Low Embodied Carbon Ductwork

Now is the Time to Offer Your Customers Pre-Insulated Ductwork

Since the early 2000s when the Kingspan KoolDuct system entered the United States market, many contractors around the country have found a solution with non-fibrous phenolic ductwork. This pre–insulated hvac ductwork system offers many benefits, including higher insulated values and less air leakage than traditional duct systems without the need for fiberglass insulation, leading to faster installation time and reduced heating and cooling loads through low air leakage rates. The last few years have seen great strides for the Phenolic industry with the leadership of SMACNA and new tools ready to equip estimation, design and fabrication for applications that require lightweight insulated hvac ductwork systems.

Installing Pre-Insulated KoolDuct Ductwork

The Koolduct system is an advanced alternative to traditional sheet metal ductwork that provides your duct and insulation in one easy to install product. With simple unflanged or 4-bolt connections (similar to TDC), fewer hangers and up to a 72% reduction in weight, this class 1 air duct can increase installation speeds and not weigh your team down...keeping your team on or ahead of schedule.

Installers should follow the practices set by both Kingspan or SMACNA in their guidelines for phenolic ductwork. For brief training from Delta Air Systems or one of our trained fabrication partners, we’re always happy to help your installation find savings go as smooth as possible!

Fabrication of Non Metal Ductwork with Kingspan KoolDuct

While many things are similar, creating ductwork out of a 3 dimensional closed cell foam material will have several differences from traditional metal ductwork. Where metal ductwork can be cut with plasma or laser based machinery, Koolduct® requires processes that can account for the Z access such as CNC or bladed machinery. Once materials have been cut, fabricators will be able to fold or assemble their ductwork to shape.

Connection types with either unflanged or flanged methods are paired with guidelines to proper reinforce by Kingspan or SMACNA guidelines to reach up to a 4” positive or 3” negative static pressure design through guidelines. KoolDuct provides versatility and can be used in a variety of applications for air distribution, with many users finding the benefits of a smooth aluminum interior without the risk of loose fibers entering the air stream. This is an excellent option for applications that require insulated ductwork but also want increased indoor air quality.

Fiberglass Free High R-Value Duct Lining

Kingspan KoolDuct fiber-free, rigid insulation core panels are also available for use as an interior duct liner. This newly developed, patented method of construction allows for the same panels used in Kingpsan's UL 181 listed system to now be applied to galvanized sheet metal ductwork for a fiber free lined duct that does not require adhesives. KoolDuct insulation panels are faced on both sides with an aluminum interior which will allow air flows over sealed foil surfaces instead of loose fibers. This allows performs better than an insulated air duct system that uses traditional limp, non-structural insulation that requires glue and pins to keep it in place. Anyone can install KoolDuct as a liner with tools you likely already have in your shop!

With a variety of panel thicknesses available for R6, R8 and R12 applications, KoolDuct can meet the needs of many applications. Find out more about our easy to install duct liner!


The Phenolic Duct Construction Standards Changed Everything

Bringing a new product to market often receives an understandable level of scrutiny. In the early years, Introducing KoolDuct pre-insulated ductwork to the US market was an uphill battle, even with the extensive testing, certifications and long history Kingspan KoolDuct had in the UK. Often engineers would ask “What does SMACNA say about Phenolic Ductwork?” regardless of their thoughts on the product's premium performance. Five SMACNA Contractors answered that question with the help of SMACNA’s Eli Howard, setting standards that would guide the emerging pre-insulated hvac ductwork industry.

The SMACNA Phenolic Duct Construction Standards were published in early 2015. This was an important step for phenolic systems, not only for those who fabricate, but for the engineering community as well and opened up the market ready for an advanced and innovative rectangular product to provide significant energy savings.

Phenolic Duct Estimation needed to be on the same playing field as Sheet Metal

Benchmark Enterprise Software launched in November 2015 as a powerful AutoCAD Add-on that includes a full library of Kingspan KoolDuct Phenolic ductwork, in addition to Sheet Metal. This allows estimators and detailers to line item costs, estimate and draw Phenolic ductwork the first time in a 3D CAD environment. Benchmark will automatically help design the right connections between ductwork and equipment using built in SMACNA construction standards, including those for Phenolic Duct Construction. When the drawing is done, Benchmark’s fabrication module will allow nesting off of the same 3D files used for estimation and detailing and output directly to a wide variety of machinery.

Having a CAD software tool designed for Phenolic Ductwork makes giving your customers the option of higher R-values and lower air leakage is a more viable option. Pre-planning is key to reduced installation time and the ability to coordinate KoolDuct's installation process ahead of time in a new way with software benefits everyone. For more information on Benchmark Enterprise Software visit www.hvaccadsoftware.com.

Fabricate Pre-Insulated Ductwork

Automation of Fabrication is Important for Long Term Growth

Sheet Metal duct fabrication has seen great improvements over the years as Plasma Cutters and Coil Lines have become more prominent. Phenolic duct fabrication has seen its fair share of improvements as well. Ductwork is fabricated using CNC machines specifically designed to handle the phenolic duct thicknesses and assembly methods are available from GoMech, Axyz, Pathfinder and others. These CNC machines can handle both fittings and straight duct. Other specialized machines and tools are available for innovative systems like KoolDuct phenolic duct as well from these manufacturers.

Supporting New HVAC Technology is Vital to the Future of Our Industry

Pre-insulated Phenolic Ductwork like Kingspan KoolDuct is changing the HVAC industry. It allows you to offer weight savings, space-saving and LEED Point eligible high performance system to your customers that can add value to their project, both now and with future energy bills. There’s never been a better time for you to get involved with your next project!

Contact us to learn more!