THE LITTLE RED BOOK
CONTRACTORS GUIDE
H&V
CONTENTS
INTRODUCTION
NATURAL VOLCANIC ROCK INSULATION
THERMAL FIRE ACOUSTIC
ROCKWOOL
A triple combination of benefits
CONTENTS
Introduction ................................................................3 ECAs .......................................................................... 4 Technical Support ....................................................... 4 Fire Safety .................................................................. 5 Ageing ........................................................................ 8 Corrosion ................................................................... 9 Cost Savings .............................................................. 10 Acoustic ................................................................... 12
Rockwool Ltd, based near Bridgend, South Wales is the UKs leading manufacturer of stone wool insulation for thermal, fire and acoustic protection. Only Rockwool is authentic and wholly natural, recreated from natural processes that exist only in nature. The natural characteristics of Rockwool stone wool provide a triple combination of advantages it is energy saving which reduces fuel bills, it is firesafe which protects buildings and it offers acoustic improvement to reduce noise nuisance.
PRODUCT RANGE
RockLap H&V pipe sections ....................................... 16 Ductslab and Ductwrap ............................................. 17 Lamella Mat .............................................................. 18 Techwrap2 and Techtube ........................................... 19 Fire Duct Systems ..................................................... 20
WHY INSULATE?
There are numerous reasons why insulation may be required on pipework and equipment, some are detailed below. Cost Saving huge savings can be made by installing insulation (see page 11) Environmental reduction in CO2 emissions Process control maintaining temperatures to meet process demands Frost Protection prevent external pipes from freezing Condensation control prevent condensation forming on cold pipes etc. Acoustic control reduction in sound break out from pipes and equipment Fire protection protection of pipes and equipment against fire
THICKNESS TABLES
Personnel Protection ................................................. 25 Condensation Control (pipes) .................................... 26 Condensation Control (ducts) .................................... 27 Heat Gain ................................................................. 28 Heat Loss (ventilation ducts) ..................................... 29 Heat Loss (heating) ................................................... 30 Heat Loss (hot water) ............................................... 31 Frost protection ........................................................ 32 Standard Schedule pipes ............................................ 34 Advice and Literature ................................................ 35
ECAs/ TECHNICAL SUPPORT
FIRE SAFETY
QUALIFY FOR ECAs WITH ROCKWOOL
ENHANCED CAPITAL ALLOWANCES
When used to thermally insulate pipes, Rockwool insulation is eligible to qualify for the Enhanced Capital Allowances Scheme. Eligibility is dependent upon use of the appropriate thickness of insulation for a given application and upon other requirements detailed on the ECA website (www.eca.gov.uk).
A1
CLASSIFICATION
ROCKWOOL INSULATION IS TOTALLY FIRESAFE.
As part of the European harmonisation process, a new reaction-to-fire classification system has been ratified for construction products. Construction products will be placed into one of seven Euroclasses A1, A2, B, C, D, E or F according to their performance in fire tests. The safest products will be in Classes A1, A2 or B and the more fire hazardous in C, D or E. Class F is used where no data is available. A1 represents virtual non-combustibility and E represents the poorest fire performance.
WHICH ROCKWOOL PRODUCTS QUALIFY?
Rockwool insulation products typically used to thermally insulate pipes are shown below. Other Rockwool products may also be suitable to insulate pipes in certain circumstances and may, therefore, also be eligible to qualify for ECAs. RockLap H&V pipe sections Process Pipe Sections Pipe Section Mat Wired Mat Matched-half Bends and Pipe Bend Segments
AVOIDING FLASHOVER
FULL TECHNICAL ADVICE SERVICE
FREE LITERATURE
Rockwool offer a full technical advice service to assist the appropriate selection of products, their correct application and to discuss any special considerations necessary at the design stage to ensure trouble free installation and use. Rockwool produce a full range of FREE technical literature to help.
Products in Classes A1, A2 and B do not reach flashover, whereas products in Classes C, D and E do. Flashover can be explained as the spontaneous ignition of hot smoke and gases and is described by the Swedish Test Institute SP as the crucial point of hazard where the death toll increases by a sudden factor of 300 per cent.
BSEN ISO 1182
Rockwool base product is non-combustible in accordance with BSEN ISO 1182.
Technical Services: 0871 222 1780
FIRE SAFETY
FIRE SAFETY
FLASHOVER DEMONSTRATED IN TEST
FIRESAFE ROCKWOOL
The graph shows the temperatures at which various insulation materials begin to disintegrate in a fire
THE FIREFIGHTERS CHOICE
1200
Rockwool
1000
1175C Volcanic rock melts after 280 minutes 530C Glass fibre melts after 7 minutes
800
Temperature (C)
600
400
200
180C Plastic melts and chars after 3 minutes
00
50
100 Time (minutes)
150
200
250
300
350
AGEING
NO CFCs, HCFCs, HFCs OR OTHER CHEMICALS WITH GLOBAL WARMING POTENTIAL
AGEING OF THERMAL CONDUCTIVITY TO ISO 8497
30 29 28 27 26 25 24 23 22 21 20 19 18
Test period Jan 1999 to Jan 2000
(ambient air temperature typ. 25C)
AGEING/ CORROSION
Mean temp. 30C 40C 50C 60C 70C
THERMAL AGEING?
Plastic foam insulation is manufactured using a blowing agent that expands to form the cells in the finished product. Types of foam insulation that rely on an entrapped blowing agent for their thermal properties include phenolic foam (PF), polyurethane (PUR), polyisocyanurate (PIR) and extruded polystyrene (XPS). The graph above shows the results of in-house tests conducted by Rockwool on foil faced phenolic foam pipe sections between January 1999 and January 2000. To represent product usage, the steel test pipes were heated to temperatures between 35C and 125C, resulting in mean insulation temperatures of 30C, 40C, 50C, 60C and 70C (shown by the graph). At the end of each weeks heating cycle, the steel pipes were cooled to ambient air temperature and then heated to 125C for one week to condition the insulation samples. The 125C conditioning cycle allowed for only a 5C surge above the maximum service temperature recommended for the phenolic pipe insulation, 120C. Although measurements were discontinued after one year, the thermal ageing process showed no signs of having ended at this time. These ad-hoc tests demonstrate the principle of thermal ageing - further tests are proposed to determine whether the results are typical of foam insulation products currently supplied in the UK. It should be noted that the proposed European product standards (ENs) for foam insulation do not require the test samples to be conditioned at temperatures greater than 70C, regardless of whether the product is intended for use at temperatures exceeding 70C.
Air is used in Rockwool insulation
Unlike many blown gas foam insulation products, Rockwool does not use, and has never used, harmful gases such as CFCs, HCFCs, HFCs, pentane or any blowing agents that have Global Warming or Ozone Depleting Potential. Specifiers can have confidence that Rockwool insulation can be relied upon not to thermally age or to damage the environment due to loss of a blowing agent.
CORROSION
Corrosion of pipework and equipment costs British Industry tens of millions per annum. Surely specifying materials which do not contribute towards corrosion is a must.
NO SPECIAL COATINGS REQUIRED
Rockwool insulation is compatible with copper and steel pipes, equipment and fittings it does not require any special coatings to prevent chemical attack of metal. Rockwool insulation is chemically inert and contains low levels of chlorides and high levels of stress corrosion inhibitors in the form of sodium and silicate ions. An aqueous extract of Rockwool insulation is neutral (pH 7) or slightly alkaline.
COST SAVINGS
10
PIPEWORK DATA
ANNUAL SAVING
PER METRE LENGTH OF PIPE
COST SAVINGS
11
The heat transfer data used below has been calculated in accordance with BS EN ISO 12241 Pipework Data Operating Temperature (C) Ambient Still Air Temperature (C) Pipe Material Pipe Emissivity (uninsulated) Pipe Orientation Rockwool Insulation Type Cladding Type Fuel Type Gross Fuel Cost (pence per kWh) Plant Efficiency (%) Net Fuel Cost (pence per useful kWh) Plant Utilisation (hours per day) Plant Utilisation (days per year) Plant Utilisation (hours per year) Net Fuel Cost (pence per W per year)
SAVE s PER METRE PER YEAR
Heat loss Rockwool (W/m) Pipe OD thickness Bare (mm) surface (mm)
21 27 34 42 48 60 89 114 140 169 40 40 45 45 50 50 60 60 60 60 60 60 178.17 221.63 270.99 326.08 366.66 446.33 632.96 789.17 948.36 1122.92 1418.20 1731.01
150 MTHW 20 Black Steel 0.9 Horizontal RockLap H & V Aluminium Gas 1 85 1.176 24 365 8760 10.31
Heat loss (W/m) Insulated surface
16.86 18.87 19.68 21.83 23.38 26.40 30.92 36.09 41.33 43.63 52.45 61.83
Heat saving W
161 203 251 304 343 420 602 753 907 1079 1366 1669
Cost saving per metre of pipe per year 16.62 20.90 25.90 31.36 35.38 43.28 62.05 77.61 93.48 111.23 140.75 172.02
Take a look at the charts above for an indication of the considerable savings that can be achieved through the correct installation of insulation.
219 273
ACOUSTIC
ACOUSTIC
12
IMPROVED ACOUSTIC CONTROL
ROCKWOOL: THE SOUND BARRIER
REDUCING NOISE FROM PLANT AND EQUIPMENT
A number of practical steps can be taken to reduce noise levels, but it is always advisable to seek expert technical opinion before undertaking any acoustic measures.
13
THE ACOUSTIC BENEFITS OF ROCKWOOL
Rockwool products are manufactured to a higher density than other stone wool slabs and provide improved acoustic control across a wide range of frequencies. Effective sound insulation is an essential requirement for modern life styles. Excessive noise can increase stress, hinder speech and can cause its own form of environmental pollution. Rockwool has been proven over many years to be the ideal insulation material for all applications where noise attenuation or noise absorption is needed in domestic, commercial, manufacturing, industrial and environmental situations.
NOISE TRANSMITTED ALONG DUCTS
Reduction of transmitted noise through pipes and air conditioning ductwork is achieved by the use of acoustic linings or claddings. Products such as Rockwool Ductslab, Ductwrap and Techwrap provide both acoustic and thermal protection.
Whenever practicable, choose quieter machines and processes. Ask for an assessment of plant and equipment, bearing in mind the acoustic environment in which they will be operating. Surround noisy machines individually, eg heavy motors, high speed fans, with an insulated enclosure, as in figure 1. Such enclosures can typically achieve about 30 dB reduction. Ideally, the design should incorporate an impervious enclosure of high mass and with an absorbent lining to prevent reflected noise build-up within the enclosure. Ventilation should be provided and any openings acoustically lined.
Noise transmitted along an air duct
ROOM TO ROOM NOISE VIA SERVICE PENETRATIONS
Airborne and structure borne noise from adjacent rooms via pipes, ducts and services can be reduced by the installation of acoustic sleeves at wall penetration points. Rockwool stone wool slab, pipe sections, mat or loose fill are ideal for this purpose.
Fig.1 Isolation of plant noise source by individual enclosure and acoustic treatment of base. Enclosure formed by steel faced partition with perforated inner sheet and incorporating Rockwool Rigid Slab (typically RW3).
Noise transmitted via a service penetration
Machines which produce vibration noise, eg ball mills, diesel engines, centrifuges, should be positioned on resilient isolation mounts, which may include rubber pads and/or Rockwool slabs. The design must take into account the loading of the machine and the vibration frequencies.
ACOUSTIC
PRODUCT RANGE
14
THE SOLUTION TO NOISE POLLUTION
15
Where there are a number of machines, treat all the interior surfaces of the room or enclosure with noise absorbing panels, as in figure 2. It should be borne in mind, however, that the maximum reduction normally achievable by lining the room is 10 dB, and in cases where only the ceiling is treated, about 5 dB. As an alternative, quiet rooms can be constructed for personnel, using the same techniques. When very noisy equipment is mounted directly on an intermediate floor, the floor itself may be subject to very high sound pressure levels, causing noise problems in the room below. Installing a concrete inertia base on resilient mounts can act as an effective barrier. Noisy pipes, ducts, and gas or liquid handling plant can be individually sound proofed by enclosing them in dense Rockwool. The bases of plant, such as pumps or fans should be acoustically treated. In special cases, eg to reduce noise levels from turbine systems in power stations, the wrapping is made up of layers of stone wool and is faced with steel sheet or similar.
Fig.2 Acoustic lining to plant room where individual enclosure is impracticable. Lining formed using Rockwool Acoustic Elements
Product Range
ROCKLAP
DUCTSLAB & DUCTWRAP
16
17
FIRESAFE NON-CORROSIVE STABLE THERMAL PERFORMANCE
ROCKLAP H&V PIPE SECTIONS
RockLap H&V pipe sections are strong lengths of pre-formed insulation with a onepiece, factory applied foil facing with integral self-adhesive lap. The integral lap ensures fast and easy installation: just snap the sections onto the pipe, peel off the backing tape and smooth down for a completely sealed joint. Size range 17mm OD to 273mm OD, 20mm to 60mm thick.
FIRESAFE HIGH DENSITY
ROCKWOOL DUCTSLAB AND DUCTWRAP
Rockwool Ductslab and Ductwrap provide thermal insulation for air conditioning, warm air and extract ducts used in the internal and external environment generally within plant rooms and boiler houses. Rockwool Ductslab is also used for the thermal insulation of cold water storage, feed and expansion tanks.
TYPICAL SPECIFICATION CLAUSE
The following specification are for guidance purposes only and should be read in conjunction with recommendations given in BS 5970.
TYPICAL SPECIFICATION
Pipes to be insulated with ..........*mm thick Rockwool RockLap H&V pipe sections, having a nominal density not less than 120 kg/m2, with a factory applied facing of reinforced aluminium foil incorporating integral lap for fixing. The whole to comply with the Building Regulations Class O definition. Fixing to be in accordance with manufacturers instructions, by peeling protective tape from self-adhesive lap and pressing lap smoothly over joint. Where adjacent Sections abut, approved 75mm wide aluminium tape to be used to maintain integrity of the vapour barrier. *Insert required thickness
For details of other specification clauses please consult the data sheet.
Horizontal ducts concealed from view
The duct insulation is to be Rockwool Ductwrap. All joints are to be securely taped with 75mm wide plain soft aluminium self-adhesive tape (Idenden type T303 or similar and approved). Self-adhesive stick pins* are to be used to support the insulation on the underside of ducting. The whole is to be further supported by means of 1922 swg 50mm mesh galvanised wire netting. Where a vapour barrier is required, care is to be taken when applying wire mesh, to avoid damage to aluminium foil.
For details of other specification clauses please consult the data sheet.
*NOTE The pins and washers are necessary, to avoid sagging of the insulation, particularly on larger size ducts and on the undersides of ducts. Fixing centres will depend on the size of the duct and the weight of the insulating material. The excess projection of the pins above the washers should be cut off and the washer sealed using the soft aluminium self-adhesive tape to maintain the integrity of the vapour barrier.
LAMELLA MAT
TECHWRAP2 & TECHTUBE
18
19
FIRESAFE COMPRESSION RESISTANT
LAMELLA MAT
Rockwool Lamella Mat is formed from strips of Rockwool stone wool bonded on edge to a flexible outer facing. The method of construction provides a strong and resilient mat which will resist flattening at bends and corners. Lamella Mat is particularly suitable for the insulation of heating and ventilation pipework and ductwork and as an overlay to upgrade existing insulation.
TECHWRAP2 AND TECHTUBE
Techwrap2 and Techtube form part of a range of high performance Rockwool acoustic insulation products. Techwrap2 and Techtube are pre-covered with a flexible polymeric acoustic mass layer, engineered to provide the highest standard of noise control to circular and rectangular ductwork, rainwater, soil-vent, service and process pipes.
TYPICAL SPECIFICATIONS
The polymeric mass layer should be positioned outermost from the sound source and overlapped at all joints.
Techwrap2
Techwrap2 should be cut 25mm oversize and a 25mm strip of Rockwool removed to create an overlap. All cutting operations can be completed using a sharp knife. 75mm wide plain aluminium foil self-adhesive tape should be used to seal the joints. Welded or mechanically attached steel pins should be used to fix Techwrap2 to the duct. However, subject to the manufacturers approval, adhesive applied insulation hangers may be used in place of welded pins. Particular attention should be paid to support of the Techwrap2 at joint locations and where sagging may occur, eg in soffit areas. The number of pins required will depend upon size and orientation of the duct. However, where pins are employed at Techwrap2 edges, 4 number are recommended at 1000mm edges and 7 number at 2000mm edges. Additional lines of pins should be at nominal 300mm spacings.
TYPICAL SPECIFICATION
1 Lamella Mat to be secured to heating pipe with lacing wire tied at 200mm centres. Joints to be securely taped with 75mm wide self adhesive foil tape. 2 Lamella Mat to be securely fixed to duct with self adhesive stick pins applied in accordance with manufacturers instructions. Where pins protrude through facings, the pins are to be cropped flush with the facing washers and covered with 75mm foil tape.
For details of other specification clauses please consult the data sheet.
Techtube
All joints should be taped with self-adhesive aluminium foil tape. Techtube is generally secured with aluminium bands at approximately 200mm maximum centres.
For details of other specification clauses please consult the data sheet.
FIRE DUCT SYSTEMS
FIRE DUCT SYSTEMS
20
WELDED PIN FIXING METHOD 1
1 All ductwork is to be insulated with ..........*mm Rockwool
Firepro Fire Duct Slab, having a factory applied reinforced aluminium foil to one face and complying with Building Regulations Class O requirements.
21
SINGLE LAYER FIRE PROTECTION
FIREPRO FIRE DUCT
Manufactured from Rockwool stone wool, Firepro Fire Duct products provide fire protection and thermal and acoustic insulation for circular and rectangular steel ductwork. The simplicity and flexibility of fixing options ensure rapid and reliable installation to both vertical and horizontal duct systems. The option to use mitre-joints at slab corners allows installation in situations where welding may not be practicable. Nails are generally spaced at 500mm maximum centres. 1 Welded pin method 1 Longitudinal corner joints fixed with pigtail screws. 2 Welded pin method 2 All joints bonded with Firepro Glue. 3 Welded pin method 3 Longitudinal corner joints fixed with pigtail screws. Cross joints protected with centrally positioned 100mm wide Fire Duct cover strips. 4 Mitre-joint method All joints bonded with Firepro Glue.
For details of other specification clauses please consult the data sheet.
2 The Firepro Fire Duct Slab is to be affixed to the duct using
2.5mm diameter welded steel pins and 38mm. spring steel washers in accordance with the Rockwool manual Firepro Fire Duct System. Firepro Glue is to be applied.
3 The foil facing is to be removed from any surfaces to which 4 All corner joints are to be fixed with pigtail screws at 250mm
maximum centres. Screw length is to be 2 slab thickness. tightly closed.
5 All cross joints are to be filled with Firepro Glue and held
2
6 Drop rods and bearers are to be at 1500mm maximum
3
centres and to be M10 steel rod and 30 30 3mm steel angle respectively. Ductwork is to be generally in accordance with HVCA Specification DW/144 . ..........*mm Firepro Fire Duct Slab or .......... ..........*mm Firepro Fire Duct Section, as appropriate. Rebates or cover pieces are to be used at duct flange and bearer locations according to site conditions and subject to Rockwool approval. edges and penetrations through the foil should be sealed using soft self-adhesive aluminium foil tape.
7 Drop rods and exposed bearers are to be insulated with
8 Where a vapour barrier is required, all exposed Fire Duct
4
*Insert Firepro Fire Duct Slab insulation thickness required. Insert appropriate overall diameter. For details of other specification clauses please consult the data sheet.
FIRE DUCT SYSTEMS
FIRE DUCT SYSTEMS
22
WELDED PIN FIXING METHOD 2
WELDED PIN FIXING METHOD 3
1 All ductwork is to be insulated with ..........*mm Rockwool
Firepro Fire Duct Slab, having a factory applied reinforced aluminium foil to one face and complying with Building Regulations Class O requirements.
23
1 All ductwork is to be insulated with ..........*mm Rockwool
Firepro Fire Duct Slab, having a factory applied reinforced aluminium foil to one face and complying with Building Regulations Class O requirements.
2 The Firepro Fire Duct Slab is to be affixed to the duct using
2.5mm diameter welded steel pins and 38mm. spring steel washers in accordance with the Rockwool manual Firepro Fire Duct System.
2 The Firepro Fire Duct Slab is to be affixed to the duct using
2.5mm diameter welded steel pins and 38mm. spring steel washers in accordance with the Rockwool manual Firepro Fire Duct System.
3 All corner joints are to be fixed with pigtail screws at 250mm
maximum centres. Screw length is to be 2 slab thickness.
3 All corner joints are to be fixed with pigtail screws at 250mm
maximum centres. Screw length is to be 2 slab thickness.
4 All joints are to be filled with Firepro Glue and held tightly
closed. If necessary, nails may be used at corner joints to aid this process.
4 All cross joints are to be covered with centrally positioned
5 Drop rods and bearers are to be at 1500mm maximum
10mm wide strips of Firepro Fire Duct Slab of the same thickness as the insulation. The cover strips are to be fixed along both edges using pigtail screws, as described above.
centres and to be M10 steel rod and 30 30 3mm steel angle respectively. Ductwork is to be generally in accordance with HVCA Specification DW/144 . ..........*mm Firepro Fire Duct Slab or .......... ..........*mm Firepro Fire Duct Section, as appropriate. Rebates or cover pieces are to be used at duct flange and bearer locations according to site conditions and subject to Rockwool approval. edges and penetrations through the foil should be sealed using soft self-adhesive aluminium foil tape.
5 Drop rods and bearers are to be at 1500mm maximum
6 Drop rods and exposed bearers are to be insulated with
centres and to be M10 steel rod and 30 30 3mm steel angle respectively. Ductwork is to be generally in accordance with HVCA Specification DW/144 . ..........*mm Firepro Fire Duct Slab or .......... ..........*mm Firepro Fire Duct Section, as appropriate. Rebates or cover pieces are to be used at duct flange and bearer locations according to site conditions and subject to Rockwool approval. edges and penetrations through the foil should be sealed using soft self-adhesive aluminium foil tape.
6 Drop rods and exposed bearers are to be insulated with
7 Where a vapour barrier is required, all exposed Fire Duct
*Insert Firepro Fire Duct Slab insulation thickness required. Insert appropriate overall diameter. For details of other specification clauses please consult the data sheet.
7 Where a vapour barrier is required, all exposed Fire Duct
*Insert Firepro Fire Duct Slab insulation thickness required. Insert appropriate overall diameter. For details of other specification clauses please consult the data sheet.
FIRE DUCT SYSTEMS
PERSONNEL PROTECTION
24
MITRE-JOINT FIXING METHOD
PERSONNEL PROTECTION
25
1 All ductwork is to be insulated with ..........*mm Rockwool
Firepro Fire Duct Slab, having a factory applied reinforced aluminium foil to one face and complying with Building Regulations Class O requirements.
Minimum insulation thickness for personnel protection from a metallic surface with a surface emissivity of 5.05 (bright aluminium foil) and a design cold face temperature of 55C.
Temperature of Contents (C) Outside diameter of steel pipe on which 100 200 300 insulation has been Thickness of RockLap H&V pipe section (mm) based (mm) 17.2 21.3 26.9 33.7 42.4 48.3 60.3 76.1 88.9 101.6 114.3 139.7 168.3 219.1 244.5 273.0 323.9 355.6 406.4 457.0 508.0 610.0 Flat 20 35 40 20 25 50
2 The Fire Duct joints at ductwork corners are to be 45 mitred. Square butt joints to be used elsewhere. 3 The foil facing is to be removed from any surfaces to which
Firepro Glue is to be applied.
4 All joints are to be filled with Firepro Glue and held tightly closed. 5 All mitred joints are to be held tightly closed with nails
(length = approx. 2 Firepro Fire Duct Slab thickness) until the glue has fully cured. 2 nails juxtaposed at 90 are to be located at 3 points per 1200mm length of mitred joint and at 4 points per 1800mm length. centres and to be M 10 steel rod and 30 30 3mm steel angle respectively, Ductwork is to be generally in accordance with HVCA Specification DW/144.
30 60 35 70 40 25 80
6 Drop rods and bearers are to be at 1500mm maximum
7 All drop rods and exposed bearers are to be insulated with ..........*mm Firepro Fire Duct Slab or .......... ..........*mm Firepro Fire Duct Section, as appropriate. Rebates or cover pieces are to be used at duct flange and bearer locations according to site conditions and subject to Rockwool approval. 8 Where a vapour barrier is required, all exposed Fire Duct
*Insert Firepro Fire Duct Slab insulation thickness required. Insert appropriate overall diameter. For details of other specification clauses please consult the data sheet.
edges and penetrations through the foil should be sealed using soft self-adhesive aluminium foil tape.
50
90
100
CONDENSATION CONTROL PIPES
26
CONDENSATION CONTROL FOR PIPES
TABLE 8 (BS5422:2001)
CONDENSATION CONTROL FOR DUCTS
TABLE 10 (BS5422:2001)
CONDENSATION CONTROL DUCTS
27
Minimum insulation thickness for chilled and cold water supplies to prevent condensation on a low emissivity outer surface (0.05) with an ambient temperature of +25oC and a relative humidity of 80%
Outside diameter of steel pipe on which insulation has been based (mm)
TEMPERATURE OF CONTENTS (OC) + 10 +5 0
Minimum insulation thickness for condensation control on ductwork carrying chilled air in ambient conditions: indoor still air temperature +25oC, relative humidity 80%, dew point temperature 21.3oC EXTERNAL SURFACE EMISSIVITY
Thickness of ROCKWOOL RockLap H&V pipe section (mm)
Minimum temperature inside duct (oC)
0.05 (eg bright aluminium foil)
0.44 (eg dusty galvanised steel)
0.90 (eg black paint)
17.2 21.3 26.9 33.7 42.4 48.3 60.3 76.1 88.9 101.6 114.3 139.7 168.3 219.1 244.5 273.0 323.9 355.6 406.4 457.0 508.0 610.0 Flat
20
25
30
35
Minimum thickness of ROCKWOOL Ductwrap (mm)
30 25 35
40 45
15 10 5 0
25 50 65 90
25 40 50
25 30
NOTE Thicknesses given are calculated specifically against the criteria noted in the tables. Adopting these thicknesses may not necessarily satisfy other design requirements.
30
40
50
45 35 50
60
70 40 60 45 50 70 80
HEAT GAIN CHILLED WATER
HEAT LOSS VENTILATION DUCTS
28
CHILLED WATER
VENTILATION DUCTWORK
29
TABLE 9 (BS5422:2001)
Environmental insulation thickness for chilled water supplies to control heat gain
Outside diameter of steel pipe on which insulation has been based (mm)
TABLE 11 (BS5422:2001)
Environmental insulation thickness on ductwork carrying warm air Temperature difference between air inside ductwork and ambient air 10oC 25oC 50oC Environmental thickness of ROCKWOOL Ductwrap and corresponding heat loss 40mm 7.2 W/m2 50mm 15.3 W/m2 60mm 26.0 W/m2
TEMPERATURE OF CONTENTS (OC) +5 +0 Thickness of Heat Heat Thickness of ROCKWOOL gain gain ROCKWOOL RockLap H&V RockLap H&V (W/m) (W/m) pipe section pipe section
(mm) (mm)
21.3 33.7 60.3 114.3 168.3 273.0 508.0 610.0
and above, including flat surfaces
25 30 35 45 60 70 75
2.9 3.5 4.5 6.1 7.2 9.9 15.8 16.2
30 35 45 60 70 80
3.4 4.0 5.0 6.5 7.9 10.6 16.5 17.2
NOTE Thicknesses given are calculated specifically against the criteria noted in the table. Adopting these thicknesses may not necessarily satisfy other design requirements.
100
NOTE 1 Thicknesses given are calculated specifically against the criteria noted in the table. Adopting these thicknesses may not necessarily satisfy other design requirements. NOTE 2 This table should be used only if the control of heat gain already provided by the insulation of chilled pipework for the purposes of condensation control as indicated in Tables 7 and 8 of BS5422:2001does not limit the distribution heat gain to a maximum of 5% of the system load. The method for calculating the system load for chilled pipework is given in annex E of BS5422:2001. Distribution pipework heat gains should be calculated using the formulae given in BS EN ISO 12241 if outside the scope of this Table 9.
HEAT LOSS HEATING
HEAT LOSS HOT WATER
30
HEATING INSTALLATIONS
TABLE 12 (BS5422:2001)
Environmental insulation thickness for non-domestic heating installations to control heat loss
HOT WATER SERVICES
TABLE 13 (BS5422:2001)
31
Environmental insulation thickness for non-domestic hot water service areas to control heat loss Outside diameter of steel pipe on which insulation thickness has been based (mm) 17.2 21.3 26.9 33.7 42.4 48.3 60.3 76.1 88.9 114.3 139.7 168.3 219.1 273.0 Above 323.9 and including flat surfaces Water temperature of 60OC Thickness of ROCKWOOL RockLap H&V pipe section (mm) Heat loss (W/m)
Outside HOT FACE TEMPERATURE (OC ) diameter 75 100 150 of steel Thickness of Thickness of pipe on Thickness of ROCKWOOL ROCKWOOL which ROCKWOOL Heat loss RockLap RockLap Heat loss Heat loss insulation RockLap (W/m) H&V pipe H&V pipe (W/m) (W/m) thickness H&V pipe section section has been section (mm) (mm) based (mm) (mm)
30
17.2 21.3 26.9 33.7 42.4 48.3 60.3 76.1 88.9 114.3 139.7 168.3 219.1 273.0
Above
30
7.7 8.4 9.2 10.1 11.4 12.1 13.5
35 40 45
10.8 11.7 12.9 14.0 15.5 16.4 18.3 20.7 22.6 26.2 29.6 33.5 40.0 46.6 90 80 70 60
16.4 17.6 19.2 20.9 23.2 24.5 27.2 30.2 32.7 37.5 42.2 46.8 55.4 64.2
35
35
40
50
40
15.5 17.0 19.7
45
45
22.5 25.5 30.9 36.3
60
50
5.6 6.1 6.7 7.4 8.2 8.7 9.7 11.0 12.1 14.0 16.0 18.1 21.6 25.1 28.5
NOTE Thicknesses given are calculated specifically against the criteria noted in the table. Adopting these thicknesses may not necessarily satisfy other design requirements.
323.9
and including flat surfaces
50 39.6 70 50.9 71.5
FROST PROTECTION
32
FROST PROTECTION
INDUSTRIAL PROCESS CONDITIONS
TABLE 22 (BS5422:2001)
FROST PROTECTION
COMMERCIAL & INSTITUTIONAL CONDITIONS
TABLE 23 (BS5422:2001)
FROST PROTECTION
33
Minimum insulation thickness to protect steel pipes against freezing under selected industrial process conditions Initial water temperature: +5oC Minimum ambient air temperature: -10oC Outside diameter of pipe (mm) Initial water temperature: +5oC Minimum ambient air temperature: -10oC
Minimum insulation thickness required to give protection against freezing under specified commercial and institutional conditions Initial water temperature: +2oC Min ambient temp: -6oC (Indoor unheated) Outside diameter of pipe (mm) Initial water temperature: +2oC Min ambient temp: -10oC (Outdoor)
Inside Evaluation period: 12h Evaluation period: 12h diameter Permitted ice Permitted ice [bore] formation: nil formation: 10% (mm) Thickness of ROCKWOOL Pipe Section [H&V or Process] (mm)
Inside Evaluation period: 12h Evaluation period: 12h diameter Permitted ice Permitted ice [bore] formation: 50% formation: 50% (mm) Thickness of ROCKWOOL Pipe Section [H&V or Process] (mm)
21.3 26.9 33.7 42.4 48.3 60.3 76.1 88.9 114.3 168.3 219.1
16.0 21.6 27.2 35.9 41.8 53.0 68.8 80.8 105.3 158.6 207.9
863 398 158 85 60 40 25
873 222 82 60 35
Copper pipes 15.0 22.0 28.0 35.0 42.0 54.0 76.1 13.6 20.2 26.2 32.6 39.6 51.6 73.1 105.0 16.0 21.6 27.2 35.9 41.8 53.0 68.8 80.8 25 25 20 25 25 20 20 59 (size not available) 269 (size not available) 50 25
25
108.0 21.3 26.9 33.7 42.4 48.3 60.3 76.1 88.9
Steel pipes 40 20 45 25
Reference notes for both tables NOTE 1 Thicknesses given are calculated specifically against the criteria noted in the table. Adopting these thicknesses may not satisfy other design requirements. NOTE 2 Some of the insulation thicknesses given are too large to be applied in practice but are included to highlight the difficulty in protecting small diameter pipes against freezing. To provide the appropriate degree of frost protection to certain sizes of pipes, it may be necessary to provide additional heat to the system, for example by circulating the water or heat tracing.
STANDARD SCHEDULE PIPES
ADVICE AND LITERATURE
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STANDARD SCHEDULE PIPES
Wall OD (mm) 17.1 21.3 26.7 33.4 42.2 48.3 60.3 73.0 88.9 101.6 114.3 141.3 168.3 219.1 273.0 323.9 355.6 406.4 457.2 508.0 558.8 609.6 thickness (mm) 2.3 2.8 2.9 3.4 3.6 3.7 3.9 5.2 5.5 5.7 6.0 6.6 7.1 8.2 9.3 9.5 9.5 9.5 9.5 9.5 9.5 9.5 Bore (mm) 12.5 15.7 20.9 26.6 35.0 40.9 52.5 62.6 77.9 90.2 102.3 128.1 154.1 202.7 254.4 304.9 336.6 387.4 438.2 489.0 539.8 590.6
ADVICE AND LITERATURE
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Nominal pipe size (inches) 3/8 _ _ 1 1_ 1_ 2 2_ 3 3_ 4 5 6 8 10 12 14 16 18 20 22 24
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