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NIA Contractor Members Discuss System Design: Gribbins Insulation & Scaffolding

NIA is proud of the professionalism, creativity, and artistry of our Contractor members. To celebrate the craftsmanship of NIA mechanical and industrial insulation contractors, in 2023 we unveiled the first-ever NIA Insulation Project Art Gallery Showcase and Competition. We invited all NIA insulation contractors to submit photographs and a brief description of projects representing their most creative and artistic efforts. At Fall Summit, we posted all the submissions anonymously, and attendees voted for the top three projects in terms of number of parts insulated, aesthetics, difficulty of installation, and well-installed application. As a regular column, we have profiled the projects submitted, focusing this month on Gribbins Insulation & Scaffolding. We encourage NIA Contractor members to participate in the Insulation Project Art Gallery Showcase and Competition, and possibly be featured in future articles.

PROJECT SNAPSHOT

Insulation Contractor: Gribbins Insulation & Scaffolding
Industry Segment: Industrial
Type of Plant/Facility: Petroleum
Temperature Range: High-Temperature System
Region: Midwest
System/Application Type: Hot Oil Tank and Vessels
Insulation Materials: 
  • Hot Oil Tank – Polyisocyanurate, Dow
  • Horizontal Vessels – Mineral Fiber, ROCKWOOL ROXUL
Jacketing: 
  • Hot Oil Tank – 0.024 Aluminum, RIDGLOK® Pre-Fabricated
  • Panel System
  • Horizontal Vessels – 0.024 Aluminum Sheeting, RIDGLOK
  • Pre-Fabricated Panel System
Insulation Support:
  • Hot Oil Tank – Cable Design, Locking Seam Panels, RIDGLOK
  • Removable Insulation Covers, Fit Tight Covers
  • Fasteners – Aluminum Banding, Screws, Pins

 

Project Description and Goals

The project involved reconditioning an existing oil tank and insulation of newly installed horizontal tanks and piping at a petroleum plant. Gribbins was responsible for installing insulation and lagging on two horizontal vessels, as well as installing a prefabricated insulated vertical panel system on a crude oil tank.

Project goals were heat conservation and personnel protection. For personnel safety, insulation was required to bring the outside surface temperature of the system below OSHA maximum limits.

Challenges

The project presented several physical challenges, one of which was site congestion. As shown in Photos 1 and 2, the crude oil tank to be insulated was virtually surrounded by obstacles, including adjacent tanks, motors, pumps, and stairs. The Gribbins insulation crews needed 100% hands-on access to the tank, while maintaining 8 to 12 inches of clearance from the face. This required a highly skilled team to design and construct scaffolding around the tank for safe access. For this aspect of the project, Gribbins was a logical choice, as industrial and commercial scaffolding is a core capability of the company, which has its own scaffolding division.

Site crowding also meant there was limited space for storage of materials and tools (see Photo 3), which required coordination among the multiple trades working on site. Gribbins was able to create temporary material storage on the scaffolding while working on the tank head (see Photo 4).

In addition, the weather presented a physical challenge: extreme heat. Project Foreman Bill White notes, “The biggest obstacle we faced was beating the heat/humidity and keeping our guys hydrated and happy in direct sunlight all day while wearing fire-retardant clothing.” To accomplish that, the team followed the tenets of the company’s safety program, fending off heat exhaustion and other complications by scheduling frequent breaks, making hydration a priority, and covering the topic in its routine on-site safety coordination meetings. As Gribbins Safety Director Adam Mayer explains, “With heat being our major obstacle, we provided our employees with proper training on how to recognize and identify the signs/symptoms related to heat stress/exposure. We mitigated heat exposure by requiring employees to take additional breaks throughout the shift and provided ample shaded and air-conditioned areas on site. Additionally, we supplied workers with cold water and hydration drinks to replace electrolytes, fluids, and sugars.”

Finally, along with the physical challenges, the customer described an additional issue they hoped the installation could address: Workers would need access to the interior of the large tank periodically for maintenance inspections.

The Gribbins Solution

As noted above, the project involved both new construction (two horizontal vessels/deaerator tanks) and the reconditioning of an existing hot oil storage tank. Although both elements were insulation installations, the differences between the structures and their applications meant that different approaches—and different solutions—were required. Gribbins Project Foremen Bill White and Rick Champell made sure that both sets of requirements were met.

Table 1 offers an overview of insulation system components, as well as product types and brands used.

Horizontal Vessels – New Construction

To address the customer’s goals for the horizontal vessels, Gribbins installed mineral wool insulation for heat conservation under 0.024 aluminum jacketing. At that thickness, the aluminum provided protection and support for the insulation underneath, while also providing aesthetic appeal. Banding was used for securement on the body jacketing, and screws with washers were used on the heads. Photos 5 through 7 show the results of the installation.

Hot Oil Storage Tank – Reconditioning

This part of the project required not only expertise in insulation installation but also in scaffolding design, installation, safe use, and dismantling. Gribbins uses industry-specific software to assist in scaffold design, considering critical factors including site conditions, access points, load capacity, and work scope. For this job, they utilized a cuplock scaffolding system for its quick assembly and versatility. The modular design, combined with the unique cup and blade locking mechanism, allows for rapid installation and easy customization to suit a variety of structure heights, shapes, and sizes. Figures 1 and 2 show the design.

Of course, design is just the first step. Gribbins maintains a team of trained, professional scaffold erectors qualified to assemble and maintain scaffolding safely during project performance, and then dismantle and remove it safely once the job is finished. Photos 8 and 9 show how Gribbins used the scaffolding to complete the complicated installation.

For the hot oil tank, Gribbins installed a dual system: polyisocyanurate insulation to limit heat transfer, with the same pre-fabricated RIDGLOK 0.024 aluminum sheet jacket. Richard Daugherty, Industrial Accounts Manager with Gribbins, explains, “Utilizing tank panels offers numerous benefits. They are less labor intensive, are cost-effective, and provide a longevity of up to 12 years for the insulation panel system.” These benefits notwithstanding, installation was not simple. As Foreman Bill White puts it, after the extreme heat, “The next challenge was getting the panels in place, then stacking the second layer and aligning the laps properly using pulleys, ropes, clamps, and good old-fashioned teamwork and communication.” Photos 10 and 11 show what the system looked like as it was being installed, giving a clear picture of why experienced, trained crews were critical to getting the job done safely and correctly.

To accommodate the additional need for worker access to the tank interior without compromising or interfering with the RIDGLOK insulation system, Gribbins coordinated with the customer to have a 4” C-Channel over a 10’ x 10’ opening, shown in Photo 12. Gribbins then had Fit Tight Covers removable insulation covers fabricated for the opening.

Safety Focus

Between the complexity of the scaffolding work and the extreme heat, this project could have been high risk for on-the-job injury or illness. A Platinum-Level NIA Safety Excellence Award winner for the past 5 years running, and certified by the Coalition for Construction Safety, Gribbins counts safety among its core values (along with integrity, quality, and service). Company founder, Jim Gribbins, was ahead of his time in 1999 when he hired a Safety Director. Now, the company has two full-time professional safety personnel in its safety department: the Safety Director and a Safety Coordinator. They spend the majority of their time on jobsites, working with project managers, supervisors, and crews to ensure that everyone is focused on safety in the performance of their work. The company’s many safety awards are truly earned in the field, on projects like this one, where Gribbins employees perform their tasks under a range of challenging conditions safely and efficiently.

Project Takeaways

The importance of a safety culture cannot be overstated, particularly in a complex project like this one, but there are several other key takeaways:
  • Safety = Quality and Efficiency
    Adhering to safety standards does not mean sacrificing efficiency. Gribbins project foremen observe that the crews’ ability to follow the instructions and standards provided actually facilitated on-time delivery of a high-quality long-term result.
  •  The Value of a Trusted Professional
    Working with a professional contractor you can trust yields benefits all through the process. In this case, consulting with Gribbins in design of the tank access point allowed the customer to get the opening for routine maintenance they need without compromising the integrity of the insulation system. Additionally, this project required not only expertise in insulation installation, but also the skills and experience to design, construct, use, and dismantle the scaffolding needed for the install.
  • Communication Is Vital to Project Success
    Communication should include all parties involved—e.g., engineers and owners consulting with the insulation contractor on how to meet design objectives; holding pre-construction meetings with all contractors before a project starts to ensure proper scheduling and job execution; and incorporating continued communication throughout project performance to identify and mitigate any potential risks early and keep the project running smoothly.

As Gribbins President Brian Willett sums it up, “This project exemplifies our commitment to delivering top-notch insulation solutions for various industries, thereby contributing to energy efficiency and the well-being of workers. The work performed on vessels and tanks stands as a testament to our dedication to safety, quality, and efficiency in the field.”

Strength in Numbers

Gribbins Insulation & Scaffolding was responsible for project performance and ultimate
customer satisfaction. At the same time, as we have seen with other projects featured in this series, many of the insulation products used were made and/or fabricated by other
NIA members, including the following:

About Gribbins Insulation & Scaffolding

Founded in 1985, Gribbins Insulation & Scaffolding has grown into a leading commercial and industrial mechanical insulation and scaffolding contractor. The company specializes in insulating mechanical and process systems—such as piping, ductwork, and special equipment—for a wide variety of facilities, including hospitals, schools, power plants, and manufacturing buildings. To better serve its customers, and meet their growing needs, Gribbins launched its scaffolding division in 2021.

Integrity, quality, safety, and service are at the core of everything they do. The company’s mission is to maximize customer satisfaction by providing the highest level of safety, quality, and productivity, leading to optimum employee fulfillment and company profit.

With multiple locations across Indiana, Kentucky, Tennessee, Illinois, and Ohio, Gribbins primarily operates throughout the Midwest, although the company’s extensive project portfolio spans states including Texas, Michigan, Kansas, Missouri, Iowa, Wisconsin, Pennsylvania, West Virginia, Alabama, Louisiana, North Carolina, Florida, and even
the Bahamas.

For more information, please visit www.gribbins.com/about.

NIA Sites > Insulation Outlook Magazine > Global

2024 Commercial Energy Code Update

Over the last year, the commercial energy code landscape has seen several new state- and local-level adoptions, in addition to the publishing of a brand new American Society of Heating and Air-Conditioning Engineers (ASHRAE) standard. ASHRAE, together with the American National Standards Institute (ANSI) and the Illuminating Engineering Society (IES), published ASHRAE 90.1-2022. The new standard is the latest in a long series of updates spanning many years. In fact, the original ASHRAE standard was published in 1975. Since then, multiple editions have been adopted throughout the United States, with each standard containing increasingly stringent requirements. Though U.S. states have yet to adopt the 2022 standard, there are some important updates that will undoubtedly set the trend for future energy code cycles.

The International Code Council (ICC) has also been busy at work with the latest edition of its model code, International Energy Conservation Code (IECC) 2024. I will cover that in more detail in the IECC 2024 section of this article, but for now it is important to note that ASHRAE and IECC have different 3-year cycles, and IECC follows behind ASHRAE by 2 years. For example, IECC 2021 references ASHRAE 90.1-2019, and IECC 2018 references ASHRAE 90.1-2016. Additionally, IECC offers less choice than ASHRAE 90.1. For example, ASHRAE offers a semi-heated space option; IECC does not. This means that IECC is ultimately a more stringent code than the ASHRAE standard.

ASHRAE 90.1-2022: What You Should Know

According to ASHRAE Standing Standard Project Committee 90.1 Chair Don Brundage, updates in the most recent standard are designed to address the demand for “reduced energy use and carbon emissions.” Important updates in the 90.1-2022 standard include:

  • A minimum prescriptive requirement for on-site renewable energy;
  • An optional mechanical system performance path, allowing HVAC system efficiency tradeoffs based on the new total system performance ratio metric;
  • New energy credit requirements for a customized approach to improving energy efficiency;
  • New informative guidance for using carbon emissions, site energy, or source energy as alternative performance metrics to the current energy cost metric;
  • Significant efficiency increases in the integrated energy efficiency ratio (IEER) for commercial rooftops and a new seasonal energy efficiency ratio 2 (SEER2)/heating seasonal performance factor 2 (HSPF2) metric for <65K-sized air-cooled heat pumps; and
  • New requirements to address the impacts of thermal bridging.

From our perspective in the insulation industry, we are most concerned with the updates pertaining to thermal bridging, which occurs when a more conductive element (i.e., something with a poor insulating value) creates an easy pathway for heat flow across a thermal barrier. The results of thermal bridging include heat loss and increased energy costs, in addition to the potential for condensation, which can have major detrimental impacts on both the building envelope and the structural framing members in a metal building application. ASHRAE 90.1-2022 provides the performance requirements for mitigated linear and point thermal bridges in Section 5.5.5, “Linear Thermal Bridges and Point Thermal Bridges.”

International Energy Conservation Code 2024 Update Established in 1994 to develop a single set of national model construction codes, the ICC is a private, nongovernmental organization responsible for the development of the IECC. After nearly 2 years of development, including a lengthy public comment period, the ICC has concluded development of the latest edition of the code, IECC 2024. Both the residential and the commercial codes are now final1 and are expected to be published in the near future.

Before we review what to expect from the newest code, it is important to note that IECC 2024 marks a major shift in the code development process. After more than 3 decades of a code process, the ICC voted to shift to a standards process.2 In the past, ICC developed the code and allowed for public comment. IECC 2024, however, was developed by residential and commercial consensus committees, which included industry experts and code officials from various sectors. The new process follows ANSI development procedures3 and took into account proposals received during an open-call period, which commenced in June 2023. The new ANSI-approved ICC consensus procedures will be utilized to develop all future I-Codes.

Compared to its 2021 predecessor, IECC 2024 is expected to improve energy efficiency by approximately 6.5% for residential buildings and 10% for commercial buildings. The major change those in the metal building industry should be mindful of pertains to air barrier testing. An air barrier is a material or system of materials designed to reduce uncontrolled air leakage and air infiltration through a building’s thermal envelope. The thermal
envelope separates conditioned space and outdoor air. An air barrier can technically be composed of different types of material and/or coatings, such as polyolefin. An air barrier can be placed on the interior side, exterior side, somewhere within assemblies composing the envelope, or any combination thereof.

Air barriers were made mandatory in IECC 2015/ASHRAE 90.1-2013, and IECC 2024 takes compliance a step further by reducing the allowable air leakage rate in the building envelope to 0.25 cfm/ft2. This translates to less unwanted air leakage and air infiltration
in the building envelope, and greater energy efficiency. The model codes have trended toward increasingly stringent air barrier requirements over the years, and IECC 2024 is
no exception.

IECC 2021: The Talk of the Town

While technically not the newest energy code, IECC 2021 is the most widely adopted code. Several states have adopted it in the past 6 months alone, so it is worth a review. To make things easy, we will compare IECC 2021/ASHRAE 90.1-2019 to IECC 2018/ASHRAE 90.1-2016.

One of the larger changes falls in the air barrier category. While air barriers were made mandatory in the IECC 2015/ASHRAE 90.1-2013 code cycle, never before were air barriers required to be verified. That all changed in IECC 2021/ASHRAE 90.1-2019, which requires the continuous air barrier to be verified by a code official, a registered design professional, or an approved agency in accordance with the following:

  • A review of the construction documents and other supporting data shall be conducted to assess compliance with the requirements in Sections C402.5.1.
  • Inspection of continuous air barrier components and assemblies shall be conducted during construction, while the air barrier is still accessible for inspection and repair, to verify compliance with the requirements of Sections C402.5.1.3 and C402.5.1.4.
  • A final commissioning report shall be provided for inspections completed by the registered design professional or approved agency. The commissioning report shall be provided to the building owner.

Other notable changes in IECC 2021 include:

  • More stringent air sealing and blower door testing requirements;
  • Mechanical systems updates, updated equipment efficiency requirements,
    and refinement of energy recovery ventilation requirements;
  • A more stringent requirement for lighting systems, such as increased lighting
    efficiency and decreased lighting power densities requirements; and
  • A requirement for electric vehicle (EV)-capable or ready charging stations with
    commercial buildings.

States That Have Adopted IECC 2021, ASHRAE 90.1-2019, or a State-Specific Code Modeled after IECC 2021/ASHRAE 90.1-2019

As of August 2024, the following states (plus the District of Columbia) have adopted IECC 2021 or ASHRAE 90.1-2019, or a state-specific code modeled after either IECC 2021 or ASHRAE 90.1-2019:

  • California
  • Colorado
  • Connecticut
  • Delaware
  • District of Columbia
  • Florida
  • Illinois
  • Maryland
  • Massachusetts
  • Minnesota
  • Montana
  • New Jersey
  • New Mexico
  • North Dakota
  • Ohio
  • Oregon
  • Utah
  • Vermont
  • Virginia
  • Washington

The Big Question: “What Do I Need to Meet Code?”

As we move toward more complexity in each code cycle, this longstanding question
will only become more common. As simple as the question is, it is difficult to answer. In short, the compliance path I recommend most often is the prescriptive approach. Per the U.S. Department of Energy, the prescriptive approach includes “requirements that either must be met by every building design, or if the requirement is not met, a tradeoff can be made to make up for not meeting that requirement.” In other words, you must meet all U-values of the roof, walls, foundation, and fenestrations. If a tradeoff is indeed needed in the end, the quoted price has covered any changes.

Some other areas of the building envelope we should take care to address come from the International Building Code—specifically, the structural code. The important section
to review is Section 1402.2: Weather Protection, which covers weather-resistive barriers
in exterior walls. If the metal building wall panel supplier has not tested their panels
per ASTM E331, compliance can be difficult. ASTM E331 is the exemption for having to
create a wall cavity designed with flashings and a means for draining water that enters
the assembly.

In order to meet the stricter insulation requirements of the last few code cycles, double-layer filled cavity systems have become the standard. The two most common include liner systems and long tab banded systems. Liner systems are private labeled and must meet ASHRAE’s requirements in order to be defined as a liner system (Ls). Long tab banded systems are usually non-proprietary and meet the specifications of a filled cavity (Fc) system.

Both systems provide High-R insulation to help meet stringent energy codes. One key difference is that certain banded liner systems also qualify as OSHA-compliant fall protection systems. Most long tab banded systems typically do not offer fall protection. Both options fulfill the metal building insulation U-value code requirements, so the system selected boils down to budget and preference.

In a banded liner system, large panels of fabric or other vapor retarder material is supported by banding and installed underneath the purlins. Multiple layers of unfaced and/or faced (air barrier) metal building insulation is installed on top of the supporting fabric and banding filling the cavity. The purlins are covered by the fabric vapor retarder in a banded liner system (see Photo 2).

A long tab banded system is a single- or multilayer filled cavity system where the first layer is laminated metal building insulation installed parallel and between the purlin space. The long tab vapor retarder is joined or seamed on top of the purlins. A second layer of unfaced insulation may be placed on top of the first layer, perpendicular to the purlins. Banding on the bottom of the purlins provides support. In a long tab banded system, the purlins are left exposed (see Photo 3).

The Bottom Line

The code cycle changes that are either here or coming soon to your state are, without a doubt, challenging to say the least. However, the newest code changes mean more efficient buildings and more innovative solutions that have greater potential to save end users money.

Online Sources:
1: www.greenbuildinglawupdate.com/2024/04/articles/codes-and-regulations/2024-iecc-is-final-after-addressing-preemption-issues
2: https://support.iccsafe.org/article-categories/iecc-development-process
3: www.iccsafe.org/wp-content/uploads/21-20411_CORP_072121_IECC_Committee_Procedures_FLR_v5_revSH-Reformat.pdf

NIA Sites > Insulation Outlook Magazine > Global

Metal Building Insulation and Air Leakage

Architects, engineers, and specifiers are required to incorporate energy efficiency codes as they continue to change with each passing cycle. One aspect strongly reflected in the approved energy codes is the tested air leakage requirements for structures, including metal building systems. A couple of states are early adopters (California and Washington), but many states—particularly those who have adopted ASHRAE 90.1-2019 and International Energy Conservation Code (IECC) 2021—will need to get ready. Now.

In this article, we will focus on air leakage reduction, which goes back to the 2012 IECC, and how fiberglass insulation systems meet all current requirements. The air leakage provisions were developed in response to the diminishing returns of adding more mass fiberglass insulation in cavity spaces and environmental pressures from various agencies.

In 2012, the IECC introduced an air leakage component and provided three paths to compliance, each governed by a respective ASTM standard and measured at a pressure differential of 75 Pascals (1.57psf). Below are the three compliance options.

  • Materials with an air permeability no greater than 0.004 cfm/ft2
  • Assemblies of materials and components not to exceed 0.04 cfm/ft2
  • Whole building air leakage test results not to exceed 0.40 cfm/ft2

In simple terms, air leakage tests incorporate a blower door, visual inspection, and infrared pictures. In a commercial building, the test involves sealing the building, using a fan (or fans, depending on building size) to create pressure differences, and measuring air flow to detect leaks. Data from pressure differentials, visual inspections, and infrared technology identify those air leak points, now mandatory for any state adopting IECC 2021 or ASHRAE 90.1 2019.

It is important to note a key difference between IECC and ASHRAE 90.1: The IECC requires a whole building test, unless an exemption applies due to climate zone or building size; whereas ASHRAE 90.1 allows the use of an installation verification program instead of a whole building test for any building.

Figure 1 shows the progression of whole building testing requirements (ASTM E779).

Many members of NIA’s Metal Building Laminator Committee are also members of the Metal Building Manufacturers Association (MBMA) and its Air Leakage Task Force. This group, with the help of third-party experts, led air leakage tests on several newly constructed metal building systems to evaluate air leakage. These studies encompassed various climate zones, building uses, and fiberglass insulation systems. It was important to test how fiberglass insulation systems perform and ensure these products would meet the air leakage requirements.

After many tests, it was concluded that all the tested fiberglass insulation systems yielded a positive result concerning the 0.40 cfm/ft² threshold. The project highlighted the importance of and level of detail needed for the installation technique used for all materials. The studies culminated in the MBMA publication of “Best Practices to Comply with Whole Building Air Leakage Testing Requirements for Metal Building Systems.”

Many states (13) have already adopted IECC 2021/ASHRAE 90.1–2019, and it is just a matter of time before other states follow. As communicated in this article, anything after the 2012 IECC will have an air infiltration component to it. Now is the time to prepare and understand what may be required.

As members of NIA’s Metal Building Laminators Committee and suppliers of fiberglass insulation systems, we are attuned to and participate in energy efficiency and building code developments. Please reach out to us if you have questions or need to understand how air infiltration will affect your project.

The following are additional resources:

 

NIA Sites > Insulation Outlook Magazine > Global

Metal Building Insulation and Surface Burning Characteristics

The NIA recently released a new, updated standard for metal building insulation. It can be found on the NIA website and is officially titled, “NIA Certified Faced Insulation® Standard (Version 404.2-2024).” One of the major changes to the standard centers on the surface burning characteristics of faced metal building insulation. The goal of this article is to explain what surface burning characteristics are, how they affect the type of insulation you choose for your building, and what the new standard has done to further promote safety within the metal building construction industry.

What Are Surface Burning Characteristics, and Why Should We Care?

The surface burning characteristics of a product are more commonly referred to as its flame spread and smoke developed index. The index rating of a product is a comparative measurement of the spread of the flame and smoke obscuration versus time for the material tested, in accordance with ASTM E84 and UL 723. The ASTM E84 and UL 723 test method and classification of products came about, over time, as a result of some horrific fires that occurred within the United States, dating back to 1942.

The common theme in all three tragedies was the rapid flame progression along the surfaces of the exposed interior finish of the walls and ceilings, which ultimately led to the adoption of the ASTM E84 Standard Test for Surface Burning Characteristics of Building Materials in 1961.

Although time has passed, the need and awareness still exist today. More than 70 years after the adoption of ASTM E84, another tragedy struck in Rhode Island, in February 2003. A fire erupted and quickly spread during a performance of the metal band, Great White, at the Station nightclub in West Warwick, leaving 100 dead and 230 injured. Once again, one of the primary factors of this tragedy was the rapid flame spread on the surface of the ignited ceilings and walls (see “20 years after the Station nightclub fire, a look at what’s changed,”GBH, www.wgbh.org/news/local/2023-02-21/20-years-after-the-station-nightclub-fire-a-look-at-whats-changed).

What Do the Building Codes Require Regarding Metal Building Insulation and Surface Burning Characteristics?

The International Building Code (IBC) assigns a Surface Burning Characteristic Classification to all building products required to be tested using the ASTM E84 Standard. More specifically, Chapter 8, Interior Finishes, of the 2024 IBC, Section 803.1.2 Interior Wall and Ceiling Finish Materials Tested in Accordance with ASTM E84, are categorized into three classes, as follows:

  • Class A = Flame spread index 0–25; smoke developed index 0–450
  • Class B = Flame spread index 26–75; smoke developed index 0–450
  • Class C = Flame spread index 76–200; smoke developed index 0–450

The following building codes and standards utilize these classes to help determine which products meet code:

  • International Building Code (IBC)
  • International Mechanical Code (IMC)
  • International Fire Code (IFC)
  • Uniform Mechanical Code (UMC)
  • National Fire Protection Association (NFPA) 1 – Fire Code
  • NFPA 101 – Life Safety Code
  • NFPA 5000 – Building Construction and Safety Code
  • NFPA 90A – Standard for the Installation of Air-Conditioning and Ventilating Systems

The primary reasons to insulate a metal building, besides meeting the codes, are for thermal and acoustic/sound purposes. When determining the materials needed to insulate a metal building, one of the main resources utilized is the ASHRAE 90.1 Energy Standard for Sites and Buildings Except Low-Rise Residential Buildings. Per ASHRAE 90.1–2022, within metal buildings, fiberglass insulation systems can be single layer, double layer, liner system, or filled cavity. In each of these systems, the fiberglass insulation can be either faced (laminated) or unfaced.

When using a faced metal building insulation-whether in the ceiling or walls of metal buildings, or both-in the vast majority of cases, the faced side of the fiberglass insulation is left exposed to the interior of the building.

Section 720.3, Exposed Installation, states, “Insulating materials, where exposed as installed in buildings of any type of construction, shall have a flame spread index of not more than 25 and a smoke-developed index of not more than 450.”

In simple terms, both concealed and exposed faced metal building insulation must be Class A to meet the IBC.

Although not common in practice, there are instances where metal building insulation becomes incorporated into the design of the plenum. In these cases, we would refer to IMC, UMC, and NFPA 90A.

Per the IMC, Section 602.2, Construction of Plenums, states, “Plenum enclosure construction materials that are exposed to the airflow shall comply with the requirements of Section 703.3 of the International Building Code or such materials shall have a flame spread index of not more than 25 and a smoke-developed index of not more than 50 when tested in accordance with ASTM E84 or UL723.”

The UMC and NFPA 90A also state that any insulation materials exposed with a plenum must have a flame spread index of not more than 25 and a smoke-developed index of not more than 50.

Although we have mentioned the more nationally recognized codes and standards, it is important to note that prior to any construction project, it is imperative that all local municipalities’ and state code adoptions be researched and recognized. The best way to do this would be to contact your local authority having jurisdiction (AHJ).

What Does All This Have to Do with the NIA Certified Faced Insulation Standard (Version 404.2–2024)?

In order to comply with the NIA Standard, metal building insulation laminators must subscribe to third-party laboratory verification of surface burning characteristics for their faced metal building insulation products AND have their product packages marked with the label of the certifying laboratory for surface burning characteristics. This allows the building owners, installation contractors, and building code officials and inspectors the ability to easily identify whether the metal building insulation supplied meets the code requirements for surface burning characteristics. It also holds our industry accountable and further advances the reputation and commitment our members have to the safety and well-being of our clients.

NIA Sites > Insulation Outlook Magazine > Global

Metal Building Insulation: It’s Sustainable!

Sustainable development requires an integrated approach that takes into consideration environmental concerns along with economic development.

In 1987, the United Nations Brundtland Commission defined sustainability as, “meeting the needs of the present without compromising the ability of future generations to meet their own needs.” Today, there are almost 140 developing countries in the world seeking ways of meeting their development needs; but with the increasing threat of climate change, concrete efforts must be made to ensure development today does not negatively affect future generations.

We are in the construction business. We love seeing growth and development. But at what cost to our environment and natural resources? Focusing on using materials and systems that will help save energy and resources is a strong way to improve our world’s environment.

Recycled Materials

Manufacturing fiberglass is environmentally friendly because it is created from recycled glass—sometimes more than 50% of its raw materials are recycled. Think of glass bottles, windows, and automobile windshields thrown away in landfills. According to the North American Insulation Manufacturers Association (NAIMA), using recycled glass reduces the demand on virgin resources, saves landfill space, and diverts glass containers and slag from the solid waste stream. Since the industry’s recycling program began in 1992, NAIMA members’ facilities have diverted more than 103.5 billion pounds of recycled materials from the waste stream. Now imagine the dual benefit as that tremendous amount of discarded material is melted down and spun into fiberglass that will further improve the environment by reducing energy demands and carbon/greenhouse gas emissions while economically insulating the buildings and equipment we use every day!

Return on Investment

The cost of energy is a big concern for building owners, but what about cost to the environment? The energy consumption used in making and distributing fiberglass gives excellent returns. Another study reported by NAIMA states that “a typical pound of fiberglass and rock and slag wool insulation saves twelve times as much energy in its first year in place as the energy used to produce it.” And that is just the impact regarding the carbon footprint. Imagine what you save in energy bills over the life of the building!

Fiberglass Improvements

The manufacturers of fiberglass are committed to the future and to investing in finding better ways and greener products. Here are a few of the improvements by manufacturers that we now enjoy in our use of fiberglass insulation.

  • Engineering improvements, such as the elimination of formaldehyde from its products;
  • Refining fiberglass to make it less “itchy” and easier to handle;
  • Testing and improving the consistency of R-values and performance in limited cavity spacings;
  • Increasing the amount of recycled glass used in its creation;
  • Eliminating waste by reengineering manufacturing processes to incorporate fiberglass production scrap back into the primary production process, or to reprocess it into other products; and
  • Using compressed packaging to cut energy requirements for transportation by allowing more insulation to be shipped in each truck.

Now and into the future, we will need to economize on our use and consumption of natural resources and energy. Fiberglass is a tried-and-true performer to preserve both.

NIA Sites > Insulation Outlook Magazine > Global

Back to Basics: R-Value and U-Value

The R-value of an insulation product is a thermal resistance rating that tells us how well a material resists heat flow. The higher the R-value, the better the insulation restricts heat transfer. Most insulation manufacturers use the ASTM C518 test to measure a material’s resistance to heat flow. Established by the American Society for Testing and Materials (ASTM), the ASTM C518 test is a standardized method that assesses the steady-state thermal transmission properties of a material using a heat flow meter apparatus. In addition to serving as an essential tool for many industries, ASTM C518 is a building code requirement for insulation.

R-values for metal building insulation range from R-8 to R-30. The most common fiberglass metal building insulation R-values include:

  • 2” (R-8, before lamination)
  • 3.4” (R-10)
  • 3.7” (R-11)
  • 4.3” (R-13)
  • 5.3” (R-13)
  • 6.3” (R-19)
  • 8.0” (R-25)
  • 9.25” (R-30)

It should be noted that thicknesses are nominal, as manufacturers produce different thicknesses to meet R-values. Commercial energy code requirements dictate the minimum R-value necessary for all new construction, additions, and alterations performed in the United States.

Once the R-value is determined, designers can use this data to better understand how a material will perform in an assembly. Heat flow through a material is driven by the temperature difference on each side of the material or assembly. Most construction types and code tables leverage the R-value table as a guide to code compliance. However, it is important to remember that the R-value table should not be mistaken as a reference for the total performance of an assembly. Metal-framed walls, wood-framed walls, and metal building walls and roofs undergo testing that determines the U-value of the entire assembly. The result of that testing can be found in the U-value table.

A U-value, also called a U-factor, measures heat transfer, or loss, through the assembly over time. While the R-value measures a single product’s ability to resist heat, the U-value measures the entire assembly’s resistance to heat transfer. The lower the U-factor, the better the insulation. Mathematically, R-values and U-values are reciprocals of one another: U-value = 1/R-value, R-value = 1/U-value. ASTM C1363 is the standard test method of U-values and includes a hot box apparatus. See Figure 1 and Figure 2.

NIA Sites > Insulation Outlook Magazine > Global

Metal Building Insulation Special Issue: An Introduction to Fiberglass Metal Building Insulation

Metal building systems (you may call them pre-engineered metal buildings) have long been favored for their strength, durability, and cost-effectiveness. However, one crucial aspect that often goes unnoticed is the insulation system. Proper insulation is essential for reducing energy consumption, maintaining comfortable indoor temperature, and ensuring the longevity of these metal structures. Among various insulation materials, fiberglass insulation stands out as a reliable and cost-effective choice. In this comprehensive article, we will explore why fiberglass insulation remains relevant and efficient for metal building systems.

Evolution – Where It Began

The evolution of fiberglass insulation use has progressed significantly since its inception, transitioning from basic single-layer applications with low R-values to sophisticated, multilayered systems that offer enhanced thermal performance and energy efficiency. Initially, fiberglass insulation was available in the form of batts or rolls, designed to be sandwiched between framing members and the roof or wall panels. While this is still a primary method of insulating a metal building, today’s energy codes have required the development of different solutions.

Over time, advancements in manufacturing and material science have led to the development of higher density fiberglass insulation products and more efficient installation techniques. Innovations include the introduction of multilayered systems, in which the installer utilizes two layers of fiberglass to further enhance performance. Modern fiberglass insulation systems often incorporate vapor barriers, reflective coatings, and other materials to address issues such as moisture control and radiant heat transfer. These systems are designed to maintain their R-value over a wider range of temperatures and conditions, ensuring consistent performance throughout the year. Unlike the single-layer fiberglass mentioned in the previous paragraph, these systems utilize the framing cavity, filling it with fiberglass to improve thermal performance.

Code Requirements

The American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) and the International Code Council (ICC) play crucial roles in developing energy codes in the United States. ASHRAE develops standards like ASHRAE Standard 90.1, which sets minimum energy efficiency requirements for commercial buildings and large multifamily housing. This standard is continuously updated through a consensus process involving industry experts, government representatives, and other stakeholders. The ICC publishes the International Energy Conservation Code (IECC), which includes energy efficiency requirements for both residential and commercial buildings. The IECC is updated every 3 years through a public consensus process, allowing for broad participation from various stakeholders. These organizations ensure that energy codes evolve to improve energy efficiency, reduce environmental impact, and promote sustainable construction practices.

Code agencies continue to value and require the properties of fiberglass insulation as a viable solution for achieving energy efficiency goals. The great news is that fiberglass insulation systems are able to meet all current energy codes.

As states adopt new codes, you will begin to see more requirements around air infiltration. This topic is becoming more relevant with each new code cycle. You should know that fiberglass insulation systems have been put to the test and perform to the current code requirements.

Benefits

Here are some of the benefits of fiberglass insulation and why it is a practical choice for metal buildings.

  • Fiberglass insulation is budget friendly, making it an attractive option for metal building projects. Although it is budget friendly, you are not sacrificing performance.
  • Fiberglass stands out for its low installed cost per R-value. R-value measures the material’s thermal resistance.
  • With the shortage of skilled labor and escalating labor costs, fiberglass insulation could be considered “user-friendly,” with its specific product markings and the general ease of handling. Its flexibility allows it to fit into irregular spaces (allowing for a filled cavity). The flexibility and ease of handling helps minimize installation costs.
  • Its durability is almost unprecedented. Unlike some materials that are prone to absorbing moisture, fiberglass insulation remains unaffected. It does not promote mold or mildew growth, ensuring a healthier indoor environment. Properly installed fiberglass insulation can last for decades without significant degradation, underscoring its cost-effectiveness over time.

Fiberglass insulation can contribute significantly to achieving, or exceeding, energy efficiency goals. The thermal performance of fiberglass insulation effectively reduces heat transfer, keeping indoor spaces warmer in winter and cooler in summer. A metal building system’s insulating properties help maintain a consistent temperature, enhancing occupant comfort, and can lead to reduced heating and cooling costs.

Tested

Metal building insulation must be tested for a myriad of safety and performance characteristics. The American Society for Testing and Materials (ASTM) is a primary agency for the development of standards that help enhance the performance of products and foster the confidence in those products that you, as both a consumer and/or architect/engineer/specifier, buy and use.

A couple of examples are:

  • ASTM E84 is the “Standard Test Method for Surface Burning Characteristics of Building Materials.” This standard should be used to measure and describe the properties of materials, products, or assemblies in response to heat and flame under controlled laboratory conditions. Fiberglass by nature is noncombustible; however, when you add a facing and some sort of adhesive material, it is important to test the final produced product.
  • ASTM C991 is the “Standard Specification for Flexible Fibrous Glass Insulation for Metal Buildings.” This specification covers the classification, composition, and physical properties of flexible fibrous glass insulation for use in metal building roofs and walls.

NIA 404 Standard

NIA and its Metal Building Laminator Committee* understand the importance of safety and performance characteristics related to the products we provide the market. The committee meets regularly and recently published a revised standard, “NIA Certified Faced Insulation Standard (Version 404.2–2024).” The specifics of the standard can be found at 404.2–2024

Metal building systems continue to be a popular choice for the one- and two-story commercial and industrial construction markets, since these projects require materials that are engineered to keep pace with constantly evolving design concepts and aggressive energy codes. As a committee, we are committed to providing a fiberglass insulation solution that meets the industry safety and quality requirements, as well as the most stringent energy efficiency codes.

This issue contains articles on the various aspects of metal building insulation systems and their benefits. If you need more information or have questions on utilizing certified faced fiberglass insulation solutions on your next project, reach out to NIA and our Metal Building Laminator Committee members at membership@insulation.org.

* A committee that meets within NIA, which is a not-for-profit service organization dedicated to meeting the needs of mechanical and specialty insulation contractors, distributors, fabricators, manufacturers, and metal building insulation laminators.

NIA Sites > Insulation Outlook Magazine > Global

Where Is this Water Coming From?

Walking through a mechanical room, you are surprised to find a small puddle on the floor  in front of you. “How did that get there?” you wonder, as you start looking around for the source. Something catches your eye, and you see a drop of water falling from above you. Does the roof have a leak? Did someone spill something above you?

Wait, is that pipe sweating?

Water vapor is part of the air around you, as water moves through the water cycle, and it is an important part of transferring heat and energy around the world.1 All air has some water vapor in it, meaning it is always present in the air around your mechanical systems. Given the right conditions, this water vapor will condense into a liquid and will greatly affect the performance of your system.

To determine whether the conditions will lead to condensation, knowledge of the relative humidity and dew point are key. The amount of moisture in the air can be measured by the relative humidity (sometimes abbreviated “RH”), defined as the percentage of water vapor in the air compared to the maximum amount of water vapor that air at that temperature could hold. For instance, in Las Vegas, Nevada, the most arid of the major cities in the United States, the average relative humidity is only 30%, meaning that, on average, only 30% of the maximum amount of water vapor at that temperature is held in the air. Most major U.S. cities average about 70% relative humidity. See Figure 1 for a sample.2

The dew point is the temperature at which water vapor in the air condenses into a liquid. The higher the relative humidity, the closer the dew point will be to the temperature of the air. Conversely, the lower the relative humidity, the cooler the dew point temperature is. For instance, at 68°F and 70% relative humidity, the dew point is 58°F, while at that same 68°F temperature and only 30% relative humidity, the dew point is a crisp 35°F.3

If a surface is below the dew point temperature, the air around it will cool, and the water vapor will condense into a liquid on the surface. Thus, maintaining the surfaces of below-ambient mechanical systems above the dew point temperature is paramount to controlling the formation of condensation.

Condensation: Raining Indoors

Below-ambient systems—such as chilled water, refrigeration, and cool air duct systems—are highly susceptible to the formation of condensation on their surfaces. With surface temperatures far below the average indoor dew point, these systems can quickly perspire and create enough condensation to form indoor rain.

Take, for example, the conditions in Figure 2: a 40°F chilled water pipe in a warm, humid space with relative humidity of 75%. The water vapor molecules in the 80°F air will condense into a liquid, as the surface temperature (Ts) of 40°F is far below the dew point of 72°F of the space.

This is obviously not an acceptable condition for a system, but what can be done to prevent it from happening?

Preventing Condensation: Use Insulation!

Keeping the surface temperature above the dew point, 72°F in the example, is of the utmost importance in preventing condensation. Adding insulation in the proper thickness to the system not only saves energy by preventing heat gains throughout the system, but it also raises the surface temperature above the dew point (Figure 3). However, if the insulation is porous, the water vapor can still find its way through the insulation and will condense on the cold surface of the pipe, regardless of the insulation thickness. If using a porous insulation material, a vapor retarder is necessary to prevent the water vapor from passing through the insulation and condensing.

These principles also hold true for duct systems. As air-conditioning systems not only cool the space but also remove humidity, condensation control is important with duct systems. The correct insulation thickness, with vapor retarder, if necessary, will prevent condensation formation on the duct surfaces, just like the below-ambient piping systems.

Why Is Condensation Forming, Even with Insulation?

Even after a system is insulated, condensation may still form as a result of a miscalculation or poor installation. If the mechanical system designer does not take the extreme humidity conditions of the space into account, or the system functions outside the normal design parameters, the insulation thickness will not be enough to make up for the increase in water vapor in the air, and condensation will form as the surface temperature falls below the dew point. The insulation also must be installed correctly: Any gap in insulation, or any small opening in the vapor retarder, will lead to condensation and must be sealed immediately.

In order to control condensation within a below-ambient system, an insulation material with low water vapor permeability must be chosen to prevent water vapor from passing through the material and condensing on the system. The proper thickness must be determined from the worst-case conditions in the space and can be confirmed with industry or manufacturers’ calculation tools. With the right thickness, low water vapor permeability, and proper installation, a system will be protected from the effects of condensation.

The Problem with Condensation

Condensation in a mechanical system does not just bring the nuisance of dripping water; it can also lead to devastating effects to the insulation or system itself. Moisture ingress is the absorption of water in a porous material that leads to an increase in thermal conductivity and the deterioration of the insulation system. Corrosion under insulation (CUI) can form when water gets trapped between the system and the insulation, heavily corroding the metal underneath. With the presence of water and a food source, mold is apt to follow any condensation that forms in the system.

Moisture Ingress: Soaking up Water Like a Sponge

Porous insulation materials rely on a vapor retarder to protect from water vapor accumulation. Unfortunately, these vapor retarders are not completely impenetrable and often get nicked or torn open during the regular maintenance process, or they are not completely sealed during installation due to difficult configurations or space constraints. With any gap in the vapor retarder, water vapor will start accumulating between the voids like a sponge soaking up water. For every 1% increase in moisture content in the material, a 7.5% loss in thermal value can be expected. After all the voids are filled, condensate will start to accumulate on the exterior surface of the insulation and the system itself, forming a thermal bridge with a thermal conductivity of water (4.1 Btu/(hr. °F. ft2/in) at 75°F mean
temperature). This thermal bridge causes large heat gains within the below-ambient system as the wet insulation allows heat to conduct to the system. When this occurs, the insulation that was used to prevent heat gain is now accelerating it, dropping the system efficiency precipitously. The water being held in close proximity of the system also can lead
to other issues, affecting the material you were trying to protect in the first place (see Figure 4 through Figure 6).

Corrosion Under Insulation

As alluded to earlier, one issue that can result from moisture ingress is CUI, or the formation of corrosion on the system surface when water is trapped between the surface of the system and the insulation. While CUI can form because of a system failure (leaks) or improper weather protection, it can also occur when condensation finds its way to the surface of a pipe through a break in the vapor barrier. Moisture ingress in porous materials can lead to CUI, as the insulation holds onto the water right next to the system itself, wrapping the metal with a wet covering and providing the means to form corrosion. CUI also can form if the water vapor finds a gap in the vapor barrier and proceeds to condense under the insulation. Any system that is subjected to corrosion will not operate as expected, as the metal starts degrading, and the maintenance cost of replacing the damaged system increases. Left alone long enough, this corrosion may lead to a complete failure of the system and the potential for catastrophic events.

Mold

Mold is various types of fungi that can grow on almost any surface that stays between 32°F and 120°F (optimally between 70°F and 90°F) with no air flow and that is damp with moisture.4 If condensation forms within the insulation and the insulation stays damp, it creates the perfect environment for mold growth to begin, often without any trace on the outside of the insulation. The mold can then propagate throughout the insulation and start to form on the surface, where it can travel throughout the air space and cause overall poor air quality within the space, potentially leading to allergies, rashes, and asthma attacks.

Conclusion: Do it Right the First Time

With below-ambient systems, condensation formation is always a risk. If the system is not insulated correctly, moisture ingress, CUI, and mold will soon follow the first drop of condensation. Not only will the insulation have to be replaced if the condensation formation is not identified in time, but the system piping, ductwork, or other components—along with any surrounding equipment that the condensation was dripping on—will have to be replaced as well. It is important to make sure the system is insulated with the right thickness of insulation so that the surface temperature is always above the dew point, and to use a complete vapor barrier to avoid condensation risks.

References
1. https://earthobservatory.nasa.gov/global-maps/MYDAL2_M_SKY_WV
2. Relative Humidity Averages in US Cities – Current Results
3. http://www.dpcalc.org/
4. Michael Pugliese, The Homeowner’s Guide to Mold, Reed Construction Data, Inc ©2006

NIA Sites > Insulation Outlook Magazine > Global

NIA Contractor Member Kerco Discusses System Design

NIA is proud of the professionalism, creativity, and artistry of our Contractor members. To celebrate the craftsmanship of NIA mechanical and industrial insulation contractors, in 2023 we unveiled the first-ever NIA Insulation Project Art Gallery Showcase and Competition. We invited all NIA insulation contractors to submit photographs and a brief description of projects representing their most creative and artistic efforts. At Fall Summit, we posted all the submissions anonymously, and attendees voted for the top three projects in terms of number of parts insulated, aesthetics, difficulty of installation, and well-installed application. As a new regular column, we will profile the projects submitted, focusing this month on Kerco, Inc. We encourage NIA Contractor members to participate in the 2024 Insulation Project Art Gallery Showcase and Competition to possibly be featured in future articles.

PROJECT SNAPSHOT

Insulation Contractor: Kerco, Inc. (www.kercoinc.com)
Industry Segment: Industrial
Type of Plant/Facility: Cold Storage Warehouse
Temperature Range: Below-Ambient System (-40°F to 25°F)
Region: Southwest
System Designed/Application Type: Ammonia Refrigeration System
Insulation Materials (in Process Room and Engine Room):
  • Type–Polyisocyanurate
  • Manufacturer–DUNA-USA
  • Fabricator–Insul-Therm
  • International, Inc.
Jacketing:
  • Interior–PVC (in various colors)
  • Exterior (on roof)–.024 white aluminum with 3/4” stainless steel banding (no screws or staples)
Vapor Barrier: 
  • Type–Mylar Vapor Barrier
  • Brand–Childers

Project Description and Goals

The project involved insulating a refrigeration system for a new cold storage warehouse/process facility operating at below-ambient temperatures ranging from -40⁰F to 25⁰F. Pipes and equipment to be insulated run ammonia (-40⁰F and -25⁰F) and glycol (25⁰F), with temperatures on the piping schedule as follows:

  • Blast and cell freezer at -35⁰F,
  • Freezer at -10⁰F,
  • Dock at 10⁰F, and
  • Glycol at 25⁰F.

Goals of the project were to achieve energy savings by optimizing process efficiency (minimizing heat loss/gain in the system) and to control condensation. In addition, the customer sought to make the complex refrigeration system easier for maintenance personnel to work with by clearly delineating different process lines and temperatures, which offered the additional benefit of enhancing personnel safety.

Challenges

Sometimes the strengths of a project also present its greatest challenges. James Kerco, President of Kerco, Inc., has been in the commercial and industrial mechanical insulation industry for more than 45 years. He says, “The project was extremely well engineered, using colored PVC jacketing indoors to signify the temperature or type of system being insulated by color.” In the dock area, for example, colors were used to indicate the purpose of each pipe—condensate drain, hot gas line, refrigeration line, etc. (see Photo 1). If system repairs need to be made in the future, the colors will make it easy to isolate the line in question. While this simplifies things for facility maintenance personnel, it created a challenge for insulation installation: More than half a dozen colors were to be used, and the right color of jacketing needed to be applied to each pipe and piece of equipment insulated (along with the usual considerations, such as appropriate thickness, etc.).

System Design

Inside the facility, Kerco used polyisocyanurate insulation, with a mylar vapor barrier, applied to pipes and vessels. For condensation control, as well as process efficiency, Kerco personnel ensured insulation was installed at the correct thickness for the specific application, given the temperature of the individual pipes and the ambient temperature of the room where they were located. They used a staggered joint approach, with vapor barrier mastic applied to all seams and joints. Per specifications (and industry best practice), they applied vapor stops and expansion joints, and back-filled all voids with foam. MICA Plate 1-660 illustrates the approach they followed (see Figure 1). “We like to get [the MICA plate] on site to show how we will insulate and seal the pipe, and to educate the end user and the engineer,” James Kerco explains. “It is so important to insulate and seal particular types of insulation systems correctly. You miss one step, and you ruin the entire refrigeration system. The system can be completely destroyed within a year or two” because it was not insulated, or was not insulated properly. In contrast, Kerco adds, a sound insulation system will perform to expectations for so long that “by doing it correctly once, you don’t have to do it again.”

In both the process room and the engine room, pipes and vessels were color-coded using .030 PVC jacketing to indicate the temperature or type of system insulated (see Photo 2). The goal was for facility personnel to be able to walk into the engine room, for example, and know even from a distance what system/temperature each pipe or piece of equipment is.

As noted earlier, this feature presented a real test for the installation group, who had to “meet the challenge that all the PVC went on correctly on each system, making sure nothing was mislabeled,” James Kerco describes. To make sure the correct colors went on each piece insulated—while ensuring the correct insulation thickness was applied to each piping system—Kerco personnel insulated one system at a time, “working hand-in-hand with the refrigeration contractors” so everything was accurate.

Kerco also insulated exterior lines on the roof that provide service to the freezers, blast cells, and dock area (see Photo 3). They used .024 aluminum (painted white), with ¾ inch white stainless steel banding. The banding was essential. James Kerco notes, “You can’t use staples or screws in refrigeration jobs because you would violate the integrity of the vapor barrier. That’s the number one item that needs preservation. If that’s defeated, the system will fail.”

Table 1 offers an overview of insulation system components, listed by location.

The “Wow” Factor

James Kerco says that when facility personnel walked through the finished product, “Everyone was starstruck because of all the different colors—especially the refrigeration plant engineer and operating engineer for the refrigeration system.” Instead of the typical all-white system with labels indicating what ran inside each pipe, at what process temperature, “everything was color-coded, and they understood immediately what the colors meant.” In the end, while the use of color required that extra level of attention to detail during installation, the results were more than worth it in terms of immediate customer satisfaction and the long-term benefits of ease of maintenance and personnel safety.

Emphasis on Safety

James Kerco also stresses that completing a project on time, within budget, and achieving all the customer’s objectives is only part of the job. It is also vital that “we make sure all our employees go home safe at night.” In the pursuit of that mission, Kerco, Inc. is a 2023 NIA Safety Star™, awarded a Bronze Safety Excellence Award in April. As part of the company’s safety plan, in addition to attending regular general safety training and on-site project safety meetings, all Kerco field personnel are specifically trained on the equipment (e.g., forklift operation) and tasks they perform, and all are OSHA 10 certified; superintendents are OSHA 30 certified; and craftsmen and staff alike are trained in CPR. On this project, Kerco’s commitment meant that not only was the customer satisfied, but all Kerco employees were safe at the end of the day.

Project Takeaways

Many aspects of work performance contributed to the project’s success, but the takeaways listed below stand out as elements that are applicable to all insulation projects, whether new construction or upgrades.

  • Communication Is Key. While coordinating schedules among different trades often can be a challenge with new construction projects, James Kerco says that working with the general contractor/refrigeration contractor kept everything running smoothly on this job. He notes, “Communication went well. Everyone knew what had to be done, and we were able to apply the insulation quite well without interruption.”
  •  Start with a Sound Design and Install per Best Practices. A well-engineered, well-specified plan executed by well-trained, experienced personnel following industrybest practices virtually guarantees that project goals will be met or exceeded.
  • Planning Ahead Lowers Risk—and Stress. To ensure that all the materials were available in time, Kerco preordered those that typically require longer lead times, such as the white-painted jacketing used on the roof (which needed to be fabricated).
  • Strength in Numbers. This project offers a real-world example of NIA President Jack Bittner’s theme, Strength in Numbers, as Kerco coordinated with fellow NIA member Insul-Therm International, Inc. (www.insultherminc.com) for fabrication of the polyisocyanurate insulation for the pipes and fittings, which was manufactured by NIA Associate member DUNA-USA (www.dunagroup.com/usa).

Energy Savings

James Kerco observes that although insulation is often among the last products considered, it is one of the most critical parts of a project, especially when it comes to energy savings. He notes, “We’ve been the energy people since insulation began. We were at the forefront when we initially began insulating pipes. We were conserving energy from Day 1.” Now, as so many in government and industry are looking for ways to achieve sustainability, that is a message worth repeating.

About Kerco, Inc.

Kerco is an industry leader in effectively utilizing 21st Century technology to better serve its clients. Using the latest in computer technology, the company can produce fast, accurate, and detailed on-site bids that take into account individual requirements, applicable government regulations, and clients’ design objectives. Kerco’s seasoned craftsmen provide the highest levels of service and technical support in the installation and maintenance of energy retention systems that impede heat gain or loss. For more information, visit www.kercoinc.com.

 

NIA Sites > Insulation Outlook Magazine > Global

Energizing Tomorrow: Waste-to-Energy Initiatives Transforming America


In a world where taking care of our environment is becoming more crucial, the United States is at a crossroads. People worldwide are coming together to tackle big issues like climate change, extending resources, and managing waste.

This article dives into why sustainability matters and how waste-to-energy (WTE) plants could be a possible solution to the U.S. waste crisis.

The Waste Crisis in America

The trash situation in the United States has become a significant issue, contributing to a global challenge. Despite being home to only 4% of the world’s population, the United States produces more than 12% of the planet’s total trash, according to Environment America.

In 2018 alone, the United States disposed of a staggering 292 million tons of municipal solid waste (MSW), as reported by the U.S. Environmental Protection Agency. That number has only increased since.

This type of waste includes materials thrown away by households, businesses, and institutions like schools and libraries. To put it in perspective, each American discards about 4.9 pounds of trash every day, accumulating to nearly 1,800 pounds of waste per person annually.

The concerning part is that a substantial portion of this waste, about 62%, either ends up in landfills or is burned in incinerators. This means that a considerable amount of our waste is not being effectively managed or repurposed, contributing to environmental challenges.

Why is this a problem? The excessive generation of trash poses several issues for the environment.

Landfills take up valuable space, leading to deforestation and habitat loss. Additionally, burning waste in incinerators releases harmful pollutants into the air, impacting air quality and contributing to climate change. The sheer volume of discarded materials also highlights a wasteful use of resources, as many items that could be reused or recycled end up being disposed of in ways that harm the planet.

Addressing the trash crisis in the United States is essential for creating a more sustainable future. It involves not only reducing the amount of waste generated, but also adopting responsible waste management practices, such as recycling and WTE initiatives.

The Rise of Waste-to-Energy Plants

The need for sustainable energy in America goes beyond producing energy without emitting greenhouse gases from fossil fuels. It involves diversifying our energy sources, lessening reliance on imported fuels, and fostering economic development and job opportunities in various sectors. By prioritizing sustainable energy, we aim to create a cleaner environment, enhance energy security, and trigger economic growth through the expansion of job markets in crucial industries.

To address the dual challenge of managing our ever-increasing waste and reducing our dependence on fossil fuels, we must have an innovative solution. This is where the concept of WTE plants emerges as a beacon of hope. WTE plants are innovative facilities that turn waste into usable energy, offering a sustainable alternative to normal waste disposal methods.

In the United States, where a whopping 390 million tons of waste is produced each year, WTE plants offer a way to responsibly manage the leftover waste after recycling and composting.

Case Study: Reworld Waste’s Impact

Reworld Waste LLC, previously known as Covanta, a leader in the field, operates state-of-the-art WTE facilities that redirect waste from landfills, harnessing its energy potential through the combustion of MSW (Multiple Solid Waste). The innovative process transforms remaining waste, post-recycling, into electricity for homes and businesses, or steam exported to industries. This high-tech, advanced approach to waste disposal not only provides a viable energy source but also addresses environmental concerns by significantly reducing greenhouse gas emissions, particularly methane.

Landfills, as identified by NASA scientists, are recognized as significant methane emitters; and methane is 84 times more potent than CO₂ as a climate-warming gas.

Reworld’s WTE facilities make a substantial impact annually:

  • They reduce 21 million tons of greenhouse gas emissions.
  • They continuously power more than 1 million homes.
  • They recycle an impressive 600,000 tons of metal.

The process involves taking non-hazardous waste, otherwise destined for landfills, and combusting it to generate steam for electricity production. The ash produced undergoes processing to recover metal for recycling, while gases are carefully collected, filtered, and cleaned to minimize environmental impact. While it sounds simple, it is an intricate process that requires advanced technology and precision, and expertise mastered by Reworld.

The benefits of WTE extend beyond efficient waste disposal:

  • It is recognized as a technology that actively mitigates climate change.
  • WTE facilities are unique in reducing greenhouse gases, playing a crucial role in addressing climate change—e.g., for every ton of municipal solid waste processed, Reworld reduces greenhouse gases by up to 1 ton.
  • WTE facilities provide reliable energy to power more than 1 million homes 24/7.
  • The process recovers more than 600,000 tons of metal each year for recycling, equivalent to the steel needed for more than 450,000 automobiles.

Reworld’s commitment to sustainable practices and cutting-edge technology highlights a significant step towards a cleaner, more environmentally responsible future.

Environmental Benefits of Waste-to-Energy Plants

Utilizing WTE plants instead of landfills brings numerous advantages.

Reducing Landfill Waste: WTE initiatives play a crucial role in cutting down the amount of waste sent to landfills. Up to 80% of materials in landfills potentially could be reused or recycled. Diverting this material to WTE plants prevents it from causing harm by releasing toxic substances into water, soil, and air.

Generating Massive Energy: Well-planned WTE plants can generate significant amounts of energy, powering the creation of heat and electricity. Recognizing that waste cannot be entirely eliminated, these initiatives provide a second life to waste materials, transforming them into essential resources for human survival.

Environmentally Sound Process: The WTE process itself is environmentally friendly. It operates without relying on fossil fuels or non-renewable resources. WTE plants can even sustain themselves, producing energy while preventing the release of greenhouse gases. According to TRVST, an environmental organization, the power generated from WTE plants has the potential to save the use of 200,000 barrels of oil annually.

Mechanical Insulation’s Role in Waste-to-Energy Plants

In the journey toward a greener and more sustainable future in the United States, mechanical insulation companies like MC&I, Inc. play a crucial role by manufacturing energy-reducing storage tank insulation systems. One of the key ways MC&I, Inc. contributes to this mission is through insulating such tanks in the WTE sector. These storage tanks are utilized for a variety of applications, such as fire protection storage water that feeds a wet sprinkler system in the facility, or for cooling water used in the process.

Why is this important?

Mechanical insulation for storage tanks in WTE plants serves as a cornerstone for environmental responsibility. By providing efficient thermal protection from the atmospheric elements, products like MC&I’s RIDGLOK® Vertical Standing Seam Panel Insulation Systems contribute to the overall effectiveness of these plants, maintaining optimal temperatures and conditions within the storage tanks to make the process even more eco-friendly. Well-insulated tanks help optimize the energy production process, making it more efficient and environmentally friendly.

This commitment to insulation aligns with the broader goal of creating a sustainable America. It is not just about converting waste into energy, but doing so in a way that minimizes environmental impact and lowering energy costs.

The mechanical insulation industry—together with companies like MC&I, Inc. and Reworld—is shaping a future where innovation and environmental consciousness go hand in hand, creating a more sustainable and greener America.

Resources/References:
1. Environment American: https://environmentamerica.org/center/resources/trash-in-america-2/#:~:text=The%20U.S.%20produces%20more%20than,such%20as%20universities%20and%20libraries
2. U.S. Environmental Protection Agency: https://www.epa.gov/facts-and-figures-about-materials-waste-and-recycling/national-overview-facts-and-figures-materials#:~:text=The%20total%20generation%20of%20municipal,25%20million%20tons%20were%20composted.
3. Reworld’s Renewable Energy Recovery: www.reworldwaste.com/what-we-do/renewable-energy-recovery
4. Reworld’s Waste-to-Energy Virtual Tour: www.youtube.com/watch?v=RAXbohaBGt8
5. TRVST: www.trvst.world/renewable-energy/benefits-of-waste-to-energy/