DUBAIWORLDCENTRALINTERNATIONALAIRPORT

PHASE I – Design of Buildings

Contract No. JXB1/BLD/431- PASSENGERTERMINALBUILDING

SECTION 15081

DUCT INSULATION

CONTENTS

PART 1 - GENERAL

1.1RELATED DOCUMENTS

1.2SUMMARY

1.3PERFORMANCE REQUIREMENTS

1.4SUBMITTALS

1.5QUALITY ASSURANCE

1.6DELIVERY, STORAGE, AND HANDLING

1.7COORDINATION

1.8SCHEDULING

PART 2 - PRODUCTS

2.1INSULATION MATERIALS

2.2FIELD-APPLIED JACKETS

2.3ACCESSORIES AND ATTACHMENTS

PART 3 - EXECUTION

3.1EXAMINATION

3.2PREPARATION

3.3GENERAL APPLICATION REQUIREMENTS

3.4MINERAL-FIBER INSULATION APPLICATION

3.5FLEXIBLE ELASTOMERIC THERMAL INSULATION APPLICATION

3.6FINISHES

3.7DUCT SYSTEM APPLICATIONS

3.8INDOOR DUCT AND PLENUM APPLICATION SCHEDULE

3.9OUTDOOR DUCT AND PLENUM APPLICATION SCHEDULE

This STD-SPC uses FIDIC Contract terms: (eg.) "Engineer", "Employer", "Commencement Date", "Time for Completion", "Taking-Over", Etc, although the terms "Project site", "Work" and "Substantial Completion" have generally been retained unchanged. If a different Form of Contract is used, change such terms to match those in that Contract.

Verify that Section titles referenced in this Section are correct for this Project’s Specification; Section titles may have changed.

All Imperial values/dimensions included in the original AIA specifications have been inserted as hidden text and all Metric values/dimensions have been retained. Where products, which are manufactured to Imperial tolerances are required, the Specification Writer must ensure that the Metric values/dimensions retained are appropriate and correct. If need be, the Specification Writer can insert the (Imperial values/dimensions) directly after the Metric values/dimensions.

All references to “Evaluations” included in the original AIA specifications have been removed because these supporting evaluations notes may not be available to all Specification Writers using these DCA Master Specifications. However, these supporting evaluation notes provide very useful information, which aid the process of preparing specifications. Where these evaluation notes are available, the Specification Writer is advised to make reference to them while preparing specification sections.

PART 1 - GENERAL

1.1RELATED DOCUMENTS

  1. Drawings and general provisions of the Contract, including Conditions of Contract and Division1 Specification Sections, apply to this Section.

1.2SUMMARY

  1. This Section includes semirigid and flexible duct, plenum, and breeching insulation; insulating cements; field-applied jackets; accessories and attachments; and sealing compounds.
  2. Related Sections include the following:

List below only products that the reader might expect to find in this Section but are specified elsewhere.

  1. Division7 Section "Through-Penetration Firestop Systems" for firestopping materials and requirements for penetrations through fire and smoke barriers.
  2. Division15 Section "Equipment Insulation" for insulation materials and application for pumps, tanks, hydronic specialties, and other equipment.
  3. Division15 Section "Pipe Insulation" for insulation for piping systems.
  4. Division15 Section "Metal Ducts" for duct liner.

1.3PERFORMANCE REQUIREMENTS

  1. 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 stainless-steel surfaces shall meet ASTM C 795 requirements. Materials shall be asbestos free.
  2. Thermal-insulation system materials shall be noncombustible, as defined by NFPA 220. Adhesives, coatings, sealants, facings, jackets, and thermal-insulation materials, except cellular elastomers, shall have a maximum flame-spread classification (FSC) of 25 and a smoke-developed classification (SDC) of 50. Flame-contributed classification (FCC) shall be as specified for the application. These maximum values shall be determined in accordance with ASTM E 84 and NFPA 255.
  3. Adhesives, coatings, and sealants shall be nonflammable in their wet state. Adhesives, coatings, and sealants shall have published or certified temperature ratings suitable for the entire range of working temperatures normal for the surfaces to which they are to be applied.

1.4SUBMITTALS

  1. Product Data: Identify thermal conductivity, thickness, and jackets (both factory and field applied, if any), for each type of product indicated.
  2. Shop Drawings: Show fabrication and installation details for the following:
  3. Removable insulation sections at access panels.
  4. Application of field-applied jackets.
  5. Applications at linkages for control devices.
  6. Samples: For each type of insulation, adhesives, coatings, and field-applied jacket. Identify each Sample, describing product and intended use. Submit 300 mm square sections of each sample material.
  7. Manufacturer's Color Charts: Show the full range of colors available for each type of field-applied finish material indicated.

Surface-burning characteristics specified in "Quality Assurance" Article should be verified by an independent testing agency. Where critical, require test report Submittals. Delete test reports below if not required.

  1. Material Test Reports: From a qualified testing agency acceptable to the Engineer, indicating, interpreting, and certifying test results for compliance of insulation materials, sealers, attachments, cements, and jackets with requirements indicated. Include dates of tests.

Retain below if "Installer Qualifications" Paragraph is retained in "Quality Assurance" Article.

  1. Installer Certificates: Signed by the Contractor certifying that installers comply with requirements.

1.5QUALITY ASSURANCE

Delete paragraph below if not required or available at Project location. Apprenticeship programs are usually associated with union shops. Other craft training programs are available.

  1. Installer Qualifications: Skilled mechanics who have completed successfully a craft training program certified by an agency acceptable to the Engineer.
  2. Fire-Test-Response Characteristics: As determined by testing materials identical to those specified in this Section according to ASTME84, UL-723, NFPA 225 or ANSI A.2.5, by a testing and inspecting agency acceptable to the Engineer. Factory label insulation and jacket materials and sealer and cement material containers with appropriate markings of applicable testing and inspecting agency.

Revise subparagraphs below to suit Project and products selected.

  1. Insulation Installed Indoors: Flame-spread rating of 25 or less, and smoke-developed rating of 50 or less.
  2. Insulation Installed Outdoors: Flame-spread rating of 75 or less, and smoke-developed rating of 150 or less.

Delete paragraph below if not required. If retaining, indicate location, size, and other details of mockups on Drawings or by inserting specific information in paragraph and subparagraphs below. Revise wording if only one mockup is required.

  1. Mockups: Before installing insulation, build mockups for each type of insulation and finish listed below to demonstrate quality of insulation application and finishes. Build mockups according to the following requirements, using materials indicated for the completed Work:
  2. Include the following mockups:
  3. One (1) 3 m section of rectangular straight duct.
  4. One (1) 90 degree square elbow and one 90 degree radius elbow.
  5. One (1) branch takeoff.
  6. One (1) transition fitting.
  7. Four (4 )support hangers.
  8. Build mockups with cutaway sections to allow observation of application details for insulation materials, mastics, attachments, and jackets.
  9. Build mockups in the location indicated or, if not indicated, as directed by the Engineer.
  10. Notify the Engineer 7 days in advance of dates and times when mockups will be constructed.
  11. Obtain the Engineer's approval of mockups before starting insulation application.
  12. Maintain mockups during construction in an undisturbed condition as a standard for judging the completed Work.
  13. Demolish and remove mockups when directed.

Delete subparagraph above or below. Below is applicable only if mockups are erected as part of building rather than separately.

  1. Approved mockups may become part of the completed Work if undisturbed at time of Substantial Completion.

1.6DELIVERY, STORAGE, AND HANDLING

Container marking is an option in ASTM standards; the default condition does not include the marking below unless specified in the Contract.

  1. Packaging: Ship insulation materials in containers marked by manufacturer with appropriate ASTM or other approved specification designation, type and grade, and maximum use temperature.

1.7COORDINATION

  1. Coordinate clearance requirements with duct Installer for insulation application.

1.8SCHEDULING

  1. Schedule insulation application after testing duct systems. Insulation application may begin on segments of ducts that have satisfactory test results.

PART 2 - PRODUCTS

2.1INSULATION MATERIALS

  1. Insulation conductance shall be maximum values, as tested at any point, not an average. Insulation conductance found by test to exceed the stipulated maximum shall either be replaced or augmented by an additional thickness to bring it to the required maximum conductance.

For operating temperatures higher than 850degF (454degC), change insulation below to ASTMC612, TypeIII.

  1. Mineral-Fiber Board Thermal Insulation: Glass fibers bonded with a thermosetting resin. Comply with ASTMC612, TypeIB, without facing and with all-service jacket manufactured from kraft paper, reinforcing scrim, aluminum foil, and vinyl film.
  2. Thermal Conductivity: 0.038W/mK at 20deg. C (68 deg. F).
  3. Density : 48kg/m3.

For operating temperatures higher than 850degF (454degC), change insulation below to ASTMC553, TypeV.

  1. Mineral-Fiber Blanket Thermal Insulation: Glass fibers bonded with a thermosetting resin. Comply with ASTMC553, TypeII, without facing and with all-service jacket manufactured from kraft paper, reinforcing scrim, aluminum foil, and vinyl film.
  2. Thermal Conductivity: 0.038W/mK at 20deg. C (68 deg. F).
  3. Density : 24kg/m3.

Flexible elastomeric thermal insulation is not suitable for temperatures lower than minus 70deg F (minus 57degC) and higher than 220degF (104degC).

  1. Flexible Elastomeric Thermal Insulation: Closed-cell, sponge- or expanded-rubber materials. Comply with ASTMC534, TypeII for sheet materials.
  2. Adhesive: Solvent base, contact adhesive as recommended by insulation material manufacturer.
  3. Ultraviolet-Protective Coating: As recommended by insulation material manufacturer.
  4. Thermal Conductivity: 0.038W/mK at 20deg. C (68 deg F).
  5. Density : 65 to 80 kg/m3.
  6. Water Vapor Permeability : 0.15 perm-inch.
  7. Noise Reduction: Up to 27 L for 20mm thick insulation.

Closed cell phenolic foam insulation is avaialable in Grades 1 and 2. Grade 1 has a lower thermal conductivity than Grade For temperatures higher than 1200degF (649degC), change insulation below to ASTMC 533, TypeII. TypeII is suitable for temperatures up to 1700degF (927degC).

2.2FIELD-APPLIED JACKETS

Insulation jackets below are for field applications. Delete below if jackets are factory applied. ASTMC921, Type1, is for use over insulation on ducts operating below ambient temperatures at least part of the time or for where a vapor retarder is required. ASTMC921, TypeII, is for use over insulation on ducts operating above ambient temperatures or for where a vapor retarder is not required.

  1. General: ASTMC921, Type1, 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 width. Jackets used on insulation exposed in finished areas shall have white finish suitable for painting without sizing.

A properly sealed foil, scrim, kraft-paper (FSK) jacket, common with most forms of factory-applied jackets for mineral-fiber insulation, meets vapor-retarder requirements of ASTM C921, TypeI.

  1. Aluminum Jacket: Aluminum jackets shall be corrugated, embossed or smooth sheet, 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.
  2. Finish and Thickness: Stucco embossed finish, 0.6 mm thick for indoor installation and 0.8 mm for outdoor installation unless otherwise noted.
  3. Moisture Barrier: 0.025 mm thick, heat bonded polyethylene and kraft paper.

Verify that moisture barrier in subparagraph below is adequate for corrosive atmospheres.

  1. Stainless-Steel Jacket: smooth surface or deep corrugated sheets of stainless steel with 0.025 mm thick factory-applied heat bonded polyethylene and kraft paper moisture barrier on inside surface complying with ASTMA666, Type304 or 316; 0.4 mm thick; and roll stock ready for shop or field cutting and forming to indicated sizes.
  2. Jacket Bands: Stainless-steel, Type304, 19 mm wide.

2.3ACCESSORIES AND ATTACHMENTS

  1. 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 stainless-steel surfaces shall meet ASTM C 795 requirements. Materials shall be asbestos free and conform to the following.
  2. Glass Cloth and Tape: Comply with MIL-C-20079H, TypeI for cloth and TypeII for tape. Woven glass-fiber fabrics, plain weave, presized a minimum of 270 g/sq. m.
  3. Tape Width: 100 mm.
  4. Bands: 19 mm wide, in one of the following materials compatible with jacket:
  5. Stainless-Steel: ASTMA666, Type304; 0.5 mm thick.
  6. Galvanized Steel: 0.13 mm thick.
  7. Aluminum: 0.18 mm thick.
  8. Brass: 0.25 mm thick.
  9. Nickel-Copper Alloy: 0.13 mm thick.
  10. Wire: 2.0 mm, nickel-copper alloy; 1.6 mm, soft-annealed, stainless steel; or 1.6 mm, soft-annealed, galvanized steel.
  11. Adhesive-Attached 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.
  12. 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.
  13. Adhesives:
  14. Cloth: Adhesives 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.
  15. Cellular Elastomer: Adhesive for cellular elastomer insulation shall be a solvent cutback chloroprene elastomer conforming to ASTM C 916, Type I, and shall be a type approved by the manufacturer of the cellular elastomer for the intended use.
  16. Coatings:
  17. 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.
  18. Cellular Elastomer Insulation: Finish coating for cellular elastomer insulation shall be a polyvinylchloride lacquer approved by the manufacturer of the cellular elastomer for the intended use.
  19. Coating Color: Coating color shall conform to color code specified or as directed by the Engineer.

PART 3 - EXECUTION

3.1EXAMINATION

  1. Examine substrates and conditions for compliance with requirements for installation and other conditions affecting performance of insulation application.
  2. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2PREPARATION

  1. Surface Preparation: Clean and dry surfaces to receive insulation. Remove materials that will adversely affect insulation application.

3.3GENERAL APPLICATION REQUIREMENTS

  1. 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.
  2. Refer to schedules at the end of this Section for materials, forms, jackets, and thicknesses required for each duct system.
  3. 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.
  4. Apply multiple layers of insulation with longitudinal and end seams staggered.
  5. Seal joints and seams with vapor-retarder mastic on insulation indicated to receive a vapor retarder.
  6. Keep insulation materials dry during application and finishing.
  7. Apply insulation with tight longitudinal seams and end joints. Bond seams and joints with adhesive recommended by the insulation material manufacturer.
  8. Apply insulation with the least number of joints practical.
  9. Apply insulation over fittings and specialties, with continuous thermal and vapor-retarder integrity, unless otherwise indicated.
  10. Hangers and Anchors: Where vapor retarder is indicated, seal penetrations in insulation at hangers, supports, anchors, and other projections with vapor-retarder mastic. Apply insulation continuously through hangers and around anchor attachments.
  11. 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.
  12. Apply insulation with integral jackets as follows:
  13. Pull jacket tight and smooth.
  14. Joints and Seams: Cover with tape and vapor retarder as recommended by insulation material manufacturer to maintain vapor seal.
  15. Vapor-Retarder Mastics: Where vapor retarders are indicated, apply mastic on seams and joints and at ends adjacent to duct flanges and fittings.
  16. Cut insulation according to manufacturer's written instructions to prevent compressing insulation to less than 75 percent of its nominal thickness.
  17. Install vapor-retarder mastic on ducts and plenums scheduled to receive vapor retarders.
  18. Ducts with Vapor Retarders: Overlap insulation facing at seams and seal with vapor-retarder mastic and pressure-sensitive tape having same facing as insulation. Repair punctures, tears, and penetrations with tape or mastic to maintain vapor-retarder seal.
  19. Ducts without Vapor Retarders: Overlap insulation facing at seams and secure with outward clinching staples and pressure-sensitive tape having same facing as insulation.
  20. Roof Penetrations: Apply insulation for interior applications to a point even with top of roof flashing.
  21. Seal penetrations with vapor-retarder mastic.
  22. Apply insulation for exterior applications tightly joined to interior insulation ends.
  23. Seal insulation to roof flashing with vapor-retarder mastic.
  24. Interior Wall and Partition Penetrations: Apply insulation continuously through walls and partitions, except fire-rated walls and partitions.
  25. Fire-Rated Wall and Partition Penetrations: Terminate insulation at fire/smoke damper sleeves for fire-rated wall and partition penetrations.
  26. Floor Penetrations: Terminate insulation at underside of floor assembly and at floor support at top of floor.
  27. For insulation indicated to have vapor retarders, taper termination and seal insulation ends with vapor-retarder mastic.

3.4MINERAL-FIBER INSULATION APPLICATION

  1. Blanket Applications for Ducts and Plenums: Secure blanket insulation with adhesive and anchor pins and speed washers.
  2. Apply adhesives according to manufacturer's recommended coverage rates per square foot, for 100 percent coverage of duct and plenum surfaces.

Edit subparagraph below to allow adhesive to be omitted from top surface of horizontal rectangular ducts.

  1. Apply adhesive to entire circumference of ducts and to all surfaces of fittings and transitions.
  2. Install anchor pins and speed washers on sides and bottom of horizontal ducts and sides of vertical ducts as follows:
  3. On duct sides with dimensions 450 mm and smaller, along longitudinal centerline of duct. Space 75 mm maximum from insulation end joints, and 400 mm o.c.
  4. On duct sides with dimensions larger than 450 mm. Space 400 mm o.c. each way, and 75 mm maximum from insulation joints. Apply additional pins and clips to hold insulation tightly against surface at cross bracing.
  5. Anchor pins may be omitted from top surface of horizontal, rectangular ducts, and plenums.
  6. Do not overcompress insulation during installation.
  7. Impale insulation over anchors and attach speed washers.
  8. Cut excess portion of pins extending beyond speed washers or bend parallel with insulation surface. Cover exposed pins and washers with tape matching insulation facing.
  9. Create a facing lap for longitudinal seams and end joints with insulation by removing 50 mm from one edge and one end of insulation segment. Secure laps to adjacent insulation segment with 13 mm staples, 25 mm o.c., and cover with pressure-sensitive tape having same facing as insulation.
  10. Overlap unfaced blankets a minimum of 50 mm on longitudinal seams and end joints. Secure with steel band at end joints and spaced a maximum of 450 mm o.c.
  11. Apply insulation on rectangular duct elbows and transitions with a full insulation segment for each surface. Apply insulation on round and flat-oval duct elbows with individually mitered gores cut to fit the elbow.
  12. Insulate duct stiffeners, hangers, and flanges that protrude beyond the insulation surface with 150 mm wide strips of the same material used to insulate duct. Secure on alternating sides of stiffener, hanger, and flange with anchor pins spaced 150 mm o.c.
  1. Board Applications for Ducts and Plenums: Secure board insulation with adhesive and anchor pins and speed washers.
  2. Apply adhesives according to manufacturer's recommended coverage rates for 100 percent coverage of duct and plenum surfaces.

Edit subparagraph below to allow adhesive to be omitted from top surface of horizontal rectangular ducts.