Collision Course with Condensation

Dripping water, water stained ceilings and that unsightly puddle on the floor, they’re all tell tale signs of unchecked condensation. It’s that time of the year again, the summer months bring higher temperatures and humidity with it. When this warm air collides with cold equipment, water condenses and any accumulation can wreak havoc within buildings and facilities.

How does condensation occur?

Condensation occurs when water vapour in the air condenses on a surface. You may hear the term ‘dew point’ when discussing condensation. The dew point for a particular space is the temperature at which air is saturated with water. Any drop in temperature from this point will cause water vapour to condense. For example, when warm air comes in contact with a cold object, one that is below the dew point of the air, the water vapour condenses to form liquid water on the surface of the object. For our discussion these objects are most likely cold pipes, ducts or mechanical equipment (ie. Circulator Pump).

You’ve spotted the signs, they’re obvious and unsightly. What’s next?

• Check for leaks

• Check for possible overflow from equipment

• Has there been recent repairs or modifications to cold systems?

• Are cold systems insulated?

• Is insulation installed correctly (continuous vapour barrier in place with no air gaps?)

Be sure to find out whether the water accumulation is due to condensation and not a leak or overflow from other equipment. Has the system pressure declined? That can be an easy determinate of a leak. Otherwise it might be best to have a professional assess the source of the water. In most cases it’s easy to see that the ‘sweating’ equipment is a condensation issue. Alternatively, call an insulation or mechanical contractor. If you’re a prospective client, an initial assessment accompanied with a solution and/or quote will most likely come at no cost.

Where can condensation be an issue?

Condensation can occur on any cold surface. If these surfaces are insulated properly condensation rarely becomes an issue. Most commonly I’ve seen it cause problems with chilled water, domestic cold water or cold air ductwork and equipment. In most cases this cold equipment has not been insulated adequately or it is missing insulation partially or entirely. Unfortunately, mechanical insulation is too often disregarded or simply overlooked.

Common causes for condensation

• Cold equipment is exposed to air and not insulated at all

• Cold equipment is only partially insulated or associated fixtures are left exposed

• Insulation has been cut or torn for a repair or material testing

• Damage to insulation from high traffic areas

• Vapour barrier on insulation system isn't continuous or sealed properly

• Insulation thickness is not sufficient

Insulating newly repaired or replaced fittings and valves for cold systems is paramount for condensation control. When the equipment lies in plain view, in a mechanical room for instance, it is easy to spot the culprit. However, if equipment isn’t insulated properly and its located in a concealed location, you’ll most likely only find out after there is a problem. Out of sight, out of mind isn’t the recipe to follow.

Will condensation cause rust? Can condensation cause mold?

Outside of ugly water stains and possible slip hazards, condensation can cause other issues. Mold is a fungus which needs moisture to thrive. Mold and mold spores can be found in many environments and the humidity and temperature present in buildings are perfect to facilitate its growth. Condensation provides a key growth factor for mold if left unchecked.

Rust is corrosion. Essentially, Iron oxidizes in the presence of water and oxygen. Oxygen combines with metal and water is the catalyst. This corrosion can destroy equipment.

On top of these major issues, condensation can damage building materials, merchandise or equipment. Also, if moisture penetrates an insulation system, thermal conductivity increases, effectively destroying the insulation value.

The Solution: Insulation for condensation control

The best time to insulate these cold systems is before condensation can become an issue. That being said when looking ahead to the summer months, make note of recent system repairs or modifications. Double check to make sure these systems are insulated properly as this will eliminate the chance of condensation. Anytime you are hiring a mechanical contractor or you are the mechanical contractor be sure to account for insulation when modifying, repairing or replacing mechanical equipment.

A properly installed insulation system needs to be a priority, especially with cold systems. Otherwise, the solution being provided by a system repair or modification could end up causing more problems than were initially present.

If a condensation issue arises and it needs to be corrected immediately to prevent further damage, consider shutting down the system or isolating the problem area so the equipment can dry out. Insulation should be applied over dry equipment to prevent corrosion under insulation. If that is not possible consider temporarily insulating the system until it is. If the former actions are not possible, make sure the contractor dries the equipment as thoroughly as possible before applying insulation.

Choose insulation materials suited for cold system applications and utilize materials and jackets that inhibit mold growth. For example, elastomeric insulation is a great option for cold system insulation (-57 C - 105 C) and pvc jacketing aids against moisture permeability and can inhibit mold growth.

Whether looking ahead to warmer temperatures or they’re already here and the problem is literally hitting you in the head, properly insulated equipment is crucial for condensation control. Insulation should always be a priority for any mechanical system but if condensation in particular is a key issue make sure cold systems are insulated sufficiently. Hire contractors who specialize in condensation control and take pride in their work or hire mechanical companies who take these issues into consideration. Consider the various insulation materials and jackets and choose which ones best suit your budget and your needs.

Let’s keep those mechanical systems neat and clean, dry and problem free. The only place you want to see condensation at this time of the year is on the side of a cold drink.

Darren Sloane, All Temperature Thermal Insulations Ltd.