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ULTIMATETM Protect The formula for efficient fire insulation of ventilation ducts
Produced with the glass wool technology of Saint-Gobain Isover, ULTIMATETM Protect is an innovative new generation mineral wool that combines all the advantages of conventional thermal and acoustic insulation with top level fire protection . The ULTIMATETM Protect product range, also known as U Protect, consists of slab and wired mat solutions, offering up to two hours fire protection for both vertical and horizontal applications of rectangular and circular ductwork systems .
U Protect Wired mat 4 .0 Alu 1 U Protect Wired mat 4 .0 Alu 1 75mm 120mm
Order code: 5200432184 Order code: 5200432186
For help choosing the right thickness for the job, please refer to the installation detail section of this document (page 11) .
ultimAtETM AccESSoriES
Fireprotect screws 140mm length, box of 500 Protect BSK Adhesive 15kg tub 310ml tube Fireprotect screws 200mm length, box of 200 Protect BSF Intumescent Paint 15kg tub 310ml tube
Contents
ULTIMATETM Protect - The formula for efficient fire insulation of ventilation ducts . . . . . . . . . . . . . . . . . 4 ULTIMATETM Protect - Specification Detail . . . . . . . . . . . . . . . . . . . . 5 Effective fire protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Ease of installation & fast installation . . . . . . . . . . . . . . . .8 Cost-effective solution & thin solutions . . . . . . . . . . . . . .9 Lightweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Excellent thermal insulation performance . . . . . . . . . . 10 Optimal acoustic performance . . . . . . . . . . . . . . . . . . . . . 10 ULTIMATETM Protect - Installation Detail . . . . . . . . . . . . . . . . . . . . 11 Before you start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Criteria for preparation of rectangular ductwork prior to insulating . . . . . . . . . . . . . . . . . . . . . . . 18 Criteria for preparation of circular ductwork prior to insulating . . . . . . . . . . . . . . . . . . . . . . . 22
ULTIMATETM Protect The formula for efficient fire insulation of ventilation ducts
U Protect comes with a unique high-performance profile . It combines top level fire resistance; easy handling and low pack weight . An all-in-one solution to meet your demands .
+
EASE of inStAllAtion
Excellent manageability ensures that cutting, bending and fitting is faster and more efficient . The U Protect wired mat range is specifically designed for easy installation on circular ductwork .
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lightWEight
65% lighter than conventional stone wool products, U Protect makes light work of installation and its low pack weight meets the most stringent of workplace Health and Safety standards .
65%
up to
Ease of installation
Lightweight
Fire outside the duct Duct orientation Horizontal Vertical Duct shape Rectangular Circular
Ducts which normally serve one floor of a building . Ducts which normally serve between floors of a building .
Rectangular shape of the metal duct . Circular shape of the metal duct .
EuroclASS hArmoniSAtion
U Protect achieves Euroclass A1 rating fire classification for product with non combustibility . Euroclass is a harmonised European classification system for products, measuring their reaction to fire and is intended to replace existing national standards, such as British Standards . This is now commonly accepted in England, Scotland and Wales . The classification levels are A1, A2, B, C, D, E and F . A1 corresponds to the safest situation, E would be the most dangerous situation and F would mean not classified .
rEAction to firE
common materials and likely Euroclass Euroclass A1 & A2 B C D E F Flashover potential No No Yes 10 minutes Yes 2-10 minutes Yes < 2 minutes Yes Early Failure or no data Example materials Glass and stone mineral wool, concrete, brick and plasterboard Typically timber products Phenolic foam (foil faced) Expanded polystyrene type A polyisocyanurate foam (foil faced) extruded polystyrene Polyurethane foam (laminate faced) Polyisocyanurate foam (sprayed) Expanded polystyrene type N Untested or fails Euroclass E
One of the most important issues studied under reaction to fire performance is the potential for flashover to occur - the spontaneous ignition of hot smoke, gases and fuel which can lead to a fire spreading uncontrollably .
clASS o compliAncE
Class O compliance can refer to Surface Spread of Flame or non-combustibility of a product . This refers only to the surface properties of a product and BS 476: Parts 6 and 7 need to be satisfied . ULTIMATETM Protect range has a Class O foil and passes both these tests . ULTIMATETM Protect system also complies with BS 476: Part 4 (non-combustibility test) . This is a measure of the combustibility or reaction to fire of the product . ULTIMATETM Protect exceeds all standards proving its excellent fire credentials .
Ease of installation
&
Fast installation
Ultra-light and adaptable, ULTIMATETM Protect range makes cutting, bending or filling, faster and more efficient than ever . U Protect perfectly adapts to all conditions saving on the time-consuming work of encasing or the cost of expensive prefabrication . Installation of U Protect can be done with almost no waste: Its pliable structure prevents it from breaking and off-cuts optimally fill niches and holes . Up to 50% quicker installation time than traditional solutions Easy to cut with a standard laggers knife Robust and stable Off-cuts can be used so virtually waste free Flexible shaping No edge breaks No need for adhesive on joints Easy to handle - lightweight No need to insulate drop rods separately*
* exception - refer to joint detail of circular duct (pg 23)
Nothing of substance has been introduced into the ductwork fire protection market for over twenty years. U Protect changes all that as its the first product thats actually user friendly and a joy to work with! Daniel Crawley, Crawley Insulations Ltd ., Kent
Crawley
I N S U L AT I O N S L I M I T E D
The Worlds Leading Acoustic and Thermal Insulation
50%
up to
Cost-effective solution
&
Thin solutions
The ULTIMATETM Protect range pays off even before the ventilation system is put into operation . Thanks to compressed packaging, the logistics including intermediate storage on site can be managed without any problems, even for larger projects . And the installation is not only done faster but also at drastically reduced material cost: No need for expensive prefabrication No glue needed except for at wall penetrations No edge breaks but higher insulation efficiency achieved with extremely low thicknesses .
Your advantages Easier and faster to install Shorter installation time, less waste Time and material saving (one layer instead of two)
Lightest product solution available in the market Flexible and timesaving Innovative, high-performance product
Lightweight
perfectly safe and secure. With ultimAtETM protect on duty.
U Protect combines peak performance in fire protection and thermal insulation with extreme light weight installation . Up to 65% lighter than conventional thermal, acoustic and fire insulation products, U Protect sets totally new standards .
With U Protect you are not only on the safe side of handling: the low pack weight and grip-friendly touch also meet the most stringent standards lighter than for Health and Safety in the workplace . traditional stone wool
65%
up to
25%
10
50%
up to
Inside
Rectangular duct
Outside
Inside
Circular duct
Outside
Commercially available thicknesses are currently in increments of 10mm with exception of 75mm wired mat .
The Worlds Leading Acoustic and Thermal Insulation
11
pin optionS
Stud welded If the screwed pins are selected, these are either; Self-drilling pins (e .g . LENNE IBS1 self-drilling screw pins) or Pins that include a steel base plate which fastens to the duct (minimum of two M4 steel self-drilling/self-tapping screws or two M4 steel rivets, e .g . Big head M5/B23 studs)
NB:
12
Exception - For an insulation thickness of 90mm, additional pins are provided on the underside of horizontal ducts . The maximum spacing of the pins along the length of the boards is reduced from 320mm to 250mm
13
For rectangular vertical ducts, apply the largest board to the longest side leaving an overlap equivalent to the thickness of the U Protect slab, on either side of the duct Repeat for the other side, then place the smaller boards between the overlaps created from the first two steps
14
Installation procedure
c. complEtE WAll / floor pEnEtrAtionS 5 StEpS to inStAllAtion
The installation through the construction is done in 5 steps . The same general principle is used for both rectangular and circular ducts regardless of orientation . Step 1: Positioning Place the duct in the penetration of the construction, with a 50mm gap between the duct wall and opening A stiffener (steel tube) should be fitted to the duct where the duct passes through the penetration NB: Stiffeners are not used with circular ducts Step 2: Insulation Using the same insulation used for the rest of the duct, fully pack the space between the duct and partition . Ensure tight compression in order to completely fill the opening
Step 3: Sealing Using a spatula apply a ~2mm thick layer of Isover Protect BSF to BOTH sides of the construction, to seal the joint
<
15
Step 4a: Reinforcing a rectangular duct Fix an L-profile (30x30x3) around the duct on both sides of the construction with steel rivets Using two steel screws for each side ensure the top and bottom profiles are fixed to the construction
Step 4b: Reinforcing a circular duct Steps 1-3 are completed using U Protect wired Mat Screw a suspension bracket (30mmx2mm) to the duct on both sides of the construction Fix long L-profiles (30mmx30mmx3mm) above and below the bracket with one rivet each (4mmx13mm) Fix short L-profiles (30mmx30mmx3mm) are fixed with nuts and bolts (M8) to the bracket eye
Step 5: Duct insulation Glue the ends of the insulation to the construction using Isover Protect BSK (thickness ~2mm) Install the insulation so that it is adjacent and tightly fitted against the penetration . The insulation must be cut leaving excess length, so that it exerts some pressure between the penetration and the last fitted piece of insulation This applies to both rectangular and circular ducts
16
No glue or pins Top slab covering side slabs Firescrews Welded pins
ULTIMATETM Protect insulation slabs need to be cut to fit the duct as tightly as possible, the insulation may need to be cut to fit around flanged duct joints (see left)
17
ShEEt thicknESS
Maximum size of duct longer side Up to 1250mm Up to 1500mm Up to 2000mm Thickness of steel sheet 0 .7mm 0 .8mm 1 .0mm
18
flAngES
As per HVCA Specification DW144, typically use J3 and above at maximum 1250mm centres At each cross joint Lindab flanges or equivalent, (minimum size 30mmx30mmx1 .2mm thick) are fastened to the duct with spot welds at 150mm nominal centres The Lindab flanges are fitted with steel corner plates, (minimum 95mmx95mmx2 .5mm thick), slot these into the flanges at each corner and bolt them together with an M10 steel nut and bolt at each corner Fasten the flanges together with 40mm steel clamps at 265mm maximum centres Use a ceramic tape gasket (20mm wide x 3mm thick) between the flanges to seal the joints . See Figure 3 below
19
StiffEnErS
Attach steel stiffeners at a 90 angle to any side of the duct section where the width or depth exceeds 500mm . Position these at mid-width/depth and mid-length in each duct section . Each stiffener should consist of a steel tube (16mm diameter x 2mm thick) The stiffeners are fastened to duct walls with a steel washer of the same size, on the outside of the duct wall Fasten the stiffeners to the washer 72mm diameter x 1mm thick, on the inside with M6 steel bolts See Figure 4 .
20
21
ShEEt thicknESS
Maximum diameter of duct Up to 1000mm Up to 1250mm Thickness of steel sheet 0 .7mm 1 .0mm
N.B: The spacing of the hangers and the size of the steel hanger components must be adjusted so that the tensile stress in the rods and the bands does not exceed 15N/mm2 for fire resistance periods up to 60 minutes and 10N/mm2 for fire resistance periods up to 120 minutes.
22
JointS
As per HVCA Specification DW144 . The spirally wound steel duct is constructed in sections up to 3000mm long using hot dipped galvanised steel sheet, mild steel sheet or stainless steel sheet, 0 .7mm thick . The spiral seam of the spirally wound ducts must be the grooved seam, as tested At each cross joint Lindab NPU steel sleeves (or equivalent), minimum size 100mm wide x 1 .2mm thick, fasten minimum M4 steel self-tapping screws to the duct at 150mm centres on both sides of the joint Fit a sealing strip of EPDM rubber and a ceramic tape gasket, 15mm wide x 3mm thick, between the sleeve and the duct, on both sides of the joint, to seal the joints
StiffEnErS
Where 120 minutes of fire resistance is required for steel ducts, 40mmx5mm steel flanges should be positioned approx 10mm from each duct connection .
or for technical advice or a full list of suggested ULTIMATETM contractors please email:
Saint-Gobain Isover UK Commercial Centre Gotham Business Park Leake Road Gotham Nottinghamshire NG11 0LB Tel: +44 (0) 115 969 8010 Fax: +44 (0) 115 983 1675 www .isover .co .uk