PERFORMANCE CHARACTERISTICS OF INDUSTRIAL INSULATION

First Quarter 2004

31. ESTIMATING SEALANTS, ADHESIVES AND COATINGS

s SUMMARY Estimating accessories for insulation is a difficult job because there are so many variables involved. Whereas there are some general and common techniques to use, the estimator must base calculations on past experience on other projects to obtain the most reliable results. For example, a variation of only 1/32" on the application of a sealant specified at 1/2" thickness, would result in a +/- 25% variance in the material which can result in a substandard application. This newsletter will address general techniques for estimating various accessory materialsincluding sealants, adhesives and coatingsto be used with FOAMGLAS cellular glass insulation. Note: This information is offered as an aid in estimating. Pittsburgh Corning Corporation will not be responsible for the accuracy of figures or for the quantity of material for any specific application estimated from the information provided. Please contact our Technical Services department for more information s PC 88 ADHESIVE To estimate the amount of PC 88 adhesive needed for a particular single layer application of FOAMGLAS insulation application, the first step is to determine the surface area. In most cases, the surface area will already be known since it is required to estimate the amount of FOAMGLAS insulation needed for the project. The surface area may then be multiplied by the factors listed in Table 1 to calculate the square feet of adhesive needed without losses. The square feet of adhesive then needs to be divided by 80 to determine the number of PC 88 adhesive kits needed. The result should be rounded to the next full kit, then an appropriate loss factor may be added. For other block sizes, the adhesive factor may be determined as follows: The Adhesive Factor* = (area of insulation block + the area of two adjacent edges) area of insulation block * Square Feet of Adhesive per Square Feet of Surface Area

TABLE 1 Square Feet of Adhesive per Square Feet of Surface Area

Block Size (Inch) 12 x 12 12 x 18 12 x 24 18 x 24 Single Layer Block Thickness (Inches) 2 3 4 11/2 1.250 1.208 1.188 1.146 1.333 1.278 1.250 1.194 1.500 1.417 1.375 1.292 1.667 1.556 1.500 1.389

5 1.764 1.694 1.625 1.486

TABLE 2 Square Feet of Adhesive per Square Feet of Surface Area

Block Size (Inch) 12 x 12 12 x 18 12 x 24 18 x 24 Double Layer Total Insulation Thickness (Inches) 3.0 2.500 2.417 2.375 2.292 4.0 2.667 2.556 2.500 2.389 5.0 2.833 2.694 2.625 2.486 6.0 3.000 2.834 2.750 2.584 7.0 3.167 2.973 2.875 2.681 8.0 3.334 3.112 3.000 2.778 9.0 3.500 3.250 3.125 2.875 10.0 3.666 3.388 3.250 2.972

EXAMPLE 1: The amount of PC 88 adhesive required to insulate a 25'-diameter 20'-tall vertical tank (area 1,570 ft2) with 12" x 24" x 2" FOAMGLAS insulation block. Factor from Table 1 =1.250 ft2 adhesive/ ft2 surface area (1.250 x 1,570) 80 = 1963 80 = 24.5 kits = 25 kits, not including losses. For double-layer applications the factors are shown in Table 2. EXAMPLE 2: The amount of PC 88 adhesive required to insulate a 25'-diameter 20'-tall vertical tank (area 1,570 ft2) with two layers of 12" x 24" x 2" FOAMGLAS insulation block. Factor from Table 2 =2.500 ft2 adhesive/ ft2 surface area (2.500 x 1,570) 80 = 3925 80 = 49.1 kits = 50 kits not including losses. As with the previous example, the results have been rounded up to the next full kit. For other sizes, the factor for double layers may be determined as follows:

Double-Layer Adhesive Factor = [(2 x area of insulation vessel or tank) + area of two adjacent block edges calculated from total insulation thickness] area of insulation vessel or tank s PITTSEAL 444N SEALANT/ PITTSEAL 727 SEALANT To estimate sealant, first determine whether the application will include block or pipe cover. FOAMGLAS insulation block For single-layer block applications, the amount of sealant needed to seal the joints full depth is calculated as follows: Gallons of sealant/100 ft2 of insulation area = (area of two adjacent sides single block area) x 100 12.8a
a

Coverage rate for sealant at 1/2" thick film

Table 3 contains factors for calculating the amount of sealant needed per 100ft2 of insulation, excluding losses. EXAMPLE 3: The amount PITTSEAL 444N sealant required to seal FOAMGLAS insulation on a 25'-diameter 20'-tall vertical tank (area

1,570 ft2) insulated with 12" x 24" x 2" FOAMGLAS insulation block; Factor from Table 3 = 1.9 gallons per 100ft2 1.9 x (1570 100) = 1.9 x 15.7 = 29.8 gallons = 30 gallons. Since pails contain 5 gallons, (30 gallons 5 gallons/pail) = 6 pails FOAMGLAS INSULATION PIPE COVER Estimating sealant for pipe covering is more complicated because of the large variance in sealant area as a function of pipe diameter, covering diameter and number of insulation segments. For pipe diameters of 10" and less, two segments are typical per pipecover section. Table 4 illustrates the typical number of insulation segments for given pipe diameters. To ensure accuracy, the fabricator should be contacted to verify the number of segments/section they will supply.

TABLE 3 Sealant Estimating, Full Joint (1/2" film) (Gallons of Sealant per 100ft2 of Insulation block)
Block (Inch) 12 12 12 18 x x x x 12 18 24 24 Block Thickness (Inches) 11/2 1.9 1.6 1.5 1.1 2.0 2.6 2.2 1.9 1.5 21/2 3.3 2.7 2.4 1.9 3.0 3.9 3.3 2.9 2.3 31/2 4.6 3.8 3.4 2.7 4.0 5.2 4.3 3.9 3.0 41/2 5.9 4.9 4.4 3.4 5.0 6.5 5.4 4.9 3.8 51/2 7.1 6.0 5.4 4.2 6 7.8 6.5 5.9 4.6

TABLE 4 Segmental Pipe Covering # of Segments

NPS Pipe 1.5 11 2 12 2 14 5 16 5 17 5 18 6 Cover Thickness 2 2.5 3 3.5 2 2 2 2 2 2 2 5 5 5 5 6 5 5 6 6 6 6 6 6 6 6 6 6 4 6 6 6 6 7 6 NPS Pipe 1.5 19 6 20 6 21 7 22 7 23 7 24 8 Cover Thickness 2 2.5 3 3.5 7 7 7 7 7 7 7 7 7 7 7 8 7 7 8 8 7 8 8 8 8 8 8 8 4 7 8 8 8 9 9

Each section of pipe cover has longitudinal and butt joint areas. Calculation of the amount of sealant needed is as follows: Longitudinal Joint Area, ft2 = [N x t x length of pipe (ft)]12 Where N = number of segments and t = actual insulation thickness (inches) Butt Joint Area, ft2 = [0.7854 (D2 d2)]144 x [(length of pipe in ft +1)B] Where D = outside diameter of pipe covering in inches d = actual outer diameter of pipe in inches B = 2 for 24" pipe cover lengths 1.5 for 18" pipe cover lengths 1 is factored in for the last joint

Amount of sealant then is the sum of the longitudinal area and the butt joint area divided by 12.8 ft2 /gal (the sealant coverage) EXAMPLE 4 The amount of sealant required for 100 lineal feet of 4" pipe insulated with 3" thick FOAMGLAS insulation pipe cover. Use information from Table 4 in this newsletter and from Pipe Insulation Dimensional Standards (English), which is on Page 19 in our product literature (FI-201) titled, FOAMGLAS INSULATION SYSTEMS FOR INDUSTRIAL APPLICATIONS WITH TEMPERATURES OF-450 F TO +900 F (-268 C TO +482 C). You can also view this literature on the Web at www.foamglasinsulation.com/FI201.pdf. D = 10.75, d = 4.5, t = 3.11, N = 2 , B = 2 Longitudinal area = (N x t x l) 12 = (2 x 3.11 x 100) 12 = 51.8 ft2 Butt area = [0.7854(10.75)2 (4.5)2] 144 x (1012) = 33.4 ft2 Total area = 51.8 ft2 + 33.4 ft2 = 85.2 ft2 Gallons of sealant = 85.2 12.8 = 6.7 (not including losses)

To determine the amount of 10 fl. oz. tubes needed multiply the number of gallons by 12.8. In Example 4 for instance, 6.7 gallons x 12.8 tubes/gallon = 85.8 tubes = 86 tubes excluding losses or roughly 7 cases + 2 tubes. Also worth noting is the requirement for PITTSEAL 444N sealant with PITTWRAP SS jacketing, PITTWRAP CW Plus jacketing or PITTWRAP CW30 jacketing. A bead of the sealant is required along the edge of longitudinal joint where the butt strip will start. Past experience has indicated that a 10-oz. tube of PITTSEAL 444N sealant will be sufficient for every 200 lineal feet of jacketing. s PITTCOTE 404 COATING To estimate the amount of PITTCOTE 404 coating needed for a project, simply multiply the area by the coverage. For PITTCOTE 404 coating, the coverage rate varies from 6 to 8 gallons per 100 ft2 for two coats, depending on applicator and the grade. Normally for estimating purposes, a coverage rate of 6 gallons per 100ft2 is used along with a loss factor ranging from 10% to 25%. The following formula may be used: Gallons of PITTCOTE 404 coating = (A 100) x C x F Where A = area to be coated in ft2, C = the coverage rate (6 gallons/100 ft2) F = correction for losses (1.1 for 10%, 1.2 for 20%, 1.25 for 25% etc.)

EXAMPLE 5 Calculate the amount of PITTCOTE 404 coating needed to coat a 90-diameter sphere insulated with 4"-thick FOAMGLAS insulation, allowing for 20% loss. Surface area (A)= 4r2 = 12.5664 x [45 + (412)]2 =25,825 ft2 Gallons of PITTCOTE 404 coating = 25,825100 x 6 x 1.2 = 1,859 gallons. s CONCLUSION As stated previously, estimating accessories for insulation is a difficult job because of the many variables. The information contained above can serve as a general guide. In most cases the examples given do not attempt to correct for on-the-job losses, since different conditions and work habits will affect the amount of losses. The best teacher in this case will be previous experience. For more information about estimating for accessory products or about the benefits of FOAMGLAS insulation, contact your Pittsburgh Corning representative.

PITTSBURGH CORNING
800 Presque Isle Drive Pittsburgh, PA 15239, U.S.A. Tel: 724-327-6100 1-800-359-8433 Fax: 724-325-9704 2003 Pittsburgh Corning Corporation FI-PC/TN31 14M 01/04 Printed in U.S.A.

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