230700_HVAC_Insulation.pdf

USDA Forest Service – Camino Real Office Building 230700 - 1

HVAC INSULATION

SECTION 230700

HVAC INSULATION

PART 1 – GENERAL

1.1 SUMMARY

A. Section Includes:

1. Insulation Materials:

a. Mineral fiber.

B. Related Sections:

1. Division 22 Section "Plumbing Insulation."

2. Division 23 Section "Metal Ducts" for duct liners.

1.2 SUBMITTALS

A. Product Data: For each type of product indicated.

1.3 QUALITY ASSURANCE

A. All products to be manufactured in the US and comply with the Buy American Act.

PART 2 – PRODUCTS

2.1 INSULATION MATERIALS

A. Comply with requirements in Part 3 schedule articles for where insulating materials shall be applied.

B. Products shall not contain asbestos, lead, mercury, or mercury compounds.

C. Foam insulation materials shall not use CFC or HCFC blowing agents in the manufac-turing process.

D. Mineral-Fiber Blanket Insulation: Mineral or glass fibers bonded with a thermosetting resin. Comply with ASTM C 553, Type II and ASTM C 1290, Type II with factory-applied vinyl jacket. Factory-applied jacket requirements are specified in "Factory-

Applied Jackets" Article.

1. Products: Subject to compliance with requirements, provide one of the follow-ing:

a. CertainTeed Corp.; Duct Wrap.

b. Johns Manville; Microlite.

c. Knauf Insulation; Duct Wrap.

USDA Forest Service – Camino Real Office Building 230700 - 2

d. Manson Insulation Inc.; Alley Wrap.

e. Owens Corning; All-Service Duct Wrap.

f. Roxul Inc.; Roxul RW.

g. Thermafiber; Thermafiber Industrial Felt.

2.2 ADHESIVES

A. Materials shall be compatible with insulation materials, jackets, and substrates and for bonding insulation to itself and to surfaces to be insulated, unless otherwise indicated.

B. Mineral-Fiber Adhesive: Comply with MIL-A-3316C, Class 2, Grade A.

1. Products: Subject to compliance with requirements, available products that may be incorporated into the Work include, but are not limited to, the following:

a. Childers Products, Division of ITW; CP-82.

b. Foster Products Corporation, H. B. Fuller Company; 85-20.

c. ITW TACC, Division of Illinois Tool Works; S-90/80.

d. Marathon Industries, Inc.; 225.

e. Mon-Eco Industries, Inc.; 22-25.

2. For indoor applications, use adhesive that has a VOC content of 80 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

2.3 FACTORY-APPLIED JACKETS

A. Insulation system schedules indicate factory-applied jackets on various applications.

When factory-applied jackets are indicated, comply with the following:

1. ASJ: White, kraft-paper, fiberglass-reinforced scrim with aluminum-foil back-ing; complying with ASTM C 1136, Type I.

2. ASJ-SSL: ASJ with self-sealing, pressure-sensitive, acrylic-based adhesive covered by a removable protective strip; complying with ASTM C 1136, Type I.

3. FSK Jacket: Aluminum-foil, fiberglass-reinforced scrim with kraft-paper back-ing; complying with ASTM C 1136, Type II.

4. FSP Jacket: Aluminum-foil, fiberglass-reinforced scrim with polyethylene backing; complying with ASTM C 1136, Type II.

5. PVDC Jacket for Indoor Applications: 4-mil- (0.10-mm-) thick, white PVDC biaxially oriented barrier film with a permeance at 0.02 perms (0.013 metric perms) when tested according to ASTM E 96 and with a flame-spread index of 5 and a smoke-developed index of 20 when tested according to ASTM E 84.

a. Products: Subject to compliance with requirements, available products that may be incorporated into the Work include, but are not limited to, the following:

1) Dow Chemical Company (The); Saran 540 Vapor Retarder Film and

Saran 560 Vapor Retarder Film.

USDA Forest Service – Camino Real Office Building 230700 - 3

2.4 TAPES

A. Aluminum-Foil Tape: Vapor-retarder tape with acrylic adhesive.

1. Products: Subject to compliance with requirements, available products that may be incorporated into the Work include, but are not limited to, the following:

a. Avery Dennison Corporation, Specialty Tapes Division; Fasson 0800.

b. Compac Corp.; 120.

c. Ideal Tape Co., Inc., an American Biltrite Company; 488 AWF.

d. Venture Tape; 3520 CW.

2. Width: 2 inches (50 mm).

3. Thickness: 3.7 mils (0.093 mm).

4. Adhesion: 100 ounces force/inch (1.1 N/mm) in width.

5. Elongation: 5 percent.

6. Tensile Strength: 34 lbf/inch (6.2 N/mm) in width.

2.5 SECUREMENTS

A. Insulation Pins and Hangers:

1. Metal, Adhesively Attached, Perforated-Base Insulation Hangers: Baseplate welded to projecting spindle that is capable of holding insulation, of thickness indicated, securely in position indicated when self-locking washer is in place.

Comply with the following requirements:

a. Products: Subject to compliance with requirements, available products that may be incorporated into the Work include, but are not limited to, the following:

1) AGM Industries, Inc.; Tactoo Insul-Hangers, Series T.

2) GEMCO; Perforated Base.

3) Midwest Fasteners, Inc.; Spindle.

b. Baseplate: Perforated, galvanized carbon-steel sheet, 0.030 inch (0.76

mm) thick by 2 inches (50 mm) square.

c. Spindle: Copper- or zinc-coated, low carbon steel, fully annealed, 0.106-inch- (2.6-mm-) diameter shank, length to suit depth of insulation indi-cated.

d. Adhesive: Recommended by hanger manufacturer. Product with demon-strated capability to bond insulation hanger securely to substrates indi-cated without damaging insulation, hangers, and substrates.

USDA Forest Service – Camino Real Office Building 230700 - 4

PART 3 – EXECUTION

3.1 PREPARATION

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

B. Coordinate insulation installation with the trade installing heat tracing. Comply with requirements for heat tracing that apply to insulation.

C. Mix insulating cements with clean potable water; if insulating cements are to be in contact with stainless-steel surfaces, use demineralized water.

3.2 GENERAL INSTALLATION REQUIREMENTS

A. Install insulation materials, accessories, and finishes with smooth, straight, and even surfaces; free of voids throughout the length of equipment, ducts and fittings, and pip-ing including fittings, valves, and specialties.

B. Install insulation materials, forms, vapor barriers or retarders, jackets, and thicknesses required for each item of equipment, duct system, and pipe system as specified in in-sulation system schedules.

C. Install accessories compatible with insulation materials and suitable for the service.

Install accessories that do not corrode, soften, or otherwise attack insulation or jacket in either wet or dry state.

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

E. Keep insulation materials dry during application and finishing.

F. Install insulation with tight longitudinal seams and end joints. Bond seams and joints with adhesive recommended by insulation material manufacturer.

G. Cut insulation in a manner to avoid compressing insulation more than 75 percent of its nominal thickness.

H. Finish installation with systems at operating conditions. Repair joint separations and cracking due to thermal movement.

I. Repair damaged insulation facings by applying same facing material over damaged areas. Extend patches at least 4 inches (100 mm) beyond damaged areas. Adhere, staple, and seal patches similar to butt joints.

J. For above ambient services, do not install insulation to the following:

USDA Forest Service – Camino Real Office Building 230700 - 5

1. Vibration-control devices.

2. Testing agency labels and stamps.

3. Nameplates and data plates.

4. Manholes.

5. Handholes.

6. Cleanouts.

3.3 MINERAL-FIBER INSULATION INSTALLATION

A. Blanket Insulation Installation on Ducts and Plenums: Secure with adhesive and insu-lation pins.

1. Apply adhesives according to manufacturer's recommended coverage rates per unit area, for 100 percent coverage of duct and plenum surfaces.

2. Apply adhesive to entire circumference of ducts and to all surfaces of fittings and transitions.

3. Install either capacitor-discharge-weld pins and speed washers or cupped-head, capacitor-discharge-weld pins on sides and bottom of horizontal ducts and sides of vertical ducts as follows:

a. On duct sides with dimensions 18 inches (450 mm) and smaller, place pins along longitudinal centerline of duct. Space 3 inches (75 mm) max-imum from insulation end joints, and 16 inches (400 mm) o.c.

b. On duct sides with dimensions larger than 18 inches (450 mm), place pins

16 inches (400 mm) o.c. each way, and 3 inches (75 mm) maximum from insulation joints. Install additional pins to hold insulation tightly against surface at cross bracing.

c. Pins may be omitted from top surface of horizontal, rectangular ducts and plenums.

d. Do not overcompress insulation during installation.

e. Impale insulation over pins and attach speed washers.

f. Cut excess portion of pins extending beyond speed washers or bend paral-lel with insulation surface. Cover exposed pins and washers with tape matching insulation facing.

4. For ducts and plenums with surface temperatures below ambient, install a conti-nuous unbroken vapor barrier. Create a facing lap for longitudinal seams and end joints with insulation by removing 2 inches (50 mm) from 1 edge and 1 end of insulation segment. Secure laps to adjacent insulation section with 1/2-inch

(13-mm) outward-clinching staples, 1 inch (25 mm) o.c. Install vapor barrier consisting of factory- or field-applied jacket, adhesive, vapor-barrier mastic, and sealant at joints, seams, and protrusions.

a. Repair punctures, tears, and penetrations with tape or mastic to maintain vapor-barrier seal.

b. Install vapor stops for ductwork and plenums operating below 50 deg F

(10 deg C) at 18-foot (5.5-m) intervals. Vapor stops shall consist of va-

USDA Forest Service – Camino Real Office Building 230700 - 6 por-barrier mastic applied in a Z-shaped pattern over insulation face, along butt end of insulation, and over the surface. Cover insulation face and sur-face to be insulated a width equal to 2 times the insulation thickness but not less than 3 inches (75 mm).

5. Overlap unfaced blankets a minimum of 2 inches (50 mm) on longitudinal seams and end joints. At end joints, secure with steel bands spaced a maximum of 18 inches (450 mm) o.c.

6. Install insulation on rectangular duct elbows and transitions with a full insula-tion section for each surface. Install insulation on round and flat-oval duct el-bows with individually mitered gores cut to fit the elbow.

7. Insulate duct stiffeners, hangers, and flanges that protrude beyond insulation sur-face with 6-inch- (150-mm-) wide strips of same material used to insulate duct.

Secure on alternating sides of stiffener, hanger, and flange with pins spaced 6 inches (150 mm) o.c.

B. Board Insulation Installation on Ducts and Plenums: Secure with adhesive and insula-tion pins.

1. Apply adhesives according to manufacturer's recommended coverage rates per unit area, for 100 percent coverage of duct and plenum surfaces.

2. Apply adhesive to entire circumference of ducts and to all surfaces of fittings and transitions.

3. Install either capacitor-discharge-weld pins and speed washers or cupped-head, capacitor-discharge-weld pins on sides and bottom of horizontal ducts and sides of vertical ducts as follows:

a. On duct sides with dimensions 18 inches (450 mm) and smaller, place pins along longitudinal centerline of duct. Space 3 inches (75 mm) max-imum from insulation end joints, and 16 inches (400 mm) o.c.

b. On duct sides with dimensions larger than 18 inches (450 mm), space pins

16 inches (400 mm) o.c. each way, and 3 inches (75 mm) maximum from insulation joints. Install additional pins to hold insulation tightly against surface at cross bracing.

c. Pins may be omitted from top surface of horizontal, rectangular ducts and plenums.

d. Do not overcompress insulation during installation.

e. Cut excess portion of pins extending beyond speed washers or bend paral-lel with insulation surface. Cover exposed pins and washers with tape matching insulation facing.

4. For ducts and plenums with surface temperatures below ambient, install a conti-nuous unbroken vapor barrier. Create a facing lap for longitudinal seams and end joints with insulation by removing 2 inches (50 mm) from 1 edge and 1 end of insulation segment. Secure laps to adjacent insulation section with 1/2-inch

(13-mm) outward-clinching staples, 1 inch (25 mm) o.c. Install vapor barrier

USDA Forest Service – Camino Real Office Building 230700 - 7 consisting of factory- or field-applied jacket, adhesive, vapor-barrier mastic, and sealant at joints, seams, and protrusions.

a. Repair punctures, tears, and penetrations with tape or mastic to maintain vapor-barrier seal.

b. Install vapor stops for ductwork and plenums operating below 50 deg F

(10 deg C) at 18-foot (5.5-m) intervals. Vapor stops shall consist of va-por-barrier mastic applied in a Z-shaped pattern over insulation face, along butt end of insulation, and over the surface. Cover insulation face and sur-face to be insulated a width equal to 2 times the insulation thickness but not less than 3 inches (75 mm).

5. Install insulation on rectangular duct elbows and transitions with a full insula-tion section for each surface. Groove and score insulation to fit as closely as possible to outside and inside radius of elbows. Install insulation on round and flat-oval duct elbows with individually mitered gores cut to fit the elbow.

6. Insulate duct stiffeners, hangers, and flanges that protrude beyond insulation sur-face with 6-inch- (150-mm-) wide strips of same material used to insulate duct.

Secure on alternating sides of stiffener, hanger, and flange with pins spaced 6 inches (150 mm) o.c.

3.4 FIELD QUALITY CONTROL

A. Perform tests and inspections.

B. Tests and Inspections:

1. Inspect ductwork, randomly selected by Contracting Officer (CO), by removing field-applied jacket and insulation in layers in reverse order of their installation.

Extent of inspection shall be limited to one location(s) for each duct system de-fined in the "Duct Insulation Schedule, General" Article.

2. Inspect field-insulated equipment, randomly selected by Contracting Officer

(CO), by removing field-applied jacket and insulation in layers in reverse order of their installation. Extent of inspection shall be limited to one location(s) for each type of equipment defined in the "Equipment Insulation Schedule" Article.

For large equipment, remove only a portion adequate to determine compliance.

C. All insulation applications will be considered defective Work if sample inspection re-veals noncompliance with requirements.

3.5 DUCT INSULATION SCHEDULE, GENERAL

A. Plenums and Ducts Requiring Insulation:

1. Indoor, concealed supply and outdoor air.

2. Indoor, concealed return located in nonconditioned space.

3. Indoor, exposed oven and warewash exhaust.

USDA Forest Service – Camino Real Office Building 230700 - 8

B. Items Not Insulated:

1. Metal ducts with duct liner of sufficient thickness to comply with energy code and ASHRAE/IESNA 90.1.

3.6 INDOOR DUCT AND PLENUM INSULATION SCHEDULE

A. Concealed, Supply-Air Duct and Plenum Insulation: Mineral-fiber blanket, 1-1/2 inches (38 mm) thick and 0.75-lb/cu. ft. (12-kg/cu. m) nominal density.

B. Concealed, Return-Air Duct and Plenum Insulation: Mineral-fiber blanket 1-1/2 inches (38 mm) thick and 0.75-lb/cu. ft. (12-kg/cu. m) nominal density.

C. Concealed, Outdoor-Air Duct and Plenum Insulation: Mineral-fiber blanket, 3 inches

(75 mm) thick and 3-lb/cu. ft. (48-kg/cu. m) nominal density.

D. Concealed, Exhaust-Air Duct and Plenum Insulation: Mineral-fiber blanket, 1-1/2 inches (38 mm) thick and 0.75-lb/cu. ft. (12-kg/cu. m) nominal density.

END OF SECTION 230700