CI/SfB

May 2002

F I R E S A F E

(5-)

Km1

(K2)

Firesafe application type

Fire

Construction type

Ductwork

I N S U L A T I O N

Conlit Ductwork System

Single layer fire protection for rectangular, circular and oval ducts

Specied with condence

Installed quickly, simply and reliably

Advantages
Fully certified to BS 47624 (duct types A and B)
1/2, 1, 11/2 and 2 hour fire protection for
stability, integrity and insulation
Choice of fixing options
Single layer, enabling verification of system
installation
Space efficient, non-brittle, strong and safe
Multi-role insulation: fire protection, acoustic
and thermal

Contents System options 2 Standards and regulations 2 Circular and oval ducts 3 Product properties 4
Fire protection thicknesses 4 Hangers, bearers and flanges 4 Ancillaries and fixings 5 Wall penetrations 6
Two and three-sided applications and elbows 6 Access hatches 6 Criteria for ductwork 7 Typical specification clauses 8

2 conlit ductwork fire protection

Conlit Ductwork System

overview and standards
System description
Manufactured from Rockwool mineral wool, Conlit Ductwork
products provide fire protection and thermal and acoustic
insulation for circular and rectangular steel ductwork.
The simplicity and flexibility of fixing options ensure rapid
and reliable installation to both vertical and horizontal duct
systems.

System options-rectangular ducts

Mitre-joint fixing methods
The use of mitre-joints at slab corners allows installation in situations where welding
may not be practicable.
Nails are generally spaced at 500 mm maximum centres (see page 5).
See Fire resistance table on page 4 for limitations on duct sizes.

Three products are available in the Conlit Ductwork range:Conlit Ductwork Slab for rectangular ducts (orange panel
opposite).
Conlit Ductwork Section for circular ducts between 17 mm
and 610 mm diameter (page 3, opposite).
Conlit Ductwork PSM for circular ducts greater than 406 mm
diameter (page 3, opposite)
All three Conlit Ductwork products are supplied faced on
one side with reinforced aluminium foil.
Full product descriptions and available sizes are given on
page 4.

The requirements for ductwork fire protection

Three performance criteria; stability, integrity and
insulation, are required in equal measure for all ducts
which pass through fire-rated walls or floors.
BS 5588 9, Clause 6.2.5.3 requires that, for fire-resisting
ductwork:
The fire resistance of the ductwork, when tested from either side,
should not be less than the fire resistance required for the elements
of construction in the area through which it passes
BS 476 24, Clause 9.1 states that:
The fire resistance of test specimens shall be the duration in
minutes, of heating in accordance with 5.1.1 until failure occurs
according to one or more of the performance criteria, ie, stability,
insulation, integrity, or until the test is terminated, whichever
is the shortest time

Conlit Ductwork System test data

The Rockwool Conlit Ductwork System has been tested and
assessed by BRE LPC in accordance with BS 476 24, Fire
tests on building materials and structures Methods for
determination of the fire resistance of ventilation ducts.
The Conlit Ductwork System can be used to provide fire
protection to horizontal, vertical, rectangular, circular,
ventilation and smoke extract steel ductwork fully in
accordance with BS 476 24, ducts Type A and Type B,
Fire break out and Fire break in.
The 1/2, 1, 11/2, and 2 hour periods of fire resistance stated in
this manual are for stability, integrity and insulation in
equal measure. For example, the 60 minutes duct
constructions shown are certified for 60 mins stability,
60 mins integrity and 60 mins insulation .

Kitchen extract ducts

These are subject to separate BS 47624 requirements, and are
additionally covered for 1/2 and 1 hour protection periods.

Mitre-joint method
All joints bonded with Conlit
Glue. Longitudinal corner
joints secured with nails
while Conlit Glue cures.

rockwool firesafe insulation 3

Figure 1 Conlit
Ductwork Section
applied to circular
duct

Welded pin fixing methods

5

Attachment by welded pins allows extremely rapid installation with slab joints simply
butted together.
4

Welded pins are generally spaced at 350 mm maximum centres along the length of the duct
and at at 500 mm maximum centres across the width and depth of the duct. Pins are
required on all four sides of vertical ducts, but may be omitted from the top face of
horizontal ducts (see page 5).

Welded pin method 1

Longitudinal corner joints
fixed with pigtail screws at
250 mm maximum centres
(screw length to be 2 slab
thickness). Side wall slabs
must overlap top and bottom
slabs (as shown). Cross joints
bonded with Conlit Glue.
Welded pin method 2
All joints bonded with
Conlit Glue. Slabs may
overlap in either direction.

Welded pin method 3

Longitudinal corner joints
fixed with pigtail screws at
250 mm maximum centres
(screw length to be 2 slab
thickness). Side wall slabs
must overlap top and bottom
slabs (as shown). Cross joints
protected with centrally
positioned 100 mm wide
Conlit cover strips. Strips
fixed with pigtail screws at
250 mm maximum centres
along both long edges.

Notes to Figures 1 and 2

1 Circular steel duct to DW/144
2 Conlit Ductwork Section/
Conlit Ductwork PSM
3 M10 steel drop rods at 1500
mm maximum centres
4 Conlit Ductwork Slab/Section
protection to hanger system
5 30 30 3 mm minimum
steel angle bearer

Figure 2 Conlit Ductwork PSM

applied to circular duct

Conlit Ductwork Section

Circular steel ducts of between 17 mm and 610 mm
diameter may be protected using Conlit Ductwork Section.
Conlit Ductwork Section must be glued with Conlit Glue at
the joints and in the grooves. Steel bands or wires must be
fitted circumferentially to the system at 300 mm nominal
centres to hold all joints and grooves tightly closed while the
glue cures.
Where required, cover strips and bearer protection pieces are
to be cut from Conlit Ductwork Section (or Ductwork PSM) of
the appropriate diameter. The foil covering is to be removed
from the area of Conlit Ductwork Section immediately
beneath the cover strips prior to gluing into position and
securing with steel nails or pins.
Self adhesive aluminium foil tape may be used to seal the
joints where a vapour barrier is required.
The hanger system is as described on page 7, with the angle
bearer formed into a circular shape to suit the diameter of the
duct or the Conlit Ductwork Section (depending on whether
the hanger is located inside or outside the protection).
Conlit Ductwork Section is used to protect the drop rods as
described on page 7. General installation principles are as
otherwise described in this manual for Conlit Ductwork Slab.

Conlit Ductwork PSM

Circular steel ducts of 406 mm and greater diameter may
also be protected using Conlit Ductwork PSM.
Conlit Ductwork PSM must be glued at the joints and in the
grooves with Conlit Glue. Steel bands or wires must be fitted
circumferentially to the system at 300 mm nominal centres to
hold all joints and grooves tightly closed while the glue cures.
General duct, hanger and installation details are as
described for Conlit Ductwork Section.

4 conlit ductwork fire protection

Product properties and fire resistance data

Product descriptions

Fire resistance

Conlit Ductwork Slab

Performance summary Conlit Ductwork Slab, Section and PSM

Size: 1200 1800 mm

Thicknesses: 25, 30, 40, 50, 70, 90 mm
Facing: reinforced aluminium foil
Surface spread of flame: Class 1 to BS 4767
Non-combustibility: ISO 1182
Thermal conductivity: 0.035 W/mK at 10C

Fire
resistance
(hours)

Duct
type

Required
Conlit
thickness
(mm)

Joint
options
(see Fig. 3
below)

1/2

Vertical
Horizontal
Kitchen extract

25
25
40

C
C
BC

30
30
30

17 30
17 30
17 30

1000 1000
1000 1000
1500 1500

Vertical
Horizontal
Kitchen extract

30
40
90

C
BC
ABC

40
40
40

17 40
17 40
17 40

1000 1000
1500 1500
1500 1500

1 1/2

Vertical
Horizontal

50
70

BC
ABC

50
50

17 50
17 50

1500 1500
1200 1200

Vertical
Horizontal

70
90

ABC
ABC

60
60

17 60
17 60

1500 1500
1000 1000

Conlit Ductwork Section

Diameters: 17 to 610 mm
Thicknesses: 25 to 90 mm*
Facing: reinforced aluminium foil

Conlit Ductwork PSM

Conlit Ductwork PSM is made of Conlit Ductwork Slab with
factory machined grooves to suit specific duct diameters.
Diameters: 406 mm and above
Thicknesses: 40, 50, 70, 90 mm*
Facing: reinforced aluminium foil

Hanger protection
Conlit
Conlit
Ductwork Ductwork
Slab
Section
(mm)
(mm)

Max. duct size for mitre-joint,

glued system (mm)

* Some thicknesses of Conlit Ductwork Section and Ductwork PSM are

not available for certain duct diameters.

Protection of bearers by Conlit Ductwork Slab,

Ductwork PSM or Ductwork Section

40 mm min
Thickness

Thickness

Thickness

Thickness

Thickness

90 mm max
40 mm min.

40 mm min

40 mm min.

Figure 3 Joint Option A Rebated protection

Joint Option B Protection using T section

Joint Option C Protection using block cover strip

Hangers, bearers and flanges

Installation methods
The Rockwool Conlit Ductwork System is approved to provide
fire protection to steel ductwork, wholly constructed using
steel fixings in accordance with current HVCA specification
DW/144 and superseded specification DW/142.
Where there are constructional options within DW/144 and
DW/142, these are expanded upon below. These details are
primarily concerned with duct joint types and the
suspension method.
DW/142 flanged cross joint types J3, J4, J5 and J6 are
acceptable for use with the Conlit Ductwork System,
without modification. For joint types J1 and J2, please
contact Rockwool for advice.

Dimensions
Item

Duct size (mm)

Up to
Up to
Up to
1500 1500 2000 2000 3000 3000*

Maximum
hanger centres (mm)

1500

1500

1500

Minimum drop
rod size

M10

M10

M12

30 30 3

50 50 5

50 50 6

Minimum
angle bearer (mm)

* DW/144 and DW/142 do not specifically cover ducts larger than 3 m

wide. Please contact Rockwool for details.

Conlit Ductwork Slab, Ductwork Section or Ductwork PSM

may be installed either outside or inside the hanger system.

M10 (min.)
steel drop rod

Bearers will require additional protection only when

positioned outside the Conlit Ductwork layer.

Binding
wire
or
nails as
convenient

Drop rods will normally be protected with Conlit Ductwork

Section or with Conlit Ductwork Slab blocks (see Figure 4).
Alternatively, the support steelwork may be sized so that
separate protection is not required. Design of this
unprotected support method is independent of the Conlit
Ductwork System.

Protection of hangers outside Conlit Ductwork System

Hangers outside the Conlit Ductwork System are protected
by cutting a rebate into a block of Conlit Ductwork Slab,
Ductwork PSM or Ductwork Section.
The rebate should be no larger than necessary to
accommodate the bearer. The block should be glued and
pinned in position (see Figure 3, Option A) or secured using
pigtail screws.

Conlit
Ductwork Slab

Conlit Ductwork
Section

Figure 4 Isometric view of drop

rod protection options

rockwool firesafe insulation 5

Ancillaries
Welded steel pins
Welded pins are generally spaced at 350 mm maximum
centres along the length of the duct and at 500 mm maximum
centres across the width and depth of the duct. Pins are
required on all four sides of vertical ducts, but may be omitted
from the top face of horizontal ducts (see Figures 5 and 6).

350
Top panel
(no pins necessary
on horizontal ducts)

350
350

Soffit panel
600 mm

Details of alternative mechanically fixed pins are available

from Rockwool on request.

Conlit Glue
Conlit Glue has a pH value of 11. It is provided in 17 kg
drums and should always be stirred before use.

Side panel
1000 mm

350

Where required, 11.5 mm of glue should be applied to each

Conlit joint. The glue is generally applied by spatula or trowel.

50

350

Where present, any foil facing must be removed from

surfaces prior to the application of Conlit Glue.

Nails (for use only with mitre-joint glued systems)

The nail length is to be 2 board thickness (see Figure 7 for
positions).

50
Figure 5 Steel pin arrangement where side panel does not exceed
1000 mm and soffit panel does not exceed 600 mm
350

Top panel
(no pins necessary
on horizontal ducts)

350

Pigtail screws

350
350

Pigtail screws are to be used at all corner joints where

Conlit Glue is not used, and to secure cross joint cover strips.

350

Soffit panel
> 600 mm

500

Side panel
>1000 mm.

500

500

Pigtail screws are to be positioned at 250 mm maximum

centres, and the screw length is to be 2 slab thickness.

350
350
500
50

For horizontal ducts, pigtail screws must be inserted

horizontally, as shown on pages 2 and 3.

350
500

350
500
50

Optional edge protection

Light gauge metal angles may be glued in position to
provide optional edge protection. The metal angles must be
de-greased. Small pins may be required to hold the angle to
the underside of the duct.

Figure 6 Steel pin arrangement where side panel is greater than

1000 mm or soffit panel is greater than 600 mm

Optional edge protection

Vapour barrier
Where a vapour barrier is required, all exposed Conlit edges
and penetrations through the foil must be sealed using
aluminium foil tape.

Nails

II

1200
Board 'length'
Glue

III

500

II

100

500
100

=
1800
100
Board 'length'
Figure 7 Rectangular ducts 45 mitre joint system,
showing installation sequence

6 conlit ductwork fire protection

Wall penetrations, elbows, 2 and 3-sided applications

and access hatches
120 mm

Wall and floor penetrations

Low density Rockwool insulation

(typically RW2)

Support to duct sides is required at all penetrations for

stability purposes. This support can be provided by:
a a 30 30 2 mm mild steel angle frame fixed to the duct
at the penetration mid point. Steel rivets should be used
at 300 mm maximum centres (Figure 8),
b locating the duct joint at the penetration mid point.
In all cases, low density Rockwool (typically RW2) is packed
tightly into the void between the Conlit and the wall
opening.

Aluminium foil

Duct wall

Figure 8 Steel angle frame support to duct at penetration mid point

120 mm wide blocks of Conlit are glued (or secured with

pigtail screws) to the duct insulation and to the wall on both
sides of the penetration.
All Conlit to wall joints are glued. Aluminium foil is located
in Conlit joints at wall penetrations (as shown).

Proprietary penetration seals

Where proprietary penetration seals are used, compatibility
with the separating element, duct construction and Conlit
Ductwork System must be demonstrated by independent
test or assessment.

Figure 9 Typical elbow detail for rectangular ducts

Elbows (rectangular ducts)

100 mm min

100 mm min

Small elbows may simply be boxed or squared off. Larger

elbows may need to be protected by cutting fan shaped pieces,
generally in accordance with the illustration (Figure 9).

Two and three-sided applications

(rectangular ducts)
The use of Conlit Ductwork Systems incorporating welded
pins is recommended for 2 and 3-sided applications.
The method illustrated (Figure 10) for three-sided applications,
may also be used for two-sided applications where the duct is
securely braced in the corner of a room.

Access hatches (rectangular ducts)

Steel access hatches which are constructed and fitted in
accordance with DW144 may be protected with Conlit
Ductwork Slab (figure 11).
The Conlit cover may be fitted in any face of the duct.
However, if the sliding cover is not in the horizontal plane
the guides must be positioned so as to prevent movement of
the cover due to weight, vibration etc.

Conlit strip

Welded
pins

Welded
pins

Welded pins
Figure 10 Three sided protection for rectangular ducts, using welded
pin fixing method
Opening in Conlit Ductwork Slab
to accommodate DW144 closed access
panel (or similar) max opening 900 900 mm

1.5 thickness (min)

Conlit Ductwork Slab guides

(guide required on third side
for openings larger than 500 500 mm)

Conlit Ductwork Slab thickness as

appropriate to fire protection required,
tight fit in guides

1.5 thickness (min)

The sliding cover must be a tight fit in the guides. No part

of the arrangement may be within 50 mm of edges or joints
within the main duct protection layer of Conlit Ductwork
Slab.
All Conlit Ductwork Slab joints (excluding sliding joints) are
to be glued and pinned as previously detailed.

thickness
thickness
1.5 thickness (min)

1.3 thickness (min)

thickness

Access hatches (circular ducts)

Details of access hatches for circular ducts are available on
request.

Figure 11 Removable cover panel for steel access hatch

Light gauge steel formed into

channel 'runners' (thickness
typically 0.5 mm, 1.0 mm max)

rockwool firesafe insulation 7

Criteria for preparation of ductwork prior to insulation

The Conlit Ductwork System is certified to provide fire protection to ductwork conforming to Construction Details 1 to 12 in the table below
and to the requirements of HVCA Specification DW/144. The table may be used as a check list for on-site verification of ductwork construction.
Project reference
Job location

1
2
3
3a

Construction detail

Requirement

Duct sheeting
Sheet thickness
Maximum duct size
Welded pin fixing
methods

Rigid steel (zinc-coated, alu-zinc coated, black or stainless).

0.8 mm or greater. See DW/144 for ducts larger than 1500 mm.

Within
Details of modification
specification? where needed

Up to 1500 mm 1500 mm: no additional system modifications.

Up to 2000 mm 2000 mm: increase angle bearer size to 50 50 5 mm min.
Up to 3000 mm 3000 mm: increase angle bearer size to 50 50 6 mm min.
Increase drop rod diameter to M12 min.
Up to 4000 mm 4000 mm: 50 50 6 mm min. bearer. M12 min. drop rod.
Incorporate additional drop rod mid-width through duct and bearer*.
Weld (or fasten with with nuts and large washers) M15 min. strengthening rod.
at mid-width of each flanged joint and penetration point to maintain cross section.
Seal all holes with mastic.
Above 4000 mm 4000 mm: 50 50 6 mm bearer. M12 min. drop rod.
Incorporate additional drop rods through duct and bearer to ensure 2000 mm max.
spacing along bearer*. Weld (or fasten with nuts and large washers) M15 min.
strengthening rod at each flanged joint and penetration point to ensure 2000 mm
max. spacing along joint. Seal all holes with mastic.
*Additional drop rods to pass through duct and bearer. Rods to support bearer.
Top of duct to be held in position with steel nuts and large steel washers.

3b

4
5
6
7
8
9

Mitre-joint fixing
methods
1/2 hr vertical duct
1/2 hr horizontal duct
1/2 hr kitchen extract
1 hr vertical duct
1 hr horizontal duct
1 hr kitchen extract
11/2 hr vertical duct
11/2 hr horizontal duct
2 hr vertical duct
2 hr horizontal duct
Flanged cross joint
Joint seal
Constructional fixings
Bearers
Drop rods
Drop rod anchors
Fixed through steel
suspension frame
Fixed into concrete

Spacing of
suspension system
10a Horizontal ducts
10b Vertical ducts: 2 or 3
sided protection
10c Vertical ducts: 4 sided
protection
11 Stiffening of duct at
penetration detail

1000 mm 1000 mm
1000 mm 1000 mm
1500 mm 1500 mm
1000 mm 1000 mm
1500 mm 1500 mm
1500 mm 1500 mm
1500 mm 1500 mm
1200 mm 1200 mm
1500 mm 1500 mm
1000 mm 1000 mm
Type J3, J4, J5 or J6 to HVCA specification DW/142.
May be included or omitted.
Steel
30 30 3 mm (min.) steel angle. See item 3a for ducts larger than 1500 mm.
M10 (min.) mild steel. See item 3a for ducts larger than 2000 mm.

If duct dimensions exceed those

shown, use welded steel pins as per
Conlit Ductwork System manual (see
item 3a.)

Strengthen joints (contact Rockwool)

Steel frame to be independently fire rated.

Fire protect steelwork.

Anchors to have confirmed fire rating.

If fire rating is unconfirmed and

anchor is all-steel, ie without plastic or
chemical components; affix 300 mm
300 mm collar of unfaced Conlit
Ductwork Slab to soffit with Conlit
Glue, keeping anchor central. Collar
thickness to equal duct encasement
layer. Optional self-tapping screws may
be used to support collar. Glue adjacent
Conlit drop rod protection to collar.

10

12

Compartment wall

1500 mm max centres.

Install additional supports
1500 mm max centres.
Support at every floor (4 m max centres)
Duct flange or
30 30 3 mm steel angle frame fixed with steel fixings at 300 mm max. centres.
To be positioned within the width of the penetration.
See item 3a for ducts larger than 3000 mm.
Fire rated masonry, concrete, brick, block, plasterboard or other fire rated
construction.

Install steel angle frame.

Typical specification clauses

Typical specification clauses for rectangular ducts
to be read in conjunction with System options on pages 23

Mitre-joint fixing method

Welded pin fixing method 1

1 All ductwork is to be insulated with ..........* mm Rockwool

Conlit Ductwork Slab, having a factory applied reinforced
aluminium foil to one face and complying with Building
Regulations Class O requirements.
2 The Conlit joints at ductwork corners are to be 45
mitred. Square butt joints to be used elsewhere.
3 The foil facing is to be removed from any surfaces to
which Conlit Glue is to be applied.
4 All joints are to be filled with Conlit Glue and held tightly
closed.
5 All mitred joints are to be held tightly closed with nails
(length = approx. 2 Conlit Ductwork Slab thickness)
until the glue has fully cured. 2 nails juxtaposed at 90
are to be located at 3 points per 1200 mm length of mitred
joint and at 4 points per 1800 mm length.
6 Drop rods and bearers are to be at 1500 mm maximum
centres and to be M10 steel rod and 30 30 3 mm steel
angle respectively. Ductwork is to be generally in
accordance with HVCA Specification DW/144.
7 All drop rods and exposed bearers are to be insulated with
..........* mm Conlit Ductwork Slab or .......... ..........* mm
Conlit Ductwork Section, as appropriate. Rebates or cover
pieces are to be used at duct flange and bearer locations
according to site conditions and subject to Rockwool
approval.
8 Where a vapour barrier is required, all exposed Conlit
edges and penetrations through the foil should be sealed
using soft self-adhesive aluminium foil tape.

1 All ductwork is to be insulated with ..........* mm Rockwool

Conlit Ductwork Slab, having a factory applied reinforced
aluminium foil to one face and complying with Building
Regulations Class O requirements.
2 The Conlit Ductwork Slab is to be affixed to the duct
using 2.5 mm diameter welded steel pins and 38 mm
spring steel washers in accordance with the Rockwool
manual Conlit Ductwork System.
3 The foil facing is to be removed from any surfaces to
which Conlit Glue is to be applied.
4 All corner joints are to be fixed with pigtail screws at
250 mm maximum centres. Screw length is to be 2 slab
thickness.
5 All cross joints are to be filled with Conlit Glue and held
tightly closed.
6 Drop rods and bearers are to be at 1500 mm maximum
centres and to be M10 steel rod and 30 30 3 mm steel
angle respectively. Ductwork is to be generally in
accordance with HVCA Specification DW/144.
7 Drop rods and exposed bearers are to be insulated with
..........* mm Conlit Ductwork Slab or .......... ..........* mm
Conlit Ductwork Section, as appropriate. Rebates or cover
pieces are to be used at duct flange and bearer locations
according to site conditions and subject to Rockwool
approval.
8 Where a vapour barrier is required, all exposed Conlit
edges and penetrations through the foil should be sealed
using soft self-adhesive aluminium foil tape.

Welded pin fixing method 2

Delete clauses 3 and 5 in Method 1 above, and insert new
clause 5:
5 All joints are to be filled with Conlit Glue and held tightly
closed. If necessary, nails may be used at corner joints to
aid this process.

Welded pin fixing method 3

Delete clauses 3 and 5 in Method 1 above, and insert new
clause 5 :
5 All cross joints are to be covered with centrally positioned
100 mm wide strips of Conlit Ductwork Slab of the same
thickness as the insulation. The cover strips are to be fixed
along both edges using pigtail screws, as described above.
* Insert Conlit Ductwork Slab insulation thickness required.
Insert appropriate overall diameter.

Rockwool Limited reserves the right

to alter or amend the specification of
products without notice as our policy
is one of constant improvement.
The information contained in this
data sheet is believed to be correct
at the date of publication. Whilst
Rockwool will endeavour to keep its
publications up to date, readers will
appreciate that between publications
there may be pertinent changes in the
law, or other developments affecting
the accuracy of the information
contained in this data sheet.
The above applications do not
necessarily represent an exhaustive
list of applications for Conlit
Ductwork Systems. Rockwool Limited
does not accept responsibility for the
consequences of using Conlit
Ductwork Systems in applications

Sitework, health and safety

different from those described above.

Expert advice should be sought where

Sitework

Technical Helpline

such different applications are

Handling

Technical advice is available from the Rockwool Industrial

Helpline on 01656 868130.

any listed application is in doubt.

The Conlit Ductwork range of products is light and easy to

handle and fix. The products can be cut and shaped using
knives, saws, etc.

contemplated, or where the extent of

F I R E S A F E

I N S U L A T I O N

Health and safety

Rockwool Limited
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