professional testing and sealing.
ACSEU’s expert technicians detect, seal and verify your ductwork to restore airtight performance and compliance.
Visual checks, airflow measurement, and airtightness testing to locate leaks.
A full diagnostic report outlining where, why, and how leaks occur.
Professional sealing, re-insulation, and duct replacement using industry-approved materials.
Post-work pressure test to confirm performance improvement.
Scheduled hygiene checks and inspections to maintain airtightness.
What Is Ductwork Leakage?
Ductwork leakage is the loss of conditioned air through holes, cracks or poor connections within your duct system.
This results in wasted energy, uneven temperatures and poor indoor air quality.
Leaking duct systems are usually caused by improper installation, damage, or ageing materials; however, this can be remedied and fixed through professional sealing. This can be done manually or using advanced aerosol systems like Aeroseal for hard-to-reach areas.
In commercial environments, leakage can occur across entire networks of ventilation ducts, extract fans and risers, often hidden above ceilings or behind walls.
Without testing, most leaks go undetected but continue costing energy and performance every day.
Causes of Ductwork Leakage?
Improper Installation
Poorly fitting joints, disconnected boots, and weak sealing at plenums and registers allow air to escape before reaching occupied areas.
Damage
Rodents, corrosion, building movement or accidental drilling can create openings in ducts and joints.
Deterioration
Ageing materials and failed taped joints naturally degrade over time, developing cracks or gaps.
Pressure Fluctuations
Regular air pressure changes inside the HVAC system can enlarge small leaks, especially around joints.
Poor Sealing
Gaps where different materials meet — such as sheetrock to return boxes or supply boots — are frequent leak points.
Consequences of Ductwork Leakage?
Increased Energy Costs
Heating, cooling, or extraction systems must work harder to replace lost air, driving up energy consumption and bills.
Uneven Temperatures
Air fails to distribute evenly, leaving some rooms too hot while others stay uncomfortably cold.
Poor Air Quality
Leaky ducts can draw in dust, insulation fibres, and mould spores from ceiling voids or crawl spaces, contaminating indoor air.
Reduced Efficiency & Lifespan
Fans and blowers run longer and louder to maintain airflow, increasing wear, noise, and maintenance costs while shortening equipment life.
Solutions for Ductwork Leakage
1. Seal Visible Leaks
Accessible ducts can often be sealed using a professional-grade mastic or aluminium tape. Standard “duct tape” isn’t suitable as it degrades quickly.
2. Use Advanced Sealants
For concealed ducts above ceilings or behind walls, ACSEU engineers can apply advanced aerosol sealants such as Aeroseal, which coat and seal leaks from the inside.
3. Professional Testing & Diagnostics
Our engineers perform pressure or airflow tests to measure total leakage, identify problem areas and verify improvements after sealing.
4. Re-insulation
Once leaks are sealed, insulation wrap helps stabilise temperature and prevent future expansion-related damage.
5. Ongoing Maintenance
Regular hygiene inspections and system health checks ensure that leaks don’t redevelop and that energy efficiency remains high.
Why Ductwork Leakage Matters for Businesses
Commercial duct systems are large and pressurised — meaning small leaks can add up to major losses. A single 10% leakage rate can translate into 20–30% higher HVAC energy costs.
Beyond efficiency, leaky ducts compromise air hygiene, comfort, and compliance with UK ventilation and fire safety standards.
By proactively addressing leakage, ACSEU clients see tangible savings, improved airflow balance, and healthier work environments.
When to Book a Duct Leakage Test
You should schedule an inspection if:
Energy bills have increased without explanation.
Ventilation seems weak or uneven in parts of the building.
Odours or dust appear around supply or return vents.
The system hasn’t been tested in several years.
You’re preparing for a compliance or insurance audit.
Why Choose ACSEU Limited
Over a decade of commercial duct cleaning & ventilation expertise
Nationwide coverage with trained and certified engineers
Solutions tailored to large, complex HVAC and extraction systems
Fully documented, measurable results — improved efficiency and compliance
Friendly, professional support from survey to certification
Ready to Seal the Leaks and Save Energy?
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