Insulating Plastic Pipes with Armaflex. Insulating Plastic Pipes With...

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1 Insulating Plastic Pipes With...

2 WORKING WITH ARMAFLEX THE CORRECT USE OF ARMAFLEX ADHESIVE Use good quality tools, in particular a sharp knife, fresh Armaflex adhesive and a good brush. Oval tubes should always be split on the flat side. Use clean Armaflex material - with no dust, dirt, oil or water on the surface, if present clean with Armaflex cleaner. Use the right dimensions! Never pull glued joints when sealing them, always push them together. Never insulate plants and systems that are in operation! Only start insulated plants after 36 hours - after this time the adhesive is fully cured. Armafinish 99 paint can be applied immediately after the insulation has been installed, with a second coat of paint applied within 3 days, to provide UV protection (see page 4). TOOLS FOR INSTALLING ARMAFLEX Folding rule / tape measure Chalk for marking irregular shapes Silver ink marker pen Dividers Callipers Knifes * Safe edge craft knife Sharpening stone T-Ruler Template (printed on every Armaflex carton) Scissors Brushs with short, firm bristles Smooth spatula for smoothing down covering Sharpened pipe ends for the most common pipe diameters Paint fabric rollers for surface gluing and smoothing down covering Gluemaster * A three knife set plus sharpening stone are available together as a tool kit Armaflex Adhesive 520 Armaflex Adhesive 520 has been specially developed to bond Armaflex. It joins the surfaces reliably and safely at medium temperatures of up to +105ºC. The bond is resistant to weathering and aging. Armaflex Adhesive HT625 Armaflex Adhesive HT625 has been specially developed to bond HT Armaflex insulation for medium temperatures of up to +150ºC*. When using HT Armaflex only Armaflex Adhesive HT625 should be used. * For temperatures below -50 C or above +150 C, please consult our Customer Services Department. PREPARING FOR WORK Check condition of Armaflex Adhesive. Cans of Armaflex Adhesive should have been stored in a cool environment wherever possible. Cans must also have been kept free from frost. Damage due to frost can be reversed by storing in warm conditions, or for immediate use by placing the can into a bucket of hot water. Shelf life approx. 1 year. 1. Where installation surfaces are soiled with dust, dirt, oil or water all of these contaminants must be removed and, where applicable, cleaned with Armaflex cleaner before starting work. In addition all surfaces to be joined must be dry before gluing begins. 2. Pay close attention to the installation instructions on the adhesive can. Use small cans during work so that the adhesive does not thicken too quickly. Refill from larger cans when necessary and keep closed when not in use to avoid thickening 3. Plants must not be in operation during the installation process! 4. Do not use adhesive under 0 C. If the adhesive is too cold it can be warmed in a bucket of hot water. At temperatures below 5 C, condensation can appear on the surfaces to be glued or the adhesive film. If this occurs the materials can be glued only with difficulty. Check whether this has happened by applying absorbent paper. When working in areas with a high atmospheric humidity and high temperatures see Hot Climates page 33 of the Armaflex application guide. 5. Stir adhesive well after opening. If left to stand, heavier components in the adhesive may settle in the bottom of the can. These must be mixed thoroughly before use in order to effectively activate the adhesive.

3 OUTDOOR USE OF ARMAFLEX Whenever used externally Armaflex (with the exception of HT Armaflex) must be either painted, covered or clad. Armafinish 99 paint will provide UV protection and can be applied immediately after the insulation has been installed, with a second coat of paint applied within 3 days. Normal consumption SELECTING THE CORRECT ARMAFLEX TUBE SIZE FOR PLASTIC PIPE Armaflex tubes are dimensioned for use on copper and steel pipes although given tolerances and the inherent flexibility of the material these tubes will also provide a good fit around the outside of plastic pipes. Where it is necessary to oversize an Armaflex tube, the presence of a small air gap between the pipe and the insulation will not impact on the thermal performance provided the insulation is sealed to the pipe at the termination points. l / m² m² / l wet film mm dry film mm 1st coat nd coat Total The UV-resistant HT/Armaflex can be used for outdoor applications without any additional UV-protection If additional mechanical protection or protection against severe weather conditions is required Arma-Chek covering systems offer a non-metallic cladding option. For installation details please see the Arma-Chek installation manual.

4 COMPATABILITY BETWEEN ARMAFLEX AND PLASTIC PIPE Armaflex is compatible with a wide range of plastic pipes. It is known to Armacell that a theoretical incompatibility exists between Class O Armaflex and ABS pipework. Although no failures have ever been observed Armacell recommends the use of HT/Armaflex on ABS pipework. If in any doubt regarding the compatibility of Armaflex with any type of plastic pipe customers are advised to confirm with both Armacell and the pipe manufacturer. Plastic Compatability Armaflex Products Class 0 Armaflex HT/Armaflex NH/Armaflex PVC-Cyes- a a a PE-Xayes a a a PE-HDyes a a a PP a a a ABS a MDPE a a a INTRODUCTION TO THE ARMAFLEX PRODUCTS CLASS O ARMAFLEX Class O Armaflex is the flexible, closed cell, elastomeric, nitrile rubber insulation that offers reliable protection against condensation and effectively prevents energy loss. Class O Armaflex is dust free, fibre free and CFC free with an ODP of zero. Its inherent attributes and combination of properties makes Armaflex a highly efficient method of insulating hot and cold water services, chilled water lines, heating systems, air conditioning ductwork and refrigerated pipework for condensation control, energy conservation and frost protection. New Built-in anti-microbial protection reduces mould and bacteria growth. Built in vapour barrier prevents condensation Reduces energy losses by up to 87% Lightweight and flexible, quick and easy installation with low maintenance requirements, resulting in time and cost savings Excellent resistance to the effects of ozone, oil and chemicals (consult product test list)

5 HT/ARMAFLEX HT/Armaflex is the insulation that meets the growing demand for a reliable and flexible insulation material that can be used at higher temperatures. Remains flexible at high temperatures of up to +150 C** UV-resistant and can be installed outdoors without additional protective measures Class 1 resistance to flame spread in accordance with BS 476 Part 7 Built-in vapour barrier prevents condensation NH/ARMAFLEX NH/Armaflex is the halogen free, flexible elastomeric, insulation material with certification for use in marine and offshore environments. It meets the demand for insulation material with minimal smoke and toxic emissions in the event of a fire. As a closed cell material, NH/Armaflex provides exceptional water vapour resistance and features all the properties expected from any Armaflex insulation material, including low thermal conductivity and an in-built water vapour barrier. Free from halogen based flame retarders Suitable for use in marine and offshore environments Suitable for computer server rooms and clean rooms Excellent thermal conductivity Built in vapour barrier prevents condensation ARMAFLEX ACCESSORIES ARMAFLEX Adhesive 520 The adhesive is particularly suitable for joining Armaflex flexible elastomeric insulation and for bonding the material to clean prepared surfaces. When properly cured the adhesive maintains the resistance to water vapour expected of Armaflex. ARMAFLEX Adhesive HT625 HT625 adhesive is a one-component adhesive which has been developed to bond Armaflex insulation applied on high temperature lines. Especially well matched with HT/Armaflex, it guarantees a homogeneous and safe bonding at joints and seams. ARMAFLEX Tape Self-Adhesive Self-Adhesive tape (available in Class O Armaflex, NH/Armaflex or HT/Armaflex) which may be used for insulating difficult shapes or areas not easily accessible

6 CUTTING ARMAFLEX TUBES INSULATING NEW PIPEWORK WITH SLEEVE-ON-TECHNIQUE Due to the oversized nature of bends and union couplings on plastic pipes, sleeving Armaflex tube over a complete pipe run is rarely possible. Fitting covers for bends, unions and valves should be fabricated separately as described in this manual. It may still be possible however to sleeve Armaflex tube over short sections of plastic pipe. Where this is the case the material should always be pushed over the pipe as shown below. Use a sharp knife. Keep knife at a low angle when slitting tube Use sharpened off-cuts of pipes to make holes. Always cut on the flat sides of tubes.

7 INSULATING EXISTING PIPEWORK WITH SNAP-ON-TECHNIQUE USING THE ARMAFLEX TEMPLATE The fabrication of bends and tees using Armaflex tube requires tubes to be cut to different angles. In order to make this process easier and quicker, the Armaflex template is provided on every box of Armaflex. 1. Place a copy of the Armaflex template face up on a table or worktop. 1. With a sharp knife, slit the flat part of the unslit tube along the entire length. 2. Place the slit tube onto the clean pipe; apply Armaflex adhesive to the two cut edges with a thin even film of adhesive using a short bristle brush. Apply the adhesive at 200mm intervals, along the tube length. 2. Line a tube of Armaflex across the template parallel along the horizontal base line. 3. Select the required angle cut from the template and cut along this line. Additional copies of the Armaflex template on hard PVC sheet are available on request (contact your local Armacell representative for more information). 3. Allow the adhesive to touch dry, test with the fingernail. 4. Free the seams from the pipe where applicable, line the edges together and press the seam detail with firm even pressure to finish. Template is printed on every Armaflex tube carton

8 INSULATING OVERSIZED PLASTIC FITTINGS USING ARMAFLEX 90 DEGREE ELBOWS, TWO SEGMENTS, 45 DEGREE FABRICATION When insulating plastic pipes using Armaflex the following procedure should be followed before beginning the fabrication of fittings 1. Install Armaflex up to the face of the 90 degree bend connection piece at each end. Apply adhesive to the surface of both the pipe and the underside of the Armaflex facing the pipe. Allow to tack dry and apply pressure to seal to the pipework. 2. Select an Armaflex tube with a bore to fit over the diameter of the oversized bend connection and make cuts as illustrated in the diagram below. 1. Install Armaflex up to the face of the fittings at each end. Apply adhesive to the surface of both the pipe and the underside of the Armaflex facing the pipe. Allow to tack dry and apply pressure to seal to the pipework. 45 Ø 2. Measure the outer diameter of the fitting and select a suitably dimensioned Armaflex bore size to be used in the fabrication of the fitting. 3. Measure the length of the fitting and allow an extra 5mm on each end, to allow for compression Ø Yellow lines indicate where cuts are to be made. For correct angle measurements please use the Armaflex template located on each tube box. 4 Proceed to cut the Armaflex to length, split with a sharp knife and install onto the fitting. Apply Armaflex adhesive to the split seam; allow too touch dry and fix 5. Straighten up the fitting cover ensuring no gaps are present and wet seal all the seams. 6. Additional information on cutting Armaflex tubes and the use of Armaflex adhesive is contained within the full Armaflex Installation Manual 3. Slit open the Elbow, it can then be slid over the pipe and resealed. Ensure that the fitting cover has 5 10mm extra on both edges to allow for compression 4. After installing and gluing the bend, Wet seal the seams in order to fully vapour seal the system Maintain the same insulation thickness on the fitting cover as the in-coming pipework connection.

9 SR PULLED BENDS 1. Install Armaflex up to the face of the fittings at each end. Apply adhesive to the surface of both the pipe and the underside of the Armaflex facing the pipe. Allow to tack dry and apply pressure to seal to the pipework. 2. Measure the outer diameter of the fitting and select a suitably dimensioned Armaflex bore size. Ensure that the Armaflex bore size is not smaller than the fitting. 5. After cutting the five segments glue all the cut edges of the Armaflex and fit them all together, reversing the angles as you go to form the bend. Split the bend with a knife and install to the fitting; (ensure that the fitting is cut bigger with a 5 10mm extra on both edges to give compression. Ensure no gaps are present before sealing together with the adhesive, This technique is only for use with tube material. 3. Measure the inside radius of the bend fitting by dropping a perpendicular line to meet the horizontal line from the reduced thickness of the fitting. This is the throat radius. 6. After installing and gluing the bend, line-up the fitting covers and proceed to Wet seal the seams in order to fully vapour seal the system. 4. Having taken the throat measurement, place the Armaflex Tube on the template and line up the degree angle. Cut three centre segments at the same angle as shown in. The shortest length of each segment should be equal to the throat measurement divided by 3 Maintain the same insulation thickness on the fitting cover fabrication as a minimum. 7. Additional information on cutting Armaflex tubes and the use of Armaflex adhesive is contained within the full Armaflex Installation Manual. The throat measurement can be obtained by taking the throat radius (obtained in step 3) and dividing by 3. Maintain the same insulation thickness on the fitting cover fabrication as a minimum.

10 DOUBLE UNION BALL VALVE 1. Install Armaflex up to the face of the fittings at each end. Apply adhesive to the surface of both the pipe and the underside of the Armaflex facing the pipe. Allow to tack dry and apply pressure to seal to the pipework 7. Measure the o.d of the isolation neck spindle Mark around the circumference at the centre point of the cut section. Punch a hole in the tube centred on the centre point. The diameter or this hole should be equal to the measured diameter of the neck spindle and a sharpened section of copper can be used for this technique 2. Measure the outer diameter of the fitting and select a suitably dimensioned Armaflex bore size. Ensure that the Armaflex bore size is not smaller than the fitting. 8. Split the Armaflex tube on the reverse side together with a split from the punched out hole. Slide the tube through the Valve spindle and apply Armaflex adhesive to the seam, allow to tack dry and fix seam together.. 3. Measure the gap between the insulated pipe and the bottom of the tap, using this measurement select an appropriate thickness of Armaflex that would be equal to the connections on the valve. 4. Determine the circumference of the pipe. Important: Always measure with a strip of Armaflex of thickness to be used for the insulation. Warning: Do not stretch the strip 9. Apply Armaflex adhesive to all the seams around the fabricated Valve cover ends 5. Apply Armaflex adhesive to the measured strips and attach around valve. 6. Measure the outer diameter of the fitting and select a suitably dimensioned Armaflex bore size

11 PIPE REDUCER USING ARMAFLEX TUBE INSULATING OVER (ENCAPSULATING) PIPE SUPPORTS On cold lines pipe supports must be insulated to prevent condensation. If no insulated pipe supports have been specified the following approach should be followed as a minimum precaution. It is best practice to always have an insulated pipe support such as Armafix or Armaload installed. 1. Insulate straight pipework 2. Cut out segments of the tube which fits the bigger pipe 3. Glue seams with Armaflex Adhesive 4. Cut reducer to size - allow compression of 5mm at each end. 1. Install the Armaflex as close to the fixing bracket as possible. Seal the ends of the tube to the pipe with Armaflex adhesive. 5. Slit fitting on the flat side 6. Install and glue seam and butt joints 2. With a large off-cut of Armaflex tube, core out a small hole to allow for the oil thread support of the bracket and slit with a small sharp knife along the flat face of the tube. 3. Place the Armaflex cover over the support area, mark and cut the true circumference of the cover. Fix and vapour seal all seams and joints in and around the attached insulation using Armaflex adhesive. Armaflex 3mm Insulating self adhesive tape can be applied mm along the attached oil thread support.

12 EQUAL T-PIECE USING ARMAFLEX TUBE PUNCHED METHOD EQUAL T-PIECE USING ARMAFLEX TUBE PUNCHED METHOD This recess will fit over the insulation on the main branch and it is better to have a cut which is a little too deep rather than too shallow. 5. Slit this section of tube open and pull over the incoming pipe. 1. Select an Armaflex tube with bore equal to the diameter of the main pipe branch. Measure and mark the point at which the incoming pipe forms a T. 6. Apply Armaflex Adhesive along all seams and joints including that contacting surface where the curved recess fits over the Armaflex at the point of the T. Apply firm pressure to seal the adhesive. 2. Using a sharpened section of copper pipe of the right diameter punch a hole in the Armaflex tube at the point previously marked. If there is a diffenece in pipe diameter between T-piece and straight sections, refer to the Pipe Reducers Using Armaflex guidance also found in this manual. 3. Slit this section of tube open (half through the hole) and slide it over the pipe. 4. Select an Armaflex tube with bore equal to the diameter of the incoming pipe. Cut a semi-circular recess into the tube at one end.

13 OVERSIZED EQUAL T-PIECE USING ARMA- FLEX TUBE 5. Select an Armaflex tube with bore equal to the diameter of the incoming pipe. Cut a semi-circular recess into the tube at one end. 1. Measure the length of the fitting and allow an extra 5mm on each end to allow for compression. Cut a section of Armaflex tube to this length. 6. At one side of the semi-circular recess, cut downward and fit on to the lower section of the fitting. Using Armaflex 520 adhesive, Glue the 2 previously cut seems back together Allow the glue to tack dry before pressing the two seems together. 2. Mark out the centre of the cut Armaflex section on the top. Measure the diameter of the lower pipe branch, finally using callipers score out where the hole will be cut for the lower pipe branch. 7 Apply Armaflex 520 Adhesive to the seems between the two sections completing the t-piece fitting. 3. Using a straight edged knife cut around the circumference of the hole. Then slit from the knewly cut hole outward (on that side of the tube only) making it possible to slot the tube section over the top of the fitting, 4. Measure the length of the lower branch. 8. Finally wet seal the straight tube sections to the t-piece fitting. If there is a diffenece in pipe diameter between T-piece and straight sections, refer to the Pipe Reducers Using Armaflex guidance also found in this manual.

14 c = circumference of end panel Insulating Plastic Pipes with Armaflex INSULATING VALVES WITH D-BOX MADE OF ARMAFLEX SHEET Fix down the end panels to the top panel making sure the edge s are in-line L Establish the following measurements: L = length of valve + 2 x thickness of insulation H = height of valve + 2 x thickness of insulation W = Ø (diameter) + 10mm Use a strip of Armaflex (used thickness) to determine the circumference around one end panel (including the top panel). Mark measurement L and circumference out and cut the body panel to size. Apply Armaflex Adhesive to the body panel end and the body panel edges as shown. top panel W L end panels H W end panels Mark out and fabricate 2x end panels and 1x top panel using the measurements made in the previous step. Cut cleanly using a small sharp knife. Gently roll the body panel edges around the end panels until the cover panel resembles a box. Fix down the square 90º edge as shown. Ensure the edge is in-line and neat. Continue to fix all edges in this way. Apply Armaflex adhesive along the edges as indicated. The glue line must be as wide as the thickness of the Armaflex in use. Cut holes for the insulated piping connections on each of the end panels and a final cut-out for the valve spindle connection at the top. Split the box into two halves and fit around the valve. If required the fitting cover can be slit through three quarters of the way round the fabrication cover and snapped over the fitting - with adhesive applied to all fixing seam details as stated. Glue the top edges of the end panels and the top panel edge. To finish, apply Armaflex adhesive to the fixing seams, allow to touch dry and fix the seams together. Vapour seal the connections (joints) to the linear insulated pipes using Armaflex adhesive. For external installations, weather-seal around the valve spindle connection cut using Arma-Chek black mastic.

15 d Insulating Plastic Pipes with Armaflex FLANGE BOXES The following section gives the installation techniques for insulating flanges. On chilled water or refrigeration applications it is advisable to pack the gaps between the nuts with strips of Armaflex insulation. h = height + 2x insulation thickness Using a small sharp knife cut out for the insulated pipe diameter. To finish fit the two half s of the flange box around the flange and wet seal all seams and joints to the insulated pipe branch. If required the fitting cover can be snapped over the fitting, by only cutting the insulation cover half way through. d = diameter + 10 mm Using a pair of callipers, determine the diameter of the flange face. Please add 10mm to this measurement. Measure the length of the flange (incl. Bolts) and add 2x the insulation thickness of the used sheet. Where applicable allow for bolt removal. Body panel circumference of disc h Disc's Transfer these measurements to a piece of Armaflex sheet. Mark out two concentric circles with dividers. Repeat on a second piece of sheet. Cut out two Armaflex rings. Determine the circumference of the disc. Roll the body panel up and a round the the end disc s, do not stretch during application. Check alignment throughout. Place the edge to the a joining seam s edge opposite.

16 ANTI-MICROBIAl PROTECTION in-built Class O Armaflex, the leading closed cell pipe and duct insulation for controlling condensation and preventing energy losses, now comes with in-built anti-microbial protection! In-built Microban technology gives Class O Armaflex an added level of protection against harmful microbes such as bacteria, mould and mildew. Because it s built in during the manufacturing process, Microban antimicrobial product protection won t wear off. For more information order our ArmaPlus CD or visit Armacell UK Ltd. Mars Street Oldham, Greater Manchester OL9 6LY Tel Fax info.uk@armacell.com Armacell provides this information as a technical service. To the extent the information is derived from sources other than Armacell, Armacell is substantially, if not wholly, relying upon the other source(s) to provide accurate information. Information provided as a result of Armacell s own technical analysis and testing is accurate to the extent of our knowledge and ability, as of date of printing, using effective standardized methods and procedures. Each user of these products, or information, should perform their own tests to determine the safety, fitness and suitability of the products, or combination of products, for any foreseeable purposes, applications and uses by the user and by any third party to which the user may convey the products. Since Armacell cannot control the end use of this product, Armacell does not guarantee that the user will obtain the same results as published in this document. The data and information are provided as a technical service and are subject to change without notice. Armacell UK Ltd. Subject to alterations Printed in UK CoPr (UK, IRL)