GEO- Global Engineering Consultants Contract Documents

Proposed Culinary and Cream Factory on Plot No. 0050000040 Mechanical Works Specifications
2nd Industrial City, Dammam, K.S.A

SECTION 03

HVAC THERMAL INSULATION

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GEO- Global Engineering Consultants Contract Documents
Proposed Culinary and Cream Factory on Plot No. 0050000040 Mechanical Works Specifications
2nd Industrial City, Dammam, K.S.A

PART 1.0 - GENERAL

1.1 WORK INCLUDED

1.1.1 Compliance with relevant General Requirements of Mechanical Services.

1.2 DESCRIPTION OF WORK

Extent of mechanical insulation is specified in this section.

1.3 REFERENCE STANDARDS

BS 476 Part 6: Fire Tests on Building Materials and Structures, Method of Test for Fire Propagation for
Products (British Standards)

BS 476 Part 7: Fire Tests on Building Materials and Structures, Method of test to determine the
classification of the surface spread of flame of products.

Factory Mutual FM 4924: Flammability standard for pipe and duct insulation.

NFPA 90A and NFPA 90B: Standard for Installation of Air Conditioning Systems.

ASTM C411: Hot-Surface Performance of High-Temperature Thermal Insulation.

ASTM E84 (UL 723, NFPA 255): Surface Burning Characteristics of Building Materials.

International Maritime Organization Resolution MSC 61(67) Part 2: Smoke density and toxicity.

ISO 354: Acoustics – Measurement of Sound Absorption in a Reverberation Room.

ISO 5659 Part 2: Smoke Generation – Determination of Optical Density with additional Gas
Analysis.

ASTM E96: Vapour Permeability of Materials.

ASTM C518: Thermal Conductivity of materials.

ASTM C871: Chemical Analysis of Thermal Insulation Materials for Leachable Chloride, Fluoride,
Silicate, and Sodium Ions.

ASTM G21: Determining Resistance of Synthetic Polymeric Materials to Fungi.

UL 181.11: Flammability of Air Ducts.

EN 13501 Part 1: Fire Classification of Construction Products and Building Elements Using Datafrom
Reaction-to-Fire Tests.

1.4 QUALITY ASSURANCE

Insulation material shall comply with the following British Standard: BS

476 (Part 4, 6, 7)
BS 874

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GEO- Global Engineering Consultants Contract Documents
Proposed Culinary and Cream Factory on Plot No. 0050000040 Mechanical Works Specifications
2nd Industrial City, Dammam, K.S.A

BS2972
BS3958 (Part 4,5)
BS 5422
BS6676 (Part 1)

1.5 SUBMITTALS

Product Data : Submit manufacturers technical product data and installation instructions for each
type of mechanical insulation, submit schedule showing manufacturer’s product number, k-value,
thickness and furnished accessories for each mechanical system requiring insulation.

Submit samples for each types of mechanical insulation.

Provide mock up installation before progressing with work.

1.6 DELIVERY, STORAGE AND HANDLING

Protect insulation from moisture and dirt by inside storage and enclosure and polythene
wrapping in accordance with the manufacturer’s recommendations.

1.7 MAINTENANCE DATA

Submit maintenance data for each type of mechanical insulation. Include this data, product data,
and certifications in the maintenance manual.

PART 2.0 – PRODUCTS

2.1 MATERIALS

2.1.1 Insulating materials shall have thermal conductivity values not more than those listed hereafter:

---------------------------------------------------------------------------------------------------
MATERIAL TYPE THERMAL CONDUCTIVITY.
W/M/DEG.C
------------------------------------------------------------------------------------------------
Fibre Glass All 0.034
Closed Cell All 0.032
-------------------------------------------------------------------------------------------------

All conductivity figures are rated at an average temperature of 24 deg C.

2.2 LAGGING ADHESIVE

Adhesive shall be a flexible, fire resistive compound suitable for vapour sealing insulated ducts
and pipes.

Adhesive shall be suitable for indoor and outdoor use and in high humidity environments.
Water vapour permeance shall not exceed 0.05 perms at 0.030 inch dry film thickness when
tested in compliance with ASTMF 1249.
When tested for surface burning characteristics in compliance with ASTM E84, flame spread
shall be 10 and smoke developed 15.

Adhesive shall be UL classified and shall meet or exceed the requirements of NFPA 90A and 90
B 25/50.

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 GEO- Global Engineering Consultants Contract Documents
Proposed Culinary and Cream Factory on Plot No. 0050000040 Mechanical Works Specifications
2nd Industrial City, Dammam, K.S.A

2.3 FUNGICIDAL PROTECTIVE COATINGS

Fungicidal protective coatings shall be applied over external surfaces of pipes and interior and
exterior surfaces of ductwork.

Coating shall be a polyacrylate copolymer emulsion specially formulated for long term fungicidal
activity with no loss of activity on aging and providing high corrosive resistant. It shall prevent the
spread of molds and odour causing bacteria on the applied surface.

Coating shall meet the requirements of NFPA 90A and 90B.

2.4 Insulation material

2.4.1 Refrigerant piping materials properties

Material: Closed cell elastomeric rubber insulation to meet the following criteria and comply with all
reference standards in section 1.3.
 Temperature Range: -40 ° C + 105 ° C.
 Thermal Conductivity: <0.034 W/mk at 23°C.
 Insulation Material shall be Anti-Microbial with Microban technology.
 Insulation Material shall be ASTM E 84 and FM Approved for all proposed thicknesses.
 The material shall be “FM Approved” and the FM Mark shall be printed on the insulation facing.
 Rating: Class 0 BS 476: Part 6 and 7 for all proposed thicknesses.
 Density: 45 kg/mз up to 65 kg/mз.
 Closed Cell Content: > 95%.
 GWP and ODP rating should be zero certified by Third Party.
 Material shall be CFC free.
 Refer to section 1.3 for compliance

2.4.2 HVAC Ducting insulation Properties

Material: Fiberglass insulation to meet the following criteria and comply with all reference
standards in section 1.3.

 Dimensional Stability: ASTM D 2126, maximum 1.0% linear change at -40ºF, ambient RH after 2
weeks max 2.0% linear change at 100ºF, 97% RH after 2 weeks.
 Durability: ASTM C 719, more than10 cycles; no cohesive failure or cracking.
 Flame Spread: ASTM E 84, Less than 25.
 Smoke Developed: ASTM E 84, Less than 450.
 Tack-Free: Dry to the touch within 20 minutes.
 Pressure Build: AAMA 812, less than 0.1 psi.
 Leakage Rate: ASTM E 283, less than 0.01 cfm/ft.2 at 1.57 psf (75 Pa) and 6.24 psf (300 Pa)
pressure.
 Fire Blocking performance: ASTM E814, pass

2.5 APPLICATION

2.5.1 Ductwork Insulation

 Concealed supply return and extract air ducts.

Unless otherwise indicated insulate all ductwork with 25 mm thick, 24 Kg/M3 density aluminium foil faced fiberglass
duct insulation. Fasten the insulation with adhesive on 200 to 250 mm centres. Butt all joints tightly and seal all breaks
and joints by adhering a 75 mm Aluminum foil vapour barrier tape or sheet with a fire-retardant adhesive.

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 GEO- Global Engineering Consultants Contract Documents
Proposed Culinary and Cream Factory on Plot No. 0050000040 Mechanical Works Specifications
2nd Industrial City, Dammam, K.S.A

Insulate flexible connections and connections to diffusers with 25 mm thick, 24 Kg/M3 density reinforced aluminium
foil faced, flame resistant flexible fiberglass insulation. Overlap onto adjacent insulation and seal with adhesive duct
tape to give good closure.
Where ductwork is installed in ceiling voids, which are not used as return air plenums insulate with 50mm thick, 48
Kg/M3 density aluminium foil faced rigid fibreglass duct insulation.

Finish all duct insulation with a 20x20 (thread/inch) woven glass cloth cover adhered between two coats of fire
resistant fungicidal protective lagging adhesive.

 Exposed supply return and extract air ducts.

For ducts exposed inside conditioned spaces, insulate as described above for concealed air ducts using 25mm thick
aluminium foil faced fiberglass boards with density 48 kg/M3.

Then apply a 20 x 20 (thread/inch) woven glass cloth cover adhered between two coats of fire resistant fungicidal
protective lagging adhesive.

Generally, Should the exposed Duct work be liable to mechanical damage, the insulation to be protected with
22-gauge stucco embossed aluminum cladding secured with pop rivets. Aluminum securing bands may be omitted
under cladding.

For ducts exposed in non-air-conditioned areas, insulate using the method described for concealed ducts, but using
insulation with a minimum thickness of 50 mm, 48 Kg/M3 density rigid fiberglass insulation. Then apply a 20x20
(thread/inch) woven glass cloth cover adhered between two coats of fire resistant fungicidal protective lagging
adhesive. Then cover with plain sheet Aluminum, 0.9 mm or thicker.

All ductwork exposed externally to the building, installed on roof and within plant rooms is to be clad with plain
aluminum, 0.9 mm or thicker.

Where ducts penetrate the building shell, the duct shall be flashed and waterproofed before any insulation is applied.

Refrigerant Pipework Insulation

Refrigerant Copper pipework shall be insulated with closed cell synthetic rubber foam insulation ,
25mm thick ; External Refrigerant pipes (on roofs and in Equipment yard) shall be insulated by 50mm
thick rigid insulation for pipe sizes up to 40 mm dia and 75 mm for for 50mm dia and above.
For both internal and external pipes the insulation shall be finished with a water proof 20x20
(thread/inch) woven glass cloth cover painted with two coats of approved anti-fungal lagging
adhesive.

Where insulated pipework is run on roof, in Equipment room / yard it shall be clad using an
outer covering of plain aluminum sheet of 0.7mm or thicker.

Where exposed, insulated pipework runs through occupied or public areas it shall be clad using
an outer covering of plain aluminum sheet of 0.7 mm or thicker.

2.5.2 Condensate drain pipework

Condensate drain pipework’s shall be provided with flexible elastomeric thermal insulation of
thickness based on pipe diameter as follows:

a. 25 mm (1 inch) to 50 mm (2 inch) Pipe: 25 mm (1 inch) minimum.

PART 3.0 - EXECUTION

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GEO- Global Engineering Consultants Contract Documents
Proposed Culinary and Cream Factory on Plot No. 0050000040 Mechanical Works Specifications
2nd Industrial City, Dammam, K.S.A

3.1 The whole of the insulation work shall be carried out by an approved specialist insulation
Contractor.
3.2 All allowances shall be included for arranging a specialist subcontract accordingly and for
informing the specialist Sub-contractor of all conditions relating to the Contract and for
coordinating his works with the remainder of the works.
3.3 All adhesives, mastics, coatings, sealers and primers shall be classified as Class 1 surface spread
when tested in accordance with B.S. 476, part 7. They shall not in any way attack the insulation
or the surface to which the insulation is being applied and shall be suitable for the working
temperatures.
3.4 The Contractor is to allow in his price for the removal and replacement of two sections of each
type of insulation. If, however, defects are revealed, further sections shall be cut out for
inspection, and all cutout sections shall be replaced at no cost to the Contract.
3.5 If further defects are revealed then the Consultant shall have the right, when in its opinion it is
necessary, to issue instructions for any part or the whole of the insulation to be removed and
replaced. The replacement with new insulation shall be to the satisfaction of the Consultant and
the cutting out and replacing shall be at no cost to the Contract.
3.6 Particular attention shall be paid to the finished appearance of all thermal insulation which must
present a neat and symmetrical appearance running true in line with pipe layouts, etc.
3.7 Any rough, irregular and badly finished surfaces shall be stripped down and re-insulated to
the Consultant’s satisfaction.
3.8 All systems are to have been tested and approved by the Consultant prior to installation of
insulation.
3.9 The insulation, in sizes indicated shall be applied over clean, dry surfaces. Adjoining sections of
insulation should be butted firmly together with the longitudinal seam of the jacket located on
the bottom half of the pipe.
3.10 Insulate and finish valves and fittings in the same manner and same thickness as piping in which
such items are installed. Moulded, factory shaped sectional pipe covering, factory- or job-
fabricated may be used subject to satisfactory visual checking by the Consultant.
3.11 Direct contact between pipe and hanger shall be avoided. Hangers shall pass outside of the sheet
metal protection saddle, which shall cover a section of high density insulation, of sufficient length
to support the pipe without crushing the insulation. The vapour barrier shall be lapped over the
saddle and securely cemented to it. Minimum thickness of metal saddle is 1.5 mm.
3.12 The insulation shall be installed in accordance with the manufacturer’s printed instructions.
3.13 Coating addendum:

- Equipment Surface coating Preparation All surfaces must be clean, sound, and free of any
oils, dirt, grease, wax and any other contamination that may interfere with coating
adhesion. In general, the surface should be cleaned by solvent or a cleaner at elevated
temperature followed by a clean water rinse. All surfaces must be dried prior to
application of coating. In cases where there is a large amount of contamination, a
commercial blast is acceptable. Contact Heresite for coil remediation process.
- Recommended Uses
Heresite VR-514 is a heavy-duty primer-finish combination material specially formulated
for marine/saltwater environments — particularly for HVAC equipment, agricultural
implements, chemical and wastewater treatment plants.
- If the VR-514 coated surfaces will be subjected to direct ultraviolet (UV) exposure, a spray-
applied topcoat of Heresite UC-5500 series should be applied
- Chemical Resistance VR-514 is chemically resistant to a wide range of acids, solvents, and
inorganic salts. Please review chemical resistance guide for further information.
- Film Thickness
For heat transfer, a 2 coat spray process will typically yield a dry film thickness of 1.5–2.5
mils (38–63.5 microns). For use with Heresite UC-5500 series, in the event of UV exposure,
apply approximately 1.5 mil (~38 microns) of VR514 followed by approximately 1.5–2.0
mils (38–50 microns) For all other surfaces, a typical dry film thickness of 4–6 mils (102–

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GEO- Global Engineering Consultants Contract Documents
Proposed Culinary and Cream Factory on Plot No. 0050000040 Mechanical Works Specifications
2nd Industrial City, Dammam, K.S.A

152 microns).
- Thinning
Reduce VR-514 with S-275 solvent to 20–25 seconds on Zahn #2 Cup. This requires
approximately 1 gallon of paint to 0.25 gallons of solvent. If using S-440, the reduction
ratio is equivalent. The amount of thinner required is dependent upon temperature,
ventilation, humidity, application type and desired film thickness.
- Spray Application: Shall be as per manufacturer’s recommendations; contractor to Consult
/ Hire a Coating specialist at no additional cost and Submit Method statements for coating
spray strategies considering all safety, Technical precautions, for engineer’s approval

- Warranty:
All coating and top coating system components furnished under this Project shall be
guaranteed against defect in design, material and workmanship for the full warranty time
which is standard with the manufacturer and/or supplier but not less than 20 year from
the date of system Application. In addition, the installing Contractor must guarantee the
design or workmanship for a period of one year from final acceptance. In the event of the
above conditions, the installing Contractor shall completely recharge and recondition the
system at no cost to the Company.

END OF SECTION

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