Insulation Manual

Process Manual
Technical guidelines for the insulation of industrial installations

RTI, excellence in firesafe solutions
Rockwool Technical Insulation (RTI), a division of the international Rockwool
Group, is the world wide market leader in technical insulation. Our experts
offer you a complete range of techniques and systems for the firesafe
insulation of technical installations. In all segments of HVAC, process
industry, ship building and passive fire protection, RTI stands for a total
approach. From quality products to reliable expert advice, from
documentation to delivery and after sales service. Throughout the whole
chain from specifier, through dealer to contractor and installer we aim to add
Process Manual
value. We don’t just sell products, we supply solutions. It’s this total approach
that makes RTI the ideal choice for professionalism, innovation and trust.
All explanations correspond to our current range of knowledge and are

therefore up-to-date. The examples of use outlined in this process manual
serve only to provide a better description and do not take special
circumstances of specific cases into account. Rockwool Technical Insulation
places great value upon continuous development of products, to the extent
that we too continuously work to improve our products without prior notice.
We therefore recommend that you use the most recent edition of our
publications, as our wealth of experience and knowledge is always growing.
Should you require related information for your specific application or have
any technical queries, please contact our sales department or visit our
website rockwool-rti.com.
Rockwool is a registered trademark of Rockwool International. Rockwool Technical Insulation
RTI/11.09/gen. edit./English RTI 410

reserves the right to change the information in this brochure without prior notice.
Rockwool Technical Insulation bv

Delfstoffenweg 2 for Belgium: +32 (0)2 715 68 20 for Poland: +48 601 848 482
NL-6045 JH Roermond for Germany: +49 (0) 2043 408 606 for Czech Republic: +420 606 702 056
Tel. +31 (0) 475 35 36 18 for France: +33 (0) 1 40 77 82 11 for Slovakia: +421 903 235 027
Fax +31 (0) 475 35 36 01 for Export (Africa, Middle East, India): for Baltics: +370 69 94 33 92
www.rockwool-rti.com +31 (0) 475 35 38 35 for Switzerland: +41 81 734 11 11
Overview RTI System solutions
1.2 Piping P. 19 1.3 Insulation of vessels P. 46 1.6 Boiler P. 68
1.2.1 Insulation with pipe sections P. 26 1.2.7 Insulation of valves and flanges P. 38 1.6.1 Insulation of boilers P. 68 Contents
1 System solutions 5
1.1 Planning and preparation 7

1.2 Insulation of piping 19
1.3 Insulation of vessels 46
1.4 Insulation of columns 52
1.2.2 Insulation with load-bearing mats P. 28 1.2.8 Insulation of pipe elbows and P. 41
1.5 Insulation of storage tanks 58
T pieces 1.6 Insulation of boilers 68
1.7 Insulation of flue gas ducts 77
1.8 Cold boxes 85
2 Theory 89
1.4 Insulation of columns P. 52
1.2.3 Insulation with wired mats P. 30 1.2.9 Reducers P. 42 2.1 Norms & standards 90
2.2 Product properties & test methods 110
1.6.2 Supercritical steam generators P. 71 2.3 Bases for thermal calculations 122
3 Tables 129
3.1 Units, conversion factors and tables 130

3.2 Product properties insulation and cladding materials 142
1.2.4 Insulation Support P. 32 1.2.10 Expansion joints P. 43 3.3 Usage tables 145
4 Products 163
Rockwool 850 165

Rockwool 851 166
ProRox WM 70 168
ProRox WM 80 170
1.2.5 Cladding P. 34 1.2.11 Tracing P. 44 1.7 Insulation of flue P. 77
ProRox WM 100 172
1.5 Insulation of P. 58 gas ducts Rockwool Duraflex

Rockwool Flexiboard
174
176
storage tanks Rockwool Multiboard

Rockwool HT600
178
180
Rockwool HT660 182
Rockwool HT700 184
P. 38 P. 45 Rockwool CRS 186
1.2.6 Pipe hangers and pipe support 1.2.12 Foot traffic Rockwool 251 188
Rockwool Rocktight 190
Rockwool Loose fill 193
Rockwool Granulate 194
1.8 Cold boxes P. 85


1.8 Cold boxes 85
2 Theory 89
3 Tables 129

4 Products 163
Rockwool 850 165

Rockwool 851 166
ProRox WM 70 168
ProRox WM 80 170
ProRox WM 100 172

Rockwool Flexiboard
174
176

Rockwool HT600
178
180
Rockwool HT660 182
Rockwool HT700 184

Contents

1.6 Insulation of boilers 68
1.8 Cold boxes 85
2 Theory 89
2.1 Norms & standards 90

2.3 Bases for thermal calculations 122
3 Tables 129

3.3 Usage tables 145
4 Products 163
Rockwool 850 165

Rockwool 851 166
ProRox WM 70 168
ProRox WM 80 170
ProRox WM 100 172
Rockwool Duraflex 174
Rockwool Flexiboard 176
Rockwool Multiboard 178
Rockwool HT600 180
Rockwool HT660 182
Rockwool HT700 184
Rockwool CRS 186
Rockwool 251 188
RTI, Excellence in Firesafe Solutions
As an independent organisation within the Dear customer,
international Rockwool group, Rockwool Technical
Insulation (RTI) is the specialist in technical Rockwool Technical Insulation (RTI) is a known entity in
insulation, passive fire safety and marine the insulation market. Specialists such as yourself often
insulation. In addition to providing a complete willingly turn to our products and expertise in technical
range of stone wool products for the insulation of insulation, passive fire protection and marine insulation.
industrial plants and technical installations in We have now packaged some of that expertise into a
buildings and ships, RTI offers an extensive range new practical guide: the ‚Industrial Insulation Process
of system solutions for preventive fire protection. Manual‘.
With its excellent products, ongoing innovation
and qualified employees, RTI is a reliable and The new manual is a handy and compact instrument
expert partner which sets new standards. which is very convenient to consult. Fold-out sections
Rockwool has been successfully meeting the take you straight to the right page, whether you are
challenges of the market with entrepreneurial looking for straightforward piping insulation or for more
creativity and technical innovative strength for complex applications for columns, tanks and boilers. In
over 60 years now, which is reflected in its range addition to the many pictures and photographs, a whole
of high quality product and system solutions. range of tables and diagrams clarify the information
provided.
2
ZEICH
TE E
Keep this manual close by. It is a handy tool for the Ü
N
application of our insulation solutions in a process
environment. Should you have any further questions
E S
INRZEUGNISSE AU L
E
M
about a specific application, procedure or practical problems, ER
ALW O
L
please don’t hesitate to contact one of the RTI sales team:

for the Netherlands: +31 (0) 475 35 36 18
for Belgium: +32 (0) 2 715 68 20
for Germany: +49 (0) 2043 408 606
for France: +33 (0) 1 40 77 82 11
for Export (Africa, Middle East, India,…): +31 (0) 475 35 38 35
for Poland: +48 601 848 482
for Czech Republic: +420 606 702 056
for Slovakia: +421 903 235 027
for Baltics: +370 69 94 33 92
for Switzerland: +41 81 734 11 11
Please consult our website: www.rockwool-rti.com

Best regards
Frank Jacobs
Managing Director
Rockwool Technical Insulation Group 3
The Rockwool Technical Insulation Process Manual
Know-how for designers, site supervisors and managers of industrial plants
Energy keeps the world in motion. Without energy, eve- overview of the possible modern insulation techniques
rything would come to a standstill. The global economy for, by way of example, chemical or petrochemical
is dependent upon a secure, efficient supply of energy. installations and power stations. Based on current stan-
Over eighty percent of the energy currently being dards and regulations the manual provides accessible,
consumed however is obtained from non-renewable practical guidelines for the implementation of numerous
resources. Energy resources are becoming increasingly insulation applications.
scarce, whilst at the same time the demand for energy
is exploding. This means that owners, designers and Restriction of thermal losses to an absolute minimum,
operators of large, industrial plants are challenged with including during transfer or storage, can considerably
the task of reducing their energy consumption as much reduce the energy consumption of industrial plants. This
as possible in order to ensure the long term sustainabili- also results in a reduction in carbon dioxide (CO2) emis-
ty of their operations. sions, which are created each time fossil fuels such as
coal or gas are burnt and which, as a greenhouse gas,
The time for making excuses for poor energy efficiency is responsible for the global increase in temperature.
is past, because nowadays there are a great many
efficient insulation systems that enable scarce energy From an environmental perspective, adequate insulation
reserves to be put to the best possible use. The Rock- of industrial plants is a significant means of reducing
wool Technical Insulation Process Manual illustrates (CO2) emissions. This measure pays off in two ways,
these systems both theoretically and practically. because within the framework of the EU Emission
Trading Scheme, CO2 reduction equally signifies a
The process manual is aimed at designers, installers reduction in emission costs.
and managers of industrial plants and provides an
4
In addition, the right insulation keeps temperatures, In the “Flow of Energy” diagram on the following page,
for example in pipes and storage tanks, within strict you will find an overview of all of the sectors in which
tolerances, thereby ensuring reliable process efficien- Rockwool is active. All of RTI’s products, such as pipe
cy. At the same time, adequate insulation protects the sections, slabs, wired mats and lamella mats, as well as
plant itself. Modern insulating materials can thoroughly loose insulating wool, fulfil the highest quality and safety
protect plant components from moisture and associated standards and comply with the strictest, and therefore
corrosion. Installation and process maintenance costs safest, fire safety classes. Stone wool is non flammable
can be reduced considerably and the effective lifetime up to temperatures of approximately 1,000 ºC and
of industrial plants can be successfully maximised. therefore provides a crucial contribution towards passive
fire protection.
Furthermore, industrial insulation also provides a
significant contribution to personal protection. Optimum As a supplement to this process manual, RTI also
insulation reduces process temperatures and noise in regularly makes information about technical innovations,
the industrial environment to an acceptable level, to the product solutions and recent and relevant documents
limits generally regarded in the industry to be those re- available online at www.rockwool-rti.com. The process
quired for a safe and comfortable working environment. manual is a guideline and can only provide general
advice for specific instances in the field of plant and pro-
With a complete range of techniques and insulation cesses. For these instances, RTI’s insulation experts are
systems, Rockwool Technical Insulation (RTI) offers available to provide advice during the design, enginee- RTI, Flow Of Energy 
designers and construction supervisors optimum tailored ring and implementation phases. Please find our contact
solutions for the petrochemical, energy, ship building details on the back cover of this manual.
and processing industries.
5
RTI, Flow Of Energy Exp
lora
tion
, dr
illin
ga
nd
pro
duc
tion
Waste
Coal
Gas
Pro
ces
Oil sing
ind
ust
ry
Power Plant
Gas Processing
Con
sum
ptio
n
Petroleum Refining Processing
Industrial
Non-residential
Residential
Petrochemicals Marine & Offshore
Rockwool Group Business Areas: End Products
Insulation for industry:

Solutions for energy saving, to optimize
production processes and sound attenuation
Conlit Fire Protection:

Solutions for passive fire protection of wall penetrations, air
ducts, cable penetrations and structural steel constructions
Insulation of technical installation in buildings:

Technical insulation that focuses on the core of buildings.
Solutions for passive fire protection with key applications
like insulation for pipe penetrations, ventilation ducts and
steel structures.
Insulation for shipbuilding and off-shore:

Products for thermal and acoustic insulations. Passive fire
protection for bulkheads and decks.
Insulation for buildings
(residential, commercial, public, industry)
Thermal and acoustic insulations.
4
1
System solutions
1. System solutions
Table of contents
1.1.1 Decision criteria for the design of an insulation system 7

A. Functional requirements 8
B. Safety aspects 12
C. Economics 13
D. Environmental 14
E. Corrosion prevention 14
1.1.2 Design & planning of the insulation work 15
1.1.3 Corrosion prevention 15
1.1.4 Storage of insulation materials 18
1.2.1 Insulation with pipe sections 26

1.2.2 Insulation with load‑bearing mats 28
1.2.3 Insulation with wired mats 30
1.2.4 Insulation support 32
1.2.5 Cladding 34
1.2.6 Pipe hangers and pipe supports 38
1.2.7 Insulation of valves and flanges 39
1.2.8 Insulation of pipe elbows and T pieces 41
1.2.9 Reducers 42
1.2.10 Expansion joints 43
1.2.11 Tracing 44
1.2.12 Foot traffic 45
1.6 Insulation of boilers 68
1.6.1 Insulation of fire tube boilers 68

1.6.2 Supercritical steam generators 71
1.7.1 Installation of the insulation systems for flue gas ducts 77

1.7.2 Cladding of flue gas ducts 81
1.7.3 Acoustic insulation of flue gas ducts 84
1.8 Cold boxes 85

Planning and
preparation
1. System solutions
1.1 Planning and preparation

The design of a suitable insulation system for technical 1.1.1. Decision criteria for the design of
installations is a major factor for its economical an insulation system
operation, functionality, security, durability and Selecting a suitable insulation system depends on the
environmental impact. Additionally, the installation- following four parameters:
specific heat losses are specified for the entire life
cycle of the plant. Corrections at a later stage, such as • A. Functional requirements
subsequently increasing the thickness of the insulation, a. Object dimensions
for example, may no longer be possible due to lack of b. Method of operating the installation
space. Corrections at a later stage may also entail a far c. Operating temperatures
greater investment compared to the original planning. d. Permissible heat losses or temperature changes
Continually rising energy costs are also often overlooked of the medium
factors when dimensioning the insulation. Insulation e. Frost protection
thicknesses that are designed to last take energy price f. Ambient conditions
increases into account. They form an important g. Maintenance and inspection
criterion for the economical operation of the installation • B. Safety aspects
after just a few years. a. Personal protection
b. Fire protection
We have an obligation to future generations to treat our c. Explosion prevention
environment with care. Correctly dimensioned d. Noise reduction within the plant
insulation systems constitute an important contribution • C. Economics
to environmental protection, carbon dioxide (CO2) a. Economical insulation thickness
reduction and to economic success, because: CO2 b. Pay-back time
reduction is also an economical operation, as it lowers • D. Environment
the costs for CO2 emission certificates. • E. Corrosion prevention
Nowadays, conservational and economical operations
are no longer conflicting ideas, but on the contrary,
they are two inseparable parameters.
7
A. Functional requirements
a) Object dimensions
The space requirements of the insulation must be taken
into account when the installation is being designed
and planned. Therefore, the insulation thicknesses
should be determined in the early planning stages and
the distances between the individual objects should be
taken into account in the piping isometrics. To
guarantee systematic installation of the insulation
materials and the cladding without increased expense,
observe the minimum distances between the objects
as specified in the following illustrations.
Minimum distances between vessels and columns (dimensions in mm)
8
Planning and
preparation
Minimum distances between insulated pipes (dimensions in mm)
Minimum distances within range of pipe flanges (dimensions in mm)
a = distance flange to normal insulation

a ≥ 50 mm
x = bolt length + 30 mm
s = insulation thickness
9
A. Functional requirements
b) Operation of the installation according to these requirements. Under extreme
To select a suitable insulation system, the operating conditions (for example, lengthy periods of storage,
method of the installation must be considered. A basic long transport routes or extreme temperatures),
distinction is made between continuous and interrupted installing tracing may be necessary, to ensure that the
operation. With continuous operation, the operating media is kept within the required temperature limits.
temperatures are constantly above or constantly below
the ambient temperatures. The interrupted operating Use “Rockassist”, a thermo-technical engineering
method, also referred to as intermittent or batch calculation program, to ensure the optimum
operation, is characterised by the fact that the engineering and design of these insulations. Please
installation is switched off between each operating visit www.rockassist.com or the rockwool-rti.com
phase and during that time can assume ambient website for consulting the Rockassist program on line.
temperatures. For special applications, so called
dual temperature systems, the operating temperature
alternates between above or below the ambient
temperature.
c) Operating temperature
The appropriate insulation material should be resistant
to the intended operating/peak temperatures.
This product property is assessed by the maximum
service temperature (also see Chapter 2.3 “Product
properties”).
Inside buildings, uninsulated or poorly insulated parts
d) Permissible heat losses or temperature changes of installations can heat the room climate unnecessarily.
of the medium This leads to higher room temperatures, which can
With many technical processes, it is essential that have a negative effect on the working environment -
media in vessels, columns or tanks do not fall below a both for the people who work long hours under these
specific lower temperature limit, otherwise chemical conditions and for the electronic components. In
processes will not proceed as intended or the media will addition to the increased heat losses, further energy
set and can no longer be pumped or extracted. consumption is required to air condition the rooms.
Over-cooling can lead to the precipitation of, for The design of the insulation and the related reductions
example, sulphuric acid in exhaust and flue gas in terms of heat losses from parts of installations should
streams, which furthers corrosion in the pipes or be relevant to the entire infrastructure and use of the
channels. building.
With flowing media, it is essential to ensure that the
temperature of the medium is still at the desired level at
the end of the pipe. The thermal insulation is designed
10
Planning and
preparation
e) Frost protection thermal conductivity and the risk of corrosion of the
Installations that are situated outside are at risk from insulated installation components.
frost in the winter. In addition to the undesirable Cladding must be installed to prevent the ingress of
malfunctioning of installations, installations also risk moisture into the system. However, with installations
damage caused by the expansion of frozen water. situated outside with operating temperatures < 120 °C
Adequate measures – so called frost protection - must or with installations operating intermittently, there is a
be taken to protect the installation from freezing. high risk of moisture accumulation. This is caused by
Insulation can reduce heat losses and postpone the moisture condensing from the ambient air inside the
moment at which the installation freezes. Insulation cladding.
alone, however, cannot indefinitely prevent the For this reason, retain an air space of at least 15 mm
installation from freezing. Installing additional tracing between the insulation and the cladding. In addition,
may be necessary between the object and the insulation. drainage and ventilation holes of minimum 10 mm
To prevent freezing, the insulation must be designed so diameter and at intervals of maximum 300 mm should
that the density of heat flow rate of the insulated object be provided on the underside or at the lowest point of
is less than the heat conducted by the tracing. the cladding. If necessary, the insulation and cladding
must resist chemical influences that develop within the
environment.
g) Maintenance and inspection

To avoid complicating routine maintenance and
inspection work unnecessarily with the insulation,
maintenance-intensive areas must be taken into
account, especially when designing the insulation work.
Removable insulation systems, such as removable
coverings and hoods, could be fitted in such areas, for
example. Easily removable covering systems are also
recommended for flanges and pipe fittings. These
coverings are generally fastened with quick-release
clamps, which can be opened without special tools.
f) Ambient conditions The insulation of fixtures such as flanges or pipe fittings
Select an insulation system that offers long-lasting must be interrupted at a sufficient distance to allow
resistance to the surrounding environment. installation or dismounting to be carried out. In this
• Atmospheric influences: wind, rain case, take the bolt length at flange connections into
• Mechanical loads such as vibrations or foot traffic consideration. The connection of the insulation should
• Corrosive environment (close to the sea, have an extremity and any fixtures in the range of the
chemicals,…) insulation, including the interruption in the installation,
should be insulated with removable coverings.
Prevent the ingress of moisture into the insulation
system. Moisture accumulation in insulation increases
11
achieved by insulation, apply additional protective

devices, such as safety guards or enclosement of
the object.
b) Fire protection
The general fire protection requirements imposed on
structural installations are usually defined within the
local Building Codes or the specifications of plant
owner. Structural installations must be designed, built,
modified and maintained to prevent the outbreak of a
fire and the 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 to determine the
B. Safety aspects nature and scope of the fire prevention measures
a) Personal protection together with the building supervisory board, the fire
Surface temperatures in excess of 60 °C can lead to brigade, insurance companies and the operator.
skin burns, if the surface is touched. Therefore, all
accessible installation components should be designed As a basic principle, consider the fact that the fire load
to prevent people being exposed to the risk of injury by in a building or technical installation can be consider-
burns. The insulation applied to such plant components ably increased by flammable insulation materials. On
must ensure that surface temperatures in excess of the other hand, non-flammable insulation materials
60 °C do not occur during operation. Use the Rockwool such as mineral wool, which has a melting point of
Thermo-technical engineering program “Rockassist” to > 1,000 °C, not only have a positive impact on the fire
calculate the required insulation thickness. All of the load, but in the event of a fire, also constitute a certain
operational parameters must be known to achieve a fire protection for the installation component.
reliable design, including, for example, the temperature
of the object, the ambient temperature, air movement, Installation components with tracing, in particular,
surface materials, distance from other objects, etc. which use thermal oil as a heat transfer medium, have
an increased risk of catching fire in the event of a leak.
Note In this case, ensure that the thermal oil cannot
As the surface temperature depends on a set of penetrate into the insulation material.
physical parameters, which cannot always be
calculated or estimated with any degree of certainty, c) Explosion prevention
the surface temperature is not a guaranteed If there is a risk of fire and explosion, the surface
measurement. Also refer to Technical Letter No. 5 temperature of the object and the cladding must be
of the German BFA WKSB “The problem of considerably lower than the ignition temperature of the
guaranteeing surface temperatures”. flammable substance and/or gas mixtures. This
If the required protection (temperature) cannot be requirement also applies to thermal bridges, such as
12
Planning and
preparation
pipe mounting supports, supporting structures and C. Economics
spacers etc. In the industry there are two grades of insulation. The
With regard to insulation systems, explosion protection first grade focuses on reducing heat losses and the
can only be achieved with a doubleskin covering. A prevention of injuries to people operating or working
doubleskin covering is a factory made cladding that has nearby the installations. The second grade of insulation,
been welded or soldered to make it air proof and the so called “economical insulation thickness” focuses
diffusion-resistant. In addition special (local) explosion on significant heat loss reduction and as a result
regulations must be observed. achieving a better return on investment.
a) Economical insulation thickness

Insulation reduces the heat losses from the object.
The thicker the insulation, the greater the heat
reduction and consequently, the more energy is saved.
However, the investment and expenditure, e.g. for
depreciation, interest rates and higher maintenance
costs also rise if the insulation thickness is increased.
At a certain insulation thickness, the sum of the two
cost flows reaches a minimum. This value is known as
the economical insulation thickness. A qualitative curve
of a similar costs function is shown below.
In many cases (e.g. the German Guideline ZH 1/200) The German VDI guideline 2055 describes in detail
electro statically charged substances, such as various calculation methods used to determine the
unearthed cladding or non-conductive plastics, are economical insulation thickness.
used in explosive areas, “static electricity” must be
Costs
earthed.
Economical
d) Noise protection
insulation
The guidelines for noise in the ordinance and thickness
Total costs
workplace are stated in the local regulations and
standards. Generally, the level of the guideline values
depends on the nature of the activity, such as:
• ARAB (Belgium) Insulation costs
• ARBO (Netherlands) Heat loss costs
• Code du travail (France) Insulation thickness
The sound propagation of installation components can

be reduced using insulation systems. The nature and
effect of the sound insulation depend on the frequency
and the sound pressure level.
13
C. Economics
The energy costs cannot be based solely on the current The increasing CO2 concentration in the Earth’s
price. Developments over recent years indicate that atmosphere plays a significant part in the global
substantial increases in energy prices are also increase in temperature, also referred to as the
anticipated for the future. Increasing energy prices are “greenhouse effect”. CO2 absorbs the thermal radiation
tending to bring about a shift in economic insulation emanating from the earth’s surface and in doing so
thicknesses towards larger thicknesses. reduces the dissipation of heat into space. This will lead
to a change in the world’s climate with as yet
b) Pay-back time inestimable consequences. Reducing CO2 emission can
In addition to the economical insulation thickness, only be achieved through more efficient management of
another frequently used economical parameter is the fossil fuels.
return on investment period (ROI), also referred to as
the payback period. This is defined as the period within Increasing the insulation thicknesses is essential for the
which the cost of the insulation is recuperated through reduction of CO2 emissions. Also refer to the Technical
savings on heat loss costs. Letter No. 6 of the German BFA WKSB “High rate of
return on environmentally friendly insulation layer
Costs of the insulation thicknesses”.
ROI period = [a]
annual saving
Reducing CO2 emissions also has a positive financial
In the case of technical insulation systems, the return benefit for businesses within the context of the EU
on investment period is generally very short, often being emissions trading scheme. The benefits of increased
much less than one year. Considering only the return
on investment period, however, can be deceptive, as
this approach disregards the service life of the
installation. With long-life installations, it is advisable to
select higher insulation thicknesses, even if this means
accepting a longer return on investment period.
Throughout the entire service life of the installation
however, the increased insulation thickness results in a
significantly higher return on the investment in
insulation and achieves a much more economic
operation of the installation.
insulation thicknesses in technical installations are
D. Environmental twofold, as the costs for both energy consumption and
The burning of fossil fuels, such as coal, oil or gas, not CO2 emissions are decreased.
only depletes the available primary energy sources, but
also, due to the emission of carbon dioxide (CO2) into E. Corrosion Prevention
the atmosphere, places a burden on the environment. See chapter 1.1.3
14
Planning and
preparation
1.1.2 Design & planning of the 1.1.3 Corrosion prevention
insulation work National economies are damaged to a great extent due
Requirements with regard to the later insulation works to the lack of, or inadequate forms of, protection against
must already be included in the design and construc- corrosion. This considerably reduces the service life of
tion phase of industrial plants. It is therefore advisable industrial plants, and more frequently, essential
to involve all project managers at an early stage, to shutdown or overhaul work impairs the efficiency of the
preclude unnecessary and unprecedented problems installation.
during the insulation works from the outset. It is commonly, but wrongly, assumed that the
insulation system also protects an installation against
All preparatory works must be completed according to corrosion. For each installation it must be determined
the relevant insulation standards such as DIN 4140, whether protection against corrosion is required and, if
AGI Q05 and the CINI manual. The following so, which are the appropriate measures.
preconditions must be fulfilled:
• If necessary, work has been carried out on the object Generally, the design of the insulation system &
to protect against corrosion corrosion protection will depend on the following
• Tracing and technical measurement equipment have parameters.
been installed • Operation of the installation
• The minimum distance between the objects has - Continuous operation
been observed (see illustrations on pages 8 and 9) - Interrupted/intermittent operation
• The surface displays no coarse impurities - Operation involving varying temperatures
• Mounting supports have been installed on the object • Operating temperatures of the installation
to accommodate the support structure (For details • Metals used
see Worksheet AGI Q153) - Non-alloy or low-alloy steel
• Collars and sealing discs have been fitted to the - Austenitic stainless steel
object (For details see Worksheet AGI Q152) - Copper
• Taps on the object are long enough to ensure that • External influences upon the installation
flanges lie outside the insulation and can be screwed - Internal/external
on without hindrance - Environment of the installation (chemically
• Supports are designed so that insulation, water aggressive?)
vapour retarders and cladding can be professionally
installed The best practices may vary per country and/or
• The insulation can be applied without any obstacles standard. The design of the corrosion protection is often
(e.g. by scaffolding) carried out in accordance with EN ISO 12944-1 to 7
• Welding and bonding work has been carried out on “Coating materials – Protection against the corrosion of
the object steelwork by means of coating systems”. However,
• The foundations have been completed since this standard does not adequately take into
account the specific features of protecting against
corrosion in insulation systems, the requirements of
15
1.1.3 Corrosion prevention

AGI Q151 “Protection against corrosion in the case of CINI Manual “Insulation for industries”
hot and cold insulation in industrial plants” must also CINI recommends applying corrosion protection prior to
be considered. the insulation work at any time.
• In all phases, pay attention to CUI (corrosion under
DIN 4140 insulation) prevention: design, construction, paint &
DIN 4140 states the following advice relating to coating work, application of the insulation system,
protection against corrosion: inspection and maintenance. Equipment and piping
• In the case of cold insulation, if the object is made of sections like nozzles and supports etc. should be
non-alloy or low alloy steel, it must be protected designed and maintained to prevent ingress of water
against corrosion. into the insulation system.
• In the case of objects made, for example, of • The “paint” specifications are split up into:
austenitic stainless steel or copper, the installation - Construction material (carbon steel, stainless steel)
must be tested in each individual case by the - Temperature ranges from minus 30 °C to 540 °C)
planner to determine whether protection against with special attention to the temperature range
corrosion is necessary. between -20 °C and 150 °C.
• Objects made from austenitic stainless steel do not • The corrosion protection can be achieved using
require protection against corrosion if the tempera- aluminium foil wrapping, thermal sprayed aluminium
ture never – even for a short period – exceeds 50 °C (so called TSA) or paint.
Note Protection against corrosion may be omitted in the case

Protection against corrosion should be applied in the of installations operating continuously under extremely
case of all installations made from non-alloy or cold conditions (< -30 °C)
low-alloy steel where the operating temperatures are
below 120 °C. Protection against corrosion may be Application
omitted in the case of: Before applying the corrosion protection coating with the
• Installations operating continuously under most layers, the surface must be free from grease, dust
extremely cold conditions (below -50 °C) such and acid and, for better adhesion, the priming coat
storage tanks, as well as should be roughened. Blasting is recommended as a
• Insulated surfaces of power plant components, such surface preparation method (with austenitic stainless
as boiler pressure components, flue gas and hot air steel, use a ferrite free blasting abrasive).
ducts and steam pipe systems with operating Observe the corresponding processing guidelines of the
temperatures that are constantly above 120 °C. coating manufacturer. If metals with different
electrochemical potentials, such as aluminium and
copper, come into contact with one another, there is a
risk of electrochemical corrosion. If necessary, this can
be avoided using insulating, intermediate layers such as
non-metallic straps. The presence of moisture will
increase the development of electrochemical corrosion.
16
Planning and
preparation
The table further on this page, which has been derived
from the standard DIN 4140, indicates the initial risks of
electrochemical corrosion in cases where various
combinations of metals are used.
Material Combination material

Austenitic
Surface ratio in proportion Zinc Aluminium Ferritic Lead Copper
Metal stainless
to combination material steel
steel
Small - M M H H H
Zinc
Large - L L L L L
Small L - L H H H
Aluminium
Large L - L M L H
Small L L - H H L
Ferritic steel
Large L L - L L L
Small L L L - H H
Lead
Large L L L - M M
Austenitic Small L L L L - M
stainless steel Large L L L L - L
Small L L L L L -
Copper
Large L L L L L -
L - Light or little corrosion to material

M - Moderate corrosion to material, for example, in very humid atmospheres
H - 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 in proportion to the
combination material”.
Example 1: Material is a zinc galvanised 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 galvanised with combination
material zinc: Row “austenitic stainless steel large”. “L” – the corrosive attack upon the austenitic steel is light.
Note
The table does not take into account forms of
corrosion with other root causes, such as stress
corrosion. For further information, see Chapter 2.3
“Product properties” – AS-quality.
17
1.1.4 Storage of insulation materials

Incorrect storage of insulation materials outdoors can –
mainly due to moisture – cause the insulation to
deteriorate. Moisture in insulation materials has the
following negative influences. The thermal conductivity
of water is approximately 25 times greater than that of
air, which is present in cells or between the fibres in
insulation. An increase in moisture therefore results in
an increase in the thermal conductivity of the insulation
and, correspondingly, a decrease in the insulation
efficiency. Even a moisture content of 1 % can result in
an increase of thermal conductivity by 25 %. A higher
moisture also means a significantly higher weight,
which, as a rule, is not taken into account in the static
design of an insulation system. Moisture causes many
types of corrosion that virtually never develop in a dry
system. The major types of corrosion in relation to
insulation technology are oxygen, electrochemical and
stress corrosion. Insulation materials for austenitic
components, which in stainless steel quality are
manufactured with a low chloride ion content,
irrecoverably lose this property when moisture is
introduced. Insulation materials must be protected
against moisture when stored, during installation and
when fitted. If storage in a closed structure is
impossible, protect the insulation material from weather
influences by covering it with waterproof material.
Ensure the insulation is not in direct contact with
the floor; otherwise it may become wet as a result of
ground moisture.
18
1. System solutions
1.2 Insulation of piping
Insulation
of piping
Piping plays a central role in many industrial processes in
chemical or petrochemical installations such as power
plants, as it connects core components such as
appliances, columns, vessels, boilers, turbines etc.
with one another and facilitates the flow of materials
and energy. To guarantee a correct process cycle, the
condition of the media within the pipes must remain within
the set limitations (e.g. temperature, viscosity, pressure,
etc.). In addition to the correct isometric construction and
fastening of the piping, the piping insulation also has an
important function. It must ensure that heat losses are Rockwool Products for pipe insulation
effectively reduced and that the installation continues to Rockwool Technical Insulation (RTI) offers a wide range
operate economically and functionally on a permanent of products for pipe insulation in industrial plants.
basis. This is the only way to guarantee the maximum Pre-formed pipe sections such as the Rockwool 850,
efficiency of the process cycle throughout the design load bearing mats such as Rockwool Duraflex, as well
service life without losses as a result of faults. as various wired mats such as ProRox WM 70 and WM
100 were developed with this specific field of
Requirements for industrial piping application in mind. All these products are easy to
The basic efficiency and productivity factors of piping for install and contribute to a high level of efficiency,
the processing industry include energy efficiency, functionality and reduced heat losses. Continuous
dependability and reliability under different conditions, internal and external inspection and high levels of
in addition to the functionality of the process control, quality assurance ensure the consistently high quality
an appropriate structure that is suitable for the operating of all RTI products.
environment, as well as mechanical durability. The
thermal insulation of piping plays a significant role in The examples of use below cannot fully take into
fulfilling these requirements. account the particular circumstances of the construc-
tion-related factors. Determine whether the products
Thermal insulation are suitable for the corresponding application in each
The functions of proper thermal insulation for piping individual case. If in doubt, consult the RTI Experts.
include:
• Reduction of heat losses (cost savings) The applicable standards and regulations must also be
• Reduction of CO2 emissions observed. A few examples follow:
• Frost protection • DIN 4140 (Insulation works on technical industrial
• Process control: ensuring the stability of the process plants and in technical facility equipment)
temperature • AGI Q101 (Insulation works on power plant
• Noise reduction components)
• Condensation prevention • CINI-Manual “Insulation for industries”
• (Personal) protection against high temperatures
19
Hot insulation systems

Principally, a thermal insulation structure for piping Using pipe sections for the insulation of pipes results in
consists of an appropriate insulating material, usually considerably reduced installation time and costs. The
covered by sheet metal cladding. This protects the object lack of spacers and “unforeseen” gaps minimises heat
and the insulation from external influences such as the losses and the risk of personal injuries due to hot spots
weather of mechanical loads. Spacers are also essential on the cladding. At temperatures above 300 °C, the
with insulation such as wired mats, which do not offer provisional application of spacers must be determined
sufficient resistance to pressure to hold the weight of in each individual case.
the cladding and other external loads. These spacers
transfer the cladding loads directly onto the object. In Pipe sections are always precisely tailored to the
the case of vertical piping, support structures are fitted corresponding pipe diameter to minimise the risk of
to take on the loads of the insulation and the cladding. convection and processing defects. Rockwool pipe
In general, support structures and spacers form thermal sections are available in diameters of 17 to 915 mm.
bridges.
Selecting a suitable insulation system depends on

numerous parameters. These are described in greater
detail in Chapter 1.1. Regarding the different forms of
piping insulation, a fundamental distinction can be
drawn between the following insulation systems.
Insulation with pipe sections

Generally, the best insulation is achieved using
Rockwool pipe sections. The sections can be used up
to temperatures of 620°C. They are supplied ready split
and hinged for quick and easy snap-on assembly and
are suitable for thermal and acoustical insulation of
industrial pipe work. Due to their excellent fit and high
compression resistance pipe sections can often be
applied in a single layer without any additional spacers.
If multiple layers are required, Rockwool Technical
Insulation can also supply double layered - so called
‘nested’ - pipe sections. This reduces installation costs
considerably. Also the number of thermal bridges,
which have a negative influence on the insulation, is
greatly reduced, while a lower thickness may be applied
compared to wired mats.
20
Insulation with load-bearing mats Insulation with wired mats
Insulation
of piping
Load bearing mats, such as Rockwool Duraflex, are the Wired Mats, such as ProRox WM 70, are lightly bonded
latest development in the insulation sector. Rockwool stone wool mats, usually stitched with galvanized wire
Duraflex is a stone wool insulation mat (with a special onto a galvanized wire mesh.
fibre structure) bonded onto fibreglass reinforced
aluminium foil. The flexible application makes the mats Pipe insulation with wired mats has been a time-tested
easy to cut. Typical applications include: universal solution for many decades now. Due to their
• pipe diameters ≥ DN 350, or; flexibility and high temperature resistance, wired mats
• piping with a high number of shaped pieces such as can be easily cut and mounted onto the piping. These
elbows or T-joints. wired mats are ideal for application in situations where
the use of pipe sections or load bearing mats is difficult
Rockwool Duraflex can be applied up to temperatures or impossible:
of 300 °C. Their high compression resistance means, • temperatures above 300 °C
that in many cases, load bearing mats can be applied • pipe diameters ≥ DN 350,
without any additional spacers. Consequently the • piping with a high number of shaped pieces such as
number of thermal bridges, which have a negative elbows or T-joints.
influence on the insulation, is greatly reduced.
Wired mats have a relatively low resistance to pressure
The result is considerably reduced installation time and and from a practical point of view should only be
costs. The lack of spacers and “unforeseen” gaps mounted in combination with spacers or support
minimises heat losses and the risk of personal injuries structures. Because of the resulting thermal bridges,
due to hot spots on the cladding. better insulation performances are often achieved in the
Load-bearing mats are tailored to the corresponding lower and middle temperature range (up to 300 °C)
length of the pipe circumference on site and are with pipe sections or load bearing mats rather than with
fastened with clamps. wired mats.
21
Comparison of the different insulation systems

The particular advantage of pipe sections and • Both products offer an even, firm surface for
load-bearing mats lies in the fact that support installing the sheet cladding
structures are not required and therefore thermal • The lack of spacers gives rise to lower heat losses.
bridges caused by the insulation are minimised or • It yields an even surface temperature across the
removed. On the other hand, wired mat systems have sheet cladding.
their advantages due to their maximum service • In comparison to wired mats, a more shallow
temperature in the case of hot face insulation. insulation thickness can be applied. The operating
costs of the installation decrease as a result of lower
The advantages of pipe sections and load-bearing mats heat losses.
at a glance are:
• I t is not necessary to install spacers or support Generally speaking, a spacer or support structure
structures. functions as a thermal bridge, as a result of which the
•T
he pipe sections and load bearing mats, such as heat loss in the total insulation is increased
Rockwool Duraflex, are applied more quickly without considerably.
the interference of spacers.
Insulation system with a spacer ring
1. Pipe - 2. Insulation: ProRox WM - Wired Mats - 3. Cladding -

4. Spacer ring
Insulation system without a spacer ring
1. Pipe - 2. Insulation: Rockwool 850 - Pipe Sections or

Rockwool Duraflex - 3. Cladding
22
Required insulation thicknesses
If the three insulation systems are compared, taking
Insulation
of piping
into consideration similar heat losses, clear advantages
are seen with regard to the insulation thicknesses with
systems using Rockwool 850 pipe sections and
Rockwool Duraflex load-bearing mats. These do not use
spacers, in contrast to insulation systems made using
wired mats. The table below shows the required
insulation thicknesses taking into account the following
boundary conditions:
• Medium temperature: 250 °C
• Ambient temperature: 10 °C
• Wind speed: 5 m/s
• Cladding: Aluminium-zinc
• Heat loss: 150 W/m
• Application of spacers in the case of wired mats
Minimum insulation thickness

Pipe sections Load bearing mats Wired mats
Nominal diameter Ø NPS Pipe diameter Rockwool 850 Rockwool Duraflex ProRox WM 70
DN (inch) mm
50 2 60 30 n.a. n.a.
80 3 89 30 n.a. n.a.
100 4 108 40 n.a. n.a.
150 6 159 60 n.a. n.a.
200 8 219 70 100 120
250 10 273 90 130 150
300 12 324 100 140 (2*70) 180 (2*90)
350 14 356 110 160 (2*80) 200 (2*100)
Multiple layer insulation n.a. = not applicable
23
Selection of pipe insulation systems

Generally, the best insulation is achieved using Rockwool Generally speaking, a spacer or support structure
pipe sections. The sections are quick and easy to install. functions as a thermal bridge, as a result of which the
Their excellent fit and high compression resistance heat loss in the total insulation is increased considerably.
means pipe sections can be applied in a single layer
without any additional spacers. They also have a lower The design of an insulation system depends upon many
insulation thickness. factors such as the dimensions, mechanical loads, safety
Load bearing mats, such as Rockwool Duraflex, are aspects, economics, etc. Consequently this also requires
usually applied for the insulation of large pipe diametres a considered selection of the insulation material. Use the
and shaped pieces like elbows and T-joints. Generally, application matrix on the next page as a guide.
wired mats such as ProRox WM are applied within the
higher temperature range (T > 300 °C).
Comparison
Pipe sections and load-bearing mats offer the
advantage that spacers are generally not required.
• Pipe sections and load-bearing mats are applied
more quickly without the interference of spacers.
• Both products offer an even, firm surface for
installing the cladding.
• The lack of spacers creates lower heat losses
• 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, the operational costs of the
installation decrease as a result of lower heat losses.
24
Load bearing
Pipe sections Wired mats
mats
Insulation
of piping
Application Temperature Rockwool 850 Rockwool ProRox WM 70 ProRox WM 100
(°C) Duraflex
< 300 °C
Piping 300 °C - 580 °C
> 580 °C
< 300 °C
Short sections,
(many) elbows, 300 °C - 580 °C
valves, flanges
580 °C - 680 °C
Piping with tracing
City heating D ≤ 356 mm

pipes D > 356 mm
Note: = most optimal product
25
1.2.1 Insulation with pipe sections Note

Generally, the best insulation is achieved using Due to their low thermal conductivity, better thermal
Rockwool pipe sections. The sections can be used up insulation values can be achieved with pipe sections
to temperatures of 620 °C. They are supplied ready than, for example, with wired mats. With insulation
split and hinged for quick and easy snap-on assembly on straight pipe sections, a combination of both
and are suitable for thermal and acoustic insulation of products in the same insulation thickness is
industrial pipe work. Their excellent fit and high therefore not advisable. If this combination is
compression resistance means pipe sections can be essential, for example, in the case of bends or
applied in a single layer without any additional spacers shaped pieces, it is vital to select the correct
or support structures. Consequently the number of insulation thickness. This is the only way to
thermal bridges, which have a negative influence on the guarantee that no unexpected, potentially hazardous
insulation, is greatly reduced, while a low thickness may surface temperatures occur.
be applied compared to wired mats.The result is
considerably reduced installation time and costs. The Insulation thicknesses to guarantee protection
lack of spacers and “unforeseen” gaps minimises heat against contact
losses and the risk of personal injuries due to hot spots The table below is an initial guide to help select suitable
on the cladding . insulation thicknesses for the guards. It is based on the
following boundary conditions:
At temperatures above 300 °C, the provisional • Ambient temperature: 25 °C
application of spacers must be determined in each • Wind speed: 0.5 m/s
individual case. Rockwool pipe sections are available in • Cladding: galvanised steel bright
a wide range of diameters, ranging from 17 to 915 mm. • Maximum surface temperature: 60 °C
• Insulation: Rockwool 850 pipe sections
External diameter Temperature of the medium (°C)

Nominal NPS (mm) ≤100 150 200 250 300 350 400 450 500
diameter Ø (inch)
DN
25 1 33,0 30 30 30 30 30 40 50 70 80
50 2 60,3 30 30 30 30 40 50 70 80 100
80 3 88,9 30 30 30 40 50 60 80 90 110
100 4 114,3 30 30 30 40 50 70 80 100 120
150 6 168,3 30 30 30 50 60 80 90 120 140
200 8 219,1 30 30 40 50 70 80 100 120 150
250 10 273,0 30 30 40 50 70 90 110 130 160
300 12 323,9 30 30 40 50 70 90 110 140 160
Multiple layer insulation
In the event of differing boundary conditions, please contact the RTI sales team. The thermo‑technical engineering program
“Rockassist” can be used to design the insulation according to the specific requirements.
26
Installation Support structures and spacers
Insulation
of piping
Before starting the insulation works, ensure that all Spacers are not generally essential in insulation
preparatory work on the object has been completed. systems with pipe sections. With pipes that are exposed
Refer to Chapter 1.1 for details. to large mechanical loads (e.g. strong vibrations) and/or
temperatures above 300 °C, determine whether a
The Rockwool 850 pipe section is mounted directly spacer ring is required in each individual case
onto the pipe to form a close fit. With horizontal pipes,
the lengthwise joint of the pipe section should be With pipes that have been installed vertically, with a
turned towards the underside at the 6 o’clock position. height in excess of four metres, fit support structures to
With vertical pipes, the lengthwise joints should be transfer the dead load of the insulation system onto the
staggered at an angle of 30 ° to one another. Secure the pipe. Attach the first support ring to the lowest point of
pipe sections with galvanised binding wire or with steel the vertical pipe. The distance between the support
bands. With an insulation thickness exceeding 120 mm rings should not exceed approximately four metres.
(or temperatures > 300 °C), install the insulation in at
least two layers. If the insulation is assembled in
multiple layers, the joints of the individual insulation
layers must be staggered.
1. Pipe - 2. Insulation: Rockwool 850 Pipe Sections -

3. Clamp or binding wire - 4. Sheet cladding - 5. Sheet-metal
screw or rivet
27
1.2.2 Insulation with load‑bearing mats

Load bearing mats (such as Rockwool Duraflex) are the The result is considerably reduced installation time and
latest development in the insulation business. Rockwool costs. The lack of spacers minimises heat losses and
Duraflex is a stone wool insulation mat (with a special the risk of personal injuries caused by hot spots on the
fibre structure) bonded onto fibreglass reinforced cladding. Load-bearing lamella mats are precisely
aluminium foil. The flexible application makes the mats tailored to the corresponding length of the pipe
easy to cut. Load bearing mats are ideal for application circumference on site and are fastened with clamps.
as pipe insulation in situations where the use of pipe
sections is difficult. For instance where pipe diameters Insulation thicknesses to guarantee protection
≥ DN 350, or in case of a high number of shaped against contact
pieces such as elbows or T-joints. The table below is an initial guide to help select suitable
insulation thicknesses for the guards. It is based on the
Rockwool Duraflex can be applied up to temperatures following boundary conditions:
of 300 °C. Due to the high compression resistance, load • Ambient temperature: 25 °C
bearing mats can be applied without additional spacers • Wind speed: 0.5 m/s
in many cases. Consequently, the number of thermal • Cladding: galvanised steel bright
bridges which have a negative influence on the • Maximum surface temperature: 60 °C
insulation, is greatly reduced. • Insulation: Rockwool Duraflex
External diameter Temperature of the medium (°C)

Nominal NPS (inch) (mm) ≤100 150 200 250 300
diameter Ø
DN
200 8 219,1 30 30 40 60 80
250 10 273,0 30 30 40 60 80
300 12 323,9 30 30 50 70 90
400 16 406,4 30 30 50 70 90
500 20 508,0 30 30 50 70 100
In the event of differing boundary conditions, please contact the RTI sales team. The thermo technical engineering program
28
Installation Support structures and spacers
Before starting the insulation works, ensure that all Spacers are not generally essential in insulation
Insulation
of piping
preparatory work on the object has been completed. systems with load bearing mats. With pipes that are
Refer to Chapter 1.1 for details exposed to large mechanical loads (e.g. strong
vibrations), determine whether a spacer ring is required
Cut the mats to the required length, based on the in each individual case
external insulation diameter (pipe diameter + two times
the insulation thickness). Fasten the mat firmly to the With pipes that have been installed vertically, with a
pipe with steel bands. Ensure that the mats form a tight height in excess of four metres, fit support structures to
joint and that no lengthwise joints or circular joints are transfer the dead load of the insulation system onto the
visible. The joints of the individual mats are securely pipe. Attach the first support ring to the lowest point of
taped with self-adhesive aluminium tape. If the the vertical pipe. The distance between the support
insulation is assembled in multiple layers, the joints of rings should not exceed approximately four metres.
the individual insulation layers must be staggered.
.
1. Pipe - 2. Insulation: e.g. Rockwool Duraflex -

3. Selfadhesive aluminium tape - 4. Steel bands -
5. Sheet cladding - 6. Sheet-metal screw or rivet
29
1.2.3 Insulation with wired mats Insulation thicknesses to guarantee protection

Pipe insulation with wired mats has been a time-tested against contact
universal solution for many decades now. Due to their The table below is an initial guide to help select suitable
flexibility and high temperature resistance, wired mats insulation thicknesses for the guards. It is based on the
can be easily cut and mounted onto the piping. These following boundary conditions:
wired mats are ideal for application on large pipe • Ambient temperature: 25 °C
diameters and shaped pieces as elbows or T-joints. • Wind speed: 0.5 m/s
• Cladding: galvanised steel bright
Wired mats have a relatively low resistance to pressure • Maximum surface temperature: 60 °C
and from a practical point of view should only be • Insulation: ProRox WM 70
mounted in combination with spacers. Because of
the resulting thermal bridges, better insulation
performances are often achieved in the lower and
middle temperature range (up to 300 °C) with pipe
sections or load bearing mats rather than with
wired mats.
External pipe diameter Temperature of the medium (°C)

Nominal NPS (mm) ≤100 200 300 400 500 600
diameter Ø (inch)
DN
200 8 219,1 30 50 90 140 200 270
250 10 273,0 30 50 100 150 210 280
300 12 323,9 30 60 100 160 220 300
400 16 406,4 30 60 110 160 230 310
500 20 508,0 30 60 110 170 240 330
Multiple layer installation

In the event of differing boundary conditions, please contact the RTI sales team. The thermo technical engineering program
30
Installation
Before starting the insulation works, ensure that all
Insulation
of piping
preparatory work on the object has been completed.
Refer to Chapter 1.1 for details.
Cut the mat to a length so that it can be fitted to the

pipe with slight pre stressing. Wire the closing joints
(lengthwise and circular) of the mats together using
steel wire (0.5 mm thickness) or secure with mat
hooks. Stainless steel pipes and pipes with an operating
temperature > 400 °C can only be insulated with wired
mats with stainless steel stitching wire and wire netting 1. Pipe - 2. Insulation: ProRox Wired Mat- 3. Joint edge
to prevent galvanic corrosion cracking. closed with mat hooks - 4. Sheet-metal cladding - 5. Sheet-
metal screw or riveted bolt - 6. Spacer ring
With an insulation thickness of more than 120 mm (or
temperatures > 300 °C), apply multiple layer Support structures and spacers
insulation. If the insulation is assembled in multiple As wired mats do not offer sufficient resistance to
layers, the lengthwise and crosswise joints of the pressure to bear the weight of the cladding, spacer or
individual insulation layers must be staggered. If support structures should be applied. More information
mechanical loads are anticipated, use steel straps to can be found in 1.2.4.
secure the wired mats.
With pipes that have been installed vertically, with a
height in excess of four metres, fit support structures to
transfer the dead load of the insulation system onto the
pipe. Attach the first support ring to the lowest point of
the vertical pipe. The distance between the support
rings should not exceed approximately four metres.
1. Pipe - 2. Insulation: ProRox Wired Mats - 3. Stitching of the

joint edge with binding wire - 4. Sheet cladding - 5. Sheet-
metal screw or riveted bolt - 6. Spacer ring
31
1.2.4 Insulation support Dimension spacers of support construction

A. Spacers The number of spacers depends on the insulation,
The purpose of spacers is to keep the cladding at a temperature and the mechanical load. Use the
predetermined distance from the pipe. Spacers are following intermediate distances as a guide.
essential when the insulation (e.g. wired mats) cannot
bear the mechanical load of the cladding. The use of Horizontal Vertical
spacers is generally not necessary if pipe sections or load Insulation piping piping
bearing mats are used. system ≤ 300 °C > 300 °C ≤ 300 °C > 300 °C
Use a support structure or spacers on pipes where
mechanical loading (e.g. strong vibrations) of the insulation
Pipe sections none 3 to 4 m none 5 to 6 m
is expected and/or the temperature is higher than 300 °C.
Load bearing mats none 3 to 4 m none 5 to 6 m
Wired mats 1m 1m 1m 1m
Spacer rings usually consist of metal rings on which the
sheet cladding rests, and metal or ceramic bars used as
spacers, which rest on the pipe. Elastic spacers such as
Omega clamps are frequently used to reduce the
transference of vibrations. With steel spacers, apply at
least three bars, whereby the maximum distance –
measured as circumference of the external ring – must
be a total of maximum 400 mm. With ceramic spacers,
apply at least four bars at a maximum permissible
distance of 250 mm.
1. Pipe - 2. Rockwool Insulation - 3. Spacer - 4. Thermal dividing

layer - 5. Cladding
The spacers on pipes are located under the circular joint

of the cladding. On shaped sections such as pipe
elbows, spacers are fitted at the start and at the end. If
1. Pipe - 2. Rockwool Insulation - 3. Spacer - 4. Thermal dividing layer - the external distance between the two spacers exceeds
5. Support ring 700 mm, place additional spacers between the two.
32
B. Support construction
The purpose of support structures is to transfer the
Insulation
of piping
mechanical load of the insulation system and the forces
affecting the insulation system onto the object. Support
structures are essential in the case of vertical piping. In
addition to the static and dynamic forces, changes in
piping length and support structures due to temperature
must also be taken into account when dimensioning.
Support structures are fastened to mounting supports,
which are welded to the pipe beforehand, or are
mounted directly onto the pipe via a clamping action
with so-called double clamping rings. With temperatures 1. Support ring - 2. Bar - 3. Rivet or screw connection -
above 350 °C, the support structures must be made of 4. Thermal decoupling - 5. Clamping screw - 6. Screw nut -
high-temperature steels. 7. Internal clamping ring
The table below is an initial dimensioning guide, and
shows the weight of the insulation system against the
nominal width of the pipe and the insulation thickness.
The table accounts for an insulation with an apparent
density of 100 kg/m³, including the spacer and a 1.0 mm
strong galvanised sheet (11 kg/m²).
Weight of the insulation (kg/m. pipe)
Weight of insu‑
External diameter Insulation thickness in mm
lation system
in relation
Nominal NPS mm 30 40 50 60 80 100 120 140
diameter (inch) to different
Ø DN insulation
thicknesses
15 ½ 21,3 kg/m 4 5 6 8 11 15 19 24
25 1 33,7 kg/m 4 5 7 8 12 15 20 25
50 2 60,3 kg/m 5 7 8 10 13 17 22 27
65 2½ 76,1 kg/m 6 7 9 10 14 18 23 28
80 3 88,9 kg/m 7 8 10 11 15 19 24 29
100 4 114,3 kg/m 8 9 11 12 16 21 26 31
200 8 219,1 kg/m 12 14 16 18 23 28 33 39
300 12 323,9 kg/m 17 19 21 24 29 35 41 47
500 20 508,0 kg/m 25 28 31 34 40 47 54 62
700 28 711,0 kg/m 34 37 41 44 52 60 69 78
planar surface kg/m2 15 16 17 18 20 22 24 26
33
1.2.5 Cladding
Suitable cladding should be applied to protect the combinations of metals that do not tend to corrode
insulation from weather influences, mechanical loads due to their electrochemical potentials (also see page
and (potentially corrosive) pollution. Selecting the 17 in section 1.1).
appropriate cladding depends on various factors, such • For acoustic insulation, a noise absorbent material
as working loads, foot traffic, wind and snow loads, (bitumen, mylar foil) is mounted on the insulation or
ambient temperatures and conditions. inside the cladding. To reduce the risk of fire, limit
the surface temperatures of the cladding to the
Note: maximum operating temperature of the noise
An insulation system resistant to foot traffic must not absorbent material.
become permanently damaged if a person weighing
100 kg, (weight including any tools being carried)
walks across it. It is not designed to bear additional
loads, such as the placing of heavy equipment. For
the purpose of the safety regulations, a durable
insulation is not considered to be a walkable surface!
When selecting the appropriate cladding, take the

following points into account:
• As a general rule, galvanised steel is used in
buildings due to its mechanical strength, fire
resistance and low surface temperature (in
comparison to an aluminium cladding).
• Aluminium is used outdoors, because it is easy to fit
and more cost-effective than stainless steel and does
not tend to corrode under common weather
conditions.
• In corrosive environments, aluminised steel, stainless
steel or glass reinforced polyester (grp: e.g.
Rocktight) is used as cladding. Stainless steel is
recommended for use in environments with a fire
risk.
• The surface temperature of the cladding is
influenced by the material type. The following applies
as a general rule: the shinier the surface, the higher
the surface temperature.
• To exclude the risk of galvanic corrosion, only use
34
Max. surface temperature
Insulation
of piping
Cladding material Areas at risk Corrosive < 50 °C < 60 °C >60 °C
of fire environment
Aluminium sheet - -
Aluminium/zinc coated steel sheet - -
Galvanised steel sheet -
Austenitic stainless steel sheet
Aluminised steel sheet
Plastic-coated steel or aluminium - -
Glass fibre-reinforced polyester (e.g. Rocktight) - 90 °C

Coatings/mastics - - 80 °C
Foils - -
The thickness of the metal sheet depends on the pipe With special acoustic requirements, a larger thickness
diameter and the type of the metal. (≥ 1 mm) is generally used.
Recommended sheet thickness and overlaps regarding cladding made from flat sheets (conform CINI)
Minimum thickness of metal cladding sheet (recomended by CINI)
External diameter of Aluminium Aluminised Alu-Zinc coated Zinc coated Austenitic stainless
the insulation (mm) (CINI 3.1.01) steel sheet steel sheet steel sheet steel sheet
(CINI 3.1.02) (CINI 3.1.03) (CINI 3.1.04) (CINI 3.1.05)
< 140 0,6 0,56 0,5 0,5 0,5

130 - 300 0,8 0,8 0,8 0,8 0,8
> 300 1,0 0,8 0,8 0,8 0,8
The recommended sheet thickness deviates to a certain The basic guidelines are:
level per standard/country. The thickness recommend- • Fasten sheet cladding on lengthwise joints with at
ed by CINI is shown in the table above. See section least six sheet metal screws or blind rivets every metre.
3.2.2 for the thickness according to DIN 4140 . • Place the screws or blind rivets equidistantly. If
screws or rivets are fitted in two rows, do not stagger
To reduce the risk of galvanic corrosion, it is very the screws or rivets.
important to use the correct screws, straps etc. See the • The cladding can also be held in place with
table on page 17 for more information. corrosion-resistant straps instead of screws or rivets.
• Do not use aluminium screws.
35
1.2.5 Cladding
Influence of the cladding on the surface Cladding in corrosive environments
temperature To guarantee the functionality of a technical insulation,
In addition to the insulation thickness, the thermal it is important to protect it against atmospheric
conductivity of the insulation and the ambient influences and prevent the ingress of moisture into the
conditions (for example temperature and wind), the insulation. Moisture in the insulation system increases
surface temperature of insulation is also influenced by thermal conductivity, thereby reducing the effectiveness
the emissions ratio of the cladding. The following of the thermal protection. It also poses a high risk of
applies as a general rule for thermal insulation: the corrosion to the component. In certain applications, the
shinier a surface is (lower emissivity), the higher the cladding system is also expected to offer chemical
surface temperature. The following example shows the resistance, as well as being resistant to cleaning
various surface temperatures that depend on the methods such as steam blasting. Alongside the
cladding: insulation and construction, selecting a suitable
• Diameter: DN 100 (114 mm) cladding system is very important as it forms the basis
• Temperature of the medium: 500 °C for a long service life, low maintenance costs and low
• Place of installation: Interior (Wind speed 0.5 m/s) heat loss of a technical insulation.
• Insulation: ProRox WM 70, wired mats; thickness: Rockwool Technical Insulation has therefore developed
100 mm an innovative cladding system for technical insulation:
• Various cladding materials Rocktight.
- Aluminium sheet
- Galvanised steel sheet, bright
- Stainless steel
- Paint-coated plastic cladding
Surface (cladding) temperature °C
Aluminium Galvanised Stainless Paint-coated

cladding steel, bright steel Plastic cladding
36
Rocktight – a durable protection for insulation and, as an unhardened Rocktight mat is highly flexible,
Insulation
of piping
Rockwool Rocktight is a fibreglass reinforced polyester it can be simply shaped to cover complex geometric
mat, which hardens when exposed to ultraviolet (UV) shapes such as pipe elbows, T-joints or pipe fittings.
light. The material contains resins, glass fibres and a Rockwool Rocktight has a protective foil on both sides.
special filling agent and is (unprocessed) protected It is supplied in rolls in cardboard packaging. The roll is
against UV rays by foils on both sides. also wrapped in black foil that is resistant to UV light.
The underside (the side facing the object) is covered
Rocktight is soft and flexible when unprocessed. It can with a dark foil and has a rough, self-adhesive surface.
be cut or trimmed in any shape and easily mounted The flat surface of the outside is covered with a white
onto the insulation in this state. The polyester then foil. After each use, place the roll in the sealed
hardens when exposed to ultraviolet (UV) light. Once cardboard packaging to minimise the risk of hardening
hardened, Rocktight is watertight and forms a caused by daylight or UV light.
mechanical protection for the insulation.
Rocktight requires a dry, clean (ventilated) work
The advantages: environment. For outdoor applications, tents should be
• Long service life: erected if necessary, to protect the unhardened
Rocktight creates a sealed, watertight cladding for Rocktight mat from UV light.
Rockwool insulation systems. This minimises damage
caused by atmospheric influences or general wear Note
and tear. Rocktight is resistant to many chemical • High temperatures: Rockwool Rocktight can be used
substances and forms a mechanical protection for the in temperatures of up to 90 °C. In case of higher
insulation. temperatures, fit an end-cap to lower the tempera-
• Easy to clean: ture.
Insulation systems cased in Rocktight can be cleaned • Chemical resistance: Rockwool Rocktight is resistant
with steam-jet air ejectors, without the risk of water to numerous chemicals.
penetrating the insulation and causing damage. • Expansion joints: fit expansion joints to accommo-
• Low start-up costs: date expansion of the Rocktight material and the
The cutting and processing take place directly on site. steel pipe.
This avoids costly prefabrications, as is the case with
sheet cladding .
• Flexible applications:
Rocktight can be used for cold and thermal insulation
of underground and aboveground pipes, for example
in offshore plants. Its high flexibility enables
application on complex, shaped objects.
Rockwool Rocktight is characterised by easy process-

ing. It can be cut easily using a knife directly on site
37
1.2.6 Pipe hangers and pipe supports Pipe support not in direct contact with the piping
There is a wide range of solutions for pipe hangers and
pipe supports. The following illustrations show the
possibilities described below 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 the piping
(commonly used with cold insulation systems)
1. Pipe - 2. Insulation: Rockwool 850 pipe sections -

Pipe hangers in direct contact with the piping 3. Sheet cladding - 4. Load-bearing insulation - 5. Seal -
6. Stirrup - 7. Pipe saddle
A basic rule applying to all pipe attachments is that the

insulation system (i.e. the insulation and cladding) must
not be damaged if the piping expands. Damage to the
cladding of outdoor installations, in particular, can allow
the ingress of moisture in the material. The result may
be permanent damage of the insulation system and as
a consequence high heat losses, and dangerously high
1. Pipe - 2. Insulation: Rockwool 850 – pipe section - surface temperatures and corrosion etc.
3. Collar - 4. Sheet cladding - 5. Pipe hanger
Pipe support in direct contact with the piping
1. Pipe - 2. Insulation: Rockwool 850 – pipe section -

3. Sheet cladding - 4. Pipe clamp - 5. Pipe saddle
38
1.2.7 Insulation of valves and flanges
Heat losses incurred through non insulated fixtures
Insulation
of piping
such as valves and flanges are substantial, even at low
temperatures. Refer to Table A14 of the VDI guideline
2055 for information about heat losses from non-insu-
lated pipe fittings and flanges (see section 3.3.11). The
table states that an uninsulated valve (DN100), located
outside loses almost as much heat at 100 °C as 36
metres of uninsulated piping. The temperature of the
medium can also decrease to such an extent at
non-insulated fittings or flanges, that process critical 1. Pipe - 2. Insulation: ProRox WM wired mats - 3. Cladding
temperatures are reached, at which point for example, - 4. Sheet-metal screw or Rivet - 5. Swage - 6. Drainage
the medium will start to crystallise. Valves and flanges opening - 7. Strap - B ≥ 50 mm - A = bolt length + 30 mm
should therefore be insulated as much as possible.
To avoid damage during inspection or repairs, the
insulation for valves and flanges is designed with A number of possible design options for insulation
removable coverings or hoods, to allow rapid disassem- systems for pipe fittings and flanges follow:
bly. Removable coverings or hoods are usually insulated
from the inside with wired mats (e.g. ProRox WM 70).
The coverings are fastened to the object with lever
fastenings, which are fixed directly onto the covering or
on to straps. Take the following conditions into account
when designing insulated coverings for fittings and
flanges:
• The overlap distance of the insulated covering over
the insulated pipe should be at least 50 mm.
• The pipe insulation should end at the flanges, leaving
a gap equal to the bolt length + 30 mm and should be
closed off with a lock washer so the flange can be
loosened without damaging the insulation.
• With valves, an extended spindle should preferably
be fitted horizontally or below the pipe to prevent
leakage along the spindle shaft. 1. Pipe - 2. Insulation: ProRox WM wired mats - 3. Cladding -
• The cladding must be fitted to prevent the ingress of 4. Sheet-metal screw or rivet - 5. Rain deflector - 6. Lock
moisture in the insulation. On inclined or vertical piping, washer - 7. Straps - 8. Rain deflector - B ≥ 50 mm - A = bolt
for example, mount rain deflectors above the removable length + 30 mm
coverings. If the ingress of moisture into the insulation
is unavoidable, make 10 mm. diameter drain holes in
the removable covering.
39
1.2.7 Insulation of valves and flanges
1. Pipe - 2. Insulation: ProRox WM wired mats - 3. Cladding

- 4. Sheet-metal screw or rivet - 5. Swage - 6. Drainage
opening - 7. Straps – B ≥ 50 mm 1. Pipe - 2. Insulation: ProRox WM wired mats - 3. Sheet -
4. Sheet-metal screw or rivet - 5. Rain deflector - 6. Lock
washer - 7. Straps - 8. Lock washer - B ≥ 50 mm - A = Screw
length + 30 mm
Leakages
With pipes where a leaking fluid content could damage
the insulation or the coating system in the removable
covering, mount flange straps with a leak detection
fitting around the flange. Flange bands can also prevent
1. Pipe - 2. Insulation: e.g. ProRox WM wired mats - flammable products from penetrating into the insulation
3. Cladding - 4. Sheet-metal screw or rivet - 5. Swage - material and can help prevent the outbreak of fire.
6. Drainage opening - 7. Straps – B ≥ 50 mm -
A = Bolt length + 30 mm
1. Pipe - 2. Insulation: e.g. Rockwool - 3. Cladding - 1. Pipe - 2. Insulation: ProRox WM wired mats - 3. Cladding -
4. Sheet-metal screw or rivet - 5. Removable coverings 4. Sheet-metal screw or rivet - 5. Swage - 6. Flange band -
(insulated from the inside with e.g. Rockwool 160 wired 7. Leak detection fitting - 8. Clamps
mats) - 6. Swage
40
radius of the pipe elbow. The pipe section segments are
fastened to the pipe elbow with clamps or binding wire.
Insulation
of piping
Joints between the individual segments are plugged
tightly with loose Rockwool.
1. Pipe - 2. Insulation - 3. Cladding - 4. Sheet-metal screw or

rivet - 5. Collar - 6. Collar - 7. Clamps - 8. Rain deflector - 1. Pipe - 2. Insulation: Rockwool 850 - pipe sections -
9. Leak detection fitting - B ≥ 50 mm - A = bolt length + 30 mm 3. Cladding - A and B = Segmented pipe sections
1.2.8 Insulation of pipe elbows and Insulation of pipe elbows with wired or load
T pieces bearing mats
The cladding of elbows and T-pieces is susceptible to If the piping is insulated with wired mats or load bearing
damage, due to expanding or vibrating pipes. There is a mats, shaped pieces such as pipe elbows or T-pieces
particular risk of moisture penetrating damaged swage are generally insulated with the same mats. In this
connections in the cladding, if the object is located case, the mats are cut into so-called fish-shaped elbow
outdoors. segments. These are mounted onto the pipe elbow to
seal the elbow. With wired mats, all the joints (both
For the insulation of shaped pieces, we recommend circular and lengthwise joints) are sewn together with
using the same insulation in the same thickness as used binding wire or mat hooks. Spacers are required at least
for the pipe. at the start and end of the elbow (for more details,
please see page 30).
Insulation of pipe elbows with Rockwool pipe
sections Load-bearing mats are fixed to the pipe elbow with
For the insulation of pipe elbows with pipe sections metal or plastic straps. Any gaps between the individual
(e.g. Rockwool 850), the pipe sections are cut into segments are plugged up with loose Rockwool. Secure
segments and tightly fitted onto the pipe elbow with the the joint edges with self-adhesive aluminium tape.
lengthwise joints facing downwards. The angular
division of the segments should correspond to the
41
1.2.7 Insulation of pipe valves and flanges 1.2.9 Reducers

The diagrams below show how the sheet is mounted Pipes that branch out with many outlets reduce the
onto shaped pieces. pipe diameter. Examples of how to install reducers
follow:
1. Pipe - 2. Rockwool Insulation - 3. Cladding - A to C: Elbow

segments of mats 1. Pipe - 2. Rockwool Insulation - 3. Cladding - 4. Sheet-metal
screw or rivet - 5. Swage - 6. Reducer
1. Pipe - 2. Rockwool Insulation - 3. Cladding
1. Pipe - 2. Rockwool Insulation - 3. Cladding - 4. Sheet-metal

screw or rivet - 5. Swage - 6. Reducer
1. Pipe - 2. Rockwool Insulation - 3. Cladding -

4. Drainage opening - 5. Edging with mastic compound
42
1.2.10 Expansion joints
In thermal insulation systems, large differences that is then insulated (see diagram). With temperatures
Insulation
of piping
between the piping and the cladding temperature can above 300 °C, do not use galvanised sheets due to the
occur. The materials used for the pipe, insulation, risk of galvanic corrosion (cracking).
insulation support and cladding also have different
thermal expansion coefficients. This leads to different
thermal elongations of the various components in the
insulation system, which must be allowed for using
constructive measures. The elongation “Δl” can be
determined as follows:
Δl = l ⋅ Δt ⋅ a
In this formula, l corresponds to the length of the pipe, Δt

corresponds to the difference in temperature between the
cold and warm pipe (or cladding) and a corresponds to 1. Pipe - 2. Insulation: ProRox WM wired mats - 3. Cladding
the linear thermal expansion coefficient (see tables in - 4. Aluminium foil - 5. Cover sheet - 6. Mat pin with clip -
chapter 4). 7. Spacer
Example for the thermal elongation of steel To compensate for thermal expansion of the cladding,
install the expansion joints shown below.
Δl(mm)/m Δt
0,55 50
1,10 100
1,65 150
2,20 200
If below expansion joints for thermal length compensa-

tion have been built into the pipe, the insulation system
must be designed so that insulation cannot enter the
bellows, thereby compromising the compensatory
effect. The expansion bellows are covered with a sheet 1. Pipe - 2. Insulation: ProRox WM wired mats - 3. Cladding
- 4. Sheet-metal screw or rivet - 5. Swage - 6. Metal strap -
7. Circumferential seam
43
1.2.11 Tracing
When 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. Insulation can reduce
heat losses and postpone the moment at which the
installation freezes. Insulation alone, however, cannot
indefinitely prevent the installation from freezing.
Installing additional tracing may be necessary between
the object and the insulation.
A distinction is made between pipe tracing and 1. Pipe - 2. Insulation: Rockwool 850 - pipe section -
electrical tracing. In pipe tracing systems, a heating 3. Electrical tracing - 4. Aluminium foil - 5. Cladding
pipe is fitted parallel and close to the media pipe.
Steam, warm water or thermal oil flows through the
tracing pipes as a heat transfer medium. Electrical
tracing consists of cables mounted onto the pipes.
These cables heat the pipes
Traced pipes can be insulated with pipe sections or

mats. Ensure that no insulation occupies the space
between the tracing and the pipe; otherwise the heat
transfer will be hampered. Pipes are therefore often
wrapped in aluminium foil. If pipe sections are used,
select a correspondingly larger internal diameter of the 1. Pipe - 2. Insulation: Rockwool Duraflex or ProRox WM -
pipe section. With vertical piping, sealing the end of wired mats - 3. Tracing - 4. Aluminium foil - 5. Cladding
each pipe section with loose Rockwool is recommended
to prevent convection (chimney effect).
The diagrams on the right show various design options.
1. Pipe - 2. Insulation: Rockwool 850 pipe section -

3.Tracing - 4. Binding tape - 5. Cladding
44
1.2.12 Foot traffic
Avoid walking on insulated pipes, as this can damage
Insulation
of piping
the insulation. Damage caused by foot traffic includes
dented sheet cladding and gaps at the sheet seams.
Water can penetrate the insulation through these gaps
and cause lasting damage to the entire insulation
system. The result is often greater heat losses and
corrosion.
Note
An insulation system resistant to foot traffic must not 1. Pipe - 2. Insulation: Rockwool 851 pipe section -
become permanently damaged if a person weighing 3. Reinforcement sheet - 4. Cladding - 5. Sheet-metal screw
100 kg, (weight including any tools being carried) walks or rivet - 6. Joggle
on it. It is not designed to bear additional loads, such as
the placing of heavy equipment. For the purpose of the
safety regulations, a durable insulation is not
considered to be a walkable surface.
In special applications, reinforcing the cladding is

recommended, e.g. using a reinforcement sheet.
Pipe insulation systems resistant to foot traffic require

an insulation material with a high mechanical strength
(e.g. Rockwool 851 pipe sections). Using other
insulation materials such as wired mats, which are not
resistant to pressure, is not recommended, as the
sheet cladding only rests on the spacers and tends
to dent when walked upon.
45
1. System solutions
1.3 Insulation of vessels

Vessels are a major component in installations for The applicable standards and regulations must also be
various procedures in almost all fields of industry. observed. A few examples follow:
Many production processes require different substanc- • DIN 4140 (Insulation works on industrial plants and
es that are stored in vessels and used in the individual building services installations)
processes later in the procedure. The vessels primarily • AGI Q05 (Construction of industrial plants)
store liquid, solid or gaseous substances, which are • AGI Q101 (Insulation works on power plant
added to the process as and when required. Raw components)
materials, fuels or end products are usually stored in • CINI-Manual: “Insulation in industry”
large storage tanks.
Before starting the insulation works, ensure that all
It is often important to store the substances within preparatory work on the object has been completed.
certain temperature limits. If the temperature is too high Refer to Chapter 1.1 for details.
or too low, the substance can spoil or set, or lose its
flowing properties and become incapable of being Insulation systems for vessels
pumped or discharged. Insulation is therefore a major An insulation system for a vessel generally consists
factor in the functionality of procedural processes. of the following components:
It also has the following purposes: • Insulation
• Reduces heat losses • Support construction and a spacer
• Guarantees protection against contact by minimising • Water vapour retarder with cold insulation systems
the surface temperature • Cladding
• Reduces cooling of the stored substance, so it
remains fluid and does not set The actual operating temperature (above or below
• Prevents the vessel from freezing (with additional ambient) is essential for the design of the insulation work.
tracers) The following chapters concentrate on hot insulation.
• Prevents heating of the stored substance (for
example, through solar radiation)
The vessels used in the different industrial processes

are so varied that the examples of use cannot fully take
into account the particular circumstances of each case.
Determine whether the products and construction

described are suitable for the corresponding application
in each individual case. If in doubt, consult the RTI
Sales Team.
46
Selection and installation of the insulation
Selecting the appropriate insulation depends on the
operating method, the installation temperature, the
dimensions and the location of the vessel.
Typical insulation materials are Rockwool Duraflex,

and board insulation like Rockwool Flexiboard and
Multiboard.
Insulation
of vessels
Since vessels are often located outdoors, it is important to
select insulation with a low thermal conductivity and
excellent water repellent properties. The insulation is
usually fastened to the cylindrical vessels with steel
straps. These should be made from stainless steel and
should be closed with butterfly nuts or quick release
fasteners. The strap measurements and intervals for
cylindrical objects shown in the table on the next page
have proved useful in many projects.
1. Vessel inlet - 2. Crane hooks - 3. Vessel head - 4.

Expansion joint - 5. Manhole - 6. Tapping point (e.g. for
sampling) - 7. Identification board - 8. Vessel base - 9. Vessel
outlet - 10. Fitting insulation - 11. Flange - 12. Vessel leg
Minimum radius Rockwool Technical Insulation slabs
Product Insulation thickness (mm)
25 40 50 60 70 80 100 120
Rockwool Flexiboard 400 500 700 900 1100 1300 1800 2000
Rockwool Multiboard 400 500 700 1000 1200 1500 1900 2400
Rockwool 233 500 700 1000 1500 2000 2500 2500 2800
47
External insulation diameter Internal insulation layer strap External or single layer Distance between the straps
measurement insulation strap measurement
200 tot 1800 mm 13 x 0.5 mm 16 x 0.5 mm 250 mm

> 1800 mm 16 x 0.5 mm 19 x 0.5 mm 250 mm
In a wide variety of applications, these values can only With wired mats, all the lengthwise and crosswise joints
be used as reference values. In each individual case, must be sewn or wired together, or joined with six mat
determine whether different strap measurements and hooks per metre. If the insulation is assembled in multiple
intervals should be used. layers, the joints of the individual insulation layers must
be staggered.
If the insulation is assembled in multiple layers, the joints
of the individual insulation layers must be staggered The following illustrations show a number of typical
(so called masonry bond). methods of insulating vessels.
For temperatures up to 300 °C, Rockwool Duraflex for

horizontal applications, Rockwool Multiboards or ProRox Insulation of a crane hook
WM 70 - wired mats are usually used to insulate vessels
with flat vertical walls. In this case, the insulation is
attached with welding pins and spring plates. On flat
surfaces, attach the wired mats using minimum six pins
per m², and minimum ten pins per m² on the under-
neath. Observe the following when pinning the insulation:
• With insulation thicknesses ≤ 120 mm, use pins with a
minimum diameter of 4 mm .
• With insulation thicknesses ranging from 130 to 230
mm, use pins with a minimum diameter of 5 mm . 1. Cladding - 2. Insulation: ProRox WM 70 – Wired Mats -
• With insulation thicknesses ≥ 240 mm, use pins with a 3. Crane hooks - 4. Insulation covering for the crane hook
minimum diameter of 6 mm.
• If the cladding rests directly on the insulation without a
gap between the two, the pins must be 10 mm shorter
than the insulation thickness.
• Fasten each insulation layer with straps and clips.
48
Insulation of a vessel base
Insulation
of vessels
1. Insulation: e.g. ProRox WM wired mats - 2. Support
construction - 3. Mounting support - 4. Conical column
head - 5. Vessel outlet - 6. Vessel leg
1. Insulation: Rockwool Duraflex - 2. Flange inlet for safety

valve - 3. Vessel filling nozzles - 4. Conical head - 5. Vessel
drawdown - 6. Conical head with manhole - 7. Vessel leg
49

Insulation of a conical head Support constructions and spacers
The application of support constructions and spacers
on vessels is essential. The objective of support
constructions is to bear the weight of the insulation
system and to bear the weight above mounting
supports on the object to be insulated. The spacers
keep the cladding of the insulation at a predetermined
distance. On vertical pipes, the substructures often
assume the function of the support construction and
spacer. The design specifications are illustrated in
Chapter 1.4. The corresponding requirements for
support constructions and spacers can be found in
Insulation of a conical head with a manhole CINI and the AGI guidelines Q153 and 154.
Before commencing the insulation works, fit mounting

supports to the vessels to which the support construc-
tions are fitted. The shape, construction and measure-
ments of mounting supports for support constructions
must enable the insulation to be fitted during assembly.
Use the design loads specified in DIN guidelines
1055-4 and 1055-5 to dimension the mounting
supports and the support constructions and spacers.
Cladding
The cladding of vessels protects the insulation against
Insulation of vessel outlet mechanical influences and the weather. There is a wide
range of different flat and profiled sheets available. See
Chapter 3.2 for an overview. Flat sheets are primarily
used to clad smaller vessels. With large-scale insulation
systems, flat sheets can only bear small, static loads
exerted by the wind. It is therefore essential to reduce
the distance between the support structures. The result
will be a higher number of support structures and
thermal bridges. On large surfaces, flat sheets are more
likely to buckle or dent, leading to optical damages,
than profiled sheets. To improve the stability and optical
characteristic, the sheets can be canted diagonally
(cambered).
50
Preferably use profiled sheets for vessels with a large Rocktight is soft and flexible when unprocessed. The
surface area. They offer structural advantages and can polyester then hardens when exposed to ultraviolet (UV)
accommodate expansions that are perpendicular to the light. Once hardened, Rocktight is waterproof and
direction of the swage. The disadvantage is that pipe forms a mechanical protection for the insulation.
protrusions are more complex from a structural Please see Chapter 1.2. for more details about
perspective. Using profiled sheets is only recommended processing Rocktight.
with cladding with a low number of protrusions.
Design profiled sheet casings so that rainfall is
Insulation
of vessels
deflected safely.
Cladding in moist or corrosive environments

To guarantee the functionality of a technical insulation,
it is important to protect it against atmospheric
influences and prevent the ingress of moisture into the
insulation. Moisture in the insulation system increases
thermal conductivity, thereby reducing the effectiveness
of the thermal protection. It also represents a high risk
of corrosion to the component. In certain applications,
the cladding system is also expected to offer chemical
resistance, as well as being resistant to cleaning
methods such as steam blasting. Alongside the
insulation and construction, selecting a suitable
cladding system is very important as it forms the basis
for a long service life, low maintenance costs and low
heat loss of a technical insulation.
Rockwool Technical Insulation has therefore developed

an innovative cladding system for technical insulation:
Rocktight.
Rocktight – for durable protection

Rockwool Rocktight is a fibre glass reinforced polyester
mat, which hardens when exposed to ultraviolet (UV)
light. The material contains resins, glass fibres and a
special filling agent and is protected against UV rays by
foils on both sides.
51
1. System solutions
1.4 Insulation of columns

Columns are pillar-shaped vessels, which are mainly The applicable standards and regulations must be
used in the (petro) chemical industry for distillation or observed. A few examples follow:
the extraction of substances. They often form the key • DIN 4140 (Insulation works on industrial plants and
elements in chemical or petrochemical plants. The building services installations)
processes in columns often only operate at certain • AGI Q101 (Insulation works on power plant
temperatures. The insulation of columns plays an components)
important role in their functionality. • CINI-Manual: “Insulation in industry”
• Reduces heat losses
• Guarantees protection against contact by minimising
the surface temperature Before starting the insulation works, ensure that all
• Reduces the cooling of the stored substance, so it preparatory work on the object has been completed.
remains fluid and does not set Refer to Chapter 1.1 for details.
• Ensures the column remains at the necessary
process temperatures Insulation systems for columns
• Prevents heating of the stored substance (for An insulation system for vessels and columns generally
example, through solar radiation) comprises the following components:
• Insulation
The columns used in the different industrial processes • Support construction and a spacer
are so varied that the examples of use below cannot • Water vapour retarder in the case of cold insulation
fully take into account the particular circumstances of systems
the construction-related factors. • Cladding
Determine whether the products and construction
described are suitable for the corresponding application The temperature of the columns, in particular, has
in each individual case. If any doubt, consult the RTI a significant impact on the optimal insulation system.
Sales Team. This chapter focuses on the insulation of hot columns.
52
Selecting the appropriate insulation depends on the
operating method, the installation temperature, the
dimensions and the location of the vessel or column.
of columns
Insulation
Insulation materials like Rockwool Duraflex or ProRox
WM 70 wired mat are primairily used for the insulation
of columns.
Since columns are often located outdoors, it is important

to select insulation with a low thermal conductivity and
excellent water repellent properties. The insulation is
usually fastened to the columns with steel straps. These
should be made from stainless steel and should be
closed with butterfly nuts or quick release fasteners. The
strap measurements and intervals for cylindrical objects
shown in the table on the next page have proved 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
53
External insulation diameter Internal insulation layer strap External or single layer Distance between the straps
measurement insulation strap measurement
200 tot 1800 mm 13 x 0.5 mm 16 x 0.5 mm 250 mm

> 1800 mm 16 x 0.5 mm 19 x 0.5 mm 250 mm
In a wide variety of applications, these values can only Insulation of a reinforcement ring
be used as reference values. In each individual case,
determine whether different strap measurements and
intervals should be used. If the insulation is assembled
in multiple layers, the joints of the individual insulation
layers must be staggered. The following illustrations
show a number of typical methods of insulating
columns.
1. Support construction - 2. Mounting support -

Insulation of conical column head 3. Reinforcement ring - 4. Insulation: e.g. Rockwool Duraflex
- 5. Cladding
1. Supporting construction - 2. Mounting support
54
Insulation of a column base
Fire protection in column skirts

The fire protection quality of a column primarily
depends on the fire resistance of the column support
frame. The RTI Conlit Systems offer proven fire
protection solutions for column support skirts. If you
have any questions, please consult the RTI Sales team.
of columns
Insulation
1. Skirt: Column support frame - 2. Sliding cover
Insulation of manhole on the column head, Insulation of manhole, horizontal connection

vertical connection
1. Manhole - 2. Insulation - 3. Cladding - 4. Sheet-metal

screw
55

Various methods for pipe penetrations
Support constructions and spacers

The application of support constructions and spacers Before commencing the insulation works, fit mounting
on columns is essential. The objective of support supports to the column to which the support construc-
constructions is to bear the weight of the insulation tions are fitted. The shape, construction and measure-
system and to bear the weight above mounting ments of mounting supports for support constructions
supports on the object to be insulated. The spacers must enable the insulation to be fitted during assembly.
keep the cladding of the insulation at a predetermined Use the design loads specified in DIN guidelines
distance. On columns, which are always perpendicular, 1055-4 and 1055-5 to dimension the mounting
the substructures often assume the functions of the supports and the support constructions and spacers.
support construction and spacer.
The corresponding requirements for support construc-

tions and spacers can be found in AGI guidelines Q153
and Q154.
56
of columns
Insulation
1. Object wall - 2. Mounting support - 3. Metric bolting -
4. Bar - 5. Omega clamp - 6. Thermal separating layer
Ladder support cleats Cladding

The cladding of columns protects the insulation against
mechanical influences and the weather. There is a wide
range of different flat and profiled sheets available. See
section 3.2.2 ‘Cladding materials’ for an overview.
Further details are also provided in Chapter 1.3
“Insulation of vessels”.

The Rockwool Rocktight cladding system has proven
its value in moist and corrosive environments.
See Chapters 1.2 and 1.3 for more details.
side view front view
57
1. System solutions
1.5 Insulation of storage tanks

The availability of raw materials, fuels and the storage of CO2 emission. Reduced breathing losses of
end products is critical in almost all fields of industry. hazardous substances prevents damage to our
Generally, large tanks are used for raw materials, fuels environment.
and end products. Small tanks or vessels (see chapter • Process control: Insulation will prevent tanks from
1.3) are used to temporarily store (semi) products. freezing or being heated by solar radiation. It will also
To conserve the substance and ensure the stability and reduce the cooling of the stored substance,
safety of the production process, it is important to keep preventing it from setting and remaining in a solid
the temperature inside the tank between certain form. In both cases additional heating or cooling may
temperature limits. be applicable.
Therefore the industrie sets high standards for the • Safety: A fire resistant insulation reduces the risk of
conditioning temperature of storage tanks. We give a fire outside the tank igniting a flammable medium.
some examples: It is also protection against contact by minimising the
- In the food industry, a milk cooling tank is a large surface (contact) temperature of the tank
storage tank used to cool and hold milk at a cold
temperature until it can be packed and transported
to the end-users.
- Storage facilities for liquefied gasses such as LNG,
operate at very low temperatures up to -168 °C.
Avoid evaporation or expansion of the liquefied gas,
as this can result into safety problems.
- In the petrochemical industry, many storage facilities
operate at high temperatures of 30 °C – 220 °C to
avoid fluids, such as bitumen, spoiling or setting -
which could result in problems with pumping or
discharging from the tank.
Properly designed insulation work mainly depends on
Conclusion: Therefore, insulation of storage tanks is a the isometrics and location of the storage tank, type of
major factor in the functionality of storage facilities. It fluid and the purpose of the insulation. Even though the
also serves the following purposes: following examples of use are restricted to hot thermal
• Costs savings: Insulation significantly reduces the insulation for outdoor application, the types of storage
heat and the so-called breathing losses of the tanks used are so varied that the examples cannot fully
substance. The pay-back time for the hot insulation take into account the particular circumstances of each
is, even at lower temperatures (30 °C), usually less case. Determine whether the products and construction
than 1 year, whereas the lifetime of the insulation described are suitable for the corresponding application
may be many years. in each individual case. If in doubt, consult the RTI
• Environment: In addition to the cost savings Sales Team.
achieved, reduced heat losses will also lead to lower
58
The applicable standards and regulations must also be
observed. A few examples follow:
• DIN 4140 (Insulation works on industrial plants and

building services installations)
• AGI Q05 (Construction of industrial plants)
• AGI Q101 (Insulation works on power plant
components)
• CINI-Manual: “Insulation in industry”
Insulation selection
Storage tanks are located outdoors, so it is important to
select a material with a low thermal conductivity and
excellent water repellent properties. Rockwool flexible
Board insulation, such as Rockwool Multiboard, is
mainly used to insulate tank walls. Applying a less water
repellent, non pressure-resistant insulation like Wired
Mats is not generally recommended. If foot traffic can
occur, a pressure-resistant slab such as Rockwool CRS
is applied for the insulation of the tank roof. If applying
storage tanks
Insulation of
a product which is resistant to foot traffic is impossible,
apply a support structure, where needed, to protect the
insulation boards. For temperatures above 100 °C
applying the insulation in at least 2 layers (so called
masonry bond) is recommended.
59
Insulation of tank roofs Construction

Insulating a tank is not easy. Corrosion of the tank roof Before starting the insulation works, ensure that all
can occur if the insulation is not properly installed and preparatory work on the object has been completed.
maintained. Therefore, many companies tend not to Refer to Chapter 1.1 for details. Outdoor storage tanks
insulate the tank roof. are continuously exposed to the environment. Wind
causes both pressure and delamination, which can
A common assumption is that the still air above the hot easily result in damage to the insulation protection –
fluid acts as insulation of the tank roof. This assumption usually aluminum sheeting. Consequently, the
is, however, not entirely correct. Due to the difference in aluminum sheeting is blown away and rain water can
temperature between the hot fluid and the non-insula- leak into the insulation. Water accumulation can cause
ted tank roof there is fairly strong convection, which corrosion resulting in severe corrosion of the tank,
results into considerable heat losses. Tank roof leakage of the substance inside etc. Correct precautions
insulation is feasible if the proper insulation material are necessary to ensure the quality and life-time of
and mounting and fixing methods are applied. the insulation.
Many systems can cope with the demands. The

appropriate system will greatly depend on the diameter,
temperature tank, the surrounding environment and
the possibilities to use scaffolding/rope access when
mounting the insulation. In addition, the plant owner
may have specific requirements. Determine whether
the products and construction described are suitable
for the corresponding application in each individual
case. If in doubt, consult the RTI Sales Team.
1. No insulation: strong convection - 2. Insulation: reduced

convection - 3. Insulation: e.g. Rockwool Multiboard
60
1. Insulation: e.g. Rockwool Multiboards - 2. Stainless steel
bands (weather proofing) - 3. Stainless steel bands -
4. Support ring - 5. Protrusion - 6. Cladding -
storage tanks
Insulation of
7. Roof/wall connection
Cladding
A metal cladding is generally applied for the tank wall
and roof. Thanks to its light weight, low costs and ease
of installation, aluminium is commonly applied as
cladding. In special circumstances (fire rating, corrosive
environment etc) other materials such as stainless steel
or Rockwool Rocktight may be used. Please note the
comments under 1.2.6 and watertight covering in this
section.
Support rings
With vertical applications, the weight of the insulation can
damage the insulation layer below. To avoid damaging
the insulation, fit horizontal support rings is higher than
61
Support rings
4 metres. The distance between the support rings should stress/tension on the insulation protection (aluminium
not exceed 3 metres. The construction should be built so sheeting) selecting a flexible insulation material such as
that leakage water can be expelled from the insulation.
m
0 m0 m
m
150150
00mmm
150105m
Rockwool Multiboard is important. For high temperatures,

anticipate further expansion by fitting profiled sheeting.
1. Tank wall - 2. Spacer - 3. Insulation: e.g. Rockwool

Multiboard Ladders and manholes
The necessary space requirements for the insulation must
be taken into account when designing and planning the
mm
00 installation. The distance between the ladder and the
15 mm
00
15
tanks should be large enough to make installing insulation
afterwards possible. Insulate manholes so they can still be
used frequently without damaging the insulation.
1. Horizontal support ring - 2. Spacer - 3. Fixing
Expansion
Large storage tanks expand due to changes in
temperature and if the substance stored is filled or
discharged (so called “bulging”). These factors can
increase/decrease the tank diameter. Example: The
diameter of a storage tank - Ø 20 m, Avg T 220 °C - will
increase approx. 60 mm. This consequently increases
the tank circumference by approx. 180 mm. To avoid
62
Tank wall and tank base connection Connection tank wall - tank roof
When a tank is filled, stress may occur at the welded
seam between the wall and base of the tank. For
5 3
inspection purposes the first 50 cm of the tank wall
should not be insulated. The first support ring is usually
welded above this level and constructed so that leakage
water can be expelled from the insulation. 1
2
4
1. Tank wall - 2. Insulation: Rockwool Multiboard -

3. Tank roof - 4. Cladding (aluminium) - 5. Deflector
Connection tank wall - tank roof with railing
storage tanks
Insulation of
>
1. Tank wall - 2. Insulation: e.g. Rockwool Multiboard -

3. Support ring - 4. Cladding - 5. Welded seam
Tank wall and tank roof connection

A rainwater shield is fitted at the seam between the
tank wall and tank roof to prevent leakage into the tank
wall insulation. Weld the safety guard / railing on this 1. Tank wall - 2. Insulation: e.g. Rockwool Multiboard -
rainwater shield. 3. L-profile - 4. Rain deflector - 5. Support strip -
6. Tank roof - 7. Insulation: e.g. Rockwool CRS - 8. Railing -
9. Not insulated roof
63
Protrusions within tank walls

Protrusions within the tank wall insulation may lead
to leakage of rainwater or pollution with chemical
substances. Keep the number of protrusions to a
minimum. Insulate any remaining protrusions as
indicated below.
Finishing of tank roofs

Similar to tank wall insulation, many constructions are In many cases, the most critical aspect of tank
possible for tank roof insulation. The appropriate insulation is preventing the leakage of rainwater inside
system greatly depends on the tank diameter and the the insulation. Water accumulation can cause corrosion
nature of the seam with the tank wall. In addition, the resulting in severe corrosion of the tank. Correct
plant owner may have specific requirements. The precautions are necessary to ensure the quality and
insulation is generally cladded with aluminium sheeting, life-time of the insulation
“rivetted” or in radial segments. As tank roofs are
vulnerable to delamination, screws may be damaged
(pulled loose).
If welding the roof is not possible, the steel radial

segments in the centre of the roof can be hooked
together in a ring around the perimeter of the roof.
Turnbuckles are used to keep the radials correctly
tensioned.
64
1. Finishing with aluminium cladding - 2. Finishing with steel
radial segments
A: welded steel bar attached

on the roof with a stainless
steel strip
storage tanks
Insulation of
C: Finishing with aluminium cladding
B: applying Rockwool
insulation
1. Tank roof - 2. Cladding - 3. Insulation: Rockwool CRS -

4. Aluminium finishing strip - 5. Bolts and rivets (stainless
steel) - 6. Strip (stainless steel) - 7.Weld - 8. Welded steel bar
65
Protrusions within tank roofs Foot traffic

Protrusions within the tank roof insulation may lead to Tank roofs are subject to foot traffic. To ensure the
leakage of rainwater or pollution with chemical insulation system is resistant to foot traffic, apply a
substances due to overfilling of the tank. Keep the pressure-resistant slab such as Rockwool CRS. If the
number of protrusions in the tank roof to a minimum. If radius of the tank roof is too large to allow the use of a
this is not possible, apply the construction stated below. rigid board, use a flexible slab such as Rockwool
Multiboard in combination with a (local) metal support
construction. The walkways need to be clearly marked.
Watertight covering
Conventional systems for tank roof insulation are often
sensitive to weather damage (water, wind, etc.) and the
effect of chemicals. The costs of maintenance, and the
consequently lower operational safety, are often higher
than the (energy) cost-savings that are realized by the
insulation. For this reason, many tank roofs, especially
in the lower temperature ranges, are not insulated.
• Rocktight is applied directly on Rockwool tank roof
insulation on site. As direct cladding supports are no
longer needed, it fits seamlessly to all parts of the
tank and has an unequalled hardness and
mechanical strength (e.g. can be walked upon).
• In situations exposed to high wind stresses, a special
cable construction can be applied. This will hold the
insulation in place under the most extreme weather
conditions.
• An anti-slip coating is available that can easily be
applied to Rocktight.
• The absence of cladding supports virtually eliminates
any risk of corrosion under the insulation.
• This ensures perfect protection to the insulation and
storage tank, which guarantees the durability of the
insulation.
For more information please contact our RTI-staff.
1. Sealing tape - 2. Insulation: e.g. Rockwool Duraflex -

3. Perforated sheet (ventilation)
66
Rockwool Rocktight is a fibreglass reinforced
polyester mat positioned between two sheets of foil.
The material contains resins, glass fibres and a
special filling agent. It is soft and flexible when
unprocessed. It can be cut or timed in any shape
storage tanks
Insulation of
and easily mounted onto the insulation in this state.
The polyester then hardens when exposed to
ultraviolet (UV) light. Once hardened, Rocktight is
absolutely watertight and forms a mechanical
protection for the insulation.
67
1. System solutions
1.6 Insulation of boilers

Hot water boilers and boilers for the production of water The fire tube boiler consists of a horizontally positioned
vapour under high pressures are considered to be cylindrical casing body with diameters of up to four
steam boilers. As a generic term, boiler is used to metres. The interior generally contains a corrugated flame
denote steam generators and hot water installations. tube, where a fuel, which is usually oil or gas, is burnt. At
Insulating boilers has the following purposes: the end of the boiler are so called reversing chambers,
• Reduces heat losses and increases the efficiency of where the flue gas is reversed and pumped back through
the boiler the boiler. Depending on the design, the boiler will have
• Guarantees protection against contact by minimising one or more gas flues, connected at the rear or the front
the surface temperature base through the reversing chamber. The chamber
• Prevents heating of the compartment air in the boiler surrounding the gas flues and the fire-tube is filled with
house, which guarantees an acceptable working the water to be heated.
The design and functionality of the boilers on the

market is so varied that the examples of use cannot
fully take into account the particular circumstances
of each case. Determine whether the products and
construction described are suitable for the correspon-
ding application in each individual case. In if doubt,
consult the RTI Sales Team.
The applicable standards and regulations must also be

observed. A few examples follow:
• DIN 4140 (Insulation works on industrial plants and
building services installations)
• AGI Q101 (Insulation works on power plant
components)
• CINI-Manual: “Insulation in industry”
1.6.1 Insulation of fire tube boilers

Fire tube boilers are often used in small and medium-
sized industrial plants, where small and medium-sized
mixtures of hot water or water vapour are required at
low pressures. These boilers are used in the technical
building appliances of large complexes, such as hotels,
hospitals etc.
68
Fire tube boiler
1. Boiler casing - 2. Insulation: Rockwool Duraflex - 3. Clad-

ding - 4. Flame tube - 5. Fire tube - 6. Reversing chamber
Applying load bearing mats such as Rockwool Duraflex even surface temperature without temperature peaks
is a proven solution in the insulation of flame (so called hot spots), which pose a hazard in the form
tube-smoke tube boilers. These mats are easily of skin burns. The balanced surface temperature profile
Insulation
of boilers
mounted onto the horizontal, cylindrical boiler surface also accounts for the thermography of a flame fire tube
and are easily fastened to the boilers with metal straps. boiler shown on this page. Wired mats are generally
Metal spacers, which always create thermal bridges, used to insulate the area of reversing chambers and are
can be omitted. Due to the compression resistance of at secured with pins and spring clips.
least 10 kPa, the cladding can be mounted directly
onto the Duraflex insulation. Alternatively, if the sheet
cladding is fitted so closely that it can adopt this
function, the fastening straps can be omitted. The
insulation is characterised by a consistent rigidity and
surface. Due to the lack of spacers, it guarantees an
69
1.6.1 Insulation of fire tube boilers

The thermography of a flame tube-smoke tube boiler, which
is insulated with Rockwool Duraflex. (Source LOOS
INTERNATIONAL, Loos Deutschland GmbH) The areas
insulated with Rockwool Duraflex show an even temperature
distribution without visibly, increased hot spots. The right
image shows the position of the thermographic camera.
Reading point Sp1 has a temperature of 21.7 °C; reading
point Sp2 is 21.2 °C and reading point Sp3 is 22.8 °C.
Insulation works on a fire tube boiler with Rockwool

Duraflex
70
1.6.2 Supercritical steam generators Handles
In the modern energy and heat economy, super critical Handles are reinforcement elements, which are fitted
steam generators, which burn fossil fuels such as vertically between the buckstays and bear the vertical
mineral coal, brown coal and anthracite etc. are used loads exerted on the buckstays on the boiler wall.
to generate steam to operate steam turbines. In current Handles can be located inside and outside the
utility steam boilers, up to 3,600 t steam is genera- insulation sections.
ted per hour under pressures of 300 bar and steam
temperatures of 620 °C. The most common type is the
Benson boiler, that is operated by forced circulation
(with boiler feed pumps). In contrast to fire tube boilers,
the water or vapour is not located in the vessel, but
in pipes, which are fitted in gas-tight, welded tube-fin
constructions and form the walls of the boiler. Generally
constructed as single-pass or two-pass boilers, these
boilers reach levels of up to 160 m, depending on the
fuel used. The bottom contains the furnace, where finely
ground fuel is burned. The flue gases flow through the
boiler and heat the water in the pipes, thereby causing it
to evaporate. The boiler casing is suspended on a frame
and can compensate for any thermal e xpansions that
occur during operation (vertical and horizontal expan-
sions). These types of expansions must be c onsidered
during the design of the insulation system. The diagram
on the right shows the most important technical
components in the insulation of a boiler.
Buckstays
Insulation
of boilers
So-called buckstays are fitted horizontally at regular
intervals around the boiler. Buckstays are reinforcement
elements, which prevent the boiler from bulging.
A distinction is made between hot buckstays, which are
located inside the insulation, and cold buckstays, which
are located outside the insulation sections.
1. Boiler roof - 2. Dead space - 3. Cross bar - 4. Collector -
Dead spaces 5. Boiler support tube - 6. Boiler wall - 7. Buckstay -
Dead spaces are located in front of the boiler wall or 8. Handles - 9. Burner port - 10. Boiler funnel
boiler roof, where installation components such as
collectors, distributors or pipes are fitted. The dead
spaces are located inside the insulation.
71
1.6.2 Supercritical steam generators

Installation of the insulation system for utility The insulation is assembled in multiple layers,
steam generators comprising two to three layers of insulation. The ProRox
The following product characteristics are important WM wired mats with a maximum service temperature of
when selecting a suitable insulation system for utility 680 °C are a tried and tested solution as a first
steam generators: insulating layer in upper temperature ranges, as are
• The insulations used must be non combustible. often encountered in dead spaces. The further layers of
• The maximum service temperature of the insulation insulation are constructed with ProRox WM 80 or WM
must be higher than the operating temperature of the 70 wired mats, depending on the temperature of the
installation component to be insulated adjacent layer. In accordance with AGI guideline Q101,
• The thermal conductivity must be specified as a galvanised wire netting and galvanised stitching wire in
function of the temperature. wired mats can only be heated up to a temperature of
• The (longitudinal) air flow resistance must be as high 400 °C. With temperatures above 400 °C, austenitic
as possible. High flow resistances reduce convection in stainless steel wire netting and stitching wire must be
the insulation. used. To reduce the convection in the insulation of
vertical constructions such as boilers, only use
In addition to protection against contact and the insulations that exhibit an air flow resistance of ≥50
maximum permissible surface temperatures of 60 °C, kPa s/m² .
industrial parameters such as efficiency factors must
be considered during the design of the insulation
thickness. The AGI guideline Q101‚ “Insulation works
on power plant components” recommends that the Diagram of a boiler insulation system with wired mats
insulation layer thicknesses for power plant compo-
nents is designed for a maximum heat flow rate density
of 150 W/m². In view of rising energy prices and the
socio political target of CO2-emission reductions, this
generally recommended value is, however, subject to
critical analysis. From an economic and environmental
perspective, a design parameter of well below 150 W/m²
is often sensible. Rockwool wired mats have proven
invaluable in the insulation of utility steam generators
over the years. They are flexible and can be easily
mounted onto the various geometries or surface
structures. Rockwool wired mats are non combustible,
have high maximum service temperatures and exhibit a
low degree of thermal conductivity across the entire
temperature range. 1. Tubed wall - 2. ProRox WM wired mats - 3. Fastening pins
with spring plates - 4. Cladding
72
Before starting the insulation works, ensure that all Diagram of a boiler insulation system with wired mats
preparatory work on the object has been completed. with a gap between the insulation and sheet cladding
Refer to Chapter 1.1 for details.
The wired mats are fastened to flat surfaces with at

least six pins per m², and on the underside with at least
ten pins per m². The pins are either welded directly
onto the surface of the object or are screwed into nuts.
With finned walls (tube-fin walls), the pins cannot be
fixed to the pipes, but must be welded onto the bars
between the pipes. Observe the following when pinning
the insulation:
• With insulation thicknesses ≤120 mm, use pins with
a minimum diameter of 4 mm.
• With insulation thicknesses ranging from 130 to
230 mm, use pins with a minimum diameter of 5 mm. 1. Finned pipe - 2. Insulation: ProRox WM wired mats -
• With insulation thicknesses ≥240 mm use pins with 3. Fastening pins with spring plates - 4. Aluminium foil if
a minimum diameter of 6 mm. necessary - 5. Metal cladding (e.g. profiled sheet)
• If the cladding rests directly on the insulation without
a gap between the two, the pins must be 10 mm
shorter than the insulation thickness.
• Fasten each insulation layer with clips.
With wired mats, all the lengthwise and crosswise joints

must be sewn or wired together, or joined with six mat
hooks per metre. If the insulation is assembled in
multiple layers, the joints of the individual insulation
Insulation
of boilers
layers must be staggered.
The following illustrations show a number of typical

methods of insulating vessels.
73

Diagram of a wired mats boiler insulation system with Barriers
no gap between the insulation and sheet cladding The following diagrams show two designs for vertical
barriers. Depending on the temperature or structural
requirements, the barrier can be manufactured from
sheet metal (≥ 0.5 mm) or aluminium foil (≥ 80 μm).
The barrier must be fastened to the object on the
heated side and must reach to the cladding on the cold
side. Fill interstices with loose rock wool. Where the
insulation is constructed in multiple layers, cascade
the barriers.
1. Tube wall - 2. Insulation: ProRox WM wired mats –

3. spring plates - 4. Aluminium foil if required - 5. Cladding
(e.g. profiled sheet)
Convection in the insulation

With vertical insulation constructions in particular,
where cavities can form on the heated side between the
object and the insulation, there is an increased risk of
heat losses – caused by convection in the insulation.
This risk equally applies to finned walls, as an insulation
that follows the contours of the object, in which the 1. Boiler wall - 2. Insulation: ProRox WM wired mats - 3. Fill
cavities in the area of the bars are sealed, cannot with loose rock wool - 4. Convection barrier sheet - 5. Alumi-
always be secured. Take the following measures to nium foil if required - 6. Metal cladding - 7. MF profile filling -
prevent convection: 8. Z-profile separating sheet
• Construct vertical barriers at intervals of 5 to 8 m.
• Only use insulations with a longitudinal flow
resistance of ≥50 kPa s/m² .
• Fitting an aluminium foil between the individual
insulation layers and/or on the exterior is recom-
mended.
74
Insulation of the buckstays
Buckstays that are exposed to heat are insulated and Buckstays that are exposed to cold are generally not
fitted with a casing. An example follows. insulated and not cladded. An example follows.
Buckstays exposed to heat on a boiler wall Buckstays exposed to cold on a boiler wall
1. Boiler wall - Insulation: ProRox WM wired mats - 3. Mat

pins with clips - 4. Buckstay deflectors - 5. Aluminium foil if
1. Boiler wall - 2. Insulation: ProRox WM wired mats - 3. Fill required - 6. Metal cladding/profiled sheet - 7. Substructure -
Insulation
of boilers
up with loose rock wool - 4. Support construction - 8. Cold buckstay - 9. Boiler handle
5. Buckstay exposed to heat - 6. Aluminium foil if required -
7. Cladding/Preformed sheet - 8. Internal buckstay cover,
made from black sheet - 9. Mat pins with clips -
10. Aluminium foil barrier - 11. Flat sheet cladding
75
1.7 Insulation of flue gas ducts

Insulation of dead spaces Support construction and spacer
Dead spaces located in front of the boiler wall or roof There are various options available to attach support
containing installation components, are enclosed with constructions and spacers to boilers. They can be
cladding, to which the insulation is then mounted. Use mounted directly onto the boiler, to auxiliary construc-
a non-scaling sheet with a minimum thickness of one tions, to buckstays, cross bars or handles. When
mm. Fasten the sheets to appropriate, structurally selecting the support construction and spacer and the
measured substructures so that the thermal expansions corresponding attachment option, a design matching
can be accommodated. The insulation is secured to the must take place between the insulator and the plant
dead space sheeting with pins as described above. manufacturer. With power plant components with
An example of dead space insulation follows. temperatures above 350 °C, use high temperature
or fireproof steel.
Dead space for boiler wall collector Cladding

With power plant components with large surface areas,
such as utility steam generators, profiled sheets are
used as cladding material for structural, economic
and design reasons. The open spans, overlaps and
connections correspond to the profile. Refer to the
instructions of the relevant profiled sheet manufacturer.
When selecting a suitable cladding material, consider

the following parameters: corrosion, temperature
a
resistance, type of construction and architectural
design. The contractor and customer should consult
about this matter.
1. Boiler wall - 2. Insulation: ProRox WM wired mats - Galvanised steel sheeting is generally used for the
3. Fill up with loose rock wool - 4. Support construction - insulation of utility steam generators, which are usually
5. Dead space sheeting - 6. Aluminium foil if required - located inside buildings.
7. Metal cladding/Preformed sheets - 8. Support construction
and spacer
76
1. System solutions

Burning fossil fuels produces flue gases, which are Furthermore, the applicable standards and regulations
guided through flue gas ducts through the various must be observed. A few examples follow:
cleaning stages, such as denitrification (DENOX) • DIN 4140 (Insulation works on industrial plants and
desulfurization (DESOX) and dust removal (EN), building services installations)
discharged into the atmosphere. Large sections of flue • AGI Q101 (Insulation works on power plant
gas ducts are often located outdoors. They are subject components)
to an extent to both internal and external extreme • CINI manual: Industrial insulation
conditions. The effects of external atmospheric
influences, such as wind and rain, as well as varying
ambient temperatures on the flue gas duct, can lead to 1.7.1 Installation of the insulation systems
intense cooling of the flue gases internally, and for flue gas ducts
therefore to the accumulation of sulphuric acids, which Rockwool wired mats have been a proven solution for
facilitate corrosion. rectangular flue gas ducts for many years. They are
flexible and can fit onto different geometries and
Insulation systems on flue gas ducts have the following surface structures. Rockwool wired mats are non-flam-
purposes: mable, have high maximum service temperatures and
• Reduce heat losses in the flue gas, thereby exhibit a low thermal conductivity across the total
preventing sub-dew point (acid or water dew point) temperature range.
conditions in the flue gas on the interior surfaces of
the flue gas duct. This also minimises the corrosion Secure the wired mats to the rectangular ducts with
risk. This also applies to areas with structural welding pins and spring clips. Before the welding pins
thermal bridges, such as support constructions, are fitted, a bonding procedure should be determined
reinforcements etc. by the plant manufacturer and insulator, which does
• Reduce the heat losses in flue gas channels of heat not damage any corrosion coating present on the inside
recovery systems and outside of the flue gas duct. For example, it may be
• Personal protection advisable to fit the welding pins before constructing the
• Adherence to technical specifications with regard to corrosion coating.
noise
The wired mats must be secured to flat surfaces with at
Designs are so varied in terms of their size and least six pins per m², and on the undersides with at
flue gas ducts
geometry, as well as the materials and layers used, that least ten pins per m².
Insulation of
the examples of use below cannot fully take into

account the particular circumstances of the construc- Observe the following when pinning the insulation:
tion-related factors. • With insulation thicknesses ≤ 120 mm, use pins with
Determine whether the products and construction a minimum diameter of 4 mm .
described are suitable for the corresponding application • With insulation thicknesses ranging from 130 to
in each individual case. If in doubt, consult the RTI 230 mm, use pins with a minimum diameter of
Sales Team. 5 mm.
77
1.7.1 Installation of the insulation systems
for flue gas ducts
• With insulation thicknesses ≥ 240 mm use pins with • Temperature variations between the inner and
a minimum diameter of 6 mm. exterior lead to stress in the profiles. If the tensile
• If the cladding rests directly on the insulation without forces become too great, this can lead to deforma-
a gap between the two, the pins must be 10 mm tions and breaking of the welding.
shorter than the insulation thickness.
• Fasten each insulation layer with clips. Preventing temperature drops on the inside wall
To prevent a drop in temperature on the inside wall in
With wired mats, all the lengthwise and crosswise joints the area of reinforcement profiles, they must always be
must be sewn or wired together, or joined with six mat insulated. The insulation thickness required depends
hooks per metre. If the insulation is assembled in on factors such as the size and geometry of the profiles,
multiple layers, the joints of the individual insulation the temperature level and rate of flow within the flue
layers must be staggered. gas duct and the operating method. Complex
calculations may be required to determine the
To reduce convection in the insulation, fitting barriers is insulation thickness. These are usually established by
recommended, for example made from steel, at the plant manufacturer, who is aware of the installation
intervals of 5 to 8 m when working on large vertical parameters. When starting up the installation, a brief
surfaces. The barrier must be effective across the entire drop in temperature below the dew point of the flue gas
section of insulation up to the cladding. is unavoidable on the inside wall of the duct.
The recommended insulation for round flue gas ducts, Reduction of stress due to temperature in the
where temperatures are below 300 °C, is load-bearing reinforcement profiles
mats Rockwool Duraflex. These are mounted directly The operating method of the installation influences the
onto the flue gas duct and are fastened with straps. problem of stress in the reinforcement profiles caused
A fastening with welding pins and spring clips is by temperature.
generally not required in this instance.
Less critical is the steady operation, where the flue gas
Insulation of reinforcement elements temperature does not change with the passage of time.
Large flue gas ducts are fitted with reinforcement Generally, stresses due to temperature are not critical if
profiles to stabilise the duct. These can consist of the implementation principles outlined in the AGI
double T-girders, hollow sections or reinforcing ribs and guideline Q101 are observed:
form potential thermal bridges. This may cause the
following problems:
• The thermal bridges cause an increased heat flow
and lead to a temperature decrease on the inside
wall of the ducts.
78
• The insulation thickness across the reinforcement
elements should be of the same thickness as the
insulation on the flue gas duct.
• In the case of ducts with reinforcing ribs up to a
height of 100 mm, the thickness of the insulation layer
across the ribs must measure at least one third of the
insulation thickness required for the duct.
Insulation of reinforcing ribs
1. Duct wall - 2. Insulation: ProRox WM Wired mat -

3. Reinforcing ribs - 4. Welding pins with clips -
5. Metal cladding
In the case of non-steady operation, for example, when • The operating speed influences the speed at which
starting up the installation causes fluctuating flue gas temperature of the flue gas increases and the tem-
temperatures , measures must be taken if necessary perature difference in the reinforcement element.
to allow even heating of the reinforcement profiles. The • High temperature differences occur in the case of
temperatures on the duct wall, as well as on the inside large profiles.
of the reinforcement element, increase rapidly when the • The shape of the reinforcement profiles influences an
installation is started up, whilst the outside of the profile even temperature distribution. Thick walled profiles,
remains cold at first and only heats up after a longer for example, do not warm up as evenly as thin walls.
flue gas ducts
delay. This leads to temperature differences, which can • The different thermal conductivities of the materials
Insulation of
cause undue stressing of the component. The extent used and the heat transfer rates lead to an uneven
of the temperature differences depends on numerous temperature distribution.
parameters. A few examples follow:
79
1.7.1 Installation of the insulation systems

for flue gas ducts
To reduce the temperature differences, the insulation Insulation of reinforcing element with cavity and
must be structurally designed to enable as much heat covering sheet
as possible to be transported by means of radiation and
convection from the duct wall to the external flange
of the reinforcement profiles. The following shows the
design details for a profile insulation system.
Insulation of reinforcing ribs
1. Duct wall - 2. Insulation: ProRox WM wired mats -

3. Reinforcing element - 4. Covering sheet - 5. Support
construction and spacer - 6. Aluminium foil (optional) -
7. Welding pins/clips - 8. Metal cladding: corrugated sheet
In the case of profiles measuring above 240 mm in

height, a covering sheet should also be installed. The
1. Duct wall - 2. Insulation: ProRox WM wired mats - 3. Metal heat transfer from the duct wall to the external flange is
cladding: corrugated sheet - 4. Reinforcing element - 5. Sup- therefore not impeded and the cavities do not need to
porting construction and spacer - 6. Aluminium foil (optional) be insulated.
- 7. Welding pins/clips
The profile insulation described leads to increased heat
This type of design is generally recommended for profiles losses through convection in the case of vertical steel
measuring up to ≤ 240 mm in height. girders. As a result, barriers – for example in the form of
sheets welded into the reinforcement elements – must
be fitted at intervals of approximately 3 to 5 m to reduce
convection.
80
1.7.2 Cladding of flue gas ducts
Due to their size and the associated high demands
placed upon the flexural rigidity of cladding, flue gas
ducts are encased with profiled sheets such as
trapezoidal sheets. Flat sheets, which are generally
cambered, can also be used. The claddings are
secured to the flue gas duct using substructures.
With ducts located outdoors with flue gas temperatures

of < 120 °C, an air space of at least 15 mm should be
left between the cladding and insulation. On clear
nights, especially, there is a risk that thermal radiation
in space (the small surface of the “flue gas duct”
radiates on an endlessly large surface “space”), will
cause the surface temperature of the cladding to fall
below the dew point temperature of the ambient air.
The atmospheric humidity from the ambient air can
then condense on the inside of the cladding. Therefore,
the insulation and cladding must not be allowed to
touch. To drain the water, drill drainage or ventilation
holes at the lowest point on the underside.
With round flue gas ducts, which are constructed with

the spacer free insulation Rockwool Duraflex,
corrugated straps or bubble wrap are inserted between
the insulation and sheet cladding as a spacer.
If the duct is located outside, the upper surface of the

cladding should have a gap of ≥ 3 %. The following
pages show two examples for the cladding of a flue gas
duct with a pent or gabled roof. flue gas ducts
Insulation of
81
1.7.2 Cladding of flue gas ducts

Duct located outdoors with a cladding constructed as
a pent roof
1. Duct wall - 2. Insulation: ProRox WM wired mat -

3. Support construction and spacer - 4. Welding pins/
clips - 5. Metal cladding: corrugated sheet - 6. Extension
(trapezoid) - 7. Z-shaped spacer
82
Duct located outdoors with a cladding constructed as a saddle roof
flue gas ducts

Insulation of
1. Duct wall - 2. Insulation: ProRox WM wired mat -

3. Support construction and spacer - 4. Welding pins/clips -
5. Metal cladding: corrugated sheet - 6. Extension (trapezoid) -
7. Z-shaped spacer - 8. Support construction - 9. Ridge
83
1.7.3 Acoustic insulation of flue gas ducts

The thermal insulation of flue gas ducts influences the
propagation of airborne noise and structure-borne
noise. The effects of this depend on many factors, such
as the frequency, the noise pressure level and the
structure. The following structural measures influence
the acoustic properties of an insulation system:
• Changing the insulation layer thickness and/or the
apparent density of the insulation
• Changing the clear distance between the flue gas
duct and the cladding
• Acoustic decoupling of the cladding from the flue gas
duct using elastic elements within the support
construction and spacer (e.g. omega clamp, rubber
elements, steel wool pads)
• Increasing the basic weight of the cladding through
the choice of material or sheet thickness
• Internal coating of the cladding with sound-
deadening materials
• Construction of the insulation in multiple layers, with
at least two separate insulating layers and cladding
84
1. System solutions
1.8 Cold boxes

Many industrial applications use gases such as oxygen, Cold boxes
nitrogen and argon. These gases are obtained using An important component in gas separation plants are
cryogenic gas separation technology, whereby air is the so-called “cold boxes”. Cold boxes are (pressure)
condensed and converted into a liquid. Afterwards, vessels that hold a gas or liquid at a very low temperature.
the various elements can be separated using fractional The distinctive feature of cold boxes is the double-wall
distillation. construction, which allows the insulation to be fitted
between the inner and outer walls. The cold box is
So-called air separation plants are characterised by an sealed after the insulation has been fitted, so the
extremely low temperature of as low as approximately insulation can no longer come into contact with, for
-200°C. In addition to the risk of water and ice forming example, water, snow, dust and contaminants.
at this cryogenic temperature, there is also the risk of
pure oxygen condensing against the cold parts of the Choice of insulation
system. The presence of oil and grease may be enough The choice of insulation material depends on a variety
to cause the high concentration of oxygen to spontane- of parameters, including the user requirement,
ously combust. This is obviously an extremely hazardous standards (e.g. AGI Q118), the operating temperature
situation. The presence of oil and grease must therefore and the accessibility of the installation. In many cases,
be avoided at all times. It is vitally important to well mineral wool fibres are used (e.g. Rockwool Granulate),
insulate all cold parts of the system, such as vessels and which contain a very low proportion of organic
pipes. Strict specifications regarding the insulation are substances- the so-called “Linde Quality”. This can be
therefore essential. A frequently applied standard for the easily injected into the vessel and has a very long
insulation of air separation plants is the AGI Q 118 lifespan. The material is easily removed for inspection
standard “insulation work on air separation plants”. purposes.
This standard describes in detail the various parts of
the installation and the insulation to be applied. Fitting the insulation
The construction method naturally depends on the In compliance with the AGI Q118 standard, the fibres
application. The following instructions are limited are fitted manually or using an injection technique. The
to the insulation of so-called cold boxes. hollow spaces in the installation must be free of water
and other liquids and contaminants. All filling openings
(and non-filling openings) must be sealed. An optimum
result is achieved by pulling the packaged, loose fibres
apart before injecting or shaking them into the vessel.
The Rockwool Granulate must be injected or shaken
into the unit in even layers. If necessary, the wool can
then be tamped to achieve the required density. To
avoid damage to the installation, manually filling certain
parts of the installation may be advisable. The ultimate
density of the fitted wool depends on how it is fitted.
Cold boxes
85
1.8 Cold boxes
Fitting the insulation

Densities of at least 150 kg/m3 are feasible. The official
requirement according to the AGI Q118 standard is 160
to 200 kg/m3. The procedure is outlined step by step as
follows:
1. Create a trial set up by filling a 60 x 60 x 60 cm crate

with an evenly distributed layer of loose wool, with a
thickness of 300 - 400 mm. Then have a man of
average weight compact this layer by treading on it.
Repeat this process until the box is full. Calculating
the quantity of wool used (in kg) afterwards allows
the feasible density to be determined. This also gives
a good idea of the tamping method required in order
to achieve an effective filling density.
2. Before starting to fill the cold box, fill the installation

with air to create a slight overpressure. This will
make any possible leaks, which can occur during
the tamping process, audible.
3. The cold box is filled with an evenly distributed layer

of Rockwool granulate, with a thickness of 300 mm
- 400 mm. Tamp down this layer until a density is
reached that corresponds to the density in step 1.
4. Repeat step 3 until the cold box is completely filled.

Check the filling density by regularly calculating the
number of kilograms used in relation to the filled
volume. The pressure required to achieve a certain
density depends on the procedure that has been
followed.
Note
As Rockwool Granulate may settle after a while or the
shape of the cold box may alter due to temperature
fluctuations, take into account that the unit will need
to be refilled.
86
4
2
Theory
2. Theory
Table of contents
2.1 Norms & Standards 90
2.1.1 Overview of different norms & standards 90

2.1.2 Insulation specification 90
a) CINI Guideline 91
b) PIP - guidelines 92
c) ASTM standards 93
d) European standardisation (CEN) 94
e) DIN standards & guidelines 95
f) AGI guidelines 95
g) BFA WKSB guidelines 97
h) FESI guidelines 97
i) ISO standards 98
j) VDI 2055 guideline 98
k) British Standard (BS) 99
l) Norme Française (NF) 100
m) Document Technique Unifié (DTU) 102
2.1.3 Relevant guidelines & standards for the technical insulation industry in Germany 103
2.1.4 Relevant guidelines & standards for the technical insulation industry within the Benelux 110
2.2.1 Fire behaviour 110

2.2.2 Thermal conductivity 112
2.2.3 Maximum service temperature 115
2.2.4 Water Leachable chloride content 118
2.2.5 Water repellency 119
2.2.6 Water vapour transmission 121
2.2.7 Air flow resistance 121
2.2.8 Compression resistance 121
2.2.9 Density 121
2.3 Bases for thermal calculations 122
89
2. Theory
2.1 Norms & Standards

2.1.1 O
verview of different norms • Shell : DEP
& standards • British Petroleum : BPS
There are numerous standards, guidelines and • Mobil standards : MS
specifications for the planning, design and construction • Exxon standards : ES
of technical insulation systems. These regulations must
be observed to guarantee the functionality, economic These specifications often refer to industrial guidelines
operation and safety of a technical installation, as well and society standards
as a long service life.
General-specific or site standards
Industrial plants are built and maintained according General project or maintenance standards for common
to a range of requirements, detailed in numerous materials and equipment adopted by owners and
technical standards that cover all design and contractors. Often, national, country-specific standards
equipment requirements. & guidelines are observed, e.g.:
• Saudi Operation Specification: SOS
An overview of the commonly used standards, • Petroleum Development Oman: POD
guidelines and specifications is mentioned below.
2.1.2 Insulation specification
Society standards The insulation specification is part of the plant owner or
Published standards from an accredited standards contractors specification. It generally contains:
developer. Common examples are ASTM, European • Guidelines for preparation prior to the insulation work
Standard (EN), DIN. Often related to product • Material specifications
performance. • Mounting instructions per application
Industrial guidelines for insulation The insulation specification also often includes the
In many cases, industrial guidelines are established to guidelines for corrosion protection. Similar to other
ease and to reduce the development & maintenance specifications, the insulation specification often refers
time and effort of specifications sharing best practices. to society standards and/or industrial guidelines.
They contain detailed technical requirements for
design, material selection/approval. These specifications The detailed lay-out per specification will depend on the
often refer to society standards and industrial guidelines. type of application, the plant owner, contractor and
Typical examples in industrial insulation are DIN 4140, country specific requirements.
AGI Q101, PIP, CINI.
A more detailed explanation of the most common
Internal plant owner or contractor specifications standards, guidelines and specifications is given in the
Detailed technical requirements for design, procure- following documents.
ment, construction, and related maintenance based on a) CINI guideline
a company’s experience (so called best practices), e.g.: b) PIP guideline
90
c) ASTM standards
d) European standardization
e) DIN standards & guidelines
f) AGI guidelines
g) BFA WKSB guidelines
h) FESI guidelines
i) ISO standards
j) VDI 2055 guideline
k) British Standard (BS)
l) Norme Française (NF)
m) Document Technique Unifié (DTU)
The wide variety per country, application and plant

owner means these documents cannot convey the
entire content and so cannot claim to be complete. For
specific applications, please contact our RTI-sales team
for advice.
a) CINI Guideline
CINI is a Dutch association, in which various compa-
nies active in the technical insulation of industrial plants
have united to develop uniform material and design
guidelines. When compiling these standards, CINI
works closely with many decision makers from within
the insulation sector.
The CINI Standards are guidelines, yet they do not

constitute national standards. Nevertheless, the CINI
standards are often adopted by operators and design
engineers in the Benelux countries, as well as by
international companies operating in the petrochemical
industry, for example, Shell. They are often used by
operators and design engineers as guidelines on
tendering procedures for insulation works. The CINI
standards also are grouped into material standards and
design rules. The validation of the material properties
is based on ASTM and AGI guidelines.
More information is available via www.cini.nl 91

CINI 2.2.01 Stone wool boards: Rockwool (RW) slabs for the thermal insulation of equipment
Wired mats: Rockwool (RW) wire mesh blankets for the thermal insulation of large
CINI 2.2.02
diameter pipes, flat walls and equipment
Insulation Pipe sections: Rockwool sections and prefabricated elbows for the thermal insulation of
CINI 2.2.03
materials pipes
(Material Loose wool: Loose rock wool without binder for the thermal insulation of valve boxes and
standards) CINI 2.2.04
the specification stuffing of insulation mattresses
Lamella mats: Rockwool lamella mats for the thermal insulation of air ducts, pipe
CINI 2.2.05
bundles and equipment
Aluminium faced pipe sections: Rockwool sections with reinforced pure aluminium foil
CINI 2.2.06
facing for the thermal insulation of pipes
CINI 3.1.02 Aluminised steel sheeting: Aluminised steel cladding for the finishing of insulation
CINI 3.1.03 Alu-zinc coated steel sheet: Alu-zinc steel cladding for the finishing of insulation
Cladding
Galvanised steel sheet: Continuous hot dip (Sendzimir) galvanised steel cladding for the
(Material CINI 3.1.04
finishing of insulation
standards)
CINI 3.1.05 Austenitic stainless steel: Stainless steel cladding for the finishing of insulation
CINI 3.1.11 GRP: Weather resistant UV-curing glass fibre-reinforced polyester (GRP)
General processing guidelines: Installation instructions for the thermal insulation of hot
CINI 1.3.10
pipelines and equipment (insulated with mineral wool)
CINI 4.1.00a Pipes: (Overview) piping insulation details
CINI 4.2.00 Columns: (Overview) insulation/finishing details overview columns
Processing CINI 4.3.00 Vessels: (Overview) insulation/finishing detail overview vertical vessels
guidelines
Heat exchangers: (Overview) insulation/finishing details overview horizontal heat
CINI 4.4.00
exchangers
Vessels: (Overview) insulation/finishing details for tanks (operating temperature from
CINI 4.5.00
20°C to 180°C
CINI 7.2.01 Corrosion protection: Corrosion protection under insulation
b) PIP - guidelines standards in many engineering disciplines. Specific

Process Industry Practices (PIP) is a consortium of Practices include design, selection and specification,
mainly US-based process industry owners and and installation information. Some of the best practices
engineering construction contractors who serve the are mentioned below.
industry. PIP was organised in 1993 and is a separately • INIH1000 - Hot Insulation Installation Details
funded initiative of the Construction Industry Initiative • INSH1000 - Hot Service Insulation Materials and
(CII) and the University of Texas at Austin. PIP Installation Specification
publishes documents called Practices. These Practices
reflect a harmonisation of company engineering More information is available via www.pip.org
92
c) ASTM standards The ASTM standards are grouped into materials
ASTM International (ASTM), originally known as the standards and validation standards for product
American Society for Testing and Materials, is an properties. International tenders for the insulation of
international organisation that develops and publishes industrial plants often refer to relevant ASTM standards.
voluntary standards for a wide range of materials,
products, systems and services. ASTM is older than The ASTM annual book of standards comprises 77
other organisations for standardisation, such as BSI volumes. The corresponding standards for insulation
(1901) and DIN (1917), however it differs from these in are incorporated into ASTM Volume 04.06 “Thermal
that it is not a national standard-setting body. This role insulation; Building and environmental acoustics”.
is performed in the USA by the ANSI Institute. A relevant extract is shown below.
Nevertheless, ASTM plays a predominant role in the
specification of standards in the USA and for many More information is available via www.astm.org
international projects – particularly in the Middle East,
Asia and South-America.
Wired mats: “Standard specification for mineral fiber blanket insulation and
ASTM C592
blanket-type insulation (Metal-mesh covered) (Industrial type)”
Pipe sections: “Rockwool sections. For the thermal insulation of pipes.
Materials ASTM C547
Standard specification for mineral fiber pipe insulation”
Slabs: “Rockwool (RW) slabs for thermal insulation of equipment.
ASTM C612
Standard specification for mineral fibre block and board thermal insulation”
Testing of the thermal conductivity (pipe sections): “Standard test method for steady-
ASTM C335
state heat transfer properties of pipe insulation”
Testing of the thermal conductivity (slabs): “Standard test method for steady-state heat
ASTM C177 flux measurements and thermal transmission properties by means of the guarded hot
plate apparatus test method”
Testing of the maximum service temperature: “Standard test method for hot-surface
ASTM C411
performance of high-temperature thermal insulation”
Testing of the flame propagation on surfaces: “Standard test method for Surface Burning
ASTM E84
Product characteristics of Building Materials”
properties
ASTM C795 “Thermal insulation for use in contact with austenitic stainless steel”
“Evaluating the influence of thermal insulations on external stress corrosion cracking

ASTM C692
tendency of austenitic stainless steel”
“Chemical analysis of thermal insulation materials for leachable chloride, fluoride,

ASTM C871
silicate plus sodium ions”
ASTM C1104/
“Determining the water vapor sorption of unfaced mineral fi ber insulation”
C1104M
Thermal Standard practice for estimate of the heat gain or loss and the surface temperatures
ASTM C680
calculations of insulated flat, cylindrical, and spherical systems by use of computer programs
93

d) European standardisation (CEN) for technical insulation are currently being compiled.
In order to remove technical barriers to trade, the For Rockwool, this product standard is the prEN 14303
European Union decided to develop uniform European “Thermal insulation products for building equipment
product standards. These product standards describe and industrial installations – Factory-made mineral wool
the product properties, as well as the methods of (MW) products – specification”. The official implemen-
testing for these properties. The minimum requirements tation of this standard is expected to take place in
for certain product properties still remain a national 2009. Following ratification, a European standard must
responsibility and are laid down in each individual be adopted as it stands by the national standardisation
country. The EU issues orders in the form of mandates organisations as a national standard. Deviating national
to CEN (the European Committee for Standardisation), standards must be retracted. Each European standard
which the CEN uses to develop relevant standards. The adopted is published in each EU country with a national
majority of orders have now been commissioned and prefix, e.g. in Germany: DIN-EN-XXXX; in United
initial harmonised standards, such as the insulation Kingdom (British Standard): BS-EN-XXX. The (as of yet)
standards for structural engineering (DIN EN 13262), unratified standards are denoted with the letters “pr”
have been published. The European product standards (for proof) e.g. prEN-XXXXX.
Product properties, test standards
Product property Standard Description

Thermal conductivity Heat insulation – Determination of steady-state thermal transmis-
EN ISO 8497
(Piping) sion properties of thermal insulation for circular pipes
Thermal performance of building materials and products – Determi-
Thermal conductivity
EN 12667 nation of thermal resistance by means of guarded hot plate and heat
(Boards)
flow meter methods - Products of high or medium thermal resistance
Water vapour diffusion Thermal insulating products for building applications – Determina-
EN 12086
resistance coefficient tion of water vapour transmission properties
Thermal insulation products for building equipment and industrial
EN 13468 Replaces AGI
AS quality installations – Determination of trace quantities of water-soluble
guideline Q135
chloride, fluoride, silicate, sodium ions and pH
Thermal insulating products for building equipment and industrial
EN 13472 Replaces AGI
Hydrophobic treatment installations – Determination of short-term water absorption by
guideline Q136
partial immersion of preformed pipe insulation
EN 14706 Thermal insulating products for building equipment and industrial
(for flat products) installations – Determination of maximum service temperature
Maximum service tem-
EN 14707 (for piping) Thermal insulating products for building equipment and industrial
perature
installations – Determination of maximum service temperature for
preformed pipe insulation
Thermal insulating products for building applications –
Compression resistance EN 826
Determination of compression behaviour
EN 29053
Acoustics; Materials for acoustical applications;
Air flow resistance Determination of airflow
Determination of airflow resistance (ISO 9053:1991)
resistance
94
e) DIN standards & Guidelines DIN standards for the validation of insulation materials
Deutsches Institut für Normung e.V. (DIN; in English, can be found under European standards. DIN 4140
the German Institute for Standardization) is the German “Insulation work on industrial installations….”gives
national organisation for standardisation and is that guidelines for the validation of insulation material,
country’s ISO member body. mounting and fixing. This standard applies to insulation
works on industrial plants. These are production and
DIN is a registered association (e.V.), founded in 1917, distribution plants for the industry and for technical
originally as Normenausschuss der deutschen Industrie building appliances, (e.g. appliances, vessels, columns,
(NADI, Standardization Committee of German Industry). tanks, steam generators, pipes, heating and ventilation
In 1926, the NADI was renamed Deutscher Norme- systems, air conditioning units, refrigeration units and
nausschuss (DNA, German Standardization Committee) hot water installations). With requirements relating to
in order to indicate that standardisation covered many fire protection, the relevant standards or national
fields, not just industrial products. In 1975 the DNA technical approvals must be observed. This standard
was finally renamed DIN. Since 1975, it has been does not apply to insulation works performed on
recognised by the German government as the national building shells, interior walls and inserted ceilings,
standards body and represents German interests at neither in the shipbuilding and vehicle manufacturing
international and European level. industry, nor within the control area of power plants.
The acronym DIN is often wrongly expanded as f) AGI

Deutsche Industrienorm (German industry standard). “Arbeitsgemeinshaft Industriebau e.V”. (AGI) is a
This is largely due to the historic origin of the DIN as German association of manufacturers, engineering
NADI. The NADI indeed published their standards as companies and universities. AGI was founded in 1958
DI-Norm (Deutsche Industrienorm, German industry to establish a common platform to exchange best
standard). practices within Industry.
These practices, which are summarised in the AGI
Designation guidelines (so called “Arbeitsblätter”) are established in
The designation of DIN standards shows its origin. cooperation with the German DIN, VDI and CEN
• DIN # is used for German standards with primarily members for insulation. The most relevant standard for
domestic significance or designed as a first step insulation work is shown on the next page.
toward international status.
• E DIN # is a draft standard and DIN V # is a More information is available via www.agi-online.de.
preliminary standard.
• DIN EN # is used for the German edition of European
standards.
• DIN ISO # is used for the German edition of ISO
standards.
• DIN EN ISO # is used if the standard has also been
adopted as a European standard.
95
Material standards and design guidelines Field of application/scope
AGI Q02: Insulation works on industrial The terms used in the AGI Q working documents are defined in this working
installations – Terms document.
This working document applies to insulation works performed on industrial instal-
AGI Q03: Construction of thermal and cold
lations. The working document classifies works into thermal insulation works for
insulation systems – Insulation works of
operating temperatures above the ambient temperature and cold insulation works
industrial plants
for operating temperatures below the ambient temperature.
AGI Q05: Construction of industrial plants

This working document has been compiled for planners and designers who have to
– Bases, design, requirements with regard
design the industrial plants, including the essential thermal or cold insulation. It
to the interfaces of plant components and
examines, in particular, the interfaces between plant construction and insulation.
insulation
Working document Q 101 applies to insulation works performed on power plant
AGI Q101: Insulation works on power plant
components such as steam generators and flue gas cleaning systems, pipe
components – Construction
systems and steel flues
AGI Q103: Insulation works on industrial This working document applies to insulation works performed on industrial plants
plants – Electrical tracing with electrical tracing.
AGI Q104: Insulation works on indus- This working document applies to insulation works performed on industrial
trial plants – Tracing systems with heat installations, which are heated and/or cooled by means of heat transfer and/or
transfer media refrigerant media, for example in tracing pipes or half pipe sections.
This working document applies to rock wool insulation, which is used for thermal,
AGI Q132: Rockwool as insulation for
cold and acoustic insulation of technical industrial plants and technical building
industrial plants
appliances.
This working document applies to corrosion protection coating systems for the sur-
faces of industrial plants, such as appliances, columns and pipes, which are insu-
AGI Q151: Insulation works – Protecting
lated against heat and cold loss. Since the DIN EN ISO 12944 standard provides no
thermal and cold insulation systems on
explanations with regard to protecting insulation systems against corrosion, this
industrial plants against corrosion
working document should be considered as a supplement to standard DIN EN ISO
12944. This working document does not apply in respect of adhesive primers.
AGI Q152: Insulation works on industrial This AGI working document applies to objects where the insulation must be pro-
plants – Protection against moisture tected against moisture and, above all, against the ingress of liquids, (e.g. water,
penetration heat transfer oil).
AGI Q153: Insulation works on industrial AGI working document Q 153 applies to the design and construction of mounting
plants – Mounting supports for support supports. They transfer the loads of the insulation onto the support constructions
constructions on the object.
AGI Q154: Insulation works on industrial
AGI working document Q 154 applies to the construction of support constructions.
plants – support constructions
96
g) BFA WKSB h) FESI
‘Deutsche Bauindustrie’ is a German branch FESI, Fédération Européenne des Syndicats
organization within the building & construction industry. d’Entreprises d’Isolation is the European Federation
Part of this organization is the so called Bundes Fach of Associations of Insulation Companies. FESI was
Abteilungen {(BFA) - ‘technical departments’} who are founded in 1970 and is the independent European
specialized in the technological developments and Federation representing the insulation contracting
lobby activities within a specific area of technical sector. FESI promotes insulation as one of the best,
expertise. One of them, the so called “BFA WKSB” the most cost effective and sustainable manners to save
{Bundes Fach Abteilung Wärme-, Kälte-, Schall-und energy. FESI represents the insulation associations from
Brand Schutz}, represents the branche members’ 16 European countries whose members are active in
interests in industrial insulation, acoustic insulation and insulation for industry, commercial building sectors,
fire proofing in buildings. As well as lobbying towards ship insulation, soundproofing, fire protection and
the various organizations and the German government, others. The most important FESI documents (guide-
they recommend best practices and provisions as lines, recommendations) are shown below.
stated in the so called technical letters. These practices
are established in cooperation with DIN, AGI, CEN, Document Description
FESI and testing bodies like FIW. The most important
technical letters for hot insulation are shown below.
Working Manual: System for measurement and
recording for industrial insulation cladding
04
(English translation of BFA WKSB letter no. 4
Technical Field of application/scope and 2).
Letter
Problems associated with the warranty of
05 specified surface temperature. (English trans-
Problems of thermal stress in metal reinforce-
lation of BFA WKBS, technical letter no. 5)
1 ments of large-dimensional object with
elevated service temperatures "High profitability through ecologically based
3 Prevention of metal corrosion 06 insulation thicknesses. (English translation of
BFA WKBS, technical letter no. 6)
System for measurement and recording for
4 "Principles of metal corrosion". (English
industrial insulation cladding.
09 translation of BFA WKBS, technical letter no.
Problems with the warranty of specified 3 and 2)
5
surface temperatures
A industrial Acoustics – B Building acoustics
A1
High profitability through ecologically based – Code of Guarantee
6
insulation thicknesses
"Problems of thermal stress in metal
reinforcements of large-dimensional objects
9 Methods of measuring 11
with elevated service temperatures" (English
translation BFA WKSB technical letter Nr. 1, 2.)
10 Measuring point for thermal insulation A2 Basics of Acoustics
“Product characteristics “ Acoustic insulation,
11 Moisture in insulation systems A3
absorption, attenuation
More information is available via www.bauindustrie.de More information is available via www.fesi.eu
97

i) ISO
The International Organization for Standardization and warm water pipes in technical building equipment
(Organisation internationale de normalisation), widely with respect to Germany, are laid down in the
known as ISO, is an international-standard-setting body regulations concerning energy-saving heat insulation
composed of representatives from various national and energy-savings in buildings (EnEV Energy Saving
standards organizations. Founded on 23 February Ordinance). The considerations expressed in this
1947, the organisation promulgates world-wide guideline may lead to other insulation thicknesses.
proprietary industrial and commercial standards. It is With regard to heat insulation in the construction
headquartered in Geneva, Switzerland.[1]. While ISO industry, both the EnEV and DIN standard 4108.
defines itself as a non-governmental organization, its Legal requirements must be observed with regard to
ability to set standards that often become law, either the fire performance of insulation and the fire
through treaties or national standards, makes it more resistance classes of insulation, such as federal state
powerful than most non-governmental organizations. In building regulations [Landesbauordnungen] and the
practice, ISO acts as a consortium with strong links to piping system guidelines of the federal states
governments. Most of the ISO standards for insulation [Leitungsanlagen-Richtlinien der Bundesländer].
focus on the testing of material properties and are
embedded in, for instance, EN standards. The VDI guideline 2055 also serves as a benchmark for
thermo technical calculations and measuring systems
More information is available via www.iso.org in relation to industrial and building services installa-
tions and for guarantees and conditions of supply with
j) VDI 2055 regard to those installations. The guideline covers in
Verein Deutscher Ingenieure (VDI) (English: Association detail the calculation of heat flow rates, the design of
of German Engineers) is an organisation of engineers the insulation thickness according to operational and
and natural scientists. Established in 1856, today the economic aspects, the technical warranty certificate
VDI is the largest engineering association in Western and the technical conditions in respect of delivery
Europe. The role of the VDI in Germany is comparable quantities and services. Furthermore, the guideline
to that of the American Society of Civil Engineers examines measuring systems and testing methods
(ASCE) in the United States. The VDI is not a union. (for quality assurance).
The association promotes the advancement of The VDI 2055 consists of:
technology and represents the interests of engineers • Part 1: Bases for calculation
and of engineering businesses in Germany. • Part 2: Measuring, testing and certification of
insulation materials
VDI 2055 is the most important guideline for technical • Part 3: Conditions of supply and purchasing of
insulation. The scope of the guideline includes heat and insulation systems
cold insulation of technical industrial plants and
technical building equipment, such as pipes, ducts,
vessels, appliances, machines and cold stores. The
minimum insulation thicknesses for heat distribution
98
k) British standard
British Standards are produced by BSI British while encouraging manufacturers to adhere to a
Standards, a division of BSI Group that is incorporated common method for such a specification.
under a Royal Charter and is formally designated as the
National Standards Body (NSB) for the UK. The The following table provides an overview of the
standards produced are titled British Standard standards and regulations that must be taken observed
XXXX[-P]:YYYY where XXXX is the number of the when insulating industrial plants with Rockwool
standard, P is the number of the part of the standard insulation. On the one hand, they are grouped
(where the standard is split into multiple parts) and according to product and material standards, which
YYYY is the year in which the standard came into effect. establish the different insulation properties, and on the
British Standards currently has over 27,000 active other hand, according to validation and design rules.
standards. Products are commonly specified as
meeting a particular British Standard, and in general
this can be done without any certification or independ-
ent testing. The standard simply provides a shorthand
method of claiming that certain specifications are met,
Standard Description
This important code of practice describes aspects of thermal insulation for pipe
BS 5970: Code of practice for thermal in-
work and equipment in the temperature range –100 °C to +870 °C. It includes
sulation of pipework and equipment in the
detailed methods of installing thermal insulation, general performance requirements
temperature range of -100 °C to +870 °C
and calculation methods.
This British Standard describes a method for specifying requirements for thermal
BS 5422: Method for specifying thermal in- insulating materials on pipes, tanks, vessels, ductwork and equipment for
sulating materials for pipes, tanks, vessels, certain defined applications and conditions within the temperature range -40
ductwork and equipment operating within degrees C to +700 degrees C. It gives the recommended thickness and perform-
the temperature range -40 °C to +700 °C ance of thermal insulation material for various applications, and details thermal
calculation procedures.
Colours for identifying pipes conveying fluids in liquid or gaseous condition in
BS 1710 Specification for identification of
land installations and on board ships. Colour specifications in accordance with
pipelines and services
BS 4800.
BS 5803-Part 1: Specification for man-
made mineral wool thermal insulation Physical and chemical requirements and dimensions for wired mats.
mats
BS 3958-Part 4: Thermal insulating
Physical and chemical requirements, dimensions and finishes for pipe sections
materials. Bonded preformed man-made
generally for use at elevated temperatures.”
mineral fibre pipe sections
BS 3958-Part 3: Thermal insulating mate-
Specifies composition, moisture content, physical and chemical requirements for
rials. Metal mesh faced man-made mineral
mineral fibre mattresses, faced on one or both sides with flexible metal mesh.
fibre mattresses
BS 3958- Part 5: Thermal insulating mate- Composition, moisture content, physical and chemical requirements, and
rials. Specification for bonded man-made s tandard sizes. Products are divided into four groups according to thermal
mineral fibre slabs conductivity and temperature range
99
Test methods
Part 4, Non combustibility test for materials

Part 6, Methods of test for fire propagation of products
BS 476-4 “Fire test on building materials”
Part 7, Method for classification of the surface spread of flame
products
BS 874 “Methods for determining thermal insulating
Determination of steady-state thermal conductivity of homogeneous
properties. Tests for thermal conductivity and related
insulating solids of medium conductivity
properties. Unguarded hot-plate method”
This standard covers the test methods for the determination of the
actual product performance.
BS 2972 Methods of testing inorganic thermal insulation
materials
Section 6: Maximum Service Temperature
Section 11: Water repellency
l) NF (Norme Française) mark This standard consists of:

The NF mark is an official French quality mark, issued • French, European or international standards
by the Association Française de Normalisation (French • Supplementary specifications regarding the product
Association for Standardization, AFNOR), which or service and the quality system in place in the
certifies compliance with the French national company as comprised in the certification rules,
standards. The use of the NF mark has been entrusted specific to each product or service.
to AFNOR Certification (a subsidiary of the AFNOR
Group). The certification standards are drawn up in collabora-
tion with all relevant stakeholders: manufacturers or
The NF quality mark is not a trademark as such, but is service providers, trade organisations, consumers,
a collective certification mark. It carries undisputable public authorities and technical bodies. Compliance
proof that a product satisfies the safety and/or quality with French standards is mandatory in France for all
specifications defined within the corresponding supply or construction contracts for public authorities
certification standard. (government contract).
More information is available via www.afnor.org
100
NF EN ISO 7345
Thermal insulation – Physical quantities and definitions
July 1996
NF EN ISO 9251
Thermal insulation – Heat transfer conditions and properties of materials - Vocabulary
July 1996
NF EN ISO 9288
Thermal insulation – Heat transfer by radiation – Physical q uantities and definitions
July 1996
General NF EN ISO 8497 Thermal insulation – Determination of steady-state thermal t ransmission properties of
December 1996 thermal insulation for circular pipes
NF EN ISO 9229
Thermal insulation – Vocabulary
September 2007
Thermal insulation for building equipment and industrial installations -
NF EN ISO 12241
Calculation rules
October 1998
Classification index P 50-730
NF EN ISO 13787 Thermal insulation products for building equipment and industrial installations -
August 2003 Determination of declared thermal conductivity
Thermal performance of building materials and products –
NF EN 12667
Determination of thermal resistance by means of guarded hot plate and heat flow meter
July 2001
methods – Products of high and medium thermal resistance
NF EN 8497 Thermal insulation - Determination of steady-state thermal transmission properties of
Property
September 1996 thermal insulation for circular pipes (ISO 8497:1994)
Thermal performance of building materials and products –
NF EN 12939
Determination of thermal resistance by means of guarded hot plate and heat flow meter
March 2001
methods – Thick products of high and medium thermal resistance
NF EN 14303 Thermal insulation products for building equipment and industrial installations -
October 2005 Factory made mineral wool (MW) products – Specification
NF EN 1609 Thermal insulating products for building applications - Determination of short term
July 1997 water absorption by partial immersion
Thermal insulating products for building equipment and industrial installations –
NF EN 13472
Determination of short term water absorption by partial immersion of preformed pipe
December 2002
insulation
NF ISO 2528 Sheet materials – Determination of water vapour transmission rate –
September 2001 Gravimetric (dish) method
NF EN 12086 Thermal insulating products for building applications –
November 1997 Determination of water vapour transmission properties
NF EN 12087 Thermal insulating products for building applications -
November 1997 Determination of long term water absorption by immersion
Test standard
NF EN 12087/A1 Thermal insulating products for building applications -
January 2007 Determination of long term water absorption by immersion
NF EN 14706 Thermal insulating products for building equipment and industrial installations -
February 2006 Determination of maximum service temperature
NF EN 14707/IN1 Thermal insulation products for building equipment and industrial installations -
March 2008 Determination of maximum service temperature for preformed pipe insulation
NF EN 14707+A1 Thermal insulation products for building equipment and industrial installations -
March 2008 Determination of maximum service temperature for preformed pipe insulation
July 1997 Determination of the apparent density
101

July 1997 Determination of the apparent density
Test standard September 1996 Determination of the apparent density
Thermal insulation products for building equipment and industrial installations -
NF EN 13468
Determination of trace quantities of water soluble chloride, fluoride, silicate, sodium ions
September 2002
and pH
NF EN 13162 Thermal insulation products for buildings – Factory made mineral wool (MW) products –
Insulating February 2009 Specification
materials NF P75-101
Thermal insulation for building purposes – Definition
October 1983
Insulation work – Thermal insulation of circuits, appliances and accessories from -80
°C to +650 °C - Part 1-1: contract bill of technical clauses - Part 1-2: general criteria
NF E86-303
for selection of materials - Part 2: contract bill of special clauses (Commercial reference
for standards NF DTU 45.2 P1-1, P1-2 and P2)
Assembly
May 1989 Industrial installations – thermal insulation of tanks – coating support
NF EN 12213 Cryogenic vessels – Methods for performance evaluation of thermal insulation
March 1999 Cryogenic vessels – Methods for performance evaluation of thermal insulation
Steel sheet and strip either coil coated or organic film counterglued or colaminated for
XP P 34-301
building purposes
Covering NF EN 485 Aluminium and aluminium alloys – Sheet, strip and plate - Part 1 - 4
Stainless steels – Technical delivery conditions for sheets and strips of corrosion resist-
NF EN 10088-2
ant steels for general purposes. Part 1-5
* Please consult the other parts for further details regarding corrosion protection of steel structures.
m) Unified Technical Document

(Document Technique Unifié, DTU)
Object and scope of the DTUs In particular, the DTUs are generally unable to suggest
technical provisions for performing work on buildings
A DTU comprises a list of contractual technical constructed using outdated techniques.
stipulations applicable to construction work contracts.
The specific documents included in the works contract, The establishment of technical clauses for contracts of
in accordance with the specifications for each this type results from a reflection on the part of those
individual project, must specify all of the required parties who are responsible for designing and
provisions that are not outlined within the DTU, or all implementing the work. Where it proves to be pertinent,
those deemed relevant for inclusion by the contracting these clauses are based on the content of the DTU, as
parties, as a complement to or in deviation from those well as on all knowledge acquired in practice in relation
specified in the DTU. to these outdated techniques.
102
The DTUs refer to construction products or procedures 2.1.3 Relevant guidelines & standards
for the execution of works, the ability of which to satisfy for the technical insulation industry
the technical provisions of the DTUs is known through in Germany
experience. The German system of standards and regulations is
primarily composed of the following constituents: DIN
Where this document refers to that effect to a Technical (German Institute for Standardisation) standards, VDI
Evaluation or Technical Application Document, or to a (Association of German Engineers) guidelines, AGI
product certification, the contractor may suggest (German Working Group for Industrial Construction)
products to the contracting authority that benefit from working documents, VDI quality assurance, and RAL
current testing methods in other Member States of the (German Institute for Quality Assurance and Certification)
European Economic Area, which they deem to be quality marks. Furthermore, there are additional
comparable and which are certified by accredited regulations for special fields of application, such as
organisations, by the organisations that are signatories working standards on the part of the operator, which
to ‘E.A.’ agreements, or in the absence thereof, which must be observed. Most of the standards, regulations
evidence their compliance with the EN 45011 standard. and guidelines are adapted within the local project
The contractor must then supply the contracting specifications.
authority with the evidence needed in order to evaluate
the comparability. The following table shows an overview of the standards
and regulations that must be observed when insulating
The conditions under which the contracting authority industrial plants with Rockwool insulation. On the one
shall accept such an equivalent are defined within the hand, they are grouped according to product and
Contract Bill of Special Clauses of this DTU. material standards, which establish the different
insulation properties, and on the other hand, according
More information is available via www.afnor.org to validation and design rules.
103
2.1.3 R
elevant guidelines & standards
for the technical insulation industry
in Germany
Material standards and design guidelines Field of application/scope
AGI Q02:
The terms used in the AGI Q working documents are defined in this working
Insulation works on industrial installa-
document.
tions – Terms
AGI Q03: This working document applies to insulation works performed on industrial instal-
Construction of thermal and cold insulation lations. The working document classifies works into thermal insulation works for
systems – Insulation works of industrial operating temperatures above the ambient temperature and cold insulation works
plants for operating temperatures below the ambient temperature.
AGI Q05:
This working document has been compiled for planners and designers that have
Construction of industrial plants – Bases,
to design the industrial plants, including the essential thermal or cold insulation.
design, requirements with regard to
In examines in particular the interfaces between plant construction and insula-
the interfaces of plant components and
tion.
insulation
AGI Q101: Working document Q 101 applies to insulation works performed on power plant
Insulation works on power plant compo- components such as steam generators and flue gas cleaning systems, pipe
nents – Construction systems and steel flues
AGI Q103:
This working document applies to insulation works performed on industrial plants
Insulation works on industrial plants –
with electrical tracing.
Electrical tracing
AGI Q104: This working document applies to insulation works performed on industrial
Insulation works on industrial plants – installations, which are heated and/or cooled by means of heat transfer and/or
Tracing systems with heat transfer media refrigerant media, for example in tracing pipes or half pipe sections.
AGI Q132: This working document applies to rock wool insulation, which is used for thermal,
Rock wool as insulation for industrial cold and acoustic insulation of technical industrial plants and technical building
plants appliances.
This working document applies to corrosion protection coating systems for the
AGI Q151: surfaces of industrial plants, such as appliances, columns and pipes, which
Insulation works – Protecting thermal are insulated against heat and cold loss. Since the DIN EN ISO 12944 standard
and cold insulation systems on industrial provides no explanations with regard to protecting insulation systems against
plants against corrosion corrosion, this working document should be considered as a supplement to
standard DIN EN ISO 12944. This working document does not apply in respect of
adhesive primers.
AGI Q152: This AGI working document applies to objects where the insulation must be
Insulation works on industrial plants – Pro- protected against moisture and, above all, against the ingress of liquids, (e.g.
tection against moisture penetration water, heat transfer oil).
AGI Q153:
AGI working document Q 153 applies to the design and construction of mounting
Insulation works on industrial plants –
supports. They transfer the loads of the insulation onto the support constructions
Mounting supports for support construc-
on the object.
tions
AGI Q154
Insulation works on industrial plants – AGI working document Q 154 applies to the construction of support constructions.
support constructions
104
This standard applies to insulation works on industrial plants. These are produc-
tion and distribution plants for the industry and for technical building appliances,
DIN 4140:
(e.g. appliances, vessels, columns, tanks, steam generators, pipes, heating and
Insulation works on technical industrial
ventilation systems, air conditioning units, refrigeration units and hot water
plants and technical building appli-
installations). In the event of requirements with regard to fire protection, the rel-
ances – Construction of thermal and cold
evant standards or national technical approvals must be taken into account. This
insulation systems
standard does not apply to insulation works performed on building shells, interior
walls and inserted ceilings, neither in the shipbuilding and vehicle manufactur-
ing industry, nor within the control area of power plants.
The scope of the guideline includes heat and cold insulation of technical indus-
trial plants and technical building equipment, such as pipes, ducts, vessels, ap-
pliances, machines and cold stores. The minimum insulation thicknesses for heat
distribution and warm water pipes in technical building equipment are laid down
with respect to Germany in the regulations concerning energy-saving heat insula-
tion and energy-saving plant engineering in buildings (Energy Saving Ordinance)
[Energieeinsparverordnung, EnEV]. The considerations expressed in this guideline
may give rise to other insulation thicknesses. With regard to heat insulation in
the construction industry, both the Energy Saving Ordinance and DIN standard
4108. Legal requirements must be taken into consideration with regard to the fire
performance of insulation and the fire resistance classes of insulation, such as
federal state building regulations [Landesbauordnungen] and the piping system
VDI 2055: guidelines of the federal states [Leitungsanlagen-Richtlinien der Bundesländer].
Thermal and cold insulation of technical
industrial plants and technical building The VDI guideline 2055 serves as a benchmark for thermo technical calcula-
equipment tions and measuring systems in relation to industrial and building services
installations and for guarantees and conditions of supply with regard to those
installations. The guideline covers in detail the calculation of heat flow rates,
the design of the insulation thickness according to operational and economic
aspects, the technical warranty certificate and the technical conditions in respect
of delivery quantities and services. Furthermore, the guideline examines measur-
ing systems and testing methods (for quality assurance purposes also). The VDI
2055 guideline consists of 3 parts:
Part 1: Bases for calculation
Part 2: Measuring, testing and certification of insulation materials
Part 3: Conditions of supply and purchasing of insulation systems
Following the completion of the official draft of Part 1, the final editorial draft
is being compiled. The final version is expected to be published in the second
quarter of 2008.
105
2.1.3 R
elevant guidelines & standards
in Germany
The following table cites a number of important test

standards for the product properties of insulation
materials.
a) Test standards (Germany)
Building material class (Fire Fire performance of building materials and building components –
DIN 4102-1
performance) Part 1: Building materials, terms, requirements and tests
Fire performance of building materials and building components –
Melting point DIN 4102-17
Part 17: Melting point of rock wool insulations
Heat insulation – Determination of steady-state thermal transmis-
Thermal conductivity (Piping) DIN EN ISO 8497
sion properties of thermal insulation for circular pipes
Thermal performance of building materials and products – Determi-
Thermal conductivity (Boards) DIN EN 12667 nation of thermal resistance by means of guarded hot plate and heat
flow meter methods - Products of high or medium thermal resistance
Water vapour diffusion resistance Thermal insulating products for building applications – Determina-
DIN EN 12086
coefficient tion of water vapour transmission properties
Thermal insulation products for building equipment and industrial
DIN EN 13468
AS quality installations – Determination of trace quantities of water-soluble
Replaces AGI Q135
chloride, fluoride, silicate, sodium ions and pH
DIN EN 13472
Hydrophobic treatment installations – Determination of short-term water absorption by
Replaces AGI Q136
partial immersion of preformed pipe insulation
DIN EN 14706
installations – Determination of maximum service temperature
(for flat products)
Maximum service temperature
DIN EN 14707 (for
installations – Determination of maximum service temperature for
piping)
preformed pipe insulation
According to VW This test procedure verifies whether the insulation is free from
Absence of silicon
test 3.10.7 paint wetting impairment substances (e.g. silicon)
Thermal insulating products for building applications – Determi-
Compression resistance DIN EN 826
nation of compression behaviour
DIN EN 29053
Acoustics; Materials for acoustical applications; Determination of
Air flow resistance Determination of
airflow resistance (ISO 9053:1991)
airflow resistance
106
b) Insulation code number according to AGI Q132
AGI guideline Q132 lays down the material properties represents rock wool. The further pairs of digits
and the requirements that are imposed on rock wool represent the:
insulation for industrial installations. The insulation • Delivery form
materials are denoted with a ten-figure code number • Thermal conductivity group
(so called “Dämmstoffkennziffer”), consisting of five • Maximum service temperature group
pairs of digits. In this case, the first pair of digits “10” • Apparent density group
Rock wool insulation Delivery form Thermal conductivity Maximum service Nominal apparent
temperature density
Group Type Group Form Group Delivery form Group °C Group kg/m3
10 Rock Wool 01 Wired 01 Limit curve 1 10 100 02 20

mats
02 Lamella 02 Limit curve 2 12 120 03 30

mats
03 Lamella mats 03 Limit curve 3 14 140 04 40
load-bearing
04 (Pipe) 04 Limit curve 4 16 160 05 50
sections
05 (Pipe) 05 Limit curve 5 • • 06 60

elbows
06 Felts • • 07 70
07 Mats • • 08 80
08 Slabs 72 720 09 90
09 Segments 74 740 10 100
10 Loose 76 760 11 110

wool
12 120
13 130
18 180
99 *
* The digits 99 apply only to (pipe) sections.
107
2.1.3 R
elevant guidelines & standards “Thermal insulation products for building equipment
for the technical insulation industry and industrial installations – Factory-made mineral wool
in Germany (MW) products – specification”. The official implemen-
tation of this standard is expected to take place in
Using Rockwool wired mat with a density of 80kg/m3 2009. Following ratification, a European standard must
as an example results in the following insulation code: be adopted as it stands by the national standardisation
organisations as a national standard. Deviating national
10.01.02.64.08 standards must be retracted.
Apparent density Each European standard adopted is published in each

80 kg/m3 EU country with a national prefix, e.g. in Germany:
DIN-EN-XXXX; in England (British Standard):
Maximum service
BS-EN-XXX. The (as of yet) unratified standards are
temperature 640 °C
denoted with the letter “pr” (for proof) e.g. prEN-
Limit curve of the 14303.
thermal conductivity
Limit curve 2 d) Quality Assurance
It is essential that, in addition to the design quality, the
Delivery form
product properties guaranteed by the insulation
Wired mats
manufacturer, for example, the thermal conductivity or
Rock wool temperature resistance, are adhered to during
processing in order to guarantee the faultless operation
c) European standardisation of a thermal or cold insulation constructed according
In order to remove technical barriers to trade, the to operational and economic criteria. Well-known
European Union decided to develop uniform European insulation manufacturers guarantee this through
product standards. These product standards describe extensive internal and external quality control. The
the product properties, as well as the methods of VDI 2055 guideline “Thermal and cold insulation
testing for these properties. The minimum requirements of industrial installations and building equipment”
for certain product properties still remain a national regulates this voluntary quality assurance.
responsibility and are laid down in each individual
country. The EU issues orders in the form of mandates The VDI 2055 quality assurance of insulation products
to CEN (the European Committee for Standardisation), is classified as a quality control, consisting of an
which the CEN uses to develop relevant standards. The external and internal quality control, as well as a
majority of orders have now been commissioned and certification of insulation materials for industrial
initial harmonised standards, such as the insulation installations. The property values specified on the
standards for structural engineering (DIN EN 13262), product data sheets, prospectuses or price lists of the
have been published. The European product standards manufacturer, such as the thermal conductivity or maxi-
for technical insulation are currently being compiled. mum service temperature for example, form the basis
For rock wool, this product standard is the prEN 14303 for the quality control. As a result , a user or producer
108
of VDI 2055 quality assured insulation products can The external quality control is made up of the following
safely assume that even publicised property values are elements:
subject to a quality control. When the product conforms • Auditing of the internal quality control
to the properties specified by the manufacturer in the • Verification of the labelling of the products
product data sheets, the certification body grants the • Product testing
manufacturer the right to use the certification mark
“Checked in accordance with VDI 2055”. Certification
Upon correct implementation of the internal and
The following text outlines the product properties that external quality control of insulation products
must, at the very least, be controlled in the case of a manufactured according to VDI 2055, DIN CERTCO
mineral wool insulation product, in order for the VDI developed a certificate with regard to conformity to VDI
2055 inspection mark to be granted: 2055, to the data sheets of the VDI AG “Quality Control”
• Thermal conductivity as a curve (λ = f(t) or f(tm)) and to the technical data of the manufacturer.
• Dimensions (length, width, depth)
• Apparent density e) RAL quality mark
• Maximum service temperature Rockwool stone wool insulation products bear the RAL
quality mark. They are therefore subject, in addition to
In addition, the following product properties are usually the stringent criteria of the quality assessment and test
controlled externally: specifications of the Mineral Wool Quality Community
• Fire performance [Gütegemeinschaft Mineralwolle e. V.], to continuous
• Hydrophobic properties inspections, which guarantee compliance with the
• Water-soluble chloride content (AS quality) criteria of the German legislation governing hazardous
substances and with the EU directive. In accordance
Internal quality control with both the German and European standards,
The manufacturer takes samples during production and bio-soluble Rockwool stone wool offers outstanding
tests for the relevant product properties. For properties thermal, cold, acoustic and fire protection whilst
such as thermal conductivity, indirect measurement meeting a high safety standard.
methods can also be used. The manufacturer must
have a quality management procedure in place, which f) No prohibition on manufacture and usage
instigates the measures required to rectify the defect in The German federal government has laid down criteria
the event of deviations from the reference values. for the appraisal of mineral wool insulation products in
the Ordinance on Hazardous Substances [Gefahrstoff-
External quality control verordnung] and the Chemicals Prohibition Ordinance
For the purposes of external quality control in [Chemikalien-Verbotsverordnung]. Products not
accordance with VDI 2055, the manufacturer must meeting these criteria cannot be manufactured and
enter into a supervision contract with a leading testing used in Germany. Rockwool stone wool insulation
body, such as the FIW (Research Institute for thermal products fulfil these requirements. The prohibition on
insulation materials). manufacture and usage does not apply to Rockwool
109
2.1.3 R
elevant guidelines & standards 2.2 Product properties &
test methods
in Germany
stone wool insulation products. Rockwool mineral wool The requirements for technical insulation are high and
insulation products are also not considered to be a varied. Piping, boilers, storage tank require insulation
probable cause of cancer in accordance with the materials with particular properties. Although the
criteria of EU directive 97/69/EG. application and type of products may vary, the basic
definition of all product properties is the same.
2.2.1 Fire behaviour
2.1.4 R
elevant guidelines & standards 2.2.2 Thermal conductivity
for the technical insulation industry 2.2.3 Maximum service temperature
within the Benelux 2.2.4 Water leachable chloride content
The local system of standards and regulations in the 2.2.5 Water repellency
Netherlands and Belgium focuses primarily on building 2.2.6 Water vapour transmission
construction. The Dutch CINI manual is adopted as a 2.2.7 Longitudinal air flow resistance
general guideline for mounting and fixing by the 2.2.8 Compression resistance
majority of industry owners and construction engineers. 2.2.9 Density
Product testing often refers to AGI, DIN and European
standards. Refer to the previous chapters for more The relevant standards, guidelines and project
information. specifications are explained in 2.1. The following text
outlines the most important product properties of
mineral wool insulation products for insulation of
technical installations.
2.2.1 Fire behaviour

a) Introduction
The fire load in a building or technical installation is
increased considerably by flammable/combustible
insulation materials. Non-combustible insulation
materials such as mineral wool, with a melting point
higher than 1000 °C, on the other hand, not only have
a positive impact on the fire load, but also constitute a
certain form of fire protection for the insulation
installations.
Often one confuses fire resistance with reaction to fire.

Fire resistance indicates how well a building compo-
nent, for instance, can hold back the fire and prevent it
110
from spreading from one room to another – for a stated burning droplets.
period of time. Does it function as a fire shield or not? • Class B product flaming must not spread more than
Fire resistance is an extremely important characteristic. 150 mm in 60 seconds, when evaluated by a small
For example, a vessel containing flammable liquids. flame test. Class B products have to be tested for fire
Serious accidents/explosions can occur if a vessel is not contribution, smoke intensity and burning droplets
protected against fire from the outside. • Class C product contributes to flashover after 10 min.
Reaction to fire indicates the smoke development and • Class D product contributes to flashover after 2 min.
combustibility / flammability if the insulation is exposed • Class E product for less than two minutes.
to fire. • Class F is not tested.
b) CEN standards Smoke intensity

A distinction is generally made between non-combusti- Smoke intensity is only tested in the classes from A2
ble and combustible building materials. The insulation to D. There are 3 intensity levels; s1, s2 and s3. Smoke
materials are exposed to fire. The flammability and intensity is vital for people trapped in a burning
smoke development and droplets of melted insulation building. The major cause of death in these circum-
are observed and rated. stances is smoke inhalation.
The classification of insulation materials depends on Burning droplets

the relevant fire standards. In the second half of the Burning droplets are also tested on building materials
20th century, almost every country in Europe developed in the classes A2 to E. There are three classes. No
their own national system for fire testing and classifica- droplets (d0). Droplets that burn out in less than 10
tion of building materials in particular. The European seconds (d1) and droplets that burn for more than 10
Community has developed a new set of CEN standards. seconds (d2).
The “Reaction to fire” classes test three properties:
spread of fire, smoke intensity and burning droplets. Rockwool products
Due to its nature, mineral wool is non combustible.
Spread of Fire Therefore all plain products are classified as class A1.
The building components are classified in class A1, A2,
B, C, D, E and F. Additional classifications provide c) Project specifications
information on products tending to produce smoke and Many industrial plant owners still refer to the “old” local
burning droplets or particles. standards or American (ASTM) Standards. Some of the
• Class A1 products are non combustible. They most important examples are stated below.
will not cause any sustained flaming in the non
combustibility test. For projects outside Europe, especially, many plant
• Class A2 product must not show any sustained owners tend to use the American ASTM E84 or the
flaming for more than 20 seconds in the non Canadian equivalent UL723. Both standards solely
combustibility test. The A2 products have to be focus on the surface burning characteristics (flame
tested for fire contribution, smoke intensity and propagation across the surface of insulation materials).
111
2.2 Product properties & test methods
2.2.1 Fire behaviour 2.2.2 Thermal conductivity

In Germany, the building material classes for insulation The heat-insulating effect of insulation materials is
materials for technical insulation are classified specified in terms of the thermal conductivity “λ”. λ is
according to DIN standard 4102-1. A distinction is conveyed in the physical unit W(m.K). It indicates the
made between non flammable building materials in quantity of heat “Q” that, in “t” amount of time and at a
class A1 and A2, and flammable building materials in temperature difference of “Δ T”, flows across the
classes B1 to B3. thickness “l” through the surface “A”.
• A1 non-flammable Q⋅l = [J] ⋅ [m] =
J
=
W
λ=
• A2 non-flammable A ⋅ t ⋅ ΔT [m2] ⋅ [s] ⋅ [K] m⋅s⋅K m⋅K
• B1 flame resistant
• B2 normally inflammable The unit of thermal conductivity is shown in terms of
• B3 highly flammable (cannot be used in Germany) J/(m·s·K) or W/(m·K). The thermal conductivity
depends on the temperature, the apparent density
Alongside the implementation of the European product and the structure of the insulation and is made up
standards for technical insulation, the “European of the following parts:
building material classes”, the Euroclasses, are also • Thermal conduction of the dormant air in spaces
being implemented. In that case, the products are between the fibres
classified in accordance with the standard DIN EN • Thermal radiation
13501-1 “Fire classification of building products and • Thermal conduction through the fibres
building elements – Part 1: Classification using test • Convection
class data from reaction to fire tests” in combination
with the specifications of the European product The fundamental dependencies of these heat
standard. transporters upon temperature and apparent density in
the case of mineral wool, are clarified in the graphs
Other local (often building) standards may apply below. The individual parts cannot be recorded using
occasionally. e.g.: measurement techniques and together form the
• NEN 6064: Netherlands thermal conductivity of an insulation material.
• NFP 92507( class M0) France
• BS 476: United Kingdom
The RTI Sales Team can advise designers and

manufacturers of installations who are faced with such
requirements. Many of the Rockwool insulation
materials are tested and/or certified in accordance
with several local and international standards for
reaction to fire.
112
Fundamental dependency of the thermal conductivity upon the apparent density at a certain temperature
1. Conduction through the dormant air - 2. Thermal

radiation - 3. Conduction of the pipe - 4. Convection -
5. Thermal conductivity of the insulation
Apparent density
Fundamental dependency of the thermal conductivity upon the temperature for a certain apparent density
1. Conduction through the dormant air - 2. Thermal

radiation - 3. Conduction of the pipe - 4. Convection -
5. Thermal conductivity of the insulation
Temperature
113
2.2.2 Thermal conductivity

Thermal conductivities for technical insulation can be The core consists of a hot pipe with a length of 3
measured according to the test methods below. metres. The thermal conductivity is calculated at the
mean temperature between the hot and cold side and
Guarded hot plate apparatus test method expressed at the mean temperature. The main
The thermal conductivity of flat products, slabs and difference is that the hot pipe apparatus test method
wired mats can be measured with the guarded hot includes the seams within the insulation. This explains
plate apparatus according to EN12677, ASTM C177 why the measured values will be higher than the
or BS874. guarded hot plate apparatus test.
A distinction is drawn between the definition of thermal

conductivity.
• Laboratory thermal conductivity
Thermal conductivity is measured under laboratory
conditions with the guarded hot plate apparatus or
hot pipe apparatus test method.
• Nominal (or declared) thermal conductivity
Thermal conductivity specified by the manufacturer,
The core components of the apparatus usually consist allowing for production related variations in quality
of two cold-surface units and a guarded hot-surface and possible ageing, for example caused by gas
unit. The insulation material to be measured is exchange in closed cell insulation materials.
sandwiched between these units. The thermal • Practical thermal conductivity
conductivity is calculated at the mean temperature Declared thermal conductivity including the
between the hot and the cold side and expressed at the influence of joints, design uncertainties, temperature
hot face temperature. differences, convection, changes in density, moisture
absorption and ageing. These effects are taken into
Hot pipe apparatus test method consideration using supplementary factors.
The thermal conductivity of pipe sections and flexible • Operational thermal conductivity
mats can be measured with the hot pipe apparatus Practical thermal conductivity, whereby the
according to EN ISO 8497 or ASTM C335. supplementary values for insulation related bridges,
such as bearing and support structures are included
in the value.
114
2.2.3 Maximum service temperature ASTM C411
The temperature at which an insulation material is used ASTM C411 is the standard test method for hot-surface
should be within the temperature range specified for performance of high-temperature thermal insulation.
the material, in order to provide satisfactory long-term This standard covers the determination of the
service under conditions of use. performance of mats, slabs and pipe sections when
exposed to simulated hot-surface application
This temperature is defined as maximum service conditions.
temperature. The following factors should be Mats and slabs are tested with the heating plate or pipe
considered when selecting insulation materials to be apparatus. The heating plate or pipe is uniformly
used at elevated operating temperatures. heated to the declared maximum service temperature.
• Ability to withstand loads and vibrations Products are exposed to one sided heating.
• Loss of compression strength after heating
• Linear shrinkage are heating ASTM C411 places no specific demands on the
• Change in thickness after heating and loading product performance after heating. Only the following
• Internal self-heating (exothermic reaction or punking) results must be reported.
phenomena • Extent of cracking, other visible changes
• Type of finishing of the insulation • Any evidence of flaming, glowing, smouldering,
• Support structures for the insulation smoking, etc.
• Support structures for the cladding • Decrease in thickness, warpage, delamination
• Sagging pipe (pipe insulation)
Important notice
The maximum service temperature of insulation BS 2972
materials can be tested in accordance with the test This standard specifies test methods for the various
methods: EN 14706 and -7 (replaces AGI Q 132), properties of inorganic thermal insulation materials.
ASTM C411 or BS2972. Each test standard has a Section six “heat stability of this standard” is designed
different test method and its own criteria. ASTM C411 to determine the performance of insulation materials
and BS2972 can be used to determine the maximum when exposed to heating for 24 hours in an oven or
operating temperature at which an insulation material furnace at the designed temperature.
can be used, without its insulating capacity
deteriorating. EN 14706 and -7 are used to classify BS 2972 places no specific demands on the product
insulation materials according to their behaviour at performance after heating. Only the following results
high temperatures based upon time-load exposure. must be reported:
Due to the effect of load during testing, the measure • Average percentage change of length, width,
maximum service temperature in accordance with EN thickness and volume of specimens;
14706 and -7 is lower than the other standards and • Percentage change of mass of the specimens before
therefore tends to reflect a more practical temperature and after the test
limit for design performance. • Change in compression strength of the specimens
before and after the test.
115
2.2.3 Maximum service temperature

According to BS 3958 “standard specification for
thermal insulation materials”, the insulation material
shall maintain its general form and shall not suffer
visible deterioration of fibrous structure when heated to
the maximum service temperature.
EN14706 (replaces AGI Q132)

The maximum service temperature replaces the term
classification temperature, which was still the
customary term in the AGI G 132 of 1996. It is
recorded in the laboratory under steady conditions, and
takes into account the delivery form. The maximum
service temperature for flat products is determined
according to the EN 14706 standard and is determined
according to the EN 14707 for pipe sections. During
the test, the sample insulation material is loaded with
500 Pa pressure, which is equal to a load of approxi-
mately 0,5 kN/m².
The sample is then heated on one side at a heating rate

of 5 K/min, until the target maximum service tempera-
ture is reached. The temperature is then maintained for
72 hours, before the insulation is allowed to cool down
naturally to the ambient temperature. The deformation
of the insulation is measured throughout the entire
procedure. The deformation is not permitted to exceed
5 % throughout the entire testing process.
116
Application of maximum service temperature temperatur”). When selecting a suitable insulation
The practical application of the test methods varies per material in terms of the maximum service temperature,
country and plant owner. In case of special conditions, the external influences affecting the insulation system
where the insulation is permanently exposed to high must be considered, for example:
dynamic loads and temperatures (e.g. Power Plants), • Static loads (e.g. cladding)
which cannot be included within the measurements, a • Dynamic loads (e.g. oscillations)
considered insulation selection is required. This can be • Type of construction (with or without a spacer).
done based on expert judgement or by using the
reduction factors (fa) as defined in the German The table shown on the following page, showing general
Standard AGI Q101 “Insulation works on power plant reduction ratios fa for determining the working
components”. The calculated service temperature temperature, is taken from AGI Q101. In this respect,
(‘Obere Anwendungstemperatur”) is generally below the maximum service temperature should be multiplied
the maximum service temperature (“Anwendungsgrenz by fa.
Reduction ratio (fa) for determining the working temperature
Reduction ration (fa) Maximum service With spacer and support Without spacer and sup- With spacer and support
temperature construction port construction construction + air space
400 oC 1.0 0.9 0.9

Pipes ≤ DN 500 580 oC 0.9 0.9 0.9
710 oC 0.9 0.8 0.8
400 oC 0.9 0.8 0.9
Pipes ≥ DN 500 580 oC 0.9 0.8 0.9
710 oC 0.9 0.8 0.9
Flue gas ducts, hot air 400 oC 0.9 0.8 0.9
ducts, steel chimneys, 580 oC 0.9 0.8 0.9
vessels, gas turbine ducts 710 oC 0.9 0.8 0.8
Boiler walls 0.8
Within range of boiler roof 0.9
Dead spaces 0.8
117
2.2.4 Water leachable chloride content

The corrosion resistance of steel is increased by the procedures for the determination of the mentioned ions
addition of alloying elements such as chromium, nickel which accelerate stress corrosion of stainless steel. If
and molybdenum. Since this alloying results in a the results of the chemical analysis for the leachable
so-called austenitic (face-centred cubic) atomic ions chloride, sodium and silicate fall in the acceptable
structure, these types of steel are also called austenitic area of the graph in ASTM C795 and also pass ASTM
steels. Despite their generally high resistance to C692, the insulation material should not cause stress
corrosion, these steels tend to exhibit stress corrosion corrosion cracking.
under certain conditions. Three boundary conditions
must all be fulfilled in order for stress corrosion ASTM C692
cracking to occur: “Evaluating the Influence of Thermal Insulations on
• The material must be susceptible to stress corrosion. External Stress Corrosion Cracking Tendency of
• Tensile stresses must be present in the component Austenitic Stainless Steel”.
(for example, as a result of thermal elongations). This standard covers the procedures for the laboratory
• There must be a specific attacking agent. evaluation of thermal insulation materials that may
actively contribute to external stress corrosion cracking
These specific attacking agents include, for example, (ESCC) of austenitic stainless steel due to soluble
chloride ions. An insulation material with an extremely chlorides within the insulation. This corrosion test
low quantity of water-leachable chlorides must therefore consists of using specimens of insulation to conduct
be used to insulate objects made from austenitic distilled or deionized water by wicking or dripping to an
stainless steel. outside surface, through the insulation, to a hot inner
surface of stressed stainless steel for a period of 28
For this application, only those insulation materials that days. If leachable chlorides are present, they will
are manufactured with a low water leachable chloride concentrate on the hot surface by evaporation. At the
content may be used. The classification criteria will conclusion of the 28-day test period, the stainless steel
depend on the used standard. In general, a distinction coupons are removed, cleaned and inspected for stress
can be made between American ASTM standards and corrosion cracks. To pass the test no cracks may be
European EN standards. found on the surface of the coupons.
AS-Quality (AGI Q135 – EN 13468) ASTM C795

The following acceptance criteria apply for insulation “Thermal Insulation for Use in Contact with Austenitic
materials of AS-Quality. The average of six test samples Stainless Steel”. This specification covers non-metallic
must exhibit a water leachable chloride content of ≤ 10 thermal insulation for use in contact with austenitic
mg/kg. The maximum value of individual measure- stainless steel piping and equipment. In addition to
ments must not exceed 12 mg/kg. meeting the requirements of this standard, the
insulation materials must pass the preproduction test
ASTM C871 requirements of ASTM C692, for stress corrosion
“Chemical analysis of thermal insulation materials for effects on austenitic stainless steel, and the confirming
leachable chloride”. This standard covers the laboratory quality control, chemical requirements when tested
118
according to ASTM C871. ASTM C795 shows the Hydrophobic treatment makes it diffi cult for water to
results of ASTM C871 in a graph to illustrate a range penetrate into the insulation and repels water affecting
of acceptable chloride concentrations in conjunction the insulation from the outside. During the mineral wool
with sodium plus silicate concentrations (see graph manufacturing process, hydrophobic oil, which
illustration below). surrounds each fibre like a protective film, is added.
This provides effective protection against moisture
penetration across the entire insulation thickness.
Hydrophobic treatment does not affect the water vapour
diffusion transmission. The effectiveness of the
hydrophobic treatment is temporary and depends on
the level of moisture. It decreases when exposed to
high temperatures. The primary objective of the
hydrophobic treatment is to protect the insulation from
short bursts of rainfall during installation, for example.
In principle, even mineral wool insulation that has been
hydrophobically treated must be protected against the
ingress of moisture during transport, storage and
application.
The water repellency of mineral wool insulation can be

Rockwool
mineral tested in accordance with several standards.
wool
EN 1609 & EN 13472 Partial immersion

Tested in accordance with two mineral wool standards,
i.e. the EN 1609 standard for slabs and the DIN EN
13472 standard for pipe insulating products. The
maximum permissible water absorption in these testing
procedures must not exceed 1 kg/m². Rockwool
2.2.5 Water repellency insulation products are hydrophobically treated and
The thermal conductivity and therefore the insulating therefore fulfill these requirements.
capacity of mineral wool insulation materials are
considerably impaired by the penetration of moisture into
the material. Wet insulation material can also contribute
to corrosion. Therefore, insulation materials must be
protected against moisture during storage, construction
and after being fitted. To protect the material against the
ingress of moisture, mineral wool insulation materials are
offered with a hydrophobic treatment.
119
2.2.5 Water repellency

BS 2972 Section 11 Total Immersion Note:
“Determining the Water Absorption of Unfaced Mineral British Petroleum places specific demands on the
Fibre Insulation exposed to Total Immersion” water repellency of mineral wool products. In
This standard covers the determination of the amount accordance with the BP172 standard, the samples
of water absorption by mineral fibre insulation. The test are heated for 24 hours at 250 °C. The water
sample is immersed completely in tap water for two repellency is tested afterwards in accordance with
hours with the upper surface approximately 25 mm BS 2972 Section 11 Partial Immersion
below the surface of the tap water. After the immersion Special water repellent grade (WRG) products are
period, the sample must be drained for 5 minutes. The available on request.
water absorption is calculated using the weight
difference before and after testing and is expressed in ASTM C1104 / 1104M
volume percentage. “Determining the Water Vapor Sorption of Unfaced
Mineral Fibre Insulation”
This standard covers the determination of the amount
of water vapor sorbed by mineral fibre insulation
exposed to a high-humidity atmosphere. The test
samples are first dried in an oven and then transferred
to an environmental chamber maintained at 49 ºC and
95 % relative humidity for 96 hours. The water vapor
sorption is calculated using the weight difference before
BS 2972 Section 11 Partial Immersion and after testing and is expressed in weight percentage
“Determining the Water Absorption of Unfaced Mineral or volume percentage.
Fibre Insulation exposed to Partial Immersion”
This standard covers the determination of the amount
of water absorption by mineral fibre insulation. The test
sample is immersed vertically with one 150 mm* 25
mm side 6 mm below the surface of tap water for 48
hours. After the immersion period the sample must be
drained for 5 minutes. The water absorption is
calculated using the weight difference before and after
testing and is expressed in kilograms per square metre.
120
Caution with regard to paint shops longitudinal flow resistance should therefore measure at
When using hydrophobically treated insulation least 50 kPa s/m² in accordance with EN 29053.
materials in spraying plants, also ensure that the
hydrophobic oil does not have any negative impact 2.2.8 Compression resistance
– e.g. by means of paint wetting impairment The resistance that an insulation system offers to
substances such as silicon oils – on the coating external mechanical loads (wind loads, people,
process. Rockwool stone wool insulation products cladding loads) is influenced by factors including the
are hydrophobically treated without silicon oils or pressure resistance of the insulation. The compressive
silicon resins and therefore also fulfil the guidelines stress of mineral wool is preferably specified at 10 %
of the automotive industry, such as VW-Test 3.10.7. compression. The compressive strength is the ratio of
They may be used in paint shops. the strength under a predetermined compression to the
loaded surface of the test sample, as identified during a
2.2.6 Water vapour transmission compression test in accordance with EN 826.
With installations constructed outdoors, the possibility
of moisture penetrating the insulation system or being 2.2.9 Density
“built in” can never be ruled out. Therefore, it is The density of mineral wool products is the amount of
important that insulation exhibits a high degree of water fibres per cubic metre. Special care should be taken
vapour permeability, which allows the water to escape when comparing only the densities of insulation
from the installation once it has been started up started products. Density influences several product properties.
through diffusion or evaporation processes. This will It is however not a product property itself. A common
prevent a negative impact on the insulation properties. assumption is that the higher the density, the more the
compression resistance, maximum service temperature
2.2.7 Air flow resistance and thermal conductivity will improve. This is only
The resistance that an insulation material offers against correct to a certain extent. A few examples:
the flow of air is referred to as air flow resistance. It
depends on the apparent density, the fibre dimensions, Binder content
the fibre orientation and the proportion of non-fibrous During the manufacture of mineral wool products, a so
elements. It determines the level of convection in the called binder is added to glue/form the fibres into the
insulation and its acoustic-technical properties. The air desired shape. The binder content positively influences
flow resistance is expressed in terms of Pa s/m² and the compression strength, but due to its organic
describes the relationship between the pressure compounds has a negative effect on the maximum
difference and flow rate in an insulation material of one service temperature and fire resistance.
metre thickness.
One of the factors that influences convection in an For high temperatures it is often better to use high
insulation material is its flow resistance. This is density (less radiation) mineral wool insulation. At
important when insulation materials adjoin air spaces, temperatures below 150 °C, the conduction throughout
such as finned walls in boilers, and there are no airtight the fibres will be more dominant, so using a lower
roofs or intermediate layers (foils). When such thermal density product is preferable.
insulation materials are constructed vertically, the
121
2.2.5 Water repellency

Fibre structure The calculation of multiple-layer insulation constructions
The (vertical, horizontal,..) orientation of the fibres is to some extent quite complex, as iterative calculation
influences the longitudinal air flow resistance, processes need to be carried out. The procedures
compressive strength, and thermal conductivity. outlined below are therefore only suitable to obtain an
Generally, the more “vertical” fibres, the better the approximate calculation of insulation constructions. The
compressive strength and the higher the thermal thermo-technical engineering program “Rockassist”
conductivity will be. offered by RTI can be used for detailed calculations.
Non-fibrous particles Heat transfer

Non-fibrous particles or shot content in mineral wool During a thermal transfer, thermal energy is transported
products have a negative influence on the thermal as a result of a temperature drop. Thermal transfers can
conductivity. For example, a mineral wool product with occur through conduction, convection or radiation.
a density of 100 kg/m3 and 15 % shot content, {(tested
in accordance with ASTM C 612 on a meshed netting • T
hermal conduction is the transport of heat from one
(150 mm, 100 mesh)}, would have the same thermal molecule to another, as a result of a drop in
conductivity as a mineral wool product with a density of temperature. In solid substances, the average
140 kg/m3 and 40 % shot content. Rockwool products distance between the individual molecules remains
have a very low shot content. Due to the unique the same. In liquids and gases however, the distance
production process, Rockwool products achieve changes.
excellent thermal conductivity, even at low densities. • In the case of convection, the thermal transfer takes
place in liquids and gases through flow processes. A
Insulation selection distinction is drawn between free convection, in which
Every mineral wool insulation product has specific the movement occurs as a result of variations in
characteristics. Insulation should therefore be based on density, and forced convection, in which the flow is
the actual product performance, not on the density. generated by external influences such as the wind and
by blowers.
• Thermal transfer through radiation takes place as a
2.3 Bases for thermal calculations result of the exchange of electromagnetic radiation
between two body surfaces, which have different
The following section outlines a number of theoretical temperatures and are separated by radiation
bases for heat transfer and basic approaches to permeable media, such as air.
thermo-technical calculations. Detailed calculation
processes are outlined in the VDI 2055, and the Terms
EN 12241 standards, as well as in various international Heat quantity Q
standards, such as ASTM C 680 and BS 5970. The The heat quantity is the thermal energy that is supplied
calculation bases are similar in all the standards. In to or dissipates from a body. The unit used to designate
Europe, the VDI 2055 is the most widely used and the heat quantity is J.
accepted calculation basis.
122
Heat flow Q` coefficients of thermal resistance. The unit used to
The heat flow Q` is the heat quantity flowing in a body or express the thermal resistance is (m² K)/W.
being transferred between two bodies per time unit. The
unit used to designate the heat flow is W (1W = 1J/s).
R
Applied insulation thickness (
s  m ⋅K

2
)  for walls
Thermal conductivity λ  W 
Heat flow density q
The heat flow density q is the heat flow being applied to d 
ln a 
the unit of the surface that the heat is flowing through.  di   (m⋅K ) 
RPipe =
2 ⋅ π ⋅ λ  W 
for pipe insulation
The unit is expressed in W/m² for surfaces or in W/m for  
pipes, for example. In the field of insulation technology,
the heat flow density refers to the surface of the Surface coefficient of heat transfer α
insulation system. The surface coefficient of heat transfer “α” gives the
heat flow density circulating at the surface of a body in
Thermal conductivity λ a medium or vice versa, when the temperature
The heat-insulating effect of insulation materials is difference between the body and the liquid or gaseous
described in terms of the thermal conductivity λ. λ is medium amounts to 1 K. The unit used to express
specified in the physical unit of W(m K). It indicates the surface coefficients of heat transfer is W/(m²K).
quantity of heat “Q&” that, in “t” amount of time and
at a temperature difference of “λT”, flows across the Heat transfer resistance 1/α
thickness “s” through the surface The heat transfer resistance “1/α” is the reciprocal of
the surface coefficients of heat transfer. The unit used
Q ⋅l J ⋅m J  W  to express the heat transfer resistance is (m²K)/W.
λ= = = =
A ⋅ t ⋅ ΔT m2 ⋅ s ⋅K m⋅ s ⋅K  m⋅K 
Coefficient of thermal transmittance k

The unit of the thermal conductivity is expressed in The coefficient of thermal transmittance “k” indicates
terms of J/(m s K) or W/(m K). the heat flow density “q” circulating through a body,
when there is a temperature difference of 1 K between
Thermal conductance Λ the two media, which are separated by the body. The
The coefficient of thermal conductance “Λ” indicates, coefficient of thermal transmittance includes the
for a given layer, the heat flow density flowing vertically thermal resistance and heat transfer components.
between the surfaces over an area of 1 m² at a The unit used to express coefficients of thermal
temperature difference of 1 K. The unit used to express transmittance is W/(m² K).
the coefficients of thermal conductance is W/(m² K).
Thermal transmission resistance 1/k
Thermal conductivity λ  W  The thermal transmission resistance is the reciprocal of
Λ= =  2 
Applied insulation thickness s (
 m ⋅K )  the coefficients of thermal transmittance. The unit used
to express thermal transmission resistance is (m²K)/W.
Thermal resistance R
The thermal resistance “R” is the reciprocal of the
123
2.3 Bases for thermal calculations
d  d  d 
1
= Heat transfer + Heat transfer + Heat transfer ln 2  ln 3  ln a 
 m⋅K 
k resistanceinside resistanceinside resistanceoutside 1 1  d1   d2   dn  1
= + + + .... + +  W 
k R di ⋅ π ⋅ α i 2 ⋅ π ⋅ λ1 2 ⋅ π ⋅ λ 2 2 ⋅ π ⋅ λ n da ⋅ π ⋅ α a  
1 1 1  m2 ⋅K 
= +R +   for a wall
k w αi w αa  W  π ⋅( ϑ M − ϑ L ) W
qR = m
d  d  d   
ln 2  ln 3  ln a 
1 1 1  m⋅K  1 d  d  d 1
= +R +  W  + 1
+ 2
+ .... + n
+
kR di ⋅ π ⋅ α i R da ⋅ π ⋅ α a   di ⋅ α i 2 ⋅ λ1 2⋅ λ2 2 ⋅ λ n da ⋅ α a
for pipe insulation

The following symbols are used in this calculation:
Calculation bases qR Heat flow density per m pipe W/m
The heat flow density through a flat wall constructed of ϑM Temperature of the medium in °C
multiple layers is calculated as follows: ϑL Ambient temperature in °C
d1 External diameter of pipe m
q = k ⋅( ϑ M − ϑ L )
da External diameter of insulated pipe m
1 1 s1 s2 s 1
= + + + ... + n + αi Surface coefficient of heat
k α i λ1 λ 2 λn α a
transfer inside W/(m² K)
(ϑ M − ϑ L ) αa Surface coefficient of heat
q=
1 s1 s2 s 1 W transfer outside W/(m² K)
+ + + .... + n +  m2 
α i λ1 λ 2 λn α a   λ1…λn Thermal conductivity of the individual insulation
layers W/(m K)
The following symbols are used in this calculation: k Coefficient of thermal transmittance W/(m² K)
q Heat flow density W/m² s1…sn Thickness of the individual layers of insulation m
ϑM Temperature of the medium in °C
ϑL Ambient temperature in °C Hint
αi Surface coefficient of W/(m² K) When performing thermo-technical calculations in
heat transfer inside insulation technology, the internal heat transfer does
αa Surface coefficient of W/(m² K) not generally need to be considered. This
heat transfer outside simplification is based on the assumption that the
s1…sn Thickness of the individual layers of insulation m medium is the same temperature as the interior of
λ1…λn Thermal conductivity of the W/(m K) the pipe. The following terms may therefore be
individual insulation layers omitted from the calculations shown above:
k Coefficient of thermal transmittance W/(m² K)
1 remove from the denominator in the equation for
With multiple-layer hollow cylinder (pipe insulation), the
α i the wall
heat flow density is calculated as follows:
qR = k R ⋅( ϑ M − ϑ L )
124
1 remove from the denominator in the equation (air movement due solely to variations in density as a
di ⋅α i for pipe insulation result of temperature), forced convection (blowers,
wind) or of a mixture of free and forced convection.
The surface temperatures ϑ O can be calculated as The convection also depends on the geometry of the
follows: building component.
kW
ϑO = ⋅( ϑ M - ϑ L)+ ϑ L °C for walls The rate of radiation depends on factors such as the
αa material of the cladding (emission ratio ε), the surface
temperature and the orientation of the object in relation
(ϑ M - ϑ L)
ϑO = + ϑ L °C to other components.
 1 s1 s2 sn 1 
α a ⋅  + + + .... + + 
 α i λ1 λ 2 λn α a 
The calculation procedures are explained in the VDI
2055 and DIN EN 12241 standards. A detailed
kR
ϑO = ⋅(ϑ M - ϑ L)+ ϑ L °C for pipe insulation description will not be given at this point.
π ⋅ da ⋅ α a
products
Use the following procedure to obtain an approximate
(ϑ M - ϑ L)
ϑO = + ϑL estimate of the external surface coefficients of heat
 d  d  d  
 ln 2  ln 3  ln a   transfer αa. It applies in respect of the following
1  d1   d2   dn  1
da ⋅ α a ⋅  + + + .... + +  °C boundary conditions:
 di ⋅ α i 2 ⋅ λ1 2⋅ λ2 2 ⋅ λ n da ⋅ α a 
  • Applicable only for free convection
 
• Δϑ = ϑ O − ϑ L ≤ 60K
( )
• ϑm = 0,5 ⋅ ϑ O − ϑ L ≈ 40° C
Hint • da ≈ 0,5m
The internal heat transfer can once again be
disregarded (see hint above). The following applies for horizontal pipes:
W
α a = A + 0,05⋅Δϑ
m ⋅K
2
The characteristic of emitting heat from a surface (e.g.
the external sheet cladding) into the surrounding
medium, which is usually air, is described by means of The following applies for vertical pipes and walls:
W
the external surface coefficient of heat transfer “αa”. α a =B+ 0,09⋅Δϑ
m ⋅K
2
The surface coefficient of heat transfer is made up of
the rate of convection and radiation. ϑ O is the surface temperature of the cladding
αa = αk + αr ϑ L is the ambient temperature
The following symbols used in this calculation:
ααk the rate of convection
ααr the rate of radiation
The rate of convection consists only of free convection
125
2.3 Bases for thermal calculations
The values for A and B have been compiled for a Supplementary values Δλ Thermal bridges
number of materials and surfaces in the table shown In addition to the insulation thickness, the total heat
below. loss from insulated objects depends on thermal
bridges, which have a negative impact on the insulation
Surface A B system. A distinction is drawn between thermal bridges
Aluminium, rolled 2,5 2,7 caused by the insulation and thermal bridges caused
by the installation.
Aluminium, oxidised 3,1 3,3
Thermal bridges caused by the insulation system
Galvanised sheet, bright 4,0 4,2
include support constructions and spacers, whereas
Galvanised sheet, tarnished 5,3 5,5
thermal bridges caused by the installation include pipe
Austenitic steel 3,2 3,4
hangings and supports, flanges and brackets.
Alu-Zinc – sheet 3,4 3,6
Non-metallic surface 8,5 8,7 Allowances are made for these thermal bridges in the
form of supplementary factors that are multiplied by the
surface coefficients of heat transfer.
Table 3 of the VDI 2055 includes relevant s upplementary

values for thermal bridges caused by the insulation.
The thermo-technical engineering calculation program

“Rockassist” can be used to calculate heat losses from
objects whilst allowing for thermal bridges. Please visit
the rockwool-rti.com website for consulting the
Rockassist program on line.
126
4
3
Tables
3. Tables
Table of contents
3.1.1 Symbols, definitions and units 130

3.1.2 Mathematical symbols 131
3.1.3 SI pre-fixes 132
3.1.4 Greek alphabet 132
3.1.5 SI units 133
3.1.6 SI derived units with special names 133
3.1.7 Compound units derived from SI-units 135
3.1.8 Temperature scales and conversions 136
3.1.9 Conversion degrees Celcius and Fahrenheit 136
3.1.10 Imperial (Anglo-Saxon) units 137
3.1.11 Conversion of energy and heat scales 140
3.1.12 Conversion power scales 140
3.1.13 Conversion of pressure scales 141
3.1.14 Conversion of SI-units into Imperial units, pre-SI units and technical scales 141
3.2.1 Insulation materials 142

3.2.2 Cladding materials 142
3.3 Usage tables 145
3.3.1 Construction materials 145

3.3.2 Fluids which are commonly used in process industry 145
3.3.3 Gases which are commonly used in process industry 146
3.3.4 Conversion factors in relation to the heat of combustion 147
3.3.5 Specific enthalpy super heated steam in kJ/kg 148
3.3.6 Density super heated steam 149
3.3.7 Dew point table 150
3.3.8 Climate data 151
3.3.9 Guidelines average velocities in pipe work 155
3.3.10 Pipe diameter 155
3.3.11 Equivalent pipe length for flanges & valves 157
3.3.12 Minimum radius Rockwool slabs 158
3.3.13 Fire curve: ISO and hydrocarbon 159
129
3. Tables
3.1 Units, conversion factors and tables

3.1.1 Symbols, definitions and units
Symbol Definition Unit
A Area m2
b Length m
C12 Radiation coefficient W/(m2 ⋅ K4)
c Specific heat capacity J/(kg ⋅ K)
cp Specific heat capacity at constant pressure J/(kg ⋅ K)
d Diameter m
f Correction factor -
H Height m
h Enthalpy J/kg
k Heat transfer coefficient W/(m2 ⋅ K), W/K, W/(m ⋅ K)
k’ Total heat transfer coefficient W/(m2 ⋅ K), W/K, W/(m ⋅ K)
l Length m
m Mass kg
.
m Massflow kg/s, kg/h
n Operation time a
P Pressure Pa
Q Heat energy J
.
Q Heat flow W
q Heat flow density W/m2 oder W/m
R Thermal resistance m2 ⋅ K/W, m ⋅ K/W, K/W
R Specific heat capacity J/(kg ⋅ K)
s Insulation thickness m
t Time h or s
T Temperature (Kelvin) K
U Circumference m
w Wind speed m/s
α Total heat transfer coefficient (incl. cold bridges) W/(m2 ⋅ K)
130
Units, conversion factors and tables
Symbol Definition Unit
α Linear expansion coefficient K-1

Λ Thermal conductance W/(m2 ⋅ K)
λ Thermal conductivity W/(m ⋅ K)
ε Emissivity -
η Yield, efficiency -
ϑ (also t) Temperature °C
μ Water vapour resistance factor -
μ Water vapour resistance -
ρ Density kg/m3
ϕ Relative humidity -
Ξ Air flow resistance Pa ⋅ s/m2
3.1.2 Mathematical symbols
Mathematical symbols
= equal to
< less than
≤ less than or equal to
<< much less than
+ plus
∞ infinite
π pi ≈ 3.14159
≈ approximately
> greater than
≥ equal to or greater than
>> much greater than
Δ Difference
Σ Sum
ln Logarithm base e
log Logarithm base 10
131
3.1 Symbols and units
3.1.3 SI pre-fixes
Decimal parts and multiples of units are conveyed by
means of prefixes and corresponding symbols. Several
prefixes cannot be compounded.
Name Symbol Conversion factor
Atto A 10-18
Femto F 10-15
Piko P 10-12
Nano n 10-9
Mikro μ 10-6
Milli m 10-3
Centi c 10-2
Deci d 10-1
Deca da 101
Hecto h 102
Kilo k 103
Mega M 106
Giga G 109
Tera T 1012
Peta P 1015
Exa E 1018
3.1.4 Greek alphabet
Greek alphabet
Α α Alpha Η η Eta Ν ν Nu Τ τ Tau

Β β Beta Θ θ Theta Ξ ξ Xi Υ υ Ypsilon
Γ γ Gamma Ι ι Iota Ο ο Omicron Φ φ Phi
Δ δ Delta Κ κ Kappa Π π Pi Χ χ Chi
Ε ε Epsilon Λ λ Lambda Ρ ρ Rho Ψ ψ Psi
Ζ ζ Zeta Μ μ Mu Σ σ Sigma Ω ω Omega
132
3.1.5 SI units
The International System of Units, also referred to as SI SI Base units
(Abbreviation for French: Système International d’unités), The SI units system is composed of seven base units.
embodies the modern metric system and is the most In order to use the base units for applications involving
widely used units system for physical units. The system different scales, certain prefixes such as Kilo or Milli are
was originally established in response to demands from used. These are also used in conjunction with derived
the field of science and research, however it is now the units and, to some extent, with units from other
prevalent units system for the economic, technological systems.
and trade industries. In the European Union (EU) and
the majority of other states, the use of the SI units system
in official and business transactions is prescribed by law;
however there are many national exceptions to this rule.
Basic unit Symbol Quantity Unit
Length l Metre m
Mass m Kilogramme kg
Time t Seconde s
Electric current I Ampere A
Thermodynamic temperature T Kelvin K
Amount of substance n Mol mol
Luminous intensity J Candela cd
3.1.6 SI derived units with special names

In addition to the base units, the International System of Some of these compounded units are assigned names
Units also includes derived units, which are made up of and symbols, which can even be combined once again
one or more of these base units by means of multipli with all of the base units and derived units. The SI unit
cation or division. The clearly defined product of powers “force” for example, the Newton (1 N = 1 kg m/s²),
of the base units are not referred to as a dimension of lends itself to express the unit “energy”, the Joule (1 J
the physical size as such, but rather the system is = 1 kg m²/s²), which is equal to the equation Newtons
formally structured in that way. It is possible for multiplied by metres. The following 22 derived units
example to express areas in terms of metres square have their own name and unit symbol.
(m²) or speeds in metres per second (m/s).
133
3.1.6 SI derived units with special names
Name Symbol Quantity Unit Expression in terms of original SI Units
Plain angle a, b, ... Radian rad

m
m (= 360°
2p )
m2
Solid angle ω Steradian sr
m2
1
Frequency f Hertz Hz
s
kg ⋅ m
Force, weight F Newton N
s2
kg N
Pressure, stress p Pascal Pa =
s2 ⋅ m m2
kg ⋅ m2
Energy, work, heat E, W Joule J =W⋅s=N⋅m
s2
kg ⋅ m2 m
=
J
Power, radiant flux P Watt W =N⋅ =V⋅A
s3 s s
Voltage, electrical potential kg ⋅ m = W = J
2
U Volt V
difference s3 ⋅ A A C
Electric charge or electric
Q Coulomb C A⋅ s
flux
kg ⋅ m 2
Magnetic flux φ Weber Wb =V⋅s
s2 ⋅ A
kg ⋅ m2 = V
Electrical resistance R Ohm Ω
s3 ⋅ A2 A
s3 ⋅ A2 = 1
Electrical conductance G Siemens S
kg ⋅ m2 Ω
kg ⋅ m2 = Wb
Inductance L Henry H
s2 ⋅ A2 A
A2 ⋅ s4 = C
Electrical capacitance C Farad F
kg ⋅ m2 V
kg Wb
Magnetic field B Tesla T = 2
s2 ⋅ A m
0°C = 273,15 K
Celsius-temperature ϑ (or t) degrees Celsius °C
1°C = 274,15 K
Luminous flux φν Lumen lm cd ⋅ sr

cd ⋅ sr = lm
Illuminance Eν Lux lx
m2 m2
Radioactivity (decays per 1
A Becquerel Bq
unit time) s
Absorbed dose (of ionising J
D Gray Gy
radiation) kg
Equivalent dose (of ionising J
H Sievert Sv
radiation) kg
mol
Catalytic activity z Katal kat
s
134
3.1.7 Compound units derived from SI-Units
Name Quantity Symbol Definition (Units)
Volume Litre l, L 1 l = 1 dm3 = 1L

Minute min 1 min = 60 s
hour h 1 h = 60 min = 3600 s
Time
Day d 1 d = 24 h = 1440 min
Year yr 1 year = 365 d = 8760 h
Tonnes t 1 t = 1.000 kg
Mass
Grammes g 1 g = 0,001 kg
Pressure Bar bar 1 bar = 105 Pa = 105 N/m2
135
3.1.8 Temperature scales and conversions
Temperature scale Unit Conversion formulas

Kelvin Celsius Fahrenheit
Kelvin ( TK ) K TK ≈ 273 + TC TK ≈ 255 +5/9*TF
Celsius ( TC ) °C TC ≈ TK - 273 TC ≈ 5/9 * (TF - 32)
Fahrenheit ( TF ) °F TF ≈ 9/5 TK - 459 TF ≈ 9/5 * TC + 32
3.1.9 Conversion degrees Celcius and Fahrenheit

The white columns show the temperature in degrees shown in the grey column. If you need to convert a
Celsius and the grey columns show the temperature temperature from Fahrenheit to Celsius, use the value
values in degrees Fahrenheit. If you need to convert a shown in the white column..
temperature from Celsius to Fahrenheit, use the value
°C °F °C °F °C °F °C °F °C °F
-200 -328 -10 14 180 356 370 698 560 1040

-190 -310 0 32 190 374 380 716 570 1058
-180 -292 10 50 200 392 390 734 580 1076
-170 -274 20 68 210 410 400 752 590 1094
-160 -256 30 86 220 428 410 770 600 1112
-150 -238 40 104 230 446 420 788 610 1130
-140 -220 50 122 240 464 430 806 620 1148
-130 -202 60 140 250 482 440 824 630 1166
-120 -184 70 158 260 500 450 842 640 1184
-110 -166 80 176 270 518 460 860 650 1202
-100 -148 90 194 280 536 470 878 660 1220
-90 -130 100 212 290 554 480 896 670 1238
-80 -112 110 230 300 572 490 914 680 1256
-70 -94 120 248 310 590 500 932 690 1274
-60 -76 130 266 320 608 510 950 700 1292
-50 -58 140 284 330 626 520 968 710 1310
-40 -40 150 302 340 644 530 986 720 1328
-30 -22 160 320 350 662 540 1004 730 1346
-20 -4 170 338 360 680 550 1022 740 1364
136
3.1.10 Imperial (Anglo-Saxon) units
The Anglo-Saxon units (also referred to as Anglo- system. Nowadays, they are only still used in the USA
American meausrement systems) are derived from old and to some extent in Great Britain and in some of the
English systems and were also used in other Common Commonwealth states.
wealth states prior to the implementation of the metric
Imperial unit, conversion to SI-Units:
Length, distance
Imperial Units Symbol Conversion to SI-Units
2,539998 cm (UK)
1 inch in.
2,540005 cm (USA)
1 foot ft. 30,48 cm
1 yard yd. 91,44 cm
1 mile 1,609 km
1 nautical mile 1,853 km
Area measurements
Imperial Units Symbol Conversion to SI-Units
1 square inch (sq.in.) 6,45 cm2

1 square foot (sq.ft.) 929,03 cm2
1 square yard (sq.yd.) 0,836 m2
137
3.1.10 Imperial units

Overview Imperial units and conversion to SI-Units:
Standard measures of volume
Imperial Units Symbol SI-Units
1 cubic inch (cu.in.) 16,39 cm3

1 cubic foot (cu.ft.) 28,32 dm3
1 cubic yard (cu.yd.) 0,7646 m3
Specific measures of volume
4,546 dm3 (UK)

1 gallon (gal.)
3,787 dm3 (USA)
163,7 dm3 (UK)
1 barrel (bbl.) 119,2 dm3 (USA)
158,8 dm3 (USA, oil)
Measures of weight and mass
1 gallon (gal.) 28,35 g

1 barrel (bbl.) 0,4536 kg
Density
Imperial Units SI-Units
1 lb/cu.in. (= 1lb/in3) 2,766*104 kg/m3

1 lb/cu.ft. (= 1 lb/ft3) 16,02 kg/m3
138
Overview Imperial units and conversion to SI-Units:
Force, weight Speed
Imperial Units SI-Units Imperial Units SI-Units
1 lbf (lb. Force) 4,448 N 0,514 m/s

1 Knot intern. (kn.)
1,852 km/h
0,0254 m/s
1 inch/second
0,0914 km/h
0,03048 m/s
Energy, work, heat 1 foot/second (ft./s.)
1,0973 km/h
0,9144 m/s
1 yard/second (yd./s.)
Imperial Units SI-Units 3,294 km/h
0,01524 m/s
1 yard/minute (yd./min.)
0,055 km/h
1 BTU 1055,06 J
0,447 m/s
1 mile per hour (m.p.h.)
1,609 km/h
Power, capacity
1 BTU/sec 1055,06 W
1 BTU/h 0,293 W
1 hp 745,7 W
Pressure, stress
1 lbg/sq in. 6894,7 N/m2

1 lbg/sq ft 47,88 N/m2
139
3.1.11 Conversion of energy and heat scales
Unit Joule Kilojoule Megajoule Kilowatt hours Kilocalorie British Thermal

(J) (kJ) (MJ) (kWh) (Kcal) Unit (BTU)
Joule (J) 0,001 10-6 2,78 * 10-7 2,39 * 10-4 9,479 * 10-4
Kilojoule (kJ) 1000 0,001 2,7810 * 10-4 0,239 0,948
Megajoule (MJ) 106 1000 0,278 238,8 948
Kilowatt hours
3,6 * 106 3600 3,6 859,8 3412,3
(kWh)
Kilocalorie
4187 4,187 4,19 * 10-3 1,2 * 10-3 3,873
(Kcal)
British Thermal
1055 1,055 1,055 * 10-3 2,933 * 10-4 0,252
Unit (BTU)
3.1.12 Conversion of power scales
Unit Watt Kilowatt Kilocalorie per Horsepower British Thermal British Thermal
(W) (kW) second (HP) Unit per second Unit per hour
(kcal/s) (BTU/s) (BTU/h)
Watt (W) 0,001 2,39 * 10-4 1,36 * 10-3 0,948 * 10-3 3415,2 * 10-3
Kilowatt (kW) 1000 0,239 1,36 0,948 3415,2
Kilocalorie per
4186,8 4,187 5,692 3,968 1,429 *103
second (kcal/s)
Horse power
735,5 0,736 0,176 0,698 2551,9
(HP)
British Thermal
Unit per second 1055,06 1,06 0,252 1,433 3600
(BTU/s)
British Thermal
Unit per hour 0,293 2,93 * 10-4 7,000 * 10-5 3,981 * 10-4 2,777 * 10-3
(BTU/h)
140
3.1.13 Conversion of pressure scales
Pascal Bar atm lb/sq ft lb/sq in.

Unit
(Pa)
Pascal (Pa) 10-5 9,869 * 10-6 0,201 1,450 * 10-4

Bar 105 0,987 2088,5 13,50
atm 101325 1,013 2116,2 14,70
lb/sq ft. 47,88 4,788 * 10 -4
4,723 * 10 -4
6,944 * 10-3
lb/sq in. 6894,8 0,0689 0,0680 144,00
3.1.14 Conversion of SI-Units into Imperial units, pre-SI units and technical scales
Symbol Quantity SI-Unit Technical scales Imperials units
Q Heat, energy J kcal = 4186,8 J 1 BTU = 1055,06 J

kcal W 1 BTU W
Q Energy, heat flux W/m2 = 1,163 2 = 3,1546
m2 h m (sq.ft.hr.) m²
1 BTU W
= 1,7307
(ft.hr.°F) (m K)
kcal W 1 BTU in W
λ Thermal conductivity W/(m K) = 1,163 = 0,1442
m2 h (m K) (sq.ft.hr.°F) (m K)
1 BTU W
= 20,7688
(in.hr.°F) (m K)
Heat resistivity coefficient K K 1 sq.ft.hr.°F K
R m2 K/W 1 m² h = 0,86 m² = 0,1761 m2
(R-value) kcal W BTU W
kcal W 1 BTU W
α Heat transfer coefficient W/(m2 K) = 1,163 = 5,6783 2
(m² h K) (m2 K) (sq.ft.hr.°F) (m K)
kcal kJ 1 BTU kJ
Cp specific heat capacity kJ/(kg K) = 4,1868 = 4,1868
(kg K) kg K (lb. °F) (kg K)
kcal W 1 BTU kJ
C Radiant coefficient W/(m2 K4) = 1,63 = 33,1156 2 4
(m2 h K4) (m2 K4) (sq.ft.hr.°R4) (m K )
141
3. Tables
3.2 Product properties insulation and cladding materials
3.2.1 Insulation materials

The characteristic properties of the individual Rockwool In any case, it is important that the product properties
products are described in Chapter 4. For special appli and processing instructions are taken into consideration
cations, such as high-temperature insulation systems, during the application of these products. Further pro
cold insulation products or an additional spacer, it may duct information can be found in the various standards
be necessary to use Rockwool products in connection and regulations, such as DIN 4140, CINI, VDI 2055 and
with other insulation products. These may include, for various other AGI Guidelines for example.
example:
• CMS Calcium-Magnesium-Silicate fibres for high-
temperature insulations
• Cellular glass as a spacer or as a support
3.2.2 Cladding materials
3.2.2.1 Application selector for claddings
Maximum surface (cladding) temperature
Cladding material Fire hazardous Corrosive < 50 °C < 60 °C >60 °C

environment environment
Aluminum - - +
Alu-zinc steel - - +
Galvanised steel + - +
Stainless steel
Aluminised steel + + +
Painted steel or aluminum - - +
Glass-fibre reinforced polyester - + 90°C

(e.g. Rocktight)
Mastics - - 80°C
Foils - - +
- not recommendable
+ suitable in general
The selection of material should be geared to each installation and/or environment.
142
3.2.2.2 Product properties and standards
Cladding material Density Linear expansion Emissivity Type of material Standard(s)

(kg/m3) coefficient 10-6 K-1
Al Mg2 Mn 0,8
Aluminium, bright 2700 23,8 0,05 EN AW 5049 DIN EN 485-2
Al MG 3 CINI 3.1.01
EN AW 5745 DIN EN 12258-1
Aluminium, oxydised 2700 23,8 0,13 AL 99,5 DIN EN 13195-1
EN AW 1050
Galvanised steel, bright 7800-7900 11,0 0,26

CINI 3.1.03,
DX 51 D
DIN EN 10327
Product properties insulation and cladding materials

Galvanised steel, oxidised 7800-7900 11,0 0,44
1.4301, 1.451, CINI 3.1.05, EDIN EN

Stainless steel 7700 - 8100 16,0 0,15
14571 10028-7, EN 10088-3
Alu-zinc steel, bright - - 0,16
Alu-zinc steel, oxidised - - 0,18
Aluminised steel 7800-7900 11,0 - DX 51 D CINI 3.1.02, DIN EN 10327
see data sheet of the
Painted steel - - 0,90
manufacturer
see data sheet
Glass fibre reinforced
- - 0,90 of the manufacturer
polyester (e.g. Rocktight)
or CINI 3.2.11
3.2.2.3 Thickness metal cladding in accordance with CINI
Sheet thickness in mm
External diameter
insulation (mm)
Aluminium Aluminised steel Alu-zinc steel Galvanised steel Stainless steel
(CINI 3.1.01) (CINI 3.1.02) (CINI 3.1.03) (CINI 3.1.04) (CINI 3.1.05)
< 140 0,6 0,56 0,5 0,5 0,5

130 - 300 0,8 0,8 0,8 0,8 0,8
> 300 1,0 0,8 0,8 0,8 0,8
143
3.2 Product properties insulation and cladding materials
3.2.2 Cladding materials

3.2.2.4 Thickness metal cladding in accordance with DIN 4140
Minimum sheet thickness Overlap
External diameter
Galvanised, Stainless steel Aluminium Longitudinal joint Circumferential joint
insulation (mm)
Aluminised, E DIN EN 10028-7
Alu-zinc and and DIN EN 10088-3
painted steel
up to 400 0,5 0,5 0,6 30

400 to 800 0,6 0,5 0,8 40
800 to 1200 0,7 0,6 0,8
50
1200 to 2000 0,8 0,6 1,0
50
2000 to 6000 1,0 0,8 1,0
> 6000 1,0 0,8 1,2
a
Smaller sheet thicknesses are also possible in consultation with the customer.
b
With regard to pipes, the circumferential joint overlap can be omitted if the circumferential joints are joined by swage and
counter swage. In the case of cladding with a large surface area and high wind loads, structural verifications may be required.
In that instance, only those binding agents permitted by the building authorities may be used. The DIN 1055-4 applies in
respect of the loading assumptions.
144
3. Tables
3.3 Usage tables
3.3.1 Construction materials
Material Density kg/m³ Thermal conductivity Specific heat capacity Linear expansion
W/(mK) at 20 °C kJ/(kg K) coefficient 10-6 K-1
Aluminum 2700 221 0,92 23,8

Concrete 2400 2,1 0,92 - 1,09 11,0 - 12,0
Bitumen (Solid) 1050 0,17 1,72 - 1,93 200,0
Bronze, red brass 8200 61 0,37 17,5
Cast iron 7100 - 7300 42 - 63 0,54 10,4
Wrought (cast) iron 7800 67 0,46 11,7
Copper 8960 393 0,40 16,5
Wet soil 1600 - 2000 1,2 - 3,0 2,0 -
Dry soil 1400 - 1600 0,4 - 0,6 0,84 -
Stainless steel 7700 - 8100 10 - 46 0,50 16,0
Iron 7850 46 - 52 0,48 11,0
3.3.2 Fluids which are commonly used in process industry
Group Material Density kg/m3 Specific heat capacity

kJ/(kg K) at 20 °C
General Water 1000 4,19

Ethanol 714 2,34
Alcohols
Methanol 792 2,495
Beer 1030 3,77
Food Milk 1030 3,94
Olive oil 920 1,97
Petrol 620 - 780 2,02
Usage tables
Diesel 830 1,93

Fuels Fuel oil (HEL) 850 1,88
Fuel oil (HS) 980 1,72
Petroleum 790 2,20
145
3.3 Usage tables
3.3.2 Fluids which are commonly used in process industry
Group Material Density kg/m3 Specific heat capacity

kJ/(kg K) at 20 °C
Silicone oil 940

Oils
Machine oil 910 1,67
Hydrochloric acid (10%) 1070 -
Hydrochloric acid (30%) 1150 3,64
Nitric acid (10 %) 1050 -
Acids Nitric acid (<90%) 1500 1,72
Sulfuric acid (10%) 1070 -
Sulfuric acid (50%) 1400 -
Sulfuric acid (100%) 1840 1,06
Ammonia (30%) 609 4,74
Bases
Sodium hydroxide (50%) 1524 -
Benzol 879 1,73
Dichlormethane 1336 1,16
Various
Toluene 867 1,72
Bitumen (fluid) 1100 - 1500 2,09 - 2,3
3.3.3 Gases which are commonly used in process industry
Gas Density Specific heat capacity kJ/(kg K) at 20 °C

at 1 bar kg/m3
Acetylene 1,070 1,687

Ammonia 0,710 2,093
Chlorine 2,950 0,477
Ethane 1,240 1,754
Ethylene 1,150 1,553
Carbon dioxide 1,780 0,846
Carbon monoxide 1,150 1,038
Air 1,190 1,007
Methane 0,660 2,227
Propane 1,850 1,671
Oxygen 1,310 0,913
Nitrogen 1,150 1,038
Hydrogen 0,820 14,34
146
3.3.4 Conversion factors in relation to the heat of combustion
Fuel Heat of combustion TJ/Gg Conversion factor tCO2 / TJ Conversion factor

kgCO2/kg fuel
Oil 42,3 73,3 3,1

Liquified gas 442 64,1 28,3
Petrol 44,3 69,2 3,1
Kerosene 43,8 71,8 3,1
Diesel 43,0 74,0 3,2
Ethane 46,4 61,6 2,9
Petroleum cokes 32,5 97,5 3,2
Black coal 28,2 94,5 2,7
Brown coal 11,9 101,1 1,2
Gas cokes 28,2 107,0 3,0
Gas 48,0 56,1 2,7
Usage tables
147
3.3 Usage tables
3.3.5 Specific enthalpy super heated steam in kJ/kg
Steam temperature in °C
Pressure
in bar
150 200 250 300 350 400 450 500 600 700 800
1 2776,1 2874,8 2973,9 3073,9 3175,3 3278,0 3382,3 3488,2 3705,0 3928,8 4159,7
5 2854,9 2960,1 3063,7 3167,4 3271,7 3377,2 3483,9 3701,9 3926,5 4157,8
10 2827,4 2941,9 3050,6 3157,3 3263,8 3370,7 3478,6 3698,1 3923,6 4155,5
20 2901,6 3022,7 3136,6 3247,5 3357,5 3467,7 3690,2 3917,6 4150,9
30 2854,8 2922,6 3114,8 3230,7 3344,1 3456,6 3682,3 3911,7 4146,3
40 2959,7 3091,8 3213,4 3330,4 3445,4 3674,3 3905,7 4141,7
50 2923,5 3067,7 3195,5 3316,3 3433,9 3666,2 3899,7 4137,0
60 2883,2 3042,2 3177,0 3301,9 3422,3 3658,1 3893,6 4132,3
70 2837,6 3015,1 3157,9 3287,3 3410,5 3649,8 3887,5 4127,6
80 2784,6 2986,3 3138,0 3272,2 3398,5 3641,5 3881,4 4122,9
90 2955,5 3117,5 3256,9 3386,4 3633,2 3875,2 4118,2
100 2922,2 3096,1 3241,1 3374,0 3624,7 3869,0 4113,5
150 2691,3 2974,7 3156,6 3309,3 3581,5 3837,6 4089,6
200 2816,9 3060,8 3239,4 3536,7 3805,5 4065,4
250 2578,1 2950,6 3164,2 3490,4 3773,0 4041,1
300 2150,7 2822,3 3083,5 3443,1 3740,1 4016,7
350 1988,3 2672,9 2997,3 3394,7 3706,9 3992,2
400 1930,8 2513,2 2906,7 3345,8 3673,8 3967,8
450 1897,3 2377,7 2814,2 3296,6 3640,7 3943,6
500 1874,1 2284,7 2724,2 3247,7 3607,8 3919,5
600 1843,0 2180,0 2571,9 3152,3 3543,5 3872,3
700 1822,8 2123,6 2466,9 3063,8 3481,9 3826,7
800 1808,7 2087,9 2397,7 2985,4 3424,2 3783,3
900 1798,4 2063,2 2350,3 2918,7 3371,1 3742,4
1000 1790,9 2045,1 2316,2 2863,4 3323,1 3704,3
148
3.3.6 Density super heated steam
Steam temperature in °C
Pressure
in bar
150 200 250 300 350 400 450 500 600 700 800
1 0,5164 0,4604 0,4156 0,379 0,3483 0,3223 0,2999 0,2805 0,2483 0,2227 0,2019
5 2,3537 2,1083 1,9137 1,7540 1,6200 1,5056 1,4066 1,2437 1,1149 1,0105
10 4,8566 4,2984 3,8771 3,5402 3,2617 3,0263 1,8241 2,4932 2,2331 2,0228
20 8,9757 7,9713 7,2169 6,6142 6,1153 5,6926 5,0101 4,4794 4,0531
30 14,172 12,326 11,047 10,065 9,2708 8,6076 7,5512 6,7390 6,0908
40 17,000 15,052 13,623 12,497 11,571 10,117 9,0121 8,1360
50 22,073 19,255 17,299 15,798 14,586 12,709 11,299 10,189
60 27,662 23,687 21,102 19,179 17,653 15,326 13,599 12,249
70 33,944 28,384 25,045 22,646 20,776 17,970 15,914 14,316
80 41,226 33,394 29,143 26,202 23,957 20,642 18,242 16,391
90 38,776 33,411 29,855 27,198 23,341 20,584 18,474
100 44,611 37,867 33,611 30,503 26,068 22,941 20,564
150 87,191 63,889 51,200 48,077 40,154 34,943 31,124
200 100,54 78,732 67,711 55,039 47,319 41,871
250 166,63 109,09 89,904 70,794 60,080 52,803
300 358,05 148,45 115,26 87,481 73,234 63,919
350 474,89 201,63 144,43 105,15 86,779 75,214
400 523,67 270,91 177,97 123,81 100,71 86,682
450 554,78 343,37 215,87 143,44 115,01 98,312
500 577,99 402,28 256,95 163,99 129,64 110,09
600 612,45 479,87 338,44 207,20 159,77 134,02
700 638,30 528,62 405,76 251,73 190,65 158,30
800 659,27 563,69 456,99 295,45 221,74 182,72
900 677,05 591,14 496,53 336,53 252,48 207,03
1000 692,58 613,80 528,21 373,93 282,36 231,03
Usage tables
149
3.3 Usage tables
3.3.7 Dew point table
Maximum cooling of air temperature (to avoid condensation) at a humidity of

Maximum
Air
water content
temperature
in g/m3
35 % 40 % 45 % 50 % 55 % 60 % 65 % 70 % 75 % 80 % 85 % 90 % 95 %
-30 0,35 11,1 9,8 8,6 7,5 6,6 5,7 4,9 4,2 3,5 2,8 2,2 1,6 1,1 0,6
-25 0,55 11,5 10,1 8,9 7,8 6,8 5,9 5,1 4,3 3,6 2,9 2,3 1,7 1,1 0,6
-20 0,90 12,0 10,4 9,1 8,0 7,0 6,0 5,2 4,5 3,7 2,9 2,3 1,7 1,1 0,6
-15 1,40 12,3 10,8 9,6 8,3 7,3 6,4 5,4 4,6 3,8 3,1 2,5 1,8 1,2 0,6
-10 2,17 12,9 11,3 9,9 8,7 7,6 6,6 5,7 4,8 3,9 3,2 2,5 1,8 1,2 0,6
-5 3,27 13,4 11,7 10,3 9,0 7,9 6,8 5,9 5,0 4,1 3,3 2,6 1,9 1,2 0,6
0 4,8 13,9 12,2 10,7 9,3 8,1 7,1 6,0 5,1 4,2 3,5 2,7 1,9 1,3 0,7
2 5,6 14,3 12,6 11,0 9,7 8,5 7,4 6,4 5,4 4,6 3,8 3,0 2,2 1,5 0,7
4 6,4 14,7 13,0 11,4 10,1 8,9 7,7 6,7 5,8 4,9 4,0 3,1 2,3 1,5 0,7
6 7,3 15,1 13,4 11,8 10,4 9,2 8,1 7,0 6,1 5,1 4,1 3,2 2,3 1,5 0,7
8 8,3 15,6 13,8 12,2 10,8 9,6 8,4 7,3 6,2 5,1 4,2 3,2 2,3 1,5 0,8
10 9,4 16,0 14,2 12,6 11,2 10,0 9,6 7,4 6,3 5,2 4,2 3,3 2,4 1,6 0,8
12 10,7 16,5 14,6 13,0 11,6 10,1 8,8 7,5 6,4 5,3 4,3 3,3 2,4 1,6 0,8
14 12,1 16,9 15,1 13,4 11,7 10,3 8,9 7,6 6,5 5,4 4,3 3,4 2,5 1,6 0,8
16 13,6 17,4 15,5 13,6 11,9 10,4 9,0 7,8 6,6 5,5 4,4 3,5 2,5 1,7 0,8
18 15,4 17,8 15,7 13,8 12,1 10,6 9,2 7,9 6,7 5,6 4,5 3,5 2,5 1,7 0,8
20 17,3 18,1 15,9 14,0 12,3 10,7 9,3 8,0 6,8 5,6 4,6 3,6 2,6 1,7 0,8
22 19,4 18,4 16,1 14,2 12,5 10,9 9,5 8,1 6,9 5,7 4,7 3,6 2,6 1,7 0,8
24 21,8 18,6 16,4 14,4 12,6 11,1 9,6 8,2 7,0 5,8 4,7 3,7 2,7 1,8 0,8
26 24,4 18,9 16,6 14,7 12,8 11,2 9,7 8,4 7,1 5,9 4,8 3,7 2,7 1,8 0,9
28 27,2 19,2 16,9 14,9 13,0 11,4 9,9 8,5 7,2 6,0 4,9 3,8 2,8 1,8 0,9
30 30,3 19,5 17,1 15,1 13,2 11,6 10,1 8,6 7,3 6,1 5,0 3,8 2,8 1,8 0,9
35 39,4 20,2 17,7 15,7 13,7 12,0 10,4 9,0 7,6 6,3 5,1 4,0 2,9 1,9 0,9
40 50,7 20,9 18,4 16,1 14,2 12,4 10,8 9,3 7,9 6,5 5,3 4,1 3,0 2,0 0,9
45 64,5 21,6 19,0 16,7 14,7 12,8 11,2 9,6 8,1 6,8 5,5 4,3 3,1 2,1 0,9
50 82,3 22,3 19,7 17,3 15,2 13,8 11,6 9,9 8,4 7,0 5,7 4,4 3,2 2,1 0,9
55 104,4 23,0 20,2 17,8 15,6 13,7 11,8 10,2 8,6 7,1 5,8 4,5 3,2 2,1 0,9
60 130,2 23,7 20,9 18,4 16,1 14,1 12,2 10,5 8,9 7,3 5,9 4,6 3,3 2,1 0,9
65 161,3 24,5 21,6 19,0 16,6 14,5 12,6 10,8 9,1 7,6 6,1 4,7 3,4 2,1 0,9
70 188,2 25,2 22,2 19,5 17,1 15,0 13,0 11,1 9,4 7,9 6,2 4,8 3,4 2,1 0,9
75 242,0 26,0 22,9 20,1 17,7 15,4 13,3 11,4 9,6 8,0 6,4 4,9 3,5 2,2 0,9
80 283,4 26,8 23,6 20,7 18,2 15,8 13,7 11,7 9,9 8,2 6,6 5,0 3,6 2,2 0,9
150
3.3.8 Climate data
3.3.8.1 Average year temperature and humidity
Europe Temperature (°C) Humidity (%)
Athens 17.6 66
Berne 8.6 -
Geneva 9.2 -
Amsterdam 9,8 83
Innsbruck 8.4 -
London 9.9 79
Madrid 13.4 67
Moscow 3.6 79
Paris 10.3 77
Rome 15.4 72
Salzburg 8.2 -
Warsaw 7.3 82
Vienna 9.8 77
Zurich 8.2 -
Other parts of the world Temperature (°C) Humidity (%)
Jakarta 25.9 85
Buenos Aires 16.1 84
Dar es Salaam 25.3 -
Havana 25.2 76
Cairo 21.1 -
Kolkata 25.5 -
New York 11.1 76
Rio de Janeiro 22.7 74
San Francisco 12.8 82
Usage tables
Santiago 13.9 68
Shanghai 15.8 -
Sydney 17.3 13.4
Tokyo 13.8 73
151
3.3 Usage tables
3.3.8 C
limate data
The Netherlands Temperature Humidity

(°C) (%)
Amsterdam (Schiphol) 9,8 84

Arnhem (Deelen) 9,4 81
Den Haag 9,9 83
Den Helder 9,6 84
Eindhoven 9,9 81
Enschede 9,3 83
Groningen 9,0 86
Leeuwarden 9,2 85
Maastricht 9,8 82
Rotterdam 10 84
‘s Hertogenbosch 9,8 82
Soesterberg 9,6 81
Utrecht (De Bilt) 9,8 82
Vlissingen 10,4 82
Belgium Temperature Humidity

(°C) (%)
Antwerpen 9,6 -
Beauvechain 9,2 -
Botrange 5,7 -
Brussel 9,7 81
Chièvres 9,0 -
Dourbes 8,6 -
Elsenborn 5,7 -
Florennes 8,2 -
Gent 9,5 -
Kleine Brogel 9,0 -
Koksijde 9,4 -
Libramont 7,5 -
Spa 7,4 -
St-Hubert 6,8 -
Virton 8,7 -
152
Germany Temperature (°C) Humidity (%)
Berlin 9.1 77
Braunschweig 8.6 -
Bremerhaven 8.8 -
Dresden 9.3 74
Essen 9.5 82
Erfurt 8.0 -
Frankfurt/M. 10.1 76
Frankfurt a.O. 8.2 -
Giessen 9.0 -
Görlitz 8.3 -
Halle 9.1 76
Hamburg 8.4 80
Magdeburg 9.1 -
Mannheim 10.2 -
Munich 8.1 -
Nuremberg 8.5 -
Plauen 7.2 -
Regensburg 8.1 -
Rostock 7.8 -
Stuttgart 8.6 -
Trier 9.1 -
France Min. Temperature (°C) Max. Temperature (°C) Humidity (%)
Ajaccio 10 20,1 -
Bourges 0,8 15,8 -
Bordeaux 8,5 18,1 -
Dijon 6,4 15,1 -
La Rochelle 9,5 16,5 -
Lille 6,5 14,1 -
Usage tables
Lyon 7,5 16,4 -

Nice 12 19,2 -
Paris 8,6 15,5 77
Perpignan 11 19,8 -
Rennes 7,6 16 -
Strasbourg 6,1 14,8 -
153
3.3 Usage tables
3.3.8.2 Wind speed
Beaufort scale Wind speed (m/s) Definition
0 0 - 0,2 Calm
1 0,3 - 1,5 Light air
2 1,6 - 3,3 Light breeze
3 3,4 - 5,4 Gentle breeze
4 5,5 - 7,9 Moderate breeze
5 8,0 - 10,7 Fresh breeze
6 10,8 - 13,8 Strong breeze
7 13,9 - 17,1 Moderate gale (strong wind)
8 17,2 - 20,7 Fresh gale (strong wind)
9 20,8 - 24,4 Strong gale (strong wind)
10 24,5 - 28,4 Whole gale / storm
11 28,5 - 32,6 Violent storm
≥12 >32,7 Hurricane
Generally speaking, the wind speed is also dependent

on the height and location (inland, coastal). In order to
calculate the insulation thickness, the following wind
speeds are generally used:
• Inside: 0,5 m/s
• Outside in protected conditions: 1 m/s
• Outside: 5 m/s
• Outside in windy conditions
(e.g. near to coast): 10 m/s
154
3.3.9 Guidelines average velocities in pipe work
Type of fluid / piping Velocity (m/s)
Steam piping Saturated steam 20 - 35

LP(low-pressure) steam 30
MP(medium-pressure) steam 40
HP(high-pressure) steam 60
(Hot) water supply Feed 2 -3
Return 1
Oil Low viscosity 1,5
High viscosity 0,5
District heating Average 2
Central heating (non residential buildings) Main feed stock 0,5
3.3.10 Pipe diameter

Many different standards exist in relation to pipe sizes, nominal pipe sizes above 14, the nominal diameter
the distribution of which varies according to the sector (DN) size corresponds to the NPS size multiplied by
of industry and geographical area. The denotation of 25 (not 25.4). These pipes are documented in the
the pipe size generally comprises two numbers; one, EN 10255 standard (formerly DIN 2448 and BS
which indicates the external diameter or nominal 1387) and in the ISO 65 standard and are often
diameter, and a further number that indicates the wall denoted as DIN- or ISO-pipes.
thickness.
• In North America and Great Britain, high-pressure In order to ensure a joint-free laying of the insulation, it
pipe systems are generally classified by means of the is important that you know the actual external diameter
Nominal Pipe Size (NPS) System in Inches. The pipe of the pipe, as there are an immense number of pipe
sizes are documented in a series of standards. In the dimensions.
USA, these standards include API 5L, ANSI/ASME
B36.10M and in Great Britain BS 1600 and BS 1387. The following table provides a general overview of
As a rule, the pipe wall thickness is the fixed variable common pipe diameters with a comparison between
and the internal diameter is permitted to vary the inches and DN size.
• In Europe, the same internal diameter and wall
Usage tables
strengths as used in the Nominal Pipe Size system

are used for high-pressure pipe systems, however
they are conveyed in a metric nominal diameter
instead in inches as given in the NPS system. For
155
3.3.10 Pipe diameter
Nominal Pipe Size Nominal diameter Outer diameter (mm)

(NPS in inch) (DN/Metric)
1/8 DN 6 10,3
1/4 DN 8 13,7
3/8 DN 10 17,1
1/2 DN 15 21,3
3/4 DN 20 26,7
1 DN 25 33,4
1¼ DN 32 42,2
1½ DN 40 48,3
2 DN 50 60,3
2½ DN 65 73,0
3 DN 80 88,9
3½ DN 90 101,6
4 DN 100 114,3
4½ DN 115 127,0
5 DN 125 141,3
6 DN 150 168,3
8 DN 200 219,1
10 DN 250 273,1
12 DN 300 323,9
14 DN 350 355,6
16 DN 400 406,4
18 DN 450 457,2
20 DN 500 508,0
22 DN 550 558,8
24 DN 600 609,6
26 DN 650 660,4
28 DN 700 711,2
30 DN 750 762,0
32 DN 800 812,8
34 DN 850 863,6
36 DN 900 914,0
156
3.3.11 Equivalent pipe length for flanges & valves
Reference values for plant related thermal bridges (table A14 - VDI 2055)
Item no. Temperature range in °C
50-100 150-300 400-500
Equivalent length in m
1 Flanges for pressure stages PN25 to PN100
1.1 Uninsulated for pipes
1.1.1 In buildings 20°C
DN 50 3-5 5 - 11 9 - 15
DN 100 4-7 7 - 16 13 - 16
DN 150 4-9 7 - 17 17 - 30
DN 200 5 - 11 10 - 26 20 - 37
DN 300 6 - 16 12 - 37 25 - 57
1.1.2 In the open air 0°C
DN 50 7 - 11 9 - 16 12 - 19
DN 100 9 - 14 13 - 23 18 - 28
DN 150 11 - 18 14 - 29 22 - 37
DN 200 13 - 24 18 - 38 27 - 46
DN 300 16 - 32 21 - 54 32 - 69
DN 400 22 - 31 28 - 53 44 - 68
DN 500 25 - 32 31 - 52 48 - 69
1.2 Insulated in buildings 20°C and in the open air 0°C for pipes
DN 50 0,7 - 1,0 0,7 - 1,0 1,0 - 1,1
DN 100 0,1 - 1,0 0,8 - 1,2 1,1 - 1,4
DN 150 0,8 - 1,1 0,8 - 1,3 1,3 - 1,6
DN 200 0,8 - 1,3 0,9 - 1,4 1,3 - 1,7
DN 300 0,8 - 1,4 1,0 - 1,6 1,4 - 1,9
DN 400 1,0 - 1,4 1,1 - 1,6 1,6 - 1,9
DN 500 1,1 - 1,3 1,1 - 1,6 1,6 - 1,8
2 Fittings for pressure stages PN 25 to PN 100
2.1 Uninsulated for pipes
2.1.1 In buildings 20°C
DN 50 9 - 15 16 - 29 27 - 39
DN 100 15 - 21 24 - 46 42 - 63
Usage tables
DN 150 16 - 28 26 - 63 58 - 90
DN 200 21 - 35 37 - 82 73 - 108
DN 300 29 - 51 50 - 116 106 - 177
DN 400 36 - 60 59 - 136 126 - 206
DN 500 46 - 76 75 - 170 158 - 267
157
3.3 Usage tables
Item no. Temperature range in °C
50-100 150-300 400-500
Equivalent length in m
2.1.2 In the open air 0°C / Only for pressure stage PN 25
DN 50 22 - 24 27 - 34 35 - 39
DN 100 33 - 36 42 - 52 56 - 61
DN 150 39 - 42 50 - 68 77 - 83
DN 200 51 - 56 68 - 87 98 - 101
DN 300 59 - 75 90 - 125 140 - 160
DN 400 84 - 88 106 - 147 165 - 190
DN 500 108 - 114 134 - 182 205 - 238
2.2 Insulated for pipes
2.2.1 In buildings 20°C and in the open air 0°C for pipes
DN 50 4-5 5-6 6-7
DN 100 4-5 5-6 6-7
DN 150 4-5 5-6 6-7
DN 200 5-7 5-9 7 - 10
DN 300 5-9 6 - 12 7 - 13
DN 400 6-9 7 - 12 8 - 15
DN 500 7 - 11 8 - 15 9 - 19
3 Pipe suspensions supplementary value Z*
3.1 In buildings 0,15
3.2 In the open air 0,25
* The ranges given cover the effect of the temperature and of the pressure stages. Flanges and fittings for higher pressure stages give higher values so
overlappings in the given temperature ranges are possible.
3.3.12 Minimum radius Rockwool slabs
Minimal radius Rockwool Technical Insulation slabs
Product insulation thickness (mm)
40 50 60 70 80 100 120
Rockwool Flexiboard 500 700 900 1100 1300 1800 2000
Rockwool Multiboard 500 700 1000 1200 1500 1900 2400
Rockwool HT600 500 700 1000 1200 1400 - -
158
3.3.13 Fire curve: ISO and hydrocarbon
ISO fire curve
1400
1200
1000
Temperature (°C)
800
600
400
200
0
0 50 100 150 200 250 300 350
Time (min.)
Hydrocarbon fire curve
1400
1200
1000
Temperature (°C)
800
600
400
200
0
Usage tables
0 50 100 150 200 250 300 350

Time (min.)
159
Notes
160
4
Products
4. Products
Application selector
Cryogen
Process Valves, Tank Acoustic instal-
Tank Voids,
bends, Columns Boilers Furnaces walls, applica- lations
pipe work flanges roofs seams
drums tions and cold
boxes
Rockwool
850
Pipe Sections
Rockwool
851
ProRox
WM 70
ProRox
Wired Mats WM 80
ProRox
WM 100
Load Rockwool
bearing mat Duraflex
Rockwool
Flexiboard
Rockwool
Multiboard
Rockwool
HT600
Rockwool
Slabs HT660
Rockwool
HT700
Rockwool
CRS
Rockwool
251
Finishing Rocktight
Rockwool
Loose Fill
Loose wool
Rockwool
Granulate
Remarks • DIN 4140 (Insulation work on industrial

Due to an almost limitless range of applications, installations and building equipment)
we have not provided detail information for all the
applications. Information is available in the following For specific applications, our RTI sales team will be
manuals/standards for industrial insulation: pleased to advise you.
• CINI manual ‘Insulation for industries’
• AGI Q101 (Dämmarbeiten an Kraftswerk
komponenten) 163
4. Products
Important Product Properties Thermal Conductivity

The thermal insulating action of insulating materials is
Maximum Service Temperature Limit defined by the thermal conductivity λ described.
The maximum service temperature limit is used to rank Lambda λ is specified in the physical unit W/(mK). The
the insulating materials in terms of their behavior at thermal conductivity is a temperature-dependent value.
higher temperatures. It replaces the term classification The thermal conductivity increases with rising
temperature, which was still in current usage in AGI temperatures. The thermal conductivity is, in other
Q132 from 1995. The maximum service temperature words, dependent on the structure, the fiber orientation
limit is determined in the laboratory during static and the bulk density of the insulating material. For pipe
loading, taking the delivery form (mat, plate, shell) insulating materials, which are used in accordance with
into account. EnEV [German Energy Saving Regulations for
Buildings], the characteristic thermal conductivity λR is
Maximum Service Temperature given at an average temperature of 40 °C. For insulating
The maximum service temperature is the temperature materials which are used in industrial plants, the
to which the insulating material can be continuously thermal conductivity is specified as a function of the
exposed, under operating conditions and the static and temperature, usually in 50 °C-stages.
dynamic loads occurring in the use case, without its
properties being impaired. Insulating materials may Insulating Material Designation Code
only be used up to a temperature at which the thermal The insulating material designation code is a 10 digit
insulating action is not unduly impaired by dimensional, code which is used to characterize insulating materials
structural or chemical changes. The maximum service for industrial plants. The insulating material designation
temperature of insulating materials is generally lower code for the Rockwool wired mat is shown here by way
than the maximum service temperature limit. of example:
AS Quality 10.01.02.64.08
Alloying elements, such as e.g. chromium, nickel or
molybdenum, are added to austenitic steels in order to
increase the corrosion resistance. Under certain Bulk density 80 kg/m3
marginal conditions, such as component stresses and
Maximum service
contact with water-soluble chloride ions, austenitic steels
temperature limit
tend to develop stress corrosion cracking. For this
640 °C
reason, only insulating materials that conform to AS
Quality requirements may be used. For these insulating Thermal conductivity
materials, the chloride ion content may not exceed a limiting curve
nominal value of 10 mg/kg. As chloride ions are present Limiting curve 2
almost everywhere in the environment, products of AS

Delivery form
quality must be stored in a dry and weatherproof Wired mat
manner.
Mineral wool
164
Rockwool 850 Industrial pipe section
Applications Advantages
Rockwool 850 is a pre-formed stone wool pipe section. • Excellent thermal and acoustic insulation
The sections are supplied split and hinged for easy • Easy to handle and install
snap-on assembly, and are suitable for the thermal and • Wide range of diameters and insulation thicknesses
acoustic insulation of industrial pipe work. • Optimal performance due to the extensive range of
diameters
• Suitable for use over stainless steel
• For temperatures up to 350°C, a support construction
is not generally necessary
• Long lasting
• Excellent fit provides optimal performance
• Fast return on investment
Product properties
Performance Standard
t°m (°C) 50 100 150 200 250 300
λ (W/mK) 0.038 0.044 0.051 0.061 0.073 0.087
Thermal conductivity EN ISO 8497, ASTM C335
t°m (°F) 100 200 300 400 500 600
λ (BTU.in/ft2.h.°F) 0.257 0.296 0.354 0.429 0.524 0.637
620 °C (1148 °F) EN 14707
Maximum Service Temperature 750 °C (1382 °F) ASTM C411
A1 EN 13501-1
Non-combustible IMO A799 (19)
Reaction to fire Low Surface Flame Spread IMO A653 (16)
Surface burning characteristics: Flame spread=passed, Smoke ASTM E84 (UL 723)
development=passed
< 10 mg/kg, AS-quality for use on stainless steel EN 13468

Water leachable chloride Conforms to the stainless steel corrosion specification as per ASTM test methods ASTM C795
content < 10mg/kg (pH-value neutral to slightly alkaline) C692 and C871 ASTM C871
Water absorption < 1 kg/m2 EN 13472

Water absorption
Water vapour absorption (vapor sorption) ± 0.02 %vol ASTM C1104/C1104M
Nominal density 100 - 125 kg/m3 (6.24 - 7.80 lb/ft3)
Water vapour resistance factor μ = 1,0 EN 13469
Rockwool sections. For the thermal insulation of pipes. CINI 2.2.03
Compliance Standard specification for mineral fibre pre-formed pipe insulation, type I, II and IV ASTM C547-06
Rockwool 850 is certificated by ButgB, technical approval ATG 2193
165
4. Products
Rockwool 851 Industrial pipe section
Rockwool 851 is a pre-formed high density stone wool • Excellent thermal and acoustic insulation
pipe section. The sections are supplied split and hinged • Easy to handle and install
for easy snap-on assembly, and are especially suitable • Wide range of diameters and insulation thicknesses
for the thermal and acoustic insulation of industrial pipe • Optimal performance due to the extensive range of
work which is exposed to high temperature and light insulation thicknesses
(e.g. vibrations) mechanical loads. • Suitable for use over stainless steel
• For temperatures up to 350 °C, support construc
tion is not generally necessary
• Long lasting
• Excellent fit provides optimal performance
• Fast return on investment
Product properties
t°m (°C) 50 100 150 200 250 300
λ (W/mK) 0.038 0.044 0.051 0.059 0.069 0.079
Thermal conductivity EN ISO 8497, ASTM C335
t°m (°F) 100 200 300 400 500 600
λ (BTU.in/ft2.h.°F) 0.255 0.298 0.353 0.416 0.490 0.574
640 °C (1184 °F) EN 14707
A1 EN 13501-1
Reaction to fire Surface burning characteristics: Flame spread=passed, Smoke ASTM E84 (UL 723)
development=passed
< 10mg/kg, AS-quality for use over stainless steel EN 13468

Water leachable chloride content Conforms to the stainless steel corrosion specification as per ASTM test ASTM C795
methods C692 and C871
<10mg/kg (ph-value neutral to slightly alkaline) ASTM C871
Water absorption < 1 kg/m 2
EN 13472
Water absorption
Nominal density 140 kg/m3 (8.75 lb/ft3)
Water vapour resistance factor μ = 1.0 EN 13469
Rockwool sections. For the thermal insulation of pipes.
Compliance CINI 2.2.03
Standard specification for mineral fibre pre-formed pipe insulation, type ASTM C547-06
I, II and IV
166
167
4. Products
ProRox WM 70 (previously Rockwool 160) Wired mat
Thickness Length Width Packaging Packaging

in mm in mm in mm m2/roll m2/pallet
50 4500 500 4,5 94,5

60 4000 500 4,0 84,0
80 3000 500 3,0 63,0
100 2500 500 2,5 52,5
120 2000 500 2,0 42,0
The following variants are available on request:

• ProRox WM 70 SW: Stainless steel mesh and stitching wire
• ProRox WM 70 S: Galvanised steel mesh and stainless steel stitching wire
• ProRox WM 70 ALU: Galvanised steel mesh and stitching wire with addition of aluminium foil between mesh and rock wool
• ProRox WM 70 SW ALU: Stainless steel mesh and stitching wire with addition of aluminium foil between mesh and rock wool
ProRox WM 70 is a lightly bonded rock wool mat • Excellent thermal and acoustic insulation
stitched on galvanised wired mesh with galvanised • Suitable for use over irregular surfaces
wire. The wired mat is suitable for thermal and acoustic • Available in a wide range of thickness up to 120 mm
insulation of industrial pipe work, boiler walls, furnaces • Suitable for use over stainless steel
and industrial smoke exhaust ducts. • Compressed and palletized packaging
168
Product properties ProRox WM 70
t° (°C) 50 100 150 200 250 300 400 500
λ (W/mK) 0.039 0.047 0.055 0.064 0.075 0.088 0.119 0.157
Thermal conductivity EN 12667, ASTM C177
t° (°F) 100 200 300 400 500 600 700 800
λ (BTU.in/ft2.h.°F) 0.262 0.316 0.380 0.455 0.543 0.645 0.763 0.897
580 °C (1076 °F) EN 14706
A1 EN 13501-1
development=passed
Conforms to the stainless steel corrosion specification as per ASTM ASTM C795
Water leachable chloride content
test methods C692 and C871
< 10mg/kg (ph-value neutral to slightly alkaline) ASTM C871
EN 1609
Water absorption Water vapour absorption (vapor sorption) ± 0.02 %vol ASTM C1104/C1104M
Rockwool (RW) wire mesh blankets for thermal insulation of large CINI 2.2.02
Compliance Standard specification for mineral fibre blanket insulation, type I and ASTM C592-06
II
169
4. Products

50 4000 500 4,0 84,0

60 3500 500 3,5 73,5
80 3000 500 3,0 63,0
100 2500 500 2,5 52,5
120 2000 500 2,0 42,0

• ProRox WM 80 SW: Stainless steel mesh and stitching wire
• ProRox WM 80 S: Galvanised steel mesh and stainless steel stitching wire
• ProRox WM 80 ALU: Galvanised steel mesh and stitching wire with addition of aluminium foil between mesh and rock wool
• ProRox WM 80 SW ALU: Stainless steel mesh and stitching wire with addition of aluminium foil between mesh and rock wool
Applications
ProRox WM 80 is a lightly bonded stone wool mat
stitched on galvanised wire mesh using galvanised
wire. The wired mat is suitable for thermal and acoustic
insulation of industrial applications reaching high
temperatures, such as industrial pipe work, boiler walls,
furnaces and smoke ducts.
Advantages
• Excellent thermal and acoustic insulation
• Suitable for use over irregular surfaces
• Available in a wide range of thicknesses up to 120 mm
• Compressed and palletized packaging
170
t° (°C) 50 100 150 200 250 300 400 500 600
λ (W/mK) 0.039 0.045 0.053 0.062 0.072 0.084 0.112 0.146 0.192
t° (°F) 100 200 300 400 500 600 700 800 900
λ (BTU.in/ft2.h.°F) 0.253 0.301 0.357 0.422 0.498 0.587 0.691 0.812 0.951
640 °C (1184 °F) EN 14706
A1 EN 13501-1
development=passed
Water leachable chloride content
EN 1609
Nominal density 80 kg/m3 (5 lb/ft3)
Compliance Standard specification for mineral fibre blanket insulation, type I ASTM C592-06
and II
171
4. Products

50 4000 500 4,0 84,0

60 3000 500 3,0 63,0
80 2500 500 2,5 52,5
100 2000 500 2,0 42,0
120 2000 500 2,0 42,0

• ProRox 100 SW: Stainless steel mesh and stitching wire
• ProRox 100 S: Galvanised steel mesh and stainless steel stitching wire
• ProRox 100 ALU: Galvanised steel mesh and stitching wire with addition of aluminium foil between mesh and rock wool
• ProRox 100 SW ALU: Stainless steel mesh and stitching wire with addition of aluminium foil between mesh and rock wool
Applications
ProRox WM 100 is a lightly bonded heavy stone wool
mat stitched on galvanised wired mesh with galvanised
wire. The wired mat is especially suitable for industrial
installations such as high-pressure steam pipes, reac
tors, furnaces, etc. where high demands are made on
the temperature resistance of the insulation.
Advantages
• Suitable for use over irregular surfaces
• Available in a wide range of thicknesses up to 120 mm
172
t° (°C) 50 100 150 200 250 300 400 500 600
λ (W/mK) 0.039 0.045 0.051 0.059 0.067 0.078 0.102 0.131 0.167
t° (°F) 100 200 300 400 500 600 700 800 900
λ (BTU.in/ft2.h.°F) 0.265 0.308 0.359 0.421 0.492 0.574 0.668 0.773 0.891
680 °C (1256 °F) EN 14706
A1 EN 13501-1
development=passed
Water leachable chloride content test methods C692 and C871
EN 1609
Compliance Standard specification for mineral fibre blanket insulation, type I ASTM C592-06
and II
173
4. Products
Rockwool Duraflex Load bearing insulation mat
Thickness Length Width Packaging m2 per

mm mm mm m2/duo roll 40ft HC container*
30 8000 500 8.0 2336

40 6000 500 6.0 1752
50 5000 500 5.0 1400
60 4500 500 4.5 1170
70 4000 500 4.0 1000
80 3500 500 3.5 875
90 3000 500 3.0 780
100 3000 500 3.0 700
Applications
Rockwool Duraflex is a stone wool insulation mat
bonded onto fibreglass reinforced aluminium foil. The
insulation mat is suitable for the thermal and acoustic
insulation of especially vessels, ducts, and equipment
up to intermediate temperatures.
Advantages
• Easy to handle and install
• No support construction needed
174
Product properties Rockwool Duraflex
t° (°C) 50 100 150 200
λ (W/mK) 0.043 0.053 0.064 0.077 EN 12667
t° (°F) 100 200 300 400 ASTM C177
λ (BTU.in/ft2.h.°F) 0.280 0.339 0.415 0.508

EN 17706
Maximum Service Temperature 300°C (572 °F). Outer foil temperature limited to 80 °C ASTM C411
A2 EN 13501-1
development=passed
Water absorption
Water vapour absorption (vapor sorption) ± 0.02 %vol ASTM C1104
< 10 mg/kg, AS-quality for use over stainless steel EN 13468
Water leachable chloride content Conforms to the stainless steel corrosion specification as per ASTM ASTM C795
test methods C692 and C871
Compression resistance > 10 kPa at 10 % deformation EN 826
Nominal density 60 kg/m (3.75 lb/ft )
3 3
Water vapour resistance

Sd ≥ 100m EN 12086
alumnium foil
Rockwool Lamella Mats for the thermal insulation of air ducts,
Compliance CINI 2.2.05
pipe bundles and equipment
175
4. Products
Rockwool Flexiboard

in mm in mm in mm m² / pack 40ft HC container*
25 1000 600 14.4 2419

30 1000 600 12.0 2016
40 1000 600 9.0 1512
50 1000 600 7.2 1210
60 1000 600 6.0 1008
70 1000 600 3.6 907
75 1000 600 4.8 806
80 1000 600 3.6 756
100 1000 600 3.6 605
Available on request with a one-sided facing of fibreglass reinforced aluminium foil (Alu) or glass tissue
Applications
Rockwool Flexiboard is a strong but flexible stone wool
board for the thermal and acoustic insulation of hori
zontal and vertical walls or acoustic panels.
Advantages
• Flexible application
176
Product properties Rockwool Flexiboard
t°m (°C) 50 100 150
λ (W/mK) 0.041 0.054 0.066 EN 12667
Thermal conductivity ASTM C177
t°m (oF) 100 200 300
λ (BTU.in/ft2.h.°F) 0.273 0.355 0.466
300 °C (572 °F) EN 14706
A1 EN 13501-1
development=passed

Conforms to the stainless steel corrosion specification as per ASTM

Water leachable chloride content ASTM C795
Rockwool (RW) slabs for thermal insulation of equipment CINI 2.2.01

Compliance Standard specification for mineral fibre block and board thermal ASTM C612-04
insulation, type IA
177
4. Products
Rockwool Multiboard

in mm in mm in mm m2 / pack 40ft HC container*
40 1000 600 6.0 1620

50 1000 600 4.8 1210
60 1000 600 4.8 1008
70 1000 600 3.6 907
75 1000 600 3.6 756
80 1000 600 3.6 756
90 1000 600 3.0 630
100 1000 600 2.4 648
Available on request with a one-sided facing of fibreglass reinforced aluminium foil (Alu) or glass tissue
Applications
Rockwool Multiboard is a strong and rigid board for the
thermal and acoustic insulation of horizontal and verti
cal walls where a stable insulation product is required.
For example, tank walls or acoustic panels.
Advantages
• Rigid product combined with aluminium foil
or fibreglass coating provides a smart, smooth
surface finish
178
Product properties Rockwool Multiboard
t°m (°C) 50 100 150
λ (W/mK) 0.039 0.048 0.058
t°m (°F) 100 200 300
λ (BTU.in/ft2.h.°F) 0.268 0.317 0.396
350 °C (662 °F) EN 14706
A1 EN 13501-1
development=passed
Water leachable chloride content test methods C692 and C871 ASTM C795

insulation, type IA and IB
179
4. Products
Rockwool HT600 High temperature board

in mm in mm in mm m2/pack 40ft HC container*
25 1000 600 9.6 2592

30 1000 600 6.0 2016
40 1000 600 6.0 1620
50 1000 600 4.8 1296
60 1000 600 3.0 1008
80 1000 600 3.0 810
100 1000 600 2.4 648
120 1000 600 1.8 529
Applications
Rockwool HT600 is a strong, rigid board, specially
developed for the thermal and acoustic insulation of
boilers, columns and high-temperature (exhaust) ducts.
Advantages
• Suitable for high temperature applications
• Retains shape
• Long lasting
• Rapid return on investment
180
Product properties Rockwool HT600
t°m (°C) 50 100 150 200 250 300
λ (W/mK) 0.038 0.044 0.052 0.062 0.074 0.088
t°m (°F) 100 200 300 400 500 600
λ (BTU.in/ft2.h.°F) 0.260 0.297 0.355 0.433 0.534 0.657
600 °C (1112 °F) EN 14706
A1 EN 13501-1
development=passed
Nominal density 80 kg/m3 (5 lb/ft3)

insulation, type IA, IB, II, III, IVA, IVB
181
4. Products
Thickness Length Width Packaging m2 / per

30 1000 600 6.0 2016

40 1000 600 4.8 1613
50 1000 600 3.6 1210
60 1000 600 3.0 1008
80 1000 600 1.8 832
Applications
Rockwool HT660 is a strong, rigid board for the thermal
and acoustic insulation of constructions where higher
temperatures and light mechanical loads (e.g. vibra
tions) occur.
Advantages
• Retains shape
• Long lasting
182
t°m (°C) 50 100 150 200 250 300
λ (W/mK) 0.038 0.043 0.049 0.058 0.067 0.078 EN 12667
Thermal conductivity ASTM C177
t°m (°F) 100 200 300 400 500 600
λ (BTU.in/ft2.h.°F) 0.259 0.291 0.340 0.402 0.481 0.576
660 °C (1220 °F) EN 14706
A1 EN 13501-1
development=passed

Compression resistance 15 kPa at 10 % deformation EN 826
Nominal density 115 kg/m (7.18 lb/ft )
3 3

183
4. Products

30 1000 600 6.0 2016

40 1000 600 4.8 1613
50 1000 600 3.6 1210
60 1000 600 3.0 1008
80 1000 600 1.8 832
Applications
Rockwool HT700 is a strong, rigid board for the thermal
and acoustic insulation of constructions where higher
temperatures and/or mechanical loads (e.g. vibrations)
occur.
Advantages
• Retains shape
• Long lasting
184
t°m (°C) 50 100 150 200 250 300 350
λ (W/mK) 0.039 0.044 0.050 0.057 0.065 0.075 0.087
t°m (°F) 100 200 300 400 500 600 700
λ (BTU.in/ft2.h.°F) 0.267 0.298 0.342 0.398 0.467 0.548 0.641
700 °C (1292 °F) EN 14706
A1 EN 13501-1
development=passed
Compression resistance 40 kPA at 10 % deformation EN 826

185
4. Products
Rockwool CRS Compression resistant slab

mm mm mm m2/pack 40ft HC container*
40 1000 600 3.0 1638

50 1000 600 2.4 1310
60 1000 600 2.4 1109
80 1000 600 1.8 832
100 1000 600 1.2 655
Applications
Rockwool Compression Resistant Slab (CRS) is a rigid,
pressure-resistant stone wool insulation slab with high
resistance to mechanical loads (e.g. foot traffic). The
Compression Resistant Slab is developed for the thermal
insulation of tank roofs subject to pedestrian traffic,
and the thermal/acoustic insulation of constructions
subject to mechanical load.
Advantages
• Resistant to foot traffic
• Resistant to mechanical loads
186
Product properties Rockwool CRS
t°m (°C) 50 100 150
λ (W/mK) 0.040 0.043 0.049
t°m (°F) 100 200 300
λ (BTU.in/ft2.h.°F) 0.270 0.302 0.345
Maximum Service Temperature 250 °C (482 °F) EN 14706, ASTM C411
A1 EN 13501-1
development=passed
Water absorption
Compression resistance 60 kPa at 10 % deformation EN 826

insulation, type IA, IB and II
187
4. Products
Rockwool 251 Industrial slab

40 1000 600 2.4 1613

50 1000 600 1.8 1285
60 1000 600 1.8 1058
80 1000 600 1.2 806
100 1000 600 1.2 655
Applications
Rockwool 251 is a highly pressure resistant stone wool
slab for the thermal and acoustic insulation of construc
tions where high temperatures and mechanical loads
(e.g. vibrations) occur.
Advantages
• Resistant to high temperatures
• Resistant to mechanical loads
188
Product properties Rockwool 251
t°m (°C) 50 100 150 200 250 300
λ (W/mK) 0.041 0.045 0.051 0.058 0.066 0.075
t°m (°F) 100 200 300 400 500 600
λ (BTU.in/ft2.h.°F) 0.276 0.309 0.353 0.405 0.468 0.541
700°C (1292 °F) EN 14706
Maximum Service Temperature 750°C (1382 °F) ASTM C411
A1 EN 13501-1
development=passed
Water absorption
Compression resistance 50 kPA at 10 % deformation EN 826

insulation, type IA, IB, II, III, IVA
189
4. Products
Rockwool Rocktight
Rocktight: or general wear and tear. It is chemically resistant
the watertight insulation system and withstands mechanical stresses (i.e. can be
walked upon).
Achieving the best insulation system for your application • Easy to clean: Rocktight can withstand spray-clean
is not easy. Besides the right choice and implementation ing. Cleaning with water is possible without damaging
of the insulation, the insulation protection system also the insulation.
plays an important role. Specific uses call for specific • Low start-up costs: processing and installation takes
solutions. Certain processes require a fully watertight place on location. This makes investments for the
and closed finish. Strong and easy to clean, with great pre-fabrication of the insulation protection unneces
durability and chemical resistance. An insulation sary.
protection that results in a high amount of operational • Flexible use: cold and hot insulation, underground
safety, low maintenance costs and limited energy costs. and above ground cables and pipes, on and offshore.
Rockwool Technical Insulation, together with FiberTec Rocktight molds itself to every technical application.
Europe, has therefore developed an innovative
protection system for Rockwool insulation: Rocktight.
Rocktight:
for a durable insulation protection
Rockwool Rocktight is a fiberglass reinforced polyester
mat positioned between two sheets of film. The material
contains resins, fiberglass and special fillers and is
ready to use. Unprocessed it is soft and malleable. In
this state, Rocktight can be cut or trimmed into any
shape which makes it easy to apply to the insulation.
The polyester subsequently cures under the influence of
ultraviolet (UV) light. After curing, Rocktight is absolutely
watertight and is able to give optimal mechanical
protection.
The advantages
The Rocktight system has important advantages that
enhances the quality of your work.
• Great durability: Rocktight forms a seamless
connection that offers a watertight protection to the
Rockwool insulation. It minimizes the damaging
effects of the weather (wind, rain, seawater, etc.)
190
Multi use • Rocktight is applied directly on Rockwool tank roof in
sulation on site. Since direct cladding supports are no
Rocktight is used in various sectors where it longer needed, it fits to all parts of the tank seamlessly
continuously satisfies the highest standards. and has an unequalled hardness and mechanical
strength (e.g. can be walked upon).
Food & Pharmaceutical: • Where there are high wind stresses, a special cable
hygiene and cleaning construction can be applied that will keep the insu
The food industry and the pharmaceutical sector also lation in its place under the most extreme weather
adhere to very rigorous standards and rules as far as in conditions.
sulation is concerned. Those strict rules and regulations • An anti-slip coating is available that can easily be
must prevent dirt, bacteria or moisture from accumula installed to Rocktight.
ting in the (damaged) insulation. • The absence of cladding supports virtually
eliminates any risk of corrosion under insulation.
• Rocktight is the ideal solution for making insulation • This ensures perfect protection to the insulation and
around pipes, cables, storage tanks, installations, etc. storage tank which guarantees the durability of the
sealed, watertight and damage resistant. insulation.
• In addition, Rocktight can withstand spray-cleaning.
The insulation material can be cleaned with water
without causing any damage. Technical information
• Thanks to the low permeability of Rocktight as well as
the thermal resistance of Rockwool insulation, a Definition
durable insulation of dual temperature systems is Rockwool Rocktight is a fiberglass-reinforced 1-compo
possible. nent polyester (GRP) that in un-processed state is soft
and malleable. The material contains resins, fiberglass
Tank roof insulation: durable & money-saving and special fillers and is ready to use. Rockwool
Conventional systems for tank roof insulation are often Rocktight can be cut or trimmed into any shape which
sensitive to damage from the weather (water, wind, etc.) makes it easy to apply to the insulation.
and the effect of chemicals. The costs of maintenance
and the consequent lowered operational safety resulting The material cures under the influence of ultraviolet light.
from this are often higher than the (energy) cost-savings Once cured, Rockwool Rocktight has an extremely high
that are realized by the insulation. For this reason many level of hardness and mechanical strength compared to
tank roofs, especially in the lower temperature ranges, conventional polyester. In addition, Rocktight is
are not insulated. impermeable and resistant to a large number of
chemicals. The fire properties are unique in its class.
191
4. Products
Ancilliaries Packaging and storage

Rockwool Rocktight HMO is used for the most common Rockwool Rocktight is supplied in rolls of 10 m in length
applications. Besides special versions (e.g. higher and 1 m in width, packed in boxes. Each roll (including
chemical resistance), related products, such as packaging) weighs approx. 30 kg. The storage life is 6
UV-curing Rocktight Primer and Gel, UV-lamps and months (after date of delivery). The contents measure 9.5
safety-goggles are available upon request. m2 per roll. Always store Rockwool Rocktight in the
original packaging in an ambient temperature of a
Curing maximum of 25 °C. Avoid direct contact with sunlight
The curing will depend upon the ambient temperature during use.
and the intensity of the UV-light. Under the influence of
sunlight or 400 W UV-lamps, placed at a distance of
0.5 meters, Rockwool Rocktight cures in 30 minutes
(T 20 °C / RV 50 %).
Product properties
Rockwool Rocktight Performances Norm

Color grey
Handling temperature min. 5°C - max. 45°C
Application temperature (cured) min. -50°C - max. 90°C
Thickness (after curing) 1,5 mm - 2,0 mm
< 20 ppm (MAC-value 25 ppm),
Styrene emission (non-cured) safety sheet available upon request
Flashpoint (non-cured) 125°C
B1 DIN 4102
Fire class Flame spread index = 0 ASTM E 84
Low flame spread characteristics IMO A.653
Specific gravity ±1800 kg/m3 DIN 53479
Compressive strength 150 N/mm2 DIN 53454
Fiber content 20% w/w DIN 53479
Linear expansion coefficient 30 * 10-6K-1 DIN 53452
Impact resistance 57,5 kJ/m2 DIN 53453
Bending strength 146 N/mm 2
DIN 53452
Tensile strength 55,7 N/mm2 DIN 53455
Stretch at breaking point 1,1% DIN 53455
Permeability 0,34 mg/100u DIN 53495
Hardness 60 Barcol
Chemical resistance Available upon request
Rocktight conforms to CINI 3.2.11 ‘Weather resistant UV-curing fiberglass reinforced polyester (GRP)’.
(Small divergences from the declared values are not fully precluded.)
192
Rockwool Loose Fill
Product Packaging kg/packaging kg per 40 ft HC Container
Rockwool Loose Fill (Rolls) Bag 15 5250
Applications
Rockwool Loose Fill is lightly bonded impregnated
stone wool. This product is especially suitable for
thermal insulation and acoustic insulation of joints and
irregularly formed constructions.
Advantages
• Flexible application
Product properties
t°m (°C) 50 100 150 200 250 300
Thermal conductivity λ (W/mK) 0.040 0.049 0.057 0.067 0.075 0.091

EN 12667, ASTM C177
(stuffing density 100 kg/m3) t°m (°F) 100 200 300 400 500 600
λ (BTU.in/ft2.h.°F) 0.276 0.338 0.393 0.462 0.517 0.628
680 °C (1256 °F) EN 14706
A1 EN 13501-1
development=passed

Water leachable chloride content test
methods C692 and C871 ASTM C871
<10 mg/kg (ph-value neutral to slightly alkaline)
Water absorption
Loose Rockwool for the thermal insulation of valve boxes and the
Compliance specification stuffing of insulation matresses CINI 2.2.04
193
4. Products
Rockwool Granulate
Product Packaging kg/packaging kg per 40 ft HC Container
Rockwool Loose Bag 20 12000
Applications
Rockwool Granulate is a stone wool granulate with no
additives. The granulate is especially suitable for the
thermal insulation of cold boxes and air separation
plants.
Advantages
• Noncombustible
• Chemically inert
• Easy to remove for inspection purposes
• Long lasting
• Short return on investment
Product properties
t°m (°C) 20 -20 -60 -100 -140 -180
Thermal conductivity λ (W/mK) 0.039 0.033 0.027 0.022 0.018 0.015

EN 12667, ASTM C177
(Stuffing density 100-200 kg/m3) t°m (°F) 50 0 -50 -150 -250 -300
λ (BTU.in/ft2.h.°F) 0.260 0.229 0.201 0.153 0.115 0.101
A1 EN 13501-1
development=passed

Water leachable chloride content test
methods C692 and C871 ASTM C871
<10 mg/kg (ph-value neutral to slightly alkaline)
Rockwool Granulate complies with AGI Q 118 “insulation work for refrigeration on industrial installations; air separations plants”
194

1.8 Cold boxes 85
2 Theory 89
3 Tables 129

4 Products 163
Rockwool 850 165

Rockwool 851 166
ProRox WM 70 168
ProRox WM 80 170
ProRox WM 100 172

Rockwool Flexiboard
174
176

Rockwool HT600
178
180
Rockwool HT660 182
Rockwool HT700 184

Process Manual
Technical guidelines for the insulation of industrial installations
RTI, excellence in firesafe solutions
Rockwool Technical Insulation (RTI), a division of the international Rockwool
Group, is the world wide market leader in technical insulation. Our experts
offer you a complete range of techniques and systems for the firesafe
insulation of technical installations. In all segments of HVAC, process
industry, ship building and passive fire protection, RTI stands for a total
approach. From quality products to reliable expert advice, from
documentation to delivery and after sales service. Throughout the whole
chain from specifier, through dealer to contractor and installer we aim to add
Process Manual
value. We don’t just sell products, we supply solutions. It’s this total approach
that makes RTI the ideal choice for professionalism, innovation and trust.
All explanations correspond to our current range of knowledge and are

therefore up-to-date. The examples of use outlined in this process manual
serve only to provide a better description and do not take special
circumstances of specific cases into account. Rockwool Technical Insulation
places great value upon continuous development of products, to the extent
that we too continuously work to improve our products without prior notice.
We therefore recommend that you use the most recent edition of our
publications, as our wealth of experience and knowledge is always growing.
Should you require related information for your specific application or have
any technical queries, please contact our sales department or visit our
website rockwool-rti.com.
Rockwool is a registered trademark of Rockwool International. Rockwool Technical Insulation
RTI/11.09/gen. edit./English RTI 410

reserves the right to change the information in this brochure without prior notice.
Rockwool Technical Insulation bv

Delfstoffenweg 2 for Belgium: +32 (0)2 715 68 20 for Poland: +48 601 848 482
NL-6045 JH Roermond for Germany: +49 (0) 2043 408 606 for Czech Republic: +420 606 702 056
Tel. +31 (0) 475 35 36 18 for France: +33 (0) 1 40 77 82 11 for Slovakia: +421 903 235 027
Fax +31 (0) 475 35 36 01 for Export (Africa, Middle East, India): for Baltics: +370 69 94 33 92
www.rockwool-rti.com +31 (0) 475 35 38 35 for Switzerland: +41 81 734 11 11

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Process Manual

Technical guidelines for the insulation of industrial installations

All explanations correspond to our current range of knowledge and are

Rockwool is a registered trademark of Rockwool International. Rockwool Technical Insulation

RTI/11.09/gen. edit./English RTI 410

Rockwool Technical Insulation bv

1.2 Piping P. 19 1.3 Insulation of vessels P. 46 1.6 Boiler P. 68

1.1 Planning and preparation 7

3.1 Units, conversion factors and tables 130

Rockwool 850 165

1.5 Insulation of P. 58 gas ducts Rockwool Duraflex

storage tanks Rockwool Multiboard

1.8 Cold boxes P. 85

1.2 Piping P. 19 1.3 Insulation of vessels P. 46 1.6 Boiler P. 68

1.1 Planning and preparation 7

3.1 Units, conversion factors and tables 130

Rockwool 850 165

1.5 Insulation of P. 58 gas ducts Rockwool Duraflex

storage tanks Rockwool Multiboard

1.8 Cold boxes P. 85

1.1 Planning and preparation 7

2.1 Norms & standards 90

3.1 Units, conversion factors and tables 130

Rockwool 850 165

please don’t hesitate to contact one of the RTI sales team:

Please consult our website: www.rockwool-rti.com

Petrochemicals Marine & Offshore

Rockwool Group Business Areas: End Products

Insulation for industry:

Conlit Fire Protection:

Insulation of technical installation in buildings:

Insulation for shipbuilding and off-shore:

1.1 Planning and preparation 7

1.1.1 Decision criteria for the design of an i­nsulation system 7

1.2 Insulation of piping 19

1.2.1 Insulation with pipe sections 26

1.3 Insulation of vessels 46

1.4 Insulation of columns 52

1.5 Insulation of storage tanks 58

1.6 Insulation of boilers 68

1.6.1 Insulation of fire tube boilers 68

1.7 Insulation of flue gas ducts 77

1.7.1 Installation of the insulation systems for flue gas ducts 77

1.8 Cold boxes 85

1.1 Planning and preparation

Minimum distances between vessels and columns (dimensions in mm)

Minimum distances within range of pipe flanges (dimensions in mm)

a = distance flange to normal insulation

g) Maintenance and inspection

achieved by insulation, apply additional protective

a) Economical insulation thickness

The sound propagation of installation components can

1.1.3 Corrosion prevention

Note Protection against corrosion may be omitted in the case

Material Combination material

L - Light or little corrosion to material

1.1.4 Storage of insulation materials

1.2 Insulation of piping

Hot insulation systems

Selecting a suitable insulation system depends on

1.1.1 Decision criteria for the design of an insulation system 7

1.2.4 Insulation support Dimension spacers of support construction

1. Pipe - 2. Insulation: ProRox WM wired mats - 3. Cladding