MECHANICAL SPECIFICATIONS – SECTIONS 02 EMAAR STANDARD SPECIFICATIONS (R9)
INSULATION
MECHANICAL SECTION: 02
INSULATION
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MECHANICAL SPECIFICATIONS – SECTIONS 02 EMAAR STANDARD SPECIFICATIONS (R9)
INSULATION
TABLE OF CONTENTS
1.0 INSULATION GENERAL.............................................................................................3
2.0 CONCEALED COLD AIR DUCTS..............................................................................5
3.0 EXPOSED COLD AIR DUCTS.....................................................................................5
4.0 ACOUSTIC INSULATION............................................................................................6
5.0 APPARATUS CASINGS................................................................................................6
6.0 PIPE INSULATION........................................................................................................6
7.0 LAGGING ADHESIVE..................................................................................................8
8.0 ALUMINIUM CLADDING............................................................................................9
9.0 SAMPLES........................................................................................................................9
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MECHANICAL SPECIFICATIONS – SECTIONS 02 EMAAR STANDARD SPECIFICATIONS (R9)
INSULATION
1.0 INSULATION GENERAL
1.1 The whole of the insulation work shall be carried out by an approved specialist insulation
Contractor. All allowances shall be included for arranging a specialist subcontract accordingly and
for informing the specialist Sub-contractor of all conditions relating to the Contract and for
coordinating his works with the remainder of the works.
1.2 All allowances shall be included for informing the specialist Sub-contractor of all details of the
building structure, program arrangements, and other relevant details at the time of tender and for all
necessary visits to site by the Sub-contractor or his workers.
1.3 All insulation shall be in accordance with British Standard Specifications (unless specified
elsewhere) and Codes of Practice in all respects. Insulation meeting A.S.T.M. Standards will be
considered if properly submitted.
1.4 In addition to complying with the relevant standards, all insulating material shall be free from
Asbestos and with low VOC complying with DM Green buildings regulations. All insulation
material shall be tested by Dubai Central Lab to confirm compliance with DM Green Buildings
Regulations. Insulation system shall be approved by local Civil Defense.
1.5 Insulating materials shall be acceptable only if they are equal to or better than the grades or classes
of fire resistance as follows:
B.S. 476, Part 4, (Noncombustible grade.)
B.S. 476 Part 5 Class P, (Not easily ignitable.)
B.S. 476, Part 6, (Fire Propagation Index a maximum of 12.6.)
B.S. 476, Part 7, Class 1, (Surface spread of flame.)
B.S. 476 Part 9, (Production of emitted smoke shall not give more than 35% obscuration of the light
beam.)
All insulation finishes and coverings shall be classified as Class 1 (one) surface spread when tested
in accordance with B.S. 476, Part 7.
Alternatively, insulation systems shall be tested according to ASTM E84, by a testing agency
acceptable to authorities having jurisdiction. They shall have a flame-spread index of 25 or less, and
smoke-developed index of 50 or less for insulation installed indoors. For outdoor insulation, Flame-
spread index of 75 or less, and smoke-developed index of 150 or less.
1.6 All adhesives, mastics, coatings, sealers and primers shall be classified as Class 1 surface spread
when tested in accordance with B.S. 476, part 7, and shall have low VOC content in accordance with
green buildings regulations.
They shall not in any way attack the insulation or the surface to which the insulation is being applied
and shall be suitable for the working temperatures.
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MECHANICAL SPECIFICATIONS – SECTIONS 02 EMAAR STANDARD SPECIFICATIONS (R9)
INSULATION
1.7 Insulating materials shall have thermal conductivity values not more than those listed as follows:
---------------------------------------------------------------------------------------------------
MATERIAL TYPE THERMAL CONDUCTIVITY.
W/M/K
--------------------------------------------------------------------------------------------------
Mineral wool Sectional 0.04
Mineral wool Slabs 0.04
Fibre Glass All 0.034
---------------------------------------------------------------------------------------------------MATERIAL
TYPE THERMAL CONDUCTIVITY.
W/M/K
--------------------------------------------------------------------------------------------------
Closed Cell All 0.038
(elastomeric foam)
Polyurethane Sectional 0.025
Styrofoam Rigid 0.026
Polyolefin All 0.035
---------------------------------------------------------------------------------------------------
All conductivity figures are rated at an average temperature of 23°C.
1.8 The closed cell elastomeric foam insulation shall have following characteristics in addition to clause
1.5 above:
a. Water vapour permeability - 0.09 ugm/Nh, BS EN ISO 844
(= 7000 to DIN EN ISO 12572)
b. Density - 55 to 70 kg / m3 or 4lb / ft3 to 5lb / ft3
c. Closed cell content - 90%.
d. Corrosion risk assessment - Din 1988-200 Certified.
e. Noise reduction - Din 4109 up to 32 dB (A).
f. Thermal conductivity of 0.037 w/m.k at 10°C and 0.038 w/m.k at 20°C to BS 874 PART
2 – 86 (DIN 52613, 52612).
The insulation thickness for pipes and ducts shall be verified by the specialist supplier/ manufacturer
to confirm no condensation.
1.9 All material delivered to site shall be new and fully dried out and so maintained throughout the
progress of the works.
All insulating materials shall be stored in storage sheds, and in accordance with the Manufacturer's
recommendations.
1.10 In order to ensure that the insulation applied is in all respects in accordance with the specification,
sections shall, as required by the Consultant, be cut from the finished insulation.
The Contractor is to allow in his price for the removal and replacement of two sections of each type
of insulation.
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MECHANICAL SPECIFICATIONS – SECTIONS 02 EMAAR STANDARD SPECIFICATIONS (R9)
INSULATION
If, however, defects are revealed, further sections shall be cut out for inspection, and all cutout
sections shall be replaced at no cost to the Contract.
If further defects are revealed then the Consultant shall have the right, when in his opinion it is
necessary, to issue instructions for any part or the whole of the insulation to be removed and
replaced. The replacement with new insulation shall be to the satisfaction of the Consultant and the
cutting out and replacing shall be at no cost to the Contract.
1.11 Particular attention shall be paid to the finished appearance of all thermal insulation which must
present a neat and symmetrical appearance running true in line with pipe layouts, etc.
1.12 Any rough, irregular and badly finished surfaces shall be stripped down and re-insulated to the
Consultant's satisfaction.
1.13 In certain cases the type of insulation specified will require a painted finish, in addition to identifying
bands and any signs which are to be applied.
1.14 All systems are to have been tested and approved by the Consultant prior to installation of insulation.
1.15 Manufacturer shall have production process control in accordance with ISO 9002 or any other
equivalent standard.
1.16 In case of heavy ducts and pipes wherein the supports are fixed directly on ducts / pipes the supports
shall be also insulated with a thermal break / barrier.
1.17 Insulation for Chilled Water Pipes in Conditioned Areas (Interior): Insulation on both primary and
secondary side of the ETS room shall be min. 50mm thickness or as per manufacturer
recommendation, whichever is higher.
2.0 CONCEALED COLD AIR DUCTS
2.1 All horizontal extract air ductwork within air-conditioned areas shall be bare GI without insulation.
The ductwork within non air-conditioned areas shall be insulated with 25mm thick, 55-70kg/m³
density closed cell elastomeric foam insulation without any additional coating.
2.2 Insulate flexible connections and connections to diffusers with 25mm thick, 24kg/m³ density
reinforced aluminium foil faced, flame resistant flexible fiberglass insulation. Overlap unto adjacent
insulation and seal with adhesive duct tape to give good closure.
2.3 Extract duct from commercial kitchen hoods shall be insulated with 50mm thick, 48kg/m³ rockwool
insulation with aluminium foil finish.
2.4 The thermal insulation performance shall be as specified in clause 1.0
3.0 EXPOSED COLD AIR DUCTS
3.1 For ductwork exposed in non-air-conditioned areas, insulate using 25mm closed cell elastomeric
foam sheets without any additional coating, or chemically cross-linked closed cell self-adhesive
polyolefin reinforced by alupet foil.
3.2 For ductwork exposed directly to sun light, insulate with 25mm thick, 55-70 kg/m³ closed cell
elastomeric foam insulation sheets, UV resistant.
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MECHANICAL SPECIFICATIONS – SECTIONS 02 EMAAR STANDARD SPECIFICATIONS (R9)
INSULATION
3.3 All ductwork in exposed areas (at roof, in car parking areas and mechanical rooms) shall be clad
with aluminium plain sheet of 0.6mm thickness. The cladding in mechanical rooms shall be up to 2.5
m from finish floor level.
3.4 Where ducts penetrate the building shell, the duct shall be flashed and waterproofed before any
insulation is applied.
3.5 The thermal insulation performance shall be as specified in clause 1.0
4.0 ACOUSTIC INSULATION
4.1 All low pressure ductwork shall be lined with acoustic insulation up to the first take off point, or 3
meters from the fan/ unit outlet.
4.2 Duct acoustic lining shall be 25mm thick, fiberglass, 24kg/m³ density. Air stream surface shall be
faced with a black coated mat bonded to a black fiberglass substrate.
4.3 Liner shall be tested to UL181 or approved equal for air velocity rating of 25m/s and air erosion
rating of 63.5m/s.
4.4 Liner will be attached by a fire resistant adhesive such as Foster 81-99, or equivalent.
4.5 All abutting edges must be caulked.
5.0 APPARATUS CASINGS
5.1. Insulate apparatus casings which are not provided with insulation as follows:
Apply generally 50mm of rigid polyurethane insulation, 24kg/m³ density. On the underside of coil
sections, apply 10mm thick polyurethane. All joints are to be sealed in cold adhesive compound.
5.2. Ensure that any access panels are insulated to the same standard and are openable.
5.3. For small units, cover the entire outside assembly with waterproof self-adhesive glass fibre tape.
This must be at least 75mm minimum width and must overlap at least 50% on each application, to
achieve watertight conditions.
5.4. For larger units, provide a weather resistant enclosure outside the insulation, subject to Consultant's
approval.
5.5. Ensure that all equipment meets these requirements, regardless of manufacturer's standard practice,
and add insulation as required to the above standard.
5.6. Where insulation, re-insulation or additional insulation is required to the casing of externally
mounted air conditioning units, the insulation shall be covered with sheet Aluminium, of 0.7mm or
thicker.
5.7. Insulation to drain pans is specified as part of the A.H.U. specification. Regardless of the
Manufacturer's standard supply, the contractor shall reinsulate on site if necessary, so that the
specification is complied with in full. This standard of insulation is also required for fan coils.
6.0 PIPE INSULATION
6.1 The following pipes shall be insulated with closed cell elastomeric rubber foam insulation with
following thickness:
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MECHANICAL SPECIFICATIONS – SECTIONS 02 EMAAR STANDARD SPECIFICATIONS (R9)
INSULATION
a) Chilled Water Pipes in Conditioned Areas:
Insulate with closed cell elastomeric foam sheet (without any coating) or chemically
cross-linked closed cell self-adhesive polyolefin reinforced by alupet foil. Thickness
of insulation shall be 19mm with 55-70 kg/m3 density for pipes up to 50mm dia.
Pipes 65mm to 200mm dia., thickness of insulation shall be 25mm, and for pipes
diameter above 200 mm insulation thickness shall be 32mm
b) Chilled Water pipes at Roof, Riser, Car Park and in Plant Room Areas (including ETS
room):
Insulate with closed cell elastomeric foam sheet without any additional coating.
Thickness of insulation shall be 25mm with 55-70 kg/m3 density for pipes up to
50mm. Apply 0.6mm aluminium cladding plain sheet on top of insulation. Roof
insulation shall be UV resistant.
Pipes 65mm diameter and above, thickness of insulation shall be 32mm.
Apply (except for riser) 0.6mm aluminium cladding plain sheet on top of insulation.
All insulated pipe work installed at roof, within plant room (up to 2.5 m height from
floor level) shall be cladded with 0.6mm thick plain aluminium sheets.
c) Refrigerant Pipework:
Insulate with closed cell elastomeric foam sheet with insulation thickness of 19mm.
For exposed pipes at roof and in unconditioned areas insulate with 25mm thickness UV
resistant insulation and apply 0.6mm aluminium cladding plain sheet.
d) AC Condensate Drain Pipework:
AC condensate drain pipes embedded in block walls shall not be insulated
Insulate with closed cell elastomeric foam sheet with insulation thickness of 13mm.
For pipes at roof insulate with 25mm thickness UV resistant insulation and apply
0.6mm aluminium cladding plain sheet.
e) Hot Water Pipework (in case of central hot water system):
Hot water pipes embedded in block walls shall not be insulated.
The hot water pipe riser (applicable for copper pipe material) shall be insulated
with performed sections of aluminium foil faced rigid fibre glass insulation, minimum
density 48 kg/m3.
Insulation thickness shall be as follows:
Pipe Size Insulation
mm thickness (mm)
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MECHANICAL SPECIFICATIONS – SECTIONS 02 EMAAR STANDARD SPECIFICATIONS (R9)
INSULATION
Up to 28 25
35 to 50 40
Above 50 50
All insulated pipe work installed at roof, within plant room (up to 2.5 m height from
floor level) shall be cladded with 0.7mm thick plain aluminium sheets.
The hot water pipe work (in PPR material) after the PRV to floor branch shall be
insulated with 19mm thick closed cell elastomeric foam insulation sheet with no
additional coating, or chemically cross-linked closed cell self-adhesive polyolefin
reinforced by alupet foil.
f) Cold Water Pipework at roof:
The cold-water pipe work at roof exposed to sun light shall be insulated with closed
cell elastomeric foam sheet with insulation thickness of 19 mm and 55-70 kg/m3
density.
For pipes at roof provide 0.6mm aluminium cladding plain sheet on top of insulation.
g) Diesel Engine Exhaust Pipe:
The Diesel engine exhaust pipe and muffler shall be insulated with 100mm thick
calcium silicate or rockwool insulation.
6.2. Pipe covering and insulation shall be manufactured by a recognized manufacturer and shall be neatly
installed to the following specifications. The general intent is to provide a sealed insulation which
will not permit sweating of the pipes and which will not retain moisture to the detriment of its
insulating capability.
6.3. The insulation, in sizes indicated shall be applied over clean, dry surfaces. Adjoining sections of
insulation should be butted firmly together with the longitudinal seam of the jacket located on the
bottom half of the pipe.
6.4. Insulate and finish valves and fittings in the same manner and same thickness as piping in which
such items are installed. Moulded, factory shaped sectional pipe covering, factory- or job-fabricated
may be used subject to satisfactory visual checking by the Consultant.
6.5. Direct contact between pipe and hanger shall be avoided. Hangers shall pass outside of the sheet
metal protection saddle, which shall cover a section of high density insulation, of sufficient length to
support the pipe without crushing the insulation. The vapour barrier shall be lapped over the saddle
and securely cemented to it. Minimum thickness of metal saddle is 1.5 mm.
6.6 Rigid rubber inserts shall be provided at the pipe supports location with thickness to be equal to the
pipe insulation thickness.
6.7 The insulation shall be installed in accordance with the manufacturer’s printed instructions.
6.8 The thermal insulation performance shall be as specified in clause 1.0
7.0 LAGGING ADHESIVE
7.1 Adhesive shall be a flexible, fire resistive, fungicidal resistant compound suitable for vapour sealing
insulated ducts and pipes.
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MECHANICAL SPECIFICATIONS – SECTIONS 02 EMAAR STANDARD SPECIFICATIONS (R9)
INSULATION
7.2 Adhesive shall be suitable for indoor and outdoor use and in high humidity environments.
7.3 Water vapour permeance shall not exceed 0.05 perms at 0.030-inch dry film thickness when tested in
compliance with ASTM F1249.
7.4 When tested for surface burning characteristics in compliance with ASTM E84, flame spread shall
be 25 and smoke developed 50.
7.5 Adhesive shall be UL classified and shall meet or exceed the requirements of NFPA 90A and 90 B
25/50.
Adhesive shall have a VOC content complying with DM requirements.
8.0 ALUMINIUM CLADDING
8.1 Aluminium cladding shall be provided to ducts with neat 90 degree joints and finish. Material shall
be with plain finish.
8.2 In pipework the longitudinal joints shall be cleated or held in position with stainless steel bands and
clips. Elbows and other fittings shall be made with mitered section and riveted. All valves strainers,
flexible connection etc. shall have easily removable boxes with stainless steel aluminium toggle
clips.
8.3 In ductwork the joints shall be riveted or banded with stainless steel band and clips to avoid sagging.
Boxes to be made around duct traverse joints.
8.4 All gaps shall be to a minimum and shall be sealed with silicon mastic suitable for outdoor.
9.0 SAMPLES
9.1 Submit samples of all types of insulation for approval. Submit pipe insulation samples 300mm long
x 25mm inside x 125mm outside diameter, and flat samples 300mm x 300mm x 2mm, minimum
size.
9.2 Submit with samples, the full technical brochures.
9.3 Where the specification calls for additional treatments, such as wrapping and waterproofing, submit
also a completed sample of similar size.
9.4 All samples after approval are to be retained on site to be a reference for future work.
END OF SECTION
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