CUSTOM MADE IN VICTORIA
HVAC Duct Board Fabrication for Commercial Projects
HVAC duct board installs up to 75% faster than sheet metal, weighs around one seventh as much, and arrives pre-insulated. Vic Air custom fabricates commercial HVAC duct board to project drawings at our Melbourne manufacturing facility, supplying commercial and light commercial contractors across Victoria.
What We Fabricate
Vic Air custom manufactures all lightweight duct board products in-house at our Melbourne facility. Send us your drawings and our estimating team will produce accurate fabrication plans and a detailed project quote.
Custom fabricated to unit specifications. Designed for tight ceiling spaces and multi-storey commercial applications where sheet metal transitions add unnecessary load and installation time.
Antimicrobial duct board for operating theatres, laboratories, pharmaceutical, and food production environments. See the ALP Active section below for full specifications.
Made to your unit dimensions. Pre-insulated V-boxes reduce on-site fabrication time and eliminate the need to insulate separately after installation.
ALP panel facings are treated for UV exposure and high-chloride environments. Suitable for rooftop plant rooms, swimming pool facilities, and coastal installations.
Fabricated to project drawings with the correct R-value for your climate zone and NCC requirements. Available with silver or black aluminium foil facing.
Custom dimensions to suit system layout and diffuser specifications. Non-corrosive closed-cell structure with no fibre release into the air stream.
The ALP Pre-Insulated Duct System
Vic Air lightweight duct board is manufactured using the ALP pre-insulated duct system. ALP has been supplying pre-insulated duct systems globally for over 40 years across commercial, residential, and specialist applications.
Key Specifications
- Board thicknesses from 20mm to 63mm
- R-values from R1.0 to R2.0+ depending on thickness
- R2.0 board: 42mm thick (vs 75mm for equivalent sheet metal)
- Pressure rated to 2000Pa
- Operating range: −35°C to +110°C
- Closed-cell polyurethane core, over 95% closed cell
- Water impermeable, non-corrosive
- No fibre release or dispersion
- Silver or black aluminium foil facing
Accreditations
- Accredited to AS 4254.2 as required by the NCC
- NATspec documented
- Full BIM Revit library available
- Covers NCC Section J insulation requirements
Specification resources available via NATspec for engineers and specifiers.
For most commercial HVAC projects, lightweight duct board is the faster, safer, and more cost-effective option. Here is where the difference is most material on the job.
If your project also requires sheet metal ductwork, visit our custom sheet metal fabrication page for the full range of fabrication capabilities available in-house at Vic Air.
ALP lightweight duct board installs up to 75% faster than sheet metal on average. Fabrication happens on site with basic hand tools. There is no sheet metal shop required, no separate insulation step, and fewer hangers to install. For a commercial project manager, that translates directly to a shorter ductwork schedule and trades moving through faster.
Lightweight duct board weighs around one seventh of an equivalent sheet metal section. Across a full commercial floor plate or an apartment block, the reduction in dead load is significant and factors into structural engineering calculations. On high-rise projects, it matters.
The product is pre-insulated. An R2.0 board is only 42mm thick, compared to 75mm for sheet metal with equivalent added insulation. That thinner profile is valuable in ceiling cavities where clearance is limited, and it delivers the required R-value without a separate insulation trade.
ALP lightweight duct board is accredited to AS 4254.2 as required by the National Construction Code. The product is NATspec documented and a full BIM Revit library is available. Vic Air compliance certificates are available on completion of installation.
ALP Active: Medical and High-Risk Environments
- For projects where air quality is a primary specification requirement, ALP Active incorporates Silver Zeolite antimicrobial technology into the panel surface, adhesives, sealants, and all accessories.
- Eliminates over 99.9% of 600 families of microbes without invasive chemical treatment
- Antimicrobial performance guaranteed for 15 years
- Suitable for operating theaters, laboratories, pharmaceutical and food production facilities
- Antimicrobial treatment extends to glues, sealants, and all system accessories
COMPLIANCE
Compliance and Project Documentation
Lightweight duct board from Vic Air is accredited to AS 4254.2, the Australian Standard for rigid ductwork in air handling systems as referenced by the National Construction Code. Compliance with AS 4254.2 is mandatory on all NCC-governed HVAC installations across Australia.
Vic Air provides HVAC compliance certificates to support installers in meeting their documentation obligations at the conclusion of an installation. If you are using lightweight duct board in combination with a zoned HVAC system, see our iZone smart zoning range for compatible zoning controllers, dampers, and accessories.
How it Works
Ordering custom lightweight duct board should not be a hassle. The process is straightforward and our team is ready to make your job simpler.
Email your project drawings to our estimating team at estimating@vicair.com.au. We handle both domestic and commercial projects with equal care. There is no minimum order requirement.
Our estimating team produces accurate fabrication drawings and a detailed project quote. We will confirm the correct board thickness and R-value for your project location and NCC climate zone.
Our Melbourne manufacturing team gets to work. All lightweight duct board products are fabricated in-house. No outsourcing, no third-party delays.
Collect from your nearest Vic Air branch in Dandenong South, Keilor Park, or Shepparton, or arrange direct delivery to your project site.
WHY CHOOSE
Why Choose Vic Air for Lightweight Duct Fabrication
One Supplier, One Order We are more than just a fabricator. Order your lightweight duct board, flexible duct, grilles, and fittings from a single supplier. We manage the integration so you build the job you designed. Capacity and Speed We are not just a fabricator. We are a complete sheet metal supply partner with our own manufacturing workshop and a comprehensive stock of fixings, brackets, and accessories. We have the capacity to handle urgent requests without compromising on quality. | Victorian Manufacturing Everything is fabricated at our Melbourne facility. Local manufacturing means shorter lead times, direct communication with the fabrication team, and no interstate freight delays on critical project materials. Technical Support Our estimating team understands HVAC. They will confirm the right board specification, check your R-value for climate zone compliance, and flag any fabrication issues before your project gets to site. |
Make your next job easier, our in-house experts can help you select the right products for your project's specific needs. If you need a complete system take-off, send your plans to our Estimation team for a comprehensive and accurate quote.
Send Your Plans to Our Estimation Team
Frequently Asked Questions
Q1. What is HVAC duct board?
HVAC duct board is a pre-insulated rigid panel system used in place of sheet metal for commercial and light commercial ductwork. It is made from high-density closed-cell polyurethane foam faced on both sides with aluminium foil. Unlike sheet metal, it arrives pre-insulated, requires no separate insulation step, and can be fabricated on site with basic hand tools. Vic Air custom manufactures HVAC duct board products including supply air transitions, V-boxes, return air boxes, and cushion boxes.
Q2. What is the difference between HVAC duct board and sheet metal?
HVAC duct board is pre-insulated, weighs around one seventh of an equivalent sheet metal section, and installs up to 75% faster. Sheet metal requires a separate insulation step, is heavier, and typically needs to be fabricated off-site in a sheet metal workshop. For most commercial HVAC installations, duct board reduces labour costs, OH&S risk, and structural load on the building. Vic Air fabricates both in-house, so the right choice depends on your project requirements.
Q3. What commercial HVAC duct products do you fabricate?
Vic Air fabricates supply air transitions, unit-specific V-boxes, return air boxes, and cushion boxes in HVAC duct board. We also supply ALP Active antimicrobial duct board for operating theatres, laboratories, and high-risk environments, and ALP outdoor panels for rooftop plant rooms and coastal applications. All products are custom fabricated to your project drawings at our Melbourne facility.
Q4. Is HVAC duct board compliant for commercial installations in Australia?
Yes. ALP HVAC duct board is accredited to AS 4254.2 as required by the National Construction Code, making it fully compliant for commercial HVAC installations across Australia. The product is NATspec documented and a full BIM Revit library is available. Vic Air compliance certificates are available on completion of installation to support sign-off and handover documentation.
Q5. What HVAC duct insulation R-values are available?
HVAC duct board from Vic Air is available in thicknesses from 20mm to 63mm, with R-values from R1.0 upward depending on board thickness. An R2.0 board is only 42mm thick, compared to 75mm for an equivalent sheet metal installation with added insulation. Our estimating team will confirm the correct R-value for your project location and NCC climate zone.
Q6. How do I get a custom HVAC duct fabrication quote?
Email your project drawings to estimating@vicair.com.au. Our estimating team will produce accurate fabrication drawings and a detailed quote. There is no minimum order requirement. For urgent projects, contact your nearest branch directly in Dandenong South, Keilor Park, or Shepparton to discuss lead times and available stock.
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