Prestige Projects

Project: Burj Al Arab Hotel, Jumeirah Beach, Dubai

Engineer: W S Atkins
Insulation Contractor: B K Gulf
Products: Kingspan Kooltherm® Pipe Insulation
Kingspan Kooltherm® Duct Insulation
Kingspan Kooltherm® Insulated Pipe Support Inserts
Volume: Kingspan Kooltherm® Pipe Insulation: >100,000 linear metres
Kingspan Kooltherm® Duct Insulation: >90,000 m2
Kingspan Kooltherm® Insulated Pipe Support Inserts: >30,000 no.
Insulation Material Value: $1.2M (US)

10
Project: Hong Kong International Airport
Architect: Foster and Partners
Consulting Engineer: Mott McDonald
Insulation Contractor: YDS
Products: Kingspan Kooltherm® Pipe Insulation
Kingspan Kooltherm® Insulated Pipe Support Inserts
Volume: Kingspan Kooltherm® Pipe Insulation: 2,700 m3
Kingspan Kooltherm® Insulated Pipe Support Inserts: 45,000 no.
Contact Value: $10,000,000 (HK)

11
 Kingspan Kooltherm® Thermal Insulation System

THE KINGSPAN KOOLTHERM® PIPE KINGSPAN KOOLTHERM® INSULATED PIPE

INSULATION SYSTEM
KINGSPAN KOOLTHERM® PIPE INSULATION
Kingspan Kooltherm® and Kingspan Kooltherm® zero
ODP Pipe Insulation comprise one metre long sections
of pre–formed, Kingspan Kooltherm®/Kingspan
Kooltherm® zero ODP rigid phenolic insulation faced
with a factory applied reinforced aluminium foil
vapour barrier jacket. They are available to suit a full
range of pipe diameters and in a full range of
insulation thicknesses. They may be used on mild
steel, stainless steel, copper and plastic pipework
operating in the temperature range of –180°C to
+120°C.
SUPPORT INSERTS
Kingspan Kooltherm® Insulated Pipe Support Inserts
are designed to be used in pipe hanger brackets and
will support the compressive loads imposed by
horizontal pipework carrying water or other liquids.
Their use enables the specified thickness of insulation
to be maintained at pipe supports. They also facilitate
the installation of a continuous and fully sealed vapour
barrier, which is particularly important on cold or
chilled pipework. Kingspan Kooltherm® Insulated Pipe
Support Inserts may be used to support mild steel,
stainless steel, copper and plastic pipework operating
in the temperature range of –180°C to +120°C.

Kingspan Kooltherm® Pipe Insulation is entirely

CFC–free. Kingspan Kooltherm® zero ODP Pipe
Insulation is entirely CFC/HCFC–free and exhibits
zero Ozone Depletion Potential (ODP). They are
available in the following densities:

● 35 kg/m3; and

● 60 kg/m3.

Please refer to Appendices A1 to A4 of the Project

Specification section of this document for product
data.

Pipe hanger

Longitudinal joint taped with

50 mm wide self-adhesive
aluminium foil tape

Kingspan Kooltherm®
Pipe Insulation

Kingspan Kooltherm® Insulated

Pipe Support Insert

12
Kingspan Kooltherm® Insulated Pipe Support Inserts
are available in the following densities:

● 60 kg/m3;

● 80 kg/m3;

● 120 kg/m3; and

● 160 kg/m3.

They are manufactured from Kingspan Kooltherm®

High–Density rigid phenolic insulation, which has an
air–filled open cellular structure. The density used
depends upon applied load.

Please refer to Appendix A7 of the Project

Specification section of this document for product
data.

KINGSPAN KOOLTHERM® COVERS

Site-fabricated bend Circumferential joint taped
with 50 mm wide
self-adhesive foil tape
50 mm wide self-adhesive
aluminium foil tape
Steel fabricated
Kingspan Kooltherm® Cover
KINGSPAN ALUMINIUM FOIL VAPOUR BARRIER
JACKET
All products in the Kingspan Kooltherm® Pipe
Insulation System have a factory–applied,
high–performance, reinforced aluminium foil vapour
barrier jacket – a resilient, protective,
low–permeability facing. The facing is
factory–applied so as to avoid site application, which
carries the risk of vapour barrier damage, and with it,
a risk to the integrity of the system. This also reduces
the labour cost for installation of the system.
A matching self–adhesive vapour barrier tape is
available to complete the vapour barrier at joints.
Kingspan Kooltherm® Covers and Kingspan
Kooltherm® zero ODP Covers complement Kingspan
Kooltherm® and Kingspan Kooltherm® zero ODP Pipe
Insulation. Together, they provide an efficient, safe,
and aesthetically pleasing finish to an insulated pipe
system. Kingspan Kooltherm® Covers and Kingspan
Kooltherm® zero ODP Covers provide an economical
answer to the criticisms of poor finish and inadequate
vapour seal often levelled at pipe insulation systems.
Kingspan Kooltherm® Covers and Kingspan Kooltherm®
zero ODP Covers can be site-fabricated from Kingspan
Kooltherm® Pipe Insulation or Kingspan Kooltherm® zero
ODP Pipe Insulation. Alternatively Kingspan Insulation
Ltd. supply factory manufactured Kingspan Kooltherm®
Covers and Kingspan Kooltherm® zero ODP Covers for
Gruvlok and Victaulic couplings.
The density of factory manufactured Kingspan Kooltherm®
Covers and factory manufactured Kingspan Kooltherm®
zero ODP Covers is 60 kg/m3. They are manufactured
from Kingspan Kooltherm® or Kingspan Kooltherm® zero
ODP rigid phenolic insulation. The wall thickness of
factory manufactured Kingspan Kooltherm® Covers and
factory manufactured Kingspan Kooltherm® zero ODP
Covers is 25 mm.
Please refer to Appendices A3 & A4 of the Project
Specification section of this document for product
data for factory manufactured Kingspan Kooltherm®
Covers and factory manufactured Kingspan Kooltherm®
zero ODP Covers.

Please refer to Appendix A8 of the Project

Specification section of this document for product
data.

13
 Kingspan Kooltherm® Thermal Insulation System
THE KINGSPAN KOOLTHERM® DUCT
INSULATION SYSTEM
KINGSPAN KOOLTHERM® DUCT INSULATION
Kingspan Kooltherm® Duct Insulation and Kingspan
Kooltherm® zero ODP Duct Insulation are faced with
reinforced aluminium foil as the outer facing and glass
tissue as the inner facing to their rigid phenolic
insulation core. The reinforced aluminium foil and
glass tissue facings are compatible with the types of
solvent–based general purpose adhesives normally
used for adhering insulation materials to ductwork.
Kingspan Kooltherm® Duct Insulation is entirely
CFC–free. Kingspan Kooltherm® zero ODP Duct
Insulation is entirely CFC/HCFC–free and exhibits
zero Ozone Depletion Potential (ODP).
The boards are available in the following sizes:
● 1,200 mm x 600 mm; and
● 2,400 mm x 1,200 mm.
Please refer to Appendices A5 & A6 of the Project
Specification section of this document for product data.
14
Kingspan Kooltherm® Rectangular Duct Support Inserts
are designed for use with air conditioning and
ventilation ductwork, where rectangular ductwork
support brackets have been specified. Their use
enables the specified thickness of insulation to be
maintained at duct supports and facilitates the
installation of a continuous and fully sealed vapour
barrier, which is particularly important on ductwork
carrying cold or chilled air.
The density of Kingspan Kooltherm® Rectangular Duct
Support Inserts is 60 kg/m3. They are manufactured
from flat strips of Kingspan Kooltherm® High–Density
rigid phenolic insulation, which has an air–filled open
cellular structure, fully adhered to a reinforced
aluminium foil vapour barrier. Kingspan Kooltherm®
Rectangular Duct Support Inserts are available in the
following dimensions:
● length – 1 metre;
● widths – 50 mm, 75 mm or 100 mm; and
● thicknesses – 20 mm and above in 5 mm
increments.
Please refer to Appendix A7 of the Project Specification
section of this document for product data.
Kingspan Kooltherm® Duct
Insulation or Kingspan Kooltherm®
zero ODP Duct Insulation
Joints sealed with 1
wide self-adhesive
foil tape
Kingspan Kooltherm® Pipe
Insulation or Kingspan Kooltherm®
zero ODP Pipe Insulation
Kingspan Kooltherm® Insulated
Duct Support Insert

Kingspan Kooltherm® Duct
Insulation or Kingspan Kooltherm®
zero ODP Duct Insulation
Kingspan Kooltherm®
Insulated Duct Support Insert
100 mm
aluminium
Joints sealed with 100 mm
wide self-adhesive aluminium
foil tape
Kingspan Kooltherm® Duct
Insulation or Kingspan
Kooltherm® zero ODP Duct
Insulation slotted to suit
circular ducting
KINGSPAN KOOLTHERM® CROCODILE STRIPS
(Insulated Circular Duct Support Inserts)
Kingspan Kooltherm® Crocodile Strips are designed
for use with circular air conditioning and ventilation
ductwork support brackets. Their use enables the
specified thickness of insulation to be maintained at
the duct support and facilitates the installation of a
continuous and fully sealed vapour barrier which is
particularly important on ductwork carrying cold or
chilled air. Crocodile Strips should not be used for
water filled pipes as they are not designed to
Joints sealed with 100 mm
wide self-adhesive withstand the loads applied by such.
aluminium foil tape
The density of Kingspan Kooltherm® Crocodile Strips
is 60 kg/m3. They are manufactured from segments
of Kingspan Kooltherm® High–Density rigid phenolic
insulation, which has an air–filled open cellular
structure, fully adhered to a reinforced aluminium foil
vapour barrier.
Please refer to Appendix A7 of the Project
Specification section of this document for product
data.
VAPOUR BARRIER JACKET
All products in the Kingspan Kooltherm® Duct
Insulation System have a factory–applied, high
performance, reinforced aluminium foil vapour barrier
jacket – a resilient, protective, low–permeability
facing. Being factory–applied avoids site application,
which carries a risk of vapour barrier damage,
and with it, a risk to the integrity of the system. This
also reduces the labour cost for installation of the
system. A matching foil self adhesive vapour barrier
tape is available to complete the vapour barrier at the
joints.
Please refer to Appendices A5, A6 & A8 of the
Project Specification section of this document for
product data.
Kingspan Kooltherm®
Crocodile Strip (Insulated
Circular Duct Support Insert)
NB: On circular ducting below 350 mm diameter use Kingspan
Kooltherm® Pipe Insulation / zero ODP Pipe Insulation and
Kingspan Kooltherm® Insulated Pipe Support Inserts
15
 Kingspan Kooltherm® Thermal Insulation System

KINGSPAN KOOLTHERM® RIGID Kingspan Kooltherm® and Kingspan Kooltherm® zero

PHENOLIC INSULATION ODP Duct Insulation are manufactured by a continuous
lamination process. All other products in the Kingspan
DESCRIPTION Kooltherm® Thermal Insulation System are cut from
Kingspan Kooltherm® rigid phenolic insulation is blocks of rigid phenolic insulation using modern
based on patented technology. Whilst retaining all the computer aided manufacturing techniques.
benefits of rigid polyurethane and rigid
polyisocyanurate insulation, Kingspan Kooltherm® rigid
phenolic insulation has far superior resistance to
burning and spread of flame and the lowest thermal
conductivity of any commonly available
insulant at 0.018 W/m.K.

Kingspan Kooltherm® High–Density rigid phenolic

insulation is used in the manufacture of ancillary
products in the Kingspan Kooltherm® Thermal
Insulation System. It’s heavier density gives it much
greater compression strength and rigidity whilst
retaining its far superior resistance to burning and
spread of flame, making it ideal for insulated pipe
and duct support inserts.

Kingspan Kooltherm® and Kingspan Kooltherm®

High–Density rigid phenolic insulation were developed
in 1982. Since then, they have gained a reputation for
quality and consistency, a reputation that has spread
world–wide since they were first exported in 1992.

TEMPERATURE RANGE
Kingspan Kooltherm® rigid phenolic insulation,
Kingspan Kooltherm® zero ODP rigid phenolic
insulation and Kingspan Kooltherm® High–Density
rigid phenolic insulation may be used for operating
temperatures from –180°C to +120°C.

MOISTURE RESISTANCE – CLOSED CELL

STRUCTURE
Kingspan Kooltherm® and Kingspan Kooltherm® zero
ODP rigid phenolic insulation have a greater than
90% closed cell structure, which makes them highly
resistant to moisture penetration and non–wicking.
They are ideal insulation materials for cold, chilled
and low–temperature hot water pipework.

Now, Kingspan Kooltherm® zero ODP rigid phenolic
insulation is available. In addition to all of the benefits of
standard Kingspan Kooltherm®, Kingspan Kooltherm®
zero ODP is entirely CFC/HCFC–free with zero Ozone
Depletion Potential (ODP). However, even with a slightly
higher thermal conductivity of 0.021 W/m.K, the
thicknesses required to meet BS 5422: 2001 are not
significantly different from CFC–free Kingspan
Kooltherm® rigid phenolic insulation.
16
INSULATION PERFORMANCE
Kingspan Kooltherm® and Kingspan Kooltherm® zero
ODP rigid phenolic insulation have a high closed cell
content and fine cell structure. The result is a thermal
conductivity of 0.018 W/m.K in the case of
Kingspan Kooltherm® and 0.021 W/m.K in the case
of Kingspan Kooltherm® zero ODP.
0.018 W/m.K is the lowest thermal conductivity of
any commonly available insulation material. A thinner
insulant often results in lower surface area and
therefore savings in finishing materials.
ENVIRONMENTAL PROPERTIES
In addition to its contributions to energy efficiency,
Kingspan Kooltherm® rigid phenolic insulation is
entirely CFC–free. Kingspan Kooltherm® zero ODP
rigid phenolic insulation is entirely CFC/HCFC–free
and exhibits zero Ozone Depletion Potential (ODP).
Kingspan Kooltherm® High–Density rigid phenolic
insulation has an air–filled open cellular structure.
They provide designers and specifiers with the
optimum solution to compliance with international
environmental agreements.

CHEMICAL RESISTANCE AND COMPATIBILITY

Kingspan Kooltherm® rigid phenolic insulation,
Kingspan Kooltherm® zero ODP rigid phenolic
insulation and Kingspan Kooltherm® High–Density
rigid phenolic insulation are resistant to a wide range
of oils, solvents and chemicals. They are compatible
with most solvent based coatings and adhesives, and
polyester and epoxy resin based coatings.
Kingspan Kooltherm® rigid phenolic insulation is Class
O to the Building Regulations and achieves a smoke
obscuration rating of less than 5% (classified as
negligible), when tested in accordance with
BS 5111: Part 1: 1974 (Laboratory methods of test
for determination of smoke generation characteristics
of cellular plastics and cellular rubber materials).

QUALITY ASSURANCE
Kingspan Kooltherm® rigid phenolic insulation,
Kingspan Kooltherm® zero ODP rigid phenolic
insulation and Kingspan Kooltherm® High–Density
rigid phenolic insulation are manufactured to the
highest quality standards under a quality control
system approved to BS EN ISO 9002: 1994
(Quality systems. Model for quality assurance in
production, installation and servicing).

TECHNICAL SERVICES

TECHNICAL DATA
For further comprehensive data on all of the
above–mentioned properties, please refer to
Appendices A1 to A8 of the Specification section of
this document.
HYGIENE
Kingspan Kooltherm® rigid phenolic insulation, TECHNICAL SUPPORT
Kingspan Kooltherm® zero ODP rigid phenolic Extensive support is available via Kingspan Insulation’s
insulation and Kingspan Kooltherm® High–Density Technical Services Department. Kingspan Insulation
rigid phenolic insulation are resistant to fungus and offers a huge wealth of project experience, supported
mould growth, will not sustain vermin, are by an in–house capability for carrying out all material
non–fibrous, odourless and non–tainting. thickness and heat loss/gain calculations. All quoted
performance data is based on accredited testing.
FIRE AND FIRE PERFORMANCE
The resistance to burning and spread of flame of
Kingspan Kooltherm®, Kingspan Kooltherm® zero ODP
and Kingspan Kooltherm® High–Density rigid phenolic
insulation is far superior to that of any other cellular
plastic insulation, regardless of facing type. In
addition, there is an almost complete absence of
smoke when subjected to a flame source.
17
 Issues to Consider
1 NEW BS 5422: 2001
1.1 A new revised version of BS 5422, BS 5422:
2001 (Method for specifying thermal insulating
materials for pipes, tanks, vessels, ductwork and
equipment operating within the temperature range
–40°C to +700°C), has been adopted. The old
version, BS 5422: 1990 (Method for specifying
thermal insulating materials on pipes, ductwork and
equipment (in the temperature range –40°C to
+700°C)), has been withdrawn. It is anticipated that
the new Standard will have a significant effect on the
insulation market.
1.2 Although the revision of BS 5422 was originally
stimulated by the need to modify it to comply
with BS EN ISO 12241: 1998 (Thermal insulation
for building equipment and industrial installations.
Calculation rules), so as to harmonise it with new
European and International calculation methods, the
opportunity has been taken to upgrade the standard
to promote the environmental benefits of the energy
saving achieved by its use. As part of the revision
the previous “economic insulation thickness”
tables have been revised and are now based on
“environmental thickness”.
1.3 BS 5422: 2001, however, is not just a standard
for energy conservation. It also covers the use of pipe
insulation for condensation control, frost protection
and personnel protection amongst others. The table
below indicates this fact, along with the tables and
annexes from BS 5422: 2001 that refer.
TABLES FROM BS 5422: 2001
Frost Condensation
Protection Control
Clause 6 2, 3, 4 & 5
(refrigeration) Ref. Annex E
Clause 7 7&8
(chilled & cold water)
Clause 8 10 (duct)
(central heating, air conditioning
ductwork and direct hot water
supply – non domestic)
Clause 9
(central heating and hot and cold
water services – domestic)
Clause 10
(process pipework and equipment)
Clause 11 22, 23, 24
(protection against freezing) & 25
18
1.4 Although “economic thickness” approaches are
still permissible, the focus of all energy–related tables
in the standard is now based on the consideration of
absolute energy usage and associated carbon
dioxide emissions. The resulting “environmental
thickness” tables offer for the first time an assurance
that energy savings for a given pipe diameter and
temperature will be equivalent, irrespective of the
insulation type selected.
1.5 This “environmental thickness” approach has
caused an overall increase in the insulation levels
stipulated for pipes over BS 5422: 1990
requirements. If these new levels were to be installed
in all existing pipe insulation applications across the
UK, they could account for up to a further 5 million
tonnes of CO2 savings per year.
1.6 The increase in stipulated levels has been
introduced with due consideration of cost/benefit and
practicality. The cost/benefit analysis has shown that
the incremental CO2 savings from pipe insulation
remain among the most cost–effective methods of
saving CO2 available to regulators.
1.7 All tables in BS 5422: 2001 are set out in a
standardised format requiring the following data in
order to use them effectively:
● application of pipe work (e.g.non–domestic
heating);
● operating temperature of pipe contents;
● size of pipe being insulated; and
● thermal conductivity of insulation being used
(at the mean operating temperature) in watts per
metre Kelvin (W/m.K).
Reasons for Insulating
Energy Conservation
Personnel Process
Protection Control Cost Saving Carbon Saving
(economic) (environmental)
Ref. Annex G Ref. Annex A
6
9 (chilled only)
11 (duct)
12 & 13
14
16, 17 & 18 19, 20 & 21 15
1.8 With this data, it is possible to use the tables to
determine the thickness of insulation required to meet
the standard. Examples of the thicknesses required by
BS 5422: 2001 are shown in the tables below.
More detail is given in the Tables in Appendix B of
the Project Specification section of this document.

ENVIRONMENTAL THICKNESS (mm) OF

INSULATION FOR CHILLED WATER SUPPLIES
(WATER AT 0°C) TO CONTROL HEAT GAIN
(Based on BS 5422: 2001 Table 9)

Steel Pipe Kingspan Kingspan Mineral Nitrile

Size Kooltherm® Kooltherm® Fibre Rubber
NB (mm) Zero ODP

15 15 15 32 43

25 15 20 38 50

80 25 30 57 71

ENVIRONMENTAL THICKNESS (mm) OF

INSULATION FOR CHILLED WATER SUPPLIES
(WATER AT 5°C) TO CONTROL HEAT GAIN
(Based on BS 5422: 2001 Table 9)

Steel Pipe Kingspan Kingspan Mineral Nitrile

Size Kooltherm® Kooltherm® Fibre Rubber
NB (mm) Zero ODP

15 15 15 27 36

25 15 15 31 40

80 20 25 44 54

ENVIRONMENTAL THICKNESS (mm) OF

INSULATION FOR NON-DOMESTIC HOT WATER ENVIRONMENTAL THICKNESS (mm) OF
(WATER AT 60°C) TO CONTROL HEAT LOSS INSULATION FOR DUCTWORK CARRYING WARM
(Based on BS 5422: 2001 Table 13) AIR TO CONTROL HEAT LOSS (Based on BS 5422:
Steel Pipe Kingspan Kingspan Mineral Nitrile 2001 Table 11)
Size Kooltherm® Kooltherm® Fibre Rubber
NB (mm) Zero ODP Temperature Kingspan Kingspan Mineral Nitrile
difference Kooltherm® Kooltherm® Fibre Rubber
15 15 15 29 33 between Zero ODP
25 15 20 33 37 air inside
ductwork and
80 25 25 41 45 ambient air
(°C)

10 20 20 34 38
ENVIRONMENTAL THICKNESS (mm) OF 25 25 30 44 50
INSULATION FOR NON–DOMESTIC HEATING
INSTALLATIONS (WATER AT 75°C) TO CONTROL
HEAT LOSS (Based on BS 5422: 2001 Table 12)

Steel Pipe Kingspan Kingspan Mineral Nitrile

Size Kooltherm® Kooltherm® Fibre Rubber
NB (mm) Zero ODP

15 15 15 30 34

25 15 20 34 38

80 25 25 40 44

19