A stable, non-toxic, mist coat applied, waterborne polymer-based acrylic sealant.

AeroBarrier is a patented air sealing system that uses a computerised process to pressurise the building and install AeroBarrier X1 to seal leaks in the building enclosure from the inside. The particles deposit only at the leak sites and build to form a complete and tight seal, remaining firmly in place for years while staying completely pliable and flexible. By reducing air leaks through the building envelope, it is possible to reduce energy loss, help mitigate moisture damage, and enhance overall comfort and health of the building.

Features & Benefits:

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 (>12 mm) manually, and ensuring systems are calibrated.

Start Sealing: The building is pressurised up to 200 Pa 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 12 mm 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. The system avoids waste by targeting only areas of leakage.

The sealant 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.

AeroBarrier X1 has been tested to the following industry standards:

GreenGuard Gold Certification.
ASTM E84: Standard Test Method for Surface Burning Characteristics of Building Materials.
ASTM C719: Standard Test Method for Adhesion and Cohesion of Elastomeric Joint Sealants Under Cyclic Movement.
ASTM D543: Standard Practices for Evaluating Chemical Compatibility.

AeroBarrier X1 EPD