Your HVAC System Is Losing 40% of Airflow Because of Duct Leakage - Gord & Ian Part 2

In this episode of the HVAC Know It All Podcast, host Gary McCreadie continues his conversations with Gord Cooke, President at Building Knowledge Canada, and Ian Walker, Sales & Marketing Manager at Aeroseal, about duct sealing and building performance. They explain how Aeroseal works by sealing leaks at the source without coating the entire duct, clearing up common misconceptions. The discussion highlights how leaky duct systems can lose a large amount of airflow, affecting comfort, balance, and system efficiency in a home. Gord shares insights on why sealing ducts improves airflow control and helps deliver air where it is needed most. They also talk about return air design, common issues with panned returns, and why proper airflow measurement matters for HVAC performance.

Gary, Ian, and Gord discuss how Aeroseal works to seal duct leaks using pressure and a targeted sealant that only sticks at gaps. They explain that the process does not coat the full duct system and instead seals leaks from the inside. The conversation covers how duct leakage can reduce airflow, comfort, and system balance in a home. They also talk about how sealing ducts can improve air delivery and make balancing systems more effective. Gord shares insights on return air design, explaining common issues with panned returns and why they often do not move much air. They finish by highlighting how proper sealing and airflow checks help improve overall HVAC performance and comfort.

Expect to Learn:

• How Aeroseal seals duct leaks by targeting gaps without coating the full duct system.

• How duct leakage can reduce airflow, comfort, and system balance in a home.

• How sealing ducts can improve air delivery and make system balancing more effective.

• Why return air systems often move less air than expected, especially when not fully ducted.

• How proper sealing and airflow checks can improve overall HVAC performance and comfort.

Episode Highlights:

[00:00] - Sponsor: Factory Direct Filters ad

[00:42] - Intro to Gord Cooke and Ian Walker in Part 02

[02:02] - Arrow Seal vs. Aero Barrier: Same tech, different application

[02:49] - Myth busted: Sealant only plugs holes, doesn't coat duct walls

[04:27] - Why seal ducts? Comfort, not just energy (30% typical leakage)

[08:34] - How AeroSeal works: Pressurize, mist, seal in 20 – 30 min

[09:59] - Cost estimate: 2,000 – 2,500 CAD for a 2,000 sq ft home

[13:11] - Panned returns leak 100% – don't expect measurable flow

[18:00] - Key difference: Stay home during AeroSeal, leave during AeroBarrier

[19:57] - Target: 1.5 ACH50 for optimal building enclosure

This Episode is Kindly Sponsored by:

Cintas: https://www.cintas.com/hvacknowitall

Cool Air Products: https://www.coolairproducts.net/

Factory Direct Filters: https://www.factorydirectfilters.com/

SupplyHouse: https://www.supplyhouse.com/tm
Use promo code HKIA5 to get 5% off your first order at Supplyhouse!

Follow the Guests Gord Cooke and Ian Walker on:

LinkedIn - Gord Cooke: https://www.linkedin.com/in/gord-cooke-4b9b3433

LinkedIn - Ian Walker: https://www.linkedin.com/in/ian-walker-930954101/

LinkedIn - Building Knowledge Canada: https://www.linkedin.com/company/building-knowledge-canada-inc./

LinkedIn - Ian Walker: https://www.linkedin.com/company/aeroseal-llc/

Follow the Host on:

LinkedIn: https://www.linkedin.com/in/gary-mccreadie-38217a77/

Website: https://www.hvacknowitall.com

Facebook: https://www.facebook.com/people/HVAC-Know-It-All-2/61569643061429/

Instagram: https://www.instagram.com/hvacknowitall1/

Follow the Podcast on:

YouTube: https://www.youtube.com/@HVACKnowItAll

Spotify: https://open.spotify.com/show/6LCBJGw0EHG03rdWHxUMce

Apple Podcast: https://podcasts.apple.com/us/podcast/hvac-know-it-all-podcast/id1359253455