Why is the PanelDuct® system so airtight?

The patented design of the PanelDuct® system incorporates airtight seals along the length of the side profile. When pressed together, these seals prevent the passage of air.


An airtight endseal is applied to either end of the assembled duct sections, so that when they are put together, an airtight seal is present between duct sections.

How long will I have to wait before a PanelDuct® system is delivered to site?

PanelDuct® panels are premanufactured in a wide variety of sizes and are available off-the-shelf for next day delivery.

Is PanelDuct® expensive?

The level of automation of the PanelDuct® production process enables us to sell the systems at a cost that is roughly equivalent to current traditional galvanised rectangular ducting.

Is PanelDuct® the same as preinsulated rigid foam board systems?

Alternative pre-insulated ducts are readily available, but none of these are available of the shelf in a variety of widths and lengths. Nor are they push fit together systems.


These large boards are typically 2500×1250 sheets which need to be cut to size, then internally mitred to fold up into the rectangular duct shape onsite. They are usually held together with duct tape. This is labour intensive, prone to error and time consuming. These are not very durable, as their outer layer is faced with 0.025mm aluminium foil.


Sample foamboard systems were tested and compared with the performance of PanelDuct® for physical parameters and air tightness per EN 1507 and EN 15727. PanelDuct® significantly outperformed the foamboards in every metric. See certifications.

Are there uninsulated PanelDuct® panels?

 Not at this time. For now, we are considering the demand for uninsulated panels.

Are any tools or hardware required to put PanelDuct® together onsite?

Panels pushfit together without the need for hardware, tools or tapes. Assembled duct sections are adhered to each other in the same way as traditional rectangular ducting.

How does the PanelDuct® system handle onsite variations?

Easily. Panels can be resized by cutting to length. Elbows / bends can be created from straight panels using a standard H-Flange connector, or simply ordered ex-stock for next day delivery.

How difficult is it to dismantle PanelDuct® panels?

Panels easily slide back out of each other if they need to be stripped and re-assembled.

Is PanelDuct® any heavier than normal ducting?

PanelDuct® panels are effectively sandwich panels: Sheet steel outer layer, foam sandwich layer and aluminium sheet inner layer. Due to the increased stiffness inherent in a sandwich panel structure, PanelDuct® panels can be constructed with thinner sheets. So PanelDuct® panels are lighter than traditional ducting.

What is Traditional Galvanised Sheetmetal Ducting?

Non-insulated galvanised steel had been the standard form of ventilation ductwork for many years. Specifications are drawn up by engineers, detailing the shape size & routing of the required duct system. These drawings are given to the fabrication shop where a sub-contractor trims standard galvanised steel sheets to the required flat pattern, folds the material into a rectangular cross-section, joins the seam and assembles roll formed flanges on either end.


Although this represents the vast majority of installed rectangular ductwork, there are many difficulties with this system. Fully assembled ductwork is awkward to handle and move about onsite.  It requires a large amount of storage space and its bulk means that it’s expensive to deliver.


The current methods of manufacture are labour intensive and are suited to low volume, manual processes. Onsite installation consists of three separate fixes:


– metal duct installation,

– insulation wrapping, and

– cladding of external duct runs.


The time required to accomplish each of these separate activities, and the intervals between each step, can be lengthy, requiring careful co-ordination of multiple onsite contractors. It can occasionally happen that suspended ceilings are put in place, before the duct insulation is applied, requiring expensive and time consuming rework. In the event of unforeseen difficulties onsite, for example a pillar in an unexpected location, or an unexpected pipe run across the ceiling, new duct sections will need to be fabricated, contributing more time and expense to the project.


PanelDuct® has a solution to all of these difficulties.

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