Technical Submission Spiralite Pre-insulated Ductwork

Transcription

1 Technical Submission Spiralite Pre-insulated Ductwork This Spiralite technical submission and performance specification covers air-distribution HVAC ductwork systems and insulation requirements. It is offered as a guide to Specifiers for exceeding the minimum performance requirements set forth by the Building Regulations in England & Wales, Northern Ireland and the Republic of Ireland, and the Building Standards in Scotland. TECHNICAL SUMMARY Spiralite is an advanced and innovative non-metal pre-insulated spiral, flat oval or rounded square ductwork system available in up to 2.95m long sections, fabricated from CFC/HCFC-free phenolic insulation board. High quality rigid phenolic panels are used in the manufacture of Spiralite. The insulation panel is precision cut in such a way as to allow it to be formed into a complete rounded duct and sealed externally with a heavy duty reinforced foil tape. The internal surface is lined using a continuous impermeable vapour proof laminate which results in a light yet very strong and extremely airtight duct system. The panels themselves are closed-cell and nonporous and therefore have excellent strength and durability. The foil tape, external and internal laminates are of the highest quality using the most advance gluing technology available. The internal lining is a three-ply laminate made with a 1 mm aluminium foil with 0.5 mm polyester film on both sides and coated with a special cold weather acrylic pressure sensitive adhesive system which combines superior quick stick at normal temperatures with superior low temperature performance below freezing. The polyester coating on both sides of the laminate prevents formation of pinholes. Duct fittings, including bends, reducers, shoes and tees are manufactured in a similar way from the same material. The joining system uses simple push fit metal connectors that are easy to fit with no outer protrusion and allow no thermal transfer. Spiralite is robust, light, airtight, easy to install and has numerous energy conservation and environmental benefits. It can also be supplied with a strong outer laminate for exterior use (weatherproofing) or use in plant rooms or other high activity areas. Spiralite is also particularly suitable for high specification projects that require durable materials to perform in moisture and hygiene controlled environments The unique fabrication method of Spiralite ducting and the jointing system is highly pressure resistant and minimises air leakage under normal operating conditions. Independent testing from BSRIA shows that it achieves the highest Class 'C' classification up to 2500 Pa. If Spiralite is properly installed and maintained (refer Spiralite Installation Guide and Spiralite Maintenance Guide) and, given that its component materials are not known to deteriorate over time and carry a 10-year product warranty, Spiralite ducting has an indeterminable lifespan and should last the lifetime of the relevant mechanical services, both internal and external to a building. Quality standards of Phenolic foam insulation panels: Comprising a thermoset phenolic core faced on both sides with a durable and protective low vapour permeability 25 micron aluminium foil reinforced with a 5mm glass tissue bonded to the phenolic core. These panels are also available with a 23 micron black coated aluminium foil, reinforced with a 5mm glass tissue facing on one side. They feature: A thermal conductivity of W/m K at 10 to 19 C mean (BS EN 12667) Density kg/metre³ Perpendicular compressive strength >200 kn/m² at 10% compression Fire and smoke performance to the Building Regulations/Standards: o Class 0 (Low Risk Scotland) fire classification 1 P a g e

2 o BS 476-6: Fire tests on building materials and structures. Method of test for fire propagation for products. Fire propagation index 12 and sub-index (i1) o BS 476-7: Fire tests on building materials and structures. Method of test to determine the classification of the surface spread of flame of products o EN 13501: Euroclass BS 1-d0 o EN ISO : Smoke Generation and Obfuscation Closed cell content > 90% for non-wicking and resistance to moisture penetration Vapour resistance (aluminium foil) of 1000 MNs/g Toxicity index <7.0 (NES 713) Oxygen Index >33% (BS EN ISO ) Ozone Depletion Potential 0 (Zero) Global Warming Potential <5 (Low) Thicknesses of 22mm and 30mm to satisfy requirements of the TIMSA Guide, BS 5422, NHS CO2, NES Specification Expert Y50 and DEO Specification 037 Operating temperature range between -20 C and 80 C (80 C max for aluminium foil face) Manufactured under a Quality Management System approved to BS EN ISO 9001 Manufactured to Environmental Management Standards approved to BS EN ISO Manufactured to BS EN and BS EN Spiralite ductwork is suitable for design within the following parameters: Suitable for low, medium and high pressure systems Mean air velocity (maximum) - 50 m/s or 10,000 fpm Air tightness Class C at 2,500 Pa Design pressure (maximum) o Positive: 2,500 Pa o Negative: 750 Pa Air leakage limits x p 0.65 litres per second per square metre of duct surface area Temperature - Internal air temperature of -20 C to +80 C / -4 F to +176 F Size 100 to 500 mm diameter as standard, up to 2,000 mm diameter non-standard (provided that the recommended Spiralite installation procedures are strictly observed) NB: Mean Air Velocity refers to the design air flow rate related to the cross sectional area of the ductwork. Design pressure relates to the actual total pressure of the relevant section of ductwork and not the fan static pressure. Total pressure is a combination of both static and dynamic pressure DUCTWORK PERFORMANCE SPECIFICATIONS The contractor shall include for the manufacture, supply, delivery and installation materials necessary for the ductwork systems described in this specification. All ventilation ductwork shall be constructed of Spiralite non-metal, pre-insulated, thermal flat oval or circular ducting incorporating KoolDuct square ducting as manufactured and supplied by Specialist Insulation Ltd. (Tel: ; info@spiralite.co.uk). It is manufactured from Kingspan Zero ODP phenolic insulated panels and constructed to suit a system static pressure of up to 1000Pa. All primary air supply and secondary ductwork and extract ductwork that forms part of a heat recovery (MVHR) recirculation system shall be insulated along its entire length in terms of Approved Document L, the Non-domestic Heating, Cooling and Ventilation and Compliance Guide and the TIMSA-HVAC Compliance Guide. All ventilation ductwork shall have a better than Class C Air Leakage rating up to a minimum of 1000Pa and all insulated ductwork shall have a complete vapour seal in accordance with the approved standards. All ductwork and its associated insulation which is visible shall be provided in a colour in accordance with the Architects requirements. 2 P a g e

3 Spiralite Ducting The installation shall be carried out by specialist operatives who have successfully completed a training course with Spiralite and be certified as approved installers. All materials and finishes shall be installed in accordance with the manufacturer's recommendations. The Contractor shall allow for inspections by Spiralite of the ductwork installation at 1st fix stage including phased attendance if necessary to meet the main contract programme. The results/comments of the inspection shall be issued to the Engineer and incorporated in the O & M Manuals. Air Leakage All ductwork, regardless of pressure class, shall achieve the air leakage rate of pressure Class C as defined in BS EN 13403: 2003, BS EN 1507:2006, BS EN 12237: 2003 and HVCA DW 144, and the maximum permitted air leakage factor (fmax) shall be no greater than: x Ps0.65 (l/s/m²). The actual air leakage of all ductwork subjected to leakage testing shall not exceed the specified maximum allowable air leakage. Spiralite ductwork has a better than Class C Air Leakage rating up to 2500Pa as tested by BSRIA (Report Nr /1). The maximum permitted air leakage shall be between Pa, Pa, Pa and Pa. Thermal Performance The thermal conductivity (λ) of insulation materials shall not exceed W/m K at 10 C mean. The thickness of insulation materials shall be such that it complies with the appropriate heat loss and heat gain figures as laid out in the TIMSA Guide and BS5422:2009 (16.34 for warm air ductwork and for chilled and dual purpose ductwork). Under no circumstance shall the installed thickness of insulation be less than the specified thickness of insulation. Should the insulation material be susceptible to compression when stretched around the ductwork during installation, a 25% compression factor shall be taken into account i.e. the installed thickness shall be assumed to be 75% (25% compression) of nominal thickness Environmental Performance The ductwork insulation panels shall be manufactured from CFC & HCFC free Phenolic foam panels thermo-bonded on both sides to a 25mm micron 1mm low vapour permeability aluminium foil facing reinforced with a 5mm glass scrim. The phenolic panels shall be closed cell with a closed cell content of >90% and a minimum compressive strength of 200 kpa The ductwork shall be constructed and installed such that the impact upon the environment is minimised. The Ecopoint score per linear metre of ductwork shall be no greater than 0.5 as determined in the 2008 BRE Global Environmental Profiles Methodology. All insulation materials shall have a Green Guide Rating no less than A as assigned by the BRE in the Green Guide 2008 Summary Ratings and published in the BRE Green Book Live. Fire and Smoke Performance The phenolic insulation panels and facings shall be rated as Class O to the Building Regulations in England and Wales, Northern Ireland and the Republic of Ireland and Low Risk to the Building Standards of Scotland when tested to BS 476 Part 6 and 7 and must achieve a Surface Burning Characteristic / Flame Spread Index of < 25/50 when tested to ASTM E 84-08a and UL P a g e

4 When tested to BS EN ISO (Smoke Density) all insulation materials shall achieve a mean maximum specific optical density no greater than 0 at 25 kw/m 2 both in the presence and absence of a pilot flame, 7 at 50 kw/m 2 in the absence of a pilot flame and 6 at 50 kw/m 2 in the presence of a pilot flame. The insulation boards (with a nominal density of 55-60kg/m3) shall be tested to BS 6401:1983 and the mean specific optical density of smoke generation in flaming mode shall not exceed 23. Other Requirements All materials used for the installation of the ductwork system shall be approved by the duct manufacturer, including internal connectors and connection accessories, fire dampers, volume control dampers, access doors and support mechanisms. Connection to standard ductwork system components such as fans, dampers etc. shall be accommodated by the selection of the appropriate sized mezz flange or by spigotted connection as outlined in the Spiralite System Installation Guide. Supports shall be provided at centres not exceeding 3m, at all changes in direction and branch connections. All ductwork plant and ancillaries shall be independently supported. All externally mounted Spiralite ductwork shall be provided with a VentureClad weatherproof protective finish, suitable for the application, (13 ply on tops and 5 ply on bottoms and sides) laminated onto the phenolic panels during the manufacture of the ductwork. Each external duct segment must be joined over internal connectors and sealed using tiger connectors and matching 100mm VentureClad tape. There should be no gaps between the segments and tape should not be applied to a damp or dirty surface. Where Spiralite ducting is installed in plantrooms and other exposed and high use areas, it shall be protected with Embossed VentureClad applied during manufacture. It shall be the responsibility of the contractor to ensure that the ductwork system is properly and adequately installed and supported. A number of support systems are available and it shall be the responsibility of the contractor to ensure that the chosen method is compatible with the Spiralite ducting system. Polyisobutylene sheet (PIB) is not an acceptable weatherproof coating for Spiralite ducting and shall not be used. Ductwork that is indicated as requiring sound abatement shall be lined with a sound absorbent material, in accordance with the manufacturers instructions. Where Spiralite ducting is exposed to view it shall be finished to the architect s requirements, ensuring the manufacturers have approved the type of finish for use. All ductwork systems shall be tested in part or in whole, as may be required, in a manner complying fully with the requirements of DW144. Spiralite ducting should not be used for: Fire Rated Ductwork Fire and Smoke Extract Ductwork Kitchen Fume Extract Ductwork ANNEXURES (all documents available on request) 1. BSRIA report air leakage report. 2. Ductwork Air Leakage Calculation report on air leakages across the different classes of ducting 4 P a g e

5 3. Kingspan KoolDuct Specification Manual 4. Spiralite Design and Dimensions Circular design details and dimensions of the circular ducting sections 5. Spiralite Design and Dimensions Flat Oval design details and dimensions of the flat oval ducting sections 6. Spiralite Flat Oval and Circular Cross Sections cross section diagrams of the flat oval and circular ducting 7. Spiralite Pressure Drops spreadsheet showing standard product range and associated pressure drops 8. Spiralite Space Saving diagram illustrating the spaced saved by using Spiralite flat oval ducting 9. External Weatherproof Ducting 5-Sided v Spiralite diagram with narrative showing the comparison and advantages of Spiralite in an external application 10. KoolDuct Benefits Summary and Technical Data benefits and qualities of the Phenolic board 11. KoolDuct Whole of Life Costs highlights the savings in initial and on-going operational costs 12. M&E Questions for Spiralite Medical and Sterile Use June Spiralite Acoustic Qualities detailing the various acoustic qualities of Spiralite and enhancement options 14. Spiralite and Fire/Smoke Performance detailing the fire and smoke performance of the ducting and the relevant tests and standards 15. Spiralite Ducting Mechanical Q&A's 16. Spiralite Installation Guide 17. Thermal Conductivity of Spiralite specifying the U and R value of Spiralite and comparable insulation materials 18. VentureTape Reinforced Foil Tape Specifications of the outer foil tape 19. VentureTape Vapour Barrier Tape Specifications of the internal lamination product 20. Kingspan Board Certification confirmation from Kingspan of the longevity and superior performance of the product and a summary of qualities of the insulation panels 21. Kingspan KoolTherm Certified Profile Report Final GG Ratings Table BRE Green Guide Global Environmental Profile report (January 2010) of Kingspan phenolic insulation panels showing A and A+ ratings for the insulation panels used in the Specialist products 22. Kingspan Phenolic Board UL Approval highlights the unique qualities of the insulation panels and the significance of UL approval in the US (see below for full report) 23. Schedule of Certifications details the relevant product tests, standards and certifications for Spiralite ducting and insulation products 24. UL Approval Report on Air Ducts March 2000 copy of the UL approval report detailing the testing undertaken. 25. Phenolic Foam document released by the European Phenolic Foam Association highlighting the advantages of phenolic over other types of insulation material. 26. Spiralite Product References various professionals that have specified and/or used Spiralite 27. Spiralite Project References a sample of projects where Spiralite products have been installed 28. Spiralite Benefits a detailed assessment of the benefits of Spiralite 29. Spiralite Cleaning Process third party confirmation of ease of the cleaning process and any implications 30. Spiralite Energy Savings and Environmental Credentials document highlighting the various energy saving characteristics of Spiralite and the environmental credentials of the products 31. FM Approval Standard for Kingspan KoolTherm Phenolic Duct insulation independent product approval report from USA standards organisation - phenolic insulation boards for internal use 32. VentureTape Data Sheet & Chemical Resistance CW-BM-TDS specifications of the external 6-ply 33. VentureTape Data Sheet & Chemical Resistance CW-WM-TDS - specifications of the external 6-ply 34. VentureTape Data Sheet & Chemical Resistance CW-WME-TDS - specifications of the external 6-ply 35. VentureTape Data Sheet & Chemical Resistance CW - specifications of the external 13-ply VentureClad Laminate 36. VentureTape Data Sheet & Chemical Resistance CMG-WM - specifications of the external 13-ply 5 P a g e

6 Spiralite pre-insulated non-metal ducting and insulation manufactured and supplied by Specialist Insulation Limited Unit 10 EuroCourt, Oliver Close, West Thurrock, Essex, RM20 3EE Tel: Fax: P a g e