06.

2015

Technical insulation
 CONTENTS
5 About Us .............................................. 3
Features of ROCKWOOL materials ........ 4
Technical and industrial insulation .... 5
Materials for technical insulation ..........5
Wound pipe sections ROCKWOOL 100 ........6
3
Wound pipe sections ROCKWOOL 150 .... 7
WIRED MAT 50, WIRED MAT 80
and WIRED MAT 105 ............................ 8
3
TECH MAT ........................................... 9
TECH BATTS ...................................... 10
4
4 LAMELLA MAT, LAMELLA MAT L....... 11
KLIMAFIX........................................... 12
INDUSTRIAL BATTS 80 ...................... 14
FIRE BATTS 110 ................................. 15
General transport and storage
requirements..................................... 16
ROCKFIRE - re protection solutions.... 17
Fire protection of ducts .................... 18
Fire protection of steel bearing
structures .......................................... 20
Fire protection of round steel column ...24
1000 Fire protection of the bearing metal
structures with CONLIT M paint ........ 25

Fire protection of oor slabs of

reinforced concrete ........................... 26
Fire protection of pipe
500

penetrations ..................................... 28
Fire protection of cable penetration ... 29

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

About Us

ROCKWOOL Group has over seventy years of experience in

thermal insulation manufacturing. The company's products
are valued worldwide for the high quality and wide selection of
material.
Zheleznodorozhny.
The company was established in 1909 in Denmark. The rst Moscow region
ROCKWOOL plant producing the basalt mineral wool began
to operate in 1937 in Hedehusene. Today the company has 28
plants in 18 countries.

ROCKWOOL operates in Russia for several decades now. Back

in 1970s, ROCKWOOL's European plants started to export the Vyborg,
products to the USSR for ship building industry. In 1995, the Leningrad region
company opened a sales ofce in Moscow. In 1999, ROCK-
WOOL acquired its rst plant in Russia located in Zhelezno-
dorozhny and modernised it to match the international stand-
ards of the Group.

To date ROCKWOOL has four enterprises in Russia, including Troitsk,

the plants in Moscow, Leningrad and Cheliabinsk regions, as Cheliabinsk region

well as the plant in Alabuga special economic area in Tatar-

stan, which has the production line with the highest capacity in
Russia, launched in early 2012.

ROCKWOOL Group includes a ROCKFON division, which Alabuga special economic

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

From lava to insulation low thermal conductivity

The key material for production of ROCKWOOL re-safe insu- re-safe
lation is basalt mineral. The production process starts from soundproof
melting the volcanic rock at +1500 . The melted rock is then water-repellent
spun into bres with addition of binders and water-repellent and vapour-permeable
components. Features of ROCKWOOL stone wool products: fatigueproof
sustainable.
chemical
and bio resistance

3
Features of ROCKWOOL materials

Low thermal conductivity

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

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

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

Water-repellent and vapour-permeable

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

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

Sustainable
ROCKWOOL stone wool is a natural sustainable material pro-
duced from gabbro-basalt minerals. ROCKWOOL thermal insu-
lation was the rst product in Russia to complete a voluntary
environment certication having obtained an EcoMaterialGreen
label, which conrms that the material is safe for people and
the environment.
Chemically resistant
The stone wools are chemically inert to oils, solvents and alkali.
Bioproof
The stone wool is inedible for rodents and insects and does not
facilitate the growth of fungi, moulds and bacteria.

4
Technical and industrial insulation
To ensure the successful economic development,
it is necessary to use the electricity and energy
resources sustainably. The utilisation of techni-
cal and industrial insulation is crucial for energy
efciency.
The heating and water supply systems represent
one of the elds, where both energy saving and
technical aspects of the technological processes
will always be relevant. These objectives can be
achieved by applying the efcient insulation..
Insulation is essential for the ventilation and air
conditioning systems. It has three key functions:
thermal insulation, sound- and reproong.
The modern industrial production always requires
Materials for technical insulation
The thermal insulation materials for technical use may be
conditionally divided into network and process segment of ap-
plication, where the former includes HVAC networks (heating,
ventilation, air conditioning) and water supply. In case of the
process application, the thermal insulation is used to maintain
the preset parameters of substances involved in the produc-
tion cycle, as well as to keep the temperature of equipment and
pipelines in a safe range for the employees.
Table 1. Materials included in the main segments
HVAC application
Wound pipe sections ROCKWOOL 100
WIRED MAT 105
WIRED MAT 80
CH (light technical mat)
KLIMAFIX self-adhesive mat
LAMELLA MAT
INDUSTRIAL BATTS 80 noise reduction slabs
* These products do not have the alufoil covering.
substantial use of energy. With the utilisation of
appropriate insulation, the issue of energy con-
sumption becomes more practical. Furthermore,
it is important to keep the equipment surface free
of condensate, which can cause the corrosion.
Many technological processes require the high-
temperature equipment. Therefore, the insulation
must also ensure the operational safety.
ROCKWOOL offers a wide selection of the ef-
cient insulation materials, which can meet all
these objectives.
The HVAC technical insulation typically includes the materials
for thermal insulation of ducts and pipes, i.e. the prefabricated
hard cylinders or exible mats. The process segment can uti-
lise the mats and cylinders too, but they require larger density
due to the higher process temperatures. Also, the various soft
and rigid slabs can be used for insulation of large-diameter
reservoirs, at surfaces of furnaces and equipment units.
The materials can be conditionally divided as follows:
Process application
Wound pipes section ROCKWOOL 150
CH BATTS 50, 75, 100, 125, 150 slabs
FIRE BATTS slabs
WIRED MAT 50
5
Wound pipe sections ROCKWOOL 100
Product description
The wound pipe sections ROCKWOOL 100 are hydrophobic pre-
formed stone wool insulation product with synthetic binder. The
cylinders are 1 m long and hollow.
They can also be covered with alufoil. The wound pipe sections
ROCKWOOL 100 have a lengthsize section on one side and a
corresponding internal cut on the opposite side for easy instal-
lation on a pipeline. The plane of section and cut lines crosses
the axis of cylinder.
The specication name consists of a trademark, index of cover-
ing, size (internal diameter, insulation thickness) and production
specication number. The specication name of a wound pipe sec-
tions ROCKWOOL 100 covered with reinforced alufoil with 45 mm
internal diameter and 40 mm insulation thickness: ROCKWOOL
100 wound pipe section, ALU, 45*40 5762-050-45757203-15.

Application
ROCKWOOL 100 wound pipe section provides outstanding per-
formance for thermal insulation and sound attenuation for
steel pipework operating at temperatures to +650C.
ROCKWOOL 100 wound pipe section, ALU is suitable for ther-
mal insulation of pipework and equipment in heating, ventila-
tion and air condition systems.
Thermal conductivity values for ROCKWOOL
100 wound pipe sections
Installation
The pipe sections shall be installed tightly to each other
with misalignment of horizontal seams and secured on
the pipe with 20 mm wide steel banding (0.7 to 0.8 mm
galvanised or corrosion-resistant steel) or a wire with
1.2-2.0 mm gauge.
It is reco mmended to install at least two bandings per one
cylinder at up to 500 mm interval.
If using the foil-covered pipe sections, a self-adhesive alumini-
um tape shall be applied on longitudinal and transversal joints.
In case of exterior piping or if necessary, a protective cover
(jacket) can be mounted on the pipe sections
Where the pipe sections are applied as insulation on vertical
pipelines, the off-loading structures (support rings) shall be
installed at a 3-4m pitch to secure the protective cover and
prevent the insulation from sliding down.
If using the pipe sections for piping insulation with the pur-
pose of preventing the condensation, it is required to apply
a vapour insulation layer with airtight joints.

Calculated thermal conductivity for different temperatures:

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

Table 2. Product properties

Parameter Units
25 50 100 150 200 250 300 350
Thermal conductivity, W/m*
0.036 0,040 0,046 0,054 0,064 0,077 0,092 0,111

Maximum service temperature +650

Wound pipe sections ROCKWOOL 100 0 (Non-combustible)

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

Density kg/m3 114

6
Wound pipe sections ROCKWOOL 150
Product description
The wound pipe sections ROCKWOOL 150 are hydrophobic pre-
formed stone wool insulation product with synthetic binder. The
cylinders are 1m long and hollow.
The wound pipe sections ROCKWOOL 150 have a lengthsize
section on one side and a corresponding internal cut on the op-
posite side for easy installation on a pipeline. The plane of sec-
tion and cut lines crosses the axis of cylinder.
The specication name consists of a trademark, size (internal di-
ameter, insulation thickness) and production specication number.
The specication name of a wound pipe sections ROCKWOOL
150 with 245 mm internal diameter and 90 mm insulation thick-
ness: ROCKWOOL 150 wound pipe section, 245*90 5762-050-
45757203-15.
Application
ROCKWOOL 150 wound pipe section provides outstanding per-
formance for thermal insulation and sound attenuation for
steel pipework operating at temperatures to +680C.
Thermal conductivity values for ROCKWOOL
150 wound pipe section
Calculated thermal conductivity for different temperatures: = 31.63 +
1.144 10-1 T + 1.165 10-4 T2 + 2.66 10-7 T3 (mW/m*K), T being
the temperature of the middle insulation layer.
Table 3. Product properties
Parameter
25 50 100
Thermal conductivity, W/m*
0.037 0,040 0,046
Maximum service temperature
Reaction to re
Density kg/m3
Installation
The pipe sections shall be installed tightly to each other with mis-
alignment of horizontal seams and secured on the pipe with band-
ing or a haywire. It is reco mmended to install at least two bandings
per one cylinder at up to 500 mm interval.
If necessary, a protective cover (jacket) can be mounted on the pipe
sections.
Where the pipe sections are applied as insulation on vertical pipe-
lines, the off-loading structures (support rings) shall be installed at
a 3-4m pitch to secure the protective cover and prevent the insula-
tion from sliding down.
If insulating the high-temperature pipelines, the double layer of
wound pipe sections ROCKWOOL 150 can be installed. In such case
it is required to maintain the misalignment of horizontal seams on
the external and internal layer of insulation.
The pipe sections are reco mmended as thermal insulation layer
for anges and anged ttings in thermal insulation structures.
The pipe sections can be used as an insert for prefabricated or
assembled constructions designed for insulation of anges or
anged ttings. The pipe sections may be attached to the surface
with forelocks.
The edges of pipe sections insulation for anges are covered with
screens made of protective material.
If insulating the elbow, the pipe section is cut into several parts. The
angle of cutting and number of parts shall be determined on site.
Units
150 200 250 300 350
0,053 0,062 0,073 0,085 0,099
+680
0 (Non-combustible)
145
7
WIRED MAT 50, WIRED MAT 80
and WIRED MAT 105
Description Application
Mats are produced of stone wool and supplied in rolls. WIRED The wired mat is especially suitable for industrial installations
MATS are stitched on galvanised wired mesh with galvanised wire such as high-pressure steam pipes, reactors, furnaces, etc.
without covering or covered with usual or reinforced foil under T where high demands are made on the temperature resistance
5762-050-45757203-15. of the insulation.

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

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

WIRED MAT 50 (Non-
Wired mat not covered with alufoil
combustible -0)
WIRED MAT 80 (Non-
Wired mat not covered with alufoil
combustible -0)
WIRED MAT 105 (Non-
Wired mat not covered with alufoil
combustible -0
Wired mat covered with the reinforced alufoil
ALU WIRED MAT 80 (1)
on one side
ALU WIRED MAT 105 Wired mat covered with the reinforced alufoil
(1) on one side
ALU1 WIRED MAT 80 Wired mat covered with the non-reinforced
(Non-combustible -0) alufoil on one side
ALU1 WIRED MAT 105 Wired mat covered with the non-reinforced
(Non-combustible -0) alufoil on one side

Table 5. Product properties

Value
Parameter Units
WIRED MAT 50 WIRED MAT 80 WIRED MAT 105

10, W/m* 0.034 0.033 0.034

25, W/m* 0.036 0.035 0.036

50, W/m* - 0.039

100, W/m* - 0.045

125, W/m* 0,057 - -

150, W/m* - 0.053 0.052

200, W/m* - 0.062 0.059

Thermal conductivity
250, W/m* - 0.072 0.068

300, W/m* 0,115 0.087 0.078

350, W/m* - 0.099 0.089

400, W/m* - 0.115 0.102

500, W/m* - 0.153 0.131

600, W/m* - 0.198

640, W/m* - 0.220

Application temperature -180 to +650 -180 to +750 -180 to +750

Density kg/m3 50 80 105

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

8
TECH MAT
Insulation of pipework:

3 1

Description 1 TECH MAT;

Mats are produced of stone wool and supplied in rolls. Mats can 2 jacket support structure;
be produced without covering or covered on one side with alufoil. 3 pipeline;
4 binding wire;
Application 5 protective jacket.
These mats ere suitable for thermal insulation of storage
tanks, chimneys, pipelines, gas and air ducts, industrial equip-
ment and power plants

Table 6. Product properties

Parameter Units Value
10, W/m* 0.034

25, W/m* 0.036

Thermal conductivity
125, W/m* 0.060

300, W/m* 0.120

Maximum service temperature +570

No covering 0 (Non-combustible)
Reaction to re
Alufoil covering 1
Density kg/m3 43

9
TECH BATTS
Table 7. Application of TECH BATTS
Description
Non load thermal insulation of horizontal and curved
Mats are produced of stone wool and supplied in rolls. Mats can TECH BATTS 50 surfaces (cylindrical, cone, etc.) surfaces of storage tanks,
be produced without covering or covered on one side with alufoil. equipment and ducts.
Thermal insulation of walls of storage tanks, horizontal,
TECH BATTS 75
vertical and inclined surfaces of equipment.
Application Thermal insulation of roofs of storage tanks,
These mats ere suitable for thermal insulation of storage TECH BATTS 100 technological equipment, heat exchangers, rectangular
tanks, chimneys, pipelines, gas and air ducts, industrial equip- gas ducts.
Thermal insulation of industrial equipment and power
ment and power plants. TECH BATTS 125 plants. Thermal insulation and soundproong of internal
surfaces of ventilation chambers and channels.
Insulation of storage tank: Thermal insulation of industrial equipment and power
plants. Additional insulation (second layer) of industrial
TECH BATTS 150
furnaces, steam boilers and other heat-generating
equipment, chimneys.

1 storage tank wall;

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

4
Installation
The slabs can be mounted on welded pins or installed between
the guides (TECH BATTS 50 and 75). The fastening method de-
pends on the type of insulated structure.

Table 8. Product properties

Value
Parameter Units
TECH BATTS 50 TECH BATTS 75 TECH BATTS 100 TECH BATTS 125 TECH BATTS 150

10, W/m* 0.036 0.035 0.035 0.036 0.037

25, W/m* 0.038 0.037 0.037 0.038 0.039

Thermal conductivity
125, W/m* 0.054 0.053 0.051 0.050 0.051

300, W/m* - - 0.081 0.079 0.077

Application temperature -180 to +450 -180 to +550 -180 to +665 -180 to +700 -180 to +750
No covering 0 (Non-combustible)
Reaction to re
Alufoil covering 1 (G1, V1, D1, 1)

Density 3 40 60 90 110 140

kg/m

10
LAMELLA MAT, LAMELLA MAT L
Description
LAMELLA MAT mats consist of lamellas of ROCKWOOL stone
wool, which are glued to the base (foil). The mats are dura-
ble and resilient, so they do not lose shape when mounted on
curves and angles.

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

Table 10. Product properties Installation

LAMELLA MAT mats are secured on the pipes with a buckle
Parameter Units Value banding or fastening wire. If installed on the ducts, the mats are
0.040
attached with the self-adhesive pins and secured with wash-
25, W/m*
Thermal conductivity ers. The joints between the mats are insulated with the self-
125, W/m* 0.068 adhesive aluminium tape.
up to +250
(temperature of foil
Application temperature
covered surface up to
+80)

Reaction to re 1 (G1, V1, D1, T1)

Density at up to 60 mm
thickness kg/m3 65

Density at over 60 mm
thickness kg/m3 60

Density of LAMELLA MAT L kg/m3 40

11
KLIMAFIX

Description Table 9. Product properties

The self-adhesive lamella mats of ROCKWOOL stone wool cov-
ered on one side with the reinforced alufoil. The bres of the Parameter Units Value
mats are located transverse to the duct surface, so the mats are Thermal conductivity 0.042
10, W/m*
durable and resilient and do not lose the original thickness when
Reaction to re 1 (G1, V1, D1, T1)
installed on curves and angles. KLIMAFI lamella mats have a
3
factory applied adhesive coat across the whole surface on the Density kg/m 36
wool side. The adhesive coating has a protective lm, which can
Maximum service temperature 50
be easily removed prior to installation.
Installation temperature +5 to +35
Application
Entire sulphur content, up to % 0.4
KLIMAFIX mats serve for thermal insulation and soundproof-
ing, prevent condensation on surfaces of the rectangular and
round ventilation facilities and air conditioning systems. These
mats will be a perfect choice for applications that require not
only insulation, but quick installation and aesthetic appearance.

12
Installation
The adhesive coat does not lose its properties over time. Com-
pared to the traditional lamella mats, KLIMAFIX products can
be installed up to 40% faster, since they do not require any
welded studs, pins, wires or steel bandings.
All the surfaces must be dried, cleaned and degreased prior
to installation. The optimal ambient temperature is 5 to 35 .
The mats are installed in stages:
a
Cut a necessary piece of mat and remove 10cm of protective
lm towards the direction corresponding to the mat structure.
Firmly press the mat against the whole surface of duct and
smooth out the mat moving from the centre to the edges.
Note that it is impossible to adjust the mat after is has been
attached.
Finally, bind together all the longitudal and transversal
joints of KLIMAFIX mat using at least 50 mm wide self-ad-
hesive aluminium tape.
If the rated thickness of a product equals or exceeds 50 mm,
and in case the installation proceeds amid high humidity, the
mats shall be mounted mechanically like the regular lamella
mats. In this case, the adhesive coat serves as additional fas- b
tening.

13
INDUSTRIAL BATTS 80
Description
The stone wool slabs with glass tissue on one side.

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

Table 11. Product properties

Parameter Units Value

Thermal conductivity 10, W/m* 0.036

Reaction to re 1 (G1, V1, D1, T1)

Density kg/m3 80

Application temperature -180 to +250

Organic substances by weight % <4.0

1
3

2
Table 12. Bafing performance of 35 mm thick INDUSTRIAL BATTS
80 installed inside the ducts, dB
1000 Hz

2000 Hz

4000 Hz

8000 Hz
250 Hz

500 Hz
125Hz
63 Hz

Duct section, mm

300 150 6 6 9 27 41 40 38 35
2
400 200 4 5 9 26 34 36 29 26
500 250 - 5 9 26 34 36 29 26 4
5

500 300 2 4 4 20 29 30 17 14

1 2
500 350 2 3 18 25 27 16 13

500 400 - 2 2 14 24 18 16 13

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

3
2

14
FIRE BATTS 110
Description Table 13. Product properties
The slabs made of stone wool. They can be produced without cov-
ering or covered on one side with alufoil (ALU FIRE BATTS 110). Parameter Units Value
25, W/m* 0.041
Application Thermal conductivity 0.054
125, W/m*
The slabs serve for thermal insulation of at surfaces of re-
300, W/m* 0.088
places.
No covering 0 (Non-combustible)
Reaction to re
Alufoil covering 1 (G1, V1, D1, 1)

Density kg/m3 100

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

Fireplace structural sketch: Insulation of boiler walls:

2
1
5

4
1 6
7
8
2
3

4
3

1 chimney 1 boiler wall

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

15
General transport and storage requirements
Transporting
ROCKWOOL products shall be transported with minimum
transfer handling.
The products must be protected from weather impact, mechan-
ical damage and moving around the vehicle.
The loading space of a vehicle must be dry, clean, free of mechanical
damage, sharp edges and curves, which may damage the products.
If ROCKWOOL items are transported together with other materi-
als, they shall be kept away from each other to avoid damaging.
The pipe sections can be transported by all types of tented vehicles
in compliance with haulage rules for each type; the pipe sections
must be protected from moisture and damage. The pipe sections
with 20, 25, 30 and 40 mm thickness and the internal diameter that
equals or exceeds 76 mm shall be transported vertically. Other
cylinders can be transported horizontally or vertically.
Packing
Most ROCKWOOL stone wool products are wrapped in poly-
ethylene shrink lm according to a packing list for this type of
product (tables 21-23).
16
Storage and handling
The products must be stored in original packaging and sorted
by type and size.
If stored outdoors, the products shall be placed above the
ground and covered with a waterproof material.
The slabs, mats and cylinders must be stored indoors or out-
doors under a tent protecting from atmospheric precipitation;
the products shall be packed and sorted by size and type. The
slabs and mats are stored horizontally, and the cylinders with
20, 25, 30 and 40 mm walls and the internal diameter that
equals or exceeds 76 mm shall be stored vertically. Other cyl-
inders can be stored horizontally or vertically.
Installation
Since the thermal insulation is used for different types of equip-
ment, pipelines and ducts, the installation method depends on
geometrical dimensions of the insulated structure and the way
it is covered.
ROCKFIRE - fire protection solutions
In Russia, the re safety requirements are stipulated mainly by
the Federal Law No. 123-FZ "Technical Rules of Fire Safety". In
accordance with this classication, there are certain require-
ments in terms of re resistance rating of constructions (not
the individual materials).
Fire resistance rating describes the time in minutes after which
a construction reaches one of the critical states indicated with
letters. "R" means loss of bearing ability (collapse or critical
sagging), "E" stands for loss of integrity (cracks, holes), "I"
means loss of thermal insulation ability (heating of surface
from a non-heated side), etc.
Different constructions have different requirements in terms
of limit states and times before they occur. The coverings are
tested for loss of integrity and bearing ability (RE), the columns
and joists only for loss of bearing ability (R), the internal walls
EI, the oor decks REI.
The re resistance rating of a construction is conrmed by a
certicate of an accredited laboratory after the re resistance
tests. The construction is built for testing in compliance with
the approved technical rules and using only the materials spec-
ied there. The construction undergoes testing with the load
corresponding to real operating conditions.
The issued re resistance certicate is valid only if the con-
struction is built in full compliance with the technical rules us-
ing the materials specied in the certicate.
If one or more materials are replaced or the building procedure
is not followed, the construction shall be tested again.
ROCKFIRE system offers solutions for reproong of:
ducts
steel bearing structures
oor slabs of reinforced concrete
cable line and pipeline passes
17
Fire protection of ducts
The ducts are reproofed with WIRED MAT 105 made of Required materials and tools
ROCKWOOL stone wool. Depending on thickness, this resafe WIRED MAT 105 stone wool mats
material ensures re resistance rating from 60 to 240 minutes. welded pins
WIRED MAT is a exible mat of stone wool wired with the fastening washers
galvanised wire and covered on one side with 25 mm galvanised self-adhesive aluminium tape (if using WIRED MAT 105 with
wire mesh. WIRED MAT can be manufactured with non- alufoil covering)
reinforced alufoil covering. tin snips
The product is used for reproong of rectangular and round wire
ducts with at least 0.8 mm metal thickness. metal hook for wire bundling
equipment for welding of pins.

Table 14. General identication of WIRED MAT resafe materials

depending on covering Table 15. Fire resistance rating of a duct with ALU1 WIRED MAT
105 insulation
WIRED MAT 105 Wired mat not covered with alufoil
WIRED MAT 105 thickness,
Wired mat covered with the non-reinforced Fire resistance rating, min
ALU1 WIRED MAT 105
alufoil on one side
mm
25 EI60
* These products do not have the alufoil covering.
30 EI90

40 EI120

Specication sample 50 EI150

WIRED MAT 105 with mesh and galvanised steel wiring, covered 60 EI180
with non-reinforced alufoil ALU1 of 6 000 mm long, 1 000 mm
70 EI240
wide and 25 mm thick: ALU1 WIRED MAT 105 6000 100 25;
T 5762-050-45757203-15.

Pins and washers Installation

Welded copper-plated steel pins CT/WP2 2 mm in diameter.
For transformer welders (Clim PW-33 etc.). Used together
with steel washers PW2/CS. Length 19 to 114 mm.
Welded copper-plated steel pins CD/WP2 2 mm in diameter.
For condenser welders (Clim DW-45, HBS CD 1501 etc.). Used
together with steel washers PW2/CS. Length 20 to 100 mm.
Steel washers PW2/CS. Used together with copper-plated
steel pins CT/WP2 and CD/WP2. External diameter 38 mm.
Welded elements CD/PWP2.7 consisting of 2.7 mm copper-
plated steel pin and 30 mm steel washer. The pin base near
washer has extra insulation for fastening the materials with
alufoil covering. Length 25 to 100 mm.
(Presented for your information based on Technical Rules No.
10-07-14)
1. Prepare the duct body. Fix the damaged geometry of body,
clean the surface, seal the ange joints of duct.
2. Do the pattern cutting of mats. The mats shall be cut to a
size that will allow to cover the whole area of duct. The mats
may be overlapped with further sealing of mat joints.
3. Secure the resafe material in one of the ways.

18
Method 1. Fastening through covering
The duct is wrapped with WIRED MAT mats, which are fastened
directly through the covering. The fasteners for this method are
the combined pins CDF and CDF-ISOL or CD/PWP 2,7 (pin with
the installed washer).

Method 2. Fastening with welded pins

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

Method 3. Fastening with banding

Bading is a galvanised metal tape, which is 0.8-2 mm thick and 15-
20 mm wide and manufactured according to GOST 356073 stand-
ard. Installed at a pitch of 500 mm along the length of the duct.
Methods 1 and 2 require the interval up to 350 mm and no more
than 100 mm distance from the duct edge to the rst row of pins.
Thus, around 9 fasteners will be required per 1 m2.
Bent pins are not allowed; make sure the pins are not bent while
installing the mat.
The mats shall be mounted to cover the ange joints and cross
frames.
The duct hangers shall be insulated with the same resafe mate-
rial, which is fastened with the galvanised wire.
If using the material covered with alufoil, the aluminium adhesive
tape must be applied on the mat joints.

19
Fire protection of steel bearing structures
The steel bearing structures are fireproofed with CONLIT SL 150 slabs
attached using the silicate heat-resistant glue CONLIT GLUE

Table 16. Product properties Table 18. Properties of CONLIT GLUE

Parameter Units Value Parameter Units Value

10, W/m* 0.037 Acidity, up to pH 12
Thermal conductivity
Consumption 2 0.7-1.0
25, W/m* 0.039 kg/m

Reaction to re 0 (Non-combustible) Bond properties when used

on metal (72 hours after MPa 0.3
Density kg/m3 165 application), at leas

Compression strength at 10% Curing time h 12

kPa 25
deformation, at least
Water absorption at short or Temperature of application,
+5
partial i mmersion, up to kg/m2 1.0 at least

CONLIT GLUE
Table 17. Thickness of CONLIT SL 150 against the re resistance CONLIT GLUE is a modied heat-resistant silicate glue used
rating and the effective thickness of metal to attach the CONLIT SL 150 slabs to each other and to the
surfaces of steel structures.
30 CONLIT GLUE can handle up to 900 .
12 11,9

40 Specication sample
11
11,0 CONLIT SL 150 slabs of 1 000 mm long, 600 mm wide and 50
25 50 mm thick: CONLIT SL 150 1000.600.50 T 5762-050-45757203-
15.
10,0
10
25
9,3
60
9,3
Packing
9
CONLIT slabs are wrapped in polyethylene shrink lm or
25 30 70
8,6 8,6 supplied on pallets. CONLIT GLUE is supplied in 20kg buckets.
40
The effective thickness of metal is a ratio between the cross
25 80
8 7,9 area of the construction and the heated perimeter. For instance,
7,7
7,6

50
when calculating the reproof material thickness for a column
30 90
25
7,0 7,0
made of double-T beam, the cross area of metal in mm2 must
7 25 25 25 6,9

40 60
be divided by the heated perimeter of four sides (three sides
6,4 6,4
100
6,3 for beams). If CONLIT SL 150 slabs are installed in casing, the
6,0
6
50 70 perimeter will equal the perimeter of the square drawn around
30 5,5 5,5 the double-T beam. If the slabs are installed along the outline,
5,4

40 60 80 the perimeter of double-T beam must be considered.

5 4,9
4,8 4,8
The installation in casing is always more efcient (faster and
4,3 50 70 90 easier) and allows to reduce the reproof material thickness
4,2
4,1
4 30 4,0 owing to the smaller heated perimeter.
3,8 100
60 80 3,6 The nomographic chart of CONLIT SL 150 layer thickness
40 3,3
3,2 3,2 against the effective thickness of metal and the required re
3
50 70 90 resistance rating is based on the critical heating of metal to 500
2,6
2,5 2,5
2,4 , when the bearing ability of metal drops.
30 60 80 100
2
15 30 45 60 90 120 150 180 240
Required materials and tools
CONLIT SL 150 stone wool slabs
CONLIT GLUE
measuring tape
putty knife
nails
knife for pattern cutting of slabs

20
Installation
(Presented for your information based on Technical Rules No. 11-07)

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

2. Preparation of silicate glue

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

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

4.Installation of the reproof set in the case of

steel double-T beam (reproong on three sides)

21
 Apply at least 2 mm of CONLIT GLUE on the edges of the
prepared inserts, which will contact the structure elements.
Brace the inserts between the anges of double-T beam.
They must overlap the anges a little. The maximum
distance between the inserts is 600 mm.
Let the glue cure for 12 hours.
Apply at least 2 mm of CONLIT GLUE on the facing side of
the attached inserts from one side of the double-T beam.
Nail the prepared pieces of main reproong to the inserts.
The nails secure the material for the time of glue curing.
Two to three nails are required per one insert.

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

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

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

heads with CONLIT GLUE.
Giving the aesthetic appearance to the metal
structures
The structures with CONLIT SL 150 reproong can be plas-
tered over breglass mesh:

1. Prepare the reinforcing cementitious plaster.

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

23
Fire protection of round steel column

Round column is one of the typical bearing structures. It is

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

Fire protection efciency

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

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

24
Fire protection of the bearing metal
structures with CONLIT M paint
ROCKWOOL designed CONLIT M paint to improve the re re-
sistance rating of couplings, trusses and elements with com-
plex geometry.
-121 CONLIT M is a one-component bloating mixture based
on solvent. If exposed to over 250 , the paint bloats and forms
a carbon substance, which has good thermal insulation proper-
ties and protects the material from heating.

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

Application
(Presented for your information based on Technical Rules No. 11-08)
Make sure that the steel structures are dry and free of dust,
mud, grease, oil and rust.
Apply the corrosion-resistant primer GF-021. The dry layer thick-
ness of the corrosion-resistant coat shall be at least 0.05 mm.
Wait for at least 24 hours after priming. The time depends on
ambient temperature.
The surface temperature of the steel structures prepared for
application of the reproof mixture must be at least 3 higher
than the dew point.
Prior to operation, let the CONLIT M paint stand for at least 20 hours
at 15-20 and then mix well for 5-10 minutes using a mixer or a
drill with agitator to give the working viscosity to the paint.
Apply CONLIT M on the prepared steel surface using a brush, a roll-
er or airless sprayer. The application method is determined based
on the surface area.
The mixture shall be applied in 2-3 layers with interim dry-
ing for at least 1 hour at 20 and 60% relative humidity.
Before applying the next layer, make sure that the previous
one is dry enough to not stick. The drying time may increase
2-3 times at up to -25 and 80% relative humidity. The
painting can be done at the temperatures from -25 to
+35 . The steel structures must be free of moisture (wa-
ter, dew, glacier, frost).
The paint coat requires about 96 hours to gain the service proper-
ties. The nal formation of the coat takes at least ve days (at over
15 and up to 80% humidity) or up to 15 days (at under 15 and
up to 80% humidity).
The thickness of wet coating at airless spraying shall not ex-
ceed 0.8 mm per one layer; if using brush or roller 0.9 mm
per one layer. If thicker coating is required, the mixture shall be
applied in several layers.
The consumption of CONLIT M is 1.53 kg/m2 exclusive of process
losses, which depend on the application method, properties of the
coated structure and working conditions.
If used on the surfaces exposed to weather impact, it is required
to apply a top protective coating based on copolymer acrylic, alkyd,
epoxide, polyurethane and other resins.

25
Fire protection of floor slabs of reinforced
concrete
The oor slabs of reinforced concrete are reproofed from the Table 19. Product properties
bottom with ROCKWOOL FT BARRIER slabs and FT BARRIER D
double density slabs. Value
Parameter Units
The slabs have the reproong and thermal insulating proper- FT BARRIER D FT BARRIER
ties and are installed using the steel dish-shaped elements.
10, W/m* 0.034 0.036
Thermal conductivity
25, W/m* 0.036 0.038

Reaction to re 0 (Non-combustible)
Fireproong efciency Upper layer 30
With 30 mm thick FT BARRIER slabs the oor slabs of re- Density kg/m3 mm 100, lower 110
layer 50
inforced concrete (at least 30 mm concrete layer before
Organics content by
the reinforcement) receive the re resistance rating (REI) weight, up to
% 3.2 3.2
of at least 150. Water absorption
With 80 mm thick FT BARRIER D slabs the oor slabs of at short or partial i kg/m2 1.0 1.0
mmersion, up to
reinforced concrete (at least 30 mm concrete layer before
the reinforcement) receive the re resistance rating (REI)
of at least 240.
With 80 mm thick FT BARRIER D slabs installed on the
oor slab with external reinforcement by polymer com-
pounds FibARM (STO 2256-002-2011, Rev. 1-3), the struc-
ture receives the re resistance rating (REI) of at least 120.

Required materials and tools

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

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

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

Storage of steel anchors

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

26
Installation
(Presented for your information based on Technical Rules No.
01-11-13 for FT BARRIER slabs and No. 01-12-14 for FT BAR-
RIER D slabs)

For convenient installation, the facing surface (dense protec-

tive layer) of FT BARRIER D double density slabs is marked
with two dark strips.

1. Apply an FT BARRIER or FT BARRIER D slab to the reinforced

concrete surface and drill ve (for 1 000x600 mm slab) or
nine (for 1 200x1 000 mm slab) holes for installation of
anchors (anchoring points: 8.4 pts/m2 for 1 000600 mm
slabs and 7.5 pts/m2 for 1 2001 000 mm slabs).
2. Drill the holes transverse to the bearing base, their depth
must be 3-5 mm higher than reco mmended (the minimum
depth of i mmersion of FT BARRIER anchors to the concrete
is 30 mm).
3. Install the anchor with dish-shaped holder in the drilled hole
and ha mmer it.
4. FT BARRIER slab must bear against the surface and be
secured with a dish-shaped holder.

27
Fire protection of pipe penetrations
The system of uninsulated penetrations in the building enve-
lope is likely to facilitate the spread of re and smoke. The pipe
penetrations are reproofed with ROCKWOOL CONLIT PS 150
stone wool pipe sections.

Table 20. Product properties

Parameter Units Value

25, W/m* 0.037

Thermal conductivity
125, W/m* 0.048

Reaction to re 0 (Non-combustible)

Density kg/m3 165

Organics content by
% 3.2
weight, up to

Fireproong efciency Installation

Vertical and horizontal structure with 159 mm and 76 mm (Presented for your information based on Technical Rules
steel piping E 240/I 180. No. 31-04)
Vertical and horizontal structure with 32 mm steel piping EI
240. 1. Make sure that the surface of steel pipe is free of dust and
other rough parts.
Required materials and tools 2. Prepare the surface using GF-021 primer or similar.
CONLIT PS 150 pipe sections 3. Pattern cut the CONLIT PS 150 segments.
2 mm fastening wire 4. Prepare the sand-cement mortar following the manufac-
2 x 30 mm metal tape turer's instructions.
Pliers 5. Grout the pass in the building envelope.
6. Install the CONLIT PS 150 segments against the surface of
The juncture seam between the CONLIT PS 150 reproof seg- the reinforced concrete structure.
ments and the concrete building envelope shall be addition- 7. Secure the segments on the steel piping using the fastening
ally sealed with sand-cement mortar. wire. Start to fasten at up to 50 mm away from the building
Follow the same procedure on the other side envelope with up to 100 mm between the loops. Secure the
segments with metal tape at a pitch of up to 600 mm.

Examples of installation: :
1 pipework
2 ROCKWOOL cylinder with alufoil covering
3 CONLIT PS 150 cylinder 4

4 building envelope
5 grouting area
6 fastening wire 5

7 banding tape

3 7
6

28
Fire protection of cable penetration
The reproong system for cable line penetrations prevents the Required materials and tools
critical temperature increase in the unheated area, on the sur- Expandable restop mastic Hilti CP 611A
face of sealant and elements in passes, as well as maintains Fireproof paint CONLIT (C)
the barrier integrity over the evacuation period. To achieve this, Fastening gun
the re resistant element must be installed in the cable line A knife for mineral wools or a hand saw
pass within the building envelope. Such element is a part of Putty knife for spreading of mastic.
ROCKFIRE system the CONLIT SL 150 slabs of ROCKWOOL
stone wool.

Fireproong efciency Installation

For 50 mm thick CONLIT SL 150 slabs installed from both sides
(100 mm) IET 60;
For 70 mm thick CONLIT SL 150 slabs installed from both sides
(140 mm) IET 90;
For 80 mm thick CONLIT SL 150 slabs installed from both sides
(160 mm) IET 120.
(Presented for your information based on Technical Rules
No. 3-06)
1. Make sure that the pass is clean and free of dust.
2. Prepare the Hilti CP 611A mastic.
3. Pattern cut the CONLIT SL 150 slabs.
4. Apply the mastic and evenly spread it with a putty knife
across the internal surface of the pass.
5. Apply the mastic on the edges across the pass.
6. Install the slab with mastic to the pass. Spread the excess
mastic with the putty knife.

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

29
Products dimensions
Table 21. Dimensions of the wound pipe sections ROCKWOOL 100 Table 22. Dimensions of the wound pipe sections ROCKWOOL 150

Thickness, mm Thickness, mm
Length, mm Length, mm
20 25 30 40 50 60 70 80 90 100 20 25 30 40 50 60 70 80 90 100
18 18
21 21
25 25
27 27
28 28
32 32
35 35
38 38
42 42
45 45
48 48
54 54
57 57
60 60
64 64
70 70
76 76
83 83
89 89
102 102
108 108
114 114
133 133
140 140
159 159
168 168
169 169
194 194
205 205
219 219
245 245
273 273

30
Table 23. Dimensions of mats Table 24. Dimensions of slabs

Length, Width, Thickness, Length, Width, Thickness,

Product name mm mm mm Product name mm mm mm
5000 50 50-200, step
TECH BATTS 50 1000 600
10mm
WIRED MAT 50 4500 1000 60
50-200, step
4000 70 TECH BATTS 75 1000 600
10mm
5000 1000 40
50-200, step
TECH BATTS 100 1000 600
4000 50 10mm
3000 60 50-180, step
TECH BATTS 125 1000 600
10mm
2000 70
50-160, step
WIRED MAT 80 2000 80 TECH BATTS 150 1000 600
1000 10mm
2000 90
30-80, step 10mm
2000 100 INDUSTRIAL BATTS 80 1000 600
15, 25, 35
2000 110
25, 30, 35, 50,
FIRE BATTS 1000 600
2000 120 75, 100
6000 25 30-200, step
FT BARRIER 1000 600
10mm
7000 30
80-200, step
5000 40 FT BARRIER D 1000 600
10mm
4000 50
20-(25,35)-100,
CONLIT SL 150 1000 600
WIRED MAT 105 2000 1000 60 step 10mm
2000 70
2000 80
2000 90
Table 25. Dimensions of CONLIT PS 150 pipe sections
2000 100
5000 50 Length, mm Diameter, mm Thickness, mm
5000 60
1000 18273 20, 25, 30, 40, 50, 60, 70, 80
TECH MAT 4000 /4500 1000 70
4000 /4500 80
4000 /4500 90
5000 40
LAMELLA MAT 4000 1000 50
4000 60
12000 20
8000 30

5000 40
LAMELLA MAT L 4000 1000 50
3000 60
2500 80
2000 100
10000 20
8000 30
KLIMAFIX 1000
6000 40

5000 50
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