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R APPLICATION MANUAL
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1 - General >> Working with Arma-Chek R APPLICATION MANUAL R
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WORKING WITH ARMA-CHEK R
• The installer should have a general knowledge of the installation techniques relating to Armafl ex tube and sheet products.
• Use high quality tools. A sharp knife, good brushes and fresh Armafl ex adhesive are required.
• Use clean Armafl ex material. No dust, dirt, oil or water should be present on the surface, if present clean with Armafl ex cleaner.
• Use the correctly dimensioned material!
• Always split oval tubes on the fl at side.
• Never pull glued joints when sealing them, always push them together fi tted under compression.
• Never insulate installations and systems that are in operation! Only start insulated plants after 36 hours - after this time the adhesive is fully cured.
• Do not apply Arma-Chek covering on seams and joints which are glued with Armafl ex adhesive until the adhesive has been given time to fully cure (typically 36 hours).
• Do not carry out fabrication on fl oors. Fabricate Arma-Chek products on a workbench as you would do metal jacketing.
• Avoid installing in very humid and wet conditions. Tent and weather protect where possible.
• Avoid installing Arma-Chek covering under tension.
• When using Arma-Chek covering on Armafl ex substrate make sure that all seams/joints are completely sealed with the correct type of Armafl ex adhesive and are damage free.
• Always use the correct specifi ed Armafl ex adhesives. Do not assume they will always do the same job! If in doubt, consult the Armacell technical department / local agent.
• On external installations always ensure a “watershed” is present on all seams and joints.
• On external installations and area’s internally that require “wash-down” always provide the Arma-Chek Mastic seal to all exposed seams and joints after the application of the specifi ed Armafl ex adhesive.
• For internal installations where the installation may be ”washed down,“ install the Arma-Chek covering as you would do for an external application, including the provision for the application of Arma-Chek Mastic .
• Minimize joints where possible and “stagger”.
• Apply Arma-Chek covering within 3 days of installing the Armafl ex insulation on external installations.
HEALTH & SAFETY
• When using adhesive and mastic sealants, the manu- facturer’s recommendations should be strictly followed. Details available from your local Armacell Customer Services Department / local agent.
• Arma-Chek coverings are easily cut with a sharp craft knife. Such knives should be handled with due care.
care.
TOOLS FOR INSTALLING ARMA-CHEK
Folding rule / tape measure Straight edge
Template (printed on every Armafl ex carton)
Scissors
Chalk for marking irregular shapes
Silver ink marker pen
Dividers
Brushs with short, fi rm bristles
Callipers Smooth spatula for smoothing down covering
Knifes * Sharpened pipe ends for the most common pipe diameters
Safe edge craft knife
Paint fabric rollers for surface gluing and smoothing down covering
Sharpening stone Gluemaster
Mastic gun
* A three knife set plus sharpening stone are available together as a
tool kit
Straight edgeStraight edge
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R APPLICATION MANUAL 1 - General >> Working with Arma-Chek D
CORRECT USE OF ARMAFLEX ADHESIVE
There are three types of accessories currently available:• Armafl ex adhesive (520 & HT625)• Arma-Chek Black and Grey Mastic
ARMAFLEX ADHESIVE
Adhesives to use are:Armafl ex adhesive HT 625 (bonding of HT/Armafl ex) Armafl ex adhesive 520 (all other Armafl ex elastomerics)
a) Before use shake and stir the adhesive thoroughly. Keep container/adhesive holder closed when not in use.
b) Use brushes with short, stiff bristles. Alternatively the Armafl ex adhesive gluemaster can be used when working with the adhesive.
c) Application procedures for installing the Arma-Chek covering to fl at and large surface area’s, where all- over adhesive coverage is required: Apply adhesive in a thin, uniform layer to both the Armafl ex surface and the inner face of the Arma-Chek R. Always ensure there is all over adhesive coverage to all surfaces with no signs of “dry spots”.
d) Allow the adhesive to “tack-dry” on overlapping details . The “tack”-time depends on the thickness of the adhesive layer and the ambient conditions (temperature, relative humidity, air movement). The correct initial drying time is checked by the “fi nger- nail test”: Touch the surface with a fi ngernail, if the fi ngernail does not adhere to the surface and the surface itself does not feel tacky the covering can be positioned and fi xed using hand pressure, a dry paint roller or a big brush to bond the covering to the Armafl ex. Apply pressure to the entire surface, smoothing the covering round making sure there are no air pockets present. Always check for alignment and avoid “creases and crinkles” during that time.
e) If the surfaces are left to dry too long, they will not bond when pressure is applied. When this happens you can re-activate by applying a further fi lm of Armafl ex adhesive following steps b) to d).
f) In general, the application of adhesives should not be carried out when the ambient temperature is below 0 °C or the relative humidity is higher than 80% (for further information see application hints for Armafl ex adhesives).
g) Use Armafl ex cleaner to clean your tools, con- taminated Arma-Chek and all seam and joint details within the Arma-Chek R system, prior to applying the bead of Arma-Chek mastic.
ARMA-CHEK MASTICThe Arma-Chek mastic is an adhesive and a sealing product designed to give additional and long life protec-tion to all Arma-Chek glued seams and joints in external environments and area’s internally that require “wash-down”.
1. Before applying the mastic to all seams and joints, check that they are completely sealed with the correct type of Armafl ex adhesive, and securely fi xed down (see item 6 below).
2. Check that the seams and joints are clean, dry and free from contamination before applying the mastic. All seam and jointing details contained within the Arma-Chek R coverings, shall be cleaned with Armafl ex Cleaner/local solvent cleaner, before applying the Arma-Chek mastic.
3. All seams and joints to have an allowance of a minimum of 10 mm wide and 3 mm thick mastic “beading” applied.
4. Smooth the mastic, with the use of a mastic spoon or a fi nger (use washing up liquid and water). The fi nish of the mastic can be enhanced by „masking“ off 5 mm either side of the seams and joints, prior to the application of the mastic. Proceed to remove the “masking tape” while the mastic is in its wet state (Take care on health and safety issues!!)
5. In general, the application of the mastic should not be carried out when the ambient temperature is below +5 °C or the relative humidity is higher than 80%.
6. The Arma-Chek mastic should not be used on a stand alone basis to fi x and bond the coverings (see item 1 above).
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ARMA-CHEK R PRE-COATED TUBES
Arma-Chek R pre-coated tubes (slit) are available in black and grey and are supplied in 1 metre lengths. The covering fi nishes approximately 10 mm before one end of the tube in order to guarantee that the insulation ma-terial is installed “under tension” around butt joints. The other butt end has a 50mm overlap of covering mate-rial.
The Arma-Chek R pre-coated tube range is available for pipes with an outer diameter of up to 89 mm.
Note: Due to the semi-fl exible nature of the products sleeving around bends is not possible!
INSULATING STRAIGHT PIPES (OD < 89 MM)
1. Clean the pipe surface with Armafl ex cleaner removing any dust or other contamination.
2. Snap the tube onto the pipe.
3. Apply the correct type of Armafl ex adhesive to the two sides of the Armafl ex cut seam detail. Allow to “touch dry” and with fi rm pressure close the adhesive seam.
4. Lay the pre-covered Arma-Chek R tightly round the tube but not under stress, remove the self-adhesive release strip and fi x down the self adhesive overlap
5. Continue along the piping line as 1-4 above and secure the butt end on the under face of the Armafl ex tube with the Armafl ex adhesive and also provide a “wet seal“ to the adjoining tube. To fi nish, fi x down in position, the additional 50mm overlap on the one end that has the overlap pre-applied.
6. To complete the system, before applying the Arma-Chek mastic to all seam and jointing details, clean all seam and joints with Armafl ex Cleaner/ local solvent cleaner.
7. Over seal all seam and jointing details of the covering with a “bead” of Arma-Chek Black or Grey Mastic. Ensure all joints are staggered away from the direct patch of rain, provide a watershed. All seams and joints to have an allowance of a minimum of
10 mm wide and 3 mm thick mastic “beading” applied.
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© ARMACELL UK LTD.
R APPLICATION MANUAL 2 - Insulating with Arma-Chek R >> Using Pre-Covered Tubes
INSULATION OF PIPE REDUCER USING ARMA-CHEK R PRE-COVERED TUBES
s
b
1. Select two different sized Arma-Chek R pre-covered tubes one to fi t the smaller bore pipe and one to fi t the larger bore pipe.
2. Push the Arma-Chek R tube designed to fi t the smaller bore pipe to the point where the pipe begins to increase in diameter and seal as described on page 5 of this manual.
25 mm
3. Sleeve the larger Arma-Chek R tube over the larger pipe. The tube should overlap the tube on the smaller pipe by 25 mm. Seal as described on page 5 of this manual.
4. Butt Seal the joint with Armafl ex Adhesive
b
a
b
a�
5. Measure the following diameters to produce a cover for the remaining Armafl ex: a - small bore insulated pipe outer diameter b - large bore insulated pipe outer diameter
6. Using Arma-Chek covering create a template by marking out 2 circles with the same center and the following measurements a - small bore insulated pipe outer diameter b - large bore insulated pipe outer diameter
7. Apply Armafl ex adhesive to one side of the Arma- Chek S+ pattern and also to the Armafl ex installed on the cap end of pipe. Allow to tack dry before applying.
8. For internal installations: Cover all seams and joint details (indicated by red arrows ) using Arma-Chek R Self-Adhesive Tape. For external installations: Cover all seams and joint details (indicated by red arrows ) using Arma-Chek R Butyl-tape. Always apply so as to allow for a watershed.
Tip: Endless endcapping on rolls may be available on request (see Okapak endcapping) and provides an al-ternative to this procedure.
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3. Seal the longitudinal seam of the covering with the correct Armafl ex adhesive. Continue to install the covering along the pipework allowing for a minimum 50 mm overlap on all ”butt“ joints.
Note:a. For outdoor application check the adhesive seams and joints on the covering for any defects and rectify as required. Apply a bead of Arma-Chek mastic along all seams and joints. Always smooth in the mastic on all the seams and joints to allow maximum bonding to occur.b. Allow for ”watershed“ where applicable on all external locations.c. Allow 36 hours curing time before turning on the equipment.
Procedures for pipework with outer diameter (in-cluding insulation thickness) ≥ 500 mm
Same application as for outer diameter < 500 mm, but: All over adhesive coverage is required. Consider also „General procedures“, topic 3 (see page 5).
Note: Check adhesive specifi cation table when installing Arma-Chek R covering (see page 11 of manual).
GENERAL PROCEDURES
1. Ensure the Armafl ex insulation surface is clean, dry, and free from all oils, greases and other contami- nants, with all the seams and joints secured with Armafl ex adhesive. Ensure that Armafl ex installa- tion procedures are followed; ensure there are no gaps present in all the seams and joints.
Note: Refer to the Armafl ex Installation Manual at all times.
2. Apply adhesive in a thin, uniform layer to both the Armafl ex surface and the inner face of the Arma-Chek R covering. A short pile sheepskin paint roller may be preferred on large circular and fl at surface areas.
3. It is recommended to fully adhere Arma-Chek R covering for cylindrical bodies with pipe outer dia- meter > 500 mm.
CYLINDRICAL BODIES(pipes, vessels, ductwork etc.)
Determine the circumference measurement of the insu-lated pipeline with an additional allowance of 50 mm for the overlap.
Proceed to cut the amount of pieces required, on a clean fl at surface.
Procedures for pipework with outer diameter (in-cluding insulation thickness) < 500 mm
1. Positioning of the covering material: Apply a minimum 50 mm glue line with the correct type of Armafl ex adhesive to the surface of the Armafl ex and the Arma- Chek R covering.
Position the Arma-Chek R covering along this line and fi x to the Armafl ex. Ensure the covering is ”in-line“ and in the desired position. Apply pressure and smooth the covering around the insultions circumference avoiding any ”air pockets“. Use a clean paint roller for this job. (Overlapping Arma-Chek R covering material: minimum 50 mm).
2. When the covering has been smoothed in position, mark the overlaps position on the under face area with a pen and continue to apply adhesive on the overlap and the under-laying covering, allow to touch dry, ”use fi ngernail test“ and fi x down making sure the overlap is completely fi xed.
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RECTANGULAR BODIES (ductwork, vessels)
To reduce labour time we recommend to install the Arma-Chek R coverings to the ductwork in one complete ”wrap-around“ application:
1. Measure the circumference of the ductwork and cut the Arma-Chek R covering to the correct dimension, allow for a 50 mm overlap of the fi xing seam. (Tip: for bigger ducts surfaces a „step-by-step“ application of the coverings in 2 or 4 sections may be the best option where there is only one installer on the appli- cation).
2. Follow “general procedures” (application of covering material) step 2 (see page 5)
3. Allow the adhesive to “tack dry” (use fi ngernail test). Position the Arma-Chek R covering and fi x to the Armafl ex, ensure the covering is ”in-line“ and in the desired position. Apply pressure and smooth the covering around the insultions circumference avoid- ing any ”air pockets“. Use a clean paint roller for this job.
4. Seal the longitudinal seam of the covering with the correct Armafl ex adhesive. Continue to install the covering along the ductwork allowing for a 50 mm overlap on all ”butt“ joints.
DUCTWORK BENDS & IRREGULAR SHAPES
1. Measure the length of the inner and outer ductwork bend. Cut the Arma-Chek R covering to the correct dimension.
2. Gluing following “General procedures” (application of covering material) step 2 (see page 5).
3. Application of the cut pieces following the procedures described before (see chapter “rectangular bodies” on this page).
4. Apply an adaquate piece of covering on the lateral face of the insulated ductwork bend. Cut this covering alongside the edges of the duct channel.
5. Gluing of the butt ends of the covering material with the correct Armafl ex adhesive.
Note:a. For areas/locations where high ambient temperatures can be expected we recommend to use the “feather- ing technique” with 50 mm overlapping (see page 5).b. For outdoor application check the adhesive seams and joints on the covering for any defects and rectify. Apply a bead of Arma-Chek mastic along all seams and joints. Always smooth in the mastic on all the seams and joints to allow maximum bonding to occur.
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c. Allow for ”watershed“ where applicable on all external locations.d. Allow 36 hours curing time before turning on the equipment.
CIRCULAR DUCTWORK
Apply the Arma-Chek R covering as you would for large bore pipework installations. (Refer to the section on large bore pipework installations on page 5.)
FITTINGS MADE OF COVERING MATERIAL
The following fi ttings can be fabricated using traditional sheet metal cladding working practices (leaf/segmenta-tion) techniques. As an alternative to these time con-suming methods below are easy step-by step details for fabricating fi tting templates. The examples below with the use of the Armafl ex Installation Manual and the Armafl ex cutting templates that are located on all our Armafl ex tube cartons should help you on the way.
SEGMENTED BENDS
When using Armafl ex tube on bend fi ttings the following fabrication technique could be used:
1. Measure the width of the throat and back of a seg- ment of the assembled segment bend and determine the circumference.
2. Transfer the circumference measurement (U) to the Arma-Chek R covering material and draw in a line dividing it in half. Now add a 50 mm wide overlap on one side.
3. Draw in the segment width for the throat seam at each end of the circumference, and the segment width for the back of the bend at the halving of the cir- cumference. Add an allowance of 5 – 10 mm (de- pending on the outer diameter of the insulated pipe) to each side for the butt overlap.
4. Connect the throat and back width measurements (to which the allowances have been added). Cut out the segment shape.
5. Optimize the shape of the curve at the widest point of the cut-out segments by rounding slightly with a pair of scissors or craft knife.
Remark: In order to cut out the same segment shape several times we recommend making a cardboard/ metal template so that the shape can be transferred to the covering material optimally. The template can be halved lengthways to make the pieces for the be- ginning of the bend.
6. Install the segments, beginning with the appropriate Armafl ex adhesive. Note: To ensure that the overlap sits tidily, the mate- rial can be feathered.
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ELBOWS
1. Measure the maximum and minimum length of the elbow segment (a) and determine the circumfer- ence.
2. Follow the same procedure as described in points 2 - 6 ”segmented bends“. (Point 2: instead of the seg- ment width for the throat seam measure/draw in the minimum elbow segment length. Instead of the seg- ment width for the back of bend measure/draw in the maximum elbow segment length (b)). Note: Draw in these lengths on one side only!! Add allowance of 5 – 10 mm for the butt overlap to one side only.)
a
b
TWO PIECE BENDS (fabricated from Armafl ex sheet material)
1. Measure the length of the inner (throat) seam of the bend and determine the number of segments. The number of segments should be chosen to achieve an exact fi t on the outer side (back) of the bend (re- commendation: minimum segment width in the throat area > 20 mm.)
2. Determine the circumference of the insulated pipe and transfer this to the covering material. Halve the circumference.
3. Transfer segment width for the throat seam to each end of the circumference drawn, and the segment width for the back of the bend to the halved circum- ference.
4. Connect the determined segment widths to each other - taking into account the additional allowance of an overlap of 5 to 10 mm at each end.
5. Extend the circumference on one side by the overlap measurement of 50 mm.
6. Cut out the fi nished segment which can be used to fabricate further segments.
7. Fabricate initial pieces for the beginning of the bend with a half segment and possibly the additional allow- ance of an appropriate bend extension.
8. Assemble the segments fi rst taking one of the initial pieces.
Note: All overlap areas require all-over coverage with the appropriate Armafl ex adhesive. On large bore “pulled bend” pipework (hydraulically bent pipes) use what is known as the ”wrap-around technique“ as a sim-pler alternative to the procedure described here. Note: Always allow for 50% overlap when using the “wrap-around technique”.
Cut out your own size bandage from the main roll you are using. For outdoor application use the bandage products only and the self adhesive tape for indoor ap-plication.
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VALVE NECK-T / PIPE-T
1. Determine the circumference of the Armafl ex insu- lated T-branch.
2. Transfer the circumference measurement on the Arma- Chek covering and mark the circumference into 4 equal sections. Add an additional 50 mm over- lap on one side of this section.
3. Measure the minimum height (a) of the insulated T-branch. Transfer these height to the marked out covering.
4. Measure the outer diameter of the insulated main pipe. Take the half of this measurement (radius r ) with a pair of dividers, mark out 2 arcs round the inter sections of the second and forth line touching the termination point of (a). Take the same measurement (radius r) and mark out three arcs around the inter sections 1, 3 and 5 touching the fi rst two arcs. That leads to joined arcs with a continuous line.
5. Add an additional 10 mm overlap to allow for ”feather- ing“ on the master pattern. Cut the pattern out with a pair of scissors.
OFFSET ANGLES
1. Determine the circumference (U) of the Armafl ex in- sulated offset angle, the maximum (a) and minimum (b) height, and the Armafl ex insulated outer diameter of the pipe (D) to which the offset angle connects.
2. Transfer the circumference (U) to the Arma-Chek R covering material. Halve the circumference.
3. Mark the minimum height (b) of the offset angle on the halving line and thus determine the termination point B. Mark the maximum height (a) on each of the side lines and thus determine the termination point A.
4. Draw a circle which stands vertically on point B and only touches it at one point (note: if the halving line is extended it runs through the centre of the circle). The diameter of the circle is a quarter diameter of the Armafl ex insulated diameter of the main pipe (D).
5. Add an overlap of 50 mm to one side.
6. Draw the jacket line by marking two arcs (radius = half circumference) between a tangent of the circle stand- ing on termination point B and the termination points A (continue the arc into the 50 mm overlap).
7. When using the feathering technique it is necessary to allow at least 10 mm parallel to the jacket line. Cut out the pattern using a pair of scissors or craft knife.
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VESSEL DOME END
When covering an Armafl ex-insulated vessel dome end with Arma-Chek R covering material it is necessary to cut out segments. (Use enough segments to ensure that the material can be applied without wrinkles.)
1. Determine the arc length of the vessel dome end us- ing a tape measure.
2. Calculate the circumference U = arc length x π and divide the circumference by the number of segments to be used.
3. Draw the fi rst segment on the covering material.
Cut out the segments adding an overlap of 50mm to one side (segment to segment).
4. Make a template by gluing the fi rst segment onto a piece of cardboard, for example.
5. Now use this template to draw and cut out the other segments. In general an overlap of at least 100 mm should be added which is then feathered and applied to the Armafl ex-insulated vessel dome end using all-over adhesive coverage.
6. On outdoor applications these seams should be secured with the Arma- Chek Mastic.
7. Finally, covering material is applied to the Armafl ex insulated vessel (jacket), beginning in the concentric 100 mm overlap of the vessel dome end. When cov- ering the vessel observe a vertical overlap of 50 mm for the covering material.
END CAPS AND TERMINATION POINTS
Method 1:
1. Measure the following diameters of the end cap: a) small (insulated) pipe diameter and b) the large bore insulated body.
2. Using Arma-Chek covering as a template, mark out 2 half-semi circles which have the following measure- ments: a) small bore insulated pipe outer diameter b) large bore insulated diameter of insulated body.
Allowance should be made to both the inner side of the small diameter and the outer side of the large diameter for feathering overlap length minimum equal to the insulation thickness of the non covered area!
Method 2:
1. Measure the following diameters of the end cap: a) smaller (insulated) outer diameter of insulated body and b) the large outer diameter of insulated body.
2. Using Arma-Chek covering as a template, mark out 2 circles with the same center and the following measurements a) outer diameter of small insulated body. b) large bore diameter of insulated body.
Allowance should be made to both the inner side of the small diameter and the outer side of the large diameter for feathering overlap of minimum equal to insulation thickness of the non covered area.
3. Cut out and modify the covering, fabrication using the ”feathering“ technique. When installing use the correct type of Armafl ex adhesive!
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4. For the quadrant overlap covering material (rolls), which can be cut into an approximate trapezium shape for the best fi t.
SEAM AND JOINT DETAILSpecifi cation Table for Arma-Chek R
Product TypeOutdoor
applicationsIndoor
applications
Adhesive + +
Arma-Chek mastic + #
+ to be used# applicable if required, in locations with high humidity and
“wash-down” areas.
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Armacell UK LimitedMars Street · Oldham, Greater Manchester · OL9 6LYTel 0161 287 7100 · Fax 0161 633 2685www.armacell.com/uk · [email protected]
Armacell provides this information as a technical service. To the extent the information is derived from sources other than Armacell, Armacell is substantially, if not wholly, rely-ing upon the other source(s) to provide accurate information. Information provided as a result of Armacell’s own technical analysis and testing is accurate to the extent of our knowledge and ability, as of date of printing, using effective standardized methods and procedures. Each user of these products, or information, should perform their own tests to determine the safety, fi tness and suitability of the products, or combination of products, for any foreseeable purposes, applications and uses by the user and by any third party to which the user may convey the products. Since Armacell cannot control the end use of this product, Armacell does not guarantee that the user will obtain the same results as published in this document. The data and information are provided as a technical service and are subject to change without notice.
© Armacell UK Ltd. · Subject to alterations · Printed in UK 037-005-0708-EN (UK,ROI,ZA)
Arma-Chek S+ The insulation system resistant to mechanical impact with a bright silver fi nish. S S
Arma-Chek D The lightweight and easy to apply insulation system resistant to mechanical impact. D D
Arma-Chek R The insulation system with extra system security that minimises the risk of under insulation corrosion (UIC) R R
Arma-Chek T The easy to apply and highly reliable solution for irregular shapes and hard to access areas. T T
Select the right Arma-Chek Covering System for your application ...
Equipment Type
General Construction Process Industries Shipbuilding
Offi ce & Commer-cial buildings
Plant buildings / Warehouses
Heavy Industry & Offshore (incl.
Petrochemical / LNG)Pharma & Food
industries
HVAC - Plant rooms D S D D R T S D T
HVAC - Service Shafts D S D D R D S T
HVAC - Suspendend Sub-Flooring D S D R D S T
AC ductwork, indoors (exposed to view) S D S D D R S D
AC ductwork, outdoors D R S D R S R D R D S
Pipe work, indoors D S R D S R
Pipe work, outdoors D S D S R T D R T T R
Process Pipework R T S R T R T
Process pipe work, Dual Temp (intermittent) R R R
Vessels & Tanks, indoors S D D R S R D S R T R
Vessels & Tanks, outdoors D S R D S R T R T T R
Engine rooms T
Where a letter appears in a full shaded circle in the table above this implies that the corresponding Arma-Chek system is particularly suited to this ap-plication. A letter in a non-shaded circle also implies a high level of suitability for the corresponding Arma-Chek system, although this is not the standard Armacell recommendation for this application.
Arma-Chek products may also be used in areas not indicated above and as such the table represents indicative advice only.
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