General installation requirements for indoor piping: 

1. Pre-formed fiberglass pipe insulation with ASJ and SSL jacket or poly exterior shall be applied to piping with all joints tightly fitted to eliminate voids.
2. Longitudinal jacket laps and butt strips shall be smoothly secured according to manufacturer’s recommendations.
3. When adhered, the lap and butt strips must be pressurized by rubbing firmly with a plastic squeegee to ensure positive closure.
4. In dual-cycle systems, the installed insulation thickness shall be enough that the outside insulation surface temperature shall be kept below 150°F (60°C).
5. All pipe insulation shall be continuous through wall and ceiling openings and sleeves, except where fire-stop materials are required.
6. Insulation on all surfaces must be applied with a continuous, unbroken vapor seal. Hangers, supports, anchors, etc., that are secured directly to cold surfaces must be adequately insulated and vapor sealed to prevent condensation.
7. Stapling is not recommended. If staples are used they shall be sealed with a vapor retarder mastic or covered with a butt strip.
8. The butt end of every fourth pipe insulation section and the ends or raw edges of insulation terminations at equipment connections, fitting and fire stop systems should be sealed with vapor retarder mastic with a perm rating of equal to or less than 0.02 (ASTM E96, method A).
   1. (Local codes and practices vary regarding the periodic sealing of butt-ends of fiberglass pipe insulation systems, and while Johns Manville believes it is a best practice to limit the risk of moisture drive within the system that can result from damage following installation, they are not a requirement of a functioning and well-designed chilled-water fiberglass pipe insulation system)
9. Rigid insulation inserts shall be installed on pipe sizes 1-½” (38 mm) or larger under outside hangers. The thickness of inserts shall be equal to the thickness of the adjoining insulation and shall be provided with vapor retarder seals.
10. Insulation inserts shall not be less than the following lengths: 

11. Pipe Size		Length
    In.	mm.	in.	mm
    1 ½ - 2 ½	40 - 65	10	254
    3 - 6	80 - 150	12	305
    8 - 10	200 - 250	16	406
    12 & up	300 & up	22	559

12. Galvanized metal shields shall be applied between hangers or supports and the pipe insulation. Shields shall be formed to fit the insulation and shall extend up to the center line of the pipe and shall be of the length specified for the insulation hanger inserts less than 4” (102 mm) to allow for vapor-retarding butt joints on each side of the shields.
13. Specified adhesives, mastics and coatings shall be applied at the manufacturer’s recommended minimum coverage.
14. When PVC jacketing is used, care shall be taken to ensure that the surface temperature of the fitting will be kept below 140°F (60°C) by the use of the proper thickness of insulation and by keeping the PVC cover away from contact with, or exposure to, sources of direct or radiant heat. 

For indoor piping in conditioned and concealed spaces exposed to physical abuse or to high humidity, such as mechanical rooms: 

1. Finish pipe insulation with Zeston PVC Cut & Curled™ jacketing.
2. Fittings, valves and flanges shall be insulated to the same thermal performance (R-Value) as the pipe insulation with Hi-Lo Temp insulation inserts or fabricated fitting insulation and covered with Zeston 2000 PVC insulated fitting covers.
3. All joints in the Zeston PVC Cut & Curled jacketing and Zeston fitting covers shall be sealed with Zeston PVC Z-Tape. 

Outdoor piping systems: 

1. The insulation shall be finished with Johns Manville aluminum, stainless steel jacketing or Zeston Series PVC jacketing.
2. Aluminum or stainless steel jacket shall be overlapped 2” to 3” (51 mm to 76 mm) and held in place with metal bands.
3. Elbows and tees for metal jacketed systems shall be finished with matching two-piece metal fitting covers.
4. Zeston PVC jacketing shall be white 30 mil (0.8 mm) stock thickness. It shall be secured by overlapping and sealing all joints with Zeston Perma-Weld® solvent welding adhesive per manufacturer’s recommended installation procedures.
5. Fittings, valves and flanges shall be insulated to the same thermal performance (R-value) as the pipe insulation with Hi-Lo Temp insulation inserts or fabricated fitting insulation and covered with Zeston 300 PVC insulated fitting covers or pre-formed metal fitting covers. All PVC jacketing joints shall be sealed using Zeston PermaWeld solvent welding adhesive per manufacturer’s recommended installation procedures.

System Insulation: 

1. All pipe insulation shall be continuous through wall and ceiling openings and sleeves, except where fire stop materials are required. 

2. All surface finishes are to be extended to protect all surfaces, ends and raw edges of insulation. 

3. Rigid insulation inserts shall be installed on pipe sizes 1-½” (38 mm) or larger under outside hangers. Inserts shall be of equal thickness to the adjoining insulation and shall be provided with vapor retarder seals where required. 

4. Insulation inserts shall not be less than the following lengths: 

5. Galvanized metal shields shall be applied between hangers or supports and the pipe insulation. Shields shall be formed to fit the insulation and shall extend up to the centerline of the pipe and the length specified for the MICRO-LOK HP • 12 CHAPTER 3: INSULSPEC™ – CSI SPECIFICATION MICRO-LOK HP • 13 insulation hanger inserts less 4” (102 mm) on each side of the shields. 

6. Specified adhesives, mastics and coatings shall be applied at the manufacturer’s recommended minimum coverage per gallon. 

Indoor piping: this portion of the installation procedure is applicable for piping in all indoor areas, including concealed spaces, mechanical rooms and inhabited areas. 

1. Pre-formed fiberglass pipe insulation with all service jacket or poly exterior shall be applied to piping with all joints tightly fitted to eliminate voids. 

2. Longitudinal jacket laps and butt strips shall be smoothly secured according to the manufacturer’s recommendations. 

3. When adhered, the lap and butt strips must be pressurized by rubbing firmly with a plastic squeegee or the back of a knife blade to ensure positive closure. 

4. The installed thickness shall be enough that the surface temperature shall be kept below 150°F (60°C). 

5. For pipe exposed in mechanical equipment rooms or in finished spaces less than 10’ (3 m) above finished floor, finish with Zeston 2000 Cut & Curled PVC or aluminum jacket. 

6. Fittings, valves and flanges shall be insulated with Zeston 2000 PVC insulated fitting covers and Hi-Lo temp insulation inserts per the manufacturer’s recommendations. 

Outdoor piping systems operating up to 850°F (454°C): 

1. Micro-Lok pipe insulation shall be installed over clean, dry pipe with all joints firmly butted together. If a vapor retarder is required, jacket system shall be sealed. 

2. The insulation shall be finished using a metal jacketing with a PFMB or with Zeston PVC jacketing, in 30 mil (0.8 mm) thickness. Metal jacketing shall be overlapped with 2” to 3” (51 mm to 76 mm) and held in place with sheet metal screws or metal bands. The Zeston PVC jacketing shall be secured by overlapping and sealing all joints with Zeston Perma-Weld solvent welding adhesive, per manufacturer’s recommended installation procedures. 

3. All insulation fittings for metal jacketed systems shall be finished with matching two-piece metal fitting covers. 

4. When Zeston 200 PVC Insulated Fitting Covers are used, care shall be taken to ensure that the surface temperature of the fitting will be kept below 140°F (60°C) by the use of a proper thickness of insulation and by keeping the PVC cover away from contact with, or exposure to, sources of direct or radiant heat.