Fast, Reliable Duct Repair & Sealing Across Boerne
Duct repair and sealing in Boerne typically runs $280-$650 for most residential jobs, with same-day service available when you call before noon. Our technicians cover both ZIP codes 78006 and 78015, from the historic limestone ranch homes near Main Street to the newer master-planned communities along the eastern edge of town. We’ve been driving these Hill Country roads for over 42 years, and we know how Boerne’s caliche dust and cedar pollen work their way into duct systems in ways that don’t happen in San Antonio or Houston.
Call (866) 347-2063 for a free estimate. We’ll answer the phone, day or night.
Why Bellows Air Duct & Vent Co. of Texas Is Boerne’s Preferred Duct Repair & Sealing Company
We’ve worked in Boerne long enough to know which homes on River Road have the original 1980s metal ductwork, and which Esperanza builds from 2012 still have flex ducts that have never been touched. That local knowledge matters when you’re crawling through an attic with limited access in a custom Hill Country home.
Our customers in Boerne call us back because we show up when we say we will, and because our 90-Day Done Right Promise means something here. If a seal fails or a repair doesn’t hold, we return at no charge. No paperwork, no arguing. That’s been our policy since 1984.
Every job gets a camera inspection before and after. You see what we see. Our background-checked, uniformed technicians carry professional-grade equipment from Rotobrush and Honeywell, and most repairs are completed in a single visit. Calls are answered by a live person 24 hours a day, not an app or a recording.
We offer a $50 discount on any repair over $250, a free second opinion on any written estimate, and a permanent 5% senior and veteran discount. The price we quote on the phone is the price on the invoice.
Our Duct Repair & Sealing Services in Boerne
Metal Duct Repair
Boerne’s older 78006 homes and many custom builds in Esperanza use galvanized metal ductwork that lasts decades when properly maintained. The problem we see most often is expansion damage. Metal ducts in Boerne attics endure 98-104°F summer heat for months straight, then contract during January nights when temperatures drop into the 30s. That thermal cycling cracks seams and separates joints, especially on longer duct runs common in Hill Country estate properties.
We fabricate custom metal sections on-site to match your existing ductwork. In historic Boerne homes near Main Street, we’ve replaced crushed or corroded metal transitions with precisely fitted pieces that preserve the original system’s airflow balance. No cobbling, no mismatched parts.
Flex Duct Repair
Flex duct is common in Boerne’s 2010s-era subdivisions, including much of 78015. It’s lightweight and easy to install, which made it popular during the building boom. But flex duct sags, gets crushed by storage items in attics, and degrades where it connects to metal plenums. We’ve found original flex duct in Esperanza homes that has never been inspected since the build crew packed up.
We replace damaged flex duct with new, insulated flex that matches or exceeds the original R-value rating. Our technicians secure it with proper supports so it doesn’t sag into the attic insulation, and we seal every connection with mastic, not tape that will dry out in Boerne’s heat.
Mastic Sealant Application
Mastic is the only sealant we trust for Boerne’s conditions. Tape fails. Glue fails. Mastic, when properly applied to clean surfaces, forms a permanent flexible seal that moves with the ductwork. But here’s the catch we learned in this market: Boerne’s unique caliche-and-cedar-pollen composite will clog mastic and cause it to fail within months if ducts aren’t pre-cleaned.
We recently repaired a crushed flex duct in a carriage-house garage apartment on Main Street in Boerne’s historic district. The homeowners had tried sealing with standard tape, but the fine caliche dust from construction continued to infiltrate through unsealed joints. We installed a reinforced metal transition and applied mastic sealant, matching the original 2015-era Honeywell zoning system, restoring quiet airflow and eliminating the dust intrusion.
Our process: camera inspection, thorough pre-cleaning, then mastic application with a minimum 1/8-inch thickness at all joints and seams. We verify the seal with a follow-up camera inspection and pressure test.
Air Leak Repair
Leaky ducts in Boerne waste more money than in milder climates. When your system runs 16-18 hours a day from June through September, every cubic foot of conditioned air lost to the attic is air you’re paying to cool twice. We pressure-test duct systems to locate leaks that aren’t visible to the eye, then seal them with the appropriate method for your duct type.
In 78015’s newer homes, we often find leaks at the junction between the main trunk line and the flexible branch ducts. In 78006’s older homes, leaks develop where metal ducts pass through unconditioned spaces or where original supports have shifted on limestone foundations.
Duct Insulation
Insulation on Boerne’s attic ductwork takes a beating. Roof temperatures in July regularly exceed 140°F, degrading insulation over time. We replace damaged insulation with fresh, properly sealed vapor-barrier insulation that maintains your system’s efficiency and prevents condensation during humid spring mornings.
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.
Trusted Brands We Service in Boerne
We carry parts and equipment from Rotobrush, Honeywell, and Aprilaire, the same brands specified by serious HVAC contractors in the Hill Country. That means faster repairs for Boerne homeowners. When we diagnose a Honeywell zoning control issue in an Esperanza home or an Aprilaire media filter housing leak near River Road, we don’t have to order parts from San Antonio and make you wait. Our trucks are stocked for the brands we see most often in this market. We also service and repair ductwork connected to any major HVAC manufacturer, including systems installed by other contractors during Boerne’s building boom.
Common Duct Repair & Sealing Problems We See in Boerne Homes
- Caliche-and-cedar composite buildup. Technicians working the 78015 subdivisions regularly find ductwork caked with a pale caliche-and-cedar-pollen composite, a gritty, yellowish-white buildup that is a direct fingerprint of Hill Country construction-era dust. This material infiltrates through even tiny leaks and accumulates in low-velocity sections of ductwork, making proper sealing impossible without thorough pre-cleaning.
- Thermal expansion damage in metal ducts. Boerne’s 98-104°F summers and occasional winter freezes create extreme thermal cycling. Metal ducts expand and contract daily, eventually cracking mastic seals at joints and seams. This is especially common in longer duct runs serving Hill Country ranch homes with distant bedrooms or guest wings.
- Undersized attic ductwork in newer homes. Many 78015 homes built during the 2010s have ductwork sized for standard loads that doesn’t account for Boerne’s extended cooling season and attic heat gain. The system runs longer, works harder, and develops leaks faster than properly sized installations.
- Limestone-foundation access challenges. Historic Boerne homes on limestone foundations often have ductwork routed through crawl spaces or partial basements with limited clearance. Original installations didn’t anticipate future service needs, making repairs a matter of careful planning and custom fabrication rather than standard replacement.
Pricing for Duct Repair & Sealing in Boerne, TX
Here’s what duct repair and sealing costs in the Boerne market:
- Single leak seal (mastic, accessible): $280-$380
- Flex duct section replacement: $340-$520
- Custom metal duct fabrication and install: $450-$650
- Full system mastic sealing (typical 2,000-2,500 sq ft home): $580-$890
- Duct insulation replacement (per section): $180-$320
Factors that move the price: accessibility of your attic or crawl space, extent of pre-cleaning needed to remove caliche and pollen buildup, whether custom metal fabrication is required, and if your system needs pressure testing to locate hidden leaks. We disclose the full price before we lift a single tool. No bait coupons, no price changes at the door.
Call (866) 347-2063 for an exact quote on your Boerne home. Estimates are free, and we honor our $50 discount on repairs over $250.
We Also Serve Cities Near Boerne
Our technicians regularly travel from Boerne to Boerne neighbors in Fair Oaks Ranch, Helotes, Timberwood Park, and Leon Valley. If you’re in one of these communities and need Duct Repair & Sealing, the same live-answer phone line and same-day scheduling apply. We know the Hill Country roads, and we don’t charge extra for the drive.
Serving Boerne, TX - Our Local Coverage Area
We’re based in the Boerne area and know this community well. Use the map below to see our service coverage - if you’re nearby, we can almost certainly help.
FAQs - Duct Repair & Sealing in Boerne
That buildup is caliche dust from Hill Country construction combined with mountain cedar pollen, a composite that is specific to the Boerne area and doesn’t occur with the same intensity in San Antonio or Houston. The ultra-fine particles infiltrate through leaks and settle in low-velocity sections of ductwork, and standard cleaning without proper sealing just lets it accumulate again. We remove the buildup with professional equipment, then seal the leaks with mastic to stop re-infiltration. Call (866) 347-2063 for a camera inspection that will show you exactly what’s inside your ducts.
Yes. We use low-impact access methods and protect finished surfaces during work in Boerne’s custom homes, including historic properties near Main Street where original woodwork must be preserved. Our technicians plan the repair path before cutting any access, and we fabricate custom metal transitions that fit existing openings without forcing or prying against finished trim. We recently completed this exact repair on a carriage-house garage apartment in Boerne’s historic district, matching the original Honeywell zoning system without touching the door or surrounding woodwork.
We replace sagging flex duct with new insulated flex that matches or exceeds the original specifications, though we don’t necessarily use the same brand the builder chose in 2012. What matters is the R-value, diameter, and pressure rating. Boerne’s attic heat means we specify higher-grade insulation than many original installations included. We also add proper supports to prevent the sagging that caused your original ducts to fail. Our 90-Day Done Right Promise covers the installation, and we’ll show you the before-and-after camera footage so you can see the difference.
Cracked mastic usually means the duct surface wasn’t properly cleaned before application, or the mastic was applied too thin. In Boerne, caliche-and-cedar composite buildup is the most common cause of mastic failure. We pre-clean all surfaces with professional equipment, apply mastic at minimum 1/8-inch thickness, and verify the seal with pressure testing and camera inspection. If a seal we apply fails within 90 days, we return and fix it at no charge. That’s our Done Right Promise, in writing.
Yes. We’ve worked on historic Boerne homes near Main Street and in the 78006 core where ductwork runs through crawl spaces, partial basements, or stone-walled chases that require custom planning. We inspect with cameras first, then fabricate metal sections or design access approaches that work with your home’s structure rather than against it. These jobs take more time than standard repairs, and we price them upfront after the inspection so you know the full cost before we begin. Call (866) 347-2063 to schedule a look at your specific layout.
Ready to get your Boerne home’s ductwork sealed right? Call (866) 347-2063 now for a free estimate. We’ll answer the phone, send a background-checked technician in uniform, and show you exactly what needs fixing before we quote a price. That’s how we’ve done it since 1984.
Written by Wade Kellerman, Owner at Bellows Air Duct & Vent Co. of Texas, serving Boerne since 1984.