35248 ISOVER Ultimate Insulation Manuallow

TheWorld’s Leading Acoustic and Thermal Insulation

ULTIMATETM Protect

The formula for efficient fire insulation of ventilation ducts

Installation & specification handbook

Produced with the glass wool technology of Saint-Gobain Isover, ULTIMATETM Protect is an innovative new generation mineral wool that combines all the advantages of conventional thermal and acoustic insulation with top level fi re protection .

The ULTIMATETM Protect product range, also known as U Protect, consists of slab and wired mat solutions, offering up to two hours fi re protection for both vertical and horizontal applications of rectangular and circular ductwork systems .

ultimAtETM protEct rAngE U Protect slab 4 .0 Alu 1 50mm Order code: 5200432634

U Protect slab 4 .0 Alu 1 60mm Order code: 5200414575





U Protect Wired mat 4 .0 Alu 175mm Order code: 5200432184

U Protect Wired mat 4 .0 Alu 1 120mm Order code: 5200432186

For help choosing the right thickness for the job, please refer to the installation detail section of this document (page 11) .

ultimAtETM AccESSoriES Fireprotect screws

140mm length, box of 500

Fireprotect screws

200mm length, box of 200

Protect BSK Adhesive15kg tub

Protect BSF Intumescent Paint 15kg tub

310ml tube 310ml tube

ULTIMATETM Protect -The formula for effi cient fi re insulation of ventilation ducts


2

Contents

ULTIMATETM Protect - The formula for efficient fire insulation of ventilation ducts . . . . . . . . . . . . . . . . . 4

ULTIMATETM Protect - Specification Detail . . . . . . . . . . . . . . . . . . . . 5

Effective fire protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Ease of installation & fast installation . . . . . . . . . . . . . . . .8

Cost-effective solution & thin solutions . . . . . . . . . . . . . .9

Lightweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Excellent thermal insulation performance . . . . . . . . . . 10

Optimal acoustic performance . . . . . . . . . . . . . . . . . . . . . 10

ULTIMATETM Protect - Installation Detail . . . . . . . . . . . . . . . . . . . . 11

Before you start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Criteria for preparation of rectangular ductwork prior to insulating . . . . . . . . . . . . . . . . . . . . . . . 18

Criteria for preparation of circular ductwork prior to insulating . . . . . . . . . . . . . . . . . . . . . . . 22


3

ULTIMATETM Protect - The formula for efficient fire insulation of ventilation ducts

U Protect comes with a unique high-performance profile . It combines top level fire resistance; easy handling and low pack weight . An ‘all-in-one’ solution to meet your demands .

+

+

=

up to

65%lighter than

traditional stone wool

EffEctivE firE protEction A top performer when it comes to material stability and thermal resistance at high temperatures, U Protect offers a Euroclass A1 fire rating and has been certified to comply with EN1366-1 .

EASE of inStAllAtion Excellent manageability ensures that cutting, bending and fitting is faster and more efficient . The U Protect wired mat range is specifically designed for easy installation on circular ductwork .

lightWEight65% lighter than conventional stone wool products, U Protect makes light work of installation and its low pack weight meets the most stringent of workplace Health and Safety standards .


4

ULTIMATETM Protect - Specification Detail

Effective fire protection

Lightweight

Thin solutions

Ease of installation

Optimal acoustic performance

Excellent thermal insulation performance

Fast installation

Cost-effective solution

The all-in-one solution to meet your needs


5

It is vital to develop safe, durable and reliable solutions for ventilation systems as a fire can easily spread from the point of origin via ductwork .

U Protect meets the highest standards for fire protection, providing excellent fire resistance and top-rated reaction to fire performance .

U Protect is a top performer for fire protection and thermal insulation, fulfilling the requirements of EN 1366-1 and BS 476: Part 24 for ventilation and smoke extract ducts .

The U Protect product range has been proven to meet the requirements of all possible scenarios . The scenarios can be identified by fire location, duct orientation and duct shape (see table below) .

Fire location Explanation

Fire inside the ductDuct opening or failure allows the fire to enter the duct . The fire must be prevented from spreading to adjacent rooms .

Fire outside the duct

The fire must be prevented from entering the duct, especially when the ventilation system continues to run during a fire . The duct can be used to extract the smoke (pre-condition: a slight negative pressure) .

Duct orientation

Horizontal Ducts which normally serve one floor of a building .

Vertical Ducts which normally serve between floors of a building .

Duct shape

Rectangular Rectangular shape of the metal duct .

Circular Circular shape of the metal duct .

EuroclASS hArmoniSAtion U Protect achieves Euroclass A1 rating fire classification for product with non combustibility .

Euroclass is a harmonised European classification system for products, measuring their reaction to fire and is intended to replace existing national standards, such as British Standards . This is now commonly accepted in England, Scotland and Wales .

The classification levels are A1, A2, B, C, D, E and F . A1 corresponds to the safest situation, E would be the most dangerous situation and F would mean not classified .

Effective fire protection


6

rEAction to firE

common materials and likely Euroclass

Euroclass Flashover potential Example materials

A1 & A2 NoGlass and stone mineral wool, concrete, brick and plasterboard

B No Typically timber products

CYes 10 minutes

Phenolic foam (foil faced)

DYes 2-10 minutes

Expanded polystyrene type A polyisocyanurate foam (foil faced) extruded polystyrene

EYes < 2 minutes

Polyurethane foam (laminate faced) Polyisocyanurate foam (sprayed)

FYes Early Failure or no data

Expanded polystyrene type N Untested or fails Euroclass E

This is a guide to common building materials and their likely Euroclassification

One of the most important issues studied under reaction to fire performance is the potential for flashover to occur - the spontaneous ignition of hot smoke, gases and fuel which can lead to a fire spreading uncontrollably .

ultimAtETM protEct DoES not promotE flAShovErTo address other hazards found in real life fires and for risk assessment, two additional classifications are also available, s and d . These provide information on smoke emission and speed (s0 means the non-existence of smoke, up to s3, which means high emissions of smoke) and on the possible fall of flaming droplets d (d0 none, up to d3) . ULTIMATETM

Protect achieves Euroclass A1 rating fire classification .

clASS ‘o’ compliAncE Class ‘O’ compliance can refer to ‘Surface Spread of Flame’ or ‘non-combustibility’ of a product . This refers only to the surface properties of a product and BS 476: Parts 6 and 7 need to be satisfied .

ULTIMATETM Protect range has a Class ‘O’ foil and passes both these tests .

ULTIMATETM Protect system also complies with BS 476: Part 4 (non-combustibility test) . This is a measure of the combustibility or reaction to fire of the product .

ULTIMATETM Protect exceeds all standards proving its excellent fire credentials .


7

Ease of installation

Fast installation &

Ultra-light and adaptable, ULTIMATETM Protect range makes cutting, bending or filling, faster and more efficient than ever .

U Protect perfectly adapts to all conditions saving on the time-consuming work of encasing or the cost of expensive prefabrication . Installation of U Protect can be done with almost no waste: Its pliable structure prevents it from breaking and off-cuts optimally fill niches and holes .

• Up to 50% quicker installation time than traditional solutions

• Easy to cut with a standard laggers knife

• Robust and stable

• Off-cuts can be used so virtually waste free

• Flexible shaping

• No edge breaks

• No need for adhesive on joints

• Easy to handle - lightweight

• No need to insulate drop rods separately*

* exception - refer to joint detail of circular duct (pg 23)

Daniel Crawley, Crawley Insulations Ltd ., Kent

up to

50%quicker

installation time than traditional solutions

“Nothing of substance has been introduced into the ductwork fire protection market for over twenty years. U Protect changes all that as it’s the first product that’s actually user friendly and a joy to work with!”

CrawleyINSULATIONS LIMITED


8

Thinsolutions&&Cost-effective

solutionThe ULTIMATETM Protect range pays off even before the ventilation system is put into operation . Thanks to compressed packaging, the logistics – including intermediate storage on site – can be managed without any problems, even for larger projects . And the installation is not only done faster but also at drastically reduced material cost:

• No need for expensive prefabrication

• No glue needed except for at wall penetrations

• No edge breaks

…but higher insulation effi ciency achieved with extremely low thicknesses .

ULTIMATETM Protect pays off every step of the way

ULTIMATETM Protect features Your advantages

■ Lightest product solution available in the market

➤ Easier and faster to install

■ Flexible and timesaving ➤ Shorter installation time, less waste

■ Innovative, high-performance product ➤ Time and material saving (one layer instead of two)

Pays off right

from the start


9

up to

65%lighter than

traditional stone wool

up to

25%lambda difference

even at 10˚C

As soon as sound waves penetrate the innovative material of ULTIMATETM Protect their acoustic energy is drastically reduced by the friction in the fibre structure .

U Protect achieves 50% better sound absorption compared with traditional stone wool .

Excellent thermal insulation performance

U Protect provides superior thermal insulation with a lambda difference of as much as 25%, even at 10˚C compared to products designed for the same application and achieves the thermal performance requirements of ventilation ductwork within UK Regulations as follows:

- England and Wales BS5422: 2009 or TIMSA Guidance for Achieving Compliance with Part L of the Building Regulations .

- Scotland BS5422: 2001 . Method for specifying thermal insulating materials on pipes, ductwork and equipment (in the temperature range -40°C to +700°C) . Also for Scotland, refer to Technical handbooks by the SBSA . Domestic Handbook 2009 and Non-Domestic Handbook 2009 Sections 6 - Energy .

Optimal acoustic performance

perfectly safe and secure. With ultimAtETM protect on duty.

Lightweight

up to

50%better sound

absorption

U Protect combines peak performance in fire protection and thermal insulation with extreme light weight installation . Up to 65% lighter than conventional thermal, acoustic and fire insulation products, U Protect sets totally new standards .

With U Protect you are not only on the safe side of handling: the low pack weight and grip-friendly touch also meet the most stringent standards for Health and Safety in the workplace .


10

A. chooSE thE inSulAtion thicknESSESChoose the appropriate thickness from the table below by selecting the desired duct type, fire rating, duct orientation and fire location .

Rectangular duct

Fire locationFire class

Duct orientationEI15 EI30 EI60 EI90 EI120

Fire inside duct

Inside30 40 60 70 80 Horizontal35 50 80 90 100 Vertical

Fire outside duct

Outside30 30 30 70 80 Horizontal30 30 30 70 80 Vertical

In case both fire locations need to be covered

Both30 40 60 70 80 Horizontal35 50 80 90 100 Vertical

Use of 1 product for both duct orientationsOutside 30 30 30 70 80

BothInside 35 50 80 90 100

Use of 1 product for all casesBoth 35 50 80 90 100 Both

In the above applications use U Protect 4 .0 Alu 1 Slab

Circular duct

Fire locationFire class

Duct orientationEI15 EI30 EI60 EI90 EI120

Fire inside duct

Inside35 50 75 95 115 Horizontal35 50 75 95 115 Vertical

Fire outside duct

Outside30 30 60 90 100 Horizontal30 30 60 90 100 Vertical

In case both fire locations need to be covered

Both35 50 75 95 115 Horizontal35 50 75 95 115 Vertical

Use of 1 product for both duct orientationsOutside 30 30 60 90 100

BothInside 35 50 75 95 115

Use of 1 product for all casesBoth 35 50 75 95 115 Both

In the above applications use U Protect 4 .0 Alu wired mat

Before you start

NB: Thicknesses shown above are minimum requirements from fire tests.

Commercially available thicknesses are currently in increments of 10mm with exception of 75mm wired mat .

ULTIMATETM Protect - Installation Detail


11

B. chooSE pinS AnD pin fixing poSitionS

StEEl pin informAtionThe insulation is fixed to the duct using steel pins, 2 .7mm to 3mm nominal diameter, and spring steel washers, minimum 38mm diameter . The pins are stud-welded or screwed to the duct .

pin optionSStud welded

If the screwed pins are selected, these are either;

Self-drilling pins (e .g . LENNE IBS1 self-drilling screw pins)

or

Pins that include a steel base plate which fastens to the duct (minimum of two M4 steel self-drilling/self-tapping screws or two M4 steel rivets, e .g . Big head M5/B23 studs)

NB: The length of pin should be equal to the insulation thickness + 3mm

pin fixing poSitionSHorizontal and vertical rectangular ducts

See figures 1 & 2 for pin patterns (see page 13 & 14)

Horizontal circular ducts

No pins required

Vertical circular ducts

Vertical installation requires that the insulation mats are to be secured with pins and washers

• Place ≥2 .7mm diameter pins and ≥38mm washers in two rows around the duct with c≤200mm, at 100 mm distance from the mat joint


12

Figure 1 - Pin positions for rectangular horizontal ducts

Exception - For an insulation thickness of 90mm, additional pins are provided on the underside of horizontal ducts . The maximum spacing of the pins along the length of the boards is reduced from 320mm to 250mm


13

Figure 2 - Pin positions for rectangular vertical ducts

• For rectangular vertical ducts, apply the largest board to the longest side leaving an overlap equivalent to the thickness of the U Protect slab, on either side of the duct

• Repeat for the other side, then place the smaller boards between the overlaps created from the first two steps


14

c. complEtE WAll / floor pEnEtrAtionS

5 StEpS to inStAllAtion The installation through the construction is done in 5 steps . The same general principle is used for both rectangular and circular ducts regardless of orientation .

Installation procedure

Step 3: Sealing• Using a spatula apply a ~2mm thick layer

of Isover Protect BSF to BOTH sides of the construction, to seal the joint

Step 2: Insulation• Using the same insulation used for the rest

of the duct, fully pack the space between the duct and partition . Ensure tight compression in order to completely fi ll the opening

• Place the duct in the penetration of the construction, with a ≤50mm gap between the duct wall and opening

• A stiffener (steel tube) should be fi tted to the duct where the duct passes through the penetration

NB: Stiffeners are not used with circular ducts

Step 1: Positioning

Isover Protect BSF Intumescent Paint 310ml tube

Isover Protect BSF Intumescent Paint 15kg tub

<

<


15

• Fix an L-profile (30x30x3) around the duct on both sides of the construction with steel rivets

• Using two steel screws for each side ensure the top and bottom profiles are fixed to the construction

Step 4b: Reinforcing a circular duct

Step 4a: Reinforcing a rectangular duct

• Steps 1-3 are completed using U Protect wired Mat

• Screw a suspension bracket (30mmx2mm) to the duct on both sides of the construction

• Fix long L-profiles (30mmx30mmx3mm) above and below the bracket with one rivet each (4mmx13mm)

• Fix short L-profiles (30mmx30mmx3mm) are fixed with nuts and bolts (M8) to the bracket eye

Step 5: Duct insulation

• Glue the ends of the insulation to the construction using Isover Protect BSK (thickness ~2mm)

• Install the insulation so that it is adjacent and tightly fitted against the penetration . The insulation must be cut leaving excess length, so that it exerts some pressure between the penetration and the last fitted piece of insulation

• This applies to both rectangular and circular ducts


16

D. complEtE thE inStAllAtion

horizontAl AnD vErticAl rEctAngulAr DuctS• Secure the corner joints with Isover FireProtect Screws (3 screws per side at 300mm

centres) . The screw length must be 2 x the insulation thickness .

horizontAl AnD vErticAl circulAr DuctS• Using clamping rings, secure the joints

of the insulation mats together; or alternatively stitch the mats together with steel thread

• Use standard threaded rods and suspension brackets as hangers for the duct . Place these hangers inside the insulation . The rods do not need to be protected by insulation excepting the first 30mm of the drop rod (see pages 22-23)

NB: There is no need to cut the insulation at the duct joint due to the flexibility of the insulation.

• ULTIMATETM Protect insulation slabs need to be cut to fit the duct as tightly as possible, the insulation may need to be cut to fit around flanged duct joints (see left)

Firescrews

No glue or pins

Top slab covering side slabs

Welded pins

Installation principle for horizontal circular ducts

Insulation Board Layout and Firescrew Layout


17

Criteria for preparation of rectangular ductwork prior to insulatingDuct ShEEting The steel duct is constructed in sections of hot dipped galvanised steel sheet, mild steel sheet or stainless steel sheet minimum 0 .7mm thick .

ShEEt thicknESSMaximum size of duct longer side Thickness of steel sheet

Up to 1250mm 0 .7mm

Up to 1500mm 0 .8mm

Up to 2000mm 1 .0mm

mAximum Duct SizESRectangular ducts 2000mm x 1500mm

Drop roDS AnD hAngErS for rEctAngulAr horizontAl DuctSEach steel hanger consists of two threaded drop rods, minimum M10, and a channel section bearer, minimum 30mmx30mmx3mm thick .

• Fasten the bearer to the drop rods using hexagonal nuts and washers

• Each hanger must be positioned so that it is adjacent to (within 250mm of) a cross joint or stiffening collar . The maximum spacing of the hangers is 1250mm

The spacing of the hangers and the size of the steel hanger components must be adjusted so that the tensile stress in the rods and the bending stress in the channels do not exceed 15N/mm2 for fire resistance periods up to 60 minutes and 10N/mm2 for fire resistance periods up to 120 minutes .

NB: The steel frame to be independently fire rated.

The drop rods and bearers are positioned inside the insulation material, with the drop rods nominally 10mm from the steel duct .


18

Drop roD AnchorSWhen fixing to a concrete construction• Use all-steel expanding anchors to fasten the threaded rod hangers to concrete soffits .

The anchors should penetrate the concrete by at least 50mm – for 120 minutes of fire resistance

When fixing to a steel supporting construction• Drill a hole through the steel member, allowing the drop rod to be supported by a steel

nut and washer above

If a clamp type fixing is used, the clamp must be steel, suitable for the purpose . It should pass around the steel member and be fastened back on itself .

NB: Clamps that rely on friction to hold them in place are not suitable.

flAngES• As per HVCA Specification DW144, typically use J3 and above at maximum

1250mm centres

• At each cross joint Lindab flanges or equivalent, (minimum size 30mmx30mmx1 .2mm thick) are fastened to the duct with spot welds at 150mm nominal centres

• The Lindab flanges are fitted with steel corner plates, (minimum 95mmx95mmx2 .5mm thick), slot these into the flanges at each corner and bolt them together with an M10 steel nut and bolt at each corner

• Fasten the flanges together with 40mm steel clamps at 265mm maximum centres

• Use a ceramic tape gasket (20mm wide x 3mm thick) between the flanges to seal the joints . See Figure 3 below

Figure 3 - Rectangular duct joints


19

StiffEnErS• Attach steel stiffeners at a 90˚ angle to any side of the duct section where the width or

depth exceeds 500mm . Position these at mid-width/depth and mid-length in each duct section . Each stiffener should consist of a steel tube (16mm diameter x 2mm thick)

• The stiffeners are fastened to duct walls with a steel washer of the same size, on the outside of the duct wall

• Fasten the stiffeners to the washer 72mm diameter x 1mm thick, on the inside with M6 steel bolts

See Figure 4 .

Figure 4 - Rectangular duct showing stiffener


20

SupportS for rEctAngulAr vErticAl DuctSFasten steel sections to the steel duct in order to support the duct system vertically .

• The steel sections either span across the opening in the concrete floor or form part of a cantilever bracket that is fastened to the building structure

• The maximum vertical distance between supports is 5 .0m

• To prevent buckling of the duct, the distance between supports should not exceed 8 times the smallest lateral dimension across the outside face of the steel duct . The weight of the duct system is taken by the building structure at each floor level

• The supporting steel members, where they emerge from the protection around the duct, must be clad with the same thickness of insulation for at least 300mm

StiffEning collArS - rEfEr to DW144 • If the longer side of the duct is greater than 1500mm, and the ducts have a section

length greater than 625mm, then a stiffening collar is required

• Fit each collar to the duct at approximately mid-length . The collar should be made to the same size steel section as the cross joints (or equivalent)

• Weld or bolt the sections together at the corners and fasten to the duct walls with steel rivets (or equivalent) at maximum 300mm centres or spot-welds at maximum 150mm centres

SuSpEnSion SyStEm SpAcingRectangular vertical ducts• The maximum vertical distance between supports is 5 .0m

Rectangular horizontal ducts• The maximum distance between supports should not exceed 1 .25m


21

Criteria for preparation of circular ductwork prior to insulatingDuct ShEEting The spirally wound steel duct is constructed in sections up to 3000mm long using hot dipped galvanised steel sheet, mild steel sheet or stainless steel sheet, 0 .7mm thick .

ShEEt thicknESS

Maximum diameter of duct Thickness of steel sheet

Up to 1000mm 0 .7mm

Up to 1250mm 1 .0mm

mAximum Duct SizES1250mm diameter .

Drop roDS AnD hAngErS for circulAr horizontAl DuctSEach steel hanger consists of two threaded drop rods, minimum M8, and a two-part circular band, 25mm wide x 2mm thick .

• The ends of each band section are bent outwards . Fasten the band sections together and attach to the drop rods with hexagonal nuts and washers

• The maximum spacing of the hangers is 1200mm

N.B: The spacing of the hangers and the size of the steel hanger components must be adjusted so that the tensile stress in the rods and the bands does not exceed 15N/mm2 for fire resistance periods up to 60 minutes and 10N/mm2 for fire resistance periods up to 120 minutes.

Drop roD AnchorSWhen fixing to a concrete supporting construction• Use all-steel expanding anchors to fasten the threaded rod hangers to concrete soffits .

The anchors should penetrate the concrete by at least 50mm – for 120 minutes of fire resistance

When fixing to a steel supporting construction• Drill a hole through the steel member, allowing the drop rod to be supported by a steel

nut and washer above

If a clamp type fixing is used, the clamp must be steel, suitable for the purpose . It should pass around the steel member and be fastened back on itself

NB: Clamps that rely on friction to hold them in place are not suitable.

• Position the drop rods and bearers inside the insulation material, with the drop rods 10mm from the steel duct


22

JointSAs per HVCA Specification DW144 .

The spirally wound steel duct is constructed in sections up to 3000mm long using hot dipped galvanised steel sheet, mild steel sheet or stainless steel sheet, 0 .7mm thick . The spiral seam of the spirally wound ducts must be the grooved seam, as tested

• At each cross joint Lindab NPU steel sleeves (or equivalent), minimum size 100mm wide x 1 .2mm thick, fasten minimum M4 steel self-tapping screws to the duct at 150mm centres on both sides of the joint

• Fit a sealing strip of EPDM rubber and a ceramic tape gasket, 15mm wide x 3mm thick, between the sleeve and the duct, on both sides of the joint, to seal the joints

StiffEnErSWhere 120 minutes of fire resistance is required for steel ducts, 40mmx5mm steel flanges should be positioned approx 10mm from each duct connection .

SupportS for circulAr vErticAl DuctSThe steel sections either span across the opening in the concrete floor or form part of a cantilever bracket that is fastened to the building structure . The maximum vertical distance between supports is 5 .0m .

• Fasten steel sections to the steel duct, either along the two longer sides or on all four sides

• The distance between supports should not exceed 8 times the smallest lateral dimension across the outside face of the steel duct, to prevent buckling of the duct . The weight of the duct system is taken by the building structure at each floor level

• Clad the supporting steel members, where they emerge from the protection around the duct, with the same thickness of insulation for at least 300mm

SuSpEnSion SyStEm SpAcingCircular horizontal ductsThe maximum distance between supports should not exceed 1200mm .

Circular vertical ductsThe maximum vertical distance between supports is 5 .0m .

For more information on the ULTIMATETM Protect system solutions from Saint-Gobain Isover, including our comprehensive range of literature:

• ULTIMATETM Protect air duct solutions . Fire safety through high performance

• ULTIMATETM Protect the HVAC Ductwork Specification Manual

or for technical advice or a full list of suggested ULTIMATETM contractors please email:

techinsulation@saint-gobain .com or call 01928 796180 .


23

Saint-Gobain IsoverUK Commercial CentreGotham Business ParkLeake RoadGothamNottinghamshire NG11 0LBTel: +44 (0) 115 969 8010Fax: +44 (0) 115 983 1675www .isover .co .uk

Technical Support: 01928 796 180 or E-mail techinsulation@saint-gobain .com

Saint-Gobain Isover reserve the right to alter or amend product specification without notice . The information given in this publication is

correct to the best of our knowledge at the time of publication . Whilst Saint-Gobain Isover will endeavor to ensure publications are up to date,

it is the users responsibility to check with us that it is correct prior to use .

Documents

35248 ISOVER Ultimate Insulation Manuallow