A key way to save money on your electrical bills is to make sure your home’s heating and cooling system is working as efficiently as possible. One easy, inexpensive DIY change you can make is to wrap exposed, bare ductwork with insulation to minimize heat loss.
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In this guide, we’ll explore the process of insulating ductwork, drawing insights from This Old House plumbing and heating expert Richard Trethewey. In the video, Trethewey helps a homeowner insulate his ductwork, demonstrating key techniques to use and what to take into consideration.
Insulating your ductwork is more than just a home improvement task — it’s an investment in your home’s comfort and energy efficiency. Here’s why duct insulation matters.
Uninsulated ducts can lose a significant amount of heat as air travels through them, especially in unconditioned spaces like attics or crawl spaces. This heat loss forces your heating system to work harder, consuming more energy and increasing your utility bills. Insulating the ducts helps contain the heat within the system, directing it to where it’s needed.
When ducts are properly insulated, the heated or cooled air maintains its temperature as it travels through the system. This results in more consistent temperatures throughout your home and faster heating or cooling of rooms. Homeowners will immediately notice improved comfort levels, with rooms reaching desired temperatures more quickly and maintaining them longer.
In cooling systems, insulation helps prevent condensation on the exterior of ducts. This is particularly important in humid climates, where moisture can lead to mold growth and potential structural damage. Condensation can also result in the deterioration of duct material over time.
Before you start, have a look at the current state of your ducts to see what they need.
Most homes have either flexible or rigid ductwork. Flexible ducts are typically made of wire coil covered with flexible plastic and insulation, while rigid ducts are usually constructed from sheet metal. The type of duct you have will influence the insulation method you choose. Rigid ducts, for instance, often require more precise cutting and fitting of insulation.
The location of the ductwork also matters. In the video, Trethewey works on exposed ductwork leading from a forced-air furnace to ducts in the basement ceiling. Attempting to insulate internal ductwork is a far more involved project that may involve cutting into walls. We recommend consulting a licensed contractor or HVAC specialist for that project.
Inspect your ducts for any visible gaps, holes, or disconnected sections. Sealing these leaks before insulating maximizes energy efficiency. As part of insulation installation, you’ll use a combination of mastic sealant and foil tape to address any leaks you find. Ensuring your ducts are leak-free will prevent the loss of conditioned air and improve the overall performance of your HVAC system.
If your ducts already have some insulation, assess its condition. Over time, insulation can deteriorate or become less effective, necessitating reinforcement. You may need to replace old, compressed, or damaged insulation entirely to ensure optimal HVAC performance.
Before you start cutting and fitting duct insulation, take the time to gather the necessary materials and clean the space.
Here’s what you’ll need for this project. The amount of insulation, tape, and mastic will depend on the length of ductwork that needs covering.
Ensure the exterior of the ducts is clean and free from dust or debris. This will help the tape and mastic adhere properly and prevent any contaminants from being trapped beneath the new insulation. You’ll also have less dust on your hands and clothes when you go to fit the insulation.
Adding insulation isn’t the only quick fix for improving your forced-air HVAC system. Trethewey shows how reducing the blower speed can improve overall system efficiency. The air takes a little longer to go through the furnace, which means it’s warmer by the time it gets to the ducts. Adjusting your system settings to match the insulated ducts can enhance performance and energy savings.
With the ducts prepared and materials gathered, you can start the process of applying new insulation.
By sealing the seams, you reduce the risk of conditioned air escaping and unconditioned air infiltrating the system.
Properly measure the insulation from the roll before you cut it. This ensures that it fits snugly around the ducts without gaps and keeps you from wasting materials.
Securing open edges will be easier if you have a helper to hold it closed while you tape. As you tape, avoid compressing the insulation, which will make it less effective.
Use preformed insulation for ducts that are difficult to access on all sides. When purchasing it, make sure you get a size that matches the diameter of your ducts.
Insulating ductwork isn’t always as simple as the video illustrates. Depending on the condition and layout of your ducts, you may run into the following situations.
Flexible ducts often come pre-insulated. However, if you need to add insulation:
Flexible ducts should be handled carefully to maintain their original shape and function while adding insulation.
Unconditioned spaces — that is, those not directly heated or cooled by your HVAC system — require higher insulation standards to prevent energy loss and condensation. When insulating ducts in attics, crawl spaces, or other unconditioned areas:
To ensure your duct insulation project is successful, avoid these common mistakes.
When wrapping ducts with insulation, ensure that seams overlap by about 2 inches. Inadequate overlap can lead to gaps, reducing the insulation’s effectiveness.
Address any existing damage to ducts or old insulation before starting your project. Ignoring issues like holes or compressed insulation can undermine your efforts. Problems with the ducts themselves will also be more difficult to access once surrounded by insulation.
Avoid compressing the insulation during installation, as this reduces its R-value and overall effectiveness. The air within the fiberglass is actually part of the barrier that prevents heat loss or gain. Allow enough space for the insulation to expand fully and perform optimally.
Proper maintenance increases the longevity and effectiveness of your insulated ductwork. Regular inspections and prompt attention to any issues can keep your system running efficiently.
Conduct visual inspections of your insulated ducts at least once a year. Look for the following:
If you notice any problems during your inspections, take action immediately.
We recommend having your HVAC system, including the ductwork, professionally inspected and serviced annually. This can help identify and address any issues before they become major problems. Many homeowners choose to do this in the fall so that their system is tuned up and in good shape before the cold weather hits.
If your exposed ductwork lacks insulation, or if the existing insulation is in poor condition, installing new insulation yourself can make a dramatic difference in your HVAC system’s efficiency. This project should also make your home more comfortable and decrease your utility bills. Ultimately, an HVAC system that doesn’t have to work as hard will have a longer lifespan, so you won’t need to take on the expense of replacing it quite as soon.
Ducts are a series of interconnecting network that helps conditioned air travel to the nook and crannies of your home. With a forced heating and cooling system being used in most of the houses in the UK, you need to ensure that you get the most out of the energy you spend to warm or condition the air indoors.
While insulating lofts, walls, roof and floor insulation are sure-shot ways to keep the heat indoors, we must remember that the smallest of gaps is sufficient for the warm air to escape. These tiny gaps, when left undetected, probably cause the most damage. Small holes or gaps, in wall insulation, may be easy to spot, but they are not easily detected on ducts.
These tiny gaps in the insulation can make you lose nearly 20-30% of heated air, thus wasting resources and hard-earned money. With nearly 30% of heat loss, the boilers will have to work extra hard to maintain the indoor temperatures.
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Ductwork needs to be properly insulated and that is why we have put together this duct insulation material guide wherein we will be discussing the cost of installing duct insulation, materials used etc.
A neatly and properly insulated ductwork ensures that every corner of your home is warm, cosy and comfortable. Duct insulation helps maintain the right air temperatures indoors. Warm air remains at the temperature you want it to be and the stale air in every corner is efficiently sucked out.
With proper duct insulation, not only do you reduce energy bills, but you also get a fresh, relaxing indoors. Also, as you do not have to spend extra energy to re-heat the air since heat loss will be minimal, your carbon footprint will automatically reduce.
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When ducts are not installed or if they have gaps or tiny cracks in them, not only do they lose heat, but they also suck the impurities in the air and circulate it throughout your home, leading to health issues. When ducts are properly insulated and secured, such instances will be a rare occurrence.
Duct insulation prevents ducts from condensing and sweating. The ducting network that pretty much runs in every corner of your house also runs by uninsulated spaces like garages or crawl spaces.
When the warm air passing through an uninsulated duct travels through spaces with little to no insulation, it will lose heat and condense. Condensation on ductwork could damage the floor, walls or roofs etc.
Since duct insulation acts as a protective cover around the ductwork, they increase the dew point, which eliminates condensation. Plus, most of the duct insulating materials like ductwrap and duct boards have factory-applied foil-facings, which act as a moisture barrier.
Duct insulation ensures that not only your ducts but your entire H&V system functions to its optimal potential. With improved energy efficiency, the H&V system will not be under too much stress and will perform better for a longer period.
Ductwrap insulation is probably the cheapest duct insulation out there. It is insulation on a roll that is very easy to work with. Ductwrap is typically made of fibreglass or mineral wool.
They are mostly used to insulate oval or circular ductwork but can also be used to insulate square and rectangular-shared ducts. Additionally, ductwrap has factory-applied foil-facing that not only reflects heat but also acts as a continuous vapour barrier.
Ductwrap insulation is very easy to install. We have discussed the details of installing ductwrap insulation in detail, in our previous blog.
Duct Insulation by Isover from Saint Gobain is probably the cheapest ducting insulation and costs around £5-£6 per square meter. Made with top-quality glass mineral wool, this ducting insulation gives top-of-the-class thermal insulation, soundproofing, fire and vapour resistance.
At Buy Insulation Online, we stock mineral wool duct insulation by Rockwool. Rockwool duct wrap insulation is made with superior-quality mineral wool. This ductwrap insulation is supplied as a meter-wide insulation roll and costs around £6-£7 per square meter
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Ducts can also be insulated using foamed nitrile rubber insulation. Nitrile rubber insulation is flexible, easy to install and highly resistant to corrosion. This feature makes the rubber foam insulation sheet ideal for insulating all types of ductwork, especially the metal duct range. Additionally, rubber insulation is ideal for insulating cold water ductwork.
These are rigid insulation duct insulation boards made of phenolic foam, polyiso (PIR) or mineral wool. Duct insulation boards are mainly used to insulate rectangular and square-shaped ducts.
As the name suggests, these duct boards are made of mineral wool. Duct boards give superior thermal insulation at a reduced thickness. At Buy Insulation Online, we stock the following duct insulation boards:
Rockwool duct insulation board is about 1m long and 600mm wide. They give superior thermal insulation to heating and ventilation ductwork and cost about £8-£9 per square meter. They have factory-applied foil facings that not only reflect radiant heat but also give superior resistance against water ingress.
We also stock specialist insulation boards like Rockwool FirePro DuctRock that can be used in applications that require superior fire resistance. This Rockwool Insulation gives up to 2 hours of fire protection.
Another specialist duct board we stock would be Rockwool DuoDuct board. These are used to insulate external ductwork carrying warm or chilled air or dual-purpose duct systems.
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Thermaduct is basically PIR insulation for ductwork. With an unmatched and low thermal thermal conductivity of 0.023 W/mK, Therma duct insulation ensures that the heat stays inside the ducts. It means that your heated or conditioned air remains at the temperature you want them to be, as PIR insulation strictly prevents heat loss. Therma duct insulation costs around £11-£12 per square meter
Phenolic foam insulation gives exceptional insulation. With similar thermal conductivity as Therma duct boards, phenolic foam insulation boards are ideal for use in all types of ductwork.
The cost of duct insulation varies depending on the types of ductwork you have and the insulating material you choose. Typically it maps out to be in the range of £900 - £.
If you have special insulation requirements like superior fire resistance etc, then obviously the cost of installation will be greater.
Some factors that affect the cost of duct insulation are
One of the factors that greatly affect the cost of installing duct insulation is the material you choose. The cost of insulating ductwork could be less if you use ductwrap insulation and more by using duct boards.
Duct insulation could be an easy DIY task. However, if you are not a competent DIYer or if ductwork is not easily accessible, then insulating it can be a messy or rather tedious job. It is best left to professionals, which adds to the cost of installing duct insulation.
Also, if you plan on saving money by installing duct insulation yourself, do not forget to factor in the expenses for protective gear like masks, gloves, cutting tools, or duct insulation accessories like duct identification labels, foil tapes or duct tapes.
The more ducts you have to insulate, the greater will be your costs. Insulation will also depend on the thickness of your ductwork, as they must be calculated according to the required building regulations.
Duct Insulation can not only reduce energy bills and improve air quality, but it helps to improve the overall energy efficiency of your building. Small changes like insulating pipes and ducts could make a big difference, which you will notice when you do not have to spend too much on energy.
Though the initial cost of insulating ducts and pipes in your H&V insulation might be steep, it can easily be recouped in just a couple of years. Additionally, they improve the lifespan of your HVAC system.
For best-in-class ducting insulation, visit Buy Insulation Online. We also stock technical insulation materials like pipe insulation, valve jacket insulation and cladding insulation. With us, you will also find loft insulation rolls, insulation batts, boards and many more at highly competitive prices.
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For more information, please visit Steel And Timber Frame Phenolic Boards.