Trusted Duct Repair & Sealing for Chicago Homeowners
Duct repair and sealing in Chicago typically costs $180 to $850 depending on the extent of damage, with most single-room repairs completed in one visit and whole-system sealing taking a full day. Bellows Air Duct & Vent Co. has fixed and sealed ductwork in Chicago homes since 2012, and we still answer our own phones around the clock. If your upstairs bedroom never warms up, your basement smells like the attic, or your energy bills keep climbing with no explanation, there’s a good chance your ducts are leaking where you can’t see them.
We’ve been called to fix jobs in Bridgeport bungalows where flex duct had pulled loose in the crawl space, to Lower West Side two-flats with galvanized metal ducts rusted through from decades of lake-effect humidity, and to Near South Side condos where builder-grade sealing tape had dried to dust. Ray Dempsey started this company on the belief that a homeowner deserves to know what’s wrong before paying to fix it. That’s why we run a camera through every system first. You see what we see. Then we give you one price, in writing, before any work begins. Most repairs are finished same day by background-checked, uniformed technicians. Call (877) 502-3903 and you’ll reach a live person, not a menu.
What Our Duct Repair & Sealing Service Includes
Duct Sealing
Duct sealing closes the gaps, cracks, and separation points where conditioned air escapes into your walls, attic, or crawl space. In Chicago, we see this problem constantly in homes built before 1990, especially in neighborhoods like McKinley Park and Brighton Park where original ductwork was never designed for modern HVAC loads. Bellows Air Duct & Vent Co. seals ducts with mastic compound and metal-backed tape rated for thermal cycling, not the cheap cloth tape that fails in two seasons. We pressure-test after sealing to verify results.
Flex Duct Repair
Flex duct, the insulated plastic tubing common in additions and retrofits, collapses, tears, or disconnects at the collar over time. Chicago’s freeze-thaw cycles accelerate the deterioration, particularly in unconditioned spaces like garages or porch ceilings in West Town and Grand Boulevard. We replace damaged flex duct with new insulated runs, support them properly so they don’t sag, and seal every connection with mechanical fasteners plus mastic. If a section can be saved, we’ll tell you. If it can’t, we won’t patch it and hope.
Metal Duct Repair
Galvanized steel and aluminum ductwork lasts decades but rusts at seams, dents from impact, or separates at joints due to thermal expansion. In older Chicago homes, especially in Douglas and South Lawndale, we’ve found original metal ducts with no sealing at all, just friction fit and gravity. Our technicians fabricate custom patch panels, re-seal longitudinal seams, and reinforce weak points with drive cleats. When a section is too far gone, we replace it with matching gauge metal and integrate it cleanly with your existing system.
Duct Insulation
Uninsulated or degraded duct insulation wastes energy and creates condensation problems that lead to mold. This is a particular issue in Chicago’s humid summers when cold supply air hits a hot, uninsulated duct in a vented attic. We install new foil-faced fiberglass insulation or closed-cell foam wrap depending on the application and space constraints. In tight Chicago Loop mechanical closets, we often use pre-formed insulation sleeves that fit where batt insulation won’t. Proper insulation pays for itself in reduced runtime and eliminated condensation damage.
Mastic Sealant
Mastic is a thick, fiber-reinforced paste that remains flexible after curing, making it the professional standard for sealing duct joints and seams. Unlike tape, it won’t dry out or peel. Bellows Air Duct & Vent Co. applies mastic with a brush or caulking gun to every accessible joint after cleaning the surface, then allows proper cure time before pressurizing the system. In Chicago’s climate, with summer humidity and winter dryness, mastic outlasts every tape product on the market. We use it on metal, flex, and fiberboard ducts.
Air Leak Repair
Air leaks are the silent thief of comfort and money, often accounting for 20 to 30 percent of heated or cooled air never reaching its destination. We locate leaks using a combination of visual inspection, camera survey, and pressure differential testing. Common leak sites in Chicago homes include the connection between trunk line and branch ducts, around filter slots, and where ducts pass through unconditioned walls. We repair each leak with the appropriate method, sealant, and reinforcement, then verify the fix with a follow-up pressure test.
What happens when you call
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A real person answersNo phone trees - you reach a local pro.
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You get an upfront price rangeHonest numbers before anyone is dispatched.
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A background-checked tech heads outLicensed & insured, dispatched right away.
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You approve before work beginsNothing starts until you say go.
Brands We Service for Duct Repair & Sealing
We’ve worked on duct systems connected to virtually every HVAC brand installed in Chicago over the past four decades. For Rotobrush equipment, we’ve performed hundreds of clean-and-seal combinations where the duct integrity directly affects the cleaning outcome, and we stock common Rotobrush fittings for quick repairs. Our technicians are equally familiar with Nikro industrial vacuums and negative air machines, which tells us how duct pressure should behave when a system is properly sealed. We’ve also sealed and repaired supply and return plenums on Honeywell and Aprilaire air cleaners and humidifiers, integrating our work with these components so nothing compromises their performance.
Whether your system is tied to one of these brands or any other make, we can help. The ductwork itself is largely universal, and our expertise crosses manufacturer lines. We carry a broad inventory of fittings, collars, and sealants so we’re not making multiple trips or asking you to wait on parts.
Signs You Need Duct Repair & Sealing Right Now
- Uneven temperatures from room to room. If your kitchen is comfortable but the back bedroom is an icebox in January, conditioned air isn’t reaching that room in the volume your thermostat expects. Leaks, blockages, or disconnected ducts are the usual cause, and they don’t fix themselves.
- Dust that returns within days of cleaning. Excess dust often means your return ducts are pulling air from a dirty attic, crawl space, or wall cavity through a gap in the system. Your filter can’t catch what enters after the air handler.
- Energy bills that climb without explanation. When 25 percent of your heated air leaks into the attic, your furnace runs longer to hit the setpoint. We’ve seen Chicago homeowners in New City and Chicago Loop pay 30 percent more than necessary for years before finding the leak.
- Musty or stale odors when the system runs. Smells mean air is passing through somewhere it shouldn’t, mold or rodent activity in a duct chase, or backdrafting from a compromised return. This isn’t just unpleasant. It’s a sign your indoor air quality is compromised.
- Visible duct damage or disconnected runs. If you can see a sagging flex duct in your basement or a rust hole in a metal trunk line, the hidden damage is almost certainly worse. These visible warnings demand prompt attention before the problem spreads.
Our Duct Repair & Sealing Process - Step by Step
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Camera inspection and assessment. We feed a high-resolution camera through your duct system to document every leak, disconnect, rust spot, and insulation failure. You see the footage. We explain what it means. No guesswork, no scare tactics.
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Upfront pricing in writing. Based on what we found, we give you one price that covers everything discussed. If we discover something unexpected, we stop and explain before proceeding. The number on the phone is the number on the invoice.
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Targeted repair and sealing. Our technicians repair or replace damaged sections, seal all accessible joints with mastic and mechanical fasteners, and reinsulate where needed. We work with professional-grade tools and materials from suppliers like Rotobrush and Nikro.
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Pressure testing and verification. After repairs, we pressurize the system and measure static pressure and airflow at key points. This confirms the leaks are sealed and your system is performing as designed.
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Final camera documentation and cleanup. We run the camera again so you can see the improvement. Then we clean our work area, review the job with you, and leave the written 90-Day Done Right Promise. If anything’s not right, we make it right. No paperwork, no arguing.
How Much Does Duct Repair & Sealing Cost in Chicago?
A typical single leak repair or small section replacement in Chicago runs $180 to $340. Whole-system duct sealing for an average single-family home generally falls between $450 and $850, with larger homes or complex routing in neighborhoods like Near South Side or Chicago Loop sometimes reaching $1,200. Flex duct replacement is priced by the linear foot, usually $12 to $18 per foot including insulation and proper support. Metal duct patching and fabrication starts around $220 for accessible areas.
Several factors move the price. Accessibility is the biggest. Ducts in an open basement are quick to reach. Ducts buried in a finished soffit or a tight crawl space under a Bridgeport bungalow take more time. The extent of damage matters too. One disconnected collar is a quick fix. A rusted trunk line with multiple failed seams requires more material and labor. The age of your system affects whether we can match existing fittings or need to fabricate adapters.
To avoid overpaying, get a written estimate that specifies exactly what’s included. Beware of phone quotes that sound too low to be real. They usually are. Our free estimate includes the camera inspection, a written scope of work, and a firm price. We also offer a free second opinion on any written estimate from another company, and $50 off any repair over $250. Seniors and veterans receive a permanent 5% discount.
Duct Repair & Sealing Near Chicago - Our Service Area
We repair and seal ducts across Chicago and into the immediate surrounding communities. Typical response time is same day or next day for most of the city, including Duct Repair & Sealing in Bridgeport, Duct Repair & Sealing in Lower West Side, McKinley Park, Douglas, Near South Side, Chicago Loop, Grand Boulevard, New City, South Lawndale, Brighton Park, and West Town. If you’re unsure whether we cover your address, call (877) 502-3903 and a live person will confirm our availability.
Serving Chicago, IL - Our Local Coverage Area
We’re based in the Chicago area and know this community well. Use the map below to see our service coverage - if you’re nearby, we can almost certainly help.
Frequently Asked Questions - Duct Repair & Sealing in Chicago
Duct repair and sealing fixes the physical damage and air leaks in your home’s forced-air distribution system. Bellows Air Duct & Vent Co. repairs disconnected, corroded, or collapsed ductwork and seals every accessible joint with mastic and mechanical fasteners so your heated and cooled air reaches the rooms it’s meant for. Call (877) 502-3903 for a free estimate and camera inspection.
Most single repairs or partial sealing jobs are completed in two to four hours. Whole-system sealing for an average Chicago home takes a full day. Bellows Air Duct & Vent Co. sends enough technicians and equipment to finish in one visit whenever possible. Call (877) 502-3903 to schedule and we’ll give you a time estimate based on your specific situation.
Single repairs typically run $180 to $340, whole-system sealing $450 to $850, and flex duct replacement $12 to $18 per linear foot. Your exact price depends on accessibility, extent of damage, and materials needed. Bellows Air Duct & Vent Co. provides free, no-obligation written estimates with camera documentation. Call (877) 502-3903 and we’ll give you a firm number before any work begins.
Yes. We regularly repair and seal ductwork connected to Honeywell and Aprilaire air quality equipment, and we maintain and repair systems cleaned with Rotobrush and Nikro professional equipment. Our technicians carry common fittings and understand how these brands integrate with residential duct systems. Call (877) 502-3903 to discuss your specific setup.
Yes. Calls are answered by a live person 24 hours a day, and we prioritize urgent situations like complete duct disconnections or systems leaking into hazardous areas. For true emergencies, we aim to have a technician on site the same day. Call (877) 502-3903 anytime, including nights and weekends.
Every job is backed by our 90-Day Done Right Promise in writing. If the repair or sealing fails or doesn’t perform as promised within 90 days, Bellows Air Duct & Vent Co. returns at no charge and makes it right with no paperwork and no arguing. This guarantee is stamped on every invoice. Call (877) 502-3903 with any concern and we’ll handle it directly.
Clear a path to your furnace or air handler and to any accessible vents or registers. If you have pets, secure them in a separate room. You don’t need to move furniture unless it blocks a vent we need to access, and we’ll tell you in advance if that’s the case. Bellows Air Duct & Vent Co. technicians wear protective covers and clean up thoroughly after the job. Call (877) 502-3903 to book your appointment.
Schedule Your Duct Repair & Sealing Service in Chicago Today
Call (877) 502-3903 now and reach a live person, any hour. We’ll schedule your free estimate, run a camera through your system so you see exactly what’s happening, and give you one honest price before any work starts. Most repairs are completed in a single visit. Every job carries our 90-Day Done Right Promise in writing. Bellows Air Duct & Vent Co. has served Chicago homeowners since 2012 because we do what we say, charge what we quote, and stand behind it without excuses.
Written by Ray Dempsey, Owner at Bellows Air Duct & Vent Co., serving Chicago since 2012.