Leaky, undersized, or aged ductwork is the single biggest hidden HVAC problem in Orange County homes. Most homes built before 2000 lose 20% to 40% of their conditioned air through duct leaks — that means your AC works harder, your bills are higher, and rooms are uneven temperatures. Aerosphere repairs, seals, replaces, and installs ductwork across OC with HERS-certified testing and verification.
Services We Provide
Duct Leak Detection & Sealing
HERS-certified blower-door + duct pressure testing to identify exact leak locations. Manual mastic sealing, foil tape, or Aeroseal aerosol sealing for hidden leaks.
Ductwork Replacement
Full replacement of aged or moldy ducts with new R-8 insulated flex duct or metal trunk lines. Sized correctly with Manual D load calculation.
New Ductwork Installation
For room additions, ADUs, or whole-home retrofits. Includes return air, supply runs, registers, dampers, and balance.
Duct Insulation Upgrade
Upgrade from R-4.2 (pre-1990 standard) to R-8 (current code) to dramatically reduce attic heat gain.
Duct Cleaning
Professional duct cleaning with HEPA vacuum after rodent damage, water damage, or mold remediation.
Zone Damper Installation
Motorized zone dampers for multi-zone HVAC systems — different temperatures in different rooms.
2026 Pricing in Orange County
| Service | Typical Cost | Notes |
|---|---|---|
| HERS duct leakage test | $250 – $450 | Required for AC permit |
| Spot duct repair / patch | $200 – $600 | Single leak fix |
| Aeroseal whole-home duct sealing | $1,500 – $3,500 | Hidden leaks, no demo |
| Ductwork replacement (typical 1,800 sq ft home) | $4,500 – $9,000 | New R-8 flex duct |
| Ductwork replacement (2,500-3,500 sq ft home) | $7,500 – $14,000 | Larger systems |
| New ductwork for ADU / addition | $2,500 – $6,500 | 1-2 zones |
| Duct insulation upgrade R-4 to R-8 | $2,500 – $5,500 | Whole home |
| Professional duct cleaning | $500 – $1,200 | HEPA vacuum service |
Why Orange County Homeowners Choose Aerosphere
- C10 + C20 licensed — Both electrical and HVAC contractor licenses (CSLB #1108650).
- Same-day response — Most calls dispatched same-day across Orange County.
- Free written estimates — No hidden fees, no high-pressure sales.
- Permits handled — We pull all required permits and coordinate city inspections.
- Full warranty — Parts and labor warranty on every job.
- Licensed and insured — General liability and workers comp.
Get a Free On-Site Estimate
Aerosphere Electric provides free written estimates across Orange County. Same-day response on emergency calls.
Call 714-499-6656Frequently Asked Questions
How do I know if my ducts are leaking?
Common signs: rooms with uneven temperatures, HVAC bills higher than neighbors with similar homes, excessive dust accumulation, AC running constantly but not cooling well, and visible dirty streaks around register boots. The only way to confirm is a HERS-certified duct leakage test, which Aerosphere provides for $250-$450.
How much does it cost to seal leaky ducts?
Spot repairs run $200-$600. Whole-home Aeroseal aerosol sealing (recommended for hidden leaks) runs $1,500-$3,500. Full duct replacement with new R-8 insulated flex duct runs $4,500-$9,000 for a typical 1,800 sq ft Orange County home.
Will sealing my ducts lower my SCE bill?
Yes — typically 15-25% reduction in cooling/heating costs. Most homes recoup the duct sealing investment in 3-5 years through lower bills. Combined with HVAC tune-up, the savings often exceed the cost in the first year.
Do I need new ductwork if I replace my AC?
Not always, but California Title 24 requires HERS duct testing on every AC install. If your ducts leak more than 15% (most homes built before 2000 do), they must be sealed or replaced before the install can pass HERS testing. Aerosphere includes this in our AC install quotes.
Service Areas
Aerosphere Electric serves all of Orange County including: Anaheim · Irvine · Santa Ana · Huntington Beach · Garden Grove · Fullerton · Costa Mesa · Mission Viejo · Fountain Valley · Yorba Linda · Lake Forest · Newport Beach · Tustin · Orange · Buena Park · Brea. C10 + C20 California contractor license 1108650.