New PROflex Master Rolls in Various Lengths: Now Available

Posted on by Ductmate Industries

You asked, we listened! Ductmate now offers PROflex master rolls in various lengths (1000 ft, 750 ft, 500 ft).  You can expect the same high-quality and customizable options from our master rolls as our standard 100 ft PROflex cartons.

What is PROflex?

PROflex is a flexible duct connector designed to isolate equipment noise and vibration from the ductwork, consisting of a fabric secured to sheet metal on both sides. Typically, the connector is inserted between the equipment and the ductwork.

Flexible duct connectors are widely used in commercial, industrial, and residential HVAC applications.  PROflex offers the following special characteristics:

  • Airtight and waterproof at 10 w.g. positive and negative
  • Double-lock gripping fingers of metal to fabric adds to holding power
  • Designed to meet NFPA 90A and 90B specifications
  • Pre-assembled with sheet metal permanently secured to the fabric
  • Fabrics are NFPA 701 listed (except Teflon®)
  • Available in six fabrics and five alloys for any configuration
  • Fabrics include UL Listed and LA Approved Super Duty Vinyl

How can PROflex master rolls increase efficiency and labor savings while reducing scrap?

PROflex master rolls, when used in conjunction with any automated flexible duct connector machinery, will significantly reduce labor time and machine downtime, resulting in notable labor savings on every project.  With less machine downtime and changeover time, your shop efficiency will skyrocket.  When PROflex master rolls are placed on a skid, loading and unloading with a forklift is a breeze, resulting in additional time savings.

PROflex master rolls are perfect for larger shops that use a large amount of flexible duct connectors.  The more you use, the more you save.

A PROflex 1000 ft master roll will significantly reduce the scrap produced compared to the standard 100 ft roll.  Over the course of a few projects, the amount of scrap coming from a standard 100 ft PROflex roll could add up to the cost of another standard 100 ft PROflex box.

An automated flexible duct connector machine used with PROflex master rolls will also allow you to take the guesswork and the possibility of user error out of the cutting process.

What if I need a smaller length of PROflex?

If you need a smaller length of PROflex, that’s not a problem!  We’ll work with your needs to minimize scrap.

Typically, PROflex is sold at a standard 100 ft length and is available with or without metal attached in various widths.

We understand that 1000 ft master rolls may be too much for most, so PROflex is also sold in multiple lengths, including 500 ft and 750 ft.

Can I customize my order of PROflex?

PROflex is available in six fabrics and five alloys for any configuration.  Specialty fabrics include UL Listed and LA Approved Super Duty Vinyl.   PROflex metals are available in galvanized, stainless, aluminum, and more.  For other alloys, fabric sizes, or chemical-resistant properties, consult your nearest Ductmate distributor.

As always, we’re happy to work with you to deliver the products you need.

Where can I buy PROflex?

Ready to buy PROflex? Ductmate products are available at over 350 locations across the US as part of a selective distribution network.  Use the Ductmate distributor locator map to find a distributor near you.

What is the QPA score of your Sealants & Adhesives?

Posted on by Ductmate Industries

At Ductmate Industries, we take our Quality, Performance, and Availability (QPA) score very seriously when formulating our HVAC Sealants and Adhesives lines.

Quality: Ductmate Industries uses only high-quality polymers and raw materials to formulate its water-based sealants and adhesives, reducing fillers and thickeners that build up and cause excessive amounts of product to be applied. This results in a line of water-based products that go on smoothly and even, providing exceptional coverage, ultimately reducing your overall material and labor costs.

Performance: The high-performance characteristics of our formulas and polymers are also second to none. Our Sealants and Adhesives are engineered to meet or exceed the most demanding industry codes and standards, yet are environmentally friendly, sustainable and LEED compliant. When you count on getting the job done right the first time, Ductmate sealants & adhesives are the number one choice.

Availability: With manpower, raw material and supply chain issues facing the construction industry, Ductmate Industry has the right solutions to meet these challenges. Ductmate has Sealants and Adhesives products for virtually any HVAC application.

If you want high Quality, Performance, readily available water-based duct sealant, anti-microbial coating, duct liner adhesive, and a wide range of other products for your HVAC project, you will find the solution you need when you need it at Ductmate Industries.

For more product information or technical assistance, browse our full line of products now. To find an authorized Ductmate distributor near you, please see our Find a Distributor page. For any other questions, please contact Ductmate Customer Service today at orders@ductmate.com or 1-800-245-3188.

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PolyArmor™ Now Available in 3″ Thickness

Posted on by Ductmate Industries

Demanding Mega-Tech HVAC System? Don’t Sweat It!

When mega tech companies have demanding HVAC systems, they look for a high-performance insulation that won’t sweat under the pressure of extreme temperature variations – they look to PolyArmor™ from Ductmate Industries. Now this high-performance, user-friendly, polyester line of insulations has been expanded to address the latest code requirements with its New R12 – 3” Thick PolyArmor Insulation.  The new 3” PolyArmor embodies all of the high-performance characteristics that have made PolyArmor the specified Insulation for some of the biggest tech companies. Despite its thickness, PolyArmor is still a user friendly, light weight, non-irritating insulation, designed to reduce energy costs and cold tracking in some of the most demanding, extreme HVAC conditions at a very competitive price. When you need an insulation that addresses the most challenging environmental and critical conditions like hospitals, schools, universities, and tech data centers, Don’t Sweat It! Choose PolyArmor from Ductmate Industries.

  • New IECC and ASHRAE codes are now requiring an R-12 thermal value for climate zones 5-8 (Northeast, Midwest (north of Kansas City), Rocky Mountains, and the Northwest)
  • Meets all 3” duct liner thermal resistance requirements and provides excellent sound absorption
  • Fiberglass free alternative, user friendly, and hypoallergenic polyester material
  • Extremely durable FSK facing and does not promote or support growth of mold or mildew
  • Made of 25% recycled Zero VOC material for increased sustainability
  • Job Specific orders only available in 50’ Rolls and widths of, 47.5”, 48”, 56.25”, 59”, & 60”
  • Use with Zero VOCs water-based adhesive & 2.75” insulated cap weld pins

R-Value, Thickness, and Width

WidthR-12
3" x 50'
47.5"PA475F3W50
48"PA48F3W50
56.25"PA5625F3W50
59"PA59F3W50
60"PA60F3W50

 

Get to Know Your Water-Based Duct Sealants

water based duct sealant

Posted on by Ductmate Industries

Technical Data Sheets – From Confusion to Clarity

Technical Data Sheets (TDS) related to water-based duct sealants can be just as intimidating as synonyms for the first word in the acronym, erudite or abstruse. These data sheets are provided to give specifics about the performance of each product for better product selection. However, the list of standards (NFPA 90A and 90B or ASTM C794), complex acronyms (TVOC Emissions CDPH Standard Method v1.1), and scientific units (cps or PLI) could leave the average person confused and allowing price to be the leading factor during selection. The truth is that engineers provide this information because they are truly dedicated to the product they worked very hard to develop, and would like to share all of the technical information possible explaining the positive attributes of the sealant itself. Ductmate understands that this information is not the easiest to grasp, and therefore, this article aims to describe a few key test specifications that may not be so obvious to understand at first glance.

Solid Content is one of the most misunderstood specifications most duct sealant manufacturers report on their technical data sheets. In most cases, more is better (unless you are playing golf). Solid content is a lot like your ideal golf game. Water-based duct sealants start out with a polymer that is the backbone of any formulation. These polymers are between 50-55% solids (the other 45-50% is water). To get the solid content to reach “typical” levels of 60-80% for the average sealant, 100% solid fillers are added. These fillers will reduce the water content in the formulation leading to quicker dry times and reduced cost, but most fillers provide little performance characteristics and will eventually lead to negative returns when added at an elevated level.

For the sealant to maintain other critical performance characteristics like flexibility and adhesion, there must be enough polymer in the formulation to hold all of the filler together. Envision a ball pit or a sandbox. In either case, it would be very difficult to cover the entire surface area of the particles without reducing the amount of those particles present. Ideally, a combination of large particles and smaller particles lends to better packing of the fillers.

This allows for the dried sealant to be a strong, flexible coating that will hold up to the harsh conditions a duct system may go through during its lifetime (vibrations, expansion/contraction as air begins to fill the duct, or transferring between cold and hot conditions). Sealants that contain too much filler, or only one size of filler, could result in cracking and poor adhesion. Just think, if there is not enough polymer to surround all of the filler present, how will there be enough to bind to the steel or hold all of the particles together during movement? Flexibility and adhesion are perhaps the two most important characteristics of any duct sealant. These characteristics can be accidentally ignored when choosing a duct sealant based on a high solid content.

Tricks of the Statistics: Solid Content can be linked to performance characteristics like Flexibility and Adhesion, but they are also typically proportional to other common specifications on a technical data sheet. For instance, when the solid content is in the 70-80% range, the density (how many lbs. are in a one-gallon pail) is also typically higher. This could lead to higher shipping costs. Viscosity is also typically affected at high solid content levels. The higher the solid content, the thicker the sealant tends to be. If the product is too thick, the sealant will be harder to brush. In this case, excess sealant is often used driving up the cost of the job.

Below is a table breaking down some key technical data and how each relates directly to a Ductmate Water-Based Sealant. We hope this chart can help end users select which sealant is right for their own use. For example, if you want a product with great adhesion to steel, is easily spreadable, LEED compliant, and matches the color of steel = EVERseal. If you want a product that adheres very well to multiple substrates, is great for outdoor use, can be used in high pressure systems, and is LEED compliant = PROseal. If you want a premium product that is also sprayable = PROseal Spray.

Ductmate SealantsAdhesion to MetalAdhesion to Flexible Duct ConnectorsFlexibilityOutdoor ApplicationsBrush DragSag Resistance<15" Water GaugeLEED CompliantFiber TextureSprayableColor Match to Galvanized Steel
PROseal

•••

•••

•••

•••

••

•••

•••

YesNoNo

•
FIBERseal

•••

•••

•••

•••

••

•••

•••

YesYesNo

•
EVERseal

•••

••

•••

••

•••

••

••

YesNoNo

••
EZseal

•••

••

•••

••

•••

••

••

YesYesNo

••
PROseal Spray

•••

•••

•••

•••

n/a

•

•••

YesNoYes

•

••• = Excellent
•• = Above Average
• = Standard

For more information, please visit our Water-Based Sealant page or to download Technical Data Sheets for any of our products, please browse our Technical Resources page.

 

Ductmate 45 Industrial Duct Connector on the Fast Track in LA

Posted on by Ductmate Industries

Contractors Turn to Ductmate’s Industrial Duct Connector for City of L.A. Transit Station Project.

The Los Angeles County California Metro is amongst the nation’s largest and premier transportation agencies, and it serves as transportation planner, coordinator, designer, builder, and operator for one of the country’s largest, most densely populated and developed counties. More than 9.6 million people – nearly one-third of California’s residents – live, work, and play within their 1,433-square-mile service area. Beginning in 2014, the LA Metro began an ambitious project to extend their existing Crenshaw/LAX transit line to better serve the cities of Los Angeles, Inglewood, El Segundo, and portions of unincorporated Los Angeles County.  This would extend the existing Metro E Line at Crenshaw and Exposition Boulevards in Los Angeles and merge it with the Metro C (Green) Line at the Aviation/LAX Station on Aviation Boulevard and Interstate 105 in the City of El Segundo.

The new state of the art Metro Rail extension would offer an alternative transportation option to congested roadways and provide significant environmental benefits, economic development, and employment opportunities throughout Los Angeles County. Riders will be able to make easy connections within the entire Metro Rail system, municipal bus lines, and other regional transportation services. Equally important, it will dramatically reduce travel times, inefficiencies, and lower transportation costs while improving the quality of life for commuters and residents as well as benefiting the surrounding environment. The ability to foresee such an innovative concept, let alone engineer such a monumental and technically complex project that would ultimately result in such a vast number of socioeconomic solutions, is hard to put into words.

It was the underground stations where Metro had a particularly challenging objective. Tunneling under countless buildings and congested streets overhead in a seismically active area, engineers and contractors had to bring in fresh air for the passengers waiting to board. At this point, the HVAC Contracting Companies of Limbach and Superior Duct were tasked with sourcing and installing the critical air systems needed. With ductwork exceeding 45 square feet in 20’ sections, the contractors had to be extremely selective in the connection system they would use on the job. It would be imperative they complete their work in a timely fashion to ensure the project kept moving and on schedule. Because of the unique belowground operation, the HVAC system has to withstand very rigorous operating standards, as well as meet the engineering standards for catastrophic events such as an earthquake. The ductwork would have to tolerate up to 14” positive and negative pressure and operating temperatures exceeding 480 degrees.

“Because we have so many types of construction, it requires so many types of specialties. The construction managers all have to have different types of training, and coordinating that to make sure we have the right resources at the project at the right time based on what’s going on – that’s a complexity for us, and something we have to manage.”

– Stephanie Leslie | Deputy Executive Officer, Construction

One of the key points the contractors have stressed as a primary reason for turning to Ductmate Industries, and making the switch from companion angle frames to Ductmate 45 Industrial Rectangular Duct Connector System on this project, is the universal acceptance of the Ductmate Brand, the product’s performance, and the engineering and technical support behind the product.

The Ductmate 35 and Ductmate 45 Rectangular Duct Connector Systems both were designed and engineered to increase the overall performance (airtight and structural integrity) of commercial and industrial HVAC systems, and are the most independently tested and widely used connector systems in the world. Ductmate Industries’ engineering department built industrial sections of duct using the DM 45 connector system and tested it well beyond the performance requirements of the LA Metro project to confirm and support testing completed to achieve approval for this project. The Ductmate Connection system has been through rigorous shaker testing and simulations specifically for critical projects in earthquake prone regions. Also, because of the extremely high temperature requirements of this project, a specialized silicone sealant was used between the flange faces at each 20’ duct joint. The silicone sealant worked perfectly with the Ductmate 45 System and achieved optimal results for this high temperature application.

In addition to the high-performance characteristics of the Ductmate system, possibly the most compelling reason the product was selected was the inherent cost savings associated with the Ductmate 45 system versus companion angle flanges. The fabrication of connections for HVAC systems utilizing companion angle is an egregiously labor-intensive process. Although project specifications can vary from project to project, in general companion angle is hard to cut, requires countless number of holes to be drilled, must be painted to prevent rust, requires certified welders to join angle together and to attach to the duct wall, and then attached with equally countless number of nuts and bolts.  Ductmate 45 is a self-sealing slide-on connector system where no welding is needed to achieve an airtight seal. Its 4 -bolt design with optional bolt-on or snap-on cleat (which replaces countless nuts and bolts) makes ease of installation and airtight integrity simple, thus it has become the clear choice over labor-intensive companion angle.

Learn How To Install The Ductmate Flange Connector System

Ductmate Industries has always been viewed as the industry leader within the commercial and industrial HVAC industry. Needless to say, due to the performance characteristics and being vastly more labor-saving, the Ductmate 45 System was approved and used over the initially specified companion angle. Once approved, the contractor drew upon Bay Insulation/CWCI for just-in-time delivery and service to ensure a seamless supply of Ductmate 45 components.

It is a unique project like the Crenshaw/LAX Transit Stations where the versatility and quality of Ductmate products and its engineering staff truly shine. For over 40 years, Ductmate has been partnering with companies in the commercial and industrial HVAC space to solve challenging and unique mechanical problems in every conceivable alloy. Ductmate products have been installed in virtually every type of commercial and industrial HVAC system imaginable including transportation hubs,  data centers, waste-water treatment plants, processing plants, and countless other project types for companies such as Google, Microsoft, Facebook and Disney, to name a few.  Upon the project’s expected completion in 2021, the LA Transit line will be one of the most advanced, efficient, safest, and environmentally friendly transit systems in the world, consisting of 3 underground terminal stations and miles of below and above grade track.  Ductmate Industries is proud to assist in making this project a success.

Crenshaw/LAX Metro Update Video | The Ductmate 45 Flange Connection System Can Be Seen Throughout

Sources:
Crenshaw/LAX Metro Website

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Clean HVAC Preventative Measures & Ductmate Solutions You Can Clearly See

Posted on by Ductmate Industries

The Fight for Indoor Air Quality Is Critical, and Ductmate Products Offer a Clear Advantage

Originally designed for use in hospitals, Ductmate’s Observation doors allow you to be vigilant over your air filtration system. Now more than ever, we must ensure our work environments are protected against harmful, air-borne substances. The Sandwich® Observation Doors are constructed from precision-stamped steel and high-impact safety glass to be used in all pressure classes, including high-pressure duct systems. The patented Ductmate Sandwich® Observation Access Door design eliminates bending metal tabs, leaking frames, and worrying about scratched or worn glass; therefore, leaving you with the peace of mind that all preventative measures have been considered.

Typical In-Duct UV Light System With Ductmate Sandwich Observation Doors

“As facilities are beginning to reopen, many companies are looking to add UV technology to help address concerns over air quality, reassuring building occupants they are doing the most they can to ensure safety in the workplace.”

– Aaron Engel, VP For Business Development, Fresh-Air UV

Below is a breakdown on all the advanced feature that Ductmate Sandwich Observation Doors offer over a basic viewport door.

Please visit the specific product page for more detailed information on each door.

16×12 Observation Door

AHU Observation Door

Single Pane Observation Door

Promotional pricing for all our Observation Doors is currently available please contact us today for more information or click here to find a Ductmate Distributor near you.

Click the button below If you would like a digital version of this information.

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Spiralmate Round Duct Connector System Working Great in South Dakota

Spiralmate completing a round duct connection

Posted on by Ductmate Industries

The Prairie Lakes Wellness Center in Watertown, SD, a modern community center conveniently located in the fastest-growing area of Watertown, opened in April 2017 and features 104,000 square feet of space. The $24 million multi-level facility features multiple basketball courts, racquetball courts, a running track, a sauna and whirlpool, a large fitness area, and a state-of-the-art pool area that includes a leisure pool and a competition pool.

Choosing the Right System for Aesthetics & Performance

For areas that are not exposed, rectangular, medium-pressure ductwork was chosen. For exposed areas, the Spiralmate® Round Duct Connection System was used. Ductmate Industries manufactured all the spiral connections.

Gary Chappell, Ductmate Regional Channel Manager, stated that the spiral ductwork is exposed and visible from multiple angles. On the second floor, where the ceiling downstairs is positioned at eye level, it was even more important to have an attractive product. Chappel said, “The project is aesthetically pleasing both close up and from a distance. From a performance standpoint, the system is airtight, efficient and doesn’t require any additional sealing.”

Jon Burri, Vice President at Creative Metal Solutions, the specifier and fabricator for this project, said everything went very smoothly on the job site. “We made custom lengths in the shop and delivered them to the jobsite, ranging in size from as large as 42” in diameter to as small as 10” in diameter. Large amounts of 28-32” ductwork were installed above the track, and 18-20” inch segments were installed in the workout areas.”

The ductwork in the pool area was constructed from double-walled aluminum to reduce the sound of the airflow from spectators and prevent corrosion from the harsh pool environment. Galvanized steel was used on all the ductwork in other areas.

MacArthur Co. was the distributor for this project. According to Chappell, “They have been a great asset and long-standing Ductmate distributor in Sioux Falls.”

Burri said that a couple of trailers of product were sent to the jobsite on and off for about six months. “We delivered in phases so that a lot of room wasn’t needed to store product during the entire job,” he said.

The company always recommends the Spiralmate® system because, Burri said, “The cost is always justified with savings in field installation time and cost, and it allows for an air-tight system that looks great.”

Faster Installation, Big Labor Savings
Active Heating, Inc., based in Watertown, S.D., was the HVAC contractor. Jason Roehrich, Vice President at the company, said the installation of the Spiralmate® system is usually fast, but this project went even faster than normal.

“The finished job features a wide-open, exposed look with neat, straight long runs,” he said. “In one area, we had a run of 100-150 feet with a 90-degree turn into another long run of about 300 feet, and it looks great.”

Roehrich added, “Our installers in the field really like the Spiralmate® system because it quickly snaps in place, provides a great seal, installs faster than other products, and it provides a straight, clean look when it’s finished.”

Another advantage of the system is that when a piece of ductwork is cut down in size, the flange can be removed and reused—unlike with other systems. This saves even more time and money.

The result was a successful project for Ductmate and everyone else involved. The state-of-the-art Prairie Lakes Wellness Center features an HVAC system that’s pleasing to the eye, energy-efficient, and will perform well for many years to come.

PROseal Spray Duct Sealant Shortens Application Time by 50%

Sprayable HVAC duct sealant - PROseal Spray

Posted on by Ductmate Industries

Studies and testing have demonstrated that heating and cooling systems can lose up to 30% of their efficiency due to leaks in the duct joints and seams. One solution is to seal the ductwork at the joints with gasket material supplied by the manufacturer. Another is the application of duct sealant that can be applied at the joints as well as duct seams for a tight connection.

New standards in the building industry now require all ducting to be sealed to prevent air leakage. Not only does it save energy, low leakage reduces the load on the heating and cooling equipment.

Scott Schindler, owner of Schindler Heating & A/C, Inc., runs his business in Boonville, IN. For over 15 years he has installed and serviced air conditioning and heating equipment in southern Indiana.

Schindler has four employees and works primarily on residential and light commercial housing. As a businessman, he believes every job he does gets 110% of his efforts—a main reason he is the HVAC installer choice for many of the largest builders in his area.

Schindler has used Ductmate’s PROseal mastic for many years. Like most duct sealants, it is applied manually and can take an entire day to finish one house. The results were always good, but if you are not careful you can wear as much as you apply.

While picking up materials at Wilhite Supply Co, his local Ductmate distributor, Schindler was introduced to PROseal Spray, Ductmate’s premium water-based, high velocity duct sealant that can be applied using a wide range of sealant application equipment. It was love at first sight!

“I’m somewhat of a tool nut and am interested in anything mechanical,” said Schindler. “The fact that you can apply duct sealant using a spray system really intrigued me; five minutes later I was a believer.”

Schindler had investigated other brands of spray mastics as well but found one major problem. Most sealant manufacturers strongly recommended using their spray system. These systems cost on average $7,500 a unit, a greater investment than he wanted to make.

“We found out that Ductmate’s PROseal Spray can be used with a variety of spray systems with no problems in application or performance,” said Schindler. “In the end I purchased a sprayer for $1,700, and that was even for a slightly better unit than I needed.”

Christian Nauman, Sealants & Adhesives Product Line Manager for Ductmate, says ProSeal® Spray offers contractors benefits other than speed of application. “Ductmate formulated ProSeal® Spray as an extension of our manually-applied ProSeal® product,” said Nauman. “Both are designed to seal metal and metal joints against air leaks in low, medium, and high pressure duct systems up to 15” w.g.”

ProSeal® is a premium water-based high-velocity duct sealant that is non-flammable with a low odor and low VOC off-gassing. This is important for contractors working in tight spaces for prolonged periods of time.

ProSeal® Spray has excellent adhesion to all types of metals, and will not drip or sag under normal application conditions. The sealant has a very low shrinkage rate and remains permanently flexible over the life of the product. It is also UV, water and mildew resistant, and can be used on painted latex or epoxy finishes.

Upon using the PROseal Spray for the first time Schindler said he was a little apprehensive it would work as promised because of the viscosity of mastic. It didn’t take long to convince him otherwise.

“Our sprayer has a 150 foot hose allowing us to reach most of the house without moving the unit,” Schindler remarked. “We can finish an entire house in 30 minutes compared to an entire day using manual application.”

Many of the builders Schindler works with construct Energy Star homes. These buildings have to pass strict requirements minimizing air leakage for the building as well as the HVAC ducting. Schindler sprays all seams and joints with PROseal Spray with great success.

Schindler says his duct installations always pass with ease, and the inspector says his work is the best he has ever seen.

Once finished, the spray unit must be cleaned before the mastic hardens. Schindler says all that is needed are a few gallons of hot water that he runs through the sprayer until it runs clear. Since PROseal Spray is water-based, no harsh cleaners are required.

In addition to duct sealing, Schindler has found another use for the product. With PROseal Spray’s excellent adhesive qualities, he uses it to seal holes and cracks in the building that he may come across in places like crawl spaces.

New Polyester Duct Liner Insulation Less Expensive & Reduces Installation Time

PolyArmor™ Duct Liner

Posted on by Ductmate Industries

Schreiber Foods is constructing a new corporate headquarters and global technology center in downtown Green Bay, Wisconsin. Founded in Green Bay in 1945, it is the world’s largest employee-owned dairy company. Its $50 million headquarters building spans 235,000 sq ft and reaches five stories high, featuring primarily office space. When completed, it will employ approximately 550 people in the greater Green Bay area.

The firm Hammel, Green and Abrahamson (HGA, Inc.) is an integrated architecture, engineering, and planning company responsible for designing the HVAC system, along with other mechanical systems, for the Schreiber Foods Project. HGA Senior Mechanical Engineer and Vice President Kevin Pope is the Engineer of Record on the project.

“For most ducting projects of this type, we typically specify a polyimide foam liner for the supply ducting and a fiberglass liner for the return,” Pope said. “The reason for this is any fibers coming off the fiberglass liner are captured in the air handling filtration system before it reenters the supply air. It’s also a way to keep costs down since fiberglass is less expensive and offers reasonable sound attenuation.”

The polyimide foam is typically coated with an acrylic-type polymer when used as a duct liner. The coating provides a protective barrier against dust and moisture from collecting in the duct. However, one of the drawbacks of polyimide foam is that it can be more expensive than other materials.

F. Ahern Co. is the mechanical contractor for the project, responsible for the sheet metal and other mechanical systems. J.F. Ahern Project Manager Shaun Neubauer has he need to control project costs as one of his primary functions.

“It’s part of my job to control project costs, so I begin immediately looking for alternative material choices,” Neubauer said. “We noticed immediately that the polyimide foam cost was coming in rather high, and we began investigating alternative duct liner material. We had an opportunity to meet with Ductmate Industries to compare their new PolyArmor polyester-based liner material.”

PolyArmor is new to the market, having been introduced only one and a half years ago. It is a polyester duct liner insulation used in forced-air heating, ventilation, and air conditioning systems. It is engineered to provide industry-leading R-values, with excellent noise reduction and superior indoor air quality.

The polyester material is webbed into a thermal blanket, which is then bonded with an FSK facing to resist damage during system installation and operation. It also provides excellent durability in the airstream.

Neubauer said the PolyArmor met the specification requirements, and he was pleasantly surprised with the cost estimate. Since the polyimide was specified, he submitted the PolyArmor cost saving and specifications to Pope and requested a substitution, which was approved.

F. Ahern and Neubauer have a long history working with Ductmate. Quite often, they specify other Ductmate products, such as access doors, connectors, and vane systems. Their relationship was a key factor in their decision to install the new PolyArmor liner material.

More emphasis was placed on noise reduction than on insulation values, although both were important. The PolyArmor proved excellent for sound attenuation, achieving a .65 NRC rating, while also delivering an R5 insulation value in one-inch material thickness.

Duct sizes vary, with dimensions up to 6’ by 3’, and they can handle an airflow of up to 80,000 CFM. The specifications called for the PolyArmor to be installed approximately 20’ downstream from each VAV discharge connection.

J.F. Ahern Shop Manager Chris Elwing was impressed with the installation performance of PolyArmor. With over 31 years of experience in the sheet metal industry, 13 of those with J.F. Ahern, he has seen his share of duct insulation.

“We install all duct liners at the shop and have had to use an elastomeric-type product for many of our installations,” Elwing said. “Elastomeric material is tough to work with because it’s hard to cut and shape into place. We had never used the PolyArmor liner before and discovered that it installs much faster and is easy to pin; it greatly reduced our man hours on the project.”

Elwing estimated that they installed 25,000 sq ft of the liner material, all of which was installed by hand using no coil machine. Even with the additional labor time required, he cut his installation time by 30% or more!

PolyArmor liner is installed on the duct surface using water-based adhesives. This eliminates the need for solvent-based bonding agents that emit VOCs for many years after installation. The polyester base material does not promote or support the growth of mold or mildew, making it very desirable for a healthy environment and occupant safety.

The net result was even better than expected.

“Not only did we reduce costs for the liner material, we saved another 30% on installation time, which is significant,” Neubauer commented.

Both companies agree they will use PolyArmor on future projects.

Introducing the 16×12 Double-Paned Observation Access Door

Posted on by Ductmate Industries

The 16×12 double-paned observation access door is now available!

This door was designed specifically for hospitals, clean rooms, pharmaceuticals, and laboratories to eliminate the danger of dust contaminating ductwork during inspections of in-duct smoke detectors, UVC emitters, fire and smoke dampers, and humidifiers.

Read more about this newest addition to the Sandwich® Access Door line here.