Project Specification - Kingspan Insulation

Project Specification
1 General
1.1 The contractor shall include for the manufacture, supply,
delivery and installation of materials necessary for the
ductwork systems described in this specification.
1.2 The fabrication and installation of the Kingspan KoolDuct ®
zero ODP System System shall be carried out
by a fabricator who is registered with Kingspan Insulation
Ltd, having successfully completed a specialist training
course. The contractor shall make himself fully acquainted
with all the site conditions and programme of works and
shall execute his works within such confines and
programme. A list of registered fabricators can be
obtained from Kingspan Insulation Ltd.
1.3 The materials used in the fabrication of the Kingspan
KoolDuct ® zero ODP System, shall be inherently proof
against rotting, mould and fungal growth and attack by
vermin, be non-hygroscopic and in all respects be suitable
for continuous use throughout the range of operating
temperatures and within the environment indicated.
1.4 Any work not of acceptable standard shall be removed
and replaced at no cost to the contract.
1.5 All materials and finishes shall be installed in accordance
with the registered fabricators recommendations.
1.6 No insulation material containing CFCs or HCFCs shall
be accepted.
2 Standard References
The materials, tests, methods of installation etc, shall conform
with the following:
2.1 British Standards
BS 476: Part 6: 1989
BS 476: Part 7: 1997
Method of test for fire
propagation for products.
Method of test to determine the
classification of the surface
spread of flame of products.
BS 4370: Part 1: 1988 Methods of test for rigid cellular
(1996) materials. Methods 1 to 5.
BS 4370: Part 2: 1993
BS 2972: 1989
BS 3927: 1986 (1996)
BS 5422: 2001
Methods of test for rigid cellular
materials. Methods 6 to 10.
Methods of test for in organic
thermal insulating materials.
Specification for rigid phenolic
foam for thermal insulation in
the form of slabs and profiled
sections.
Method for specifying thermal
insulating materials for pipes,
tanks, vessels, ductwork and
equipment operating within the
temperature range –40°C to
+700°C.
2.2 Other Standards
HVAC DW 144
BS EN ISO 9001: 2000
NHS CO2
NES Specification
Expert Y50
Specification for sheet metal
ductwork and duct air leakage.
Quality management systems.
Requirements.
National Health Service. Model
engineering specifications. CO2.
Thermal insulation.
Thermal Insulation.
Defence Estate Organisation Ministry of Defence
Specification 037: 1997
Air conditioning, air cooling
and mechanical ventilation
for buildings.
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2.3 Building Regulations/Standards
England & Wales: The Building Regulations 2000.
Approved Document B. 2002
Edition. Appendix A 12(b).
Scotland:
Northern Ireland:
The Building Standards
(Scotland) Regulations 1990
as amended. Technical
Standards Part E. 1997 Edition.
Table 2 to (E6.1)a.
The Building Regulations
(Northern Ireland) 1994.
Technical Booklet E.
Paragraph 2.4.
Irish Republic: The Building Regulations 1997.
Technical Guidance Document
B. Appendix A. Paragraphs A9
and A10.
3 Fire Ratings
3.1 The rigid phenolic insulation panels used in the fabrication
of the Kingspan KoolDuct ® zero ODP System shall
achieve the following:
Test
BS 476: Part 6: 1989
BS 476: Part 7: 1997
Result
of low contribution to
fire growth with fire
propagation indices
not exceeding
1=12 and i=6
of very low surface
spread of flame (Class 1)
3.2 Systems which meet the required combined standards as
detailed above are defined as Class O/low risk to the
Building Regulations/Standards.
3.3 Insulation materials and facings installed on ductwork and
equipment, external to buildings shall be rated as Class 1
when tested to BS 476: Part 7: 1987.
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Project Specification
4 Scope Of Works
Unless otherwise indicated, the Kingspan KoolDuct ® zero
ODP System can be installed in the following applications:
a) warm air ventilation distribution ductwork;
b) air conditioning distribution ductwork;
c) fresh air intake ducts to plant; and
d) returning air to a plantroom.
Where the ductwork is exposed on a roof or other
external locations, an additional weatherproof finish
is required.
5 Materials
5.1 Kingspan KoolDuct ® zero ODP rigid phenolic insulation
panels shall be manufactured of CFC/HCFC-free closed
cell phenolic insulation of total thickness 22 mm,
autohesively bonded on both sides to a 25 micron
aluminium foil facing reinforced with a 5 mm glass
tissue scrim.
5.2 The thermal conductivity of the rigid phenolic insulation
panel shall be no greater than 0.021 W/m.K at 10°C
mean temperature.
5.3 The density of the rigid phenolic insulation panel’s core
shall not be less than 55 kg/m 3 with a minimum
compressive strength of 200 kN/m 2 .
5.4 The panels shall be Kingspan KoolDuct ® zero ODP rigid
phenolic insulation panels, as manufactured by Kingspan
Insulation Ltd. (App. A1)
5.5 All other components required for the fabrication of duct
sections including the contact adhesive, reinforced
aluminium tape, silicone sealant, self adhesive gasket,
aluminium reinforcement and flanges are to be original,
factory approved as supplied by Kingspan Insulation Ltd.
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6 Fabrication of the Kingspan KoolDuct ®
zero ODP System
6.1 All Kingspan KoolDuct ® zero ODP duct sections shall be
fabricated according to approved methods as detailed in
the ‘Kingspan KoolDuct ® zero ODP System Fabrication
Manual’.
6.2 Rectangular duct sections shall be fabricated either on
site or in the workshop utilising the “V” groove method
of fabrication.
6.3 External seams where two separate panels have been
joined must be taped to achieve a permanent bond and
wrinkle free appearance.
6.4 Internal seams must be fully sealed with an unbroken
layer of silicone sealant.
6.5 Each duct section must be flanged with aluminium profile
and silicone sealant should be applied to the internal
corners of the flange in order to seal the rigid phenolic
insulation panel and ensure minimum leakage.
6.6 Duct reinforcement, if necessary, should be applied to
protect against side deformation from both positive and
negative pressure.
6.7 The design of ductwork fittings shall be in conformance
with DW 144.
6.8 Access doors shall be provided where shown on the
drawings and at all dampers. These may be as part of
the Kingspan KoolDuct ® zero ODP System or a
commercially available, pre-insulated access door, may
be incorporated. This access door must be insulated to
the same standard as the Kingspan KoolDuct ® zero
ODP System and the integrity of the vapour barrier must
be maintained.
Handling of Duct Sections
6.9 Care shall be exercised in the handling and
transportation of duct sections in order to prevent
damage to the outer surface.
7 Installation of the Kingspan KoolDuct ®
zero ODP System
7.1 Kingspan KoolDuct ® zero ODP duct sections shall only
be installed in accordance with the ‘Kingspan KoolDuct ®
zero ODP System Fabrication Manual’.
Jointing
7.2 The jointing of Kingspan KoolDuct ® zero ODP duct
sections shall be accomplished using the jointing
procedure outlined in the ‘Kingspan KoolDuct ® zero ODP
System Fabrication Manual’.
7.3 Connection to standard ductwork system components
such as fans, dampers etc. shall be accommodated by
the selection of the appropriate aluminium flange as
outlined in the ‘Kingspan KoolDuct ® zero ODP System
Fabrication Manual’.
7.4 Flexible connections shall be made between the
ductwork and any item which is subject to vibration
or movement.
Support
7.5 It shall be the responsibility of the registered fabricator to
ensure that the ductwork system is properly and
adequately supported. A number of support systems are
available and are outlined in the ‘Kingspan KoolDuct ®
zero ODP System Fabrication Manual’. It shall be the
responsibility of the registered fabricator to ensure that
the chosen method is compatible with the Kingspan
KoolDuct ® zero ODP System.
7.6 All metal support members, in contact with the
ductwork, shall be separated by a soft gasket material.
7.7 Supports on straight runs of ductwork shall be
positioned at centres not exceeding 3 metres.
Additionally, ductwork shall be supported at changes of
direction, at branch duct connections, Tee fittings etc.
7.8 All duct accessories such as dampers shall be
independently supported.
6.10 All duct sections shall be stored under cover and
protected from the weather. In cases where the duct
sections are to be stored for prolonged periods, the
open ends of the ducts shall be sealed with polythene
sheet or other suitable materials to prevent the ingress
of foreign matter.
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Project Specification
Appendix A – Materials Technical Data
and Information
Internal Ductwork
7.9 All internal and exposed to view Kingspan KoolDuct ®
zero ODP System shall be provided with a protective
finish.
7.10 This finish shall be either:
a) factory applied reinforced aluminum foil facing, rated
as Class O/low risk to the Building Regulations/
Standards (App. A1);
b) aluminium zinc alloy coated steel sheet (0.7 mm)
(e.g. Dobel Aluzink or equivalent) which is introduced
during the fabrication of the ducting (App. A2); or
External Ductwork
7.11 All externally mounted Kingspan KoolDuct ® zero ODP
shall be provided with a protective weatherproof finish.
7.12 This finish shall be either:
a) aluminium zinc alloy coated steel sheet (0.7 mm)
(e.g. Dobel Aluzink or equivalent) which is introduced
during the fabrication of the ducting (App. A2);
b) overcoated with a fibre reinforced plastic (e.g Fibaroll
FR Grade or equivalent) (App. A3); or
c) overcoated with a polymeric weather covering.
A1
A2
A3
Kingspan KoolDuct ® zero ODP (CFC/HCFC-free rigid
phenolic insulation panels with zero Ozone Depletion
Potential (ODP)
Dobel Aluzink sheet
(Aluminium zinc alloy coated steel sheet)
Fibaroll FR Grade
(Fibre reinforced plastic coating for insulation)
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Appendix A1 – Kingspan KoolDuct ® zero ODP
(CFC/HCFC–Free Rigid Phenolic Insulation
Panels with Zero Ozone Depletion Potential (ODP))
Description
Kingspan KoolDuct ® zero ODP rigid phenolic insulation panels
have a CFC/HCFC–free rigid phenolic insulation core with a
density of 55-60 kg/m 3 . Manufactured by a continuous
process, the quality of the insulation is constantly monitored
and controlled. A closed cell structure gives the product
excellent thermal properties as well as resistance to moisture
penetration and wicking. Kingspan KoolDuct ® zero ODP
System rigid phenolic insulation panels are faced on both sides
with a protective low vapour permeability 25 micron aluminium
foil reinforced with a 5 mm glass tissue scrim which is
extremely durable.
Kingspan KoolDuct ® zero ODP rigid phenolic insulation panels
are able to withstand temperatures from –20°C to +80°C. They
also have an exceptional resistance to burning and spread of
flame. The composition of Kingspan KoolDuct ® zero ODP rigid
phenolic insulation panels is such that when subjected to fire
the outer surface forms a carbonaceous layer which retards
further flame spread and penetration. Kingspan KoolDuct ®
zero ODP rigid phenolic insulation panels satisfy the
requirements of BS 5422: 2001 along with other major national
specifications including NHS CO2, NES Specification Expert
Y50 and DEO Specification 037. Kingspan KoolDuct ® zero
ODP rigid phenolic insulation panels are manufactured under a
quality control system approved to BS EN ISO 9001: 2000
(Quality management systems. Requirements).
Application
The Kingspan KoolDuct ® zero ODP rigid phenolic insulation
panels are a core component of the Kingspan KoolDuct ® zero
ODP System of pre-insulated ducting, which is an alternative
to traditional sheet metal ductwork in Building Services/HVAC
applications. The durable and puncture resistant aluminium foil
facings on the Kingspan KoolDuct ® zero ODP rigid phenolic
insulation panels are used to prevent the ingress of moisture,
dust and dirt into the insulation.
Availability
● Insulation panel dimensions: 2950 mm x 1200 mm.
● Insulation panel thickness: 22 mm.
®
Physical Properties Test Method Value
(Rigid Phenolic Insulation Core)
Nominal Density (BS 4370: Part 1: 1988 (1996)) 55-60 kg/m 3
Thermal Conductivity at 10°C Mean Temp (BS 4370: Part 2: 1993) 0.021 W/m.K
Colour
Pink
Minimum Closed Cell Content (BS 4370: Part 2: 1993) >90%
Water Vapour Resistivity
240 MN.s/g.m
Moisture Vapour Permeability (BS 4370: Part 2: 1993) 10 µg.m/N.h
At 38˚C, 88% RH
Compressive Strength at 10% Compression
Parallel to Rise (BS 4370: Part 1: 1988 (1996)) 200 kPa
Average Flexural Strength (BS 2972: 1989) 1200 kPa
Operating Temperature Limits of Board
Upper Limit
+80°C
Lower Limit
–20°C
Specific Heat Capacity
1.88 kJ/kg.°C
Physical Properties Test Method Value
(Aluminium Foil Vapour Barrier Jacket)
Composition
Aluminium
25 microns
Glass Fibre Scrim
5 mm x 5 mm
Glass Fibre
35 g glass
Caseine Latex Adhesive 20 g/m 2
Water Vapour Permeance
0.0006 g/s.MN
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Project Specification
Fire Test Classifications Test Method Value
(Rigid Phenolic Insulation Core)
Fire Performance BS 476: Part 6: 1989 I < 12 i < 6*
Surface Spread of Flame BS 476: Part 7: 1997 Class 1*
*These results conform to Class O/low risk to the Building Regulations/Standards
Fire Test Classifications Test Method Value
(Aluminium Foil Vapour Barrier Jacket)
Fire Performance BS 476: Part 6: 1989 I < 12 i < 6*
Surface Spread of Flame BS 476: Part 7: 1997 Class 1*
*On rigid phenolic insulation these results conform to Class O/low risk to the Building Regulations/Standards
Rigid phenolic insulation is organic and hence combustible. Care should be taken to avoid ignition since the burning rate of the insulation,
if exposed, can be significantly greater than that of wood. The contribution to fire growth of this product is controlled by the type of finish of facing
used in conjunction with the insulation.
Thermal Conductivity Design Values
Mean Temperature (°C) +10 0 –10 –20
Thermal Conductivity (W/m.K) 0.021 0.021 0.021 0.021
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Appendix A2
Dobel Aluzink steel sheet
Aluminium zinc alloy coated steel sheet
Refer to:
SSAB Dobel Coated Steel Ltd
Narrowboat Way
Hurst Business Park
Brierley Hill
West Midlands
DY5 1UF
Tel: 01384 74660
www.dobel.co.uk
Appendix A3
Fibaroll FR Grade
Fibre reinforced plastic coating for insulation
Refer to:
Fiba Tech Industries Ltd
Waterlip
Shepton Mallet
Somerset
BA4 4RN
Tel: 01749 881920
www.fibaroll.co.uk
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