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Use Proseal® for: Sealing metal & flex duct joints in low/medium/high pressure HVAC systems (up to 15" WG), ensuring airtightness & code compliance.
Ductmate Proseal® is a premium, water-based duct sealant engineered specifically for sealing metal joints and connections in low, medium, and high-velocity HVAC systems operating at pressures up to 15 inches Water Gauge (approx. 3740 Pa). This high-performance sealant ensures airtight seals, contributing to improved system efficiency and energy savings. Critically, Proseal® is UL 181B-M Listed and UL 723 Classified (Flame Spread 0, Smoke Developed 5), demonstrating compliance with key North American safety and performance standards often referenced in Australian building codes for HVAC installations. Its water-based formulation offers significant advantages: low odour, easy cleanup with soap and water (when wet), and low VOCs making it LEED® Compliant. Proseal® applies smoothly with low brush drag, reducing labour time, and cures to a tough, permanently flexible seal that resists cracking, water, mould, and UV degradation, suitable for both indoor and outdoor applications.
Surface Preparation: Ensure surfaces of ductwork joints are clean, dry, and free from any dirt, oil, grease, water, or foreign matter before application for optimal adhesion.
Cure Time: Proseal® typically becomes dry to the touch in approximately 1 hour under standard conditions. Full cure, required before pressure testing the system or covering duct ends, takes 24 to 72 hours or more, depending heavily on ambient temperature, humidity, and application thickness. Allow longer cure times in cool or humid conditions typical of some Australian environments.
Coverage Rate: Apply at the recommended wet film thickness. For sealing sheet metal joints, apply at approximately 1/32" (0.8mm) thick, which covers roughly 1.2 square metres per litre (50 sq ft/gal). For sealing connections involving UL 181 listed flexible air ducts, a thicker coat of 1/16" (1.6mm) is required, covering approximately 0.6 square metres per litre (25 sq ft/gal).
Application Temperature Range: Proseal® can be applied in temperatures ranging from 2°C to 43°C (35°F to 110°F). Store sealant at room temperature for at least 24 hours before use for best brushability. Do not apply if rain or freezing temperatures are expected within 36 hours.
Service Temperature Range: The cured sealant performs effectively in typical HVAC operating temperatures, ranging from -18°C to 104°C (0°F to 220°F).
Chemical Properties: Proseal® is a synthetic latex emulsion (water-based). It dries to a tough, permanently flexible seal with excellent resistance to water, mold/mildew, and UV.
Key Features of Ductmate Proseal®
- High-Velocity Rated (Up to 15" WG): Specifically designed and tested for sealing joints in low, medium, and high-pressure HVAC duct systems.
- UL Listed & Classified: Meets critical standards: UL 181B-M for duct sealant integrity and UL 723 for low surface burning characteristics (Flame 0, Smoke 5). Conforms to NFPA 90A/90B requirements.
- Water-Based Formulation: Low odour, easy cleanup with water (when wet), non-flammable during application, and low VOC (LEED® Compliant).
- Excellent Durability: Cures to a tough, permanently flexible seal that is highly crack resistant and offers excellent resistance to water, mold/mildew, and UV degradation. Suitable for indoor/outdoor use.
- Application Efficiency: Features low brush drag and good spreadability, reducing application time and labour costs. Will not drip or sag.
- Paintable Surface: Can be painted over with latex or epoxy-based paints once fully cured.
- Versatile Packaging: Available in tubes, pails, and drums to suit different job sizes.
Why Choose Ductmate Proseal®:
- Ensure System Performance & Efficiency: Creates reliable, long-lasting airtight seals, preventing air leakage and improving HVAC system energy efficiency.
- Meet Code Compliance: Using a UL Listed/Classified sealant helps meet stringent building code requirements for safety and performance in HVAC installations.
- Enhance Durability: Provides a flexible, crack-resistant seal that withstands vibration and thermal movement, outlasting tapes and lower-quality sealants.
- Improve Application Speed: Easy workability and water cleanup save time and effort for HVAC installers.
- Promote Safer Work Environments: Water-based, low odour, low VOC formulation is better for installers and building occupants.
When to Choose Ductmate Proseal® versus Alternatives:
- Choose Proseal® over Duct Tapes (Fabric/Foil) when: A permanent, airtight, flexible *seal* is required, not just a mechanical fastening. Proseal® meets pressure ratings and fire codes that tapes often fail to meet long-term. Essential for compliant, efficient systems.
- Choose Proseal® over General Purpose Silicones/Caulks when: Specific compliance with HVAC standards (UL 181B-M, UL 723, NFPA 90A/B) is required, pressure rating is needed, or easy water cleanup is desired. Proseal® is purpose-built for ductwork.
- Choose Proseal® over Solvent-Based Duct Sealants when: Low odour, low VOCs (LEED compliance), non-flammability during application, and easy water cleanup are priorities. Ideal for occupied spaces or environmentally conscious projects.
- Consider other options when: Sealing requires extreme temperature resistance beyond -18°C to 104°C, specific chemical resistance is needed beyond typical HVAC conditions, or structural bonding is required.
Trade-Specific Applications for Ductmate Proseal®:
For HVAC Installers / Technicians:
- Sealing Duct Joints: Apply to transverse joints (e.g., TDF/TDC, slip & drive) and longitudinal seams (e.g., Pittsburgh lock) of metal ductwork during installation.
- Connecting Flex Duct: Seal the connection between flexible ducts and metal take-offs or fittings, ensuring an airtight transition (apply at 1/16" thickness).
- System Testing Prep: Ensures ductwork is properly sealed prior to pressure testing for leakage (allow 24-72+ hrs cure).
- Performance Benefits: Meets code, ensures airtightness, easy application & cleanup reduces installation time.
For Sheet Metal Workers (Duct Fabricators/Installers):
- Sealing Fabricated Sections: Apply sealant to joints and seams during ductwork fabrication or assembly in the workshop or on site.
- Ensuring Quality Seals: Use Proseal® for reliable sealing performance that meets specified pressure classes and standards.
- Handling Different Gauges: Effectively seals standard gauge sheet metal used in commercial and residential ductwork.
- Performance Benefits: UL listed assurance, good workability, compatible with standard fabrication methods.
For Facility Maintenance Teams:
- Repairing Leaks: Identify and seal leaking duct joints or seams in existing HVAC systems to restore efficiency and performance.
- Preventative Maintenance: Re-seal joints where previous sealants may have failed or where tape was improperly used.
- Maintaining Indoor Air Quality: Helps prevent ingress of unfiltered air or contaminants through duct leaks.
- Performance Benefits: Durable long-term seal, easy application for repairs, improves system efficiency.
Application Information
- Required Tools: Sealant brush (low drag), caulking gun (for tubes), trowel, putty knife, or spray equipment (check compatibility).
- Surface Preparation: Surfaces must be clean, dry, and free of oil, grease, dust or other contaminants. Store sealant at room temperature (approx. 20°C+) for 24 hours prior for best brushability.
- Application Method: DO NOT THIN. Apply sealant to the inside of female fittings and outside of male fittings before assembly. Assemble joint. Brush a generous coat over the assembled joint and any fasteners (screws), ensuring a complete seal typically 50-75mm (2-3") wide.
- Recommended Thickness: Apply approx. 1/32" (0.8mm) wet film thickness for metal-to-metal joints. Apply approx. 1/16" (1.6mm) wet film thickness when sealing flexible duct connections.
- Curing: Protect from rain and freezing for at least 36 hours after application. Allow minimum 24-72 hours cure time (longer in cold/humid conditions) before pressure testing or fully enclosing duct ends.
Storage and Shelf Life
- Storage Requirements: Store unopened containers in a dry area between 2°C and 43°C (35°F to 110°F). CRITICAL: Protect from freezing. Product exhibits 5-cycle freeze-thaw stability but repeated freezing should be avoided.
- Shelf Life Information: 1 year from date of manufacture when stored correctly in original, unopened containers.
- Handling: Keep containers closed when not in use.
Certifications and Compliance
- UL 181B-M Listed: Meets Underwriters Laboratories standard for materials for use with flexible air ducts and air connectors (specifically the sealant component 'M').
- UL 723 Classified: Tested for Surface Burning Characteristics, achieving low ratings (Flame Spread 0, Smoke Developed 5) required for use in plenums and air distribution systems.
- NFPA 90A/90B Conformance: Meets requirements relevant to materials used in air conditioning and ventilating systems as outlined in these National Fire Protection Association standards.
- LEED® Compliant: Suitable for use in projects seeking Leadership in Energy and Environmental Design certification due to its water-based, low-VOC nature.
Frequently Asked Questions About Ductmate Proseal®
Q: Is Proseal® completely waterproof? Can water run over it?
A: Yes, once fully cured, Proseal® exhibits excellent water resistance. It's designed for indoor/outdoor use and can withstand typical weather exposure on external ductwork. However, it's a duct sealant, not a pond liner or roofing membrane for constant immersion.
Q: How critical is the application thickness for Proseal®?
A: Applying the correct thickness is important for performance. The TDS recommends 1/32" (~0.8mm) wet film thickness for sheet metal joints and a thicker 1/16" (~1.6mm) for sealing connections to flexible air ducts to ensure a robust, airtight seal that meets UL listing requirements.
Q: Can I paint over Proseal® Duct Sealant?
A: Yes, Proseal® is paintable once fully cured. The TDS recommends using latex (water-based) or epoxy-based paints for best results. Allow the sealant to cure completely (24-72+ hours) before painting.
Q: What does the UL 181B-M listing mean?
A: UL 181B covers closure systems for flexible air ducts and connectors. The "-M" specifically designates "Mastic" (sealant). This listing indicates that Proseal® has been tested and meets specific UL requirements for adhesion, aging, temperature, and humidity resistance when used as part of a listed closure system for flexible ducts.
Q: How long do I really need to wait before pressure testing the duct system?
A: The TDS recommends waiting a minimum of 24 to 72 hours, but notes that longer times may be required depending on temperature and humidity. Applying pressure before the sealant has adequately cured can compromise the seal. It's best to err on the side of caution, especially in cool or humid conditions.
Q: Is this product suitable for use under Australian building codes?
A: Proseal® meets stringent North American standards (UL, NFPA) related to fire safety and performance for HVAC systems. While these standards are often recognised or referenced, always verify compliance with the specific requirements of the National Construction Code (NCC) and relevant Australian Standards (e.g., AS 4254 series) with the project engineer or certifier.
Use Ductmate Proseal® for:
- Sealing Transverse Joints: Effectively seals connections like TDC/TDF, slip & drive, S & drive, and other flanged or slip-fit joints in metal ductwork.
- Sealing Longitudinal Seams: Provides an airtight seal along Pittsburgh lock seams, snap lock seams, and other longitudinal seams in fabricated duct sections.
- Connecting Flexible Ducts: Creates a durable, airtight seal between flexible air ducts and metal fittings, collars, or equipment connections.
- Low, Medium & High-Pressure Systems: Suitable for sealing ductwork operating up to 15 inches Water Gauge (approx. 3740 Pa).
- Indoor & Outdoor Applications: Durable formulation with UV and water resistance allows for use on both internal and external ductwork.
- Meeting Code Requirements: Helps achieve compliance with HVAC codes requiring listed/classified duct sealants (UL 181B-M, UL 723, NFPA 90A/B).
Why Use Ductmate Proseal® for:
- Preventing Air Leakage: Creates permanent, airtight seals that significantly reduce energy loss and improve HVAC system efficiency.
- Ensuring Compliance: Utilises a UL Listed and Classified product to meet stringent fire safety and performance requirements in building codes.
- Long-Term Durability: Cures to a tough, flexible seal that resists cracking, water damage, mold growth, and UV degradation over time.
- Improving Installation Efficiency: Easy application with low brush drag and simple water cleanup saves labour time on site.
- Enhancing Indoor Air Quality: Properly sealed ducts prevent infiltration of dust, insulation fibres, or contaminants into the conditioned airstream.
- Safe Handling & Use: Water-based, low odour, low VOC formulation provides a safer alternative to solvent-based sealants.
How to apply Ductmate Proseal®:
- Preparation: Ensure duct surfaces are clean, dry, and free from oil, grease, dust, etc. Store Proseal® at room temperature (around 20°C+) for at least 24 hours before use for optimal consistency and brushability.
- Check Conditions: Do not apply if the temperature is below 2°C (35°F) or above 43°C (110°F). Do not apply if rain or freezing temperatures are expected within 36 hours.
- Application to Joints (Metal Duct): DO NOT THIN the product. Apply sealant by brush, hand, trowel, or spray. Apply to the inside surface of the female fitting and the outside surface of the male fitting before joining sections.
- Assemble & Over-Seal: Assemble the joint securely using appropriate mechanical fasteners (screws, rivets). Apply a generous coat of Proseal® over the entire assembled joint, ensuring complete coverage of the seam and any fasteners with a band typically 50-75mm (2-3") wide. Aim for approx. 1/32" (0.8mm) wet film thickness.
- Application to Flex Duct Connections: Apply a thicker coat of Proseal® (approx. 1/16" or 1.6mm wet film thickness) over the connection between the flex duct and the metal collar/fitting, ensuring coverage over the mechanical fasteners used as per duct manufacturer's instructions.
- Curing: Allow the sealant to air dry. Protect from rain/freezing for 36 hours. Wait a minimum of 24-72 hours (longer in cool/humid conditions) before pressure testing the system or enclosing/covering the sealed joints (e.g., with insulation or duct covers like ProGuard).
- Clean Up: Clean tools, brushes, and spills immediately with warm, soapy water while the sealant is still wet. Cured sealant requires mechanical removal.
Ductmate Proseal® limitations:
- Not a Structural Adhesive: Designed purely as a sealant to prevent air leakage, not to provide mechanical strength to joints.
- Cure Time Dependent on Conditions: Drying and cure times vary significantly with temperature, humidity, and application thickness.
- Requires Protection During Early Cure: Must be protected from rain and freezing temperatures for at least 36 hours after application.
- Minimum Application Temperature: Do not apply below 2°C (35°F).
- Do Not Thin: Product should be used as supplied for proper performance.
- Not for Constant Immersion: While water resistant, not intended for applications involving continuous submersion in water.
Safety precautions when using Ductmate Proseal®:
- Personal Protective Equipment (PPE): While water-based and low odour, wearing safety glasses and gloves is recommended as good practice when handling any sealant.
- Ventilation: Use with adequate ventilation, especially when working in confined spaces.
- Handling: Keep out of reach of children. Avoid ingestion. Wash hands after use. Consult the Material Safety Data Sheet (MSDS/SDS) before use for detailed safety information.
- First Aid: Consult SDS. General advice: Eyes: Flush with water. Skin: Wash with soap and water. Ingestion: Seek medical advice.
- Disposal: Dispose of waste product and containers according to local council regulations.
Ductmate Proseal® can be used on the following substrates:
- Sheet Metal Ductwork: Primarily designed for galvanised steel ducting commonly used in HVAC systems. Ensure surfaces are clean and dry.
- UL 181 Listed Flexible Air Ducts: For sealing connections between flex duct and metal collars, take-offs, or equipment. Requires thicker application (1/16" or 1.6mm).
- Note: Surface preparation (clean, dry, free of contaminants) is essential for good adhesion.
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