SECTION 15560 HVAC PIPE INSULATION

This spec was part of the Des Plaines, IL River WRF project that bid Feb 26, 2015.


SECTION 15560 HVAC PIPE INSULATION

PART 1 - GENERAL

1.1 SUMMARY

A. This section contains piping insulation requirements for the following HVAC system piping:

1. Hydronic Piping for HVAC Systems

2. Refrigerant Piping for HVAC Systems

1.2 QUALITY ASSURANCE

A. Fire-Test-Response Characteristics: As determined by testing materials identical to those specified in this Section according to ASTM E 84, by a testing and inspecting agency acceptable to authorities having jurisdiction. Factory label insulation and jacket materials and sealer and cement material containers with appropriate markings of ap- plicable testing and inspecting agency.

1. Insulation Installed Indoors: Flame-spread rating of 25 or less, and smoke- developed rating of 50 or less.

2. Insulation Installed Outdoors:   Flame-spread rating of 75 or less, and smoke- developed rating of 150 or less.

1.3 DELIVERY, STORAGE, AND HANDLING

A. Packaging: Ship insulation materials in containers marked by manufacturer with ap- propriate ASTM specification designation, type and grade, and maximum use tempera- ture.

1.4 COORDINATION

A. Coordinate size and location of supports, hangers, and insulation shields

B. Coordinate clearance requirements with piping Installer for insulation application.

1.5 SCHEDULING

A. Schedule insulation application after testing piping systems and, where required, after installing and testing heat-trace tape. Insulation application may begin on segments of piping that have satisfactory test results.

PART 2 - PRODUCTS

2.1 MANUFACTURERS – HYDRONIC SYSTEM INSULATION

A. Manufacturers:  Subject to compliance with requirements, provide products by one of the following:

1. Mineral-Fiber Insulation:

a. CertainTeed Manson.
b. Knauf FiberGlass GmbH.
c. Owens-Corning Fiberglas Corp.
d. Schuller International, Inc.

2.2 INSULATION MATERIALS – HYDRONIC SYSTEMS

A. Mineral-Fiber Insulation:   Glass fibers bonded with a thermosetting resin complying with the following:

1. Preformed Pipe Insulation:   Comply with ASTM C 547, Type 1, with factory- applied, all-purpose, vapor-retarder jacket.

2. ASTM C 553, Type IV, has similar properties to ASTM C 547, Type I. For op- erating temperatures higher than 850 deg F (454 deg C), change insulation below to ASTM C 553, Type V.

3. Fire-Resistant Adhesive:   Comply with MIL-A-3316C in the following classes and grades:

a. Class 1, Grade A for bonding glass cloth and tape to unfaced glass-fiber in- sulation, for sealing edges of glass-fiber insulation, and for bonding lag- ging cloth to unfaced glass-fiber insulation.
b. Class 2, Grade A for bonding glass-fiber insulation to metal surfaces.

4. Vapor-Retarder Mastics:  Fire- and water-resistant, vapor-retarder mastic for in- door applications.  Comply with MIL-C-19565C, Type II.

5. Mineral-Fiber Insulating Cements:  Comply with ASTM C 195.

6. Expanded   or   Exfoliated   Vermiculite   Insulating   Cements: Comply   with ASTM C 196.

7. Mineral-Fiber, Hydraulic-Setting Insulating and Finishing Cement:  Comply with ASTM C 449/C 449M.

B. Accessories

1. Adhesives:  Compatible with insulation.

2.3 FIELD-APPLIED JACKETS – HYDRONIC SYSTEMS

A. General: ASTM C 921, Type 1, unless otherwise indicated.

B. PVC Jacket: High-impact-resistant, UV-resistant PVC complying with ASTM D 1784, Class 16354-C; 30 mils thick; roll stock ready for shop or field cutting and forming. Thickness is indicated in field-applied jacket schedules.

1. Adhesive:  As recommended by jacket material manufacturer.

2. PVC jackets are available in several colors. Colored jackets may be used to re- place field painting. UV rays fade colors in exterior applications. Some colors (black, gray, and white) do not fade as quickly as other colors (red, orange, and green). Colored jackets have different emissivity and are not recommended for outdoor use.

3. Color:  White

C. Standard PVC Fitting Covers: Factory-fabricated fitting covers manufactured from 20- mil- thick, high-impact, ultraviolet-resistant PVC.

1. Shapes: 45- and 90-degree, short- and long-radius elbows, tees, valves, flanges, reducers, end caps, soil-pipe hubs, traps, mechanical joints, and P-trap and supply covers for lavatories for the disabled.

2. Adhesive:  As recommended by insulation material manufacturer.

2.4 ACCESSORIES AND ATTACHMENTS – HYDRONIC SYSTEMS

A. Glass Cloth and Tape: Comply with MIL-C-20079H, Type I for cloth and Type II for tape. Woven glass-fiber fabrics, plain weave, presized a minimum of 8 oz./sq. yd..

1. Tape Width: 4 inches.

B. Bands: 3/4 inch wide, in one of the following materials compatible with jacket:

1. Stainless Steel: ASTM A 666, Type 304; 0.020 inch thick.

2. Galvanized Steel: 0.005 inch thick.

3. Aluminum:  0.007 inch thick.

4. Brass: 0.010 inch thick.

5. Nickel-Copper Alloy: 0.005 inch thick.

C. Wire: 0.080-inch, nickel-copper alloy; 0.062-inch, soft-annealed, stainless steel; or 0.062-inch, soft-annealed, galvanized steel.

2.5 VAPOR RETARDERS

A. Mastics: Materials recommended by insulation material manufacturer that are compat- ible with insulation materials, jackets, and substrates.

2.6 INSULATION MATERIALS FOR REFRIGERATION PIPING

A. Flexible Elastomeric Insulation: Closed-cell, sponge- or expanded-rubber materials. Comply with ASTM C 534, Type I for tubular materials.

1. Products:  Subject to compliance with requirements, provide one of the follow- ing:
a. Aeroflex USA, Inc.; Aerocel.
b. Armacell LLC; AP Armaflex.
c. K-Flex USA; Insul-Lock, Insul-Tube, and K-FLEX LS.


PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine substrates and conditions for compliance with requirements for installation and other conditions affecting performance of insulation application.

B. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 PREPARATION

A. Surface Preparation: Clean and dry pipe and fitting surfaces. Remove materials that will adversely affect insulation application.

3.3 GENERAL APPLICATION REQUIREMENTS

A. Apply insulation materials, accessories, and finishes according to the manufacturer's written instructions; with smooth, straight, and even surfaces; free of voids throughout the length of piping, including fittings, valves, and specialties.

B. Refer to schedules at the end of this Section for materials, forms, jackets, and thick- nesses required for each piping system.

C. Use accessories compatible with insulation materials and suitable for the service. Use accessories that do not corrode, soften, or otherwise attack insulation or jacket in either wet or dry state.

D. Apply insulation with longitudinal seams at top and bottom of horizontal pipe runs.

E. Apply multiple layers of insulation with longitudinal and end seams staggered.

F. Do not weld brackets, clips, or other attachment devices to piping, fittings, and special- ties.

G. Seal joints and seams with vapor-retarder mastic on insulation indicated to receive a vapor retarder.

H. Keep insulation materials dry during application and finishing.

I. Apply insulation with tight longitudinal seams and end joints. Bond seams and joints with adhesive recommended by the insulation material manufacturer.

J. Apply insulation with the least number of joints practical.

K. Apply insulation over fittings, valves, and specialties, with continuous thermal and va- por-retarder integrity, unless otherwise indicated. Refer to special instructions for ap- plying insulation over fittings, valves, and specialties.

L. Hangers and Anchors: Where vapor retarder is indicated, seal penetrations in insula- tion at hangers, supports, anchors, and other projections with vapor-retarder mastic.

1. Apply insulation continuously through hangers and around anchor attachments.

2. For insulation application where vapor retarders are indicated, extend insulation on anchor legs at least 12 inches from point of attachment to pipe and taper insu- lation ends. Seal tapered ends with a compound recommended by the insulation material manufacturer to maintain vapor retarder.

3. Install insert materials and apply insulation to tightly join the insert. Seal insula- tion to insulation inserts with adhesive or sealing compound recommended by the insulation material manufacturer.

4. Cover inserts with jacket material matching adjacent pipe insulation. Install shields over jacket, arranged to protect the jacket from tear or puncture by the hanger, support, and shield.

M. Insulation Terminations: For insulation application where vapor retarders are indicat- ed, taper insulation ends. Seal tapered ends with a compound recommended by the in- sulation material manufacturer to maintain vapor retarder.

N. Apply adhesives and mastics at the manufacturer's recommended coverage rate.

O. Apply insulation with integral jackets as follows:

1. Pull jacket tight and smooth.

2. Circumferential Joints: Cover with 3-inch- wide strips, of same material as insu- lation jacket. Secure strips with adhesive and outward clinching staples along both edges of strip and spaced 4 inches o.c.

3. Longitudinal Seams: Overlap jacket seams at least 1-1/2 inches. Apply insula- tion with longitudinal seams at bottom of pipe. Clean and dry surface to receive self-sealing lap. Staple laps with outward clinching staples along edge at 4 inch- es o.c.

a. Exception:  Do not staple longitudinal laps on insulation having a vapor re- tarder.

4. Vapor-Retarder Mastics: Where vapor retarders are indicated, apply mastic on seams and joints and at ends adjacent to flanges, unions, valves, and fittings.

5. At penetrations in jackets for thermometers and pressure gages, fill and seal voids with vapor-retarder mastic.

P. Exterior Wall Penetrations: For penetrations of below-grade exterior walls, terminate insulation flush with mechanical sleeve seal. Seal terminations with vapor-retarder mastic.

Q. Interior Wall and Partition Penetrations:  Apply insulation continuously through walls and floors.

R. Fire-Rated Wall and Partition Penetrations: Apply insulation continuously through penetrations of fire-rated walls and partitions.

1. Install approved firestopping and fire-resistive joint sealers at fire rated penetra- tions

S. Floor Penetrations:  Apply insulation continuously through floor assembly.

1. For insulation with vapor retarders, seal insulation with vapor-retarder mastic where floor supports penetrate vapor retarder.

3.4 MINERAL-FIBER INSULATION APPLICATION

A. Apply insulation to straight pipes and tubes as follows:

1. Secure each layer of preformed pipe insulation to pipe with wire, tape, or bands without deforming insulation materials.

2. Where vapor retarders are indicated, seal longitudinal seams and end joints with vapor-retarder mastic. Apply vapor retarder to ends of insulation at intervals of 15 to 20 feet to form a vapor retarder between pipe insulation segments.

3. For insulation with factory-applied jackets, secure laps with outward clinched staples at 6 inches o.c.

4. For insulation with factory-applied jackets with vapor retarders, do not staple longitudinal tabs but secure tabs with additional adhesive as recommended by the insulation material manufacturer and seal with vapor-retarder mastic.

B. Apply insulation to flanges as follows:

1. Apply preformed pipe insulation to outer diameter of pipe flange.

2. Make width of insulation segment the same as overall width of the flange and bolts, plus twice the thickness of the pipe insulation.

3. Fill voids between inner circumference of flange insulation and outer circumfer- ence of adjacent straight pipe segments with mineral-fiber blanket insulation.

4. Apply canvas jacket material with manufacturer's recommended adhesive, over- lapping seams at least 1 inch, and seal joints with vapor-retarder mastic.

C. Apply insulation to fittings and elbows as follows:

1. Apply premolded insulation sections of the same material as straight segments of pipe insulation when available. Secure according to manufacturer's written in- structions.

2. When premolded insulation elbows and fittings are not available, apply mitered sections of pipe insulation, or glass-fiber blanket insulation, to a thickness equal to adjoining pipe insulation. Secure insulation materials with wire, tape, or bands.

3. Cover fittings with standard PVC fitting covers.

D. Apply insulation to valves and specialties as follows:

1. Apply premolded insulation sections of the same material as straight segments of pipe insulation when available. Secure according to manufacturer's written in- structions.

2. When premolded insulation sections are not available, apply glass-fiber blanket insulation to valve body. Arrange insulation to permit access to packing and to allow valve operation without disturbing insulation. For check valves, arrange insulation for access to stainer basket without disturbing insulation.

3. Apply insulation to flanges as specified for flange insulation application.

4. Use preformed standard PVC fitting covers for valve sizes where available. Se- cure fitting covers with manufacturer's attachments and accessories. Seal seams with tape and vapor-retarder mastic.

5. For larger sizes where PVC fitting covers are not available, seal insulation with canvas jacket and sealing compound recommended by the insulation material manufacturer.

3.5 INSTALLATION OF FLEXIBLE ELASTOMERIC INSULATION

A. Seal longitudinal seams and end joints with manufacturers recommended adhesive to eliminate openings in insulation that allow passage of air to surface being insulated.

B. Insulation Installation on Pipe Flanges:

1. Install pipe insulation to outer diameter of pipe flange.
a. Make width of insulation section same as overall width of flange and bolts, plus twice the thickness of pipe insulation.
b. Fill voids between inner circumference of flange insulation and outer cir- cumference of adjacent straight pipe segments with cut sections of sheet insulation of same thickness as pipe insulation.
c. Secure insulation to flanges and seal seams with manufacturer's recom- mended adhesive to eliminate openings in insulation that allow passage of air to surface being insulated.

2. Insulation Installation on Pipe Fittings and Elbows:
a. Install mitered sections of pipe insulation.
b. Secure insulation materials and seal seams with manufacturer's recom- mended adhesive to eliminate openings in insulation that allow passage of air to surface being insulated.

3. Insulation Installation on Valves and Pipe Specialties:
a. Install preformed valve covers manufactured of same material as pipe insu- lation when available.
b. When preformed valve covers are not available, install cut sections of pipe and sheet insulation to valve body. Arrange insulation to permit access to packing and to allow valve operation without disturbing insulation.
c. Install insulation to flanges as specified for flange insulation application.
d. Secure insulation to valves and specialties and seal seams with manufac- turer's recommended adhesive to eliminate openings in insulation that al- low passage of air to surface being insulated.

3.6 PIPING SYSTEM APPLICATIONS

A. Insulation materials and thicknesses are specified in schedules at the end of this Sec- tion.

B. Items Not Insulated:  Unless otherwise indicated, do not apply insulation to the follow- ing systems, materials, and equipment:

1. Vibration-control devices.

2. Below-grade piping, unless otherwise indicated.

3. Chrome-plated pipes and fittings, unless potential for personnel injury.

4. Air chambers, unions, strainers, check valves, plug valves, and flow regulators.

3.7 FIELD QUALITY CONTROL

A. Inspection:  Perform the following field quality-control inspections, after installing in- sulation materials, jackets, and finishes, to determine compliance with requirements:

1. Inspect fittings and valves randomly selected by Engineer.

2. Remove fitting covers from 20 elbows or 1 percent of elbows, whichever is less, for various pipe sizes.

3. Remove fitting covers from 20 valves or 1 percent of valves, whichever is less, for various pipe sizes.

B. Insulation applications will be considered defective if sample inspection reveals non- compliance with requirements. Remove defective Work and replace with new materi- als according to these Specifications.

C. Reinstall insulation and covers on fittings and valves uncovered for inspection accord- ing to these Specifications.

3.8 INSULATION APPLICATION SCHEDULE, GENERAL

A. Refer to insulation application schedules for required insulation materials, vapor re- tarders, and field-applied jackets.

B. Application schedules identify piping system and indicate pipe size ranges and materi- al, thickness, and jacket requirements.

3.9 INTERIOR INSULATION APPLICATION SCHEDULE

A. Service:  Hydronic Piping

1. Operating Temperature: 70 to 250 deg F.

2. Insulation Material: Mineral fiber.
a. Insulation Thickness:
1) NPS 1-1/2 and Smaller: 1 inch thick minimum.
2) NPS 2 and Larger:  2 inch thick minimum..

3. Vapor Retarder Required: No.

4. Finish:  In areas that are listed as Corrosive and/or High Moisture areas, cover piping with PVC jacket. In normal areas, ASJ is acceptable.

B. Refrigerant Suction and Hot-Gas Piping and Flexible Tubing:

1. Insulation Material: Mineral fiber or flexible elastomeric.

2. Insulation Thickness: 1 inch thick minimum.

3. Factory-Applied Jacket: None

4. Field-Applied Jacket: Indoors: None,  Outdoor  Exposure,  paint  on  two  (2) coats Latex UV retarder coating.


END OF SECTION