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CONTENTS PAGE
1.0 SCOPE 2
3.0 DEFINITIONS 2
4.0 REQUIREMENTS 3
4.1 General 3
4.2 Materials 4
4.3 Insulation system 7
4.4 Construction 7
4.5 Design 7
5.1 Sampling 9
7.1 Marking 11
7.2 Packing 11
7.3 Transport 11
7.4 Storage 11
7.5 Training 12
1.0 SCOPE
This specification details the requirements for the thermal insulation of chilled water pipes including
flanges, valves and other fittings installed underground, and covers pre-insulation on surface and
in-situ applications underground.
3.0 DEFINITIONS
S : British Standard
PE : Polyethylene
4.0 REQUIREMENTS
4.1 General
Insulation produced by the chemical reaction of two or more components, which during the
chemical action produce a water vapour or contain an acid shall not be injected or cast into a closed
void.
Insulation produced by the chemical reaction of two or more constituents, one of which is an acid,
shall not be used as slab stock in voids which have metallic walls unless a vapour barrier covers the
insulation.
The Data Sheet in Appendix C shall be completed and submitted with the tender. If the Data Sheet
is not supplied the tender will be disqualified.
ANGLOGOLD ASHANTI SPECIFICATION
4.2 Materials
4.2.1 Protective cover: A protective cover (made of either UPVC, stainless steel, galvanised steel or
rockshield reinforced cloth) shall be located on the external surface of the insulation systems and
shall comply with the requirements specified in Table 1.
1 2 3
MATERIAL REQUIREMENTS TEST METHOD
UPVC UL 214 CSIR Test
1. Thickness 3.2 mm and non-combustible
(See note below) Method, Modified
2. Comply with AECI Specification No.
130/S/03 or Approved equivalent
4. UPVC sleeves shall be colour coded blue
Steel (Grade 430
Minimum thickness 0.3 mm
stainless steel)
Minimum thickness 0.8 mm for pipes installed
Steel (hot dip in shafts (Grade Z600).
SABS ISO 4998
galvanised) Minimum thickness 0.5 mm for pipes installed
in haulages (Grade Z275)
1. 50% linear LDPE / 50% Polypropyleyne
Rockshield reinforced cloth UL 214 CSIR Test
reinforced cloth 2. Flame retardant added Method, Modified.
3. Minimum thickness 0.8 mm
Note: Where uPVC or rockshield covered piping is routed closer than 6.0 m from
fuelling bays oil stores, conveyor belts, oil-filled transformers and switchgear,
timber supports, etc, external steel cladding shall be applied, see AngloGold Ashanti
Drawing No. Y1903.
The combination of an UPVC cover and phenolic foam or nitrile rubber insulation is
not acceptable as the toxicity index exceeds 5.
ANGLOGOLD ASHANTI SPECIFICATION
4.2.2 Water vapour barrier: The water vapour barrier shall comply with the requirements specified in
Table 2.
1 2 3
PROPERTY/
REQUIREMENTS TEST METHOD
MATERIAL
1. 0.0 g maximum per m²/24 h at 38°C dry
bulb ± 2 % and 90 % ± 5 % R.H.
Water vapour 2. The vapour barrier shall cover the entire
transmission (includes insulation section from all sides and be
ASTM E96
bonding/sealing thermally sealed along the seam and not
compounds) glued.
3. Minimum width of thermal seal shall be at
least 6 mm.
SABS 952 – 1985
Tensile strength Not less than 2.24 N/mm
Subsection 5.6
To breaking point
SABS 952 - 1985
Elongation In machine direction – not less than 30 %
Subsection 5.6
In cross direction – not less than 22 %
SABS 952 – 1985
Joint seal (if applicable) Breaking strength – not less than 1.6 N/mm
Subsection 5.6
In machine direction – not less than 1 120
mN/sheet
BS 782, Part 3,
Tear strength
In cross direction – not less than 1 870 Method 360B
mN/sheet
Note: Foam glass and nitrile rubber insulation do not require a vapour barrier as these materials
have a closed cell structure and are not affected when in contact with water.
ANGLOGOLD ASHANTI SPECIFICATION
4.2.3 Insulation: The insulation shall comply with the requirements specified in Table 3
1 2 3
PROPERTY/
REQUIREMENTS TEST METHOD
MATERIAL
UL 214 CSIR Test
Combustibility Pass
Method, modified
Phenolic foam:--------------------0.022 W/m°C
Rock wool:-------------------------0.035 W/m°C ASTM C177 (read
Maximum thermal
Foam Glass (T4):----------------0.039 W/m°C in conjunction with
conductivity at 10°C
Nitrile rubber:----------------------0.040 W/m°C ASTM C518)
Polyethylene foam:--------------0.048 W/m°C
Phenolic foam:-------------------- 60 kg/m3
Rock wool:-------------------------160 kg/m3
Density (allowing a 5%
Foam Glass (T4):----------------120 kg/m3 SABS Method 79
tolerance)
Nitrile rubber(superlon):--------- 77 kg/m3
Polyethylene foam:----------------40 kg/m3
Water vapour For insulation systems that do not use a water
transmission (includes vapour barrier: a maximum of 0.05 g per
ASTM E96
bonding/sealing m²/24 h at 32°C dry bulb ± 2 % and 90 % ± 5
compounds) % R.H.
Note: Any insulation, which physically or chemically decomposes when in contact with
water must be covered with a water vapour barrier.
ANGLOGOLD ASHANTI SPECIFICATION
The insulation system shall comply with the requirements specified in Table 4.
1 2 3
PROPERTY/
REQUIREMENTS TEST METHOD
MATERIAL
SABS Method T1 /
Toxicity index = 5 maximum
NES 713;
Flame spread = pass
CSIR Boutek, Fire
For the complete
Engineering
system as installed
Sciences full scale
(Insulation / water
test
vapour barrier / joint Smoke production max index = pass
CSIR Boutek, Fire
seal / cover)
Engineering
Sciences small
Smouldering combustion = not allowed
scale test
Minimum thickness of
insulation based on Phenolic foam:--------------------15 mm
insulation properties in Rock wool:-------------------------20 mm
SABS approved
table 3, allowable heat Foamglass:------------------------25 mm
measuring tape
gains in Table 6 and Nitrile rubber (Superlon):-------25 mm
conditions specified in Polyethylene foam:--------------30 mm
Table 5
Thermal conductivity As given in table 3 ASTM C177
Note: The overall length of insulation system on pre-insulated pipes shall allow adequate access
to flange bolt holes to prevent damage during bolt on/off action.
4.4 Construction
4.4.1 Insulant: The insulation shall be homogenous, free of voids and shall occupy all cavities with.
4.4.2 Water vapour protection: Water vapour protection of the insulation shall be such that the
insulation is encapsulated in a material which complies with the requirements of a water vapour
barrier detailed in Table 2. Where this material is joined, it shall be thermally sealed and not glued.
4.4.2 Products of organic nature: Polyurethane or polystyrene-based materials shall not be used.
4.5 Design
The Contractor shall provide dimensioned drawings, completed data sheet (as given in appendix C)
and certified test certificates (as required by this specification) with his tender.
The Contractor shall also provide for Approval, the methods and materials to be used for fixing in-
situ type insulation to the pipes.
ANGLOGOLD ASHANTI SPECIFICATION
4.5.1 Calculations: The parameters detailed in Table 5 shall be used for design purposes.
1 2
PARAMETER VALUES
Water velocity 1 m/s
Water temperature 5°C
Pipe diameter range 100 mm – 300 mm
Pipe wall thickness 6 mm
Pipe thermal conductivity 45 W/m°C (mild steel)
Air temperature 32°C dry bulb
Air velocity 5 m/s
Note: If pipes of different thermal conductivity pipe diameter and wall thickness are
used, this shall be specified by the company.
4.5.2 Design performance requirements: The maximum heat gain per linear metre of insulated pipe
shall not exceed the value given in Table 6.
Note: The value given is for the combined insulating value of pipe wall, vapour barrier and sleeve
and is based on a dry clean sleeve outer surface.
1 2 3
PIPE : NOMINAL SIZE HEAT GAIN
TEST METHOD
(mm) (W/linear m)
100 17
150 25
200 32 See Clause 6.1.2 of
250 39 this specification
300 45
ANGLOGOLD ASHANTI SPECIFICATION
4.5.3 Designed maximum outside diameter: The designed maximum diameter of the insulation shall
comply with the requirements of Table 7.
1 2
NOMINAL STEEL PIPE SIZE INSULATIONS SYSTEM OUTSIDE
(mm) DIAMETER (mm)
100 225
150 290
200 350
250 420
300 470
1 2
INSULATIONS SYSTEM OUTSIDE
NOMINAL uPVC PIPE SIZE (mm)
DIAMETER (mm)
OD ID
105 88.6 216
155 130.8 266
210 177.2 321
250 211.0 361
5.1 Sampling
Sampling for type testing shall be as determined by the AngloGold Ashanti Manager Occupational
Environment.
Sampling for production testing shall be in accordance with the requirements detailed in the
Approved Quality Plan.
6.1.1 Full scale fire test (CSIR Boutek, Fire Engineering Sciences): Full-scale pipe insulation tests
shall be performed on two 200 mm diameter insulated pipes complete with vapour barriers, bonding
and external protective cover. The pipes shall be installed in parallel.
ANGLOGOLD ASHANTI SPECIFICATION
Production tests shall be performed on samples as detailed in the Quality Plan and at the frequency
specified in Table 8.
1 2 3
DEFECTIVE
LOT SIZE SAMPLE SIZE
ACCEPTABLE
Up to and including 25 3 0
26 – 50 5 0
51 - 150 8 0
Extracted from BS 6001 AQL 6.5)
6.2.1 Small scale flame spread: Combustibility shall be tested in accordance with the requirements of
UL 214 CSIR Method, Modified.
6.2.2 Toxicity: Toxicity shall be tested in accordance with the requirements of SABS Method T1 (NES
713).
6.2.3 Conductivity: The conductivity of a sample of the insulation shall be tested according to ASTM
C177.
6.2.4 Water vapour transmission: The water vapour transmission values of the water vapour barrier
shall be tested according to ASTM E96.
6.2.5 Tensile strength: The tensile strength shall be tested in accordance with SABS 952-1985 –
subsection 5.6.
6.2.6 Elongation: The elongation shall be tested in accordance with SABS 952-1985 – Subsection 5.6.
6.2.7 Joint heat seal breaking strength: The joint heat seal breaking strength shall be tested in
accordance with SABS 952-1985 – Subsection 5.6.
6.2.8 Tear strength: The tear strength shall be tested in accordance with BS 2782, Part 3, Method
360B.
6.2.9 Mass: The mass shall be tested in accordance with SABS Method 79.
6.2.10 Thickness: The thickness shall be tested in accordance with SABS 952-1985 – Subsection 5.6.
6.2.11 Density of insulant: Remove a cube from an insulated pipe and determine its mass. Calculate
the volume of the cube and determine the density of the insulant by dividing the mass by the
volume. Express the result in kg/m³. The result shall comply with the requirements of Table 3.
6.2.12 Thickness of insulant: The thickness of the insulant shall be measured prior to encapsulation in
the vapour barrier and outside protective sleeve for in-situ type insulation.
ANGLOGOLD ASHANTI SPECIFICATION
For pre-insulated pipes, the circumference of the pipe and the outside circumference of the
protective sleeve of the insulated pipe shall be measured.
The following tests are required per batch of insulation / insulation system produced:
If any of these tests do not pass the specifications, then the batch shall be rejected. When the
insulation is delivered, a batch certificate with acceptable test results, shall be provided to
AngloGold Ashanti before payment can be made. The batch number shall be clearly and
permanently marked on the insulation. The batch number shall give the date of manufacture and
the run number.
7.1 Marking
The outer surface of all insulation sections and the water vapour barrier shall be marked with the
following information:
7.2 Packing
Packing shall provide protection during transit from the place of manufacture to the underground
installation site. All insulation sections which have water vapour barriers, shall be contained in a
reinforced bag which will prevent damage during transit.
7.3 Transport
Transport, loading and unloading shall be performed in a manner which will prevent any damage to
the insulation system.
7.4 Storage
Pipes shall be stored so that damage to the insulation system by mechanical means or by adverse
weather conditions is prevented.
ANGLOGOLD ASHANTI SPECIFICATION
7.5 Training
Awareness training shall be given for the transportation, storage, installation and maintenance of
the insulation system offered, by the Contractor.
ANGLOGOLD ASHANTI SPECIFICATION
The latest issues of the following documents shall be deemed to form part of this specification:
ASTM C177 : Test method of steady-state heat flux measurements and thermal
transmission properties by means of guarded-hot-plate apparatus
AngloGold Ashanti QSP 101 : Quality requirements for minor products and standard stock
consumable items
BS 782 Part 3 Method 360B : Determination of tear strength of sheet and sheeting
NES 713 (Royal Navy) : Determination of the toxicity index of the products of
Combustion from shall specimens of materials
UL 214 CSIR Method Modified : Fire testing of materials, components and elements
ANGLOGOLD ASHANTI SPECIFICATION
1 2 3 4
SUPPLIER
COMPONENT REQUIREMENTS TEST METHOD CONFORMANCE
Yes or No?
1. UL 214
CSIR Test
As per table 1 of Spec 412/10 Method,
Protective Cover
Issue 4 modified
2. SABS ISO
4998
1. ASTM E96
2. UL 214
Water vapour As per table 2 of Spec 412/10
CSIR Test
barrier Issue 4
Method,
modified
1. UL 214
CSIR Test
Method,
modified
2. ASTM C177
As per table 3 of Spec 412/10 (in
Insulation
Issue 4 conjunction
with ASTM
C518)
3. ASTM E96
4. SABS
Method 79
1. SABS
Method T1 /
NES 713
Insulation As per table 4 of Spec 412/10 2. CSIR, Full
System Issue 4 scale fire
test
3. CSIR, Small
scale test
1. SABS
approved
As per table 7 of Spec 412/10
Installed sizes measuring
Issue 4
tape