Everything You Need To Know To Find The Best Phenolic Ductwork
Phenolic Duct Specification - Thermaduct Round and Flat Oval
Installs Faster, With Smaller Crews
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InspiralR and Floval are designed to move quickly on site. Pre-insulated and delivered in long sections, they come ready to hang with no field wrapping or separate insulation required. With lightweight panels and simple connection methods, crews can install duct in tight ceilings and crawlspaces without fighting rigid metal sections or custom transitions.
Because most sections are designed and cut before delivery, teams can skip the layout guesswork and move straight to setting duct. Whether you’re working overhead or across finished spaces, fewer moving parts means fewer delays.
Easier on Crews, Especially Overhead
Anyone who's hauled 24" duct overhead knows what it does to your back. Floval and InspiralR systems are built from phenolic insulation—making them a fraction of the weight (over 70% lighter) of traditional metal duct with external wrap. That means easier lifts, safer handling, and less strain on your crew day to day.
The lightweight design also eliminates the need for oversized supports or trapeze hangers. Systems can hang cleanly with minimal supports, making them ideal for ceiling installs or long corridor runs where overhead clearance is tight.
No Special Tools, No Extra Trades
InspiralR and Floval can be installed using common hand tools—no sheet metal brakes, no pin spotters, and no field-fabricated insulation. Everything needed for assembly is included: flanges, sealants, gaskets, or adhesives depending on the system.
For project managers and foremen, this means less dependency on specialized labor. Crews familiar with duct installation can assemble phenolic systems with minimal training (we have a brief online training video) or adding insulators to the job. It’s ductwork—just streamlined.
Sealed from the Start
InspiralR and Floval are designed to meet or exceed SMACNA phenolic duct construction standards, including low-leakage performance for both pressure and return systems. With tight seals at the flanged joints and no exposed liner to fail, airflow stays where it belongs.
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That means fewer adjustments during balancing, more predictable system performance, and peace of mind knowing you won’t need to revisit joints that fail under pressure testing.
Ideal for Finished Interiors and Space-Constrained Projects
Floval’s flat oval design is ideal for corridors, drop ceilings, or tight plenum spaces where rectangular duct doesn’t fit and spiral might hang too low. InspiralR is well suited for straight runs and vertical drops that benefit from a round form with cleaner airflow.
Both systems are built for low-profile installs—pre-insulated, clean-looking, and field paintable for retrofits, schools, hospitals, and interior renovations. No wrap, no mess, and less disruption to building occupants.
Phenolic Duct Systems: Pros and Cons - JADE Learning
Phenolic Duct Systems: Pros and Cons
By: JADE Learning | Jan 06,
Phenolic insulation is an alternative to galvanized sheet metal. Many HVAC professionals have turned to this option when installing or replacing duct systems. Learn about some of the pros and cons of phenolic duct systems to determine if it might be right for your project.
Pros of Phenolic Duct Systems
Some of the advantages that make a phenolic duct system viable for HVAC professionals include:
- Lighter weight. Phenolic duct systems weigh considerably less than steel or fiberglass systems. The reduced weight of phenolic systems is ideal for replacement projects in old buildings that may have a hard time supporting the weight of a metal system.
- Longer sections. Phenolic duct systems come in longer lengths than metal, making them easier and faster to transport and install.
- Saves space. Because there’s no need to install a separate layer of insulation on a phenolic setup, it can be installed flush against ceilings, walls, and floors.
- Easy to modify. Phenolic systems are flexible and easy to modify to adapt to unusual designs and improvisations.
- Easy to integrate. Phenolic systems can easily integrate with existing metal duct work, so you don’t need to tear down an entire system just to replace one particular section.
- Easy to install. Phenolic ducts are a single-fix installation with no need to install insulation as a separate step, saving both time and money during the installation process.
For home and building owners, using a phenolic duct system brings a host of additional benefits such as fire and smoke resistance, low air leakage, better air quality, and increased efficiency and energy savings.
Cons of Phenolic Duct Systems
The many benefits of phenolic duct systems easily outweigh the few disadvantages, which include:
- Strength and durability. The alternative, galvanized metal duct systems, are strong and durable and provide a long-lasting system that is difficult to puncture or damage.
- Commonality. While phenolic ducts are rising in popularity, traditional metal systems remain the most common. As such, the materials and labor may be easier to come by for traditional systems.
Improve Your HVAC Knowledge
The tradeoffs of phenolic duct systems are just one of the many things you can learn from HVAC continuing education from JADE Learning. Learn more about how JADE Learning helps thousands of HVAC professionals renew their license every year and how we can help you, too.
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