Pittsburgh Corning CHILLED Issues and Challenges The FOAMGLAS® Insulation Solution

The design and specification of insulation on a chilled water distribution network might be considered routine by some engineers and designers. Yet, a survey by HPAC Engineering magazine revealed that almost one out of 10 of respondents had been involved with a failed chilled water insulation project within the previous 12 months.

Insulation Efficiency Water vapor intrusion is the single- most destructive force for an insulation system. During construction, relative in a building can reach close to 100%. Because of this, most Corrosion There is no value in compromising quality insulation system failures begin during For corrosion to occur, conditions that in a chilled water system. Improperly construction because air-conditioning include water, oxygen and temperature designed systems can lead to dripping systems are typically turned on before need to be in place. Chemical presence condensation, wet ceiling tiles and the building is completely enclosed, will also contribute to corrosion. damage to anything below including thereby creating a vapor drive to the Wet insulation provides a perfect furniture, electronics and slippery floors. cold piping and equipment. environment of water and oxygen The cost to remove and replace a failed for metal corrosion to occur. Many system is often 3-5 times the initial cost FOAMGLAS® insulation is 100% organic insulations contribute to the and can be even greater. Wet insulation impermeable and will not fail before the added property of chemical attack, can also contribute to mold growth, building is built. accelerating the corrosion process. another costly problem when remediation In commercial buildings, repairing is involved. Fire Safety corroded pipes often requires the Fire is probably the most serious of all removal of drywall, ceiling tiles and Insulation is very much an investment in safety issues in any public or occupied other items which block pipe access. your building and should be designed to building. During a fire, some insulations last the life of the building. burn at an incredible rate while popping FOAMGLAS® insulation is not organic, flaming embers into the air and will not absorb water and contains no FOAMGLAS® insulation stands the test emitting lethal gasses such as carbon corrosive chemicals. of time and will last for many years. We monoxide, carbon dioxide, hydrochloric have case studies which illustrate this acid, nitrous oxides, formaldehyde and Cost-Longevity unparalleled field history. acrylonitrile. That’s why it is important The price of a chilled water system is to have an insulation that will not burn usually dictated by: or give off toxic smoke. • Insulation type • Insulation thickness • Application specifications • Insulation finish Determining Potential Moisture Intrusion

No matter where your chilled water Myth system is located—indoors, outdoors, Vapor drive can never be reduced underground, above ground, subject to to zero. Applying a so-called vapor high or low humidity, or in conditioned “barrier” over insulation will not solve or non-conditioned surroundings—there the problem. Thus, the term vapor is a potential for moisture penetration barrier has more or less been replaced into the insulation system. It is never by vapor “check” or “retarder.” a good practice to install a permeable insulation on a below-ambient system. If your insulated cold piping is exposed While systems in all areas of the country to ambient or non-conditioned air, it are subject to moisture damage, should receive special attention. When there are certain “bands” more prone cold piping operates year-round, a to degradation. The following map constant vapor drive exists. In permeable illustrates moisture intrusion potential type insulations, moisture inevitably across the United States: accumulates, regardless of vapor retarders, jackets, and vapor sealing Design vs. Real-World of joints and fittings. If the insulation Performance absorbs just 4% moisture, it will lose System design should maintain the outer 70% of its thermal efficiency. Wet surface temperature of the insulation insulation acts as a thermal conductor above the dew point for the likely range rather than an insulator. in ambient air conditions.

Pittsburgh Corning offers computerized services for determining required insulation thickness to prevent surface condensation. A variety of techniques provide insulation thicknesses of adequate accuracy for most applications. However, any method will be only as good as the design and specification in ambient conditions. Designers are cautioned that calculating average ambient conditions for a particular location may provide quite reasonable High insulation thickness values, but this is likely to result in a number of days Moderate during which sweating and dripping of condensate occur. Low

2 FOAMGLAS® Insulation Meets All Challenges

FOAMGLAS® cellular glass insulation is a lightweight, rigid insulating material composed of millions of completely sealed glass cells, each an insulating space. This all-glass, closed-cell structure provides an unmatched combination of physical properties ideal for piping and equipment below or above ground, indoors or outdoors, at operating temperatures from -450°F to +900°F (-268°C to +482°C). Billions

of square feet have been installed FOAMGLAS® Insulation is completely impermeable to moisture, noncombustible, throughout the world in thousands of dimensionally stable and offers high compressive strength among other attributes. industries and operations because it is:

FOAMGLAS® insulation’s diverse equipment, and helps minimize • Resistant to water in both liquid and properties results in a unique and subsequent plant shutdown time vapor forms unmatched combination of benefits, • Virtual elimination of the potential • Noncorrosive proven by in-the-field performance: for auto-ignition from absorbed • Noncombustible/nonabsorbent of combustible liquids or fire from • Constant, long-term energy efficiency combustible liquids condensed low-temperature gasses provides low, predictable energy costs • Resistant to most industrial reagents • Proven durability for underground and • Enhanced process control allows • Dimensionally stable under a exterior installations improved, consistent product quality variety of temperature and humidity • Manufacturing of FOAMGLAS® • Minimal maintenance/repair/ conditions insulation puts no stress on the replacement of insulation or facility • Superior compressive strength atmosphere’s ozone layer, while its infrastructure reduces life cycle costs long-term thermal efficiencies reduce • Resistant to vermin and microbes • Corrosion resistance and fire energy demand and the effects of • Fiber, CFC and HCFC free resistance protects the insulated burning fossil fuels on the environment

FOAMGLAS® Insulation is the obvious choice when there are fire and smoke concerns in commercial buildings.

3 Through-Penetration Fire Stop Systems

The FOAMGLAS® Insulation fire-stop system is simple and relatively inexpensive.

Because it is all-glass and inherently pipe size tested for these applications For a listing of UL Through-Penetration noncombustible, FOAMGLAS® insulation is 20 inches. Fire-Stop Approved Systems, please will not add any fuel to the fire and will search the UL Database at not produce any toxic fumes. If your insulated cold piping is exposed http://www.ul.com/database/index.htm. to ambient or non-conditioned air, it There are currently numerous should receive special attention. When Once on this page, click on “Fire UL-approved through-penetration fire- cold piping operates year-round, a Resistive Assemblies and Systems” to stop systems using FOAMGLAS® insulation constant vapor drive exists under access the individual system information are available through several fabricators/ humid air conditions. In permeable page. Then, type the System Number in distributors located throughout the type insulations, moisture inevitably the designated box exactly as it appears country. The approved systems use 1-1/2 accumulates, regardless of vapor (with hyphens, lower case is acceptable) to 3-inch-thick insulation. The maximum retarders, jackets, and vapor sealing and submit. of joints and fittings.

FOAMGLAS® Insulation has a 3-hour fire-stop rating and will not add any fuel to a fire or toxic smoke.

4 The FOAMGLAS® Insulation Solution

Importance of Compatible Metal jacketing is commonly used for Accessories outdoor, above-ground systems and is Regardless of the amount of time spent not a vapor retarder. A major concern on analyzing a particular insulation’s with using metal jacketing is its inability ability to meet your needs, if quality, to provide vapor retarder protection, compatible accessories are not used, the especially on vertical runs. Once dependability of the system could be water enters these systems, it may be placed at unnecessary risk. Accessory impossible to remove. products are often viewed—incorrectly— as commodities with little differentiation On piping and equipment with operating among competitive products, and are temperatures below ambient, highly Accessories such as sealants and jacketing often selected as an afterthought. Also, reflective materials with low emissivity are key to a system’s overall performance. the contractor sometimes changes the such as unpainted metal jacketing will choice of accessories at the last minute— decrease heat gains. As a result, the and this is often unknown to the end surface temperature will be reduced For most indoor insulation systems, user. PC® accessories are known as and the potential for condensation laminates are the preferred jacketing. being among the best for complimenting will increase. When designing below- For permeable insulation systems, a "top-knotch" insulation system. ambient insulation systems for maximum they are much less than perfect as a condensation protection, less reflective vapor retarder. Because FOAMGLAS® SEALANTS: materials with a higher emissivity such insulation is impervious to water Locally applied at the jobsite, sealants as painted metal, PVC, ASJ or mastic vapor, an additional vapor retarder— are utilized at joints, metal jacketing should be selected for the outer surface such as a laminate jacketing—is laps and around protrusions. Sealants of the insulation system. not required. Laminate jacketing, prevent water vapor entry on low- and however, is commonly applied to indoor intermediate-temperature and cyclic Plastic jacketing comes most commonly FOAMGLAS® insulation systems for systems. Their function, however, is not in the form of solid polyvinyl chloride cosmetic purposes only. to mask poor-fitting insulation. (PVC). This is usually seen on indoor, above-ground installations. On underground systems, special Butyl and MS Polymer Based bituminous-containing laminates are sealants are appropriate for use with Laminate jacketing consists of any non- available. Their primary function is to FOAMGLAS® insulation because of cellulous multiply laminated fiberglass provide a waterproof membrane and their durability and low-temperature reinforced polypropylene, PVC, or vinyl to absorb the shock of soil and rock flexibility. Contact Pittsburgh Corning faced/metalized film backed Jacket. overburden when the insulated pipeline for specifications and recommendations Formats include: (1) all service jacketing is direct buried. for appropriate PC® sealants for your (ASJ), with a low flame-spread- treated chilled water applications. kraft paper, usually a glass fiber scrim and aluminum inner face, (2) JACKETING: vinyl/ scrim/foil jacketing (VSF), (3) Jacketing provides mechanical protection polypropylene, scrim and foil (PPSF), a on either above- or below-ground combination with very low flame spread installations and can act as a weather or that is more economical than VSF and vapor retarder. Jacketing can be made (4) PVC/scrim/foil. of metal, single-layer plastic or laminates incorporating various materials.

Thermal imaging can identify hidden problems.

5 Testing Methods

When analyzing test results for insulation ASTM E-84 • Technical Service—Pittsburgh Corning’s performance, it is important to use the (Standard Test Method for Surface Technical Service Staff provides appropriate test methods for determining Burning Characteristics of Building product, application and materials performance in a chilled water system: Materials) testing, standardized and customized specifications, on-site customer ASTM E-96 This test observes the comparative assistance and installation guidance. A (Standard Test Methods for Water Vapor surface burning characteristics of network of local sales representatives Transmission of Materials) building materials—versus red oak and and distributors are available for inorganic reinforced cement board. consultation and problem resolution. There is both a “wet cup” and a “dry “Flame spread index” is a comparative, • Energy Analysis Service—To simplify cup” method to perform this test, which numerical measure relating to the your insulation specification process, measures water vapor permeability. The progress of a flame zone. “Surface flame Pittsburgh Corning offers an Energy/ “dry cup” method measures materials spread” is the advancement of flame Economic Analysis Service and our at 0% relative humidity (RH) on one away from an ignition source across a exclusive Energy Analysis Report (EAR). side and 50% on the other side. The specimen’s surface. “Smoke developed Developed with customer-specific data “wet cup” method measures materials at index” is a comparative classification subjected to computer analysis and 100% RH on one side and 50% RH on based on smoke observation. other calculations, EARs assist systems the other side. The “wet cup” method designers in specifying the proper of testing is more indicative of chilled ® FOAMGLAS insulation is 100% glass insulation thicknesses for: water piping applications in humid and contains no binders. Glass will not – condensation control climates. FOAMGLAS® insulation has a burn. Therefore there is no smoke or – process control permeability that is thousands of times ® flame propagation with FOAMGLAS – outlet temperature less than that of organic foam. Even ® insulation. FOAMGLAS insulation has a – thickness recommendations due to when tested under “dry cup.” “flame spread” rating of 0 and a “smoke different type of jacketings development” rating of 0 when tested When analyzing test results for insulation according to ASTM E-84. To order an energy analysis report, performance, it is important to use the please log on to: www.foamglas.com/ appropriate test methods for determining Value-Added Services From industry/en/technical_services/energy_ performance in a chilled water system: Pittsburgh Corning analysis_report In addition to industry-leading insulation Chilled water insulation should be and accessory products, Pittsburgh • Energy Survey Service—Assists in the selected based on ASTM E-96 “water Corning offers a number of valuable planning for building renovations and method” test values. These values client services: also identifies deteriorating insulation are not always provided by the systems. It helps to determine payback manufacturer. • Worldwide Availability—With multiple periods for reinsulated systems. This plants in the United States and will evaluate the performance of Europe, Pittsburgh Corning can existing on piping uniquely provide consistency of supply, and equipment. They are conducted millions of units of unequaled capacity on-site and can result in: and ready availability. – energy savings – condensation-ice control

These are free services offered to prospective clients.

6 The FOAMGLAS® Insulation Solution

National Institutes of Health MD Anderson Cancer Center wet pipe. If insulation is permeable to The NIH in Washington is also one of The University of Texas MD Anderson moisture, it will not be used for chilled the largest chilled water facilities in Cancer Center is located in hot, water piping here at MD Anderson." the world, consisting of 55,000 tons of humid central Houston, and has been installed chilled water capacity—more using FOAMGLAS® insulation for In addition, FOAMGLAS® insulation is than 10 linear miles of chilled water decades, particularly on chilled water environmentally friendly and offers lower piping supply and return lines in its utility distribution lines. life-cycle costs than other materials tunnel network and trench systems. because of its proven long-term Considering the capital investment that According to the engineering staff at MD performance. NIH made in its chilled water system, Anderson, "The only insulation that is the selection of insulation plays a critical acceptable for chilled water facilities here role in the ability of the system to is FOAMGLAS® insulation." operate efficiently and maintenance-free. System designers chose FOAMGLAS® According to the engineering staff, insulation because it is moisture resistant the reason is simple: "The product is and acts as a vapor barrier to protect glass, it’s recyclable, it’s impermeable to the chilled water piping. moisture and it can even be installed on

MD Anderson Cancer Center in Houston.

Chilled water piping at NIH.

7 Capitol Visitors Center Dublin Airport Greater Pittsburgh In August 2002, construction began on Over the past decade, passenger traffic International Airport the 580,000 square-foot Capitol Visitor at Dublin airport has increased twofold, When the $750 million Greater Pittsburgh Center (CVC), which officially opened to making it the 8th largest airport facility International Airport was built, it was the public in December 2008. Because in Europe for international traffic. a great improvement over the older, the facility’s entire piping system is Recently, an additional increase in existing facility. The 3.2 million square- located underground in tunnels, there passenger traffic prompted a significant foot complex includes three major were design challenges for both the redevelopment of the existing airport buildings and seven underground tunnels immediate and long-range future facilities. Fire safety and sustainability for utility service, baggage handling operation of the system. The designers were important considerations in the and passenger transportation. Two specified FOAMGLAS® cellular glass expansion effort, which led to the criteria were deemed most important insulation in thicknesses from 2” thick selection of FOAMGLAS® insulation when selecting the insulation for chilled on the chilled water lines to up to 4” for internal and external pipe work water lines: impermeability for thermal thick on the steam lines. FOAMGLAS® in the terminals, piers and energy protection and performance; and insulation was chosen because it is center. As the centerpiece of the compressive strength for protection all glass and cannot absorb moisture, airport redevelopment, Terminal 2 against physical abuse. As a result, ensuring long-term thermal efficiency comprises 96,875 square feet of retail FOAMGLAS® insulation was installed on and protection against corrosion and and catering space, 58 check-in desks, a total of 64,000 lineal feet of piping other failures. Additionally, because and new baggage handling and energy throughout the entire airport complex, of its composition, it cannot burn and center facilities. Approximately 8 miles ranging in diameter from 24 inches to won’t contribute to flame or smoke of FOAMGLAS® piping insulation has 3/4 inch. According to the specifer, the spread, an important factor for any been applied since construction began need for the benefits of FOAMGLAS® building occupied by people. in 2007. Much of the pipe work was insulation isn’t exclusive in the south and pre-insulated offsite and brought in as its high humidity conditions. She said that modules, which were easily and quickly many northern locations have the same lifted into place. The compressive humidity problems. Pittsburgh has an strength of FOAMGLAS® made this average relative humidity of 50 percent. process possible without compromising While Jacksonville, Fla., may have much the insulation system. higher temperatures, the average relative humidity is also 50 percent.

Chilled water piping at Dublin Capitol Visitors Center in Washington D.C. International Airport.

8 Specifier Information

Physical and Thermal Properties of FOAMGLAS® Insulation

PHYSICAL AND THERMAL PROPERTIES OF FOAMGLAS® ONE™ INSULATION

ASTM EN ISO PHYSICAL PROPERTIES SI ENGLISH Method Method

EN 1609 0.2% 0.2% C 240 Absorption of Moisture EN 12087 (Water % by Volume) Only moisture retained is that adhering to surface cells after immersion E96 EN 12086 Water-Vapor Permeability 0.00 perm-cm 0.00 perm-in Wet Cup EN ISO 10456 Procedure B Acid Resistance Impervious to common acids and their fumes except hydrofluoric acid

Capillarity None Noncombustible - will not burn Combustibility & E 136 EN ISO 1182 Flame Spread 0 Reaction to Fire E84 (Class A1) Smoke Development 0 Composition Soda-lime silicate glass – inorganic with no fibers or binders 620 kPa 90 psi C 165 EN 826 Compressive Strength, Block C 240 Strength for flat surfaces Method A capped with hot asphalt. C 552 Density 120 kg/m3 7.5 lb/ft3 C 303 EN 1602 EN 1604 Dimensional Stability Excellent—does not shrink, swell or warp (DS 70/90) C 203 EN 12089 Flexural Strength, Block 480 kPa 70 psi C 240 (BS450) Hygroscopicity No increase in weight at 90% relative humidity Coefficient of Linear 9.0 x 10-6/K 5.0 x 10-6/°F E 228 EN 13471 Thermal Expansion 25ºC to 300ºC 75°F to 575°F Maximum Service Temperature 482˚ C 900˚ F EN 826 Modulus of Elasticity, Approx. 900 MPa 1.3 x 105 psi C 623 Method A1 W/mK Btu-in/hr.ft2.°F EN 12667 C 177 Thermal Conductivity 0.040 @ 10°C 0.28 @ 50°F EN 12939 C 518 0.042 @ 24°C 0.29 @ 75°F ( D (90/90) 0.041 W/mK @ 10˚ C) Specific Heat 0.84 kJ/kg.K 0.18 Btu/lb.°F Thermal Diffusivity 4.2 x 10-7 m2/sec 0.016 ft2/hr Note: FOAMGLAS® ONE™ is manufactured to meet or exceed the minimum requirements of ASTM C552-07 Standard Specification for Cellular Glass Insulation (or most recent revision). Unless otherwise specified, measurements were collected using ASTM guidelines at 24°C (75ºF) and are average or typical values recommended for design purposes and not intended as specification or limit values. Values under EN ISO are declared as limit values under the specific set of standard test conditions. Properties may vary with temperature. Where testing method or reporting values differ between ASTM and EN ISO methodologies, values are denoted within parentheses in the EN ISO column.

Recommended Thickness of Pittsburgh Corning FOAMGLAS® Insulation for Chilled Water Systems Jacketing: ASJ, PVC, Painted surfaces

75°F Ambient Temperature 80°F Ambient Temperature 85°F Ambient Temperature 90°F Ambient Temperature PIPE RT HG RH RT HG RH RT HG RH RT HG RH 0.5 1.5 2.9 92% 1.5 3.3 92% 1.5 3.8 91% 1.5 4.2 90% 1 1.5 3.2 91% 1.5 3.7 90% 1.5 4.2 90% 1.5 4.7 89% 2 1.5 3.8 90% 1.5 4.3 89% 1.5 4.9 88% 1.5 5.5 88% 3 1.5 4.2 89% 1.5 4.8 88% 2 4 90% 2 4.4 89% 4 1.5 4.4 88% 1.5 5 88% 2 4.2 89% 2 4.7 89% 6 1.5 4.8 87% 1.5 5.5 86% 2 4.5 89% 2 5 88% 8 1.5 4.8 87% 1.5 5.5 86% 2 4.7 88% 2 5.2 88% 10 1.5 4.7 87% 1.5 5.4 86% 2 4.6 88% 2 5. 88% 12 1.5 4.8 87% 1.5 5.5 86% 2 4.7 88% 2 4.2 88% 16 2 3.9 89% 2 4.5 88% 2.5 4.1 89% 2.5 4.6 89% 18 2 4 89% 2 4.6 88% 2.5 4.2 89% 2.5 4.6 89% 24 2 4 89% 2 4.7 88% 2.5 4.2 89% 2.5 4.8 88% 30 2 4.1 89% 2 4. 88% 3 3.6 90% 3 4 90% 36 2 4.1 88% 2.5 3.8 89% 3 3.6 90% 3 4.1 90%

9 Cradle Schedules

T L Nominal Pipe Insulation Cradle Thickness Cradle Thickness Cradle Length Span Diameter in (mm) Thickness in (mm) in (mm) for Clevis Hangers in (mm) for Point Load in (mm) ft (m) and Roller Applications

1/ 2 to 1 1 1/2 to 3 14 GA/0.0747 in 1/4 / 0.25 in 12 7 (21 to 33) (39 to 76) (1.89) (6.35) (305) (2.13)

1 1/2 to 2 1 1/2 to 3 1/2 14 GA/0.0747 in 1/4 / 0.25 in 12 10 (48 to 60) (39 to 89) (1.89) (6.35) (305) (3.04)

2 1/2 to 2 1 1/2 to 4 12 GA/0.1046 in 1/4 / 0.25 in 12 12 (73 to 89) (39 to 102) (2.65) (6.35) (305) (3.65)

3 1/2 to 4 1 1/2 to 4 1/2 12 GA/0.1046 in 1/4 / 0.25 in 12 14 (102 to 114) (39 to 114) (2.65) (6.35) (305) (4.27)

5 & 6 1 1/2 to 4 1/2 10 GA/0.1344 in 1/4 / 0.25 in 12 17 (141 to 168) (39 to 114) (3.41) (6.35) (305) (5.18)

8 & 12 1 1/2 to 5 1/2 10 GA/0.1344 in * 18 20 (219 to 324) (39 to 140) (3.41) (457) (6.10)

14 to 20 1 1/2 to 6 3/16 /0.187 in * 24 20 (356 to 508) (39 to 152) (4.74) (607) (6.10)

22 to 24 1 1/2 to 6 1/2 3/16 /0.187 in * 24 20 (559 to 619) (39 to 165) (4.74) (607) (6.10)

Cradle/shield material ASTM A 1011 Galvanized Carbon Steel. Table based on spans for ASTM A53 Grade A Carbon Steel pipe, maximum allowable stress in tension 12,000 psi. For conditions not covered in this table, contact Pittsburgh Corning.

For more information about physical and thermal properties, as well as other important technical issues, visit us on the web at: www.foamglas.com/industry

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Telephone and Fax: +81 50 7554.0248

The information contained herein is accurate and reliable to the best of our knowledge. But, because Pittsburgh Corning has no control over installation, workmanship, accessory materials or conditions of application, NO EXPRESS OR IMPLIED WARRANTY OF ANY KIND, INCLUDING THOSE OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, IS MADE as to the performance of an installation containing Pittsburgh Corning products. In no event shall Pittsburgh Corning be liable for any damages arising because of product failure, whether incidental, special, consequential or punitive, regardless of the theory of liability upon which

F1-188 3M Rev. 01/11 Replaces Rev. 06/04