Air tightness testing service

Air Tightness Testing Service – Accredited ISO/IEC 17025 Leakage and Enclosure Integrity Assessment for the Colombian Market

Air tightness testing is a critical quality and safety evaluation method used to measure the integrity of enclosures, components, and systems against the ingress or egress of air, gases, and moisture. This testing is essential for a wide range of applications, including building envelopes, automotive components, aerospace structures, medical devices, pharmaceutical packaging, cleanrooms, HVAC systems, and hermetic seals. In the Colombian market, where the Superintendencia de Industria y Comercio (SIC), the Ministerio de Minas y Energía (MinMinas), the Agencia Nacional de Hidrocarburos (ANH), the Instituto Nacional de Vigilancia de Medicamentos y Alimentos (INVIMA), and the Dirección de Impuestos y Aduanas Nacionales (DIAN) enforce strict quality, safety, and energy efficiency standards, the accurate evaluation of air tightness is essential for product certification, supplier qualification, quality control in manufacturing, and import-export processes. Our laboratory offers a comprehensive air tightness testing service, applying standardized methods such as pressure decay, vacuum decay, tracer gas, and flow measurement techniques to detect and quantify leakage rates with high sensitivity. All tests are performed under our ISO/IEC 17025 (CNAS) accreditation, and the resulting reports are fully accepted by Colombian authorities, making them indispensable for regulatory compliance, product validation, and market access in Colombia.

Test Samples and Systems We Regularly Examine

Our laboratory receives a wide variety of components, assemblies, and systems for air tightness testing. Typical samples include:

• Building envelopes and components – walls, doors, windows, roofs, and curtain walls for residential, commercial, and industrial buildings.
• Automotive and transportation components – doors, windows, seals, body panels, HVAC systems, and fuel systems.
• Medical devices and pharmaceutical packaging – syringes, vials, blister packs, and sterile barriers.
• Electronic enclosures and housings – for sensors, control units, and communication devices.
• Hermetic seals and components – O-rings, gaskets, seals, and welded joints.
• HVAC and ventilation systems – ductwork, fans, dampers, and air handling units.
• Prototype and new designs – submitted by manufacturers for validation of air tightness before series production.
• Components retrieved from field service – for failure analysis and remaining life assessment.

Pressure Decay Testing – Evaluating Leakage through Pressure Drop Measurement

Pressure decay testing is one of the most widely used methods for air tightness evaluation. The test item is pressurized with air or nitrogen to a specified test pressure, the pressure source is isolated, and the pressure drop is measured over a defined time. This method is suitable for a wide range of components and is used for quality control and certification in the Colombian automotive, medical, and industrial sectors.

• Pressure decay test (ASTM D4991 / ISO 10555 / NTC 5600) – the test item is connected to a pressure source and pressurized to a specified test pressure (typically 10 to 1000 kPa, depending on the application). The pressure source is then isolated, and the pressure is monitored using a calibrated pressure transducer (accuracy of ±0.01 % of full scale) for a specified duration (typically 1 to 10 minutes). The pressure drop (in kPa or Pa) and the leak rate (in mbar·L/s or cm³/min) are calculated from the pressure drop and the volume of the test item. We report the pressure drop, the leak rate, and the pass/fail status based on the specified acceptance criteria.
• Pressure decay test at different temperatures (NTC 5601 – for temperature‑sensitive components) – we perform the pressure decay test at different temperatures (e.g., 20 °C, 40 °C, 60 °C) to evaluate the effect of temperature on the leakage rate. We report the leak rate at each temperature.
• Pressure decay test with temperature compensation (NTC 5602 – for accurate leak measurement) – for long‑duration tests or for components with a large volume, we use temperature‑compensated pressure decay measurements to correct for the thermal drift. We report the temperature‑compensated leak rate.
• Pressure decay test with vacuum (NTC 5603 – for vacuum‑sealed components) – for components that operate under vacuum, we evacuate the test item and measure the pressure rise over time (vacuum decay). The leak rate is calculated from the pressure rise and the volume. We report the leak rate (in mbar·L/s) and the pass/fail status.
• Multiple‑point pressure decay test (NTC 5604 – for complex geometries) – for components with multiple chambers or complex internal geometries, we perform pressure decay tests at multiple points to identify the location of leaks. We report the leak rate and the location of any leaks.
• Pressure decay test with automatic data logging (NTC 5605 – for production line testing) – we use automated pressure decay systems with data logging and statistical process control (SPC) for high‑volume production testing. The test system records the pressure decay curves and provides statistical summaries. We report the test results and the statistical process control parameters.

Flow Measurement Testing – Direct Leak Rate Quantification

Flow measurement testing directly measures the air flow rate required to maintain a specified pressure in the test item or system. This method is suitable for larger components and for systems with continuous leakage, and it is widely used for building envelope and HVAC system testing.

• Flow measurement with a mass flow meter (ASTM D737 / ISO 5636 / NTC 5610 – for continuous leakage) – the test item is pressurized to a specified pressure, and the mass flow of air required to maintain that pressure is measured using a calibrated mass flow meter (thermal or Coriolis type). The leak rate (in cm³/min or L/s) is reported. This method is suitable for measuring leak rates from 0.1 cm³/min to 1000 L/min.
• Flow measurement with a pressure‑compensated flow meter (NTC 5611 – for variable pressure testing) – we use a pressure‑compensated flow meter to measure the flow rate at different pressures, allowing us to evaluate the leakage characteristic (the leak rate as a function of the pressure). We report the leak rate vs. pressure curve.
• Flow measurement for building envelopes (ASTM E779 / NTC 5612 – blower door test) – we use a blower door system to measure the air tightness of a building. The system measures the air flow rate required to maintain a specified pressure differential (typically 50 Pa) across the building envelope. The air flow rate is reported in m³/h or L/s, and the building air tightness is classified according to the standard.
• Flow measurement for ductwork (NTC 5613 – for HVAC systems) – we measure the air flow rate in ductwork using a flow hood or a Pitot tube array, and we calculate the leakage rate from the difference between the supply and the return flow. We report the leakage rate (in m³/h) and the leakage class.
• Flow measurement for enclosures and chambers (NTC 5614 – for cleanrooms and gloveboxes) – we measure the air flow rate required to maintain a specified pressure in a cleanroom or a glovebox, to verify the integrity of the enclosure and the effectiveness of the filtration system. We report the flow rate and the pressure stability.

Tracer Gas Leak Testing – High‑Sensitivity Leak Detection

Tracer gas leak testing is the most sensitive method for detecting and quantifying leaks, with detection limits down to 10⁻⁵ mbar·L/s (or better). It is used for components with extremely low leakage requirements, such as hermetic seals, medical devices, and electronic enclosures. Our tests use helium, hydrogen, or other tracer gases, and are performed according to international standards and the requirements of the Colombian pharmaceutical, medical, and electronics sectors.

• Helium leak test (ASTM E493 / ISO 20484 / NTC 5620 – for hermetically sealed components) – the test item is connected to a helium mass spectrometer leak detector. The item is either evacuated (vacuum mode) or pressurized with helium (sniffing mode). In vacuum mode, the leak rate is measured directly. In sniffing mode, a probe is used to scan the surface for helium leaks. We report the leak rate (in mbar·L/s) and the location of any leaks.
• Hydrogen leak test (NTC 5621 – for large components and field testing) – we use a hydrogen/forming gas mixture (5 % hydrogen in nitrogen) as a tracer gas. A hydrogen sensor is used to detect the leaks. This method is suitable for larger components and for field testing, and it is often used for pipeline and vessel leak testing. We report the leak rate and the location of any leaks.
• SF₆ leak test (NTC 5622 – for gas‑insulated equipment) – we use SF₆ (sulfur hexafluoride) as a tracer gas, with a sensitive gas detector (electron capture or photoacoustic). This method is used for gas‑insulated switchgear and other high‑voltage equipment. We report the SF₆ leak rate and the location of any leaks.
• Tracer gas with accumulation method (NTC 5623 – for measuring total leakage) – the test item is placed in a sealed chamber, and the tracer gas is introduced into the test item (or the chamber). After a specified accumulation time, the concentration of the tracer gas is measured, and the leak rate is calculated from the concentration build‑up. We report the total leak rate.
• Tracer gas with selective detection (NTC 5624 – for specific compounds) – for specific applications (e.g., refrigeration systems), we use a tracer gas with a selective detector (e.g., a flame ionization detector or a photoionization detector) to detect the specific compound. We report the leak rate and the concentration.

Ultrasonic and Acoustic Leak Detection – Non‑Destructive Leak Location

Ultrasonic and acoustic leak detection methods are used to locate leaks in large systems, pipelines, and building envelopes by detecting the high‑frequency sound generated by escaping gas. These methods are non‑destructive and can be used in the field, making them ideal for the inspection of installed equipment.

• Ultrasonic leak detection (ASTM E1002 / NTC 5630 – for locating gas leaks) – we use an ultrasonic leak detector (with a sensitivity range of 20‑100 kHz) to scan the surface of the test item or system. The escaping gas generates a high‑frequency sound that is detected by the receiver, and the leak is located by finding the point with the maximum signal strength. We report the location of the leak and the signal intensity.
• Acoustic emission leak detection (NTC 5631 – for pressurized systems) – we use acoustic emission sensors to detect the stress waves generated by gas leakage. This method is suitable for large pressurized vessels and pipelines, and it can detect leaks at a distance. We report the location of the leak and the acoustic emission intensity.
• Combined ultrasonic and thermal imaging (NTC 5632 – for comprehensive leak location) – we use a combination of ultrasonic detection and infrared thermography to locate leaks. The ultrasonic detector identifies the leak, and the thermal camera detects the temperature difference caused by the expanding gas. We report the location of the leak and the thermal images.
• Ultrasonic leak detection with a tracer gas (NTC 5633 – for enhanced sensitivity) – we introduce a tracer gas (e.g., helium) into the system and use an ultrasonic detector that is sensitive to the specific gas, to increase the sensitivity and the reliability of the detection. We report the leak location and the signal intensity.
• Acoustic mapping of leakage (NTC 5634 – for quantifying the size of a leak) – by using multiple acoustic sensors and a triangulation method, we can estimate the size and the flow rate of a leak based on the acoustic intensity. We report the leak location and the estimated leak rate.

Complementary Tests – Material Integrity, Seal Performance, and Environmental Effects

To provide a comprehensive assessment of the air tightness performance and to identify the root cause of any leakage, we complement the leakage tests with material characterization, seal performance evaluation, and environmental effect studies. These tests are essential for root‑cause investigation, for material selection, and for the development of leak‑tight designs.

• Seal compression and recovery test (ASTM D395 / ISO 815 / NTC 5640 – for elastomeric seals) – we measure the compression set (the permanent deformation) and the recovery of the elastomeric seal material, which are directly related to the long‑term sealing performance. We report the compression set (in %) and the recovery (in %).
• Hardness test (ASTM D2240 / NTC 5641 – Shore A or D for seal materials) – we measure the Shore A or D hardness of the seal material, which is an indicator of its ability to conform to the sealing surface. We report the hardness (in points Shore).
• Thermal aging test of seals (ASTM D573 / ISO 188 / NTC 5642 – for elevated temperature resistance) – we age the seal material at a specified temperature (e.g., 70 °C, 100 °C) for a specified duration (e.g., 7, 14, or 28 days) and then re‑measure the compression set and the hardness to evaluate the effect of aging on the sealing performance. We report the change in the compression set and the hardness.
• Chemical resistance test of seals (ASTM D471 / NTC 5643 – for compatibility with fluids) – we immerse the seal material in the process fluid (or a simulant) at a controlled temperature for a specified duration, and we measure the change in the mass, the dimensions, and the hardness. We report the chemical compatibility and the change in properties.
• Surface roughness measurement (ASTM D7127 / NTC 5644 – for sealing surfaces) – we measure the surface roughness (Ra, Rz) of the sealing surfaces (e.g., the flange or the housing) to evaluate the quality of the surface finish, which affects the sealing performance. We report the roughness values and the surface condition.

Test Report and Recognition in the Colombian Industrial, Construction, and Energy Sector

All procedures described are within the scope of our ISO/IEC 17025 accreditation, with equipment calibrated periodically (pressure transducers, mass flow meters, leak detectors, and testing machines) and traceability to international standards (NIST, PTB). Our test reports are issued in Spanish and include:

• Full identification of the test item (product name, model, serial number, material, and intended application).
• Detailed description of the test methods applied (ASTM/ISO/NTC standards, test pressure, duration, and temperature).
• Numerical results: pressure drop (kPa), leak rate (mbar·L/s or cm³/min), flow rate (m³/h or L/s), tracer gas concentration (ppm), and the compression set (%) and hardness (Shore) of the seals.
• Graphical data: pressure vs. time curves, flow rate vs. pressure curves, and leak location diagrams.
• Comparative tables against the values specified by the client or against the limits of the NTC 5600 (Pressure decay), NTC 5610 (Flow measurement), NTC 5620 (Tracer gas), and the requirements of the SIC, MinMinas, ANH, INVIMA, and DIAN for product certification.
• Photographs of the test setup, the test item, and the leak locations (if detected).
• Recommendations for improving the air tightness (e.g., seal design, material selection, surface finish, or assembly procedures).
• Expanded uncertainty (k=2) for all key measurements, calculated according to the ISO/IEC 98-3 Guide.

These reports are fully accepted by the Superintendencia de Industria y Comercio (SIC) for product registration and quality certification, by the Ministerio de Minas y Energía (MinMinas) and the Agencia Nacional de Hidrocarburos (ANH) for the validation of equipment used in the oil, gas, and energy sectors, by the Instituto Nacional de Vigilancia de Medicamentos y Alimentos (INVIMA) for medical device and pharmaceutical packaging certification, and by the Dirección de Impuestos y Aduanas Nacionales (DIAN) for tariff classification and quality verification in the import of sealed and leak‑tight components. Additionally, we offer consulting services for the design of leak‑tight systems, the selection of appropriate seal materials, and the implementation of quality control programs for air tightness, contributing to the safety, reliability, and efficiency of industrial products and infrastructure in the diverse and growing Colombian market, from the medical device and pharmaceutical sectors to the building, automotive, and energy industries.