BS 5422 - 2001 Insulation of Ductwork

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BRITISH STANDARD
Method for specifying

thermal insulating
materials for pipes,
tanks, vessels,
ductwork and
equipment operating
within the temperature
range 40 C to +700 C
ICS 23.040.01; 27.220
12&23<,1*:,7+287%6,3(50,66,21(;&(37$63(50,77('%<&23<5,*+7/$:
BS 5422:2001
Incorporating
Corrigendum No. 1
BS 5422:2001
Committees responsible for this

British Standard
The preparation of this British Standard was entrusted to Technical
Committee RHE/9, Thermal insulating materials, upon which the following
bodies were represented:
Association of Building Component Manufacturers
Autoclaved Aerated Concrete Products
BEAMA Ltd. Power Generation Contractors Association
Chartered Institution of Building Services
Concrete Block Association
Cork Industry Federation
Cranfield University
Department of the Environment, Transport and the Regions (represented by
the Building Research Establishment)
Electricity Association
Energy Industries Council
EURISOL UK Mineral Wool Association
European Phenolic Foam Association
Gypsum Products Development Association
National Physical Laboratory
Thermal Insulation Contractors Association
Thermal Insulation Manufacturers and Suppliers Association
Co-opted members
The following bodies were also represented in the drafting of the standard,
through subcommittees:
British Refrigeration Association
British Rigid Urethane Foam Manufacturers Association
This British Standard, having
been prepared under the
direction of the Engineering
Sector Policy and Strategy
Committee, was published
under the authority of the
Standards Policy and Strategy
Committee on
05 December 2001
HEVAC Association
Insulation Jacket Manufacturers Federation
Polyethelene Foam Insulation Association
BSI 13 November 2002

First published July 1977
Second edition July 1990
Third edition December 2001
The following BSI references
relate to the work on this
British Standard:
Committee reference RHE/9
Draft for comment 01/706326 DC
ISBN 0 580 38645 7
Amendments issued since publication

Amd. No.
Date
13982
13 November 2002 Changes to Table 19, Table 20, Table 21,

Table A.1 and Table C.1
Corrigendum No. 1
Comments
BS 5422:2001
Contents
Committees responsible
Foreword
Page
Inside front cover
iii
Introduction
1
Scope
2
Normative references
3
Definitions
4
Application of this standard
5
General requirements
6
Refrigeration applications
7
Chilled and cold water applications
8
Central heating, air conditioning and direct hot water supply
installations in non-domestic applications
9
Central heating and hot and cold water services for domestic
applications
10
Process pipework and equipment applications
11
Protection against freezing
Annex A (informative) Determination of environmental thickness
Annex B (informative) Default values for use in BS EN ISO 12241 heat
transfer calculations
Annex C (informative) Summary of criteria used to establish the tables
Annex D (informative) Outside diameters of steel and copper pipes
Annex E (informative) Explanation of Class 0 rating and limited
combustibility
Annex F (normative) Method for assessing the system load for refrigeration
pipe-work
Annex G (normative) Calculation of economic insulation thickness
Bibliography
Figure 1 Flow chart indicating application of the standard
Figure 2 Graph to determine environmental heat gain for intermediate
temperatures
Figure A.1 Heat loss related to pipe diameter for non-domestic heating
pipe at 75 C insulated in accordance with Table 12
Figure F.1 Example of Mollier diagram for R-22
Figure G.1 Economic thickness
Table 1 Maximum permitted water vapour permeance in relation to plant
temperature at an ambient temperature of +20 C (dry bulb)
Table 2 Minimum insulation thickness for refrigeration applications to
prevent condensation on a high emissivity outer surface (0.90) with an
ambient temperature of +20 C and a relative humidity of 70 %
prevent condensation on a low emissivity outer surface (0.05) with an
prevent condensation on a high emissivity outer surface (0.90) with an
prevent condensation on a low emissivity outer surface (0.05) with an
Table 6 Environmental insulation thickness for refrigeration applications
to control heat gain
Table 7 Minimum insulation thickness for chilled and cold water supplies
to prevent condensation on a high emissivity outer surface (0.90) with an
1
1
1
2
3
5
8
16
18
23
24
36
41
43
45
46
47
48
50
52
4
21
41
49
50
8
10
11
12
13
14
17
i
BS 5422:2001
Page
Table 8 Minimum insulation thickness for chilled and cold water supplies
to prevent condensation on a low emissivity outer surface (0.05) with an
17
Table 9 Environmental insulation thickness for chilled water supplies to
control heat gain
18
Table 10 Minimum insulation thickness for condensation control on
ductwork carrying chilled air in ambient conditions: indoor still air
temperature +25 C, relative humidity 80 %, dewpoint temperature 21.3 C 20
Table 11 Environmental insulation thickness on ductwork carrying
warm air
21
Table 12 Environmental insulation thickness for non-domestic heating
installations to control heat loss
22
Table 13 Environmental insulation thickness for non-domestic hot water
service areas to control heat loss
23
Table 14 Environmental insulation thickness for domestic central heating
installations and hot water systems in potentially unheated areas to control
heat loss
24
Table 15 Environmental insulation thickness for process pipework and
equipment to control heat loss
26
Table 16 Insulation thickness for personnel protection from a non-metallic
surface with a surface emissivity of 0.90 and design cold face temperature
of 59 C
28
Table 17 Insulation thickness for personnel protection from a metallic
30
of 50 C
Table 18 Insulation thickness for personnel protection from a non-metallic
of 50 C
32
Table 19 Heat loss from bare surfaces calculated in accordance with
BS EN ISO 12241 (black steel pipes)
34
BS EN ISO 12241 (copper pipes commercial grade, scoured to a shine)
35
BS EN ISO 12241 (copper pipes oxidized)
36
Table 22 Minimum insulation thickness to protect steel pipes against
freezing under selected industrial process conditions
37
Table 23 Minimum insulation thickness required to give protection
against freezing under specified commercial and institutional conditions
38
Table 24 Minimum insulation thickness to protect against freezing for
domestic cold water systems (12 h)
39
Table 25 Minimum insulation thickness to protect against freezing for
domestic cold water systems (8 h)
40
Table A.1 Environmental thickness methodologies
42
Table B.1 Surface emissivity (()
43
Table B.2 Default data for use in BS EN ISO 12241 calculations
44
Table C.1 Summary of criteria used to establish the tables
45
Table D.1 Outside diameter of steel pipe (from BS 3600)
46
Table D.2 Outside diameter of copper pipe (from BS EN 1057)
46
ii
BS 5422:2001
Foreword
This British Standard has been prepared by Technical Committee RHE/9,
Thermal insulating materials. It supersedes BS 5422:1990, which is withdrawn.
The methods of calculation used in this standard have been revised to harmonize
with the methods in BS EN ISO 12241, which were developed to give uniform
international methods of calculation, and differ slightly from those given in the
previous edition of BS 5422.
All tables of insulation thicknesses have been reviewed. The assumptions on
which the tables are based are given in each case.
The previous economic insulation thicknesses have been revised in the context
of their potential to limit carbon dioxide (CO2) emissions, whilst maintaining due
consideration of both economic and practical factors. This new approach is
referred to as the environmental thickness calculation. Annex A shows the way
in which the environmental thickness was derived from the economic thickness.
The frost protection tables have been revised to reflect more accurately UK design
and operating conditions.
The standard is not prescriptive, and recognizes that there are many reasons why
the insulation of pipes, tanks, vessels, ductwork and equipment may be required.
It is therefore important that specifiers state the criteria or specific clause or
reference in this standard in any specification.
Insulation thicknesses are given for a range of thermal conductivities appropriate
to the usual materials used for the application; thicknesses for intermediate
thermal conductivities and pipe sizes may be deduced by calculation or
interpolation. For assistance in selecting an appropriate type of insulation and
suitable methods of application, reference should be made to BS 5970.
Unless otherwise stated, the temperature of the surface to be insulated is taken
to be the temperature of the fluid inside the pipe, tank, duct, vessel or other piece
of equipment.
NOTE Requirements in this standard are expressed in accordance with BS 0-3:1997, 10.1.3.1.1,
which states, Requirements shall be expressed using wording such as: When tested as described in
annex A, the product shall ... . This means that only those products that are capable of passing the
specified test will be deemed to conform to this standard.
Annex F and Annex G are normative. Annex A, Annex B, Annex C, Annex D and
Annex E are informative.
This publication does not purport to include all the necessary provisions of a
ontract. Users are responsible for its correct application.
Compliance with a British Standard does not of itself confer immunity
from legal obligations.
Summary of pages
This document comprises a front cover, an inside front cover, pages i to iv,
pages 1 to 53 and a back cover.
The BSI copyright notice displayed in this document indicates when the
document was last issued.
iii
iv
blank
BS 5422:2001
Introduction
In any single application, thermal insulation material can perform a variety of functions simultaneously,
including:
a) inhibit freezing in an unheated pipe;
b) prevent condensation on a chilled or cold pipe;
c) protect personnel from exposure to extremes of temperature;
d) conserve energy for both cooled and heated systems;
e) control process temperatures.
Even within the range listed, consideration should be given to sub-sectors of these functions.
For example, energy conservation can be driven by two distinct considerations. The first, and more
traditional, reason for seeking energy saving is to save cost. The second, and more recent, reason for
seeking energy saving is to minimize carbon dioxide emissions from the associated power source. Although
any insulation measure has desired effects in both of these areas simultaneously, the extent of insulation
that can be justified varies with the comparative costs of energy on the one hand, and alternative costs of
carbon dioxide emission abatement on the other. Since thermal insulation of pipework and equipment
represents one of the most cost-effective ways available of limiting carbon dioxide emissions, this standard
highlights a series of environmental thicknesses within its core tables. (The derivation of these thicknesses
from the previous edition of BS 5422 is explained in Annex A.) Nonetheless, it is still possible, and fully
justified, to choose an economic insulation thickness where carbon dioxide emissions are of lower
importance (e.g. with low carbon fuels) and cost minimization is the priority.
Although the tables provided in this standard offer a simple method of determining the minimum thickness
levels, their use will require the basic information outlined in clause 4 and, in some cases, additional
information may be required. This specific information is outlined in the clauses pertaining to specific
applications.
It is also common that information such as the thermal conductivity of the chosen insulation material or
the pipe diameter do not conform to the categories highlighted in the relevant tables. Under these
circumstances, it is possible to interpolate between either columns or rows where the margin of error is not
likely to be critical. For situations where the application parameters differ from those covered within the
scope of a table (e.g. different ambient air temperature), the specifier will need to revert to first principles
by using methods set out in BS EN ISO 12241.
The default values for use in BS EN ISO 12241 heat transfer calculations are given in Annex B, the criteria
used to establish the tables are summarized in Annex C, and the diameters of pipes considered are given
in Annex D.
1 Scope
This British Standard describes a method for specifying requirements for thermal insulating materials on
pipes, tanks, vessels, ductwork and equipment for certain defined applications and conditions within the
temperature range 40 C to +700 C. It also specifies physical requirements for the insulating materials.
It is intended for use by specifiers, contractors and manufacturers of thermal insulation.
This British Standard does not apply to pipelines that are embedded underground, nor does it refer to the
insulation of building construction.
2 Normative references
The following normative documents contain provisions which, through reference in this text, constitute
provisions of this British Standard. For dated references, subsequent amendments to, or revisions of, any
of these publications do not apply. For undated references, the latest edition of the publication referred to
applies.
BS 476-6:1989, Fire tests on building materials and structures Part 6: Method of test for fire propagation
for products.
BS 476-7:1997, Fire tests on building materials and structures Part 7: Method of test to determine the
classification of the surface spread of flame of products.
BS 5422:2001
BS 476-12:1991, Fire tests on building materials and structures Part 12: Method of test for ignitability of
products by direct flame impingement.
BS 3177, Method for determining the permeability to water vapour of flexible sheet materials used for
packaging.
BS 4370-2:1993, Methods of test for rigid cellular materials Part 2: Methods 6 to 10.
BS 5970: 2001, Code of practice for thermal insulation of pipework and equipment (in the temperature
range 100 C to +870 C).
BS EN ISO 12241:1998, Thermal insulation for building equipment and industrial installations
Calculation rules.
ISO 1182, Fire tests Building materials Non-combustibility tests.
3 Definitions
For the purposes of this British Standard, the following definitions apply.
3.1
assumed lifetime
lifetime assumed for insulation installed in a defined application
NOTE
This is used to provide an assessment of the amount of energy (and hence carbon dioxide) saved by the use of the insulation.
3.2
chilled water
water that has been processed through cooling plant (typically 0 C to +10 C)
3.3
cold water
water delivered from the mains or natural supply
3.4
economic thickness
thickness of insulation that minimizes the total cost (investment and running costs) over a chosen
evaluation period (usually significantly less than the assumed lifetime)
3.5
environmental thickness
thickness of insulation that delivers energy saving at an investment level commensurate with other
measures to save carbon dioxide (CO2) and offers parallel performance to other insulation materials
selected to the same criteria
3.6
evaluation period
time over which the heat transfer through insulated surfaces is to be calculated, e.g. to carry out frost
protection or economic thickness calculations
3.7
finishing materials
materials used to cover the insulation, whether pre-applied or applied on site
3.8
insulation thickness
thickness of insulating material, excluding any finish or covering
3.9
pre-applied
applied to the insulation prior to delivery to the point of use
3.10
termination point
point at which the thermal insulation applied to a pipe, duct or vessel is terminated, e.g. at a valve or
flange, or where traversing a wall or ceiling
BS 5422:2001
3.11
vapour barrier
water-vapour-retarding layer
NOTE
Permeance values for vapour barriers are given in Table 1.
4 Application of this standard

A specification produced in accordance with this British Standard shall specify only those elements of the
standard to which conformity is required for a specific application. A specification shall be deemed to
conform to this British Standard if it makes reference to the clauses and tables within this standard that
pertain to the application being specified. The selection of materials and the insulation thickness to be
specified shall be determined according to the intended function of the insulation (see Figure 1).
The specification shall state the prime purpose of the insulation and shall specify the performance
requirements for the selected insulation system. The specification shall identify the minimum thickness
requirements for each parameter of performance and shall identify the parameter that requires the
greatest thickness for the application in question.
The performance requirements shall be specified in accordance with the appropriate clauses and tables of
this standard, which shall be determined from the following factors:
a) system operating temperature;
b) design ambient air temperature;
c) relative humidity of the ambient air;
d) air velocity;
e) location of the plant (indoors or outdoors);
f) pipe diameter (or flat surface dimensions);
g) orientation of pipes (horizontal or vertical);
h) vertical dimensions of flat surfaces;
i) emissivity of outer surface.
For refrigerated, chilled and other cold applications the following performance requirements, if applicable,
shall also be specified in accordance with the appropriate clauses and tables of this standard:
j) resistance of the insulation material to the passage of water;
k) permeance of any vapour barriers used.
BS 5422:2001
Select the reasons

for insulating
Inhibit
freezing
Control
condensation
Protect
personnel
Control
processes
Conserve
energy
Cost saving Carbon saving

(economic) (environmental)
Clause 6
Tables 2, 3, 4, and 5
Table 6
Clause 7
Tables 7 and 8
Table 9
Clause 8
Table 10 (duct)
Tables 12 and 13
Table 14
Clause 9
Table 15
Tables 16, 17, 18
Clause 10
Clause 11 Tables 22, 23, 24, 25
Annex
A and F
Figure 1 Flow chart indicating application of the standard
BS 5422:2001
5 General requirements
5.1 Physical characteristics
The manufacturer or specifier shall specify requirements for the physical characteristics of the insulating
material, including finishing materials whether pre-applied or applied on site, to conform to the
appropriate British Standard.
Where combustible insulating materials are used, the fire performance shall conform to 6.2.2, 7.2.2, 8.2.2,
9.2.2, or 10.2.2, as appropriate.
The manufacturer or supplier shall specify requirements, together with appropriate methods for
verification, for the insulating material to conform to whichever of the following conditions are deemed to
be appropriate.
a) The materials do not contain substances that will support pests or encourage the growth of fungi.
b) The materials are free from objectionable odour at the temperatures at which they are to be used.
NOTE 1
Transient effects during the initial period of use may generally be ignored.
c) The materials do not suffer permanent structural or physical deterioration as a result of contact with
moisture.
d) The insulation is suitable for specified conditions of use without the physical properties falling outside
the tolerances allowed in the appropriate British Standard for the material.
e) The materials in contact are compatible and do not cause corrosion or degradation under normal site
conditions.
f) The materials and their method of application do not constitute a known risk to health during
application or use.
NOTE 2 Reference should be made to BS 5970 for health hazards when selecting, storing or removing insulation. Attention is
also drawn to the latest edition of HSE Guidance Note EH 40 [1].
5.2 Installation requirements

NOTE
Guidance on the correct application of insulation and associated attachments is given in BS 5970.
If different forms of insulation are likely to be used for specific areas of the installation, the specifier shall
indicate whether or not such areas are to be treated identically or differently.
The specifier shall state the type of finish to be applied if additional protection is required.
5.3 Thermal conductivity
5.3.1 General
Manufacturers of insulating materials shall supply a table of declared thermal conductivity values based
on results of tests carried out in accordance with the appropriate British Standards. The information shall
include the corresponding cold face temperatures and the product identification. Thermal conductivity
shall be expressed in Watts per square metre for 1 m thickness and a temperature difference of 1 K.
NOTE 1 The values for thermal conductivity quoted in the tables relate to the appropriate insulation mean temperature, which is
defined as the mean of the operating temperature of the system added to the temperature of the outer surface of the insulation system.
NOTE 2 In terms of unit symbols thermal conductivity should be expressed as Wm/(m2K) but in normal practice it is simplified
to W/(mK).
5.3.2 Single-layer insulation (or multilayer insulation where the layers are of the same
composition)
In all cases the contractor shall state the manufacturers declared values of thermal conductivity for each
material proposed. These declared values shall be appropriate to the mean temperature of the applied
insulation.
5.3.3 Composite insulation
When two or more layers of dissimilar insulating material are to be used, the contractor shall provide
the declared value of thermal conductivity for each layer under the appropriate temperature conditions.
The thickness of each layer shall also be stated.
BS 5422:2001
5.3.4 Design value of thermal conductivity and thermal bridges

Additional allowances shall be made to ensure that the specified performance is achieved where system
inefficiencies are created through the ageing of the product, or by the use of uninsulated valves or other
ancillary fittings.
NOTE 1
An appropriate methodology for ensuring compliance is given in BS EN ISO 12241:1998, Annex A.
NOTE 2 To limit heat transfer through supports, load-bearing insulating material should be used on the pipe or vessel between the
support and the surface to be insulated. If a water vapour barrier is required, the sealing of the load-bearing material should conform
to the same requirements as the basic insulation and fitted so that the integrity of the vapour barrier of the system is maintained.
Where the heat transfer through the supports does not need to be limited but a water vapour barrier is required, the edges of the
insulation, where interrupted at the support, should be sealed to maintain the effectiveness of the vapour barrier.
NOTE 3 Although it is possible to compensate for uninsulated valves by increasing insulation levels elsewhere, it can prove more
cost-effective to insulate the valves themselves using appropriate fittings which should be selected on the basis of ease of access where
necessary.
5.4 Temperature limitations

The manufacturer shall state the maximum and minimum continuous operating temperatures of the
products specified, and any other temperature limitation appropriate to the anticipated service conditions.
If the temperature of the surface to be insulated is above the limiting temperature of the preferred main
insulating material, composite or alternative insulation shall be specified. Where composite insulation is
specified, the thickness of each layer shall be calculated to ensure that the interface temperature between
the two materials does not exceed the limiting temperature for the material of the outer layer.
5.5 Thickness
If thicknesses are required other than those given in the tables in the appropriate section, or bases other
than those from which they were derived, the specification shall state the thickness required or the bases
to be used in the calculation.
If the thicknesses given in, or interpolated from, the tables do not correspond with available thicknesses,
the nearest higher available thickness shall be used.
In multilayer applications, where material thicknesses are rounded up to suit available thicknesses, a
further calculation in accordance with BS EN ISO 12241 shall be made to ensure that each interface
temperature is below the maximum continuous operating temperature of the materials involved.
NOTE 1 Additional allowances should be made for heat transfer through joints, valves and other fittings when determining
insulation thickness in accordance with BS EN ISO 12241.
NOTE 2 Thicknesses given in the tables within this standard are specifically calculated against the criteria noted in each table.
Adopting these thicknesses may not necessarily satisfy other design requirements.
5.6 Fire performance

5.6.1 Different levels of fire performance, the requirements for which are given in 5.6.2, 5.6.3, 5.6.4, 5.6.5,
5.6.6, 5.6.7, 5.6.8, 5.6.9, 5.6.10 and 5.6.11, shall be specified according to the type of application.
The particular requirements to be specified for each type of application shall be selected in accordance
with 6.2.2, 7.2.2, 8.2.2, 9.2.2 or 10.2.2.
NOTE In the event of a fire some insulation systems can generate appreciable quantities of smoke and toxic fumes. Consideration
should be given to the choice of materials bearing in mind their location, e.g. enclosed areas or adjacent to air ducts through which
the smoke or fumes may spread.
5.6.2 When tested in accordance with BS 476-12:1991, insulation materials shall be resistant to ignition
sources types A and B.
5.6.3 When tested in accordance with BS 476-7:1997, the complete assembly of insulation materials, as
installed, shall conform to the class 1 spread of flame requirements.
5.6.4 Where the insulating material itself (i.e. without any facing) is not rated class 1 when tested in
accordance with BS 476-7:1997, particular care shall be taken with the added facing material to ensure
that all joints and seams, etc. are fitted correctly, so that the underlying insulation is not left exposed and
does not therefore provide a potential ignition source.
NOTE Where the complete assembly is liable to mechanical damage in use, the final finish should be sufficiently strong to ensure
that the insulation does not become exposed.
BS 5422:2001
5.6.5 Fire certification for faced materials shall state the nature of the facing material, the type and weight
of any reinforcement, the type and weight of adhesive, the type and manufacturer of the substrate and any
other factors pertinent to the fire performance of the system.
5.6.6 When tested in accordance with BS 476-7:1997, the insulation material itself (i.e. without any facing)
shall conform to the class 1 spread of flame requirements.
5.6.7 When tested in accordance with BS 476-6:1989, the complete insulation assembly as installed, and
the insulation material itself where it is used unfaced, shall achieve a fire propagation index (I) not
exceeding 12.0, of which the initial subindex of performance (i1) shall be not more than 6.0.
5.6.8 When tested in accordance with ISO 1182, insulation systems on pipework or ductwork traversing a
fire-resisting division shall be shown by independent data to maintain the level of fire resistance of the
wall, floor or cavity barrier through which they pass.
5.6.9 In underground or windowless buildings, the thermal insulation material used for external insulation
of ventilation ductwork or pipes greater than 100 mm nominal bore size, when tested in accordance with
ISO 1182, shall itself be of limited combustibility or non-combustible, with a weight loss during the test
of not more than 50 %. In addition, the complete insulation assembly as installed shall conform to the
class 1 spread of flame requirements when tested in accordance with BS 476-7:1997, and the fire
propagation requirements when tested in accordance with BS 476-6:1989 (see 5.6.7).
NOTE
See Annex E for an explanation of limited combustibility.
5.6.10 When tested in accordance with ISO 1182, insulation materials for use at temperatures
above 230 C (excluding finishing materials) shall be of limited combustibility or non-combustible, with
a weight loss during the test of not more than 50 %.
NOTE
See Annex E for an explanation of limited combustibility.
5.6.11 If there is a potential hazard from contamination by oil or other flammable chemicals, a suitably
resistant finish, e.g. a metal sheet or appropriate non-absorbent coating, shall be applied over the
vulnerable areas. The lapped joints of sheet finishes shall be arranged to shed contaminating fluids away
from the insulating material.
5.7 Vapour barrier Permeance requirements
NOTE 1 Condensation of water vapour will occur on a surface that is at a temperature below the atmospheric dew point
temperature. Moisture can be deposited within the insulating material and on the insulated metal surface. Where the insulated
surface is likely to be at or below the dew point temperature during any part of its operating cycle, an effective vapour barrier should
be applied on the warmer face of the insulation to avoid deposition of moisture within the insulating system. The presence of water
within an insulation system can reduce thermal effectiveness and lead to corrosion of metal components.
For the purpose of this standard an effective vapour barrier shall be deemed to be one that meets the water
vapour permeance requirements given in this subclause.
Different levels of water vapour permeance shall be specified according to the type of application. Where
the insulating material itself does not conform to the water vapour permeance requirement, a vapour
barrier on the outside (warm side) of the insulation shall be used.
The vapour barrier shall take the form of a coating or sheet material. Any joints in the coating or sheet
material or in the insulating material itself, where it is providing the water vapour permeance
requirement, shall be fully sealed.
NOTE 2
This is to ensure that the vapour permeance performance is maintained continuously in the system as installed.
Particular care shall be taken at termination points. The external vapour barrier, where required, shall be
pre-applied or applied immediately after fitting the insulating material and before the fluid in the pipe,
duct, or vessel is cooled.
When a vapour barrier is used, the system as installed, when tested in accordance with the various
methods specified in 5.6, shall have a fire performance at least equal to that specified in 5.6 as appropriate
to the type of application.
BS 5422:2001
The water vapour permeance of a flexible sheet material used as the vapour barrier shall be assessed in
accordance with the method given in BS 3177. The test conditions, e.g. temperate or tropical, and the
thickness of the test specimen shall be stated. Where the apparatus for the method in BS 3177 is unsuitable
because of the thickness of the test specimen, BS 4370-2:1993, method 8 shall be used. The permeance of
the vapour barrier shall be selected according to its relationship to the cold surface temperature of the plant
and to the temperature difference, in degrees centigrade (C), between the plant temperature and ambient
temperature as indicated in Table 1.
Table 1 Maximum permitted water vapour permeance in relation to plant temperature at an
ambient temperature of +20 C (dry bulb)
Water vapour permeance of barrier
g/(sMN)
Temperature of plant (cold surface)

C
10
5
0
5
10
15
20 to 40
0.050
0.015
0.010
0.004
0.002
0.0015
0.0010
NOTE 3 The permeance values given in Table 1 are applicable at an ambient temperature of 20 C and a relative humidity of 70 %,
and other environmental conditions resulting in an equal or lesser partial vapour pressure difference. In order to calculate the partial
vapour pressure difference, the internal temperature should be assumed to be equal to the plant temperature and the internal relative
humidity to be 100 %. In situations where the environmental conditions are normally 25 C and a relative humidity of 80 % the vapour
barrier permeance is selected from the table by subtracting 10 C from the plant operating temperature.
Where an external vapour barrier is used in service, separate layers in the form of coatings or sheet
material shall be used for the individual purposes. The specifier shall state the type of finish to be applied
where additional protection is required. Where such additional protection is specified, the installer shall
ensure that its application does not cause any damage to the vapour barrier during its installation and is
unlikely to cause damage in service. (For further details see BS 5970:2001.)
NOTE 4 The use of an external vapour barrier where specified is an essential requirement for the proper functioning of the
insulation system. It is essential that its use for this purpose is not compromised by its additional use for other purposes e.g. as a form
of weather protection or as mechanical protection for the thermal insulation.
5.8 Tests on physical properties

Where particular physical properties are required the specifier shall nominate the appropriate British
Standard test methods. Only where no suitable British Standard test methods exist shall the specifier
authorize the use of an alternative test method to determine whether the required level of performance is
met.
6 Refrigeration applications
6.1 Information to be supplied by the specifier
The specifier shall supply details of the intended function and performance requirements of the application,
and the materials to be used, in accordance with clause 4.
NOTE In addition to the parameters outlined in clause 4, items such as specific heat capacity and mass flow rates of fluids may also
be required under certain circumstances, particularly where calculating from first principles using BS EN ISO 12241. However, these
additional parameters are not required for the use of the tables contained in this standard.

6.2.1 General
The physical characteristics of the insulating material including finishing materials and vapour barriers,
whether applied during manufacture or on site, shall conform to 5.1, 6.2.2 and 6.2.3.
BS 5422:2001
6.2.2 Fire performance

Insulation materials and systems used for refrigeration shall conform to 5.6.2, 5.6.3, 5.6.5, 5.6.8 and 5.6.9.
Insulation materials and systems used for refrigeration shall also conform to 5.6.4 except where the
installed insulation assembly is unfaced, when 5.6.6 shall apply.
Where the equipment and pipework is located in non-domestic buildings, but excluding process
applications, the insulation system shall conform to 5.6.7.
6.2.3 Water vapour barrier Permeance requirements
Insulation materials and systems used for refrigeration shall be installed in accordance with and shall
conform to the permeance requirements specified in 5.7.
When tested in accordance with BS 3177 or BS 4370-2, as appropriate, the permeance of the material used
as a vapour barrier shall not exceed the values given in Table 1 for the appropriate temperature of the
plant.
6.3 Insulation thickness
6.3.1 Protection against condensation
In the absence of specific instructions from the specifier, the insulation thickness shall be not less than that
given in Table 2, Table 3, Table 4 and Table 5, as appropriate.
6.3.2 Insulating to minimize heat gain
NOTE Under certain circumstances, typically where heat gain from distribution pipes represents greater than 5 % of the total
system refrigeration load, it may be appropriate to consider insulating to minimize heat gain. This can require greater thicknesses
than those required for condensation control.
If insulation is used to minimize heat gain, the insulation thickness shall be not less than that given
in Table 6 for the temperature range 0 C to 40 C.
Outside diameter of
steel pipe on which
has been based
(mm)
21.3
33.7
60.3
114.3
168.3
273.0
508.0
610.0
Flat surfaces
Insulation thickness (mm)

t=0
t = 10
t = 20
t = 30
t = 40
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
5
5
6
6
7
7
7
8
8
7
8
8
9
10
10
11
11
11
9
10
11
12
13
13
14
15
15
11
12
13
15
16
17
18
18
18
8
8
9
10
11
12
12
12
12
11
12
13
15
16
17
18
18
18
14
15
17
19
21
22
24
24
24
16
18
21
24
25
27
29
30
30
10
11
13
14
15
16
17
17
17
14
16
18
20
22
23
25
25
26
18
20
23
26
28
30
33
33
34
22
24
28
32
34
37
40
41
43
13
14
16
18
19
20
22
22
22
18
20
22
25
27
29
32
32
33
22
25
29
33
35
38
41
42
44
27
30
34
40
43
47
51
52
55
15
17
19
21
23
24
26
27
27
21
23
27
30
33
35
38
39
40
26
29
34
39
42
46
50
51
54
31
35
41
47
51
56
62
63
67
Key
t = temperature of contents (C)
2 = thermal conductivity at mean temperature of insulation [W/(mK)]
NOTE
Thicknesses given are calculated specifically against the criteria noted in the table. These thicknesses may not satisfy other design requirements.
BS 5422:2001
10
Table 2 Minimum insulation thickness for refrigeration applications to prevent condensation on a high emissivity outer
surface (0.90) with an ambient temperature of +20 C and a relative humidity of 70 %
Table 3 Minimum insulation thickness for refrigeration applications to prevent condensation on a low emissivity outer
Outside diameter of
steel pipe on which
has been based
(mm)
21.3
33.7
60.3
114.3
168.3
273.0
508.0
610.0
Flat surfaces

t=0
t = 10
t = 20
t = 30
t = 40
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
9
10
12
14
16
17
20
21
20
13
14
17
20
23
26
30
31
30
16
19
22
27
30
34
39
41
40
20
23
27
33
36
41
49
51
50
14
16
19
23
25
29
33
35
34
20
23
27
33
37
42
49
52
51
26
30
35
43
48
55
65
68
68
31
36
43
52
59
67
80
84
85
19
22
26
31
35
40
46
49
48
27
31
37
45
50
58
68
71
72
35
40
48
58
65
75
89
94
96
42
49
59
71
80
92
110
115
119
24
27
33
39
44
50
59
62
62
34
39
47
57
64
73
87
91
93
44
50
60
73
82
95
113
119
123
53
61
73
89
101
116
139
146
154
28
33
39
47
53
61
72
75
76
41
47
56
68
76
88
105
110
113
52
60
72
88
99
114
137
144
151
64
73
88
107
121
140
167
176
188
Key
NOTE
BS 5422:2001
11
Outside diameter of
steel pipe on which
has been based
(mm)
21.3
33.7
60.3
114.3
168.3
273.0
508.0
610.0
Flat surfaces

t=0
t = 10
t = 20
t = 30
t = 40
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
2p =
0.020
2p =
0.030
10
11
12
13
14
15
16
16
16
14
15
17
19
20
22
23
24
24
17
19
22
25
26
28
30
31
32
21
23
26
30
32
35
37
38
39
13
15
17
19
20
21
23
23
23
19
21
24
27
29
31
33
34
35
24
26
30
34
37
40
44
44
46
28
32
36
42
45
49
54
55
58
17
19
21
24
26
27
29
30
31
23
26
30
34
37
40
43
44
46
29
33
38
44
47
51
56
58
61
35
40
46
53
57
63
69
71
76
20
22
26
29
31
33
36
37
38
28
31
36
41
44
48
53
54
57
35
39
45
53
57
62
69
70
76
42
47
55
63
69
76
84
86
94
23
26
30
34
36
39
43
44
45
32
36
42
48
52
57
62
64
68
Key
NOTE
2p =
0.040
41
46
53
61
66
73
81
83
90
2p =
0.050
49
55
63
74
80
88
99
102
113
BS 5422:2001
12
Table 4 Minimum insulation thickness for refrigeration applications to prevent condensation on a high emissivity outer
Table 5 Minimum insulation thickness for refrigeration applications to prevent condensation on a low emissivity outer
Outside diameter of
steel pipe on which
has been based
(mm)
21.3
33.7
60.3
114.3
168.3
273.0
508.0
610.0
Flat surfaces

t=0
t = 10
t = 20
t = 30
t = 40
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
2p =
0.020
2p =
0.030
19
22
27
32
36
40
47
49
49
28
32
38
46
51
59
69
73
73
36
41
49
60
67
77
91
95
97
43
50
60
73
82
94
112
117
122
27
31
37
45
51
58
68
71
72
39
45
53
65
73
84
99
104
107
50
58
69
84
94
109
130
136
143
61
70
84
102
115
133
159
167
179
35
40
48
58
65
75
88
93
95
50
57
68
83
93
108
128
135
142
64
74
88
107
121
140
167
176
189
79
90
107
131
147
170
205
216
236
42
48
58
70
79
91
108
113
117
60
69
83
101
113
131
157
165
176
78
90
107
130
146
169
203
214
234
96
109
130
158
178
206
249
262
292
49
57
68
82
93
107
127
134
140
71
81
97
118
133
154
184
194
210
2p =
0.040
92
105
125
152
171
198
239
252
280
2p =
0.050
113
129
153
185
209
242
291
308
349
Key
NOTE
BS 5422:2001
13
Outside
t=0
t = 10
t = 20
diameter of
Heat
Heat
Heat
steel pipe on
gain
gain
gain
which
2p =
2p =
2p =
2p =
2p =
2p =
2p = (W/m) 2p =
2p =
2p =
2p =
2p =
2p =
2p = (W/m) 2p =
2p =
2p =
2p =
2p =
2p =
2p = (W/m)
insulation
0.020 0.025 0.030 0.035 0.040 0.045 0.050
0.020 0.025 0.030 0.035 0.040 0.045 0.050
0.020 0.025 0.030 0.035 0.040 0.045 0.050
thickness has
been based
(mm)
21.3
33.7
60.3
114.3
168.3
273.0
508.0
610.0 and
above,
including
flat surfaces
12
15
21
29
34
39
45
52
17
21
28
39
45
51
57
67
23
29
37
50
57
64
71
82
32
38
48
63
71
78
84
98
43
50
61
77
85
93
99
115
57
64
76
93
102
109
114
132
76 3.4 15
82 4.0 19
94 5.0 27
112 6.5 39
120 7.9 45
127 10.6 53
131 16.5 62
151 17.2 71
22
28
37
53
61
69
80
91
32 44 61 84
39 52 70 92
50 66 85 108
69 88 111 136
78 97 120 145
88 108 130 154
99 119 141 164
113 136 161 187
114 4.2 19
120 4.9 24
136 6.0 34
162 7.5 47
174 9.1 55
180 12.0 65
189 18.0 78
214 18.9 87
28 40 58 81
35 50 69 94
48 66 88 116
64 85 109 138
74 96 121 150
86 109 135 164
101 126 154 183
113 141 171 203
113
127
151
173
184
197
214
237
157
170
194
214
223
233
248
274
4.9
5.6
6.7
8.6
10.3
13.3
19.3
20.6
Key
NOTE 1
Heat gain is related to the specific insulation thickness.
NOTE 2 This table should be used only if the control of heat gain already provided by the insulation of refrigeration pipework for the purposes of condensation control as
indicated in Table 2, Table 3, Table 4 and Table 5 does not limit the distribution heat gain to a maximum of 5 % of the system load. The method for calculating the system load for
refrigeration pipework is given in Annex F. Distribution pipework heat gains should be calculated using the formulae given in BS EN ISO 12241 if outside the scope of Table 6.
BS 5422:2001
14
Table 6 Environmental insulation thickness for refrigeration applications to control heat gain
Table 6 Environmental insulation thickness for refrigeration applications to control heat gain (concluded)
Outside
diameter of
steel pipe on
which
insulation
thickness has
been based
(mm)
t = 30
t = 40

2p =
0.020
21.3
22
33.7
28
60.3
40
114.3
53
168.3
63
273.0
75
508.0
91
101
610.0 and
above,
including
flat surfaces
2p =
0.025
33
41
57
73
86
100
119
131
2p =
0.030
48
59
79
98
113
128
149
164
2p =
0.035
69
82
107
128
144
160
182
200
2p =
0.040
99
113
143
163
180
196
218
238
2p =
0.045
141
154
188
205
223
237
257
280
2p =
0.050
198
210
247
257
273
283
300
325
Heat
gain
(W/m)
5.6
6.4
7.5
9.7
11.4
14.6
20.9
22.5

2p =
0.020
24
32
44
59
70
85
104
114
2p =
0.025
36
48
63
82
96
114
136
149
2p =
0.030
54
70
89
111
126
147
172
188
2p =
0.035
80
100
121
146
162
185
211
230
2p =
0.040
116
140
163
188
205
228
254
275
2p =
0.045
166
195
217
239
255
278
302
325
2p =
0.050
237
269
287
302
315
334
354
379
Heat
gain
(W/m)
6.3
7.0
8.4
10.7
12.6
15.8
22.3
24.1
Key
NOTE 1
Heat gain is related to the specific insulation thickness.
NOTE 2 This table should be used only if the control of heat gain already provided by the insulation of refrigeration pipework for the purposes of condensation control as indicated
in Table 2, Table 3, Table 4 and Table 5 does not limit the distribution heat gain to a maximum of 5 % of the system load. The method for calculating the system load for
refrigeration pipework is given in Annex F. Distribution pipework heat gains should be calculated using the formulae given in BS EN ISO 12241 if outside the scope of Table 6.
BS 5422:2001
15
BS 5422:2001
7 Chilled and cold water applications


7.2.1 General
The physical characteristics of the insulating material, including fixing and finishing materials whether
pre-applied or applied on site, shall conform to 5.1, 7.2.2 and 7.2.3.
Insulation materials and systems used for chilled and cold water applications shall conform to 5.6.2, 5.6.3,
5.6.5, 5.6.6, 5.6.7, 5.6.8 and 5.6.9.
Insulation materials and systems used for chilled and cold water applications shall be installed in
accordance with and shall conform to the permeance requirements specified in 5.7.
as a vapour barrier shall not exceed the values given in Table 1 for the relevant temperature of the plant.
7.3.1 Protection against condensation
given in Table 7 or Table 8 as appropriate.
7.3.2 Insulating to minimize heat gain to chilled water pipes
NOTE 1 Under certain circumstances, typically where the heat gain of the distribution network represents more than 5 % of the
design chiller load, it may be appropriate to consider insulating to minimize heat gain. This can require greater thicknesses than those
required for condensation control.
If insulation is specified to minimize heat gain, the insulation thickness shall be not less than that specified
in Table 9 for pipes carrying fluids at 5 C or lower. Where fluid temperatures exceed 5 C in any part of a
chilled water system, the thicknesses required for 5 C shall be maintained.
Table 9 shall be used only if the control of heat gain already provided by the insulation of chilled pipework
for the purposes of condensation control as indicated in Table 7 and Table 8 does not limit the distribution
heat gain to a maximum of 5 % of the system load, which shall be calculated in accordance with Annex F.
NOTE 2 Distribution pipework heat gains should be calculated using the formulae given in BS EN ISO 12241 if the values are
outside the scope of Table 9.
16
BS 5422:2001
Table 7 Minimum insulation thickness for chilled and cold water supplies to prevent
condensation on a high emissivity outer surface (0.90) with an ambient temperature of +25 C
and a relative humidity of 80 %
Outside diameter of
steel pipe on which
has been based
(mm)
21.3
33.7
60.3
114.3
168.3
273.0
508.0
610.0
Flat surfaces
t = +10
t = +5
t=0
2p =
0.020
6
6
7
8
8
8
9
9
9
2p =
0.030
8
9
10
11
11
12
13
13
13
2p =
0.040
10
11
13
14
15
16
17
17
17
2p =
0.050
12
14
15
17
18
19
21
21
21
2p =
0.020
8
9
10
10
11
12
12
12
12
2p =
0.030
11
12
14
15
16
17
18
18
18
2p =
0.040
14
15
17
19
21
22
24
24
24
2p =
0.050
17
19
21
24
25
27
29
30
30
2p =
0.020
10
11
12
13
14
15
16
16
16
2p =
0.030
14
15
17
19
20
22
23
24
24
2p =
0.040
17
19
22
25
26
28
30
31
32
2p =
0.050
21
23
26
30
32
35
37
38
39
Key
NOTE Thicknesses given are calculated specifically against the criteria noted in the table. These thicknesses may not satisfy
other design requirements.
Table 8 Minimum insulation thickness for chilled and cold water supplies to prevent
condensation on a low emissivity outer surface (0.05) with an ambient temperature of +25 C
and a relative humidity of 80 %
Outside diameter of
steel pipe on which
has been based
(mm)
21.3
33.7
60.3
114.3
168.3
273.0
508.0
610.0
Flat surfaces
t = +10
t = +5
t=0
2p =
0.020
11
13
15
18
20
22
26
27
26
2p =
0.030
16
18
22
26
29
33
38
40
39
2p =
0.040
20
24
28
34
38
43
50
52
52
2p =
0.050
25
29
34
41
46
53
62
65
65
2p =
0.020
15
18
21
25
28
31
37
38
38
2p =
0.030
22
25
30
36
40
46
54
56
56
2p =
0.040
28
32
39
47
52
60
71
74
75
2p =
0.050
34
39
47
57
64
74
87
91
93
2p =
0.020
19
22
27
32
36
40
47
49
49
2p =
0.030
28
32
38
46
51
59
69
73
73
2p =
0.040
36
41
49
60
67
77
91
95
97
2p =
0.050
43
50
60
73
82
94
112
117
122
Key
NOTE Thicknesses given are calculated specifically against the criteria noted in the table. These thicknesses may not satisfy
17
BS 5422:2001
Table 9 Environmental insulation thickness for chilled water supplies to control heat gain
Outside diameter of
steel pipe on which
has been based
(mm)
21.3
33.7
60.3
114.3
168.3
273.0
508.0
610.0 and above,
including flat
surfaces
t = +5
t=0

2p =
0.020
10
13
17
23
28
32
35
42
2p =
0.025
14
18
23
30
37
41
45
54
2p =
0.030
20
24
30
38
46
51
55
66
2p =
0.035
27
31
38
47
57
62
66
78
2p =
0.040
36
40
47
58
69
72
77
91
Heat
gain
(W/m)
2.9
3.5
4.5
6.1
7.2
9.9
15.8
16.2

2p =
0.020
12
15
21
29
34
39
45
52
2p =
0.025
17
21
28
39
45
51
57
67
2p =
0.030
23
29
37
50
57
64
71
82
2p =
0.035
32
38
48
63
71
78
84
98
2p =
0.040
43
50
61
77
85
93
99
115
Heat
gain
(W/m)
3.4
4.0
5.0
6.5
7.9
10.6
16.5
17.2
Key
NOTE 1 Thicknesses given are calculated specifically against the criteria noted in the table. These thicknesses may not satisfy
NOTE 2
Some thicknesses in this table are less than those in Table 8.
8 Central heating, air conditioning and direct hot water supply installations in
non-domestic applications

8.2.1 General
The physical characteristics of the insulating material, together with adhesive, fixing, vapour barrier and
finishing material, whether pre-applied or applied on site, shall conform to 5.1, 8.2.2 and 8.2.3.
Insulation materials and systems used for central heating, air conditioning and direct hot water supply
installations in non-domestic applications shall conform to 5.6.2, 5.6.3, 5.6.5, 5.6.7, 5.6.8, 5.6.9 and 5.6.11.
Insulation materials and systems used for central heating, air conditioning and direct hot water supply
installations in non-domestic applications shall also conform to 5.6.4 except where the installed insulation
assembly is unfaced, when 5.6.6 shall apply.
If pipework or ductwork for central heating, air conditioning or direct hot water supply systems is likely to
have a surface temperature below the dew point temperature, the insulation materials and system shall
conform to the permeance requirements and installation methods for water vapour barriers detailed in 5.7.
18
BS 5422:2001
Insulation materials and systems used for chilled air ductwork shall be installed in accordance with and
shall conform to the permeance requirements specified in 5.7.
as a vapour barrier shall not exceed the values given in Table 1 for the appropriate temperature of the
plant.
8.3.1 Minimum insulation thickness to prevent condensation on ductwork carrying chilled air
given in Table 10.
19
Minimum air
temperature
inside duct
(C)
15
10
5
0
Minimum thickness of insulating material (mm)

2p = 0.020
(p =
0.05
15
26
37
48
(p =
0.44
8
10
19
25
2 = 0.025
(p =
0.90
5
9
12
16
(p =
0.05
18
32
47
60
(p =
0.44
9
17
24
31
2 = 0.030
(p =
0.90
6
11
15
20
(p =
0.05
22
39
56
72
(p =
0.44
11
20
28
37
2 = 0.035
(p =
0.90
7
13
18
24
(p =
0.05
25
45
64
84
(p =
0.44
13
23
33
43
2 = 0.040
(p =
0.90
8
15
21
27
(p =
0.05
29
52
75
96
(p =
0.44
15
26
38
49
2 = 0.045
(p =
0.90
10
17
24
31
(p =
0.05
32
58
83
108
(p =
0.44
17
29
42
56
2 = 0.050
(p =
0.90
11
19
27
35
(p =
0.05
36
64
92
120
(p =
0.44
18
33
47
61
(p =
0.90
12
21
30
39
Key
2 = thermal conductivity of insulating material at a mean temperature of 10 C [W/(mK)]
( = external surface emissivity
NOTE 1
Thicknesses calculated in accordance with BS EN ISO 12241 based on 0.6 m vertical flat surface of rectangular duct but are also adequate for horizontal surfaces.
NOTE 2
NOTE 3
Refer to Annex B, Table B.1 for surface emissivities of common finishing materials.
BS 5422:2001
20
Table 10 Minimum insulation thickness for condensation control on ductwork carrying chilled air in ambient conditions:
indoor still air temperature +25 C, relative humidity 80 %, dewpoint temperature 21.3 C
8.3.2 Environmental insulation thickness for ductwork carrying warm air

In the absence of specific instructions from the specifier, the thickness applied shall be not less than that
given in Table 11 and Figure 2.
Table 11 Environmental insulation thickness on ductwork carrying warm air
Environmental insulation thickness and corresponding heat loss (see Note 2)
Temperature difference = 10 C
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
2p =
0.020
2p =
0.030
2p =
0.040
2p =
0.050
19 mm 29 mm 38 mm 47 mm 25 mm 38 mm 50 mm 63 mm 32 mm 47 mm 63 mm 79 mm
15.3 W/m2
26.0 W/m2
7.2 W/m2
Key
Temperature difference = difference between air inside ductwork and ambient air
2 = thermal conductivity at mean temperature of insulating material [W/(mK)]
NOTE 1 Equivalent environmental thicknesses and heat loss values calculated in accordance with BS EN ISO 12241 based
on 0.6 m depth of vertical flat surface of rectangular duct but are also adequate for horizontal surfaces.
NOTE 2 Heat loss values shown in the table are based on insulation with a low emissivity finish (0.05), in ambient still air
at 10 C.
NOTE 3 For intermediate temperature differences, the insulation thickness can be derived by interpolation, or calculated from
first principles such that the heat loss given in Figure 2 is not exceeded.
30
25
Heat loss, W/m2
BS 5422:2001
20
15
10
5
0
0
10
20
30
40
50
60
Temperature difference, C
Figure 2 Graph to determine environmental heat gain for intermediate temperatures

8.3.3 Determination of environmental thickness
NOTE
The relevant thicknesses defined in Table 12 and Table 13 have been derived using the methodology set out in Annex A.
In the absence of specific instructions from the specifier, the insulation thickness shall be as given in
Table 12, Table 13 or Table 14.
21
Outside
t = 75
t = 100
t = 150
diameter of
Heat
Heat
Heat
steel pipe on
loss
loss
loss
which
2p =
2p =
2p =
2p =
2p =
2p =
2p = (W/m) 2p =
2p =
2p =
2p =
2p =
2p =
2p = (W/m) 2p =
2p =
2p =
2p =
2p =
2p =
2p = (W/m)
insulation
0.025 0.030 0.035 0.040 0.045 0.050 0.055
0.025 0.030 0.035 0.040 0.045 0.050 0.055
0.025 0.030 0.035 0.040 0.045 0.050 0.055
thickness has
been based
(mm)
17.2
21.3
26.9
33.7
42.4
48.3
60.3
76.1
88.9
114.3
139.7
168.3
219.1
273.0
323.9 and
above,
including
flat surfaces
13
14
16
17
19
19
21
22
23
25
26
27
28
29
32
18
19
21
23
24
25
27
29
30
31
32
33
35
36
39
24
26
28
30
31
32
34
36
37
38
39
40
42
43
46
32
34
36
38
39
40
42
43
44
46
47
48
49
50
54
43
44
46
47
49
49
51
52
53
54
55
56
57
58
63
55
56
57
58
59
60
61
62
62
63
64
64
65
66
71
71
72
72
72
72
72
72
72
73
73
73
73
73
74
80
7.7
8.4
9.2
10.1
11.4
12.1
13.5
15.5
17.0
19.7
22.5
25.5
30.9
36.3
39.6
Key
t = hot face temperature (C)
NOTE
Heat loss relates to the specified thickness and temperature.
14
15
17
19
21
22
24
26
27
29
30
32
34
35
38
20
21
23
26
28
29
31
33
35
37
38
40
42
43
47
27
29
31
33
36
37
39
42
43
45
47
48
50
52
56
36
38
40
43
45
47
49
51
52
54
56
57
59
61
65
48
50
52
54
56
58
60
62
63
64
66
67
69
70
76
62
64
65
68
69
70
72
74
75
76
76
77
79
80
87
81
81
82
84
84
85
86
87
88
88
88
89
90
91
98
10.8
11.7
12.9
14.0
15.5
16.4
18.3
20.7
22.6
26.2
29.6
33.5
40.0
46.6
50.9
16
18
21
23
25
26
28
31
33
35
37
39
42
44
47
23
26
28
31
33
35
37
40
42
45
47
50
53
55
57
32
35
38
41
44
45
48
51
53
56
58
61
64
66
69
44
47
50
53
55
57
59
63
65
68
70
73
76
78
81
58
62
65
67
70
71
74
77
78
81
84
86
89
91
95
77
80
83
85
87
88
90
92
94
96
98
100
103
105
109
101
104
105
107
108
108
109
110
111
113
115
116
118
119
124
16.4
17.6
19.2
20.9
23.2
24.5
27.2
30.2
32.7
37.5
42.2
46.8
55.4
64.2
71.5
BS 5422:2001
22
Table 12 Environmental insulation thickness for non-domestic heating installations to control heat loss
BS 5422:2001
Table 13 Environmental insulation thickness for non-domestic hot water service areas to
control heat loss
Outside diameter of steel
pipe on which insulation
thickness has been based
(mm)
17.2
21.3
26.9
33.7
42.4
48.3
60.3
76.1
88.9
114.3
139.7
168.3
219.1
273.0
323.9 and above,
including flat surfaces
Water temperature of 60 C
2p =
0.025
12
14
15
17
18
19
21
23
24
25
27
28
29
31
32
2p =
0.030
17
19
21
22
24
25
27
29
30
32
33
35
36
38
39
2p =
0.035
24
25
27
29
30
32
34
36
37
39
40
42
43
45
46
2p =
0.040
32
33
35
37
39
40
42
44
45
47
48
49
51
53
54
2p =
0.045
41
43
45
46
48
49
51
53
54
55
56
58
59
61
63
2p =
0.050
54
55
56
57
58
60
61
62
63
64
65
67
68
69
71
2p =
0.055
69
69
70
70
71
72
73
73
74
74
75
76
77
78
81
Heat loss
(W/m)
5.6
6.1
6.7
7.4
8.2
8.7
9.7
11.0
12.1
14.0
16.0
18.1
21.6
25.1
28.5
Key
NOTE 1
NOTE 2
Thicknesses in this table are based on a greater heat utilization than those for heating installations.
9 Central heating and hot and cold water services for domestic applications

9.2.1 General
The physical characteristics of the insulating material, together with adhesive, fixing, vapour barrier and
finishing materials, shall conform to 5.1, 9.2.2 and 9.2.3.
Insulation materials and systems used for central heating and hot and cold water supply installations for
domestic applications shall conform to 5.6.2, 5.6.3, 5.6.5, 5.6.8 and 5.6.9. Insulation materials and systems
used for central heating and hot and cold water supply installations for domestic applications shall also
conform to 5.6.4 except where the installed insulation assembly is unfaced, when 5.6.6 shall apply.
Where insulation is used on the exterior of pipework that is exposed within the building, the complete
assembly of materials as installed shall have a rating for the surface spread of flame of not less than that
for the wall or ceiling it traverses.
23
BS 5422:2001
9.2.3 Vapour barriers Permeance requirements

Insulation materials and systems used for cold water services shall be installed in accordance with and
shall conform to the permeance requirements specified in 5.7.
for the vapour barrier shall not exceed the values given in Table 1 depending on the temperature of the
plant.
9.3 Thickness
9.3.1 Environmental thickness for central heating and hot water installations
NOTE The requirements for domestic heating and hot water are combined into one table for ease of material handling on site. In
addition the distinction between heated and unheated areas was removed because of concerns over the validity of the assumption of
continuous background heat. The basic methodology and approach is outlined in Annex A.
specified in Table 14.
Table 14 Environmental insulation thickness for domestic central heating installations and
hot water systems in potentially unheated areas to control heat loss
Outside diameter of
copper pipe on which
insulation thickness has
been based
(mm)
10.0
12.0
15.0
22.0
28.0
35.0
42.0
54.0
Cylinders

2p =
0.025
10
12
15
19
21
22
23
25
35
2p =
0.030
16
18
22
26
28
30
31
33
42
2p =
0.035
22
26
31
35
38
39
41
42
50
2p =
0.040
31
36
42
47
49
51
52
53
58
2p =
0.045
44
49
58
62
64
64
65
65
67
Heat loss
at 60 C
6.8 W/m
7.3 W/m
7.8 W/m
8.2 W/m
9.0 W/m
10.0 W/m
11.0 W/m
12.8 W/m
38.2 W/m2
Heat loss
at 75 C
8.6 W/m
9.2 W/m
9.7 W/m
10.2 W/m
11.3 W/m
12.6 W/m
13.8 W/m
16.0 W/m
47.9 W/m2
Key
NOTE 1
NOTE 2 Water temperatures considered are 75 C for central heating and 60 C for hot water with an ambient still air
temperature of 1 C.
10 Process pipework and equipment applications

10.1.1 General
and the materials to be used, in accordance with clause 4, as well as the requirements specified in 10.1.2
and 10.1.3.
NOTE 1 For the applications appropriate to this clause, the specifier typically indicates the precise performance requirements of
the insulation system.
NOTE 2 In addition to the parameters outlined in clause 4, items such as specific heat capacity and mass flow rates of fluids may
also be required under certain circumstances, particularly where calculating from first principles using BS EN ISO 12241. However,
these additional parameters are not required for the use of the tables contained in this standard.
10.1.2 Special service requirements

Reference shall be included in the specification to any difficult or unusual site conditions that influence the
selection and/or application of insulating materials, e.g. relevant to transport, access, storage, scaffolding
and weather protection.
24
BS 5422:2001
10.1.3 Basis on which thickness is to be determined

The specifier shall state the basis for selection to be used and provide the relevant information giving due
consideration to safety and environmental requirements.
NOTE
See 10.3.

10.2.1 General
The physical characteristics of the insulating material, fixing and finishing materials, whether applied
during manufacture or on site, shall conform to 5.1, 10.2.2 and 10.2.3.
Insulation materials and systems used for process applications shall conform to 5.6.2, 5.6.3, 5.6.5, 5.6.8,
5.6.9, 5.6.10 and 5.6.11. Insulation materials and systems used for process applications shall also conform
to 5.6.4 except where the installed insulation assembly is unfaced, when 5.6.6 shall apply.
NOTE 1 Process applications can encompass systems running at temperatures throughout the full range of this standard, 40 C
to +700 C, and beyond.
Where a process application has a normal operating temperature below ambient temperature, the
insulation material and systems used for such an application shall be installed in accordance with and shall
conform to the permeance requirements for water vapour barriers specified in 5.7.
Where a process application has a normal operating temperature above ambient temperature, and a water
vapour barrier is installed, the system shall be installed in accordance with and shall conform to the
permeance requirements specified in 5.7.
NOTE 2 The need to apply a vapour barrier is dependant upon whether such a system can on occasion have a surface temperature
below the dew point temperature.
as a vapour barrier shall not exceed the values given in Table 1 depending on the temperature of the plant.
10.3.1 Environmental
NOTE The environmental insulation thickness for process conditions has been derived according to the methodology given in
Annex A. However, in this instance, cost effectiveness assessments have taken into account gas prices available to the industrial
sector. Recognizing the need to reduce carbon dioxide emissions, particularly in the process sector, the thicknesses given in Table 15
are intended to achieve this result by reducing the heat loss.
In the absence of specific instructions from the specifier, the insulation thickness shall be as given
in Table 15.
10.3.2 Economic
Where economic thickness determination is deemed to be the most appropriate approach, it shall be
calculated in accordance with Annex G.
NOTE Environmental thicknesses are preferred where practicable because of their greater contribution to environmental objectives
in this sensitive sector.
10.3.3 Other design criteria

Where the requirements for personal protection are pre-eminent, the insulation thickness shall be as given
in Table 16, Table 17 and Table 18.
Where other design criteria are identified, e.g. a specified heat loss (see Table 19, Table 20 and Table 21),
a specified temperature on the outer surface, or a special condition at the point of delivery, the calculation
shall be in accordance with BS EN ISO 12241 (see also BS 5970).
25
Outside diameter of steel
pipe on which insulation
thickness has been based
(mm)
17.2
21.3
26.9
33.7
42.4
48.3
60.3
76.1
88.9
101.6
114.3
139.7
168.3
219.1
244.5
273.0
323.9
355.6
406.4
457.0
508.0
610 and above,
including flat surfaces
t = 100
t = 200

2p =
0.020
11
12
14
15
17
18
20
23
24
26
27
29
31
34
35
37
38
39
41
42
43
49
2p =
0.030
22
24
27
29
32
33
36
39
42
45
48
49
52
56
57
59
61
62
65
66
68
77
2p =
0.040
40
44
47
50
53
55
58
62
65
67
69
72
77
81
82
85
87
89
91
92
95
107
2p =
0.050
72
76
78
80
83
85
88
92
94
96
98
101
107
110
112
114
117
118
121
122
124
141
2p =
0.060
125
128
128
128
128
129
130
131
133
134
136
137
143
145
146
149
150
151
153
154
157
177
Heat
loss
(W/m)
10.4
11.1
12.1
13.2
14.5
15.3
16.8
18.7
20.1
21.5
22.8
25.4
27.8
32.5
34.8
37.1
41.5
44.2
48.2
52.5
56.2
59.4
t = 300

2p =
0.030
20
22
25
28
32
34
37
41
44
47
49
53
57
63
65
68
71
73
76
78
80
89
2p =
0.040
36
40
43
47
52
55
60
64
68
71
74
79
85
92
94
98
102
105
107
110
113
125
2p =
0.050
63
67
71
76
81
84
90
95
100
103
106
111
118
126
129
133
138
141
143
146
149
167
2p =
0.060
106
109
113
118
123
126
132
136
141
144
147
152
159
167
169
174
179
181
183
186
189
211
2p =
0.070
176
176
176
179
183
185
189
191
195
197
198
202
209
216
217
222
226
228
229
233
237
260
Heat
loss
(W/m)

2p =
0.030
24.8 23
26.5 26
28.6 29
30.8 32
33.3 36
34.9 39
37.9 43
41.8 48
44.5 51
47.2 53
49.9 56
54.8 61
59.6 67
68.1 73
72.6 76
76.6 80
84.5 84
89.4 85
97.5 89
105.3 92
112.3 94
120.6 100
2p =
0.040
43
46
51
55
60
64
70
76
80
83
87
93
100
108
112
116
121
123
127
131
134
147
2p =
0.050
75
79
84
90
96
100
108
114
119
122
126
134
142
151
154
160
165
166
170
175
181
195
2p =
0.060
129
132
137
141
148
152
161
167
171
173
177
185
194
202
206
212
216
217
220
226
230
249
2p =
0.070
218
218
218
219
223
227
235
237
241
240
242
250
259
264
267
273
275
277
280
286
287
308
Heat
loss
(W/m)
36.5
38.9
41.8
45.0
48.5
50.6
54.5
59.7
63.5
67.5
71.1
77.3
83.6
95.4
101.1
106.5
117.5
124.7
135.2
144.5
154.9
168.0
Key

NOTE 1 The heat losses applicable to pipe diameters of above 610.0 mm and flat surfaces should be calculated on the basis of a 610.0 mm diameter surface.
NOTE 2 Heat loss measured in Watts per metre (W/m) relates to the specified thickness and temperature.
NOTE 3 The thermal conductivity of insulation materials increases with mean temperature and for any given material. The use of a different thermal conductivity can be
required for each operating temperature.
NOTE 4 To simplify the use of this table, the values shaded have been adjusted to avoid the specification of apparently anomalous results given by the calculation method in
BS EN ISO 12241, due to the transition from turbulent to laminar flow.
NOTE 5 These thicknesses may not satisfy other design requirements, in particular those for personal protection (see Table 16, Table 17 and Table 18).
BS 5422:2001
26
Table 15 Environmental insulation thickness for process pipework and equipment to control heat loss
Table 15 Environmental insulation thickness for process pipework and equipment to control heat loss (concluded)
Outside diameter
t = 400
t = 500
t = 600
t = 700
of steel pipe on
Heat
Heat
Heat
which insulation
loss
loss
loss
thickness has been
2p =
2p =
2p =
2p =
2p = (W/m) 2p =
2p =
2p =
2p =
2p = (W/m) 2p =
2p =
2p =
2p =
2p = (W/m) 2p =
2p =
2p =
2p =
2p =
based
0.040 0.050 0.060 0.070 0.080
0.050 0.060 0.070 0.080 0.090
0.060 0.070 0.080 0.090 0.100
0.070 0.080 0.090 0.100 0.110
(mm)
Heat
loss
(W/m)
17.2
33
56
92
148
236
55.3
43
69
107
165
252
77.2
42
62
90
130
186
112.1
52
73
103
145
202
21.3
36
60
96
151
238
58.9
48
74
113
170
253
81.9
47
67
96
136
191
118.7
56
79
110
152
209
141.1
149.1
26.9
41
65
102
157
239
63.0
53
81
121
178
260
87.2
52
74
104
144
199
126.4
63
87
119
162
218
158.3
33.7
45
71
108
163
241
67.6
59
88
128
185
265
93.1
57
79
110
149
202
135.8
68
93
125
167
221
169.9
42.4
51
78
118
173
251
72.2
65
95
136
193
270
100.0
65
90
123
164
220
143.3
78
105
139
184
240
179.2
48.3
54
83
123
179
256
75.1
69
100
142
199
276
103.9
70
95
129
172
228
148.6
83
111
146
191
248
185.9
60.3
60
91
133
189
267
80.5
77
110
154
213
290
110.8
78
101
141
186
242
158.3
93
123
160
206
265
197.4
76.1
66
98
140
196
270
87.8
84
118
163
220
295
120.5
85
113
150
194
250
172.0 102
132
170
216
273
213.8
88.9
70
103
145
201
273
93.4
90
125
170
228
301
127.3
91
121
158
203
258
181.4 109
140
179
226
283
224.9
101.6
74
107
150
204
274
98.7
94
130
175
232
303
134.3
97
127
164
210
265
190.2 115
147
186
233
290
235.9
114.3
77
111
153
207
276
103.9
98
134
179
235
305
141.2 101
132
170
215
270
199.2 119
152
191
238
300
247.0
139.7
84
119
163
217
285
112.5 107
144
191
248
317
152.0 111
143
182
228
283
214.2 131
165
206
254
315
264.6
168.3
92
128
174
229
297
120.9 116
155
203
260
334
163.2 121
155
195
243
302
229.1 143
179
221
274
333
282.0
219.1
100
139
185
240
308
136.9 127
168
216
276
345
183.6 134
170
211
263
320
255.7 158
195
242
293
352
314.0
244.5
105
144
191
246
315
143.9 133
174
223
284
353
192.4 139
176
221
270
327
268.2 164
204
250
302
361
328.6
273.0
109
149
196
251
319
152.1 138
181
228
292
361
202.1 146
184
230
280
338
280.4 169
214
260
312
371
343.9
323.9
114
154
200
257
321
167.6 144
189
239
297
364
221.6 154
193
237
287
343
306.9 182
223
268
320
377
375.0
355.6
117
158
204
262
325
175.8 149
194
244
302
368
232.6 160
200
244
294
351
320.4 186
227
272
323
380
394.6
406.4
121
162
211
266
327
190.5 154
200
251
308
373
250.2 165
204
248
297
352
347.0 194
236
281
333
389
421.5
457.0
126
170
218
272
333
203.1 161
206
256
313
376
267.6 172
213
258
308
363
366.7 203
245
292
343
400
445.7
508.0
130
173
222
275
336
216.7 165
210
261
317
380
284.7 178
220
265
315
370
387.9 210
253
300
351
408
470.5
610 and above,

including flat
surfaces
141
186
236
292
354
237.2 180
228
281
340
405
308.6 195
239
287
340
397
418.6 230
275
325
380
439
506.1
Key
NOTE 1
The heat losses applicable to pipe diameters of above 610.0 mm and flat surfaces should be calculated on the basis of a 610.0 mm diameter surface.
NOTE 2
Heat loss measured in Watts per metre (W/m) relates to the specified thickness and temperature.
NOTE 4 To simplify the use of this table, the values shaded have been adjusted to avoid the specification of apparently anomalous results given by the calculation method in BS EN ISO 12241, due to the
transition from turbulent to laminar flow.
NOTE 5
These thicknesses may not satisfy other design requirements, in particular those for personal protection (see Table 16, Table 17 and Table 18).
27
BS 5422:2001
NOTE 3 The thermal conductivity of insulation materials increases with mean temperature and for any given material. The use of a different thermal conductivity can be required for each operating
temperature.
Outside diameter of
steel pipe
(mm)
t = 100
t = 200
t = 300
2p =
0.025
17.2
21.3
26.9
33.7
42.4
48.3
60.3
76.1
88.9
101.6
114.3
139.7
168.3
219.1
244.5
273.0
323.9
355.6
406.4
457.0
508.0
610.0
Flat surfaces
2
2
2
2
2
2
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
2p =
0.035
3
3
3
3
3
3
3
3
3
4
4
4
4
4
4
4
4
4
4
4
4
4
4
2p =
0.045
3
4
4
4
4
4
4
4
4
4
4
5
5
5
5
5
5
5
5
5
5
5
5
2p =
0.055
4
4
4
4
5
5
5
5
5
5
5
5
6
6
6
6
6
6
6
6
6
6
6
2p =
0.035
7
8
8
9
9
9
10
10
10
11
11
11
11
12
12
12
12
12
13
13
13
13
13
2p =
0.045
9
10
10
11
11
12
12
13
13
13
13
14
14
15
15
15
16
16
16
16
16
16
17
2p =
0.055
11
11
12
13
13
14
14
15
15
16
16
17
17
18
18
18
19
19
19
20
20
20
20
2p =
0.065
12
13
14
15
15
16
17
17
18
18
19
19
20
21
21
21
22
22
23
23
23
23
24
2p =
0.035
12
12
13
14
14
15
15
16
17
17
17
18
19
19
20
20
20
21
21
21
22
22
22
2p =
0.045
14
15
16
17
18
18
19
20
21
21
22
23
23
24
25
25
26
26
27
27
27
27
28
2p =
0.055
17
18
19
20
21
22
23
24
25
25
26
27
28
29
30
30
31
31
32
33
33
33
34
2p =
0.065
19
20
22
23
24
25
26
28
29
29
30
31
32
34
35
35
36
37
37
38
39
39
41
Key
t = hot face temperature at mean temperature (C) (with ambient still air at 20 C)
NOTE 1
BS 5422:2001
28
Table 16 Insulation thickness for personnel protection from a non-metallic surface with a surface emissivity of 0.90 and design
cold face temperature of 59 C
cold face temperature of 59 C (concluded)
Outside diameter
of steel pipe
(mm)
17.2
21.3
26.9
33.7
42.4
48.3
60.3
76.1
88.9
101.6
114.3
139.7
168.3
219.1
244.5
273.0
323.9
355.6
406.4
457.0
508.0
610.0
Flat surfaces
t = 400
t = 500
t = 600
t = 700
2p =
0.045
2p =
0.055
2p =
0.065
2p =
0.075
2p =
0.085
2p =
0.055
2p =
0.065
2p =
0.075
2p =
0.085
2p =
0.095
2p =
0.065
2p =
0.075
2p =
0.085
2p =
0.095
2p =
0.105
2p =
0.065
2p =
0.075
2p =
0.085
2p =
0.095
2p =
0.105
19
20
21
22
24
24
26
27
28
29
30
31
32
33
34
35
36
36
37
37
38
38
40
22
24
25
26
28
29
31
32
33
34
35
37
38
40
41
42
43
43
44
45
46
46
49
26
27
29
30
32
33
35
37
38
40
41
42
44
46
47
48
50
51
52
53
53
53
57
29
30
32
34
36
37
40
42
43
45
46
48
50
53
54
55
57
58
59
60
61
61
66
32
34
36
38
40
42
44
47
48
50
51
54
56
59
60
61
63
64
66
67
67
67
75
27
29
31
33
35
36
38
40
42
43
44
46
48
50
51
52
54
55
56
57
58
58
63
32
33
35
38
40
41
44
46
48
49
51
53
55
58
60
61
63
64
65
67
67
67
74
35
37
40
42
45
46
49
52
54
56
57
60
63
66
68
69
71
73
74
76
76
76
85
39
42
44
47
50
51
54
58
60
62
64
67
70
74
75
77
80
81
83
85
85
85
97
43
46
48
51
55
56
60
63
66
68
70
73
77
81
83
85
88
90
92
92
92
92
108
37
39
42
44
47
49
52
55
57
59
60
63
66
70
71
73
75
77
79
80
80
80
91
42
44
47
50
53
55
58
62
64
66
68
71
74
79
81
83
85
87
89
89
89
89
104
46
49
52
55
59
61
64
68
71
74
76
79
83
88
90
92
95
97
100
100
100
100
118
51
54
57
61
64
67
71
75
78
81
83
87
91
97
99
101
105
107
110
110
110
110
132
55
58
62
66
70
72
77
81
85
88
90
95
99
105
108
111
115
117
117
117
117
120
146
43
45
48
51
54
56
59
63
66
68
70
73
76
81
83
85
87
89
91
91
91
91
107
48
51
54
57
61
63
67
71
74
76
79
82
86
91
94
96
99
101
104
104
104
104
124
53
56
60
64
68
70
74
79
82
85
87
92
96
102
104
107
111
113
113
113
113
116
140
59
62
66
70
74
77
81
86
90
93
96
100
105
112
115
117
122
124
124
124
125
128
156
64
67
71
76
80
83
88
94
97
101
104
109
114
122
125
128
133
135
135
135
136
139
173
NOTE 1
29
BS 5422:2001
Key
Outside diameter of
steel pipe
(mm)
t = 100
t = 200
t = 300
2p =
0.025
17.2
21.3
26.9
33.7
42.4
48.3
60.3
76.1
88.9
101.6
114.3
139.7
168.3
219.1
244.5
273.0
323.9
355.6
406.4
457.0
508.0
610.0
Flat surfaces
5
5
6
6
6
6
7
7
8
8
8
8
9
9
10
10
10
10
11
11
11
12
12
2p =
0.035
7
7
7
8
8
9
9
10
10
11
11
11
12
13
13
14
14
14
15
15
16
16
16
2p =
0.045
8
9
9
10
11
11
12
12
13
13
14
14
15
16
17
17
18
18
19
19
20
21
21
2p =
0.055
10
10
11
12
13
13
14
15
15
16
17
17
18
20
20
21
22
22
23
23
24
25
25
2p =
0.035
17
18
19
21
22
23
25
27
28
29
30
32
33
36
37
38
40
41
42
43
45
45
46
2p =
0.045
21
23
24
26
28
29
31
33
35
36
38
40
42
45
47
48
50
52
53
55
57
57
59
2p =
0.055
25
27
29
31
33
35
37
40
42
44
45
48
50
54
56
58
61
62
65
67
69
69
72
2p =
0.065
29
31
34
36
39
40
43
46
49
51
52
56
59
63
65
68
71
73
75
78
80
80
85
2p =
0.035
27
28
31
33
35
37
39
42
44
46
48
50
53
57
59
61
64
66
68
70
72
72
76
2p =
0.045
33
35
38
41
44
46
49
53
55
57
60
63
67
72
75
77
81
83
86
89
92
92
98
2p =
0.055
40
42
46
49
52
55
58
63
66
69
71
76
80
87
90
93
97
100
104
107
107
107
120
2p =
0.065
46
49
53
57
61
63
68
73
77
80
83
88
93
101
104
108
113
116
121
121
121
121
141
Key
NOTE 1
BS 5422:2001
30
Table 17 Insulation thickness for personnel protection from a metallic surface with a surface emissivity of 0.05 and design cold
face temperature of 50 C
Table 17 Insulation thickness for personnel protection from a metallic surface with a surface emissivity of 0.05 and design cold
face temperature of 50 C (concluded)
Outside diameter
of steel pipe
(mm)
17.2
21.3
26.9
33.7
42.4
48.3
60.3
76.1
88.9
101.6
114.3
139.7
168.3
219.1
244.5
273.0
323.9
355.6
406.4
457.0
508.0
610.0
Flat surfaces
t = 400
t = 500
t = 600
t = 700
2p =
0.045
2p =
0.055
2p =
0.065
2p =
0.075
2p =
0.085
2p =
0.055
2p =
0.065
2p =
0.075
2p =
0.085
2p =
0.095
2p =
0.065
2p =
0.075
2p =
0.085
2p =
0.095
2p =
0.105
2p =
0.065
2p =
0.075
2p =
0.085
2p =
0.095
2p =
0.105
45
48
51
55
59
62
66
71
74
78
80
86
91
98
101
105
110
113
118
118
118
118
137
54
57
61
66
71
74
79
85
89
93
96
102
108
118
121
126
132
136
141
141
141
141
167
62
67
71
76
82
85
91
98
103
108
112
119
126
136
141
146
154
158
158
158
158
158
198
71
76
81
87
93
97
104
112
117
122
127
135
143
155
160
166
175
175
175
175
175
175
228
80
85
91
97
104
109
116
125
131
137
142
151
160
173
179
186
186
186
186
186
187
192
259
67
72
77
82
88
92
99
106
111
116
120
128
136
147
152
157
166
166
166
166
166
166
215
79
84
90
96
103
107
114
123
129
135
140
149
157
171
177
183
183
183
183
183
184
190
254
90
95
102
109
117
122
130
140
147
153
158
169
179
194
201
208
208
208
208
208
208
214
293
101
107
114
122
131
136
146
156
164
171
177
189
200
217
224
224
224
224
224
226
230
237
332
112
119
127
135
145
151
161
173
181
189
196
208
221
221
221
224
231
236
242
247
252
260
371
95
101
108
115
123
128
137
147
154
161
167
178
188
204
211
211
211
211
211
214
218
224
311
108
115
123
131
140
146
156
167
175
183
190
202
214
232
232
232
232
232
235
240
245
253
358
122
129
138
147
157
163
174
187
196
204
212
225
239
239
239
240
249
253
260
266
271
280
406
135
143
153
163
174
181
193
207
217
226
234
249
249
250
256
262
271
277
284
291
297
307
454
148
157
168
179
191
198
211
226
237
247
256
272
272
272
277
283
294
300
308
315
322
333
501
111
117
125
134
143
149
159
171
179
187
194
206
218
237
237
237
237
237
240
245
250
258
367
126
134
143
153
163
170
181
194
204
212
220
234
248
248
248
248
257
262
269
275
281
290
423
142
151
161
171
183
190
203
218
228
237
246
262
262
262
267
274
284
289
297
304
311
321
480
158
167
178
190
203
211
225
241
252
262
272
272
272
284
291
298
310
316
325
333
340
352
536
174
184
196
209
222
231
246
264
276
287
287
287
290
307
315
323
335
342
351
360
368
381
593
NOTE 1
31
BS 5422:2001
Key
Outside diameter of
steel pipe
(mm)
t = 100
t = 200
t = 300
2p =
0.025
17.2
21.3
26.9
33.7
42.4
48.3
60.3
76.1
88.9
101.6
114.3
139.7
168.3
219.1
244.5
273.0
323.9
355.6
406.4
457.0
508.0
610.0
Flat surfaces
3
3
3
4
4
4
4
4
4
4
4
4
4
5
5
5
5
5
5
5
5
5
5
2p =
0.035
4
4
5
5
5
5
5
5
5
6
6
6
6
6
6
6
6
6
6
7
7
7
7
2p =
0.045
5
5
6
6
6
6
6
7
7
7
7
7
7
8
8
8
8
8
8
8
8
8
8
2p =
0.055
6
6
7
7
7
7
8
8
8
8
8
9
9
9
9
9
10
10
10
10
10
10
10
2p =
0.035
10
11
11
12
13
13
13
14
14
15
15
16
16
17
17
17
18
18
18
18
19
19
19
2p =
0.045
13
13
14
15
15
16
17
18
18
18
19
20
20
21
21
22
22
22
23
23
23
24
24
2p =
0.055
15
16
16
17
18
19
20
21
22
22
23
23
24
25
26
26
27
27
28
28
28
29
29
2p =
0.065
17
18
19
20
21
22
23
24
25
26
26
27
28
29
30
30
31
32
32
33
33
34
35
2p =
0.035
15
16
17
18
19
20
21
22
23
23
24
25
26
27
27
28
28
29
29
30
30
31
31
2p =
0.045
19
20
21
23
24
25
26
27
28
29
30
31
32
34
34
35
36
36
37
37
38
39
40
2p =
0.055
22
24
25
27
28
29
31
32
34
35
35
37
38
40
41
42
43
44
44
45
46
46
49
2p =
0.065
26
27
29
31
32
33
35
37
39
40
41
43
44
47
48
49
50
51
52
53
54
54
58
Key
NOTE 1
BS 5422:2001
32
cold face temperature of 50 C
cold face temperature of 50 C (concluded)
Outside diameter
of steel pipe
(mm)
17.2
21.3
26.9
33.7
42.4
48.3
60.3
76.1
88.9
101.6
114.3
139.7
168.3
219.1
244.5
273.0
323.9
355.6
406.4
457.0
508.0
610.0
Flat surfaces
t = 400
t = 500
t = 600
t = 700
2p =
0.045
2p =
0.055
2p =
0.065
2p =
0.075
2p =
0.085
2p =
0.055
2p =
0.065
2p =
0.075
2p =
0.085
2p =
0.095
2p =
0.065
2p =
0.075
2p =
0.085
2p =
0.095
2p =
0.105
2p =
0.065
2p =
0.075
2p =
0.085
2p =
0.095
2p =
0.105
25
26
28
30
32
33
34
36
38
39
40
42
43
45
46
47
49
49
50
51
52
52
56
29
31
33
35
37
39
41
43
45
46
47
49
51
54
55
56
58
59
61
62
63
63
68
34
36
38
40
43
44
47
50
51
53
55
57
59
63
64
66
68
69
70
72
73
73
80
38
40
43
45
48
50
53
56
58
60
62
64
67
71
73
74
77
78
80
82
83
83
93
42
45
47
50
53
55
58
62
64
67
68
72
75
79
81
83
86
87
90
92
89
90
105
36
38
41
43
46
47
50
53
55
57
59
61
64
68
69
71
73
74
76
78
79
79
87
42
44
47
50
53
54
58
61
63
66
67
71
74
78
80
82
85
86
88
90
92
92
103
47
49
53
56
59
61
65
69
72
74
76
80
83
88
90
93
96
98
100
102
102
102
119
52
55
58
62
66
68
72
76
79
82
84
89
93
98
101
103
107
109
112
114
114
114
135
57
60
64
68
72
74
79
84
87
90
93
97
102
108
111
114
118
120
123
123
123
124
151
49
52
55
58
62
64
68
72
75
78
80
84
87
93
95
97
101
103
105
108
108
108
126
55
58
62
66
70
72
76
81
84
87
90
94
99
105
107
110
114
116
120
120
120
121
145
61
65
69
73
77
80
85
90
94
97
100
105
110
117
120
123
127
130
133
133
133
135
165
67
71
75
80
85
88
93
99
103
106
109
115
120
128
131
135
140
143
143
143
144
148
184
73
77
82
87
92
95
101
107
111
115
119
125
131
139
143
147
152
156
156
156
157
161
203
56
59
63
67
71
74
78
83
86
89
92
96
101
107
110
112
117
119
122
122
122
123
149
63
67
71
75
80
83
88
93
97
100
103
109
114
121
124
127
132
134
138
138
138
140
172
70
74
79
84
89
92
97
103
107
111
114
120
126
134
138
141
147
150
150
150
152
155
194
77
81
86
92
97
100
106
113
118
122
125
132
138
147
151
155
161
165
165
165
166
171
217
84
88
94
99
105
109
116
123
128
132
136
143
150
160
164
169
176
176
176
178
181
186
240
NOTE 1
33
BS 5422:2001
Key
Outside
diameter
of pipe
(mm)
12.0
15.0
17.2
21.3
22.0
26.9
28.0
33.7
42.0
42.4
48.3
54.0
60.3
67.0
76.1
80.0
88.9
101.6
108.0
114.3
139.7
168.3
219.1
273.0
323.9
Flat surfaces
Heat loss (W/m for pipes and W/m2 for flat surfaces)
t = 50
17
20
23
27
28
33
35
41
49
50
56
61
68
74
83
87
95
107
113
119
142
167
212
258
301
285
t = 100
57
69
78
93
96
114
118
139
168
169
190
209
230
253
283
295
324
365
385
405
484
571
722
880
1 027
1 212
t = 150
110
133
150
180
186
221
229
269
326
329
369
407
448
492
551
576
632
712
752
791
947
1 119
1 419
1 731
2 021
2 405
t = 200
176
214
241
290
299
356
369
435
528
532
598
660
728
800
896
938
1 031
1 162
1 228
1 292
1 549
1 833
2 330
2 848
3 331
3 949
t = 250
257
313
353
427
439
525
544
641
781
788
885
979
1 081
1 188
1 333
1 395
1 535
1 733
1 832
1 929
2 316
2 746
3 498
4 283
5 016
5 897
t = 300
356
435
491
594
611
732
759
897
1 094
1 104
1 242
1 374
1 519
1 672
1 878
1 966
2 165
2 447
2 588
2 726
3 279
3 894
4 971
6 098
7 151
8 317
t = 350
476
582
658
798
821
985
1 022
1 209
1 478
1 491
1 679
1 860
2 058
2 268
2 550
2 670
2 943
3 330
3 523
3 714
4 474
5 321
6 806
8 362
10 254
11 286
t = 400
620
758
859
1 043
1 074
1 291
1 340
1 588
1 944
1 961
2 212
2 452
2 715
2 994
3 370
3 530
3 894
4 410
4 668
4 922
5 939
7 072
9 063
11 152
13 667
14 890
t = 450
791
969
1 099
1 337
1 378
1 658
1 721
2 042
2 505
2 527
2 853
3 165
3 508
3 871
4 360
4 569
5 044
5 718
6 056
6 387
7 716
9 200
11 809
14 550
17 813
19 226
t = 500
993
1 220
1 384
1 687
1 738
2 095
2 175
2 585
3 175
3 203
3 619
4 018
4 456
4 921
5 548
5 815
6 424
7 287
7 721
8 147
9 853
11 760
15 117
18 647
22 798
24 396
t = 550
1 231
1 514
1 720
2 099
2 164
2 611
2 711
3 226
3 968
4 004
4 527
5 029
5 582
6 167
6 958
7 296
8 064
9 155
9 703
10 241
12 399
14 812
19 065
24 221
28 737
30 515
Key
t = operating temperature (C)
Operating conditions: ambient still air temperature 20 C; surface emissivity 0.9; height of flat surface 0.6 m; surface orientation horizontal
t = 600
1 509
1 859
2 113
2 583
2 662
3 217
3 341
3 979
4 901
4 945
5 595
6 220
6 908
7 636
8 621
9 041
9 998
11 358
12 042
12 713
15 406
18 420
23 736
30 135
35 754
37 700
t = 650
1 832
2 260
2 571
3 146
3 243
3 923
4 075
4 859
5 990
6 045
6 843
7 612
8 458
9 354
10 566
11 084
12 263
13 940
14 782
15 609
18 932
22 653
29 220
37 067
43 978
46 081
t = 700
2 206
2 723
3 100
3 798
3 916
4 742
4 926
5 878
7 254
7 320
8 292
9 228
10 258
11 350
12 827
13 459
14 897
16 942
17 969
18 979
23 036
27 582
35 609
45 134
53 549
55 794
BS 5422:2001
34
Table 19 Heat loss from bare surfaces calculated in accordance with BS EN ISO 12241 (black steel pipes)
BS 5422:2001
Table 20 Heat loss from bare surfaces calculated in accordance with BS EN ISO 12241
(copper pipes commercial grade, scoured to a shine)
Outside diameter
of pipe
(mm)
12.0
15.0
17.2
21.3
22.0
26.9
28.0
33.7
42.0
42.4
48.3
54.0
60.3
67.0
76.1
80.0
88.9
101.6
108.0
114.3
139.7
168.3
219.1
273.0
323.9
Flat surfaces
t = 50
11
12
14
16
17
19
20
23
27
28
31
33
36
39
43
45
49
54
57
59
69
80
98
116
133
119
t = 100
36
43
47
56
57
66
69
79
93
94
104
113
123
134
148
153
166
184
193
202
236
272
334
396
452
647
t = 150
66
79
87
103
105
123
127
146
173
174
192
210
228
248
273
284
308
341
358
374
437
505
619
735
840
1 244
t = 200
100
119
132
156
160
186
192
222
263
265
292
319
347
377
416
432
469
520
545
570
666
770
946
1 123
1 284
1 938
Key
Operating conditions: ambient still air temperature 20 C;s surface emissivity 0.07; height of flat surface 0.6 m;
surface orientation horizontal
35
BS 5422:2001
Table 21 Heat loss from bare surfaces calculated in accordance with BS EN ISO 12241
(copper pipes oxidized)
Outside diameter
of pipe
(mm)
12.0
15.0
17.2
21.3
22.0
26.9
28.0
33.7
42.0
42.4
48.3
54.0
60.3
67.0
76.1
80.0
88.9
101.6
108.0
114.3
139.7
168.3
219.1
273.0
323.9
Flat surfaces
t = 50
15
18
21
25
25
30
31
36
44
44
50
55
60
66
73
77
84
94
99
104
124
146
184
224
261
245
t = 100
52
63
70
84
87
103
106
124
150
151
169
186
205
224
250
261
286
321
339
356
424
499
629
763
888
1 076
t = 150
99
120
135
162
166
197
204
239
289
292
326
359
395
433
484
505
554
623
657
691
824
971
1 226
1 491
1 737
2 125
t = 200
158
191
215
258
265
315
326
383
464
468
524
578
636
698
781
816
895
1 007
1 063
1 118
1 336
1 577
1 997
2 432
2 837
3 464
Key
Operating conditions: ambient still air temperature 20 C;s surface emissivity 0.7; height of flat surface 0.6 m;
surface orientation horizontal
11 Protection against freezing


NOTE 1 The use of insulation alone does not afford complete protection against the freezing of water in pipes and vessels under all
atmospheric conditions. If the ambient temperature remains low enough for a sufficiently long period and the movement of water
through the pipe or vessel is very slow or if the water is static, no insulation, however thick, will prevent internal freezing.
Nonetheless, insulation does reduce the rate of cooling and delays the onset of freezing, such that the formation of ice may be avoided
if the time intervals during which the water is static are short enough, or if more heat is supplied from the water passing through the
system than is lost from the surface of the insulation together with the associated losses through the metal supports and hangers, or
if supplementary heating is used, even if only in local areas.
36
BS 5422:2001
Where an insulation material is used with a heat trace, the heat loss shall be calculated according to the
known worst case design condition and the insulation thickness shall be such that it limits the heat loss
to 10 % less than the maximum heat output of the heat trace.
NOTE 2 The time taken for water to reach its freezing point under given initial conditions and ambient temperatures is a function
of the ratio between the heat capacity of the system (including that of the containing vessel and of the insulation) and the rate of heat
loss from it. Consequently pipes of small bore are more vulnerable than those of larger bore and therefore the smaller pipes require
relatively greater thicknesses of insulation for the same degree of protection against freezing.
Where protection against freezing is required, the insulation thickness shall, wherever possible
(see notes 3 and 4), be in accordance with the values given in Table 22, Table 23, Table 24 or Table 25, as
appropriate.
NOTE 3 Calculations of the insulation thickness have been made ignoring the heat capacity of the insulation and the surface
resistance of the outer finish in order to give a worst case condition which allows for the common situation where the temperature of
the insulation is lower than the initial temperature of the water.
A separate calculation is required if the conditions indicated in Table 22, Table 23, Table 24 or Table 25 do not apply.
NOTE 4 Some of the theoretical thicknesses in the tables are impractical to accommodate, and in such cases other means of
protection, e.g. trace-heating, drain-down, frost-stats or water-flow, should be adopted to supplement the protection that is afforded
by the reduced thickness of insulating material.
Where insulating materials of alternative thermal conductivity are proposed, calculation methods in accordance with
BS EN ISO 12241 can be used to ensure that the thickness selected affords at least the equivalent degree of frost protection.
For smaller pipes it is not practical to install thermal insulation of sufficient thickness to avoid entirely the possibility of ice formation
overnight in sub-zero temperatures.
Table 22 Minimum insulation thickness to protect steel pipes against freezing under selected
industrial process conditions
Outside diameter Inside diameter
of pipe
(bore)
(mm)
(mm)

Specified conditions 1
2p =
0.020
21.3
26.9
33.7
42.4
48.3
60.3
76.1
88.9
114.3
168.3
219.1
16.0
21.6
27.2
35.9
41.8
53.0
68.8
80.8
105.3
158.6
207.9
5 028
716
203
124
66
41
31
22
14
10
2p =
0.030
4 812
708
340
141
75
54
35
21
16
2p =
0.040
2 349
875
275
123
84
51
29
21
2p =
0.050
2 195
513
193
122
70
37
27
2p =
0.020
1 034
179
74
37
28
19
13
11
8
5
4
2p =
0.030
10 350
715
194
75
51
32
21
17
12
8
6
2p =
0.040
2 740
472
137
85
48
30
23
17
10
8
2p =
0.050
1 119
240
135
69
40
31
21
13
10
Key
Specified conditions 1: water temperature +5 C; ambient temperature 10 C; evaluation period 12 h; permitted ice formation nil
Specified conditions 2: water temperature +5 C; ambient temperature 10 C; evaluation period 12 h; permitted ice
formation 10 %
2 = thermal conductivity [W/(mK)]
NOTE 2 Some of the insulation thicknesses given are too large to be applied in practice but a selection is included to highlight the
difficulty in protecting small diameter pipes against freezing. To provide the appropriate degree of frost protection to certain sizes
of pipes, it may be necessary to provide additional heat to the system, for example by circulating the water or heat tracing.
NOTE 3 Assumed densities (@) and heat capacities (cp) are as follows:
@ water = 1 000 kg/m3, cp water = 4 200 J/kgK;
@ steel = 7 840 kg/m3, cp steel = 455 J/kgK.
37
BS 5422:2001
Table 23 Minimum insulation thickness required to give protection against freezing under
specified commercial and institutional conditions
Outside
diameter
(mm)
Copper pipesa
15.0
22.0
28.0
35.0
42.0
54.0
76.1
108.0
Steel pipesb
21.3
26.9
33.7
42.4
48.3
60.3
76.1
88.9
Inside
diameter
(bore)
(mm)

2p =
0.020
2p =
0.025
2p =
0.030
2p =
0.035
2p =
0.040
2p =
0.020
2p =
0.025
2p =
0.030
2p =
0.035
2p =
0.040
13.6
20.2
26.2
32.6
39.6
51.6
73.1
105.0
23
10
7
5
4
3
2
2
35
14
9
7
5
4
3
2
53
18
11
8
6
5
3
2
78
23
13
10
7
5
4
3
113
28
16
11
9
6
4
3
68
21
13
9
7
5
4
3
126
30
17
12
9
7
5
3
229
42
22
15
11
8
5
4
413
58
28
18
13
9
6
4
740
78
35
22
16
11
7
5
16.0
21.6
27.2
35.9
41.8
53.0
68.8
80.8
18
10
7
5
4
3
3
2
26
13
9
6
5
4
3
3
35
17
12
8
6
5
4
3
48
21
14
9
7
6
4
4
64
26
17
11
9
7
5
4
44
20
13
9
7
5
4
3
71
28
18
11
9
7
5
4
112
39
23
14
11
8
6
5
173
52
29
17
13
10
7
6
265
68
36
20
16
11
8
7
Key
Specified conditions 1: water temperature 2 C; ambient temperature 6 C; evaluation period 12 h; permitted ice formation 50 %;
indoor
Specified conditions 2: water temperature 2 C; ambient temperature 10 C; evaluation period 12 h; permitted ice
formation 50 %; outdoor
a
b
Dimensions in accordance with BS EN 1057:1996, Table 3.

Dimensions in accordance with BS 1387:1985, Table 4.
NOTE 2 Some of the insulation thicknesses given are too large to be applied in practice but are included to highlight the
difficulty in protecting small diameter pipes against freezing. To provide the appropriate degree of frost protection to certain sizes
of pipes, it may be necessary to provide additional heat to the system, for example by circulating the water or heat tracing.
NOTE 3 Assumed densities (@) and heat capacities (cp) are as follows:
@ water = 1 000 kg/m3, cp water = 4 200 J/kgK;
@ steel = 7 840 kg/m3, cp steel = 455 J/kgK;
@ copper = 8 900 kg/m3, cp copper = 390 J/kgK.
38
BS 5422:2001
Table 24 Minimum insulation thickness to protect against freezing for domestic cold water
systems (12 h)
Outside
diameter
(mm)
Copper pipesa
15.0
22.0
28.0
35.0
42.0
54.0
76.1
Steel pipesb
21.3
26.9
33.7
42.4
48.3
60.3
76.1
Inside
diameter
(bore)
(mm)

2p =
0.020
2p =
0.025
2p =
0.030
2p =
0.035
2p =
0.040
2p =
0.020
2p =
0.025
2p =
0.030
2p =
0.035
2p =
0.040
13.6
20.2
26.2
32.6
39.6
51.6
73.1
20
9
6
5
4
3
2
30
12
8
6
5
4
3
43
16
10
7
6
4
3
62
20
12
9
7
5
4
88
24
14
10
8
6
4
23
10
7
5
4
3
2
35
14
9
7
5
4
3
53
18
11
8
6
5
3
78
23
13
10
7
5
4
113
28
16
11
9
6
4
16.1
21.7
27.3
36.0
41.9
53.0
68.8
15
9
7
5
4
3
2
21
12
8
6
5
4
3
29
15
10
7
6
5
3
38
18
12
8
7
5
4
50
22
15
10
8
6
4
18
10
7
5
4
3
3
26
13
9
6
5
4
3
35
17
12
8
6
5
4
48
21
14
9
7
6
4
64
26
17
11
9
7
5
Key
normal installation, i.e. inside the building and inside the envelope of the structural insulation
extreme installation, i.e. inside the building but outside the envelope of the structural insulation
a
b

NOTE 1 Some of the insulation thicknesses given are too large to be applied in practice. The purposes of including very high
thicknesses is to demonstrate that the application of a material of the given thermal conductivity is not able on the pipe size
indicated to provide the degree of frost protection under the design conditions. Therefore in order to increase the degree of frost
protection it is necessary to increase the pipe size, select an insulation with a lower thermal conductivity or use some means of
putting heat back into the system.
39
BS 5422:2001
Table 25 Minimum insulation thickness to protect against freezing for domestic cold water
systems (8 h)
Outside
diameter
(mm)
Copper pipesa
15.0
22.0
28.0
35.0
42.0
54.0
76.1
Steel pipesb
21.3
26.9
33.7
42.4
48.3
60.3
76.1
Inside
diameter
(bore)
(mm)

2p =
0.020
2p =
0.025
2p =
0.030
2p =
0.035
2p =
0.040
2p =
0.020
2p =
0.025
2p =
0.030
2p =
0.035
2p =
0.040
13.6
20.2
26.2
32.6
39.6
51.6
73.1
11
6
4
3
3
2
2
15
7
5
4
3
3
2
20
9
6
5
4
3
2
26
11
7
6
5
3
3
34
13
9
7
5
4
3
12
6
4
4
3
2
2
17
8
6
4
4
3
2
23
10
7
5
4
3
2
31
12
8
6
5
4
3
41
15
10
7
6
4
3
16.1
21.7
27.3
36.0
41.9
53.0
68.8
9
6
4
3
3
2
2
12
7
5
4
3
3
2
15
9
7
5
4
3
2
19
11
8
5
5
4
3
24
13
9
6
5
4
3
10
6
5
3
3
2
2
14
8
6
4
4
3
2
18
10
7
5
4
3
3
23
12
9
6
5
4
3
29
15
10
7
6
4
3
Key
normal installation, i.e, inside the building and inside the envelope of the structural insulation
extreme installation, i.e, inside the building but outside the envelope of the structural insulation
a
b

NOTE 1 Some of the insulation thicknesses given are too large to be applied in practice. The purposes of including very high
thicknesses is to demonstrate that the application of a material of the given thermal conductivity is not able on the pipe size
indicated to provide the degree of frost protection under the design conditions. Therefore in order to increase the degree of frost
protection it is necessary to increase the pipe size, select an insulation with a lower thermal conductivity or use some means of
putting heat back into the system.
40
Annex A (informative)
Determination of environmental thickness
NOTE This annex explains the way in which the environmental thickness used in the present edition of BS 5422 was derived from
the economic thickness used in the 1990 edition.
The environmental thickness of a selected insulation material of pre-determined thermal conductivity is

defined by the thickness required to ensure that:
a) the heat transfer for all insulation types is equivalent for each specific combination of pipe diameter
and operating temperature;
b) carbon dioxide abatement (based on gas as a fuel type) through the application of this standard
remains among the most cost-effective abatement measures available to regulators.
Consideration was also given to the practical limits of space utilization. In common with BS 5422:1990, it
was recognized that it is not practical for heat loss per metre of pipe to be constant for pipes of differing
diameters and operating temperatures. The consequences are shown for non-domestic pipe at 75 C
in Figure A.1.
40
35
30
Heat loss, W/m
BS 5422:2001
25
20
15
10
5
0
0
50
100
150
250
Outside pipe diameter, mm
Figure A.1 Heat loss related to pipe diameter for non-domestic heating pipe at 75 C
insulated in accordance with Table 12
The basis for each environmental thickness table in this standard has been established by applying an
incremental percentage increase to the defined thicknesses set out in the equivalent tables of
BS 5422:1990. Since the previously used economic thickness method did not provide constant heat loss
assessments with varying thermal conductivity, it proved necessary to define a specific thermal
conductivity in the BS 5422:1990 standard to provide the baseline. The following table gives details of the
selections made for the various tables covered by environmental thickness methodologies.
To ensure compliance with the cost-effectiveness criteria set out above, the lifetime costing of each measure
was assessed based on the incremental cost and carbon dioxide (CO2) benefit of the upgrade from previous
BS 5422:1990 values.
41
BS 5422:2001
The formula used for the lifetime costing model was as follows:
C LT
C CO = ------------2
S CO
2
where
C CO
is the life-time cost;
C LT
S CO
is the cost per tonne of CO2 saved;
is the annual savings of CO2 resulting;
and
C LT = C II S E
where
C II
is the initial investment cost;
SE
is the net present value of energy savings per year.
A target of break-even or better was set for each measure based on gas as the fuel and an assumed 15 year
lifetime for pipe insulation in non-domestic applications. The results of this approach are set out in
Table A.1. Prices for gas were based on ECON 19 [2].
Table A.1 Environmental thickness methodologies
Application
Refrigeration
Chilled water
Non-domestic heating
Non-domestic hot water
Domestic heating
Domestic hot water
Process pipework
a
Table
reference
6
9
12
13
14
14
15
Table reference
for source data
BS 5422:1990
5
7
12
11
19
22
24
Fuel type
BS 5422:1990
Gas
Solid fuel
Gas
Gas
N/A
Increase
applied
Data column to which

increase is applied
W/(mK)
0.040
0.040
0.040
0.040
0.035
0.035
0.040 to 0.110a
50 %
50 %
50 %
50 %
6%
6%
20 %
0.040 at 100 C; 0.050 at 200 C; 0.050 at 300 C; 0.060 at 400 C; 0.070 at 500 C; 0.090 at 600 C; 0.100 at 700 C.
42
BS 5422:2001
Annex B (informative)
Default values for use in BS EN ISO 12241 heat transfer calculations
B.1 General
Compared with the present standard, the calculation procedures given in BS EN ISO 12241 require a
greater amount of information from the user. Complete information is not always available at the
preliminary design stages. Additionally, the effect that small changes in some design parameters can have
may not be immediately apparent. To provide common guidance on the selection of physical data, values of
surface emissivity are given in Table B.1 for various common surfaces, together with typical default
information for other physical properties.
Table B.1 Surface emissivity (()
Material
Aluminium, bright
Aluminium, oxidized
Aluminium foil, bright reinforced
Aluminium foil, polyester faced reinforced
Alu-zinc
Austenitic steel
Brass, dull tarnished
Brass, unoxidized
Cast iron (and iron)
Cast iron, rusted or oxidized
Chrome, polished
Cloth
Copper, commercial scoured to a shine
Copper, oxidized
Copper, polished
Fire brick
Galvanized steel, blank
Galvanized steel, dusty
Paint, black
Paint, other colours
Paint, white
Paint, aluminium weathered
Paint, aluminium new
Roofing felt
Rubber, black
Rubber, grey
Steel
Steel, black painted
Steel, oxidized
White lacquer
0.05
0.13
0.05
0.40
0.18
0.15
0.61
0.035
0.35
0.65
0.10
0.90
0.07
0.70
0.02
0.75
0.26
0.44
0.95
0.90
0.85
0.55
0.30
0.94
0.95
0.85
0.35
0.90
0.80
0.95
NOTE The above values provide a useful guide to surface emissivity. However, it should be noted that the emissivity of a
material varies with temperature and surface finish. Therefore, the precise material emissivity should be ascertained where a high
degree of accuracy is required.
43
BS 5422:2001
B.2 Default data

The information given in Table B.2 is intended to provide assistance to the user on the following basis.
Conditions shown in italics are the most onerous. These conditions will require the largest insulation
thickness for a given application. The values shown in parentheses ( ) are typical default values.
The information should be used only as general guidance in the absence of specific site data. It is extremely
important to note that physical variations that result in a change from laminar to turbulent airflow over
the insulated surface may affect the validity of this guidance. In particular, use of those default conditions
annotated in the table should be treated with caution for the following applications:
hot pipes located in still air and typically larger than 300 mm OD;
hot flat surfaces located indoors typically having a height greater than 700 mm;
cold flat surfaces located indoors typically having a height greater than 1 500 mm.
Table B.2 Default data for use in BS EN ISO 12241 calculations
Variable
Diameter
Orientation
Height
Surface
emissivity
Air velocity
Flat or
cylindrical
Flat
Cylindrical
Flat
Cylindrical
Flat
Cylindrical
Flat
Cylindrical
Flat
Cylindrical
Ambient air Flat

temperature
Cylindrical
Condition
P1
P2
P3
P4
N/A
Largest a
N/A
Vertical
Smallest b (600 mm
for horizontal ducts,
3 000 mm for vertical
ducts and for vessels)
N/A
Highest
Highest
Highest
(still air)
Highest
(still air)
Lowest for hot
surfaces, highest for
cold
(20 C)
Lowest for hot
surfaces, highest for
cold
(20 C)
N/A
Largest a
N/A
Horizontal
Greatest b (600 mm
N/A
Lowest
Lowest
Lowest
(still air)
Lowest
(still air)
Highest
(20 C)
N/A
Largest
N/A
Horizontal
Greatest c (600 mm
N/A
Lowest
Lowest
Lowest
(still air)
Lowest
(still air)
Highest
(25 C)
N/A
Smallest
N/A
N/A
N/A
Highest
(20 C)
Highest
(25 C)
N/A
N/A
N/A
N/A
N/A
Lowest
Lowest
Key
P = Purpose of insulation:
P1 = Reduce total heat loss/gain;
P2 = Minimize temperature on hot surfaces;
P3 = Prevent condensation on cold surface;
P4 = Inhibit freezing.
NOTE
a
b
c
The use of annotated default conditions should be treated with caution for the following applications:
Hot pipes located in still air and typically larger than 300 mm OD.
Hot flat surfaces located indoors typically having a height greater than 700 mm.
Cold flat surfaces located indoors typically having a height greater than 1 500 mm.
44
BS 5422:2001
Annex C (informative)
Summary of criteria used to establish the tables
The criteria used to establish the tables are summarized in Table C.1.
Table C.1 Summary of criteria used to establish the tables
Table
Description
Horizontal Height
Outer
Contents
Max outer
Ambient Ambient air Relative Evaluation
or vertical
(flat
surface
temperature humidity time and ice temperature
surface
air
(pipes
surfaces emissivity velocity
C
(r.h.) and
formation
C
temperature
C
only)
only)
dew point
m/s
m
temp.
Vapour barrier
permeances
Refrigeration
condensation
40 to +10
Horizontal 0.6
0.90
20
70 %
14.4 C
40 to 0
Refrigeration
condensation
Horizontal 0.6
0.05
20
70 %
14.4 C
40 to 0
Refrigeration
condensation
Horizontal 0.6
0.90
25
80 %
21.3 C
40 to 0
Refrigeration
condensation
Horizontal 0.6
0.05
25
80 %
21.3 C
40 to 0
Refrigeration
environmental
Horizontal 0.6
0.05
25
40 to 0
Chilled and cold Horizontal 0.6

condensation
0.90
25
80 %
21.3 C
0, 5, 10

condensation
0.05
25
80 %
21.3 C
0, 5, 10

environmental
0.05
25
0, 5
10
Chilled air duct Horizontal 0.6

condensation
0.05, 0.44, 0
0.90
25
80 %
21.3 C
0 to 15
11
Warm air duct

environmental
Horizontal 0.6
0.05
10
20 to 60
12
Non-domestic
heating
environmental
Horizontal 0.6
0.05
20
75, 100, 150
13
Non-domestic
hot water
environmental
Horizontal 0.6
0.05
20
60
14
Domestic
Horizontal 0.6
heating and hot
water
environmental
0.05
60, 75
15
Process
environmental
Horizontal 0.6
0.05
20
100 to 700
16
Personnel
protection
Horizontal 0.6
0.90
20
100 to 700
59
17
Personnel
protection
Horizontal 0.6
0.05
20
100 to 700
50
18
Personnel
protection
Horizontal 0.6
0.90
20
100 to 700
50
19
Heat loss from Horizontal 0.6

bare steel pipes
0.90
20
50 to 700
20
Heat loss from

bare bright
copper pipes
Horizontal 0.6
0.07
20
50 to 200
21
Heat loss from

bare oxidized
copper pipes
Horizontal 0.6
0.70
20
50 to 200
22
Industrial
process freezing
10
12 h
5
nil and 10 %
23
Commercial
and industrial
freezing
6, 10
12 h
50 %
24
Domestic
freezing
12 h
50 %
2, 7
25
Domestic
freezing
8h
50 %
2, 7
45
BS 5422:2001
Annex D (informative)
Outside diameters of steel and copper pipes
Table D.1 and Table D.2 give the outside diameters of steel and copper pipes and are taken from BS 3600
and BS EN 1057.
Table D.1 Outside diameter of steel pipe (from BS 3600)
Nominal size
mm
10
20
25
32
40
50
65
80
90
100
125
150
200
250
300
350
400
450
500
600
NOTE 1
Outside diameter
in
)
#
1
1
1
2
2
3
3
4
5
6
8
10
12
14
16
18
20
24
mm
17.2
26.9
33.7
42.4
48.3
60.3
76.1
88.9
101.6
114.3
139.7
168.3
219.1
273.0
323.9
355.6
406.4
457.0
508.0
610.0
in
0.677
1.059
1.327
1.669
1.900
2.375
3.000
3.500
4.000
4.500
5.500
6.625
8.625
10.750
12.750
14.000
16.000
18.000
20.000
24.000
Table D.1 and Table D.2 give sizes of pipe commonly used in the engineering and process industries.
NOTE 2 Although the pipework may be ordered and referred to generally by quoting nominal (metric) sizes and thickness, for
insulating materials, the listed outside diameters should be quoted for pipe conforming to specific British Standards.
NOTE 3
Reference should be made to BS 1387 for the outside diameters and bore diameters of pipes not covered by BS 3600.
Table D.2 Outside diameter of copper pipe (from BS EN 1057)

Outside diameter
mm
10
12
15
22
28
35
42
54
76.1
108
46
Internal diameter (bore)

mm
8.8
10.8
13.6
20.2
26.2
32.6
39.6
51.6
73.1
105.0
BS 5422:2001
Annex E (informative)
Explanation of Class 0 rating and limited combustibility
E.1 Class 0
Class 0 is a term defined in The Building Regulations 1991, Approved Document B, Appendix A [3] which
makes use of British Standard performance ratings to limit the surface spread of flame of a material or
product (BS 476-7) and the rate at which heat is released from it (BS 476-6).
Class 0 is not a classification identified in a British Standard test, and is considered to be a higher class
than class 1.
A class 0 insulating material or the surface of a composite insulating product is one of the following:
a) composed throughout of material which when tested in accordance with BS 476-4 is rated
non-combustible;
b) composed throughout of material which when tested in accordance with BS 476-11 gives a
temperature rise on the specimen of less than 35 C, a temperature rise of the furnace of less than 25 C
and a flaming time of less than 10 s;
c) a class 1 material in accordance with BS 476-7 which has a fire propagation index (I) of not more
than 12.0 and a subindex value (i1) of not more than 6.0 when tested in accordance with BS 476-6.
E.2 Limited combustibility
Limited combustibility refers to insulation materials of less than 300 kg/m3 which satisfy a) or b) in the
class 0 definition.
E.3 Euro-classes
During the lifetime of this standard, class 0 and limited combustibility ratings will be replaced by reaction
to fire classes i.e. Euro-classes A1, A2, B, C, D, E and F.
Euro-class A1 is the safest fire classification, and Euro-class E is the most fire hazardous. Products with
Euro-classes A1, A2 and B do not flash over, whereas those to Euro-classes C, D and E do. Euro-class F
denotes products which have not been tested or do not meet the requirements of classes A1 to E.
NOTE The relationship between existing British Standards/classifications and the new Euro-classes is not always self-evident and
the UK government is continuing to sponsor work to determine the best methods of alignment of old and new. It is therefore
premature at the time of publication for this standard to attempt to replace existing fire classifications with alternatives based on
Euro-classes.
47
BS 5422:2001
Annex F (normative)
Method for assessing the system load for refrigeration pipe-work
F.1 Determination of total system heat gain
The total system heat gain (x) shall be calculated from the sum of the heat gains of the various components
of the system, in both air conditioning and refrigeration applications. This calculation shall adopt standard
methodologies for which both ASHRAE and CIBSE provide appropriate guidance (these normally exclude
pipe-work).
NOTE Further information can be obtained from the CIBSE Guides, particularly Volume A [4], and the ASHRAE Handbooks, in
particular that covering Systems and Equipment [5].
F.2 Determining the Coefficient of Performance (CoP) for the system

NOTE The coefficient of performance of a refrigeration system describes the additional efficiency improvement arising from the
direct expansion of the refrigerant, and the value for the CoP is therefore defined for each refrigerant type and shall be determined
by reference to the appropriate Mollier diagram. (An example for HCFC-22 (R-22) is shown in Figure F.1.)
In order to establish the real impact of the total system heat gain (x) on the energy demand of the system,
the value shall be adjusted using the CoP as follows:
x
----------- = y 1
CoP
where
x
y1
is the total system heat gain;

is the energy demand.
F.3 Assessing the distribution pipe-work load

NOTE 1 The contribution of distribution pipe-work to the total system heat gain is typically relatively minimal and has therefore
often been omitted from assessments historically. However, there are circumstances where the contribution from distribution
pipe-work can become more significant and, under these circumstances, the thicknesses specified in Table 6 and/or Table 9 of this
standard may be justified.
In order to determine whether the contribution from distribution pipe-work is significant, heat gains shall
be calculated according to BS EN ISO 12241 on the assumption that the pipe-work is already insulated to
control condensation assuming the use of a high emissivity surface (emissivity = 0.90). The resulting
pipe-work heat gain (z) shall then be used to determine the energy demand (y2) arising from the
distribution pipe-work as follows:
z---------= y2
CoP
where
z
y2
is the total pipework heat gain;

is the energy demand.
The percentage of the overall system load [I] represented by the pipework shall then be given by:
y2
I = ----------------------- 100 %
( y1 + y2 )
NOTE 2
This assumes that y1 has been calculated without any consideration of distribution heat gains.
NOTE 3 As can be seen from F.2 and F.3, the same CoP is common to both calculations and can be cancelled out in the final
determination of the percentage impact. Accordingly, there is normally no need to consider the impact of CoP for calculation purposes.
In reality, CoPs can have a significant impact in overall energy demand terms. Typical CoPs vary from levels as low as 1.5 up to values
greater than 4. At these higher levels, the positive benefit of CoP in overall energy demand terms could justify different consideration
than systems with lower CoPs. However, to simplify the calculation a threshold value of 5 % has been set as indicated in the footnotes
of both Table 6 and Table 9. In this way, the application of the thicknesses outlined in Table 6 and Table 9 is appropriately limited to
those refrigeration and chilled water systems where environmental considerations warrant it.
48
15
10
R-22
4.0
2.0
Pressure, MPa
1.0
0.4
0.2
0.1
0.04
0.02
150
20
250
300
350
400
450
Enthalpy, kJ/kg
49
Figure F.1 Example of Mollier diagram for R-22
500
550
600
BS 5422:2001
0.01
100
Annex G (normative)
Calculation of economic insulation thickness
G.1 Principle
The cost of the energy consumed by a process and the cost of providing insulation to reduce this
consumption is different for every project.
The installation of the economic thickness of insulation results in the lowest combined cost of insulation
plus energy consumption over a given period of time (evaluation period).
NOTE
Figure G.1 illustrates this principle.
Total cost
Cost of lost heat
Cost,
BS 5422:2001
Minimum
total cost
Cost of insulation and

installation
Economic thickness
Thickness of insulation
Figure G.1 Economic thickness
50
BS 5422:2001
G.2 Method of calculating economic thickness

The following information shall be used to calculate the economic insulation thickness:
a) cost of fuel;
b) process efficiency (e.g. boiler efficiency);
c) total hours of operation per year;
d) number of years over which the investment in insulation is to be evaluated;
e) installed cost of the proposed insulation in various thicknesses;
NOTE 1
Total installed cost encompasses insulation material, fixings, cladding, labour and all ancillaries.
f) heat transfer, both insulated and uninsulated.

NOTE 2 Heat transfer (usually stated in W/m for pipes and W/m2 for flat surfaces) depends on type of insulation, insulation
thickness, pipe diameter, pipe orientation, height of flat surfaces, operating temperature, surface emissivity of outer face, air
velocity and ambient air temperature.
The economic insulation thickness shall be calculated either by tabulation, as follows, or by another method
that can be demonstrated to give the same result.
1) Starting with the uninsulated condition, tabulate the cost of installing successive, commercially
available thicknesses of a particular insulation material (including labour and ancillaries).
NOTE 3 Inclusion of the uninsulated condition provides a comparison of potential savings. The additional costs associated with
the installation of multiple layers of insulation should be considered.
2) Tabulate the cost of the energy consumption for each of the insulation thicknesses considered over the
evaluation period.
3) Add the costs to identify the minimum total and the associated economic insulation thickness.
51
BS 5422:2001
Bibliography
Standards publications
BS 0-3:1997, A standard for standards Part 3: Specification for structure, drafting and presentation.
BS 476-4:1970, Fire tests on building materials and structures Part 4: Non-combustibility test for
materials.
BS 476-11:1982, Fire tests on building materials and structures Part 11: Method for assessing the heat
emission from building materials.
BS 1387:1985, Specification for screwed and socketed steel tubes and tubulars and for plain end steel tubes
suitable for welding or for screwing to BS 21 pipe threads.
BS 3600:1997, Specification for dimensions and masses per unit length of welded and seamless steel pipes
and tubes for pressure purposes.
BS EN 1057:1996, Copper and copper alloys Seamless, round copper tubes for water and gas in sanitary
and heating applications.
Other publications
[1] HEALTH AND SAFETY EXECUTIVE. Occupational exposure limits 2000 Containing the list of
maximum exposure limits and occupational exposure standards for use with the Control of Substances
Hazardous to Health Regulations 1999. HSE Guidance Note EH 40:2000. London: The Stationery Office.1)
[2] BUILDING RESEARCH ENERGY CONSERVATION SUPPORT UNIT. Energy use in offices.
ECON 19:2000. Watford: BRECSU.2)
[3] GREAT BRITAIN. The Building Regulations 1991. Approved Document B, Fire safety. London:
The Stationery Office.1)
[4] CHARTERED INSTITUTION OF BUILDING SERVICES ENGINEERS. CIBSE Guide Volume A,
Environmental design, 1999. London: CIBSE.3)
[5] AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS,
INC. ASHRAE HVAC Systems & Equipment Handbook, 2000. Atlanta, Georgia, USA: ASHRAE.4)
Available from HSE Books, PO Box 1999, Sudbury, Suffolk CO10 2WA. Tel: 01787 881165.
Website: http://www.hse.gov.gsi.uk.
2) Available from BRECSU, Building Research Establishment, Garston, Watford WD2 7JR. Tel: 01923 664258.
Website: http://www.bre.co.uk/brescu/.
3) Available from The Chartered Institution of Building Services Engineers, 222 Balham High Road, Balham,
London SW12 9BS. Tel: 020 8675 5211. Website: http://www.cibse.org.
4) Available from ASHRAE, 1791 Tullie Circle, NE, Atlanta, GA 30329, USA. Website: http://www.ashrae.org.
1)
52
blank
53
BS 5422:2001
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BS 5422 - 2001 Insulation of Ductwork

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Licensed Copy: Technical Information Services Dept .

A single copy of this British Standard is licensed to

This is an uncontrolled copy. Ensure use of the most

Method for specifying

ICS 23.040.01; 27.220

Committees responsible for this

BSI 13 November 2002

ISBN 0 580 38645 7

Amendments issued since publication

13 November 2002 Changes to Table 19, Table 20, Table 21,

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Permeance values for vapour barriers are given in Table 1.

4 Application of this standard

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Select the reasons

Cost saving Carbon saving

Tables 16, 17, 18

Figure 1 Flow chart indicating application of the standard

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5.2 Installation requirements

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5.3.4 Design value of thermal conductivity and thermal bridges

An appropriate methodology for ensuring compliance is given in BS EN ISO 12241:1998, Annex A.

5.4 Temperature limitations

5.6 Fire performance

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See Annex E for an explanation of limited combustibility.

See Annex E for an explanation of limited combustibility.

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Temperature of plant (cold surface)

5.8 Tests on physical properties

6.2 Physical characteristics

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6.2.2 Fire performance

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Insulation thickness (mm)

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BSI 13 November 2002

Insulation thickness (mm)

Insulation thickness (mm)

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Insulation thickness (mm)

Heat gain is related to the specific insulation thickness.

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BSI 13 November 2002

Insulation thickness (mm)

Insulation thickness (mm)

Heat gain is related to the specific insulation thickness.

7 Chilled and cold water applications

7.2 Physical characteristics

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Insulation thickness (mm)

Insulation thickness (mm)

Insulation thickness (mm)

Insulation thickness (mm)

Insulation thickness (mm)

Insulation thickness (mm)

BSI 13 November 2002