KoolDuct- What is it, and why is it a great ductwork solution?

Introducing Kingspan KoolDuct System

The KoolDuct System is a premium, pre-insulated Kingspan phenolic duct product that is both the ductwork and insulation all in one, providing labor savings and improved energy efficiency while also eliminating the need for an insulator. This innovative interior duct solution has been installed throughout the United States, Europe and Middle East and is also used in outdoor duct solutions such as the Pro-R duct system.

What is KoolDuct? What are Features of KoolDuct?

Kingspan KoolDuct System is a revolutionary HVAC ductwork product. KoolDuct is pre-insulated and is made of closed-cell foam. Its innovative design offers unmatched savings in energy costs in the HVAC industry, providing R-values from R-6 up to R-47 and incredibly low air leakage rates. Additionally, KoolDuct’s non-fibrous, rigid phenolic insulation core provides significant indoor air quality benefits. This leads to a high-performing building.

KoolDuct Features:

• UL 181 Listed for fire and smoke performance and mold growth test due to smooth aluminum interior surface

• Space-saving- can be installed directly along ceilings, walls, and floors

• LEED Point eligible- contributing toward a LEED rating

• Cost savings- Lightweight duct work reduces installation labor costs due to less time and fewer crew members required

• High R-Values from R-6 to R-24

• 13 ft. joints helps save on labor and material costs for installation

• Up to 72% less weight compared to traditional ductwork methods

• Ideal for mechanical rooms, attics, shafts, and hard-to-reach interior spaces

• Lightweight Kingspan KoolDuct closed cell phenolic insulation delivers high energy savings

• Available with TDC and 4 bolt connections, making installation contractor-friendly

• Near-zero air leakage, easily achieves SMACNA Class 3

Why Phenolic Ductwork?

Phenolic ductwork is made using a high-performing alternative duct material. Phenolic duct systems like KoolDuct reduce duct leakage and increase thermal efficiency of HVAC systems. Using this type of duct product means that a contractor does not have to deal with separate ductwork and separate insulation, as it is pre-insulated, saving time, money, and reducing project timelines.

Kingspan KoolDuct can be installed internally or externally, above a false ceiling, or visibly mounted. It is quite versatile, providing an opportunity for plenums, risers, and other individual system components to be integrated to a standard sheet metal duct system.

KoolDuct Applications

The Kingspan KoolDuct® System is engineered to be used in building services and HVAC applications. It is perfect for both new and renovation projects on all levels- residential, commercial, industrial, and leisure sectors. KoolDuct is the preferred choice for the food, beverage, pharmaceutical industries, and other industries that require clean and hygienic air. In addition, high humidity environments are another application that KoolDuct outperforms competitors on due to its UL181 mold growth test. Swimming pools are no problem! Kingspan KoolDuct also is a top choice for communication or server rooms where non-fibrous material is preferred to keep everything running smoothly.

What are the Indoor Air Quality Benefits of KoolDuct

A big advantage to KoolDuct is that its insulation is fiber-free, offering a higher level of indoor air quality (IAQ) than standard ductwork. Traditional duct utilizes fiberglass insulation that releases fibers overtime and is also susceptible to mold due to its ability to absorb water.

Why You Should Choose Kingspan KoolDuct

If you are looking for a duct system product that offers thermal efficiency, unmatched cost savings on labor, IAQ benefits and a lightweight design that can be installed virtually anywhere, then KoolDuct would be an excellent choice for you.

To learn more about the Kingspan KoolDuct system, contact us for a free consultation by calling us at 651-265-0605 or at info@ductsandcleats.com.

Minimize Ductwork Leakage and Maximize Energy Efficiency

The Kingspan KoolDuct System Pairs Quality Ductwork with High-Caliber Insulation to Minimize Air Leakage and Maximize Performance

Reducing operational costs and maximizing building performance is dependent on the best choice of insulation material selected. Considering the options for insulation (e.g. rigid board, mineral wool, spray foam, pre-insulated metal panels, etc.), the selection of the right product can be daunting.

This selection of the best insulation product also applies to ductwork. Insulation of ductwork is critical in ensuring that the air moving through the ductwork remains at the temperature intended for delivery throughout the building. Insulation can be in the form of a liner inside of the duct or as a wrap on the exterior of the duct. When insulation is properly installed in ductwork, condensation and air leakage is minimized, staving off numerous issues.

One particular issue that can arise due to improper insulation installation is air leakage. Air leakage from ductwork significantly increases energy loss in buildings. In fact, up to $25 billion in energy losses has been attributed to duct leakage based on estimates from the U.S. Department of Energy.

The Kingspan KoolDuct System combats air leakage from its ductwork by using premium-performance panels, advanced and innovative fabrication methods, presence of coupling systems, and the provision of a complete offering of accessory items. The Kingspan KoolDuct System ductwork can be fabricated in rectangular sections reaching up to 13 feet (3.93 m) in length which promotes a faster installation rate. Additionally, KoolDuct has been found to weigh up to 72% less than typical standard galvanized sheet metal that has been insulated with mineral fiber. Furthermore, because KoolDuct is comprised of a rigid, phenolic insulation core and not mineral fiber, there is a significant reduction of the chance of fibers entering the airstream through the ductwork.  

The Kingspan KoolDuct System is the first phenolic pre-insulated ductwork in the world to be UL 181 Listed as a Class 1 Air Duct. Because of its outstanding features, the Kingspan KoolDuct System has no problem obtaining a SMACNA Class 3 air leakage rating. Benefits of the product include reduction of energy consumption, operational and service costs, and carbon dioxide emissions.

The Kingspan KoolDuct System is designed to be the best choice for a wide array of construction projects, working in both new and refurbishment projects, as well as residential and commercial construction. The ductwork is designed to be able to handle indoor or outdoor placement. Furthermore, the product is easily hidden above false ceilings or below raised floors. 

KoolDuct for Outdoor Applications

Watch: KoolDuct for Outdoor Applications - The Patented Pro-R Duct System

Kingspan KoolDuct should not be installed outdoors by itself. KoolDuct needs a protective weather barrier to be a successful solution for outdoor ductwork applications. The Pro-R Ductwork system (www.prorduct.com) is a patented product that utilizes KoolDuct within a protective metal weather barrier for the ultimate solution in durability and energy efficiency.

Whole-Life Cost of Ductwork Systems

The Positive Effects of Kingspan Pre-insulated Ductwork on Project Whole-Life Cost

Low capital cost has been a constant top priority in building design in order to boost profits. However, operating cost is another important feature for buildings that are part of rental contracts because they require continuous maintenance and services provided by the lessor. This can also be the case for forward-thinking clients who want to consider sustainability as part of their building design and thus want to minimize service costs of the building over time.

The concept of “whole life cost” encompasses the total cost of the building over its life which includes, but not limited to, capital and operation/maintenance costs. Thus, in order to minimize the whole life cost of a building, products and systems must be selected that are low cost and meet design requirements that will also provide the lowest whole life cost. In consideration of this, the proper selection of ductwork and its insulation are of utmost importance.

KoolDuct Analysis

Cyril Sweett, an independent consultant, was tasked by Kingspan Insulation to assess whole life costs of various ductwork systems in the UK. The analysis showed that the Kingspan KoolDuct System:

• Can save more than 21% over a 30-year life cycle

• Provide a 20% savings in operating and whole life cost

An additional analysis completed by the mechanical and electrical engineering firm, MDA Engineering Inc., examined empirical data collected from two independent buildings owned and operated by Luther Home of Mercy. The findings collected from the analysis showed that the Kingspan KoolDuct System:

• Saved over 16% in capital costs over a 30-year life cycle

• Is predicted to have over a 14% saving on whole life cost

Overall, the Kingspan KoolDuct System is a top product when choosing an insulated HVAC ductwork system where whole life cost is a vital component to project design.

KoolDuct as an Outdoor Duct System

Our patented pro-R duct system utilizes the KoolDuct system as an internal core and integrates it with a durable and weatherproof metal exterior, providing the ultimate solution in efficiency and durability. In addition, TDC connections make it easy for contractors to work with and the various color choices allow for an attractive exterior.

Impacts of Ductwork Weight on Project Viability

The Kingspan KoolDuct System Boosts Project Viability Due to Lower Weight

The Kingspan KoolDuct system is a pre-insulated, low-weight HVAC ductwork that provides a variety of benefits for building projects, especially construction dealing with refurbishment or retrofit. Benefits include:

• Easy installation, which results in lower handling cost

• Minimizes the risk of surpassing the maximum manual handling and lifting limits for workers, thus ensuring the following of health and safety regulations

• Minimizes the need for specialized installation equipment

• Allows for the installation of lighter supports at space-efficient centers

• Reduces the need for extra structural support in renovation construction

Kingspan Insulation had an independent review of six UK case studies completed by Rider Levett Bucknall, an independent consulting firm. The review was intended to examine standard types of insulated sheet steel ductwork and Kingspan KoolDuct System ductwork. The review assessed each type’s performance relative to weight and the benefits provided.

The independent review found that the Kingspan KoolDuct System weighs up to 72% less than the standard galvanized sheet steel ductwork that is insulated with glass fiber duct wrap. Benefits identified from this lower weight includes the following:

• Reduction of cost for projects

• Increased project viability due to lower cost

• May be only practical product for some projects

Reviewing the findings of the analysis, it is clear that the benefits from the lower weight of the Kingspan KoolDuct System make the product a top choice for construction projects where ductwork weight is of importance.

Choosing Pre-Insulated Ductwork Helps to Save Space

The Kingspan KoolDuct System Maximizes Space Efficiency

Maximizing space efficiency in the construction of new buildings or remodeling of pre-existing buildings is an important aspect that engineers have to consider when designing a building. This is especially true for buildings where there is already less space per occupant available (e.g. healthcare facilities and schools).

Typically, available space in a building is calculated in terms of “building floor area.” However, volume should also be taken into consideration when determining available space. Most commercial and institutional buildings have to accommodate necessary services (e.g. IT & communications, fire suppression, HVAC systems, electrical, structural, etc.) that are required for the businesses or institutions within. In order to meet the requirements for these buildings, space efficiency should be a top item when considering how to design a particular building.

The Kingspan KoolDuct System is pre-insulated ductwork designed to minimize the amount of space required to be dedicated for ductwork in any building by eliminating the extra space needed to manually install a layer of insulation around the ductwork.

KoolDuct (left) can be mounted flush to ceiling, whereas traditional ductwork (right) needs 6-8” of room to apply insulation

The Kingspan KoolDuct System defies the normal space requirements by being pre-insulated. Because it is pre-insulated, KoolDuct has the ability to be constructed with flush joints between sections. This allows KoolDuct to be installed even between members of steel roof trusses or other structural features. This type of installation allows for the maximization of space that can then be dedicated to other services, or just reduce the amount of service space altogether. The use of this product is particularly advantageous with main riser ductwork, and if used early on in the design process, could lead to an increase in usable floor space.

An independent consulting company, Rider Levett Bucknall, conducted research on the Kingspan KoolDuct System and found that amongst the most frequent types of responses were those regarding the space efficiency of KoolDuct. To further their research, Rider Levitt Bucknall completed an independent cost analysis of the benefits of the product in a space-saving facility. The results indicated that the use of KoolDuct could reduce 1-2% in overall construction cost for that particular project. This reduced cost stems from the reduced structure, internal wall, wall finishing and cladding required.

Considering the benefits of the Kingspan KoolDuct System, this should be the HVAC ductwork product used when designing a building that maximizes on space efficiency.

For indoor applications such as mechanical rooms, shafts and other high traffic areas where increased durability is desired, the pro-R duct system should be considered. pro-R utilizes the proven KoolDuct system but goes a step further by integrating KoolDuct with a tough and durable metal exterior. pro-R was designed to withstand harsh weather in outdoor applications and serves as an excellent choice for indoor applications as well.