Kaiflex Specification: Food Manufacturing

Food Manufacturing Environments - Insulation Specification

S1 – General

S1.01 Scope

All cold and chilled water pipework shall be insulated to prevent condensation and energy losses. All air-conditioning and refrigeration pipework shall be insulated to prevent condensation and energy losses. All low and medium temperature heating pipework, domestic hot water pipework and solar hot water pipework shall be insulated to prevent energy losses. All valves, fittings, flanges and associated equipment shall be insulated to the same standards as the linear pipe runs.

Where services have the potential to generate or carry nuisance mechanical noise, acoustic insulation, including sound absorption and anti-vibration, shall be applied.

S1.02 References

The materials, components and completed installations shall conform to applicable Standards current at the time of tendering.

Relevant standards may include:

BS 353 Glossary of terms relating to thermal insulation.

BS 476 Fire Tests on Building Materials and Structures.

BS 874 Methods of determining thermal properties, with definitions of thermal insulating

terms.

BS 5970 Thermal insulation of pipework and equipment in the temperature range of -100°C

to +870°C

EN ISO 8497 Determination of steady-state thermal transmission properties of thermal insulation

for circular pipes

EN 12086 Thermal insulating products for building applications. Determination of water vapour

transmission properties

EN 12667 Determination of thermal resistance by means of guarded hot plate and heat flow

meter methods. Products of high and medium thermal resistance

EN ISO 846 Evaluation of the action of microorganisms

EN ISO 12241 Thermal insulation for building equipment and industrial installations -- Calculation

rules

EN ISO 14304 Thermal insulation products for building equipment and industrial installations.

Factory made flexible elastomeric foam (FEF) products. Specification

S1.03 Services to be Insulated

Cold water pipework

Chilled water pipework

Air-conditioning pipework

Refrigeration pipework

Low temperature heating pipework

Medium temperature heating pipework

Domestic hot water pipework

Solar hot water pipework

Air-conditioning ductwork

S1.04 Pipe Clearances

Shall be sufficient to allow for the full thickness of insulation to be applied around all pipework. The mechanical contractor shall be responsible for ensuring this detail.

S1.05 Pipe Clamps

Shall only be applied around high density load bearing sections at least matching the thermal performance of the thickness of insulation applied to linear pipe runs. The mechanical contractor shall be responsible for ensuring this detail.

S2 Materials

S2.01 General

All insulation materials shall be:

Formaldehyde free.

Shown to inhibit the growth of mould.

Installed to the manufacturers recommendations. In particular all insulation shall be fully vapour sealed using an approved adhesive or mastic around all pipe supports, clamps, valves and flanges.

Class O fire rated under BS 476 Parts 6 & 7 when used indoors.

Either inherently UV resistant or otherwise treated with compatible UV resistant paint or coatings when used on pipework outdoors.

Provided with a compatible weather & UV resistant finish appropriate to the environment when used on pipework outdoors which is likely to experience damage.
Manufactured in accordance with a fully certified EN ISO 9001 quality management system.

S3 – Thermal Insulation

S3.01 Insulation Specification

Materials shall be as described:

Kaiflex ST Class O:

Flexible Nitrile rubber insulation temperature resistant up to 100°C with a closed cell structure and a built in vapour barrier. The material shall exhibit a Class 1 surface spread of flame rating when tested in accordance with BS 476 Part 7 and a Class 0 fire rating when tested in accordance BS 476 Part 6.

The material shall be dust and fibre free and incorporate an anti-microbial additive to prevent mould growth.

The thermal conductivity shall be no greater than 0.034 W/(m·K) at 0°C and 0.038 W/(m·K) at 40°C when tested in accordance with EN ISO 8497 or EN 12667. Water vapour transmission shall be no less than 10,000 when tested in accordance with EN 12086.

Resistance to bacterial and mould growth shall be no less than Class 1 when tested in accordance with EN ISO 846.

Tube material shall be supplied in 2 m lengths or 15 m long coils. Sheets shall be supplied in 1 m continuous rolls. The material shall be black in colour.

Kaiflex TC:

Flexible Nitrile rubber insulation temperature resistant up to 80°C with a closed cell structure and a built in vapour barrier. The material shall exhibit a Class 1 surface spread of flame rating when tested in accordance with BS 476 Part 7 and a Class 0 fire rating when tested in accordance BS 476 Part 6.

The material shall be dust and fibre free and incorporate an anti-microbial additive to prevent mould growth.

Resistance to bacterial and mould growth shall be no less than Class 1 when tested in accordance with EN ISO 846.

The material shall be provided with a black or white PVC film pre-applied. The PVC film shall be UV resistant and waterproof.

Tube material shall be supplied in 2 m lengths. Sheets shall be supplied as 2 x 0.5 m flat sheet. The material shall be black in colour with either a black or white finish.

Kaiflex RT-ST

High density load bearing PIR pipe sections with a Nitrile rubber facing to provide a full water vapour seal between the pipe support and the adjoining insulation.

S3.02 Technical Values

Material / Temp Range / “λ” Value W/mK at mean temp / ODP
Rating / GWP
Rating / Fire Class / Typical material density kg/m3
Kaiflex ST Class O / -196ºC to +105ºC / 0.034 @ 0ºC
0.036 @ 20ºC / 0 / 0 / Class O / 50-55
Kaiflex TC / -10ºC to +80ºC / 0.034 @ 0ºC
0.036 @ 20ºC / 0 / 0 / Class O / 50-55

S3.03 Material Selection

Shall be:

Internal / External
Concealed / Exposed / Concealed / Exposed
Domestic Hot Water Pipe / Kaiflex ST Class O / Kaiflex ST Class O* / Kaiflex TC / Kaiflex TC
Cold Water Pipe / Kaiflex ST Class O / Kaiflex ST Class O* / Kaiflex TC / Kaiflex TC
Chilled Water Pipe / Kaiflex ST Class O / Kaiflex ST Class O* / Kaiflex TC / Kaiflex TC
Low Temperature Heating Pipe / Kaiflex ST Class O / Kaiflex ST Class O* / Kaiflex TC / Kaiflex TC
Medium Temperature
Heating Pipe / Kaiflex ST Class O / Kaiflex ST Class O* / Kaiflex TC / Kaiflex TC
Split Air-Conditioning Pipe / Kaiflex ST Class O / Kaiflex ST Class O* / Kaiflex TC / Kaiflex TC
Ductwork / Kaiflex ST Class O / Kaiflex ST Class O* / Kaiflex TC / Kaiflex TC

*See coverings selection for acceptable finishes

S3.04 Material Thickness

For each service the thickness of insulation applied shall not be less than that defined in the tables below. The following thickness’s shall be taken to represent reasonable provision for the control of energy loss, prevention of pipe freezing and the prevention of surface condensation.

S3.04.01 Domestic Hot Water

Pipe O.D / Kaiflex ST
Class O / Kaiflex
TC
Insulation Thickness
mm / mm / mm
10 / 13 / 13
12 / 19 / 19
15 / 19 / 19
22 / 25 / 25
28 / 25 / 25
35 / 25 / 25
42 / 25 / 25
54 / 25 / 25
67 / 25 / 25
76.1 / 25 / 25
88.9 / 25 / 25

S3.04.02 Cold Water

Pipe O.D / Kaiflex ST
Class O / Kaiflex
TC
Insulation Thickness
mm / mm / mm
10 / 25* / 25*
12 / 25* / 25*
15 / 25* / 25*
22 / 19 / 19
28 / 9 / 9
35 / 9 / 9
42 / 9 / 9
54 / 9 / 9
67 / 9 / 9
76.1 / 9 / 9
88.9 / 9 / 9

*Thickness not sufficient to provide 12 hours of protection against freezing at -6°C. Insulation should be used in combination with trace heating or other frost protection measures.

S3.04.03 Chilled Water

5°C Line Temperature

Pipe O.D / Kaiflex ST
Class O / Kaiflex
TC
Insulation Thickness
mm / mm / mm
21.3 / 9 / 9
26.9 / 13 / 13
33.7 / 13 / 13
42.4 / 13 / 13
48.3 / 13 / 13
60.3 / 13 / 13
76.1 / 13 / 13
88.9 / 13 / 13
114.3 / 13 / 13
273 / 19 / 19

0°C Line Temperature

Pipe O.D / Kaiflex ST
Class O / Kaiflex
TC
Insulation Thickness
mm / mm / mm
21.3 / 13 / 13
26.9 / 13 / 13
33.7 / 13 / 13
42.4 / 19 / 19
48.3 / 19 / 19
60.3 / 19 / 19
76.1 / 19 / 19
88.9 / 19 / 19
114.3 / 19 / 19
273 / 19 / 19

S3.04.04 Low Temperature Heating

Pipe O.D / Kaiflex ST
Class O / Kaiflex
TC
Insulation Thickness
mm / mm / mm
21.3 / 19 / 19
26.9 / 19 / 19
33.7 / 19 / 19
42.4 / 19 / 19
48.3 / 19 / 19
60.3 / 19 / 19
76.1 / 19 / 19
88.9 / 19 / 19
114.3 / 19 / 19
273 / 19 / 19

S3.04.05 Medium Temperature Heating

Pipe O.D / Kaiflex ST
Class O / Kaiflex
TC
Insulation Thickness
mm / mm / mm
21.3 / 25 / 25
26.9 / 25 / 25
33.7 / 25 / 25
42.4 / 25 / 25
48.3 / 25 / 25
60.3 / 25 / 25
76.1 / 25 / 25
88.9 / 25 / 25
114.3 / 25 / 25
273 / 25 / 25

S3.04.06 Split Air-Conditioning

Pipe O.D / Kaiflex ST
Class O / Kaiflex
TC
Insulation Thickness
mm / mm / mm
10 / 13 / 13
12 / 13 / 13
15 / 13 / 13
22 / 13 / 13
28 / 13 / 13
35 / 13 / 19
42 / 19 / 19
54 / 19 / 19
67 / 19 / 19
76.1 / 19 / 19
88.9 / 19 / 19

S3.04.08 Air-Conditioning Ductwork

Kaiflex ST Class O
Emissivity: 0.05 / Emissivity: 0.9
Insulation Thickness
mm / mm
19 / 26

S4 - Protective Coverings

S4.01 – Covering Specification

Materials shall be as described:

Kaiflex TC Film:

UV resistant PVC film. The colour shall be either white or black.

All seams and joints should be covered using a matching 25 or 50 mm wide self-adhesive tape.

Application should be at ambient temperatures between 10°C and 30°C and a maximum relative humidity of 75%. The Kaiflex TC surface should be free from all dust, oil, grease and other contaminants before applying Kaiflex TC self-adhesive tape.

S4.02 – Covering Selection

Shall be:

For Kaiflex ST Class O:

Internal / External
Concealed / Exposed / Concealed / Exposed
Domestic Hot Water Pipe / None required / None required
or Kaiflex TC / Kaiflex TC / Kaiflex TC
Cold Water Pipe / None required / None required
or Kaiflex TC / Kaiflex TC / Kaiflex TC
Chilled Water Pipe / None required / None required
or Kaiflex TC / Kaiflex TC / Kaiflex TC
Low Temperature Heating Pipe / None required / None required
or Kaiflex TC / Kaiflex TC / Kaiflex TC
Medium Temperature
Heating Pipe / None required / None required
or Kaiflex TC / Kaiflex TC / Kaiflex TC
Split Air-Conditioning Pipe / None required / None required
or Kaiflex TC / Kaiflex TC / Kaiflex TC
Ductwork / None required / None required
or Kaiflex TC / Kaiflex TC / Kaiflex TC

S5 – Additional Details

S5.01 – Water Vapour Barriers

Shall be built into the insulation material itself wherever possible. The water vapour resistance factor of the insulation shall be no less than 10,000 for Kaiflex ST Class O and no less than 4,000 for Kaiflex EPDM.

Along all insulation seams and joints Kaiflex Adhesive shall be applied to form a water vapour tight seal between two pieces of Kaiflex. Every 2 m and wherever insulation terminates Kaiflex shall be fixed directly to the pipe using Kaiflex Adhesive to form a water vapour tight seal.

S5.02 – Insulation of Pipe Supports

Wherever possible the mechanical contractor shall ensure that all pipe clamps are installed around high density load bearing insulation sections at least matching the thermal performance of the insulation on all linear pipe runs. It is the responsibility of the insulation contractor to ensure that the water vapour barrier is continuous around this load bearing section.

Where the mechanical contractor has installed pipe clamps directly around the pipe the insulation contractor shall note this and, if appropriate, wrap insulation of at least the same thickness as used on adjoining linear pipe runs around the pipe clamp. It is the responsibility of the insulation contractor to ensure that adhesive has been applied to form a water vapour tight seal at this point.

S5.03 – Insulated Valve and Flange Cover Boxes

Shall be manufactured directly from Kaiflex sheet of at least the same thickness as used on linear pipe runs following the manufacturers recommendations. The covering shall match that used on the linear pipe runs.

Where possible contractors shall apply velcro strips to the valve or flange box seams.

S5.04 – Fire Resistant Walls

At points where pipework passes through fire resistant walls the fire resistance of the wall shall be maintained.

The mechanical contractor shall be responsible for ensuring this detail and obtaining from the manufacturer all relevant test certificates.