Project Name Specification for Mechanical Works

www.sutcliffeconsulting.co.uk

12.0 THERMAL INSULATION

12.1 Introduction

12.1.1 All insulation works shall be carried out by a specialist firm which is a member of
the Thermal Insulation Contractors Association (TICA).

12.1.2 All materials shall be applied in accordance with manufacturers

recommendations.

12.1.3 Insulation thickness shall conform to the BS 5422:2009 Environmental Thickness

Tables specified by the DETR as the basis of qualification for Enhanced Capital
Allowances for thermal insulation.

12.1.4 Thermal insulation materials and installation methods shall be strictly in

accordance with the appropriate British Standard Specifications and Codes of
Practice sections:
BS 3533 Glossary of thermal insulation terms.

BS 5422 -2009 Method for specifying thermal insulating materials on pipes,

ductwork and equipment (in the temperature range -40°C to
+700°C).

BS 5970 -2001 Code of Practice for thermal insulation of pipework and

equipment (in the temperature range -100°C to +870°C).

BS 3927- 1986 Specification for rigid phenolic foam (PF) for thermal insulation in
the form of slabs and profiled sections.

BS 3958 - Thermal insulating materials.

Part 3: Metal mesh faced man-made mineral fibre mattresses
Part 4: Bonded preformed man-made mineral fibre pipe sections
Part 5: Specification for bonded man-made mineral fibre slabs

BS 476 - Fire tests on building materials and structures

Part 4: Non-combustibility test for materials
Part 6: Method of test for fire propagation for products
Part 7: Surface spread of flame tests for materials.
(Note Part 5 has been withdrawn by BSI)

BS 5111- Methods of test for determination of smoke generation

characteristics of cellular plastics and cellular rubber
materials

12.2 General Requirements

12.2.1 Materials delivered to site shall be new and dry and be maintained in good
condition throughout the progress of the works.

12.2.2 Insulating materials, coverings and coatings shall be of a uniform thickness

throughout.

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12.2.3 The insulation shall have a smooth lineable finished surface and rigid sections
shall be concentric and accurately matched. The Engineer will not accept
insulation sections having damaged ends or edges or irregularities in the
thickness of materials. To ensure that the correct thickness has been applied the
Engineer reserves the right to cut out specimen sections of each type of duct or
pipe insulation for inspection. If the inspection reveals that the insulation is not in
accordance with this specification all insulation shall be stripped off and
reinstated at the Contractors expense.

12.2.4 Each pipe shall be insulated separately so that adjacent parallel pipes are not
married together in one insulation covering. There shall be a minimum
clearance of 25mm between adjacent insulation surfaces.

12.2.5 All joints, surfaces, edges and overlaps shall be neatly finished. Where possible,
overlaps shall be arranged on the blind side or on the water shedding side.

12.2.6 A sound continuous vapour barrier shall be provided on all cold surfaces
comprising a factory applied "Bright Class O" reinforced aluminium foil vapour
barrier jacket. Where this is not possible the vapour barrier shall be effectively
sealed to the pipe or duct to prevent any ingress of moisture or water vapour.

12.2.7 Where allowance for expansion and/or contraction has to be accommodated

the insulation shall be finished in an acceptable manner permitting ease of
access to disconnect the removable section/sections without disturbing the
surrounding insulation.

12.2.8 Where an insulated duct or pipe enters the building, adequate precautions shall
be taken to prevent the ingress of water.

12.2.9 No thermal insulation materials shall be applied to any part of the works until the
installation or sections of the installation have been pressure tested.

12.2.10 All surfaces to be insulated shall be clean, dry and free from rust and foreign
matter, including surplus soldering flux and building materials debris and dust.

12.2.11 All insulating materials shall have a Building Regulations "Class O" Fire Rating and
a Smoke Emission Rating less than 5% in accordance with BS 5111.

12.3 Low Temperature Hot Water

12.3.1 The Insulation Material to be used for the low temperature hot water heating
pipework shall be as follows:
Kooltherm Pipe Insulation; cfc-free phenolic foam, bore-coated preformed
sections with factory applied Bright Class O reinforced aluminium foil jacket.

Standard density: 35kg/m3

Thermal Conductivity: 0.023W/m·K at 50°C mean temperature of
insulation
Fire Rating: Class O in accordance with the Building
Regulations, Approved Document B, Appendix
A12.
Smoke Emission Rating: Less than 5% in accordance with BS 5111
Colour: Grey

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Factory applied facing: Bright Class O reinforced aluminium foil

Manufacturer: Kingspan Industrial Insulation Products Ltd

Location: Internal Pipework in Concealed Locations ref TI-1

12.3.2 All pipelines shall be insulated with Kooltherm Pipe Insulation having a factory
applied Bright Class O reinforced aluminium foil facing. The sections shall be
close butted together and all joints sealed with 50mm matching self-adhesive
foil tape. Sections shall be firmly secured by two 15mm aluminium bands per
metre run equally spaced between the circumferential joints.

12.3.3 Pipe fittings shall be insulated with segments of insulation secured with adhesive
and finished in the appropriate facing material. Mitred pipe sections shall be
used for small pipework. All joints shall be sealed with 50mm matching self-
adhesive foil tape.

Location: Internal Pipework within boiler rooms & plant rooms ref TI-2

12.3.4 All pipework within the cleaner’s cupboard shall be insulated with Kooltherm
Pipe Insulation as above. The sections shall be close butted together and all
joints sealed with 50mm matching self-adhesive foil tape. Sections shall be firmly
secured by two additional bands of 50mm self-adhesive foil tape per metre run
equally spaced between the circumferential joints. An Isogenopak PVC finish
shall be applied in accordance with the manufacturer’s recommendations.

12.3.5 Pipe fittings shall be insulated with segments of insulation secured with adhesive
and finished in the appropriate facing material. Mitred pipe sections shall be
used for small pipework.

Location: Pipework Outside the Building Ref: TI-3

12.3.6 All pipework, valves, strainers and other fittings shall be insulated with Kooltherm
Pipe Insulation as above. The sections shall be close butted together and all
joints sealed with 50mm matching self-adhesive foil tape. Sections shall be firmly
secured by two additional bands of 50mm self-adhesive foil tape per metre run
equally spaced between the circumferential joints.

12.3.7 Insulation shall be protected with weatherproof 20 gauge Hammerklad

aluminium sheeting overlapped and secured with suitable bands. All
longitudinal and radial joints shall be overlapped by a minimum of 50mm.
Terminal end caps shall be applied at the square ends of insulation. Alternative
weatherproof cladding may also be provided such as Plysolene PIB jacketing or
Venture Clad Jacketing or other approved product.

12.3.8 Valves shall be insulated with weather-proof removable split aluminium covers
lined with insulation and fitted with quick release toggle fasteners.

12.4 Air Conditioning and Warm Air Ductwork

12.4.1 The Insulation Material to be used for the air conditioning and warm air
ventilation ductwork shall be as follows:
Kooltherm Duct Insulation; cfc-free rigid phenolic foam laminated slabs with
factory applied Bright Class O reinforced aluminium foil facing.
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Standard density: 40 kg/m3

Thermal Conductivity: 0.018 W/m·K at 10°C mean temperature of
insulation
Fire Rating: Class O in accordance with the Building
Regulations,
Approved Document B, Appendix A12.
Smoke Emission Rating: Less than 5% in accordance with BS 5111
Manufacturer: Kingspan Industrial Insulation Products Ltd

Or;
Crown Mineral Wool flexible ductwrap insulation with factory applied Bright
Class O facing.

Nominal Density: 45kg/m3

Thermal Conductivity: 0.040 W/m·K at 10°C mean temperature of
insulation
Manufacturer: Owens Corning-Alcopor or other approved.

Location: Internal Ductwork in Concealed Locations Ref: TI-4

12.4.2 Circular/Oval ductwork shall be insulated with Crown Ductwrap Insulation

having a factory applied reinforced aluminium foil laminate facing complying
with BS 5422 (table 1) and BS 5970 (table 8) water vapour permeability and
Building Regulations Class 'O' definition.

12.4.3 The insulation shall be bonded to the ductwork by means of a suitable adhesive
in accordance with the manufacturer's recommendations. Joints shall be
securely taped with 100mm minimum wide soft aluminium self adhesive tape,
Idenden Type T303 or other approved.

12.4.4 The insulation shall be supported by means of 19-22 swg x 50mm mesh
galvanised wire netting. Care shall be taken to avoid damaging the aluminium
foil vapour barrier.

12.4.5 On the exposed edges of the slab, e.g. corners provision shall be made to carry
the aluminium foil to the adjoining slab to maintain the integrity of the vapour
barrier.

Location: Ductwork Outside the Building Ref: TI-5

12.4.6 Rectangular ductwork shall be insulated with Kingspan Duct Insulation, rigid foil
faced slabs having a factory applied reinforced aluminium foil facing
complying with BS 5422 (table 1) and BS 5970 (table 8) water vapour
permeability and Building Regulations Class 'O' fire rating definition.

12.4.7 Duct supports shall be fitted with Kooltherm purpose designed high density
phenolic foam foil faced duct support strips as manufactured by Kingspan
Industrial Insulation Products Ltd.

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12.4.8 The insulation shall be bonded to the ductwork by means of a suitable adhesive
in accordance with the manufacturer's recommendations. Joints shall be
securely taped with 75 mm minimum wide soft aluminium self adhesive tape,
Idenden Type T303 or other approved.

12.4.9 The insulation on the underside of the duct shall be additionally secured by
means of suitable insulation hangers spaced at maximum 300mm centres
square spacing.

12.4.10 Where support pins/hangers puncture the foil, they shall be cropped back to
the washers and sealed using an aluminium foil tape to maintain the vapour
barrier.

12.4.11 On the exposed edges of the slab, e.g. corners provision shall be made to carry
the aluminium foil to the adjoining slab to maintain the integrity of the vapour
barrier.

12.4.12 The whole of the insulation shall be encased with 22 gauge stucco embossed
aluminium cladding secured with pop rivets at 225mm centres and
incorporating a "water shed" on the top. All joints shall be sealed with mastic to
provide a water proof installation. Alternative weatherproof cladding may also
be provided such as Plysolene PIB jacketing or Venture Clad Jacketing or other
approved product.

12.4.13 Extreme care shall be exercised when cladding air conditioning ductwork to
ensure any riveting of the aluminium cladding does not perforate the foil facing
on the insulation and destroy the vapour barrier.

12.5 Domestic Hot and Cold Water

12.5.1 The Insulation Material to be used for domestic hot and cold water pipework
shall be as follows:
Kooltherm Pipe Insulation; cfc-free phenolic foam, bore-coated preformed
sections with factory applied Bright Class O reinforced aluminium foil jacket.

Standard density: 35kg/m3

Thermal Conductivity: 0.018W/m·K at 10°C mean temperature of
insulation
Fire Rating: Class O in accordance with the Building
Regulations,
Approved Document B, Appendix A12.
Colour: Grey
Factory applied facing: Bright Class O reinforced aluminium foil
Manufacturer: Kingspan Industrial Insulation Products Ltd

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Location: Internal Pipework in Concealed Locations ref TI-6

12.5.2 All pipelines shall be insulated with Kooltherm Pipe Insulation having a factory
applied Bright Class O reinforced aluminium foil facing. The sections shall be
close butted together and all joints sealed with 50mm matching self-adhesive
foil tape. Sections shall be firmly secured by two 15mm aluminium bands per
metre run equally spaced between the circumferential joints.

12.5.3 Pipe fittings shall be insulated with segments of insulation secured with adhesive
and finished in the appropriate facing material. Mitred pipe sections shall be
used for small pipework. All joints shall be sealed with 50mm matching self-
adhesive foil tape.

Location: Internal Pipework within boiler rooms & plant rooms ref TI-7

12.5.4 All pipelines shall be insulated with Kooltherm Pipe Insulation having a factory
applied Bright Class O reinforced aluminium foil facing. The sections shall be
close butted together and all joints sealed with 50mm matching self-adhesive
foil tape. Sections shall be firmly secured by two 15mm aluminium bands per
metre run equally spaced between the circumferential joints.

12.5.5 Pipe fittings shall be insulated with segments of insulation secured with adhesive
and finished in the appropriate facing material. Mitred pipe sections shall be
used for small pipework. All joints shall be sealed with 50mm matching self-
adhesive foil tape.

12.5.6 An Isogenopak PVC finish shall be applied in accordance with the

manufacturer’s recommendations.

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12.6 Insulation Thickness Tables – In Accordance with BS 5422:2009

12.6.1 Thicknesses shown in the tables are based on manufacturers typical declared
thermal conductivity values at the appropriate mean temperature of insulation
as follows;
Table 7: Typical Thermal Conductivity Values of Insulation

Mean temperature of insulation (ºC)

Insulating material 0 +10 +50 +75 +100
Thermal conductivity (W/m·K)
Phenolic foam (PF) 0.018 0.018 0.023 0.025 *
Mineral wool (MW) 0.032 0.034 0.037 0.040 0.044
Nitrile rubber (NR) 0.035 0.037 0.040 0.043 *

* Not recommended for use at these mean temperatures

12.6.2 Thickness of insulation for chilled and cold water supplies to prevent
condensation on a low emissivity outer finish in an ambient still air temperature
of 25ºC and relative humidity of 80%. (In accordance with BS 5422:2009 - Table
8)
Table 8: Chilled and Cold Water Services

Temperature of water (ºC)

Pipe size
+10 +5 0
(mm)
Thickness of insulation (mm)
Phenolic Mineral Phenolic Mineral Phenolic Mineral
NB OD
foam wool foam wool foam wool
15 21 15 20 20 25 20 30
20 27 15 25 20 30 25 40
25 34 15 25 20 30 25 40
32 42 15 25 20 30 25 50
40 48 15 30 25 30 30 50
50 60 20 30 25 40 30 50
65 76 20 30 25 40 30 50
80 89 20 30 25 40 35 50
100 114 20 30 30 40 35 50

Vessels and flat

30 50 40 65 55 80
surfaces
Note: For frost protection applications refer to Table 14 within this section of the
specification.

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12.6.3 Indicative thickness of insulation for non-domestic heating services to control

heat loss. (In accordance with BS 5422:2009 - Table 15)
Table 9: Non-Domestic Heating Installations

Hot face temperature of installation (ºC)

Steel pipe size
+75 +100 +125
(mm)
Thickness of insulation (mm)
Phenolic Mineral Phenolic Mineral Mineral Calcium
NB OD
foam wool foam wool wool silicate
15 21 15 30 20 30 30 65
20 27 20 35 20 35 40 80
25 34 20 35 25 40 50 95
32 42 20 40 25 45 60 120
40 48 25 40 25 45 65 120
50 60 25 45 30 50 70 125
65 76 25 45 30 55 75 130
80 89 25 45 30 55 75 135
100 114 30 50 35 60 80 140

Vessels and flat

35 50 45 70 95 145
surfaces

12.6.4 Indicative thickness of insulation for non-domestic hot water service areas to
control heat loss. (In accordance with BS 5422:2009 - Table 17)
Table 10: Non-Domestic Hot Water Services (600C)

Steel pipe size Water temperature of 60ºC

(mm) Thickness of insulation (mm)
NB OD Phenolic foam Mineral wool
15 21 15 25
20 27 15 30
25 34 20 30
32 42 20 30
40 48 20 35
50 60 20 35
65 76 25 35
80 89 25 40
100 114 25 40
150 168 30 50
200 219 30 50
250 273 30 50
300 324 30 50
Vessels and flat
35 50
surfaces

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12.6.5 Indicative thickness of insulation for domestic heating and hot water systems
having low emissivity outer surfaces. (In accordance with BS 5422:2009 - Table
19).
Table 11: Domestic Central Heating Installations (750C) and Hot Water Systems
(60°C)

Water temperature of 60ºC/75ºC

Outside diameter
of copper pipe Thickness of insulation (mm)
(mm)
Phenolic foam Mineral wool
10 15 25
12 15 25
15 15 30
22 20 40
28 20 40
35 25 40
42 25 40
54 25 50
Cylinders 35 50

12.6.6 Indicative thickness of insulation for ductwork carrying warm air to control heat
loss. (In accordance with BS 5422:2009 - Table 13)
Table 12: Ductwork Carrying Warm Air
Temperature difference between air inside ductwork and minimum ambient air
(ºC)
10 25 50
Environmental thickness of insulation (mm)
Phenolic Mineral Phenolic Mineral Phenolic Mineral
foam wool foam wool foam wool
20 40 25 50 35 65

12.6.7 Thickness of insulation for condensation control on ductwork carrying chilled air
in ambient conditions 25ºC, 80% RH. (In accordance with BS 5422:2009 - Table
12)
Table 13: Ductwork Carrying Chilled Air

Minimum air temperature inside the ductwork (ºC)

15 10 5 0
Thickness of insulation (mm)
Phenolic Mineral Phenolic Mineral Phenolic Mineral Phenolic Mineral
foam wool foam wool foam wool foam wool
20 30 25 50 40 75 50 100

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12.6.8 Minimum thickness of insulation required to give protection against freezing

under specified commercial and institutional conditions (In accordance with BS
5422:2009 - Table 29)

Table 14: Frost Protection

Initial water temperature + 2 ºC + 2 ºC

-6 ºC (Indoor
Minimum ambient temperature -10 ºC (Outdoor)
unheated areas)
Evaluation period 12 h 12 h
Permitted ice formation 50 % 50 %
Pipe size (mm) Thickness of insulation (mm)
Phenolic Mineral Phenolic Mineral
O.Dia Bore
foam wool foam wool
Copper pipes
15,0 13,6 23 (25) 78 (80) 68 (70) 413 (420)
22,0 20,2 10 (15) 23 (25) 21 (25) 58 (60)
28,0 26,2 7 (15) 13 (20) 13 (15) 28 (30)
35,0 32,6 5 (15) 10 (20) 9 (15) 18 (20)
42,0 39,6 4 (15) 7 (20) 7 (15) 13 (20)
54,0 51,6 3 (15) 5 (20) 5 (15) 9 (20)
76,1 73,1 2 (15) 4 (20) 4 (15) 6 (20)
108,0 105,0 2 (15) 3 (20) 3 (15) 4 (20)
Steel pipes
21,3 16,0 18 (20) 48 (50) 44 (45) 173 (175)
26,9 21,6 10 (15) 21 (25) 20 (20) 52 (60)
33,7 27,2 7 (15) 14 (20) 13 (15) 29 (30)
42,4 35,9 5 (15) 9 (20) 9 (15) 17 (20)
48,3 41,8 4 (15) 7 (20) 7 (15) 13 (20)
60,3 53,0 3 (15) 6 (20) 5 (15) 10 (20)
76,1 68,8 3 (15) 4 (20) 4 (15) 7 (20)
88,9 80,8 2 (15) 4 (20) 3 (15) 6 (20)

12.6.9 Thicknesses given are minimum calculated specifically against the criteria noted
in the table. Adopting these thicknesses may not satisfy other design
requirements. Thicknesses shown in brackets are nearest standard thicknesses
normally available from manufacturers.

12.6.10 Some of the insulation thicknesses calculated are too large to be applied in
practice but are included to highlight the difficulty in protecting small diameter
pipes against freezing under extreme conditions. In these cases, to provide the
appropriate level of frost protection to certain sizes of pipes, it may be necessary
to provide additional heat to the system, for example by controlled periodic
circulation of the water or by heat tracing.

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