Phenolic Foam Duct Insulation Range

The Complete Guide to Phenolic Duct Board in the UK

Phenolic duct board is a high-performance insulation material used in duct systems to enhance thermal efficiency and reduce energy consumption. Known for its low thermal conductivity, phenolic insulation boards provide exceptional fire performance and are widely used in HVAC applications across the UK. Leading products such as Kingspan Kooltherm K112, K118, and K103 set the standard for rigid thermoset phenolic insulation.

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What is Phenolic Duct Board?

Phenolic duct board is made from rigid phenolic foam with a closed-cell structure, providing excellent thermal insulation and fire resistance. It is often pre-insulated and foil faced or glass tissue faced, ensuring durability and moisture resistance. Available in standard sizes such as mm x mm, phenolic duct boards are ideal for ductwork systems and outdoor duct installations.

Benefits of Phenolic Duct Board

• Exceptional Thermal Performance – Phenolic insulation products offer low thermal conductivity, enhancing energy efficiency and reducing heat loss.

• Fire Performance – Kingspan Kooltherm phenolic insulation has a Class 1 fire rating, providing superior fire resistance for ductwork.

• Space Saving – Due to its high thermal efficiency, phenolic duct board can achieve excellent insulation values with thinner insulation compared to other materials.

• Lightweight and Durable – The rigid thermoset phenolic insulation core ensures durability while remaining lightweight for easy handling.

• Moisture and Vapour Resistance – Phenolic boards provide a vapour barrier, preventing moisture ingress and ensuring long-term performance.

• Energy Savings – By improving thermal efficiency, phenolic duct board helps reduce energy costs and lowers carbon emissions.

Applications of Phenolic Duct Board

• HVAC Duct Systems – Used extensively in heating, ventilation, and air conditioning systems.

• Pitched Roofs and Walls – Provides thermal insulation in duct systems for commercial and residential buildings.

• Outdoor Duct Insulation – Pre-insulated phenolic ductwork is ideal for external applications, offering protection from environmental factors.

• Industrial and Commercial Projects – Suitable for large-scale duct systems requiring high-performance insulation.

Popular Phenolic Insulation Products

• Kingspan Kooltherm K112 Framing Board – A versatile solution for framing and partition walls.

• Kingspan Kooltherm K118 Insulated Plasterboard – Provides superior thermal performance for duct and wall applications.

• Kingspan Kooltherm K103 – Used for floor and roof insulation, delivering outstanding energy efficiency.

• Kingspan Kooltherm K107 – Pre-insulated phenolic ductwork that reduces air leakage and enhances energy efficiency.

Why Choose Phenolic Duct Board?

• Industry-Leading Performance – Phenolic insulation boards provide high resistance to fire, moisture, and air leakage.

• Reduced Energy Consumption – High thermal resistance helps minimise energy costs and supports sustainability goals.

• Lightweight and Easy to Install – Phenolic insulation is easy to handle and can be cut to fit various ductwork system designs.

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• Long-Lasting – The rigid thermoset fibre-free structure ensures the insulation is built to last without degrading over time.

How to Install Phenolic Duct Board

1. Measure and Cut – Use standard tools to cut the phenolic insulation board to the required dimensions.

2. Secure and Seal – Attach the board to the duct system and seal joints with foil tape to ensure airtight connections.

3. Fit and Finish – Ensure a snug fit around all sections of the duct to avoid gaps and air leakage.

4. Inspect and Maintain – Regularly inspect the insulation for signs of wear and reseal any areas as needed.

Conclusion

Phenolic duct board is a leading solution for thermal and fire insulation in ductwork systems. With products like Kingspan Kooltherm K112 and K118, phenolic insulation boards offer unparalleled energy efficiency, fire safety, and long-term performance.

Duct Material Comparison for Residential Installations

By: Reggie Hucks | Sep 26,

When homeowners receive quotes from HVAC contractors, they typically are given two duct replacement options: sheet metal or fiberglass duct board. There is a third option, phenolic duct, that is made of plastic foam with a foil liner on the inside and exterior. It hasn’t been on the market long enough to weigh in on its merits and shortcomings and will not be included in this comparison. Homeowners usually go for the product their HVAC contractor recommends; however, all systems have their strengths and weaknesses. Here are the advantages and disadvantages of two of these materials when installed in the typical residence.

Sheet Metal

Let’s start with sheet metal since it has been around longer. Sheet metal, made of galvanized steel or aluminum, is fabricated into round or rectangular duct for transporting air. When properly installed, sheet metal systems are robust and can provide many years of service. Air moves easily in metal duct systems with less friction loss. Expensive machinery is required to fabricate the sheet metal ductwork; therefore, fabrication costs are more. Where the material is fastened together, care must be taken to tightly seal the joint to prevent energy loss. Listed tapes or mastics are used to seal the metal.

Metal systems must be insulated in unconditioned spaces for energy efficiency and to prevent condensation. Insulation is placed on the interior or exterior of metal duct. When wrapping the duct exterior, staples and tapes are used to secure the insulation. The wrap shouldn’t be pulled too tightly or a loss in the insulation effectiveness will occur. Placing insulation on the interior means cutting the insulation to fit and fastening the material in place.

One health benefit of metal duct is that it doesn’t expose the system’s airflow to fiberglass if externally insulated. When insulation is installed on the duct’s interior, building occupants are exposed to fiber particulates from the airflow. In some parts of the country, the use of fiberglass insulation in the air stream includes health hazard warning statements. Therefore, the contractor can choose external insulation for most installations.

Duct Board

Duct board is a second option that contractor’s frequently offer. This material has been around for fifty years or more and is basically large sheets of rigid fiberglass insulation with an attached foil vapor barrier. It has several advantages over metal installations that contractors prefer. It produces very little air noise when under pressure. Fabrication is faster and less labor intensive. Special knives cut the duct into square or rectangular shapes as needed, therefore, expensive machinery is not required. The material is also easy to seal air tight.

Duct board installations have a few drawbacks too. Because duct board consists of rigid insulation, fibrous material can erode into the airstream. It should be noted that duct board can be bought with a treated surface that resists erosion. The treated duct board can be harder to fabricate than the untreated variety and costs more to install.

Water and duct board do not play well together. Wet duct board can produce mildew and encourage mold growth. Mold needs an organic food source, low light levels, and water to thrive. Installing duct board in areas such as a wet crawlspace creates an environment that mold needs to start growing. Basically, the fiberglass absorbs moisture and provides a breeding ground for mold spores. Therefore, duct board should only be used where it will not be exposed to damp conditions.

The winner is… 

Both systems have been used for years and, when installed appropriately, will give good service. Overall, the edge probably goes to professionally installed metal systems that are externally insulated. Potential health hazards are lower, and a longer service life can be expected.

If you want to learn more, please visit our website Phenolic Duct Insulation.