In the sterile insect technique, it is important to measure the impact of mass-rearing and handling of sterile males to allow a successful control of the target wild population. This study evaluates the effect of pre-release chilling on the survival, escape ability, and sexual competitiveness of male Aedes aegypti. To determine survival and escape ability, mosquitoes were chilled at 4 °C using four different treatments of either one exposure (25 min) or two consecutive exposures (25 + 25 min, 25 + 50 min, 25 + 100 min). For sexual competitiveness, two different treatments were evaluated, chilling for 25 min once and twice. Results showed that the longest exposure to chilling caused a significant reduction of survival time, from 67 to 54 days. Escape ability was reduced by the first chilling from 25 to 7% and with the second chilling, it was reduced from 30 to 24% in the control to 4.9, 2.0 and 0.5% for 25, 50 and 100 min, respectively. Sexual competitiveness index was reduced from 1.16 in the control, to 0.32 and − 0.11 for treatments involving one and two chilling periods, respectively. It is recommended to increase the chilling temperature and reduce the exposure time to reduce the harmful effects on sterile males.