ROXUL Process Manual 082714 - Compliance to CINI

8/20/2019 ROXUL Process Manual 082714 - Compliance to CINI

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e) Frost protectionInstallations that are situated outside are at risk

from frost in the winter. In addition to themalfunctioning of installations, installations alsorisk damage caused by the expansion of frozenwater. Adequate measures against frost protectionare critical to protect the installation fromfreezing. Insulation can reduce heat loss and aidin frost protection. Insulation alone cannotindefinitely prevent the installation from freezing.

Installing additional tracing may be necessarybetween the object and the insulation. To preventfreezing, the insulation must be designed so theheat flow rate of the insulated object is less thanthe heat provided by the tracing.

f) Ambient conditionsSelect an insulation system that offers long-lasting

resistance to the surrounding environme nt.Atmospheric influences: wind, rain

Mechanical loads such as vibrations orfoot traffic

Corrosive environment (proximity to sea,chemicals,…)

Moisture accumulation in insulation increases

thermal conductivity and the risk of corrosion ofthe insulated installation components. Claddingmust be installed to prevent the ingress ofmoisture into the system. If the ingress ofmoisture into the insulation is unavoidable, retain

an air space of at least 2/3” (15 mm) between theinsulation and the cladding, and create 0.4”(10 mm) diameter ventilation and drain holes inthe covering at intervals at a maximum of 12"(300 mm). If necessary, the insulation andcladding must resist chemical influences thatdevelop within the environment.Installations operating below ambient

temperatures have a high risk of moisturecondensing from the ambient air inside thecladding. Use a continuous vapor retarder onpiping operating below ambient temperatures andseal all joints, surfaces, seams and fittings toprevent condensation (use of staples is notrecommended).

g) Maintenance and inspectionTo avoid complicating routine maintenance andinspection work unnecessarily, maintenance-intensive areas must be taken into account,especially when designing the insulation work.Removable insulation systems, such as removablecoverings and hoods, could be fitted in such areas,for example. Easily removable covering systems

are also recommended for flanges and pipefittings. These coverings are generally fastenedwith quick-release clamps, which can be openedwithout special tools.The insulation of fixtures such as flanges or pipefittings must be interrupted at a sufficientdistance to allow installation or dismounting to becarried out. In this case, take the bolt length at

flange connections into consideration. Any fixturesin the range of the insulation, including theinterruption in the installation, should beinsulated with removable coverings overlappingthe insulation and maintaining continuity acrossthe fixture.


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1.1 Planning and preparation1.1 Planning and preparation

B. Safety aspectsa) Personal protectionSurface temperatures in excess of 140 °F (60 °C)can lead to skin burns, if the surface is touched.Therefore, all accessible installation componentsshould be designed to protect personnel andprevent injuries. The insulation applied to suchplant components must ensure that surface

temperatures in excess of 140 °F (60 °C) do notoccur during operation. Consult our TechnicalServices Team to determine the requiredinsulation thickness to aid in personnelprotection. All of the operational parameters mustbe known to achieve a reliable design, including,for example, the temperature of the object, theambient temperature, air movement, surface

materials, distance from other objects, etc.

NOTEAs the surface temperature depends on a setof physical parameters, which cannot alwaysbe calculated or estimated with any degreeof certainty, the surface temperature is not

a guaranteed measurement. If the requiredprotection (temperature) cannot be achievedby insulation, apply additional protectivedevices, such as safety guards or enclosementof the object.

b) Fire protection

The general fire protection requirements imposedon structural installations are usually definedwithin the local Building Codes or thespecifications of plant owner. Structuralinstallations must be designed, built, modified andmaintained to prevent the outbreak of a fire andthe spread of fire and smoke. In the event of a fire,the rescuing of people and animals and effectively

extinguishing the fire must be made possible.During the design of the installation, it is vital todetermine the nature and scope of the fireprevention measures together with the buildingsupervisory board, the fire department, insurance

companies and the operator.As a basic principle, consider the fact that the fireload in a building or industrial installation can beconsiderably increased by flammable insulationmaterials. On the other hand, non-flammableinsulation materials such as mineral wool (stone

wool), which has a melting point of >2150 °F(>1,177 °C), not only have a positive impact on thefire load, but in the event of a fire, also constitutea certain fire protection for the installationcomponent.

Installation components with tracing, in particular,which use thermal oil as a heat transfer medium,

have an increased risk of catching fire in the eventof a leak. In this case, ensure that the thermal oilcannot penetrate into the insulation material.

c) Explosion preventionIf there is a risk of fire and explosion, the surfacetemperature of the object and the cladding mustbe considerably lower than the ignition

temperature of the flammable substance and/orgas mixtures. This requirement also applies tothermal bridges, such as pipe mounting supports,supporting structures and spacers etc.With regard to insulation systems, explosion

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protection can only be achieved with a doubleskincovering. A doubleskin covering is a factory madecladding that has been welded or soldered tomake it air proof and diffusion-resistant. Inaddition special (local) explosion regulations mustbe observed.

In explosive areas electrostatically chargedsubstances like unearthed cladding or non-conductive plastics must be grounded (earthed).For further guidance please consult your local

safety guidelines relating to static electricity.

d) Noise protectionThe guidelines for noise in the ordinance andworkplace are stated in the local regulations andstandards. Generally, the level of the guideline valuesdepends on the nature of the activity.

The sound propagation of installation componentscan be reduced using insulation systems. Thenature and effect of the sound insulation dependon the frequency and the sound pressure level.

C. EconomicsIn the industry there are two grades of insulation.The first grade focuses on reducing heat lossesand the prevention of injuries to people operatingor working nearby the installations. The secondgrade of insulation, the so called “economicalinsulation thickness” focuses on significant heatloss reduction and as a result achieving a better

return on investment.

a) Economical insulation thicknessInsulation reduces the heat losses from theobject. The thicker the insulation, the greaterthe heat reduction and consequently, the moreenergy is saved. However, the investment andexpenditure, e.g. for depreciation, interest rates

and higher maintenance costs also rise if theinsulation thickness is increased. At a certaininsulation thickness, the sum of the two cost flowsreaches a minimum. This value is known as theeconomical insulation thickness. A qualitativecurve of a similar costs function is shown below.

The energy costs cannot be based solely on thecurrent price. Developments over recent years

indicate energy costs will continue to rise.

C o s

t s

Insulation costs

Economicalinsulationthickness

Total costs

Heat loss costs

Insulation thickness


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1.1 Planning and preparation1.1 Planning and preparation C. EconomicsIncreasing energy prices are tending to bringabout a shift in economic insulation thicknessestowards larger thicknesses.

b) Pay-back timeIn addition to the economical insulation thickness,another frequently used economical parameter isthe return on investment period (ROI), also

referred to as the payback period. This is definedas the period within which the cost of theinsulation is recuperated through savings on heatloss costs.

ROI period =Costs of the insulation

[a]annual saving

In the case of industrial insulation systems, thereturn on investment period is generally veryshort, often being much less than one year.Considering only the return on investment period,however, can be deceptive, as this approachdisregards the service life of the installation.With long-life installations, it is advisable to select

higher insulation thicknesses, even if this meansaccepting a longer return on investment period.Throughout the entire service life of theinstallation however, the increased insulationthickness results in a significantly higher returnon the investment in insulation and achieves amuch more economic operation of the installation.

D. EnvironmentalThe burning of fossil fuels, such as coal, oil orgas, not only depletes the available primaryenergy sources, but also, due to the emission ofcarbon dioxide (CO²) into the atmosphere, placesa burden on the environment.

The increasing CO ² concentration in the Earth’s

atmosphere plays a significant part in the globalincrease in temperature, also referred to as the“greenhouse effect”. CO ² absorbs the thermalradiation emanating from the earth’s surfaceand in doing so reduces the dissipation of heatinto space. This is leading to a change in theworld’s climate with as yet inestimableconsequences. Reducing CO ² emission can only

be achieved through more efficient managementof fossil fuels. Increasing the insulationthicknesses is essential for the reduction of CO ² emissions.

Reducing CO² emissions also has a positivefinancial benefit for businesses within the contextof an emissions trading scheme. The benefits of

increased insulation thicknesses in industrialinstallations are twofold, as the costs for bothenergy consumption and CO ² emissions aredecreased.

E. Corrosion PreventionSee Chapter 1.1.3

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1.1.2 Design & planning of theinsulation work

Requirements for insulation work must beincluded in the design and construction phase ofindustrial plants. It is advisable to involve allproject managers at an early stage to avoidunnecessary issues or delays.

All preparatory works must be completedaccording to the relevant insulation standards.The following preconditions must be fulfilled:

If necessary, work has been carried out on theobject to protect against corrosion

Tracing and technical measurement equipmenthave been installed

The minimum distance between the objects

has been observed (see illustrations on pages12 and 13) Surfaces have no coarse impurities Mounting supports have been installed on theobject to accommodate the support structure

Collars and sealing discs have been fitted tothe object

Taps on the object are long enough to ensure

that flanges lie outside the insulation and canbe screwed on without hindrance Supports are designed so that insulation,water vapor retarders and cladding can beprofessionally installed

The insulation can be applied without anyobstacles (e.g. scaffolding)

Welding and bonding work has been carried out

on the object The foundations have been completed

1.1.3 Corrosion preventionIndustrial facility disruptions are due to the lackof, or inadequate forms of, protection againstcorrosion. This considerably reduces the servicelife of industrial plants, and more frequently,essential shutdown or overhaul work impairs theefficiency of the installation.It is commonly, but wrongly, assumed that the

insulation system also protects an installationagainst corrosion. For each installation it must bedetermined whether protection against corrosionis required and, if so, which are the appropriatemeasures.

Generally, the design of the insulation system &corrosion protection will depend on the following

parameters. Operation of the installation - Continuous operation - Interrupted/intermittent operation - Operation involving varying temperatures - Type of plant (e.g. Petrochemical, pharmaceutical, etc)

Operating and Ambient temperatures of the

installation Metals and Materials Used - Non-alloy or low-alloy steel - Austenitic stainless steel - Copper

External influences upon the installation - Environment of the installation (chemically

aggressive?)

- Location

The best practices may vary per country and/orstandard. The design of corrosion protection isoften carried out on the basis of a small selectionof standards, such as ASTM C795, that do notadequately take into account all the specificfeatures of protecting against corrosion in

insulation systems. For further details oncorrosion protection we recommend referringNACE SP0198 and the ROXUL® Corrosion UnderInsulation (CUI) brochure.


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1.1 Planning and preparation1.1 Planning and preparation 1.1.3 Corrosion prevention

In the case of cold insulation, if the object ismade of non-alloy or low alloy steel, it must beprotected against corrosion.

In the case of objects made, for example, ofaustenitic stainless steel or copper, theinstallation must be tested in each individualcase by the planner to determine whetherprotection against corrosion is necessary.

Objects made from austenitic stainless steel donot require protection against corrosion if thetemperature never – even for a short period –exceeds 120 °F (50 °C)

NOTE Protection against corrosion should be applied

in the case of all installations made fromnon-alloy or low-alloy steel where theoperating temperatures are below250 °F (120 °C). Protection against corrosionmay be omitted in the case of:

Installations operating continuously underextremely cold conditions [below -50 °F(-50 °C)] such storage tanks.

Insulated surfaces of power plantcomponents, such as boiler pressurecomponents, flue gas and hot air ducts andsteam pipe systems with operatingtemperatures that are constantly above250 °F (120 °C).

If austenitic stainless steel is insulated with anytype of insulation - For temperatures of up to930 °F (500 °C), aluminum foil of not less than.06 mm thick to be applied to the steel surface,arranged to shed water with overlaps of not lessthan 2" (50 mm) at the joints.

CINI Manual “Insulation for industries”CINI recommends applying corrosion protectionprior to the insulation work at any time.

In all phases, pay attention to CUI (corrosionunder insulation) prevention: design,construction, paint & coating work, applicationof the insulation system, inspection andmaintenance. Equipment and piping sectionslike nozzles, supports etc. should be designedand maintained to prevent ingress of water intothe insulation system.

The “paint” specifications are split up into: - Construction material

(carbon steel, stainless steel) - Temperature ranges from -22 °F (-30 °C) to

1000 °F (540 °C) with special attention to the

temperature range between 0 °F (-20 °C) and300 °F (150 °C). The corrosion protection can be achieved usingaluminum foil wrapping, thermal sprayedaluminum (TSA) or paint.

Protection against corrosion may be omitted in thecase of installations operating continuously under

extremely cold conditions [< -22 °F (-30 °C)]

ApplicationBefore applying corrosion protection coating, thesurface must be free from grease, dust and acidand, for better adhesion, the priming coat shouldbe roughened. Blasting is recommended as asurface preparation method (with austenitic

stainless steel, use a ferrite free blastingabrasive).Observe the corresponding processing guidelinesof the coating manufacturer. If metals withdifferent electrochemical potentials, such asaluminum and copper, come into contact with oneanother, there is a risk of electrochemicalcorrosion. If necessary, this can be avoided using

insulating, intermediate layers such as non-metallic straps. The presence of moisture willincrease the development of electrochemicalcorrosion.

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The table further on this page, which has beenderived from the standard DIN 4140, indicates theinitial risks of electrochemical corrosion in caseswhere various combinations of metals are used.

NOTE The table does not take into account formsof corrosion with other root causes, such asstress corrosion. For further information, seeChapter 2.2 “Product properties & testmethods” – AS-Quality on page 115.

Material Combination material

Metal Surface ratio in proportion tocombination material Zinc AluminumFerriticsteel Lead

Austeniticstainless

steelCopper

ZincSmall - M M H H H

Large - L L L L L

AluminumSmall L - L H H H

Large L - L M L H

Ferritic steelSmall L L - H H L

Large L L - L L L

LeadSmall L L L - H H

Large L L L - M M

Austenitic stainlesssteel

Small L L L L - MLarge L L L L - L

CopperSmall L L L L L -

Large L L L L L -

L - Light or little corrosion to material

M - Moderate corrosion to material, for example, in very humid atmospheresH - Heavy electrochemical corrosion to material

Observation: The table shows the corrosion of the “material”, and not that of the “combination material”.“Light” means: “small-scale in proportion to the combination material”, “heavy” means: “large-scale inproportion to the combination material”.

Example 1: Material is a zinc galvanized screw in combination material, a cladding made from austenitic

stainless steel: Row “zinc small”: “H” – heavy corrosion of the screw.

Example 2: Material , a cladding made from austenitic stainless steel screwed on with a screw galvanizedwith combination material zinc: Row “austenitic stainless steel large”. “L” – the corrosive attack upon theaustenitic steel is light.

Electrochemical Corrosion Potential


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I n s u l a t i o n

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1. System solutions1.2 Insulation of piping Piping plays a central role in many industrialprocesses in chemical or petrochemicalinstallations such as power plants, as it connectscore components such as appliances, columns,vessels, boilers, turbines etc. with one anotherand facilitates the flow of materials and energy.To guarantee a correct process cycle, thecondition of the media within the pipes mustremain within the set limitations (e.g.temperature, viscosity, pressure, etc.). In additionto the correct isometric construction andfastening of the piping, the piping insulation alsohas an important function. It must ensure thatheat loss are effectively reduced and that the

installation continues to operate economically andfunctionally on a permanent basis. This is the onlyway to guarantee the maximum efficiency of theprocess cycle throughout the design service lifewithout losses as a result of faults.

Requirements for industrial pipingThe basic efficiency and productivity factors of

piping for the processing industry include: energyefficiency, dependability and reliability underdifferent conditions, functionality of the processcontrol, appropriate support structure suitable forthe operating environment, as well as mechanicaldurability. The thermal insulation of piping plays asignificant role in fulfilling these requirements.

Thermal insulationThe functions of proper thermal insulation forpiping include:

Reduction of heat losses (cost savings) Reduction of CO² emissions Frost protectionProcess control: ensuring the stability ofthe process temperature

Noise reduction Condensation prevention Personnel protection against high temperatures

ProRox ® products for pipe insulationROXUL Inc offers a wide range of high-quality stonewool insulation products for the insulation ofindustrial plants. These products are part of ourextensive ProRox ® range for industrial insulation.With this specific field of application in mind we

developed our pre-formed pipe sections and pipewrap (mat) products for pipe insulation. All theseproducts are easy to install and contribute to a highlevel of efficiency, functionality and reduced heatlosses. Continuous internal and external inspectionand high levels of quality assurance ensure theconsistently high quality of all ROXUL® products.

The examples of use below cannot fully take intoaccount the particular circumstances of theconstruction-related factors. Determine whetherthe products are suitable for the correspondingapplication in each individual case. If in doubt,consult the ROXUL Technical Services Team.

The applicable standards and regulations must

also be observed. A few examples follow: NACE SP0198 (Control of corrosion underthermal insulation and fireproofing materials - asystems approach)

MICA (National Commercial & IndustrialInsulation Standards)

DIN 4140 (Insulation works on technicalindustrial plants and in technical facility

equipment) AGI Q101 (Insulation works on power plantcomponents) CINI-Manual “Insulation for industries” BS 5970 (Code of practice for the thermal

insulation of pipework, ductwork, associatedequipment and other industrial


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1.2 Insulation of piping

Hot insulation systemsPrincipally, a thermal insulation structure forpiping consists of an appropriate insulatingmaterial, usually covered by sheet metal cladding.This protects the object and the insulation fromexternal influences such as the weather andmechanical loads. Spacers are also essential withinsulation such as wired mats, which do not offersufficient resistance to pressure to hold theweight of the cladding and other external loads.These spacers transfer the cladding loads directlyonto the object. In the case of vertical piping,support structures are fitted to take on the loadsof the insulation and the cladding. In general,support structures and spacers form thermalbridges.

Selecting a suitable insulation system depends onnumerous parameters. These are described ingreater detail in Chapter 1.1. Regarding thedifferent forms of pipe insulation, a fundamentaldistinction can be drawn between the followinginsulation systems.

Insulation with pipe sectionsGenerally, the best insulation is achieved usingProRox ® Pipe Sections and can be used up totemperatures of 1400 °F (760 °C) when usingProRox ® PS 980NA Type V insulation. They aresupplied ready split and hinged for quick and easysnap-on assembly and are suitable for thermaland acoustical insulation of industrial pipe work.

Due to their excellent fit and high compressionresistance, pipe sections can often be applied ina single layer without any additional spacers.If multiple layers are required, ROXUL ® can alsosupply double layered - ‘nested’ - pipe sections.This reduces installation costs considerably. Alsothe number of thermal bridges, which have anegative influence on the insulation, is greatly

reduced, while a lower thickness may be appliedcompared to wired mats.

Using pipe sections for the insulation of pipesresults in considerably reduced installation timeand costs. The lack of spacers and “unforeseen”

gaps minimizes heat losses and the risk ofpersonal injuries due to hot spots on the cladding.At temperatures above 550 °F (300 °C), theprovisional application of spacers must bedetermined in each individual case.

Pipe sections are always precisely tailored to thecorresponding pipe diameter to minimize the riskof convection and processing defects. ROXUL pipesections are available in diameters ofNPS 1/2" (23 mm) to NPS 28" (713 mm).

Insulation with load-bearing pipe wraps(mats)Load-bearing pipe wraps (mats), such asENERWRAP® MA 960NA are the latest development

in the insulation sector. ENERWRAP®

MA 960NA

isa stone wool (mineral wool) insulation wrapavailable with a black mat or reinforced foil facingand is designed for easy installation of largediameter pipes. Typical applications include:

pipe diameters >NPS 12" (326 mm), or; piping with a high number of shaped piecessuch as elbows or T-joints.

ENERWRAP® MA 960NA can be applied up totemperatures of 1200 °F (650 °C). It is highlycompression resistant and can be applied withoutany additional spacers.


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Consequently the number of thermal bridges,which have a negative influence on the insulation,is greatly reduced.

The result is considerably reduced installationtime and costs. The lack of spacers and

“unforeseen” gaps minimizes heat losses and therisk of personal injuries due to hot spots on thecladding. Pipe wraps (mats) are tailored to thecorresponding length of the pipe circumferenceon site and are fastened with clamps.

Insulation with wired matsWired mats, are lightly bonded stone wool wraps

(mats), usually stitched with galvanized wire ontoa galvanized wire mesh. For more details onProRox ® wired mat insulation products, contactyour ROXUL® representative.

Pipe insulation with wired mats has been atime-tested universal solution for many decadesnow. Due to their flexibility and high temperatureresistance, wired mats can be easily cut andmounted onto piping. Wired mats are ideal forapplication in situations where the use of pipesections or load bearing wraps (mats) is difficultor impossible. Historically this included largediameter pipes and high temperatures (where thewired mat provided structural integrity to theinsulation at high temperatures), but advancedmodern ProRox ® pipe section and ProRox ® pipewraps (mats) have provided a suitable alternativeto wired mats. Wired mat is still used today inpiping with a high number of shaped pieces suchas elbows or T-joints.

Wired mats have a relatively low resistance topressure and from a practical point of view shouldonly be mounted in combination with spacers orsupport structures. Because of the resultingthermal bridges, better insulation performancesare often achieved in the lower and middle

temperature range [up to 550 °F (300 °C)] withpipe sections or load bearing wraps (mats).


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1. Pipe - 2. Insulation: ProRox ® Pipe Sections or Pipe Wraps (Mats): ENERWRAP® MA 960NA - 3. Cladding

1. Pipe - 2. Insulation: ProRox®

Wired Mats - 3. Cladding - 4. Spacer ring

Insulation system with a spacer ring

Insulation system without a spacer ring

Comparison of the different insulationsystemsThe particular advantage of pipe sections and pipewraps (mats) lies in the fact that supportstructures are not required and therefore thermalbridges caused by the insulation are minimized orremoved. On the other hand, wired mat systemshave their advantages due to their ability to bestructurally sound when insulating aroundirregularly shaped pipe sections.

The advantages of pipe sections and load-bearingpipe wraps (mats) at a glance are:

It is not necessary to install spacers or supportstructures.

Faster application without the interference ofspacers.

Both products offer an even, firm surface forinstalling the sheet cladding.

The lack of spacers gives rise to lower heatlosses.

It yields an even surface temperature acrossthe sheet cladding.

In comparison to wired mats, a more shallowinsulation thickness can be applied. The operatingcosts of the installation decrease as a result oflower heat loss.

Generally speaking, a spacer or support structurefunctions as a thermal bridge, as a result of whichthe heat loss in the total insulation is increasedconsiderably.


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Required insulation thicknessesIf the three insulation systems are compared,taking into consideration similar heat losses,clear advantages are seen with regard to theinsulation thicknesses with systems using pipesections or pipe wraps (mats). These do not usespacers, in contrast to insulation systems madeusing wired mats. The table below shows therequired insulation thicknesses taking intoaccount the following boundary conditions:

Medium temperature: 480 °F (250 °C) Ambient temperature: 50 °F (10 °C) Wind speed: 1.1 mph (5 m/s) Cladding: Aluminum Heat loss: 150 BTU/ft.hr (150 W/m) Application of spacers in the case of wired mats

Pipe DiameterMinimum Insulation Thickness

Pipe sections Pipe wraps (mats)Wired mats

NPS(inch)

Nominal diameterØ DN

Pipe diameter(mm)

ProRox® PS 960NA ENERWRAP® MA 960NA

inch inch inch

2 50 60 1" n.a. n.a.

3 80 89 1" n.a. n.a.

4 100 108 1.5" n.a. n.a.

6 150 159 2" n.a. n.a.

8 200 219 2.5" n.a. 5"

10 250 273 3" n.a. 6"

12 300 324 4" 4" 7.5"

14 350 356 4.5" 4.5" 8"

Multiple layer insulation n.a. = not applicable


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Selection of pipe insulation systemsGenerally, the best insulation is achieved usingProRox ® Pipe Sections. The preformed sectionsare quick and easy to install. Their excellent fitand high compression resistance means pipesections can be applied in a single layer withoutany additional spacers. They also have a lowerinsulation thickness. Pipe wraps (mats), areusually applied for the insulation of large pipediameters and can be applied to shaped pieceslike elbows and T-joints.

Comparison ProRox® pipe sections and pipe wraps (mats)offer the advantage that spacers are generallynot required.

ProRox® pipe sections and pipe wraps(mats) are applied more quickly without theinter ference of spacers.

Both products offer an even, firm surfacefor installing the cladding.

The lack of spacers creates lower heat loss. It yields an even surface temperature

across the cladding. In comparison to wired mats, a more

shallow insulation thickness can be used.With a same insulation thickness, theoperational costs of the installationdecrease as a result of lower heat losses.

Generally speaking, a spacer or support structurefunctions as a thermal bridge, as a result of whichthe heat loss in the total insulation is increasedconsiderably.

The design of an insulation system depends uponmany factors such as the dimensions, mechanicalloads, safety aspects, economics, etc.Consequently this also requires a consideredselection of the insulation material.


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1.2.1 Insulation with pipe sectionsGenerally, the best insulation is achieved usingProRox ® Pipe Sections. The sections can be usedup to temperatures of 1400 °F (760 °C) whenusing ProRox ® PS 980NA Type V insulation. Theyare supplied ready split and hinged for quickand easy snap-on assembly and are suitable forthermal and acoustic insulation of industrial pipework. Their excellent fit and high compressionresistance means pipe sections can be appliedin a single layer without any additional spacersor support structures. Consequently the numberof thermal bridges, which have a negativeinfluence on the insulation, is greatly reduced,while a low thickness may be applied comparedto wired mats. The result is considerably reducedinstallation time and costs. The lack of spacersand “unforeseen” gaps minimizes heat loss andthe risk of personnel injuries due to hot spots onthe cladding. At temperatures above 550 °F (300 °C), theprovisional application of spacers must bedetermined in each individual case. ProRox ® Pipe Sections are available in a wide range ofdiameters, ranging from NPS 1/2" (23 mm) to36" (914 mm)

NOTEDue to their low thermal conductivity, betterthermal insulation values can be achievedwith pipe sections than with wired mats.With insulation on straight pipe sections, acombination of both products in the sameinsulation thickness is therefore not advisable.If this combination is essential, for example,in the case of bends or shaped pieces, it isvital to select the correct insulation thickness.This is the only way to guarantee that nounexpected, potentially hazardous surfacetemperatures occur.

Insulation thicknesses to guaranteeprotection against contactThe table below is an initial guide to help selectsuitable insulation thicknesses for the guards.It is based on the following boundary conditions:

Ambient temperature: 75 °F (25 °C) Wind speed: 1.1 mph (0.5 m/s) Cladding: Aluminum Maximum surface temperature: 140 °F (60 °C) Insulation: ProRox ® PS 960NA pipe sections

Pipe Diameter Temperature

NPS(inch)

Nominaldiameter

Ø DN

Pipediameter

(mm)


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InstallationBefore starting the insulation works, ensurethat all preparatory work on the object has beencompleted. Refer to Chapter 1.1 for details.

The ProRox® PS 900 Series pipe sections aremounted directly onto the pipe to form a closefit. With horizontal pipes, the lengthwise joint ofthe pipe section should be turned towards theunderside at the 6 o’clock position. With verticalpipes, the lengthwise joints should be staggeredat an angle of 30 ° to one another. Secure the pipesections with galvanized binding wire or with steelbands. With an insulation thickness exceeding5 inches (120 mm) [or temperatures > 550 °F(300 °C)], install the insulation in at least twolayers. If the insulation is assembled in multiplelayers, the joints of the individual insulation layersmust be staggered.

Support structures and spacersSpacers are not generally essential in insulationsystems with pipe sections. With pipes that areexposed to large mechanical loads (e.g. strongvibrations) and/or temperatures above550 °F (300 °C), determine whether a spacer ringis required in each individual case.

With pipes that have been installed vertically,with a height in excess of 13 feet (4 m), fit supportstructures to transfer the dead load of theinsulation system onto the pipe. Attach the firstsupport ring to the lowest point of the verticalpipe. The distance between the support ringsshould not exceed approximately 13 feet (4 m).


1. Pipe - 2. Insulation: ProRox ® Pipe Sections -3. Clamp or binding wire - 4. Sheet cladding -5. Sheet-metal screw or rivet


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1.2.2 Insulation with pipe wraps (mats)Pipe wraps (mats), such as ENERWRAP ® MA 960NA are the latest development in the insulationbusiness. ENERWRAP ® MA 960NA is a stone woolinsulation wrap available with black mat orreinforced foil facing. The flexible applicationmakes the product easy to cut and install. Pipewraps (mats) are ideal for installations involvinglarge diameter pipes and a high number of shapedpieces such as elbows or T-joints.

ENERWRAP® MA 960NA can be applied up totemperatures of 1200 °F (650 °C). Due to the highcompression resistance, pipe wraps (mats) can beapplied without additional spacers in many cases.Consequently, the number of thermal bridgeswhich have a negative influence on the insulation,is greatly reduced.

The result is considerably reduced installationtime and costs. The lack of spacers minimizesheat loss and the risk of personal injuries causedby hot spots on the cladding. Pipe wraps (mats)are precisely tailored to the corresponding lengthof the pipe circumference on site and are fastenedwith clamps.

Insulation thicknesses to guaranteeprotection against contactThe table below is an initial guide to help selectsuitable insulation thicknesses for the guards. It isbased on the following boundary conditions:

Ambient Temperature 75 °F (25 °C) Wind speed: 1.1 mph (0.5 m/s) Cladding: Aluminum Maximum surface temperature: 140 °F (60 °C) Insulation: ProRox ® PS 960NA

Pipe Diameter Temperature

NPS(inch)

Nominaldiameter

Ø DN

Pipediameter

(mm)


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InstallationBefore starting the insulation works, ensure thatall preparatory work on the object has beencompleted. Refer to Chapter 1.1 for details.

Cut the wraps (mats) to the required length, basedon the external insulation diameter (pipe diameter+ two times the insulation thickness). Fasten thewrap (mat) firmly to the pipe with steel bands.Ensure that the wraps (mats) form a tight jointand that no lengthwise joints or circular joints arevisible. The joints of the individual wraps (mats)are securely taped with self-adhesive aluminumtape. If the insulation is assembled in multiplelayers, the joints of the individual insulation layersmust be staggered.

Support structures and spacersSpacers are not generally essential in insulationsystems with load bearing wraps (mats). Withpipes that are exposed to large mechanical loads(e.g. strong vibrations), determine whether aspacer ring is required in each individual case.

With pipes that have been installed vertically, witha height in excess of 14 feet (4 m), fit supportstructures to transfer the dead load of theinsulation system onto the pipe. Attach the firstsupport ring to the lowest point of the verticalpipe. The distance between the support ringsshould not exceed approximately 14 feet (4 m).


1. Pipe - 2. Insulation: ENERWRAP® MA 960NA - 3. Self-adhesive aluminum tape - 4. Steel bands - 5. Sheet cladding -6. Sheet-metal screw or rivet


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1.2.3 Insulation with wired matsPipe insulation with wired mats has been atime-tested universal solution for many decadesnow. Due to their flexibility and high temperatureresistance, wired mats can be easily cut andmounted onto the piping. These wired mats areideal for application on large pipe diameters andshaped pieces as elbows or T-joints.

Wired mats have a relatively low resistance topressure and from a practical point of view shouldonly be mounted in combination with spacers.Because of the resulting thermal bridges, betterinsulation performances are often achieved in thelower and middle temperature range [up to 550 °F(300 °C)] with pipe sections or load bearing wraps(mats) rather than with wired mats.

InstallationBefore starting the insulation works, ensure thatall preparatory work on the object has beencompleted. Refer to Chapter 1.1 for details.

Cut the wrap (mat) to a length so that it can befitted to the pipe with slight pre stressing. Wirethe closing joints (lengthwise and circular) of thewraps (mats) together using steel wire or securewith wrap (mat) hooks. Stainless steel pipes andpipes with an operating temperature > 750 °F(400 °C) can only be insulated with wired matswith stainless steel stitching wire and wire nettingto prevent galvanic corrosion cracking.

With an insulation thickness of more than 5 inches(120 mm) [or temperatures > 550 °F (300 °C)],apply multiple layer insulation. If the insulation isassembled in multiple layers, the lengthwise andcrosswise joints of the individual insulation layersmust be staggered. If mechanical loads areanticipated, use steel straps to secure the wiredmats.

Support structures and spacersAs wired mats do not offer sufficient resistanceto pressure to bear the weight of the cladding,spacer or support structures should be applied.More information can be found in 1.2.4.

With pipes that have been installed vertically,with a height in excess of 14 feet (4 m), fit supportstructures to transfer the dead load of theinsulation system onto the pipe. Attach the firstsupport ring to the lowest point of the vertical

pipe. The distance between the support ringsshould not exceed approximately 14 feet (4 m).

1. Pipe - 2. Insulation: ProRox ® Wired Mats - 3. Stitchingof the joint edge with binding wire - 4 Sheet cladding -

1. Pipe - 2. Insulation: ProRox ® Wired Mat- 3. Jointedge closed with mat hooks - 4. Sheet-metal cladding -5. Sheet-metal screw or riveted bolt - 6. Spacer ring

1 2 Insulation of piping


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1.2.4 Insulation supportA. SpacersThe purpose of spacers is to keep the cladding ata predetermined distance from the pipe. Spacersare essential when the insulation (e.g. wired mats)cannot bear the mechanical load of the cladding.The use of spacers is generally not necessaryif pipe sections or pipe wraps (mats) are used.Consideration should be given to supportstructure or spacers on pipes where mechanicalloading (e.g. strong vibrations) of the insulation isexpected and/or the temperature is higher than550 °F (300 °C).

Spacer rings usually consist of metal rings onwhich the sheet cladding rests, and metal orceramic bars used as spacers, which rest on thepipe. Elastic spacers such as Omega clamps arefrequently used to reduce the transference ofvibrations. With steel spacers, apply at least threebars, whereby the maximum distance – measuredas circumference of the external ring – must be atotal of maximum 16 inch (400 mm). With ceramicspacers, apply at least four bars at a maximumpermissible distance of 16 inch (400 mm).

Dimension spacers of support constructionThe number of spacers depends on the insulation,temperature and the mechanical load. Use thefollowing intermediate distances as a guide.

Insulationsystem

Horizontalpiping

Verticalpiping

≤ 550 °F > 550 °F ≤ 550 °F > 550 °F

Pipe sections none 10 to 13 ft none 16 to 20 ft

Load bearing wraps (mats) none 10 to 13 ft none 16 to 20 ft

Wired mats 3.3 ft 3.3 ft 3.3 ft 16 to 20 ft

The spacers on pipes are located under thecircular joint of the cladding. On shaped sectionssuch as pipe elbows, spacers are fitted at the startand at the end. If the external distance betweenthe two spacers exceeds 27 inch (700 mm), place

additional spacers between the two.


1. Pipe - 2. ProRox ® insulation - 3. Spacer - 4. Thermaldividing layer - 5. Support ring

m a x

.

1 6 " (

4 0 0 m

m )

1. Pipe - 2. ProRox® insulation - 3. Spacer - 4. Thermaldividing layer - 5. Cladding

m a x

.

2 7 "

( 7 0

0 m m )


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B. Support constructionThe purpose of support structures is to transferthe mechanical load of the insulation system andthe forces affecting the insulation system onto theobject. Support structures are essential in thecase of vertical piping. In addition to the static anddynamic forces, changes in piping length andsupport structures due to temperature must alsobe taken into account when dimensioning. Supportstructures are fastened to mounting supports,which are welded to the pipe beforehand, or aremounted directly onto the pipe via a clampingaction with so-called double clamping rings. Withtemperatures above 650 °F (350 °C), the supportstructures must be made of high-temperature steels. The table below is an initial dimensioning guide,and shows the weight of the insulation systemagainst the nominal width of the pipe and theinsulation thickness. The table accounts for aninsulation with an apparent density of 6 lb/ft 3 (100 kg/m³), including the spacer and a 0.20 inch(1.0 mm) strong galvanized sheet.

Weight of the insulation (lb/ft pipe)

1. Support ring - 2. Bar - 3. Rivet or screw connection -4. Thermal decoupling - 5. Clamping screw - 6. Screwnut - 7. Internal clamping ring

Pipe DiameterUnits of weight ofinsulation system

Insulation Thickness (inch)

NPS(inch)

Nominaldiameter

Ø DN

Pipediameter

(mm)1.00 1.50 2.00 2.50 3.00 4.00 5.00 6.00

0.5 15 21 lb / ft 0.3 0.5 0.8 1.1 1.5 2.5 3.7 5.2

1.0 25 34 lb / ft 0.5 0.7 1.0 1.4 1.8 2.8 4.1 5.7

2.0 50 60 lb / ft 0.8 1.1 1.5 1.9 2.4 3.6 5.0 6.7

2.5 65 76 lb / ft 1.0 1.3 1.7 2.2 2.7 4.0 5.5 7.2

3.0 80 89 lb / ft 1.2 1.5 2.0 2.5 3.0 4.3 5.9 7.7

4.0 100 114 lb / ft 1.5 2.0 2.5 3.0 3.6 5.1 6.8 8.7

8.0 200 219 lb / ft 2.9 3.6 4.4 5.2 6.1 8.1 10.3 12.8

12.0 300 324 lb / ft 4.4 5.3 6.3 7.4 8.5 11.0 13.8 16.8

20.0 500 508 lb / ft 7.2 8.6 10.2 11.8 13.5 17.0 20.8 24.8

28.0 700 711 lb / ft 10.0 12.0 14.0 16.2 18.4 22.9 27.8 32.9

planar surface lb / ft2 1.3 1.6 1.8 2.1 2.3 2.8 3.3 3.8



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1.2.5 CladdingSuitable cladding should be applied to protect theinsulation from weather influences, mechanical loadsand (potentially corrosive) pollution. Selecting theappropriate cladding depends on various factors, suchas working loads, foot traffic, wind and snowaccumulations, ambient temperatures and conditions.

NOTE An insulation system resistant to foot trafficmust not become permanently damaged if aperson weighing 220 lbs (100 kg), (weightincluding any tools being carried) walksacross it. It is not designed to bear additionalloads, such as the placing of heavy equipment.For the purpose of the safety regulations, adurable insulation is not considered to be awalkable surface.

When selecting the appropriate cladding, take thefollowing points into account:

As a general rule, galvanized steel is used inbuildings due to its mechanical strength, fireresistance and low surface temperature (incomparison to an aluminum cladding).

Aluminum is used outdoors, because it is easyto fit and more cost-effective than stainlesssteel and does not tend to corrode undercommon weather conditions.

In corrosive environments, aluminized steel,stainless steel or glass reinforced polyester isused as cladding. Stainless steel isrecommended for use in environments with afire risk.

The surface temperature of the cladding isinfluenced by the material type. The followingapplies as a general rule: the shinier thesurface, the higher the surface temperature.

To exclude the risk of galvanic corrosion, onlyuse combinations of metals that do not tend tocorrode due to their electrochemical potentials(also see page 21 in Chapter 1.1).

For acoustic insulation, a noise absorbentmaterial (bitumen, mylar foil) is mounted on theinsulation or inside the cladding. To reduce therisk of fire, limit the surface temperatures ofthe cladding to the maximum operatingtemperature of the noise absorbent material.


Max. surface temperature

Cladding material Areas at riskof fire

Corrosiveenvironment

< 120 °F(50 °C)

< 140 °F(60 °C)

> 140 °F(60 °C)

Aluminum sheet - -

Aluminum/zinc coated steel sheet - -

Galvanized steel sheet -

Austenitic stainless steel sheet

Aluminized steel sheet

Plastic-coated steel or aluminum - -

Glass fiber-reinforced polyester

(e.g. ProRox®

Rocktight)- < 190 °F (90 °C)

Coatings/mastics - - 175 °F (80 °C)

Foils - -

The thickness of the metal sheet depends on the pipe dameter and the type of the metal.With special acoustic requirements, a larger thickness [> 0.04" (1 mm)] is generally used.


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The recommended sheet thickness deviates to acertain level per standard/country. The thicknessrecommended by CINI is shown in the table above(values converted to inches). See page 148 inChapter 3.2.2 for the thickness according to DIN4140 and BS 5970.

To reduce the risk of galvanic corrosion, it isimportant to use the correct screws, straps etc.See the table on page 21 for more information.

The basic guidelines are: Fasten sheet cladding on lengthwise joints withat least six sheet metal screws or blind rivetsevery meter.

Place the screws or blind rivets equidistant.If screws or rivets are fitted in two rows, do notstagger the screws or rivets.

The cladding can also be held in place withcorrosion-resistant straps instead of screwsor rivets.

Do not use aluminum screws.

Influence of the cladding on thesurface temperatureIn addition to the insulation thickness, the thermalconductivity of the insulation and the ambientconditions (for example temperature and wind),the surface temperature of insulation is alsoinfluenced by the emission ratio (emissivity) of thecladding.

The following applies as a general rule forthermal insulation: the shinier a surface is (loweremissivity), the higher the surface temperature.The following example shows the various surfacetemperatures that depend on the cladding:

Diameter: 4 1/2" (114 mm) Temperature of the medium: 930 °F (500 °C) Place of installation: Interior [Wind speed 1.1mph (0.5 m/s)]

Insulation: ENERWRAP® MA 960NA pipe wrap (mat), thickness 4" (100 mm)

Various cladding materials- Aluminum sheet

- Galvanized steel sheet, bright - Stainless steel - Paint-coated plastic cladding

Recommended sheet thickness and overlaps regarding cladding made from flat sheets (CINI)

External diameter ofthe insulation (in)

Minimum thickness (inches) of metal cladding sheet (recomended by CINI)

Aluminum(CINI 3.1.01)

Aluminizedsteel sheet(CINI 3.1.02)

Alu-Zinc coatedsteel sheet(CINI 3.1.03)

Zinc coatedsteel sheet(CINI 3.1.04)

Austenitic stainlesssteel sheet(CINI 3.1.05)

< 5.5" 0.024 0.022 0.020 0.020 0.020

5" to 12" 0.031 0.031 0.031 0.031 0.031

> 12" 0.039 0.031 0.031 0.031 0.031

S u r f a c e ( c l a d d i n g ) t e m p e r a t u r e ° F

Aluminumcladding

100

105

110

115

120

125

130

Galvanizedsteel

Stainlesssteel

Paint-coatedPlastic

cladding



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p p g 1.2.5 Cladding

Cladding in corrosive environmentsTo guarantee the functionality of industrial/mechanical insulation (sometimes referred to astechnical insulation), it is important to protect itagainst atmospheric influences and prevent theingress of moisture into the insulation. Moisture inthe insulation system increases thermal conductivity,thereby reducing the effectiveness of the thermalprotection. It also poses a high risk of corrosion tothe component. In certain applications, the claddingsystem is also expected to offer chemical resistance,as well as being resistant to cleaning methods suchas steam blasting. Alongside the insulation andconstruction, selecting a suitable cladding system isvery important as it forms the basis for a long servicelife, low maintenance costs and low heat loss of aindustrial/mechanical insulation. ROXUL ® offersProRox® Rocktight, an innovative fiberglass polyestercladding system.

ProRox ® Rocktight – a durable protectionfor insulationProRox® Rocktight is a fiberglass reinforcedpolyester wrap, which hardens when exposed toultraviolet (UV) light. The material contains resins,glass fibers and a special filling agent and is(unprocessed) protected against UV rays by foils onboth sides.

ProRox® Rocktight is soft and flexible whenunprocessed. It can be cut or trimmed in any shapeand easily mounted onto the insulation in this state.

The polyester then hardens when exposed toultraviolet (UV) light. Once hardened, ProRox® Rocktight is watertight and forms a mechanicalprotection for the insulation.

The advantages: Long service life: ProRox® Rocktight creates a sealed, watertightcladding for ROXUL insulation systems. Thisminimizes damage caused by atmosphericinfluences or general wear and tear. ProRox ® Rocktight is resistant to many chemicalsubstances and forms a mechanical protection forthe insulation. Easy to clean: Insulation systems cased in ProRox ® Rocktight canbe cleaned with steam-jet air ejectors, without therisk of water penetrating the insulation andcausing damage. Low start-up costs: The cutting and processing take place directly onsite. This avoids costs associated withprefabrication of steel cladding. Flexible applications: ProRox® Rocktight can be used for cold andthermal insulation of underground andaboveground pipes, for example in offshore plants.Its high flexibility enables application on complex,shaped objects.

ProRox® Rocktight is characterized by easyprocessing. It can be cut easily using a knife directlyon site and, as an unhardened ProRox ® Rocktightwrap (mat) is highly flexible, it can be simply shapedto cover complex geometric shapes such as pipeelbows, T-joints or pipe fittings. ProRox® Rocktighthas a protective foil on both sides. It is supplied inrolls in cardboard packaging. The roll is alsowrapped in black foil that is resistant to UV light. Theunderside (the side facing the object) is covered witha dark foil and has a rough, self-adhesive surface.The flat surface of the outside is covered with a whitefoil. After each use, place the roll in the sealedcardboard packaging to minimize the risk ofhardening caused by daylight or UV light.


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Pipe hangers in direct contact with the piping

ProRox® Rocktight requires a dry, clean (ventilated)work environment. For outdoor applications, tentsshould be erected if necessary, to protect theunhardened ProRox ® Rocktight wrap (mat) from UVlight.

NOTE

High temperatures: ProRox ® Rocktight canbe used in temperatures of up to 190 °F(90 °C).

Chemical resistance: ProRox ® Rocktight isresistant to numerous chemicals.

Expansion joints: fit expansion joints toaccommodate expansion of the ProRox ® Rocktight material and the steel pipe.

1.2.6 Pipe hangers and pipe supportsThere is a wide range of solutions for pipehangers and pipe supports. The followingillustrations show the possibilities describedbelow for insulation systems:

Pipe hangers in direct contact with the piping Pipe supports in direct contact with the piping Pipe supports not in direct contact with thepiping (commonly used with cold insulationsystems)

A basic rule applying to all pipe attachments isthat the insulation system (e.g. the insulation andcladding) must not be damaged if the pipingexpands. Damage to the cladding of outdoorinstallations, in particular, can allow the ingressof moisture in the material. The result may bepermanent damage of the insulation systemand as a consequence high heat losses,dangerously high surface temperatures andcorrosion etc.

1. Pipe - 2. Insulation: ProRox ® PS 960NA pipe sections -3. Sheet cladding - 4. Load-bearing insulation -5. Seal - 6. Stirrup - 7. Pipe saddle

Pipe support not in direct contact with the piping

1. Pipe - 2. Insulation: ProRox ® Pipe Sections -3 Collar - 4 Sheet cladding - 5 Pipe hanger

1. Pipe - 2. Insulation: ProRox ® PS 960NA – pipe section- 3. Sheet cladding - 4. Pipe clamp - 5. Pipe saddle

Pipe support in direct contact with the piping



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1.2.7 Insulation of valves and flangesHeat loss incurred through non insulated fixturessuch as valves and flanges are substantial, even atlow temperatures. An uninsulated valve locatedoutside loses as much heat at 250 °F (120 °C) as100 ft (30.5 m) of uninsulated piping. Thetemperature of the medium can also decrease tosuch an extent at non-insulated fittings or flanges,that process critical temperatures are reached, atwhich point for example, the medium will start tocrystallize. Valves and flanges should therefore beinsulated as much as possible. To avoid damageduring inspection or repairs, the insulation forvalves and flanges is designed with removablecoverings or hoods, to allow rapid disassembly.Removable coverings or hoods are usuallyinsulated from the inside with wired mats orflexible ProRox ® insulation (FSL Series). Thecoverings are fastened to the object with leverfastenings, which are fixed directly onto thecovering or on to straps. Take the followingconditions into account when designing insulatedcoverings for fittings and flanges:

The overlap distance of the insulated coveringover the insulated pipe should be at least 2"(50 mm).

The pipe insulation should end at the flanges,leaving a gap equal to the bolt length +1.2"(30 mm) and should be closed off with a lockwasher so the flange can be loosened withoutdamaging the insulation.

With valves, an extended spindle shouldpreferably be fitted horizontally or below thepipe to prevent leakage along the spindle shaft.

The cladding must be fitted to prevent theingress of moisture in the insulation. Oninclined or vertical piping, for example, mountrain deflectors above the removable coverings.If the ingress of moisture into the insulation isunavoidable, make 0.4" (10 mm). diameter drainholes in the removable covering.

1. Pipe - 2. ProRox® insulation -3. Cladding - 4. Sheet-metal screw or Rivet -5. Swage - 6. Drainage opening - 7. Strap - B ≥ 2" (50 mm) - A = bolt length + 1.2" (30 mm)

1. Pipe - 2. ProRox® insulation - 3. Cladding - 4. Sheet-metal screw or rivet - 5. Rain deflector - 6. Lock washer- 7. Straps - 8. Rain deflector -B ≥ 2" (50 mm) - A = bolt length + 1.2" (30 mm)

2 "

( 5 0 m m )

5

0.8"(20 mm)

A number of possible design options for insulationsystems for pipe fittings and flanges follow:


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LeakagesWith pipes where a leaking fluid content coulddamage the insulation or the coating system inthe removable covering, mount flange straps witha leak detection fitting around the flange. Flangebands can also prevent flammable products frompenetrating into the insulation material and canhelp prevent the outbreak of fire.

1. Pipe - 2. ProRox ® insulation - 3. Cladding - 4. Sheet-metal screw or rivet - 5. Swage - 6. Drainage opening- 7. Straps – B ≥ 2" (50 mm) - A = Bolt length + 1.2"(30 mm)

1. Pipe - 2. Insulation: ProRox ® Pipe Sections -3. Cladding - 4. Sheet-metal screw or rivet -5. Removable coverings (insulated from the inside) -6. Swage

2 "

( 5 0 m m )

0.8"(20 mm)

1. Pipe - 2. ProRox® insulation - 3. Sheet -4. Sheet-metal screw or rivet - 5. Rain deflector -6. Lock washer - 7. Straps - 8. Lock washer -B ≥ 2" (50 mm) - A = Screw length +1.2" (30 mm)

1. Pipe - 2. ProRox® insulation - 3. Cladding - 4. Sheet-metal screw or rivet - 5. Swage - 6. Flange band - 7.Leak detection fitting - 8. Clamps

1. Pipe - 2. ProRox® insulation - 3. Cladding - 4. Sheet-metal screw or rivet - 5. Swage - 6. Drainage opening- 7. Straps – B ≥ 2" (50 mm)



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1.2.7 Insulation of valves and flanges

1.2.8 Insulation of pipe elbows andT pieces

The cladding of elbows and T-pieces is susceptibleto damage, due to expanding or vibrating pipes.There is a particular risk of moisture penetratingdamaged swage connections in the cladding, if theobject is located outdoors.

For the insulation of shaped pieces, werecommend using the same insulation in thesame thickness as used for the pipe.

Insulation of pipe elbows with ROXUL ® pipe sectionsFor the insulation of pipe elbows with pipesections (e.g. ProRox ® PS 960NA), the pipe sectionsare cut into segments and tightly fitted onto thepipe elbow with the lengthwise joints facingdownwards. The angular division of the segmentsshould correspond to the radius of the pipe elbow.The pipe section segments are fastened to the

pipe elbow with clamps or binding wire. Joints

between the individual segments are pluggedtightly with loose ROXUL insulation.

Insulation of pipe elbows with wiredmats or ProRox ® pipe wraps (mats)If the piping is insulated with wired mats or pipewraps (mats), shaped pieces such as pipe elbowsor T-pieces are generally insulated with the samewraps (mats). In this case, the wraps (mats) arecut into so-called fish-shaped elbow segments.These are mounted onto the pipe elbow to seal theelbow. With wired wraps (mats), all the joints (bothcircular and lengthwise joints) are sewn togetherwith binding wire or wrap (mat) hooks. Spacersare required at least at the start and end of theelbow (for more details, please see page 34).

Pipe wraps (mats) are fixed to the pipe elbow withmetal or plastic straps. Any gaps between theindividual segments should be plugged withinsulation. Secure the joint edges with self-adhesive aluminum tape.

1. Pipe - 2. ProRox ® insulation - 3. Cladding - 4. Sheet-metal screw or rivet - 5. Collar - 6. Collar -7. Clamps - 8. Rain deflector - 9. Leak detection fitting -B ≥ 2" (50 mm) - A = bolt length + 1.2" (30 mm)

1. Pipe - 2. Insulation: ProRox ® Pipe Sections -3. Cladding - A and B = Segmented pipe sections


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1.2.9 ReducersPipes that branch out with many outlets reducethe pipe diameter. Examples of how to installreducers follow:

The diagrams below show how the sheet is

mounted onto shaped pieces.

1. Pipe - 2. ProRox® insulation - 3. Cladding - A to C:Elbow segments of wraps (mats)

1. Pipe - 2. ProRox ® insulation - 3. Cladding

1. Pipe - 2. ProRox ® insulation - 3. Cladding -4. Drainage opening - 5. Edging with mastic compound

0 . 6 " (

1 5 m m )

0 . 4

" ( 1 0 m m )

1. Pipe - 2. ProRox® insulation - 3. Cladding - 4. Sheet-metal screw or rivet - 5. Swage - 6. Reducer

1. Pipe - 2. ProRox® insulation - 3. Cladding - 4. Sheet-metal screw or rivet - 5. Swage - 6. Reducer



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1.2.10 Expansion jointsIn thermal insulation systems, large differencesbetween the piping and the cladding temperaturecan occur. The materials used for the pipe,insulation, insulation support and cladding alsohave different thermal expansion coefficients.This leads to different thermal elongations of thevarious components in the insulation system,which must be allowed for using constructive

measures. The elongation “Δl” can be determinedas follows:

Δ l = l ⋅ Δ t ⋅ a

In this formula, l corresponds to the length of thepipe, Δt corresponds to the difference intemperature between the cold and warm pipe (orcladding) and a corresponds to the linear thermalexpansion coefficient (see tables in Chapter 3).

If bellow expansion joints for thermal lengthcompensation have been built into the pipe, theinsulation system will also bellow along with thepipe movements, potentially compromising theinsulation. The expansion bellows are coveredwith a sheet that is then insulated (see diagramson the right). With temperatures above 550 °F(300 °C), do not use galvanized sheets due to therisk of galvanic corrosion (cracking).

To compensate for thermal expansion of thecladding, install the expansion joints shown below.

Example for the thermal elongation of steel

Δ l (inch per foot) Δ t (°F) Δ t (°C)

0.004 50 28

0.008 100 56

0.012 150 83

0.016 200 111

4"(100 mm)

4" (100 mm)

1. Pipe - 2. ProRox ® insulation - 3. Cladding -4. Aluminum foil - 5. Cover sheet - 6. Wrap (mat) pin withclip - 7. Spacer

1. Pipe - 2. ProRox® insulation - 3. Cladding -4. Sheet-metal screw or rivet - 5. Swage -6. Metal strap - 7. Circumferential seam


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1.2.11 TracingWhen media are transported over long distances,in particular, the media inside the piping can spoil,set or be at risk from frost in the winter. Insulationcan reduce heat losses and postpone the momentat which the installation freezes. Insulation alone,however, cannot indefinitely prevent theinstallation from freezing. Installing additionaltracing may be necessary between the object and

the insulation.

A distinction is made between pipe tracing andelectrical tracing. In pipe tracing systems, aheating pipe is fitted parallel and close to themedia pipe. Steam, warm water or thermal oilflows through the tracing pipes as a heat transfermedium. Electrical tracing consists of cablesmounted onto the pipes. These cables heat thepipes

Traced pipes can be insulated with pipe sectionsor wraps (mats). Ensure that no insulationoccupies the space between the tracing and thepipe; otherwise the heat transfer will behampered. Pipes are therefore often wrapped inaluminum foil. If pipe sections are used, select acorrespondingly larger internal diameter of thepipe section. With vertical piping, sealing the endof each pipe section with loose ROXUL ® insulationis recommended to prevent convection (chimneyeffect).

The diagrams on the right show various designoptions.

1. Pipe - 2. Insulation: ProRox ® Pipe Sections -3. Electrical tracing - 4. Aluminum foil - 5. Cladding

1. Pipe - 2. Insulation: ENERWRAP® MA 960NA or WiredMats - 3. Tracing - 4. Aluminum foil -5. Cladding

1. Pipe - 2. Insulation: ProRox ® Pipe Sections -3. Tracing - 4. Binding tape - 5. Cladding



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1.2.12 Foot trafficAvoid walking on insulated pipes, as this candamage the insulation. Damage caused by foottraffic includes dented sheet cladding and gaps atthe sheet seams. Water can penetrate theinsulation through these gaps and cause lastingdamage to the entire insulation system. The resultis often greater heat losses and corrosion.

NOTE An insulation system resistant to foot trafficmust not become permanently damaged if aperson weighing 220 lbs (100 kg), (weightincluding any tools being carried) walks on it.It is not designed to bear additional loads,such as the placing of heavy equipment. Forthe purpose of the safety regulations, adurable insulation is not considered to be awalkable surface.

In special applications, reinforcing the cladding isrecommended, e.g. using a reinforcement sheet.

Pipe insulation systems resistant to foot trafficrequire an insulation material with a highmechanical strength (e.g. ProRox ® PS 980NA pipesections). Using other insulation materials suchas wired mats, which are not resistant topressure, is not recommended, as the sheetcladding only rests on the spacers and tendsto dent when walked upon.

1. Pipe - 2. Insulation: ProRox® PS 980NA PipeSections - 3. Reinforcement sheet (may not berequired) - 4. Cladding - 5. Sheet-metal screw or rivet -

6. Joggle

1. System solutions


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I n s u l a t i o n

o f v e s s e l s

1.3 Insulation of vesselsVessels are a major component in installations forvarious procedures in almost all fields of industry.

Many production processes require differentsubstances that are stored in vessels and used inthe individual processes later in the procedure.The vessels primarily store liquid, solid or

gaseous substances, which are added to theprocess when required. Raw materials, fuels orend products are usually stored in large storagetanks.

It is often important to store the substances withincertain temperature limits. If the temperature istoo high or too low, the substance can spoil or set,or lose its flowing properties and becomeincapable of being pumped or discharged.Insulation is therefore a major factor in thefunctionality of procedural processes. It also hasthe following purposes:

Reduces heat loss Aids protection against contact by minimizingthe surface temperature

Reduces cooling of the stored substance, so itremains fluid and does not setPrevents the vessel from freezing (withadditional tracers)

Prevents heating of the stored substance (forexample, through solar radiation)

The vessels used in the different industrialprocesses are so varied that the examples of usecannot fully take into account the particularcircumstances of each case.

Determine whether the products and constructiondescribed are suitable for the correspondingapplication in each individual case. If in doubt,consult the ROXUL® Technical Services Team.

The applicable standards and regulations mustalso be observed. A few examples follow:

ASTM C1696 "Standard Guide for IndustrialInsulation Systems"

NACE SP0198 (Control of corrosion underthermal insulation and fireproofing materials -a system approach)

ASME "Boiler and Pressure Vessel Code" MICA "National Commercial & IndustrialInsulation Standards"

DIN 4140 (Insulation works on industrial plantsand building services installations)

AGI Q05 (Construction of industrial plants) AGI Q101 (Insulation works on power plantcomponents)

CINI-Manual: “Insulation in industry” BS 5970 (Code of practice for thermal insulation

of pipe work, equipment and other industrialinstallations)

PIP (Process Industry Practices)

NOTE

Before starting the insulation works,ensure that all preparatory work on theobject has been completed. Refer to Chapter1.1 for details.

Insulation systems for vesselsAn insulation system for a vessel generallyconsists of the following components:

Insulation Support construction and a spacer Water vapor retarder with cold insulationsystems

Cladding

The actual operating temperature (above or belowambient) is essential for the design of theinsulation work. The following chaptersconcentrate on hot insulation.

1.3 Insulation of vessels


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Selection and installation of the

insulationSelecting the appropriate insulation depends onthe operating method, the installation temperature,the dimensions and the location of the vessel.

Typically recommended insulation materials areProRox® wraps (mats) and ProRox ® flexible andsemi rigid boards (slabs) like the SL 920 NA,

SL 930NA and ENERWRAP® MA 960NA.

Since vessels are often located outdoors, it isimportant to select insulation with a low thermalconductivity and excellent water repellentproperties. The insulation is usually fastened tothe cylindrical vessels with steel straps. Theseshould be made from stainless steel and should

be closed with butterfly nuts or quick releasefasteners. The strap measurements and intervalsfor cylindrical objects shown in the table on thenext page have proved useful in many projects.

1. Vessel inlet - 2. Crane hooks - 3. Vessel head -4. Expansion joint - 5. Manhole - 6. Tapping point -7. Identification board - 8. Vessel base - 9. Vessel outlet- 10. Fitting insulation - 11. Flange - 12. Vessel leg

Minimum radius ProRox® insulation boards (slabs)

ProductInsulation thickness (inches)

1 1.5 2 2.5 3 3.5 4 5

ProRox® SL 920NA 16 21 30 40 50 60 72 84

ProRox® SL 930NA 16 22 32 42 60 66 76 100

ProRox® SL 960NA 20 30 48 66 92 100 100 120

ENERWRAP® MA 960NA 12 16 20 24 28 32


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I n s u l a t i o n

o f v e s s e l sThese values can only be used as referencevalues. In each individual case, determine

whether different strap measurements andintervals should be used.

If the insulation is assembled in multiple layers,the joints of the individual insulation layers mustbe staggered (e.g. masonry bond pattern).

For semi-rigid boards (slabs) and wired matsusually used the insulate vessels with flat verticalwalls the insulation is attached with welding pinsand spring plates. On flat surfaces, attach thewired mats using minimum 5 pins per board (or6 pins per m 2), and a minimum of 8 pins per board(or 10 pins per m 2) on the underneath. Observethe following when pinning the insulation:

With insulation thicknesses ≤ 5" (120 mm), use8GA (6AWG) pins with a minimum diameter of0.162" (4 mm).

With insulation thicknesses ranging from 5 1/2"to 10" (130 to 240 mm), use 6GA (4AWG) pinswith a minimum diameter of 0.2043" (5 mm).

With insulation thicknesses ≥ 10" (240 mm) use4GA (3AWG) pins with a minimum diameter of1/4" (6 mm).

If the cladding rests directly on the insulationwithout a gap between the two, the pins mustbe 3/8" (10 mm) shorter than the insulationthickness.

Fasten each insulation layer with clips.

With wired mats, all the lengthwise and crosswise joints must be sewn or wired together, or joinedwith 2 mat hooks per foot. If the insulation isassembled in multiple layers, the joints of theindividual insulation layers must be staggered.

The following illustrations show a number oftypical methods of insulating vessels.

1. Cladding - 2. ProRox® insulation - 3. Crane hooks -4. Insulation covering for the crane hook

External insulationdiameter

Internal insulation layer strapmeasurement

External or single layer insulationstrap measurement

Distance betweenstraps

8" to 72" (200 to 1800 mm) 1/2" x 0.02" (13 x 0.5 mm) 5/8" x 0.02" (16 x 0.5 mm) 10" (250 mm)

> 72" (1800 mm) 5/8" x 0.02" (16 x 0.5 mm) 3/4" x 0.02" (19 x 0.5 mm) 10" (250 mm)

Insulation of a crane hook

1.3 Insulation of vesselsSelection and installation of the insulation

1.3 Insulation of vessels


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Selection and installation of the insulation

Insulation of a vessel base

2 "

( 5 0 m m )

2"(50 mm)

1. ProRox® insulation - 2. Support construction - 3. Mounting support - 4. Conical column head -5. Vessel outlet - 6. Vessel leg

1. ProRox® load bearing insulation - 2. Flange inlet for safety valve - 3. Vessel filling nozzles -4. Conical head - 5. Vessel drawdown - 6. Conical head with manhole - 7. Vessel leg


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I n s u l a t i o n

o f v e s s e l s

Support constructions and spacers

The application of support constructions andspacers on vessels is essential. The objective ofsupport constructions is to bear the weight of theinsulation system and to bear the weight abovemounting supports on the object to be insulated.The spacers keep the cladding of the insulation ata predetermined distance. On vertical pipes, thesubstructures often assume the function of the

support construction and spacer. The designspecifications are illustrated in Chapter 1.4.The corresponding requirements for supportconstructions and spacers can be found in MICANational Insulation Standards and the AGIguidelines Q153 and 154.

Before commencing the insulation works, fit

mounting supports to the vessels to which thesupport constructions are fitted. The shape,construction and measurements of mountingsupports for support constructions must enablethe insulation to be fitted during assembly. Ifdesired use the design loads specified in DINguidelines 1055-4 and 1055-5 to dimension themounting supports and the support constructionsand spacers.

CladdingThe cladding of vessels protects the insulationagainst mechanical influences and the weather.There is a wide range of different flat and profiledsheets available. See Chapter 3.2 for an overview.Flat sheets are primarily used to clad smallervessels. With large-scale insulation systems, flatsheets can only bear small, static loads exerted bythe wind. It is therefore essential to reduce thedistance between the support structures.

The result will be a higher number of supportstructures and thermal bridges. On largesurfaces, flat sheets are more likely to buckle ordent, leading to optical damages, than profiledsheets. To improve the stability and opticalcharacteristic, the sheets can be canteddiagonally (cambered).

8 "

( 2 0 0 m m )

Insulation of a conical head

Insulation of a conical head with a manhole

Insulation of vessel outlet

1.3 Insulation of vesselsSelection and installation of the insulation


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Preferably use profiled sheets for vessels with alarge surface area. They offer structuraladvantages and can accommodate expansionsthat are perpendicular to the direction of theswage. The disadvantage is that pipe protrusionsare more complex from a structural perspective.Using profiled sheets is only recommended withcladding with a low number of protrusions.

Design profiled sheet casings so that rainfall isdeflected safely.

Cladding in moist or corrosiveenvironmentsTo guarantee the functionality of industrial/mechanical insulation, it is important to protect itagainst atmospheric influences and prevent theingress of moisture into the insulation. Moisture inthe insulation system increases thermalconductivity, thereby reducing the effectiveness ofthe thermal protection. It may also increase therisk of corrosion to the component. In certainapplications, the cladding system is also expectedto offer chemical resistance, as well as being

resistant to cleaning methods such as steamblasting. Alongside the insulation andconstruction, selecting a suitable cladding systemis very important as it forms the basis for a longservice life, low maintenance costs and low heatloss of a industrial/mechanical insulation.

ROXUL Inc. has developed an innovative cladding

system for industrial/mechanical insulation:ProRox® Rocktight.

ProRox ® Rocktight – for durableprotectionProRox® Rocktight is a fiberglass reinforcedpolyester wrap, which hardens when exposed toultraviolet (UV) light. The material contains resins,

glass fibers and a special filling agent and isprotected against UV rays by foils on both sides.

ProRox® Rocktight is soft and flexible whenunprocessed. The polyester then hardens whenexposed to ultraviolet (UV) light. Once hardened,ProRox® Rocktight is waterproof and forms amechanical protection for the insulation.

Please see Chapter 1.2. for more details aboutprocessing ProRox ® Rocktight.

1. System solutions1 4 I l i f l


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I n s u l a t i o n

o f c o l u m n s

1.4 Insulation of columnsColumns are pillar-shaped vessels, which aremainly used in the (petro) chemical industry fordistillation or the extraction of substances. Theyoften form the key elements in chemical orpetrochemical plants. The processes in columnsoften only operate at certain temperatures. Theinsulation of columns plays an important role in

their functionality. Reduces heat loss Aids protection against contact by minimizingthe surface temperature

Reduces the cooling of the stored substance, soit remains fluid and does not setEnsures the column remains at the necessaryprocess temperatures

Prevents heating of the stored substance (forexample, through solar radiation)

The columns used in the different industrialprocesses are so varied that the examples of usebelow cannot fully take into account the particularcircumstances of the construction-related factors.Determine whether the products and construction

described are suitable for the correspondingapplication in each individual case. If any doubt,consult the ROXUL® Technical Services Team.

The applicable standards and regulations must beobserved. A few examples follow:

ASTM C1696 "Standard Guide for IndustrialInsulation Systems"

NACE SP0198 (Control of corrosion underthermal insulation and fireproofing materials -a system approach)

ASME "Boiler and Pressure Vessel Code" MICA "National Commercial & IndustrialInsulation Standards"

DIN 4140 (Insulation works on industrial plantsand building services installations)

AGI Q101 (Insulation works on power plantcomponents)

CINI-Manual: “Insulation in industry”

BS 5970 (Code of practice for thermal insulationof pipe work, equipment and other industrialinstallations)

PIP (Process Industry Practices)

NOTE Before starting the insulation works,

ensure that all preparatory work on the objecthas been completed. Refer to Chapter 1.1 fordetails.

Insulation systems for columnsAn insulation system for vessels and columnsgenerally comprises the following components:

Insulation Support construction and a spacer Water vapor retarder in the case of coldinsulation systems

Cladding

The temperature of the columns, in particular, hasa significant impact on the optimal insulation system.This chapter focuses on the insulation of hot columns .

1.4 Insulation of columns Insulation systems for columns


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Selection and installation of the

insulationSelecting the appropriate insulation depends on theoperating method, the installation temperature, thedimensions and the location of the vessel orcolumn.

Insulation materials such as ProRox ® are suitablefor use of the insulation of columns.

Since columns are often located outdoors, it isimportant to select insulation with a low thermalconductivity and excellent water repellentproperties. The insulation is usually fastened tothe columns with steel straps. These should bemade from stainless steel and should be closedwith butterfly nuts or quick release fasteners. The

strap measurements and intervals for cylindricalobjects shown in the table on the next page haveproved useful in many projects.

1. Column head - 2. Reinforcement ring - 3. Expansion joint - 4. Working platform - 5. Identification board -6. Column base - 7. Column skirt


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I n s u l a t i o n

o f c o l u m n s

1. Support construction - 2. Mounting support -3. Reinforcement ring - 4. ProRox ® insulation -5. Cladding

In a wide variety of applications, these values can

only be used as reference values. In eachindividual case, determine whether different strapmeasurements and intervals should be used. Ifthe insulation is assembled in multiple layers,the joints of the individual insulation layers mustbe staggered. The following illustrations show anumber of typical methods of insulating columns.

External insulation

diameter

Internal insulation layer strap

measurement

External or single layer insulation

strap measurement

Distance between

the straps

8" to 72" (200 to 1800 mm) 1/2" x 0.02" (13 x 0.5 mm) 5/8" x 0.02" (16 x 0.5 mm) 10" (250 mm)

> 72" (1800 mm) 5/8" x 0.02" (16 x 0.5 mm) 3/4" x 0.02" (19 x 0.5 mm) 10" (250 mm)

2 "

( 5 0 m m

)

Insulation of conical column head

1. Supporting construction - 2. Mounting support

Insulation of a reinforcement ring

1.4 Insulation of columns Selection and installation of the insulation


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Fire protection in column skirtsThe fire protection quality of a column primarilydepends on the fire resistance of the

ROXUL Process Manual 082714 - Compliance to CINI

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