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PIR Composite Duct Boards

PIR Composite Duct Boards deliver high-performance, environmentally sustainable air distribution for modern HVAC systems. Constructed as an integrated sandwich panel with aluminum foil facings and rigid PIR foam core, they outperform traditional galvanized steel ducts requiring on-site insulation. Featuring low energy loss and eco-friendly formulation, they support energy conservation and meet green building requirements. Ideal for hotels, office complexes, airports, hospitals and other commercial and public buildings.

This "sandwich" board is a composite of two main materials:

The Core: Polyisocyanurate (PIR) Foam

Serving as the thermal insulation layer, this closed-cell foam features outstanding thermal performance with thermal conductivity as low as approximately 0.022 W/m·K, alongside reliable fire resistance.

The Facings: Aluminum Foil or Aluminum Sheet

Laminated onto both sides of the foam core, the facings deliver protection, airtightness and corrosion resistance. Multiple thickness options are available: 60μm or 80μm for indoor applications, while 200μm is adopted for enhanced durability under outdoor conditions.

Structure: Silver Aluminum/ PIR Foam/ Silver Aluminum
Thermal Conductivity: 0.022w/m.K

Fire Rating: Class 0 (BS 476 Part 6&7)

Key Features and Advantages of PIR Composite Duct Boards

Feature	Description
Thermal Performance	The PIR core is an excellent insulator, which helps keep air at the desired temperature as it travels through the duct, reducing energy loss.
Fire Safety	PIR foam has a high fire resistance rating (often Class 0 or B1-s2,d0), making it a safe choice for building ventilation systems.
Lightweight	The panel is substantially lighter than conventional galvanized steel ductwork, simplifying handling and lowering structural loads on buildings.
Installation Efficiency	Duct sections are fabricated via cutting, folding and sealing the panels. This workflow is more efficient and demands fewer heavy-duty machines compared with metal duct manufacturing.
Durability	The aluminum facing delivers sturdy, corrosion-resistant surfaces. The system is engineered for an extended service life of 15–20 years and beyond.

Panel thickness is selected according to specific project requirements; 20 mm and 30 mm are the most widely used specifications. Standard dimensions including 3950 mm × 1200 mm are available to facilitate efficient duct fabrication.

Construction Efficiency and Cost of PIR Composite Duct Boards

Integrated prefabricated panels allow one-stage cutting and assembly, effectively shortening construction schedules:

Labor Efficiency Metrics

When fabricating an equal area of ductwork, traditional galvanized steel duct systems involve subsequent external insulation procedures, with a daily output of 18 m² per worker. PIR pre-insulated panels are assembled directly on-site, reaching a daily output of 30 m² per worker. Accordingly, installation time is reduced by 40%–60%, and labour costs drop by 45%.

Full-Lifecycle Cost Breakdown

Despite higher unit costs for the panels compared to galvanized steel sheets, expenses for secondary insulation, damp-proof membranes and abundant hangers are eliminated. The total cost of the complete duct system is equivalent or up to 8% lower.

Transportation Merits

Foldable packaging maximises cargo utilisation, lifting vehicle loading volume by 2.3 times and cutting domestic and marine logistics expenditure by 50%. Such logistics advantages stand out for overseas projects executed under DAP Incoterms.

Why Choose PIR Composite Duct Boards?

Thermal Insulation, Low Smoke Emission and Low Toxicity

PI foam exhibits inherent flame retardancy for enhanced fire safety. Its Limiting Oxygen Index (LOI) is typically higher than 34%, significantly surpassing the standard requirements for most flame-retardant materials.

Excellent Acoustic and Thermal Insulation Performance

With an open-cell structure featuring an open-cell fraction of up to 99%, PI foam achieves exceptional sound absorption. It attains a Noise Reduction Coefficient (NRC) of maximum 0.54 within the frequency range of 125–4000 Hz, efficiently attenuating airflow noise and mechanical operating noise in HVAC installations. Its thermal conductivity is lower than 0.022 W/(m·K), enabling reliable thermal insulation at low areal weight.

Ultra-Low Outgassing and Chemical Stability

Volatile substances released by materials under vacuum may lead to contamination of precision apparatus. Thanks to its ultra-low outgassing property, PI foam is widely utilised in aerospace applications and semiconductor cleanroom environments. The material also offers resistance against weak acid, weak alkali and common oils such as 93# gasoline, demonstrating excellent chemical inertness.