Vaillant recoVAIR EPP ducting 210/180 mm, length 1000 mm

Product detailed description

Vaillant recoVAIR EPP ducting 210/180 mm, length 1000 mm is a basic building block of the air distribution ductwork for the entire range of decentralised and centralised recoVAIR VAR ventilation units with heat recovery. It is a straight section of ducting with a flat oval cross-section of 210 x 180 mm, made of expanded polypropylene (EPP) - a material that has become established in premium mechanical ventilation with heat recovery precisely because of its unique combination of low weight, high rigidity and excellent thermal insulation properties.

The one-metre-long section (1000 mm) is the most common modular length used when designing the duct run in suspended ceilings, attic spaces or installation shafts, since it allows longer straight sections to be covered efficiently with a minimal number of joints, which are always a potential point of pressure loss and leakage.

Why EPP material

Expanded polypropylene (EPP) is a closed-cell foam material produced by fusing small beads of expanded polypropylene together under the action of steam and pressure in a mould. The resulting product has the following key properties relevant to ventilation ducting:

• Low thermal conductivity - thanks to the large proportion of enclosed air in the cellular structure of the material, the duct wall itself also acts as thermal insulation, so on most of the run there is no need to add separate duct insulation, as is common with smooth metal or plastic ducting.
• Low weight - a metre of ducting with this cross-section weighs only a fraction of a comparable metal duct, which significantly simplifies handling, overhead installation (into suspended ceilings) and reduces the demands on anchoring and the load-bearing structure of the hangers.
• High rigidity at low weight - the ducting retains its cross-sectional shape even over longer unsupported sections and withstands moderate mechanical stress without deforming, unlike flexible hose ducting.
• Moisture resistance - the closed cellular structure does not absorb moisture, which is particularly important on exhaust branches of the ductwork, where slight condensation can occur during colder months.
• Easy to work with - the material can be cut on site with an ordinary saw (for example a hand saw or a circular saw with fine teeth), allowing the duct length to be precisely adjusted directly at the installation site without the need for special tools.

Flat oval cross-section versus round ducting

The 210/180 mm cross-section is not round but flat oval - this design choice has a practical reason in systems such as recoVAIR: for the same free cross-sectional area (and therefore comparable airflow capacity), the flat profile is lower, which in many buildings allows the ducting to be routed in a thinner suspended ceiling or interfloor space where a round duct of larger diameter simply would not fit. This type of ducting is therefore often referred to as "flat" or "low-profile" ducting and is typical of premium heat recovery solutions in new builds with low ceiling clearance.

Use in the recoVAIR ductwork

The one-metre-long section of 210/180 mm EPP ducting is used in practice for:

• routing the main (trunk) branches of the air distribution between the recoVAIR unit and the air distributor/collector,
• connecting the unit to the facade grille on both the intake and exhaust sides,
• extending or supplementing the run in combination with elbows, couplings and T-pieces of the same cross-section, if the 500 mm section is not sufficient for the given run,
• and as a modular component that can be cut to the exact length needed for a given section without having to order custom-made ducting.

By combining 1000 mm and 500 mm sections (and cutting them to size where needed), it is possible to cover virtually any length of straight run with minimal material waste and a minimal number of joints.

Installation and recommendations for installers

1. Design the run so that the number of changes of direction (elbows) is as small as possible - every elbow increases the pressure loss in the system and therefore also the noise level and energy demand of the recoVAIR unit's fan.
2. Cut the ducting to size using a fine-toothed saw, making the cut perpendicular to the duct axis so that the end fits properly into the coupling or end element.
3. Join sections with couplings designed for this cross-section, which ensure a tight joint and prevent air leakage (and thus energy loss) between the individual segments of the ductwork.
4. Anchor the ducting with universal mounting brackets at regular intervals (as recommended in the project documentation, generally no more than 1-1.5 m), to prevent the duct from sagging and to avoid excessive stress on the joints from its own weight.
5. Avoid sharp bends outside the prescribed elbows - EPP ducting should not be forcibly bent into a curve; always use the appropriate 90° elbow to change direction.
6. Mark the duct run in the project documentation or directly on site, so that future construction work (e.g. drilling into the ceiling) does not accidentally damage the ducting.

Compatibility

This ducting is fully compatible with the entire range of Vaillant recoVAIR accessories with a 210/180 mm cross-section - that is, with 90° elbows, couplings, T-pieces, the connection adapter to the air distributor/collector, facade grilles and the noise silencer. It is intended for use with all units in the recoVAIR VAR series (60/4, 150/4, 260/4, 360/4) wherever the project requires ducting of this specific cross-section - smaller or decentralised solutions may use reduced diameters, so always check the required cross-section according to the project documentation or the technical data sheet of the specific unit when ordering.

Maintenance

The ducting itself does not require active maintenance during operation, as it is located in concealed spaces (suspended ceiling, attic, shaft) beyond the reach of routine cleaning. However, as part of the regular servicing of the ventilation system (together with replacing the filters in the recoVAIR unit), it is recommended to visually inspect accessible sections of ducting and joints for mechanical damage, loosened couplings, or moisture ingress, which could indicate a leak in the system.

Why an original Vaillant part

Using original Vaillant EPP ducting throughout the entire run guarantees that the actual airflow, noise level and heat recovery efficiency correspond to the values declared by the manufacturer for the given recoVAIR unit. Combining components from different manufacturers with different dimensions or sealing systems can lead to leaks, increased pressure loss and, ultimately, lower real-world efficiency and higher fan electricity consumption.

Acoustic properties and airflow in the ducting

In addition to its thermal insulation properties, the thick-walled EPP construction of the ducting also has a beneficial effect on the acoustics of the system. The duct material dampens, to a certain extent, the noise spreading from the recoVAIR unit's fan towards the individual rooms, and also limits the transfer of noise between rooms through the shared ductwork (so-called cross-talk between rooms). The smooth inner surface of the ducting also reduces the frictional resistance to airflow compared with flexible hoses, whose corrugated surface causes turbulence and the associated increase in noise and pressure loss. This is precisely why, in projects where quiet operation is a priority (bedrooms, children's rooms, studies), straight, rigid sections of EPP ducting are recommended over long flexible hose connections wherever the layout of the building allows it.

Comparison with other types of ductwork

In addition to flat EPP ducting, the ventilation market commonly also features round galvanised sheet-metal ducting or flexible hoses made of aluminium foil reinforced with a wire spiral. Compared with these alternatives, the recoVAIR EPP solution offers several advantages:

• Compared with galvanised sheet-metal ducting, the EPP variant is significantly lighter, does not require separate thermal insulation (sheet-metal ducting almost always needs to be additionally insulated against condensation and heat loss), and its installation is faster, since it is not joined by riveting or screwing but simply slid into couplings.
• Compared with flexible hoses, EPP ducting has significantly lower airflow resistance (a smooth inner surface instead of a corrugated one), which means lower fan energy consumption for the same airflow and quieter operation. Flexible hoses can also sag or become compressed over time through careless handling, which limits the actual airflow, whereas rigid EPP ducting permanently maintains its full cross-section.

The disadvantage of rigid EPP ducting compared with flexible solutions is lower versatility on complicated, space-constrained runs with many changes of direction over a short section - in such cases, a short flexible section is sometimes used only for the final connection to the distributor or the end outlet, while the main run remains routed in rigid EPP ducting.

Environmental aspects of the EPP material

Expanded polypropylene belongs to the thermoplastics, which can be recycled at the end of their service life, unlike some combined insulation materials (e.g. sheet metal wrapped in mineral wool and foil), where separating the individual components for recycling is more complicated. The low weight of the material also means lower energy demand for transport from the factory to the construction site compared with heavier metal alternatives, which slightly reduces the carbon footprint associated with the logistics of the building material.

Typical installation mistakes and how to avoid them

• Too many joints over a short section - try to use longer (1000 mm) sections wherever the run allows, instead of assembling the run from a larger number of shorter pieces, which increases the number of potentially leaky points.
• Insufficient support of the ducting - long sections without a sufficient number of mounting brackets can sag over time, creating spots where dust unnecessarily collects inside the duct and increasing stress on the joints.
• Angled or imperfect cuts when shortening - an uneven cut makes it harder to seat the duct reliably into the coupling and can cause microscopic leaks, so always cut perpendicular to the duct axis and gently smooth the edge if needed.
• Combining with incompatible accessories from another manufacturer - even if they may appear similar in size, small deviations in tolerance can cause a leaky joint and loss of the system warranty.

Summary

The Vaillant recoVAIR 210/180 mm EPP ducting, 1000 mm long, is a basic, universal building component for installing the air distribution ductwork of recoVAIR VAR ventilation units. Its low weight, excellent thermal insulation properties, ease of processing and full compatibility with the rest of the system's accessories make it a practical and reliable choice for installers and investors alike who want to achieve the declared efficiency and quiet operation of their heat recovery system.