AeroBarrier UK

AeroBarrier incorporates the latest sealant technology to prevent air leakage and draughts.

A waterborne, non-toxic sealant is compressed into a mist and released into a pressurised home where it plugs gaps up to 12mm (about the width of a board game dice). The sealant mist is drawn into visible and invisible gaps where it solidifies to create a seal and improve air tightness. Construction can resume shortly after the process is complete with little or no impact on standard schedules.

The AeroBarrier system provides measurements in real-time, ensuring that specific air leakage requirements can be achieved consistently. AeroBarrier is already successfully established in the US and Canadian markets, where it has been used on tens of thousands of new builds.

• Seals leaks up to 12 mm wide (½”) and as small as a human hair.
• Class A2 Fire Rating - the UK's only Class A rated airtightness product
• GreenGuard Gold certified - safe to use in any type of building.
• Ultra-Low VOC with no off-gassing.
• Most economical to install at weathertight (dry shell) or plasterboarding stage of construction but can be applied to unoccupied, finished spaces.
• In multi-family applications, a tighter building envelope offers reduction in noise transmission, mitigates odour transfer, reduces pest migration and enhances climate control.
• Sealant does not stick to vertical surfaces like walls, windows, or doors.
• Used by The Hill Group, Willmott Dixon, Vistry, Wates and other national, regional, SME and self-builders throughout the UK.

The AeroBarrier Process

Preparation & Setup: Certified AeroBarrier technicians set up sealing stations, a blower door, and computer systems. Up to 60% of on-site time is spent on prep - covering any finished horizontal surfaces, sealing large gaps (> 12mm) manually, and ensuring systems are calibrated.

Start Sealing: The building is pressurised up to 200Pa and a pre-seal airtightness test is conducted. Sealant is misted into the air through sealing stations, controlled in real-time via the AeroBarrier platform to ensure even coverage.

Monitor & Seal: As leaks are sealed, real-time data helps the technicians achieve the desired airtightness (from Building Regs to Passivhaus). Gaps larger than 12mm are sealed manually. The building is then depressurised.

Verify & Certify: A final airtightness test is carried out, and a sealing report is issued. This showcases the starting airtightness, the final airtightness and the % reduction in airtightness achieved. A Building Regs-compliant test can also be performed if required.

The full process takes around 4 hours for a typical 3-bed home, with minimal disruption to construction schedules. When targeting reduced envelope leakage levels of Passivhaus, additional time may be required.

When is the best time to apply AeroBarrier?

AeroBarrier can be applied at a range of points during the build process, usually between the ‘dry shell’ stage, where all external windows and doors are fitted, up to finished flooring and carpet fitout. Finished horizontal surfaces must be covered, while vertical surfaces usually don’t require protection.

AeroBarrier is applied as a mist, so the further along a build is, the more preparation work is needed, which has an impact on cost.

What is the AeroBarrier Sealant?

AeroBarrier X1 is a stable, non-toxic, mist coat applied,

waterborne polymer-based sealant. The sealant is vapour-permeable, non-toxic, and ultra-low in VOCs, with no chemical off-gassing. It’s GreenGuard Gold Certified and tested to ASTM and NFPA 285 standards. The system avoids waste by targeting only areas of leakage.

The sealant deposits only at the leak sites and forms a complete and tight seal, remaining firmly in place for years while staying completely pliable and flexible.

Cleanup is simple using citrus-based cleaners. After sealing, the building is aired out for 30 minutes, and construction can resume shortly after.