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Best way to insulate supply duct with minimal clearance

Home Improvement Asked by jipster on March 31, 2021

I wanted to wrap the supply side ductwork, but the return is mounted so close to it, in some spots barely 3/4 of an inch of space between them. What is the best way to insulate in this case? Supplies both heat and AC located in an unfinished uninsulated basement of a 2 story house in Chicago area, basement is pretty chilly right now in March and the supply spans the whole length of the house so there is a pretty large temperature difference when you get to the end of the run 30-40 feet away from the actual blower.

I thought of 2 possible ways I would do it:

  1. Getting 3/4" foam board and shoving it up in the space and then use R-6 fiberglass duct wrap on the other 3 sides.
  2. Fill the gap with spray foam, as this would also close up any leaks. Then again use fiberglass duct wrap on the other 3 sides.

Supply is the smaller duct on the right in this picture, the gap looks much larger than it is in the pic, on average about 3/4 spacing.
enter image description here

One Answer

I'd go with the foam board. Spray foam expansion could collapse the duct somewhat and maybe cause some airflow volume issues. Main reason I wouldnt use it would be working on the duct work later would be terrible with all that foam stuck to everything. Just my initial thoughts.

Answered by roasthead on March 31, 2021

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