Outdoor Ductwork: Thermaround® vs. Traditional Rooftop Systems
On most commercial jobs, outdoor ductwork ends up driving more of the schedule than expected. It’s not just installing duct, but what often comes with it. The coordination of insulation, cladding, and multiple trades on the roof can extend the project further with each one dependent on the last one being completed. When something slips, the entire sequence gets pushed.
That’s the standard process contractors are used to, which can work, but it introduces variables, that can be quite large on extensive rooftop runs where coordination becomes more difficult to manage.
Thermaduct®'s Thermaround® takes a different approach by combining duct, insulation, and exterior protection into a single system that arrives ready to install.
What Thermaround® Changes on the Jobsite
With traditional outdoor ductwork, installation happens in phases. The duct is set first, then insulation is applied, and finally the system is clad for weather protection. Each of those steps may involve a different crew, and each introduces an opportunity for delay.
Thermaround® removes those additional steps. The system arrives pre-insulated with a built in exterior clad, so the same crew that installs the duct is also completing the insulation and exterior protection at the same time. Once sections are connected with our flanged connections and draw bands, that portion of the system is finished - no cover system required!
This changes how the job flows. Instead of working around multiple trades and return trips to complete the system, installation becomes a single, continuous process. On rooftop applications, that often means fewer delays and less exposure to weather during construction.
Installation Time and Coordination
With a pre-insulated system, installation stays with one crew from start to finish. There’s no waiting for insulation or cladding, and no need to reopen completed sections to finish the system. That typically results in a faster install, but more importantly, a more predictable one.
For contractors, the benefit isn’t just speed...it’s control over the schedule!
Performance Over Time
With Thermaround®, you don't have to worry about the issues that can arise from field-applied insulation. Because our duct is pre-insulated under factory-controlled conditions before it reaches the jobsite, you don't have to worry about compression, gaps and moisture intrusion. That removes some of the variability associated with field installation and helps maintain more consistent thermal performance over time.
Both traditional and pre-insulated outdoor ductwork systems can meet design requirements when installed correctly. The difference is how much of that performance depends on field conditions.
Cost Considerations for Outdoor Ductwork
Material cost is often the first thing contractors look at, and pre-insulated systems typically come in higher upfront than traditional duct alone. However, outdoor ductwork costs don't just include the ductwork because of the need for insulation, cladding, vapor barriers, and the labor to install all of it.
When those components are considered together, the difference between systems becomes less about material and more about total installed cost. Labor, coordination, and schedule all play a role in that equation.
On projects where labor is limited or timelines are tight, reducing the number of steps required with a pre-insulated system can have a measurable impact on overall cost.
Durability in Outdoor Applications
Outdoor ductwork is constantly exposed to weather, including UV, temperature swings, and moisture. The long-term performance of the system depends on how well it holds up under those conditions. No system eliminates all maintenance considerations, but steps can be taken to reduce the number of variables experienced in the field.
Traditional systems rely on field-applied cladding to protect insulation. If that protection is compromised, moisture can affect the insulation and reduce performance over time.
With Thermaround®, factory applied UV stable vinyl cladding or durable kynar exterior offer a durable exterior finish from the start with a duct geometry that naturally sheds water! Pair this with our closed cell Thermatuff® insulation and you have a high insulated value interior with zero facing perforations.
When Each Approach Makes Sense
By combining duct, insulation, and cladding into a single system, it reduces the number of steps required on the jobsite and limits the variables that come with field-applied insulation. For contractors, that typically means a more controlled installation process and fewer coordination challenges on the roof.
If you find yourself wanting to increase the efficiency of your duct systems, both indoor and out, talk to your Local Thermaduct Expert or Contact Us to help you develop a plan for your building.
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