230700 hvac insulation.pdf

F5W61608 USPFO Warehouse Ohio Army National Guard Rev. 0 Defense Supply Center Columbus, Ohio 30 January 2009 Bid Final

HVAC INSULATION 230700 - 1

SECTION 230700 - HVAC INSULATION

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. Section Includes:

1. Insulation Materials:

a. Flexible elastomeric.

b. Mineral fiber.

2. Insulating cements.

3. Adhesives.

4. Mastics.

5. Lagging adhesives.

6. Sealants.

7. Factory-applied jackets.

8. Field-applied jackets.

9. Tapes.

10. Securements.

11. Corner angles.

B. Related Sections:

1. Division 22 Section "Plumbing Insulation."

1.3 SUBMITTALS

A. Product Data: For each type of product indicated. Include thermal conductivity, thickness, and jackets (both factory and field applied, if any).

B. LEED Submittal:

1. Product Data for Credit EQ 4.1: For adhesives and sealants, including printed statement of VOC content.

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C. Shop Drawings:

1. Detail application of protective shields, saddles, and inserts at hangers for each type of insulation and hanger.

2. Detail insulation application at pipe expansion joints for each type of insulation.

3. Detail insulation application at elbows, fittings, flanges, valves, and specialties for each type of insulation.

4. Detail removable insulation at piping specialties, equipment connections, and access panels.

5. Detail application of field-applied jackets.

6. Detail application at linkages of control devices.

7. Detail field application for each equipment type.

D. Material Test Reports: From a qualified testing agency acceptable to authorities having jurisdiction indicating, interpreting, and certifying test results for compliance of insulation materials, sealers, attachments, cements, and jackets, with requirements indicated. Include dates of tests and test methods employed.

1.4 QUALITY ASSURANCE

A. Fire-Test-Response Characteristics: Insulation and related materials shall have fire-test-response characteristics indicated, as determined by testing identical products per ASTM E 84, by a testing and inspecting agency acceptable to authorities having jurisdiction. Factory label insulation and jacket materials and adhesive, mastic, tapes, and cement material containers, with appropriate markings of applicable testing and inspecting agency.

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

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

1.5 DELIVERY, STORAGE, AND HANDLING

A. Packaging: Insulation material containers shall be marked by manufacturer with appropriate ASTM standard designation, type and grade, and maximum use temperature.

1.6 COORDINATION

A. Coordinate size and location of supports, hangers, and insulation shields specified in Division 23 Section "Hangers and Supports for HVAC Piping and Equipment."

B. Coordinate clearance requirements with piping Installer for piping insulation application, duct Installer for duct insulation application, and equipment Installer for

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equipment insulation application. Before preparing piping and ductwork Shop Drawings, establish and maintain clearance requirements for installation of insulation and field-applied jackets and finishes and for space required for maintenance.

1.7 SCHEDULING

A. Schedule insulation application after pressure testing systems.. Insulation application may begin on segments that have satisfactory test results.

B. Complete installation and concealment of plastic materials as rapidly as possible in each area of construction.

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. Products that come in contact with stainless steel shall have a leachable chloride content of less than 50 ppm when tested according to ASTM C 871.

D. Insulation materials for use on austenitic stainless steel shall be qualified as acceptable according to ASTM C 795.

E. Foam insulation materials shall not use CFC or HCFC blowing agents in the manufacturing process.

F. Flexible Elastomeric: Closed-cell, sponge- or expanded-rubber materials. Comply with ASTM C 534, Type I for tubular materials and Type II for sheet materials.

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. Aeroflex USA Inc.; Aerocel.

b. Armacell LLC; AP Armaflex.

c. RBX Corporation; Insul-Sheet 1800 and Insul-Tube 180.

G. 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 III with factory-applied FSK jacket III. Factory-applied jacket requirements are specified in "Factory- Applied Jackets" Article.

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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. CertainTeed Corp.; Duct Wrap.

b. Johns Manville; Microlite.

c. Knauf Insulation; Duct Wrap.

d. Owens Corning; All-Service Duct Wrap.

H. Mineral-Fiber Board Insulation: Mineral or glass fibers bonded with a thermosetting resin. Comply with ASTM C 612, Type IA or Type IB. For duct and plenum applications, provide insulation with factory-applied ASJ. For equipment applications, provide insulation. Factory-applied jacket requirements are specified in "Factory- Applied Jackets" Article.

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. CertainTeed Corp.; Commercial Board.

b. Johns Manville; 800 Series Spin-Glas.

c. Knauf Insulation; Insulation Board.

d. Owens Corning; Fiberglas 700 Series.

I. Mineral-Fiber, Preformed Pipe Insulation:

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. Johns Manville; Micro-Lok.

b. Knauf Insulation; 1000 Pipe Insulation.

c. Owens Corning; Fiberglas Pipe Insulation.

2.2 INSULATING CEMENTS

A. Mineral-Fiber Insulating Cement: Comply with ASTM C 195.

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. Insulco, Division of MFS, Inc.; Triple I.

b. P. K. Insulation Mfg. Co., Inc.; Super-Stik.

2.3 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.

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B. Flexible Elastomeric Adhesive: Comply with MIL-A-24179A, Type II, Class I.

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. Aeroflex USA Inc.; Aeroseal.

b. Armacell LCC; 520 Adhesive.

c. Foster Products Corporation, H. B. Fuller Company; 85-75.

d. RBX Corporation; Rubatex Contact Adhesive.

2. For indoor applications, use adhesive that has a VOC content of 50 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

C. 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).

D. ASJ Adhesive: Comply with MIL-A-3316C, Class 2, Grade A for bonding insulation jacket lap seams and joints.

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 50 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

E. PVC Jacket Adhesive: Compatible with PVC jacket.

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. Dow Chemical Company (The); 739, Dow Silicone.

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b. Johns-Manville; Zeston Perma-Weld, CEEL-TITE Solvent Welding Adhesive.

c. P.I.C. Plastics, Inc.; Welding Adhesive.

d. Speedline Corporation; Speedline Vinyl Adhesive.

2. For indoor applications, use adhesive that has a VOC content of 50 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

2.4 MASTICS

A. Materials shall be compatible with insulation materials, jackets, and substrates;

comply with MIL-C-19565C, Type II.

1. For indoor applications, use mastics that have a VOC content of 50 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

B. Vapor-Barrier Mastic: Water based; suitable for indoor and outdoor use on below ambient services.

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-35.

b. Foster Products Corporation, H. B. Fuller Company; 30-90.

c. ITW TACC, Division of Illinois Tool Works; CB-50.

d. Marathon Industries, Inc.; 590.

e. Mon-Eco Industries, Inc.; 55-40.

f. Vimasco Corporation; 749.

2. Water-Vapor Permeance: ASTM E 96, Procedure B, 0.013 perm at 43-mil dry film thickness.

3. Service Temperature Range: Minus 20 to plus 180 deg F.

4. Solids Content: ASTM D 1644, 59 percent by volume and 71 percent by weight.

5. Color: White.

C. Vapor-Barrier Mastic: Solvent based; suitable for indoor use on below ambient services.

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-30.

b. Foster Products Corporation, H. B. Fuller Company; 30-35.

c. ITW TACC, Division of Illinois Tool Works; CB-25.

d. Marathon Industries, Inc.; 501.

e. Mon-Eco Industries, Inc.; 55-10.

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2. Water-Vapor Permeance: ASTM F 1249, 0.05 perm at 35-mil dry film thickness.

3. Service Temperature Range: 0 to 180 deg F.

4. Solids Content: ASTM D 1644, 44 percent by volume and 62 percent by weight.

5. Color: White.

D. Vapor-Barrier Mastic: Solvent based; suitable for outdoor use on below ambient services.

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; Encacel.

b. Foster Products Corporation, H. B. Fuller Company; 60-95/60-96.

c. Marathon Industries, Inc.; 570.

d. Mon-Eco Industries, Inc.; 55-70.

2. Water-Vapor Permeance: ASTM F 1249, 0.05 perm at 30-mil dry film thickness.

3. Service Temperature Range: Minus 50 to plus 220 deg F.

4. Solids Content: ASTM D 1644, 33 percent by volume and 46 percent by weight.

5. Color: White.

2.5 LAGGING ADHESIVES

A. Description: Comply with MIL-A-3316C Class I, Grade A and shall be compatible with insulation materials, jackets, and substrates.

1. For indoor applications, use lagging adhesives that have a VOC content of 50 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

2. 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-52.

b. Foster Products Corporation, H. B. Fuller Company; 81-42.

c. Marathon Industries, Inc.; 130.

d. Mon-Eco Industries, Inc.; 11-30.

e. Vimasco Corporation; 136.

3. Service Temperature Range: Minus 50 to plus 180 deg F.

4. Color: White.

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2.6 SEALANTS

A. Joint Sealants:

B. Metal Jacket Flashing Sealants:

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-76-8.

b. Foster Products Corporation, H. B. Fuller Company; 95-44.

c. Marathon Industries, Inc.; 405.

d. Mon-Eco Industries, Inc.; 44-05.

e. Vimasco Corporation; 750.

2. Materials shall be compatible with insulation materials, jackets, and substrates.

3. Fire- and water-resistant, flexible, elastomeric sealant.

4. Service Temperature Range: Minus 40 to plus 250 deg F.

5. Color: Aluminum.

6. For indoor applications, use sealants that have a VOC content of 250 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

C. ASJ Flashing Sealants and PVC Jacket Flashing Sealants:

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-76.

2. Materials shall be compatible with insulation materials, jackets, and substrates.

3. Fire- and water-resistant, flexible, elastomeric sealant.

4. Service Temperature Range: Minus 40 to plus 250 deg F.

5. Color: White.

6. For indoor applications, use sealants that have a VOC content of 250 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

2.7 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 backing;

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.

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3. Vinyl Jacket: White vinyl with a permeance of 1.3 perms when tested according to ASTM E 96, Procedure A, and complying with NFPA 90A and NFPA 90B.

2.8 FIELD-APPLIED FABRIC-REINFORCING MESH

A. Woven Glass-Fiber Fabric for Pipe Insulation: Approximately 2 oz./sq. yd. with a thread count of 10 strands by 10 strands/sq. inch for covering pipe and pipe fittings.

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. Vimasco Corporation; Elastafab 894.

B. Woven Glass-Fiber Fabric for Duct and Equipment Insulation: Approximately 6 oz./sq. yd. with a thread count of 5 strands by 5 strands/sq. inch for covering equipment.

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; Chil-Glas No. 5.

C. Woven Polyester Fabric: Approximately 1 oz./sq. yd. with a thread count of 10 strands by 10 strands/sq. inch, in a Leno weave, for duct, equipment, and pipe.

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. Foster Products Corporation, H. B. Fuller Company; Mast-A-Fab.

b. Vimasco Corporation; Elastafab 894.

2.9 FIELD-APPLIED CLOTHS

A. Woven Glass-Fiber Fabric: Comply with MIL-C-20079H, Type I, plain weave, and presized a minimum of 8 oz./sq. yd..

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. Alpha Associates, Inc.; Alpha-Maritex 84215 and 84217/9485RW, Luben 59.

2.10 FIELD-APPLIED JACKETS

A. Field-applied jackets shall comply with ASTM C 921, Type I, unless otherwise indicated.

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

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. Johns Manville; Zeston.

b. P.I.C. Plastics, Inc.; FG Series.

c. Proto PVC Corporation; LoSmoke.

d. Speedline Corporation; SmokeSafe.

2. Adhesive: As recommended by jacket material manufacturer.

3. Color: White.

4. Factory-fabricated fitting covers to match jacket if available; otherwise, field fabricate.

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

5. Factory-fabricated tank heads and tank side panels.

C. Metal Jacket:

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; Metal Jacketing Systems.

b. PABCO Metals Corporation; Surefit.

c. RPR Products, Inc.; Insul-Mate.

2. Aluminum Jacket: Comply with ASTM B 209, Alloy 3003, 3005, 3105 or 5005, Temper H-14.

a. Sheet and roll stock ready for shop or field sizing or Factory cut and rolled to size.

b. Finish and thickness are indicated in field-applied jacket schedules.

c. Moisture Barrier for Indoor Applications: 1-mil- thick, heat-bonded polyethylene and kraft paper .

d. Moisture Barrier for Outdoor Applications: 2.5-mil- thick Polysurlyn.

e. Factory-Fabricated Fitting Covers:

1) Same material, finish, and thickness as jacket.

2) Preformed 2-piece or gore, 45- and 90-degree, short- and long-radius elbows.

3) Tee covers.

4) Flange and union covers.

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5) End caps.

6) Beveled collars.

7) Valve covers.

8) Field fabricate fitting covers only if factory-fabricated fitting covers are not available.

D. Self-Adhesive Outdoor Jacket: 60-mil- thick, laminated vapor barrier and waterproofing membrane for installation over insulation located aboveground outdoors; consisting of a rubberized bituminous resin on a crosslaminated polyethylene film covered with stucco-embossed aluminum-foil facing.

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. Polyguard; Alumaguard 60.

2.11 TAPES

A. ASJ Tape: White vapor-retarder tape matching factory-applied jacket with acrylic adhesive, complying with ASTM C 1136.

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 0835.

b. Compac Corp.; 104 and 105.

c. Ideal Tape Co., Inc., an American Biltrite Company; 428 AWF ASJ.

d. Venture Tape; 1540 CW Plus, 1542 CW Plus, and 1542 CW Plus/SQ.

2. Width: 3 inches.

3. Thickness: 11.5 mils.

4. Adhesion: 90 ounces force/inch in width.

5. Elongation: 2 percent.

6. Tensile Strength: 40 lbf/inch in width.

7. ASJ Tape Disks and Squares: Precut disks or squares of ASJ tape.

B. PVC Tape: White vapor-retarder tape matching field-applied PVC jacket with acrylic adhesive. Suitable for indoor and outdoor applications.

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 0555.

b. Compac Corp.; 130.

c. Ideal Tape Co., Inc., an American Biltrite Company; 370 White PVC tape.

d. Venture Tape; 1506 CW NS.

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2. Width: 2 inches.

3. Thickness: 6 mils.

4. Adhesion: 64 ounces force/inch in width.

5. Elongation: 500 percent.

6. Tensile Strength: 18 lbf/inch in width.

C. 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.

3. Thickness: 3.7 mils.

4. Adhesion: 100 ounces force/inch in width.

5. Elongation: 5 percent.

6. Tensile Strength: 34 lbf/inch in width.

2.12 SECUREMENTS

A. Bands:

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; Bands.

b. PABCO Metals Corporation; Bands.

c. RPR Products, Inc.; Bands.

2. Stainless Steel: ASTM A 167 or ASTM A 240/A 240M, Type 304; 0.015 inch thick, 3/4 inch wide with wing or closed seal.

3. Aluminum: ASTM B 209, Alloy 3003, 3005, 3105, or 5005; Temper H-14, 0.020 inch thick, 3/4 inch wide with wing or closed seal.

B. 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:

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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 thick by 2 inches square.

c. Spindle: Copper- or zinc-coated, low carbon steel, fully annealed, 0.106-inch- diameter shank, length to suit depth of insulation indicated.

d. Adhesive: Recommended by hanger manufacturer. Product with demonstrated capability to bond insulation hanger securely to substrates indicated without damaging insulation, hangers, and substrates.

2. Self-Sticking-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 TSA.

2) GEMCO; Press and Peel.

3) Midwest Fasteners, Inc.; Self Stick.

b. Baseplate: Galvanized carbon-steel sheet, 0.030 inch thick by 2 inches square.

c. Spindle: Copper- or zinc-coated, low carbon steel, fully annealed, 0.106-inch- diameter shank, length to suit depth of insulation indicated.

d. Adhesive-backed base with a peel-off protective cover.

3. Insulation-Retaining Washers: Self-locking washers formed from 0.016-inch-thick, galvanized-steel sheet, with beveled edge sized as required to hold insulation securely in place but not less than 1-1/2 inches in diameter.

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.; RC-150.

2) GEMCO; R-150.

3) Midwest Fasteners, Inc.; WA-150.

4) Nelson Stud Welding; Speed Clips.

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b. Protect ends with capped self-locking washers incorporating a spring steel insert to ensure permanent retention of cap in exposed locations.

C. Staples: Outward-clinching insulation staples, nominal 3/4-inch- wide, stainless steel or Monel.

D. Wire: 0.062-inch soft-annealed, galvanized steel.

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

a. C & F Wire.

b. Childers Products.

c. PABCO Metals Corporation.

d. RPR Products, Inc.

2.13 CORNER ANGLES

A. PVC Corner Angles: 30 mils thick, minimum 1 by 1 inch, PVC according to ASTM D 1784, Class 16354-C. White or color-coded to match adjacent surface.

B. Aluminum Corner Angles: 0.040 inch thick, minimum 1 by 1 inch, aluminum according to ASTM B 209, Alloy 3003, 3005, 3105 or 5005; Temper H-14.

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.

1. Verify that systems and equipment to be insulated have been tested and are free of defects.

2. Verify that surfaces to be insulated are clean and dry.

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

3.2 PREPARATION

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

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B. Surface Preparation: Clean and prepare surfaces to be insulated. Before insulating, apply a corrosion coating to insulated surfaces as follows:

1. Stainless Steel: Coat 300 series stainless steel with an epoxy primer 5 mils thick and an epoxy finish 5 mils thick if operating in a temperature range between 140 and 300 deg F. Consult coating manufacturer for appropriate coating materials and application methods for operating temperature range.

2. Carbon Steel: Coat carbon steel operating at a service temperature between 32 and 300 deg F with an epoxy coating. Consult coating manufacturer for appropriate coating materials and application methods for operating temperature range.

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

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

3.3 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 piping 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 insulation 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. Install multiple layers of insulation with longitudinal and end seams staggered.

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

G. Keep insulation materials dry during application and finishing.

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

I. Install insulation with least number of joints practical.

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J. Where vapor barrier is indicated, seal joints, seams, and penetrations in insulation at hangers, supports, anchors, and other projections with vapor-barrier mastic.

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

2. For insulation application where vapor barriers are indicated, extend insulation on anchor legs from point of attachment to supported item to point of attachment to structure. Taper and seal ends at attachment to structure with vapor-barrier mastic.

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

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

K. Apply adhesives, mastics, and sealants at manufacturer's recommended coverage rate and wet and dry film thicknesses.

L. Install insulation with factory-applied jackets as follows:

1. Draw jacket tight and smooth.

2. Cover circumferential joints with 3-inch- wide strips, of same material as insulation jacket. Secure strips with adhesive and outward clinching staples along both edges of strip, spaced 4 inches o.c.

3. Overlap jacket longitudinal seams at least 1-1/2 inches. Install insulation 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 inches o.c.

a. For below ambient services, apply vapor-barrier mastic over staples.

4. Cover joints and seams with tape as recommended by insulation material manufacturer to maintain vapor seal.

5. Where vapor barriers are indicated, apply vapor-barrier mastic on seams and joints and at ends adjacent to duct and pipe flanges and fittings.

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

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

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

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

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1. Vibration-control devices.

2. Testing agency labels and stamps.

3. Nameplates and data plates.

3.4 PENETRATIONS

A. Insulation Installation at Roof Penetrations: Install insulation continuously through roof penetrations.

1. Seal penetrations with flashing sealant.

2. For applications requiring only indoor insulation, terminate insulation above roof surface and seal with joint sealant. For applications requiring indoor and outdoor insulation, install insulation for outdoor applications tightly joined to indoor insulation ends. Seal joint with joint sealant.

3. Extend jacket of outdoor insulation outside roof flashing at least 2 inches below top of roof flashing.

4. Seal jacket to roof flashing with flashing sealant.

B. Insulation Installation at Aboveground Exterior Wall Penetrations: Install insulation continuously through wall penetrations.

1. Seal penetrations with flashing sealant.

2. For applications requiring only indoor insulation, terminate insulation inside wall surface and seal with joint sealant. For applications requiring indoor and outdoor insulation, install insulation for outdoor applications tightly joined to indoor insulation ends. Seal joint with joint sealant.

3. Extend jacket of outdoor insulation outside wall flashing and overlap wall flashing at least 2 inches.

4. Seal jacket to wall flashing with flashing sealant.

C. Insulation Installation at Interior Wall and Partition Penetrations (That Are Not Fire Rated): Install insulation continuously through walls and partitions.

3.5 GENERAL PIPE INSULATION INSTALLATION

A. Requirements in this article generally apply to all insulation materials except where more specific requirements are specified in various pipe insulation material installation articles.

B. Insulation Installation on Fittings, Valves, Strainers, Flanges, and Unions:

1. Install insulation over fittings, valves, strainers, flanges, unions, and other specialties with continuous thermal and vapor-retarder integrity, unless otherwise indicated.

2. Insulate pipe elbows using preformed fitting insulation or mitered fittings made from same material and density as adjacent pipe insulation. Each piece shall

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be butted tightly against adjoining piece and bonded with adhesive. Fill joints, seams, voids, and irregular surfaces with insulating cement finished to a smooth, hard, and uniform contour that is uniform with adjoining pipe insulation.

3. Insulate tee fittings with preformed fitting insulation or sectional pipe insulation of same material and thickness as used for adjacent pipe. Cut sectional pipe insulation to fit. Butt each section closely to the next and hold in place with tie wire. Bond pieces with adhesive.

4. Insulate valves using preformed fitting insulation or sectional pipe insulation of same material, density, and thickness as used for adjacent pipe. Overlap adjoining pipe insulation by not less than two times the thickness of pipe insulation, or one pipe diameter, whichever is thicker. For valves, insulate up to and including the bonnets, valve stuffing-box studs, bolts, and nuts. Fill joints, seams, and irregular surfaces with insulating cement.

5. Insulate strainers using preformed fitting insulation or sectional pipe insulation of same material, density, and thickness as used for adjacent pipe. Overlap adjoining pipe insulation by not less than two times the thickness of pipe insulation, or one pipe diameter, whichever is thicker. Fill joints, seams, and irregular surfaces with insulating cement. Insulate strainers so strainer basket flange or plug can be easily removed and replaced without damaging the insulation and jacket. Provide a removable reusable insulation cover. For below ambient services, provide a design that maintains vapor barrier.

6. Insulate flanges and unions using a section of oversized preformed pipe insulation. Overlap adjoining pipe insulation by not less than two times the thickness of pipe insulation, or one pipe diameter, whichever is thicker.

7. Cover segmented insulated surfaces with a layer of finishing cement and coat with a mastic. Install vapor-barrier mastic for below ambient services and a breather mastic for above ambient services. Reinforce the mastic with fabric-reinforcing mesh. Trowel the mastic to a smooth and well-shaped contour.

8. For services not specified to receive a field-applied jacket except for flexible elastomeric and polyolefin, install fitted PVC cover over elbows, tees, strainers, valves, flanges, and unions. Terminate ends with PVC end caps. Tape PVC covers to adjoining insulation facing using PVC tape.

9. Stencil or label the outside insulation jacket of each union with the word "UNION." Match size and color of pipe labels.

C. Insulate instrument connections for thermometers, pressure gages, pressure temperature taps, test connections, flow meters, sensors, switches, and transmitters on insulated pipes, vessels, and equipment. Shape insulation at these connections by tapering it to and around the connection with insulating cement and finish with finishing cement, mastic, and flashing sealant.

D. Removable insulation covers shall conform to the following:

1. Make removable flange and union insulation from sectional pipe insulation of same thickness as that on adjoining pipe. Install same insulation jacket as adjoining pipe insulation.

2. When flange and union covers are made from sectional pipe insulation, extend insulation from flanges or union long at least two times the insulation thickness

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over adjacent pipe insulation on each side of flange or union. Secure flange cover in place with stainless-steel or aluminum bands. Select band material compatible with insulation and jacket.

3. Construct removable valve insulation covers in same manner as for flanges except divide the two-part section on the vertical center line of valve body.

4. When covers are made from block insulation, make two halves, each consisting of mitered blocks wired to stainless-steel fabric. Secure this wire frame, with its attached insulation, to flanges with tie wire. Extend insulation at least 2 inches over adjacent pipe insulation on each side of valve. Fill space between flange or union cover and pipe insulation with insulating cement. Finish cover assembly with insulating cement applied in two coats. After first coat is dry, apply and trowel second coat to a smooth finish.

5. Unless a PVC jacket is indicated in field-applied jacket schedules, finish exposed surfaces with a metal jacket.

3.6 FLEXIBLE ELASTOMERIC INSULATION INSTALLATION

A. Seal longitudinal seams and end joints with manufacturer's 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.

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

3. Fill voids between inner circumference of flange insulation and outer circumference of adjacent straight pipe segments with cut sections of sheet insulation of same thickness as pipe insulation.

4. Secure insulation to flanges and seal seams with manufacturer's recommended adhesive to eliminate openings in insulation that allow passage of air to surface being insulated.

C. Insulation Installation on Pipe Fittings and Elbows:

1. Install mitered sections of pipe insulation.

2. Secure insulation materials and seal seams with manufacturer's recommended adhesive to eliminate openings in insulation that allow passage of air to surface being insulated.

D. Insulation Installation on Valves and Pipe Specialties:

1. Install preformed valve covers manufactured of same material as pipe insulation when available.

2. 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.

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

4. Secure insulation to valves and specialties and seal seams with manufacturer's recommended adhesive to eliminate openings in insulation that allow passage of air to surface being insulated.

3.7 MINERAL-FIBER INSULATION INSTALLATION

A. Blanket Insulation Installation on Ducts and Plenums: Secure with adhesive and insulation pins.

1. Apply adhesives according to manufacturer's recommended coverage rates per unit area, for 50 percent coverage of duct and plenum surfaces.

2. Apply adhesive to entire circumference of ducts and to all surfaces of fittings and transitions. Adhesive may be omitted from top surface of horizontal rectangular ducts.

3. For ducts and plenums with surface temperatures below ambient, install a continuous unbroken vapor barrier. Create a facing lap for longitudinal seams and end joints with insulation by removing 2 inches from 1 edge and 1 end of insulation segment. Secure laps to adjacent insulation section with 1/2-inch outward-clinching staples, 1 inch 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 at 18-foot intervals. Vapor stops shall consist of vapor-barrier mastic applied in a Z-shaped pattern over insulation face, along butt end of insulation, and over the surface. Cover insulation face and surface to be insulated a width equal to 2 times the insulation thickness but not less than 3 inches.

4. Overlap unfaced blankets a minimum of 2 inches on longitudinal seams and end joints. At end joints, secure with steel bands spaced a maximum of 18 inches o.c.

5. Install insulation on rectangular duct elbows and transitions with a full insulation section for each surface. 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 surface with 6-inch- wide strips of same material used to insulate duct. Secure on alternating sides of stiffener, hanger, and flange with pins spaced 6 inches o.c.

B. Board Insulation Installation on Ducts and Plenums: Secure with adhesive and insulation pins.

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1. Apply adhesives according to manufacturer's recommended coverage rates per unit area, for 50 percent coverage of duct and plenum surfaces.

2. Apply adhesive to entire circumference of ducts and to all surfaces of fittings and transitions. Adhesive may be omitted from top surface of horizontal rectangular ducts.

3. For ducts and plenums with surface temperatures below ambient, install a continuous unbroken vapor barrier. Create a facing lap for longitudinal seams and end joints with insulation by removing 2 inches from 1 edge and 1 end of insulation segment. Secure laps to adjacent insulation section with 1/2-inch outward-clinching staples, 1 inch 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 at 18-foot intervals. Vapor stops shall consist of vapor-barrier mastic applied in a Z-shaped pattern over insulation face, along butt end of insulation, and over the surface. Cover insulation face and surface to be insulated a width equal to 2 times the insulation thickness but not less than 3 inches.

4. Install insulation on rectangular duct elbows and transitions with a full insulation 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.

5. Insulate duct stiffeners, hangers, and flanges that protrude beyond insulation surface with 6-inch- wide strips of same material used to insulate duct. Secure on alternating sides of stiffener, hanger, and flange with pins spaced 6 inches o.c.

3.8 FIELD-APPLIED JACKET INSTALLATION

A. Where glass-cloth jackets are indicated, install directly over bare insulation or insulation with factory-applied jackets.

1. Draw jacket smooth and tight to surface with 2-inch overlap at seams and joints.

2. Embed glass cloth between two 0.062-inch- thick coats of lagging adhesive.

3. Completely encapsulate insulation with coating, leaving no exposed insulation.

B. Where FSK jackets are indicated, install as follows:

1. Draw jacket material smooth and tight.

2. Install lap or joint strips with same material as jacket.

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3. Secure jacket to insulation with manufacturer's recommended adhesive.

4. Install jacket with 1-1/2-inch laps at longitudinal seams and 3-inch- wide joint strips at end joints.

5. Seal openings, punctures, and breaks in vapor-retarder jackets and exposed insulation with vapor-barrier mastic.

C. Where PVC jackets are indicated, install with 1-inch overlap at longitudinal seams and end joints; for horizontal applications, install with longitudinal seams along top and bottom of tanks and vessels. Seal with manufacturer's recommended adhesive.

1. Apply two continuous beads of adhesive to seams and joints, one bead under lap and the finish bead along seam and joint edge.

D. Where metal jackets are indicated, install with 2-inch overlap at longitudinal seams and end joints. Overlap longitudinal seams arranged to shed water. Seal end joints with weatherproof sealant recommended by insulation manufacturer. Secure jacket with stainless-steel bands 12 inches o.c. and at end joints.

3.9 FINISHES

A. Duct, Equipment, and Pipe Insulation with ASJ, Glass-Cloth, or Other Paintable Jacket Material: Paint jacket with paint system identified below and as specified in Division 09 painting Sections.

1. Flat Acrylic Finish: Two finish coats over a primer that is compatible with jacket material and finish coat paint. Add fungicidal agent to render fabric mildew proof.

a. Finish Coat Material: Interior, flat, latex-emulsion size.

B. Flexible Elastomeric Thermal Insulation: After adhesive has fully cured, apply two coats of insulation manufacturer's recommended protective coating.

C. Color: Final color as selected by Owner’s representative. Vary first and second coats to allow visual inspection of the completed Work.

D. Do not field paint aluminum jackets.

3.10 FIELD QUALITY CONTROL

A. Testing Agency: Owner’s representative shall engage a qualified testing agency to perform tests and inspections.

B. Perform tests and inspections.

C. Tests and Inspections:

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1. Inspect ductwork, randomly selected by the Owner’s representative, 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 defined in the "Duct Insulation Schedule, General" Article.

2. Inspect field-insulated equipment, randomly selected by the Owner’s representative, 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.

3. Inspect pipe, fittings, strainers, and valves, randomly selected by Architect, by removing field-applied jacket and insulation in layers in reverse order of their installation. Extent of inspection shall be limited to three locations of straight pipe, three locations of threaded fittings, three locations of welded fittings, two locations of threaded strainers, two locations of welded strainers, three locations of threaded valves, and three locations of flanged valves for each pipe service defined in the "Piping Insulation Schedule, General" Article.

D. All insulation applications will be considered defective Work if sample inspection reveals noncompliance with requirements.

3.11 DUCT INSULATION SCHEDULE, GENERAL

A. Plenums and Ducts Requiring Insulation:

1. Indoor, concealed supply and outdoor air.

2. Indoor, exposed supply and outdoor air.

3. Indoor, concealed return located in nonconditioned space.

4. Indoor, exposed return located in nonconditioned space.

5. Outdoor, exposed supply and return.

B. Items Not Insulated:

1. Exhaust air ductwork

2. Fibrous-glass ducts.

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

4. Factory-insulated flexible ducts.

5. Factory-insulated plenums and casings.

6. Flexible connectors.

7. Vibration-control devices.

8. Factory-insulated access panels and doors.

3.12 INDOOR DUCT AND PLENUM INSULATION SCHEDULE

A. Concealed, round, supply-air duct insulation shall be the following:

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1. Mineral-Fiber Blanket: 2 inches thick and 1.5-lb/cu. ft. nominal density.

B. Concealed, round, return-air duct insulation shall be the following:

1. Mineral-Fiber Blanket: 2 inches thick and 1.5-lb/cu. ft. nominal density.

C. Concealed, round, outdoor-air duct insulation shall be the following:

1. Mineral-Fiber Blanket: 2 inches thick and 1.5-lb/cu. ft. nominal density.

D. Concealed, rectangular, supply-air duct insulation shall be the following:

1. Mineral-Fiber Board: 2 inches thick and 2-lb/cu. ft. nominal density.

E. Concealed, rectangular, return-air duct insulation shall be the following:

1. Mineral-Fiber Board: 2 inches thick and 2-lb/cu. ft. nominal density.

F. Concealed, rectangular, outdoor-air duct insulation shall be the following:

1. Mineral-Fiber Board: 2 inches thick and 2-lb/cu. ft. nominal density.

G. Exposed, round, supply-air duct insulation shall be the following:

1. Mineral-Fiber Blanket: 2 inches thick and 1.5-lb/cu. ft. nominal density.

H. Exposed, round, return-air duct insulation shall be the following:

1. Mineral-Fiber Blanket: 2 inches thick and 1.5-lb/cu. ft. nominal density.

I. Exposed, round, outdoor-air duct insulation shall be the following:

1. Mineral-Fiber Blanket: 2 inches thick and 1.5-lb/cu. ft. nominal density.

J. Exposed, rectangular, supply-air duct insulation shall be the following:

1. Mineral-Fiber Board: 2 inches thick and 2-lb/cu. ft. nominal density.

K. Exposed, rectangular, outdoor-air duct insulation shall be the following:

1. Mineral-Fiber Board: 2 inches thick and 2-lb/cu. ft. nominal density.

3.13 PIPING INSULATION SCHEDULE, GENERAL

A. Acceptable preformed pipe and tubular insulation materials and thicknesses are identified for each piping system and pipe size range.