1. Outstanding heat preservation and energy-saving performance
Ultra-low thermal conductivity: The core material, rigid polyurethane foam (PUR) or superior polyisocyanurate foam (PIR), features an extremely low thermal conductivity (typically 0.022-0.028 W/(m·K)). This makes it one of the air duct plates with the highest insulation efficiency on the current market.
Significant energy-saving effect: The excellent insulation performance minimizes the energy loss (cold/heat loss) of the air duct system during the transportation of cold and hot air to the greatest extent, effectively reducing the energy consumption of system operation and saving long-term operating costs for users.
Preventing condensation: The powerful insulation layer effectively isolates the temperature difference between the air inside the pipe and the external environment, greatly reducing the risk of condensation on the outer surface of the air duct, protecting the building structure and preventing mold growth.
2. It combines high strength with light weight
Stable structure: Polyurethane /PIR foam itself has a certain strength. After being combined with a high-strength surface layer, the overall bending and compressive resistance of the board is excellent, ensuring the structural integrity and shape stability of the air duct during installation and use.
Lightweight and easy to install: Compared with the traditional solution of adding external insulation to metal air ducts, the overall weight of polyurethane composite air duct panels is significantly reduced. This not only reduces transportation costs, but also simplifies the difficulty and intensity of on-site handling and installation (cutting, assembly, connection), effectively improving construction efficiency.
3. Excellent fire safety performance
High flame retardant grade: High-quality polyurethane duct panels, especially the PIR type, through formula optimization and the addition of flame retardants, can meet the B1 grade (difficult-to-burn material) stipulated in the national standard GB- or even higher fire resistance grades (such as the European standard B-s1, d0).
Low smoke and non-toxic: When exposed to fire and burning, high-quality products can effectively suppress the spread of flames and significantly reduce the generation of smoke and toxic gases (meeting relevant low smoke and non-toxic standards), buying precious time for personnel evacuation and fire rescue, and enhancing the fire safety level of buildings.
4. Convenient and efficient installation process
Integrated molding: The sheet material itself serves as both the structural layer and the insulation layer of the air duct, eliminating the cumbersome subsequent process of wrapping insulation materials around traditional metal air ducts (such as attaching insulation cotton, wrapping aluminum foil, etc.).
Special connection method: With a unique "T" -shaped or "Ω" -shaped flange design, combined with special adhesives (such as polyurethane glue) and inner and outer corner guards/I-shaped inserts, it can achieve rapid and precise splicing and sealing of air ducts. This "flangeless" connection method significantly increases the construction speed and shortens the project period.
Easy processing: The sheet material can be easily cut and grooved (V-shaped or U-shaped grooves) with special tools, facilitating on-site bending into shape (rectangular or circular air ducts) and the production of various pipe fittings (elbows, tees, reducers, etc.) as needed, with high flexibility.
5. Environmental protection and health security
Environmentally friendly foaming agents: Modern production processes generally adopt environmentally friendly foaming agents (such as HFCS or gradually shift to alternatives with lower GWP) to reduce damage to the ozone layer and the impact of the greenhouse effect.
Clean inner surface: The smooth and dense aluminum foil lining effectively prevents the escape of substances such as glass fiber, avoiding contamination of the conveyed air quality and meeting the requirements of places with high air cleanliness standards such as hospitals, laboratories, and electronic factories. At the same time, it inhibits the growth of microorganisms.
No fiber disturbance: Unlike fiber-based insulation materials such as glass wool, polyurethane has a closed-cell foam structure. During installation and use, it will not produce irritating fiber dust, improving the working environment for workers.
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6. Outstanding air tightness and low air leakage rate
Good overall sealing performance: The board itself has few seams. Combined with dedicated adhesives and sealing processes (such as internal and external corner guard seals), it can build a highly airtight air duct system.
Reduce energy loss: A low air leakage rate (far superior to traditional air ducts) means that less processed air escapes from the pipe gaps, ensuring air supply efficiency, reducing energy waste, and enhancing the operational efficiency of the entire air conditioning system.
7. Good acoustic performance
Sound absorption and noise reduction: The porous polyurethane foam structure and the aluminum foil lining with micro-pores or embossing treatment have a certain absorption and attenuation effect on medium and high-frequency airflow noise, which helps to reduce the noise generated by the operation of the air duct system and improve the comfort of the indoor acoustic environment.
8. Comprehensive economic advantages
In the U.S., over 76 million homes rely on central HVAC systems, making the duct system a critical part of the nation’s energy infrastructure. With an average home using 300 feet of air ducts, residential installations alone exceed 800,000 miles—enough to wrap around the Earth more than 32 times.
Given this scale, choosing the right type of ducting is essential. It directly affects airflow efficiency, insulation value, labor costs, and the comfort of building occupants. While sheet metal and flexible ducts remain common, fiberglass duct board is gaining traction—especially in residential and light commercial settings—due to its built-in insulation, ease of installation, and cost-effectiveness.
This guide will examine what fiberglass duct board is, how it compares to traditional ducting, and where it fits best in modern HVAC applications.
Duct board provides continuous thermal insulation across all duct surfaces, minimizing thermal bridging and leakage. Most formulations meet or exceed ASTM E84 and NFPA 90A/90B standards, ensuring compliance with U.S. building codes for flame spread and smoke development. The non-metallic structure inherently reduces vibration noise, while the sealed, foil-lined exterior offers moisture and condensation resistance, especially in humid environments. Additionally, the lightweight design eases handling and reduces the need for structural support in ceiling installations.
Compared to traditional ducting, duct board systems are quieter, lighter, easier to install, and more thermally efficient—making them a preferred solution in residential and light commercial duct systems, where energy codes, installation labor, and indoor air quality are closely scrutinized by both contractors and building occupants.
Duct boards are manufactured in several structural configurations to meet different installation and durability needs. Some panels are single-sided, with one laminated surface—typically used when the duct is mounted flush against structural elements or walls. Others are double-faced, where both sides are factory-laminated for full vapor barrier protection and enhanced mechanical strength, particularly important for suspended or exposed ductwork. High-performance duct boards may also feature multi-layer composite facings, combining aluminum foil, woven fabric, and polymer coatings to meet stringent requirements for hygiene, durability, or chemical resistance.
In terms of fabrication, most duct boards are supplied in flat panel form and cut on-site using the score-and-fold method, allowing installers to shape and seal ducts quickly with minimal tools. This approach offers excellent adaptability to on-site conditions and irregular spaces. Alternatively, some systems—particularly those using PIR or phenolic cores—are designed for modular prefabrication, where duct sections are fabricated in a controlled environment with pre-formed elbows, transitions, and joints. These pre-engineered systems are especially advantageous in large commercial projects or fast-track construction timelines.
Proper installation is essential to duct board system performance and code compliance. Most assemblies—particularly those using fiberglass duct board or phenolic foam—are fabricated using the score-and-fold method. Panels are cut with grooving tools or slot cutters to create V-grooves, allowing clean folding without damaging the facing. Joints are sealed using UL 181-approved foil tape, mastic, or mechanical fasteners, depending on system pressure and project requirements.
Different core materials require tailored handling. Phenolic boards need precise scoring to avoid cracking, while MgO-based boards require dust control and carbide tools due to their density. Fiberglass cores are the most installer-friendly but still demand proper sealing, especially in humid environments. All seams, corners, and take-offs must be sealed tightly to ensure airtightness and energy efficiency, with vapor-barrier reinforcement recommended for rooftop or high-humidity areas.
Duct board is best suited for low to medium pressure systems (up to 2″ WG). For long runs or higher pressure zones, supports like hangers or saddles must be added at regular intervals. Installation should follow SMACNA’s guidelines for fibrous glass ducts for joint construction, reinforcement, and layout best practices.
Compared to sheet metal, duct board reduces labor and eliminates external insulation. It is ideal for retrofits, confined plenums, and projects where acoustic performance and installation speed are key. Common mistakes—like under-sealed corners or over-bent joints—can lead to leakage or structural failure and should be verified through pressure or smoke testing.
When installed correctly and in accordance with ASHRAE 90.1, IECC, and local codes, duct board systems offer reliable thermal insulation, air control, and indoor air quality performance.
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