AEROFLEX EPDM™ Elastomeric Duct Insulation

Duct insulation is used in HVAC systems to control temperature, reduce energy loss, prevent condensation, and attenuate unwanted sound (noise).

It is typically installed in two ways:

• Duct wrap – applied externally for thermal insulation and condensation control
• Duct liner – installed inside sheet metal ductwork for acoustic absorption, airflow noise reduction, and thermal insulation

Aeroflex Breathe-EZ can be utilized as both a duct wrap and a duct liner, offering a closed-cell elastomeric alternative to traditional fibrous materials.

Why Duct Insulation Matters in HVAC Systems

Duct insulation plays a critical role in HVAC air distribution system performance by controlling design temperatures, acoustics, moisture, and energy efficiency. Whether used as duct liner (internal insulation) or duct wrap (external insulation), these functions directly impact occupant comfort and long-term system reliability.

Temperature Control

Duct insulation helps maintain the design temperature of conditioned air as it moves through HVAC ductwork, ensuring delivery at the desired temperature to meet building occupancy requirements. By reducing heat loss or gain, duct insulation supports consistent indoor comfort, proper operating temperatures for equipment, and system performance.

Acoustical Control

Duct liner insulation absorbs noise generated by air-handling equipment (i.e. fans or sheet metal rumble & vibration) and airflow within the duct system. It also helps reduce noise traveling between spaces through shared ductwork, an important consideration in commercial, healthcare, and institutional buildings. Due to its closed–cell structure and density, elastomeric duct insulation can address problematic frequencies in the 250–500 Hz range, serving as an alternative to dedicated acoustic equipment such as silencers. 

Condensation Control

Properly specified duct insulation helps prevent condensation from forming on duct surfaces. Closed-cell insulation materials are particularly effective at limiting moisture intrusion, reducing the risk of mold growth, corrosion, and damage to surrounding building materials.

Energy Conservation

Duct insulation improves HVAC system efficiency by minimizing heat transfer through duct walls. This reduces energy loss, lowers operating costs, and supports compliance with building energy codes, including ASHRAE Standard 90.1 and the International Energy Conservation Code (IECC).  Elastomeric duct insulation is available in thicknesses to meet the minimum R-value requirements of ASHRAE 90.1 and IECC.

Selecting a duct insulation material that performs across all four functions helps ensure consistent HVAC systems perform as designed over time. 

One Material for Duct Liner and Duct Wrap Applications

AEROFLEX EPDM duct insulation is designed to perform as both a duct liner and a duct wrap, reducing the need to specify and source multiple insulation materials.

Benefits of a Single Material System

• Simplifies specification across duct liner and wrap applications
• Reduces material coordination and substitution risk
• Supports consistent performance throughout the HVAC system
• Streamlines installation and material handling on-site
• Maintains listed & labeled compliance across applications

This approach is particularly valuable in large-scale projects where efficiency, consistency, and risk reduction are critical.

Why Choose Elastomeric Duct Insulation for Liner and Wrap Applications

Selecting the right duct insulation material can require balancing installation efficiency, long-term performance, indoor environmental quality (IAQ), and cost.

AEROFLEX elastomeric duct insulation is engineered to perform.

Installation Efficiency & Jobsite Simplicity

AEROFLEX duct insulation is designed to simplify installation across both duct liner and duct wrap applications, helping reduce labor time and installation complexity.

• Available with factory-applied pressure-sensitive adhesive (PSA) for faster installation
• Flexible material easily installs on rectangular, round (≥ 12”), and oval ductwork (≥ 12”)
• Low thermal conductivity can reduce required insulation thickness
• Built-in vapor retarder eliminates the need for an additional vapor barrier in most applications*

*Supplemental vapor barriers or protective jacketing for duct wrap may be required in extreme temperature or high-humidity environments.

Faster installation and fewer system components help reduce labor costs and coordination challenges on-site.

Moisture Resistance & Long-Term Thermal Performance

Closed-cell elastomeric duct insulation is engineered to maintain performance in environments where moisture and condensation are a concern.

• Closed-cell structure resists moisture absorption, helping control condensation
• Hydrophobic, nonpolar material repels water vapor

Key Performance Benefits

AEROFLEX elastomeric duct insulation is engineered to address the performance challenges that impact HVAC systems over time—particularly moisture, acoustics, and indoor air quality. 

• Fiber-free – No fibers particulating into the airstream
• Low-VOC – GREENGUARD Gold Certified for low chemical emissions
• Attenuates low-frequency noise generated by fans and air movement
• Reduces breakout noise into occupied spaces
• Controls condensation – Closed-cell structure resists moisture absorption
• Smooth, cleanable surface (skin) for improved maintenance