Answer 1

Spiralite^® ducting is a pre-insulated non metal ductwork system fabricated by Specialist Insulation Limited using rigid phenolic insulation board instead of insulated galvanised sheet metal. In the UK Kingspan KoolDuct^® rigid phenolic insulation panels are used. The insulation panel is cut in such a way as to allow it to be formed into a complete
circular duct and sealed with a heavy duty reinforced foil tape. The internal surface is lined using an aluminium foil based laminate sealed onto itself to give a strong airtight duct system.

Its other qualities are:
• A thermal conductivity of 0.021 W/m*K at 10°C mean, the lowest of any commonly available insulation material
• Fire & smoke performance with a Class 0/Low Risk fire classification to the Building Regulations/Standards:
- BS 476-6: 1989 (Fire tests on building materials and structures. Method of test for fire propagation for products)
- BS 476-7: 1997 (Fire tests on building materials and structures. Method of test to determine the classification of the surface spread of flame of products)
• < 5% smoke obscuration when tested to BS 5111-1: 1974
• > 90% closed cell content making it non-wicking & highly resistant to moisture penetration
• Thicknesses of 22mm (standard), 30mm and 33 mm (special) to satisfy requirements of the TIMSA Guide, BS 5422: 2009, NHS CO2, NES Specification Expert Y50 and DEO Specification 037
• Suitable for continuous operating temperatures between -20°C and +80°C
• Manufacturing under a quality control system approved to BS EN ISO 9001: 2000
• BSRIA Airtightness test in accordance with BS EN 13403:2003 – ductwork made from insulation duct boards

This specification covers only metal ductwork and governs, inter alia, air leakages and pressures. As detailed in the BSRIA report, Spiralite^® exceeds these DW/144 specifications and the BS standards (BSEN 13403:2003) – see page 4 paragraph 1.1

Furthermore, the Spiralite^® ducting material conforms to all the relevant building standards and certifications, as follows:
• BS EN 1507:2006 – Pre-insulated Ductwork Systems
• Approved Document L – Conservation of fuel and power
• TIMSA-HVAC Compliance Guide – Insulation of Ductwork
• Non-domestic Heating, Cooling and Ventilation Compliance Guide – Insulation of Ductwork
• A and A+ ratings in BRE Global Environmental Profiles January 2010
• European Ventilation Standard EN1886 Air Leakage Class L1(M)

The lifespan of Spiralite^® is at least equal to that of traditional sheet metal ducting on the assumption that it is properly cleaned and maintained. In fact, tests have shown it to be highly robust and we offer an unprecedented 10 year warranty on all products.

The internal laminate is also highly durable and has shown no deterioration in quality in over 12 years of testing. The supplier boasts some of the best gluing and lamination technology in the world and there is no internal degradation that may affect air or
airflow quality.

Spiralite^® has a very simple, robust and durable connecting system between sections of the same size and using reducers/tapers where the dimensions change – safeseal connectors, tiger clips and tape.

Connecting Spiralite^® to standard duct ancillaries e.g. fire dampers, VCD’s, attenuators, heating & cooling batteries, etc is also a simple process of connecting the ducting to the circular spigots coming off a square ancillary or a simple push connection for circular and applying tape (and mastic where no rubber safeseal). These can also be mechanically fixed using an aluminium plate or flange and fix screws, bolts or rivets.

100 to 500 mm is standard; up to 850 mm is non-standard for specific orders; could go bigger and the largest to date is a RS section of 2m x 2m.

Phenolic foam has the highest rating (Class O) for combustibility, prevention of the spread of flame, smoke generation and toxicity, but fire resistance is only possible with the Conlit, Vicuclad or Durasteel systems applied to steel ducting.

Spiralite^® will only burn at very high temperatures (see Q5 above) and no toxicity is released if burnt. As stated above, the fire and smoke performance has the optimal rating at Class 0/Low Risk fire classification and has less than 5% smoke obscuration when tested to BS 5111-1: 1974.

As with mineral wool and glass silk, if the phenolic material is returned in a clean form then it will be recycled. The KoolDuct panel, from which Spiralite^® is made, gains maximum BREEAM credits for its zero ODP and low GWP. Kingspan, the manufacturers of KoolDuct, are currently working with the DTI in the ROPOF Initiative, which is looking
at ways of treating foam waste on building and demolition sites. Finally, Kingspan are about to begin testing the KoolDuct system to the European Standard, namely EN 13403 Ventilation for Buildings – Non-metallic Ducts – Ductwork made from insulated ductboards. This standard is within a series of British Standards for Mechanical Building Services – Ventilation and Air Conditioning Systems. This standard and the series are likely to be featured in future regulations.

The unique construction of Spiralite^® ducting and the jointing system allows only minimal leakage of air. The only leakage apparent in the BSRIA tests came from the cap ends where BSRIA’s own measurement and test instruments were inserted into the ducting. Spiralite ducting therefore offers running cost savings over conventional ductwork systems as all the air heated, cooled or extracted reaches its destination. This contributes positively to reducing the carbon footprint of any building.

Yes, at all stages – manufacture, installation and usage. The embodied energy and carbon footprint is significantly lower than traditional steel ducting and insulation; the entire installation process is quicker, simpler and much more energy efficient and subsequent usage results in substantial energy savings. This is due to enhanced airflow efficiencies, minimal leakages, superior thermal properties of the insulation panels and reduced AHU duties. This is more detailed in the Advantages of Spiralite^® document and the Ductwork Air Leakage report on the cost of energy wasted.

None recorded to date and none foreseen (after over 10 years of usage and testing).

There is the same cleaning process using access hatches as with metal ducting. This has been tested by Systems Hygienic, who are part of the Hotchkiss Group and who have found Spiralite^® to be easier to clean using their equipment due to the movement of their brushes. The inner lining is highly durable and does not deteriorate in quality as
a result of the application of the brushes (assuming abrasive brushes are not used). Furthermore, due to the significantly reduced ingress of air and dirt, it may be that substantially less access doors are required as the cleaning requirements and regularity thereof are materially reduced.

Where access doors are required, there is a simple installation process – a hole in the duct is cut, the access door fitted and mastic applied with fastening screws through to the inner lip. The fitting is secure and the duct retains its strength and durability. Finally, access doors can easily be fitted on site or in the factory as part of the ductwork
fabrication process.

Yes, it can be painted or otherwise decorated in the normal way. All ducting and fittings come foil faced (standard) or with an optional 3-ply white outer laminate for internal use or a 5- or 13-ply VentureClad weatherproof laminate (white, black, silver stucco) for external or plant room applications.

Square lagged ductwork from an AHU has metal square-to-rounds attached with metal spigots, to which Spiralite can be easily attached, as with metal ductwork. There are similar connections to the fire dampers and VCD’s as these are normally circular in a circular system. Conversion from rectilinear to spiral/circular is simply done with standard connectors.

We also have flat oval sections and fittings that are fabricated in a similar way using the same board and the continuous internal laminate, thereby giving the same qualities as Spiralite^® round ducting with vastly enhanced airflow and air retention efficiencies. We also manufacture rounded square ducting which completes the full range of airconditioning ductwork.

Connections or transformations from flat oval to round and rounded square ducting, and visa versa, are also manufactured and supplied by us. These are done by either reducers/expanders incorporating a change in shape or a box join connecting one shape
to another using spigots or doby flanges.

As with metal ductwork, if it is mishandled then it could get damaged. However, with a small amount of training and instruction most damage can be avoided. Provided Spiralite^® is handled and stored properly, damage through carelessness will be avoided. Accidental damage is easy to repair or replace with new. Minor damage can be repaired with reinforced foil tape and a more seriously damaged section can easily be cut out and a new section inserted using standard connecting pieces. To date damage has not been a problem on the sites that have used Spiralite^®. These include installations in glacial tunnels in Norway and repeated installation and removal in the Chanel Pavilion, without any damage.

Due to the closed cell and non-porous qualities of the insulation board used in the manufacture of Spiralite^®, it will not be damaged by rain or other exposure to water.

The outer reinforced foil laminate offers additional protection, but the material should be stored under cover as watermarks could stain the foil.

Spiralite^® is suitable for low-cost transportation in that it is very light and minimal support is required to secure the components in the shipping process. Furthermore, different sizes of ductwork can easily fit inside each other, so less space is needed.

The inner lining gives a smooth finish which offers less resistance to airflows while the circular shape reduces airflow friction and allows air to pass with less internal turbulence. The Spiralite^® air flight profiles and pressure drops are therefore at least equal to that of steel spiral ducting, which profiles and drops we recommend for use in the system design stage.

Yes, in the normal via flexible ducting and/or plenums/grille boxes.

By using a cravat in the normal way – constructed to be sealed to the outer circumference of the ducting with an overhang up to 4 inches greater than the outer perimeter of the roof shaft.

No, turning veins are only required for square KoolDuct ducting and for our flat oval ducting – for the rest of the range of Spiralite^® ducting all the bends are rounded and veins are therefore not required. This is one of the ways that airflow efficiency is enhanced and pressure drops are lowered.

There are three advantages to be derived from the installation of Spiralite^® in such areas:
• The installed ducting is more flexible and better suited to bear movements and shudders in the building structure. This is most suitable where gripple wire hangers are used, as recommended, rather than rigid hanging braces.
• The ducting is lighter and much less liable to cause damage should it dislodge and fall.
• Spiralite is easier to re-use and repair in the re-building process.