Mechanical Services Standard Specification Thermal Insulation. May For ROYAL HOLLOWAY UNIVERSITY OF LONDON

Transcription

1 Mechanical Services Standard Specification Thermal Insulation May 2010 For ROYAL HOLLOWAY UNIVERSITY OF LONDON

2 Prepared For The Estates Division By: Hulley & Kirkwood Consulting Engineers Ltd Castle House, Horizon Centre Upper High Street Epsom Surrey KT17 4RS (t): (f): (e): (w): Author: Checked: Approved: David Bantock/Andrew Wakelam Wayne Shipley Wayne Shipley Page 2

3 AMENDMENTS Author Date/Rev Description D Bantock / A Wakelam January 2010 Draft Issue W Shipley May 2010 Comments incorporated after meeting with RHUL Page 3

4 Index: 11.1 INTRODUCTION GENERAL Thermal Insulation Materials Thermal Insulation Finishes External Exposed Ductwork and Pipework Insulation Thicknesses Pipework Valves and Flanges Ductwork Painting Identification of Insulated Services Exposed Ironwork System Testing...14 Page 4

5 11.1 INTRODUCTION This specification covers the requirements for the supply and installation of insulation materials in order to meet the minimum requirements of the Current Building Regulations and provide protection against freezing or condensation when applicable. The services involved includes:- Low Temperature Hot Water Heating Chilled Water Domestic Hot Water Domestic Cold and Mains Water Condensation Drains Rain water and Foul Drainage Systems Sheet Metal Ductwork Systems (Heating and Cooling) NOTE: Where existing systems are to be repaired or extended materials of the same type shall be used unless a specific request or operational condition requires an alternative solution. Agreement shall be sought from Royal Holloway University of London before proceeding with any works. ALL WORKS ARE TO BE INSPECTED BY THE TENDERING CONTRACTOR PRIOR TO PRICING HEALTH AND SAFETY STATEMENT Health and Safety precautions are required to be taken during the process of undertaking works within buildings cannot be underestimated. Reference shall be made to Royal Holloway University of London Health and Safety Policy and Contractors Guidance documents available from Royal Holloway University of London Estates Office. The Health and Safety Executive (HSE) publish a series of guidance documents regarding all many different methods of protecting the workforce and people in general when working with hazardous chemicals (COSH) and undertaking potential dangerous work activities. Page 5

6 11.2 GENERAL Thermal insulation materials and installation shall comply with the requirements of BS5422:2001, BS5970:2009, and shall be HCFC/CFC free with zero ozone depletion potential (ODP). All companies manufacturing and supply of the insulation shall be accredited by the Quality Standard BSEN ISO9002. All thermal insulation shall be installed by a specialist Installer with the required experience. Insulation materials and finishes shall be inherently proof against rotting, mould and fungal growth, be non-hygroscopic and in all respects be suitable for continuous use throughout the range of operating temperatures and within the environment indicated. All thermal insulation materials used within the building shall meet the Class O requirements of the UK Building Regulations Approved Document B, Appendix A, Paragraph A12(b). The mixing of manufacturer or type of insulation will not be permitted unless otherwise agreed by Royal Holloway University of London prior to works commencing. No insulation shall be applied to any part of the work until that particular part has undergone successful inspection and pressure testing. All tested pipes shall be clean, dry and grease free before the application of insulation. Insulation materials and protective coverings shall be protected during the progress of the work and maintained dry. All material shall be insulated separately and adjacent runs of pipework shall not be married together in one insulation covering. To ensure the correct thickness and type of insulation has been applied, one section for examination of each type of insulation specified may be cut out to verify the thickness, at the direction of Royal Holloway University of London. If the examination reveals any defects, it shall be necessary for the installation to be corrected and no cost or delay to Royal Holloway University of London. The finish of all thermal insulation shall present a neat and symmetrical appearance. Irregular or badly finished surfaces shall be stripped down and reinsulated to the satisfaction of the Engineer at the Installers expense. Scope of the Works The Installer shall be provided with a scope of works relating specifically to the project and shall carry out the thermal installation of the systems in accordance with this specification. Page 6

7 Supply, delivery, erection finishing and painting of Thermal Insulation materials for the following: Production of All Pipework and Plant The Insulation Installer shall take appropriate steps to prevent damage to new and existing pipework and plant during the progress of the works. Access platforms and the like shall be independently supported and the use of installation shall not be accepted. Operating Conditions The following table provides guidance as to the operating temperatures of systems which shall be verified prior to any works being carried out. Service Operating Temperature C Mains Water Services 5 C Cold Water Services 10 C Domestic Hot Water F&R 60 C Supply Air Heated Ductwork 30 C Supply Air Cooled Ductwork 14 C Toilet Supply Air Ductwork 26 C Office Exhaust Air Ductwork 22 C Condensate Pipework 10 C Low Temperature Hot Water 90 C Chilled Water 6 C Rainwater Pipework 5 C Page 7

8 Thermal Insulation Materials The following thermal insulation materials shall be used as indicated in table. SERVICE LOCATION INSULATION MATERIALS Heating/DHWS Concealed Rockwall preformed sections VAPOUR BARRIER No FINISH Exposed to view at high level None No Painted Exposed to view at low level Plant Room None (except where boxed in) as concealed Rockwall, preformed sections No No Painted Aluminium Cladding CWM/CWS / Chilled Water *Note Cold water mains and CWS systems shall be insulated except where short sections may be exposed in kitchens or toilet areas Concealed Exposed to view at high level Exposed to view at low level Plant Room Rockwall preformed sections Rockwall preformed sections Rockwall preformed sections Yes Yes Yes Aluminium Cladding Air conditioning Ductwork Concealed Rockwall Slabs Yes Exposed to view at high level land low level Rockwall Slabs Yes Plant Room Rockwall Sections Yes Page 8

9 SERVICE LOCATION INSULATION MATERIALS Condensate / All Rainwater Rockwall Sections VAPOUR BARRIER Yes FINISH External Services Exposed Insulation as detailed for independent service To suit service Weatherproofed Aluminium Cladding Ventilation Ductwork Heated Concealed Exposed to view at high level and low level Rockwall Slabs Rockwall Slabs No No Plant Room Rockwall Sections No Aluminium Cladding Rigid Phenolic Foam The following thermal insulation material shall be used: Phenolic Foam Type: Class O CFC Free Pipework Minimum Density: 35kg/m 3 Ductwork Minimum Density: 40kg/m 3 Aged Thermal Conductivity: 0.021W/mk at 10 o C mean temp. Bonded Mineral Fibre - Rigid Section Bonded fibre material consisting of mineral drawn out into long fibres and formed into rigid sections. The density of the material shall be in the range 80 to 110 Kg/m³ and the thermal conductivity shall be not more than W/m C at 100 C. Bonded Mineral Fibre : Semi-Rigid Slab Bonded fibre material consisting of mineral drawn out into long fibres and formed into semi-rigid slabs with finishes as per Appendix 2. The density of the material shall be in the range 32 to 48 Kg/m³ with a thermal conductivity of not more than W/m C at 25 C. Unbonded Mineral Fibre Mattresses Unbonded mineral fibre wool faced on both sides with wire mesh and cloth to form a firm and flexible insulating mattress. The density of the mattress shall be 90 Kg/m³ with a thermal conductivity of W/m C at 100 C. Note: Rockwool Lamella mat shall not be used for any part of the installation. Page 9

10 N.B. Where vapour finish is stated this must be continuous and include all valves, fittings, etc. Valves where vapour seals are required shall be provided with insulation jackets Thermal Insulation Finishes Thermal insulation finishes shall be used as indicated in Clause Vapour seals shall be provided by Idenden, Tel: to completely vapour seal pipework and ductwork where specified as required to match the insulation finish. Backing (forms composite component of thermal insulation) Finished with aluminium foil/draft paper laminate reinforced with glass fibre which shall act as a longitudinal hinge or rigid section pipework insulation. The foil shall have a 50mm overlap along the longitudinal seam which shall be sealed with self-adhesive tape to provide an effective vapour barrier. On semi-rigid slabs all joints and overlaps shall be properly sealed or taped in accordance with Manufacturer s recommendations to provide an effective vapour barrier External Exposed Ductwork and Pipework In order to provide mechanical protection and full weather protection an additional covering shall be applied to suit the application. The covering shall comprise hammer clad aluminium, Aluzinc or other similar material affording the same protection against damage and water ingress. All sections will be securely fastened and all then protected from both mechanical damage and moisture ingress by the provision of 0.6mm (Plain or Stucco Aluminium) sheeting, fabricated to follow the contour of the service, fixed by banding and pop rivets as required. The valves, flanges and other fittings shall be supplied with purpose made removable aluminium boxes fitted with quick release toggle type fasteners or self tapping screws as appropriate. All joints in the cladding will be suitably overlapped and arranged to shed water and if located outdoors sealed with a waterproof mastic. Page 10

11 Insulation Thicknesses The thickness of thermal insulation not including finishes shall comply with Part L of the Building Regulations and shall be not less than the following based on Phenolic sections: Pipework PIPE SIZE CWM, CWDS & CHW HWS, LPHW CONDENSATE 15mm 20mm 20mm 20mm 20mm/22mm 20mm 20mm 20mm 25mm/28mm 20mm 20mm 20mm 32mm/35mm 20mm 20mm 20mm 40mm/42mm 20mm 20mm - 50mm/54mm 25mm 25mm - 65mm/67mm 25mm 25mm - 80mm/76mm 25mm 25mm - 100/108mm 25mm 25mm - 125/133mm 30mm 30mm - Ductwork DUCTWORK SIZE SUPPLY EXTRACT All 30mm 30 mm thick where concealed above false ceiling and used for heat recovery Where the thickness of insulation does not correspond exactly to a commercial thickness the next highest commercial thickness shall be used. NOTE: The finished thickness shall also be dependent upon the material selected for the installation. Page 11

12 Pipework Pipework Insulation This shall be pre-formed rigid sectional insulation to the specified thicknesses supplied, either in two halves and wired on, or alternatively with attached close mesh fabric or reinforced aluminium foil backing with a lap not less than 50mm and secured with odourless, heat resisting adhesive. In each case, the sections shall be further secured with 50mm wide selfadhesive tape or foil around the insulation joints and seams, etc. not exceeding 1200mm centres. The sections shall be close fit to the pipes, butted hard together, bends and fittings neatly mitred and all joints sealed and filled so as to be airtight. The sections shall be neatly cut and trimmed at all flanged joints and pipe fixings to allow sufficient space for the removal or tightening of bolts, without disturbing the insulation. Materials and Finishes Materials and finishes shall be as specified in clause Chilled and Cold Water Services To maintain the vapour barrier to these services all butt and longitudinal joints and termination points shall be bonded with a sealer as Foster Sealfast or equivalent and all overlaps shall be cemented down with Idendum or equivalent. Adjacent Parallel Pipework Each pipe shall be separately insulated and adjacent parallel pipes shall not be married together with common insulation covering. Pipes Through Walls Where the hole through the wall is large enough and in the case of chilled or cold water, the insulation shall be carried through, otherwise the insulation shall stop 13mm to 20mm clear of the wall for pipework not subject to condensation. However continuous insulation is preferred where possible. Pipework Supports insulation shall be finished square 20mm short of the support. For chilled and cold water pipework insulation shall be carried through to bracket with a high density insert to maintain proper support without damage to the insulation. Pipework Trace Heating All exposed pipework subject to frost damage thermally insulated and where required be trace heated. Page 12

13 Valves and Flanges All valves and flange joints shall be insulated by rigid pre-formed covers moulded from PIR foams. The materials shall have a mean density of kg/m 3 and thermal conductivity at 10 C of W/m K. The covers shall be in two halves secured by plastic locking bands. The finish to the covers shall be as adjacent pipework insulation i.e. aluminium clad in plant rooms or foil where concealed. The finish, whether aluminium or foil, shall be easily removable from the covers for maintenance access. The covers shall have a waterproof non-setting injected between the pipe insulation and ends of the covers, between the two halves of the covers and between the valve stem and cover Ductwork The insulation shall be finished in the following manner: The slabs shall be secured to the ductwork by adhesive and piercing fasteners fixed to the ductwork at 500mm centres. Exposed edges and butt joints to be finished with tape. Holes through the vapour barrier made by the piercing fasteners must be sealed with foam mastic and adhesive tape to ensure continuity of the vapour barrier. Acoustic Insulation Ventilation ductwork between silencers and air handling plant, where the potential for noise break outs/break in the ductwork shall be acoustically insulated. The ductwork shall be insulated initially with 25mm semi-rigid mineral fibre slab and then finally wrapped with sound barrier mat, (7Kg/m 2 ). A vapour barrier shall be maintained as required. The Installer shall ensure that the entire surface of the ductwork is properly insulated so that the acoustic performance of the insulation is not impaired. All joints shall be properly sealed and taped utilising recommenced materials Painting General All surfaces to which paint shall be applied shall be properly cleaned and prepared before painting and this work shall be undertaken only be Tradesmen who are skilled in this work. Insulation This work shall comprise the painting for protection and identification purposes of all insulation applied without aluminium or weatherproofing finish. Colours shall be as agreed by Royal Holloway University of London for identification purposes in accordance with BS requirements. The paint shall consist of one coat primer, one coat undercoat and one coat gloss paint. The paint shall be capable of withstanding a temperature of 50 C. Page 13

14 Valve boxes and flange boxes shall also be painted in the identifying colour of the service. Plant and Other Metal Surfaces The work shall comprise the preparation and painting of all items of equipment which are not pre-painted/finished. The items are to be wire brushed or scraped to remove all rust or other encrustments and then primed. Two coats of undercoat shall then be applied and finally a finish coat of agreed colour gloss applied Identification of Insulated Services The Installer shall include for the identification of all insulated services by means of BS.1710 colour band 50mm (2 ) wide painted around the insulation at 20mm maximum centres and adjacent to all valves at all changes of direction, at all inlets and exists to ducts and buildings and at either side of walls and floors. Valves, handwheels and exposed bodies of valves shall be painted to the identifying colour of the service. Care shall be taken not to paint over any labels or screw threads Exposed Ironwork All exposed ironwork supplied by the Installer shall have been supplied rust free and prepainted with Red Oxide primer and weatherproof exposing finish protective paint before erection System Testing The installation shall have been successfully hydraulically tested by the Installer before any insulation is applied to the water services. Page 14