Insulation

The Kingspan System

US Units
October 2018

The Kingspan KoolDuct System

Training Manual

Phenolic Ductwork Fabrication

and
Installation Guidelines

1
The Kingspan System
Training Manual - Contents
Page Page

3 Chapter 1 - Introduction 49 Chapter 3 – Couplings and connections

4 Notice to user 50 4-Bolt Flange coupling system

5 Health and safety 53 Grip Flange coupling system

6 Storage and handling 58 Bayonet Cleat

7 The KoolDuct panel 59 Tiger Clip coupling system

8 KoolDuct System operational limits 62 Connection to duct system components

9 Information required for fabrication 64 Connections with Tiger Unit

10 Fabrication procedure 65 Connection of Inspection doors

11 Cutting: Machines and Hand tools

14 Assembly: Tiger Clips

16 Sealing 66 Chapter 4 – Duct reinforcement

71 Pressure class tables

17 Chapter 2 – Rectangular duct 78 Non-standard reinforcement

construction

18 Straight duct (Cutting methods 1-8)

79 Chapter 5 – Hangers and supports
23. Panel joint
80 Tiger supports and conventional supports
24. Multiple duct design
83 Supports for vertical ductwork
25. End cap
85 Weight of KoolDuct ductwork
26. Transition, Offset

29 Double offset
87 Chapter 6 – Maintenance and external
30 Take off ductworks

33 Round fitting 88 Cleaning KoolDuct

35 Grille / diffuser Installation 89 Building Management Systems

36 Square elbow with turning vanes 90 Damage repair

37 Radius elbow 91 Protective treatment and external ductwork

42 Elbow, 45 Deg throat, radius heel

44 Dynamic branch 92 Appendixes

2
The Kingspan System

Training Manual

Chapter 1

Introduction

3
The Kingspan System
Notice to User
Kingspan Insulation Ltd provide this publication to Kingspan Insulation’s Delivery
Partners and KoolDuct fabricators for information purposes as part of their Technical
Support Documentation that give broad directions and process recommendations for
the design and use of the Kingspan KoolDuct System.

This manual is not to be used as the sole reference material for the fabrication and
installation of Kingspan KoolDuct System ductwork; reference should also be made to
The Kingspan KoolDuct System Fabrication Manual (latest edition).
For specification details, reference should be made to The Kingspan KoolDuct System
Specifier’s Guide (latest edition).

All principles and techniques contained in this Training Manual were developed using
reliable engineering principles and research, plus consultation with manufacturers,
users, testing laboratories, and others having specialised experience.
This manual is subject to revision as further experience and investigation may show is
necessary or desirable.

Kingspan Insulation assume no responsibility and accept no liability for the application
of the principles or techniques contained in this publication. Authorities considering
adoption of any standard contained herein should review all state, local and contract
regulation applicable to specific installations.

The Delivery Partner and/or KoolDuct fabricators shall have full regard to Kingspan’s
Technical Support Documentation for the KoolDuct System and shall ensure that in any
design and any erection of using the Kingspan KoolDuct System, the guidelines in the
Technical Support Documentation are followed by it and any sub-contractors engaged
to design and/or assemble the ductwork.

Notice on the Installation of the KoolDuct System

KoolDuct Delivery Partners and KoolDuct fabricators shall only use reputable
contractors for the installation of the Kingspan KoolDuct System. Such contractors
shall be reasonably experienced in installing HVAC ductworks and must understand
the differences between the Kingspan KoolDuct System and conventional sheet metal
ductwork. The Delivery Partner and KoolDuct fabricator is responsible for ensuring
that any contractor / other personnel it uses in relation to the Kingspan KoolDuct
System have been provided with the appropriate training to enable them to install the
Kingspan KoolDuct System according to good installation practice.

In the event of any doubt please do not hesitate to contact us for further assistance.

Kingspan Insulation Limited, Torvale Industrial Estate, Pembridge, Nr. Leominster,

Herefordshire HR6 9LA, United Kingdom, Tel: +44 1544 388 601, www.kingspan.com

4
The Kingspan System
Health and Safety
Kingspan KoolDuct panels are chemically inert and safe to use.

Wear gloves when handling and cutting the product: particles of the
glass fibre reinforced facings can be irritating to the skin.
Use suitable protective clothing (e.g. long-sleeved garments).

The reflective surface on this product will reflect light as well as heat,
including ultraviolet light. If this board is being installed during very
bright or sunny weather, wear UV protective sunglasses or goggles,
and if the skin is exposed for a significant period of time, protect the
bare skin with a UV block sun cream.

The facing used on this product can be slippery underfoot specially

when allowed to get wet.

When hand tools with blades, saws or other cutting tools are used,
please handle the tools with caution.

Do not stand on or otherwise support your weight on KoolDuct panels

and fabricated ducts.

Dust is NOT normally a hazard.

When mechanical cutting is used, dust extraction shall be used (eye
protection and disposable dust mask shall be worn when appropriate).
Minimise dust and slipping hazards by disposing of the excess material
and keeping the working place tidy.

Safety Data Sheet are available for the adhesive and silicone sealant
supplied by Kingspan Insulation
The application of adhesive and sealant shall be performed in a well
ventilated area, wearing protective gloves.

5
The Kingspan System
Storage and Handling

To prevent damage, care must be exercised in the storage, handling

and transportation of both panels and ductwork sections fabricated
from the Kingspan KoolDuct System.

Please note that the factory applied packaging shall not be considered
weatherproof.

Any panels or sections which have been allowed to get wet shall not be
used.

INSIDE STORAGE
Wherever possible, both Kingspan KoolDuct panels and ductwork
sections shall be stored inside, under cover, and clear of the ground.

Once the duct sealant has fully cured, the open ends of the
ductwork sections shall be fully sealed with a weatherproof sheet to
prevent the ingress of foreign matter.

OUTSIDE STORAGE
Where storage inside a building is not possible, Kingspan KoolDuct
panels and ductwork sections shall be stored clear of the ground
protected and secured against all weather, including wind, rain, and
sunlight, by an opaque light coloured weatherproof material suitable for
the climate in which it is to be stored. As above, the open ends of the
ductwork shall be fully sealed with a weatherproof sheet to prevent the
ingress of foreign matter.

6
 The Kingspan System
KoolDuct Panel
47 ¼” (3.94 ft)

Printed foil
facing shall
be kept inside
ductwork

154 ¾” (12.89 ft)

Factory applied aluminum facings

Silver
Black
(NOTE: The black faced KoolDuct is NOT part of the
UL listed duct system)

KoolDuct Panel Dimensions

USA and North 7/
8” x 47 ¼ x 154 ¾ “ (R-6)
America 1 3/16” x 47 ¼ x 154 ¾ “ (R-8)
1 3/4” x 47 ¼ x 154 ¾ “ (R-12)
UK / Ireland: 22 x 1200 x 2950 mm
30 x 1200 x 2950 mm
Australia: 20 x 1200 x 3930 mm
30 x 1200 x 3930 mm
42 x 1200 x 3930 mm
Middle East and NA 20 x 1200 x 3930 mm
30 x 1200 x 3930 mm
Rest of the world: 20 x 1200 x 3930 mm
22 x 1200 x 3930 mm
30 x 1200 x 3930 mm

7
The Kingspan System
KoolDuct System Operational Limits

Mean Air Velocity 5000 fpm (25.4 m/s)

Design Pressure (Max) Positive: 4 in.w.g. (1000 Pa)

Negative: 3 in.w.g. (750 Pa)
Temperature -15°F (-26°C) to +185°F (+85°C) during
continuous operation
Size Unlimited (provided that Kingspan KoolDuct
System fabrication techniques and procedures
are observed)

KoolDuct System Application and Limitation

• Supply and Return air ductwork for heating, ventilation and air conditioning
• Fresh air intake ductwork to plant / Make-up air
• Swimming Pools
• Non Ferrous Applications
• Outdoor applications, provided the specified external finish is applied
• Class 0 or 1 air ducts UL 181 Listed are permitted as vertical ducts serving not
more than two adjacent stories in height (per NFPA 90A and 90B)

Not Applicable
• Where fire dampers cannot be used and fire rated ductwork must be used:
• Kitchen extract systems
• Smoke extractions of products of combustion
• Enclosed car park extract systems
• Pressurisation systems for protected staircase, lobby, corridors
• Conveyance of solid particles
• Chemical or fume exhaust systems (please check compatibility with Kingspan)
• For use with extreme heat above 185°F (85°C)
• High Pressure systems above 4.in.w.g. (1000 Pascal) positive
• Outdoor use without additional protection

The UL Listing for KoolDuct

The UL listing requires that ductwork is fabricating using:
• 25/ "-1 25/ “ (20-45 mm) Kingspan KoolDuct panels, faced with
32 32
silver aluminum foil on both sides and displaying the UL Listed Mark
• the 4-bolt, aluminum grip and / or Tiger Clip coupling systems;
• 2 1/2" (63 mm) wide (minimum) aluminum foil vapor barrier tape that
is UL 181 A–P Listed to Standard for Safety UL 181 A; and
• Kingspan High Performance Silicone Sealant / Caulk.

8
The Kingspan System
Information Required for Fabrication and Installation
Information to be provided by the designer for the fabrication and installation of
KoolDuct pre-insulated ductwork

Comprehensive ductwork layout drawings indicating:

GENERAL
• Ductwork sizes
• Routing of the ductwork system
• Types of fittings to be used (i.e., square bends versus radius bends,
concentrical transitions versus eccentrical transitions, etc.)
• Pressure classification (the higher among design, commissioning and
testing pressure shall be used as the reference for ductwork reinforcement)

STANDARDS
• Insulation panel thickness
• Special requirements (if any)

OTHER COMPONENTS OF THE DUCTWORK SYSTEM

• Details of offsets required to route ductwork around obstructions (columns,
beams, etc.)
• Inspection/servicing/cleaning access openings: number and location of
access openings, number and location of test holes
• Regulating Dampers: location and connection type (flange/spigotted
connection)
• Smoke damper, smoke/fire dampers: location and connection type
(flanged/spigotted connection)
• Round Flexible ducts: location
• Flexible joint connections: location

PARTICULAR REQUIREMENTS
• Air leakage testing: leakage classification required and testing pressure
• Protective finishes (i.e. indoor / outdoor installation, etc.)
• Special supports (if any)
• Attachment to building structure: specific requirements for the junction of
ductwork to building openings
• Air terminal units: location
• Other requirements

9
The Kingspan System
Basic KoolDuct Fabrication Procedure
1. TRACING
2. CUTTING
3. ASSEMBLY:
• with Tiger Clips (for pressure classes up to 1000 Pascal) or
• with Adhesive (for pressure classes up to 750 Pascal)
4. TAPING
5. REINFORCING
6. COUPLING/JOINING
7. SEALING: with KoolDuct Silicone sealant.
8. FABRICATION INSPECTION

KoolDuct Section – End View

UL 181 A-P
Generous and
Listed Aluminum
continuous bead of
Tape at corners
Kingspan approved
where KoolDuct
silicone placed in
foil has been
ALL FOUR interior
cut.
joints extending for
full length of duct.

Factory applied
aluminum facings
on air stream and
exterior surfaces.

NO YES

10
The Kingspan System
Machine Cutting
Specific training to be provided by the manufacturer of the machine

Straight cutting machine

CNC machine

11
 The Kingspan System
Cutting - Jack Planes for 7/8” (22 mm) Panels, R-6
# 511 - Jack Plane, two blades at 45°

Blades set 1/32” less than

Panel thickness

To Set the Cut Height:

A) Unloose big screw (1) on the back
1 B) Operate on smaller screws (2) at the
2
bottom of Jack Plane
C) Tighten big screw (1)
3
To Change Blades:
D) Operate on stopping screws (3) at the
bottom of Jack Plane

# 513U, 514U, 515U - Small Jack Planes, one blade

Cut 7/8” thickness R-6 with Blade # 741
Ref.514U - Small Jack Plane Ref.513U - Small Jack Plane Ref.515U - Small Jack Plane
45 Degrees Left 90 Degrees 45 Degrees Right

1” 1” 1”

1 1/2” 1 1/2” 1 1/2”

3” 3” 3”

# 741 – Blade for 7/8” Panel, R-6

Clamping
Rule

2 3/8”
12
The Kingspan System
Cutting - Jack Planes for 1 3/16” (30 mm) Panels, R-8
# 516 - Jack Plane, two blades

Blades set 1/32” less than

Panel thickness

# 513U, 514U, 515U - Small Jack Planes, one blade

Cut 1 3/16” thickness R-8 with Blade # 744

Ref.514U - Small Jack Plane Ref.513U - Small Jack Plane Ref.515U - Small Jack Plane
45 Degrees Left 90 Degrees 45 Degrees Right

1 ¼” 1 ¼” 1 ¼”

1 1/2” 1 1/2” 1 1/2”

3” 3” 3”

Ref.744 – Blade for 1 3/16” Panel, R-8

Clamping
Ruler

2 ¾”

13
The Kingspan System
Assembly option 1 - Tiger Clips # 364
ALL duct sections MUST be assembled with Tiger Clips or Adhesive

Example 1: Duct 18” x 12”, at 2 in.w.g. Example 2: Duct 18” x 12”, at 4 in.w.g.

T. Closures only on the open mitred joints T. Closures on ALL the mitred joints
Max spacing: 20” Max spacing: 10”

MAXIMUM TIGER CLIPS SPACING

Pressure Straight Duct Max Spacing Application

Size
0 – 2 in.w.g. Any size 20 inches Longitudinal
(0 - 500 Pa) (500 mm) Seams Only
>2 – 4 in.w.g Any size 10 inches Longitudinal
(501 - 1000 Pa) (250 mm) Seams Only

Tiger Clips on folded mitre joints ONLY required if the alum. facing has cut or tears

14
The Kingspan System
Assembly option 2 – Adhesive # 212 (or spray)
ALL duct sections MUST be assembled with adhesive or Tiger Clips

Adhesive for pressure

classes up to 3 in.w.g.
• Shake well
• Protect board
from over spray
• Apply by brush 1 layer or
spray 2 or more layers
• Let cure
• Assembly
• Use Rigid spatula
# 526

Taping – Aluminum Tape UL Listed 181 A-P

Pressure Sensitive Tape

• Surface preparation: free of oils, dust and dirt.
• Clean surface if required (Typical cleaning solvent Isopropyl alcohol - IPA).
• Use Tape marker #521. Press tape firmly with the adhesive face on the
ductwork facing.
• Wipe tape firmly with the Soft spatula # 525
15
The Kingspan System
Sealing – Extended Silicone Tool # 444
ALL ductwork sections MUST be sealed with sealant
compliant with the UL Listed KoolDuct System

Suggested silicone coverage and application

• For low pressure applications up to 2 in.w.g. (500 Pa): Minimum 3/16” (4 mm) diameter
bead (prior to tooling), approx. 66 linear feet (20 m) per tube of 10.5 oz. (310ml)
• For medium pressure applications up to 4 in.w.g. (1000 Pa): Minimum 1/4” (6 mm)
diameter bead (prior to tooling), approx. 12 linear meter per tube of 10.5 oz. (310ml)
• Silicone application temperature: +5°C +40°C (+41°F +104°F)
16
The Kingspan System

Training Manual

Chapter 2

Rectangular Duct Construction

17
The Kingspan System
Straight Duct - Cutting METHOD 1
Cutting along the panel length
7/ 1 3/4” or 1 3/4” or 1 3/4” or 7/
8” or 8” or
1 3/16” H 2 3/
8”
W 2 3/
8”
H 2 3/
8”
W 1 3/16”

H + W + H + W + (7” R-6) or (9 ½“ R-8)

• 7/
8” R-6: The sum of 4 internal sides less than 40 ¼” (2H + 2W)
• 1 3/16” R-8: The sum of 4 sides less than 37 ¾“ (2H + 2W)

SEQUENCE OF
ASSEMBLY

Extended Sealant Tool # 444

Aluminum Tape

18
The Kingspan System
Straight Duct - Cutting METHOD 2
Cutting along the panel length

7/ 1 3/4” or 1 3/4” or 7/ 7/
8” or
7/
8” or 8” or 8” or
1 3/16” H 2 3/
8”
W 2 3/
8” H 1 3/16” 1 3/16” W 1 3/16”

47 ¼ “

• 7/
8” R-6: The sum of 3 sides less than 42” (2H + W or 2W + H)
• 1 3/16” R-8: The sum of 3 sides less than 40 1/8 ” (2H + W or 2W + H)

SEQUENCE OF
ASSEMBLY

19
The Kingspan System
Straight Duct - Cutting METHOD 3
Cutting along the panel length
7/ 1 3/4” or 7/ 7/ 1 3/4” or 7/
8” or 8” or 8” or 8” or
1 3/16” H 2 3/
8”
W 1 3/16” 1 3/16” H 2 3/
8”
W 1 3/16”

47 ¼ “ 47 ¼ “

• 7/
8” R-6: The sum of 2 sides less than 43 ¾“ (W + H)
• 1 3/16” R-8: The sum of 2 sides less than 42 ½“ (W + H)

SEQUENCE OF
ASSEMBLY

20
The Kingspan System
Straight Duct - Cutting METHOD 4
Cutting along the panel length
7/ 7/ 7/ 7/
8” or 7/
8” or 8” or 7/
8” or 8” or 7/
8” or 8” or 7/
8” or
1 3/16” H 1 3/16” 1 3/16” W 1 3/16” 1 3/16” H 1 3/16” 1 3/16” W 1 3/16”

47 ¼ ” 47 ¼ ” 47 ¼ ” 47 ¼ ”

• 7/
8” R-6: Each side less than 45 ½ “
• 1 3/16” R-8: Each side less than 44 7/8 “

Set Square Rule # 436

NOTE
• When assembling the four sides, the duct should be checked (with the
T square rule) and held in position

21
The Kingspan System
Straight Duct - Cutting METHODS 5-8
Cutting along the panel width

• 7/
8” R-6: Width or Height more than 45 ½ “
• 1 3/16” R-8: Width or Height more than 44 7/8 “
H W H W

Panel length 154 ¾ “

H W H W

Panel length

H W H W

Panel length

H W H W

Panel
length

• Cutting along the panel width

• Duct Length limited to 47 ¼ “

22
The Kingspan System
Panel joint
Tiger Clips on external side

Adhesive

Tape

250

• Bevelled edges of the two panels to be jointed

• Adhesive on all bevel joints
• Tiger clips at a maximum of 10” centres, along the external side
• Tiger clips and panel joint are covered with UL tape on both sides
• When reinforcement is required:
• install extra reinforcement along the joint in addition to the
standard reinforcement.
• 1 reinforcing bar installed at the same centres as the standard
reinforcement

23
The Kingspan System
Multiple Duct Design

Application: Alternative fabrication method for large ductwork with w and

or h >1200mm. Likely to require less reinforcement than Methods 5-8.

Circular/Rectangular holes min 8”

Flange and foam Seal exposed foam in opening with UL Tape
gasket

joint
when
Grip
Flange
is used

Exposed edges 1” setback for flange Fasten ducts

sealed with UL together with
Tape mechanical fix
(e.g. non corrosive
threaded bar, discs
and nuts)

24
 The Kingspan System
End Cap
Option 1: Short Duct or Plenum Option 2: Long Duct > 40”

Adhesive # 212

Cut End Cap at 45 degrees

Cut End Cap at 45 Degrees.

Assembly with Adhesive or Tiger Clips

Apply sealant around

internal perimeter
Fix End Cap to duct end
Silicone # 231G

TClip # 364

Fix End Cap to duct end

Apply tape around End Cap
Tiger Clips Max spacing: 10”

Silicone
# 231G

Seal with silicone inside duct and End Cap Apply UL tape around End-Cap

25
The Kingspan System
Transition

W
W1

W1
W

A
A

Concentric transition Eccentric transition

θ max. 22.5°(D ≥ 2.5 x A) θ max. 22.5°(D ≥ 2.5 x A)

Splitters are required for angles greater than 22.5°.

Note: SMACNA recommended max. angles for diverging/converging transitions are
acceptable

Offset
W1

Angled Offset
W1

θ max. 15°(D ≥ 4 x A)
W
W
W

W
W

W
W

A
A

Mitred Offset
θ max. 30°(D ≥ 2 x A) Radius Offset
(B = 0.27 x W) θ max. 30°
(200mm Radius minimum)
26
The Kingspan System
Eccentric Transition
Minimum Neck size: 100 mm

Crease Outside

Crease Inside

TH 2xTH 2xTH” TH Cover

12” 22” 12” 22”

Min
4” Crease Outside

Crease D
D Lines

Min 4” Crease Inside

18” 22” 18”

• Dimensions in inches
• D minimum = 2.5 x (18”-12”) = 2.5 x 6” = 15”
27
The Kingspan System
Concentric Transition
Minimum Neck size: 100 mm

Crease Outside

Crease Inside

Crease Inside

Crease Outside

Cover
TH TH

12” 22”

Min 4”
Crease Outside

D Crease D
Lines

Min 4” 3” Crease Inside

18”

• Dimensions in inches
• D minimum = 2.5 x 3” = 7 ½ ”
28
The Kingspan System
Double Offset
Minimum Neck size: 4”

TH TH
TH TH

29
 The Kingspan System
Take-Off

Straight Branch Angle Branch

Boot Branch Boot Branch

(Flanged Connection) (Un-flanged Connection)

Boot Branch
6 ¾”

# 512, # 519
Jack Plane 22.5º

4”
2½“

4” 2”
TH Jack Plane 22.5º
45.0° 5¾“

4”
W1=16” *
*Note 45.0°
W=12” W1 = W+1/4 W, min. 4” UL tape
UL tape
TH

10” 30
The Kingspan System
Small Take-Off – Un-flanged Connection
Duct side up to 24”, and Low Pressure up to 2 in.w.g.

SUGGESTED TIGER CLIP

PLACEMEMENT
Opening No. Tiger
w or h Clip per Side
4”-6” 1
7”-12” 2
13”-20” 3
21”-24” 4
31
The Kingspan System
Large Take-Off – Flanged Connection
Duct side larger than 24”, Pressure up to 4 in.w.g.

Mechanical fix:
• 75mm (3”) from corners
• 300mm (12”) maximum intervals

“F” Profile
Take-off inside dim. – 6 mm

Screws/rivets: minimum 2 per side, located at 300mm (12”) max spacing

Suggested blind rivets with aluminum body:
• Minimum diameter 4.0mm (5/32”)
• Through flange only: rivet grip range 3-8mm (1/8" to 5/16“)
• Through flange and panel:
• For 22mm KoolDuct: rivet with grip range 25-30mm (1" to 1 3/16“)
• For 30mm KoolDuct: rivet with grip range 33-38mm (1 5/16" to 1 1/2" ) 32
The Kingspan System
Boot Branch with round fitting

Silicone bead
around exterior
circumference

Large round fitting – Flanged Connection

Mechanical Fix required for diam. larger than 12” and/or Pressure > 2 in.w.g.

Seal all around

with Silicone

Mechanical Fix
for diam. larger than 12”
and/or Pressure > 2 in.w.g.
U profile U profile

33
The Kingspan System
Round Fitting for Round Diffusers and Flexible Ducts
Mechanical Fix required for diam. larger than 12” and/or Pressure > 2 in.w.g.

Round metal
fitting
with folding Round take off
tabs spigot with
spiral tube

Silicone bead Seal exposed

around exterior insulation
circumference
Mech. fix
tube to spigot Round Hole
Cutter # 443

34
 The Kingspan System
Grille / Register / Diffuser Installation
with Aluminum Profile

“U” Profile

Clip Clip
“U” Profile

Grille / Grille /
Diffuser Diffuser

35
The Kingspan System
Square Elbow With Turning Vanes
Turning Vanes required when either duct dimension greater than 8”
(3 ½”)
1) The elbow top and bottom sides are cut in a
90° “L” shape

(1 ¼”) 2) For the Turning Vane assembly, please follow

the manufacturer recommendations.

3) Fit the completed turning vane assembly into

the duct with the first turning vane set at 2 3/8”
from the inside throat of the elbow

4) Secure permanently the turning vanes:

• for elbow size less than 24” and low
pressure less than 2 in.w.g. only silicone
sealant required
• For larger or higher pressure elbow
mechanical fix is required (Reinforcing
Bars or aluminum strips positioned on the
outer surface of the elbow )

Typical double NOTE: Minimum Bend Neck: 4”

skin vane

Cut vane
6 to 8mm less
than duct height

Reinforcing Bar

(2 3/8”)

Mechanical fix 1: Reinforcing Bar

Mechanical fix 2: Aluminum strip

Mechanical fix suggested spacing:

• 150mm (6”) maximum intervals
36
 The Kingspan System
Symmetric Radius Elbow
NECK
TH

Splitter

24” = W 6

1/3 W
ER=32” SR=16” = 8”

8” = IR 5
NECK

1/3 W 4” Min
= 8” 4

TH 24” = W 8” = IR 4” Min

1 2 3

SPLITTER for Short radius elbows

LEGEND Elbow side (inches) Splitters Position
TH = Panel Thickness 0 – 20” 0 -
ER = External Radius 20” – 32” 1 W/3
IR = Internal Radius (min 8”) 32” – 64” 2 W/4 W/2
SR = Splitter Radius Over 64” 3 W/8 W/3 W/2
Splitter not required in angles less than 45°:
• Dimensions in inches SMACNA number of short radius vane selection is
also acceptable
• Numbers in the hoop show
suggested tracing procedure NOTE: Minimum Bend Radius: 8”
Minimum Neck: 4”

37
The Kingspan System
Asymmetric Radius Elbow
NECK
TH

Splitter

18” = W2 4

ER=32”
1/3 W2
SR=16” = 6”

8” = IR 5

2”
6” 6
NECK

1/3 W1 7
4” Min
= 8”

TH 24” = W1 8” = IR 4” Min ER minus IR

1 2 3 minus
1 4

LEGEND
TH = Panel Thickness
ER = External Radius
IR = Internal Radius (minimum 8”)
SR = Splitter Radius

• Dimensions in inches
• Numbers in the hoop show NOTE: Minimum Bend Radius: 8”
suggested tracing procedure Minimum Neck: 4”

38
The Kingspan System
Symmetric/Asymmetric Radius Elbow

Ends of panels cut square (90°)

Inner strip exterior surface crimped

- 7/8” panel: every 3”, or
- 1 3/16” panel :every 4”
(min. 8” radius)

45°taper
edges
toward air
stream
Ends of panels cut
square (90°)

Outer strip interior surface crimped

as required to fit radius (crimp
spacing 4”)

Bending Machine # 441

Seal with silicone ALL

interior corners and around
Splitters

Splitter fasten in
place with adhesive
(or Tiger Clips) and
silicone

39
The Kingspan System
Elbow assembly with Tiger Clips – # 364
Can be used instead of the Adhesive for duct assembly

Max TC Spacing

2”

MAXIMUM TIGER CLIPS SPACING

Pressure Duct Size (Elbow, Max Spacing Application

Tee, etc.)

0 to 4 in.w.g. Any Size 4” All mitre joints

(Internal Radius)

0 to 4 in.w.g. Any Size 10” All mitre joints

(External Radius)

40
 The Kingspan System
Symmetric Elbow with Templates

B l A
Use the Elbow Template with side l required

Asymmetric Elbow with Templates

l1

C E C

B l A B l A

1 - Use the Elbow Template with smaller 2 - Use the Elbow Template with bigger side
side l to trace the lines AB and BC l1 to trace the lines AD and DE

3 - Use a ruler to trace the segment EC

41
The Kingspan System
Elbow, 45 Deg Throat, Radius Heel
Alternative Elbow Design*

Splitter

SPLITTER
Elbow side (inches) Splitters Position
0 – 20” 0 -
20” – 32” 1 W/3
32” – 64” 2 W/4 W/2
Over 64” 3 W/8 W/3 W/2
Splitter not required in angles less than 45°:
SMACNA vane selection is also acceptable

42
The Kingspan System
Elbow, 45 Deg Throat, Radius Heel
Alternative Elbow Design
# 512, 519 Jack Plane 22.5 degrees

Clamp
Blades set 1/32” less than Panel ing
thickness Rule
2 ½”
2 ¾”
3 1/8” 3 1/8”

Cut 1:
Setup tool
Neck size +2 ¾“
from panel end

Cut 2
Setup tool
Throat size +2 ¾“ from
cut 1 centre

43
 The Kingspan System
Dynamic Branch – “Y” branch with radius elbow
10

20”
NECK
NECK

Min 4”
4

ER = 32”
D
24”

2xTH 1/3 = 8”

8” = IR
2
NECK

1/3 Min 4”
= 6” 2”
1

TH 16” 18” 8” = IR 6” Min 4”

9 5 6 7 8

3 minus 5

• Dimensions in inches
• Numbers in the hoop show suggested tracing procedure
• D minimum = 2.5 x (20”-16”) = 10”

NOTE: Minimum Bend Radius: 8”

Minimum Neck: 4”

44
The Kingspan System
Assembly Procedure

2 1 4 6

• Place 1 on the table

• Join section 2 and section 3 to 1
• Install section 4
• Install section 5
• Install section 6

3
6
45
 NECK NECK
TH

12” ER1
ER2
8
20” 3

2xTH
IR
The Kingspan

IR
2
Min 100
10
Min 4”
1

Min 4” 4” IR 8” 16” IR 4” Min 4”

System

14 13 12 11 4 5 6 7

8 minus 11 3 minus 4
• Dimensions in inches
Dynamic Branch – Tee Branch (external sides flushed)

46
• Numbers in the hoop show suggested tracing procedure NOTE: Minimum Bend Radius: 8”
Minimum Neck: 4”
 TH

8”
ER2 = 32” NECK

24”
ER2 = 24”
3
16”
8
1/3 2xTH
The Kingspan

= 8”

8” = IR
8” = IR
2 9

1/3
1” = 7” N
N
10
1
System

Min 4” 4” 200 = IR 20” 12” 8” = IR 4” Min 4”

7 6 5 4 11 12 13 14

3 minus 4 8 minus 11
• Dimensions in inches
Dynamic Branch – Tee Branch (internal sides flushed)

47
• Numbers in the hoop show suggested tracing procedure NOTE: Minimum Bend Radius: 8”
Minimum Neck: 4”
 ASSEMBLY PROCEDURE

4 7 8 3 2
The Kingspan

7
1
8

• Place section 1 on the table

• join section 2 and 3 only the neck section
System

• Option: add holder pieces 5 e 6 with tape only

5 6
• install bigger circumference section with cover 7
• install section 8
3 2
• remove section 5 and adhesive section 3 4

• remove section 6 and adhesive section 2

48
The Kingspan System

Training Manual

Chapter 3

Coupling Systems
for joining ductwork sections

49
The Kingspan System
4-Bolt Flange – # 380-385
Assembly

1) Cut flange 20mm (¾ “) short of the duct 2) For any Duct size: Add Tiger Units,
internal dimensions: one each side of each corner,
i.e. h - 20 mm (h – ¾ “) Total no.8 Tiger Units
w - 20mm (w – ¾ “)

Corner hole Joggle hole

3) Tape 4) Fit corner pieces into the flange to make

NOTE: 50 mm (2”) wide tape acceptable up the full rectangular shape.
Gently taper the ends of the duct section with
the black Rigid Spatula #526 #258 (259) Corner Piece for (22mm) (7/8 “) Panel
#268 (269) Corner Piece for 30mm (1 3/16”) Panel

Sealant on both edges

3/8” Outside Facing

3/8” Inside Facing

5) Apply sealant inside the flange at both edges.

50
The Kingspan System
4-Bolt Flange – # 380-385
Assembly

6) 4-Bolt flange bonded to the duct. 7) Screws

Use mallet to carefully apply the flange
in its final position.
Suggested screws:
• Diameter 4mm (5/32”)

Tiger Unit
4-Bolt flange
4-Bolt flange

Screw Tiger Unit

Screw
Tape

8) Detail

51
The Kingspan System
4 Bolt Flange – # 380-385
Coupling

A
Seal here

B
C
D Clip (not supplied by Kingspan)

• Attach gasket to one flange face. Attach in G-Clamp (not supplied by Kingspan)
one piece working around the corners.
• The preferred gasket shall be # 242
polyurethane 5/8” wide and 5/8” thick (15mm)
• Apply silicone to exposed corner edges
• Fit Bolts into the corner holes (loose bolts)
• If necessary align the corner holes by use of
the Joggle holes
• Insert Clamps or Clips in sufficient numbers
to ensure that there are no gaps in the seam
• Tighten Clamps or Clips - Suggested: at max
12” centres (300mm) about 3” (75 mm) from
corners
• Finally tighten the bolts

Silicone

52
The Kingspan System
Aluminum Grip Flange System
7/ 1 3/16” R-8
8” R-6

External Grip Grip Flange for Bayonet

# 312

Internal Grip External U Grip U Grip Flange

for 7/8” # 315
LKDA 311

Internal Grip
for 1 3/16”
External h Grip h “Chair” Grip Flange
LKDA 317
# 314

External F Grip F Grip Flange

# 313

53
The Kingspan System
Grip Flange System – 7/8” (22mm), R-6
May be used with pressure up to 2 in.w.g. (or Tiger Clip when possible)
Must be used with static pressure > 2 in.w.g. (or 4-Bolt flange)

Bayonet Cleat # 321

External Grip # 312

Gasket
# 242
SUGGESTED GASKET
PU 5/8” x 5/8”

Internal Grip for 7/8 “ R-6

# 311

54
The Kingspan System
Grip Flange System – 1 3/16” (30 mm), R-8
May be used with pressure up to 2 in.w.g. (or Tiger Clip when possible).
Must be used with static pressure > 2 in.w.g. (or 4-Bolt flange)

Bayonet Cleat # 321

External Grip # 312

Gasket SUGGESTED GASKET

# 242 PU 5/8” x 5/8”

Internal Grip for 1 3/16” R-8

# 317

EXPOSED INSULATION
Prior to insertion of the
R-8 Grip flange, the ends of
the duct section (or just the
corners) should be covered
with UL tape to seal the
External Grip
exposed insulation.
Internal Grip Flange, ref 312
Flange for R8,
ref 317

55
The Kingspan System
Grip Flange Assembly
Features:
• Positive air-tight joint on panels of varying thickness (¾” to 1” and 1 3/16” to 1 5/16”)
• No need of adhesive or rivets.
• Strengthen the ends of the duct
• Aerodynamic

External Grip Profile:

Mark notching points: see the Appendix

Each dimension mark represents the centre line of a “V” 90° cut.
Fold the external male flange section at each cut to form a rectangular shape.

Internal Grip Profile:

A. Two sections of internal (female) flange are square cut to a dimension equal to the
internal duct width less 1/8” .
B. Two sections are square cut to a dimension equal to the internal duct height l
less 1/8”.

Installation:
All internal Grip (female) pieces are applied with light pressure until the total flange
assembly is formed. Only when one piece is properly engaged and correctly
positioned, it should be forced into the final locking grip using a rubber mallet.

V cut V cut

Straight cut

Grip FACING DOWN

V Cut using Grip Notcher:
External Grip # 312 Grip FACING UP
External F Grip # 313 V Cut using Grip Notcher:
External U Grip # 315 External h Grip # 314
56
 Grip Flange Cuts
External Grip Flange Profile (see the Appendix at the end of this Manual for the Notches position)

1/2 w h w h 1/2 w (-2mm)

w = External Duct Width
The Kingspan

h = External Duct Height

External joint
about centre of duct
Grip Notcher
# 451

Small notch cut

Internal Grip Flange
This should be the last to
be installed h
System

Silicone

Internal Grip # 311

Internal dim. – – 1/8” External Grip Flange # 312
Complete Grip Flange
applied on the duct

57
The Kingspan System
Duct-to-Duct Coupling
Aluminum Grip with Bayonet Cleat

Grip
Flange

Gasket # 242 (PU 5/8” x 5/8” )

One piece of self-adhesive gasket
with overlap

Note: Kool Clamp #

2 453 and WD-40
can assist with
Bayonet
application.

Nylon Cap # 281 for visibly mounted

installations (optional)

Horizontal Bayonet overlap Vertical Bayonet # 321

w+½“

Vertical Bayonet # 321

h
w

58
The Kingspan System
Tiger Clip Coupling – # 364
LIMITATIONS:
• Low Pressure applications only (below 2 in.w.g)

STEP 1
Both ends of the KoolDuct duct must
be flat and perfectly squared
Aluminum tape is applied on
both ends of the duct segments.

STEP 2
Apply a continuous bead of
Kingspan approved silicone to one
end of one segment.

STEP 3
The two duct segments are joined together.
Tiger Clips (# 364) are placed on all four corners
of the duct
Tiger Clips (# 364) are placed on all four sides of
the duct. # 364
bent

No. Tiger Clips per

w or h Max pressure # 364
side in addition to
(inches) (in.w.g.) flat
those at corners
4” – 5” 0 2”
6” – 11” 1 2”
12” – 19” 2 2”
20” – 39” 3 2”
40” – 45” 4 2”
46” – 49” 4 1”
50” – 60” 5 1”

STEP 4
Apply aluminum tape around the connection
of the two duct segments

59
 The Kingspan System
Aluminum Flange Profiles
for Connection To Duct System Components

“F” GRIP FLANGE # 311 + 313 “F” STRUCTURAL FLANGE # 332

“h” GRIP FLANGE # 311 + 314 “h” STRUCTURAL FLANGE # 333

“U” GRIP FLANGE # 311 + 315 “U” STRUCTURAL FLANGE # 334

Example: h flange

60
The Kingspan System
Structural Aluminum Profiles
(Alternative to Grip for 7/8” R-6 KoolDuct only)

Structural U Profile # 334

Internal dim. – 1/8”

Adhesive inside
each profile

EXAMPLE:
STRUCTURAL
FLANGE
Aluminum Tape
on corners
Prior to insertion of the
Structural flanges, the
ends of the duct
section (both inner and
outer surfaces) should
be gently tapered
with the black Rigid
Spatula

Structural F # 332
Internal dim. – 1/8”

Adhesive inside
each profile

EXAMPLE:
“F” STRUCTURAL Aluminum Tape
FLANGE on corners

61
 The Kingspan System
Connection To Duct System Components
Gasket
Gasket

KoolDuct KoolDuct KoolDuct KoolDuct

Fitted with fitted with fitted with Fitted with
U Profile F Profile h Profile U Profile

Rivet “S” slip Rivet

when suitable
Flanged Connection Spigotted Connection

Gasket Gasket

The external dimension

KoolDuct of KoolDuct 4 Bolt flange KoolDuct
Fitted with shall match the external Fitted with
4 Bolt flange dimension of the flanged 4 Bolt flange
connection

Bolt
Rivet
Flanged Connection using Spigotted Connection using
The 4 Bolt flange The 4 Bolt flange

Screws/rivets: minimum 2 per side, located at 300mm (12”) max spacing.

62
The Kingspan System
Connection To a Fire Damper
with break-away joint

Aluminum Rivet Tape to cover insulation

And h Profile
Aluminum Rivet and metal plate
Or large flat square washer

KoolDuct Fire KoolDuct

Ductwork Damper Ductwork

“S” slip Aluminum Rivet and

and h Profile U Profile

NOTE: The installation of fire dampers and their connection to ductwork fabricated
from the Kingspan KoolDuct system should always be in accordance with the building
regulations

Rivets: minimum 2 per side, located at 300mm (12”) max spacing

Suggested blind rivets with aluminum body:
• Minimum diameter 4.0mm (5/32”)
• Through flange only: rivet grip range 3-8mm (1/8" to 5/16“)
• Through flange and panel:
• For 22mm KoolDuct: rivet with grip range 25-30mm (1" to 1 3/16“)
• For 30mm KoolDuct: rivet with grip range 33-38mm (1 5/16" to 1 1/2" )

63
The Kingspan System
Alternative Connection With Tiger Unit # 363
Low Pressure only ≤1 in.w.g.

UL TAPE FIRST

VCD
TIGER UNIT
After connection :
• Apply UL tape over Tiger Units KoolDuct
• Seal with sealant

For VCD dimensions (w and h) ≤ 24” DETAILED VIEW

Duct Connection to VCD (Volume Control Damper)

FAN KoolDuct
COI
L
UNI
T
UL TAPE FIRST
TIGE
After connection : R
• Apply UL tape over Tiger Units UNIT
For any dimension of FCU • Seal with sealant DETAILED VIEW

Duct Connection to Fan Coil Unit

Suggested Tiger Unit spacing at 12“ (300mm) maximum intervals

64
The Kingspan System
Connection of Inspection Doors
Option 1: KoolDuct door Option 2: Pre fabricated door

Connect safety restraints to access

panels located in riser ducts.

Seal the frame

with Silicone

KoolDuct Door Pre Fabricated Door

65
The Kingspan System

Training Manual

Chapter 4

Duct Reinforcement

66
The Kingspan System
Duct Reinforcement

It is required to ensure that the true rectangular cross section of the duct is maintained.

Reinforcement Requirements
The ductwork may require reinforcement, check the following:
• Duct Size (both width and height must be evaluated)
• System Pressure inside ductwork (static plus dynamic)
Refer to the following Schedule.

Installation of Duct Reinforcement

• Reinforcing bars, both Positive and Negative Pressure, any duct side
• Panel as reinforcement, Negative Pressure ONLY, duct side less than 24”.

Reinforcement for all Ductwork shapes

Both straight ductwork and fittings (e.g. elbows, transitions, etc.) shall be included in the
reinforcement procedure

Areas where over pressure may exceed design pressure

Where occasional inadmissible over pressure would exceed design pressure and
would compromise the integrity of the ductwork, a Pressure Relief Damper and
bypass duct is recommended.

Large Ductwork
For ductworks larger than those covered by the Schedule of duct reinforcement in this
manual, the Multiple Duct method of construction can be used, in this case each one of
the multiple smaller ductworks shall be reinforced independently.

Alternatively, reinforcements shall be designed to suit the applications, please contact

Kingspan Insulation for details

67
The Kingspan System
Reinforcement System
Always install reinforcement for both Positive and Negative Pressure

Speed Clip Reinforcement Disc #353

(capped inlock washer)

KoolDuct Panel

Outer tube
(Negative Pressure) Reinforcement Disc #353
= Internal duct dim.

Inner tube
(Positive Pressure)
= External duct dim. + ½ “

1) Aluminum Reinforcement – Tube encased Tube

with Discs and Speed Clips (capped inlock washers)

Threaded Nut Reinforcement Disc #353

KoolDuct Panel

Outer tube Reinforcement Disc #353

(Negative Pressure)

Threaded rod
(Positive Pressure)

2) Tubing encased threaded rod with Discs and Threaded Nuts

Bolt Reinforcement Disc #353

KoolDuct Panel

Threaded insert
Reinforcement Disc #353

Outer tube
(Negative Pressure)

3) Tubing and Threaded Inserts with Discs and Bolts

68
The Kingspan System
Reinforcement System
Always install reinforcement for both Positive and Negative Pressure

REINFORCING BARS SELECTION – POSITIVE PRESSURE

Aluminum Tube Max Length

10 mm (3/8”) OD 2134 mm (84”)

Threaded Rod Max Length

8 mm (5/16”) 2134 mm (84”)

REINFORCING BARS SELECTION – NEGATIVE PRESSURE

Max
O.D I.D. Thickness
Alu Tube Length
mm mm mm
mm

9/16" 14 11 1.5 914

1/2" 17.9 15.8 1.07 1168

3/4" 23.4 20.9 1.25 1527

1" 29.5 26.6 1.45 1880
1 1/4" 38.4 35.1 1.65 2591

Max
Rigid O.D I.D. Thickness
Length
Conduit mm mm mm
mm
1/2" 21.3 16.1 2.65 1320

3/4" 26.7 21.2 2.72 1676

1" 33.4 27.0 3.20 2134

Note on Reinforcing Bars for Negative Pressure: Max Length (L) established to limit the
compression stress to that associated with a Max Ratio of 200 L/rg
rg = Radius of Gyration

69
The Kingspan System
Reinforcement Application
Reinforcing Bars
Add reinforcement for each duct segment, based on duct size and pressure. Both
straight ductwork and fittings (e.g. elbows, transitions, etc.) shall be included in the
reinforcement procedure.

Flanged Joint
when required

Reinforcements Reinforcements
on the sides required on elbows, transition, tee, etc.

D = Recommended Step Interval (see Schedule of Duct Reinforcement)

D1 = See the notes bottom of the graphs for max distance from ductwork ends

70
The Kingspan System
KoolDuct 7/8” (R-6) - Schedule of Duct Reinforcement
Grip flange and Bayonet Coupling
Max Duct
Pos Pressure
Duct Dimension segment Static Pressure Positive and Negative
only
length
inches inches 1/2 in.w.g. 1 in.w.g. 2 in.w.g. 3 in.w.g. 4 in.w.g.
4-8 154 3/4"
9 - 12 154 3/4" NO REINFORCEMENT
13 - 16 154 3/4"
19 - 20 154 3/4"
21 - 24 154 3/4" 1@36" 1@36"

25 - 28 154 3/4" 1@36" 1@36"

29 - 32 154 3/4" 1@36" 1@36" 1@24"

33 - 36 154 3/4" 1@36" 1@36" 2@24"

37 - 40 154 3/4" 1@36" 1@36" 1@24" 2@24"

41 - 45 154 3/4" 1@36" 1@36" 1@24" 2@24"

46 - 48 47 1/4" 1@24" 1@24" 2@24"

49 - 52 47 1/4" 1@24" 2@24" 2@24"

53 - 56 47 1/4" 1 BAR CENTERED 1@24" 2@24" 2@24"

57 - 60 47 1/4" 1 BAR CENTERED 1@24" 2@24" 3@24"

61 - 64 47 1/4" 1 BAR CENTERED 2@24" 2@24" 3@24"

65 - 68 47 1/4" 1 BAR CENTERED 2@24" 2@24" 3@24"

69 - 72 47 1/4" 1@24" 2@24" 2@24" 3@24"

73 - 76 47 1/4" 1 BAR CENTERED 1@24" 2@24" 3@24" 3@24"

79 - 80 47 1/4" 1 BAR CENTERED 1@24" 2@24" 3@24" 3@24"

Over 2000 Consult with Kingspan

NOTES

1@36" Reinforcing Bars shall be placed at a maximum of 36" centers, and

Aluminium Grip: FIRST and LAST bar at MAX 18" FROM JOINT

1 BAR CENTERED One Reinforcing Bar centered equal distance between joints

1@24" Reinforcing Bars shall be placed at a maximum of 24" centers, and

Aluminium Grip: FIRST and LAST bar at MAX 12" FROM JOINT

2@24" Reinforcing Bars shall be placed as a pair at a maximum of 24" centers, and
Aluminium Grip: FIRST and LAST pairs at MAX 12" FROM JOINT

3@24" Reinforcing Bars shall be placed as a trio at a maximum of 24" centers, and
Aluminium Grip: FIRST and LAST trio at MAX 12" FROM JOINT
71
The Kingspan System
KoolDuct 7/8” (R-6) - Schedule of Duct Reinforcement
4-Bolt Coupling
Max Duct
Pos Pressure
Duct Dimension segment Static Pressure Positive and Negative
only
length
1/2 in.w.g. 1 in.w.g. 2 in.w.g. 3 in.w.g. 4 in.w.g.
4-8 154 3/4"
9 - 12 154 3/4" NO REINFORCEMENT
13 - 16 154 3/4"
19 - 20 154 3/4"
21 - 24 154 3/4" 1@36" 1@36"

25 - 28 154 3/4" 1@36" 1@36"

29 - 32 154 3/4" 1@36" 1@36" 1@24"

33 - 36 154 3/4" 1@36" 1@36" 2@24"

37 - 40 154 3/4" 1@36" 1@36" 1@24" 2@24"

41 - 45 154 3/4" 1@36" 1@36" 1@24" 2@24"

46 - 48 47 1/4" 1 BAR CENTERED 2 BARS CENTERED 2@24"

49 - 52 47 1/4" 1 BAR CENTERED 2 BARS CENTERED 2@24"

53 - 56 47 1/4" 1 BAR CENTERED 2@24" 2@24"

57 - 60 47 1/4" 1 BAR CENTERED 2@24" 3@24"

61 - 64 47 1/4" 1 BAR CENTERED 2 BARS CENTERED 2@24" 3@24"

65 - 68 47 1/4" 1 BAR CENTERED 2 BARS CENTERED 2@24" 3@24"

69 - 72 47 1/4" 1 BAR CENTERED 2 BARS CENTERED 2@24" 3@24"

73 - 76 47 1/4" 1 BAR CENTERED 2 BARS CENTERED 3@24" 3@24"

79 - 80 47 1/4" 1 BAR CENTERED 2 BARS CENTERED 3@24" 3@24"

Over 2000 Consult with Kingspan

NOTES

1@36" Reinforcing Bars shall be placed at a maximum of 36" centers, and

4-Bolt Flange: FIRST and LAST bar at MAX 36" FROM JOINT

1 BAR CENTERED One Reinforcing Bar centered equal distance between joints

2 BARS CENTERED Two Reinforcing Bars centered equal distance between joints

1@24" Reinforcing Bars shall be placed at a maximum of 24" centers, and

4-Bolt Flange: FIRST and LAST bar at MAX 24" FROM JOINT

2@24" Reinforcing Bars shall be placed as a pair at a maximum of 24" centers, and
4-Bolt Flange: FIRST and LAST pairs at MAX 12" FROM JOINT

3@24" Reinforcing Bars shall be placed as a trio at a maximum of 24" centers, and
4-Bolt Flange: FIRST and LAST trio at MAX 12" FROM JOINT 72
The Kingspan System
KoolDuct 7/8” (R-6) - Schedule of Duct Reinforcement
Tiger Clip Coupling
Max Duct
Pos Pressure
Duct Dimension segment Static Pressure Positive and Negative
only
length
1/2 in.w.g. 1 in.w.g. 2 in.w.g. 3 in.w.g. 4 in.w.g.
4-8 154 3/4"
9 - 12 154 3/4" NO REINFORCEMENT NOT APPLICABLE
13 - 16 154 3/4"
19 - 20 154 3/4"
21 - 24 154 3/4" 1@Joint

25 - 28 154 3/4" 1@Joint 1@Joint

29 - 32 154 3/4" 1@Joint 1@Joint 1@36"

33 - 36 154 3/4" 1@Joint 1@Joint 1@36"

37 - 40 154 3/4" 1@Joint 1@36" 1@36"

41 - 45 154 3/4" 1@Joint 1@36" 1@36"

46 - 48 47 1/4" 1@24" 1@24"

49 - 52 47 1/4" 1@24" 1@24"

53 - 56 47 1/4" 1@24" 1@24"

57 - 60 47 1/4" 1@24" 1@24"

61 - 64 47 1/4"
65 - 68 47 1/4"
69 - 72 47 1/4" NOT APPLICABLE
73 - 76 47 1/4"
79 - 80 47 1/4"
Over 2000

NOTES

1@Joint Reinforcing Bars shall be placed at Joint only, and

Tiger Clip: Reinfoircing bar at MAX 12" FROM JOINT, on both sides of the joint

1@36" Reinforcing Bars shall be placed at a maximum of 36" centers, and

Tiger Clip: FIRST and LAST bar at MAX 12" FROM JOINT

1@24" Reinforcing Bars shall be placed at a maximum of 24" centers, and

Tiger Clip: FIRST and LAST bar at MAX 12" FROM JOINT

73
The Kingspan System
KoolDuct 1 3/16" (R-8) - Schedule of Duct Reinforcement
Grip flange and Bayonet Coupling
Max Duct
Pos Pressure
Duct Dimension segment Static Pressure Positive and Negative
only
length
1/2 in.w.g. 1 in.w.g. 2 in.w.g. 3 in.w.g. 4 in.w.g.
4-8 154 3/4"
9 - 12 154 3/4" NO REINFORCEMENT
13 - 16 154 3/4"
19 - 20 154 3/4"
21 - 24 154 3/4" 1@36" 1@36"

25 - 28 154 3/4" 1@36" 1@36"

29 - 32 154 3/4" 1@36" 1@36" 1@24"

33 - 36 154 3/4" 1@36" 1@36" 1@24"

37 - 40 154 3/4" 1@36" 1@36" 1@36" 1@24"

41 - 45 154 3/4" 1@36" 1@36" 1@36" 1@24"

46 - 48 47 1/4" 1 BAR CENTERED 1@24" 2@24"

49 - 52 47 1/4" 1 BAR CENTERED 1@24" 2@24"

53 - 56 47 1/4" 1 BAR CENTERED 1 BAR CENTERED 2@24" 2@24"

57 - 60 47 1/4" 1 BAR CENTERED 1@24" 2@24" 2@24"

61 - 64 47 1/4" 1 BAR CENTERED 1@24" 2@24" 2@24"

65 - 68 47 1/4" 1 BAR CENTERED 2@24" 2@24" 2@24"

69 - 72 47 1/4" 1 BAR CENTERED 2@24" 2@24" 3@24"

73 - 76 47 1/4" 1 BAR CENTERED 1@24" 2@24" 2@24" 3@24"

79 - 80 47 1/4" 1 BAR CENTERED 1@24" 2@24" 2@24" 3@24"

Over 2000 Consult with Kingspan

NOTES

1@36" Reinforcing Bars shall be placed at a maximum of 36" centers, and

Aluminium Grip: FIRST and LAST bar at MAX 18" FROM JOINT

1 BAR CENTERED One Reinforcing Bar centered equal distance between joints

1@24" Reinforcing Bars shall be placed at a maximum of 24" centers, and

Aluminium Grip: FIRST and LAST bar at MAX 12" FROM JOINT

2@24" Reinforcing Bars shall be placed as a pair at a maximum of 24" centers, and
Aluminium Grip: FIRST and LAST pairs at MAX 12" FROM JOINT

3@24" Reinforcing Bars shall be placed as a trio at a maximum of 24" centers, and
Aluminium Grip: FIRST and LAST trio at MAX 12" FROM JOINT
74
The Kingspan System
KoolDuct 1 3/16" (R-8) - Schedule of Duct Reinforcement
4-Bolt Coupling
Max Duct
Pos Pressure
Duct Dimension segment Static Pressure Positive and Negative
only
length
inches inches 1/2 in.w.g. 1 in.w.g. 2 in.w.g. 3 in.w.g. 4 in.w.g.
4-8 154 3/4"
9 - 12 154 3/4" NO REINFORCEMENT
13 - 16 154 3/4"
19 - 20 154 3/4"
21 - 24 154 3/4" 1@36" 1@36"

25 - 28 154 3/4" 1@36" 1@36"

29 - 32 154 3/4" 1@36" 1@36" 1@24"

33 - 36 154 3/4" 1@36" 1@36" 1@24"

37 - 40 154 3/4" 1@36" 1@36" 1@36" 1@24"

41 - 45 154 3/4" 1@36" 1@36" 1@36" 1@24"

46 - 48 47 1/4" 1 BAR CENTERED 1 BAR CENTERED 2 BARS CENTERED

49 - 52 47 1/4" 1 BAR CENTERED 1 BAR CENTERED 2@24"

53 - 56 47 1/4" 1 BAR CENTERED 2 BARS CENTERED 2@24"

57 - 60 47 1/4" 1 BAR CENTERED 2 BARS CENTERED 2@24"

61 - 64 47 1/4" 1 BAR CENTERED 2 BARS CENTERED 2 BARS CENTERED 2@24"

65 - 68 47 1/4" 1 BAR CENTERED 2 BARS CENTERED 2 BARS CENTERED 2@24"

69 - 72 47 1/4" 1 BAR CENTERED 2 BARS CENTERED 2@24" 3@24"

73 - 76 47 1/4" 1 BAR CENTERED 2 BARS CENTERED 2@24" 3@24"

79 - 80 47 1/4" 1 BAR CENTERED 2 BARS CENTERED 2@24" 3@24"

Over 2000 Consult with Kingspan

NOTES

1@36" Reinforcing Bars shall be placed at a maximum of 36" centers, and

4-Bolt Flange: FIRST and LAST bar at MAX 36" FROM JOINT

1 BAR CENTERED One Reinforcing Bar centered equal distance between joints

2 BARS CENTERED Two Reinforcing Bars centered equal distance between joints

1@24" Reinforcing Bars shall be placed at a maximum of 24" centers, and

4-Bolt Flange: FIRST and LAST bar at MAX 12" FROM JOINT

2@24" Reinforcing Bars shall be placed as a pair at a maximum of 24" centers, and
4-Bolt Flange: FIRST and LAST pairs at MAX 12" FROM JOINT

3@24" Reinforcing Bars shall be placed as a trio at a maximum of 24" centers, and
4-Bolt Flange: FIRST and LAST trio at MAX 12" FROM JOINT
75
The Kingspan System
KoolDuct 1 3/16" (R-8) - Schedule of Duct Reinforcement
Tiger Clip Coupling
Max Duct
Pos Pressure
Duct Dimension segment Static Pressure Positive and Negative
only
length
1/2 in.w.g. 1 in.w.g. 2 in.w.g. 3 in.w.g. 4 in.w.g.
4-8 154 3/4"
9 - 12 154 3/4" NO REINFORCEMENT NOT APPLICABLE
13 - 16 154 3/4"
19 - 20 154 3/4"
21 - 24 154 3/4"
25 - 28 154 3/4" 1@Joint

29 - 32 154 3/4" 1@Joint 1@36"

33 - 36 154 3/4" 1@Joint 1@36"

37 - 40 154 3/4" 1@Joint 1@36" 1@36"

41 - 45 154 3/4" 1@Joint 1@36" 1@36"

46 - 48 47 1/4" 1@24" 1@24"

49 - 52 47 1/4" 1@24" 1@24"

53 - 56 47 1/4" 1@24" 1@24"

57 - 60 47 1/4" 1@24" 1@24"

61 - 64 47 1/4"
65 - 68 47 1/4"
69 - 72 47 1/4" NOT APPLICABLE
73 - 76 47 1/4"
79 - 80 47 1/4"
Over 2000

NOTES

1@Joint Reinforcing Bars shall be placed at Joint only, and

Tiger Clip: Reinfoircing bar at MAX 12" FROM JOINT, on both sides of the joint

1@36" Reinforcing Bars shall be placed at a maximum of 36" centers, and

Tiger Clip: FIRST and LAST bar at MAX 12" FROM JOINT

1@24" Reinforcing Bars shall be placed at a maximum of 24" centers, and

Tiger Clip: FIRST and LAST bar at MAX 12" FROM JOINT

76
The Kingspan System
Duct Reinforcement
Examples

Example A: 7/8”, R-6 KoolDuct

Ductwork section size: 40” (w) x 20” (h)
Ductwork section length: 100”
Pressure: 1 in.w.g.

Reinforcements Reinforcements

R-6 with Grip flange and bayonet joint: R-6 with 4-Bolt flange :
Side 40”: 1@36”, bar max 18” from flange Side 40”: 1@36”, bar max 36” from flange
Side 20”: No reinforcement Side 20”: No reinforcement

Example B: 1 3/16”, R-8 KoolDuct

Ductwork section size: 68” (w) x 48” (h)
Ductwork section length: 47 ¼ “
Pressure: 2 in.w.g.

R-8 with Grip flange and bayonet joint: R-8 with 4-Bolt flange
Side 68”: 2@24”, bar max 12” from flange Side 68”: 2 Centered
Side 48”: 1 Centered Side 48”: 1 Centered

77
The Kingspan System
Non-standard reinforcement
Where the standard reinforcing bars cannot be installed:
• top of a large square elbow
• where a large branch takes off from a large duct
• large end cap.

Non-standard reinforcement options :

• Duct fabrication using the dual or multiple duct design
• Angle profiles or reinforcing channels mechanically fixed inside/outside ductwork
• Single duct design reinforced with “Bent” reinforcing bars that suit the shape of
the ductwork.

Reinforcement – End Caps

• Reinforcement required whenever the schedule of reinforcement for straight duct of the
same dimension shows reinforcement is required.
• Reference is the SMALLEST size of the end cap. E.g. end cap size 56” x 40”: check the
schedule of duct reinforcement for 40”
• Specifically designed reinforcement, e.g. channel profiles 1 5/8” x 13/16 “, 16 gage
(40x20mm, min 1.5mm thick)
Long Screw

Reinforcing Disc

Reinforcing Channel
min 1 5/8” x 13/16 “ (40x20mm)
min 16 gage (1.5mm thick)

Threaded nut and

washer

78
The Kingspan System

Training Manual

Chapter 5

Hangers and Supports

79
The Kingspan System
Hangers and Supports - Ductwork
KoolDuct ductwork installed according to the principals of HVCA DW/144 Chapter
6 or SMACNA HVAC Duct Construction Standard Chapter 5

Suitable Duct Support: Metal Channel, Angle, Tiger Support

Tiger Support #266:

• for small and medium size horizontal ductworks (duct side up to 700 x 700 mm)
• for risers of any size.

Suitable Hanger: Threaded rod, Wire rope, Flat strap

Threaded rod Wire rope
6 or 8 mm 2.7 mm
Flat strap (¼ “)
25 x 0.8 mm (12 GA)
(1 in x 22 GA)
Threaded
rod

Tiger
Support

Washer
Nut

As a finish, apply aluminum tape on the Steel channel

bottom of the Tiger Support.

The selection of all supports and hangers shall be based on the weight of KoolDuct
ductwork, according to the recommendations of the support/hanger manufacturer.
See tables Weight of KoolDuct.

Hangers and Supports – Components

All components, such as volume control dampers, flexible ducts etc. should be fully
and independently supported, with their weight neutralised by supports and not
loading the KoolDuct system

80
The Kingspan System
Horizontal Ductwork - Max Spacing Between Supports

Ductwork Longer Maximum Spacing

Inside Dimension - w or h (inches) Between Supports
<47” 13 feet
from 47” to 80” 6 feet
>80” Special Analysis Required

Note: Closer spacing may be required due to limitations of the building structure or to
achieve the necessary duct rigidity

Horizontal Ductwork – Hanger Minimum Size

Hanger Minimum Size (mm)

Largest Duct Side
Hanger Type
(mm) Pair at 3930 mm Pair at 1800 mm Pair at 1200 mm
spacing spacing spacing
Rod 100 - 1150 6.4 6.4 6.4
Rod 1151 - 2000 n.a. 6.4 6.4

Strap 100 - 1150 25.4 x 0.85 25.4 x 0.85 25.4 x 0.85

Strap 1151 - 2000 n.a. 25.4 x 0.85 25.4 x 0.85

Wire 100 - 900 2.7 2.7 2.7

Wire 901 - 1150 3.2 2.7 2.7
Wire 1151 - 1500 n.a. 2.7 2.7
Wire 1501 - 2000 n.a. 3.2 2.7

Single Hanger Maimum Allowable Load

Rod Strap Wire

2.7 – 36 kg
6.4 – 122 kg 25.4 x 0.85 – 118 kg
3.2 – 54 kg

Note: When available, please follow the specific recommendations of the hanger
Manufacturer

81
The Kingspan System
Hangers and Supports – Hanging Duct Fittings
The KoolDuct System is light weight, so duct support and hangers do not have to
be as robust nor as numerous as with sheet metal ducts.

It is the responsibility of the registered fabricator/installer to determine both spacing

and placement of supports. Ductwork shall be supported at branch connections, tee
fittings and at changes of direction as necessary.

Max 600mm
24”

Square Elbow suggested support Take-off suggested support

TOP VIEW TOP VIEW

Offset suggested support (bottom flat) Offset suggested support

TOP VIEW (bottom inclined)
SIDE VIEW

NOTE: Caution labels are available

(a) Ductwork and duct supports are not designed for man access
either inside or on top of the ductwork.
(b) Ductwork and duct supports are not designed to accommodate
additional loadings from other services.

82
The Kingspan System
Hangers and Supports – Vertical Ductwork
KoolDuct

Roll steel angle

Metal sleeve inside
KoolDuct

50mm (2”) min

sleeve height Fasteners
above and below 75mm (3”) from duct edges
At max 300mm (12”) spacing
Option 1

KoolDuct

Strut channel
Tiger Supports at every
corner of the duct

Threaded bar

Option 2
Note that the couplings of ductwork fabricated from the Kingspan KoolDuct system are
NOT designed to take the vertical load of ductwork.

83
The Kingspan System
Hangers and Supports – Vertical Ductwork

Brackets/supports should be installed to bases of vertically orientated ductwork when

possible.

WEIGHT OF KOOLDUCT

The weight of the ductwork section shall always be independently determined by the
Trained Fabricator / Installer, and the appropriate gauge of supports and hanger
chosen in accordance with the relevant manufacturer's guidelines.

84
The Kingspan System
Hangers and Supports – Weight of KoolDuct 7/8” R-6
7/8" R-6 KoolDuct
Weight in [lbs per foot length] depending on width / height
Duct connecting joint : 4 BOLT FLANGE
Width (inch)
8" 12" 16" 20" 24" 28" 32" 36" 40" 44" 48" 52" 56" 60" 64" 68" 72" 76" 80"
8" 1.5 1.8 2.0 2.3 2.6 2.8 3.2 3.5 3.8 4.0 5.8 6.2 6.6 7.0 7.4 7.8 8.2 8.5 8.9 8"
12" 2.0 2.3 2.6 2.8 3.1 3.5 3.8 4.0 4.3 6.2 6.6 7.0 7.3 7.8 8.2 8.6 8.9 9.3 12"
16" 2.6 2.8 3.1 3.4 3.8 4.1 4.3 4.6 6.6 7.0 7.4 7.7 8.2 8.6 9.0 9.4 9.7 16"
Height (inch)

20" 3.1 3.4 3.7 4.1 4.4 4.6 4.9 7.0 7.4 7.8 8.1 8.6 9.0 9.4 9.8 10.1 20"
24" 3.7 3.9 4.4 4.6 4.9 5.2 7.4 7.8 8.2 8.5 9.0 9.4 9.8 10.2 10.5 24"
28" 4.2 4.7 4.9 5.2 5.5 7.8 8.2 8.5 8.9 9.5 9.8 10.2 10.6 10.9 28"
32" 5.2 5.5 5.7 6.0 8.2 8.6 8.9 9.3 9.9 10.2 10.6 11.0 11.4 32"

Height (inch)
36" 5.7 6.0 6.3 8.6 8.9 9.3 9.7 10.3 10.6 11.0 11.4 11.8 36"
40" 6.3 6.6 9.0 9.3 9.7 10.1 10.7 11.0 11.4 11.8 12.2 40"
44" 6.9 9.4 9.7 10.1 10.5 11.1 11.5 11.8 12.2 12.6 44"
10.0 10.4 10.8 11.2 11.8 12.2 12.6 13.0 13.4 48"
Weight based on 12.9 ft long ducts 10.8 11.2 11.6 12.2 12.6 13.0 13.4 13.8 52"
KoolDuct panel weight 0.34 lbs/ft2 11.6 11.9 12.6 13.0 13.4 13.8 14.2 56"
Reinforcement based on low pressure (2 in.w.g Pascal) 12.3 13.0 13.4 13.8 14.2 14.6 60"
13.7 14.1 14.6 15.0 15.4 64"
14.6 15.0 15.4 15.8 68"
15.4 15.8 16.2 72"
Weight based on 4 ft long ducts 16.2 16.6 76"
Reinforcement based on low pressure (2 in.w.g.) 17.0 80"

Duct connecting joint : ALUMINIUM GRIP + BAYONET

Width (inch)
8" 12" 16" 20" 24" 28" 32" 36" 40" 44" 48" 52" 56" 60" 64" 68" 72" 76" 80"
8" 1.4 1.7 1.9 2.2 2.5 2.7 3.1 3.4 3.6 3.9 5.4 5.7 6.1 6.4 6.9 7.3 7.6 7.9 8.3 8"
12" 1.9 2.2 2.5 2.7 3.0 3.4 3.7 3.9 4.2 5.8 6.1 6.4 6.8 7.3 7.7 8.0 8.3 8.7 12"
16" 2.5 2.7 3.0 3.2 3.7 3.9 4.2 4.5 6.1 6.5 6.8 7.2 7.7 8.1 8.4 8.8 9.1 16"
Height (inch)

20" 3.0 3.2 3.5 4.0 4.2 4.5 4.7 6.5 6.8 7.2 7.5 8.1 8.5 8.8 9.2 9.5 20"
24" 3.5 3.8 4.3 4.5 4.8 5.0 6.9 7.2 7.6 7.9 8.5 8.9 9.2 9.6 9.9 24"
28" 4.0 4.5 4.8 5.1 5.3 7.3 7.6 8.0 8.3 9.0 9.3 9.6 10.0 10.3 28"
32" 5.0 5.3 5.5 5.8 7.7 8.0 8.4 8.7 9.4 9.8 10.1 10.4 10.8 32"

Height (inch)
36" 5.6 5.8 6.1 8.1 8.4 8.7 9.1 9.8 10.2 10.5 10.8 11.2 36"
40" 6.1 6.4 8.4 8.8 9.1 9.5 10.2 10.6 10.9 11.3 11.6 40"
44" 6.7 8.8 9.2 9.5 9.8 10.6 11.0 11.3 11.7 12.0 44"
9.2 9.6 9.9 10.3 11.1 11.4 11.8 12.1 12.5 48"
Weight based on 12.9 ft long ducts 9.9 10.3 10.6 11.5 11.8 12.2 12.5 12.9 52"
KoolDuct panel weight 0.34 lbs/ft2 10.7 11.0 11.9 12.3 12.6 12.9 13.3 56"
Reinforcement based on low pressure (2 in.w.g Pascal) 11.4 12.3 12.7 13.0 13.3 13.7 60"
12.8 13.2 13.5 13.8 14.2 64"
13.6 13.9 14.2 14.6 68"
14.3 14.7 15.0 72"
Weight based on 4 ft long ducts 15.1 15.4 76"
Reinforcement based on low pressure (2 in.w.g.) 15.8 80"

Duct connecting joint : TIGER CLIP

Width (inch)
8" 12" 16" 20" 24" 28" 32" 36" 40" 44" 48" 52" 56" 60" 64" 68" 72" 76" 80"
8" 1.3 1.5 1.7 1.9 2.2 2.4 2.7 3.0 3.2 3.4 3.7 4.0 4.2 4.4 n.a. n.a. n.a. n.a. n.a. 8"
12" 1.7 1.9 2.2 2.4 2.7 3.0 3.2 3.5 3.7 4.0 4.3 4.5 4.7 n.a. n.a. n.a. n.a. n.a. 12"
16" 2.2 2.4 2.7 2.9 3.3 3.5 3.7 3.9 4.3 4.5 4.7 5.0 n.a. n.a. n.a. n.a. n.a. 16"
Height (inch)

20" 2.6 2.9 3.1 3.5 3.7 4.0 4.2 4.5 4.8 5.0 5.2 n.a. n.a. n.a. n.a. n.a. 20"
24" 3.2 3.4 3.8 4.0 4.3 4.5 4.8 5.0 5.3 5.5 n.a. n.a. n.a. n.a. n.a. 24"
28" 3.6 4.1 4.3 4.5 4.8 5.1 5.3 5.5 5.8 n.a. n.a. n.a. n.a. n.a. 28"
32" 4.5 4.8 5.0 5.3 5.6 5.8 6.1 6.3 n.a. n.a. n.a. n.a. n.a. 32"
Height (inch)

36" 5.0 5.3 5.5 5.9 6.1 6.3 6.6 n.a. n.a. n.a. n.a. n.a. 36"
40" 5.5 5.8 6.1 6.4 6.6 6.9 n.a. n.a. n.a. n.a. n.a. 40"
44" 6.0 6.6 6.9 7.2 7.4 n.a. n.a. n.a. n.a. n.a. 44"
6.9 7.2 7.4 7.7 n.a. n.a. n.a. n.a. n.a. 48"
Weight based on 12.9 ft long ducts 7.4 7.7 8.0 n.a. n.a. n.a. n.a. n.a. 52"
KoolDuct panel weight 0.34 lbs/ft2 7.9 8.2 n.a. n.a. n.a. n.a. n.a. 56"
Reinforcement based on low pressure (2 in.w.g Pascal) 8.5 n.a. n.a. n.a. n.a. n.a. 60"
n.a. n.a. n.a. n.a. n.a. 64"
n.a. n.a. n.a. n.a. 68"
n.a. n.a. n.a. 72"
Weight based on 4 ft long ducts n.a. n.a. 76"
Reinforcement based on low pressure (1 in.w.g.) n.a. 80"
85
The Kingspan System
Hangers and Supports – Weight of KoolDuct 1 3/16” R-8
1 3/16" R-8 KoolDuct
Weight in [lbs per foot length] depending on width / height
Duct connecting joint : 4 BOLT FLANGE
Width (inch)
8" 12" 16" 20" 24" 28" 32" 36" 40" 44" 48" 52" 56" 60" 64" 68" 72" 76" 80"
8" 1.9 2.3 2.6 2.9 3.3 3.6 4.0 4.4 4.7 5.1 6.9 7.4 7.8 8.2 8.7 9.2 9.6 10.1 10.5 8"
12" 2.6 2.9 3.3 3.6 3.9 4.4 4.7 5.1 5.4 7.4 7.8 8.3 8.7 9.1 9.7 10.1 10.6 11.0 12"
16" 3.3 3.6 3.9 4.3 4.8 5.1 5.4 5.8 7.8 8.3 8.7 9.2 9.6 10.2 10.6 11.0 11.5 16"
Height (inch)

20" 3.9 4.3 4.6 5.1 5.4 5.8 6.1 8.3 8.7 9.2 9.6 10.1 10.6 11.1 11.5 11.9 20"
24" 4.6 5.0 5.5 5.8 6.1 6.5 8.8 9.2 9.6 10.1 10.5 11.1 11.5 12.0 12.4 24"
28" 5.3 5.8 6.2 6.5 6.8 9.2 9.6 10.1 10.5 11.0 11.6 12.0 12.4 12.9 28"
32" 6.4 6.7 7.1 7.5 9.7 10.1 10.5 11.0 11.4 12.0 12.5 12.9 13.3 32"

Height (inch)
36" 7.1 7.5 7.8 10.1 10.6 11.0 11.4 11.9 12.5 12.9 13.4 13.8 36"
40" 7.8 8.2 10.6 11.0 11.5 11.9 12.3 13.0 13.4 13.9 14.3 40"
44" 8.5 11.0 11.5 11.9 12.3 12.8 13.4 13.9 14.3 14.8 44"
11.7 12.2 12.6 13.1 13.5 14.3 14.7 15.2 15.6 48"
Weight based on 12.9 ft long ducts 12.6 13.1 13.5 14.0 14.7 15.2 15.6 16.1 52"
KoolDuct panel weight 0.44 lbs/ft2 13.5 14.0 14.5 15.2 15.6 16.1 16.6 56"
Reinforcement based on low pressure (2 in.w.g Pascal) 14.5 14.9 15.7 16.1 16.6 17.0 60"
15.4 16.1 16.6 17.0 17.5 64"
16.9 17.4 17.9 18.4 68"
17.9 18.4 18.8 72"
Weight based on 4 ft long ducts 18.8 19.3 76"
Reinforcement based on low pressure (2 in.w.g.) 19.8 80"

Duct connecting joint : ALUMINIUM GRIP + BAYONET

Width (inch)
8" 12" 16" 20" 24" 28" 32" 36" 40" 44" 48" 52" 56" 60" 64" 68" 72" 76" 80"
8" 1.9 2.2 2.5 2.9 3.2 3.5 4.0 4.3 4.6 5.0 6.4 6.8 7.2 7.7 8.1 8.7 9.1 9.5 9.9 8"
12" 2.5 2.9 3.2 3.5 3.9 4.3 4.7 5.0 5.3 6.8 7.2 7.7 8.2 8.6 9.2 9.6 10.0 10.4 12"
16" 3.2 3.5 3.9 4.2 4.7 5.0 5.4 5.7 7.3 7.7 8.1 8.6 9.0 9.6 10.1 10.5 10.9 16"
Height (inch)

20" 3.9 4.2 4.5 5.0 5.4 5.7 6.0 7.7 8.1 8.5 9.0 9.5 10.1 10.5 10.9 11.3 20"
24" 4.5 4.9 5.4 5.7 6.1 6.4 8.1 8.5 8.9 9.5 9.9 10.6 11.0 11.4 11.8 24"
28" 5.2 5.8 6.1 6.4 6.7 8.5 8.9 9.4 9.9 10.3 11.1 11.5 11.9 12.3 28"
32" 6.3 6.6 7.0 7.3 9.0 9.4 9.8 10.4 10.8 11.6 12.0 12.4 12.8 32"

Height (inch)
36" 7.0 7.3 7.7 9.4 9.8 10.2 10.8 11.3 12.1 12.5 12.9 13.3 36"
40" 7.7 8.0 9.9 10.3 10.7 11.3 11.7 12.5 12.9 13.3 13.8 40"
44" 8.4 10.3 10.7 11.1 11.7 12.1 13.0 13.4 13.8 14.2 44"
10.7 11.1 11.5 12.2 12.6 13.5 13.9 14.3 14.7 48"
Weight based on 12.9 ft long ducts 11.5 11.9 12.6 13.0 14.0 14.4 14.8 15.2 52"
KoolDuct panel weight 0.44 lbs/ft2 12.4 13.1 13.5 14.4 14.8 15.2 15.6 56"
Reinforcement based on low pressure (2 in.w.g Pascal) 13.5 13.9 14.9 15.3 15.8 16.2 60"
14.4 15.4 15.8 16.2 16.6 64"
16.0 16.4 16.8 17.2 68"
16.9 17.3 17.7 72"
Weight based on 4 ft long ducts 17.7 18.2 76"
Reinforcement based on low pressure (2 in.w.g.) 18.6 80"

Duct connecting joint : TIGER CLIP

Width (inch)
8" 12" 16" 20" 24" 28" 32" 36" 40" 44" 48" 52" 56" 60" 64" 68" 72" 76" 80"
8" 1.7 2.0 2.3 2.6 2.9 3.2 3.6 3.9 4.2 4.5 4.8 5.1 5.4 5.7 n.a. n.a. n.a. n.a. n.a. 8"
12" 2.3 2.6 2.9 3.2 3.5 3.9 4.2 4.5 4.8 5.2 5.5 5.8 6.1 n.a. n.a. n.a. n.a. n.a. 12"
16" 2.9 3.2 3.5 3.8 4.2 4.5 4.8 5.1 5.5 5.8 6.1 6.4 n.a. n.a. n.a. n.a. n.a. 16"
Height (inch)

20" 3.5 3.8 4.1 4.5 4.8 5.1 5.4 5.8 6.1 6.4 6.7 n.a. n.a. n.a. n.a. n.a. 20"
24" 4.0 4.4 4.9 5.1 5.4 5.7 6.2 6.5 6.8 7.1 n.a. n.a. n.a. n.a. n.a. 24"
28" 4.7 5.2 5.5 5.8 6.1 6.5 6.8 7.1 7.4 n.a. n.a. n.a. n.a. n.a. 28"
32" 5.8 6.1 6.4 6.7 6.8 7.1 7.4 7.7 n.a. n.a. n.a. n.a. n.a. 32"
Height (inch)

36" 6.4 6.7 7.0 7.4 7.7 8.0 8.3 n.a. n.a. n.a. n.a. n.a. 36"
40" 7.0 7.3 7.7 8.0 8.3 8.7 n.a. n.a. n.a. n.a. n.a. 40"
44" 7.6 8.3 8.6 9.0 9.3 n.a. n.a. n.a. n.a. n.a. 44"
8.6 9.0 9.3 9.6 n.a. n.a. n.a. n.a. n.a. 48"
Weight based on 12.9 ft long ducts 9.3 9.6 10.0 n.a. n.a. n.a. n.a. n.a. 52"
KoolDuct panel weight 0.44 lbs/ft2 9.9 10.3 n.a. n.a. n.a. n.a. n.a. 56"
Reinforcement based on low pressure (2 in.w.g Pascal) 10.6 n.a. n.a. n.a. n.a. n.a. 60"
n.a. n.a. n.a. n.a. n.a. 64"
n.a. n.a. n.a. n.a. 68"
n.a. n.a. n.a. 72"
Weight based on 4 ft long ducts n.a. n.a. 76"
Reinforcement based on low pressure (1 in.w.g.) n.a. 80"
86
The Kingspan System

Training Manual

Chapter 6

Maintenance and External Ductwork

87
The Kingspan System
Cleaning KoolDuct
KoolDuct ductwork shall be cleaned in accordance to the Guide of Good Practice
HVCA TR/19 or NADCA. Dry Cleaning and non-abrasive methods only :

Dry Cleaning Method Energy Source Method of Removing Deposit

Mechanical

Rotary Brushing (A) Compressed Brushing the duct surface

- soft brush only air/Electricity

Air Whip/Skipper Ball (A) Low volume Directional jet nozzle on the
- plastic ball only compressed air end of a flexible hose

Air Lance (A) Low volume Air gun with a trigger to direct
compressed air compressed air locally

Manual
Hand Wipe Manual Wiping of duct surface

Hand brushing Manual Sweeping the duct surface

–soft brush only with a brush and collection
device
Hand Vacuum Electricity/Manual Removal of deposit by means
of vacuum

Where Note (A) appears, particulates should be collected using an air movement and
containment machine with appropriate filtration for contaminants.

KoolDuct is unsuitable for Wet Cleaning methods and any technique considered to
be abrasive such as hard brushing, scraping or high pressure systems.

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Building Management Systems
Building Management Systems include sensors / controllers that may need to be
installed inside/outside the ductwork to monitor temperature, pressure and other
parameter of the HVAC system.

These sensors / controllers typically have a mounting plate with mounting holes
and are fixed to steel ductwork using screws.
A hole is also drilled into the ductwork to allow the insertion of the measuring
probe.

With ductwork fabricated from the KoolDuct system, a protective metal plate
needs to be installed inside the ductwork using adhesive/sealant before the
sensor / controller is fixed to the outside KoolDuct ductwork wall, so that the
insulating panel is protected by the sandwich type of installation - mounting plate
outside KoolDuct, metal plate inside KoolDuct.
Once the protective metal plate is installed, standard fixing operation can follow
(e.g. drilling, fixing screws).

In case the sensor / controller needs to be installed after the duct is already in
place, an access door will be required on KoolDuct, to allow the above mentioned
installation.

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Damage Repair
Superficial damage can be repaired with UL tape only
More substantial damage can be cut out and replaced.

Silicone # 231G

Add Tiger Clips #364

Aluminum Tape

Aluminum Tape

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Protective treatment and External ductwork
Internal Installation
No special treatment required for conventional internal installations

External Installation
Ductwork subjected to the elements must be weather proofed.
Kingspan preferred finishes should be applied in factory controlled conditions and shall
be either

a) self-adhesive foil laminate (e.g. Venture Clad by 3M or equivalent) :

b) cladding of either aluminum-zinc coated steel sheet 24 gage (0.7 mm) typical (e.g.
Dobel Aluzinc or equivalent); or
c) fibre reinforced plastic (e.g. Fibaroll by FTI or equivalent)

The chosen finish shall be installed in accordance with the manufacturer’s instructions
Note that all external couplings must be fully sealed.

Painting
Kingspan KoolDuct System can be painted for decorative purposes with paint that it is
compatible with aluminum.

Please bear in mind the project specification with regards to fire performance
requirements of the duct when selecting the paint.

Note: that paint is not an acceptable weatherproof solution for external installations

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Training Manual

Appendixes

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Appendix 1

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Appendix 2

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Appendix 3
Commissioning

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Appendix 3

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Bibliografy
The Kingspan KoolDuct System
Kingspan Insulation, The Kingspan KoolDuct System - Fabrication Manual
Kingspan Insulation, The Kingspan KoolDuct System - A Specifier’s Guide
Kingspan Insulation, The Kingspan KoolDuct System – Technical Data Sheet
Kingspan Insulation,Technical Note, Ductwork Commissioning And Testing

HVAC Ductwork
ASHRAE Handbook, HVAC Systems, Chapter 18 “Duct Construction”, 2008
ASHRAE Handbook, Fundamentals, Chapter 21 “Duct Design”, 2009
BESA, DW /144 - Specification for Sheet Metal Ductwork, 2013
BESA, DW /143 - Specification for Ductwork Leakage Testing, 2000
BESA TR19 Internal Cleanliness of Ventilation Systems, 2013
BSRIA, Commissioning Air Systems, 2013
BSRIA, Structural Fixings for Ductwork Systems, 2010
CIBSE Guide B2-Ventilation and Ductwork, 2016
NADCA – Introduction to HVAC systems cleaning services, 2005
NADCA – Assessment cleaning and restoration of HVAC systems, 2006
SMACNA - HVAC Systems Duct Design, 2006
SMACNA - HVAC Duct Construction Standards, Metal and flexible, 2005
SMACNA - HVAC Air Duct Leakage Test Manual, 2012
SMACNA – Phenolic Duct Construction Standards, 2015
TIMSA TGN3 - Thermal Insulation of H & V Ductwork, 1998

Standards
ANSI/ASHRAE/IES Standard 90.1, Chapter 6 “Heating, Ventilating, and Air
Conditioning”, 2010
BS EN 13403 - Ventilation for Buildings - Non-metallic ducts - Ductwork made from
insulation ductboards
BS EN 12097 - Ventilation for buildings - Ductwork - Requirements to facilitate
maintenance (access panels and openings)
BS EN 15780 - Ventilation for buildings - Ductwork - Cleanliness of ventilation systems
BS 9999 - Fire precautions - Air-Conditioning Ductwork
IECC - International Energy Conservation Code, 2012
IMC - International Mechanical Code, Chapter 6 “Duct Systems”, 2012
NFPA 90A - Standard for the Installation of Air-Conditioning and Ventilating Systems
NFPA 90B - Standard for the Installation of Warm Air Heating and Air-Conditioning
Systems
UL 181 – Standard for Safety - Factory-Made Air Ducts and Air Connectors, 2013

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