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PIR Ducting Board

Pre-insulated PIR air duct panels act as a high-performance sustainable solution adopted in modern HVAC systems. Manufactured as an integrated sandwich assembly clad with aluminum foil facings and a rigid PIR foam core, they achieve superior performance versus conventional galvanized steel ducts which rely on on-site insulation installation. The eco-friendly PIR core delivers excellent thermal efficiency to reduce operational carbon emissions, with environmentally benign raw materials compliant with global sustainable construction criteria. These panels are extensively specified for hotels, office buildings, airports, hospitals and other commercial and public facilities.

These panels adopt a composite sandwich structure:

Core Material The insulating core is rigid PIR foam. It delivers high thermal resistance and structural rigidity whilst maintaining a lightweight profile.

Facings Protective, airtight facings are permanently bonded to both sides of the foam core. Two common options are available:

Aluminum Foil: Standard 80-micron foil, ideal for general indoor applications.

Aluminum Sheet: 200-micron sheet offering enhanced strength and durability, suited for outdoor installations.

The "lightweight revolution" of PIR Ducting Board

In the HVAC sector, the PAL prefabricated insulated duct system transcends a single product category. It delivers a revolutionary construction mindset, shifting the workflow from field fabrication to modular assembly. Constructed with PIR (polyisocyanurate) or phenolic foam core and dual-side aluminium foil cladding, the system distinguishes itself from traditional galvanized steel ductwork in material characteristics and construction logic.

Conventional duct projects demand separate shipment of galvanized steel panels, rock wool/fiberglass insulation, adhesives and auxiliary components. Such materials are bulky and susceptible to abrasion and damage.

The PAL system panels achieve a density of roughly 50 kg/m³, and completed ducts weigh only 15% of comparable galvanized steel alternatives. Economically for logistics, unit-area transport costs are reduced, while the space required for on-site material storage decreases by over 60%.

Service Life, Environmental Protection and Hygiene of PIR Ducting Board

1) Durability Data: The PIR ring-shaped macromolecular structure is stable, with the thermal conductivity decreasing by no more than 5% within 25 years. The designed service life is 20–25 years; iron sheet ducts will corrode and leak within 5–8 years, rock wool will powderize and fail within 5 years, and the total life cycle replacement cost is reduced by 70%.

2) Environmental Testing: The release of harmful substances such as formaldehyde and benzene is 0, and it does not contain asbestos; the production foaming loss rate is only 3%, and the leftover materials can be recycled for secondary processing, which is suitable for green buildings LEED and domestic green building three-star certification bonus items.

3) Cleanliness Performance: The double-sided smooth antibacterial aluminum foil surface layer reduces the internal wall wind resistance by 12%, and it is not prone to dust accumulation and mold growth; it is suitable for food factories, operating room purification ventilation, and does not require additional antibacterial coating inner lining, and the additional consumables for clean renovation are zero.

On-Site Fabrication Process of PIR Ducting Board

Once the panels arrive on-site, they are fabricated into the final duct shape. This is a relatively simple process that can be done with hand tools . The key steps are:

Tracing/Marking: The shape of the duct pieces, including allowances for folds and joins, is marked on the panel based on the design plans . This step requires precision, as it accounts for the material that will be cut away.

Cutting: The panels are cut to size using standard tools like a cutter or a specialized "V" groove cutting tool. This tool creates a 45° groove along the edges where the duct will be folded. This V-shaped channel not only allows for a clean fold but also creates a larger, stronger surface for gluing .

Folding: The panel is folded along the pre-cut and scored lines to form the rectangular duct shape . The PIR foam's structure makes it easy to create crisp, accurate folds.

Gluing & Sealing: A specialized HVAC-grade adhesive is applied to the 45° edges or joining surfaces . The pieces are firmly pressed together and held until the adhesive sets to form a strong, airtight bond .

Taping & Reinforcement: The seams are further sealed with reinforced aluminum tape to ensure the duct is completely airtight, which is crucial for energy efficiency . For larger ducts, additional reinforcement sections may be added to provide structural support .

Installing Flanges: If required for the connection to other duct sections or the HVAC unit, flanges are installed at the ends of the duct pieces .

This streamlined fabrication process-eliminating the need for a separate, heavy insulation wrapping step-is why PIR ducts are considered highly efficient to install .