Pre Insulated Ductwork: Features, Materials, and Installation

Overview of Pre Insulated Ductwork

In modern HVAC systems, Pre Insulated Ductwork is gaining popularity due to its efficiency, clean appearance, and ease of installation. A typical form of pre insulated ductwork is the PUR Panel duct, which is made by bonding non-combustible surface layers like aluminum foil onto a thermal insulation core Duct Polyurethane Insulation Board. This structure offers both air distribution and thermal insulation in one integrated system.

Over the past two decades, composite ducts have rapidly developed in the world and are now widely used across commercial and industrial HVAC installations.
The most commonly used composite Air Conditioning Duct is: Polyurethane aluminum foil Air Conditioning Duct

Key Advantages of PUR Air Conditioning Duct

These types of pre insulated ductwork bring multiple advantages that meet the evolving needs of energy-efficient building designs:

• Lightweight and streamlined appearance
• No need for external insulation
• High thermal performance with low air leakage
• Fast installation and reduced labor requirements
• Reliable quality through mechanized panel production

The use of high-quality PUR Air Conditioning Duct ensures excellent fire resistance, thermal insulation, and durability, making composite ducts a compelling alternative to traditional galvanized steel ductwork.

Manufacturing and Installation Requirements

To ensure safety, efficiency, and long-term performance, all components of the duct system must come from the same manufacturer or be approved as compatible. This includes duct boards, accessories, adhesives, and specialized tools.
Additionally, all materials—particularly polyurethane insulation boards—must come with certified documentation proving fire resistance and insulation performance.

Structural Reinforcement Guidelines

For rectangular ducts with a side length over 320 mm, it's necessary to install galvanized right-angle corner plates (≥0.75 mm thick) at the plug-in joints. These reinforcements prevent deformation caused by internal air pressure concentration at the corners.

Characteristics of Composite Duct Fabrication

1. Lower Resistance to Impact: These ducts, especially those using PUR panels or foam-based cores, must be handled with care during transport and storage.
2. Easy On-Site Fabrication: Using only basic tools, technicians can cut and assemble ducts on-site. This feature supports the quick deployment of pre insulated ductwork.
3. Low-Noise Production: The fabrication process generates minimal noise, though dust or fibers may be released during cutting—requiring masks and ventilation.
4. Use of Adhesives: Flammable adhesives are used extensively and must be stored safely with strict fire precautions in place.
5. Internal Support Rods: Galvanized steel threaded rods are typically used internally to reinforce duct walls.

Connection Methods and Application Limits

Composite ducts can be connected in three ways:

• Adhesive bonding
• Plug-in joints
• Flange connection

Adhesive and plug-in methods are most common, but excessive use of direct adhesive bonding outside the recommended size limits must be avoided.
Due to the structural limitations of materials like polyurethane insulation boards, composite ducts are best suited for:

• Static pressure ≤ 2000 Pa
• Air velocity ≤ 12 m/s
• Maximum side length ≤ 2000 mm

Ducts made with PUR panels and 80mic aluminum foiled are also compatible with cleanroom HVAC systems that demand high cleanliness and consistent airflow.

Conclusion of Pre Insulated Ductwork

As the demand for efficient, space-saving HVAC systems continues to rise, pre insulated ductwork made with aluminum foil and polyurethane insulation boards offers a reliable solution. With benefits such as low leakage, high thermal performance, and fast installation, composite ducts are set to become a staple in modern HVAC engineering.

At GFI Duct, we specialize in manufacturing high-quality PUR panel duct systems, designed to meet the rigorous demands of commercial and industrial HVAC projects. Partner with us for reliable performance, streamlined installation, and long-term energy savings.