How to develop a construction plan for insulation layers?

There are plenty of insulation layers; where exactly is the insulation installation taking place? Civil engineering, equipment? For the insulation of equipment, refer to GB8175-87 \"Guidelines for the Design of Equipment and Pipeline Insulation.\" Here is a construction plan for roof insulation; once the main structural work carried out by the civil engineering team is completed, work begins on cleaning the substrate, applying the insulation layer, and installing the leveling layer. After completing the roof leveling layer, check the weather forecast; if 3–4 days of good weather are predicted, proceed with the installation of the roof waterproofing layer continuously. Once it has been inspected and found to be satisfactory, carry out the installation of the protective layer promptly. 3.2 Based on the actual conditions of the project: the roofing work is carried out from east to west, starting with the north side and then moving on to the south side. 3.3 Sequence of work: Insulation layer → Slope creation and leveling layer → Waterproofing layer → Waterproof protective layer → Roof surface layer. 4. Construction preparation 4.1 Technical preparation: 4.1.1 Before starting construction, organize the technical staff to carefully study the construction drawings and provide detailed technical instructions for each task. The five key production factors—human resources, machinery, materials, methods, and the environment (i.e., labor force, tools, materials, components, techniques, construction processes, as well as conditions such as temperature or night lighting)—must be planned and organized carefully to ensure that construction can proceed according to schedule. 4.1.2 The roof waterproofing layer shall be installed by a qualified waterproofing team, and the workers must hold relevant certificates to carry out the work. 4.2 Material Preparation: Cement: P.O32.5 cement shall be used. The cement must come with a factory certification and test reports; it also needs to undergo further testing upon arrival, and can only be used if it passes these tests. Sand: medium sand, with a silt content of less than 5%; raw material testing is required upon arrival. Single-component polyurethane waterproof coating: It must come with a factory certification, test reports, and environmental protection certifications. After it arrives on site, further testing is required, and it can only be used if it passes these tests. Extruded boards: They must come with a factory certification and performance test reports; on-site sampling and retesting are required before they can be used. Ceramic pellets: They must come with a factory certification and test reports; upon arrival, further testing is required, and they can only be used if they pass these tests. Modified asphalt SBS (I) waterproofing material: It must come with a factory certification and test reports; upon arrival at the site, further testing is required, and it can only be used if it passes these tests. Roof cement tiles: They must come with a factory certification or quality inspection report. 5. Main construction methods and quality standards 5.1 Insulation layer 5.1.1 Process flow: Clean the base surface → Seal and fix the holes at the pipe roots → Lay polystyrene boards 5.1.2 Key points and precautions for construction: 5.1.2.1 Clean the roof of dust and debris before starting construction. 5.1.1.2 The roots of pipes passing through structural layers such as rooftops and wall surfaces should be filled tightly with pea gravel concrete (mixed with 3% micro-expansive agent) to secure them in place. 5.1.2.3 The insulation board should be placed closely against the surface of the base layer, and leveled and secured using dry-hard cement mortar. Control lines should be set during laying to ensure flatness; for sloped roofs, polymer mortar should be used to ensure a tight and secure fit. 5.1.2.4 Do not walk or use transport carts directly on the already laid insulation layer; a scaffold plank should be laid along the walking path. 5.1.2.5 After the insulation layer has been installed, a leveling layer should be applied promptly to reduce the risk of moisture absorption and water intrusion; especially during construction in the rainy season, measures such as covering should be taken immediately. 5.1.3 Quality Standards 5.1.3.1 Key Control Items 5.1.3.1.1 The apparent density and thermal conductivity of the insulation material, as well as the strength and water absorption rate of the panels, must meet the design requirements. 5.1.3.1.2 The moisture content of the insulation layer must meet the design requirements. 5.1.3.2 General requirements 5.1.3.2.1 The insulation layer should be laid closely against the base surface, smoothed out and secured firmly, with tight joints and proper grading. 5.1.3.2.2 The allowable deviation for the thickness of the insulation layer is ±5%, and it shall not exceed 4 mm. 5.2 Construction of slope formation and leveling layer 5.2.1 Process flow: Substrate treatment → Marking the slope → Wetting with water → Marking points and creating guides → Constructing the slope formation and leveling layer (polishing) → Curing → Filling joint gaps with sealant 5.2.2 Key points and precautions for construction 5.2.2.1 Before constructing the slope formation and leveling layer, it is necessary to remove any loose debris from the structural layer and insulation layer; any protruding hard objects on the substrate surface should be leveled and cleaned away. 5.2.2.2 For the slope layer between the leveling layers of a flat roof, use C15 fine aggregate concrete with a thickness of 30 mm at the thinnest sections, creating a 2% slope leading toward the drainage outlet ； The leveling layer for the pitched roof is 20 mm thick, made of 1:3 cement mortar ； The slope finishing and drainage layer for the inter-story slopes is CL7.5 ceramsite concrete ； Before applying the leveling layer, moisten the surface first and apply a coat of plain cement paste (for sloped roofs, it is required to use a textured cement paste). 5.2.2.3 Before constructing the slope layer, it is necessary to mark the slope lines on the side walls first, and then mark dots and create guides along those lines. 5.2.2.4 Joint gaps should be provided in the leveling layer, with a width of 20 mm ； The location of the partition joints should be at the ends of the slab, and the maximum spacing between vertical and horizontal joints must not exceed 6 m ； Sealing material should be filled in the partition joints. 5.2.2.5 The junctions and corners between the leveling layer and the structures that protrude from the roof should be made in an arc shape, with a radius of 50 mm; the areas where water drains off should be formed as slightly recessed pits. 5.2.2.6 After the leveling layer has been smoothed and compacted, it should be watered for curing at room temperature after 24 hours; the curing period is generally not less than 7 days. Once it is dry, the waterproofing layer can be applied.

It should be made clear which type of insulation it is

Insulation layer installation: 1. The installation of the insulation layer around the equipment should start from the support plates, working from bottom to top; the thickness of the insulation material must meet the design requirements, and the joints between sections must be sealed tightly. Each piece of insulating material must be securely tied down with at least two strands of 14# galvanized iron wire; the spacing between the wires should be even and consistent. When the insulating material consists of two or more layers, it should be tied up layer by layer. In the same layer, the joints should be offset; the upper and lower joints should be pressed together, and any holes should be filled tightly with filler material. 2. If there is no insulation support ring and welding is not permitted at the site, an insulated support ring with a detachable structure can be fabricated. V. Construction of the outer protective layer: Method: (Construction using composite aluminum silicate plaster material): 1. Wire mesh installation: When installing galvanized wire mesh, the two sections of mesh should be joined together; the mesh and the hooks must be secured firmly to ensure that it stays in close contact with the insulation layer. After completion of construction, there should be no exposed wire ends on the surface of the wire mesh, nor any bulges or voids. Generally, galvanized wire mesh with a diameter of 1.6 mm and a mesh size of 20 mm×20 mm is used. 2. Application of the plaster layer: The plaster layer should be applied in two stages; the second application should be carried out once the first layer has dried slightly ； For the first time, it is required to be smooth and tightly compressed; for the second time, it is required to be polished and smoothed. When a long period has passed since the previous construction, the existing plaster layer should be roughened up and lightly moistened with water before proceeding with further work. Depending on the degree of expansion, grid-shaped or circular expansion joints should be provided in the finishing layer, with a width of 5 to 10 mm being appropriate. The surface of the finishing layer should be smooth and even, with clean edges; its flatness should not exceed 3 mm/m. In a cold state, the surface must be free of cracks.

It’s of course the equipment – the construction plan for the insulation layer of the equipment.

Construction Plan for Anti-corrosion and Insulation of Equipment and Pipelines 1 Scope This technical standard applies to the insulation of pipes and equipment used for heating, domestic hot water, or steam, as well as to the anti-condensation insulation of water supply and drainage pipes. 2 Construction Preparation 2.1 Material Requirements: 2.1.1 The performance and specifications of the insulation materials must meet the design requirements, and they must come with certificates of conformity. Commonly used materials include: 2.1.1.1 Pre-fabricated tiles: such as foam concrete, perlite, vermiculite, and asbestos tiles. 2.1.1.2 Tubing and casing products: including rock wool, slag wool, glass wool, rigid polyurethane foam plastics, polystyrene foam plastic tubing and casings, etc. 2.1.1.3 Coiled materials: include polystyrene foam plastic, rock wool, etc. 2.1.1.4 Other materials: lead wire mesh, asbestos ash, or construction or bonding using the above pre-fabricated panels, etc. 2.1.2 The materials for the protective casing include hemp fiber, lime, or asbestos, cement, hemp fiber ； Glass fiber cloth, plastic sheeting, burlap soaked in asphalt, asphalt shingle, industrial cotton cloth, aluminum foil, iron sheeting, etc. 2.2 Main tools: 2.2.1 Tools: grinding saw, welding machine. 2.2.2 Tools: rebar, fabric scissors, hammer, chisel, hook, shovel, ash bucket, flat trowel, curved trowel. 2.2.3 Others: steel tape measures, steel pins, straightedges, wedge feelers, etc. 2.3 Operating conditions: 2.3.1 Insulation of pipes and equipment shall be carried out only after the anti-corrosion treatment and hydrostatic testing have been completed successfully. If insulation is to be applied first, the joints and welds of the pipes must be left unrecovered; insulation shall be applied to those joints only after the hydrostatic testing is successful. 2.3.2 For the ceilings of buildings and the pipes located in ductwork that require insulation, the civil work can be finalized only after the anti-corrosion pressure test is successful and the insulation work has passed its hidden inspection; it is strictly prohibited to carry out construction in the reverse order. 2.3.3 Before insulation, all debris inside the trench ducts must be removed. Debris left over from the construction process should be cleared at all times to ensure that the trenches remain unobstructed. 2.3.4 For plaster protective shells in wet work, anti-freezing measures shall be taken during winter construction. 3 Operating Procedures 3.1 Process Flow: 3.1.1 Prefabricated tiles: Disperse tiles → Cut galvanized steel wires → Mix with ash → Apply filler → Assemble tiles → Bind with steel wires → Fill gaps → Apply protective coating 3.1.2 Pipe and casing products: Disperse pipe and casing components → Assemble them → Wrap with a protective coating 3.1.3 Insulation wrapping: Cut materials → Wrap with insulating material → Apply a protective layer 3.1.4 Insulation for equipment and tanks using wire mesh and asbestos ash: Weld hooks → Apply oil → Bind with wire mesh → Apply asbestos ash → Apply a protective layer 3.2 The various prefabricated tiles are transported to the construction site; when laying them along the pipelines, it is necessary to ensure that their dimensions match those of the pipeline diameter. 3.3 When installing insulation tiles, 5–10 mm of asbestos plaster should be applied to the inner side of the tiles as a filler. The vertical joints of the bricks should overlap in a staggered manner, while the horizontal joints should face upward and downward. 3.4 For precast tiles, galvanized steel wires of size 18 to 20 are used for binding and securing them; the binding joints should not be too long, and these joints should be inserted into the tiles. 3.5 After the precast tiles have been tied together, the gaps should be filled with asbestos plaster, and the joints should be smoothed out. 3.6 An asbestos-cement protective coating (with a ratio of asbestos ash to cement of 3:7) shall be applied in a thickness specified by the design and then smoothed and compacted; if no specification is given in the design, the thickness shall be 10–15 mm. 3.7 When insulating vertical pipes, if the floor height is 5 m or less, one support tray should be provided per floor; if the floor height is greater than 5 m, at least 2 trays are required per floor. The support trays should be welded to the pipe wall, with their position located 200 mm above the pipe clamps. The diameter of the trays should not exceed the thickness of the insulation layer. 3.8 Insulation of pipeline accessories: Apart from flanges, valves, and other accessories that are exposed outdoors in cold regions or used indoors to prevent condensation, and which require insulation as per design specifications, ordinary flanges, valves, expansion joints, etc., should not be insulated. A gap of 70–80 mm should be left on both sides of these components, and a slope of 60°–70° should be created at the ends where insulation is applied. The ends of the insulation layers on the manholes, handholes, and removable components on the equipment container should be shaped as 45° slopes. 3.9 Expansion joints should be provided at the supports of insulated pipes, and these joints should be filled with asbestos rope or glass wool. 3.10 Pre-made tiles are used as insulation for pipes; on straight sections, an expansion joint with a gap of 5 mm should be provided every 5–7 meters. At bends, when the pipe diameter is 300 mm or less, an expansion joint with a gap of 20–30 mm should be installed. These expansion joints are filled with asbestos rope or glass wool, as shown in Figure 1-51. 3.11 When using tubular products as insulation, the operation is generally carried out by two people working together: one person splits the tubular section and wraps it around the tube, applying pressure with both hands, while the other person wraps the protective cover around it, making sure to apply even pressure, maintain a smooth seam, and keep the thickness consistent. When using unedge-sealed glass fiber cloth as the protective cover, the frayed edges must be folded so that they are not exposed. 3.12 For bulk insulation materials using wrap-type insulation (such as polyethylene foam plastic), a lap allowance should be left according to the pipe diameter; the material should be cut accordingly. To ensure a neat and aesthetically pleasing appearance, the lap should generally be placed on the inside of the pipe. Other requirements are the same as those in 3.11. 3.13 The pipeline insulation shall be protected by iron sheet, the longitudinal seams of which should face downward; the overlap length of the iron sheet is 30 mm for circular shapes. The structure of the metal protective layer at the elbow is shown in Figure 1-52. 3.14 Insulation for equipment and tanks generally involves large surfaces; commonly used methods include constructing foam concrete blocks or perlite blocks, followed by applying a protective layer made of plaster, lime, or cement. The insulation method using wire mesh and asbestos plaster involves welding hooks to the outside surface of the equipment to secure the insulation layer; the spacing between these hooks is generally 200–250 mm, their diameter is usually 6–10 mm, and their height matches the thickness of the insulation layer. The cut wire mesh is fixed to the hooks with wires, after which asbestos plaster is applied. The first layer should not be too thick, to prevent it from falling off due to poor adhesion. Once the first layer has gained sufficient strength, further layers can be applied until the desired thickness is achieved. Once the insulation layer is completed and has gained sufficient strength, apply the protective cover, making sure to smooth it out evenly. 4 Quality Standards 4.1 Assurance items: The strength, bulk density, thermal conductivity, specifications of the insulation material, as well as the methods of insulation application, shall meet the requirements of the design and the provisions of the construction specifications. Inspection method: Check the factory certification and instructions for the insulation material. 4.2 Basic requirements: The surface of the insulation layer should be smooth, the installation method correct, the overlaps proper, and the seals tight, with no bulging or loosening. Inspection method: Visual inspection. 4.3 Allowable deviation items: The allowable deviation items are shown in Table 1-42. Allowable deviations for insulation layers: Table 1-42. Item, Allowable deviation (mm), Inspection method: +0.1, -0.05. For rolled or sheet materials: 5; for coatings or other methods: 10. 5.1 For the insulation of pipes and equipment, it is necessary to ensure that the trenches and pipe shafts have been cleaned first. Insulation can be applied only if there is no risk that subsequent work will damage the insulation layer. 5.2 Generally, pipe insulation work should be carried out only after the hydraulic test is successful and anti-corrosion treatment has been completed; the sequence of operations must not be reversed. 5.3 Insulation materials shall not be exposed to rain or stored in humid areas upon arrival at the site. 5.4 The debris remaining after insulation should be cleaned up by the construction team responsible for the work. 5.5 Insulation for exposed pipes: if grouting is carried out after civil work, measures should be taken to prevent contamination of the insulation layer. 5.6 In case of special circumstances that require the removal of the insulation layer for pipe work or if the insulation layer is damaged during construction by other trades, it must be repaired promptly in accordance with the original requirements. 6 Quality issues that require attention 6.1 Improper use of insulation materials, lack of clear instructions, and unclear practices. One should be familiar with the drawings and understand the design requirements; it is not allowed to modify the insulation methods without permission, and construction must be carried out strictly in accordance with the design specifications. 6.2 The thickness of the insulation layer is not constructed in accordance with the design requirements. Construction is mainly carried out based on experience, with a limited understanding of the requirements regarding insulation. 6.3 The surface is rough and unsightly. It’s mainly due to careless handling and lax requirements. 6.4 Hollow drums and loose, imperfect fit. The main reasons are that the size of the insulation material is inappropriate, the force applied during wrapping is uneven, and the overlapping positions are not proper. 7 Quality records required 7.1 Insulation materials and associated materials shall come with factory certification of conformity. 7.2 There should be acceptance records upon entry, and its performance and specifications shall meet the design requirements. 7.3 Before insulation, the pipelines and equipment shall have records of concealed inspection and acceptance. 7.4 There should be acceptance records after the insulation work is completed.

The insulation material for pressure vessels is selected based on temperature, with a thickness of generally 50–100 mm