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Insulation prevents condensation and dripping from ducts. Un-insulated cold air ducts
very often have surface temperatures below the local dew point. At this temperature,
condensate will form and eventually drip off, causing an uncontrolled accumulation of
moisture on the outside surface of the duct. Duct insulation eliminates the formation of
condensate and consequently prevents rusting and staining.
Extra heating (or cooling) energy required to compensate for reduced thermal
performance of un-insulated duct has a negative effect on the HVAC system's life-cycle
cost. Therefore, duct insulation always presents an optimization problem. Since
insulated duct costs much more than un-insulated, the recommended air velocity
becomes a key factor in optimization. For instance, a higher air velocity reduces duct
surface area and thus insulation cost.
Because of the relatively small temperature differences between supply air ducts and
the spaces through which they ductwork are routed, a one-inch-thick fiberglass blanket
is almost always sufficient. Insulation should be wrapped around the duct's exterior. A
protective cover with a vapor barrier such as an aluminum foil, referred to as FKS,
should be included in insulation specifications. Care must be exercised to protect
exterior insulation integrity where insulation comes in contact with hangers, supports,
and other structural members. Interior duct insulation (lining) should not be used in
laboratory or clean room applications because the insulation tends to entrain
microscopic particles into the airflow.