Aeroseal – Miamisburg, Ohio

August 29, 2024

Aeroseal

Energy Efficiency in Construction and Retrofitting

Transforming the building industry with innovative air-sealing solutions that boost energy efficiency and tackle climate challenges head-on.

Aeroseal, a cutting-edge climate tech company, offers innovative air sealing solutions aimed at transforming the energy efficiency and comfort of residential and commercial buildings. This technology empowers builders with unprecedented control over air leakage, a previously unmanageable variable, enhancing the sustainability of their constructions. Aeroseal’s solutions span across new constructions and retrofitting existing homes, making significant strides in future proofing buildings against the against the elements and significantly increasing their overall energy efficiency.

Troy Wilbanks, the director of sales for residential new construction, explains, “We work directly with builders of all types, whether custom home builders or national builders. Our technology allows them to control air leakage, which is critical for moving from a code-built house to an Energy Star house or achieving net zero and passive house standards.”

Addressing the trend towards passive homes, which require extremely high levels of sustainability, Wilbanks notes that not all builders are venturing into this territory. “We guarantee that builders meet their original requirements specific to passive house standards,” he states. “In the Northeast, particularly in Massachusetts, passive house standards are essentially code for multifamily builds. This presents significant challenges, especially in single-family wood and multifamily constructions, to meet air sealing requirements.”

The challenge extends to achieving the compartmentalization of each unit within a building. Aeroseal’s technology provides a comprehensive solution, ensuring builders meet these stringent requirements. “We developed solutions that guarantee compliance with ease, virtually without intruding on the builder’s schedule,” Wilbanks explains. “Our process is meticulously monitored and regulated, removing any manual guesswork. Traditionally, builders rely on manual air sealing techniques and products, such as specialty membranes and tapes. While those are still important, our technology takes the guesswork out of the equation.”

Wilbanks highlights the broader impact of Aeroseal’s technology on the housing market, particularly considering current macroeconomic trends. With a significant push towards new construction to address housing shortages and the retrofitting of existing buildings to enhance energy efficiency, Aeroseal’s solutions are more relevant than ever.

Aeroseal’s Innovation and Market Growth

As Aeroseal continues to push the boundaries of energy efficiency in the construction industry, the company has made significant strides in product innovation and market expansion over the past two years. Jarrod Scott, the director of sales for residential retrofit, provides insights into the latest advancements and the growing demand for Aeroseal’s technology.

“In terms of product, we have innovated almost all of our offerings over the last couple of years,” he reveals. “Starting with the duct sealing side, we have transitioned from using equipment that relies on compressed air to an airless model. Our soon-to-launch second version of this airless model simplifies the application process for contractors, reducing the amount of equipment needed on-site and making the process faster and less complicated.”

Scott details the improvements made to the sealant, emphasizing its enhanced performance and safety. “We’ve modified the sealant to have a 90% reduced tack and six times improved bonding strength while maintaining high safety standards. It remains an atomized polymer product, ensuring reliability and effectiveness.”

While the duct sealing technology has seen significant updates, he notes that the building envelope material has not recently undergone the same level of innovation. However, he mentions the release of a new version of their building envelope technology this year, iterating on developments since 2018. “Our R&D department is one of the largest in the company, continuously working on product development and improving application processes,” he says.

Scott acknowledges the challenges in raising awareness among homeowners by discussing the demand for Aeroseal’s products in the residential retrofit market. “Homeowners are often aware of the symptoms of duct leakage—hot upstairs rooms in summer, dust issues, and high utility bills—but they might not know to look for duct sealing solutions,” he explains. “Our focus is on training contractors to identify airflow issues and integrate duct sealing into their proposals.”

Aeroseal’s policy department, led by Maggie McCarey, plays a crucial role in connecting the benefits of duct sealing with energy efficiency programs. “Utility programs are increasingly recognizing the value of Aeroseal duct sealing,” Scott notes. “Maggie is making significant progress in incorporating our solutions into these programs, making it beneficial for contractors and providing homeowners with rebate opportunities.”

Company Philosophy and Workforce Challenges

Aeroseal’s company philosophy revolves around innovation, environmental impact, and addressing the evolving demands of the workforce. Residential Program Director Tracy Martin discusses these core values influence the company’s operations and client interactions.

“Skilled labor has always been a challenge for our industry, particularly in HVAC,” she explains. “It’s tough to find good people, and the nature of work has changed significantly. Younger workers entering the workforce now often seek flexible work hours and remote work options, which isn’t always feasible in our line of work.”

Martin highlights how Aeroseal’s mission resonates with the new generation of workers. “One of the biggest opportunities for attracting younger workers is emphasizing that our technology is designed to improve the world by focusing on climate change improvement. This resonates with the younger workforce, giving them a sense of purpose and meaning in their daily work.”

Aeroseal’s recruitment strategy leverages this sense of purpose, making it a compelling factor for potential employees. “I’ve seen some dealers take a creative approach by highlighting how their work with Aeroseal technology can positively impact homeowners in their communities. This strategy has proven to be effective in attracting new talent,” Martin notes.

Despite being a growing company, Aeroseal maintains a small team dynamic. Martin points out the challenges this poses, especially in managing their extensive network. “We’re a small team in many ways, with about four account managers overseeing a network of a thousand strong. This can become overwhelming quickly, particularly on the retrofit side of the business.”

To manage this effectively, Aeroseal focuses on making a significant impact and ensuring long-term benefits. “We aim to serve our customers so they, in turn, can serve their customers. The key is to stay focused on helping the end user rather than just selling another product,” Martin emphasizes. “Our technology can help people live more comfortably, breathe healthier air, and save money on their bills. It might be mundane to think about ducts, but their benefits are substantial.”

New Construction and Commercial Expansion

Builders and Commercial Contractors often face common pain points regarding air sealing. Aeroseal’s innovative solutions significantly impact residential and commercial new construction sectors, positioning it as a critical partner in ensuring air sealing and duct sealing efficiency.

Wilbanks shares, “Both envelope sealing and duct sealing technology are perfect solutions for residential and commercial new construction. We provide a solution to a persistent issue that builders encounter daily. Air sealing is often a shared responsibility among many trades, leading to inevitable mistakes and failed tests. Our technology ensures that builders meet their air sealing requirements, whether to pass a blower door test or achieve high-performance building standards.”

Builders often grapple with the complexity of air sealing due to the involvement of multiple trades, which can lead to errors and inefficiencies. Aeroseal’s approach takes full ownership of the air sealing process, eliminating the hassle and uncertainty for builders. “Our solution guarantees that builders meet their air sealing requirements,” Wilbanks states. “Whether it’s code compliance or enhancing a building’s performance, we provide a reliable and efficient solution.”

Global Expansion and Future Opportunities

Aeroseal’s future looks promising, with ambitious plans for growth and global expansion. Wilbanks expresses optimism about the company’s trajectory, predicting significant developments in the next 18 months.

Reflecting on the company’s growth over the past few years, he highlights the remarkable achievements in the new construction market. “In the past four years, we’ve seen year-over-year growth north of 70%. We’re working with 12 of the nation’s largest 15 builders. These national builders construct tens of thousands of homes each year, and we’re doing meaningful work with almost all of them,” he says.

The impressive growth extends beyond national builders, as Aeroseal also collaborates with regional and custom builders, tailoring solutions to meet their specific goals. “Each builder is unique, and we develop meaningful partnerships to help deliver on their objectives,” Wilbanks explains. “Our headcount has doubled in the last year, reflecting the significant expansion and demand for our products.”

“I see the opportunity to double the business,” he asserts. “We’re not just talking about growth in the United States; our expansion into Canada, Europe, New Zealand, Australia, and the Middle East is gaining massive attention and demand. This growth spans both residential new construction and commercial sectors.”

Wilbanks emphasizes the unique challenges and opportunities in international markets. “In Europe, for example, dense populations and older building stock present significant energy challenges. Our solutions can dramatically increase efficiency with minimal intrusion. Our duct solutions decrease leakage by up to 95%. The demand is real, and we’re meeting it head-on.”

Martin also shares her enthusiasm for Aeroseal’s growth. She highlights how Aeroseal’s technology complements duct cleaning services, offering a substantial revenue boost. “Coupling Aeroseal with duct cleaning can double or triple revenue overnight. HVAC dealers who adopt Aeroseal can maintain and even grow their revenue by delivering efficiency and comfort. It’s a natural fit.”

Scott adds to the conversation, focusing on the challenges and opportunities in the solar sector. “Solar is having a rough go, but there’s big potential for improvement. Aeroseal can help by reducing energy usage, making solar solutions more attractive and cost-effective. This aligns well with our core focus on HVAC contractors, making our products easier, faster to use, and better integrated into their schedules.”

The following 18 months promise to be a period of significant growth and innovation for Aeroseal. With a clear focus on expanding domestically and internationally and leveraging synergies with complementary industries, the company is poised to continue its upward trajectory.