KoolDuct Product Wedge

High Performance Rigid Pre-Insulated Ductwork

The panels from which Kingspan KoolDuct System ductwork is fabricated, comprise a fibre-free premium performance rigid thermoset phenolic insulation core, faced on both sides with an extremely durable and protective low vapour permeability reinforced aluminium foil. Both facings are autoheasively bonded to the core during manufacture. 
Kingspan KoolDuct panels are CFC/HCFC-free and are manufactured with a blowing agent that has zero Ozone Depletion Potential (ODP) and low Global Warming Potential (GWP).
The insulation core of Kingspan KoolDuct panels has 90% (or greater) closed cell structure, which means that they are non-wicking and highly resistant to moisture penetration. In addition, the risk of moisture absorption into the core is effectively eliminated as the factory applied aluminium foil facings provide a high performance and impervious vapour barrier.

Product Information

UL Listed

Ductwork fabricated from the Kingspan KoolDuct System is UL Listed as a Class 1 rigid air duct to Standard for Safety UL 181 when fabricated to a specification clearly defined by UL.
A UL 181 Listed duct system is constructed with specific components that have been tested as part of that duct system and verified by UL-Underwriters Laboratories for compliance to the UL 181 Standard for Factory-Made Air Ducts And Air Connectors.

The UL 181 Listing for the Kingspan KoolDuct system requires that ductwork is fabricated as recommended by Kingspan for KoolDuct, using:

  • 20–45 mm Kingspan KoolDuct phenolic panels with silver aluminium facings and with UL labels applied at Kingspan’s factory
  • a 63 mm wide (minimum) aluminium foil vapour barrier tape that is UL Listed to Standard for Safety UL 181A Standard for Closure Systems for use with Rigid Air Ducts, with visible UL markings on the foil tape;
  • Kingspan KoolDuct High Performance Silicone Sealant / Caulk
  • duct-to-duct joints that are part of the KoolDuct UL 181 file, such as the Kingspan aluminium Grip coupling system, the Kingspan aluminium Tiger Clip coupling system and the Kingspan 4-Bolt flange coupling system

To meet Class 1 Air Duct requirements, ductwork must withstand rigorous physical tests e.g. surface burning characteristics; burning; flame penetration; mould growth and humidity; puncture; pressure; erosion; static load; impact; collapse; air leakage; low and high temperatures.

The UL 181 Listing means that not only Underwriters Laboratories has tested and determined that the product meets the specific, defined requirements of Standard UL181, it also means that the manufacturer maintains periodic inspections by UL to assure production of the listed product is in accordance with the listing (KoolDuct UL file number MH25124). Having UL Listing guarantees that the product fully complies with each and every one of  UL's requirements in the applicable Standard, and the manufacturer's product can then bear the UL Mark.

Low Air Leakage

The air leakage rate of Kingspan KoolDuct System ductwork can be a fraction of that typical of insulated sheet metal ductwork – up to 80% less¹, and can easily meet the requirements of BS EN 13403: 2003 – Class C, BS EN 1507: 2006 – Class D, HVCA DW 144 – Class D and SMACNA – Class 3.
This can yield significant electrical consumption savings because of reduced heating and cooling loads – saving up to 30% on the annual cost of running a fan². Furthermore, over a 30 year life it can also make a saving of over 20% on operating costs³.

¹ Figure based on research conducted in the US by independent consultants MDA Engineering inc. 2010
² Figure based on research conducted in the UK by independent consultants Rider Levett Bucknall 2005
³ Figure based on research conducted in the UK by independent consultants Cyril Sweett 2007

Lower Embodied Energy

The embodied energy of a ductwork section fabricated from the Kingspan KoolDuct System can be up to 30% less than that for galvanised sheet steel insulated with mineral fibre.

Indoor Air Quality

Distributed air flows over sealed aluminium surfaces, minimising any risk of loose fibres entering the air handling system. In addition, Kingspan KoolDuct panels have a fibre-free insulation core, are non-deleterious, odourless and non-tainting. They will resist attack from mould and microbial growth and do not provide any food value to rodents or vermin.

Space Saving

Kingspan KoolDuct System ductwork can be installed flush to the ceiling eliminating the space required for the manual process of applying the insulation above the ductwork as a second fix. This can save up to 150 - 200 mm of valuable space.


The exceptional strength to weight ratio of ductwork fabricated from the System results in ductwork that is easier to handle and quicker to install. Weighing up to 75% less than sheet metal ductwork, it can overcome severe constraints on structural loadings in older buildings that cannot support additional weight.

Faster Installation

The ability to fabricate ductwork in up to 4 m long sections means fewer sections and less handling. This combined with the requirement for fewer supports and its single fix installation results in a fast track installation – up to three times faster. Faster installation obviously means lower costs and less disruption for other trades on site.

Fabricated & Installed by Trained Contractors

To ensure that uniform quality standards are maintained, Kingspan KoolDuct Systemductwork is fabricated and installed only by trained fabricators and installers who have attended a specialised training program and whose competence is continually monitored and controlled.

Thermal Conductivity (λ-Value) as low as 0.023 W/m·K  
Operating Temperature Limits -26oC to +85oC
Board Dimensions 3930 mm x 1200 mm
Board Thickness 22*, 30, 46 mm
* Minimum order quantities apply

Assumption and Key

Ductwork and installation shall comply with AS 4254 – ‘Ductwork for Air-Handling Systems in Buildings' and AS/NZS 4859.1:2018 – ‘Thermal Insulation materials for buildings.’

All pre-insulated ductwork fabricated from the Kingspan KoolDuct System shall be manufactured and installed by registered contractors utilizing approved materials and in complete accordance with the Kingspan KoolDuct Specification and Fabrication manuals.

Unless otherwise indicated, the Kingspan KoolDuct System is suitable for the fabrication of the following:

  • Warm air ventilation distribution ductwork (insulated to suit temperatures);

  • Air conditioning distribution ductwork (insulated and vapour sealed);

  • Fresh air intake ductwork to plant (insulated and vapour sealed);

  • Ductwork returning air to a plant room (insulated to suit temperature); and

  • Ductwork exposed in external locations (with an additional weatherproof finish).

Installed Material R-values

Product Thickness R-value
22 mm R0.92
30 mm R1.35
46 mm R2.0


Specification Clause

Ductwork shall be comprised of Kingspan KoolDuct rigid insulation panels, comprising 55 - 60 kg/m3 nominal density, CFC/HCFC free rigid thermoset insulation with zero ODP, autohesively bonded on both sides with a 25 micron aluminium foil facing with reinforced 5 mm glass tissue scrim.

Management Standards

Standard Management System
ISO 9001:2015 Quality Management
ISO 14001:2015 Environmental Management
ISO 45001:2018 Occupational Health And Safety Management
ISO 50001:2018 Energy Management

Product Testing

Characteristic Test Method / Standard Specification
Minimum Closed Cell Content BS EN ISO 4590:2003 ≥90%
Nominal Density Range    55-60 kg/m3
Compressive Strength at 10% Compression  BS EN 826:1996 200 kPa
Thermal Conductivity (23oC mean)   ASTM C 518:2004 as low as 0.023 W/m.K
Water Vapour Resistance Z (23oC & 50% RH) BS EN 12086:1997 Method A 617 MN.s/g
Operating Temperature Limits  AS/NSZ 4201.1 -26oC to +85oC
Specific Optical Density of Smoke BS 6401: 1983 With Pilot Flame: 22.7
Without Pilot Flame: 15
Specific Optical Density of Smoke ASTM E 662: 2006 Flaming: 46.4
Non-flaming: 48.0
Surface Burning Characteristics ASTM E 84: 2008a / UL 723 < 25/50
Burning UL 181 Pass
Early Fire Hazard Rating AS/NZS 1530-3: 1999  Ignitability Index: 0
Flame Spread Index: 0
Heat Developed Index: 0
Smoke Developed Index: 0-1
Toxicity Index Defence Standard 02-713: 2006 4.93

Environmental Data Table

Recyclability Non-contaminated insulation site waste is recyclable, but there are currently no facilities in Australia to process returned material
Re-usability Re-usable if removed with care (long term of service expected)
Water Use No water used in Kingspan Insulation's manufacturing process
Blowing Agent Global Warming Potential (GWP) Manufactured with a blowing agent that has low GWP
Blowing Agent Ozone Depletion Potential (ODP) Manufactured with a CFC/HCFC-free blowing agent that has zero ODP
Packaging Contains 0% recycled product. Polythene wrap and EPS skids are 100% recyclable

Do you need ducting help and advice on your project?

Our teams are dedicated to helping you make process as easy as possible and ensure you get the right materials for your needs.

Contact our Technical Team

Contact Information

Kingspan Insulation Australia

Kingspan Insulation operates Australia wide. Contact us to find your local State Representative. For any enquiries, call 1300 247 235 or send an email to

Head Office

25 Oherns Road,

Somerton, VIC


Call: 1300 247 235

Fax: 1300 247 329