Where To Start With Mechanical Insulation?

The proper installation of the mechanical services is of the utmost importance when dealing with mechanical insulation.

From the mechanical perspective, the fluid in the pipes gets to where it should, the air in the ducts gets to the diffusers, the toilets flush and the faucets work, so it is all good. If the pipes were installed too close together for the Mechanical Insulation to be installed properly it can become a big problem. If the pipe or conduit has been installed using the sheet metal duct as a support system it may require that the conduit and/or pipe be insulated with the duct.

A simple rule of thumb is that the outside edge of parallel pipes that require insulation should be at least double the insulation thickness plus one-half inch apart. If a duct system requires Mechanical Insulation, the electrician, fitter, plumber, cable installer or any other trade should not use the duct as a support system; the duct should be installed with enough clearance to insulate around the entire duct.

If pipes, ducts or equipment require Mechanical Insulation, they should be installed with enough clearance to allow for the proper installation of Mechanical Insulation materials.

Make sure that the proper Mechanical Insulation is being installed on the specific mechanical service. Many materials look alike but are not similar.

Check the labels on the materials to ensure the proper thickness are on the jobsite ready for installation.

This can be accomplished by a quick walk-through of the facility. All major Mechanical Insulation manufacturers label their materials properly and you should be able to see the labels at a glance.

Never force the Mechanical Insulation contractor to install material prior to establishing a dry building. If Mechanical Insulation is installed before the roof or windows are on the building, you may experience moisture-damaged insulation.

Wet Mechanical Insulation will support mold growth and reduce the effectiveness of those materials. If you force the insulation contractor to install material before the building is ready you are doing this at your risk. Highrise buildings frequently require Mechanical Insulation to begin on the lower floors while the upper floors are still under construction.

There are no windows or roof on the building, but the schedule requires completion on a certain date. This means the pressure is on to insulate now. Rain, snow and ice can enter the upper floors and melt down onto the materials that were installed on the lower floors.

This is a problem you do not want to deal with. In the industrial sector it is just the reality that material must be installed in inclement weather.

In most cases, however, the materials are protected immediately following insulation application.

Look for little transgressions that can become big problems later. One such transgression is the lack of properly butting the Mechanical Insulation to one another as they are installed.

A small gap between the insulation sections may seem like a little thing, but this can become very expensive. If the gap is on a cold pipe system, it can allow for condensation to form on the pipe at the opening.

This can lead to mold growth on the Mechanical Insulation or on the ceiling where the condensation drips and forms a moist area for mold to grow. The dripping condensation can also lead to unsafe conditions on the floor where the moisture can collect and cause a slipping hazard.

Make sure the Mechanical Insulation is installed with properly butted joints and vapor barriers. Duct systems, too, can have the same types of problems as pipe systems with regard to this gap.

If it does not look clean and sharp when it is finished, it probably has not been installed properly.

On the hot side, the small gap is not as noticeable. It just allows for heat loss for the life of the building (see above Lesson 2). That heat loss translates to dollars out the window for the facility owner.

 

Vapor barriers are extremely important when insulating cold systems. Improperly installed vapor barriers can cost significantly when the failures become know to the owner.

Most pipe insulation materials are furnished with factory applied vapor barriers from the manufacturer. It is at the irregular surfaces that we see many failures of the vapor barrier system.

Cold Mechanical Insulation systems require a vapor barrier mastic to seal the fittings, valves, strainers, valve stems, etc. Look to see that small appurtenances are insulated to avoid condensation that can creep back into the main causing possible mold problems and dripping.

Ask to look at the mastic containers to ensure that the product is a vapor barrier material.

When the wrong mastic is used for the service, the costs to fix the problems can be very high.

It can include removing the old materials and replacing them with new materials.

What are pipe support systems and what is the proper way to insulate them?

Pipes must be supported by hanger systems that are installed by the pipe fitting contractor.

There are many types of support systems but they all require some insulation between or over the pipe and hanger.

When walking through the facility pay particular attention to the pipe support systems on all services. Most specifications require some sort of insulation protection at the pipe supports.

There are many different systems to alleviate this pipe support problem. Insulation support saddles are designed to spread the weight of the pipe over a larger area at the hanger.

Wood plugs can be inserted between the insulation support saddle and the pipe.

Special treated wood saddles, half the diameter of the pipe, can be used between the pipe hanger and the insulation.

Heavy density materials can be installed at each pipe support to protect the insulation. Special insulation protection systems are manufactured by several companies that will support the pipe at the proper level while performing the insulation function required.

If there is no insulation protection saddle at the support the chances are good that the insulation will be crushed when liquid is placed in the pipes.

 The crushing of the material will decrease the value of the insulation and may cause breaks in the vapor barrier which will allow for failure in the future.

Every project should be kept as clean as possible. The floors should be kept clean of insulation scraps, lap backings, empty boxes, materials that are not being used, and other items that can create a danger to the insulator or other trades people. Protective covering should be placed under areas where mastic is being applied to avoid splattering of these materials should they fall from the applicator. Protective equipment should be worn by all trades people at all times when on the project site. Ladders should be inspected and used only if in good order. All OSHA rules and regulations should be adhered too at all times while on the project site. Follow OSHA regulations and remember that a dirty job is one that is trouble waiting to happen.

One of the most important parts of an outdoor installation is the weather protection.

Many facilities use various gauges of metal products to protect the mechanical insulation from snow, rain, wind, ice and abuse.

If the protection fails, water may enter the mechanical insulation system and begin the process of corrosion on the pipes under the mechanical insulation as well as cause the failure of the material to perform as specified. Failure points can be found in many places on outdoor systems.

The lap of the jacketing on straight pipes should be facing down at four o’clock or eight o’clock. On risers, the lap should be away from the direction of the prevailing wind.

All joints should be overlapped by at least 3” to ensure that no moisture can be driven into the system. On risers, the circumferential lap from the piece of jacket above should be over the jacket below to ensure that water will flash away from the insulation system.

Valve bodies, elbows, tees and other areas where irregular insulation is used should be properly flashed so the water will run away from the system not into it.

The edge may be cleaner if the jacket is run up and over the downside of the elbow cover, but the moisture will run down and into the mechanical insulation system if this practice is used. Common sense should dictate how flashings are done.