Streamlining ductwork installs

Thursday 13 November 2025

Carrying out ductwork installations with traditional galvanised steel ductwork, either as part of a new-build or a refit, can be a laborious and time-consuming process.

The runs of ductwork are heavy to lift and require a significant number of hangers/supports to hold them in place. They can also be time-consuming to adjust onsite and need to be lagged with insulation in a separate operation.

Pre-insulated phenolic ductwork, such as the Kingspan KoolDuct System, provides a lightweight alternative which can support ease and speed of installation and enhance whole-life system performance.

Pre-insulated benefits

The Kingspan KoolDuct System is formed from rigid thermoset phenolic insulation boards which are faced with silver aluminium foil on both sides. This pre-insulated design can provide a number of advantages over traditional galvanised steel approaches.

The lightweight phenolic ductwork system can be rapidly installed and is capable of achieving low levels of air-leakage, reducing long-term energy demands and cost.

The panels can be used to rapidly fabricate ductwork runs in section lengths up to 2.95m which can be easily modified onsite to deal with any design changes.

Phenolic ductwork can weigh up to 70% less than galvanised steel ductwork lagged with mineral fibre, reducing the support requirements and making them well suited for refurbishment applications where the load capacities of existing building structures are limited.

As it can be fitted in a single-fix, with no separate lagging process, installations can be accelerated and the ductwork can be fitted tight to structures – typically saving up to 150-200mm in a single dimension.

The Kingspan KoolDuct System is an innovative pre-insulated phenolic rectangular HVAC ductwork system.

Pre-insulated ductwork can also provide clear operational performance benefits. Ductwork fabricated from the Kingspan KoolDuct System can achieve air leakage rates which are a fraction of those typical of rectangular sheet metal ductwork. This can allow the use of smaller, more energy efficient fans whilst still providing effective ventilation, potentially delivering considerable whole life savings in both energy costs and operational carbon emissions.

Rreduce embodied carbon

Use of pre-insulated phenolic ductwork also reduces the amount of steel needed for a project which can notably reduce embodied carbon.

To support specification, the Kingspan KoolDuct System is available with a verified EPD which can be accessed via: http://www.kingspanductwork.co.uk/koolduct. The KoolDuct insulation board holds a Euroclass B reaction to fire rating certified under AVCP System 1 on both 22mm and 30mm thickness.

If you are interested in learning more about pre-insulated ductwork, and the advantages it can offer, Kingspan Technical Insulation offers an in-person or remote CPD: Introduction to Air Ductwork. This CIBSE approved seminar covers both traditional and pre-insulated systems along with key regulations and other considerations. Book a free session at: https://www.kingspan.com/gb/en/education-training/introduction-to-air-ductwork/