06.

2015

Technical insulation

CONTENTS
5

About Us .............................................. 3
Features of ROCKWOOL materials ........ 4
Technical and industrial insulation .... 5
Materials for technical insulation ..........5
Wound pipe sections ROCKWOOL 100 ........6

Wound pipe sections ROCKWOOL 150 .... 7

WIRED MAT 50, WIRED MAT 80
and WIRED MAT 105 ............................ 8

TECH MAT ........................................... 9

4
4

TECH BATTS ...................................... 10

LAMELLA MAT, LAMELLA MAT L....... 11
KLIMAFIX........................................... 12
INDUSTRIAL BATTS 80 ...................... 14
FIRE BATTS 110 ................................. 15
General transport and storage
requirements..................................... 16
ROCKFIRE - re protection solutions.... 17
Fire protection of ducts .................... 18
Fire protection of steel bearing
structures .......................................... 20
Fire protection of round steel column ...24

1000

Fire protection of the bearing metal

structures with CONLIT M paint ........ 25

500

Fire protection of oor slabs of

reinforced concrete ........................... 26
Fire protection of pipe
penetrations ..................................... 28
Fire protection of cable penetration ... 29
2

Products dimensions. .........................30

About Us
ROCKWOOL Group has over seventy years of experience in
thermal insulation manufacturing. The company's products
are valued worldwide for the high quality and wide selection of
material.
Zheleznodorozhny.
Moscow region

The company was established in 1909 in Denmark. The rst

ROCKWOOL plant producing the basalt mineral wool began
to operate in 1937 in Hedehusene. Today the company has 28
plants in 18 countries.
ROCKWOOL operates in Russia for several decades now. Back
in 1970s, ROCKWOOL's European plants started to export the
products to the USSR for ship building industry. In 1995, the
company opened a sales ofce in Moscow. In 1999, ROCKWOOL acquired its rst plant in Russia located in Zheleznodorozhny and modernised it to match the international standards of the Group.

Vyborg,
Leningrad region

To date ROCKWOOL has four enterprises in Russia, including

the plants in Moscow, Leningrad and Cheliabinsk regions, as
well as the plant in Alabuga special economic area in Tatarstan, which has the production line with the highest capacity in
Russia, launched in early 2012.

Troitsk,
Cheliabinsk region

ROCKWOOL Group includes a ROCKFON division, which

produces the acoustic ceilings. In 1962, the Group started to
produce the acoustic ceilings at its plants in Poland, France
and the Netherlands. The rst ROCKFON production line in
Russia was launched in March 2012 at the ROCKWOOL plant
in Vyborg, Leningrad region. ROCKFON was the rst foreign
manufacturer of acoustic ceilings to start the own production
in Russia.

Alabuga special economic

area in The Republic
of Tatarstan

From lava to insulation

The key material for production of ROCKWOOL re-safe insulation is basalt mineral. The production process starts from
melting the volcanic rock at +1500 . The melted rock is then
spun into bres with addition of binders and water-repellent
components. Features of ROCKWOOL stone wool products:

low thermal conductivity

re-safe
soundproof
water-repellent
and vapour-permeable
fatigueproof
sustainable.
chemical
and bio resistance

Features of ROCKWOOL materials

Low thermal conductivity

ROCKWOOL materials ensure the efcient thermal insulation
for heating and water supply systems, ventilation and air conditioning, as well as the industrial equipment.

Fire-safe
ROCKWOOL thermal insulation is based on basalt minerals,
the melting point of which is +1500 . Thus, the products are
re-safe reaction to re - Non-combustible and can restrict the
spread of re and the critical heating of bearing constructions.

Soundproof
The structure of the stone wool provides great acoustic performance improving the sound insulation of ducts and reducing
the sound pressure in adjacent premises.

Water-repellent and vapour-permeable

All ROCKWOOL materials contain water-repellent components.
Therefore, our materials have low level of water absorption and
do not absorb moisture from air. The water does not get inside
the material, so its properties remain unchanged.

Fatigueproof
The resistance to mechanical impact ensures lack of
shrinkage during the entire life cycle of material. If the
material is unable to maintain the required thickness
in conditions of mechanical impact, it loses the insulation properties. Most bres of the stone wool lie horizontally, while the
rest are positioned vertically. Therefore, the general structure
has no particular direction, which ensures high stiffness of
thermal insulation.

Sustainable
ROCKWOOL stone wool is a natural sustainable material produced from gabbro-basalt minerals. ROCKWOOL thermal insulation was the rst product in Russia to complete a voluntary
environment certication having obtained an EcoMaterialGreen
label, which conrms that the material is safe for people and
the environment.

Chemically resistant
The stone wools are chemically inert to oils, solvents and alkali.

Bioproof
The stone wool is inedible for rodents and insects and does not
facilitate the growth of fungi, moulds and bacteria.

Technical and industrial insulation

To ensure the successful economic development,
it is necessary to use the electricity and energy
resources sustainably. The utilisation of technical and industrial insulation is crucial for energy
efciency.

substantial use of energy. With the utilisation of

appropriate insulation, the issue of energy consumption becomes more practical. Furthermore,
it is important to keep the equipment surface free
of condensate, which can cause the corrosion.
Many technological processes require the hightemperature equipment. Therefore, the insulation
must also ensure the operational safety.

The heating and water supply systems represent

one of the elds, where both energy saving and
technical aspects of the technological processes
will always be relevant. These objectives can be
achieved by applying the efcient insulation..

ROCKWOOL offers a wide selection of the efcient insulation materials, which can meet all
these objectives.

Insulation is essential for the ventilation and air

conditioning systems. It has three key functions:
thermal insulation, sound- and reproong.
The modern industrial production always requires

Materials for technical insulation

The thermal insulation materials for technical use may be
conditionally divided into network and process segment of application, where the former includes HVAC networks (heating,
ventilation, air conditioning) and water supply. In case of the
process application, the thermal insulation is used to maintain
the preset parameters of substances involved in the production cycle, as well as to keep the temperature of equipment and
pipelines in a safe range for the employees.

The HVAC technical insulation typically includes the materials

for thermal insulation of ducts and pipes, i.e. the prefabricated
hard cylinders or exible mats. The process segment can utilise the mats and cylinders too, but they require larger density
due to the higher process temperatures. Also, the various soft
and rigid slabs can be used for insulation of large-diameter
reservoirs, at surfaces of furnaces and equipment units.
The materials can be conditionally divided as follows:

Table 1. Materials included in the main segments

HVAC application

Process application

Wound pipe sections ROCKWOOL 100

Wound pipes section ROCKWOOL 150

WIRED MAT 105
WIRED MAT 80
CH (light technical mat)

KLIMAFIX self-adhesive mat

LAMELLA MAT
INDUSTRIAL BATTS 80 noise reduction slabs

CH BATTS 50, 75, 100, 125, 150 slabs

FIRE BATTS slabs
WIRED MAT 50

* These products do not have the alufoil covering.

Wound pipe sections ROCKWOOL 100

Product description
The wound pipe sections ROCKWOOL 100 are hydrophobic preformed stone wool insulation product with synthetic binder. The
cylinders are 1 m long and hollow.
They can also be covered with alufoil. The wound pipe sections
ROCKWOOL 100 have a lengthsize section on one side and a
corresponding internal cut on the opposite side for easy installation on a pipeline. The plane of section and cut lines crosses
the axis of cylinder.
The specication name consists of a trademark, index of covering, size (internal diameter, insulation thickness) and production
specication number. The specication name of a wound pipe sections ROCKWOOL 100 covered with reinforced alufoil with 45 mm
internal diameter and 40 mm insulation thickness: ROCKWOOL
100 wound pipe section, ALU, 45*40 5762-050-45757203-15.

Application
ROCKWOOL 100 wound pipe section provides outstanding performance for thermal insulation and sound attenuation for
steel pipework operating at temperatures to +650C.
ROCKWOOL 100 wound pipe section, ALU is suitable for thermal insulation of pipework and equipment in heating, ventilation and air condition systems.

Thermal conductivity values for ROCKWOOL

100 wound pipe sections

Installation
The pipe sections shall be installed tightly to each other
with misalignment of horizontal seams and secured on
the pipe with 20 mm wide steel banding (0.7 to 0.8 mm
galvanised or corrosion-resistant steel) or a wire with
1.2-2.0 mm gauge.
It is reco mmended to install at least two bandings per one
cylinder at up to 500 mm interval.
If using the foil-covered pipe sections, a self-adhesive aluminium tape shall be applied on longitudinal and transversal joints.
In case of exterior piping or if necessary, a protective cover
(jacket) can be mounted on the pipe sections
Where the pipe sections are applied as insulation on vertical
pipelines, the off-loading structures (support rings) shall be
installed at a 3-4m pitch to secure the protective cover and
prevent the insulation from sliding down.
If using the pipe sections for piping insulation with the purpose of preventing the condensation, it is required to apply
a vapour insulation layer with airtight joints.

Calculated thermal conductivity for different temperatures:

= 35.43 + 7.794 10-2 T + 2.381 10-4 T2 + 4.444 10-7 T3
(mW/m*), T being the temperature of the middle insulation layer.

Table 2. Product properties

Parameter
Thermal conductivity, W/m*

Maximum service temperature

Units
25

50

100

150

200

250

300

350

0.036

0,040

0,046

0,054

0,064

0,077

0,092

0,111

+650

Reaction to re

Wound pipe sections ROCKWOOL 100 0 (Non-combustible)

Wound pipe sections ROCKWOOL 100 ALU 1 (G1, V1, D1, 1)

Density kg/m3

114

Wound pipe sections ROCKWOOL 150

Product description
The wound pipe sections ROCKWOOL 150 are hydrophobic preformed stone wool insulation product with synthetic binder. The
cylinders are 1m long and hollow.
The wound pipe sections ROCKWOOL 150 have a lengthsize
section on one side and a corresponding internal cut on the opposite side for easy installation on a pipeline. The plane of section and cut lines crosses the axis of cylinder.
The specication name consists of a trademark, size (internal diameter, insulation thickness) and production specication number.
The specication name of a wound pipe sections ROCKWOOL
150 with 245 mm internal diameter and 90 mm insulation thickness: ROCKWOOL 150 wound pipe section, 245*90 5762-05045757203-15.

Application
ROCKWOOL 150 wound pipe section provides outstanding performance for thermal insulation and sound attenuation for
steel pipework operating at temperatures to +680C.

Thermal conductivity values for ROCKWOOL

150 wound pipe section

Calculated thermal conductivity for different temperatures: = 31.63 +

1.144 10-1 T + 1.165 10-4 T2 + 2.66 10-7 T3 (mW/m*K), T being
the temperature of the middle insulation layer.

Installation
The pipe sections shall be installed tightly to each other with misalignment of horizontal seams and secured on the pipe with banding or a haywire. It is reco mmended to install at least two bandings
per one cylinder at up to 500 mm interval.
If necessary, a protective cover (jacket) can be mounted on the pipe
sections.
Where the pipe sections are applied as insulation on vertical pipelines, the off-loading structures (support rings) shall be installed at
a 3-4m pitch to secure the protective cover and prevent the insulation from sliding down.
If insulating the high-temperature pipelines, the double layer of
wound pipe sections ROCKWOOL 150 can be installed. In such case
it is required to maintain the misalignment of horizontal seams on
the external and internal layer of insulation.
The pipe sections are reco mmended as thermal insulation layer
for anges and anged ttings in thermal insulation structures.
The pipe sections can be used as an insert for prefabricated or
assembled constructions designed for insulation of anges or
anged ttings. The pipe sections may be attached to the surface
with forelocks.
The edges of pipe sections insulation for anges are covered with
screens made of protective material.
If insulating the elbow, the pipe section is cut into several parts. The
angle of cutting and number of parts shall be determined on site.

Table 3. Product properties

Parameter
Thermal conductivity, W/m*

Maximum service temperature

Units
25

50

100

150

200

250

300

350

0.037

0,040

0,046

0,053

0,062

0,073

0,085

0,099

+680

Reaction to re

0 (Non-combustible)

Density kg/m3

145

WIRED MAT 50, WIRED MAT 80

and WIRED MAT 105
Description

Application

Mats are produced of stone wool and supplied in rolls. WIRED

MATS are stitched on galvanised wired mesh with galvanised wire
without covering or covered with usual or reinforced foil under T
5762-050-45757203-15.

The wired mat is especially suitable for industrial installations

such as high-pressure steam pipes, reactors, furnaces, etc.
where high demands are made on the temperature resistance
of the insulation.

Installation
The installation procedure and required accessories depend on
the insulated equipment.

Table 4. General identication of WIRED MAT mats based on covering

WIRED MAT 50 (Noncombustible -0)

Wired mat not covered with alufoil

WIRED MAT 80 (Noncombustible -0)

Wired mat not covered with alufoil

WIRED MAT 105 (Noncombustible -0

Wired mat not covered with alufoil

ALU WIRED MAT 80 (1)

Wired mat covered with the reinforced alufoil

on one side

ALU WIRED MAT 105

(1)

Wired mat covered with the reinforced alufoil

on one side

ALU1 WIRED MAT 80

(Non-combustible -0)

Wired mat covered with the non-reinforced

alufoil on one side

ALU1 WIRED MAT 105

(Non-combustible -0)

Wired mat covered with the non-reinforced

alufoil on one side

Table 5. Product properties

Parameter

Thermal conductivity

Units

Value
WIRED MAT 50

WIRED MAT 80

WIRED MAT 105

10, W/m*

0.034

0.033

0.034

25, W/m*

0.036

0.035

0.036

50, W/m*

0.039

100, W/m*

0.045

125, W/m*

0,057

150, W/m*

0.053

0.052

200, W/m*

0.062

0.059

250, W/m*

0.072

0.068

300, W/m*

0,115

0.087

0.078

350, W/m*

0.099

0.089

400, W/m*

0.115

0.102

500, W/m*

0.153

0.131

0.198

600, W/m*

0.220

-180 to +650

-180 to +750

-180 to +750

kg/m3

50

80

105

640, W/m*
Application temperature
Density

*WIRED MAT 50 mats are produced without covering only and have a galvanised wire mesh.

TECH MAT
Insulation of pipework:

5
4

2
3

Description
Mats are produced of stone wool and supplied in rolls. Mats can
be produced without covering or covered on one side with alufoil.

Application

1 TECH MAT;
2 jacket support structure;
3 pipeline;
4 binding wire;
5 protective jacket.

These mats ere suitable for thermal insulation of storage

tanks, chimneys, pipelines, gas and air ducts, industrial equipment and power plants
Table 6. Product properties
Parameter

Thermal conductivity

Maximum service temperature

Reaction to re
Density

Units

Value

10, W/m*

0.034

25, W/m*

0.036

125, W/m*

0.060

300, W/m*

0.120

+570

No covering 0 (Non-combustible)
Alufoil covering 1
kg/m3

43

TECH BATTS
Table 7. Application of TECH BATTS

Description
Mats are produced of stone wool and supplied in rolls. Mats can
be produced without covering or covered on one side with alufoil.

Application
These mats ere suitable for thermal insulation of storage
tanks, chimneys, pipelines, gas and air ducts, industrial equipment and power plants.

TECH BATTS 50

Non load thermal insulation of horizontal and curved

surfaces (cylindrical, cone, etc.) surfaces of storage tanks,
equipment and ducts.

TECH BATTS 75

Thermal insulation of walls of storage tanks, horizontal,

vertical and inclined surfaces of equipment.

TECH BATTS 100

Thermal insulation of roofs of storage tanks,

technological equipment, heat exchangers, rectangular
gas ducts.

TECH BATTS 125

Thermal insulation of industrial equipment and power

plants. Thermal insulation and soundproong of internal
surfaces of ventilation chambers and channels.

TECH BATTS 150

Thermal insulation of industrial equipment and power

plants. Additional insulation (second layer) of industrial
furnaces, steam boilers and other heat-generating
equipment, chimneys.

Insulation of storage tank:

1 storage tank wall;

2 jacket support structure;
3 TECH BATTS;
4 protective jacket.

3
2

Installation
The slabs can be mounted on welded pins or installed between
the guides (TECH BATTS 50 and 75). The fastening method depends on the type of insulated structure.

Table 8. Product properties

Parameter

Thermal conductivity

Application temperature

Units

Value
TECH BATTS 50

TECH BATTS 75

TECH BATTS 100

TECH BATTS 125

TECH BATTS 150

10, W/m*

0.036

0.035

0.035

0.036

0.037

25, W/m*

0.038

0.037

0.037

0.038

0.039

125, W/m*

0.054

0.053

0.051

0.050

0.051

300, W/m*

0.081

0.079

0.077

-180 to +450

-180 to +550

-180 to +665

-180 to +700

-180 to +750

110

140

No covering 0 (Non-combustible)
Reaction to re
Alufoil covering 1 (G1, V1, D1, 1)
Density

10

kg/m

40

60

90

LAMELLA MAT, LAMELLA MAT L

Description
LAMELLA MAT mats consist of lamellas of ROCKWOOL stone
wool, which are glued to the base (foil). The mats are durable and resilient, so they do not lose shape when mounted on
curves and angles.

Application
Thermal insulation of pipelines, storage tanks and air ducts.
Thanks to lamellas, mats do not bend at angle edges of ducts
and equipment and maintain the even resistance to heat transfer across the whole thermal insulation structure.
The foil in mats is not wired, so the mats are often installed on
ducts transporting the cold air to prevent condensation. It is required to apply the self-adhesive aluminium tape on the mat joints.

Installation

Table 10. Product properties

Parameter
Thermal conductivity

Application temperature

Units

Value

25, W/m*

0.040

125, W/m*

0.068

up to +250
(temperature of foil
covered surface up to
+80)

Reaction to re

LAMELLA MAT mats are secured on the pipes with a buckle

banding or fastening wire. If installed on the ducts, the mats are
attached with the self-adhesive pins and secured with washers. The joints between the mats are insulated with the selfadhesive aluminium tape.

1 (G1, V1, D1, T1)

Density at up to 60 mm
thickness

kg/m3

65

Density at over 60 mm
thickness

kg/m3

60

Density of LAMELLA MAT L

kg/m3

40

11

KLIMAFIX

Description
The self-adhesive lamella mats of ROCKWOOL stone wool covered on one side with the reinforced alufoil. The bres of the
mats are located transverse to the duct surface, so the mats are
durable and resilient and do not lose the original thickness when
installed on curves and angles. KLIMAFI lamella mats have a
factory applied adhesive coat across the whole surface on the
wool side. The adhesive coating has a protective lm, which can
be easily removed prior to installation.

Application
KLIMAFIX mats serve for thermal insulation and soundproofing, prevent condensation on surfaces of the rectangular and
round ventilation facilities and air conditioning systems. These
mats will be a perfect choice for applications that require not
only insulation, but quick installation and aesthetic appearance.

12

Table 9. Product properties

Parameter
Thermal conductivity

Units

Value

10, W/m*

0.042

Reaction to re

1 (G1, V1, D1, T1)

3

kg/m

36

Maximum service temperature

50

Installation temperature

+5 to +35

Entire sulphur content, up to

0.4

Density

Installation
The adhesive coat does not lose its properties over time. Compared to the traditional lamella mats, KLIMAFIX products can
be installed up to 40% faster, since they do not require any
welded studs, pins, wires or steel bandings.
All the surfaces must be dried, cleaned and degreased prior
to installation. The optimal ambient temperature is 5 to 35 .
The mats are installed in stages:
Cut a necessary piece of mat and remove 10cm of protective
lm towards the direction corresponding to the mat structure.
Firmly press the mat against the whole surface of duct and
smooth out the mat moving from the centre to the edges.
Note that it is impossible to adjust the mat after is has been
attached.
Finally, bind together all the longitudal and transversal
joints of KLIMAFIX mat using at least 50 mm wide self-adhesive aluminium tape.
If the rated thickness of a product equals or exceeds 50 mm,
and in case the installation proceeds amid high humidity, the
mats shall be mounted mechanically like the regular lamella
mats. In this case, the adhesive coat serves as additional fastening.

13

INDUSTRIAL BATTS 80
Description
The stone wool slabs with glass tissue on one side.

Application
INDUSTRIAL BATTS 80 slabs are serving for thermal insulation
and soundproong of internal surfaces of the ventilation boxes.
They are installed in slot and chamber bafes and used to form
the sound-absorbing screens.

Table 11. Product properties

Units

Value

10, W/m*

0.036

Parameter
Thermal conductivity
Reaction to re

1 (G1, V1, D1, T1)

kg/m3

80

Application temperature

-180 to +250

Organic substances by weight

<4.0

Density

1
3
2

8000 Hz

4000 Hz

2000 Hz

1000 Hz

500 Hz

250 Hz

125Hz

Duct section, mm

63 Hz

Table 12. Bafing performance of 35 mm thick INDUSTRIAL BATTS

80 installed inside the ducts, dB

300 150

27

41

40

38

35

400 200

26

34

36

29

26

500 250

26

34

36

29

26

500 300

20

29

30

17

14

500 350

18

25

27

16

13

500 400

14

24

18

16

13

2
4

Examples of installation: :
1 ventilation box
2 INDUSTRIAL BATTS 80
3 z-shaped prole
4 chamber bafe
5 hull
3
2

14

FIRE BATTS 110

Description

Table 13. Product properties

The slabs made of stone wool. They can be produced without covering or covered on one side with alufoil (ALU FIRE BATTS 110).

Application
The slabs serve for thermal insulation of at surfaces of replaces.

Parameter

Thermal conductivity

Units

Value

25, W/m*

0.041

125, W/m*

0.054

300, W/m*

0.088

No covering 0 (Non-combustible)
Reaction to re
Alufoil covering 1 (G1, V1, D1, 1)
Density

kg/m3

100

up to +750 (temperature
of the foil covering up
to +500)

Maximum service temperature

Fireplace structural sketch:

Insulation of boiler walls:

2
1
5

1 chimney
2 box
3 grille
4 foyer
5 FIRE BATTS.

1 boiler wall
2-3 FIRE BATTS / TECH BATTS 150 /
WIRED MAT 50, 80, 105
4 spacer
5 welded pin
6 washer
7 backband
8 jacket of steel corrugated sheet.

15

General transport and storage requirements

Transporting

Storage and handling

ROCKWOOL products shall be transported with minimum

transfer handling.
The products must be protected from weather impact, mechanical damage and moving around the vehicle.
The loading space of a vehicle must be dry, clean, free of mechanical
damage, sharp edges and curves, which may damage the products.
If ROCKWOOL items are transported together with other materials, they shall be kept away from each other to avoid damaging.
The pipe sections can be transported by all types of tented vehicles
in compliance with haulage rules for each type; the pipe sections
must be protected from moisture and damage. The pipe sections
with 20, 25, 30 and 40 mm thickness and the internal diameter that
equals or exceeds 76 mm shall be transported vertically. Other
cylinders can be transported horizontally or vertically.

The products must be stored in original packaging and sorted

by type and size.
If stored outdoors, the products shall be placed above the
ground and covered with a waterproof material.
The slabs, mats and cylinders must be stored indoors or outdoors under a tent protecting from atmospheric precipitation;
the products shall be packed and sorted by size and type. The
slabs and mats are stored horizontally, and the cylinders with
20, 25, 30 and 40 mm walls and the internal diameter that
equals or exceeds 76 mm shall be stored vertically. Other cylinders can be stored horizontally or vertically.

Packing
Most ROCKWOOL stone wool products are wrapped in polyethylene shrink lm according to a packing list for this type of
product (tables 21-23).

16

Installation
Since the thermal insulation is used for different types of equipment, pipelines and ducts, the installation method depends on
geometrical dimensions of the insulated structure and the way
it is covered.

ROCKFIRE - fire protection solutions

In Russia, the re safety requirements are stipulated mainly by

the Federal Law No. 123-FZ "Technical Rules of Fire Safety". In
accordance with this classication, there are certain requirements in terms of re resistance rating of constructions (not
the individual materials).
Fire resistance rating describes the time in minutes after which
a construction reaches one of the critical states indicated with
letters. "R" means loss of bearing ability (collapse or critical
sagging), "E" stands for loss of integrity (cracks, holes), "I"
means loss of thermal insulation ability (heating of surface
from a non-heated side), etc.
Different constructions have different requirements in terms
of limit states and times before they occur. The coverings are
tested for loss of integrity and bearing ability (RE), the columns
and joists only for loss of bearing ability (R), the internal walls
EI, the oor decks REI.

The re resistance rating of a construction is conrmed by a

certicate of an accredited laboratory after the re resistance
tests. The construction is built for testing in compliance with
the approved technical rules and using only the materials specied there. The construction undergoes testing with the load
corresponding to real operating conditions.
The issued re resistance certicate is valid only if the construction is built in full compliance with the technical rules using the materials specied in the certicate.
If one or more materials are replaced or the building procedure
is not followed, the construction shall be tested again.
ROCKFIRE system offers solutions for reproong of:
ducts
steel bearing structures
oor slabs of reinforced concrete
cable line and pipeline passes

17

Fire protection of ducts

The ducts are reproofed with WIRED MAT 105 made of
ROCKWOOL stone wool. Depending on thickness, this resafe
material ensures re resistance rating from 60 to 240 minutes.
WIRED MAT is a exible mat of stone wool wired with the
galvanised wire and covered on one side with 25 mm galvanised
wire mesh. WIRED MAT can be manufactured with nonreinforced alufoil covering.
The product is used for reproong of rectangular and round
ducts with at least 0.8 mm metal thickness.

Table 14. General identication of WIRED MAT resafe materials

depending on covering
WIRED MAT 105
ALU1 WIRED MAT 105

Required materials and tools

WIRED MAT 105 stone wool mats

welded pins
fastening washers
self-adhesive aluminium tape (if using WIRED MAT 105 with
alufoil covering)
tin snips
wire
metal hook for wire bundling
equipment for welding of pins.

Table 15. Fire resistance rating of a duct with ALU1 WIRED MAT
105 insulation

Wired mat not covered with alufoil

Wired mat covered with the non-reinforced
alufoil on one side

WIRED MAT 105 thickness,

mm

Fire resistance rating, min

25

EI60

30

EI90

40

EI120

Specication sample

50

EI150

WIRED MAT 105 with mesh and galvanised steel wiring, covered
with non-reinforced alufoil ALU1 of 6 000 mm long, 1 000 mm
wide and 25 mm thick: ALU1 WIRED MAT 105 6000 100 25;
T 5762-050-45757203-15.

60

EI180

70

EI240

* These products do not have the alufoil covering.

Pins and washers

Installation

Welded copper-plated steel pins CT/WP2 2 mm in diameter.

For transformer welders (Clim PW-33 etc.). Used together
with steel washers PW2/CS. Length 19 to 114 mm.
Welded copper-plated steel pins CD/WP2 2 mm in diameter.
For condenser welders (Clim DW-45, HBS CD 1501 etc.). Used
together with steel washers PW2/CS. Length 20 to 100 mm.
Steel washers PW2/CS. Used together with copper-plated
steel pins CT/WP2 and CD/WP2. External diameter 38 mm.
Welded elements CD/PWP2.7 consisting of 2.7 mm copperplated steel pin and 30 mm steel washer. The pin base near
washer has extra insulation for fastening the materials with
alufoil covering. Length 25 to 100 mm.

(Presented for your information based on Technical Rules No.

10-07-14)
1. Prepare the duct body. Fix the damaged geometry of body,
clean the surface, seal the ange joints of duct.
2. Do the pattern cutting of mats. The mats shall be cut to a
size that will allow to cover the whole area of duct. The mats
may be overlapped with further sealing of mat joints.
3. Secure the resafe material in one of the ways.

18

Method 1. Fastening through covering

The duct is wrapped with WIRED MAT mats, which are fastened
directly through the covering. The fasteners for this method are
the combined pins CDF and CDF-ISOL or CD/PWP 2,7 (pin with
the installed washer).

Method 2. Fastening with welded pins

The pins are welded to the duct, the mats are impaled on them
and secured with locking washers.

Method 3. Fastening with banding

Bading is a galvanised metal tape, which is 0.8-2 mm thick and 1520 mm wide and manufactured according to GOST 356073 standard. Installed at a pitch of 500 mm along the length of the duct.
Methods 1 and 2 require the interval up to 350 mm and no more
than 100 mm distance from the duct edge to the rst row of pins.
Thus, around 9 fasteners will be required per 1 m2.
Bent pins are not allowed; make sure the pins are not bent while
installing the mat.
The mats shall be mounted to cover the ange joints and cross
frames.
The duct hangers shall be insulated with the same resafe material, which is fastened with the galvanised wire.
If using the material covered with alufoil, the aluminium adhesive
tape must be applied on the mat joints.

19

Fire protection of steel bearing structures

The steel bearing structures are fireproofed with CONLIT SL 150 slabs
attached using the silicate heat-resistant glue CONLIT GLUE
Table 16. Product properties

Table 18. Properties of CONLIT GLUE

Parameter
Thermal conductivity

Units

Value

10, W/m*

0.037

Parameter
Acidity, up to
Consumption

0.039

25, W/m*

Units

Value

pH

12
2

kg/m

0.7-1.0

MPa

0.3

kg/m3

165

Bond properties when used

on metal (72 hours after
application), at leas

Compression strength at 10%

deformation, at least

kPa

25

Curing time

12

Water absorption at short or

partial i mmersion, up to

kg/m2

1.0

Temperature of application,
at least

+5

Reaction to re

0 (Non-combustible)

Density

CONLIT GLUE
Table 17. Thickness of CONLIT SL 150 against the re resistance
rating and the effective thickness of metal
30
12

11,9

Specication sample

40
11,0

11

50

25

CONLIT SL 150 slabs of 1 000 mm long, 600 mm wide and 50

mm thick: CONLIT SL 150 1000.600.50 T 5762-050-4575720315.

10,0

10

25

60
9,3

25

9,3

70

30
8,6

40

25

7,9

8,6

80

7,7

25

25

7,6

50

30

25
7

CONLIT GLUE is a modied heat-resistant silicate glue used

to attach the CONLIT SL 150 slabs to each other and to the
surfaces of steel structures.
CONLIT GLUE can handle up to 900 .

7,0

25
40

7,0

60
6,4

6,0

50

30
5

4,3

30

50

30

45

90
4,2

100
3,2

90
2,6

2,5

2,4

3,6

80

30

60

80

100

60

90

120

150

4,8

4,1

3,3

70

50

5,5

4,8

70

60

6,3

80

3,8

3,2

15

60

4,0

40

2,5

4,9

6,9

100

70
5,5

5,4

40

6,4

90

180

240

Packing
CONLIT slabs are wrapped in polyethylene shrink lm or
supplied on pallets. CONLIT GLUE is supplied in 20kg buckets.
The effective thickness of metal is a ratio between the cross
area of the construction and the heated perimeter. For instance,
when calculating the reproof material thickness for a column
made of double-T beam, the cross area of metal in mm2 must
be divided by the heated perimeter of four sides (three sides
for beams). If CONLIT SL 150 slabs are installed in casing, the
perimeter will equal the perimeter of the square drawn around
the double-T beam. If the slabs are installed along the outline,
the perimeter of double-T beam must be considered.
The installation in casing is always more efcient (faster and
easier) and allows to reduce the reproof material thickness
owing to the smaller heated perimeter.
The nomographic chart of CONLIT SL 150 layer thickness
against the effective thickness of metal and the required re
resistance rating is based on the critical heating of metal to 500
, when the bearing ability of metal drops.

Required materials and tools

20

CONLIT SL 150 stone wool slabs

CONLIT GLUE
measuring tape
putty knife
nails
knife for pattern cutting of slabs

Installation
(Presented for your information based on Technical Rules No. 11-07)

1. Surface preparation
The steel structures must be dry and clean. The surfaces must
be degreased with a solvent and covered with GF-021 primer.

2. Preparation of silicate glue

The steel structures must be dry and clean. The surfaces must
be degreased with a solvent and covered with GF-021 primer.

3. Preparation of inserts
The inserts are cut in form of bars at least 100 mm wide and
40 mm thick and installed at a pitch of 600 mm. The height
of the insert in the reproof cover of double-T beam or beam
channel is determined based on the prole size, in particular
the distance between the beam anges plus 5 mm margin.

4.Installation of the reproof set in the case of

steel double-T beam (reproong on three sides)

21

 Apply at least 2 mm of CONLIT GLUE on the edges of the

prepared inserts, which will contact the structure elements.
Brace the inserts between the anges of double-T beam.
They must overlap the anges a little. The maximum
distance between the inserts is 600 mm.
Let the glue cure for 12 hours.
Apply at least 2 mm of CONLIT GLUE on the facing side of
the attached inserts from one side of the double-T beam.
Nail the prepared pieces of main reproong to the inserts.
The nails secure the material for the time of glue curing.
Two to three nails are required per one insert.

Apply at least 2 mm of CONLIT GLUE on the edges of the

reproof slabs used for facing of the beam anges.
Nail the glued facing to the mounted slabs on the side of
beam anges. The length of nails must exceed the thickness
of applied material two times.
Apply CONLIT GLUE on the joints.
The same procedure is performed for the side of the
double-T beam located on the other side of the wall. Apply
CONLIT GLUE both on the edges and the front side of the
facing on the side of beam ange.
Attach the prepared facing on the side of the beam ange
and partially nail the facing.

Once the glue is cured, remove the nails or cover their

heads with CONLIT GLUE.

Giving the aesthetic appearance to the metal

structures
The structures with CONLIT SL 150 reproong can be plastered over breglass mesh:
1. Prepare the reinforcing cementitious plaster.
2. Apply the reinforcing layer on the slab. Layer thickness: 3-4
mm. Consumption: 4 kg/m2.
3. Bury the reinforcing alkali-resistant berglass mesh in the
applied mortar.
4. Reinforce the external angles with a special PVC prole with
mesh to achieve higher shock resistance. Mesh consumption
per 1 m2 is 1.15 m2.
5. Apply the decorative plaster. Consumption: 2.5-2.8 kg/m2.
6. Paint the decorative layer to achieve the desired colour.
Consumption of silicone paint is 0.4l per 1 m2.

23

Fire protection of round steel column

Round column is one of the typical bearing structures. It is
difcult to improve its re resistance rating with slabs, if it is
required to preserve the round shape. To meet this objective,
ROCKWOOL designed the ROCKFIRE system which utilises
CONLIT PS 150 pipe sections and CONLIT GLUE.

Fire protection efciency

R60 re resistance rating is achieved when installing the 50
mm thick CONLIT PS 150 cylinders on the round steel columns
76 mm in diameter (effective thickness of metal: 3.5 mm) and
159 mm in diameter (effective thickness of metal: 5 mm).

Installation
The column must be cleaned of dust, mud and rust and covered with GF-021 primer. Once the primer is cured, the resafe material can be installed.
CONLIT PS 150 products are solid and hollow and include two
semicylinders with Z-lock for tight connection. Depending
on diameter of the insulated column, the pipe sections may
have different internal diameter with 50 mm rated thickness
of walls. The CONLIT PS 150 pipe sections are 1 000 mm long.
The 2-3 mm layer of CONLIT GLUE is applied on the joints.
Then the segments are locked around the column to form a
tight connection and are secured with a 2 mm fastening wire.
CONLIT GLUE is applied on the edges of the installed pipe
sections; after that the next pipe sections is installed as described above while ensuring the tight connection of the items
and the misalignment of seams. The excess glue on the vertical and horizontal seams is spreaded with a putty knife. Once
CONLIT GLUE is cured (24 hours in normal conditions), the
fastening wire is removed. The client may decide to apply a
decorative nish.

24

Fire protection of the bearing metal

structures with CONLIT M paint
ROCKWOOL designed CONLIT M paint to improve the re resistance rating of couplings, trusses and elements with complex geometry.
-121 CONLIT M is a one-component bloating mixture based
on solvent. If exposed to over 250 , the paint bloats and forms
a carbon substance, which has good thermal insulation properties and protects the material from heating.

Efciency
When applied on steel structure with 3.4 mm effective thickness, CONLIT M allows this structure to obtain the 6th grade
of re resistance according to GOST R 53295-2009 (at least 30
min), while the paint consumption is 1.53 kg/m2 with at least
0.80 mm dry layer thickness applied on the corrosion resistant
primer (GF-021 GOST 25129-82) with at least 0.05 mm dry layer
thickness. The total dry layer thickness of the paint coat is at
least 0.85 mm.

Application
(Presented for your information based on Technical Rules No. 11-08)
Make sure that the steel structures are dry and free of dust,
mud, grease, oil and rust.
Apply the corrosion-resistant primer GF-021. The dry layer thickness of the corrosion-resistant coat shall be at least 0.05 mm.
Wait for at least 24 hours after priming. The time depends on
ambient temperature.
The surface temperature of the steel structures prepared for
application of the reproof mixture must be at least 3 higher
than the dew point.
Prior to operation, let the CONLIT M paint stand for at least 20 hours
at 15-20 and then mix well for 5-10 minutes using a mixer or a
drill with agitator to give the working viscosity to the paint.
Apply CONLIT M on the prepared steel surface using a brush, a roller or airless sprayer. The application method is determined based
on the surface area.
The mixture shall be applied in 2-3 layers with interim drying for at least 1 hour at 20 and 60% relative humidity.
Before applying the next layer, make sure that the previous

one is dry enough to not stick. The drying time may increase
2-3 times at up to -25 and 80% relative humidity. The
painting can be done at the temperatures from -25 to
+35 . The steel structures must be free of moisture (water, dew, glacier, frost).
The paint coat requires about 96 hours to gain the service properties. The nal formation of the coat takes at least ve days (at over
15 and up to 80% humidity) or up to 15 days (at under 15 and
up to 80% humidity).
The thickness of wet coating at airless spraying shall not exceed 0.8 mm per one layer; if using brush or roller 0.9 mm
per one layer. If thicker coating is required, the mixture shall be
applied in several layers.
The consumption of CONLIT M is 1.53 kg/m2 exclusive of process
losses, which depend on the application method, properties of the
coated structure and working conditions.
If used on the surfaces exposed to weather impact, it is required
to apply a top protective coating based on copolymer acrylic, alkyd,
epoxide, polyurethane and other resins.

25

Fire protection of floor slabs of reinforced

concrete
The oor slabs of reinforced concrete are reproofed from the
bottom with ROCKWOOL FT BARRIER slabs and FT BARRIER D
double density slabs.
The slabs have the reproong and thermal insulating properties and are installed using the steel dish-shaped elements.

Table 19. Product properties

Parameter

FT BARRIER D

Thermal conductivity

10, W/m*
25, W/m*

Reaction to re

Required materials and tools

Steel anchor with steel dish-shaped holder according to
the Technical Rules
Pneumatic ha mmer
8 mm boer
Measuring tape
ROCKWOOL hobby knife or hand saw
Hammer or sledgeha mmer up to 800g

Warning! Do not bury the dish-shaped holder to the thermal

insulation slab. This may cause early destruction of material
when exposed to re.
After all the slabs are installed, they can be covered with FT
Decor decorative coating .
If the drill meets a hollow space in the slab, it is reco mmended
to repeat the drilling at least 40 mm away. Clean the drilled hole
of dust using a hand pump or a blower.

Storage of steel anchors

The steel anchors with dish-shaped holders must be stored indoors in the package at up to 60% relative humidity. High temperature and humidity uctuations must be avoided to prevent
condensation and package soaking. If the above conditions are
met, the product has unlimited shelf life.

26

FT BARRIER

0.034

0.036

0.036

0.038

0 (Non-combustible)

Fireproong efciency
With 30 mm thick FT BARRIER slabs the oor slabs of reinforced concrete (at least 30 mm concrete layer before
the reinforcement) receive the re resistance rating (REI)
of at least 150.
With 80 mm thick FT BARRIER D slabs the oor slabs of
reinforced concrete (at least 30 mm concrete layer before
the reinforcement) receive the re resistance rating (REI)
of at least 240.
With 80 mm thick FT BARRIER D slabs installed on the
oor slab with external reinforcement by polymer compounds FibARM (STO 2256-002-2011, Rev. 1-3), the structure receives the re resistance rating (REI) of at least 120.

Value

Units

kg/m3

Upper layer 30
mm 100, lower
layer 50

110

Organics content by
weight, up to

3.2

3.2

Water absorption
at short or partial i
mmersion, up to

kg/m2

1.0

1.0

Density

Installation
(Presented for your information based on Technical Rules No.
01-11-13 for FT BARRIER slabs and No. 01-12-14 for FT BARRIER D slabs)
For convenient installation, the facing surface (dense protective layer) of FT BARRIER D double density slabs is marked
with two dark strips.
1. Apply an FT BARRIER or FT BARRIER D slab to the reinforced
concrete surface and drill ve (for 1 000x600 mm slab) or
nine (for 1 200x1 000 mm slab) holes for installation of
anchors (anchoring points: 8.4 pts/m2 for 1 000600 mm
slabs and 7.5 pts/m2 for 1 2001 000 mm slabs).
2. Drill the holes transverse to the bearing base, their depth
must be 3-5 mm higher than reco mmended (the minimum
depth of i mmersion of FT BARRIER anchors to the concrete
is 30 mm).
3. Install the anchor with dish-shaped holder in the drilled hole
and ha mmer it.
4. FT BARRIER slab must bear against the surface and be
secured with a dish-shaped holder.

27

Fire protection of pipe penetrations

The system of uninsulated penetrations in the building envelope is likely to facilitate the spread of re and smoke. The pipe
penetrations are reproofed with ROCKWOOL CONLIT PS 150
stone wool pipe sections.

Table 20. Product properties

Parameter

Units

Value

25, W/m*

0.037

125, W/m*

0.048

Thermal conductivity

Reaction to re

0 (Non-combustible)

Density

kg/m3

165

3.2

Organics content by
weight, up to

Fireproong efciency

Installation

Vertical and horizontal structure with 159 mm and 76 mm

steel piping E 240/I 180.
Vertical and horizontal structure with 32 mm steel piping EI
240.

(Presented for your information based on Technical Rules

No. 31-04)

Required materials and tools

CONLIT PS 150 pipe sections

2 mm fastening wire
2 x 30 mm metal tape
Pliers

The juncture seam between the CONLIT PS 150 reproof segments and the concrete building envelope shall be additionally sealed with sand-cement mortar.
Follow the same procedure on the other side

1. Make sure that the surface of steel pipe is free of dust and
other rough parts.
2. Prepare the surface using GF-021 primer or similar.
3. Pattern cut the CONLIT PS 150 segments.
4. Prepare the sand-cement mortar following the manufacturer's instructions.
5. Grout the pass in the building envelope.
6. Install the CONLIT PS 150 segments against the surface of
the reinforced concrete structure.
7. Secure the segments on the steel piping using the fastening
wire. Start to fasten at up to 50 mm away from the building
envelope with up to 100 mm between the loops. Secure the
segments with metal tape at a pitch of up to 600 mm.

Examples of installation: :
1 pipework
2 ROCKWOOL cylinder with alufoil covering
3 CONLIT PS 150 cylinder
4 building envelope
5 grouting area
6 fastening wire
7 banding tape

28

Fire protection of cable penetration

The reproong system for cable line penetrations prevents the
critical temperature increase in the unheated area, on the surface of sealant and elements in passes, as well as maintains
the barrier integrity over the evacuation period. To achieve this,
the re resistant element must be installed in the cable line
pass within the building envelope. Such element is a part of
ROCKFIRE system the CONLIT SL 150 slabs of ROCKWOOL
stone wool.

Required materials and tools

Expandable restop mastic Hilti CP 611A

Fireproof paint CONLIT (C)
Fastening gun
A knife for mineral wools or a hand saw
Putty knife for spreading of mastic.

Fireproong efciency

Installation

For 50 mm thick CONLIT SL 150 slabs installed from both sides

(100 mm) IET 60;
For 70 mm thick CONLIT SL 150 slabs installed from both sides
(140 mm) IET 90;
For 80 mm thick CONLIT SL 150 slabs installed from both sides
(160 mm) IET 120.

(Presented for your information based on Technical Rules

No. 3-06)
1. Make sure that the pass is clean and free of dust.
2. Prepare the Hilti CP 611A mastic.
3. Pattern cut the CONLIT SL 150 slabs.
4. Apply the mastic and evenly spread it with a putty knife
across the internal surface of the pass.
5. Apply the mastic on the edges across the pass.
6. Install the slab with mastic to the pass. Spread the excess
mastic with the putty knife.

1
3
2

1 concrete
2 CONLIT SL 150 reproong
3 Hilti CP 611A mastic
4 AKVVG aluminium control cable
5 AAShv aluminium power cable with PVC wrap
6 AVVG aluminium power cable with PVC insulation

29

Products dimensions
Table 21. Dimensions of the wound pipe sections ROCKWOOL 100
Length, mm

30

Thickness, mm
20

25

30

40

50

60

70

80

90

100

Table 22. Dimensions of the wound pipe sections ROCKWOOL 150

Length, mm

18

18

21

21

25

25

27

27

28

28

32

32

35

35

38

38

42

42

45

45

48

48

54

54

57

57

60

60

64

64

70

70

76

76

83

83

89

89

102

102

108

108

114

114

133

133

140

140

159

159

168

168

169

169

194

194

205

205

219

219

245

245

273

273

Thickness, mm
20

25

30

40

50

60

70

80

90

100

Table 23. Dimensions of mats

Product name

Length,
mm

Table 24. Dimensions of slabs

Width,
mm

5000
WIRED MAT 50

4500

50
1000

4000
5000

WIRED MAT 80

Thickness,
mm

TECH BATTS 50

1000

600

50-200, step
10mm

TECH BATTS 75

1000

600

50-200, step
10mm

TECH BATTS 100

1000

600

50-200, step
10mm

TECH BATTS 125

1000

600

50-180, step
10mm

TECH BATTS 150

1000

600

50-160, step
10mm

INDUSTRIAL BATTS 80

1000

600

40

4000

50

3000

60

2000

70

2000

Width,
mm

60
70

1000

Length,
mm

Product name

80
1000

2000

90

2000

100

2000

110

2000

120

6000

25

7000

30

5000

40

4000
WIRED MAT 105

TECH MAT

LAMELLA MAT

LAMELLA MAT L

2000

60

2000

70

2000

80

2000

90

2000

100

5000

50

5000

60

4000 /4500

1000

70

4000 /4500

80

4000 /4500

90

5000

40

4000

1000

50

4000

60

12000

20

8000

30

5000

40

4000

1000

3000

50
60

2500

80

2000

100

10000

20

8000
KLIMAFIX

30-80, step 10mm

15, 25, 35
FIRE BATTS

1000

600

25, 30, 35, 50,

75, 100

FT BARRIER

1000

600

30-200, step
10mm

FT BARRIER D

1000

600

80-200, step
10mm

CONLIT SL 150

1000

600

20-(25,35)-100,
step 10mm

50
1000

30
1000

6000

40

5000

50

Thickness,
mm

Table 25. Dimensions of CONLIT PS 150 pipe sections

Length, mm

Diameter, mm

Thickness, mm

1000

18273

20, 25, 30, 40, 50, 60, 70, 80

Professional consultations:
Azerbaijan, Kazakhstan
+7 343 319 41 08
konstantin.borozdin@rockwool.ru
Ukraine, Moldova, Georgia
+ 38050468 25 35
andrey.lavrentiev@rockwool.com
Belarus
+375 296 06 06 79
andrei.muravlev@rockwool.by

Saint Petersburg (Northwest region)

+7 921 995 62 00
alexander.zozulya@rockwool.ru
+7 921 953 60 85
anton.stefanovich@rockwool.com
Voronezh
+7 910 746 22 22
artem.arefyev@rockwool.com

Kazan, Samara (the Volga region)

+7 987 226 98 66
dmitry.dudkov@rockwool.ru
Ekaterinburg (Ural region)
+7 343 319 53 23
alexey.kalmykov@rockwool.ru

Novosibirsk (Siberia and the Far

East)
Nizhny Novgorod, Saransk, Che- +7 383 299 46 24
boksary
nikolay.nikitin@rockwool.ru
Moscow and Moscow region (cen- +7 953 415 41 86
+7 913 917 08 43
tral part of the Russian Federation) anatoly.babanin@rockwool.ru
valery.zaprudsky@rockwool.com
+7 967 097 92 72
andrey.vinogradov@rockwool.ru
Rostov-on-Don, Volgograd, Astra- Tyumen, Khanty-Mansi Autono+7 963 677 36 54
khan and Elista (Southern Federal mous District, Yamalo-Nenets Auroman.bochkov@rockwool.ru
District)
tonomous District
+7 903 724 79 65
+7 918 558 73 21
+7 929 269 44 14
natalya.koscheeva@rockwool.com alexander.chernyshev@rockwool.ru dmitry.goncharov@rockwool.ru

ROCKWOOL company:
Zemlyanoy Val, 9, Moscow, 105064
Phone.: +7 495 995 77 55
Fax: +7 495 995 77 75
Training center: +7 963 996 64 94
Design center: design.centre@rockwool.com
www.rockwool.ru

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