Technical Code v2 - tipsasa.co.za · Physical Address: Benchmark Office Park, Suite 1, 1 Larch...

THERMAL INSULATION TECHNICAL CODE COMPLIANCE GUIDE

Technical Code Version 1.1 – March 2018

Fire and Thermal Testing Requirements in accordance with the application of the South African National Building Regulations SANS 10400, South African National

Standards (SANS) and European Standards (EN).

THERMAL INSULATION PRODUCTS & SYSTEMS ASSOCIATION SA (TIPSASA)Reg. No. 2015/287405/08

Physical Address: Benchmark Office Park, Suite 1, 1 Larch Nook, CENTURION, 0157

Postal Address: P. O. Box 11484, ZWARTKOPS, 1685.

Tel: +27 (12) 663 1480

Fax2E-mail: 086 684 3061

Email: [email protected]

Website: www.tipsasa.co.za

Acknowledgements

TIPSASA wishes to acknowledge the valuable assistance of the TIPSASA Technical Committee Members.

Disclaimer

All information, recommendation or advice contained in this TIPSASA Publication is given in good faith to the best of TIPSASA’s knowledge and based on current procedures in effect.

Because actual use of TIPSASA Publications by the user is beyond the control of TIPSASA such use is within the exclusive responsibility of the user. TIPSASA cannot be held responsible for any loss incurred through incorrect or faulty use of its Publications.

Great care has been taken to ensure that the information provided is correct. No responsibility will be accepted by TIPSASA for any errors and/or omissions, which may have inadvertently occurred. ©

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TIPSASA . TECHNICAL CODE: Version 1.1

TABLE OF CONTENTS

1. FOREWORD 5

2. INTRODUCTION 5

3. PURPOSE & SCOPE 5

4. NORMS AND STANDARDS 5

5. TERMS & DEFINITIONS 9

6. FIRE PERFORMANCE 14

GENERAL 14

6.1 Fire performance testing 14

6.2 New product testing 14

6.3 Product testing period and validity 14

6.4 Scope of work 14

6.5 Scheduling 16

6.6 Test Specimen 16

6.7 Test Methods 16

6.8 International Test Reports 16

6.9 Reporting 16

6.10 Manufacturer’s Responsibility 17

6.11 Testing Authority’s Responsibility 17

6.12 Classification 17

6.13 Marking and Identification of Product 18

6.14 Impartiality 18

6.15 TIPSASA Ad-hoc Quality Assurance Tests 18

7. TESTING – THERMAL 19

7.1 General 19

7.2 Bulk Insulation 19

7.2.1 Detrimental Effects of Compression on Bulk Insulation 20

7.2.2 Spacer Systems Example 21

7.2.3 Detrimental Effects of Moisture on Insulation Materials 22

7.2.4 Packing of Materials 23

7.3 Rigid Foam insulation 23

7.3.1 Aging of Foam Insulation materials 23

7.4 Spray Foam Insulation 24

7.5 Reflective Insulation (RI) 24

7.6 Cool Coatings reliant on solar reflectance 26

7.7 Insulated Sandwich Panels 26

8. LABELLING, MARKING AND DATA SHEETS 28

8.1 General 28

8.2 Usage of TIPSASA Logo 29

9. GUARANTEES FROM TIPSASA MANUFACTURERS 30

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10. INSTALLERS OF THERMAL INSULATION 31

10.1 General 31

10.2 Key Health & Safety Requirements 31

10.3 Guarantees & Warranties from the TIPSASA Contractor 36

11. DECLARATION OF COMPLIANCE (EXAMPLE) 37

ANNEX A – 5 YEAR FIRE TESTING CYCLE (Alphabetical) 39

ANNEX B – SANS 428 FIRE CLASSIFICATION 41

ANNEX C – EXAMPLE: TIPSASA FIRE DATABASE 44

ANNEX D – TIPSASA FIRE CERTIFICATE OF COMPLIANCE 45

ANNEX E – EXAMPLE TIPSASA PRODUCT COMPLIANCE CERTIFICATE 46

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1. FOREWORD

In accordance with TIPSASA’s Code of Ethics. Members AGREE to comply with applicable laws, regulations and responsibilities in an effort to create transparency in all operations. Members also AGREE to abide by the governing documents and policies of the Association and to be accountable for adhering to the Code of Ethics.

The members of TIPSASA, the Thermal Insulation Products & Systems Association of SA, agreed to a protocol of routine product testing of identified physical attributes and properties of thermal insulation products in accordance with the application of the South African National Building Regulations SANS 10400. Where relevant BS, EN or ISO Standards will apply.

2. INTRODUCTION

This protocol is intended to preserve and advance the image of TIPSASA and its members as being honest, transparent and motivated by simple good practice.

TIPSASA Manufacturers agree to comply with the requirements of the Association in order to achieve and maintain quality assurance in the Industry.

Members in compliance with the testing protocol requirements will enjoy the benefit of the protection from erroneous or false claims of others.

3. PURPOSE & SCOPE

This protocol aims to establish agreed norms for routine product testing in accordance with the requirements of:

SANS 10400-T Fire Protection; and

SANS 10400-XA Energy usage in buildings.

Relevant International Standards

Results obtained by the use of the various test methods, are representative of that specific specimens performance and only applicable to the conditions of the tests

4. NORMS AND STANDARDS

The following referenced documents are indispensable for the application of this document. All normative documents are subject to revision and, since any reference to a normative document is deemed to be a reference to the latest edition of that document, parties to agreements based on this document are encouraged to take steps to ensure the use of the most recent editions of the normative documents indicated.

An overview of the commonly used standards, guidelines and specifications, applicable to thermal insulation, is mentioned in the tables below.

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Type Standard Description

Regulatory Requirements

Application of National Building Regulations

SANS10400-A The application of the National Building Regulations Part A: General principles and requirements

SANS 10400-B The application of the National Building Regulations - Part B Structural design.

SANS 10400-L The application of the National Building Regulations Part L: Roofs

SANS 10400-T The application of the National Building Regulations - Part T Fire Protection

SANS 10400-XA The application of the National Building Regulations Part X: Environmental sustainability - Part XA: Energy usage in buildings.

Energy Efficiency SANS 204 Energy efficiency in buildings

Insulation Material Standards - SA

SANS 1381-1 Materials for thermal insulation of buildings

Part 1: Fibre thermal insulation mats.

SANS 1381-4 Materials for thermal insulation of buildings Part 4: Reflective foil laminates (rolls, sheets and sections).

SANS 1381-6 Materials for thermal insulation of buildings Part 6: Cellulose loose fill thermal insulation material.

Insulated Sandwich Panel Standard

SANS 54509 EN 14509

Self-supporting double-skin metal-faced insulating panels – Factory made products – specifications.

Fire Standards SA SANS 428 Fire performance classification of thermal insulated building envelope systems.

SANS 10177-2 Fire testing of materials, components and elements used in buildings Part 2: Fire resistance test for building elements.

SANS 10177-5 Fire testing of materials components and elements used in buildings Part 5: Non-combustibility at 750 ºC of building materials.

SANS 10177-10 Fire testing of materials, components and elements used in buildings Part 10: Surface burning characteristics of building materials using the inverted channel tunnel test

SANS 10177-11 Fire testing of materials, components and elements used in buildings Part 11: Large-scale fire performance evaluation of building envelope thermal insulation systems (with or without sprinklers).

Fire Standards for ETICS

SANS 8414-1 BS 8414-1

Fire performance of external cladding systems – Part 1: Test method for non-loadbearing external cladding systems applied to the face of the building.

BS 8414-2 Fire performance of external cladding systems – Part 2: Test method for non-loadbearing external cladding systems fixed to and supported by a structural steel frame.

Thermal Conductivity & Resistance

(Products)

SANS 8301 ISO 8301

Thermal insulation -- Determination of steady-state thermal resistance and related properties -- Heat flow meter apparatus.

SANS 8302 ISO 8302

Thermal insulation -- Determination of steady-state thermal resistance and related properties -- Guarded hot plate apparatus.

ASTM C 518 Standard Test Method for Steady-State Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus.

Thermal Performance

(Systems)

ASTM C 1363 Standard Test Method for Thermal Performance of Building Materials and Envelope Assemblies by Means of a Hot Box Apparatus.

ISO 8990 Thermal insulation -- Determination of steady-state thermal transmission properties -- Calibrated and guarded hot box

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Thermal Calculation ISO 6946 Building components and building elements -- Thermal resistance and thermal transmittance -- Calculation method

Emissivity SANS 1789 ASTM C 1371 EN 16012

Standard test method for determination of emittance of materials near room temperature using portable emissometers. Covers a technique for determination of the emittance of typical materials using a portable differential thermopile emissometer.

Pipe work SANS 612

BS 5970

Code of practice for thermal insulation of pipework and equipment in the temperature range of -100 degrees C to +870 degrees C.

Fire Standards for ETICS

SANS 8414-1 BS 8414-1

Fire performance of external cladding systems – Part 1: Test method for non-loadbearing external cladding systems applied to the face of the building.

BS 8414-2 Fire performance of external cladding systems – Part 2: Test method for non-loadbearing external cladding systems fixed to and supported by a structural steel frame.

Thermal Conductivity & Resistance

(Products)

SANS 8301 ISO 8301

Thermal insulation -- Determination of steady-state thermal resistance and related properties -- Heat flow meter apparatus.

SANS 8302 ISO 8302

Thermal insulation -- Determination of steady-state thermal resistance and related properties -- Guarded hot plate apparatus.

ASTM C 518 Standard Test Method for Steady-State Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus.

Thermal Performance

(Systems)

ASTM C 1363 Standard Test Method for Thermal Performance of Building Materials and Envelope Assemblies by Means of a Hot Box Apparatus.

ISO 8990 Thermal insulation -- Determination of steady-state thermal transmission properties -- Calibrated and guarded hot box

Thermal Calculation ISO 6946 Building components and building elements -- Thermal resistance and thermal transmittance -- Calculation method

Emissivity SANS 1789 ASTM C 1371 EN 16012


Pipe work SANS 612 BS 5970

Code of practice for thermal insulation of pipework and equipment in the temperature range of -100 degrees C to +870 degrees C.


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ADOPTION OF EUROPEAN STANDARDS


Insulation Material

Standards - EN

SANS 13162 EN 13162

Thermal insulation products for buildings - Factory made mineral wool (MW) products – Specification

SANS 53163 EN 13163

Thermal insulation products for buildings - Factory made products of expanded polystyrene (EPS) – Specification

SANS 53164 EN 13164

Thermal insulation products for buildings - Factory made products of extruded polystyrene foam (XPS) – Specification

SANS 53165 EN 13165

Thermal insulation products for buildings - Factory made rigid polyurethane foam (PUR) products – Specification

SANS 13166 EN 13166

Thermal insulation products for buildings - Factory made products of phenolic foam (PF) – Specification

SANS 13167 EN 13167

Thermal insulation products for buildings - Factory made cellular glass (CG) products – Specification

EN 13168 Thermal insulation products for buildings - Factory made wood wool (WW) products – Specification

SANS 13169 EN 13169

Thermal insulation products for buildings - Factory made products of expanded perlite (EPB) – Specification

SANS 13170 EN 13170

Thermal insulation products for buildings - Factory made products of expanded cork (ICB) – Specification

SANS 13171 EN 13171

Thermal insulating products for buildings - Factory made wood fibre (WF) products - Specification

Fire Classification EN 13501-1 Fire classification of constructions products and building elements – Part 1 Classification using test data from fire reaction to fire tests (Foreign Standards)

Fire Standards EN

&

Product properties

SANS 11820 EN 1182

Reaction to fire tests for building products - Non-Combustibility

SANS 1743 EN 1716

Reaction to fire tests for building products – Determination of Calorific potential

SANS 11925-2 EN 11925-2

Reaction to fire tests for building products – Part 2: Ignitability when subject to direct impingement of flame

SANS 53823 EN 13823

Reaction to fire tests for building products - Building products excluding floorings exposed to the thermal attack by a single burning item

Fire Standards EN

(cont.)

ISO 9705 Room/Corner Test: Simulations, Correlations and Heat Flux Measurements

SANS 54390 EN 14390

Fire test – Large scale room reference test for surface products

Floor Coverings EN 9239-1 Reaction to fire tests for floorings – Part 1: Determination of the burning behaviour using a radiant heat source

Cool Roofs & Surfaces

SANS 1789 ASTM C 1371

Standard test method for determination of emittance of materials near room temperature using portable emissometers

SANS 1982 ASTM C 1549

Standard test method for determination of solar reflectance near ambient temperature

SANS 1932 ASTM E 903

Standard Test Method for Solar Absorptance, Reflectance, and Transmittance of Materials Using Integrating Spheres


Standard Test Method for Measuring Solar Reflectance of Horizontal and Low-Sloped Surfaces in the Field


Standard Practice for Calculating Solar Reflectance Index of Horizontal and Low-Sloped Opaque Surfaces

SPF -

Spray-applied polyurethane foam

SANS 8873-1 ISO 8873-1

Rigid cellular plastics - Spray-applied polyurethane foam for thermal insulation Part 1: Material specifications

SANS 8873-2 ISO 8873-2

Rigid cellular plastics - Spray-applied polyurethane foam for thermal insulation Part 2: Application

SANS 8873-3 ISO 8873-3

Rigid cellular plastics - Spray-applied polyurethane foam for thermal insulation Part 3: Test methods

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5. TERMS & DEFINITIONS

For the purposes of this document, the following definitions apply:

5.1 absorbtance Symbol “a” The ratio of the radiant, or luminous, flux absorbed by a body to the flux falling on it. The absorbtance of a black surface or body is by definition “1”

5.2 absorbtion The take-up of heat, especially radiant heat, by a surface of mass or membrane barrier, which contributes to the heat gain and loss through a wall or roof construction (system)

5.3 added R-Value The added R-Value is the value of the insulating material added to achieve a certain value required

5.4 acceptable acceptable to the authority administering this standard, but in relation to the requirements contemplated in the National building regulations

5.5 Agrément certificate certificate confirming fitness-for-purpose of a non-standardized product, material or component or the acceptability of the related non-standardized design and the conditions pertaining thereto (or both) issued by the Board of Agrément of South Africa

5.6 approved approved by the approving authority

5.7 approving authority any local authority having jurisdiction or an independent body or organisation appointed by the local authority having jurisdiction

5.8 building envelope elements of a building that separate a habitable room from the exterior of a building or a garage or storage area

5.9 bulk insulation materials of low thermal conductivity, that mainly resists (slows) the transfer of conducted and convected heat, relying on pockets of trapped air or low conductive gasses within its structure. Its thermal resistance is essentially the same regardless of the direction of heat flow through it and is proportional to its thickness, density and upper & lower operating temperature.

5.10 C-value thermal capacity (kJ/m2·K) of a material, which is the ability to store heat energy, and is the arithmetical product of specific heat capacity (kJ/kg·K), density (kg/m3) and thickness (m)

5.11 CR-value time constant (hours) of a composite element, such as a wall, and being the arithmetical product of total C-value and the total R-value.

NOTE: The higher the CR-value the greater the ability of the composite element to moderate and minimise the effects of external climatic conditions on the interior of a building.

5.12 cavity wall cavity walls consist of two ‘skins’ separated by a hollow space (cavity). The skins are commonly masonry such as brick or concrete block

5.13 ceiling upper interior surface, not being a roof covering, of a room or similar compartment including all materials comprising such ceiling, for example, insulation

5.14 ceiling area The area is measured in square metres, measured to the inside of outerwalls

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5.15 certified thermal calculation software software that is certified by the Board of Agrément South Africa, in terms of Agrément South Africa’s Energy Software Protocols, as being fit for thermal modelling or calculation purposes in terms of the National Building Regulations

5.16 climatic zone region in which the climatic conditions are similar

NOTE: The zones have been adjusted to simplify use of the energy efficiency measures. A map of South Africa indicating the various climatic zones and a table specifying the zones for major cities and towns on the borders of climatic zones.

5.17 combustible combustible as determined by SANS 10177-5

5.18 competent person person who is qualified by virtue of his education, training, experience and contextual knowledge to make a determination regarding the performance of a building or part thereof in relation to a functional regulation or to undertake such duties as may be assigned to him in terms of the National Building Regulations

5.19 composite insulation two or more types of material combined to achieve a required level of performance, example: bulk insulation and reflective insulation used in combination.

5.20 core thermal resistance thermal resistance of the product from face to face at the tested thickness, excluding the contribution of any low emissivity outer surface or any air space(s) adjacent to the product

5.21 declared thermal performance value of thermal performance, declared by a manufacturer, which is derived from measured values under the specified conditions and rules given in the relevant standard

5.22 deemed-to-satisfy a level of performance for a given criteria which will satisfy the requirements

5.23 deemed-to-satisfy requirement non-mandatory requirement, the compliance with which ensures compliance with a functional regulation

5.24 density the mass of a substance per unit of volume. SI unit of measure is kg/m³.

5.25 direction of heat flow most significant heat flow at a given time

NOTE Heat flow from hot to cold environments is considered to be the direction of natural heat flow. Therefore “upwards” implies heat flow from a conditioned space through the ceiling or roof, and “downwards” implies the opposite. Likewise, horizontal flows can be described as “inwards” and “outwards”.

5.26 emissivity – symbol “e” emissivity is a measure of the efficiency in which a surface emits thermal energy. It is defined as the fraction of energy being emitted relative to that emitted by a thermally black surface (a black body). A black body is a material that is a perfect emitter of heat energy and has an emissivity value of 1.

NOTE: A material with an emissivity value of 0 would be considered a perfect thermal mirror.

For example, if an object had the potential to emit 100 units of energy but only emits 90 units in the real world, then that object would have an emissivity value of 0.90. In the real world there are no perfect “black bodies” and very few perfect infrared mirrors so most objects have an emissivity between 0 and 1.

5.27 energy efficiency minimizing energy consumption while still achieving the required output.

NOTE In the context of buildings this will be the maintenance of required indoor comfort conditions and the provision of necessary power for correct operation of all installed services. Designing for energy efficiency involves the design, selection of materials, components and systems to minimize energy consumption. Achieving energy efficiency involves design, operation, maintenance and ongoing adjustments to minimize energy consumption.

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5.28 external walls complete walling system, as measured from the outer skin exposed to the environment, to the inside of the inner skin exposed to the interior of the building, and does not include glazing

5.29 fire resistance the shortest period for which a building insulation element or component will comply with the requirements for stability and integrity when tested in accordance to SANS 10177-2

5.30 insulated ceilings any non-insulated ceiling installed inside a building that does not form part of the roof that requires insulation to prevent heat transfer from the outside or roof space above

5.31 insulated roof building panels that are installed to form an adjacent wall and roof or ceiling surfaces

5.32 manufacturer anything produced from raw materials and made by hand or machine

5.33 non-combustible non-combustibility as determined by SANS 10177-5

NOTE: Non-combustibility does not imply that the material has good fire resistance properties, or vice versa, nor does it imply that such material will not burn under any conditions.

5.34 occupancy particular use or the type of use to which a building or portion thereof is normally put or intended to be put

NOTE: Regulation A20 (see table 1 in annex A of SANS 10400-A) classifies and designates occupancies

5.35 R-value measurement of the thermal resistance of a material which is the effectiveness of the material to resist the flow of heat, i.e. the thermal resistance (m²·K/W) of a component calculated by dividing its thickness by its thermal conductivity

5.36 radiant energy the rate of energy emitted from a surface depends on its absolute temperature and surface characteristics

5.37 rational design

any design by a competent person involving a process of reasoning and calculation, and may include a design based on a standard or other suitable document.

5.38 rational assessment assessment by a competent person of the adequacy of the performance of a solution in relation to requirements by a process of reasoning, calculation and consideration of accepted engineering principles, based on a combination of deductions from available information, research and data, appropriate testing and service experience

5.39 radiant barrier system (RBS) A building construction system consisting of a low emittance (normally 0.1 or less) surface (normally aluminium) bounded by an open air space.

NOTE: A RBS is used for the sole purpose of limiting heat transfer by radiation and not specifically intended to reduce heat transfer by convection or conduction.

5.40 reflective insulation (RI) material with a reflective surface such as a reflective foil laminate, reflective barrier or foil batt capable of reducing radiant heat flow, in combination with air spaces and low emissive surfaces

5.41 regulation National Building Regulation

National regulations promulgated in terms of the National Building Regulations and Building Standards act, 1977 (Act No. 103 of 1977)

5.42 roof assembly building cover and its supporting structure including any ceiling attached to such structure and include any additional components, such as insulation (panels, laminates and blankets)

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5.43 roof spacer a roof spacer raises the roof sheet above the purlin, creating a defined space between the purlin, insulation support system and the roof sheet.

NOTE: To achieve the thermal insulation values, the roof system must allow sufficient space under the roof sheet for the insulation to recover to its design thickness to provide its rated insulation value. Failure to provide enough space will result in compression of the insulation and reduce its performance.

5.44 solar energy electromagnetic energy radiated from the sun

5.45 sponsor responsible person or company

5.46 sprinkler system approved system of piping and sprinkler heads connected to a water supply which, when activated by the effect of fire, automatically releases water

5.47 surface fire index classification awarded to a combustible surfacing material (in excess of 1 mm in thickness)

5.48 suspended ceiling ceiling supported on a system of hangers

5.49 system R-Value

See 5.56

5.50 the Act National Building Regulations and Building Standards Act, 1977 (Act No. 103 of 1977)

5.51 thermal break an element of low thermal conductivity placed in an assembly to reduce or prevent the flow of thermal energy (transfer of heat) from one component to another.

5.52 thermal bridging the transfer of heat across building elements, which have less thermal resistance than the added insulation. This decreases the overall R-Value. Wall frames and ceiling beams are examples of thermal bridges, having a lower R-Value than the insulating material placed between them. Because of this, the overall R-Value of a typical ceiling and/or wall is reduced.

5.53 thermal capacity ability of a material to store heat energy

NOTE Thermal capacity is measured as a C-value; the higher the C-value the greater the heat storing capability.

5.54 thermal conductivity – Symbol “k” the thermal transmission through a unit area of a material. It is measured per unit temperature difference between the hot and cold faces, and the unit is W/(m.K).

NOTE:

It is the rate of heat flow through a unit area (1m²) of 1 metre thick homogenous material in a direction perpendicular to isothermal planes; induced by a unit temperature gradient viz 1 metre cube of material will transmit heat at a rate of 1 watt for every degree of temperature difference between opposite faces.

A “k” value cannot be given for Reflective Sheet Insulation as these are highly dependable upon orientation and position of surrounding air spaces. The heat flow across an air space is not directly proportional to its thickness. Variations in direction of heat flow, the position of the air space (viz horizontal, vertical, etc) and variance in mean temperature etc, affects the thermal resistance of the system.

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5.55 thermal mass the ability of building materials to store heat. The basic characteristic of materials with thermal mass is their ability to absorb heat, store it, and at a later time release it.

NOTE: By adding thermal mass within the insulated building envelope it helps to reduce the extremes in temperature experienced inside the home/building, making the average internal temperature more moderate year-round and the home/building more comfortable. Building materials that are heavyweight store a lot of heat and have high thermal mass. Materials that are lightweight do not store much heat and have low thermal mass

5.56 thermal resistance resistance to heat transfer across a material

NOTE: Thermal resistance is measured as an R-value; the higher the R-value the better the ability of the material to resist heat flow.

5.57 total R-value sum of the R-values of the individual component layers in a composite element, including the air space and associated surface resistances measured in m²·K/W

5.58 total U-value thermal transmittance (W/m2·K) of the composite element including the air space and associated surface transmittance

NOTE: The U-value addresses the ability of a material to conduct heat, while the R-value measures the ability to resist heat flow; the higher the U-value number, the greater the amount of heat that can pass through that material. A lower value would mean a better insulator.

5.59 U-Value measures the transfer of heat through a material, a building element or sandwich panel (thermal transmittance).

5.60 under-roof insulating panels, blankets or foil laminates or composites that are installed to the inside of the external cladding

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6. FIRE PERFORMANCE

General

FIRE PERFORMANCE IN ACCORDANCE WITH SANS 10400-T FIRE PROTECTION

Any insulation, insulating panel or lining used as a thermal insulation system under an external covering as part of a roof or wall assembly (thermal insulated building envelope), tested in accordance with SANS 10177-5 and found to be combustible, shall be acceptable if, when classified in terms of the SANS 428 protocol, its use and application are acceptable.

NOTE: The classification methodology contained in SANS 428 is intended to classify thermal insulation materials in accordance with their fire safety performance in respect of thermal insulated building envelopes, and to recommend the usage of the materials in accordance with its classification. SANS 428 further specifies marking and installation requirements in respect of classified products. The classification protocol makes provision for both horizontal and vertical applications, with or without the use of a fixed water-extinguishment (sprinkler) system.

Designers should take note under which circumstances the thermal insulation materials were classified.

6.1 Fire performance testing

This will be independent testing of fire performance characteristics, for ALL products manufactured for the purpose of providing a thermal insulated building envelope systems i.e. in roofs, ceilings, walls and side-cladding of buildings (see testing flow diagram on page 15).

6.2 New product testing

Any new products or major changes and variation in product composition or manufacturing methods will require new test reports.

TIPSASA shall maintain a complete record of the status of testing and test results.

Exclusion:

Members can choose to have products excluded from this protocol. An application and motivation to this effect shall be addressed in writing. These products shall not appear In the TIPSASA Fire Data Base in publications and brochures as they will not be part of the TIPSASA routine fire testing protocol.

6.3 Product testing period and validity

All attributes and parameters quoted on commercially available leaflets, publications and websites, shall be tested and the validity of the report shall be for a 5-year period unless product parameters change i.e. suppliers and manufactures.

The five-year cycle commences on 1 January 2017 (See Annex A).

Note: Due to the instability and irregular testing as well as the proposed changes to EN fire testing the cycle will only commence once stability is assured. In the interim members must endeavour to comply with current standards and terms in place.

6.4 Scope of workTest work shall be conducted by SABS or Firelab – hereafter referred to as the laboratory. Test work will include scheduling, sampling, transport cost, testing and reporting.

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6.5 Scheduling

The annual testing cycle shall run from 1 January to 31 December, commencing 2017.

See note in 6.3

6.6 Test Specimen

The test specimen shall be clearly identified with the brand name, batch number and date manufactured and shall be representative of the construction for which classification it is intended for, as to materials, workmanship and details and shall be built/installed under conditions representative of those obtained in the building construction and erection.

6.7 Test Methods

Test methods shall be in accordance with the requirements of SANS 428 Fire performance classification of thermal insulated building envelope systems.

The following four attributes shall be tested for each product type to comply with SANS 428;

1. combustibility;

2. surface fire properties;

3. designated use and

4. application

6.8 International Test Reports

International test reports from an accredited testing authorities shall be evaluated in terms of suitability for the intended use and application in terms of SANS 428. If not suitable, products must be retested in accordance with SANS 428, where appropriate.

In the absence of a South African National Standard, where a product or system is not addressed in SANS 10400-T, an international fire test certificate from an accredited testing authority shall be acceptable.

6.9 Reporting

A duplicate test report shall be compiled for each sample tested and submitted directly to TIPSASA and the manufacturer. The results of this report will be published in the TIPSASA Fire Data Base Register (See Annex C).

Each test report shall assess compliance with the relevant requirements in SANS 10400 Part T of the application of the National Building Regulations, and shall contain the following:

a) The date and the report number. The date shall be written in the approved ISO manner. The report number shall consist of a combination of the code number that identifies the testing authority or the particular department or division of the testing authority (e.g. 123), the contract number (e.g. 007), when applicable, and the report identification number (e.g. UFO 543).

Example of date: 2004-09-28

Example of full report number: 123/007/UFO543.

The report number shall relate the report and any other relevant documentation to one specific sample only and in case of queries, the full number and date shall be quoted as recorded.

b) The name and address of the sponsor/s.

c) The trade name and the descriptive name of the product tested and the identifying dimension of the sample tested.

d) The density of the product. Sheets in gsm and bulk in kg/m³.

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e) If the sponsor does not wish to have details of the product revealed in the test report, he shall nevertheless make such details available to the testing authority, which shall treat the information as confidential.

f ) The test method used, together with deviations from the procedure that are requested by the sponsor shall be set out in detail.

g) Observations made during the test that may be indicative of the behaviour of the product in a fire.

h) The duration of the test.

i) Compliance or non-compliance with set requirements.

j) The report shall be the approved original or authorized abridgements, signed by an authorized officer of the testing authority.

6.10 Manufacturer’s Responsibility

6.10.1 The sponsor/manufacturer shall be responsible for the delivery of the identifiable test sample(s) to the test laboratory and follow-up tests will be purchased at random.

6.10.2 The sponsor/manufacturer shall be responsible for the correct installation specifications of the specimen. Although it is permissible that he contracts the erection work to the testing authority or to a third person, he shall retain the responsibility for correct erection.

6.10.3 The sponsor/manufacturer will make every reasonable effort to supply all necessary instructions and other assistance to the installer to ensure a proper installation.

6.10.4 The sponsor/manufacturer shall provide the testing authority with a full description and details of the sample, including drawings (if required) and proposed installation applications.

6.10.5 The sponsor/manufacturer shall give the testing authority a written request for the test to be carried out.

6.10.6 The sponsor/manufacturer shall use the report only under the conditions laid down by the testing authority.

6.10.7 The sponsor/manufacturer shall be responsible for the removal of the specimens after the test(s). He may, however, contract this work to the testing authority or to a third person.

6.10.8 The manufacturer shall notify TIPSASA of any changes in their products prior to general sale and distribution.

6.10.9 The manufacturer agrees that the use of the TIPSASA name or certification mark is subject to the compliance of the terms and conditions of this protocol.

6.10.10 TIPSASA will issue a “SANS 428 Certificate of Compliance” on receipt of the fire test report from the Manufacturer. (See Annex D).

6.11 Testing Authority’s Responsibility

The testing authority shall provide the sponsor/manufacturer with an estimate of the cost, the date of the test (if applicable) and the date of completion of the work, including the report.

6.11.1 The testing authority shall treat the samples with reasonable care and shall report to the sponsor/manufacturer any damage that may have occurred prior to the test.

6.11.2 The testing authority shall carry out the test(s) strictly in accordance with the relevant test method(s) in terms of the protocol, unless otherwise agreed to between the SPONSOR/MANUFACTURER/TIPSASA and the testing authority, in WRITING.

6.11.3 The testing authority shall keep all testing information confidential.

6.12 Classification

This classification is required in terms of SANS 10400 Part T of the application of the National Building Regulations. (See Annex C).

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Example of product identification:

Combustible/Surface fire properties/Use/Application – B/B1/2/HV

6.13 Marking and Identification of Product

The approved products shall bear the manufacturer’s name, trade name, and fire classification obtained. This information shall be fixed permanently to the original product, data sheet and/or container/packaging. Where it is not possible to mark the material, a printed label/document should be provided to the client, for identification purposes.

6.14 Impartiality

In the event that a laboratory is not SANAS accredited, additional test certification is available through TúV Rheinland an International Certification Agency to verify compliance with the relevant test standard. Advance notification of this service is required.

6.15 TIPSASA Ad-hoc Quality Assurance Tests

Ad hoc quality assurance tests may be conducted periodically on products that are manufactured without an ISO 9001 Certificate, to ensure quality assurance. The audit test(s) are commissioned by TIPSASA to confirm that a product continues to conform to the requirements of a standard and to provide information to assess the effectiveness of the manufacturer’s production control.

In the event of non-compliance, the member will be notified and the product will be removed from the test register.

The cost of purchasing the sample shall be added to the cost of testing and the total cost shall be billed directly to the member.

In accordance with the Consumer Protection Act 60 and 61, the member is liable for any unsafe goods and shall notify customers that may have been prejudiced by this variation, and inform them accordingly.

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7. TESTING – THERMAL

7.1 General

ALL products and systems manufactured by TIPSASA members shall be tested to determine the thermal resistance (R-value) of the product or system (Rsys).

In accordance with SANS 10400 XA Energy usage in buildings, insulation shall comply with minimum required R-values.

Insulation shall be installed so that it:

a) abuts or overlaps adjoining insulation, or is sealed,

b) forms a continuous barrier with ceilings, walls, bulkheads or floors that contribute to the thermal

barrier, and

c) does not affect the safe or effective operation of any services, installation, equipment or fittings.

Note: The installation of a consistent and continuous barrier is important as any gaps within the barrier will allow heat in or out, which will undermine the effectiveness of the overall energy efficiency measures. However, it is recognised that certain gaps are essential especially adjoining services and light fittings where the close proximity of insulation may create a fire hazard.

7.2 Bulk Insulation

Thermal resistance shall be determined in accordance with the test methods prescribed in the product material standards:


Product material standards

SANS 1381-1 Materials for thermal insulation of buildings Part 1: Fibre thermal insulation mats.

SANS 1381-6 Materials for thermal insulation of buildings Part 6: Cellulose loose fill thermal insulation material.

For comparison of bulk products, thermal resistance shall be determined at a standard mean temperature of 23 ±1°C for products sold in South Africa.

Bulk insulation shall be installed so that:

a) it maintains its position and thickness, other than where it crosses roof battens, water pipes or electrical cabling, and

b) in ceilings, it overlaps the wall member by not less than 50 mm, or is tightly fitted against a wall where there is no insulation in the wall.

NOTE: Compression can severely reduce the effectiveness of bulk insulation in roofs, ceilings and walls. Compression is when something occurs that reduces the thickness of bulk insulation.

A few common scenarios are:

• Blanket insulation that is compressed under metal roof sheeting.

• Fixings that compress insulation. Sometimes, the insulation only retains its original thickness about halfway between each point of contact.

• Thick wall batts which are compressed to fit into wall cavities.

The direct consequence of compression is reduced R-value. An important point to remember is that published R-values for bulk insulation are always for products of a particular thickness. When a product is compressed, the R-value on the specification sheet or the packaging no longer applies.

When installing bulk insulation blanket under metal roof sheeting, use roof spacers to prop up the roof sheeting so the insulation doesn’t get compressed, in accordance with SANS 10400-XA.

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7.2.1 DETRIMENTAL EFFECTS OF COMPRESSION ON BULK INSULATION

Bulk insulation needs to maintain its thickness and position throughout the building envelope assembly in order to achieve its designed thermal resistance. Compression of bulk insulation will proportionately lower the thermal resistance of the material resulting in a reduced thermal performance. In instances where compression is unavoidable due to specific design constraints it is extremely important to compensate for these localised R-value losses by increasing the overall depth of the specified insulation throughout the envelope assembly accordingly. Accurate calculations or thermal modelling should be carried out to determine the additional thickness of insulation required to achieve the prescribed minimum total R-value for the assembly.

Energy efficiency standards in countries such as South Africa are in relative infancy compared to the UK. Insulation installation details in South Africa have come under scrutiny recently to establish whether the current construction details and methods being used are achieving the National Building Standards prescribed R-values for building envelope systems. It is relatively common practice for a glass fibre quilt/blanket to be installed over purlin below a single skin steel roof assembly often without the use of a roof spacer system or profiled steel liner sheet. The insulation is supported by basic straining wire and draped between purlins to allow for some recovery in the materials loft. Variations of this detail utilising continuous XPS or timber spacer are sometimes employed to improve loft recovery but these methods still result in varying degrees of compression.

A recent series of independent compression tests were carried out by Oxford Brookes University in the UK to establish the effect of this compression on the thermal conductivity and thermal resistance of a 155mm 12kg/m³ Glass Fibre Quilt under these particular assembly conditions. The tests revealed that the 155mm glass fibre quilt is compressed over the purlins to a thickness of 5.0mm with a density of 328.6kg/m³ when fixed below a steel roof sheet and/or spacer. The thermal conductivity of the compressed insulation increased marginally from 0.038 W/mK to 0.046W/mK whilst the thermal resistance decreased dramatically from 4.079m²K/W to 0.109m²K/W.

South African Building Standards stipulate that an overall minimum R-Value has to be achieved by building envelopes but allows for insulation to be compressed at purlin lines provided that a thermal break of 0.2m²K/W is introduced. The Oxford Brookes University test results confirmed that a compressed 155mm 12kg/m3 glass fibre quilt between a single skin steel weather sheet and purlin does not achieve this required thermal break requirement.

Description - 135mm Glass Fibre 12kg/m³ Over Purlin 1500mm Centres, No Spacer, Concealed Fix Weather Sheet. Courtesy: Ash & Lacy Thermal Modelling Report. Accredited Third Party Laboratory Tests: Oxford Brookes University.

Description - 135mm Glass Fibre 12kg/m³ Over Purlin 1500mm Centres, 75mm Spacer, Concealed Fix Weather Sheet. Courtesy: Ash & Lacy Thermal Modelling Report. Accredited Third Party Laboratory Tests: Oxford Brookes University.

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Description - 135mm Glass Fibre 12kg/m³ with 135mm Mechanical Spacer System. Courtesy: Ash & Lacy Thermal Modelling Report. Accredited Third Party Laboratory Tests: Oxford Brookes University.

7.2.2 SPACER SYSTEMS EXAMPLE

Non-rigid bulk insulation materials such as quilts, batts & semi-rigid boards should always be installed in conjunction with spacer systems to prevent compression. Spacer support systems are designed to reduce or prevent compression of bulk insulation installed over purlin by raising the height of the outer weather sheet.

Mechanical spacer systems are engineered to perform as structural components of the roof assembly. They comprise of lightweight structural steel purlins with engineered support brackets that mechanically lock into position at specified centres. Mechanical spacer systems provide a structural interface between the primary purlin and the raised outer weather sheet. The support brackets are manufactured in a variety of heights to accommodate corresponding insulation thicknesses. The support brackets are secured directly to the primary purlins creating a defined cavity for the insulation material. The outer weather sheet is secured directly to the spacer systems raised structural purlin ensuring clip or halter alignment and fastener performance. Specific loading requirements are achieved by varying the support bracket centres.

Mechanical spacer systems form the backbone of single & dual skin built-up systems where specific structural, thermal and fire performance is required. *Only accredited independently tested mechanical spacer systems should be used.

Compressing the insulation quilt below the base of the spacer system support brackets will result in the insulation being compressed to a thickness of less than 5mm below the bracket with a thermal resistance in the region 0.1m²K/W and a ‘pillowing’ tapered compression of the insulation radiating outwards from the spacer system brackets. If this method is employed it is imperative that a second layer of insulation be installed to counteract this tapering compression ensuring that the overall specified thickness of insulation is achieved. The second layer of insulation must be installed to form a tight fit around the spacer system brackets thus minimising the potential for thermal bridging or voids forming.

XPS continuous spacers are manufactured from high density extruded closed cell rigid foam. These spacers are secured directly to the purlins in continuous lengths after the insulation blanket has been draped over purlin. They still cause compression at the purlin but allow the blanket to regain some loft between purlins by simultaneously elevating the weather sheet and providing the required thermal break. Draping the insulation over purlin results in a tapered compression which reduces the overall R-value of the installed insulation. It is extremely important to compensate for this loss in overall R-value by increasing the depth of the specified insulation blanket and spacer accordingly. Accurate thermal modelling should be carried out to determine the additional depth of insulation required.

IMPORTANT NOTE: Foam spacers have a number of design constraints that limit their application:

• NOT Suitable for any form of concealed fix roofing profiles

• NOT Suitable for roof pitches exceeding 5°

• NOT Suitable for high wind zones.

• NOT Suitable for roof surfaces that support static or dynamic loads – including but not limited to loads such as foot traffic, air conditioning units, hot flues, vents, aerials, walkways, solar panels, etc.

• NOT Suitable as a wall spacer system.

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Estimated reduction of thermal performance of flexible bulk insulation when compressed.

Type of Roof system “Standard” with 1500mm Purlins

Declared R-Value m²K/W

Compressed No spacer

(Rsys) m²K/W

Percentage % shortfall with SANS

10440-XA compliance

With 70mm spacer

(Rsys) m²K/W

Percentage % shortfall with

SANS 10400-XA compliance

50mm Glass Fibre 1.25 0.8013 78.34 1.6460 55.51

100mm Glass Fibre 2.50 1.0461 71.72 2.4503 33.77

135mm Glass Fibre 3.37 1.0464 71.71 2.9167 21.17

150mm Glass Fibre 3.75 1.0462 71.72 3.1042 16.10

“Standard” with 1500mm Purlins



(Rsys) m²K/W

Percentage % shortfall with compliance

With 135mm mechanical

Spacer

Percentage % shortfall with compliance

150mm Glass Fibre 3.75 1.0462 71.72 3.914 0

Built-up Insulated Metal Roof System (1500mm Purlins)



(Rsys) m²K/W

Percentage shortfall with compliance

With 135mm mechanical

spacer

Percentage shortfall with compliance

135mm Glass Fibre 3.37 1.0464 71.71 3.6785 0

The table below gives examples of modelling 6 different insulated roof assemblies using the highest required R-Value of 3.7 m²K/W and glass fibre insulation with a thermal conductivity of 0.040 W/m.K and THERM 7.4.3 in order to calculate their actual R-Values as an assembly when taking into account compression.

7.2.3 DETRIMENTAL EFFECTS OF MOISTURE ON INSULATION MATERIALS

Moisture is, by far, the largest factor which impacts on the performance and durability of a building as well as the component parts of buildings such as rotting of timber, corrosion of metals, hydration of plastics, spalling of concrete and masonry as well as the growth of mould and mildew, the effects together with damp may lead to serious illnesses and structure failure

As moisture is a component of, and transported by air, it is by far the most complicated and challenging, especially so in climatic regions where air being introduced to the building envelope needs to be hydrated or dehydrated, cooled or heated, etc. It is an engineering science of a specialised field and best left to consultants who specialize in the field.

Thermal Insulation must be dry in order to be most effective in impeding heat flow into or out of a building. The thermal resistance (R-Value) will be reduced when exposed to moisture. Some insulation products are not absorbent and, if exposed to moisture, will not wick up or hold water. If allowed to dry out insulation may retain its original R-Value. In wall applications certain insulation material may be applied as vapour retarders, or moisture barriers.

Foil membranes are excellent vapour barriers and are often applied, as such, in providing protection for mass or bulk type insulation applications directly under the roof cover, against moisture migration into the insulation or moisture flowing onto the roof cover and condensating.

In high humidity regions a double layer of foil, above and below the insulation, may be best in practice.

In wall applications for most climatic regions a vapour barrier is not best practice therefore a vapour retarder pegboard or pinhole type foil membrane is the better choice, so as to allow the moist air to move inward and outward through the wall via capillary action.

Selected products of the mass or bulk type materials are often applied as moisture retarders in a wall construction, producing acceptable results however, as moisture is a conveyor of heat, allowance in design must allow for the increase of heat flow (conductance) and lowering of resistance through the insulation material as a result of the moisture present.

Well documented research shows that a take up of 1% moisture by volume will decrease or lower the efficiency of certain bulk mass type insulations by as much as 25 - 30%.

The general guidelines (house rules) in terms of location of vapour barriers and moisture retarders is to install them on the warmer surface side, which in itself is a challenge to determine the location.

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• Daytime - Due to Radiation and Heat Build-up, the outside is warmer.

• At Night - The inside surface is warmer.

In a controlled temperature within a building having a temperature of e.g. 24ºC the outside air during the day may rise to 35ºC, the outside is the warmer surface. A sudden downpour or cold front reduces the outside air temperature to 16ºC, the inside surface is now the warmer surface. Placing a retarder at both inner and outer surfaces may be the only solution in some climatic zones.

Basic Guidelines are:

a) Identify the climate

b) Identify whether it is heating or cooling or both

c) Identify the means of transport, via air movement, capillary suction, visible wet liquid flow or vapour diffusion.

d) Select moisture control options / applications for draining, venting etc.

7.2.4 PACKING OF MATERIALS

The insulation material or assembly shall be packaged by the manufacturer or agent in such a way as to provide adequate protection during handling, transport and storage.

Packaging shall be adequate to provide reasonable expectation that performance will be maintained through normal storage and handling, with particular regard to the possible effects of excessive compression.

Mats shall be so packed or tied that they are protected from damage during normal handling, transportation and storage in accordance with the manufacturer’s recommendations

7.3 Rigid Foam insulation

The declared values of thermal resistance and thermal conductivity of a product are the expected values of these properties during an economically reasonable working life under normal conditions, assessed through measured data at reference conditions.

Thermal resistance shall be determined in accordance with the test methods prescribed in the product material standards:


Product material standards

SANS 53163 Thermal insulation products for buildings – Factory made products of expanded polystyrene (EPS)- Specification

SANS 53164 Thermal insulation products for buildings – Factory made products of extruded polystyrene foam (XPS) - Specification

SANS 53165 Thermal insulation products for buildings – Factory made rigid polyurethane foam (PUR) products - Specification

SANS 13166 Thermal insulation products for buildings – Factory made products of phenolic foam (PF) - Specification

Thermal conductivity shall be determined according to SANS 8301 at a mean temperature of either 23°C or 10°C.

7.3.1 AGING OF FOAM INSULATION MATERIALS

All insulation materials are subject to deteriorating performance due to environmental factors which reduce their thermal resistance or emissivity. These include moisture ingress, dust deposition, compression, chemical agents, ultra violet light, poor installation practices, vermin or gas exchange over time.

Users and specifiers need to establish which factors most affect particular insulation options for a given solution, through reference to the manufacturer and TIPSASA website. These factors must be considered in the design and construction phase of building, in order that required and intended thermal resistances are sustained

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7.4 Spray Foam Insulation

SANS 8873 defines the requirements for rigid cellular plastic spray polyurethane foam when used as a thermal insulation in buildings and non-buildings.

The spray-applied polyurethane rigid cellular plastic thermal insulation is not to be used when the continuous service temperature of the substrate is outside the range of -60°C to +80°C.

The test methods used to determine the material properties provide a means of comparing different cellular plastic thermal insulations. They are intended for use in specifications, product evaluations and quality control. They are not intended to predict end-use product performance.

Spray-applied polyurethane rigid cellular plastics are to be applied (installed) in accordance with the manufacturer’s instructions and the requirements of SANS 8873-2. Applications, requirements for applications and limitations of use are included in SANS 8873-2.

Rigid cellular plastics – spray applied polyurethane foam for thermal insulation shall comply with:

• SANS 8873 Part 1: Material specifications

• SANS 8873 Part 2: Application

• SANS 8873 Part 3: Test methods

7.5 Reflective Insulation (RI)

Reflective insulation is a thin film or sheet, which makes use of a low emissivity surface to increase the thermal resistance of adjacent or enclosed air space(s), but which has no significant thermal resistance of its own.

The thermal resistance of a reflective material or assembly shall be expressed as either system R-value (Rsys) or total R-value (Rt), and shall be the combined thermal resistance arising from:

a) Contributions by any bulk material that is part of the material or assembly; and

b) Contributions by the adjacent spaces or air spaces that the material or assembly reflectively bounds.

Where insulating materials or assemblies achieve some or all of their thermal resistance through the reflective nature of their external surfaces, and these surfaces are claimed to have an infrared emittance less than 0.9, the infrared emittance of these surfaces shall be determined. Measurement shall be in accordance with SANS 1789 (or ASTM C 1371 and/or EN 16012), and shall be stated on the label and literature and in conjunction with measurements or calculations of thermal resistance.

The R-value of reflective insulation is affected by the airspace between a reflective side of the reflective insulation and the building lining or cladding. Dust build-up reduces R-values.

System Thermal Resistance Testing & Calculations

Two tests were performed on each sample under the following conditions: The first with the sample “as new” and the second with the sample “covered with dust”. To simulate “dust covered” the reflective side of the specimen is coated with matt grey paint, allowed to dry and tested. (Refer ASHRAE Handbook)

NOTE: The reported values for thermal conductivity are the equivalent thermal conductivity values (in W/mK) for a system, consisting of a sample of reflective foil mounted between the two plates of the apparatus with specified air gaps, not for the foil sample in isolation.

Performance of systems tested were as follows:

1. Test with no air gap.

2. a) Test with no air gap on the “hot” side (upper top) at 36 °C and an air gap of 80 mm on the “cold” side (lower bottom) at 10 °C by mounting the sample on a frame and setting up the apparatus for a manual sample thickness of 100 mm (in accordance with requirements).

b) Repeat test, simulated as dust covered.

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3. a) Test with an air gap of 20 mm on the “hot” side (upper top) at 36 °C and similarly, an air gap of 80 mm on the “cold” side (lower bottom) at 10 °C by mounting the sample on a frame and setting up the apparatus for a manual sample thickness of 100 mm (in accordance with requirements).


4. a) Test with an air gap of 40 mm on the “hot” side (upper top) at 36 °C and similarly, an air gap of 60 mm on the “cold” side (lower bottom) at 10 °C by mounting the sample on a frame and setting up the apparatus for a manual sample thickness of 100 mm (in accordance with requirements).


The following table below presents the reflective insulation tested with various air gaps in the Laserccomp Fox 314 equipment in accordance with ISO 8301 with deviations.

DescriptionTemperature range: 36°/10°C (mean 23 °C)

Direction of heat flow downwards

Horizontal Installation -

Air gaps system: above/below

0/0 0/80 20/80 40/60

Thermal Resistance Performance of system (Rsys)

λ-value W/m.K

λ-value W/m.K

(Rsys)

m².K/W λ-value W/m.K

(Rsys)

m².K/W λ-value W/m.K

(Rsys)

m².K/W

Double sided Reflective Foil

No value registered 0.08 1.25 0.07 1.36 0.06 1.57

Notes:

1. When double sided RI is tested in a heat flow apparatus with no air gaps present, it is impossible to determine λ-values for the product with the ‘hot’ and ‘cold’ plates touching the product. Due to foil’s excellent conduction of energy, the machine is unable to register a value.

2. The thermal resistance of various RI products were tested with various unventilated air spaces under laboratory conditions. The variance in performance were negligible.

3. The thermal resistance of RI is influenced by the air spaces of the system.

4. The thermal performance of RI is influenced by dust and could be adversely effected.

5. Reflective insulation has very low emittance values “E-values” (typically between 0.03 – 0.05, compared to 0.90 for most insulation) and that significantly reduces heat transfer by radiation.

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7.6 Cool Coatings reliant on solar reflectance

All cool coatings shall comply with the requirements of the Cool Roof Rating Council Standard (CRRC-1).

Solar-reflective materials or coatings which receive direct or indirect solar radiation and are intended to influence the thermal performance of the building through reflection or absorption of this radiation shall comply with the requirements as per the table below.


Thermal Emittance (TE).

SANS 1789 ASTM C 1371 EN 16012


Solar Reflectance Index (SRI).


Standard Test Method for Measuring Solar Reflectance of Horizontal and Low-Sloped Surfaces in the Field

SANS 1982 ASTM C 1549 Standard test method for determination of solar reflectance near ambient temperature

Calculation SANS 1980 ASTM E 1980

Standard Practice for Calculating Solar Reflectance Index of Horizontal and Low-Sloped Opaque Surfaces

Reflectance and Emittance Requirements for upper roof surface.

The requirements in this section apply to all building types and all climate/energy zones. Roof surfaces shall comply with all of the following:

a) meet or exceed the minimum initial thermal emittance requirement in Table 1

b) meet or exceed the minimum initial solar reflectance requirement in Table 1

c) be equal to or greater than the Solar Reflectance Index (SRI) requirement in Table 1.

Table 1: Reflectance and Emittance Requirements for upper roof surface.

INITIAL SOLAR REFLECTANCE

ρ

(1) WEATHEREDSOLAR REFLECTANCE

ρaged

INITIAL THERMAL EMITTANCE

ε

(2) SOLAR REFLECTANCE INDEX

SRI

Roof ≥ 0.65 ≥ 0.49 ≥ 0.75 ≥ 75

Notes:(1) If an aged solar reflectance is not available for any roofing products, the aged value shall be derived from the initial tested value. See Annex X(2) SRI shall be calculated and be based on medium wind speed of 2-6 meters per second. The Aged SRI aged shall be calculated based on the aged reflectance value of the roofing products.

Exceptions: Roofs where at least 75% of the surface is covered with a vegetative roof systems or is covered by photovoltaic arrays, building integrated photovoltaic arrays, or solar or water collectors.

7.7 Insulated Sandwich Panels

Insulated Sandwich Panel Standard shall be tested in accordance with SANS 54509 (EN 14509) Self-supporting double-skin metal-faced insulating panels – Factory made products – specifications.

What is a sandwich panel?

Insulated (sandwich) panels are single piece factory engineered units typically comprising two metal faces and a fully insulating core. The facings are fully bonded to the core so that the panel acts compositely when under load, in most cases, providing free standing and load bearing panels. Facings used for insulated panels are predominantly of steel.

The core material is usually a material that provides good thermal insulation properties. The insulating core is typically bonded to the facings using a conventional adhesive bond.

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Insulated (sandwich) panels are never used on its own; it is always incorporated into a “system” and needs to be tested as such to determine the fire and thermal performance.

Core Materials

• Typical generic core material types used in panels:

• CG (Cellular glass thermal insulation)

• EPS (Expanded polystyrene)

• MW (Mineral wool)

• PIR (Polyisocyanurate)

• PF (Phenolic Foam)

• PUR (Polyurethane)

• XPS (Extruded Polystyrene)

Note: Only non-combustible cores are allowed to be used in: cooking areas, hot areas, bakeries, fire breaks in combustible insulating panels and fire stop insulating panels.

Why are Insulated (sandwich) panels used?

Insulated (sandwich) panels (ISP) are used extensively for the external roof and wall cladding of buildings in most construction sectors. They are selected for their thermal and energy saving properties and their construction and installation cost saving benefits.

Typical applications

ISP’s were initially used for buildings such as cold stores, however as the benefits of using ISP’s have become more widely known for their use it has been spread to a variety of other applications such as:

• Temperature controlled rooms/buildings

• Cold rooms

• Food production facilities

• Housing

• Schools

• Storage facilities.

South African Regulatory Requirements

National Regulations typically have specific requirements relating to wall and ceiling linings and/or insulated (sandwich) panels, for both “fire performance” properties and “fire resistance” properties. For both properties, fire-testing standards are typically referenced from which ratings of products can be determined and used to show compliance against nationally accepted thresholds.

A separate guiding document will be developed for Insulated Sandwich Panels.

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8. LABELLING, MARKING AND DATA SHEETS

8.1 General

Labelling shall include at least one of the terms; ‘R-value’, ‘R-value’ ‘Thermal Resistance’ to describe thermal resistance values. These terms shall be qualified with the term ‘declared’ together with one of the terms ‘material’, ‘system’ or ‘total’

The declared R-value shall be the long-term value and shall take into account the derating that may arise through aging or environmental factors.

Type of material Information required

All types

The manufacturer’s name, and trade name or trade mark, or both

Description of contents

Batch identification or date of manufacture or other traceability information

The nominal length in m, width and thickness in mm of the material;

The nominal area of the material in m²

One or more declared R-values (m².K/W), accompanied by a clear statement as to the conditions under which it/they apply and preceded by one or more of the qualifiers ‘Total’, ‘System’ or ‘Material’ as appropriate. When ‘heat flow up’ or ‘heat flow down’ or ‘Summer’ and ‘Winter’ R-values are different, all values shall be quoted with equal emphasis.

The fire performance classification in accordance with SANS 428

A statement that the material is “combustible” or “non-combustible”, as relevant

Safety instructions - a warning, referring to precautions for health and safety during handling and installation of the insulation material

Recommendations for transportation and storage of the material.

Installation guidelines.

NOTE The user’s attention should be drawn to the existence of a data sheet (including installation guidelines) for the product, also indicating where it is available from.

Reflective

A statement “the contribution of this product to total R-value depends on air spaces, installation and environmental conditions”

A statement “Dust build-up reduces R-values”

Loose fill

Nominal coverage (area per unit mass) and stabilized thickness (mm), for

each declared R-value

Nominal net weight of contents or supplied quantity (kg)

A statement ‘the total R value depends on installation and may be greater than or less than the R value of the product’

Declared material R-value

Type of material Information required

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Formed shapes

Number of pieces

Nominal total area (m²)

Nominal length, width and thickness of each piece

Nominal net weight of contents or supplied quantity (kg)

A statement ‘the total R value depends on installation and may be greater than or less than the R value of the product’

Declared material R-value

Low-density fibrous

The statement ‘This pack complies with SABS 1381-1 for a net weight of

xx kg, a total area of yy m² and a mean thickness of zz mm’ where xx, yy and zz appear on a valid and current report of measurement of thermal resistance in accordance with the Standard

Nominal total area (m²)

Nominal length and width of each roll

Nominal stabilized thickness

A statement of the time after installation to achieve nominal stabilized thickness and R-value.

A statement ‘the performance of this product may be reduced if stored for too long in its compression packaging’

8.2 Usage of TIPSASA Logo

The TIPSASA logo design and the artwork is the intellectual property of the copyright and/or trademark holder (in this case TIPSASA) and is offered to members as a convenience for lawful use with proper permission from TIPSASA only.

Before members use or reproduce this artwork in any manner, members agree to obtain the express permission of the copyright and/or trademark holder. Failure to obtain such permission is a violation of international copyright and trademark laws subject to specific financial and criminal penalties.

Unless authorized by TIPSASA, use of its logo is prohibited. TIPSASA reserves the right to take appropriate action when its logo is used without its permission, or if it is adapted or modified.

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9. GUARANTEES FROM TIPSASA MANUFACTURERS

The thermal, acoustic and fire performance of the insulation material is based on the guarantee of its structural integrity. The structural integrity of the insulation is generally guaranteed up to the stated years, depending on the manufacturer who supplied the insulation. Like most guarantees this is subject to a list of requirements to ensure its validity:-

1. The product must be stored, handled and installed in accordance with the manufacturers recommended instructions.

2. There is to be no physical damage caused to the product either during its installation or in subsequent periods.

3. There is to be no ingress of water or other liquids due to leaks or any other manners which will cause loss of properties. Any such leaks will invalidate the product guarantee.

4. There is to be a recorded maintenance plan to show it has been maintained in accordance with manufacturer’s recommendations.

Failure of the above will lead to the product guarantee becoming invalid.

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10. INSTALLERS OF THERMAL INSULATION

10.1 General

Installation of thermal insulation shall be strictly in accordance with the manufacturer’s installation specifications.

Guiding documents:

• Cellulose Loose-fill Insulation; Installation Guide

• Thermal Insulation - A Guide for the Installation of Fibrous Blankets/Mats/Batts

The Building Insulation Installer (BII) shall provide the client/ customer with a “Declaration of Compliance”.

This requirement is introduced to ensure TIPSASA BII’s comply with the Code of Ethics, with particular emphasis on the following:

a) Comply with applicable laws, regulations and responsibilities in an effort to create transparency in all operations.

b) Abide by the governing documents and policies of the Association.

c) Abide by the Advertising Standards Authority of South Africa’s (ASA) Code of Advertising Practice as a guiding document for members.

d) Be accountable for adhering to the Code of Ethics.

e) Act at all times in accordance with the highest ethical standards and in the best interest of the Association, its members, consumers, donors and reputation.

f ) Openly and honestly tell the truth.

g) Not be deceptive in our activities or in prospecting for new members to join the Association.

PLEASE NOTE: It is imperative to provide, to comply with the energy efficiency requirements and to issue the correct information, as to what insulation product has been installed, in view of Energy performance certificates for buildings (EPC’s) being issued in the future.

10.2 Key Health & Safety Requirements

Typical Requirements of a Contractor for Working at Height Projects e.g. Roofing & Insulation Works

Please note: these requirements are not meant to supercede any regulation, standard or law.

Legislation Section Legislated Requirement

Notification of construction work

Construction Regulations 2014

A contractor who intends to carry out any construction work must at least 7 days before that work is to be carried out notify the provincial director in writing.

Duties of contractor


A contractor must-

Provide and demonstrate to the client a suitable, sufficiently documented and coherent site specific health and safety plan, based on the client’s documented health and safety specifications, which plan must be applied from the date of commencement of and for the duration of the construction work and which must be reviewed and updated by the contractor as work progresses.



A contractor must-

Open and keep on site a health and safety file, which must include all documentation required in terms of the Act and the Regulations, which must be made available on request to an inspector, the client, the client’s agent or a contractor.

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A contractor must-

On appointing any other contractor, in order to ensure compliance with the provisions of the Act-

• provide contractors who are tendering to perform construction work for the contractor, with the relevant sections of the health and safety specifications pertaining to the construction work which has to be performed;

• ensure that potential contractors submitting tenders have made sufficient provision for health and safety measures during the construction process;

• ensure that no contractor is appointed to perform construction work unless the contractor is reasonably satisfied that the contractor that he or she intends to appoint, has the necessary competencies and resources to perform the construction work safely;

• ensure prior to work commencing on the site that every contractor is registered and in good standing with the compensation fund or with a licensed compensation insurer as contemplated in the Compensation for Occupational Injuries and Diseases Act, 1993;

• appoint each contractor in writing for the part of the project on the construction site;

• take reasonable steps to ensure that each contractor’s health and safety plan is implemented and maintained on the construction site;

• ensure that the periodic site audits and document verification are conducted at intervals mutually agreed upon between the contractor and any contractor, but at least once every 30 days;

• stop any contractor from executing construction work which is not in accordance with the client’s health and safety specifications and the contractor’s health and safety plan for the site or which poses a threat to the health and safety of persons;

• where changes are brought about to the design and construction, make available sufficient health and safety information and appropriate resources to the contractor to execute the work safely; and

• discuss and negotiate with the contractor the contents of the health and safety plan and must thereafter finally approve that plan for implementation.



A contractor must-

• ensure that a copy of his or her health and safety plan as well as the contractor’s health and safety plan is available on request to an employee, an inspector, a contractor, the client or the client’s agent.



A contractor must-

• hand over a consolidated health and safety file to the client upon completion of the construction work and must include a record of all drawings, designs, materials used and other similar information concerning the completed structure.



A contractor must-

• include and make available a comprehensive and updated list of all the contractors on site accountable to the contractor, the agreements between the parties and the type of work being done.



A contractor must-

• ensure that all his or her employees have a valid medical certificate of fitness specific to the construction work to be performed and issued by an occupational health practitioner.

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Management and supervision of construction work


A contractor must-

• in writing appoint one full-time competent person as the construction manager with the duty of managing all the construction work on a single site, including the duty of ensuring occupational health and safety compliance, and in the absence of the construction manager an alternate must be appointed by the contractor.

Risk assessment for construction work


A contractor must, before the commencement of any construction work and during such construction work, have risk assessments performed by a competent person appointed in writing, which risk assessments form part of the health and safety plan to be applied on the site



A contractor must ensure that all employees under his or her control are informed, instructed and trained by a competent person regarding any hazard and the related work procedures and or control measures before any work commences, and thereafter at the times determined in the risk assessment monitoring and review plan of the relevant site.



A contractor must ensure that all contractors are informed regarding any hazard that is stipulated in the risk assessment before any work commences, and thereafter at the times that may be determined in the risk assessment monitoring and review plan of the relevant site.



A contractor must consult with the health and safety committee or, if no health and safety committee exists, with a representative trade union or representative group of employees, on the monitoring and review of the risk assessments of the relevant site.



A contractor must ensure that copies of the risk assessments of the relevant site are available on site for inspection by an inspector, the client, the client’s agent, any contractor, any employee, a representative trade union, a health and safety representative or any member of the health and safety committee.

Fall protection


A contractor must designate a competent person to be responsible for the preparation of a fall protection plan.

Fall protection


A contractor must ensure that the fall protection plan is implemented, amended where and when necessary and maintained as required.

Fall protection


A contractor must take steps to ensure continued adherence to the fall protection plan.

Fall protection


A fall protection plan contemplated must include-

• a risk assessment of all work carried out from a fall risk position and the procedures and methods used to address all the risks identified per location;

• the processes for the evaluation of the employees’ medical fitness necessary to work at a fall risk position and the records thereof;

• a programme for the training of employees working from a fall risk position and the records thereof;

• the procedure addressing the inspection, testing and maintenance of all fall protection equipment; and

• a rescue plan detailing the necessary procedures, personnel and suitable equipment required to affect a rescue of a person in the event of a fall incident to ensure that the rescue procedure is implemented immediately following the incident.

Fall protection


A contractor must ensure that a construction manager appointed under regulation 8(1) is in possession of the most recently updated version of the fall protection plan.

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Fall protection


A contractor must ensure that-

• all unprotected openings in floors, edges, slabs, hatchways and stairways are adequately guarded, fenced or barricaded or that similar means are used to safeguard any person from falling through such openings;

• no person is required to work in a fall risk position, unless such work is performed safely;

• fall prevention and fall arrest equipment are-

- approved as suitable and of sufficient strength for the purpose for which they are being used, having regard to the work being carried out and the load, including any person, they are intended to bear; and

- securely attached to a structure or plant, and the structure or plant and the means of attachment thereto are suitable and of sufficient strength and stability for the purpose of safely supporting the equipment and any person who could fall; and

• fall arrest equipment is used only where it is not reasonably practicable to use fall prevention equipment.

Fall protection


Where roof work is being performed on a construction site, the contractor must ensure that it is indicated in the fall protection plan that-

• the roof work has been properly planned;

• the roof erectors are competent to carry out the work;

• no employee is permitted to work on roofs during inclement weather conditions or if any conditions are hazardous to the health and safety of the employee;

• all covers to openings and fragile material are of sufficient strength to withstand any imposed loads;

• suitable and sufficient platforms, coverings or other similar means of support have been provided to be used in such a way that the weight of any person passing across or working on or from fragile material is supported; and suitable and sufficient guard-rails, barriers and toe-boards or other similar means of protection prevent, as far as is reasonably practicable, the fall of any person, material or equipment.

Housekeeping and general safeguarding on construction sites


A contractor must ensure that suitable housekeeping is continuously implemented on each construction site.

Stacking and storage on construction sites



• a competent person is appointed in writing with the duty of supervising all stacking and storage on a construction site;

• adequate storage areas are provided;

• there are demarcated storage areas; and

• storage areas are kept neat and under control.

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Fire precautions on construction sites



• all appropriate measures are taken to avoid the risk of fire;

• sufficient and suitable storage is provided for flammable liquids, solids and gases;

• smoking is prohibited and notices in this regard are prominently displayed in all places containing readily combustible or flammable materials;

• in confined spaces and other places in which flammable gases, vapours or dust can cause danger-

- only suitably protected electrical installations and equipment, including portable lights, are used;

- there are no flames or similar means of ignition;

- there are conspicuous notices prohibiting smoking;

- oily rags, waste and other substances liable to ignite are without delay removed to a safe place; and

- adequate ventilation is provided;

• combustible materials do not accumulate on the construction site;

• welding, flame cutting and other hot work are done only after appropriate precautions have been taken to reduce the risk of fire;

• suitable and sufficient fire-extinguishing equipment is placed at strategic locations or as may be recommended by the Fire Chief or local authority concerned, and that

• such equipment is maintained in a good working order;

• the fire equipment is inspected by a competent person, who has been appointed in writing for that purpose, in the manner indicated by the manufacturer thereof;

• a sufficient number of workers are trained in the use of fire- extinguishing equipment; where appropriate, suitable visual signs are provided to clearly indicate the escape routes in the case of a fire;

• the means of escape is kept clear at all times;

• there is an effective evacuation plan providing for all-

- persons to be evacuated speedily without panic;

- persons to be accounted for; and

- plant and processes to be shut down; and

- a siren is installed and sounded in the event of a fire.

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HEALTH AND SAFETY REQUIREMENTS TIPSASA CONTRACTOR

Letter of Good Standing.

Health & Safety and Environmental Management Plan.

Health and Safety Policy (Signed and dated by CEO).

Site specific Health and Safety File.

Has the contractor made allowance for Health and Safety in their tender pricing?

Is the contractor competent to carry out the works e.g. have they and their staff received the necessary training.

Do ALL of the contractors’ team members have a valid occupational health and safety medical certificate which declares them fit for work?

Do ALL of the contractors’ team members who work at heights have a valid certificate and has that training been given by a certified professional using the correct Unit Standards?

Do ALL inspection, management and assessors of the works have a valid working at heights certificate?

Has a risk a Risk Assessment been undertaken and by a competent person? Have they undergone training or have qualifications that are registered in terms of the National Qualifications Framework Act, 2000Have Safe Working Procedures been established and compiled by a competent

person?

Has a Fall Protection Plan been created and by a competent person?

10.3 Guarantees & Warranties from the TIPSASA Contractor

This requirement is introduced to ensure TIPSASA contractors provide an all-encompassing guarantee & warranties:-

a) To ensure a product guarantee can be supplied by the manufacturer, the TIPSASA contractor ensures that the insulation has been installed in accordance with the manufactures instructions.

b) Should a metal roof system be installed with the insulation then a TIPSASA contractor will provide the following all for the same length of term as the roof sheet guarantee:-

• A project specific material roof sheet guarantee

• A project specific flashing material roof sheet guarantee

• A project specific fixings and fasteners guarantee

• A project specific insulation product guarantee

• A project specific guarantee against water ingress from the roof sheet and perimeter and penetration metal flashings

• A project specific installation warranty

All of the above guarantees will have the same length of term.

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11. DECLARATION OF COMPLIANCE (EXAMPLE)

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ANNEX A – 5 YEAR FIRE TESTING CYCLE (ALPHABETICAL)

Based on current regulations in place and no changes to product.

Manufacturer ProductTest

Date

SANS 428

Classification

Next

Test Due

Afripack

Sisalation 405 2011/10/01 B/B1/2 H only 2016/10/01

Sisalation FR 405 2015/08/31 B/B1/2/H&V (SP & USP) 2020/08/31

Sisalation FR 430 2014/03/31 B/B1/2/H only (USP) 2019/03/31

Alucushion Alucushion 2906 2016/10/24 B/B1/2/H only (SP) 2021/10/24

ATI

Alulite 2016/07/20 B/B1/2 H only 2021/07/20

Alububble 2906 2010/07/19 B/B1/2/H (SP & USP) 2015/07/19

Alububble 1983 2016/07/20 B/B1/2/H (SP) 2021/07/20

Alutherm Fibre Glass 2010/07/19 B/B1/2/H only (USP) 2015/07/19

Alutherm Polyester 2010/07/19 B/B1/2/H only (USP) 2015/07/19

Brits Nonwoven

Isotherm 2013/05/06 B/B1/2 H only 2018/05/06

MBI Foil Faced 2013/09/05 A/A1/1 H&V (SP & USP) 2018/09/05

MBI White Faced 2013/09/05 A/A1/1 H&V (SP & USP) 2018/09/05

MBI White WMF C 2015/08/04 A/A1/1 H&V (SP & USP) 2020/08/04

Eco Insulation Eco Insulation 2012/12/04 B/B1/2 H only 2017/12/04

D&D

Starfibre (Polyester) 2016/01/05 B/B2/2 H only 2021/01/05

Starlite (Acrylic) 2014/05/16 A/A1/1 2019/05/16

Starlite AC (Acrylic) FF 2012/12/11 A/A1/1/H&V (SP & USP) 2017/12/11

Starlite (Glass Fibre) WF 2012/12/11 A/A1/1/H&V (SP & USP) 2017/12/11

Starlite (Glass Fibre) FF 2012/12/11 A/A1/1/H&V (SP & USP) 2017/12/11

Starlite PH (Phenolic) WF 2012/08/29 A /A1/1/H only (SP& USP) 2017/08/29

Starlite PH (Phenolic) FF 2012/08/29 A /A1/1/H only (SP& USP) 2017/08/29

Starlite Foil (AFT) 2012/12/03 A /A1/1/H only (SP& USP) 2017/12/03

Datlink

Romatherm (White) 2011/10/26 B/B1/2 H only 2016/10/26

Romatherm/EMSulation 2016/01/05 B/B2/2 H only 2021/01/05

ThermocousTex Board 2015/07/07 B/B1/2 H only 2020/07/07

ThermocousTex FF 2015/07/08 B/B1/2/H (USP) 2020/07/08

IC&D Massterliner Foil Faced 2016/09/20 A/A1/1/H only (SP & USP) 2021/09/20

Isofoam Isoboard 2015/08/24 B/B1/2/H&V (SP & USP) 2020/08/24

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Isover

Aerolite 2013/08/20 A/A1/1 2018/08/20

StyFRene 2013/08/19 B/B1/2/H&V (USP) 2018/08/19

Factorylite WMF 2010/11/15 A/A1/1/H only (SP & USP) 2015/11/15

Factorylite Foil Faced 2013/09/06 A/A1/1 H&V (SP & USP) 2018/09/06

Factoryboard WMF 2011/03/02 B/B1/2/H&V (SP & USP) 2016/03/02

Factoryboard Foil Faced 2010/12/01 B/B1/2/H&V (SP & USP) 2015/12/01

Factoryboard LR3010B 2011/07/19 B/B1/2/H&V (SP & USP) 2016/07/19

Kulite White Vynide Face 2011/06/15 B/B1/2/H only (USP) 2016/06/15

Knauf Insulation Knauf Ceiling Roll 2017/10/18 A/A1/1

Platinum Fibre Fabufill 2014/03/11 B/B2/2 H only 2019/09/19

Spunchem

Spunsulation 3 2012/12/19 B/B3/3 H only 2017/12/19



Spunsulation Illumina 2012/03/22 B/B1/2/H only (SP) 2017/03/22

Spunsulation 5 Industrial 2011/10/01 B/B1/2/H&V (SP & USP) 2016/10/01

Technopol

Neopor 2013/09/05 B/B1/2/H&V (USP) 2018/09/05

Polycool 2017/06/19 B/B3/3 H only (USP) 2022/06/19

Polycool 2017/07-24 B/B1/2/H only (USP) 2022/07/24

StyFRene 2013/08/19 B/B1/2/H&V (USP) 2018/08/19

Supacool White Faced 2016/11/16 B/B1/2/H only (USP) 2021/11/16

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ANNEX B – SANS 428 FIRE CLASSIFICATION

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Use of Materials

Limitations on the use of materials

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ANNEX C – EXAMPLE: TIPSASA FIRE REGISTER

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ANNEX D – EXAMPLE: TIPSASA FIRE CERTIFICATE OF COMPLIANCE

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ANNEX E – EXAMPLE TIPSASA PRODUCT COMPLIANCE CERTIFICATE

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NOTES

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