T

National Bureau of Standards

Library, E-01 Admin. Bldg.

octi 1981 MBS SPECIAL PUBLICATION

131095

606

U.S. DEPARTMENT OF COMMERCE / National Bureau of Standards

Criteria for the Installation of

Energy Conservation Measures

QC

100

.U57

no. 606

1981

. c» 2
NATIONAL BUREAU OF STANDARDS

The National Bureau of Standards' was established by an act of Congress on March 3, 1 90 1

The Bureau's overall goal is to strengthen and advance the Nation's science and technology

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research and provides: (1) a basis for the Nation's physical measurement system, (2) scientific and technological services for industry and government, (3) a technical basis for equity in trade, and (4) technical services to promote public safety. The Bureau's technical work is per- formed by the National Measurement Laboratory, the National Engineering Laboratory, and

the Institute for Computer Sciences and Technology.

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'Headquarters and Laboratories at Gaithersburg, MD, unless otherwise noted; mailing address Washington, DC 20234.

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Criteria for the Installation of

Energy Conservation Measures

*ATiO/iAL BURBAP

lUt STANDARUg

IdS&ART

AUG 3 1981

Heinz R. Trechsel

/9?t

U.S. Department of Commerce *

Center for Building Technology

National Engineering Laboratory

National Bureau of Standards

Washington, DC 20234

and

Shelia J. Launey

U.S. Department of Energy

Office of Assistant Secretary for Conservation and Renewable Energy

1000 Independence Ave., SW

Washington, DC 20585

U.S. DEPARTMENT OF COMMERCE, Malcolm Baldrige, Secretary

NATIONAL BUREAU OF STANDARDS, Ernest Ambler, Director

Issued July 1981
Library of Congress Catalog Card Number: 81-600055

National Bureau of Standards Special Publication 606

Nat. Bur. Stand. (U.S.), Spec. Publ. 606,203 pages (July 1981) CODEN: XNBSAV

U.S. GOVERNMENT PRINTING OFFICE

WASHINGTON: 1981

For sale by the Superintendent of Documents. U.S. Government Printing Office. Washington, DC 20402 Price $6.00

(Add 25 percent for other than U.S. mailing)
ACKNOWLEDGMENTS

This document was prepared by the National Bureau of Standards (NBS) for the Department of

Energy (DoE) under DoE/NBS Task Order No. AOOB BCS, No. IA-7 7-01-601 6. The document will

be used in the implementation of the Residential Conservation Service Program. Its publication also completes Information Coordination Milestone No. 9 of the National Program Plan

for Building Thermal Envelope Systems and Insulating Materials, DoE/CS-0059, January 1979.

The development of the installation practices was an interagency, interdisciplinary effort

conducted over a period of more than 3 years and involving many individuals. The

efforts of several persons were so considerable that they require special mention.

In resolving technical issues, the authors drew most heavily on recent research by

P. Reece Achenbach and Douglas Burch on moisture control; Burch on attic ventilation;

Lawrence Galowin and Thomas Faison on electrical wiring; and Michael Fulcomer on surface

and recessed lighting fixtures. Richard Grot's support in developing the section on diagnostic tools was invaluable, and Maureen Breitenberg assisted in preparing the section on product certification and laboratory accreditation.

The assistance of the following is acknowledged in the preparation of individual

installation practices: Bradley Peavy, Walter Rossiter, and Frank Powell on insulation,

S. Robert Hastings on window and door devices, and William Mulroy on oil burner replacements. The practice for the installation of vent dampers is based on guidelines prepared

by Donald Adams of Calspan. Keith Long of Iowa State University assessed in the development of the UF-foam installation practice. The practice for the installation of automatic

intermittent pilot ignition systems was extracted with the assistance of Stanley Blachman

of the American Gas Association from draft ANSI standards.

Throughout its development, Henry Londner and Henry Fostel of Hittman Associates, Inc.,

have provided tireless services in collecting reference materials, proofreading, and

rewriting the early versions of this publication. Richard Crenshaw, Charles Mahaffey,

Frank Powell and Mary Reppert of NBS and Phillip Thor of DoE have given the manuscript

their thorough review and provided many helpful suggestions. Tracey Kistler has done an

excellent and patient job typing and retyping the final manuscript.

The standards in draft and proposed form were published in September 1978 and March 1979.

A total of over 400 comments were received and considered in the preparation of the final

document. Although the large number of comments prevents us from mentioning individuals

and organizations, the valuable help and assistance provided by those commenting have

greatly enhanced the quality and utility of the installation practices.

The authors wish to acknowledge the great help received from all the above and to express

their most sincere thanks to all of them. However, full responsibility for all the content

of this publication rests with the authors.

iii
CRITERIA FOR THE INSTALLATION OF ENERGY CONSERVATION MEASURES

* Heinz R. Trechsel and Shelia J. Launey

ABSTRACT

Standard installation practices were developed to assist in assuring the effectiveness and

safety of energy conservation measures installed under the Residential Conservation Service

(RCS). They serve as mandatory standards under RCS but are recommended guides for all

installations of the covered materials and products. The criteria are being used by DoE

to develop training manuals for installers, inspectors^ and energy auditors.

Part I provides information on the intended use of the practices, outlines the RCS program,

and discusses specific major technical and related issues that were considered in the

development of the standards: moisture and building retrofit, attic ventilation, electrical

wiring, recessed and surface-mounted fixtures, the use of diagnostic tools (infrared thermography, air change rate, and window air leakage measurements), and product certification.

Part II provides the actual practices together with commentary and additional recommendations. The products covered are loose-fill, batts and blankets, rigid foam boards, UF foam and reflective insulations, window devices, caulks and sealants, water heater insulation, oil burner replacements, and vent dampers.

Key words: automatic ignition devices; caulks; effectiveness; energy conservation; energy

conservation measures; installation; insulation; oil burners; practices;

safety; sealants: standards; storm doors; storm windows; vent dampers; water

heaters; windows.

DISCLAIMER:

Certain trade names and company products are identified. In no case does such identification

imply recommendation or endorsement by the National Bureau of Standards, nor does it imply

that the products are necessarily the best available for the purpose.

* Current address: H. R. Trechsel Associates, Building Construction Consultants,

P. 0. Box 211, Germantown, MD 20767.

iv
CONTENTS

Page

Acknowledgments iii

Abstract iv

Part I - GENERAL INFORMATION 1

1. INTRODUCTION 1

2. THE RESIDENTIAL CONSERVATION SERVICE 3

2.1 General Program Provisions 3

2.2 Material Standards 4

2.3 Standard Installation Practices 5

2.4 Further Information 6

3. METHOD OF INSTALLATION PRACTICES DEVELOPMENT 7

4. TECHNICAL ISSUES 8

4.1 Moisture and Building Retrofit 8 4.1.1 Previous Moisture Problems 8 4.1.2 Control of Condensation in Walls 9 4.1.3 Attic Ventilation 12

4.2 Electrical Services 13

4.2.1 Wiring 14

4.2.2 Recessed Lighting Fixtures 17 4.2.3 Surface-Mounted Lighting Fixtures 19

5. DIAGNOSTIC TOOLS 20

5.1 Infrared Remote Sensing (Thermography) 20

5.1.1 Need for Thermographic Surveys 20

5.1.2 Types of Equipment 21

5.1.3 Use of Thermography 22

5.2 Air Tightness and Air Change Rate 23

5.2.1 Air Tightness Test by Fan Pressurization 23

5.2.2 Air Change Rate Test by Dilution Methods 23

5.3 Window Air Infiltration Rate 24

6. PRODUCT CERTIFICATION AND LABORATORY ACCREDITATION 26

6.1 Product Certification 26

6.2 Laboratory Accreditation 28

REFERENCES TO PART I 30

PART II - STANDARD PRACTICES 50

PREFACE 50

v
CONTENTS (Cont.)

Page

Standard Practice for the Installation of Loose-Fill Thermal Insulation .. 51

Standard Practice for the Installation of Mineral Fiber Batts and Blankets

Thermal Insulation 71

Standard Practice for the Installation of Organic Cellular Rigid-Board

Thermal Insulation 86

Interim Standard Practice for the Installation of Urea-Formaldehyde

Foamed- in-Place Insulation 107

Standard Practice for the Installation of Reflective Insulation 127

Certification Procedures for the Installation of Thermal Insulation

Materials 134

Standard Practice for the Installation of Caulks and Sealants 136

Standard Practice for Installation of Storm Windows, Replacement Windows,

Multi-Glazing, Storm Doors, and Replacement Doors 139

Standard Practice for the Installation of Thermal Insulation on Domestic

Hot Water Heaters 155

Standard Practice for the Installation of Replacement Oil Burners in

Residential Heating Systems 162

Standard Practice for the Installation of Automatic Vent Dampers on Existing Gas-Fired Central Furnaces and Low Pressure Domestic Hot Water

Boilers 172

Standard Practice for the Installation of Automatic Intermittent

Pilot Ignition System 189

vi

I
PART I - GENERAL INFORMATION

1. INTRODUCTION

Building construction as practiced today was developed over many centuries. Construction

methods that proved unsafe or caused early deterioration were discredited and discontinued.

Practices pertaining to the health and safety of building occupants and that have withstood

"the test of time" were continued, and many of them were finally incorporated into building

codes. Construction methods are sets of a great many practices and materials acting individually and in concert. Changes in one material, or in one individual practice, can have

unforeseen impact on many other parts of the total building. For example, the addition of

insulation to walls can alter the migration and condensation patterns of water vapor in a way that adversely affects certain building materials. The enclosure of electrical wiring

in thermal insulation prevents the natural cooling of wires, thus leading to elevated wire

temperatures. Were energy conservation retrofits installed gradually, that is, in a few

buildings at a time, undesirable side effects would occur on a limited number of houses,

the practice could be changed, and the defects in the few affected houses could be

corrected. However, because of both high energy cost and the various government programs

such as the U.S. Department of Energy (DoE) Residential Conservation Service (RCS) which

are designed to stimulate retrofitting, a gradual installation pattern and "the test of

time" cannot be relied upon to unveil major problems. Therefore, a concerted effort

must be made through the development of training and inspection programs, feedback mechanisms, and quality assurance programs so that undesirable side effects can be controlled,

if not eliminated. This effort must have as its centerpiece the establishment and

continual upgrading of material standards and standard installation practices.

Material Standards: These attempt to present reliable data concerning critical properties

of products so that effective, durable, and safe installations can be made. The American

Society for Testing and Materials (ASTM) and the American National Standards Institute

(ANSI) are two of the major voluntary standards organizations. Technical committees within

ASTM and ANSI have addressed properties of energy conservation materials has the Consumer

Products Safety Commission (CPSC) which develops standards it deems necessary to protect

the public. Federal Specifications used in the purchasing process by the Federal Government also address this subject. For the RCS Program, DoE has established material standards to assist in assuring that the energy conservation measures installed meet minimum

requirements for effectiveness and safety. DoE standards, mandated by Congress, were published in the RCS Rule, Federal Register notice of November 7, 1979 [l].*

Standard Practices: Even the highest quality material may not perform properly if

installed incorrectly. Improper installation also can seriously affect the durability and

general performance of adjacent materials and components. The National Energy Conservation

and Policy Act (NECPA) [2] therefore requires that DoE also establish standard installation

practices for the RCS Program. It is these practices that this publication addresses,

often simply by the term "practices." What precisely is a standard practice? It is, in

short, and with respect to energy:

A description of critical requirements for the installation of an energy

conservation measure (material or product) which must be followed so that

the measure performs after installation as effectively and safely as intended, and which helps to assure that the installation will not

adversely affect, in whole or in part, the recipient building.

The need for practices in energy conservation retrofit is particularly pronounced in light

of the fact that high and rising energy costs can be expected to induce most homeowners to seek relief from burdensome heating and cooling bills. While the RCS practices are mandatory only for the RCS Program, it is hoped that they will serve as a quality yardstick for

energy conservation installations in general. The standard practices offer the following:

Numbers in brackets indicate references listed at the end of Part I.

1
° To the homeowner, they provide assurance that the products bought will actually perform after installation at or near the level assumed on purchase;

To the material producer, they give assurance that his/her product is installed

in such a way as to provide safely the performance level of service for which

it was designed, thus producing a satisfied customer and reducing call-backs;

0 To the auditor, they indicate the precautions that need to be taken to assure a safe and effective installation, to permit an estimate of the cost of

installing the conservation measures, and to identify cost-effective energy

conservation measures;

° To the installer, they provide guidance on correct installation, a common

basis for the bidding process to guard against unfair competition, and

protection from unreasonable liability; and

To the inspector, they give guidance on what constitutes "good practice" for

the safe and effective installation of the energy-conserving product involved.

This publication was prepared as a source document and technical backup for those who need

to know (1) what the RCS standard practices are, (2) their technical background and why

major provisions were chosen, and (3) the principal issues considered in their development.

This document will assist those developing RCS State plans; those conducting training programs for RCS installers, auditors, and inspectors, and all others concerned with the

implementation of the RCS Program; and homeowners who want to know more about the installation of energy conservation measures. Specifically, DoE has prepared training manuals for

installers [3] and inspectors [4] based on the technical content of this publication. It

is also hoped that this publication represents a contribution to the development of standards, and the voluntary standards organizations are invited to adopt, through their consensus process, those practices they consider appropriate.

The recently published Office of Management and Budget (OMB) Circular A-119 [5] establishes

as Federal policy the use of voluntary standards in procurement whenever feasible and con- sistent with the provisions of the laws and regulations of the agency. DoE has expanded on

this policy in the RCS Program, preferring as a general rule to adopt existing voluntary

standards rather than to develop new ones. Voluntary standards, however, cannot be incorporated into the Rules without careful review by DoE to ascertain that the standards do not

unduly restrict trade and that they are consistent with the agency's mandate [6,7]. The

standard practices will be used as one element in determining whether future voluntary

standards address the concerns of the RCS; DoE encourages the conversion to voluntary

standards of those practices generated specifically for the RCS Program.

Part I of this publication consists of an introduction, a brief description of the RCS Program, discussions of the major technical issues considered in developing the practices, an outline of examples of diagnostic tools that can be used to determine whether a particular

installation meets the criteria of the practices, and a discussion of product certification

and laboratory accreditation.

Part II describes the individual practices. Mandatory provisions are set apart from

recommendations. Where desirable, a commentary outlines the reason or rationale for the

provision, along with the requirement's significance and the potential consequences of

ignoring or violating it. The recommendations cover precautions that might be taken in

addition to the mandatory requirements. Although the recommendations are not mandatory

under the RCS Program, their use should be considered on a specific, house-by-house basis.

One final word. Only through careful installation of appropriate materials can the concern

for the national goal for energy conservation effectiveness be balanced with the concern

for safety and durability of every individual house retrofitted. Such proper balance will

both reduce energy use in residential buildings and increase the value of the Nation's

housing stock. The standard practices contained in Part II will assist in finding the

proper balance.

2
2. THE RESIDENTIAL CONSERVATION SERVICE

2.1 GENERAL PROGRAM PROVISIONS

The National Energy Conservation Policy Act (NECPA) [2] requires DoE to establish a national residential energy conservation program to assist homeowners in saving both energy

and money. The RCS Program requires large utilities and participating heating oil suppliers to offer services to their residential customers which will encourage the installation

of energy conservation and renewable resource measures. Although the RCS is a national

program, each State may develop and implement its own State plan. The purpose of the

program is to provide residential energy users with information on the cost-effectiveness

of energy conservation measures and techniques, to give assistance to homeowners in having

measures installed and in securing financing, and to protect the consumer from unsafe

installations and unfair business practices.

Utility customers who are occupants of residential buildings of up to four dwelling units

can take advantage of the services offered by their utilities and will gain several

benefits, including:

° Information about estimated savings in energy cost for selected energy

conservation and renewable resource measures;

° Information about precautions needed to assure a safe installation;

° Energy audits upon request to identify specific measures that would be

cost effective when installed in the customer's residence. During the

audit, the home will be inspected for energy inefficiencies and potential

safety problems that may result from retrofit;

° Arranging services for the purchase, installation, financing, and billing

of program measures;

Safe and effective installations by contractors who are qualified to perform

the work, are bonded, and have agreed to follow the installation practices;

s Special procedures for consumer protection, including grievance procedures,

warranties, and post-installation inspections to verify the safe and effective installation of measures.

Suppliers and installation contractors who participate will get:

° More business opportunities. Energy conservation is an expanding market

area. As a result of the RCS Program, an estimated $6.7 billion will be

invested in the purchase and installation of energy conservation products

and materials^

A marketing advantage. DoE standards require that the products and materials installed are dependable and of consistently high quality, and that

they are labeled as meeting DoE standards;

Reputation for quality installation. Procedures outlined in the RCS

regulations are Government-required minimums for installing conservation

products and materials. Where contractors follow these practices, their

customers will be assured of safe and effective installations.

Installation contractors are required to meet the following requirements to conduct

business under the RCS Program:

Comply with the standard practices applicable to a given installation;

Comply with all applicable local, State, and Federal (apart from RCS)

regulations and codes;

3
° Install only materials which comply with DoE material standards and are so labeled;

° Install only measures covered by the RCS warranty;

° Furnish the customer with a written contract;

° Agree to consumer conciliation procedures, and agree to correct any violation

of the RCS standard practices without cost to the customer;

° Comply with bonding and liability insurance provisions;

Suppliers and lenders have to agree to supply measures that meet the DoE Standards and

carry the measures warranty, to meet appropriate requirements relating to product certification, and to participate in conciliation procedures in order to conduct business under

RCS.

Lenders have to agree to comply with specific provisions relating to security in real

property used as principal residence, to allow rebate on unearned finance charges and to participate in conciliation procedures.

2.2 MATERIAL STANDARDS

The RCS Program has promulgated standards for safety and effectiveness for most products

and materials covered by the Program. These standards expand on and incorporate features

of existing standards developed by nationally recognized organizations. When appropriate,

the DoE standards provide references to relevant existing standards. All products installed

under RCS must be labeled by manufacturers as complying with the DoE Material Standards;

installers must agree to use only products so labeled. To date DoE Material Standards have

been issued for the following materials and products:

Energy conservation measures

Loose-fill cellulosic or wood-fiber thermal insulation;

° Loose-fill mineral-fiber thermal insulation;

° Mineral-fiber blanket-and-batt thermal insulation;

° Vermiculite thermal insulation;

Perlite thermal insulation;

° Polystyrene thermal insulation board;

0 Polyurethane and polyisocyanurate thermal insulation board;

Urea-formaldehyde f oamed-in-place insulation (interim standard);

0 Aluminum foil reflective thermal insulation;

° Caulks and sealants;

0 Water heater insulation;

Heating and air conditioning duct insulation;

° Pipe insulation;

° Storm and thermal windows, multiglazing, storm and thermal doors;

4
° Furnace efficiency modifications, including vent dampers and automatic

intermittent pilot ignition devices for gas-fired furnaces and replacement

oil burners, replacement heating systems with the same fuel type;

° Replacement central air conditioners;

° Load management devices.

The DoE Material Standards were published as part of the Rule for the Residential

Conservation Service [1].

Renewable resource measures

0 Solar domestic hot water and active solar space heating systems;

° Thermosyphon hot water systems;

° Swimming pool heaters;

° Wind energy devices.

2.3 STANDARD INSTALLATION PRACTICES

The RCS Program has promulgated standard practices to help ensure the safe and effective

installation of conservation and renewable resource measures. These cover the following

materials and products:

Energy conservation measures

° Loose fill insulation;

0 Mineral fiber blanket and batt insulation (including duct insulation);

° Organic cellular rigid board insulation;

° Reflective insulation;

° Urea-formaldehyde f oamed-in-place insulation (interim standard);

0 Water heater insulation;

° Storm windows, thermal windows, multi-glazing, storm doors, thermal doors;

° Caulks and sealants;

° Replacement oil burners;

° Vent dampers;

Automatic intermittent pilot ignition devices (interim standard).

Renewable resources measures

Solar domestic hot water and active solar space heating systems;

Thermosyphon hot water heaters;

Swimming pool heaters;

Wind energy devices.

This publication addresses only the practices for the energy conservation measures.
2.4 FURTHER INFORMATION

The RCS program is administered by a lead agency in each State. For detailed information

on the various aspects or the State plan and its implementation, the State lead agency

should be contacted. Although the exact name of the agencies differ from State to State,

the responsible agency is in most cases either a State energy office or a State public

utility commission.

6
3. METHOD OF INSTALLATION PRACTICES DEVELOPMENT AND TECHNICAL BASIS FOR PROVISIONS

The standard practices included in this publication were developed jointly by DoE and the

National Bureau of Standards (NBS), with substantial assistance from other Federal agencies

and private consultants. The effort was coordinated through the DoE/RCS "Installation

Standards Committee" which drew on experts as required and which undertook the preparation

of the practices in a variety of ways. Some practices, such as that for water heater insulation, were prepared by a consultant and reviewed and revised by the Committee. Others were more directly written by the Standards Committee, individual members contributing

specific chapters, sections) or provisions. The practice for window devices was developed

jointly with ASTM Subcommittee E06.51, Performance of Windows, Doors, and Curtain Walls.

(This practice was adopted by ASTM as E737-80, in March 1980) [8].

A first draft of some of the practices was published in November 1978 in a DoE report [9],

and through posting of an appropriate notice in the Federal Register [10] interested persons were requested to comment. Based on the comments, Proposed Installation Standards

were included in the March 19, 1979, Federal Register Notice as part of the Proposed Rule

for the RCS Program [11]. Over 400 written comments were received in response to the

publication, and many more were received in oral testimonies during RCS public hearings

held in seven cities. Extensive improvements based on the public comments were included

in the final practices published on November 7, 1979 (amended on August 11, 1980 [12]).

Some practices were published as proposed on December 21, 1979 [13], and as final on September 24 and 25, 1980 [14,15].

Early in the development of the practices, it was decided to base their provisions wherever

possible on existing standards. Thus, provisions of the HUD Minimum Property Standards

(MPS), Federal Specifications, ASHRAE Guidelines, and ASTM Standards were reviewed. Where

appropriate, individual provisions (such as the MPS requirements for attic ventilation)

were adopted. However, in existing buildings (to which the RCS Program is directed) some

of the provisions included in codes and standards for new buildings would be difficult or expensive to implement. This applied, for example, to the requirements for vapor barriers

in wall constructions. For this type of situation, the installation committee initiated

research or fact-finding activities to assist in preparing appropriate provisions. In the

above-mentioned vapor barrier issue, a panel of experts under contract to NBS assisted in

formulating the provisions discussed under "Moisture and Building Retrofit" and in the

individual practices. In other cases, such as attic ventilation and electrical hazards,

DoE sponsored research activities to develop a technical basis for appropriate provisions.

Since some of this research requires several years to complete or at least involves observation and tests over a full annual cycle, not all results are yet available. Thus, the

provisions included in the practices are based on the best available' data to date, and

future revisions may be needed.

Where no applicable standards existed, the guiding principle was that the overall level of

safety of the building should not be decreased by the installation of the energy conservation measure. Where /trade-offs between potential hazards and effective installation were

unavoidable, DoE adopted provisions as conservative as judged compatible with the overall

purpose of RCS — to assist homeowners in saving energy.

Many local, State, and Federal agencies regulate aspects of building constructions and their

operations. Whenever possible, those requirements which affect the installation of energy

conservation measures (or are affected by them) were identified and are specifically

included in the standard practices. Thus, the Federal requirement for safety glazing in

doors is referenced in the standard practice for window and door devices. However, it

would have been an impossible task to review all local, State, and Federal regulations

possibly relating to the installation of energy conservation measures. Accordingly, the

RCS Rule includes a general statement that the standards are not intended to supersede

local, State and other Federal codes and standards [16]. The most significant application

of this principle is in the provisions for electrical wiring discussed in detail under

"Technical Issues."

7
4. TECHNICAL ISSUES

In the course of developing the standard practices, a great many technical issues were considered. Where appropriate, these are mentioned in the "Commentary" accompanying individual

provisions of the practices in Part II. Brief descriptions of the most significant, or most

difficult, technical issues follow.

4.1 MOISTURE AND BUILDING RETROFIT

"Except for structural errors, about 90 percent of all building construction problems are associated with water in some way," states the 1980 ASTM Book of Standards [17]. Construction measures which control moisture adequately will deliver safe and effective performance

over a long period of time. Structures that do not control moisture will experience early

deterioration through fungus growth in wooden structures, paint peeling, staining of interior surfaces, warping and resultant air leakage, spalling in masonry walls, and corrosion

of metal building components. Besides causing damage to the structure, moisture also may

sometimes reduce the effectiveness of thermal insulation [18].

Moisture can enter building elements primarily by two means: by penetration of water from

the outside of the house, such as rainwater leakage or a burst pipe, and by vapor diffusion

and air penetration into cavities from the inside of the house. In either case, the most

serious problems arise when moisture accumulates for extended periods of time.

The control of moisture needs to be considered in energy conservation retrofit for several

reasons:

Insulation placed in walls reduces the temperature at the plane of condensation, thus raising the water vapor pressure difference between the inside of

the house and the cold surface, increasing the amount of condensed water

[19,20].

0 Installation of weatherstripping, caulking, thermal windows, and vent dampers

reduces air infiltration [21] and raises the indoor relative humidity. Higher

indoor moisture levels increase vapor transfer through the building envelope

and thereby increase the amount of interstitial moisture accumulation.

Some insulations contain considerable amounts of moisture when installed.

This moisture must be vented to the outdoors to prevent the deterioration

of the structure. This venting is particularly important when insulation

is installed during cold weather.

For the above reasons, a house free of moisture problems prior to retrofit could develop

such problems after the installation of energy conservation measures. It is possible that

the first sign of such a problem (maybe slight peeling of paint) will show up shortly after

the retrofit, allowing for timely corrective action. But in some cases no such telltale

signs will signal the major trouble that may lie several years ahead. In a house with no signs of prior water leakage or condensation, the likelihood of a moisture problem can be

reduced by conscientiously following the installation practices given in this book. Addition information, suggestions for identifying special types of previous moisture damage, means of preventing their recurrence-, and evaluative tests that the homeowner can perform

to determine whether additional precautions may be justified are given below.

4.1.1 Previous Moisture Problems

As has been noted, the installation of insulation increases the risk of moisture accumulation within constructions. It is therefore important that any already existing problems

be corrected and the causes of leaks or condensation be minimized or eliminated. What

follows are brief descriptions of the more likely causes of previous problems. Also presented is information on how each problem can be recognized, how to determine whether it

still is a problem, and how the problem can be corrected and its cause eliminated.

8
Rainwater leakage is generally recognizable by pronounced streaks emanating from one or more clearly identifiable locations. If the sources of leakage are small cracks or openings, caulking or patching in good condition should be assumed to have corrected the leakage unless actual moisture is present. If not previously corrected, small leaks around

openings and flashings should be sealed with appropriate caulking compound (see DoE

Material Standards), using techniques prescribed by the manufacturer and in the material

standards and installation practices. Roof leaks generally will require the replacement

of the roofing material or repairs using supplemental waterproof membranes.

Leaking or burst pipe is recognizable by pronounced streaks or actual spraying or dripping

emanating from a water pipe or from a space containing a pipe. Check for actual moisture

present while pipe is under normal operating pressure for at least 15 minutes. If leak is

apparent, repair piping in accordance with good plumbing practice. Where local code

requires, repairs are to be made only by approved personnel.

Flooding is indicated by distinct horizontal markings showing the highest water level.

Frequency and time of last occurrence determines most reliably whether the cause of the

flooding has previously been eliminated. If flooding occurs only at intervals of more

than five years, the potential for damaging the added insulation or for deterioration of

the structure due to the water retention of insulation is minimal. Remedial action depends

on the type of flooding. This may be due to sewer backup, or to seepage of groundwater

through the wall or floor (see below). Since the success of the wall treatment cannot be

determined by visual inspection during dry weather, it is necessary to await wet weather

to evaluate whether flooding has stopped.

Seepage through walls below grade is generally marked by large discolored areas with

clearly defined edges on basement or crawl space walls. Determine frequency of occurrence.

If occurrence is at intervals of five years or more, or if seepage has not occurred since

the application of remedial action, the risk for potentially serious damage to insulation

or structure can be discounted. Minor seepage through masonry walls can often be stopped

by the application of sealer on the interior surface of the wall. Major seepage is difficult to stop and professional advice is required. The only effective remedial action may

be to excavate the ground around the location of the seepage, to apply a waterproof membrane on the outside surface of the wall, and to provide drainage at the bottom of the

wall. To prevent future moisture problems, the ground around the building should always

be sloped away from the wall.

Condensation should be suspected whenever no other cause of a prior moisture problem is

apparent and is most likely to occur in walls and attics of high moisture areas such as in

bathrooms and unvented kitchens and laundries. It may also be suspected where the outside

sheathing and finish of the exterior wall are of vapor-impervious materials, such as oilbase painted wood siding over plywood sheathing and asphalt impregnated felt or construction paper and where a vapor barrier is not provided on the interior surfaces of exterior

walls. It is also to be suspected in ceilings without adequate attic ventilation. It should also be suspected whenever there is paint peeling on exterior surfaces. Remedial

actions are discussed below in section on "Control of Condensation." If it is determined

that remedial action is not feasible, too costly, or not desired by the homeowner, no insulation should be installed in the immediate area (such as within the stud or joist

space) of the moisture damage. The energy conservation impact of leaving such spaces

uninsulated is proportional to the ratio of insulated to uninsulated areas. For example,

if a single stud space among 100 total stud spaces were left uninsulated, the loss of

effectiveness of the insulation job would be one percent.

4.1.2 Control of Condensation in Walls

The ASHRAE Guide states that "a typical family of four may produce as much as 11 kg

(25 lbs) per day of water vapor, or more, if humidifiers, automatic washers, and clothes

dryers are used" [22]. More recent data indicate that a range of 8 to 9 kg (18 to 20 lbs)

per day may be a better estimate because of less floor scrubbing, cooking, and indoor

clothes drying, and fewer daily hours of house occupancy for modern families as compared

to the situation 30 years ago [23]. The principal sources of moisture in houses are respiration, perspiration, cooking, bathing, laundering, and of course, humidif ication.

9
Some of these moisture-generating processes take place throughout a house but the moisture

release in bathrooms, kitchens, and laundry rooms is typically much higher than for other

rooms.

The moisture generated in a house is dissipated in one or more of the following three ways:

by exfiltration or ventilation, by diffusion or mass transport through the envelope materials, and by condensation on windows or other cold surfaces. These processes may all occur simultaneously, and there may be interactions among them. During cold winter months, water

vapor that permeates through an exterior wall from inhabited space may condense and accumulate in the outer parts of the wall. The amount of such moisture accumulation depends on climate, relative humidity of the indoor air and relative permeance of the interior and

exterior wall surfaces.

The principal methods available for controlling winter condensation within existing walls

when installing insulation are [24]: sealing of openings on the inside surface of the

exterior walls to prevent leakage of room air into wall cavities; installation of a vapor

barrier on the warm side of the wall, venting the wall cavity to the outside; maintaining

low indoor humidity in cold weather; and allowing intermittent condensation in limited

amounts to occur. Many experts in moisture control agree that air leakage through interior

wall surfaces (such as at electrical outlets, pipe penetrations and cracks) is a more significant moisture transfer mechanism than diffusion through the wall coverings. Therefore,

sealing air leaks that allow air to enter the wall construction should have first priority

for controlling condensation.

Little field data are available on actual moisture damage in insulated walls and ceilings

of occupied houses. In two recent field studies conducted independently on insulated

side-walls in Portland, Oregon for the Oregon Department of Energy [25] and in various

locations of the midwest, northeast and middle atlantic states for the National Bureau of Standards [26], no adverse effects were found to have been caused by the installation of

thermal insulation, even though in some of the walls inspected vapor barriers either were totally missing or were found to be installed on the exterior of the insulation in

violation of accepted "good practice."

Existing "good practice" recommendations and standards (ASHRAE Guide [27] and HUD MPS [28])

require vapor barriers on the interior of walls and ceilings in all three condensation

zones of figure 1.^ Because such requirements are expensive to implement in existing

buildings, and because the need for such stringent precautions has not been shown conclusively, the moisture control provisions of the practices in this publication and in the DoE

Standards differ from the new building requirements:

° Vapor barriers are required in condensation zones 1 and 2 where the installation

of a vapor barrier is no more difficult and costly to install than in new buildings. In all cases, a vapor barrier is required in condensation zone 1 in high

humidity rooms such as bathrooms and unvented kitchen and laundry rooms;

° The sealing of cracks on the interior side of exterior walls and ceilings of

high humidity rooms is required in condensation zone 1.

0 For condensation zone 2, the same precautions in high humidity rooms are recommended, but not mandatory.

0 In zone 1 and 2, in attics which have existing insulation, a vapor barrier

(paint) is recommended.

The requirements depend somewhat on insulation material type. For detailed information

consult the specific standard practice in Part II.

Figures are shown at end of Part I. 10
The above and the standard practices provide minimum requirements to prevent long-term

moisture damage. Additional precautions may need to be taken in homes with the potential

for high indoor relative humidity, such as:

° Homes with an area of less than 75 m^ (800 ft^);

° Homes with less than 23 m^ (250 ft^) per occupant;

° Homes with tight wall and ceiling construction and weatherstripped windows

and doors;

Electrically heated homes or homes with a heating system which uses outside

combustion air; and

° Homes that are humidified during the winter.

To determine whether houses with one or more of the above characteristics need additional

precautions, the indoor relative humidity is a fairly good indicator of the potential for

moisture condensation occurring inside building walls. For any given outdoor climate and a particular insulated wall construction, there is an indoor relative humidity level below

which no condensation will occur at any position inside the wall. Likewise, for any given

rate of moisture generation in a house, there is a minimum ventilation or infiltration rate

which will prevent that indoor relative humidity level and therefore prevent condensation.

A relative humidity indicator can thus give a good measure of whether in the particular

house such precautions as caulking of cracks and added vapor barriers are needed to reduce

the potential for serious condensation problems. Below are recommendations for the use of

the humidity indicators and the steps that can be taken to reduce the likelihood of any

serious problems:

Install the relative humidity indicator near the thermostat. Inexpensive color-change

relative humidity indicators as shown on figure 2 are available that are of sufficient

accuracy for the purpose. During the heating seasons, compare the readings of the relative

humidity indicator with the values shown in table 13 for the applicable Climate Zone and

month.

If the relative humidity as measured in the house is consistently higher than the values

shown in table 1 for the particular climate zone and month, the following steps should

be considered to assure that no serious deteriorative moisture problems occur:

Caulk or seal openings at the interior surface of the exterior walls and in

the ceiling^ that permit convection of room air into the wall cavity or through the ceiling (zones 1 and 2). The more important openings are:

a. Joints around window and door frames

b. Electrical switches and service outlets and the power cord to electric range (preformed foam gaskets are available for this

purpose)

c. Wall-mounted and ceiling-mounted^ light fixtures

d. Duct openings (between grille and wall) in exterior walls and

ceiling^

e. Plumbing penetrations: floor, wall, and ceiling^

Tables are shown at end of Part I

.

Joints around utility penetrations of ceilings do not require sealing when the amounts

of attic ventilation specified in the standard practices are provided.

4

11
f. Joint between wall and floor at the top of the baseboard and also

at the bottom of the baseboard if carpeting does not prevent it

g. Joint between wall and ceiling

h. Built-in cabinets not tightly fitted into exterior walls.

Apply low permeability paint or wallpaper to all untiled interior surfaces

of exterior walls unless they are already covered with such materials. Low

permeability paints and wallpapers have a permeance of less than one perm

as defined in ASTM C755-73.

0 Do not caulk or seal exterior surfaces of outside walls around window and

door frames and at the joint between foundation and wall except as required

to prevent rain leakage into the wall.

0 Vent clothes dryer to outdoors (zones 1 and 2).

Do not dry laundry indoors unless additional natural ventilation is provided

by opening windows or an exhaust fan is running.

If the exterior of a house being retrofitted has a low-permeability

finish (e.g., metal, plastic, or heavily painted wood) steps should be

taken to open up the siding construction in ways that would increase

outdoor venting of the wall without increasing rain penetration.

If the suggested steps above are not taken, it is strongly recommended that the house be

carefully observed after installing insulation, caulking, weatherstripping, or thermal

windows. Should early signs of moisture problems appear, particularly paint blistering or excessive condensation on windows, immediate correction action should be taken. Such

action could include as a temporary measure the opening of one or more windows by a fraction of an inch and operating kitchen and bathroom fans to reduce indoor humidity. However, these later actions should be taken only as a last resort and only to the extent

required inasmuch as they are energy consuming. The extensive use of fans to ventilate

the house's interior can also affect the operation and safety of fossil fuel heating

systems located within the building envelope. The negative pressure resulting from fan

operation can draw such poisonous combustion products as carbon monoxide into the living

space.

4.1.3 Attic Ventilation

A portion of the up to 11 kg (25 lbs) of water per day released in the average home reaches

the attic space either by diffusion through ceiling materials or by being carried through

mass transport in air that penetrates cracks, access doors, and other openings in the ceiling. Unless the vapor is vented from the attic to the outdoors, it may condense during

cold weather on the cold surfaces of the underside of the roof. A thick layer of frost

resulting from such condensation on the underside of roof sheathing is shown in figure 3. During warm periods the ice melts, wetting insulation on the attic floor, rendering the

insulation ineffective and causing the deterioration of ceiling materials, structural

members, or electrical systems. Also, the roof sheathing may absorb the condensed moisture, promoting fungus growth. Installing attic and ceiling insulation, or increasing it,

will cause attics to be colder in winter, thus increasing the potential for moisture

problems in attic spaces.

Both ASHRAE recommendations and HUD Minimum Property Standards call for attic ventilation.

The requirements that follow were established by the HUD MPS and are adopted for the RCS

program.

a. 0.1 m^ (1 ft^) minimum of free ventilation area per 15 m^ (150 ft^) of attic

floor area, if no vapor barrier exists in the attic

12
b. 0.1 m^ (1 ft^) minimum of free ventilation area per 30 m^ (300 ft^) of attic

floor area if a vapor barrier does exist

c. 0.1 m^ (1 ft^) minimum of free ventilation area per 30 m^ (300 ft^) of attic

floor space if at least 50 percent of the required ventilating area is provided with fixed ventilation located in the upper portion of the space to be

ventilated (at least 900 mm (3 ft) above eave or soffit vents) with the

remainder of the required ventilation provided by eave or soffit vents, if no vapor barrier exists.

It should be noted that the requirements for attic ventilation are primarily related to the prevention of moisture condensation in the attic space during cold weather. Attic

ventilation also lowers the attic temperature in summer. In uninsulated attics, the

lowering of these temperatures in the summer may increase the thermal comfort in the

habitable space below, but comfort is more effectively improved by the installation of

attic insulation.

In insulated attics, the increased summer comfort, or in the case of air conditioned

houses, the amount of cooling energy savings resulting from increased attic ventilation, were found to be negligible [29]. Accordingly, the requirements for attic ventilation are governed by the need to prevent the condensation of water vapor penetrating from habitable

spaces into the attic during cold weather.

While the given requirements have proven generally adequate in the past, they have been

questioned as to their validity in retrofit. Some of the questionable aspects are:

° If a house already has attic insulation, but slightly less than the above

"minimum" requirements, is the expense of providing a minimal additional

amount of ventilation justified?

° Is it possible that a single requirement for attic ventilation can cover

all types of climates—hot, cold, dry, and moist?

° Does the use of increased attic insulation and the corresponding lowering

of attic temperatures require increased attic ventilation?

° Does caulking of walls and weathers tripping of windows cause more moisture

to migrate from the habitable space to the attic, increasing the potential

for condensation and moisture damage in the attic?

While experts on attic moisture problems agree that insufficient attic ventilation can lead to problems, they disagree on the amount of attic ventilation required for their

prevention.

In an effort to resolve these differences, NBS has developed a mathematical model for

predicting the required attic ventilation rate for preventing condensation or frost

accumulation on the underside of roof sheathing. This mathematical model indicates that

the ASHRAE/ HUD MPS requirements are generally valid for ASHRAE Condensation Zone I, provided the house is not humidified [30]. Under DoE sponsorship, the model is currently

being improved upon, expanded to other zones, and will be experimentally validated. If,

based on the experimental work, any changes in the DoE/RCS practices are indicated, such

changes will be incorporated in later issues of the installation practices.

4.2 ELECTRICAL SERVICES

All electrical systems, while being operated, generate heat. When properly designed for

the imposed loading conditions and environment, such generated heat will dissipate harmlessly. However if the loading conditions are changed, for example, by overlamping of

fixtures (meaning installing lamps of higher wattage than the fixtures were designed

for), or if the environment is changed, for example, by electrical wiring surrounded by

thermal insulation, harmless heat dissipation may no longer be possible. There are three

13
electrical service components that are of primary importance as they relate to the

installation of insulation in walls and ceilings: wires and fuses, surface-mounted

lighting fixtures, and recessed lighting fixtures.

4.2.1 Wiring

The National Electrical Code (NEC) [31] stipulates the temperatures that electrical wires

may safely operate under (See Part III). This temperature for most residential wiring is

60°C (140°F) for polyvinyl insulation and 50°C (122°F) for "code rubber" wire used generally before 1940. According to the Fire Protection Handbook, "it is generally agreed

that 100°C (212°F) is the highest temperature to which wood can be continuously exposed

without risk of ignition," [32]. Schaffer [33] cites several sources which indicate that

"safe" levels of long term exposure are between 100°C (212°F) and 150°C (302°F). Ignition

temperature for wood (short-term exposure) is most commonly quoted as 200°C (392°F) [32].

The melting point on polyvinyl chloride (PVC) insulation commonly used for electrical

insulation is 115°C (239°F) [34]. To assure that the allowed ampacity in the wire is not exceeded, the NEC also requires that all branch circuits be protected by overcurrent protection devices, either fuses [35] or circuit breakers [36]. These devices are designed

to interrupt the current upon sensing a surge of current or after a steady draw of 135

percent of rated current for one hour.

The NEC requirements apply to wires installed in open air at an ambient temperature of not more than 30°C (86°F). If ambient air exceeds 30°C (86°F), the circuit must be derated.

Thus, when wires and protection devices are properly matched, even an excessive load on the

circuit cannot cause an overheating of the wire installed in an open air space. In actual

service and in open air, the wire temperatures are normally substantially below the 60°C

(140°F) limit. However, if the wires are surrounded by thermal insulation, thus reducing

the heat dissipation, temperatures near or above those stipulated have been observed in

laboratory tests. Figure 4 shows a summary of exploratory tests conducted at NBS [37],

More recent tests at NBS have confirmed the tendency toward elevated temperatures on electrical wiring surrounded by thermal insulation, and similar results were obtained by Hill

[38] and by Drucker [39]. In tests conducted by the Stevens Institute of Technology [40],

the 60°C (140°F) NEC temperature limit was exceeded when three adjacent cables carried

full rated load simultaneously, and when a single cable carrying full rated load was sandwiched between layers of thermal insulation. These tests also showed that gypsum

board ceilings in contact with electrical cables provided an effective heat sink. Wood

joists in contact with cables provided a lesser heat sink effect. The experimental results

have been confirmed in analytical work by Evans [41].

There still remains a question as to what degree high amperage and elevated temperatures

actually occur in service. To get at least some preliminary data on field conditions,

DoE and NBS are conducting a study in which utility companies in various parts of the

country have installed temperature sensors on branch circuit wiring in attics, particularly

on wires buried in thermal insulation. Preliminary results based on sensors installed over

a two- to six-month period (generally Fall, Winter and Spring months) indicate that of

approximately 2000 circuits monitored, approximately 5 percent reached temperatures of

68 °C (155°F) or higher, that is temperatures in excess of the limits stipulated in NEC

[42]. This experiment indicates only the highest temperature reached within the range

of the sensor, 50°-88°C (122°-190°F). The length of time the wire was exposed to the

elevated temperature could not be obtained with the type indicator used. Nevertheless,

the experiment does indicate that in-service temperatures of electrical wiring encapsulated

in thermal insulation can, and approximately 5 percent of the cases did, exceed the NEC

limits. These findings provide substantial agreement with laboratory and analytical investigations for in-service conditions. One of the most serious concerns is that of long-term

degradation of the dielectric and physical properties of the insulating material on the

electrical conductors.

Single Cables

In the NBS laboratory tests at rated ampacity, the temperature in a 3-wire single cable

surrounded by thermal insulation exceeded the NEC provisions in less than 1 hour, and at

14
135 percent of rated ampacity the temperature was exceeded in less than 20 minutes and

reached 98°C (208°F) within 1 hour. Thus under the laboratory test conditions the wire

temperatures exceeded those stipulated by NEC, and if experienced in a building would con- stitute a violation of NEC. However, the recorded temperatures (assuming properly matched

overcurrent protection devices were installed) should last for only a limited time.

No tests are reported on circuits with overcurrents above the 135 percent limit set by

proper overcurrent protection. Such higher currents could flow through wires if the overcurrent protection device is mismatched to the wire. For example, in a circuit designed

for 15 ampere and wired with #14 wire, the 15-ampere fuse might be replaced with a 30-ampere

fuse. This fuse would now permit a continuing load of 30 amp and a 1-hour load of 40.5

ampere. Other tests conducted at NBS on electrical wiring covered with cellulosic insulation

showed that smoldering fires were initiated at overloads corresponding to 190 to 200

percent of rated current [43].

The consideration of circuits with improperly matched overcurrent protection devices might

be assumed an academic exercise, were it not for a recent survey which indicated that some

45 percent of all houses in a sample of low income homes in some 14 localities of the

United States had at least one improperly matched circuit [44]. In the DoE/NBS conducted

study with utility companies, preliminary data showed that 37 percent of the houses had at least one improperly matched overcurrent protection device. The survey data do not indicate a reason for the mismatched overcurrent protection. In circuits with fuses, such

mismatch can result from "blown" fuses being replaced by the homeowner with fuses of

incorrect rating. Where this is done on a random basis, all circuits in a house could

eventually be mismatched (the higher rated fuses would never "blow"). However, unless

the circuits actually carry a higher load for extended periods, no increased hazard would

result. The mismatch could also be deliberate, in that a fuse which "blows" frequently is

replaced with one of a higher rating to mistakenly "cure" the problem. In this case, it

would be precisely those circuits which have shown a history of carrying excessive currents

that are incorrectly protected. An NBS staff member recently discussed with eight homeowners the reasons for improperly matched overcurrent protection devices. One of the owners

indicated that he deliberately "cured" his fuse-blowing problem by replacing the blown

fuses with a higher rated fuse [45].

Parallel (Multiple) Cables

For comparison, figure 4 also shows the temperatures reached by three parallel cables in

contact with each other. When all three cables each carried full load (20 amps) the temperatures were similar to those observed when the single cable carried 27 amps (135%).

When the three cables each carried 27 amps (135%), the temperature rose within 1 hour

to 148°C (298°F). Although the temperatures reached by parallel wires during laboratory

tests were high, the frequency of several parallel wires in close proximity each carrying

simultaneously full or excessive loads is not known. It appears unlikely that this occurs with any significant frequency.

Significance

Excessive temperatures of wires surrounded with thermal insulation can impact three building elements: the electrical cable itself, the thermal insulation, and adjacent building

elements.

The temperature levels and their duration observed for residential branch circuits with

properly matched overcurrent protection devices do not seem to constitute significant

hazards. Ignition of the electrical insulation, thermal insulation, or adjacent structure

is unlikely. The electrical insulation could experience a long-term degradation and

reduced service life, but the available data do not support a more definitive statement.

Few data exist regarding the duration of load and temperature levels possible on wires in

circuits with incorrectly matched overcurrent protection devices. However, it appears that

elevated temperatures could exist for sufficient duration to cause melting and possible

ignition of the electrical insulation on encapsulated cabels in improperly protected circuits. The temperature of wiring and duration of exposure should not lead to the ignition

15
of approved (labeled as meeting DoE standards) insulation. However, if a wire in an improperly protected circuit under loaded conditions were sandwiched between existing

combustible insulation (such as untreated paper or wood shavings), and new insulation

(regardless of the new insulation's properties), initiation of smoldering of the old

insulation could occur. If adjacent wood construction were in contact with electrical

wires in circuits with mismatched overcurrent protection devices, long-term exposure to elevated wire temperatures could result in chemical change, charcoal formation, and eventual initiation of smoldering. From the above, it appears that hazards from surrounding

electrical wiring with thermal insulation are closely related to the issue of circuits

that are incorrectly protected against overcurrent. Fact Sheet No. 18 on Home Electrical

Systems of the Consumer Product Safety Commission [46] warns against overfusing. It also

recommends as a precaution against overfusing that all Edison-based fuses (which allow

higher rated fuses) be replaced by "S" type non-interchangeable fuses (figure 5).

The same fact sheet also recommends that houses showing signs that their electrical systems

are beginning to fail be inspected by a licensed electrician or by the local power company

(if it makes inspections). The signs are: light dimming, fuses blowing or circuit

breakers tripping frequently, overheated or glowing receptacles, and flickering lights.

Remaining Questions

Several questions remain unanswered regarding potential hazards associated with electrical

wiring surrounded with thermal insulation:

0 How frequently and for what length of time do cables in residences actually

carry the overcurrents that could cause a hazard? Actual currents and their

duration in typical or in overfused residential circuits have never been

measured

.

What effect, if any, does a temperature slightly higher than the NEC limits,

both short-term and prolonged, have on electrical wiring or on surrounding

materials?

° How widespread is the practice of installing parallel (or "bunched") wires

in residential applications, and with what frequency do such parallel wires

carry near full ampacity at the same time?

° To what degree do gypsum wallboard or ceilings, wood joists or studs and

siding serve as heat sinks, and what effects do these have on the temperature

of wires?

0 Why have we apparently not experienced a rash of fires or at least electrical breakdowns in the many millions of homes retrofitted to date?

Code Rubber Wiring

A further potential hazard exists with houses that have so-called "Code Rubber" wiring.

The temperature limits for that wire were set by NEC at 50°C (120°F). Laboratory tests

show that thi^ temperature will be exceeded by a wire carrying the full rated load for

less than half an hour when the wire is surrounded by thermal insulation. Unless circuits

consisting of code rubber wire are derated, no insulation should be placed over them.

Code rubber was regularly installed until about 1940. Since, to begin with, such houses

frequently do not have adequate electrical circuits for today's heavy loads, (particularly

for window air conditioners, color television sets, and portable electric room heaters),

the potential for overloaded circuits is all the greater. Because there is a lack of data

on the performance and safety of circuits with code rubber type wiring, it is recommended

that houses with such wiring be inspected by an approved electrician and that upgrading of

the electrical service or derating of circuits be done prior to installing thermal

insulation in contact with this electrical wiring [47]

.

16
Insulation in Electrical Boxes

An additional potential hazard can result from the penetration of loose fill or foamed-inplace insulation into electrical boxes [48]. Insulation in junction, switch, and outlet

boxes can cause galvanic corrosion of the boxes and their components and can lead to short

circuits and arcing with corresponding fire risk (see figure 6). Therefore, after the

installation of loose fill or foamed in place insulation, electrical boxes, need to be inspected and any insulation that has lodged in the boxes must be cleaned out. Prior to this inspection and cleaning-out operation, electrical current in the particular circuit

must be shut off .

Conclusions and Recommendations

Test results and analytical studies show a potential violation of NEC provisions when

overloaded residential branch circuits are surrounded by thermal insulation. However,

such overload appears only possible if the circuits are improperly protected. Since the

installation of electrical circuits and related safety features are the subject of NEC and

are under the jurisdiction of local and State agencies, the RCS installation practices do

not contain mandatory provisions regarding the encapsulation of electrial wiring with

thermal insulation. DoE believes that the general statement in the RCS Rule to the effect

that existing local and State codes and standards are not superseded by the standard practices sufficiently addresses the potential violations of the National Electrical Code.

DoE is closely monitoring the results of ongoing research and should evidence appear that

a significant hazard is likely to result from surrounding wiring with insulation, the

installation practices will be amended accordingly.

However, in recognition of the fact that placing thermal insulation over and around

electrical circuits may aggravate such potential hazards as may already exist in circuits

with incorrectly matched overcurrent protection devices, it appears prudent to take the

following precautions prior to installing thermal insulation so as to surround or encapsulate electrical wiring:

° Conventional Edison-base fuses should be replaced with S-type fuse adaptors

(S-type fuse adaptors only accept correct fuses);

0 Oversized circuit breakers should be replaced with correctly rated ones;

In houses in which signs of beginning failure in electrical systems are apparent, an inspection should be performed prior to the installation of

thermal insulation, by either a licensed electrician or the local power

company;

° Houses with code rubber wiring (generally those built prior to 1940) should

be inspected by an approved electrician prior to the installation of thermal

insulation which will encapsulate the wiring.

These recommendations are in general agreement with the practices followed by the DoE

Weatherization Assistance Program and with similar recommendations provided by CSA in

their efforts to advise low income families. These recommendations are also in agreement

with the conclusions reached by Drucker: "House wiring embedded in good thermal insulating material is dangerous under conditions of electrical overloading of the circuits",

but he continues: "there appears to be no cause for alarm in houses where circuits are all correctly protected."

4.2.2 Recessed Lighting Fixtures

The National Electric Code for 1981 specifies that "thermal insulation shall not be

installed within three inches of the recessed fixture enclosure, wiring compartment or ballast and shall not be so installed above the fixture as to entrap heat and prevent the

free circulation of air unless the fixture is otherwise approved for this purpose," [49]. To conform with this NEC requirement, the RCS standard practices for thermal insulations

include a similar statement.

17
NBS has conducted an investigation to determine the effectiveness of various protective

barriers in maintaining the requisite 3-inch spacing and in preventing over-temperature

conditions when loose-fill insulation is installed around recessed lighting fixtures [50].

For the devices tested, the results indicate that properly installed open-top barriers are sufficient to allow the fixture and associated branch circuit wiring to operate within

specified ratings. However, a barrier closed at the top by any method can cause branch

circuit wiring, the external surface of the barrier and/or parts of the fixture to operate

at temperatures above those designated as "safe".

The tests were conducted on three fixture types, A, B and C, as shown on figure 7. Types A

and B were each tested with three barriers, X, Y, and Z (rectangular). Type C fixture was tested with the same barriers but with two shapes of Barrier Z (rectangular and square).

The four barriers tested were:

Barrier X consisted of asbestos sides and metal clip connectors. It measured 304 x 406 x

3.2 mm (12 x 16 x 1/8 inch).

Barrier Y is cut from a 356 mm (14 inch) by 7300 mm (24 foot) long roll of 0.25 mm 30 gage

aluminum with fold-out tabs for stapling or taping in place.

Barrier Z is a 0.55 mm (26 gage) galvanized steel sheet box which is available in two sizes

° 280 mm (11 inches) high and 370 mm (14 1/2 inches) square

0 280 mm (11 inches) high and 370 mm (14 1/2 inches) wide by 510 mm (20 inches)

long.

Table 2 shows selected temperatures as measured during the tests. The results can be

summarized as follows:

0 Properly installed open-topped barriers are effective in maintaining the 75 mm

(3-in) spacing between thermal insulation and the light fixture enclosure.

° The 75 mm (3-in) clearance requirements of the NEC, as provided by the opentopped barriers, are sufficient to allow these fixtures and associated branch

circuit wiring to operate within their specified temperature rating.

° Barriers in which the air flow is restricted by covering the top can cause branch circuit wiring, and in some cases, fixture wiring to operate above

their rated "safe" temperatures.

° The branch circuit wiring was always the first item to exceed its rating.

0 When a barrier is closed on top by a layer of insulation, temperatures

on the exterior surface of the barrier can exceed the 90°C (194°F) limit

specified by the National Electric Code, and temperatures on various parts

of the fixture itself can exceed the 150°C (302°F) limit required by Underwriter's Laboratory Standard for Safety for Electric Lighting Fixtures

(UL-57).

0 Significantly lower maximum temperatures are observed as the volume of the

enclosed barrier is increased.

° Fixtures rated for and operated with lower wattage lamps provide wider margin of

safety than do fixtures rated for and operated with high wattage lamps.

18
4.2.3 Surface-Mounted Lighting Fixtures

While the hazards associated with covering recessed lighting fixtures are generally acknowledged, well documented, and addressed in the RCS installation standards, hazards associated

with installing insulation on ceilings over surface-mounted incandescent fixtures have not been widely recognized. However, recent CPSC-sponsored research at NBS [51] has shown that

such practice can lead to electrical component temperatures (wires and junction boxes) well

above those permitted by the National Electrical Code [31]. Table 3 shows some representative temperatures observed in the NBS tests conducted with the fixtures shown in figures 8 through 11.

As can be seen from the table, some temperatures of electrical system components above sur- face-mounted (both flush and semi-flush) incandescent lighting fixtures were found to be

running above the NEC code requirements even before the addition of thermal insulation.

While this shows that a potential hazard is present even without thermal insulation, the

table also shows that the temperature increase with the addition of thermal insulation is

in the range of 20°C (68°F) to 30°C (86°F) for fixtures with more than one lamp and 10°C

(50°F) to 15°C (59°F) for single-lamp fixtures. This temperature increase results in an

increased potential hazard. It is further seen that "over-lamping" can cause additional

significant temperature rises.

While these results indicate the potential for violations of NEC, (covered under local and

State codes), the level of hazard has not been determined and DoE did not therefore include

mandatory installation standards provisions for precautions to be taken by the installer to reduce the hazard. However, it is recommended that prior to the installation of insulation

above ceiling-mounted fixtures, the following precautions be taken for fixtures not

specifically approved for installation under insulated ceilings:

° Assure that the lamps used in the fixture are of no greater wattage than the

fixture was designed for. For example, a fixture designed to carry two 60-

watt bulbs should never carry two 100-watt bulbs (or one 60 and one 100-watt

bulb). If the fixture does not carry a marking stating the maximum allowable

wattage (or a recommended wattage), assume that 60 watt per bulb is the

maximum allowable.

0 Install a barrier around the ceiling box so as to provide a 75 mm (3 inch) air

space around the box and at least as high as the intended level of attic insulation. This barrier is to be of the same type as that required for recessed

lighting fixtures. No insulation material should be placed inside the barrier

or on top so as to restrict free air circulation.

A surface-mounted fixture is one that is mounted directly to the underside of a ceiling

and either is fully enclosed with a cover ("flush") or provided with an air gap of only

38 mm (1 1/2 inch) or less between the enclosure and the ceiling ("semi-flush"). Not

included as surface mounted fixtures are hanging or pendant fixtures in which the lamp

is substantially below the ceiling.

19
5. DIAGNOSTIC TOOLS

Several diagnostic tools are available for the detection of energy losses in buildings.

Their use during energy audits is useful to assure that significant cost-effective energy

conservation opportunities are not missed (audit test). The same or similar tools are also

useful for evaluating the level of compliance with the standard practices (inspections) and

for the quality assurance programs of installation contractors (post installation test).

Selected commonly used tools are described below. As the interest in energy audits, quality assurance and inspection grows, many more, less costly, but also more accurate diagnostic tools will be developed.

5.1 INFRARED REMOTE SENSING (THERMOGRAPHY)

The installation standards include a general requirement that insulation be installed in

such a way as not to leave any gaps or voids. Where the installation is open for visual

inspection, it is easy for the contractor, inspector, or homeowner to assure himself that

this installation requirement has been met. However, where insulation is installed in

enclosed cavities, or where insulation is covered by a finish material (as is required for

plastic foam boards), visual inspection is not possible. Similarly, an auditor may not be

able to determine visually whether a house already has sufficient wall insulation, or whether existing wall insulation was installed without leaving major gaps or unfilled

spaces.

The only practical means for determining whether insulation in cavities or behind finish

material was installed in accordance with the DoE installation practices, is by infrared

remote sensing devices: thermographic imaging systems, line scanners, or spot radiometers.

With the use of this equipment, the auditor can determine whether a house was previously

insulated and the degree of voids left. The contractor can assure himself that his installation crews have performed a credible job. The inspector can determine compliance with

the installation standards. The homeowner finally can have a record (hardcopy/photograph)

of the quality of the installation useful at time of resale. Thermographic imaging systems

and line scanners have been used successfully by specialized auditing firms in residential

energy surveys. New home builders [53] sometimes use this equipment as do insulation contractors for existing buildings. The major drawbacks of using infrared remote sensing

devices are the cost of the equipment, time for survey and evaluation, and the necessity

for training operators and evaluators. Also, infrared sensing can only be done under

indoor-to-outdoor temperature differences of at least 10°C (lb°F). For practical purposes,

this limits its use to the colder season and to the northern part of the country.

The information below is given to assist those involved in home retrofit, specifically

administrators, auditors, contractors, and inspectors working under RCS to evaluate the

usefulness of thermographic surveys in their own particular situation. Those interested

in more detail on thermography will find the references and bibliography helpful.

In addition to its use for detecting missing insulation, thermography can also be used to locate major air leaks in a building. This can be done under natural atmospheric conditions, but is more effective if done in conjunction with fan pressurization test (see

below). This method is particularly well suited to detect air leakage bypasses in attics

at flues, chimneys, interior and exterior walls, and at windows in walls. Since stopping

of bypasses, once located, is often easy and inexpensive, this method is particularly well

suited in cases where a "low cost-no cost" energy retrofit is combined with the audit.

5.1.1 Need for Thermographic Surveys

Since equipment, operators, training, and time for thermographic surveys are relatively

expensive, DoE has sponsored joint research at NBS and the New England Innovation Group

to evaluate the cost effectiveness of such surveys [52], The study found that: (1) typical

insulating jobs in wall cavities often leave substantial portions of walls uninsulated, and

(2) that infrared thermography, used and evaluated by trained personnel, can detect faulty

installations. Specifically, the following deficiencies were found in 65 homes in eight

cities: 20 percent of the homes had over 10 percent of the wall area insulation missing.

For these homes the price of the missing insulation was usually more than the cost of a

20
thermographic survey by private contractors. Approximately 30 percent of the homes had

insulation missing in 5 to 10 percent of the insulated wall. For most homes this is still more than 4.65 m^ (50 ft^) of missing insulation. About 50 percent of the homes inspected

had less than 5 percent of the wall area uninsulated. Thus, more than half of the installations in the sample houses would not have been in compliance with the DoE Installation Standards. Shrinkage and fissures occurred in about two-thirds of the inspected homes, and

about one-third had defective ceiling insulation. Improperly installed weatherstripping

around the doors was noted in about half of the homes, and heat losses around the doors and

windows were observed in 31 percent and 72 percent of the dwellings, respectively. Joint

heat losses occurred at the wall-to-wall joints in 74 percent of the dwellings, at the wallto-ceiling joint in 51 percent of the dwellings and at the wall to floor joint (baseboard)

in 23 percent of the dwellings. Abnormal heat losses from the attic, as revealed by exterior inspections of the loss from the living areas or basement into the attic, were observed

in 32 percent of the dwellings. Excessive heat loss from the basement or crawl space was observed in about 15 percent of the dwelling. Air penetration into interior ceilings

between floors or under insulation was noted in 44 percent of the dwellings. As the above

data indicate, serious defects still existed in over two-thirds of the thermographically

inspected dwellings after weatherization by professional installers. Some of these defects

result from poor quality workmanship—missing insulation, air leakage at doors, and shrinkage or fissures, for example. Others, such as frame heat loss, excessive heat loss from

basements/crawl spaces, air penetration into ceilings, and excessive heat loss from attics

at soffits and eaves can be corrected, but are usually not considered normal weatherization

measures. Finally, other thermal defects such as joint heat losses and thermal bridges

cannot be corrected unless interior or exterior insulation is applied to the dwelling.

Based on the work to date, it can be assumed that if major expenditures are being made

for the installation of energy conservation measures in homes, a quality control inspection using thermography may be necessary to provide confidence that the building will

actually accrue the full savings expected from the measures. However, at present the

thermographic inspection services being provided by private inspection contractors vary

greatly in consistency, and few if any services to date specialize in residential insulation void detection. Unless done by qualified personnel, such inspections are of little

value. The significance of the findings described above for the RCS Program is that auditors, installation contractors, quality assurance personnel, and inspectors would be

well advised to use infrared thermography in their work, even if it is only on a spot-check

basis. Such use would be cost effective for the homeowner, would add to customer satisfaction and would promote more effective installation of energy conservation measures, particularly insulation. However, it also indicates the need for adequate training of RCS,

(auditors, inspectors) and installer's personnel in operating the equipment, in techniques

of inspecting buildings, and in analyzing the results of thermographic survey data.

5.1.2 Types of Equipment

There are three basic types of thermographic equipment that may be suited for use in con- junction with residential building retrofit: thermographic imaging systems, line scanners, and spot radiometers. Each of the three types has its own advantages and drawbacks, as sum- marized below. A more detailed description of individual systems and lists of manufacturers

are provided in "Status of Thermal Imaging Technology as Applied to Conservation" [53] and

in "Thermographic Instruments and Systems" [54], For a brief introduction, see also the DoE

Fact Sheet, "Infrared - An Energy Tool" [55].

Thermographic Systems: With this equipment, a two-dimensional thermal image of the surveyed

body or area is produced on a TV-like screen and hardcopy "thermograms" can be produced for

the record. The image shows surface temperatures in shades of black, gray and white (black

and white equipment) or in color (color equipment). Figure 12 shows an example of a thermogram of a room wall interior with defects noted, and figure 13 shows the same wall as a photograph. Figures 14 and 15 show photographs of typical systems.

The equipment provides thermal resolutions down to 0.2°C (0.36°F) and spatial resolutions

to 100 m^ (1080 ft^). The available resolutions permit the distinction between wall areas insulated with R-5 and R-15 (thus distinguishing between noninsulated and insulated wall

21
areas); and under more favorable conditions, between R-10 and R-15. The equipment is portable and for higher resolution systems consists of a camera, control and display units.

Some lower-resolution systems are hand-held. The cost for systems suitable for on-ground

work in conjunction with residential energy conservation audits and inspections is in the

range of $8,000 to $40,000. The majority of specialized infrared survey firms appear to be

using the more expensive models, but equipment at the lower end of the cost range has been

used successfully in residential conservation work under reasonably favorable conditions

and with proper care.

Line Scanners : Unlike imaging equipment which produce a two-dimensional display, line scanners only produce a one-dimensional measure of the apparent radiant temperatures

along a line in the optically viewed scene. In order to obtain meaningful results, the area to be surveyed has to be "scanned" and if hard copy is required for the record, it

is necessary to take a number of photographs. Each of the photographs may show a visual

image and a line indicating the apparent temperature variations along the scale line.

Figure 16 gives an example of a line display. Figure 17 shows a photograph of a typical

system.

According to manufacturer's literature, the equipment provides thermal resolutions similar

to those for imaging systems. The equipment is a hand-held, one-piece unit. The cost for

the equipment is in the $8,000 range.

Spot Radiometers : While imaging equipment produces a two-dimensional display and line scanners a one-dimensional representation of the apparent temperature along a line, the

spot radiometer measures the apparent temperature of a small area (hence "spot") on the

surface surveyed. The equipment is thus not well suited for conducting a complete survey

of a house, but can be used to determine whether a wall is insulated at all, and can be

used as a spot check to identify voids; for example, at the top of cavities filled with

loose-fill insulations. Figure 18 shows a photograph of a typical spot radiometer. The

read-out is a numerical meter indicating the apparent temperature of the surface target.

Through appropriate instrument adjustments and calculations, radiometer readings can be

corrected to measure actual surface temperatures.

According to manufacturer's literature, thermal resolutions are similar to those of the

imaging and line scanning equipment. The unit is relative small and lightweight. The

cost is in the $300 to $1200 range.

5.1.3 Use of Thermography

A complete thermographic survey of a house may take as little as 45 minutes or as much as three hours of a trained and experienced operator's time, and commercial thermographic sur- vey firms charge between $45 and $200 for residential surveys [53] . The cost of surveys

as part of audits, installation and inspection should be lower since separate travel to and from the site is not required. Also, it may be possible to develop ir dividual survey

techniques specifically suited to each of the three potential uses in RCS Program retrofit.

Thermography is a powerful tool for auditing, quality control, and inspections. However,

the usefulness of this technique depends on several factors:

° Most importantly, thermography is not for use by untrained and inexperienced

personnel. Unreliable results must be anticipated if used without proper

training

.

0 Although individual equipment may have different requirements, the following

are some general guidelines and limitations:

- Inside-to-outside temperature differential should be at least 10°C

(18°F) to provide image discrimination adequate to identify air leaks

and areas of missing insulation.

- Interior surveys are preferred, except where cabinets, radiators and

similar obstructions prevent the viewing of the interior wall surfaces.

22
- Exterior surveys cannot be done reliably when the sun is shining on the surface surveyed, and are best done at nighttime; exterior surveys may be needed to detect heat and air leaks at ceiling/wall

and ceiling/floor joints, crawl spaces and under the eaves;

For best results when checking for air leaks, the building should be

under pressure or under a partial vacuum. For interior thermography,

a partial vacuum will show air leaks most effectively; for exterior

application, a positive pressure is required; (see Section 5.2.1 for an outline of pressurization and evacuation of houses by the "fan door").

- The American Society of Heating, Refrigerating and Air Conditioning

Engineers (ASHRAE) has published a proposed standard for the "Application of Infrared Sensing Devices to the Assessment of Building

Heat Loss Characteristics" [56]. All surveys should be conducted in

accordance with this standard.

5.2 AIR TIGHTNESS AND AIR CHANGE RATE

Air leakage accounts for approximately 20 to 40 percent of all heat losses in houses [57].

Control of air leakage through caulking of walls, sealing of attic bypasses, and weatherstripping of windows and doors (or replacement of leaky windows and doors) thus is a major

and often inexpensive means of improving the energy efficiency of a house. To determine

whether a particular house has excessive air leakage or not, air change rate or air tightness measurements are useful as part of an effective audit.

Air Leakage Rate is the volume of air movement per unit time across the boundary of the

conditioned space, normally expressed as cubic metre per hour (m-Vh) (cubic feet per minute

(cfm)). Air leakage rate is used to describe the air tightness of a building envelope.

Air Change Rate is the air leakage rate in volume per hour divided by the building space

volume, normally expressed by air changes per hour (ACH or ACPH).

5.2.1 Air Tightness Test by Fan Pressurization

The tests of air tightness consist of pressurizing the interior of the house or creating a partial vacuum in the house, and measuring the air volume required to maintain the pressure

or vacuum. This test is less realistic than the air change rate methods described below,

as it imposes an artificial pressure differential across the entire building envelope.

However, it is more readily reproducible and if the tests are performed both with pressure

(positive) and partial vacuum (negative), the results should provide a meaningful measure

of the building's air tightness. For research purposes, fan pressurization tests often use

heavy, expensive, and complex equipment. Princeton University has developed a simplified

type of equipment commonly called a "fan door" [58] specially designed for use in energy

audits. Figure 19 shows a fan door which is used to induce the pressure and vacuum

required for the air tightness test. The fan door is installed in lieu of the regular

door and sealed into place. The fan is then run (usually by electric motor) to produce

the air pressure differential desired. The air volume required to produce the pressure

differential is determined based on the fan's air-handling capacity as measured by the

fan's RPM and the pressure drop across the fan. All air tightness tests should be con- ducted in accordance with the provisions of ASTM Standard Practice E 779-81 [59].

5.2.2 Air Change Rate Test by Dilution Methods

Air change rate is customarily measured by the tracer gas dilution technique. In this

technique, a known concentration of a gas (the "tracer") is released in the indoor air and

the decay rate of its concentration is measured under ambient in-service conditions [bOj.

Although the exact measurement of the decay rate involves either time-consuming sampling

over an extended period or the use of sophisticated equipment (see figure 20), a new and

much simplified method was developed jointly by Princeton University and NBS in which a known amount of tracer gas is released at one point in time and the sample air is collected

23
at a single interval (generally 1 hour) or in two separate samples, and the samples are sent to a laboratory for analysis [61]. Figure 21 shows the release of the gas and figure

22 shows the air sampling in a sealed bag. Figure 23 shows the automated equipment used in

the laboratory to analyze the sample. This method provides an integrated measure of air

change rate over time (1 to 2 hours), but the results are dependent on both indoor/outdoor

temperature differences and on average wind speed during the testing period. Thus tracer

gas dilution tests for measuring air change rates should not be performed at extreme

temperatures and extreme wind conditions. Air change rate tests should be conducted in

accordance with the provisions of ASTM Standard Practice E 741-80 [62],

Both the tracer gas and container method and the fan pressurization method are being used

to monitor some 300 weatherized homes of the Community Services Administration (CSA) wea- therization demonstration in 14 different climatic regions [63]. Comparative tests were also performed in the Princeton Twin Rivers project. To date, a definitive correlation

between the two methods has not been established. However, in combination, the two methods appear to be well suited to establish the air infiltration characteristics of homes

5.3 WINDOW AIR INFILTRATION RATE

Energy loss through windows account for some 5 percent of total energy use in this country

[64]. It is for this reason that thermal replacement windows, among other window retrofit

measures, are one of the energy conservation measures approved for the RCS Program. It is

also for this reason that the DoE standard for thermal windows specifies a maximum allowable air infiltration rate. The measurement of air infiltration rates through windows thus

is one element in the inspection of proper installation of windows. ASTM Standard

Method for measurement of Air Leakage through installed exterior Windows and Doors, ASTM

E 783-81 [65] should be used for field tests. ASTM E 283-73 [66] is for use in the

laboratory and should not be used for field tests.

The air infiltration of windows installed in a building is usually greater than that

measured in the laboratory. Nevertheless, the air tightness of good quality windows

(either thermal windows or storm windows) measured in the field after installation can equal the tightness measured in the laboratory, if the installation is performed in accordance with good practice and the manufacturer's instructions. This is indicated by Weidt

[67] reporting on a study performed for DoE in the Minneapolis/St. Paul area on field air

leakage in newly installed residential windows: "Field air leakage performance of windows

ranged from 0.06 m

3 /h«m (0*01 cfm/lf) (an extremely tight window) to 13.68 nrVh'm (2.28

cfm/lf) (an extremely leaky window), while manufacturer's performance specification ranged

from 0.016 m

3 /h«m (0.003 cfm/lf) to 0.08 m3 /h«m (0.50 cfm/lf)."

All field tests for air infiltration on windows use the same principle: an "air chamber"

is built onto the window opening. Air is either blown into or evacuated from the chamber

to create a predetermined pressure difference between the air in the "chamber" and the air

on the other side of the window. The volume of air measured in cubic metre (cubic feet)

required per hour (minutes) to maintain the pressure is then the air leakage rate of the

window at the particular pressure difference. For comparison purposes, it is common to divide the total window air leakage rate by the length of "crack" (the length of joint

between the movable sash and the stationary window frame). This then gives an air infiltration charcacteristic shown as m

3 /h«m (cfm/lf). Alternatively, the total leakage is

sometimes also divided by the area of the window (width times height) and given as m3 /h*m^

(cfm/sf t).

The "chamber" used in a field test consists frequently of a simple 0.15 mm (0.006 inch)

thick polyethylene film adhered to the window or opening with masking or duct tape.

Sometimes a plywood panel, cut to the appropriate dimension and adequately supported, is

used instead of the film. Other equipment necessary is a blower, an air flow meter, an

air pressure gage and appropriate hoses. As a blower, a vacuum cleaner has been used;

flow meters are usually either of the variable area type or simple gas meters, and for

pressure measurements, inclined manometers are most frequently used. The accuracy and

tolerances required in field tests should be approximately those specified in ASTM E283-73.

When conducting tests with a polyethylene film, it is most important to prevent the film

24
from acting as a sealer on the crack. The use of the film is therefore difficult in tests

where the partial vacuum (negative pressure) is to be created between the film and the

window.

Figure 24 gives a schematic drawing of the test installation used by Princeton University

on the Twin Rivers Project. Notice that the flow of air could be reversed since, in

service, windows experience both air flow from the outdoor to the indoors (infiltration)

and from indoors to the outdoors (exf iltration) . A single window can even experience both

infiltration and exfiltration at the same time. For example, infiltration can occur on the

bottom and exfiltration on the upper half of the window. Therefore, tests should be

conducted twice—once each with air flowing in and with air flowing out.

Figure 25 shows a photograph of a portable instrument package which contains a blower and

both the air flow meter and the pressure indicator.

A note to those interested in conducting field window air infiltration tests: Only personnel versed in measurement technology in building construction and in the various leakage

and bypass paths through and around window openings should be conducting and interpreting

test results. However, used judiciously by trained auditors, inspectors and installers

field tests on existing windows can be very useful to determine whether a window needs

replacement (audit test) or whether the replacement by a thermal window has achieved its

stipulated reduced air leakage level of 0.08 m^/mh (0.5 cfm/ft min) (inspection test).

25
6. PRODUCT CERTIFICATION AND LABORATORY ACCREDITATION

Under the RCS Rule, only program measures identified as conforming to DoE standards" may

be installed, and only materials meeting the DoE material standards may be so identified.

Thus, manufacturers who want to supply products for use under RCS need to engage in some

type of certification process. Since the RCS Rule does not specify any details of the

certification program required, State planning and administrative personnel, auditors,

installers, lenders and inspectors should be familiar with the types of certifications

available. Specifically, they may want to determine the reliability of a particular

certification program, to distinguish between manufacturer's self-certification and thirdparty certification, and between accredited and nonaccredited laboratories.

6.1 PRODUCT CERTIFICATION

The quality of a product depends on two major elements:

° The design or formulation of the product; and

° The care and consistency of the manufacturing process.

The design or formulation of the product is, or can generally be, evaluated against

specific criteria by physical testing or by design specification review. Tests done on prototype models, which are not necessarily identical to the production line output, indicate how the product, material, or formulation might perform rather than how it will perform. While successful prototype testing does not necessarily ensure that the production

model performs as required, such tests are useful and for simple products sometimes

sufficient.

The care and consistency of the manufacturing process depends on many variables such as, but not limited to, equipment used, equipment calibration and maintenance, training and

experience of production and supervisory personnel, "workmanship", and sometimes environmental conditions (temperature and relative humidity) in the production room. The process

that the manufacturer uses to assure himself of producing a product of consistent quality

is called a quality control or quality assurance program.

When a supplier identifies his product as conforming to DoE standards, he certifies that

the product as sold consistently meets or surpasses all the provisions of the appropriate

DoE material standards. This is called self-certification. It does not mean that DoE has

tested the product, or that DoE has checked the manufacturer's quality control program.

The confidence that the buyer has in the self-certification label is dependent on his or her confidence in the integrity and capability of the manufacturer.

Third-Party Certification is the process where an outside organization other than the manufacturer supplier (such as an independent testing laboratory) assesses the manufacturer's

quality control program. Thus the third-party certification is an extension, and not a replacement for the manufacturer's own in-house quality control program. With third-party

certification, the buyer in general can have greater confidence that the products meet the

standards consistently.

Third-party certification programs vary greatly. In some, one or several specimens of the

product are tested once and no further follow-up testing or plant visits are conducted.

Depending on the product involved, third-party programs of this type by themselves may be

worth less than the self-certification by a reputable supplier. Other certification

programs call for periodic product testing at appropriate intervals with or without prior

notice to the manufacturer. In yet others, product testing is combined with regular checks

on the manufacturer's own quality control program. Equipment used in the quality assurance program (for example, scales) may also be calibrated by the third party. The confidence of

the buyer in the usefulness of the third-party certification of a particular product is

thus dependent on the type and extent of that third-party's certification program.

The level of effort that is appropriate for the certification of a particular product

depends on the complexity of the manufacturing process, the tolerances required and the

26
consequences of a product's performance. Thus a product that is characterized by a simple

manufacturing process, little need for close tolerances, and no significant safety hazards

when installed will justify only a relatively low level of effort for certification. On

the other hand, a complex product requiring many different processes for manufacture, very

exacting tolerances, and posing severe safety consequences when malfunctioning in service

will require a very comprehensive certification program. An example of the latter type of

product may be electrically operated vent dampers and of the former, weatherstripping.

In practice, most certification programs are somewhere between these extremes.

In third-party certification, an outside organization other than the manufacturer/marketer

provides the manufacturer/marketer and the user with assurances that the product meets a particular standard. The third-party certifier can conduct all or only some of the certification procedures, and may contract with others (or have the manufacturer contract with

others) to conduct the remaining procedures. A third-party certifier can be:

° A professional or technical society such as the American Society of

Mechanical Engineers (ASME);

° A trade association, such as the Association of Home Appliance Manufacturers

(AHAM) or the American Gas Association (AGA);

An independent testing organization such as Underwriters Laboratories (UL),

Factory Mutual Engineering and Research (FM), or ETL Testing Laboratories;

0 A consumer organization, such as Consumers Union (CU);

° An organization of producers, testing laboratories, and sometimes consumers within a specific industry or combination of industries concerned with the

well-being of that industrial group and/or its customers, such as the Solar

Energy Industries Association (SEIA); or

A government agency, such as the Department of Housing and Urban Development

(HUD).

The types of procedures used in certification programs can be grouped as follows [68]:

Type-testing/initial Inspection - By itself this only provides assurance that

the manufacturer's design specification can produce a product that conforms

to a particular standard. It gives no guarantees, however, of the ability

of the manufacturer to consistently produce products that meet the design

specification.

° Audit-Testing - This procedure involves testing samples selected from the

marketplace. A high level of this type of testing is usually required to provide adequate assurance that products are meeting the desired standard.

Surveillance of the Manufacturing Process - This involves periodic assessment of a manufacturer's production and control processes. With minimum

cost, it can provide assurance that the manufacturer's quality control procedures are adequate.

Fjeld Investigations - This involves investigating alleged failures of

products in use to determine the cause of failure and to take the appropriate corrective action.

Batch-testing - This involves selecting a sample from a batch of products and

testing it for conformance to the standard. Provided the sampling procedure

is adequate, batch-testing can provide confidence that all products in that

batch will likely conform to the standard. It does not provide any assurance

of the quality of products produced in earlier or subsequent batches. This

is the procedure used by many certification programs relating to building

products, such as energy conservation measures.

27
0 100 Percent Testing - This procedure involves testing each individual product to determine if it meets the desired standard. If the testing procedures are adequate, the procedure does provide the highest level of assurance that the product conforms to a particular standard. It can also

be a very expensive procedure.

A certification program may use one or more of the above procedures to assure that a product conforms to a particular standard. The procedure(s) used can have a great bearing

on the level of confidence that can be placed in the certification program. It will also

affect the cost of the program [69].

ANSI has developed criteria to evaluate certification procedures [70] and to accredit thirdparty certification programs [71]. To date two product-certification programs have received

ANSI accreditation, both relating to products that are used as energy conservation measures: Aluminum Windows and Sealed Insulating Glass.

6.2 LABORATORY ACCREDITATION

Related to the accreditation of product-certification programs is laboratory accreditation.

The purpose of laboratory accreditation is to provide a mechanism which assures the manufacturer or user of a product that certain laboratories are technically qualified to conduct

specific tests.

The most significant laboratory accreditation system which addresses energy conservation measures is the National Voluntary Laboratory Accreditation Program (NVLAP). The program

is conducted by the Department of Commerce. NVLAP only concerns itself with products and

tests which an industry group requests be included in the program. To date the program

includes the accreditation of laboratories for specific tests related to: thermal insulation materials, freshly mixed field concrete, and carpets. The tests that laboratories

currently can be accredited for are listed in the "Criteria" published in the Federal

Register on January 23, 1980 [72]. The list includes some 50 tests related to thermal

insulation and attached membranes, including many tests referenced in the DoE/RCS Material

Standards.

Under NVLAP, both the manufacturer's own laboratories as well as commercial or independent

laboratories can be accredited. Thus a NVLAP-accredited laboratory is not always an independent or third-party laboratory. The reason for this is that NVLAP only determines

whether the laboratory is technically capable of performing the specified tests, whether

it has available the required and properly calibrated equipment and appropriately trained

personnel. It does not guarantee that a laboratory has no financial interest in the outcome of the product testing, nor does it guarantee that the laboratory will always perform

the tests properly, or that the laboratory is capable of performing other tests for which

it is not accredited. NVLAP only accredits testing capability. It is not concerned with

other aspects of certification, such as the conduct of inspections or the evaluation of a manufacturer's quality assurance program.

The following describes some programs for tests and products other than those covered by NVLAP:

HUD requires that third-party certifiers (validators) approve laboratories to test building materials;

The Department of Defense, the General Services Administration, and other

Federal agencies accredit laboratories to test products for conformance to procurement specifications;

0 States and cities accredit laboratories to test for compliance with their

regulatory requirements;

° Industry associations operate programs to accredit laboratories to test products for certification purposes;

28
° The American Association for Laboratory Accreditation, currently in its

formative stages, proposes to accredit laboratories using ASTM criteria for

evaluating testing laboratories.

Laboratory accreditation does not eliminate the need for or desirability of either self- or third-party certification, but accreditation does provide the consumer or user with assurance that tests are performed by qualified personnel using appropriate equipment. In the

absence of a formal certification program, or if reliance is on self-certification such as under RCS, the knowledge that tests were performed by an accredited laboratory provides a measure of assurance that the product meets the quality standards prescribed.

29
REFERENCES TO PART I

Federal Register, Volume 44, No. 217, Wednesday, November 7, 1979, pages 64642 through

64727.

National Energy Conservation Policy Act (NECPA), Public L. No. 95-619, 92 stat

3206, Part 1 of Title II.

"Residential Conservation Service Installers Training Manual," U.S. Department of

Energy, Washington, D.C. 20585, 1981.

"Residential Conservation Service Inspectors Training Manual," U.S. Department of

Energy, Washington, D.C. 20585, 1981.

Office of Management and Budget, Circular No. A-119, "Federal Participation in the

Development and Use of Voluntary Standards," January 17, 1980.

Hamilton, Robert W., "The Role of Non-Governmental Standards in the Development of

Mandatory Federal Standards Affecting Health and Safety," Texas Law Review, Vol. 56,

Number 8, November 1978.

Harter, Philip J., "Regulatory Use of Standards: The Implications for Standards

Writers," National Bureau of Standards GCR 79-717, November 1979.

"Standard Practice for the Installation of Storm Windows, Replacement Windows, MultiGlazing, Storm and Replacement Doors," ASTM E737-80. 1980 Annual Book of Standards,

Part 18,' American Society for Testing and Materials, Philadelphia.

"Materials Criteria and Installation Practices for the Retrofit Application of Insulation and Other Weatherization Materials," DoE/CS-0051 . November 1978.

Federal Register, Volume 43, No. 222, November 16, 1978, pages 53494 and 53495.

Federal Register, Volume 44, No. 54, Monday, March 19, 1979, pages 16546 through

16797.

Federal Register, Volume 45, No. 156, Monday, August 11, 1980, pages 53422 through

53432.

Federal Register, Volume 44, No. 247, Friday, December 21, 1979, pages 75956 through

75987.

Federal Register, Volume 45, No. 187, Wednesday, September 24, 1980, pages 63432

through 63459.

Federal Register, Volume 45, No. 188, Thursday, September 25, 1980, pages 63786

through 63810.

Federal Register, Volume 44, No. 217, page 64687, 456.904, (a)(3).

"Standard Recommmended Practices for Increasing Durability of Building Constructions

Against Water-Induced Damage," ANSI/ASTM E 241-77. 1979 Annual Book of ASTM Standards,

Part 18, page 884, American Society for Testing and Materials, Philadelphia, Pennsylvania, 1979.

Kusuda, Tamami, and Walter Ellis, "Vapor Condensation in Air Pervious Insulation."

Commission B.l-Thermodynamics and Transport Processes, International Institute of

Refrigeration, Washington, D.C, September 1976.

Anderson, L. 0., "Condensation Problems: Their Prevention and Solution," EPL 132.

Forest Products Research Laboratory, U.S. Department of Agriculture, Madison, 1972.

30
Barre, Henry J., "The Relation of Wall Construction to Moisture Accumulation in FillType Insulation," Research Bulletin 271, April, 1940, Agricultural Experiment Station,

Iowa State College of Agriculture and Mechanic Arts.

Burch, D. M. , and C. M. Hunt, "Retrofitting an Existing Wood Frame Residence for

Energy Conservation—An Experimental Study," NBS Building Science Series 105, 1978.

ASHRAE Handbook and Product Directory, 1977, Fundamentals Volume, Chapter 20, Page

20.1, New York.

Burch, Douglas M. , and Stephen J. Treado, "A Technique for Protecting Retrofitted

Wood-Frame Walls from Condensation Damage." American Society of Heating, Refrigerating

and Air Conditioning Engineers, Transactions 1978.

Trechsel, H. R. , P. R. Achenbach, and S. J. Launey, "Control of Condensation in the

Walls and Ceilings of Retrofitted Houses," presented at an ASTM Symposium on October 6, 1980, to be published in the proceedings as an ASTM Special Publication

(in review).

Seaton, Johnson and Odell, with George Tsongas, "A Field Study of Moisture Damage in

Walls Insulated Without a Vapor Barrier," The Oregon Department of Energy, Salem,

Oregon, 1979 November, 95 pp.

Weidt, John L. , Robert J. Saxler, and Walter J. Rossiter, Jr., "Field Investigation

of the Performance of Residential Retrofit Insulation," National Bureau of Standards

(U.S.) Technical Note 1131, 1980 September, 67p.

ASHRAE Handbook and Product Directory, 1977, page 20.9.

HUD Minimum Property Standards, One and Two Family Dwellings 4900.1, Chapter 6,

Division 7, 607-2.4, Department of Housing and Urban Development.

"Summer Attic and Whole-House Ventilation," Proceedings of a Workshop held on July

13, 1978, at the National Bureau of Standards, Gaithersburg, Maryland. Edited by

M. Reppert. NBS Special Publication 548, July 1979.

Burch, D. M. , and D. E. Luna, "A Mathematical Model for Predicting Attic Ventilation

Rates Required for Preventing Condensation on Roof Sheathing," ASHRAE Proceedings,

to be published.

National Electric Code, NFPA-70. National Fire Protection Association, Boston,

Massachusetts, 1981, Tables 310-16 through 310-19.

Fire Protection Handbook, National Fire Protection Association, 14th Edition,

1976, page 3-5.

Schaffer, E. L., "Smoldering Initiation of Cellulosics Under Prolonged Low Level

Heating," Fire Technology, February 1980.

Harwood, Beatrice, "Residential Electrical Wiring Systems and Thermal Insulation,"

U.S. Consumer Product Safety Commission, Washington, D.C. , August 1979, p. 18.

Plug Fuses, UL 198.5. Underwriters Laboratories Inc., May 30, 1973.

Molded-Case Circuit Breakers and Circuit-Breaker Enclosures, UL 489. Underwriters

Laboratories, Inc., November 1, 1972.

Beausoliel, Robert W. , William J. Meese, and Lawrence Galowin, "Exploratory Study of

Temperatures Produced by Self-Heating of Residential Branch Circuit Wiring When Surrounded by Thermal Insulation," NBSIR 78-1477. 1978.

31
Hill, Richard to Sandy Monje, "Fire Hazard Associated with Cellulosic Insulation

Covering Electric Wires," October 23, 1979.

Drucker, Eugene E. , "Electrical Wiring Hazards in Insulated Wall Cavities," Firebrand,

April, 1979, page 8.

Pecker, C. , "Investigation of Possible Hazard of Electrical Wiring Covered by Thermal

Insulation," Draft Report, Stevens Institute of Technology, Hoboken, N.J. 07030,

November, 1980.

Evans, David D. , "Modeling for Determination of Temperatures of Electrical Cables

Within Thermally Insulated Walls," NBSIR 80-2129, 1980.

NBS Letter Report: Progress Report on First Return of Thermal Indicating Flexible

Strips Installed on Residential Branch Circuits Covered with Thermal Insulation.

T. Faison to S. Launey, July 1980.

Gross, Daniel, "A Preliminary Study of the Fire Safety of Thermal Insulation for

Use in Attics or Enclosed Spaces in Residential Housing," NBSIR 78-1497, 1978,

page 14.

Vaishnav, M. P., "Electrical Aspects of the CSA/NBS Weatherization Study;

NBSIR 81-2203, January 1981.

Private Communication, Jenkins Washington, March 14, 1980.

Consumer Product Safety Commission Fact Sheet No. 18: The Home Electrical System,

July 1979.

"Determination of Current Carrying Capacity of Rubber Insulated Conductors for Code,

Performance and Heat-Resistant Grades of Insulation," Final Report of NEMA Subcommittee on Determination of Maximum Permissible Current Capacity, June 27, 1938.

Beausoliel, Robert W. , William J. Meese, and Lawrence Galowin, "Exploratory Study of

Temperatures Produced by Self-Heating of Residential Branch Circuit Wiring When

Surrounded by Thermal Insulation," NBSIR 78-1477, 1978, p. 32.

National Electric Code, NFPA-70, 1981, 410-66.

Fulcomer, P. Michael, "Temperature Measurement on Operating Recessed Lighting Fixtures," National Bureau of Standards Report, NBSIR 79-1913, September 1979.

Fulcomer, P. Michael, "Temperature Measurement on Operating Surface-Mounted Lighting

Fixtures," National Bureau of Standards Report NBSIR 79-1912, September 1979.

Grot, Richard A., "An Assessment of the Application of Thermography for the Quality

Control of Weatherization Retrofits." Proceedings of Thermosense 2, American Society

of Photometry, Fall Church, VA, 1980.

Snow, Frank J., James T. Wood, Robert C. Barthle Jr., "Status of Thermal Imaging

Technology as Applied to Conservation — Update 1," Prepared for the U.S. Department of Energy, Assistant Secretary for Conservation and Solar Applications, Under

Contract No. EM-78-C-01-4228, December, 1979.

Madding, Robert P., "Thermographic Instruments and Systems," University of Wisconsin,

Madison, 1979.

Infrared — An Energy Tool, Department of Energy Fact Sheet, Department of Energy,

1000 Independence Ave., Washington, DC 20585.
"Application of Infrared Sensing Devices to the Assessment of Building Heat Loss

Characteristics," ASHRAE Standard 101 P (Proposed), American Society of Heating,

Refrigerating, and Air-Conditioning Engineers, 1979.

"Residential Energy Conservation," Office of Technology Assessment, Congress of

the United States, Washington, D.C. 20510, March, 1979, p. Xl-7.

Harrje, David T. , Blomsterberg, Ake, and Persily, Andrew, "Reduction of Air Infiltration Due to Window and Door Retrofits in an Older Home," The Center for Energy and

Environmental Studies, Princeton University Report PU/CEES 85, May 1979.

ASTM Standard Practice for Air Leakage Measurement by the Fan Pressurization Method,

E 779-81. American Society for Testing and Materials, Philadelphia, PA.

Hunt, Charles M. , and Stephen J. Treado, "A Prototype Semi-Automated System for

Measuring Air Infiltration in Buildings Using Sulfur Hexafluoride as a Tracer,"

NBS Technical Note 898 1976.

Grot, Richard A., "A Low-Cost Method for Measuring Air Infiltration Rates in a Large

Sample of Dwellings," NBSIR 79-1728.

ASTM Standard Practice for Measuring Air Leakage Rate by the Tracer Dilution Method,

E741-80, 1980 Annual Book of Standards, Part 18, American Society for Testing and

Materials, Philadelphia.

Crenshaw, Richard, Roy Clark, Robert Chapman, Richard Grot, McClure Godette, "'CSA'

Weatherization Demonstration Project Plan," NBSIR 79-1706.

Berman, Samuel M., and Stephen E. Selkowitz, "DoE/LBL Window Research, Energy Effective Windows," NBS Special Publication 512, April 1978, p. 15.

"Standard Method for Measurement of Air Leakage Through Installed Exterior Windows

and Doors," ANSI/ASTM E 783-81, 1981 Annual Books of Standards, Part 18, American

Society for Testing and Materials.

"Standard Test Method for Rate of Air Leakage Through Exterior Windows, Curtain Walls,

and Doors," ANSI/ASTM E 283-73, 1980 Annual Book of Standards, Part 18, American

Society for Testing and Materials, Philadelphia, Pa.

Weidt, John and Zenney Weidt , "Air Leakage of Newly Installed Residential Windows,

Lawrence Berkeley Laboratory, LBL-11111 UC-94d EEB-W-80-12 W-68, June, 1980.

Thomas, Douglas B. NVLAP Glossary of Terms for Laboratory Accreditation, Product

Certification and Standardization. U.S. National Bureau of Standards, Washington,

D.C. 1980.

Rawie, Carol Chapman, "Economics of the Products Certification Industry: Some Research

Needs," NBSIR 80-2001.

American National Standards Institute (ANSI). "American Standard Practice for Certification Procedures. " No. Z34. 1-1947 (R1975), ANSI, New York.

American National Standards Institute (ANSI). "Self-Certification by Producer

or Supplier," No. Z34. 2-1980, ANSI, New York.

Federal Register, Vol. 45, No. 16, Wednesday, January 23, 1980, pages 5572 through

5600.
TABLE 1. NORMAL INDOOR RELATIVE HUMIDITY

CONDENSATION INDOOR RELATIVE HUMIDITY, % ZONE (MONTH)

NOV DEC JAN FEB MAR

1 35 20 20 20 20

2 50 35 35 35 50

3 No Control Needed to Prevent Condensation

34
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35
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37
38
°c

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CO

LU

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00

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Ll_ o

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or

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orLU

Q.

100 —

50

°F

200°C (392°F) IGNITION —I 400

TEMPERATURE OF WOOD

- 300

MELTING TEMPERATURE OF POLYVINYL

CL0RIDE ELECTRICAL INSULATION

115°C (239°F)

60 C (140 °F) MAX. ALL OWABLE

TEMPERATURE, UL 719~

50 C (122°F) MAX. ALLOWABLE FOR CODE RUBBER

3 PARALLEL CABLES, 35% OVERLOAD • SINGLE CABLES, 35% OVERLOAD

A 3 PARALLEL CABLES, 100% LOAD

O SINGLE CABLE, 100% LOAD

200

— 100

32

1h 2h

TEST TIME - HOURS

3h

FIGURE 4 - TEMPERATURES OF ELECTRICAL CABLES ENCAPSULATED IN THERMAL INSPECTION

Non-Metallic-Sheathed Cable (Type NM-#12 AWG Solid Copper 2 Conductors With Cround), Between Two Layers of R-ll Glass Fiber Batts, Carrying 20 Amperes (100% Load) and

27 Amperes (135% Load).

FROM REFERENCE [37] .

39
"S"-type fuse and adapter

FIGURE 5 - EDISON AND S-TYPE FUSES FROM REFERENCE [46].

FIGURE 6 - PENETRATION OF CELLULOSE THERMAL INSULATION INTO WALL OUTLET BOX. FROM REFERENCE [37].

40
7V,

i* | B T

-IB R

*y,

FIXTURE

A

-12 —

mm ;e°

FIXTURE

B

TO JUNCTION BOX

INCHES AWAY

ay,

FIXTURE

C

2%

A-Y C-Y

14%

5

A-Z

• Fixtures are mounted equidistant between

2x6 joists.

• Joists are spaced 16 inches on center.

• Branch circuit wiring is shown entering

and leaving box for fixtures A and C.

B - Ballast

R - Reflector

S - Socket

C-Za

Vh C-Zb

FIGURE 7 - DIAGRAMS OF RECESSED LIGHTING FIXTURE/BARRIER CONFIGURATIONS.

FROM REFERENCE [50]

.

41
FIGURE 9 ~ FIXTURE B Semi Flush Mount,

Three Lamps Rated

for 60 Watts Max

42

FIGURE 14 - HIGH RESOLUTION THERMAL IMAGING EQUIPMENT.

FROM REFERENCE [53].

FIGURE 15 - HAND HELD THERMAL IMAGING APPARATUS.

FROM REFERENCE [53],

44
FIGURE 16 - LINE SCANNER DISPLAY.
FIGURE 19 - PHOTOGRAPH OF FAN DOOR (BY PERMISSION OF PRINCETON UNIVERSITY).

46
FIGURE 20 - EQUIPMENT FOR SF, TRACER GAS AIR EXCHANGE MEASUREMENT.

FIGURE 21 - TRACER GAS CONTAINER METHOD - RELEASE OF GAS.

47
FIGURE 22 - TRACER GAS CONTAINER METHOD - AIR SAMPLING.
SENSITIVE LOW

PRESSURE GAUGE TO

~ I Pa INCREMENTS AP = 0

INDUSTRIAL VACUUM

CLEANER

GAS METER

WALL

SECTION

FIGURE 24 - WINDOW AIR LEAKAGE TEST - SCHEMATIC OF EQUIPMENT.

FIGURE 25 - COMMERCIALLY AVAILABLE PRE-PACKAGED UNIT.

49
PART II - STANDARD PRACTICES

PREFACE

In this part, the individual standard practices are provided essentially as published in

the Federal Register. Where appropriate, additional recommendations for safer and more effective installations are also given, together with a commentary on the purpose or origin

of major provisions. For clarity, the recommendations and commentary are indented, the

actual rule provisions are not.

In general, the practices are included verbatim, except:

* For greater ease in use, a decimal numbering system for paragraphs replaces

the identification method given in the rule;

° Sections provided in the rule as "Additional Requirements" but applying to all

standards were included within the practices;

Sections on "Applicable Documents," "Materials" and "Significance" were added

for completeness and greater usefulness. The format thus obtained is that

commonly used by ASTM and should facilitate the conversion of the standard into

voluntary consensus documents;

° The SI conversion for all common units was placed in front, instead of behind

the common units;

° Minor editorial revisions were incorporated, mostly to achieve greater

consistency and compatibility of all standard practices. This applied

particularly to the practices for urea-formaldehyde foam, vent dampers, and

automatic intermitent ignition device;

Many of the referenced documents have been updated since the publicaiton of

the RCS Rule. While for regulatory purposes such references need to be

updated according to the procedures of the Administrative Procedure Act,

the most recent issue of all documents is referenced in this publication.

Each of the standards presented below is given in its entirety and complete in itself.

This leads to some repetition of similar or identical provisions, recommendations and

commentary. However, it is felt that clarity and ease of reference more than compensate

for the repetitions. Also, individual users may well be interested only in the installation

requirements for one particular product. For them, the format used will be more convenient.

Notes and references, tables, and figures are numbered starting with 1 in each practice.

The practices include all amendments published in the Federal Register , Vol. 46, No. 3,

Tuesday, January 6, 1981, pages 1616 through 1625.

50
STANDARD PRACTICE FOR THE INSTALLATION

OF LOOSE-FILL THERMAL INSULATION

SCOPE

This practice covers the installation of dry organic (cellulosic or wood) and

mineral (rock, slag, or glass) fiber loose-fill thermal insulation on ceilings,

attics, and in frame wall cavities, and mineral cellular (perlite or vermiculite)

loose-fill thermal insulation in attics, and various masonry wall cavities of

existing residential buildings.

Loose fill thermal insulation is sometimes also installed in floors

over unheated space. However, such applications are rare and are

therefore not covered by this practice

.

A working knowledge of the terminology and fundamentals of construction and

applicable codes is necessary for the proper application of this standard.

This practice is intended to establish a minimum level of performance for safety

and effectiveness. When a manufacturer's installation instructions regarding

specific requirements that affect safety and effectiveness result in a higher

level of performance for these characteristics, such manufacturer's installation

instructions may be used.

Under the DoE residential conservation service (RCSJ program,

manufacturer' s installation instructions may be used in lieu of

these practices only with the approval of the cognizant assistant

secretary of DoE.

This practice is not intended to supersede the authority of State and local codes

but is intended to establish minimum criteria for safety and effectiveness. When

State or local codes specifically address the substance of provisions contained

herein, they may apply; when State and local codes do not address the substance

of specific provisions contained herein, this practice shall prevail.

This practice further:

Applies only to the installation of dry loose-fill thermal insulation

consisting of organic or mineral materials, by blowing or pouring. It

does not apply to material installed in a wet condition or where liquid

is added at any stage of the installation process.

Covers the installation process from pre-installation procedures through

post-installation procedures. It does not cover the production of the

insulation materials, whether such production takes place in a factory

or at the installation site.

Describes , in general terms, the procedures to follow so that a safe and

effective installation is assured. It does not describe in detail the

terminology and fundamentals of residential construction, or the codes

or regulations that may be imposed by other Federal, State, or local

agencies

.
Covers aspects of installation relating to the effectiveness,

durability , and safety of insulation in service. It does not address

the safety of the person( s ) installing the insulation.

Conditions in buildings vary greatly and in some cases substantial

additional care and precaution may have to be taken to ensure effective

and safe installation.

2. APPLICABLE DOCUMENTS

ASTMl C168-80a: Standard Definitions of Terms Relating to Thermal Insulating

Materials.

ASTM C 755-73 (1979): Standard Recommended Practice for Selection of Vapor Barriers

for Thermal Insulation.

ASTM E 136-79: Test for Non-Combustibility of Elementary Materials.

NFPA^ -31: Standard for the Installation of Oil Burning Equipment.

NFPA-54: National Fuel Gas Code.

NFPA-70: National Electrical Code (Section 410-66).

NFPA-211: Standard for Chimneys, Fireplaces, and Vents.

3. SIGNIFICANCE

3.1 This practice recognizes that effectiveness , safety, and durability of

insulation depend not only on the quality of the insulating materials

,

but also on their proper and workmanlike installation.

3.2 Improper installation of insulation may reduce its thermal

effectiveness , cause fire hazards and other unsafe conditions , and

promote the deterioration of the structure in which it is installed

.

3.3 Specific hazards that can result from improper installation include:

Fire caused by heat buildup from recessed lighting fixtures covered by

insulation;

Deterioration of wood structures , paint failures , and corrosion of metal

fasteners and electrical components caused by prolonged moisture accumulation within building components; and

1 American Society for Testing and Materials, 1916 Race Street, Philadelphia, PA. 19103.

2 National Fire Protection Association, 470 Atlantic Avenue, Boston, MA. 02210.

52
Deterioration or failure of electrical wiring components and heat

buildup resulting from overcurrent protection devices (fuses and circuit

breakers ) incorrectly matched to wire.

4. DEFINITIONS

Certain technical terms relating to insulation but not defined below are used in

this subpart in accordance with the definitions given in ASTM C 168-67.

Approved - acceptable to the authority which regulates the activity or material and its use. Such authority is usually a municipal, State, or Federal

agency or a third party certification, inspection, or rating service.

Conditioned Space - any space in a residential building which is served by a heating or cooling system.

Mineralcellular loose-fill thermal insulating materials - (such as perlite

or vermiculite) [3] mineral particular material in granular, modular, powdery, or similar form designed to be installed dry by pouring, blowing, or hand placement

between retaining surfaces or as a covering layer.

Mineral fiber loose-fill thermal insulating materials - (such as fiberglass

or rock wool)3 insulation composed of mineral substances such as slag, rock,

or glass suitable for pneumatic or poured application.

Organic loose-fill thermal insulating materials - (such as cellulose or wood

fiber) thermal insulation composed of chemically treated cellulosic or wood

fibers, or any combination thereof suitable for pneumatic or poured application.

Unconditioned space - any space, out-of-doors or in a residential building,

which is not served by a heating or cooling system.

A space only intermittently or rarely heated or cooled could also be

considered as a "unconditioned space," as long as its heating or cooling system is totally separate from the main system serving the

residence .

Vapor Barrier - any material (as defined in ASTM C 755-73) that has a water

vapor permeance (perm) rating of 5.7 ykPa • s • m^ (1 perm) or less.

The following materials , upon proper application, constitute vapor

barriers: asphalt-impregnated kraft paper, aluminum foil, plastic

film, and paint and wallcoverings which are labeled by the manufacturer

as having a perm rating of one (1) or less when applied in accordance

with the manufacturer' s instructions .

The use of a trade name does not connotate recommendation, but simply indicates

commonly recognized generic types of materials.
5. MATERIALS

5.1 Under the Residential Conservation Service program (RCS), install only loose-fill

thermal insulating materials identified as complying with DoE standards.

This marking indicates that the manufacturer certifies that the product

meets the applicable DoE standards . The label does not imply that DoE

has conducted tests on the material or that the manufacturer uses an

approved quality assurance program. See Part I, Section 6.1 for a more detailed discussion.

5.2 It is recommended that all insulation materials installed be tested by

laboratories accredited by NVLAP for the particular tests, or have

third-party

.

5.3 Some important characteristics of loose-fill thermal insulation

material are given in table 1.

6. SAFETY PRECAUTIONS

6.1 During installation, do not smoke in the attic or in any truck or van used for

install ation.

Even if the insulation material used is non-combustible or treated

with fire retardant , sparks from cigarettes , other smoking materials

or discarded matches may initiate smoldering combustion or ignite

flammable materials such as vapor barriers or stored old newspapers.

Sparks that drop into the hopper of insulation-blowing equipment on

trucks or vans may be conveyed into attics, causing fires.

6.2 Loose-fill thermal insulation should not be installed so as to surround electrical cables in buildings with improperly matched

overcurrent protection devices, because such cables could reach temperatures above those permitted by the National Electrical Code (NEC).

Accordingly , prior to installing insulation, it should be ascertained

that all electrical circuits have correctly matched overcurrent

protection devices. See Part I, Section 4.2.1 for further discussion.

If Edison type fuses are found to be installed , these should be

replaced with S-type fuse adaptors; where incorrectly matched circuit

breakers are installed, they should be replaced prior to installing

thermal insulation.

6.3 Because code rubber wires have a lower NEC-allowed temperature limit, no insulation should be placed so as to encapsulate such wire until

the electrical system has been inspected by an approved electrician. . Code rubber wiring is usually found in houses built prior to 1940.

See Part I, Section 4.2.1 for further discussion.

54
7. PRE- INSTALLATION PROCEDURES

7.1 GENERAL

7.1.1 Identify all recessed lighting fixtures (including wiring compartments and

ballasts), furnaces, vents, chimneys, and other heat-producing devices in all areas where insulation is to be installed, so that adequate clearances from

combustible materials and insulation can be provided.

All surface-mounted lighting fixtures should also be identified so

that required clearances from combustible materials and insulation

ca n be provided

.

Pre-installation inspection is necessary to identify any potential

safety hazards in the building and to assure that the installation can be performed effectively and without substantially decreasing the

safety or durability of the structure . Certain precautions and preliminary steps must be taken so that the installation can be performed as

prescribed in the Installation Procedures section.

7.1.2 Install blocking, such as wood, metal or unfaced mineral fiber batts, around all heat-producing devices to permanently maintain the clearances specified in

paragraphs 7.1.3 and 7.1.4. Install all blocking at least as high as the height

of the finished insulation and in a manner that ensures that all devices which

may require maintenance or servicing remain accessible after the insulation is

installed.

The clearances are required to provide free air circulation to prevent

heat buildup.

7.1.3 Install blocking to provide a 75 mm (3 in) clearance around all recessed lighting

fixtures (including associated wiring compartments and ballasts) and other heat

producing devices not covered in paragraph 7.1.4. (See Figure 1.) Do not cover

these devices so as to entrap heat or prevent the free circulation of air unless

they are approved for the purpose.

This requirement is based on section 410-66 of the National Electrical

Code ( NFPA-70 ) . Recessed lighting fixtures rely on the free movement

of air around and above them to dissipate the heat generated by the

bulbs, ballasts , and wiring compartments. Even if the insulation

material itself is non-combustible, if it is installed above or around

a recessed lighting fixture, temperatures within the fixture may become

sufficiently high to ignite fixture components and surrounding framing

members. It is recommended that blocking and clearances similar to those required for recessed lighting fixtures also be provided around

the junction box over surface mounted lighting f ixtures . See Part I,

Sections 4.2.2 and 4.2.3 for additional information.

7.1.4 Install blocking around gas-fired appliances to provide the minimum clearances

specified in NFPA-54. Install blocking around oil-fired appliances to provide

the minimum clearances specified in NFPA-31. Install blocking around masonry

chimneys (or masonry enclosing a flue) to provide a minimum 50 mm (2 in) clearance from the outside face of the masonry. Install blocking around vents, chimney and vent connectors, and chimneys other than masonry chimneys, to provide the

minimum clearances specified in NFPA-211.

55
To provide a safe installation in accordance with recognized national

codes and standards.

7.1.5 When installing mineral fiber or mineral cellular thermal insulation which, in

addition to meeting all the requirements specified in DoE Material Standards,

also has successfully passed ASTM Test E 136-79, the blocking and airspaces

around vents and chimneys need not be provided.

The DoE material standards do not require that loose-fill thermal

insulation meet the requirements of ASTM E 136-79. It should not be

assumed that the material being installed has passed the test unless

the label specifically states so.

7.1.6 Inspect the roof, walls, ceilings and attic floors to identify areas where a previous moisture problem has caused paint peeling, warpage, stain, visible

fungus growth, rotting, or other structural damage. Do not install insulation

in such areas until the resident has been informed and these conditions have

been corrected and their source(s) eliminated. If the resident, after being

informed of the moisture condition and the effect of installing insulation in

such areas, elects to proceed with the insulation, the resident must so state in

writing on the contract.

Installing insulation in an area which exposes it to moisture may

contribute to further deterioration of the structure and loss of effectiveness of the insulation. Insulation in such areas may prolong expo- sure of components to moisture, creating a potential for fungus growth,

rotting, and leaching of boric acid used as fire-retardant in some types

of loose-fill insulation. Insulation should not be installed in the

immediate area of the moisture damage. Immediate area is defined as the

stud or joist space(s) in which prior moisture problems were observed.

For information regarding the identification and evaluation of previous

moisture problems, see Part I, Section 4.1.1.

7.1.7 Block all openings in ceilings, floors, and sidewalls through which the insulating

material may escape. Seal all wall cavities which open into a basement or crawl

space before wall insulation is installed.

It is especially important to ensure that all wall cavities are sealed

properly in homes of balloon frame construction (see figure 2) since

open-ended cavities are inherent in this type of design. Also, seal

around plumbing and electrical openings , particularly beneath sinks,

to prevent filling up a cabinet below the sink.

7.2 WALLS

7.2.1 For buildings located in Zone I of Figure 3, provide a vapor barrier on the

interior surface of all walls to be insulated in bathrooms, and unvented kitchens

and laundry areas. Caulk or seal all major cracks on the interior face of exterior walls of these rooms, including joints between the floor and wall (except

where impractical because of carpeting), between wall and ceiling, at joints

around window frames, and around wall penetrations for electrical services (outlets and switches) and plumbing stacks, and heating and air-conditioning ducts.

It is recommended that a vapor barrier and caulking , such as described

in this paragraph, also be provided on all walls to be insulated in

bathrooms and unvented kitchens and laundry areas in buildings in

Zone II of Figure 3 .

56
The above requirements for ventilation and moisture control are minimum

requirements needed to prevent long-term moisture damage. Homes which are characterized by one or more of the following conditions are more

likely to experience excessive moisture accumulation which can be

corrected by application of a vapor barrier and caulking as described

above and/or additional venting of the wall cavity from the exterior

or additional ventilation of the occupied space.

(a) Homes with an area of less than 75 m2 (800 ft*);

(b) Homes with less than 23 m2 (250 ft 2

) per occupant;

(c) Homes with tight wall and ceiling construction and weatherstripped

windows and doors;

(d) Electrically heated homes or homes with a heating system which uses outside combustion air'f

(e) Homes that are humidified during the winter.

A relative humidity indicator may be installed to monitor the humidity

level and determine when excessive moisture accumulation is likely to occur

.

Although existing guidelines (such as ASHRAE) and standards (such as HUD

Minimum Property Standards) emphasize the use of vapor barriers for the

control of moisture damage, experts in the field now agree that moisture

enters wall cavities more by mass transport through cracks and other

openings than by diffusion through interior finish materials

.

Compared to existing guidelines and standards , the above requirements are very lenient. The reasons are (a) the relative high cost of implementing current "good practice" in retrofit of existing buildings and

(b) the lack of definitive analytical and experimental data to support more stringent requirements. See Part I, Section 4.1.2 for a more

detailed discussion.

7.3 ATTICS AND CEILINGS

7.3.1 Identify and measure ventilation area in attics. Do not install insulation in

attics unless ventilation openings in attic areas conform to one of the following

requirements:

0.1 m^ minimum of free ventilation area per 15 m^ (1 ft^ per 150 ft^) of attic

floor area, if no vapor barrier exists in the attic;

0.1 m^ minimum of free ventilation area per 30 (1 ft^ per 300 ft^) of attic

floor area if a vapor barrier does exist;

0.1 m^ minimum of free ventilation area per 30 (1 ft^ per 300 ft^) of attic

floor space if at least 50 percent of the required ventilating area is provided

with fixed ventilation located in the upper portion of the space to be ventilated,

with the remainder of the required ventilation provided by eave or soffit vents at least 900 mm (3 ft) below those located in the upper portion, if no vapor barrier

exists.

If the free ventilation area of louvers is not known, assume that it is half of

the gross area of the ventilation opening and increase the gross opening area

accordingly.

57
Many louvers and vents have their free ventilation area stamped on their frames.

Adequate attic ventilation is necessary to carry to the outdoors any moisture

that enters the attic from the house.

More ventilation area needs to be provided in homes which do not have

a vapor barrier on the attic floor or ceiling surface because moisture

can be transmitted more readily through such ceilings . Where the

location of attic vents is such that efficient air currents for ventilation will result, the ventilation requirements can be lower even

where no vapor barrier exists. See discussion on attic ventilation in

Part I, Section 4.1.3 for more details.

7.3.2 Ensure that all ventilation openings have suitable louvers or screens to prevent

rain or snow from entering the attic.

Rain or snow entering the attic would wet the insulation, reduce its

effectiveness and promote fungus growth (dry rot). Moisture above

gypsum and gypsum board ceilings also accelerates their deterioration.

7.3.3 For buildings located in Zone 1 of Figure 3, if there is no existing insulation

or if existing insulation is to be removed, provide a vapor barrier membrane on the upper surface of the ceiling material. Never install a vapor barrier on top

of existing insulation .

A vapor barrier installed on top of insulation may trap moisture in the

insulation and in construction components . This moisture may reduce the

effectiveness of the insulation and may lead to the deterioration of the

structure. Exposed vapor barriers can also increase flame spread in

case of fire.

For buildings in Zones 1 and II of Figure 3, where there is existing

ceiling insulation and no vapor barrier, it is recommended that a vapor

barrier paint or wall covering be installed on the interior ceiling

surface of bathrooms and unvented kitchens and laundry areas. It is

also recommended that all cracks and penetrations on the interior ceiling surface of these rooms (such as around lighting fixtures and at

wall and ceiling joints) be caulked.

The above requirements for ventilation and moisture control are minimum

requirements needed to prevent long-term moisture damage. Homes which are characterized by one or more of a , b, c, or d of 7.2.1 are more

likely to experience excessive moisture accumulation which can be cor- rected by application of a vapor barrier and caulking as described above

or by additional ventilation of the occupied space.

A relative humidity indicator may be installed in the residence to monitor the humidity level and determine when excessive moisture

accumulation is likely to occur.

See discussion in Part I, Section 4.1.2 for a more detailed discussion,

including instructions for the use of humidity indicators

.

7.3.4 Install permanent blocking around attic trap doors (see Figure 4) and vents which open into the attic, if the level to which the insulation will be installed

exceeds their height. Ensure that the blocking is installed around vent openings

in a manner that enables the free movement of air through the vent into the attic.

The venting of bathroom and kitchen air (and clothes dryers) into the

attic is an undesirable building practice because it introduces exces- sive moisture into the attic which may condense when exposed to cooler

58
attic temperatures . The potential for condensation is further

increased as insulation is added because the insulation reduces the

rate of heat flow from the living area to the attic, causing attic

temperatures to be lower. It is recommended that all such vents be

extended and vented to the outside.

7.3.5 Cover all bathroom and kitchen vent openings in the attic with temporary blockings

prior to the installation of insulation to assure that no insulation material

falls into the vents.

7.3.6 Install permanent blockings to restrain loose-fill insulation from clogging

soffit vents at the eaves restricting attic ventilation. Install blocking so

as to ensure free movement of air through soffit vents into the attic. See

Figures 5 and 6.

Research work by Princeton University at Twin Rivers4 has shown that

leaks of warm air around vertical chases account for substantial energy

losses. All such chases should be sealed. Where the chase holds a chimney or prefabricated flue, the material used to block or seal the

opening must pass the ASTM E 136-79 test. The conditions are shown in

Figures 7 and 8.

8. INSTALLATION PROCEDURES

8.1 GENERAL

8.1.1 Do not install insulation unless the pre-installation procedures have been

carried out and any defects which were identified were corrected and their

causes el iminated.

The purpose of the pre-installation procedures is to assure that the

installation can be performed effectively and without adverse side

effects detrimental to other building components and materials . For

lasting results, it is important not only to correct effects, such as

by replacing rotten wood, but to eliminate the source of the defect,

such as water leaks which promoted the rot in the first place. In

many instances , corrective measures can be taken with relative ease prior to the installation of insulation. After installation,

correction may be more difficult and costly.

8.1.2 Structural damage can be caused by excessive pressures during the installation or

can result from installing insulation in constructions too weak to support the

imposed load. Install insulation with care to avoid any of the following

conditions:

Separation of finish materials from joists or studs.

Cracking of finish materials or opening of joints between boards.

Deflection of finish material of more than 1/200 of the joist or stud spacing.

4 Socolow, Robert H., Saving Energy in the Home, Ballinger Publishing Company,

Cambridge, Massachusetts, 1978, pages 105 through 110.

59
The strength of ceiling materials , such as gypsum board and lath and

plaster, depends on many factors, including thickness , composition of

materials, relative humidity , and temperature. For gypsum board, the

strength also depends on whether the board is installed with its long

side parallel or at right angle to the joists. Table 2 is provided as an aid in determining whether a particular gypsum board ceiling will

adequately support the load of insulation. The table is based on

tests and other data submitted by gypsum board manufacturers

.

8.1.3 Handle all insulation material in accordance with manufacturer's instructions and

keep it dry and free of extraneous materials.

Some materials can be crushed or otherwise rendered less effective by

incorrect handling . Moisture in the material can both affect the

effectiveness of insulations and support fungus growth. Extraneous

materials , such as untreated organic matter, can reduce effectiveness,

increase potential for fungus growth, and lead to insect and vermin

infestation.

8.1.4 For pneumatic installation, use only equipment compatible with the insulation

material, and operate the equipment in accordance with the manufacturer's

instructions.

Effectiveness of installed loose-fill insulation is related to the

installed density of the material . The installed density in turn

is dependent on proper air flow rate in pneumatic equipment.

8.1.5 Install loose-fill insulation so that it will not be in contact with the ground

or other sources of water.

Many loose-fill insulation materials are hygroscopic and may saturate

themselves when in contact with ground or moist areas, losing effectiveness and promoting fungus growth, and corrosion of metal fasteners

and electrical services components, and accelerating structural failure

when condition persists

.

8.1.6 For energy conservation, install insulation only between conditioned interior

living areas and unconditioned spaces.

Insulation is only effective in conserving energy when placed between

conditioned (served by a heating and/or cooling system) and unconditioned spaces (such as outdoors, an unheated garage, or the ground).

Where adjacent conditioned spaces are maintained at different temperatures, the temperature differential is seldom such that the insulation

would be cost-effective. One possible exception would be the case where one of two adjacent conditioned spaces is frequently , and for

prolonged periods, neither heated or cooled at all, while the other is

conditioned. In this case, the frequently unconditioned space should

be treated as such. An example of this would be a home workshop

attached to a house but only occupied and heated on week-ends

.

Partitions between conditioned spaces are sometimes insulated to

increase sound insulation. However, such applications do not con- serve energy and are therefore outside the scope of HCS-arranged

installations

.

60
8.2 WALLS

8.2.1 Do not fill wall cavities which themselves are air ducts for heating, ventilation,

and/or cooling systems.

8.2.2 Locate entry holes in walls (if required) to permit the complete filling of wall

cavities.

A minimum of two openings per floor per stud space is recommended. The

lower port should be no further than 1200 mm (4 feet J from the bottom

of the wall and the upper port no more than 460 mm ( 1 .5 ft) from the

top of the wall. The number of holes required is based on the density

of the material and its capability to flow within the wall during

application. See Figure 9 for typical layout of fill ports. Follow

the material manufacturer' s recommendations for the number and location

of entry holes. Points of entry in a typical wall are shown in Figures

10, 11, and 12. Some construction types may not require the drilling

of entry holes to gain access to every cavity. It may be possible to gain access through eaves or overhang panels. In balloon construction, access may also be gained from the attic.

Entry holes should be opened in such a way as to permit easy closing

and refinishing compatible with the appearance of the building

.

8.2.3 After the entry holes have been opened, use them to check the wall cavity for

fire stops and other obstructions which will necessitate additional entry holes

to assure complete filling of the cavity.

Internal obstructions can be located by inserting a stiff piece of wire

or plumb line into the wall cavity.

8.2.4 With the exception of spaces identified in the pre-instal lation inspection (7.1.2,

7.1.3, and 7.1.4), completely fill wall cavities in accordance with the insulation

manufacturer's recommendations.

Follow the manufacturer' s recommendations for air pressure and density.

Keep a record of the number of bags used to ensure the installed insulation conforms to the manufacturer' s recommended coverage shown on

the material label.

8.2.5 Close all entry holes in a workmanlike manner using materials compatible with the

original materials. Do not close entry holes in sheathing which is covered by an exterior brick veneer or siding.

Jt is not necessary to seal entry holes in sheathing if the exterior

finish will protect the area from water leakage. It is, in fact,

desirable to leave these open to enable additional ventilation of the

cavity to ensure that no moisture condensation and accumulation occurs.

61
8.3 ATTICS AND CEILINGS

8.3.1 For pneumatic installation in ceiling areas, use the least air pressure meeting

the manufacturer's instructions.

Follow the manufacturer' s instructions for spread rate and install the

insulation to a uniform depth at the recommended density for the R-value

to be installed . The correct density and application rate is shown on

the bag label . Keep a record of the number of bags used to ensure the

installed insulation conforms to the manufacturer' s recommended coverage

shown on the material label.

8.3.2 Do not blow insulation into electrical devices or vents which open into the attic

or other spaces identified in paragraphs 7.1.3 and 7.1.4.

Blowing insulation into these spaces would defeat the purpose of the

blocking . If insulation accidentally is blown in, such insulation must

be removed carefully to prevent damage to electrical wiring and fixture

components

.

8.3.3 Fit the attic side of trap doors or panels with insulation batt (or equivalent

material) except where prevented by a retractable ladder.

Secure the insulation in place using staples or other appropriate

fasteners . Insulation may be installed to the exterior of trap doors

which have retractable ladders mounted on their interior. If the

insulation is installed to the exterior (underside) of the trap door,

a finish material (such as gypsum board) should be provided for

appearance and to protect the insulation. Weatherstripping should be

installed along the contact edge between the access panel and frame to reduce air infiltration.

9. POST- INSTALLATION PROCEDURES

9.1 Inspect the coverage and depth of the insulation. Fill all "pockets" and voids in the insulation. Level insulation in a manner which will not damage electrical

wiring or any other items.

Ensure that the quantity of insulation specified on the bag label to provide the desired R-value for the area to be insulated has been

installed . The depth or thickness of the insulation and density should

conform to the information on the bag label.

9.2 Turn off electric power and clear all electric wall outlet boxes and switch boxes

of any insulation material.

Electric power shut-down is essential to prevent electric shock hazard

during the cleaning operation. It is necessary to clear electric boxes

to prevent stray currents , to protect the building against possible

ignition of combustible materials in the proximity of electrical

contacts , and to prevent the corrosion of electrical components in

contact with chemicals used as fire retardants in certain types of

insulation. See section 4.2.1 of part I for details.

62
9.3 Remove all temporary blockings which were installed over vent openings in attics.

Temporary blockings are those that were provided during the preinstallation procedures (7.3.5) over bathroom, kitchen, and laundry

vents which open into the attic. Do not remove any of the blockings

that were installed to permanently prevent insulation inundation in

vents, heat-producing devices, and other areas specified in this

practice.

9.4 Comply with the "Certification Procedures for the Installation of Thermal

Insulation Materials.

63
TABLE 1. CHARACTERISTICS OF LOOSE-FILL THERMAL INSULATING MATERIALS5

Material Type Mineral Fiber Loose-Fill Organic Loose-Fill Mineral Cellular Loose-Fill

Common Name Fibergl ass Rock Wool Cel 1 ulose Perl ite vermicul ite

Thermal resistance

per unit thickness @ 24°C (75°F)

m.K

W 0.39 0.51 0.56 - 0.65 0.44 - 0.56 0.42 -0.53

R =

( ft 2 .h.°F}

in v BtU'in ; (2.2) (2.9) (3.2 - 3.7) (2.5 - 3.7) (2.4 - 3.0)

Location of

appl i cat ion Attics, CeilingsAttic Floors

Frame Wall Cavities

Attics, Ceilings

Attic Floors Frame Wall Cavities

Attic Floors

Masonry Wall Cavities

Method of

appl ication Blown or Poured Blown or Poured Usually Poured

Fire Safety:

Physical

characteristics

Some pass ASTM E 136-79 tests

Do not pass ASTM E 136 test; Treated with fire- retardant chemicals

Pass ASTM E 136-79 test

Fire Safety:

Appl ication restrictionsDo not place near heat source unless material

is labeled as ASTM

E 136-79 test passing

Do not place near

heat sources, even

if treated

None

Moisture

absorption

< 1%

by wei ght 2%by weight

5 - 20% by weight Negl i gible None

Density: kg/m3 10 - 16 35 - 48 35 - 48 32 - 176 64 - 160

(lb/ft 3

) (0.6 - 1.0) (1.5 - 2.5) (2.2 - 3.0) (2 - 11) (4 - 10)

TABLE 2. SUGGESTED MAXIMUM LOADS SUPERIMPOSED ON GYPSUM COARD CEILINGS6

Gypsum board

ceil ing thickness

Frame spacing

Suggested imposed

uniform load*

13 mm (1/2 in.) 13 mm (1/2 in.)

16 mm (5/8 in.)

610 mm (24 in.) o.c. 405 mm (16 in.) o.c. 610 mm (24 in.) o.c.

6.3 kg/ni2 (1.3 psf) 10.7 kg/m2 (2.2 psf) 10.7 kg/m2 (2.2 psf)

* Includes the the weight of both the new and any existing

insulation

5 Extracted from "An Assessment of Thermal Insulation Materials and Systems for Building

Applications", Brookhaven National Laboratory, BNL-50862, 1978.

6 Adapted from "Gypsum Construction Handbook", United States Gypsum Company, Chicago,

Illinois, 1978, page 94.
FIGURE 1 - BLOCKING AROUND RECESSED LIGHTING FIXTURES.

FIGURE 2 - BALLOON FRAMING.

65
FIGURE 3 - CONDENSATION ZONE MAP.

FIGURE 4 - BLOCKING AROUND ATTIC TRAP DOOR.

66
LOOSE-FILL

INSULATION

FIGURE 5 - BLOCKING AT SOFFIT VENT USING RIGID BAFFLE.

FIGURE 6 - BLOCKING AT SOFFIT VENT USING INSULATION BATT.

67
FIGURE 7 - BLOCKING OF PIPE CHASE.

STIFF BLOCKING

CEILING JOIST

FLUE

REQUIREDCLEARANCE

FILL-SPACE WITH MATERIAL LABELED AS PASSING ASTM E 136 TEST

CEILING

FIGURE 8 - BLOCKING AROUND FLUE.

68
FIGURE 9 - TYPICAL WALL LAYOUT FOR FILL PORTS.

INTERIOR^

FINISH

STUD WALL

FILL PORT WORK THRU

REMOVED

SIDING

SIDING

£2

o

(0

FIGURE 10 - WOOD FRAME CONSTRUCTION, TOP OF WALL

ALTERNATE POINTS OF ENTRY.

69
FIGURE 11 - WOOD FRAME CONSTRUCTION, BOTTOM OF

WALL ALTERNATE POINTS OF ENTRY.

FIGURE 12 - WOOD FRAME WITH BRICK VENEER, ALTERNATE POINTS OF ENTRY.

70
STANDARD PRACTICE FOR THE INSTALLATION OF MINERAL

FIBER BATTS AND BLANKETS THERMAL INSULATION

1. SCOPE

1.1 This practice covers the installation of mineral (rock, slag, or glass) fiber

batt and blanket thermal insulation in ceilings, attics, floors, walls, and on basement and crawl space walls and ducts of existing residential buildings.

1.2 A working knowledge of the terminology and fundamentals of construction and

applicable codes is necessary for the proper application of this standard.

1.3 This practice is intended to establish a minimum level of performance for safety

and effectiveness. When a manufacturer's installation instructions regarding

specific requirements that affect safety and effectiveness result in a higher

level of performance for these characteristics, such manufacturer's installation

instructions may be used.

Under the DoE residential conservation service (RCS) program,

manufacturer' s installation instructions may be used in lieu of

these practices only with the approval of the cognizant assistant

secretary of DoE.

1.4 This practice is not intended to supersede the authority of State and local codes

but is intended to establish minimum criteria for safety and effectiveness.

When State or local codes specifically address the substance of provisions

contained /herein, they may apply; when State and local codes do not address the

substance of specific provisions contained herein, this practice shall prevail.

1.5 This practice further:

Covers the installation process from pre-installation procedures through

post- installation procedures . It does not cover the production of the

insulation materials , whether such production takes place in a factory

or at the installation site.

Describes , in general terms, the procedures to follow so that a safe

and effective installation is assured. It does not describe in detail

the terminology and fundamentals of residential construction, or the

codes or regulations that may be imposed by other Federal, State, or

local agencies.

Covers aspects of installation relating to the effectiveness

,

durability , and safety of insulation in service. It does not address

in detail the safety of the person(s) installing the insulation.

Provides minimum requirements that will help to ensure the installation

of mineral fiber batts and blankets thermal insulation in a safe and

effective manner. Actual conditions in buildings vary greatly and in some cases substantial additional care and precaution may have to be

taken to ensure effective and safe installation.

71
2. APPLICABLE DOCUMENTS

ASTM* C 168-80a: Standard Definitions of Terms Relating to Thermal Insulating

Materials.

ASTM C 755-73 (1979): Standard Recommended Practice for Selection of Vapor

Barriers for Thermal Insulation. ASTM E 119-80: Standard Methods of Fire Tests

of Building Construction and Materials.

ASTM E 119-80: Standard Methods of Fire Tests of Building Construction and

Material s.

ASTM E 136-79: Test for Non-Combustibility of Elementary Materials.

NFPA^ -31: Standard for the Installation of Oil Burning Equipment.

NFPA-54: National Fuel Gas Code.

NFPA-70: National Electrical Code, (Section 410-66).

NFPA-211: Standard for Chimneys, Fireplaces, and Vents.

3. SIGNIFICANCE

3.1 This practice recognizes that effectiveness, safety, and durability of

insulation depend not only on the quality of the insulating materials

,

but also on their proper and workmanlike installation.

3.2 Improper installation of insulation may reduce its thermal effectiveness, cause fire hazards and other unsafe conditions , and promote the

deterioration of the structure in which it is installed .

3.3 Some specific hazards that can result from improper installation

incl ude:

Fire caused by heat buildup from recessed lighting fixtures covered by

insulation;

Deterioration of wood structures, paint failures, and corrosion of

metal fasteners and electrical components caused by prolonged moisture

accumulation within building components; flame spread on exposed

flammable vapor barriers; and

Deterioration or failure of electrical wiring components surrounded by

thermal insulation and heat buildup resulting from overcurrent protection devices (fuses and circuit breakers J incorrectly matched to wire.

1 American Society for Testing and Materials, 1916 Race Street, Philadelphia, PA 19103.

2 National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210.

72
DEFINITIONS

Certain technical terms relating to insulation not defined below are used in this

subpart in accordance with the definitions given in ASTM C 168-67.

Approved - acceptable to the authority which regulates the activity or material

and its use. Such authority is usually a municipal, State, or Federal agency or

a third-party certification, inspection, or rating service.

Conditioned space - any space in a residential building which is served by a heating or cooling system.

Mineral fiber batt and blanket thermal insulation materials - flexible units

composed ot felted inorganic fibers with or without binders in rolls or strips,

with or without attached membrane covering.

Unconditioned space - any space, out-of-doors or in a residential building,

which is not served by a heating or cooling system.

A space only intermittently or rarely heated or cooled could also be

considered as a "unconditioned space," as long as its heating or

cooling system is totally separate from the main system serving the

residence.

Vapor Barrier - any material (as defined in ASTM C 755-73) that has a water

vapor permeance (perm) rating of one (1) or less.

The following materials, upon proper application, constitute vapor

barriers: asphalt impregnated kraft paper, aluminum foil, plastic

film, and paint and wallcoverings which are labeled by the manufacturer as having a perm rating of one (1) or less when applied in

accordance with the manufacturer' s instructions.

MATERIALS

Under RCS, install only mineral -fiber batt and blanket thermal insulating

materials identified as complying with DoE standards.

This marking indicates that the manufacturer certifies that the product

meets the applicable DoE standards . The label does not imply that DoE

has conducted tests on the material or that the manufacturer uses an

approved quality assurance program. See Part I, Section 6.1 for a more detailed discussion.

It is recommended that all insulation materials installed be tested by

laboratories accredited by NVLAP for the particular tests or have

third-party certification.

For duct insulation, use only mineral fiber batt and blanket insulation that

meets the specific DoE Material Standards for this application.

73
6. SAFETY PRECAUTIONS

6.1 During installation, do not smoke in the attic.

Even if the insulation material used has passed ASTM Test E 136 or is fire retardant treated, sparks from cigarettes and other smoking

materials , and discarded matches may initiate smoldering combustion or ignite flammable materials (such as vapor barriers or stored old

newspapers

)

.

6.2 Batt and blanket insulation should not be installed so as to sandwich

electrical cables between two layers of insulation in the house with

improperly matched overcurrent protection devices, because such cables

could reach temperatures above those permitted by the National Electrical

Code (NEC). Accordingly, prior to installing insulation, it should be

ascertained that all circuits have properly matched overcurrent

protection devices. See Part I, Section 4.2.1 for further discussion.

If Edision type fuses are found to be installed , these should be

replaced with "S" type fuse adaptors; where incorrectly matched circuit

breakers are installed , they should be replaced.

6.3 Because code rubber wires have a lower NEC allowed temperature limit, no insulation should be placed so as to encapsulate such wires until

the electrical system has been inspected by an approved electrician.

Code rubber wiring is usually found in houses built prior to 1940.

(See Part I, Section 4.2.1 for further discussion)

.

6.4 To prevent electrical shock hazard to installers and building occupants,

metallic foil-backed batt or blanket insulation should not be installed

in areas with deteriorated electrical wiring or ungrounded electrical

equipment , or ungrounded metallic heating or air-conditioning ducts.

7. PRE- INSTALLATION PROCEDURES

7.1 GENERAL

7.1.1 Identify all recessed lighting fixtures (including wiring compartments and

ballasts), furnaces, vents, chimneys, and other heat-produci ng devices in all areas where insulation is to be installed.

All surface mounted lighting fixtures should also be identified

.

Pre-installation inspection is necessary to identify any potential

safety hazards in the building and to assure that the installation can be performed effectively and without substantially decreasing the safety

or durability of the structure. Certain precautions and preliminary

steps must be taken so that the installation can be performed as prescribed in the Installation Procedures section.

7.1.2 Inspect the roof, walls, and ceilings, and attic floors to identify areas where

a previous moisture problem has caused paint peeling, warpage, stain, visible

fungus growth, rotting, or other structural damage. Do not install insulation

in such areas until the resident has been notified and these conditions have

74
been corrected and their source(s) eliminated. If the resident, after being

informed of the moisture condition and the effect of installing insulation in

such areas, elects to proceed with the insulation, the resident must so state

in writing on the contract.

The installing of insulation in a moist area contributes to the deterioration of the structure and reduces the effectiveness of the insulation. Insulation in such areas may prolong exposure of components to

moisture, thus increasing the potential for fungus growth and rotting.

DoE recommends against installing insulation in the immediate area of

prior moisture damage unless the source of the damage has been eliminated. Immediate area is defined as the stud or joist space(s) in

which prior moisture problems were observed. For information regarding

the identification and evaluation of previous moisture problems, see

Part I, Section 4.1.1 for further discussion.

7.2 ATTIC AND CEILINGS

7.2.1 Identify and measure ventilation area in attics. Do not install insulation in

attics unless ventilation openings in attics conform to one of the following

requirements:

0.1 m2 minimum of free ventilation area per 15 m2 (1 ft 2 per 150 ft 2

) of attic

floor area, if no vapor barrier exists in the attic;

0.1 m2 minimum of free ventilation area per 30 m2 (1 ft2 per 300 ft 2

) of attic

floor area if a vapor barrier does exist;

0.1 m2 minimum of free ventilation area per 30 m2 (1 ft 2 per 300 ft2

) of attic

floor space if at least 50 percent of the required ventilating area is provided

with fixed ventilation located in the upper portion of the space to be ven- tilated, with the remainder of the required ventilation provided by eave or soffit vents at least 900 mm (3 ft) below those located in the upper portion, if

no vapor barrier exists.

7.2.2 If the free ventilation area of louvers is not known, assume that it is half of

the gross area of the ventilation opening and increase the. gross opening area

accordingly.

On many louvers and vents the free ventilation area is stamped on their frames.

Adequate attic ventilation is necessary to carry to the outdoors any moisture

that enters the attic from the house.

More ventilation area needs to be provided in homes which do not

have a vapor barrier on the attic floor or ceiling surface because

moisture can be transmitted more readily through such ceilings. Where

the location of attic vents is such that more efficient air currents

for ventilation will result, the ventilation requirements can be

lower even where no vapor barrier exists. See discussion on attic

ventilation in Part I, Section 4.1.3 for more details.

7.2.3 Ensure that all ventilation openings have suitable louvers or screens to prevent

rain or snow from entering the attic.

Rain or snow entering the attic could wet the insulation and reduce its

effectiveness, and promote fungus growth (dry rot). Moisture above

gypsum and gypsum board ceilings accelerates their deterioration.

75
7.2.4 For buildings located in Zone 1 of Figure 1, if there is no existing insulation

or if existing insulation is to be removed, provide a vapor barrier membrane on the upper surface of the ceiling material. Never install a vapor barrier on top

of existing installation .

In cold climates , a vapor barrier is required to prevent moisture from

penetrating into the cold attic where it could condense and cause moisture damage.

A vapor barrier installed on top of insulation may trap moisture in the

insulation and in construction components . This moisture may reduce

the effectiveness of the insulation and may lead to the deterioration

of the structure. Exposed vapor barriers can also increase flame

spread in case of fire.

If separate membrane-type vapor barriers are installed , all tears,

penetrations and joints which are not overlapped by at least 75 mm

(3 in) should be taped. Vapor barriers attached to batts and blankets

should be stapled to joists with the barrier toward the conditioned

space.

For buildings in Zones I and II of Figure 1, where there is existing

ceiling insulation and no vapor barrier, it is recommended that a vapor

barrier paint or wall covering be installed on the interior ceiling sur- face of bathrooms and unvented kitchens and laundry areas. It is also

recommended that all cracks and penetrations on the interior ceiling

surface of these rooms (such as around lighting fixtures and at wall

and ceiling joints) be caulked.

The above requirements for ventilation and moisture control are minimum

requirements needed to prevent long-term moisture damage. Homes which are characterized by one or more of a, b, c, or d below are more likely

to experience excessive moisture accumulation which can be corrected by

application of a vapor barrier and caulking as described above or by

additional ventilation of the occupied space.

(a) Homes with an area of less than 75 m2 (800 ft2

);

(b) Homes with less than 23 m2 (250 ft 2

) per occupant;

(c) Homes with tight wall and ceiling construction and weathers tripped

windows and doors;

(d) Electrically heated homes or homes with a heating system which

uses outside combustion air;

(e) Homes that are humidified during the winter.

A relative humdity indicator may be installed to monitor the humidity

level and determine when excessive moisture accumulation is likely to occur. See Part I, Section 4.1.2 for discussion on use of relative

humidity indicator.

Although existing guidelines (such as ASHRAE) and standards (such as HUD Minimum Property Standards) emphasize the use of vapor barriers for

the control of moisture damage, experts in the field now agree that

moisture enters wall cavities more by mass transport through cracks and

other openings than by diffusion through interior finish materials

.

76
Compared to existing guidelines and standards, the above requirements are very lenient. The reasons are (a) the relative high cost of implementing current "good practice" in retrofit of existing buildings and

(b) the lack of definitive analytical and experiental data to support more stringent requirements. See Part I, Section 4.1.2 for a more

detailed discussion.

7.3 FLOORS, BASEMENTS AND CRAWL-SPACE WALLS

7.3.1 Where insulation is to be installed beneath floors over crawl-space walls,

install a ground cover which acts as a vapor barrier (such as 0.15 mm (6-mil)

polyethylene sheeting lapped at the joints). Turn the ground cover up at least

150 mm (six inches) at the walls.

Moisture in the soil beneath the building may evaporate and condense in

the insulation causing loss of thermal effectiveness and leading to possible fungus growth in the wood structure and corrosion in fasteners and

electrical service components. This provision conforms to major building code requirements for new construction.

7.3.2 Where practical in crawl spaces provide a free ventilation area of 0.1 m2 for

every 150 (1 ft^ for every 1500 ft^) of the ground area of the crawl space.

Provide cross ventilation where possible. (See paragraph 7.2.2, for guidance on estimating free ventilation area.)

This is to allow for the venting of the crawl space, preventing the

build-up of moisture in the crawl space during the summer season. This provision conforms to major building code requirements for new

construction.

7.3.3 Where insulation is to be installed on crawl-space walls, provide a means to seal

off the ventilation area(s) during the heating season.

The purpose of the crawl-space wall insulation is to maintain a warmer

crawl space in winter. The ventilation area, if not sealed, will permit the infiltration of cold air and thus defeat the purpose of the

insulation.

7.3.4 Install insulation only to within 50 mm (2 in) of any existing termite

shields, unless they are extended to reach beyond the installed

insulation.

7.3.5 Provide a vapor barrier on the winter warm side of floor insulation in buildings

located in Zones I and II of Figure 1.

That is to prevent vapor permeation from the warm and humid conditioned

space through the floor. Such vapor, if condensed inside the floor

construction may cause the insulation to become wet and less effective

,

and promote fungus growth on wood structures and corrosion on metal

fasteners and electrical service components.

Insulation of floors over unheated spaces will cause these spaces to be

colder. Accordingly, appropriate measures may need to be taken to keep

water pipes from freezing during cold weather.

77
7.4 DUCTS

7.4.1 Inspect duct to assure that it is dry and clean and that all joints are securely

connected. Seal all joints that do not appear airtight with duct tape or other

appropriate materials.

Insulation of ducts located in unheated spaces will cause these spaces

to be colder. Accordingly , appropriate measures may need to be taken

to keep pipes in such spaces from freezing during cold weather.

8. INSTALLATION PROCEDURES

8.1 GENERAL

8.1.1 Do not install insulation unless the pre-instal lation procedures have been carried

out and any defects which were identified were corrected, and their causes eliminated.

The purpose of the pre-installation procedures is to assure that the

installation can be carried out effectively and without adverse side

effects detrimental to other building components and materials . For

lasting results, it is important not only to correct symptoms , such as

replacing rotten wood, but to eliminate the source of the defect, such as water leaks, which promoted the rot in the first place. In many

instances corrective measures can be taken with relative ease prior to the installation of insulation. After installation correction may be more difficult and costly.

8.1.2 Handle all insulation material in accordance with manufacturer's instructions and

keep it dry and free of extraneous materials.

Some materials can be crushed or otherwise rendered less effective by

incorrect handling . Moisture in the material can both affect the

effectiveness of insulations and support fungus growth. Extraneous

materials , such as untreated organic matter, can reduce effectiveness,

increase potential for fungus growth and lead to insect and vermin

infestation.

8.1.3 Install insulation so that it will not be in contact with the ground or other

sources of water.

Many mineral-fiber batt and blanket insulations are hygroscopic and

may saturate themselves when in contact with ground or moist areas,

losing effectiveness and promoting fungus growth when the condition

persists

.

8.1.4 For energy conservation, install insulation only between conditioned and

unconditioned spaces.

Insulation is only effective in conserving energy when placed between

conditioned (served by a heating and/or cooling systemj and unconditioned spaces (such as outdoors, an unheated garage or the ground).

Where adjacent conditioned spaces are maintained at different temperatures, the temperature differential is seldom such that the insulation

78
would be cost-effective. One possible exception would be the case where one of two adjacent conditioned spaces is frequently , and for

prolonged periods, neither heated or cooled at all, while the other is

conditioned. In this case, the frequently unconditioned space should

be treated as such. One example of this would be a home workshop

attached to the house but only occupied and heated on weekends.

Partitions between conditioned spaces are sometimes insulated to

increase sound insulation. However, such applications do not conserve

energy and are therefore outside the scope of RCS-arranged

installations

.

8.1.5 Install insulation so that it fits tightly between framing members on all sides.

Cut insulation that is too long for a space to the correct size. If insulation is

too short for a space, cut a piece to fill the void and tightly butt-joint batts.

Do not double over or unnecessarily compress insulation.

8.1.6 Permanently maintain the clearances specified in paragraphs 8.1.7 and 8.1.8 below

around all heat-producing devices.

The clearances are needed to prevent heat build-up, damage to electrical

services equipment , and to appliances and their components, and to prevent

initiation of smoldering or ignition of combustible materials in the proximity of heat-producing devices.

8.1.7 Provide a 75 mm (3 in) minimum clearance around all recessed lighting fixtures

(including wiring compartments and ballasts) and other heat-producing devices

not covered in paragraph 8.1.8. Do not cover these devices so as to entrap heat

or prevent the free circulation of air unless they are approved for the purpose.

This requirement is based on section 410-66 of the National Electrical

Code (NFPA-70 ) . Recessed lighting fixtures rely on the free movement

of air around and above them to dissipate the heat generated by the

bulbs, ballasts, and wiring compartments. Even if the insulation

material itself is non- combustible, if it is installed above or around

a recessed lighting fixture, temperatures within the fixture may become

sufficiently high to ignite fixture components and surrounding framing

members. It is recommended that clearances similar to those required

for recessed lighting fixtures also be provided around the junction

box over surface mounted lighting fixtures. See Part I, Section 4.2.2

and 4.2.3 for additional information.

8.1.8 Provide the minimum clearances around gas-fired appliances specified in NFPA-54,

the National Fuel Gas Code. Around oil-fired appliances, provide the minimum

clearances specified in NFPA-31, Standard for the Installation of Oil Burning

Equipment. Around masonry chimneys (or masonry enclosing a flue) provide a mini- mum 50 mm (2 in) clearance from the outside face of the masonry. Around vents,

chimney and vent connectors and chimneys other than masonry chimneys, provide the

minimum clearances specified in NFPA-211, Standard for Chimneys, Fireplaces, and

Vents.

This is to provide a safe installation in accordance with recognized

national codes and standards.

8.1.9 When installing mineral-fiber blanket insulation having no membrane (or having

a non-flammable membrane) which, in addition to meeting all the requirements

79
specified in the DoE Material Standards, also has successfully past ASTM Test

E 136-79, the airspaces specified in this section need not be provided around

vents and chimneys.

The DoE Material Standards do not require that thermal insulation and

vapor barriers meet the requirements of ASTM E 136-79. It should not

be assumed that the material being installed has passed the test unless

the label specifically states so.

8.1.10 Assure that all devices which may require periodic servicing remain accessible

after the insulation is installed.

8.2 WALLS

8.2.1 In Zones I and II of Figure 1, install a vapor barrier on the winter warm side

of insulation installed in exterior walls. Secure the vapor barrier to the studs

so as to avoid gaps and fishmouths. If the insulation does not have a vapor barrier attached to it provide a separate vapor barrier on the winter warm side over

the installed insulation.

This is to conform with generally accepted practice, codes and

standards in new building construction. This more stringent requirement (than that for loose-fill insulationj was adopted since when

installing batt and blanket insulation, the cost for providing the

vapor barrier is not different than that in new construction.

8.2.2 With duct tape (or equivalent), tape all tears and penetration in the vapor

barrier and all joints which are not overlapped by at least three inches.

The vapor barrier must cover the insulated area completely and

uniformly . Gaps through which moisture can migrate may result in

excessive moisture accumulation, leading to a reduction in thermal

effectiveness and other undesirable side effects. See Part I,

Section 4.1.2 for a more detailed discussion.

8.2.3 If the insulation material is provided with a flammable vapor barrier, or if a separate vapor barrier which is flammable is installed, cover the insulation with

a finish material having a finish rating of not less than 15 minutes when tested

according to ASTM Designation E 119-80. For purposes of this standard 12.5 mm

(0.5 in) or thicker plaster board, installed in accordance with the manufacturer's instructions is deemed to meet this requirement.

This is to assure that overall fire safety of the building is not diminished through the installation of the vapor barrier.

8.3 ATTICS, CEILINGS, AND FLOORS

8.3.1 Always place vapor barriers on the winter warm side of the insulation. Never

install a combustible vapor barrier so that it remains exposed.

It is the purpose of the vapor barrier to prevent moisture from

migrating from the warm interior space into or through the insulation.

80
An exposed combustible vapor barrier is a fire hazard. It can be

ignited easily and in case of a fire can contribute to rapid flame

spread.

8.3.2 When installing insulation around bridging or cross bracing of ceiling or floor

joists, fit the insulation material tightly around these obstructions and assure

that there are no gaps in the insulation.

8.3.3 When recessing insulation batts in floor joist cavities turn insulation up at the

header or cut and attach pieces of insulation to the header to avoid heat loss

through the header.

8.3.4 Fit insulation tightly in floor joist areas and secure in place with either wire

fasteners, galvanized wire, or nylon mesh or galvanized screen held in place by

stapling or nailing, or galvanized wire lacing held in place by stapling or

nailing. See Figure 2.

Insulation must be held securely in place for long service life.

Friction fit alone is not acceptable as a means of holding the

insulation in place between the floor joists.

8.3.5 Do not cover soffit vents with insulation nor in any other way restrict attic

ventilation.

This is to assure that the purpose of attic ventilation is not defeated

by improper installation of insulation.

8.3.6 Install insulation around vents which open into the attic in a manner that will ensure free movement of air through the vent into the attic.

The venting of bathroom and kitchen air (and clothes dryer) into the

attic is an undesirable building practice because it introduces exces- sive moisture into the attic which may condense when exposed to cooler

attic temperatures. The potential for condensation is further

increased as insulation is added because the insulation reduces the

rate of heat flow from the living area to the attic, causing attic

temperatures to be even lower. It is recommended that such vents be

extended and vented to the outside.

8.3.7 Fit the attic side of trap doors or panels with insulation batt except where

prevented by a retractable ladder.

Secure the insulation in place using staples or other appropriate

fasteners. Insulation may be installed to the exterior of trap doors

which have retractable ladders mounted on their interior. If the

insulation is installed to the exterior ( underside) of the trap door,

a finish material ( such as gypsum board) should be provided for

appearance and to protect the insulation.

Weatherstripping should be installed along the contact edge between the access panel and frame to reduce air infiltration.

81
8.4 BASEMENT AND CRAWL SPACE WALLS

8.4.1 Where the joists run parallel to the wall, install the wall insulation by stapling

the top of each batt to the band joist. Where the joists run at right angles to the wall, install short pieces of insulation against the header, ensuring that

there are no gaps in the insulation. Then, install the wall insulation by

stapling the top of each batt to the sill. See Figure 3.

8.4.2 Ensure that the batts fit snugly against each other and that they are sufficiently

long to cover the wall and two feet of the crawl space floor.

The perimeter of the crawl space floor is a potential area for heat

leaks. Insulation of the two feet of floor area adjacent to the crawl

space wall will reduce this energy loss.

8.5 DUCTS

8.5.1 Install duct insulation only on ducts located in unconditioned spaces.

Insulating ducts in conditioned spaces will produce only insignificant

energy savings, leading to an installation that is not cost-effective

.

8.5.2 Install insulation batt or blanket with the vapor barrier on the outside.

8.5.3 Butt joints of batts tightly and in such a way that a vapor barrier tab overlaps

the joints by at least two inches. Mechanically fasten the tab to the underlying vapor barrier and seal the joint with duct tape, or alternatively, overlay

insulation and tape when vapor barriers are attached.

8.5.4 On rectangular ducts, install insulation so that at the corners it is not compressed more than 50 percent of its nominal thickness.

Excessive compression results in reduced thermal effectiveness of the

insulation.

8.5.5 On horizontal ducts over 600 mm (24 in) wide, secure the bottom of the insulation

with mechanical fasteners as required by the manufacturer. Seal fastener

penetrations to provide an airtight system.

8.5.6 Install any protective covers required by local codes and regulations.

9. POST- INSTALLATION PROCEDURES

9.1 Ensure that insulation does not restrict attic soffit vents.
9.2 Ensure that all required clearances have been maintained.

9.3 Ensure that, where required, all insulation is covered with a suitable covering

material as required in Section 8.2.3.

9.4 Comply with the "Certification Procedures for the Installation of Thermal

Insulation Materials.

83
FIGURE 1 - CONDENSATION ZONE MAP.
FIGURE 3 - CRAWL SPACE INSULATION.

85
STANDARD PRACTICE FOR THE INSTALLATION OF ORGANIC

CELLULAR RIGID-BOARD THERMAL INSULATION

1. SCOPE

1.1 This practice covers the installation of organic cellular rigid-board thermal

insulation on concrete floors, foundation perimeters, interior of masonry walls,

interior of frame walls and ceilings, and as exterior sheathing on walls and

roofs of existing residential buildings.

1.2 This practice covers the installation of the rigid-board but does not include in detail the installation of exterior siding and roofing required to protect rigidboard insulation from the effects of weather, or the installation of interior

fire protective coverings.

1.3 A working knowledge of the terminology and fundamentals of construction and

applicable codes is necessary for the proper application of this standard.

1.4 This practice is intended to establish a minimum level of performance for safety

and effectiveness. When a manufacturer's installation instructions regarding

specific requirements that affect safety and effectiveness result in a higher

level of performance for these characteristics, such manufacturer's installation

instructions may be used.

Under the DoE residential conservation service (RCS) program,

manufacturer's installation instructions may be used in lieu of these

practices only with the approval of the cognizant assistant secretary

of DoE.

1.5 This practice is not intended to supersede the authority of State and local codes

but is intended to establish minimum criteria for safety and effectiveness.

When State or local codes specifically address the substance of provisions

contained therein, they may apply; when State and local codes do not address the

substance of specific provisions contained herein, this practice shall prevail.

1.6 This practice further:

Covers the installation process from pre- installation procedures through

post-installation procedures. It does not cover the production of the

insulation materials , whether such production takes place in a factory

or at the installation site.

Describes , in general terms, the procedures to follow so that a safe and

effective installation is assured. It does not describe in detail the

terminology and fundamentals of residential construction, or the codes

or regulations that may be imposed by other Federal, State, or local

agencies . A working knowledge of the terminology and fundamentals of

construction and applicable codes is necessary for the proper

application of this standard

.

Covers aspects of installation relating to the effectiveness

,

durability, and safety of insulation in service. It does not address

the safety of the person(s) installing the insulation.

86
1.7 Provides minimum requirements that will help to ensure the installation

of organic cellular rigid board thermal insulation in a safe and effective manner. Actual conditions in buildings vary greatly and in some

cases substantial additional care and precaution may have to be taken

to ensure effective and safe installation.

2. APPLICABLE DOCUMENTS

ASTM* C 168-80a: Standard Definitions of Terms Relating to Thermal Insulating

Materials.

ASTM C 272-53 (1980): Test for Water Absorption of core materials for

structural sandwich constructions.

ASTM C 355-64 (1973): Test for Water Vapor Transmission of Thick Materials.

ASTM C 755-73 (1979): Standard Recommended Practice for Selection of Vapor

Barriers for Thermal Insulation.

ASTM E 119-80: Fire Tests of Building Constructions and Materials.

ASTM E 136-79: Test for Non-Combustibility of Elementary Materials.

NFPA2 -31: Standard for the Installation of Oil Burning Equipment.

NFPA-54: National Fuel Gas Code.

NFPA-70: National Electrical Code (Section 410-66).

NFPA-211: Standard for Chimneys, Fireplaces, and Vents.

3. SIGNIFICANCE

3.1 This practice recognizes that effectiveness, safety, and durability of

insulation depend not only on the quality of the insulating materials,

but also on their proper and workmanlike installation.

3.2 Improper installation of insulation may reduce its thermal effectiveness, cause fire hazards and other unsafe conditions , and promote the

deterioration of the structure in which it is installed .

1 American Society for Testing and Materials, 1916 Race Street, Philadelphia, PA. 19103.

2 National Fire Protection Association, 470 Atlantic Avenue, Boston, MA. 02210.

87
3.3 Specific hazards that can result from improper installation include:

Fire caused by heat buildup from recessed lighting fixtures covered by

insulation/

Deterioration of wood structures, paint failures, and corrosion of

metal fasteners and electrical components caused by prolonged moisture

accumulation within building components; and

Ignition of and flame spread on insulation board not protected by an

appropriate cover,

4. DEFINITIONS

Certain technical terms relating to insulation not defined below are used in this

subpart in accordance with the definitions given in ASTM C 168-67.

Approved - acceptable to the authority which regulates the activity or material and its use. Such authority is usually a municipal State, or Federal

agency or a third-party certification, inspection or rating service.

Conditioned Space - any space in a residential building which is served by a heating or cooling system.

Organic Cellular Rigid Board Thermal Insulation - An organic plastic foam composed

principally of polymerized styrene resin or catalyzed reaction products expanded

with a fluorocarbon blowing agent to form a homogeneous rigid mass of cells.

Unconditioned Space - any space, out-of-doors or in a residential building, which

is not served by a heating or cooling system.

Vapor Barrier - any material (as defined in ASTM C755-73) that has a water vapor

permeance (perm) rating of one (1) or less.

The following materials, upon proper application, constitute vapor

barriers: asphalt-impregnated kraft paper, aluminum foil, plastic

film, and paint and wallcoverings which are labeled by the manufacturer as having a perm rating of one or less when applied in accordance with

the manufacturer' s instructions

.

5. MATERIALS

5.1 This practice applies to the installation of organic, cellular, rigid

polystyrene, polyurethane and polyisocyanurate thermal insulation board.

5.2 Under RCS, install only organic cellular rigid-board thermal insulating materials

identified as complying with DoE standards.

This marking indicates that the manufacturer certifies that the product

meets the applicable DoE standards . The label does not imply that DoE

has conducted tests on the material or that the manufacturer uses an

approved quality assurance program. See Part I, Section 6.1 for

further discussion.

88
5.3 It is recommended that all organic cellular rigid-board thermal

insulation materials installed have third-party certification. If and

when the National Voluntary Laboratory Accreditation Program (NVLAP)

accredits laboratories to conduct tests on organic cellular rigidboard, it is recommended that the tests be performed by NVLAP

accredited laboratories.

5.4 Install only insulation boards compatible with the particular

application.

6. SAFETY PRECAUTIONS

6.1 Do not smoke in any area in which insulation is being installed or cut.

Sawdust from foam board can easily be ignited and combustion products are toxic.

6.2 The vapors of many solvents used in the adhesives for the installation of organic

cellular rigid board thermal insulation are flammable. Keep solvents in approved

containers and follow the specific label instructions.

Provide adequate ventilation to prevent hazardous accumulation of

solvent vapor during installation.

7. GENERAL REQUIREMENTS

7.1 For all rigid-board applications, carry out the pre-instal lation, installation,

and post- install at ion procedures in the order prescribed in 7 through 18.

It is important that pre-installation procedures be carried out to assure that the installation can be performed effectively and without

causing adverse side effects detrimental to other building components.

For lasting results, do not only correct symptoms (such as replacing

rotten wood) but eliminate the source of the problem (such as a water

leak which promoted the rot in the first place) . The procedures need

to be taken in correct order. Some pre-installation checks and

precautions can not be taken after the insulation is installed.

7.2 For interior applications of rigid-board insulation on walls and ceilings install,

on all exposed faces and exposed edges of the insulation material, a cover having

a finish rating of not less than 15 minutes, when tested according to ASTM

E 119-76. For purposes of- this standard, 12.5 mm (0.5 in) or thicker plaster

board, installed in accordance with the manufacturer's instructions, is deemed

to meet this requirement.

To prevent ignition of and retard flame spread on combustible

insulating materials. This assures that the dwelling after installation of board insulation provides the same level of safety as before

the installation. The requirement is also in conformance with most

local and State building codes.

7.3 Install insulation only between conditioned and unconditioned spaces for energy

conservation, except as provided in paragraphs 8, 9 and 11.

89
Insulation is only effective in conserving energy when placed between

conditioned (served by a heating and/or cooling system) and unconditioned spaces (such as outdoors or an unheated garage). Where adjacent

conditioned spaces are maintained at different temperatures , the temperature differential is seldom such that the insulation would be cost

effective. One possible exception would be the case where one of two adjacent conditioned spaces is frequently, and for prolonged periods,

neither heated nor cooled at all, while the other is conditioned . In

this case, the frequently unconditioned space could be treated

" unconditioned .

Partitions between conditioned spaces are sometimes insulated to decrease sound transmission. However, such applications do not conserve energy and are therefore outside the scope of RCS arranged

installations

.

Follow the requirements applicable to the control of moisture in buildings to be

installed as detailed in Table 1.

Table 1 applies to frame exterior walls. For masonry walls, ceiling

and roof application, use requirements for filled cavities

.

See also Part I, Section 4.1.2 for information regarding moisture

control

.

Install all vapor barriers required by this practice on the interior of the

innermost insulation.

Installed insulation board should be continuous and without gaps. If a vapor barrier is recommended and is provided as an integral part of the

insulation board material, the joint of two insulation boards should be

sealed to assure continuous moisture protection.

If a vapor barrier is installed separately from the insulation, the

barrier should be overlapped and taped. Flammable vapor barriers should

not be left exposed but should be covered by a material having a finish

rating of 15 minutes. 12.5 mm (0.5 in) or thicker plaster board,

installed in accordance with the manufacturer' s instructions, is

deemed to meet this requirement

.

Follow all insulation manufacturer's recommendations relative to the venting of

wall constructions.

Ensure that only mastics and solvents compatible with the board insulation

material are used.

To effect a good bond. Incompatible mastic or solvent can also damage

or even dissolve the insulation board.

To ensure proper adhesion of rigid board, the surfaces to which the

materials will be applied should be smooth and clean. Horizontal sur- faces should be in broomswept condition prior to the installation of

rigid board.
To prevent deterioration from exposure to ultraviolet radiation,

insulation board materials should not be exposed to sunlight for

extended periods.

To ensure that the insulation does not become wet and subject to degradation, it should not be in contact with the ground or other sources of water, except in the case of slab perimeter installations where

insulation board specifically designed for this application is used.

Provide a 75 mm (3 in) minimum clearance around all recessed lighting fixtures

(including wiring compartments and ballasts) and other heat-producing devices not covered in the paragraph below. Do not install insulation so as to cover these

devices and entrap heat or prevent the free circulation of air unless they are approved for the purpose.

This requirement is based on section 410-66 of the National Electrical

Code (NFPA-70 ) . Recessed lighting fixtures rely on the free movement of

air around and above them to dissipate the heat generated by the bulbs,

ballasts , and wiring compartments . If insulation board is installed

above or around a recessed lighting fixture, temperatures within the

fixture may become sufficient to ignite fixture components and

surrounding framing members. See Part I, Section 4.2.2 for further

discussion.

Provide the minimum clearances specified in NFPA-31 around oil-fired appliances.

Install insulation around masonry chimneys or masonry enclosing a flue to provide

a minimum 50 mm (two-inch) clearance from the outside face of the masonry.

Install insulation around vents, chimney and vent connectors, and chimneys other

than masonry chimneys so as to provide the minimum clearances specified in

NFPA-211. Consult the foam manufacturer for additional requirements regarding

the protection of foam from excessive heat.

To provide a safe installation in accordance with recognized national

codes and standards

.

FOUNDATION PERIMETER

APPLICABILITY

This section applies to the installation of organic cellular rigid board thermal

insulation to the exterior of foundation walls and around the perimeter of

concrete slab-on-grade floors. Only closed cell insulation boards which have a moisture absorption rate no greater than 0.3 percent when tested in accordance

with ASTM C 272-53 and a water vapor transmission rate no greater than 2 perm

per inch when tested in accordance with ASTM C 355-64 (1973) may be used for

this application.

Because of its exposure to groundwater, only insulation board with low

water absorption and permeance is suitable for this application.

PRE-INSTALLATION PROCEDURES

Identify any termite shields that would be covered by the insulation. Do not install board insulation unless the termite shield is effectively extended beyond

the insulation and cover to be installed.
Installing materials that allow a by-pass of the termite shield will

defeat the purpose of the shield and increase the risk of termite

infestation in the structure of the house.

8.2.2 Prepare a trench of not less than 300 mm (12 inches) in depth on the exterior of

the foundation.

The depth below grade to which the insulation is effective depends on

local climate conditions . It is recommended that the insulation be

installed to at least the depth of the frost line or to the bottom of

the footing (if any), whichever is less.

8.2.3 Install any anchoring devices required for the application of the covering

material

.

Only anchoring methods recommended by the board manufacturer should be

used

.

8.2.4 Identify surface projections such as electrical outlets, utility meters, piping,

and faucets, which will require special attention.

8.3 INSTALLATION PROCEDURE

8.3.1 Do not install insulation board with adhesives when the wall surface is wet or the temperature is below freezing.

Wet or below freezing conditions are detrimental to a permanent bond.

8.3.2 Cut board insulation to fit around any surface projections, around windows, and at corners so as to fit tightly against each other and against the anchoring devices.

8.3.3 Attach the insulation board against the wall or slab edge.

The insulation boards should be secured to the wall or slab firmly

either mechanically or with adhesives in accordance with the insulation

board manufacturer' s recommendations

.

8.3.4 To provide impact resistance to those parts of the boards which will remain

exposed after backfilling, install a protective cover.

Various protective covers include, but are not limited to, metal and

cementitious boards, wire and fiber reinforced cement plaster and

heavy-bodied latex coatings. Consult the insulation board

manufacturer for compatible coatings

.

8.3.5 Back-fill and tamp ground around foundation or slab edge to slope away from the

building.

To assure good drainage, to prevent water accumulation and prevent

potential freeze damage.

92
8.4 POST- INSTALLATION PROCEDURES

Ensure that any termite shields are effectively extended beyond the insulation

and its cover.

Give specific attention to corners and door sills to assure that no paths for termite passage exist.

Ensure that all joints in the cover are tight and that cement plaster

covers are not cracked.

Ensure that all surface projections identified in preinstallation

procedures are properly treated and that the installation does not

interfere with the proper operation of the devices.

Ensure that all trenches that were dug are fully backfilled and tamped,

and that they slope away from the wall or slab edge.

9. CONCRETE FLOORS

9.1 APPLICABILITY

9.1.1 This section applies to the installation of organic cellular rigid-board thermal

insulation on concrete floors over unheated basements and crawl spaces or on concrete slabs on grade.

9.2 PRE-INSTALLATION PROCEDURES

9.2.1 Ensure that the concrete floor surface is clean, dry, and free of oil and loose

pai nt.

Unless surface is clean, and dry, the waterproof barrier required under

9.2.5 will not adhere properly.

9.2.2 Fill any cracks in concrete floors with patching cement several days prior to

installation.

To provide an even and continuous surface.

9.2.3 Seal joints between the floor and walls to reduce air infiltration.

Sealing of this joint is easy at this point and is an effective energy

conservation method.

9.2.4 Identify all floor drains. Do not cover such drains unless permitted by local

codes.

Most codes do not permit such cover. (Traps in drains may dry out,

possibly resulting in sanitary or explosive hazards .)

9.2.5 Prior to installing insulation on a slab on grade, provide a waterproof barrier

such as two separate brushed-on coatings of asphalt emulsion.

93
To prevent groundwater seeping through the concrete floor from contact

with insulation.

9.3 INSTALLATION PROCEDURE

9.3.1 Cut the insulation board to appropriate size so as to provide tight but not force-fitted joints.

9.3.2 Adhere the insulation board to the concrete, assuring an intimate and continuous

bond.

The insulation board should be installed as recommended by the

manufacturer .

9.3.3 Mechanically fasten to the concrete floor slab a subfloor of sufficient strength

to distribute any imposed, concentrated load so as not to crush the insulation.

Examples of suitable subflooring materials are 12.5 mm (1/2-inch)

exterior grade plywood secured directly on top of the insulation

board/ or as an alternative, the subfloor can be fastened to sleepers

which in turn are attached to the concrete slab. The joint between

sleepers and insulation board should be tight but not force fitted.

The subfloor joints should coincide with the center of the sleepers

.

If sleepers are used, a subfloor of 19 mm (3/4-inch) exterior grade

plywood is suitable.

9.3.4 Protect the floor area around any permanently installed heat-producing equipment

in accordance with the requirements of NFPA 31, or NFPA 54. Consult the manufacturer for additional requirements regarding the protection of the insulation

from excessive heat.

9.4 POST- INSTALLATION PROCEDURES

9.4.1 Ensure that the subfloor is flat, all subfloor panel butt or tongue and groove

joints are tight, and the subfloor is securely fastened.

An uneven subfloor causes early wear of the finish flooring

material

.

9.4.2 Ensure that, where required, protective coverings around heat-producing equipment

have been provided.

10. MASONRY WALL INTERIOR

10.1 APPLICABILITY

10.1.1 This section applies to the installation of organic cellular rigid-board

insulation to the interior of masonry walls, particularly basement walls, which

separate conditioned and unconditioned spaces.

94
10.2 PRE-I NSTALLATION PROCEDURES

10.2.1 Ensure that the walls are structurally sound; that they are dry and do not show

signs of recent dampness (such as mold); and are clean, free of grease, loose

paint, and loose material.

Structural rehabilitation, where required , needs to precede the

installation of insulation board. Insulation board will not adhere

properly to moist, molded or unclean areas.

10.2.2 Remove any baseboards or moldings on walls to be insulated.

10.2.3 Install any anchoring devices required for the application of the covering

material

.

Only anchoring methods and devices recommended by the manufacturer

should be used.

10.2.4 Determine edge treatment to be provided at windows and doors after the insulation

and covering are installed.

10.2.5 Identify all electrical outlets and switches. Have an approved electrician extend

these to the level of the new surface, if required.

10.2.6 Identify and seal cracks at ceiling/wall and floor/wall joints and around window

and door frames to reduce air infiltration.

10.3 INSTALLATION PROCEDURE

10.3.1 Cut the board insulation to fit around any surface projections such as windows,

electrical outlets, conduits, and surface-mounted water and drain pipes.

10.3.2 Attach the insulation board to the wall.

Attachment can be directly to the wall or to furring strips. The

latter method may be desirable if the masonry wall is not plumb or straight, or is uneven.

10.3.3 Do not cover water or drain pipes with insulation board. If possible, wedge some insulating board pieces between the pipes and the outside of the wall.

During cold weather, heat from the house may be required to prevent the

pipes from freezing.

10.3.4 After all insulation board is applied, install a cover having a finish rating of

not less than 15 minutes when tested according to ASTM E 119-76. For purposes of

this standard, 12.5 mm (0.5 in) or thicker plaster board, installed in accordance

with the manufacturer's instructions, is deemed to meet this requirement. Water

and drain pipes may be covered with approved covering material.

95
10.3.5 Cover the edges of the insulation around electrical outlets and switches, leaving

sufficient space to permit their convenient use.

10.3.6 Replace moldings at floors and install trim as needed around doors and windows.

10.4 POST-INSTALLATION PROCEDURES

10.4.1 Ensure that electrical outlets and switches operate freely.

10.4.2 Ensure that the required clearances around heat-producing equipment have been

maintained.

10.4.3 Ensure that all areas of insulation board, including edges, are covered

by material having the required finish rating of 15 minutes.

11. MASONRY CRAWL SPACE WALLS

11.1 APPLICABILITY

This section applies to the installation of organic cellular rigid-board insulation

to the interior of crawl space walls as an alternative to insulating the floor over

a crawl space.

11.2 PRE-INSTALLATION, INSTALLATION, AND POST-INSTALLATION

11.2.1 Ensure that all applicable provisions of the masonry wall section are carried out.

11.2.2 Do not cover ventilation openings but provide a means for closing the openings

during the heating season.

To allow for the venting of the crawl space, preventing the build-up

of moisture in the crawl space during the summer seasons. The free

ventilation area should be 0 . 1 m2 for every 150 m2 (1 ft2 for every

1500 ft2

) . This provision conforms to major building code requirements

for new construction. The ventilation area, if not sealed in winter,

will result in cold air infiltrating the crawl space, defeating the

purpose of the insulation. Crawl space ventilation openings should be

provided with insect screens and louvers. If louvers are provided

,

the "free area" is usually stamped on the frame. If the free area is

not known, assume it is one half of the total opening area (gross

area)

.

11.2.3 Cover the ground surface with a ground cover which acts as a vapor barrier (such

as 0.15-mm (6-mil) polyethylene sheeting lapped at the joints). Turn the ground cover up at least 150 mm (6 in) at the walls.

Moisture in the soil beneath the building may evaporate and condense on

the underside of the floor above. This can promote fungus growth, cor- rosion of metal fasteners and electrical components. This provision

conforms to major building code requirements for new constructions

.

96
12.

12.1

12.2

12.2.1

12.2.2

12.2.3

12.3

12.3.1

12.3.2

12.4

12.4.1

13.

13.1

13.1.1

FRAME WALL INTERIOR

APPLICABILITY

This section applies to the installation of organic cellular rigid-board

insulation to the interior of finished framed wall constructions which separate

conditioned from unconditioned spaces.

PRE -INSTALLATION PROCEDURES

Ensure that all provisions of paragraph 10.2 are carried out.

Secure any anchoring devices required for the application of the covering

material to the wall framing studs.

Identify water and drain pipes both on the surface of the wall and in the wall

cavities. Provide nailers as needed for attaching the cover material.

INSTALLATION PROCEDURE

Install insulation boards in accordance with the requirements of paragraph 10.3

of this practice.

Do not install insulation over stud spaces that contain water supply or waste

pipes. The fire protective covering material may be placed over stud spaces

containing pipes.

During cold weather, heat from the house may be required to prevent the

pipes from freezing.

POST-INSTALLATION PROCEDURES

Conduct post-installation procedures in accordance with paragraph 10.4 of this

practice.

GYPSUM PLASTER OR PLASTERBOARD CEILINGS

APPLICABILITY

This section applies to the installation of organic cellular rigid-board

insulation to the underside (winter warm side) of existing plaster or gypsum

board ceilings. See the following section on wood deck ceilings for requirements

for the interior installation of insulation board to wood roof decks.

97
13.2

13.2.1

13.2.2

13.2.3

13.2.4

13.2.5

13.3

13.3.1

13.3.2

13.3.3

13.3.4

PRE-INSTALLATION PROCEDURES

Ensure that the ceilings are structurally sound; that they are dry and do not show signs of recent dampness, such as mold; and are clean, free of grease,

loose paint, and loose material.

The insulation board and the finish material will impose an additional

load to the ceiling and should not be installed if the ceiling is

structurally unsound. Dampness , grease and loose materials can prevent

an effective bond between ceiling and insulation board. If the ceiling

is damp or shows signs of recent dampness , the roof above should be

inspected and any leaks should be repaired prior to installing the

insulation.

Remove any existing molding at the wall-to-ceiling joints or on the ceiling

itself.

Identify electrical outlets and recessed lighting fixtures. Have an approved

electrician lower these to the level of the new finished ceiling surface, if

requi red.

Identify the location of ceiling joists.

Seal all cracks at wall-to-ceiling joints, and any other cracks such as at electrical outlets.

This reduces air infiltration and can be done readily at this time.

It also reduces air leakage into the ceiling with the potential for

excessive moisture condensation in the attic.

INSTALLATION PROCEDURE

Cut the insulation board to appropriate size and attach the board to the ceiling.

Install a cover having a finish rating of not less than 15 minutes when tested

according to ASTM E 119-76. For purposes of this standard 12.5 mm (0.5 in) or thicker plaster board, installed according to the manufacturer's instructions,

is deemed to meet this requirement.

If the cover consists of gypsum or similar board material, install the cover so that the joints fall on the center line of the ceiling joists and nail the cover

to the joists with nails of sufficient length to penetrate the cover material,

the insulation board, the existing ceiling, and into the ceiling joist.

Finish the ceiling joints with tape and finish with filler as required.

Some gypsum board finish ceiling materials may not require taping

and finishing if rated at 15 minutes without such finishing.

98
13.4

13.4.1

13.4.2

14.

14.1

14.1.1

14.2

14.2.1

14.3

14.3.1

14.3.2

14.3.3

14.3.4

14.3.5

14.4

14.4.1

POST-INSULATION PROCEDURES

Ensure that all surfaces and edges of insulation board are covered with a material having a finish rating of at least 15 minutes when tested according to

ASTM E 119-76.

Ensure that the required clearances around heat-producing equipment have been

maintained.

EXPOSED WOOD DECK CEILINGS

APPLICABILITY

This section applies to the installation of organic cellular rigid-board

insulation to the underside (winter warm-side) of exposed wood roof decks.

PRE-INSTALLATION PROCEDURES

Apply all provisions of paragraph 13 of this practice.

INSTALLATION PROCEDURE

Cut the insulation board to fit snugly between any exposed joists or rafters.

Install the insulation board securely to the wood deck. If mechanical fasteners

are used, do not puncture the roofing.

Install a cover having a finish rating of not less than 15 minutes when tested in

accordance with ASTM E 119-76. For purposes of this standard 12.5 mm (0.5 in) or thicker plaster board, installed according to the manufacturer's instructions,

is deemed to meet this requirement.

Secure the cover through the insulation board to the wood deck. Do not puncture

the roofing.

Finish the ceiling with tape and spackle as required and install edge trim as needed.

Some gypsum board ceilings may not require finishing. See 13.3.4.

POST-INSTALLATION PROCEDURES

Ensure that all surfaces and edges of insulation board are covered with a material having a finish rating of at least 15 minutes when tested according to

ASTM E 119-76. For purpose of this standard, 12.5 mm (0.5 in) or thicker plaster

board, installed according to the manufacturer's instructions, is deemed to meet

this requirement.

99
14.4.2 Ensure that the required clearances around heat-producing equipment have been

maintained.

15. FRAME WALL EXTERIOR

15.1 APPLICABILITY

15.1.1 This section applies to the installation of organic cellular rigid-board thermal

insulation to the exterior of frame walls.

15.2.1 Assure that the walls are free of fungus growth (dry rot) and that they can support the load of the insulation and the weather resistant exterior finish.

If the existing exterior wall cover is sound and free of rot, insulation can be

installed over the existing siding. If the existing surface is attacked by

fungus growth, remove the old siding. If the old siding is removed, assure

that the structural integrity of the wall is maintained, either by the remaining

cross bracing or the installation of new siding.

The siding, the interior face of exterior walls, and the roof should

be inspected to identify areas where previous moisture problems have

caused paint peeling, warpage, stain, fungus growth, rotting, or other

structural damage. Insulation board should not be installed in these areas unless the causes of such moisture problems have been eliminated.

15.2.2 Remove any projecting trim around windows, doors, corners, and at the sills as required to install the insulation.

15.2.3 Identify any termite shields that would be covered by the insulation. Do not

install board insulation unless termite shields are effectively extended beyond

the insulation and cover to be installed.

15.2.4 Determine edge treatment to be given at corners, sills, windows, and doors.

15.2.5 Identify surface projections, such as electrical outlets, utility meters, and

water faucets, which will require special attention.

15.3 INSTALLATION PROCEDURE

15.3.1 If the existing wood siding is sound and left in place, install the insulation

board with mechanical fasteners to the wood siding in accordance with the

manufacturer's instructions.

15.2 PRE-INSTALLATION PROCEDURES

When used as exterior sheathing on buildings of more than one story,

the insulation board should be fire-stopped at each floor level, at

the ceiling of the uppermost story, and in between dwelling units.

100
15.3.2

15.3.3

15.3.4

15.3.5

15.3.6

15.3.7

15.3.8

15.3.9

15.4

15.4.1

15.4.2

15.4.3

15.4.4

If the existing siding was removed, or if the siding consists of light gauge metal over an "insulation board" sheathing, install the organic cellular rigid insulation board with mechanical fasteners to the wall studs or to an existing wood

sheathing in accordance with the manufacturer's instructions.

Maintain the clearances around chimneys and vents specified in NFPA 211, Standard

for Chimneys, Fireplaces, and Vents. Consult the foam manufacturer for additional

requirements regarding the protection of foam from excessive heat.

Cover the insulation board with a suitable weather resistant exterior finish,

such as wood, metal or plastic siding, wood or asbestos shingles, or metal lath

and stucco.

Attach the cover through the insulation board and to the existing wood siding or sheathing or to the wood frame studs; or attach furring strips or a plywood

nailer through the insulation board to the stud wall and attach the finish to the strips or nailer.

Install flashing and trim at windows, doors, corners, and sills so as to preclude

the penetration of water into the wall cavity.

Install flashing and seal around any obstructions, such as at water faucets and

electrical outlets.

Provide for weepage at the sill plate as required.

Where insulation board is installed on walls that have cavity insulation, provide

for moisture control in accordance with the requirements of Table 1.

POST- INSTALLATION PROCEDURES

Ensure that the required clearances around chimneys and vents have been

maintained.

Ensure that all surfaces of insulation board are covered with a suitable weather

resistant finish material.

Ensure that joints in trim, flashing, and protective cover at windows, doors, corners, faucets, and electrical outlets are tight and sealed as required.

Ensure that weepage in the cover is provided as required and is free of

clogging material

.

101
16. MASONRY WALL EXTERIOR

16.1 APPLICABILITY

16.1.1 This section applies to the installation of organic cellular rigid-board

insulation to the exterior of masonry or masonry veneer walls.

16.2 PRE-INSTALLATION PROCEDURES

16.2.1 Ensure that the walls are free of grease, loose paint and material, and major

cracks or bulges.

16.2.2 Remove any protruding trim around windows, doors, corners, and at the sill as required to install the insulation.

16.2.3 Identify any termite shields that would be covered by the insulation. Do not install board insulation unless the termite shield is effectively extended beyond

the insulation and cover to be installed.

16.2.4 Determine edge treatment to be given at corners, sills, windows, and doors.

16.2.5 Identify surface projections such as electrical outlets, utility meters, and

faucets which will require special attention.

16.3 INSTALLATION PROCEDURE

16.3.1 Attach the insulation board to the wall as recommended by the manufacturer.

16.3.2 Maintain the clearances around chimneys and vents specified in NFPA 211, Standard

for Chimneys, Fireplaces, and Vents. Consult the foam manufacturer for additional

requirements regarding the protection of foam from excessive heat.

16.3.3 Cover the insulation board with a suitable weather resistant exterior finish,

such as wood, metal or plastic siding, wood or cementitious shinjles, or metal

lath and stucco.

16.3.4 Fasten the cover through the insulation board onto the masonry wall; or secure furring strips or a plywood nailer base through the insulation board onto the

masonry wall and attach the finish to the strips or nailer base.

16.3.5 Install flashing and trim at windows, doors, corners, and sills so as to drain

penetrated water to the outside.

16.3.6 Flash and seal around any obstructions such as at water faucets and electrical

outlets.

102
16.3.7 Provide weepage holes at the sill plate as required.

16.4 POST- INSTALLATION PROCEDURES

16.4.1 Ensure that the required clearances around chimneys and vents have been maintained.

16.4.2 Ensure that the insulation board has been properly covered.

16.4.3 Ensure that all required flashing and sealing has been provided.

16.4.4 Check that necessary weepage at the sill plate has been provided and is

unobstructed.

17. ROOF EXTERIOR

17.1 APPLICABILITY

17.1.1 This section applies to the installation of organic cellular rigid-board insulation

to the exterior of sloped roofs.

17.2 PRE- INSTALLATION PROCEDURE

17.2.1 Inspect the roof to assure that it is not sagging or showing evidence of rot in

shingles, sheathing, or structural members. Do not install insulation on roofs

that are not able to support the additional load of the insulation and new roofing

system, or over roofs that show signs of rot.

Any corrections to deteriorated conditions of the existing roof,

waterproof membranes or flashing should be performed by personnel

qualified and approved for such work. Such corrections should be made

prior to installing the insulation.

17 .2.2 If there are two or more layers of roofing, remove all roofing. Insulation may be

applied over a single layer of roofing.

Good roofing industry practice does not allow more than a total of two

layers of shingles

.

17.2.3 Install nailers the thickness of the insulation board along all edges and along

the ridge.

This is to provide a firm basis for attaching plywood overlay at a critical location. Figure 2 illustrates location of nailers.

It is further recommended to install nailers to provide firm

support at all plywood overlayment joints.

103
17.3 INSTALLATION PROCEDURE

17.3.1 Do not install insulation board on roofs over unheated attics.

Such insulation would not save appreciable amounts of energy and is

thus not cost-effective.

17.3.2 Install insulation board as recommended by the manufacturer. Use an application

method which fastens the insulation to the roof sheathing. Do not use adhesive

to fasten the insulation to shingles or roofing felt only.

Maintain the clearances around chimneys and vents specified in NFPA 211, Standard

for Chimneys, Fireplaces, and Vents. Consult the foam manufacturer for additional

requirements regarding the protection of foam from excessive heat.

Install a plywood overlay, mechanically fastened to the original sheathing, on top

of the insulation board and cover the plywood with roofing.

17.4.1 Ensure that the required clearances around chimneys and vents have been

maintained.

17.4.2 Ensure that the new roofing entirely covers the insulation.

17.4.3 Ensure that all flashing is properly installed, particularly at edge nailers,

dormers, chimneys, or where the roof adjoins vertical wall sections.

Use proper length roofing nails so as not to penetrate insulation.

Install flashing as required to prevent penetrating into the space

between new and old roofing.

17.4 POST- INSTALLATION PROCEDURES

18. CERTIFICATION

18.1 Comply with the "Certification Procedures for the Installation of Thermal

Insulation."

104
TABLE 1. MOISTURE CONTROL REQUIREMENTS APPLICABLE TO THE INSTALLATION

OF RIGID BOARD THERMAL INSULATION ON FRAME WALLS

MATERIAL

WHERE

INSTALLED

WALL

CAVITY REQUIREMENT

Board with vapor barrier facings

(Also boards which are rated by

the manufacturer to have a water

Interior filled or emptyNo additional winter-warm

side vapor barrier

vapor permeance of less than

57 u/kPa«s»m2 (1 perm)

in the thickness in which they

will be installed)

Exterior filled In Zones 1 and 2 of Figure

1, vapor barrier on the

winter warm-side and sealing

of interior cracks

Exterior empty No additional winter warmside vapor barrier

Board without vapor barrier

facings having boards or a permeance of 57 y/kPa»s»m2

(1 perm) or less.

Interior f il led or empty

In Zones 1 and 2 of Figure

1, vapor barrier on the

winter warm-side and sealing

of interior cracks

•

Exterior filled In Zones 1 and 2 of Figure

1, vapor barrier and sealing

of interior cracks only in

bathrooms and other high

moisture areas

Exterior empty No additional winter warmside vapor barrier required

105
FIGURE 1 - CONDENSATION ZONE MAP.

106
INTERIM STANDARD PRACTICE FOR THE INSTALLATION OF

UREA-FORMALDEHYDE FOAMED- IN- PLACE INSULATION

This practice is an interim standard pending the results of research on potential health

effects of UF foam, sponsored by the Consumer Products Safety Commission.

To be compatible in form and style with the other practices, this practice was slightly

revised editorially from that published in the Federal Register .

1. SCOPE

1.1 This practice covers the installation of urea- formaldehyde (UF) foamed- in-pl ace insulation in masonry and frame wall cavities of existing residential buildings.

1.2 This practice covers the installation process from pre-installation procedures

through post-installation procedures. It does not cover the manufacture of the

material components, but it does cover the process of combining components to

form foam and it also covers field quality control procedures.

1.3 This practice provides minimum requirements that will help to ensure the

installation of insulation in a safe and effective manner. It must be noted

that actual conditions in existing buildings vary greatly and in some cases

substantial additional care and precaution may have to be taken to assure effective and safe installation.

1.4 This practice covers aspects of installation relating to the safety of installers,

building occupants and property, effectiveness and durability of insulation in

service, and the prevention of related structural damage to the residence.

1.5 A working knowledge of the terminology and fundamentals of construction and

applicable codes is necessary for the proper application of this standard.

1.6 This practice is intended to establish a minimum level of performance for safety

and effectiveness. When a manufacturer's installation instructions regarding

specific requirements that affect safety and effectiveness result in a higher

level of performance for these characteristics, such manufacturer's installation

instructions may be used.

1.7 This practice is not intended to supersede the authority of State and local codes

but is intended to establish minimum criteria for safety and effectiveness. When

State or local codes specifically address the substance of provisions contained

herein, they may apply; when State and local codes do not address the substance

of specific provisions contained herein, this practice shall prevail.

1 .8 This practice describes in general terms the procedures to follow for a safe and effective installation. It does not describe in detail the

terminology and fundamentals of residential construction, or the codes

or regulations that may be imposed by other Federal, State, or local

agencies .

107
2. APPLICABLE DOCUMENTS

ASTM* C 168-80a: Standard Definition of Terms Relating to Thermal Insulating

Materials.

ASTM C 755-73 (1979): Standard Recommended Practice for Selection of Vapor

Barriers for Thermal Insulation.

NFPA2 - 31: Standard for the Installation of Oil Burning Equipment.

NFPA-54: National Fuel Gas Code.

3. SIGNIFICANCE

3.1 This practice recognizes that effectiveness , durability , prevention of

related structural damage, and safety of insulation depend not only on

the quality of the insulating materials , but also on their proper and

workmanlike installation.

3.2 Improper installation of insulation may reduce its thermal

effectiveness , cause damage to the structure and cause unsafe

conditions

.

3.3 Specific hazards that can result from improper installation include:

Fire caused by heat buildup from recessed lighting fixtures covered by

insulation;

Deterioration of wood structures, paint failures , and corrosion of

metal fasteners and electrical components caused by prolonged moisture

accumulation within building components;

Acceleration and aggravation of the deterioration or failure of

electrical wiring components and heat buildup resulting from overcurrent

protection devices (fuses and circuit breakers) incorrectly matched to

wire; and

Unpleasant odor for prolonged time after installation.

3.4 The potential for adverse health effects is currently the subject of

extensive study by the Consumer Products Safety Commission ( CPSC)

.

1 American Society for Testing and Materials, 1916 Race Street, Philadelphia, PA 19103.

2 National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210

108
4. DEFINITIONS

4.1 Certain technical terms relating to insulation not defined below are used in this

subpart in accordance with the definitions given in ASTM C 168-67.

Approved - acceptable to whatever authority regulates the activity

or material and its use. Such authority is usually a municipal , State, or Federal agency or underwriters' inspection or rating bureau.

Conditioned Space - any space in a residential building that is served by a heating or cooling system.

Foamed- in-pl ace - sprayed or pumped in place to form rigid or semi-rigid

insulation in its permanent location.

Independent test laboratory - a test facility which has no organizational tie

or financial interest in a manufacturer, or in the promotion of the type of

product being tested. It must have sufficient breadth of interest or activity

so that the loss or award of a specific contract for test services would not be

a substantive factor in financial well-being of the facility. It may offer

test services under contract or on a fee basis and may be a profit or non-profit

activity.

Insulation installer (installer) - the person who combines the component

materials and foams the insulation in place.

Insulation manufacturer (manufacturer) - the organization or person that

supplies the resin, foaming agent, and other ingredients to the foam insulation

distributor and/or installer.

Unconditioned space - any space, out of doors or in a residential building,

which is not served by a heating or cooling system.

Urea-formaldehyde foam insulation (UF foam) - A cellular plastic material

generated in a continuous stream by mixing the components which are a urea-formaldehyde resin, air, and a foaming agent.

Vapor barrier - any material (as defined in ASTM Designation C 755-73) that

has a water vapor permeance (perm) rating of one (1) or less.

The following materials, upon proper application, constitute vapor

barriers: Asphalt impregnated kraft paper, aluminum foil, plastic

film such as polyethelene and paint and wallcoverings which are labeled

by the manufacturer as having a perm rating of one (1) or less when

applied in accordance with the manufacturer's instructions

.

5. MATERIALS

5.1 Under RCS, install only urea-formaldehyde component materials identified as complying with DoE standards.

109
This marking indicates that the component manufacturer certifies that

the product meets the applicable DoE standards . The label does not

imply that DoE has conducted tests on the material or that the

manufacturer uses an approved quality assurance program.

Under RCS, the component materials manufacturer must have a continuing annual

program of product testing by an independent laboratory. When accreditation by

the National Voluntary Laboratory Accreditation Program (NVLAP) is available,

such independent laboratory tests must be performed by NAVLAP accredited

laboratories.

DoE has requested that the Department of Commerce incorporate UF-foam

test procedures into the National Voluntary Laboratory Accreditation

Program (NVLAP).

SAFETY PRECAUTIONS

PRECAUTIONS RELATED TO THE INSTALLER

Wear safety equipment to protect hands and eyes against acid contained in the

chemical s.

Avoid contact between the uncombined chemical components of UF-foam and building

materials to prevent staining or corrosion.

Follow label instructions regarding hazards related to the materials.

Observe all safety rules provided by the installation equipment manufacturer.

Properly set relief valves on pressurized liquid and air vessels and exercise

care in the use of electrical power tools.

Keep all persons not involved in the installation a safe distance from work areas

and installation equipment.

Maintain proper ventilation on the job to prevent excessive exposure to formaldehyde gas.

Follow the manufacturer's instructions for storage of UF-foam components and

follow proper methods of disposal of old or unusable resin and foaming agent

sol utions.

Precautions related to occupant and building safety.

UF foam should not be installed in cavities which contain electrical

cables of circuits with improperly matched overcur,rent protection

devices because such cables could reach temperatures above those

permitted by the National Electrical Code (NEC). Accordingly, prior

to installing insulation, it should be ascertained that all

electrical circuits have correctly matched overcurrent protection

devices. See Part I, Section 4.2.1 for further discussion.

110
6.2.2 Edison-type fuses should be replaced with S-type fuse adaptors;

where incorrectly matched circuit breakers are installed , they should

be replaced with correct ones.

6.2.3 Because code rubber wires have a lower NEC-allowed temperature limit, no insulation should be placed in cavities containing such wire until

the electrical system has been inspected by an approved electrician.

Code rubber wiring is usually found in houses built prior to 1940.

See Part I, Section 4.2.1 for further discussion.

7. INSTALLER REQUIREMENT

7.1 Under RCS, the installation of UF-foam may be performed only by insulation

installers trained and certified by the material components manufacturer.

The DoE interim material standard for UF-foam provides a complete list

of subjects to be covered by the component material manufacturer'

s

training activity . The relevant section of the material standard

456 .8 10(d)( 12 ) is appended to this practice as Appendix C.

7.2 Persons installing UF foam must have a working knowledge of the applicable codes

and regulations, tools, equipment, and methods necessary for the installation of

thermal insulation materials. These persons are also required to have an understanding of the fundamentals of residential construction that affect the

installation of insulation.

The rigorous training and qualification requirements for persons

installing UF foam is deemed appropriate as one element that can help

to assure that this insulation material is installed in a safe and

effective manner. The requirements are responsive to the fact that

the installation of UF-foam is more complex, requires greater care, and is subject to more errors than the installation of other insulation

materials

.

8. EQUIPMENT

8.1 Use only equipment which has been recommended by the manufacturer for use with

the manufacturer's product.

The use of equipment not properly matched to the specific component

materials can lead to incorrect mixing and an unsatisfactory

installation.

8.2 Ensure that hose lengths conform to the insulation manufacturer's requirements.

8.3 Check the equipment for proper functioning and cleanliness before starting a job.

Clean and maintain the equipment according to the equipment manufacturer's

instructions but at a minimum, at the following intervals:

Before installing each new batch of UF foam.

After every down time of more than 15 minutes.

Ill
At the conclusion of the installation process.

Proper functioning of equipment is essential for safety and

effectiveness of UF foam-in-place insulation. Cleanliness is a major

element in assuring proper functioning

.

9. FOAM GENERATION AND FIELD QUALITY CONTROL PROCEDURES

9.1 Follow the manufacturer's instructions for generating the foam.

In addition to general application guidelines , different products

require specific foam generation techniques because of differences in

component material formulation from manufacturer to manufacturer

.

Quality control procedures specific to individual products are not covered in this practice,

9.2 Do not use containers of resin or foaming agent after the shelf-life expiration

specified on the container labels by the manufacturer.

Chemical reactions take place continuously in the container. When

these reactions have taken place to a certain (product specific)

degree, proper mixing and curing of the foam components is no longer

possible.

9.3 Use only materials supplied by the same insulation manufacturer and, where that

manufacturer supplies more than one product, ensure that the individual

components to be combined are compatible.

The manufacturer formulates individual component materials which are

compatible to produce a foam with specific properties and characteristics. If incompatible components are combined , the foam may not meet

applicable standards

.

9.4 Handle all insulation materials in accordance with the manufacturer's

instructions. Keep powdered products dry and free of extraneous materials.

9.5 Perform all field quality control checks prescribed by the manufacturer. At a minimum, perform the following checks at the specified frequencies:

9.5.1 Setting time (gel time). Test in accordance with Standard for Urea-Formaldehyde

Foamed- in-Pl ace Insulation [see Appendix A]. Test before installation each day

on each job for each material batch. Check setting time after any change in

chemical concentration. Setting time must conform with the manufacturer's recom mendations for the type of structure and procedure being used but shall not exceed 60 seconds nor be less than 10 seconds.

See 11.12 for additional requirement regarding setting time to cavity

size.

9.5.2 Wet density. Test in accordance with Standard for Urea-Formaldehyde

Foamed-in-Place Insulation [see Appendix B], and ensure that wet density is within manufacturer's specifications. Check the wet density prior to each new job and new batch of materials, and after each down time of at least 45 minutes.

Whenever changing from an empty to full container, the density must be retested.

112
The density must also be repetitively tested throughout the foam-making period

at a frequency depending on the setting time: for a set time of 20 seconds,

check the density at intervals of no more than twenty (20) minutes; for a 60

second set time, check the density at intervals of no more than sixty (60)

minutes.

For each manufacturer' s system, there is a correlation between wet

and dry density. Thus the wet density provides a measure on whether

the foam will meet the manufacturer' s intended dry density.

9.5.3 Ratio of resin to foaming agent. Determine the ratio of resin to foaming agent

for each batch of materials on each day on each job by measuring the number of

gallons of each liquid used.

Assure that ratio is in agreement with that specified by the

manufacturer of the component materials. If the ratio is found not to be in agreement with the specification determine why the ratio is out

of specification. Adjust equipment to correct the problem. Recheck

setting time and wet density, and redetermine ratio of resin to foaming

agent on a small test batch.

9.5.4 Temperature of liquids. The temperature of the liquids shall be within the

acceptable range specified by the manufacturer.

Proper chemical reaction and handling requires for materials to be

within specified temperature ranges.

9.5.5 Specific gravity of dilute resin. Check the specific gravity of each batch of

dilute resin with a hydrometer to ensure that the specific gravity is within the

upper and lower limits specified by the manufacturer. Do not use materials whose

specific gravity is out of range.

During the measurement of specific gravity, assure that material is

thoroughly mixed and is not stratified.

9.5.6 Water temperature and hardness. When reconstituting powdered UF foam components, ensure that the water temperature and hardness are within the acceptable ranges

specified by the manufacturer. Maintain a reconstitution record for each batch

of material prepared.

The solubility of the dry resin in water is affected by temperature and

hardness of water. If the resulting resin solution does not have the

correct concentration, poor foam will result.

9.5.7 Ensure that the foam is characterized by uniform cell distribution.

Conduct a visual inspection of slices of the setting time sample taken

in 9.5 .1.

9.6 Maintain a record of the results of all field quality control checks and of other

pertinent information required by the manufacturer, including, but not limited to:

Date of application;

Outdoor ambient air temperature;

Material lot number(s);

Expiration date(s) (shelf-life);

Equipment identification number.

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10. PRE- INSTALLATION PROCEDURES

10.1 Inspect and identify areas where a previous moisture problem has caused paint

peeling, warpage, stain, visible fungus growth, rotting, or other structural

damage. Do not install insulation in such areas until the resident has been

notified and these conditions have been corrected and their source(s) eliminated.

If the resident, after being informed of the moisture condition and the effects

of installing insulation in such areas, elects to proceed with the installation,

the resident must so state in writing on the contract.

Installing insulation in an area which exposes it to moisture may

contribute to further deterioration of the structure and loss of effectiveness of the insulation. Insulation in such areas may prolong expo- sure of components to moisture, creating a potential for fungus growth

and rotting. DoE recommends against installing insulation in the

immediate area of the moisture damage. Immediate area is defined as the stud or joist space(s) in which prior moisture problems were

observed. For further information regarding the identification and

evaluation of previous moisture problems, see Part I, Section 4.1.1.

10.2 Block all openings in sidewalls through which the insulation material may escape.

Seal all wall cavities which open into an attic, basement, or crawl space prior

to installing insulation.

It is especially important to ensure that all wall cavities are sealed

properly in homes of balloon frame construction (see figure 1) since

open-ended cavities are inherent in this type of design. Also, seal

around plumbing and electrical openings , particularly beneath sinks,

to prevent filling up a cabinet below the sink.

10.3 For buildings located in Zone I of Figure 2, provide a vapor barrier on the

interior surface of all walls to be insulated in bathrooms and unvented kitchens

and laundry areas. Caulk or seal all major cracks on the interior face of exterior walls of these rooms including joints between the floor and wall (except

where impractical because of carpeting), between wall and ceiling, at joints

around window frames, and around wall penetrations for electrical services (outlets and switches), plumbing stacks, and heating and air-conditioning ducts.

It is recommended that a vapor barrier and caulking, such as described

in this section, also be provided on all walls to be insulated in bath- rooms and unvented kitchens and laundry areas in buildings in Zone II of Figure 2 .

The above requirements for moisture control are minimum requirements

needed to prevent long-term moisture damage. Homes which are characterized by one or more of the following conditions are more likely to experience excessive moisture accumulation which can be corrected by

application of a vapor barrier and caulking as described above and/or

additional venting of the wall cavity from the exterior or by additional

ventilation of the occupied space:

(a) Homes with an area of less than 75 m2 (800 ft 2

)

(b) Homes with less than 23 m2 (250 ft 2

) per occupant

.

(c) Homes with tight wall and ceiling construction and weatherstripped

windows and doors.

114
(d) Electrically heated homes or homes with a heating system which uses outside combustion air.

(e) Homes humidified during the winter.

A relative humidity indicator may be installed to monitor the humidity

level and determine when excessive moisture accumulation is likely to occur. See Part I, Section 4.1.2 for discussion on use of relative

humidity indicator.

10.4 Examine the material on the indoor side of wall cavity. Ensure that it has a finish rating of at least 15 minutes when tested in accordance with ASTM E 119-76.

Gypsum board 12.5 mm (0.5 in) thick installed according to the manufacturer is

deemed to have the required rating.

UF-foam insulation should not be installed if the indoor side of the

wall cavity does not have the required finish rating. Some UF foam

manufacturers do not recommend applying foam directly against certain

types of wall coverings, such as wood and particle board. Check with

the manufacturer prior to installation.

10.5 Determine if the structure has dissimilar metals with large surface areas exposed

in the same cavity. (Since the foam is wet with mild acidity, rapid electrochemical corrosion can take place.) Contact the manufacturer to obtain assistance

with such application, and follow the manufacturer's recommendations.

An example condition that might lead to electrolytic corrosion following

UF-foam insulation installation is an exterior wall cavity enclosing

both copper plumbing lines and aluminum electric wiring.

10.6 Inspect window frames. Identify any windows which contain internal mechanisms

such as springs, counterbalance weights, friction strips, etc. in their frames.

Follow the manufacturer's specific installation procedures for foaming these

areas.

Incorrect foaming around windows with internal mechanisms can immobilize

the mechanism and prevent future opening or closing of the window.

10.7 Provide the customer with a statement identifying the effective thermal

resistivity of the material to be installed, as determined by the test method in

the DoE material standard for Urea-Formaldehyde Foamed-in-place Insulation, and

a statement containing the safety information contained in Appendix D.

11. INSTALLATION PROCEDURES

11.1 Do not install insulation unless the pre-installation procedures have been

carried out and any defects which were identified were corrected and their

causes eliminated.

The purpose of the pre-installation procedures is to assure that the

installation can be carried out effectively and without adverse side

effects detrimental to other building components and materials . For

lasting results, it is important not only to correct symptoms , such as

replacing rotten wood, but to eliminate the source of the defect, such as water leaks which promoted the rot in the first place. In many

instances corrective measures can be taken with relative ease prior to

115
the installation of insulation. After installation, correction may

be more difficult and costly.

Do not install insulation unless all field quality control and equipment checks

required to be performed prior to installation have been completed. Conduct

tests as required during the installation.

Install UF-foam in exterior sidewalls only. Do not install the material in

attics, above ceilings, in knee walls, under floors or below grade, between a dwelling and other spaces, such as garages or storage areas, and in mobile homes.

High temperatures and humidity in attics and above ceilings may cause hydrolytic deterioration of the foam resulting in offgassing of formaldehyde vapors. Because the vapors are denser than air, they may sink

into the living spaces below.

Attic kneed walls face similar conditions as atttics.

Under floors or below grade, installations are likely to have high

relative humidities . Also, vapors and moisture can not be vented

to the exterior of the residence.

The installation of UF-foam in walls with both sides facing enclosed

spaces does not permit the rapid venting of vapors and moisture to the

exterior of the residence .

Most mobile homes have an impermeable exterior metal skin which

restricts venting to the outdoors.

Operate all installation equipment in accordance with the equipment manufacturer'

instructions.

Structural damage can be caused by excessive pressure during installation or can result from installing UF-foam insulation in constructions too weak to withstand

normal pressures. Assure that installation does not cause the failure of the

wall construction or its components. Specifically, the following conditions

must not result from the installation:

Separation of finish materials from studs

Cracking of materials or openings of joints betweeen boards

Deflection of more than 1/200 of the stud spacing.

Open all entry holes with a technique that permits refinishing with little or no change in appearance.

Do not install insulation in wall cavities which themselves are air ducts for

heating, ventilation, and/or cooling systems.

Do not install insulation when the atmospheric relative humidity, or outdoor

ambient temperature, or cavity temperature is not within the acceptable range

specified by the manufacturer.
Ambient conditions affect the curing of the foam. The limits of

acceptable ambient conditions differ with the products formulated

by different manufacturers

.

11.9 Install insulation only in cavities which will preclude contact by the insulation

with the ground or other sources of water.

11.10 UF-foam is a combustible material. Install UF-foam so as to meet the applicable

requirements listed below:

If a wall cavity contains recessed lighting fixtures or other heat-producing

devices, either provide a three-inch minimum clearance around the recessed lighting

fixtures (including wiring compartments and ballasts) and other heat-producing

devices not covered in paragraph (B) or do not install UF-foam in the cavity con- taining such heat producing device(s). Do not cover these devices so as to entrap

heat or prevent the free circulation of air, unless they are approved for such

purpose.

Provide the minimum clearances around gas-fired appliances specified in NFPA-54,

the National Fuel Gas Code. Around oil-fired appliances, provide the minimum

clearances specified in NFPA-31, Standard for the Installation of Oil Burning

Equipment. Around masonry chimneys or masonry enclosing a flue, provide a minimum

two-inch clearance from the outside face of the masonry. Around vents, chimney and

vent connectors and chimneys other than masonry chimneys, provide the minimum

clearances specified in NFPA-211, Standard for Chimneys, Fireplaces, and Vents.

11.11 Remove any foam which is inadvertently sprayed on glass or exterior siding before

drying occurs.

The foam can permanently stain the siding and may be hard to remove

after drying.

11.12 Setting time must be sufficient in duration to permit complete filling of the

cavity before setting begins.

Depending upon the application technique, larger. cavities may need

longer setting time than that required for small cavities . See also

section 13.4 for additional applicable criteria for setting time when

applying foam in continuous masonry wall cavities

.

12. INSTALLATION PROCEDURE - FRAME WALLS

Insulation frame construction walls (including masonry veneer construction) by

either Method A or B.

12.1 METHOD A

12.1.1 Do not foam cavities in excess of 3 m (10 ft) in height by this method.

12.1.2 Make an entry hole (fill port) between half and three quarters of the way up the

wall. Make the fill port at least 12.5 mm (1/2 in) larger in diameter than the

outside diameter of the hose to allow air relief and maneuvering of the hose.

117
12.1.3

12.1.4

12.1.5

12.1.6

12.2

12.2.1

12.2.2

12.2.3

12.2.4

13.

13.1

13.2

Probe the cavity for blockages and make additional fill ports as necessary to ensure complete filling of the cavity. For a typical layout of fill ports, see Figure 3.

Insert the applicating hose into the cavity within approximately 50 to 100 mm

(2 to 4 in) from the bottom (see Figure 4, Position "A").

Retrieve the hose at a rate approximately equal to the rate of foam dispensation

unless the manufacturer specifically recommends that the hose remain at the

extremity of the cavity for the total filling time.

When the foam reaches the level of the fill port repeat the procedure for the

upper part of the cavity (see Figure 4, Position "B").

METHOD B

This method may be used to foam cavities in excess of 3 m (10 ft) in height as well as shorter cavities.

For each unobstructed cavity, make at least three entry holes which correspond to the size of the applicating hose (or adaptor, if used). Place the fill ports at approximately 1200 mm (4 ft) from the bottom and 450 mm (1-1/2 ft) from the top

of the cavity (see Figure 5). An air relief hole may also be provided at the

very top of the cavity.

Place the applicating hose up to or just inside the bottom fill port and dispense

the foam until the next fill port level is reached.

Repeat this procedure by foaming through the top level fill port until foam

reaches the center fill port.

INSTALLATION PROCEDURES -- MASONRY CAVITY WALLS

This method applies to the installation of UF foam in masonry cavity walls

consisting of concrete block, brick, or brick and block. Do not apply this

method to brick veneer on wood frame construction. Attempts to fill brick veneer construction by this method may cause buckling, breaking, or other damage to the

walls. Brick veneer construction should be foamed in accordance with the

instructions for frame construction in paragraphs 12.1 and 12.2.

The internal void area (cavity) in masonry wall constructions usually runs the

entire distance of the wall. Provide holes at 900 mm (3 ft) -- intervals along

the horizontal distance of the wall at 600 mm (2 ft) -- intervals along the

vertical distance of the wall. Begin the bottom-most row of holes at a distance

of between 300 and 600 mm (1 and 2 ft) from the bottom of the wall cavity.

Application of this method requires that the wall cavity is continued

over a length greater than typical stud spacing. It may not be applicable to masonry walls with window or door openings at frequent

intervals .

118
13.3 Begin foaming at one of the bottom corners of the wall and continue foaming until

foam is detected at the horizontally adjacent hole.

13.4 Ensure that the setting time is longer than the time it took the foam to travel

between the horizontal holes.

13.5 Move to the adjacent horizontal hole and repeat the procedure specified above.

13.6 After the bottom row has been foamed, proceed to the next row and repeat the

procedure until the entire wall has been filled.

14. INSTALLATION PROCEDURE — WALLS WITH EXTERIOR METAL SURFACES

Buildings with a metal exterior surface require special installation techniques.

UF foam should not be installed in these buildings unless adequate means are provided to allow for moisture and other vapor to escape to the outside. Follow

the manufacturer's specific instructions for application of foam to these types

of structures.

15. INSTALLATION PROCEDURE — WINDOW AND DOOR FRAMES

15.1 Do not apply UF-foam to window and door frames until after the walls have been

insulated.

15.2 Drill entry holes which correspond to the size of the applicating hose (or

adaptor, if used) into the void areas around the frames. Drill holes into the

fascia of the frame wherever possible.

15.3 Foam each entry hole until foam appears at the adjacent hole or until foam emerges

from cracks in and around the moldings.

15.4 If the window has any moving parts within the space to be insulated, work the

mechanism of the closure. For a fast setting time (10 seconds) work the mechanism within 15 minutes of filling. For a slow setting time (60 seconds) work the

mechanism within 30 minutes of filling.

This procedure will ensure that the interior mechanisms of the unit

remain operative after the installation of UF-foam insulation.

16. POST- INSTALLATION PROCEDURES

16.1 Seal all entry holes on the exterior of the wall system in a manner compatible

with the original materials and appearance. Seal all entry holes on the interior

of the wall system immediately following the completion of foaming.

16.2 Determine if many coats of exterior paint or caulking form an impermeable vapor

barrier on the exterior wall. Take corrective measures, such as loosening up the

siding, removing caulking between wood laps, or installing vents/diffusers, to

reduce the effect of moisture barrier and allowing drying to take place. Ensure

that the venting provided does not result in rain water leakage into the wall

system.

119
Substantial amounts of water are introduced in the wall cavity during

foaming. This water, in the form of water vapor, should be allowed

to escape from the cavity to the outdoors. A tight moisture barrier

at the outside face of the wall will either result in a potential for

increased venting to the indoors (with potential odor and health problems) or may be retained in the wall cavity, possibly leading to fungus

growth and rot problems

.

16.3 Inspect the interior of electrical wall outlet boxes and other electrical devices

and, where necessary, remove any insulation which entered during the foaming pro- cess. Ensure that electrical power has been turned off prior to conducting this

procedure.

16.4 Ensure that windows and doors operate properly.

16.5 Ensure that any insulation which has come in contact with glass, aluminum, or

vinyl building components or has otherwise permeated the interior of the residence

has been cleaned off.

16.6 Offer the customer a sample of the foam installed at the customer's premises, at no cost to the customer. The sample must be approximately the size required for

the dry density test, packaged in a manner to prevent deterioration for at least

three years.

16.7 Comply with the "Certification Procedures for the Installation of Thermal

Insulating Materials.

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APPENDIX A

EXCERPT FROM INTERIM STANDARD FOR UREA-FORMALDEHYDE FOAMED- IN- PLACE INSULATION 456.810 (f)

( Federal Register , September 25, 1980)

(9) Test Method for Setting Time

A conical specimen with a bottom diameter of approximately 30 cm (12 in) and a height of

approximately 30 cm (12 in) shall be made by foaming from a hose. Start a stopwatch

immediately after the cone has been formed and immediately commence slicing the cone with a spatula. Record the time when the foam no longer slices as if it were whipped cream but

shears off leaving a smooth surface. This time is the setting time.

APPENDIX B

EXCERPT FROM INTERIM STANDARD FOR UREA- FORMALDEHYDE FOAMED- IN- PLACE INSULATION 456.810(f)

( Federal Register , September 25, 1980)

(5) Test Method for Wet Density

Weight to the nearest gram a measured quantity of freshly foamed material in a tared

container within five minutes after formation. Calculate wet density using the formula:

Weight of Foam and _ Tare Weight of

Density in kg/m3( lbs/ft2 ) = 1000 x Container in g (lbs) Container in g (lbs)

Volume in cm^ (ft^)

APPENDIX C

EXCERPT FROM INTERIM STANDARD FOR UREA-FORMALDEHYDE FOAMED- IN- PLACE INSULATION 456.810(d)

( Federal Register , September 25, 1980)

( 12) Training Requirements

(i) The manufacturer of the UF-foam components shall train and certify the installers of

UF foamed-in-place thermal insulation. An approved training course and comprehensive

examination shall require and demonstrate proficiency in the following:

(A) Overview of heat transfer and thermal insulation

(1) condensation control /vapor barriers

(2) effects of moisture on thermal insulations

(3) air infiltration

(B) Overview of UF-foam insulation

(1) physical properties

(2) mechanical properties

(3) thermal properties

(4) chemical properties

(C) UF-foam technology

(1) manufacture and composition of UF-foam components, i.e., resin and

catalyst solutions

(2) chemical reactions during production of UF-foam and of final foamed product

(3) field manufacture of UF foam in situ

121
(D) Post- installation curing of UF foam

(1) shrinkage

(i) normal

(ii) excessive

(2) formaldehyde release

(i) inherent post-instal lation release

(ii) possible delayed release

(iii) solids content of components and foam

(iv) factors affecting rate of drying

(E) Installation procedures

(1) general guidelines

(i) vapor barriers

(ii) wall venting

(iii) drilling and plugging requirements

(iv) problem installations

(2) specific guidelines (covers opening and closing techniques and equipment

and tools to use)

(i) brick-on- brick

(ii) concrete block

(iii) brick veneer on frame construction

(iv) drill and plug

(v) wood shingle and wood shake siding

(vi) slate shingles

(vii) aluminum, vinyl, and steel siding

(viii) clapboard wood siding

(ix) metal-clad buildings

(x) stucco and pebbledash

(xi) imitation brick asphalt roll or sheet

(xii) balloon construction

(xi i i ) pipe chases

(xiv) windows and door frames

(F) Problem applications

(1) knee walls

(2) mobile homes

(3) ceilings

(4) below grade

(G) Proper cavity fill techniques

(1) stud cavity

(i) check for obstructions

(ii) how to determine number of holes per cavity necessary for complete fill

(iii) methods of preventing overpressurized or ruptured walls

(iv) demonstration of proper fill technique

(2) continuous cavity, i.e., brick-on-brick

(i) methods of preventing overpressurized or ruptured walls

(ii) demonstration of proper fill technique

(3) other cavities

(i) methods of preventing overpressurized or ruptured walls

(ii) demonstration of proper fill techniques

(H) Resin and foaming agent/catalyst handling

(1) storage conditions

(2) solution temperatures during application

(3) shelf life

122
(4) safety precautions

(5) shipping requirements

(I) Practical demonstration

(1) proper foaming technique

(i) pre-foaming quality control checks

(ii) pre-installation quality control checks

(iii) quality control checks during installation

(2) trouble shooting off-specification foam

(i) off- ratio foam

(ii) incorrect density foam

(iii) overaged resin

(iv) incorrect solution temperatures

(v) faulty, malfunctioning, or inadequate equipment

(vi) overacidified or underacidified foaming agent

(vii) effects of using equipment not properly maintained

(J) Equipment

(1) manufacturer's recommended equipment

(2) proper care and maintenance

(3) troubleshooting

(K) Recordkeeping

(1) required disclosures to consumer

(2) manufacturer's required recordkeeping

APPENDIX D

Interim Standard for Urea- Formaldehyde Foamed- in-Pl ace Insulation, §456.810 (d) (11) (ii).

This product may release formaldehyde gas into your home over a long period of time.

Formaldehyde gas may cause eye, nose, and throat irritation, coughing, shortness of

breath, skin irritation, nausea, headaches, and dizziness. People with respiratory

problems or allergies may suffer more serious reactions, especially persons allergic to

formaldehyde.

The symptoms may appear immediately, or not until months after installation.

The U.S. Department of Energy recommends application of U-F foam in exterior sidewalls

only, because other installations may increase the likelihood of formaldehyde release into

the home. In some instances the formaldehyde gas cannot be controlled by ventilation or other means.

If you have health concerns, call your doctor. Also, contact (installer-phone) or

(material supplier-phone).

0

123
FIGURE 1 - BALLOON FRAME CONSTRUCTION.

FIGURE 2 - CONDENSATION ZONE MAP.

124
1500 mm

5 FT. ) MAX.

1500 mm

( 5 FT. ) MAX.

1500 mm

( 5 FT. ) MAX.

H

\w

\\

w

w

• w

,\ n n

:

1500 mm

( 5 FT, ) MAX.Tl" ~l

FIGURE 3 - FILL PORT LAYOUT IN FRAME CONSTRUCTION, METHOD A.

EXTERIOR WALL

FIGURE 4 - POSITIONS OF APPLICATION HOSE, METHOD A.

125
POSITION 2

UNINSULATED SPACE

POSITION 3

APPLI GATING HOSE

POSITION 1 START FOAMING AT POSITION 1 UNTIL FOAM REACHES LEVEL AT POSITION 3. THEN PROCEED

FOAMING IN SAME MANNER AT POSITION 2.

FILL PORTS IN FRAME WALL, METHOD B.

126
STANDARD PRACTICE FOR THE INSTALLATION

OF REFLECTIVE INSULATION

1. SCOPE

1.1 This practice covers the installation of reflective (aluminum foil) insulation in

ceilings, attics, floors and wall cavities of existing residential buildings.

1.2 A working knowledge of the terminology and fundamentals of construction and

applicable codes is necessary for the proper application of this standard.

1.3 This practice is intended to establish a minimum level of performance for safety

and effectiveness. When a manufacturer's installation instructions regarding

specific requirements that affect safety and effectiveness result in a higher

level of performance for these characteristics, such manufacturer's installation

instructions may be used.

1.4 This practice is not intended to supersede the authority of State and local codes

but is intended to establish minimum criteria for safety and effectiveness.

When State or local codes specifically address the substance of provisions

contained herein, they may apply; when State and local codes do not address the

substance of specific provisions contained herein, this practice shall prevail.

1.5 This practice further:

Describes , in general terms, the procedures to follow so that a safe

and effective installation is assured. It does not describe in detail

the terminology and fundamentals of residential construction, or the

codes or regulations that may be imposed by other Federal, State, or

local agencies.

Covers aspects of installation relating to the effectiveness,

durability , and safety of insulation in service. It does not primarily

address the safety of the person(s) installing the insulation.

Provides minimum requirements that will help to ensure the installation

of insulation in a safe and effective manner. Actual conditions in

buildings vary greatly and in some cases substantial additional care and precaution may have to be taken to ensure effective and safe

installation.

2. APPLICABLE DOCUMENTS

ASTMl C 168-80a: Standard Definitions of Terms Relating to Thermal Insulating

Materi al s.

American Society for Testing and Materials, 1916 Race Street, Philadelphia, PA 19103.

127
ASTM C 755-73 (1979): Recommended Practice for Selection of Vapor Carriers

for Thermal Insulations.

NFPA2 -70: National Electrical Code (Section 410-66).

3. SIGNIFICANCE

3.1 Effectiveness , safety, and durability of insulation depend not only on

the quality of the insulating materials , but also on their proper and

workmanlike installation.

3.2 Improper installation of insulation can reduce its thermal effectiveness, cause fire and electrical hazards and other unsafe conditions,

and promote deterioration of the structure in which it is installed .

3.3 Due to its electrical conductance, reflective foil poses hazards from

electrical shocks during and after installation if installed so as to be in contact with ungrounded electrical service components

.

3.4 Specific hazards that can result from improper installation include

electrical fires due to wiring with frayed, cracked, deteriorated , or missing electrical insulation in contact with the insulation, electrical shock hazards from improper grounding , deterioration in wood structures due to moisture accumulation, and corrosion of metal fasteners

and wiring components .

4. DEFINITIONS

Certain technical terms relating to insulation but not defined below are used in

this subpart in accordance with the definitions given in ASTM C 158-80a.

Approved - acceptable to the authority which regulates the activity or material and its use. Such authority is usually a municipal, State, or Federal

agency or a third-party certification, inspection or rating service.

Conditioned space - any space in a residential building which is served by a heating or cooling system.

Reflective thermal insulation - thermal insulation depending for its efficiency

in large part on reduction of radiant heat transfer across spaces by use of one

or more surfaces of high reflectance and low emittance.

Unconditioned Space - any space, out-of-doors or in a residential building,

which is not served by a heating or cooling system.

Vapor Barrier - any material (as defined in ASTM C 755-73 (1979)) that has a water

vapor permeance rating of 57.4 yg/kPa'S'm2 (1 perm) or less.

2 National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210.

128
The following materials , upon proper application, constitute vapor

barriers: asphalt-impregnated Kraft paper, aluminum foil, plastic

film, and paint and wallcovering which are labeled by the manufacturer

as having the above permeance rating or less when applied in accordance

with the manufacturer' s instructions.

5. MATERIALS

5.1 Under RCS, install only reflective insulating materials labeled as complying

with DoE standards.

This marking indicates that the manufacturer certifies that the product

meets the applicable DoE standards . The label does not imply that DoE

has conducted tests on the material or that the manufacturer uses an

approved quality assurance program. See Part I, Section 6.1 for

further discussion.

5.2 It is recommended that reflective insulation materials installed have

third-party certification.

6. SAFETY PRECAUTIONS AND PRE- INSTALLATION PROCEDURES

6.1 GENERAL

6.1.1 Identify and examine all visible wiring, junction boxes, and other metallic or electrical equipment in the areas where insulation is to be installed. Do not install reflective insulation if the wiring is found to have frayed, cracked,

deteriorated, or missing electrical insulation.

Contact of metallic reflective insulation with deteriorated electrical

wiring can lead to shock hazard and potential fire risk.

6.1.2 Ensure that all electrical equipment in the building is grounded. Do not install

reflective (aluminum foil) insulation in buildings in which electrical equipment

is not grounded.

Contact of metallic reflective insulation with ungrounded electrical

equipment can lead to shock hazards and potential fire risk.

6.1.3 Identify air supply and return ducts, pipes, electrical wires, and other

obstructions located in spaces between joists and studs. Ground all metallic

heating and air conditioning ducts which may come in contact with the installed

insulation. Do not install reflective insulation where metallic heating and air

conditioning ducts are not grounded.

Repairs or replacement of electrical wiring to eliminate defects, as

well as all other electric-related activities , are to be carried out

only by personnel approved for such work.

Insulation of floors over unheated spaces will cause these spaces to be

colder. Accordingly , appropriate measures may need to be taken to keep

water pipes from freezing during colder weather.

129
6.2 ATTICS AND CEILINGS

6.2.1 Identify and measure ventilation area in attics. Do not install insulation in

attics unless 0.1 m^ minimum of free ventilation area per 30 m2 (1 ft^ per

300 ft^) of attic floor area is provided.

Adequate attic ventilation carries to the outdoors moisture that enters

the attic from the house. For additional information see Part I,

Section 4 .1 .3 .

6.2.2 If the free ventilation area of louvers is not known, assume that it is half of

the area of the gross ventilation opening and increase the gross opening accordingly. Many louvers have their free ventilation area stamped on their frames.

6.2.3 Ensure that all ventilation openings have suitable louvers or screens to prevent

rain or snow from entering the attic.

6.2.4 Identify all recessed lighting fixtures (including wiring compartments and

ballasts) and other heat-producing devices in areas to be insulated.

Identification is necessary prior to installation so that proper

precautions can be taken during installation,

6.3 FLOORS

6.3.1 Where insulation is to be installed beneath floors over crawl spaces, cover the

ground surface with a ground cover which acts as a vapor barrier (such as 0.15 mm

(6-mil) polyethylene sheeting lapped at the joints). Turn the cover up at least

150 mm (6 inches) at the walls.

6.3.2 Where practical in crawl spaces, provide a free ventilation area of 0.1 m^ for

every 150 m2 (1 ft^ for every 1,500 ft<?) of the ground area of the crawl space.

Provide cross-ventilation where possible. (See 7.2.2 for guidance on estimating

free ventilation area.)

To allow for venting of the crawl space to prevent moisture build-up.

This provision conforms to major building code requirements. Provision

should be made to close off the ventilation opening during cold weather.

7. INSTALLATION PROCEDURES

7.1 GENERAL

7.1.1 Do not install insulation unless the pre-instal lation procedures have been carried

out and any defects which were identified have been corrected and their causes

el iminated.

The purpose of the pre-installation procedures is to assure that the

installation can be carried out effectively and without adverse side

effects detrimental to other building components and materials. For

lasting results, it is important not only to correct symptoms , such as

replacing rotten wood, but to eliminate the source of the defect, such

130
as water leaks which promoted the rot in the first place. In many

instances corrective measures can be taken with relative ease prior to

the installation of insulation. After installation correction may be more difficult and costly.

7.1.2 Install insulation only between conditioned and unconditioned spaces.

Insulation is effective in conserving energy only when placed between

conditioned (served by a heating and/or cooling system) and unconditioned spaces (such as outdoors or an unheated garage J. Where adjacent

conditioned spaces are maintained at different temperatures , the temperature differential is seldom such that the insulation would be costeffective. One possible exception would be the case where one of two

adjacent conditioned spaces is frequently , and for prolonged periods,

neither heated or cooled at all, while the other is conditioned . In

this case, the frequently unconditioned space could be treated as

such. One example of this would be a home workshop attached to the

house but only occupied and heated on weekends.

7.1.3 Do not cover recessed lighting fixtures (including wiring compartments and

ballasts) and other heat-producing devices so as to entrap heat or prevent free

circulation of air unless they are approved for the purpose. See Part I, Section 4.2.2 for additional information.

This requirement is based on Section 410-66 of the National Electrical

Code (NFPA-70 ) . Recessed lighting fixtures rely on the free movement

of air around and above them to dissipate the heat generated by the

bulbs, ballasts, and wiring compartments.

7.1.4 Handle the insulation materials in accordance with the manufacturer's

instructions.

7.1.5 Ensure that the reflective surfaces are free of dirt, oil film, and other surface

coatings which can reduce the effective reflectance of the surfaces.

Coating of the reflective surfaces may reduce the thermal effectiveness

of the material.

7.1.6 Install reflective insulation flush or recessed with the framing members, as shown in Figures 1 and 2.

The reflective insulation must be properly mounted in place to achieve

the proper air space.

7.1.7 Secure the insulation in place with aluminum, coated copper-clad steel, plastic,

or coated galvanized steel fasteners.

Uncoated metal fasteners can cause galvanic corrosion.

7.1.8 Ensure that the insulation is cut to the correct size, fits tightly between

joists and studs on all sides, and that there are no wrinkles or fishmouths.

Where wrinkles and fishmouths cannot be avoided, tape the joint between the

insulation and framing members, or between adjacent sections of insulation

(in flush installations).

131
Air circulation around foil decreases its effectiveness

.

7.1.9 Ensure that where the material is installed to form multiple reflective air

spaces, the spaces measure, at a minimum, 20 mm (3/4 in). Maintain the distance

between reflective surfaces as uniformly as possible. Reflective surfaces must

not touch each other or the thermal performance of the insulation will be reduced.

Air spaces less than 20 mm (3/4 in) have reduced thermal effectiveness.

7.1.10 Tape and seal all splices and tears in the insulation. Seal all punctures in the

insulation by taping reflective material to the damaged area.

Air leakage between insulating spaces reduces the insulation'

s

effectiveness

.

7.1.11 Avoid joints within joist or stud spaces. Seal any required joints with tape.

7.1.12 Tightly seal the ends of reflective insulation against the surfaces which they

contact.

7.1.13 Fit insulation closely around plumbing and other obstructions and tape securely

to eliminate gaps through which air may pass into the reflective air spaces.

7.2 WALLS

7.2.1 Do not install insulation in contact with the ground or other sources of water.

This prevents the paper backing of the insulation from becoming wet and

prevents its deterioration.

7.3 ATTIC, CEILINGS, FLOORS

7.3.1 When installing insulation around bridging or cross bracing of ceilings or floor

joists, ensure that the insulation material is fitted tightly around these

obstructions and that there are no gaps in the insulation.

7.3.2 Do not cover soffit vents with insulation or in any other way restrict attic

ventilation.

7.3.3 Install insulation around vents which open into the attic in a manner that will ensure the free movement of air through the vent into the attic.

The venting of bathroom and kitchen (and clothes dryer) air into the

attic is an undesirable building practice because it introduces into

the attic excessive moisture which may condense when exposed to cooler

attic temperatures. The potential for condensation is further

increased as insulation is added, because the insulation reduces the

rate of heat flow from the living area to the attic, causing attic

temperatures to be even lower. It is recommended that all such vents

be extended and vented to the outside.

132
7.3.4 Fit the attic side of access doors or panels with insulation batt (or equivalent

material) except where prevented by a retractable ladder.

Secure the insulation in place using staples or other appropriate

fasteners. Insulation may be installed to the exterior of trap doors

which have retractable ladders mounted on their interior. If the

insulation is installed to the underside of the trap door, a finish

reasons and to protect the insulation. Weatherstripping should be

installed along the contact edge between the access panel and frame

to reduce infiltration losses in this area.

8.

8.1

POST- INSTALLATION PROCEDURES

Ensure that the reflective insulation provides a continuous and unbroken surface

between framing members, that no gaps, tears, and other openings exist, and that

all joints are tightly taped.

8.2 Ensure that insulation installed in attics does not restrict soffit or other vents

which open into the attic.

8.3 Ensure that the required clearances around heat-producing devices have been

i-» w-» /"\ « i « r\ r\ r\

FLOOR SHEATHING

JOIST

FASTENER

FIGURE 1 - ATTACHMENT OF REFLECTIVE INSULATION ON FACE OF JOISTS OF STUDS.

FLOOR SHEATHING

JOIST

FASTENER

FIGURE 2 - ATTACHMENT OF REFLECTIVE INSULATION OF SIDE OF JOISTS OR STUDS,

133
CERTIFICATION PROCEDURES FOR THE INSTALLATION OF THERMAL INSULATION MATERIALS

1. SCOPE AND PURPOSE

1.1 Upon completion of each installation of thermal insulation materials performed

under the RCS Program, the person responsible for carrying out such installation

shall complete, in triplicate, a "Certification of Insulation" form such as exhibited in Figure 1.

Because insulation is installed in areas not easily visible to the

homeowner, a "certificate" is required to provide a permanent record

of what was installed. Such a record is needed particularly if at a later date (when fuel prices are higher) the installation of additional

insulation is contemplated . To serve its intended purpose, it is

necessary that this information be available not only to the present

but also to future owners.

2. CONTENT

The certificate of installation shall contain the following information:

Address of the building;

Date of completion of installation,

Name and address of the contractor;

Insulation type;

Insulation manufacturer;

Location and dimension in square meter (feet) of each space which was insulated,

The amount of insulation which was installed in each of the locations identified

given in the units in which the material is most commonly available, such as the

number of batts, bags, etc., of a specified size or the number of square meters

(feet), etc.;

The R value installed in each of the locations;

A statement, signed by an authorized individual, certifying that the installation

was carried out in conformance to the applicable standard practices, codes, and

regulations.

This refers to the DoE Material Standards , DoE Installation Practices,

building codes applicable in the particular locality , and any other

regulations imposed by local, State, and Federal standards.

134
3. DISTRIBUTION AND POSTING

The "Certification of Installation," shall be distributed and posted as follows

One copy shall be permanently affixed to the structure in an accessible but

inconspicuous location;

One copy shall be submitted to the homeowner or building occupant; a nd

One copy shall be retained for a period of five years by the agency responsible

for the installation.

PART I - GENERAL

ADDRESS OF RESIDENCE: NAME AND ADDRESS OF CONTRACTOR:

PART II - AREAS INSULATED

WALLS ( sq. ft.) CEILINGS (_

TYPE OF INSULATION:

sq. ft.) FLOORS ( sq. ft.)

TYPE OF INSULATION: TYPE OF INSULATION:

MANUFACTURER: MANUFACTURER: MANUFACTURER:

R VALUE AMOUNT

INSTALLED INSTALLED

R VALUE AMOUNT

INSTALLED INSTALLED

R VALUE AMOUNT

INSTALLED INSTALLED

PART- III - CERTIFICATION

I, _ certify that the residence identified in PART I was (PRINT NAME)

insulated as specified in PART II and that the installation was conducted in conformance

to applicable codes, standards, and regulations.

Date Authorized Signature

FIGURE 1 - CERTIFICATION OF INSULATION

135
STANDARD PRACTICE FOR THE INSTALLATION OF CAULKS AND SEALANTS

1. SCOPE

1.1 These practices apply to the on-site installation of caulks and sealants used to

control rain water leakage and major air infiltration through building walls.

1.2 These practices do not apply to the sealing of minor cracks at the building's

exterior.

2. APPLICABLE DOCUMENTS

ASTM* C 790-74 (1979), Standard Recommended Practices for Use of Latex Sealing Compounds

ASTM C 797-75, Standard Recommended Practices and Terminology for Use of Oil

and Resin Based Putty and Glazing Compounds.

ASTM C 804-75, Standard Recommended Practices for Use of Solvent-Release Type

Sealants.

Federal Specif ication^ TT-S-00230C "Sealing Compounds, Elastomeric Type, Single

Component (for Caulking, Sealing and Glazing in Buildings and Other Structures)."

Federal Specification TT-S-00227E "Sealing Compound, Elastomeric Type, MultiComponent (for Caulking, Sealing and Glazing in Buildings and Other Structures)."

I

Federal Specification TT-S-001657 "Sealing Compound, Single Component Butyl Rubber

Base, Solvent Release Type (for Buildings and Other Types of Structures)."

Federal Specification TT-S-001543A "Sealing Compound, Silicone Rubber Base (for

Caulking, Sealing, and Glazing in Buildings and Other Structures)."

1 Federal Specification TT-C-00598C "Caulking Compound, Oil and Resin Base Type (for

Building Construction)."

Federal Specification TT-P-00791B "Putty Lindseed-Oil Type, (for Wood-SashGlazing)."

ASTM Committee C 16 is currently developing and revising standard

practices for the installation of caulks and sealants . Users of

this publication are urged to contact ASTM for status of the various

practices under C 16 's jurisdiction.

1 American Society for Testing and Materials, 1916 Race Street, Philadelphia, PA 19103.

2 Federal Specifications, Customer Service, Publications and Forms Center,

5801 Tabor Avenue, Philadelphia, PA 19120.

136
3. SIGNIFICANCE

3.1 Water leakage, air leakage, excessive energy use, accelerated

deterioration, and reduced comfort can result from lacking, inadequate

or improperly installed caulks and sealants

.

3.2 This practice recognizes that effectiveness and durability of caulked

and sealed joints depends not only on the quality of materials used

but also on their proper and workmanlike installation.

3.3 Improper installation of caulks and sealants may also contribute to

moisture condensation and accumulation within building elements which can lead to various forms of deterioration such as fungus growth on

wood structure, corrosion of metal fasteners, pipes and electrical

service components. Moisture also can reduce the effectiveness of

insulations . With some insulation materials , excessive moisture can also cause the leaching of fire retardants and thus contribute to increased fire hazards.

4. MATERIALS

4.1 Under RCS, install only caulks and sealants identified as complying with DoE

standards.

This marking indicates that the manufacturer certifies that the product

meets the applicable DoE standards. The label does not imply that DoE

has conducted tests on the material or that the manufacturer uses an

approved quality assurance program. See Part I, Section 6.1 for

further discussion.

5. MATERIAL SELECTION, JOINT PREPARATION AND INSTALLATION PROCEDURES

5.1 The type of caulk or sealant chosen for a given application depends on the

composition of the adjacent materials, temperature fluctuation, exposure to direct sunlight, width and depth of the crack or joint to be sealed, and movement

in the joint. Select caulks and sealants, prepare the joint and substrate, and

install the material in conformance with the following standards and provisions:

Putty and Oil and Resin Base Types: ASTM C-797-75.

Acrylic (Solvent Type) and Butyl Rubber: ASTM C-804-75.

Latex Sealing Compounds: ASTM C-790-74.

Chlorosulphonated Polyethylene, Polysulf ide-Single Component, PolysulfideMulti component, Polyurethane-Si ngle Component, Polyurethane-Si ngle Component,

Polyurethane-Multi-Component and Silicone: Follow the provisions relating to application and use included in the applicable Federal Specifications (see

Section 2 above).

137
PROVISIONS TO PREVENT MOISTURE DAMAGE RESULTING FROM CAULKING AND SEALING JOINTS

In WALLS

On the exterior of building walls, joints should be sealed at head,

jambs, and sills of windows, louvered openings , exterior access panels,

and at penetrations of plumbing and electrical supply lines to prevent

rain water from entering the building construction and wall cavities

from the outside.

Weep holes such as at windows, doors, and access panels should not be

sealed.

Major and obvious locations of excessive air leakage at the exterior of

building walls should be sealed. Minor cracks at the building exterior

should not be sealed except where necessary to prevent rain water leakage. Some air exchange between wall cavities and outside is desirable

.

To reduce air infiltration and reduce the potential for hidden

condensation, it is recommended to seal and caulk on the interior

face of exterior walls all cracks such as at window and door frames,

ceiling/wall and ceiling/floor joints, plumbing penetrations , electrical

fixtures and electrical outlet and switch boxes, air supply and return

registers

.

For electrical outlet and switch boxes, foam rubber gaskets can be used

to seal against air leakage instead of the sealants indicated (see

Section 4)

.

138
STANDARD PRACTICE FOR INSTALLATION OF STORM WINDOWS, REPLACEMENT

WINDOWS, MULTI-GLAZING, STORM DOORS, AND REPLACEMENT DOORS*

1. SCOPE

1.1 This practice covers the installation of storm windows, replacement windows,

multi-glazing, storm doors, and replacement doors in residential buildings.

1.2 This practice applies to wood, metal, and plastic-framed storm windows or replacement windows, sealed multi-glazing units, non-sealed multi-glazing systems,

storm doors, and replacement doors. This practice also applies to multi-glazing

systems which include heat-absorbing or heat-reflective glazing.

This practice does not cover the installation of temporary plastic

films where such films are attached to the window or its framed opening

directly

.

1.3 This practice covers the installation process from pre-installation procedures

through post-installation procedures. It does not cover the fabrication or assembly of units, whether such fabrication takes place in a factory or at the

installation site.

Specifically, this practice does not cover the assembly of knock-down

units, or the installation of glazing into storm or replacement windows,

with the exception of the installation of multi-glazing in existing

windows or doors.

1.4 This practice covers aspects of installation relating to effectiveness,

durability, and safety in service. It does not cover aspects relating to the

safety of the person installing the units.

1.5 This practice provides minimum requirements that will help to ensure the

installation of storm windows, replacement windows, multi-glazing, storm doors,

and replacement doors in a safe and effective manner. Actual conditions in

existing buildings vary greatly, and in some cases substantial additional care

and precaution may have to be taken.

2. APPLICABLE DOCUMENT

2.1 ASTM2 Standard C 755-73 (1979): "Recommended Practice for Selection of Vapor

Barriers for Thermal Insulation."

1 This practice was developed jointly by the American Society for Testing and Materials,

the Department of Energy, and the National Bureau of Standards. It was published

originally as part of the RCS Rule in the Federal Register of November 7, 1979, and

was issued by ASTM under the designation E 730-80 in March, 1980. The DoE standard was withdrawn and replaced by a reference to the ASTM Standard by notice in the Federal

Register , Vol. 46, No. 3, Tuesday, January 6, 1981.

2 American Society for Testing and Materials, 1916 Race Street, Philadelphia, PA 191U3.

139
3. SIGNIFICANCE

3.1 This practice recognizes that effectiveness, safety, and durability of installed

units depend not only on the choice and quality of materials, design, adequacy of

assembly, and support system, but also on their proper and workmanlike

installation.

3.2 Improper installation of units may reduce their thermal effectiveness, lead to

excessive air and water leakage and condensation, and may promote the deterioration of wall constructions, windows and doors, and their respective finishes.

Additionally, improper installation of metal units may result in accelerated

corrosion of metal frames, trim, anchors, fasteners, and finishes. Also, unsafe

conditions are created when frames require excessive force for operation because

of poor installation.

3.3 The application of this practice requires a knowledge of applicable Federal,

State, and local codes and regulations, specifically, but not limited to required means of egress and requirements for safety glazing.

3.4 The application of this practice also requires a working knowledge of the tools,

equipment, and methods necessary for the installation of storm windows, thermal

windows, and multi-glazing and storm doors. It further assumes familiarity with

caulking and sealing and with glass handling procedures, painting where applicable, and an understanding of the fundamentals of residential construction that

affect the installation of these units.

This practice applies to the installation of units by professional

installers . It does not address untrained homeowners. Where home- owners or other untrained persons plan to install units, it is recom- mended that they consult available "how-to" or "do it yourself" books,

carefully read the manufacturers' instruction, or seek assistance from

qualified persons prior to starting with the installation.

4. DEFINITIONS

Galvanic corrosion - a form of deterioration resulting from the electrochemical

reaction that occurs when certain dissimilar metals are in contact in the presence

of moisture.

In the installation of metal windows and doors, dissimilar metals that

should not be in direct contact are aluminum and steel or iron, aluminum

and bronze, and aluminum and brass. Aluminum should only be used in

contact with other aluminum or stainless steel, and not with other

dissimilar metals.

Multi-glazing - an arrangement of two or more separated layers of glazing

providing one or more insulating air spaces. Multi-glazing can be achieved by

installing a pre-assembled, sealed insulating glass unit or by affixing one or more additional sheets of glazing onto an existing window, sash, or ylass.

Prime window (door) - the original window (door) to which a storm window (door) or multi-glazing is added to provide greater thermal resistance.

140
Heat-absorbing glass - glass having the property of absorbing a substantial

percentage of radiant energy in the visible and near-infrared region of the solar

spectrum.

Reflective glass - glass having the property of reflecting a substantial

percentage of radiant energy in the visible and near-infrared region of the solar

spectrum.

Replacement door - a door that is intended to replace an existing prime door.

It is often a door with improved thermal performance through insulating

construction and effective weatherstripping.

Under RCS, only thermal doors meeting DoE standards for thermal doors

and so identified may be installed as replacement doors. The identification indicates that the manufacturer certifies his product to meet

the applicable DoE standards. It does not imply that DoE has conducted

tests on the product or that the manufacturer uses an approved quality

assurance program. See Part I, Section 6.1 for further discussion.

Replacement window - a window that is intended to replace an existing prime

window. It is often a window system with improved thermal performance through

the use of multiple glazing and more airtight construction. Some replacement

windows also provide an insulating frame and sash to provide greater thermal

efficiency.

Under RCS, only replacement windows meeting DoE standards for thermal

windows and so identified may be installed as replacement windows.

Residential building - any building used or intended for residential occupancy.

Storm door - a door installed outside or inside a prime door, creating an insulating air space.

Under RCS, only storm doors meeting DoE standards and so identified may

be installed.

Storm windows - a unit consisting of glazing installed in a window opening

either outside or inside a prime window, creating an insulating air space. The

storm window may be removable or permanently attached, operable or fixed.

If the storm window is placed outside of the prime window, it should be

less airtight ; if placed inside, it should be tighter than the prime

window. This is to prevent excessive condensation from occurring at

the interior face of the outer window.

Under RCS, only storm windows meeting DoE standards and so identified

may be installed.

Unit - a storm window, replacement window, multi-glazing, storm door, or replacement door as defined herein. It is a manufactured item assembled in a factory, or a knockdown unit assembled at the site before installation.

Vapor barrier - any material (as defined in Recommended Practice ASTM C 755-73

(1979)) that has a water vapor permeance rating of 57.4 yg/kPa-s-m^ (1 perm)

or less.

141
The following materials, upon proper application, constitute vapor

barriers: asphalt-impregnated kraft paper, aluminum foil, plastic

film, and paint and wallcoverings that are labeled by the manufacturer

as having the permeance rating given above when applied in accordance

with the manufacturer' s instructions

.

Descriptions of terms used in this practice are in accordance with those contained

in Figures 1 through 3.

5. SAFETY PRECAUTIONS

5.1 Do not install window or door devices that would restrict means of egress

required by applicable codes and regulations.

Both windows and doors may be required means of egress for use during an

emergency such as a fire. Some door devices are difficult to open by

children or handicapped persons and their installation is not permitted

.

Consult local or State codes for details.

5.2 In doors, sidelights, and panels, install only safety glazing in accordance with

Consumer Product Safety Commission requirements.

3

6. STORM WINDOWS

6.1 PRE-INSTALLATION PROCEDURES

6.1.1 Examine the framing of the prime window to ensure that it is sound, free of decay,

corrosion, or other deterioration and will provide secure anchorage for the storm

frames.

Proper performance of storm windows depends on their secure fastening

.

Fasteners do not hold reliably in decayed structures.

6.1.2 Examine and repair weatherstripping and sealant of the prime window.

Where the prime window is not weatherst ripped , it is recommended that

weatherstripping be installed

.

6.1.3 Ensure that the frame contact areas are free of protrusions that would interfere

with proper installation of the storm window.

Protrusions prevent proper seating of storm windows and can lead to twisted installed units which are difficult to open and close, and which

may not provide the required water and air tightness

.

6.1.4 Measure and plumb the prime window or its opening in accordance with the

manufacturer's instructions, noting if it is out of square or not in plane.

3 Federal Register , vol. 43, No. 4, January 6, 1977, p. 1428-1450.

142
6.1.5 Ensure that the storm window is the correct size and type for the opening,

including tolerances and provisions for adjustment to out of squareness.

If opening and window units are not properly matched, a good

installation can not be achieved and should not be attempted . Instead,

either the opening should be adjusted or a new window unit ordered and

installed.

Aesthetically , it is desirable that the meeting rails or stiles of storm

windows align with the meeting rails or stiles of the prime window.

6.1.6 Ensure that the storm window has not been damaged during shipping or assembly.

6.1.7 Ensure that adequate weepage is provided for exterior storm windows.

It is usually difficult to provide weepage after installation of the

storm window.

6.2 INSTALLATION PROCEDURES

6.2.1 Do not install storm windows unless the pre-instal lation preparation has been

performed, any identified defects correct, and their causes eliminated.

6.2.2 Give a liberal brush treatment of commercially available water repellent

preservative to all cut or planed edges of wood storm windows.

Application of the preservative is particularly important on edges that

will be covered or enclosed after installation. Lack of drainage can

lead to prolonged exposure to moisture promoting fungus growth (dry

rot) in such areas.

6.2.3 Position storm windows to provide a minimum gap of 12 mm (1/2 in) between the

prime and storm glass.

It is the air space between the storm and prime windows which provides

the primary insulating and energy conservation benefits of storm windows.

An air space of less than 12 mm (1/2 in) is not as effective.

6.2.4 Where both the storm and prime windows are metal, either position the storm window

frame so that it does not contact the prime window frame or secure a nonmetallic

spacer between the prime and storm window frames.

The purpose of the space or spacer is to provide a thermal break

between the outside and inside of the prime/storm window frame combination. Without the thermal break, frost could build up on the interior

frame surfaces during cold weather. The following materials are exam- ples of acceptable spacers: 3 mm (1/8 in) thick spacers of waterrepellent preservative-treated wood; vinyl; rubber; or high-density

polyurethane.

6.2.5 Secure aluminum storm windows only with aluminum or compatible stainless steel

fasteners to avoid galvanic corrosion.

143
In some very dry climates , such ds in some parts of the Southwest,

plated steel fasteners may perform adequately . On the other hand,

in maritime climates , particularly in the San Francisco Bay area, stainless steel type 316 may be required to prevent pitting and

staining

.

6.2.6 In exterior installed storm windows, seal the joints at jambs and head to resist

rain penetration.

The prime purpose of sealing the storm window is to exclude water.

Deletion of sealant at the sill will aid in draining any int iltrated

water,

6.2.7 Seal indoor storm window systems to provide greater airtightness than that of the

prime window.

The purpose of the requirement is to prevent warm moist indoor air from

penetrating into the insulating air space between the prime and storm

windows, causing condensation on the colder prime window. In extreme

cases, such condensed water could flow down onto the sill, accumulate

and cause the deterioration of the sill and of both windows.

6.3 POST- INSTALLATION PROCEDURES

6.3.1 Ensure that all weep holes are clear and provide complete drainage of the sill area.

6.3.2 Check removable storm windows for ease of removal and reinstallation. Ensure that

storm windows fit snugly with minimal apparent opportunity for air leakage through

perimeter cracks.

6.3.3 Ensure that operable storm sash moves freely within the storm frame and that all hardware operates properly.

7. REPLACEMENT WINDOWS

Most commentary provided under storm windows is also applicable to Replacement Windows and is not repeated here.

7.1 PRE- INSTALLATION PROCEDURES

7.1.1 Examine the existing window opening for signs of decay, corrosion, or other

deterioration.

7.1.2 Measure and plumb the window opening in accordance with the manufacturer's

instructions, noting if it is out of square or not in plane, to ensure that

the unit can be installed plumb, square, and level.

7.1.3 Check for damage to interior finishes. If water damage is found to be caused by

leakage from the outside, as opposed to condensate, locate the source of the

leakage and establish whether replacing the window will correct the problem.

144
If replacing the window will not correct the problem, take necessary corrective measures before installing the thermal window.

Water leakage may have been the prime reason for the deterioration of

the original window in the first place. Unless the cause of such

leakage is eliminated, the replacement window may also deteriorate.

Moisture within the wall also reduces the effectiveness of insulation

and causes the deterioration of the wall construction.

7.1.4 Ensure that the replacement windows are the correct size and type for the

openings, including tolerances and provisions for adjustments to out of

squareness.

7.1.5 Ensure that no replacement windows are damaged and, where sealed glass units are

used, that their inside surfaces are free of condensation, fogging, or staining.

7.1.6 Ensure that the frames are free of any burrs or splinters, that the sash operates

freely within the frame and latches securely, and that the weatherstrippi ng is

properly installed in all locations specified.

7.2 INSTALLATION PROCEDURES

7.2.1 Do not install replacement windows unless the pre-instal 1 ation preparation has

been performed, any identified defects corrected, and their causes el irni nateci.

7.2.2 Remove the existing window in a manner that will minimize damage to the remaining

construction. Remove all fasteners, and clear the frame opening of obstructions

or protrusions that would interfere with the installation of the replacement

wi ndow.

7.2.3 Examine the exposed wall frame and remaining window construction, and replace

unsound materi al

.

New sound wood in contact or proximity of rotten wood will soon also

deteriorate. Also, fasteners will not hold in unsound materials

.

7.2.4 Where the existing window openings are reframed to a smaller size, insulate

the voids between framing members and the window. Install a vapor barrier on the room side of the insulation and provide interior and exterior coverings

compatible with the existing construction.

7.2.5 Install flashing at the head, jambs, and sill of the window as required to

preclude the penetration of water into the wall cavity.

7.2.6 Give a liberal brush treatment of commercially available water-repellent

preservative to all cut or planed edges of wood replacement windows.

7.2.7 Anchor the unit in accordance with the manufacturer's instructions. Ensure that

clearances specified in the manufacturer's instructions are maintained.

7.2.8 For aluminum units use only aluminum or compatible stainless steel anchors and

fasteners.

145
7.2.9 Shim the replacement window as necessary to ensure it is plumb, square, and level.

7.2.10 Separate metal windows from incompatible materials (such as siding or frames of

dissimilar metals) in the structure or frame with a nonmetallic spacer to prevent

galvanic corrosion.

7.2.11 Fill all gaps of 6 mm (1/4 in) or more with backup or filler materials such as nonabsorbing foam or sponge before installing the sealant.

7.2.12 Seal the joints between the supporting structure and window frame, using one of

the following sealants: acrylic, butyl, chlorosulfonated polyethylene, polysulfide, polyurethane, or silicone. Apply sealants in accordance with sealant

manufacturer's instructions. Use only sealant material that the manufacturer

recommends for the intended application.

The installation of replacement windows is a costly undertaking . As

sealants are critical to the long-term performance of the installation

and their cost is a minor part of the total installation cost, only

high quality sealants should be used. Under RCS, use only sealants

labeled as meeting DoE Standards .

7.2.13 The seal between the supporting structure and the window frame should not be

adhered to the coverings, such as siding or shingles, but adhered to the sheathing

below.

Many sealants do not perform reliably when applied in thicknesses

greater than 6 mm (1/4 in). See also requirements of the "Standard

Practice for the Installation of Caulks and Sealants."

Sealing between the covering (such as shingles, metal or plastic siding J can leave open air and water bypasses from the outside into the wall

cavity

.

7.3 POST- INSTALLATION PROCEDURES

7.3.1 Ensure that the sashes move freely within the frames, and that all hardware

operates correctly.

7.3.2 Ensure that window frame and sashes are square, plumb, and level.

7.3.3 Ensure that all weatherstrippi ng makes full contact with mating surfaces.

8. MULTI-GLAZING — SEALED INSULATING GLASS

»

8.1 PRE- INSTALLATION PROCEDURES

8.1.1 Measure and plumb the opening for the sealed insulating glass unit. Note if it is out of square and not in plane.

8.1.2 Inspect the opening to ensure that there are no burrs, dirt, or deformation of

glazing channels which may cause stress concentrations in the glass.

146
8.1.3 To prevent the prolonged exposure of sealed insulating edges, ensure that an adequate weeping system is incorporated in the glazing system as recommended by

the sealed insulating glass manufacturer.

Three weep holes 9 mm (3/8 in) or more in diameter, one each near the

jambs and one in the middle, have been recommended by one manufacturer

.

8.1.4 Ensure that clearances and nominal "bite" (containment of the glass) are as specified by the manufacturer.

Incorrect clearances can lead to glass falling out of the frames under

wind pressure or to glass breakage resulting from thermal stresses

.

8.1.5 During handling, place cushioning material between the glass and hard materials,

and do not set the glass on hard surfaces or turn it on its corners. This can damage the glass or seal, or both.

8.1.6 Ensure that neither the glass nor the edge seal are damaged, and that the units

exhibit no signs of fogging and condensation. Do not install defective units.

8.2 INSTALLATION PROCEDURES

8.2.1 Face Glazed Systems

8.2.1.1 Do not install sealed insulating glass units unless the pre-i nstal lation

preparation has been performed, any identified defects corrected, and their

causes eliminated.

8.2.1.2 Set the glass on two identical setting blocks of Shore A durometer 90 neoprene or equivalent material. The blocks shall be located equidistant from the center of

the edge, preferably at the quarter points. They may, however, be moved towards

the vertical edges but not closer than 150 rnm (6 in) or 1/8 the glass width,

whichever is greater.

Resilient setting blocks assure that the weight-bearing surface of the

glass is in total contact with the glass. The spacer blocks, while

being small in contact area, do provide uniform bearing over their

entire area. Only two blocks should be used to avoid glass stresses.

8.2.1.3 Do not locate setting blocks so as to obstruct the weeping arrangement provided in

the glazing system according to 8.1.3.

8.2.1.4 Use setting blocks that are narrower than the full channel width but that are at least 1.5 mm (1/16 in) wider than the insulating glass and high enough to ensure

minimal edge clearance but provide required bite for the glass.

The spacers should be narrower than the channel so that they do not bind

when inserted

.

8.2.1.5 Install sealed insulating glass units containing heat-absorbing or reflective

glass so that the heat-absorbing or reflective sheet is the outermost sheet.

This allows the heat-absorbing glass to reradiate the greater part of absorbed

147
heat to the outdoors, and the reflective glass to reflect the greater part of

the impinging solar radiation to the outdoors4 . Follow all additional precautions for installation prescribed by the manufacturer of the heat-absorbing

or reflective glass.

If a so-called "heat mirror" is used, it should be installed in such a way as to reflect the heat back into the room.

8.2.1.6 Where necessary, set jamb blocks in place before installing glass to ensure proper

lateral positioning of the glass. Maintain recommended clearances and bite.

8.2.1.7 Use only continuous resilient spacers to maintain face clearances. Do not use intermittent shims.

Continuous resilient spacers provide continuous support for the glass

under positive and negative wind pressures . Continuous spacers also

reduce water leakage into the glazing channel

.

8.2.1.8 Install only glazing sealants that are resilient, nonhardening compounds, tapes,

or gaskets. Install only sealants recommended by the manufacturers of the unit

and sealants recommended by their manufacturer for the intended use.

Non-hardening glazing seala nts do allow thermal movement of the glass,

and impose no stress points under wind load. These situations could cause glass breakage or damage to the edge seal . Sealants should

comply with manufacturers' specifications. Sealants which contain

solvents that are incompatible with the sealant used in organically

sealed insulating glass units can cause the early deterioration of

the insulating seal.

8.2.1.9 Install glazing compounds with a slope to ensure rainwater runoff.

8.2.2 Channel (Marine) Glazed Systems

8.2.2.1 Apply the wrap-around vinyl or neoprene gasket in one piece around the entire

perimeter of the sealed insulating glass, ensuring that the glass is engaged by

full channel depth of the wrap-around vinyl. Ensure that the seam in the

wrap-around vinyl occurs at the head of the unit.

8.2.2.2 Prevent corner bulges of wrap-around vinyl or neoprene, and provide for water

drainage by a 90° cutout.

8.2.2.3 Install only gaskets with a slope to ensure rainwater runoff.

8.2.2.4 See 8.2.1.5 for requirements regarding heat-absorbing or reflective glass.

8.3 POST- INSTALLATION PROCEDURES

4

S. Robert Hastings, Richard W. Crenshaw, "Window Design Strategies to Conserve Energy,"

NBS Building Science Series 104, 1977, pp. 4-10.

148
8.3.1 Ensure that weep holes are not blocked.

8.3.2 Ensure that gaskets and sealants are properly installed.

9. MULTI-GLAZING — UNSEALED INSULATING GLASS

9.1 Various innovative products are now being marketed that permit the installation of

multi-glazing other than through the use of factory- sealed insulating glass.

Since the products, systems, and methods in such innovative applications differ

widely, no generally applicable installation instructions can be given. However,

the principles given under Sections 5, 6, and 7 must be considered and the

manufacturer's installation instructions followed.

10. STORM DOORS

Many commentaries provided under storm windows also apply to storm

doors. These are not repeated here.

10.1 PRE- INSTALLATION PROCEDURES

10.1.1 Examine the framing of the prime door to ensure that it is sound, free of decay

and corrosion, and provides secure anchorage for the storm door.

10.1.2 Ensure that the frame contact areas are free of protrusions that would interfere

with proper installation of the storm door.

10.1.3 Measure and plumb the door opening in accordance with the manufacturer's

instructions, noting if it is out of square or not in plane.

10.1.4 Ensure that the storm door is the correct size and type for the opening, including

tolerances and provisions for adjustment to out-of- squareness.

10.1.5 Ensure that the storm door has not been damaged.

10.1.6 Ensure that the storm door meets applicable standards for safety glazing.

10.1.7 Ensure that adequate weepage is provided on exterior storm doors.

10.2 INSTALLATION PROCEDURES

10.2.1 Do not install storm door unless the pre-instal lation preparation has been

performed, any identified defects corrected, and their causes eliminated.

10.2.2 If required for proper fit, adjust the storm door or its frame to the size and

out-of- squareness of prime door frame.

149
10.2.3 Give a liberal brush treatment of commercially available water-repellent

preservative to all cut or planed edges of wood storm door.

10.2.4 Anchor the storm door to the framed opening in accordance with the manufacturer's

instructions. Secure aluminum storm door only with aluminum or compatible

stainless steel fasteners to avoid galvanic corrosion.

10.2.5 Install the door catches, closers, and chains in accordance with the

manufacturer's instructions.

10.2.6 Install weatherstripping in accordance with the manufacturer's instructions.

10.2.7 Maintain a gap of at least 1.5 mm (1/16 in) between the storm door and frame

opening, unless otherwise specified by the manufacturer.

10.2.8 For an expander-type aluminum storm door, ensure that the expander edges are flush with the frame opening. Secure the expander edges using hardware and

fasteners compatible with aluminum.

10.2.9 Do not use excessive force when installing the storm door frame of a pre-hung

door into the door opening.

10.2.10 Seal the joint between the storm door frame of the pre-hung door and the framed

opening to prevent rain penetration.

10.3 POST- INSTALLATION PROCEDURES

10.3.1 Ensure that adequate drainage is provided to prevent water accumulation at the

sill.

10.3.2 Ensure that the storm door operates freely and does not bind when closed.

10.3.3 Ensure that the weatherstripping is installed properly and forms a weathertight

seal

.

10.3.4 Ensure that the closer and chain assemblies operate properly, that the door

handles and latch assemblies properly secure and lock the storm door, and that

the hardware of the storm door does not interfere with the operation of the

prime door.

10.3.5 If the storm door includes operable sashes, ensure that the sashes operate

properly.

11. REPLACEMENT DOORS

Many commentaries provided for storm windows, replacement windows and

storm doors apply also to replacement doors. These are not repeated

here.

150
11.1

11.1.1

11.1.1.1

11.1.1.2

11.1.1.3

11.1.1.4

11.1.1.5

11.1.2

11.1.2.1

11.1.2.2

11.1.2.3

11.1.2.4

11.1.2.5

11.1.3

11.1.3.1

11.1.3.2

11.1.3.3

REPLACEMENT OF DOOR LEAF ONLY

Pre- Instal 1 ation Procedures

Examine the existing door frame to ensure that it is sound, free of decay or corrosion, and provides secure anchorage for the replacement door.

Ensure that the frame contact areas are free of protrusions that would interfere

with the proper installation or operation of the replacement door.

Measure and plumb the door opening in accordance with the manufacturer's

instructions, noting if it is out of square or not in plane.

Ensure that the replacement door is the correct size and type for the opening,

including tolerances and provisions for adjustment to out squareness.

Ensure that the replacement door has not been damaged.

Installation Procedures

Do not install replacement doors unless the pre-installation inspection and

preparation has been performed, any identified defects corrected, and their

causes eliminated.

Give a liberal brush treatment of commercially available water-repellent

preservative to all cut or planed edges of wood replacement doors.

Anchor the replacement door to the existing frame in accordance with the

manufacturer's instructions. Secure steel doors with plated steel fasteners,

and aluminum doors with aluminum or compatible stainless steel fasteners, to

avoid corrosion. Install lock hardware in accordance with the lock manufacturer's installation instructions.

Maintain a clearance of at least 1.5 mm (1/16 in) between the replacement door and

the door opening unless otherwise specified by the manufacturer.

If the threshold does not seal tightly against the bottom cap of the thermal door,

replace the threshold.

Post-Installation Procedures

Ensure that adequate drainage is provided to prevent water accumulation at the

threshol d.

Ensure that the door operates freely and does not bind when closed.

Ensure that weatherstripping is installed properly and forms a weathertiyht seal.

151
11.1.3.4

11.1.3.5

11.1.3.6

11.2

11.2.1

11.2.1.1

11.2.1.2

11.2.1.3

11.2.1.4

11.2.2

11.2.2.1

11.2.2.2

11.2.2.3

11.2.2.4

11.2.2.5

11.2.2.6

Ensure that the threshold is adjusted to provide a tight seal against the bottom

edge of the door.

Ensure that the door catches, handles, and latch assemblies properly secure and

lock the replacement door.

Ensure that the entire wood door including top and bottom edges is sealed in

accordance with 11.1.2.2.

REPLACEMENT OF DOOR FRAME

Pre-Installation Procedures

Remove the existing door frame in a manner that will minimize damage to the

remaining construction. Remove all fasteners and clear the frame opening of

obstructions or protrusions that would interfere with the installation of the

replacement door frame.

Examine the existing rough framing for signs of decay, corrosion, or other

deterioration, to provide secure anchorage for the replacement frame.

Measure and plumb the door opening, and note if it is. out of square or not in plane.

Ensure that the replacement frame or its parts, or both, have not been damagea.

Installation Procedures

Do not install replacement door frames unless the pre-i nstal 1 ation preparation

has been performed, any identified defects corrected, and their causes eliminated.

Give a liberal brush treatment of commercially available water-repellent

preservative to all cut or planed edges of replacement door frame.

Install flashing at head, jambs, and sill as required to preclude the penetration

of water into the wall cavity.

Anchor the replacement door frame to the rough opening. Secure steel frames with

plated steel fasteners, and aluminum frames with aluminum or compatible stainless

steel fasteners, to avoid galvanic corrosion.

Shim frame to provide an opening that is plumb and square, giving particular

attention to jamb at lockstrike and hinges.

Seal the joints between the supporting structure and replacement door frame in

accordance with the provisions in 7.2.10, 7.2.11, and 7.2.12.

152
11.2.2.7 Install the door leaf in accordance with 11.1. Do not prepare the door frame

for lock hardware until the installation of the door leaf.

11.2.3 Post-Installation Procedures

11.2.3.1 Ensure that adequate drainage is provided to prevent water accumulation at the

sill.

11.2.3.2 Ensure that the replacement frame provides an opening that is plumb and square.

11.2.3.3 Ensure that weatherstripping is installed properly and forms a weathertiyht seal.

11.2.3.4 Ensure that all parts of a wood frame are sealed in accordance with 6.2.2.

11.3 PRE-HUNG DOORS

11.3.1 Pre-Installation Procedures

Conduct pre-instal lation preparation according to the provisions of 11.2.1.

11.3.2 Installation Procedures

11.3.2.1 Conduct installation according to the provision of 11.2.2.

11.3.2.2 Do not use excessive force when installing the pre-hung door into the opening.

11.3.2.3 Anchor the pre-hung door to the opening in accordance with the manufacturer's

instructions.

11.3.3 Post-Installation Procedures

Conduct post-installation procedures according to the provisions of 11.1.3 and

11.2.3.

The standard as published by ASTM also has the following patent and

policy notes appended:

"The American Society for Testing and Materials takes no position

respecting the validity of any patent rights asserted in connection

with any item mentioned in this standard . Users of this standard are

expressly advised that determination of the validity of any such patent

rights, and the risk of infringement of such rights, are entirely their own responsibility.

This standard is subject to revision at any time by the responsible

technical committee and must be reviewed every five years and if not

revised, either reapproved or withdrawn. Your comments are invited

either for revision of this standard or for additional standards and

153
should be addressed to ASTM Headquarters , Your comments will receive

careful consideration at a meeting of the responsible technical committee, which you may attend. If you feel that your comments have not received a fair hearing you should make your views known to the ASTM

Committee on Standards, 1916 Race Street, Philadelphia, PA, 19103,

which will schedule a further hearing regarding your comments . Failing

satisfaction there, you may appeal in the ASTM Board of Directors ."

FIGURE 1 - EXTERIOR STORM WINDOW. FIGURE 2 - THERMAL WINDOW

FIGURE 3 - MULTI-GLAZING.

154
STANDARD PRACTICE FOR THE INSTALLATION

OF THERMAL INSULATION ON DOMESTIC HOT WATER HEATERS

1. SCOPE

1.1 This practice covers the installation of insulation around gas-fired, oil-fired,

and electric resistance water heaters.

1.2 A working knowledge of the terminology and fundamentals of domestic hot water

heaters and applicable codes is necessary for the proper application of this

standard.

1.3 This practice is intended to establish a minimum level of performance for safety

and effectiveness. When a manufacturer's installation instructions regarding

specific requirements that affect safety and effectiveness result in a higher

level of performance for these characteristics, such manufacturer's installation

instructions may be used.

1.4 This practice is not intended to supersede the authority of State and local codes

but is intended to establish minimum criteria for safety and effectiveness.

When State or local codes specifically address the substance of provisions

contained herein, they may apply; when State and local codes do not address the

substance of specific provisions contained herein, this practice shall prevail.

This practice further:

1.5 Covers the installation process from pre-installation procedures through

post-installation procedures. It does not cover the production of tne

insulation materials , whether such production takes place in a factory or at the installation site.

1.6 Describes, in general terms, the procedures to follow so that a safe

and effective installation is assured. It does not describe in detail

the terminology and fundamentals of domestic hot water heating or of

residential construction, or the codes and regulations that may be

imposed by other Federal, State, or local agencies.

1.7 Covers aspects of installation relating to the effectiveness , durability

,

and safety of insulation in service. It does not address the safety of

the person(s) installing the insulation.

2. APPLICABLE DOCUMENTS

2.1 NFPA1 211: "Standard for Chimneys, Fireplaces and Vents."

1 National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210.

155
3. SIGNIFICANCE

3.1 This practice recognizes that effectiveness, safety, and durability of

water heater insulation depend not only on the quality of the insulating

materials, but also on their proper and workmanlike installation.

3.2 Improper installation of insulation may reduce its thermal

effectiveness, cause fire hazards and other unsafe conditions , and

promote the deterioration of the water heater to which it is installed

.

4. DEFINITIONS

Approved - acceptable to the authority which regulates the activity or material

and its use. Such authority is usually a municipal, State, or Federal agency or

a third-party certification, inspection or rating service.

Barometric draft regulator - a component of oil-fired water heaters which mixes

secondary air with the combustion gases leaving the unit, thus enabling a smooth,

continuous relief of gases up the vent pipe.

Draft hood - a component of gas-fired water heaters which mixes secondary air

with the combustion gases leaving the unit, thus enabling a smooth, continuous

relief of gases up the vent pipe.

Hi-limit switch - a temperature control that senses temperature changes in

electric, gas, and oil-fired water heaters and cuts off the energy supply or

fuel flow to the unit when the internal water temperature rises above a certain

point.

Pressure relief valve - a safety valve which opens to vent pressure when the

pressure in the water tank exceeds a preset level due to excessive water

temperature.

Vent pipe - an exhaust pipe carrying products of combustion from oil-fired and

gas-fired water heaters to the outside environment.

Vent damper - a device which automatically closes the vent on oil- and gas-fired

appliances to prevent the escape of heat through the vent pipe when the main

burner is not being fired.

5. MATERIALS

5.1 Under RCS, install only materials identified as conforming to DoE standards for

water heater insulation.

This marking indicates that the manufacturer certifies that the product

meets the applicable DoE standards . The identification does not imply

that DoE has conducted tests on the material or that the manufacturer

uses an approved quality assurance program.

156
5.2 The material may be packaged specifically for the purpose of insulating water

heaters or it may not be so packaged. In either case under RCS, it must be

labeled as required in 5.1. In addition, the material must also be marked with

the R- value and the flame spread rating of the facing.

6. PRE-INSTALLATION PROCEDURES

6.1 GENERAL

6.1.1 Determine the fuel type (gas, electrical, oil) of the water heater.

The installation criteria differ with fuel type used.

6.2 ELECTRIC RESISTANCE WATER HEATER

6.2.1 Determine the location of the pressure relief valve, thermostat control, and

hi-limit switch (see Figure 1).

The pressure relief valve needs to be left exposed to assure its proper

functioning . The thermostat control and hi-limit switch need access

for adjustments . The drain valve must remain exposed so that the

heater can be drained periodically

.

6.3 GAS-FIRED WATER HEATER

6.3.1 Determine whether the gas-fired water heater is equipped with a vent damper. Do

not insulate gas-fired water heaters so equipped.

Insulation of water heaters equipped with vent dampers may lead to

overheating equipment because the heat from the pilot light does not as readily escape through a closed vent. To a similar extent, this

problem may be caused by excessively large burners in older model water

heaters (i.e., older than 8 to 10 years old J. -For water heaters

equipped with automatic ignition devices, insulation could be installed even if the heaters were equipped with a vent damper.

6.3.2 Determine the location of the pressure relief valve and draft hood on the water

heater (See Figure 2).

The pressure relief valve needs to be left exposed to assure its proper

functioning. Care must be exercised not to cover the draft hood, since

this would interfere with proper combustion and lead to safety hazards.

6.3.3 Determine the location of the burner air inlet, pilot light access plate, and

drain valve (See Figure 2).

Care must be exercised not to cover the burner air inlet since this

would interfere with proper combustion and lead to safety hazards.

Covering of the pilot light access plate would require removal of

insulation whenever the pilot needs to be relighted. The drain valve

must remain exposed so that the heater can be drained periodically.

157
6.4 OIL-FIRED WATER HEATER

6.4.1 Determine the location of the pressure relief valve, vent pipe, and barometric

draft gauge (see Figure 3).

The pressure relief valve needs to be left exposed to assure its proper

functioning,- the vent pipe needs to be identified to determine whether

the top of the heater can be insulated; the barometric draft gauge needs

to be left exposed for proper functioning and adjustment .

6.4.2 Determine the location of the thermostat control, peep sight, and drain valve

(see Figure 3).

The thermostat control needs to be left exposed for proper functioning

and adjustment . The peep sight must be open for inspection and the

drain valve must remain exposed so that the heater can be drained

periodically

.

7. INSTALLATION PROCEDURES

7.1 GENERAL

7.1.1 Do not install insulation unless the pre-installation procedures have been carried

out.

7.1.2 Handle insulation in accordance with manufacturer's instructions and keep dry and

free of extraneous materials.

Protect the material from accidental wetting and contamination.

Prepare the section( s ) of insulation in accordance with the insulation

manufacturer' s instructions . If no instructions are available, the

following procedure is recommended:

Cut the insulation such that the finished height is 100 imn (4 in) less

than the distance from the floor to the top of the water heater and

the length is 180 mm (7 in) greater than the circumference (distance

around) of the water heater.

Cut an additional piece of insulation to fit the top of electric water

heaters only. Slit the piece to enable mounting around pipes on top

of the unit

.

7.1.3 Apply the insulation to the water heater with the facing to the outside.

The facing is designed to protect the insulation from damage.

7.1.4 Secure the sections of insulation to the water heater using a tape of the size and

type recommended by the insulation manufacturer.

Vinyl duct tape 76 mm (3 in) or wider is recommended unless the

insulation manufacturer specifically recommends another product.

158
It is recommended that the insulation be secured as shown m Figure 4 to minimize the likelihood of the insulation slipping down.

Do not install insulation over the water heater operating instructions and other

components identified below.

Easy access to operating instructions is necessary for continued safe

and effective operation, particularly for future homeowners and repair

personnel. Covering of the instruction plate could result in less than

adequate maintenance and operation of the water heater.

ELECTRIC RESISTANCE WATER HEATER

Ensure that the exterior facing of the insulation material is marked as

having a flame spread rating of no more tlian 15V. This rating is

required in the RCS Material Standard for material used to insulate

electric resistance water heaters.

Install insulation on the sides and top plate of the water heater.

Cut the insulation to leave holes for the pressure relief valve, thermostat

control, hi-limit switch, plumbing pipes, and other necessary access plates.

This will provide the needed access for servicing the water heater

after insulation installation, and for proper operation of the water

heater

.

GAS-FIREL WATER HEATER

Ensure that the exterior facing of the insulation material is marked as having a flame spread of no more than 25. The rating is required in

the RCS Material Standard for material used to insulate gas-fired water

heaters.

Do not install insulation on the top plate of gas-fired water heaters.

The pilot light of a gas-fired water heater continuously generates heat.

The uninsulated top of the water heater provides for the necessary heat

loss to prevent or reduce substantially the potential for overheating

.

Furthermore, the draft hood is sometimes blocked if insulation is

installed on the top of gas water heaters. A partially blocked draft

hood and insufficient flue draft could prevent carbon monoxide from

properly venting to the outdoors and could cause hazardous indoor air

poll ution.

Cut the insulation

pilot light access

pi ates.

to leave holes for the burner air inlet, thermostat control,

plate, drain valve, plumbing pipes, and other necessary access
7.4 OIL-FIRED WATER HEATER

7.4.1 Ensure that the exterior facing of the insulation material is marked

as having a flame spread rating of no more than 25 . This rating is

required in the RCS material standard for material used to insulate

oil-fired water heaters.

7.4.2 If the vent pipe is top mounted, do not install insulation on the top plate of the

water heater.

Flue pipe temperature may range from 370°C (800°F) to 430°C (800°F).

The placement of insulation closer than four inches from such pipes

may expose the material to temperatures which may cause ignition of

its coverings. For top mounted pipes, the 100 mm (4 in) clearance

requirement makes the insulation of the remaining top impractical and

not cost-effective.

7.4.3 If the vent pipe is side mounted, maintain the minimum vent connector clearances

specified in the latest edition of NFPA 211.

This recommended clearance could be as much as 18 inches for single-wall

metal pipe chimney connectors. See Table 5-5(a) in NFP/i 211 for

specific installation criteria.

7.4.4 Cut the insulation to leave holes for the pressure relief valve, thermostat

control, flame peep sight, burner access plate, drain valve, pluinbiny pipes,

and other necessary access plates.

Covering of the items indicated in the pre- installation procedure would

prevent access for needed servicing and operation of the water heater

after the installation of insulation

.

8. POST-INSTALLATION PROCEDURES

8.1 Ensure that the insulation is securely attached to the water heater.

Insecure attachment may allow the insulation to slide down or to the

floor, or off the appliance entirely . This will reduce the effectiveness of the insulation. If the insulation slips down over the burner

air inlets on gas- and oil-fired appliances , it will interfere with

proper combustion and reduce efficiency , and may cause the release of

toxic combustion products.

8.2 Ensure that the required clearances have been maintained around vent pipes and

that insulation has not been installed on the top of oil-fired water heaters which

have a top-mounted vent pipe, or on ijas-fired water heaters.

8.3 Ensure that air inlets, access plates, drain valves, temperature controls, and

pressure relief valves are not covered by insulation.

160
INSULATION***

ACCESS

PLATE TO HEATING

ELEMENT*

ACCESS

PLATE TO TEMPERATURE

CONTROLS AND HEATING ELEMENT

PRESSURE RELIEF VALVE

ORAFTHOOO

INSULATION

ACCESS

TO PILOT

LIGHT 6 TEMPERATURE

CONTROLS

PRESSURE RELIEF VALVE

DRAIN VALVE

DRAIN _J \ BURNER AIR

VALVE INLET

FIGURE 1 - ELECTRIC WATER HEATER. FIGURE 2 - GAS FIRED WATER HEATER

BAROMETRIC

DRAFT GAUGE

VENT**

PIPE

INSULATION***

TEMPERATURE^

CONTROLS

-PEEP SIGHT

-OIL BURNER

FIGURE 3 - OIL FIRED WATER HEATER.

FIGURE 4 - RECOMMENDED METHOD FOR

SECURING INSULATION.

3"x36" tape across top ol water heater

* only found on water heaters with two

heating elements

** the pipe may be side-mounted

*** top insulated on all electic water

heaters and oil fired water heaters

with side-mounted five pipes.

161
STANDARD PRACTICE! FOR THE INSTALLATION OF REPLACEMENT OIL BURNERS IN RESIDENTIAL HEATING SYSTEMS

1. SCOPE

1.1 This practice provides minimum requirements for the installation of replacement

oil burners for the purpose of significantly reducing the amount of fuel oil

consumed by increasing combustion efficiency and reducing firing rate. It is intended for use on warm air, hot water, and steam systems, but does not cover firing rate reductions for steam heating systems.

Steam boilers are considerably less flexible in accepting firing rate

modifications than furnaces or hot water boilers because of the steam

boilers' need to provide the rate of generation required to obtain

suitable steam distribution throughout the system.

1.2 This practice covers the installation process from pre-i nstallation inspection for

inefficient operation through post-installation tune-up for best efficiency.

Special considerations for maximizing system efficiency are emphasized.

1.3 This practice is intended to establish a minimum level of performance for safety

and effectiveness. When a manufacturer's installation instructions regarding specific requirements that affect safety and effectiveness result in a higher level

of performance for these characteristics, such manufacturer's installation

instructions may be used.

1.4 This practice is not intended to supersede the authority of State and local cooes

but is intended to establish minimum criteria for safety and effectiveness.

When State or local codes specifically address the substance of provisions

contained herein, they may apply, when State and local codes do not address the

substance of specific provisions contained herein, this practice shall prevail.

1.5 This practice is intended for use by approved installers. It outlines the general

procedure to be followed, but leaves the detailed step-by- step methodology to the

approved installers. It is therefore not intended for use by the general public

or by untrained persons, since such use may be unsafe or result in damaged

equipment.

1.6 This practice covers aspects of installation relating to the

effectiveness , durability , and safety of replacement oil burners in

service. It does not address the safety of the installer

2. APPLICABLE DOCUMENTS

ANSI1/ASTM2 2156-65 (1975): ANSI Standard Method of Test for Smoke Density

in the Flue Cases from Distillate Fuels."

1 American National Standards Institute, 1430 Droadway, New York, NY 10018.

2 American Society for Testing and Materials, 1916 Race Street, Philadelphia, PA 19103.

162
ANSI Z91. 2-1976: Performance Requirements for Automatic Pressure Oil Burners

of the Mechnical Draft Type.

ANSI Z95.1 - 1974 (NFPA3 31-1974): Standard for the Installation of Oil

Burning Equipment.

ANSI Z96. 2-1974 UL4 296: Oil Burners.

EPA5 600/2-75-069 a (October 1975): Guidelines for Residential Oil Burner

Adjustments.

3. SIGNIFICANCE

3.1 This practice recognizes that effectiveness, safety, and durability of

replacement oil burners depends not only on the quality of the materials but also on their proper and workmanlike installation.

3.2 Substantial amounts of fuel oil can be conserved by replacing burners

that are inefficient through design, wear, or extreme oversizing with

respect to the building' s heating requirements, with new, properly

sized, high-efficiency burners.

3.3 Even where a burner was properly sized at the time of its installation

in an uninsulated and unweatherstripped house, the installation of

energy conservation measures may have improved the thermal performance

of the building' s envelope to the degree that the burner is now substantially oversized and inefficient

.

4. DEFINITIONS

4.1 Approved - acceptable to whatever authority regulates the installation of

replacement burners Such authority is usually a municipal, State, or Federal

agency.

4.2 Draft regulator - A component of oil-fired furnaces which mixes secondary air

with the combustion gases leaving the unit, thus enabling a smooth, continuous

release of gases up the vent pipe.

4.3 Oil burner - A device which, for oil-fired heating equipment in a residential

building, atomizes, vaporizes, or otherwise disperses the fuel-air mixture, and

is an integral part of an oil-fired furnace or boiler, including the combustion

chamber.

3 National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210,

4 Underwriters Laboratory, 207 E Ohio Street, Chicago, IL 60611.

5 Environmental Protection Agency, 401 M Street, SW, Washington, DC 20460.

163
4.4 Replacement oil burner - An oil burner which, because of its design, achieves a reduction in the oil used from that used by the device which it replaces.

5. MATERIALS

5.1 Under the Residential Conservation Service program (RCS), install only oil

burners labeled as complying with Dot standards.

This marking indicates that the manufacturer certifies that the product

meets the applicable DoE standards. The label does not imply that DoE

has conducted tests on the material or that the manufacturer uses an

approved quality assurance program.

Applicable State and local codes require that all replacement oil

burners have third-party certification.

5.3 Under RCS, replacement oil burners must conform to the requirements of the most

recent revisions of American National Standard Safety Standard for Oil Burners,

Z96.2 (UL 296) and American National Standard Performance Requirements for Automatic Pressure Atomizing Oil Burners of the Mechanical Draft Type, Z91.2.

6. TUNE-UP AND EVALUATION OF EXISTING BURNER

6.1 Clean, adjust, and measure the efficiency of the existing burner. Carry out the

following procedures:

6.1.1 Clean soot from heat transfer surfaces.

6.1.2 Seal air leaks around burner tube, and clean-out doors, and seal secondary air

dampers and firing doors on converted coal burners.

6.1.3 Clean or replace air filter.

6.1.4 Clean or replace oil filters.

6.1.5 Check flame ignition. Ignition should be nearly instantaneous. Adjust electrodes

or make other repairs necessary to achieve nearly instantaneous ignition.

6.1.6 Observe flame color. Repair or adjust burner to achieve an acceptable flame color

for the type of furnace being evaluated.

6.1.7 Observe flame shape. If the flame is lopsided or distorted, replace the nozzle,

adjust the electrodes, or repair the air cone.

6.1.8 Check for flame impingement on walls of furnace or combustion chamber. Correct

impingement resulting in soot or petroleum coke deposits on the target wall.

6.1.9 Check for flame cut off. The flame should disappear within three seconds of cut

off. If the flame lingers check that the burner is level. It may be necessary

to install an oil supply line solenoid to ensure rapid cut off.

164
6.1.10

6.1.11

6.1.12

6.1.13

6.1.14

6.1.15

6.1.16

6.1.17

6.1.18

7.

7.1

If possible check the nozzle size, type, and spray angle against the burner

specifications recommended by the manufacturer. Manufacturers' nozzle

specifications should always be followed.

Start the burner. Determine and correct the cause of any abnormal starting or running noise.

Measure either flue or over-fire draft as specified by the manufacturer. Adjust

draft regulator to provide the manufacturer-specified draft. Ensure that the

draft regulator is operating smoothly.

Check oil supply pressure. Adjust pressure regulator to manufacturer's

specification.

Check oil pressure entering pump. Reading should be 6.76 to 10.14 kPa (two to six inches of mercury) vacuum when the tank is below the burner and zero or above when the tank is above the burner. If there is a low reading, correct a possible restriction in the fuel supply.

Allow the burner to run at least 15 minutes to reach a steady- state operating

condition. Check for odor at observation port and draft regulator and, if

appropriate, correct improper draft, improper venting, or a defective nozzle.

Adjust the air gate to give a smoke reading of #1 or greater when measured in

accordance with the procedure outlined in American National Standard ANSI/ASTM

D2156-65 (1975) [after 6.1.17 below has been completed, restore burner to a smoke reading of #1 or less].

Measure the flue gas temperature and the percentage of CO2 in the flue gas

through a 6 mm (1/4 in) diameter hole in the flue located between the barometric

draft regulator and the furnace flue outlet.

Using Figure 1, determine the steady-state efficiency of the furnace from the

flue gas temperature and percent CO2 concentration. As an alternative, steady

state efficiency may be calculated using the procedures given in Appendix A.

Cleaning , adjustment and efficiency measurements are needed to

determine whether the replacement of the oil burner is cost effective.

Tuning, cleaning , and optimizing the nozzle size may increase the

efficiency of the existing oil burner considerably so that a replacement burner may no longer be justified

.

As a further alternate method for determining steady state efficiency

,

DoE has approved the use of oxygen concentration.

REPLACEMENT CRITERIA

Replace the burner only if the estimated savings resulting from installation of a more efficient burner will pay for the cost of the replacement burner. If the

savings calculated in Table 1 below, multiplied by the homeowner's desired payback

period in years exceed the total cost of burner replacement (labor plus parts),

the burner should be replaced.

165
7.2 Table 1 shows the annual dollar savings per $100 of annual fuel costs that can be

achieved by increasing furnace efficiency.

7.3 The efficiency of the furnace with a new burner conforming to the requirements of

ANSI Z91.2 may be estimated by assuming a stack CO2 concentration of 10 percent

and a stack temperature equal to that measured in 6.1.8. If the burner manufacturer specifies a CO2 concentration greater than 10 percent for his burner when

tested in accordance with ANSI Z91.2, this should be used instead of the minimum

value of 10 percent which that standard requires.

As an example, if the original stack conditions were 6 percent CO2 and

260°C (500"F) (72 percent efficiency) and the manufacturer of the

replacement burner stated that 12 percent CO2 was obtainable with

his burner, the assumed new conditions with the replacement burner

installed would be 12 percent C02 and 260°C (500°F) (81 percent efficiency).^ Using these values, an estimated annual saving of $11.10

per $100 of annual fuel cost can be read. If the annual fuel costs were $1000, the annual savings would be $11.10 x 10 = $111. If the

desired payback period were seven years, the total savings justifying

burner replacement would be $111 x 7 = $777. In this example the

burner should be replaced if the total replacement cost (labor plus

parts) is less than $777 and should not be replaced if the total

replacement cost is more than $777.

Use an additional average savings of $5.80 per $100 of annual fuel cost

in the payback period calculation if the firing rate of the new burner

is optimized as described in paragraph 8.1 and the resulting value is

smaller than the original firing rate by 20 percent or more.

8. SELECTION OF REPLACEMENT BURNER

8.1 Determine design nozzle size. Using the local outdoor design temperature for the

area and the measured average winter K-factor for the residence (degree days per

gallon) determine the minimum nozzle size by the formula:

efficiency of furnace

minimum nozzle size = ( 65 - Tn) x measured in 6.1.17.

(in gallons per hour) (K factor) (24) expected efficiency of

furnace with new burner

as calculated in 7.3.

where is the local outdoor design temperature in °F and the K-factor

is in degree days per gallon of oil . If the outdoor design temperature

is not known, refer to Chapter 33 of the ASHRAE Handbook and Product

Directory - 1977 Fundamentals. Use the 97.5 percent values for the

nearest weather station listed.?

8.2 The winter K-factor is an average value derived over one or more complete heating

seasons. The K-factor for a residence is defined as the number of degree days

occurring in a time period divided by the total number of gallons of oil used

during the same period to maintain a house at its normal thermostat setting.

Determine from the occupant whether storm windows or a substantial amount of new

i- t 0 Instructions for calculating furnace efficiency are given in the appendix.

1 Because of incompatibility of weather data records, calculations involving degree days

can not at this time be expressed in SI units.

166
8.4

i

8.5

8.6

8.7

i

9.

9.1

9.2

9.3

insulation has been installed since the last heating season. If so, the calculation of the K-factor with the above formula may be too low and must be adjusted

accordingly.

If the heat requirement of the house has been significantly reduced by

insulation of storm windows and/or insulation, it may also be possible

to reduce the cutoff set point of the aquastat on hot water boilers by

10° to 20°F to reduce standby heat losses. This setback may not be

desirable, however, if the boiler is used to heat domestic hot water.

Thermostat setback is to be encouraged as an additional energy conservation

practice. If the owner plans to practice nighttime setback, in order to ensure

adequate temperature recovery, increase the size of the burner replacement nozzle

by adding a value in (liters) gallons per hour equal to the heated house floor

area in m? (ft)2, times the pickup capacity factor (PCF), divided by 39,000

(140,000), where PCF is given in Table 2.

Select a nozzle that gives the spray pattern and angle recommended by the

manufacturer of the replacement burner that is not larger than the original

nozzle.

Choose the replacement burner recommended by its manufacturer for use with the

design nozzle size calculated in 8.1 above.

Do not select a flame retention replacement burner for use on a hot water or steam boiler equipped with a stainless steel combustion chamber.

Higher temperature levels produced by high performance flame retention

burners may cause the combustion chamber to burn out. See also 9.3

below.

INSTALLATION OF REPLACEMENT BURNER

Install fixed firing rate replacement burner with a nozzle of the size calculated

in paragraph 8. above.

Replace the burner in accordance with the manufacturer's instructions following

normal good installation practices.

It is anticipated that most burner replacements will involve replacing a conventional burner with a high speed, flame retention head burner. If this is

done, the combustion chamber must be brought into conformance with the burner

manufacturer's specifications for size and design. In addition, the combustion

chamber material must have a minimum rating of 1260°C (2300°F) (most existing

chambers for conventional burners have a rating of 980°C (1800°F)).

Flame retention burners operate at 980°C higher temperatures of 1260"C

vs. 980° C (2300"F vs. 1800° F) than conventional burners and could cause damage to a firebox refractory designed for use with conventional

burners.

167
10. POST- INSTALLATION PROCEDURES

10.1 Check that the completed installation is in conformance with all local and state

building and fire safety codes. Where local codes do not exist, verify confor- mance with American National Standard Installation of Oil Burning Equipment,

Z95.1 1974 (NFPA 31 - 1974).

10.2 Test-operate the installed burner and measure its efficiency following the

guidelines of U.S. Environmental Protection Agency Report No. EPA 600/2-7 5-069a

(October 1975), "Guidelines for Residential Oil Burner Adjustments." If the

replacement burner results in an appreciable reduction in stack temperature, the

stack switch heat controls (if the unit is so equipped) for ignition cutoff may

need to be readjusted.

10.3 The temperature of the combustion gases entering the draft regulator must be at least 188°C (370°F) for chimneys enclosed within the insulated structure to prevent condensate and subsequent corrosion. The temperature of the combustion

gases entering the draft regulator must be at least 232°C (450°F) if 2 or 3 sides

of the chimney are exposed to an outdoor ambient design temperature of -18°C

(0°F) or less, to prevent condensation and freezing within the chimney. If

the temperature of the combustion gases entering the draft regulator is below

the specified minimum value, fit a larger nozzle to increase that temperature.

10.4 Record the following information in duplicate and leave one copy with the owner

and one as a tag attached to the equipment:

Date of replacement

Name of installing mechanic and company

The original burner make, model, model number, and nozzle size

The replacement burner make, model number, and nozzle size

The number and size of any additional nozzles tried in the replacement burner

Other modifications to the unit.

The initial and final CO2 concentration, net stack temperature, efficiency,

and smoke readings.

This information will be helpful for future servicing of the unit and

in troubleshooting any problems which arise immediately after burner

replacement and/or firing rate reduction.

168
APPENDIX

DETERMINATION OF STEADY-STATE EFFICIENCY

The steady- state efficiency of the furnace may be determined directly from Figure 2 for

furnaces using No. 2 fuel oil.

Alternatively, t\\e following equations may be used to calculate the furnace efficiency:

NSS

R T,F

" 100 " k,A - L S ,SS,A

= A + _J

l co2

,s

L S,SS,A

where

N SS

L L,A

L S,SS,A

RT,F

X C02,F

TF,SS

TRA

ITM z [(1 + A/F) (CF(1)] + (A/F)(RT F

- 1)(CA(1))]

HHVa i=l

x [(TF.SS + 460)1 _ (TRA + 460)1]

steady-state, full-load efficiency %

average latent loss, % = { 6 - 55 for No - 1 oil

1 6.50 for No. 2 oil

average sensible heat loss, %

ratio of combustion air to stoichiometric air

concentration by volume of CO2 present in dry flue gas, %

flue gas temperature at steady-state, °F

ambient temperature in furnace room, °F

Additional required constants are as follows:

For No. 1 oil For No. 2 oil

HHVA 19,800 19,500

A/F 14.56 14.49

A 0.0679 0.06668

B 14.22 14.34

CF (1) 2.4416834 x 10-1 2.4361163 x 10-1

CF (2) 3.3711449 x 10-6 3.6702686 x 10-6

CF (3) 8.8906305 x 10-9 8.7098897 x 10-9

CF (4) -1.3619019 x 10-12 -1.3094378 x 10-12

CF (5) -1.4367410 x 10-16 -1.5029209 x 10-16

169
For Air

CA (1) 2.5462121 X io-i

CA (2) -3.0260126 X 10-5

CA (3) 2.7608571 X 10-8

CA (4) -7.4253321 X 10-12

CA (5) 6.4307377 X 10-16

This calculation procedure is explained more fully in NBSIR 78-1543, "Recommended Testing

and Calculation Procedures for Determining the Seasonal Performance of Residential Central

Furnaces and Boilers," and Department of Energy "Final Energy Conservation Test

Procedures," Federal Register, Part II, May 10, 1978, 43 FR 20128 through 20147.

3 4 5 6 7 8 9 10 11 12 13 14 15

C0 2 CONCENTRATION IN FLUE GAS, %

FIGURE 1 - EFFECT OF NET FLUE GAS TEMPERATURE AND PERCENT C0? CONCENTRATION

ON EFFICIENCY FOR FURNACES OPERATING ON NO. 1 AND NO. 2 HEATING OIL.

Note: The RCS practice published in the Federal Register on November 7, 1979,

contained separate figures for No. 1 and No. 2 fuel oil. However, the difference

was insignificant for the intended use and a single figure is shown.

170
TABLE 1. ANNUAL DOLLAR SAVINGS FOR $100 OF ANNUAL FUEL COST

AS A RESULT OF INCREASED FURNACE EFFICIENCY

To an increased efficiency of (percent)

From original

efficiency* of

(Percent) 74 76 78 80 82 84 86

50 $32.40 $34.20 $35.90 $37. 50 $39.00 $40. 50 $41.90

52 29.70 31.60 33. 30 35.00 36.60 38. 10 39.50

54 27.00 28.90 30.80 32.50 34. 10 35. 70 37.20

56 24.30 26.30 28 20 30 00 31 70 33 30 34.90

58 21.60 23.70 25 60 27 50 29 30 31.00 32.60

60 18.90 21.10 23. 10 25.00 26.80 28.60 30.20

62 16.20 18.40 20.50 22.50 24.40 26.20 27.90

64 13.50 15.80 17.90 20.00 22.00 23.80 25.60

66 10.80 13.20 15.40 17.50 19.50 21.40 23.30

68 8.10 10.50 12.80 15.00 17.10 19.00 20.90

70 5.40 7.90 10.30 12.50 14.60 16.70 18.60

72 2.70 5.30 7.70 10.00 12.20 14.30 16.30

74 2.60 5.10 7.50 9.80 11.90 14.00

76 2.60 5.00 7.30 9.50 11.60

The original furnace efficiency is the value calculated in 6.1.18.

TABLE 2. PICKUP CAPACITY FACTOR AS A FUNCTION

OF OUTDOOR DESIGN TEMPERATURE

Outdoor Design

Temperature

°C °F

Pickup Capacity Factor*

W/m2 Btu/h/ft2

.

5 -- 28.7

40 —- 9.5

0 — 39.4

30 —- 13.0

- 5 -- 45.7

20 — 14.9

-10 — 48.8

10 - — 15.8

-15 — 52.0

0 — 17.0

-20 - 54.0

-10 — 17.7

-25 — 56.9

.20 — 18.8

-30 — 60.5

This table is based on a 6°C (10°F) thermostat

setback and a two-hour pickup time.

171
STANDARD PRACTICE FOR THE INSTALLATION OF AUTOMATIC VENT DAMPERS ON EXISTING

GAS-FIRED CENTRAL FURNACES AND LOW PRESSURE DOMESTIC HOT WATER BOILERS*

1. SCOPE

1.1 This practice applies to the field installation of electrically-operated,

mechanically-actuated, and thermally-actuated automatic vent dampers on existing

gas-fired central furnaces and low pressure hot water boilers in existing

residential buildings.

1.2 This practice applies only to the installation on individual, automatically

operated, gas-fired, hot air (forced or gravity) central furnaces and gas-fired

low pressure hot water boilers equipped with draft hoods.

1.3 This practice is intended for use by qualified approved installers only.

This practice outlines in general terms the procedures to be followed,

but leaves the installed step-by-step methodology to the approved

installer . It is therefore not intended for use by the general public or by untrained persons, since such use may be unsafe or result in

damaged equipment.

This practice covers aspects of installation relating to the

effectiveness , durability , and safety of installed vent dampers in

service. It does not primarily address the safety of the installer

1.4 Proper application of this practice requires specialized training in the

installation of vent dampers and a working knowledge of the applicable codes

and regulations, tools, equipment and methods necessary for the safe installatio

of vent dampers, and an understanding of the fundamentals of gas-fired heating

and domestic hot water systems.

Because of the potential hazards involved, vent dampers should never

be installed by untrained people. This requirement is also consistent

with existing codes and rules in many localities and States.

1.5 This practice outlines the general procedure to be followed. No procedure can anticipate all situations. Accordingly, in some cases deviation from this

procedure may be necessary for a safe installation.

When departing from the substance of this practice, details and

rationale for such departures should be noted on the verification card

required under 9.19 and in the DoE Material Standards for Vent Dampers

1.6 This practice is intended to establish a minimum level of performance for safety

and effectiveness. When a manufacturer's installation instructions regarding

specific requirements that affect safety and effectiveness result in a higher

level of performance for these characteristics, such manufacturer's installation

instructions may be used.

This practice is based on guidelines developed by the Calspan Advanced Technology

Center, a division of Calspan Corporation and on the applicable documents identified.

The guidelines have been revised editorially to be compatible with the format of the

other practices in this publication.

172
1.7 This practice is not intended to supersede the authority of State and local codes

but is instead intended to establish minimum criteria for safety and effectiveness. When State or local codes specifically address the substance of provisions

contained herein, they may apply. When State and local codes do not address the

substance of specific provisions contained herein, this practice shall prevail.

1.8 This practice covers the installation process from pre-installation

through post-installation procedures. It does not cover the production

of the vent dampers or their assembly, whether such production or assembly takes place in a factory or at the installation site. The HCS

Material Standards require that only factory assembled vent damper be

installed.

2. APPLICABLE DOCUMENTS

ANSI 2 Z21. 66-1977: American National Standard for Electrically-Operated

Automatic Vent Damper Devices for Use with Gas-Fired Appliances.

ANSI Z21. 67-1978: American National Standard for Mechanically-Actuated

Automatic Vent Damper Devices for Use with Gas-Fired Appliances.

ANSI Z21. 68-1978: American National Standard for Thermal ly-Actuated Vent Damper

Devices for Use with Gas-Fired Appliances.

ANSI Z21. 13-1977: American National Standard for Gas-Fired Low Pressure Steam

and Hot Water Boilers.

ANSI Z21. 47-1978: American National Standard for Gas-Fired Central Furnaces

(except direct vent and separated combustion central furnaces).

ANSI Z223. 1-1974 (NFPA [3] 54-1974): "American National Standard National Fuel

Gas Code, Part 1, Installation of Gas Piping and Gas Equipment on Noni ndustri al Premises.

NFPA3 70-1975: National Electrical Code.

3. SIGNIFICANCE

3.1 Improper installation can result in injury or death from venting exhaust gases,

including carbon monoxide, into the residence.

Automatic vent dampers are potentially very dangerous if they are not installed properly . Vent dampers are intended to shut off the flow up

the vent during periods when the burner is not firing, thereby saving

the loss of conditioned air. However, during periods when the burner

2 American National Standards Institute, 1430 Broadway, New York, NY 10018.

3 National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210.

173
is firing, the damper must be open to allow hazardous combustion products to be vented outside of the residence. If improperly installed,

the vent damper could shut off the vent during burner firing, and cause hazardous combustion products to be vented into the residence with

possibly fatal results .

3.2 Improper installation can also result in electrical shock hazard to the installer

or others.

4. DEFINITIONS

4.1 Additional Gas Valve (also sometimes called a "Redundant" Gas Valve) - A second operating gas valve in series with another operating gas

valve, both of which operate with each call for heat. The additional

(redundant) gas valve may be either an additional valve (without pilot

features) located in the gas line between the existing valve and the

main burner or a replacement valve that includes two operating valves

within a single unit.

4.2 Heating Appliance - An individual , automatically-operated, gas-fired

hot air (forced or gravity) furnace or gas-fired low pressure hot-water

boiler equipped with a draft hood.

4.3 Approved - acceptable to the authority which regulates the activity or material

and its use. Such authority may be a municipal, State, or Federal agency or underwriters' inspection or rating bureau.

4.4 Boilers - a self-contained, gas burning appliance intended to supply

hot water at gage pressures not exceeding 1.1 mPa (160 psi) having

residential space heating as primary purpose.

4.5 Comfort Thermostat - An automatic control device for a residential

space heating system actuated by room air temperature and designed to

respond to the room air temperature.

4.6 Furnace - a self-contained, gas-burning appliance for heating air by

the transfer of heat from combustion through metal to the air for the

purpose of residential space heating.

4.7 Vent Damper - a device which automatically closes vents on gas-fired appliances

to prevent the escape of heat through the vent pipe when the main burner is not being fired. The device may be electrically-operated, mechanically-actuated, or thermally actuated.

5. MATERIALS

5.1 Under the Residential Conservation Service program (RCS), install only vent dampers identified as complying with DoE standards.

This marking indicates that the manufacturer certifies that the product

meets the applicable DoE standards . The label does not imply that DoE

174
has conducted tests on the material or that the manufacturer uses an

approved quality assurance program.

5.2 In addition, all vent damp~"s installed under RCS also must carry a label stating:

"This device must be installed only by a qualified installer."

5.3 A safe installation requires that safe vent damper and heating appliance designs

be used.

5.3.1 The vent damper must, as a minimum, be listed by a nationally recognized testing

laboratory and must meet ANSI Standards Z21. 66-1977, Z21. 67-1978 or Z21. 68-1978.

5.3.2 Heating appliances to which vent dampers are installed must meet currently

applicable State and local codes and the appropriate nationally recognized

standards in force at the time of their manufacture. The most recent of these

standards are listed under "2. APPLICABLE DOCUMENTS.

Often the authority having jurisdiction over the installation of gas

equipment in a locality will have requirements that must be met before

equipment is considered safe and is approved for use in that locality

.

Often equipment must be listed before it is approved. Listed equipment

is that included in a list published by a nationally recognized testing

laboratory that maintains periodic inspection of the production of

equipment that it lists. Each listing states that the equipment

either meets nationally recognized standards or has been tested and

found suitable for use in a specified manner. Listed vent dampers and

heating appliances are intended to include only safe designs. However,

using a listed vent damper on a listed heating appliance does not

necessarily imply a safe retrofitted system, since not all listed

vent dampers are compatible with all listed heating appliances . In

addition, the safety of a retrofitted system depends not only on the

safe designs of the existing heating appliance and vent damper but

also on the manner in which the vent damper is installed.

6. SAFETY PRECAUTIONS

6.1 If at any point during the pre-installation (7), installation (8), or postinstallation (9) procedures it is determined that there is a condition which could

result in unsafe operation of the heating system, the appliance must be shut off,

the owner informed of the required repairs, and the repairs made before continuing

with the installation.

7. PRE-INSTALLATION PROCEDURES

7.1 Perform pre-installation procedures before making an attempt to install a vent damper. Do not install the vent damper on the appliance if the determinations

required below can not be made.

The purpose of the pre-installation procedure is to determine that the

gas heating appliance is properly installed and is in a safe condition

for continuing use.

7.2 Determine that the heating appliance is not in a space that is essentially at outdoor temperature, such as an unheated attic, crawl space (unless the crawl

175
space serves as a heating plenum), or basements with openings directly to the

outdoors.

Vent dampers save energy by reducing the flow of heated air up the vent

during periods when the main burner of the heating appliance is off.

If the appliance is located in an unheated area, the air flow prevented

during periods when the main burner is off is not heated air.

7.3 Because vent capacities are reduced when the difference between indoor and outdoor

temperatures are the least, and, generally, when wind velocities are low, all checks of venting capacity or draft hood spillage must be conducted when the out- side temperature is above 18°C (65°F) and the wind velocity is less than 16 km/h

(10 mph). Exception : When it is necessary to conduct tests of venting capacity

or draft hood spillage when outdoor temperatures are below 18°C (65°F) and/or wind

velocities higher than 16 km/h (10 mph), the installer must employ another method

to ensure that the entire venting system will have adequate capacity and will not produce draft hood spillage. One acceptable alternate method is a thorough

inspection of the venting system wherein the interior of the flue of the heating

appliance, the vent connector, and the chimney flue are visually inspected for

obstructions, blockage, or restrictions such as might be caused by fallen mortar

or bricks, a dead bird, bird nest, etc. This inspection is in addition to the

inspections called for in 7.7 below. Venting may be particularly dependent on wind conditions in certain special situations. Extra caution must be exercised

in certain special situations that include exposed locations in high wind areas; locations in very hilly terrain; difficult constructional features for venting

purposes, such as high pitched roofs; and neighborhoods with sharply varying

building heights. In these situations, wind currents directed at the top of the

chimney may cause downdrafts at times. If any of these situations are suspected

of causing draft problems, it will be necessary to conduct the vent capacity or draft hood spillage checks on several days under various wind conditions.

7.4 Determine with suitable instruments that there is no detectable concentration of

combustible gas in the vicinity of the heating appliance. The absence of combustible gas is indicated by a reading of less than 20 percent of the lower explosive limit on the appropriate instrument or by a smell test indicating complete

freedom from odor. (The lower limit for detecting fuel gas by smell is approximately 20 percent of the lower explosive limit^). The absence of CO is indicated

by a reading of less than 50 ppm, which is the lowest marking on several CO test

instruments in common use.

Limits of combustible gas and carbon monoxide concentrations are set as

a preliminary indication of a safety hazard. The given levels are both

quite detectable and provide satisfactory safety.

7.5 Determine that the heating system installation meets the requirements of all applicable codes and regulations. The heating system installation should at least meet

the requirements of the National Fuel Gas Code, ANSI 2 223.1-1974 (NFPA No. 54-1974).

The purpose of this practice is to provide a minimum requirement. It

does not have the authority to supersede State and local codes.

7.6 Conduct a gas leakage test of the appliance piping and control system downstream

of the shut-off valve in the supply line to the appliance. Do not use a flame or other source of ignition to check for gas leaks.

4 Gas Engineers Handbook, Section 861, Industrial Press Inc., New York, NY 10016,

1974, p. 9/108-9/111.

176
This is to serve as an initial check for the safety of the installer

and for continued safe operation.

7.7 Inspect the venting system to determine that the cross-sectional area of the vent connector is not less than the area of the draft hood outlet (the chimney side of

the draft hood) and that the area of the vent is not less than the area of the

largest connected draft hood outlet plus 50 percent of the areas of additional

connected draft hood outlets. If these criteria are not met, the vent system must

meet the provisions of the National Fuel Gas Code (ANSI Z 223.1-1974) paragraphs

1.5.6.3 and 1.5.8.3. Determine that there are no manually adjustable dampers in

the vent system. Also visually inspect for positive horizontal pitch [not less

than 20 mm/m (1/4 in/ft)] and determine that there is no blockage, restriction,

leakage, corrosion, etc., which could cause an unsafe condition.

Existing safety standards have specified vent sizes as providing

adequate vent capacity . Positive pitch is required to reduce the

collection of condensate.

7.8 Determine that the outside termination of the vent is satisfactory (see ANSI

Z 223.1-1974, 1.5.5.2 and 1.5.6.3). Determine that the chimney is unobstructed,

does not have excessive soot buildup, is in good condition, and is either a lined

masonry chimney or an approved Type B or Type L vent, or factory built chimney.

Do not install a vent damper in a heating system using any other chimney type,

including unlined masonry chimneys and uninsulated, single-wall metal pipes.

Determine that the vent connector does not project into the chimney.

A satisfactory chimney is necessary for proper draft and to prevent

leakage of hazardous combustion products into the living area.

7.9 Determine that the comfort thermostat(s) is (are) in satisfactory operating

condition. Check for excessive dust, corrosion, pitted contacts, and cracked

or broken base or housing. Note the comfort thermostat setting so it can be

reset after the installation is completed, then adjust the thermostat for con- tinuous operation. Determine that the burner input is in accordance with the

heating appliance manufacturer's instructions.

A stuck thermostat could cause hazardous overheating and an open

thermostat could cause dangerously low temperatures . The burner

input must be in accordance with the heating appliance manufacturer'

s

instructions to be operating within its design parameters . Operating

at other than rated input could cause flame impingement , excess carbon

monoxide production, poor ignition, and a variety of other hazardous

conditions

.

7.10 Visually determine that the main burner gas is burning properly and that there

is no floating, lifting, or flashback. Adjust the primary air shutter(s) as required. If the appliance is equipped with flame modulation, check for proper

main burner operation at low and high flame. Observe burner for evidence of

plugged burners, improper flame alignment, combustion product leakage, and

improperly adjusted pilot lights.

These determinations are required to indicate necessary adjustments

that could affect later tests and are necessary for proper operation

of appliances . Improper burning could cause excessive carbon monoxide,

overheating of furnace components , fire hazard from exposed flame, or leakage of hazardous combustion products.

177
7.11 Shut off all gas to the appliance using the shut-off valve in the supply line to the appliance. Shut off the main burners of all other appliances located within

the same room or connected to the same vent. Note the settings of any thermostats

that are to be changed so they can be reset after the installation is completed.

The heating appliance is shut off so that some inspections can be made

while the appliance is off and to allow time for the appliance to cool

before conducting the draft hood spillage test. Other appliances

located in the same room or connected to the same vent are turned off

to minimize vent system priming. They will be turned on later to provide full vent loading and to maximize combustion air requirements

7.12 Determine that there is sufficient combustion air. In unconfined spaces in

buildings of conventional frame or masonry construction, infiltration normally

is adequate to provide air for combustion, ventilation, and dilution of flue

gases. If the unconfined space is within a building of unusually tight construction, air must be obtained from outdoors or from spaces freely connected with

outdoors. Permanent openings having a total free area of not less than 100 mm^

in 230 W (1 in^ in 5000 Btu/h) of total input rating of all appliances must be

provided. For appliances located within confined areas, follow the recommendations of the National Fuel Gas Code ANSI Z223. 1-1974, paragraphs 1.3.4.3 through

1.3.4.6. Check any ducts for obstructions and other unsafe conditions.

This requires that sufficient combustion air be available, gives a specification for the area of openings required , and indicates a source of additional information for unusual situations . Insufficient

combustion air could cause large increases in carbon monoxide and

poor combustion, with attendant hazards.

If the combustion and dilution air is obtained from the outside, the

provisions of 7.2 apply and no vent damper should be installed.

7.13 Shut off electricity to the heating appliance. Determine that no electrical

wiring at the appliance has loose connections, charred insulation, cracked or worn insulation, or potential shorting to ground. Determine that fuses and

circuit breakers are of correct size and that wires are of correct size for

the appliance. Turn on electricity.

Incorrect or deteriorated electrical systems components could result in

shock hazards or improper furnace operation.

7.14 Determine that no appliance burners and gas manifolds are blocked or corroded.

Determine that the burner is properly aligned and shows no evidence of burner

misalignment that could cause hot spots on the heat exchanger.

Requires burner and manifold inspections that are not included in the

existing standards . The listed defects could cause improper burner

operation.

7.15 Applicable only to furnaces: Determine that the heat exchanqer does not have

cracks, openings, leakage deposits, excessive corrosion, and/or evidence of

excessive hot spots. Determine that the recirculating air section of the appli- ance does not incorporate flammable materials or materials that could emit toxic

fumes on being heated.

Leakage paths could result in the leakage of hazardous combustion

products

178
7.16 Applicable only to boilers : Determine that there is no evidence of water or combustion product leaks.

Leaks could cause improper boiler operation.

7.17 Insofar as is practical, close all building outside doors and windows. Turn on

all exhaust fans (range hood, bathroom exhausts, etc.) so they will operate at maximum capacity. Turn on any clothes dryers vented to the outside. Do not operate summer exhaust fans. Make certain that no fireplace(s) is (are)

operating. Close all fireplace dampers.

This is to decrease the pressure in the heating appliance area for the

required tests below, exhaust fans must be turned on. A requirement

for burning on any clothes dryers vented outside is specifically

included since this exhaust fan might otherwise be neglected . The

required position of inside doors is given in 7.18.

7.18 For the following vent system checks, the worst venting conditions that may

reasonably exist should be duplicated. The worst venting conditions exist when

the space occupied by the heating appliance is at the lowest pressure. If there

are exhaust fans in the same room as the heating appliance, or if there are no exhaust fans in the residence, the lowest pressure will probably occur when the

doors to other spaces of the building are closed. If there are exhaust fans in

other rooms, the pressure will probably be lowest when doors connecting these

rooms with the heating appliance space are open. Based on these considerations,

open or close doors to other spaces of the building as required to produce the

lowest pressure in the space occupied by the heating appliance. If it is not known which condition results in the lowest pressure, apply the requirements of

7.18 through 7.22 twice--once with doors to other spaces of the building open

and once with the doors closed. After the appliances have been off for at least

30 minutes, turn on the gas to the appliance being inspected and place it in

operation. Follow the manufacturer's lighting instructions . Adjust the comfort

thermostat for continuous, full-burner appliance operation.

The worst venting conditions mus*- be duplicated to ensure that the

following test is adequate to determines that spillage and attendant

hazards do not occur under any foreseeable combination of ventilator

operations and door openings and closings

.

7.19 Conduct test for spillage at the draft hood relief opening at 2 minutes after

start of main burner operation. This short time is necessary if the test is to simulate a reasonably severe condition. Use a device that will produce unpressurized flame or smoke, such as a match flame or cigarette smoke. Considerable

care must be used to determine if flow is in or out of the draft hood. Adequate

lighting must be provided for observation and the flow through all areas of the

draft hood opening(s) must be carefully observed. After testing for spillage at the heating appliance draft hood, test also for spillage at other draft hoods

connected to the same vent.

The tendency for spillage is greatest at the beginning of the burner

firing cycle because the vent system is cool and vent flows have not

been established . Therefore, it is important that spillage tests be

conducted at a specified time that is short compared to the burner

firing time. The National Bureau of Standards has determined that

3.87 minutes is an average burner firing time for furnaces , and 9.68

179
minutes is an average burner firing time for boilers

5 Many operating

cycles would have a shorter burner firing time. On the other hand, the

amount of spillage may be only a very small percentage of the total

gases being vented and this spillage may have been tolerated in the

past. However, recent measurements indicate that inside pollution

levels may be adversely affected by even small amounts of spillage

Based on the above considerations , a time of 2 minutes of testing for

spillage of was determined to be necessary . Also, because of the

critical nature of this test, some additional instructions are given

for conducting it. Because spillage at other draft hoods connected to the same vent is also a hazardous situation, a spillage check at these

other draft hoods is also required

7.20 Shut off the main burner and let the appliance cool for at least 15 minutes.

The main burner is shut off and the heating appliance is allowed to

cool to minimize priming of the vent system. Although full cooling

may require a longer period, the 15 minutes of cooling is used to shorten the installation time.

7.21 Turn on all other fuel -burning appliances that are within the same room or that

are connected to the same vent so they will operate at their full inputs. Turn

on the appliance being inspected so that it will operate at its full rated input.

All other fuel-burning appliances within the same room and connected to the same vent are turned on to create the greatest load on the vent system and to maximize combustion air requi rements

7.22 Repeat requirements and provisions given in 7.19.

Paragraph 7.19 included a test for spillage with only the heating

appliance operating . Other appliances connected to the same vent may

induce additional flow from the heating appliance draft hood outlet- or, conversely , they may cause an increase in the vent system load

and reduce flow from the heating appliance draft hood outlet. Therefore, both conditions must be duplicated . Also, the increase in

combustion air requirements reduces the pressure in the room in which

the heating appliance is located and thereby promotes spillage

7.23 After 5 minutes of main burner operation, measure the flue gas temperature and

carbon monoxide (CO) concentration at a point 25 mm (1 in) before the inlet to

the draft hood at the center of the flue passage(s). This temperature should be

at least 93°C (200°F). This temperature is necessary to limit condensation

within the vent. This temperature should also be less than 288°C (550°F), the

vent damper's maximum design temperature. The maximum carbon monoxide concentration should be 0.04 percent (400 ppm), as permitted for new heating appliances.

If the heating appliance is equipped with flame modulation, rerun the minimum

93°C (200°F) flue gas temperature test and the CO test at the lowest flame

conditions.

There are three levels of temperature that are important to the installation of vent dampers. A minimum temperature is required to limit

condensation within the vent system that could lead to corrosion

5 Joseph Chi, George E. Kelly, "A Method for Estimating the Seasonal Performance of

Residential Gas and Oil-Fired Heating Systems," ASHRAE Transactions, 1978, Vol. 84,

Part 1, p. 411.

180
damage. This minimum temperature is dependent on the characteristics

of the particular vent system. Therefore, no one value is satisfactory

for all vent systems, but values of about 93°C (200°F) have generally

been accepted as adequate. This single value of 93°C (200°F) has

been given to provide a usable installation guideline that will provide more protection than existing standards , which do not require any

minimum temperature.

Listed vent dampers are tested at a maximum temperature of 300 +_ 15°C

(575 +^ 25°F) and, therefore , the vent temperature should be limited to 290°C (550°F). The temperature is to be measured in the flue because

it represents the maximum temperature to which the vent damper could

be exposed in operation. This exposure would occur under the condition

of no diluting air flow. At the time of measurement, there may be

diluting air entering the draft hood, reducing the temperature at the

location where the vent damper will be installed, but this may not be

the condition at some later time.

Listed heating appliances must meet the requirement of a maximum of

(0.04 percent) of carbon monoxide (air free). All appliances to be

retrofitted should also meet at least the specified carbon monoxide

concentra t ion

.

7.24 For thermally-actuated vent dampers only : Measure the temperature at the center

of the vent connector 150 mm (6 in) six inches downstream the outlet of the draft

hood. The vent gas temperature must be at least 188°C (370°F) but less than 288°C

(550°F). The damper design has been tested for flow restriction at 188°C (370°F).

Lower vent gas temperatures at full input could result in flow restriction and

spillage.

7.25 For electrically-operated and mechanically-actuated vent dampers only : If the

vent damper is not installed with a redundant gas valve, it must be equipped

with a damper-closing temperature control, and the temperature at the center of

the vent connector, 150 mm (6 in) downstreams of the outlet of draft hood must be

measured. This damper closing temperature control is intended to keep the

damper open whenever the main burner is operating. The vent gas temperature

must be more than 190°C (375°F) under normal conditions to ensure that the

damper-closing temperature control will function properly (i.e., hold the damper

open) under an abnormal condition of restricted fuel gas input. If the vent gas

temperature at full output is not above 190°C (375°F), do not install a vent

damper with a damper-closing temperature control.

Listed dampers that have a damper-closing temperature control must not automatically close when the vent gas temperature is above 107°C (225°F)

when tested under specified conditions . The purpose of damper-closing

temperature control is to keep the damper open if there is a malfunction

of the automatic gas valve such that gas flows without a call for heat.

This can occur if the automatic gas valve sticks open or if contamination holds it open. With these types of automatic gas valve malfunctions, the amount of gas flowing may be any value between zero and

full flow. Listed vent dampers with damper-closing temperature controls

must have 10 percent open area in the nominally closed position.

Therefore, the damper-closing temperature control must protect against

automatic gas valve leakage rates from full flow down to 10 percent of

full flow.

It has been calculated that a vent gas temperature of 190°C (375°F)

measured at full gas flow will provide a vent gas temperature of at

least 107°C (225°F) for the majority of hazardous leaking valve

181
conditions . If the above conditions are not met the damper could be

closed during an automatic gas valve malfunction with resulting

continuous spillage—a hazardous condition.

7.26 Return doors, windows, exhaust fans, fireplace dampers, and other appliances to

their previous conditions of use.

7.27 Determine that the pilot light(s) is (are) burning properly and that main burner

ignition is satisfactory by turning the main power supply switch for the heating

appliance off and on. Test the pilot safety device to determine if it is operating properly by extinguishing the pilot burner(s) when the main burner is off

and determine that the main gas valve does not open upon a call for heat beyond

the safety shut-off time specified by the automatic gas ignition device manufacturer. If this time is not known, a safety shut-off time of one minute must be

met. Relight the pilot(s) after this time check.

This specifies checks of the pilot light and safety device. Listed

automatic ignition devices are required to shut off main gas flow in

the absence of a flame within the times specified by their manufacturer.

This step requires that a check be made of the shut-off time. In many

instances , the manufacturer' s specified shut-off time will not be

known because this fact is not required to be marked on the ignition

device. In these cases, a shut-off time of one-minute has been

specified because this is representative of the shorter shut-off times

of ignition devices that may be found in the field.

7.28 Applicable only to furnaces : Check both the limit control and the fan control to determine that they operate within the heating appliance manufacturer's specfications.

Improper operation could result in overheating or excessive fan

operation.

7.29 Applicable only to hot water boilers : Test low-water cutoffs, automatic-feed

controls, high-pressure limit controls, high-temperature-limit controls, relief

valves, water pumps, and the circulating system to determine that they are operating within the manufacturer's specifications.

To test operation of the safety features.

8. INSTALLATION PROCEDURES

8.1 Do not install vent dampers unless the pre-instal lation procedures have been

carried out, the heating appliance has been found to be properly installed and in

a safe condition, and that any required repairs have been made.

8.2 If at any point during the pre-i nstal 1 ation procedures or anytime during

installation it is it was determined that there is a condition that could result

in unsafe operation of the heating system, the appliance must be shut off, the owner informed of the necessary repairs, and the repairs made before the

installation is continued.

8.3 This general installation procedure is to be used in conjunction with installation instructions supplied by the automatic vent damper manufacturer to ensure

the safe installation of the vent damper on an existing appliance.

182
8.4 Install mechanically-actuated vent dampers only on appliances with which they are compatible. Determine compatibility by comparing the appliance with diagrams furnished by the damper manufacturer showing interconnections among the heating

appliance, the damper, the motive force and the control circuits. Install

electrically-operated vent dampers and thermal vent dampers with electrical con- nections only on appliances where the wiring diagrams supplied by the vent damper

manufacturer show the device to be compatible with the appliance. Do not install

the vent damper if a wiring or interconnection diagram applicable to the heating

system is not supplied by the vent damper manufacturer.

8.5 Determine that the heating system and vent damper are both listed and approved

models. Ensure that the damper and other materials are in good condition and

free of damage resulting from shipping or other causes and ensure that all parts

are included. Determine whether the vent damper includes a damper-closing temperature control. On any damper with electrical connections, ensure that the

required voltage of the damper is compatible with the voltage of the control

circuit of the heating appliance. If the damper installation requires interconnection with the heating appliance's automatic gas valve, determine whether

this gas valve has a manual override feature which would permit operation of the

heating appliance while the damper is in the closed position or while any damper

safety system is not operational. If a valve with such an override feature is

found, the manual override feature must be removed or replaced before proceeding

with installation of the interconnected damper.

8.6 For mechanically-actuated vent dampers only : Determine that the range of

available motive force (gas pressure, water pressure, etc.) is within the vent

damper manufacturer's specified operating range. Determine that the heating

appliance automatic gas valve does not have a manual override feature that

would permit manual operation of the heating appliance while the damper remains

closed.

8.7 Shut off all gas and electricity to the heating appliance. To shut off the gas, use the shut-off valve in the supply line to the appliance. To shut off the

electricity, use the main power switch for the heating appliance.

The heating appliance is shut off to prevent accidental operation of

the appliance during the vent damper installation. The electricity is

shut off to eliminate electrical shock hazards.

8.8 Install the automatic vent damper in accordance with the manufacturer's

installation instructions. Make certain that the damper is located in the

portion of the venting system that serves only the appliance on the which the

damper is being installed and that it is between the appliance draft hood and

the first branch (if any) in the vent system. The vent damper must be installed

after the draft hood, that is, between the draft hood and the chimney. If the

damper is equipped with a damper-closing temperature control, the damper must be

located within three diameters of the draft hood. The inlet size of the vent

damper must not be less than the outlet size of the draft hood. Do not add any

components (such as relays) not specified by the manufacturer .

Listed vent dampers are required to have most of these instructions

included . They are reiterated here because of their importance to the

safe installation of vent dampers. The installer is cautioned not to add any components that are not specified by the manufacturer . Adding

such components could create a hazardous failure mode that might not be

evident immediately

.

183
8.9 Determine that the vent system is adequately supported to hold the additional

weight of the vent damper without sagging. This may require band iron straps

attached overhead and/or self-tapping screws at each joint. Visually inspect

the modified venting system for proper horizontal pitch [not less than 20 mm

per 1 m (1/4 in/ft)].

Some precautions are given relative to the support of the vent system so

that it does not fail structurally during operation, resulting in leakage

of hazardous combustion products. A significant number of improper

support conditions have been found in a field evaluation by Walden^ .

8.10 For installation of electrically-operated or mechanically-actuated vent dampers

only : If the vent damper is not equipped with a damper-closing temperature con- trol, an additional ("redundant") approved automatic gas valve must be installed

in accordance with the vent damper manufacturer's installation instructions?

This gas valve is intended to shut off gas flow if the other gas valve should

fail to close completely. It may be either an additional valve (without pilot

features) located in the gas line between the existing valve and the main burner

or a replacement valve that includes all main gas valves within the single unit.

Follow vent damper manufacturer's instructions. After installing a new gas valve,

purge air from the affected gas lines and conduct a gas leakage test of the appli- ance piping and control system downstream of the shut-off valve in the supply line

to the appliance.

The additional ("redundant" J automatic gas valve is critical to the

safety of dampers not equipped with a damper-closing temperature control.

The importance of this valve needs to be stressed. The system would

operate properly until there was a malfunction of the existing automatic

gas valve. If only one automatic gas valve were installed , and it malfunctioned, gas could be flowing but the damper would be closed resulting in continuous spillage—a hazardous condition .

8.11 Assure that electrical connections are tight and wires are clear of

high-temperature locations and are properly supported. Route wires to minimize

the possibility of their being damaged. All wiring must meet the requirements of

all applicable codes and regulations. As a minimum, wiring must meet the

requirements of the National Electrical Code.

9. POST- INSTALLATION PROCEDURE

9.1 This post-installation procedure determines that the automatic vent damper is properly installed and that the retrofitted system is in a safe condition for use. If

at any point it is determined that there is a condition that could result in unsafe

operation of the heating system, the appliance must be shut off, the owner informed,

and the necessary repairs made before permitting the operation of the appliance

to which the vent damper was installed.

9.2 Turn on electrical power to the heating appliance.

9.3 For the installation of electrically-operated and mechanically-actuated vent

dampers only : By operating the furnace burner through the control circuit, deter6 L. Katzman and J. Monat, "Study to Evaluate the Energy Efficiency Improvement of

Residential Heating Equipment Modifications," Walden Division of Abcor, Inc.,

Wilmington, Massachusetts, May 1978, pp. 4-7.

184
mine that the damper operates properly and is correctly sequenced with the heating

appliance's operating controls (comfort thermostat). The damper must be nearly

open before the gas valve(s) opens and it must remain open when there is a call

for main burner operation. The gas valve(s) must close when the damper begins to

close. The gas valve and damper should remain closed when there is no call for

heat. The damper must open and close freely without evidence of interference or binding. Also determine that the gas valve(s) and damper close fully. If boiler

gas valve(s) is sequenced by an aquastat, determine that the damper has opened

fully or is nearly open prior to the opening of gas valve(s).

Improper sequencing could indicate the absence of proper interlock

between the damper and the automatic gas valve. This could result in

a hazardous condition at a future time if the damper did not open for

some reason.

9.4 If the damper has electrical current requirements, determine the amperage draw of

all circuits served by the heating appliance transformer (including such items as thermostats, humidifers, controls for electrical filters, etc.) and the vent

damper. Check the heating appliance transformer for adequate capacity. Replace

the transformer if it does not have adequate capacity.

It must be determined that the appliance transformer has adequate

capacity since the vent damper may put additional load on the

tra nsformer

.

9.5 Check the setting of any heat anticipator in the comfort thermostat and readjust

as necessary. Replace the heat anticipator if it does not have sufficient

amperage capacity.

The vent damper may change the current flow through the thermostat.

This may require a readjustment of a heat anticipator for the same

level of comfort. If the heat anticipator does not have sufficient

amperage capacity , it could eventually burn out.

9.6 Insofar as is practical, close all building outside doors and windows. Turn on any exhaust fans (range hood, bathroom exhausts, etc.) so they will operate at maximum speed. Turn on any clothes dryers vented to the outside. Do not operate

summer exhaust fans. Make certain that no fireplace(s) is (are) operating.

Close all fireplace dampers.

9.7 For installation of thermally-actuated vent dampers only : For the following vent

system checks, the worst venting conditions that may reasonably exist should be

duplicated. The worst venting conditions exist when the space occupied by the

heating appliance is at the lowest pressure. If there are exhaust fans in the

same room as the heating appliance, or if there are no exhaust fans in the residence, the lowest pressure will probably occur when the doors to other spaces of

the building are closed. If there are exhaust fans in other rooms, the pressure

will probably be lowest when doors connecting these rooms with the heating appliance space are open. Based on these considerations, open or close doors to other

spaces of the building as required to produce the lowest pressure in the space

occupied by the heating appliance. If it is not known which condition results

in the lowest pressure, perform the work specified in 9.7 through 9.9 twice--once

with doors to other spaces of the building open and once with doors closed.

After the appliances have been off for at least 30 minutes, turn on the gas to

the appliance on which the damper has been installed and place the appliance in

operation. Follow the manufacturer's lighting instructions . Adjust the comfort

thermostat for continuous full burner appliance operation.

185
9.8 For installation of electrically-operated and mechanically-actuated vent dampers

only : Turn on the gas to the heating appliance and place it in operation. Follow

the manufacturer's lighting instructions . Adjust the comfort thermostat for

continuous full-burner operation.

9.9 Test for spillage at the draft hood relief opening for 2 minutes of main burner

operation. This short time is necessary to simulate a reasonably severe test. Use a device that will produce unpressurized flame or smoke, such as a match

flame or cigarette smoke. Considerable care must be used to determine if flow

is in or out of the draft hood. Adequate lighting must be provided for

observation and the flow through all areas of all openings must be carefully

observed.

9.10 For thermally-actuated vent dampers only : If the appliance is equipped with flame

modulation, repeat 9.6 and 9.7 at the lowest flame conditions.

This is to confirm proper burner operation after the installation of

the vent damper.

9.11 Visually determine that main burner gas is burning properly and that there is no floating, lifting, or flashback. If the appliance is equipped with flame modulation, determine that proper main burner operation at low and high flame is

mai ntai ned.

9.12 Determine that the pilot light(s) is (are) burning properly and that main burner

ignition is satisfactory by turning the main power supply switch for the heating

appliance off and on. Test the pilot light safety device to determine that it is operating properly by extinguishing the pilot burner(s) when the main burner

is off and determining that the main gas valve does not remain open upon a call

for heat beyond the safety shut-off time specified by the automatic gas ignition

device manufacturer. If this time is not known, a safety shut-off time of no longer than 1 minute must be met. Relight the pilot(s) after this check.

This is to confirm proper operation after installation of the vent

damper.

9.13 For thermally-actuated vent dampers only . Cycle the heating appliance through at least three normal operating cycles. The damper must open and close properly

without evidence of interference or binding. Determine that the damper closes

fully. The damper may not close immediately with the thermostat but after a period of time, it should close.

9.14 For electrically-operated and mechanically-actuated vent dampers only : Cycle the

heating appliance through at least three normal operating cycles. Determine that

the damper is nearly fully open before the main burner gas flow begins and that

the main burner gas flow stops as the damper begins to close. The damper must

open and close freely without evidence of interference or binding. The damper

must close fully. If the vent damper includes a damper-closing temperature

control, the damper may not close immediately with the thermostat. Test this by

operating the heating appliance for 10 minutes. Then lower the setting on the

comfort thermostat to shut off the main burner gas flow. The damper should

remain open for a period of time and then close.

If the heating appliance is equipped with flame modulation and the vent damper

includes a damper-closing temperature control, operate the heating appliance for

10 minutes at the lowest flame conditions. Then reduce the comfort thermostat to

186
shut off the main burner gas flow. The damper should remain open for a period of

time and then close.

This is to confirm proper damper operation and sequencing with the

heating appliance in operation. Paragraph 9.3 required a preliminary

check of damper operation without the heating appliance in operation.

A check of the damper-closing temperature control, if included , is

also required for added safety.

9.15 Applicable only to furnaces : If the furnace electrical circuit has been modified

during vent damper installation, check both the limit control and the fan control

to determine that they operate within the heating appliance manufacturer's

specifications.

This is to confirm proper furnace limit control and fan control

operation after installation of the vent damper, in case the installation caused a change. If there is a change, improper installation is

indicated.

9.16 Applicable only to boilers : If the boiler electrical circuit has been modified

during vent damper installation, test low-water cutoffs, automatic-feed controls,

high-temperature-limit controls, water pumps, and the circulating system to

determine that they are operating within manufacturer's specifications.

This is to confirm proper operation of boiler controls after

installation of the vent damper.

9.17 For thermally-actuated vent dampers only : Return doors, windows, exhaust fans,

fireplace dampers, other appliances, and comfort thermostat (s) to their previous

conditions of use.

9.18 Fill in a label with the name and address of the installing company and the full name of the individual installer and the date of the installation, and apply to the vent damper.

9.19 Complete the verif ication-of-instal lation card supplied by the vent damper

manufacturer pursuant to the DoE Material Standard and return this promptly to

the manufacturer.

The verification card completed by the installer and returned to the

manufacturer facilitates notification of homeowners if there is a product recall. Any departure from the installation practice should be

marked on the verification-of-installation card or in a separate letter

to the manufacturer

.

9.20 Leave the vent damper manufacturer's homeowner's operation and maintenance

instructions in a conspicuous location near the heating appliance and urge the

resident to read these instructions, especially for observations to be performed

by the resident.

The homeowners' manual needs to be available to the homeowner (and

future homeownersJ to assure proper operation and maintenance of the

vent damper.

187
9.21 As required by codes and regulations, notify the appropriate authority that the

installation has been completed and turn off the heating appliance until the

required inspection is completed.

Under RCS, every installation of vent dampers must be inspected.

These practices, the vent damper manufacturer's installation instructions and a DoE prepared check list will form the basis for the

inspection*

The requirement for inspection of vent damper installations is

consistent with many existing State and local codes and regulations.

188
STANDARD PRACTICE FOR THE INSTALLATION OF AUTOMATIC

INTERMITTENT PILOT IGNITION SYSTEMS

The Federal Register Notice of September 24, 1980 1 requires that

automatic intermittent pilot ignition systems be installed in accord- ance with the provisions if the first draft (dated October, 1979 J of

the applicable proposed American National Standard (ANSI)^

.

A revised second draft of the ANSI standard was circulated for comment

and review in September, 1980, and was revised during a working committee on October 1, 1980. The September draft, including the December

1980 revisions are referred to in this document as the "1980 draft."

The relevant provisions for the installation are Exhibit A, Recommended

Procedures for Safety Inspection of an Existing Appliance Installation

as a Preliminary Step to Applying an Automatic Intermittent Pilot

System, and Exhibit B, Procedures for Installing Automatic Intermittent Pilot Systems. The 1979 and 1980 draft of the inspection and

installation procedures (Exhibit A and B) do not differ substantially

and DOE has decided not to issue a revision to the rule prior to the

final adoption of the ANSI standard

.

Below is reprinted, verbatim, the first (October 1979) draft of

Exhibits A and B with notes, pointing out the differences of this

first draft with the 1980 draft. The notes are shown indented , the

1979 draft provisions are not indented. The ANSI draft standard'

s

scope and selected definitions are also included. Installers of automatic intermittent pilot ignition systems are urged to consult with

ANSI regarding the status of the standards provisions at the time of

installation.

The draft standard is reprinted with the permission of the Chairman of

ANSI Committee Z21. The cooperation of ANSI and its relevant committee

is gratefully acknowledged.

Excerpts from ANSI Standard Relating to Installation

Part I

1.1 SCOPE

1.1.1 This standard applies to the construction3 and installation procedures for newly

produced automatic intermittent pilot ignition systems (see Part II, Definitions), hereinafter referred to as "systems", constructed entirely of new, unused parts and materials and designed to be adapted to existing continuous

pilot burners on listed forced air heating appliances and boilers equipped with

atmospheric burners.

1 Federal Register, Vol. 45, No. 187, Wednesday, September 24, 1980, page 63453, § 456.915,

Residential Conservation Service Program, Final Rule.

2 American National Standards Institute, 1430 Broadway, New York, NY 10018.

3 Construction features are included in the draft ANSI standard; they are not within the

scope of the DoE Installation Practice.

189
1.1.2 This standard does not apply to a system for use on appliances equipped with

power burners or to direct vent appliances.

1.1.3 Systems covered by this standard shall be comprised of:

The 1980 draft adds at the end of the sentence "at least."

a. Pilot igniter(s) and cable(s),

b. Pilot flame sensor(s),

c. Associated system control,

d. Two automatic valves in series, controlling main burner gas,

e. Associated system wiring, and

f. Class II pressure regulator(s)

In the 1980 draft the "Class II" is deleted.

1.6 INSTRUCTIONS

1.6.1 Each system shall be accompanied by printed instructions and diagrams adequate

for its proper field assembly, installation, checkout procedure, safe operation

and servicing. These instruction shall include the following:

In the 1980 draft, the words "adequate for" are replaced by "clearly

describing ."

b. A statement that the qualified installer must fill in and attach the label

specified in 1.6.1-m.

The relevant statement 6 . of the 1980 draft reads:

b. A statement that the qualified installing agency must fill in and

attach the label specified in 1.6. l-o.

m. The location and instructions for applying a label stating the appliance has

been modified to use an automatic intermittent pilot system. This label

should warn the homeowner not to try to lighting the appliance manually.

In the 1980 draft, a similar statement is given as 1.6.1-n:

Application of a label in a prominent location on the appliance stating

that the appliance has been modified to use an automatic intermittent

pilot system and warning the homeowner not to try to light the appli- ance manually as burn injury on electrical shock may result.

This label shall be provided, shall be made of material not adversely

affected by water and shall be attachable by means of non-water-soluble

adhesive

n. Provisions for showing date of installation, name of installer and where

installer can be reached, either by address or telephone number. This

information may be provided on the label specified in "m" above or on a separate label

In the 1980 draft, this statement is 1.6. l-o and the reference to the

label is n.

190
1.7 HOMEOWNER'S INFORMATION

1.7.1 Each automatic intermittent pilot system shall be accompanied by separate printed

instructions for use by the homeowner.

1.7.2 These instructions shall contain clearly defined, legible and complete instructions for at least the following:

The 1980 draft reads: These instructions shall be clear, concise and

shall provide a least the following:

a. A statement that the appliance has been modified from a continuously burning

pilot to an intermittent pilot operation;

b. Operation instructions;

The September 1980 draft reads:

b. Complete operating instructions for the system,- and

c. A statement that if system will not operate, the installer must be called for service;

and

The September 1980 draft reads:

c. A statement that if the system fails to operate or becomes

inoperative, it is recommended that the installer or a qualified

servicing agency be contacted for service.

d. A recommendation that the appliance be inspected annually be a qualified service

person.

In the September 1980 draft, this statement d. is deleted.

PART II

Definitions

In addition to those given below, many applicable definitions are given

in the Standard for Automatic Gas Ignition Systems and Components,

ANSI Z21.20. These also apply to this practice.

Automatic Intermittent Pilot Ignition System - For the purpose of this standard, a system

comprised of a pilot ignition device, pilot flame sensing means, control system and

associated automatic valving for application to an existing pilot burner and design to:

1. Ignite the pilot burner gas on a call for heat,

2. Prove the presence of the pilot and allow man burner gas to flow, and

191
3. Automatically act to shut off the gas supply to the main burner and pilot

burner when the pilot is not proved.

The September 1980 draft reads:

3. Automatically act to shut off the gas supply to:

a. the main burner( s) ,• and

b. the pilot burner when used with gases having a specific

gravity greater than 1.0.

Listed - Equipment or materials included in a list published by a nationally

recognized testing laboratory that maintains periodic inspection of production of

listed equipment or materials and whose listing states either that the equipment

or material meets nationally recognized standards or has been tested and found

suitable for use in a specified manner.

Main Burner - A device or group of devices essentially forming an integral unit

for the final conveyance of gas, or a mixture of gas and air, to the combustion

zone, and on which combustion takes place to accomplish the function for which an appliance is designed.

Pilot - A gas flame(s) utilized to ignite gas at the main burner(s).

EXHIBIT A

RECOMMENDED PROCEDURE FOR SAFETY INSPECTION OF AN EXISTING APPLIANCE

INSTALLATION AS A PRELIMINARY STEP TO APPLYING AN AUTOMATIC

INTERMITTENT PILOT SYSTEM

The following procedure is intended as a guide to aid in determining that an appliance is properly installed and is in a safe condition for continuing use.

This procedure is predicated on central furnace and boiler installations equipped

with an atmospheric gas burner(s) and not of the direct vent type. It should be

recognized that generalized test procedures cannot anticipate all situations.

Accordingly, in some cases, deviation from this procedure may be necessary to detrmine safe operation of the equipment.

a. This procedure should be performed prior to any attempt at modification of

the appliance or the installation.

b. If it is determined there is a condition which could result in unsafe

operation, the appliance should be shut off and the owner advised of the

unsafe condition.

The following steps should be followed in making the safety inspection:

1. Conduct a gas leakage test of the appliance piping and control system

downstream of the shutoff valve in the supply line to the appliance.

2. Visually inspect the venting system for proper size and horizontal pitch

and determine there is no blockage or restrictions, leakage or corrosion

or other deficiencies would could cause an unsafe condition.

192
3. Shut off all gas to the appliance and shut off any other fuel-burning

appliance within the same room. Use the shutoff valve in the supply line

to each appliance .

4. Inspect burners and crossovers for blockage and corrosion.

5. Applicable only to warm air heating appliances . Inspect heat exchangers

for cracks, openings or excessive corrosion.

6. Applicable only to boilers . Inspect for evidence of water or combustion

product leaks.

7. Insofar as is practical, close all building doors and windows and all doors

between the space in which the appliance is located and other spaces of

the building. Turn on the clothes dryers. Turn on any exhaust fans, such

as range hoods and bathroom exhausts, so they will operate at maximum speed.

Do not operate a summer exhaust fan. Close fireplace dampers. If after

completing Steps 7 through 12, it is believed sufficient combustion air is not available, refer to 1.3.4 of the National Fuel Gas Code (Z223.1)4 for

guidance.

8. Place in operation the appliance being inspected. Follow the lighting

instructions . Adjust thermostat so appliance will operate continuously.

9. Determine that the pilot is burning properly and that main burner ignition

is satisfactory by interrupting and reestablishing the electrical supply to the appliance in any convenient manner.

The September 1980 draft reads:

9. a. Determine that the pilot is burning properly and that main

burner ignition is satisfactory by interrupting and reestablishing the electrical supply to the appliance in any

convenient manner,

b. Determine manifold pressure in order to match input after the new control is installed.

10. a. Visually determine that main burner gas is burning properly: i.e., no floating, lifting or flashback. Adjust the primary air shutter(s) at low flame.

11. Test for spillage at the draft hood relief opening after 5 minutes of main

burner operation. Use a draft gage, the flame of a match or candle, or smoke from a cigarette, cigar or pipe.

12. Return doors, windows, exhaust fans, firplace dampers and all other fuelburning appliances to their previous conditions of use.

13. Applicable only to warm air heating appliances . Check both limit control

and fan control for proper operation. Limit control operation can be

checked by temporarily disconnecting the electrical supply to the blower

motor and determining that the limit control acts to shut off the main

burner gas.

14. Applicable only to boilers :

a. Determine that the water pumps are in operating condition.

4 "National Fire Code", National Fuel Gas Code, National Fire Protection Association,

470 Atlantic Avenue, Boston, MA 02210.

193
In the 1980 draft, the word "circulating" is inserted in front of

"water pumps."

b. Test low water cutoffs, automatic feed controls, pressure and

temperature limit controls and relief valves in accordance with the

manufacturer's recommendations and instructions to determine they are

in operating condition.

In the 1980 draft, the word "water" is inserted between "feed" and

"controls"

EXHIBIT B

PROCEDURE FOR INSTALLING AUTOMATIC INTERMITTENT PILOT SYSTEMS

Prior to beginning this procedure, a preliminary examination of the appliance and

the automatic intermittent pilot system should be made to determine that the

automatic intermittent pilot system can be properly applied to the appliance.

This procedure is intended as a guide to aid in safety installing a listed

automatic intermittent pilot system on an existing listed appliance equipped with

an atmospheric gas burner(s) and not of the direct vent type.

This procedure is based on the assumption that the history of the specific

installation has been one of safe and satisfactory operation.

This procedure is predicated on central furnace and boiler installations, and

it should be recognized that generalized procedures cannot anticipate all situations. Accordingly, in some cases deviation from this procedure may be necessary

to determine safe operation of the equipment.

The following steps should be followed in making the modifications:

1. Perform a safety inspection of the existing appliance installation. See

Exhibit A for a recommended procedure for such a safety inspection.

2. Shut off all gas and electricity to the appliance. To shut off gas use the

shutoff valve in the supply line to the appliance . Do not use the shutoff

valve which is provided as part of a combination control.

3. Install the automatic intermittent pilot system in strict accordance with

the manufacturer's installation instructions.

4. Turn on all gas and electricity to the appliance.

5. Determine that the appliance transformer has adequate capacity by following

the steps outlined below:

a. Compute the total current draw by adding the current draw of the automatic

intermittent pilot system to (1) the current draw of the associated valving,

and (2) the current draw of any relays or other devices operated by the

transformer.

The September 1980 draft reads:

a . Compute the approximate current draw by adding the current draw of- the automatic intermittent pilot system to ( 1) the current draw of

the associated valving, and (2) the current draw of any relays or other devices operated by the transformer

194
b. Multiply the total current draw as computed above by 24V to determine

the total VA (volt-ampere) required.

c. The total VA (volt-ampere) required should be equal to or less than

the VA rating of the transformer.

d. If the total VA (volt-ampere) required is greater than the VA rating

of the transformer, the transformer must be replaced with a Class 2 transformer of adequate rating.

6. Check the heat anticfpator in the comfort thermostat to determine if it is

properly adjusted to the current draw of the control system. Follow the

thermostat manufacturer's instructions.

7. Make certain wiring connections are tight and wires are positioned and

secured so they will not be able to contact high temperature locations.

8. Conduct a gas leakage test of the appliance piping and control system

downstream of the shutoff valve in the supply line to the appliance.

9. Adjust the thermostat to its highest temperature setting. Visually

determine that main burner gas is burning properly: i.e., no floating,

lifting or flashback. Adjust the primary air shutter(s) as required.

The September 1980 draft reads:

9. a. Adjust the thermostat to its highest temperature setting and

test manifold pressure and adjust the pressure regulator to match original input as required. (Refer to Exhibit A,

Step 9b).

b. Visually determine that main burner is burning properly: i.e., no floating, lifting or flashback. Adjust the primary air

shutter( s) as required.

10. If the appliance is equipped with high and low flame controlling or flame

modulation, check for proper main burner operation at both high and low

flame.

11. Determine that the pilot is igniting and burning properly and that main

burner ignition is satisfactory by interrupting and reestablishing the

electrical supply to the appliance in any convenient manner. Make this

determination with the appliance burner both cold and hot. Perform this

step as many times as is necessary to satisfy yourself that the automatic

intermittent pilot system is operating properly.

12. Test the pilot safety device: (1) to determine if it is operating properly,

and (2) for turndown characteristics according to the manufacturer's

installation instructions.

The September 1980 draft adds:

No adjustments should be made other than those recommended by

the system manufacturer

.

13. Sequence the appliance through at least three operating cycles.

14. Applicable only to furnaces . Check both the limit control and the fan

control for proper operation. Limit control operation can be check by

blocking the circulating air inlet or temporarily disconnecting the

electrical supply to the blower motor and determining that the limit control

acts to shut off the main burner gas.

195
15. Applicable only to boilers .

a. Determine that the water pumps are in operating condition.

b. Test low water cutoffs, automatic feed controls, pressure and

temperature limit controls and relief valves in accordance with the

manufacturer's recommendation to determine they are in operating

condition.

16. Add the labels (see 1.6.1-m and -n) on the appliance.

In the September 1980 draft, the reference is to 1.6.1-n and -o.

196
NBS-U4A irev. 2-eo

U.S. DEPT. OF COMM. BIBLIOGRAPHIC DATA

SHEET (See instructions)

1, PUBLICATION OR

REPORT NO. NBS SP 606

2. Performing Organ. Report No. 3. Publication Date July 1981

4. TITLE AND SUBTITLE

Criteria for the Installation of Energy Conservation Measures

5. AUTHOR(S)

Heinz R. Trechsel and Shelia J. Launey

6. PERFORMING ORGANIZATION (If joint or other than NBS, see instructions)

NATIONAL BUREAU OF STANDARDS

DEPARTMENT OF COMMERCE

WASHINGTON, D.C. 20234

7. Contract/Grant No.

8. Type of Report & Period Covered Final

9. SPONSORING ORGANIZATION NAME AND COMPLETE ADDRESS (Street. City. State, ZIP)

National Bureau of Standards U. S. Department of Energy

Department of Commerce and 1000 Independence Ave. , SW

Washington, DC 20234 Washington, DC 20585

10. supplementary NOTES Library Q f Congress Catalog Card Number: 81- 600055

Contains material previously published in the Federal Register as standards in support

of the Residential Conservation Service Program.

' ~| Document describes a computer program; SF-185, FIPS Software Summary, is attached.

11. ABSTRACT (A 200-word or less factual summary of most si gnificant information. If document includes a significant

bibliography or literature survey, mention it here) \ Standard installation practices were developed to assist in assuring the. effectiveness

and safety of energy conservation measures installed under the Residential Conservation Service (RCS) . They serve as mandatory standards under RCS but are recommended

guides for all installations of the covered materials and products. The criteria are being used by DoE to develop training manuals for installers, inspectors, and energy

auditors

.

Part I provides information on the intended use of the practices, outlines the RCS

program, and discusses specific major technical and related issues that were

considered in the development of the standards: moisture and building retrofit, attic

ventilation, electrical wiring, recessed and surface-mounted fixtures, the use of

diagnostic tools (infrared thermography, air change rate, and window air leakage

measurements) , and product certification.

Part II provides the actual practices together with commentary and additional recommen- dations. The products covered are loose-fill, batts and blankets, rigid foam boards,

UF foam and reflective insulations, window devices, caulks and sealants, water heater

insulation, oil burner replacements, and vent dampers.

12. KEY WORDS (Six to twelve entries; alphabetical order; capitalize only proper names; and separate key words by semicolons)

automatic ignition devices; caulks; effectiveness; energy conservation; energy conser- vation measures; installation; insulation; oil burners; practices; safety; sealants;

standards; storm doors; storm windows; vent dampers; water heaters; windows.

13. AVAILABILITY

Unlimited

[ | For Official Distribution. Do Not Release to NTIS

}fv] Order From Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Order From National Technical Information Service (NTIS), Springfield, VA. 22161

14. NO. OF

PRINTED PAGES

203

15. Price

$6.

USCOMM-DC 6043-P80

*U S GOVERNMENT PRINTING OFFICE: 1981 349^345/8527

NBS TECHNICAL PUBLICATIONS

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JOURNAL OF RESEARCH—The Journal of Research of the National Bureau of Standards reports NBS research and develop- ment in those disciplines of the physical and engineering sciences in which the Bureau is active. These include physics, chemistry,

engineering, mathematics, and computer sciences. Papers cover a broad range of subjects, with major emphasis on measurement

methodology and the basic technology underlying standardization. Also included from time to time are survey articles on topics

closely related to the Bureau's technical and scientific programs. As a special service to subscribers each issue contains complete

citations to all recent Bureau publications in both NBS and non- NBS media. Issued six times a year. Annual subscription: domestic

$13: foreign $16.25. Single copy. $3 domestic; $3.75 foreign. NOTE: The Journal was formerly published in two sections: Section A "Physics and Chemistry" and Section B "Mathematical

Sciences." DIMENSIONS/NBS—This monthly magazine is published to in- form scientists, engineers, business and industry leaders, teachers, students, and consumers of the latest advances in science and

technology, with primary emphasis on work at NBS. The magazine

highlights and reviews such issues as energy research, fire protection, building technology, metric conversion, pollution abatement,

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standards and techniques, properties of matter and materials, engineering standards and services, instrumentation, and

automatic data processing. Annual subscription: domestic $11;

foreign $13.75. NOIMPERIODICALS

Monographs—Major contributions to the technical literature on

various subjects related to the Bureau's scientific and technical activities. Handbooks—Recommended codes of engineering and industrial practice (including safety codes) developed in cooperation with in- terested industries, professional organizations, and regulatory

bodies. Special Publications—Include proceedings of conferences sponsored by NBS, NBS annual reports, and other special publications

appropriate to this grouping such as wall charts, pocket cards, and

bibliographies.

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studies of special interest to physicists, engineers, chemists,

biologists, mathematicians, computer programmers, and others engaged in scientific and technical work.

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the authority of the National Standard Data Act (Public Law

90-396).

NOTE: The principal publication outlet for the foregoing data is the Journal of Physical and Chemical Reference Data (JPCRD)

published quarterly for NBS by the American Chemical Society

(ACS) and the American Institute of Physics (AIP). Subscriptions,

reprints, and supplements available from ACS, 1 155 Sixteenth St., NW, Washington, DC 20056.

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test methods, and performance criteria related to the structural and

environmental functions and the durability and safety characteristics of building elements and systems.

Technical Notes—Studies or reports which are complete in themselves but restrictive in their treatment of a subject. Analogous to monographs but not so comprehensive in scope or definitive in treatment of the subject area. Often serve as a vehicle for final reports of work performed at NBS under the sponsorship of other government agencies.

Voluntary Product Standards—Developed under procedures

published by the Department of Commerce in Part 10, Title 15, of

the Code of Federal Regulations. The standards establish nationally recognized requirements for products, and provide all concerned interests with a basis for common understanding of the

characteristics of the products. NBS administers this program as a supplement to the activities of the private sector standardizing

organizations. Consumer Information Series—Practical information, based on NBS research and experience, covering areas of interest to the con- sumer. Easily understandable language and illustrations provide

useful background knowledge for shopping in today's tech- nological marketplace. Order the above NBS publications from: Superintendent oj Documents. Government Printing Office, Washington. DC 20402. Order the following NBS publications—FIPS and NBSlR's—from

the National Technical Information Services. Springfield. VA 22161

.

Federal Information Processing Standards Publications (FIPS

PUB)—Publications in this series collectively constitute the Federal Information Processing Standards Register. The Register

serves as the official source of information in the Federal Govern- ment regarding standards issued by NBS pursuant to the Federal Property and Administrative Services Act of 1949 as amended.

Public Law 89-306 (79 Stat. 1127), and as implemented by Executive Order 11717 (38 FR 12315, dated May 11, 1973) and Part 6 of Title 15 CFR (Code of Federal Regulations).

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(both government and non-government). In general, initial dis- tribution is handled by the sponsor; public distribution is by the National Technical Information Services, Springfield, VA 22161,

in paper copy or microfiche form.
U.S. DEPARTMENT OF COMMERCE

National Bureau of Standards

Washington,

D C. 20234

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