Sports and Fitness Center at RGO Stadium Seeb

Mechanical, Electrical & Plumbing Specifications

SECTION M.04
THERMAL AND ACOUSTIC INSULATION
M.04.01
1.

SCOPE OF WORK
The thermal insulation materials specified herein shall be applied to the following,
where applicable.
i)
Air Conditioning ductwork.
ii)

Chilled water pipework, valves, strainers, flanges, and fittings etc.

iii)

Supply and Extract Ducting, or Fresh Air Inlet Ducting, exposed on the roof.

iv)

All hot water services pipework and fittings inside the buildings, including
that within shafts, voids, wall chases, screeds etc.

v)

All sections of hot water heater cold feed pipes, which are within the room
where the heaters are located.

vi)

All cold water services exposed on the roof, or at the Services Compound.

vii)

All copper condensate drain pipework, and UPVC condensate drain

pipework within false ceilings.

viii)

Both refrigeration pipes on AC Split Units.

ix)

Elsewhere as directed by the Engineer and as may be expected in accordance

with good engineering practice.

2.

Acoustic insulation shall be provided internally within ductwork as indicated on the

drawings. All plenum boxes shall be acoustically lined, together with all ducting to
and from split units.

3.

The material shall be manufactured and supplied by a specialist firm and the
Contractor shall carry out the actual application on Site, and the insulation must be
applied strictly in accordance with the manufacturer's method of application. The
manufacturer in this case shall provide all the necessary insulation material,
wrapping, finishes, fixing bands, etc, pre-formed and moulded to suit the plant and
pipework and full installation instructions to enable the Contractor to satisfactorily
apply on Site.
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4.

M.04.02

Insulation on bends and tees shall be cut and metered on Site to fit. Suitable
insulation lining shall be provided for valves and flanges and shall be readily
removable for maintenance purposes.
INSTALLATION WORK

1.

All insulating material shall be in close contact with the protected surface and all
joints shall be sealed.

2.

Each pipe shall be insulated separately and adjacent parallel pipes shall not be
insulated together.

3.

All insulation joints shall be wrapped with overlapping sections of the specified
finish.

M.04.03

IDENTIFICATION OF PIPEWORK AND DUCTWORK

1.

The Contractor shall provide and fix approved identification labels to all pipework,
and Ductwork indicating the service and direction to be used. These must be
approved by the Engineer, but shall generally be in accordance with BS.1710 and
DW. 161 - Identification of Ductwork.
The identification, direction of flow and colour bands for piping shall be in self
adhesive heavy duty plastics supplied by an approved manufacturer.

M.04.04

AIR CONDITIONING DUCTWORK INSULATION

1.

a)
b)
c)
d)
e)
f)

Air Conditioning ductwork installed internally within the building shall be Flexible
Elastomeric Thermal Insulation: Closedcell, sponge or expandedrubber materials.
Comply with ASTM C 534, Type n for sheet materials.
Adhesive: Solvent base, contact adhesive as recommended by insulation material
manufacturer.
UltravioletProtective Coating: As recommended by insulation material manufacturer.
Thermal Conductivity: 0.038W/mK at 20deg. C (68 deg F).
Density: 65 to 80 kg/ml
Water Vapor Permeability: 0.15 perminches.
Noise Reduction: Up to 27 AL for 20mm thick insulation.

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M.04.04

AIR CONDITIONING DUCTWORK INSULATION (cont'd)

2.

Field applied jacket shall be ASTM C 921, Type I, maximum moisture vapor
transmission 0.02 perms, (measured before factory application or installation),
minimum puncture resistance 50 Beach units on all surfaces. Minimum tensile
strength, 6.1 N/mm. Jackets used on insulation exposed in finished areas shall have
white finish suitable for painting without sizing.

3.

Aluminum Jacket: Embossed or smooth sheets, manufactured from aluminum alloy

complying with ASTM B 209M, and having an integrally bonded moisture barrier
over entire surface in contact with insulation. Corrugated aluminum jacket shall not
be used outdoors.
Finish and Thickness: Stucco embossed finish, 0.6 mm thick for indoor installation
and 0.8 mm for outdoor, unless otherwise noted.

4.

Materials shall be compatible and shall not contribute to corrosion, soften, or

otherwise attack surfaces to which they are applied in either the wet or dry state.
Materials to be used on stainlesssteel surfaces shall meet ASTM C 795
requirements. Materials shall be asbestos free and conform to the following.

5.

Glass Cloth and Tape: Comply with MILC20079H, Type I for cloth and Type II
for tape. Woven glassfiber fabrics, plain weave, pre sized a minimum of 270 g/sq.
m.
Tape Width: 100 mm.

6.

Bands: 19 mm wide, in one of the following materials compatible with jacket:

a)
b)
c)
d)
e)

StainlessSteel: ASTM A 666, Type 304; 0.5 mm thick.

Galvanized Steel: 0.13 mm thick
Aluminum: 0.18 mm thick.
Brass: 0.25 mm thick.
NickelCopper Alloy: 0.13 mm thick.

7.

Wire: 2.0 mm, nickelcopper alloy; 1.6 mm, softannealed, stainless steel; or 1.6
mm, soft annealed, galvanized steel.

8.

AdhesiveAttached Anchor Pins and Speed Washers: Galvanized steel plate, pin,
and washer manufactured for attachment to duct and plenum with adhesive. Pin
length sufficient for insulation thickness indicated.
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a) Adhesive: Recommended by the anchor pin manufacturer as appropriate for

surface temperatures of ducts, plenums, and breechings; and to achieve a holding
capacity of 45 kg for direct pull perpendicular to the adhered surface.

9.

Adhesives:
a) Cloth: Adhesive for adhering, sizing and finishing open weave glass cloth shall
be pigmented polyvinyl acetate emulsion and shall conform to the requirements
of ASTM C 916, Type I.
b) Cellular Elastomer: Adhesive for cellular elastomer insulation shall be a solvent
cutback chloroprene elastomer conforming to ASTM C 916, Type 1 and shall be
of cellular elastomer for the internal use.

10.

Coatings:
a) Outdoor and Indoor Non Vapor Barrier Finishing: Coatings for outdoor and
indoor non vapor barrier finishing of insulation surfaces shall be pigmented
polymer emulsion recommended by the insulation material manufacturer for
the surface to be coated and shall be applied to the specified dry film thickness.
b) Cellular Elastomer Insulation: Finish coating for cellular elastomer insulation
shall be a polyvinyl chloride lacquer approved by the manufacturer of the
cellular elastomer for the intended use.
c) Coating Color: Coating color shall conform to color code specified or as directed
by the Engineer.

11.

Apply insulation materials, accessories, and finishes according to the manufacturer's

written instructions; with smooth, straight, and even surfaces; and free of voids
throughout the length of ducts and fittings.

12.

Refer to schedules at the end of this Section for materials, forms, jackets, and
thicknesses required for each duct system.

13.

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.

14.

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

15.

Seal joints and seams with vaporretarder mastic on insulation indicated to receive a
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vapor retarder.
16.

Keep insulation materials dry during application and finishing.

17.

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

18.

Apply insulation with the least number of joints practical.

19.

Apply insulation over fittings and specialties, with continuous thermal and
vaporretarder integrity, unless otherwise indicated.

20.

Hangers and Anchors: Where vapor retarder is indicated, seal penetrations in

insulation at hangers, supports, anchors, and other projections with vaporretarder
mastic. Apply insulation continuously through hangers and around anchor
attachments.

21.

Insulation Terminations: For insulation application where vapor retarders are

indicated, seal ends with a compound recommended by the insulation material
manufacturer to maintain vapor retarder.

22.

Apply insulation with integral jackets as follows:

a) Pull jacket tight and smooth.
b) Joints and Seams: Cover with tape and vapor retarder as recommended by
insulation material manufacturer to maintain vapor seal.
c) VaporRetarder Mastics: Where vapor retarders are indicated, apply mastic on
seams and joints and at ends adjacent to duct flanges and fittings.

23.

Cut insulation according to manufacturer's written instructions to prevent

compressing insulation to less than 75 percent of its nominal thickness.

24.

Install vaporretarder mastic on ducts and plenums scheduled to receive vapor

retarders.
a) Ducts with Vapor Retarders: Overlap insulation facing at seams and seal with
vapor retarder mastic and pressuresensitive tape having same facing as
insulation. Repair punctures, tears, and penetrations with tape or mastic to
maintain vaporretarder seal.
b) Ducts without Vapor Retarders: Overlap insulation facing at seams and secure
with outward clinching staples and pressuresensitive tape having same facing as
insulation.
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25.

Roof Penetrations: Apply insulation for interior applications to a point even with top
of roof flashing.
a) Seal penetrations with vaporretarder mastic.
b) Apply insulation for exterior applications tightly joined to interior insulation
ends.
c) Seal insulation to roof flashing with vaporretarder mastic.

26.

Interior Wall and Partition Penetrations: Apply insulation continuously through

walls and partitions, except fire rated walls and partitions.

27.

FireRated Wall and Partition Penetrations: Terminate insulation at fire smoke

damper sleeves for fire rated wall and partition penetrations.

28.

Floor Penetrations: Terminate insulation at underside of floor assembly and at a

floor support at top of floor.
a) For insulation indicated to have vapor retarders, taper communication and seal
insulation ends with vapor retarder mastic.

29.

Air Conditioning and Extract Ventilation Ducting installed externally on the roof
shall be insulated with 50 mm. thick polystyrene slabs.

30.

This insulation should be secured using a suitable adhesive applied to the entire duct
surface, together with self adhesive stick-clips/hangers and washers at 8 or 10 per
square metre of insulation.

31.

External ductwork insulation shall be finished as described below

a) The entire surface should then have a tack-coat of internal grade sealant/coating,
applied by brush at the rate of 1-litre per 1m2 No.20 mesh open weave glass
cloth not less than 3 ply should then be immediately embedded into the wet film,
allowing an overlap of 75mm at all longitudinal and butt joints. The glass cloth
should be smoothed out to eliminate all wrinkles, and then allowed to dry.
b) The entire surface of ductwork insulation shall then have a second coating of
internal grade sealant/coating applied by brush at the rate of 1-litre/1m2.
c) When this coating is thoroughly dry, one coat of External grade Vapour barrier
coating should be applied by brush to the entire surface, at the rate of 1-litre per
4m2.
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d) When this coating is thoroughly dry, a second coat of External grade Vapour
Barrier Coating should then be brushed onto the entire surface, again at the rate
of 1-litre per 4m2 and allowed to dry. Further coats of this sealant will then be
applied as necessary to ensure that the finish is completely smooth and without
any wrinkles or perforations, to the entire satisfaction of the Engineer.

32.

M.04.05

When the vapour seal is dry, and following inspection and approval by the Engineer,
the external ductwork shall be clad with aluminium sheeting as described elsewhere
in this section of the Specification.

FLEXIBLE ELASTOMERIC THERMAL INSULATION APPLICATION

1.

Flexible elastomeric cellular insulation shall be installed with seams and joints sealed
with rubberized contact adhesive. Insulation with preapplied adhesive is not
permitted. Flexible elastomeric cellular insulation shall not be used on surfaces
greater than 93 degrees C. Seams shall be staggered when applying multiple layers
of insulation. Insulation exposed to weather and not shown to have jacketing shall be
protected with two coats of UV resistant finish as recommended by the manufacturer
after the adhesive is dry. A brush coating of adhesive shall be applied to both butt
ends to be joined and to both slit surfaces to be sealed. The adhesive shall be allowed
to set until dry to touch but tacky under slight pressure before joining the surfaces.
Insulation seals at seams and joints shall not be capable of being pulled apart one
hour after application. Insulation that can be pulled apart one hour after installation
shall be replaced.

2.

Apply insulation to ducts and plenums as follows:

a) Follow the manufacturer's written instructions for applying insulation.
b) Seal longitudinal seams and end joints with manufacturer's recommended
adhesive. Cement to avoid openings in insulation that will allow passage of air to
the duct and plenum surface.
c) Install insulation sheets of the largest manageable size.
d) Apply full coverage of adhesive to the surfaces of duct and to the insulation.
e) Butt insulation joints firmly together and apply adhesive to insulation edges at
joints.

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M.04.06
1.

M.04.07

FIELDAPPLIED JACKET APPLICATION

Apply metal jacket where indicated, with SOmm 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 stainlesssteel bands 300 mm o.c. and at end joints. Secure jackets according to
jacket manufacturer's written instructions
FINISHES

1.

Flexible Elastomeric Thermal Insulation: After adhesive has fully cured,

apply two coats of insulation manufacturer's recommended protective coating.

2.

Color: Final color as selected by the Engineer. Vary first and second coats to
allow visual inspection of the completed Work.

M.04.08

DUCT SYSTEM APPLICATIONS

1.

Insulation Materials and thicknesses are specified in schedules at the end of this
Section.

2.

Materials and thicknesses for system listed below are specified in the schedule at the
end of this Section.

3.

Insulation the following plenums and duct systems:

a) Indoor concealed supply, return, and outsideair ductwork
b) Indoor exposed supply, return, and outsideair ductwork
c) Outdoor supply and return ductwork.

4.

Items Not Insulated: Unless otherwise indicated, do not apply insulation to the
following systems, materials, and equipment:
a) Metal ducts with duct liner.
b) Factoryinsulated flexible ducts.
c) Factoryinsulated plenums, casings, terminal boxes, and filter boxes and
sections.
d) Flexible connectors.
e) Vibrationcontrol devices.
f) Testing agency labels and stamps.
g) Nameplates and data plates.
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h) Access panels and doors in airdistribution systems.

M.04.09
1.

INDOOR DUCT AND PLENUM APPLICATION SCHEDULE

Service: Supplyair ducts.
a) Material: Flexible elastomeric.
b) Thickness: 19 mm.
c) FieldApplied Jacket: Aluminum jacket where exposed to view or in mechanical
rooms.
d) Vapor Retarder Required: No.

2.

Service: Returnair ducts.

e) Material: Flexible elastomeric.
a) Thickness: 19 mm.
b) FieldApplied Jacket: Aluminum jacket where exposed to view or in mechanical
rooms, .
c) Vapor Retarder Required: No.

3.

Service: Outsideair ducts.

a) Material: Flexible elastomeric.
b) Thickness: 32 mm.
c) FieldApplied Jacket: Aluminum jacket where exposed to view or in mechanical
rooms,
d) Vapor Retarder Required: No.

M.04.10
1.

OUTDOOR DUCT AND PLENUM APPLICATION SCHEDULE

Service: Supplyair ducts.
a)
b)
c)
d)

2.

Material: Flexible elastomeric.

Thickness: 32 mm.
FieldApplied Jacket: Aluminum jacket.
Vapor Retarder Required: No.

Service: Returnair ducts.

a) Material: Flexible elastomeric
b) Thickness: 32 mm.
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c) FieldApplied Jacket: Aluminum jacket

d) Vapor Retarder Required: No.

M.04.12

ACOUSTIC INSULATION

1.

This insulation shall comprise 25mm thick Fibreglass faced on one side with a black
coated glass tissue. The insulation shall have a minimum density of 32kg/m3.

2.

Acoustic insulation shall be fixed to the inside of the ductwork with the black coated
tissue face in the air stream, using an adhesive supplied by the insulation
manufacturer, together with self adhesive stick-clips and washers.

3.

Acoustic insulation shall be non-combustible when tested in accordance with

BS.476. Part 4 (1984).

M.04.12

ACOUSTIC INSULATION (Cont'd)

4.

The dimensions of the ductwork indicated on the Drawings shall be the actual clear
internal dimensions of the duct, measured inside the lining and the actual dimensions
of the steel ductwork shall be increased accordingly.

5.

Acoustic Insulation shall be applied to the following:-

M.04.13

i)

SA, Plenum Boxes and Ducting of Concealed Fancoil Units.

ii)

SA, RA, and EA plenum boxes.

iii)

Elsewhere as shown on the drawings.

HOT AND COLD WATER PIPEWORK

1.

These Services shall be insulated with 19mm thick closed cell rubber tubular type
insulation.

2.

It is vital that this insulation is installed strictly in accordance with the

manufacturers' written instructions.

3.

All pipework exposed on the roof or at the Service Compound, shall be wrapped
with 20 gauge open weave fibre glass cloth and then painted with minimum of 2coats of appropriate weatherproof sealant (white). The finish shall be completely
smooth and without any perforations or wrinkles.
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4.

All hot water services valves within plantrooms, or accessible voids, or shafts etc.
shall be fitted with a valve box made from 19mm. thick closed cell rubber tubing
and sheets as specified for the insulation, with the hand wheels accessible for
operation.

5.

All hot and cold water pipework which is insulated in plantrooms or hot water heater
rooms etc. shall be finished with a suitable flexible paint, colour white, as provided
by the insulation manufacturer.

6.

The hot and cold water pipework insulation shall have the following properties:
- 0.036 W/m.oC
Thermal Conductivity at 20oC
Fire Rating:
BS.476. Part 7: 1971, Surface Spread of Flame
-Class'0'
BS.476. Part 6: 1968, Fire Propagation:
Total Index of Performance - 14.2
Sub- Index
- 5.5
BS.476. Part 5: 1979, Ignitability
- Class P.

M.04.14
1.

M.04.15
1.

TESTING
No insulation shall be applied until pipework has been successfully pressure tested
and approved by the Engineer, and painted.

HAMMERED ALUMINIUM SHEET CLADDING

All ductwork, valves and fittings exposed, or on the roof/plant room shall be
finished in 24 gauge "Hammered" Aluminium sheeting. This shall be installed over
the finished vapour seal, neatly, with no sharp edges or corners, and secured by
rivets generally on the "blind" side of the pipe or duct. etc.

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