5 Most Common Thermal Insulation Materials - Thermaxx Jackets

Fiberglass is the most common insulation used in modern times. Because of how it is made, by effectively weaving fine strands of glass into an insulation material, fiberglass is able to minimize heat transfer. The main downside of fiberglass is the danger of handling it. Since fiberglass is made out of finely woven silicon, glass powder and tiny shards of glass are formed. These can cause damage to the eyes, lungs, and even skin if the proper safety equipment isn’t worn. Nevertheless, when the proper safety equipment is used, fiberglass installation can be performed without incident.

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Fiberglass is an excellent non-flammable insulation material, with R-values ranging from R-2.9 to R-3.8 per inch. If you are seeking a cheap insulation this is definitely the way to go, though installing it requires safety precautions. Be sure to use eye protection, masks, and gloves when handling this product.

2. Mineral Wool

Mineral wool actually refers to several different types of insulation. First, it may refer to glass wool which is fiberglass manufactured from recycled glass. Second, it may refer to rock wool which is a type of insulation made from basalt. Finally, it may refer to slag wool which is produced from the slag from steel mills. The majority of mineral wool in the United States is actually slag wool.

Mineral wool can be purchased in batts or as a loose material. Most mineral wool does not have additives to make it fire resistant. However, it is a non-combustible material, so can prevent the spread of fires up to 1,400 degrees Fahrenheit, but may not always be the best option when extreme heat is present. Mineral wool has an R-value ranging from R-2.8 to R-3.5.

3. Cellulose

Cellulose insulation is perhaps one of the most eco-friendly forms of insulation. Cellulose is made from recycled cardboard, paper, and other similar materials and comes in loose form. Cellulose has an R-value between R-3.1 and R-3.7. Some recent studies on cellulose have shown that it might be an excellent product for use in minimizing fire damage. Because of the compactness of the material, cellulose contains next to no oxygen within it. Without oxygen within the material, this helps to minimize the amount of damage that a fire can cause.

So not only is cellulose perhaps one of the most eco-friendly forms of insulation, but it is also one of the most fire resistant forms of insulation. However, there are certain downsides to this material as well, such as the allergies that some people may have to newspaper dust. Also, finding individuals skilled in using this type of insulation is relatively hard compared to, say, fiberglass. Still, cellulose is a cheap and effective means of insulating.

4. Polyurethane Foam

While not the most abundant of insulations, polyurethane foams are an excellent form of insulation. Nowadays, polyurethane foams use non-chlorofluorocarbon (CFC) gas for use as a blowing agent. This helps to decrease the amount of damage to the ozone layer. They are relatively light, weighing approximately two pounds per cubic foot (2 lb/ft^3). They have an R-value of approximately R-6.3 per inch of thickness. There are also low density foams that can be sprayed into areas that have no insulation. These types of polyurethane insulation tend to have approximately R-3.6 rating per inch of thickness. Another advantage of this type of insulation is that it is fire resistant.

5. Polystyrene

Polystyrene is a waterproof thermoplastic foam which is an excellent sound and temperature insulation material. It comes in two types, expanded (EPS) and extruded (XEPS) also known as Styrofoam. The two types differ in performance ratings and cost. The more costly XEPS has a R-value of R-5.5 while EPS is R-4. Polystyrene insulation has a uniquely smooth surface which no other type of insulation possesses.

Typically the foam is created or cut into blocks, ideal for wall insulation. The foam is flammable and needs to be coated in a fireproofing chemical called Hexabromocyclododecane (HBCD). HBCD has been brought under fire recently for health and environmental risks associated with its use.

Other Common Insulation Materials

Although the items listed above are the most common insulation materials, they are not the only ones used. Recently, materials like aerogel (used by NASA for the construction of heat resistant tiles, capable of withstanding heat up to approximately degrees Fahrenheit with little or no heat transfer), have become affordable and available.  One in particular is Pyrogel XT. Pyrogel is one of the most efficient industrial insulations in the world. Its required thicknesses are 50% – 80% less than other insulation materials. Although a little more expensive than some of the other insulation materials, Pyrogel is being used more and more for specific applications. Other materials used can be ceramic fiber, flexible closed cell sheet insulation and mass loaded vinyl.

Best Thermal Insulation Material for Steam Pipes

The best material for steam pipe insulation is the type you can remove to perform regular inspections. While fiberglass has been a popular choice in the past, it cannot be taken off to allow for inspections, which means it’s no longer the best material for steam pipes.

A Thermaxx insulation jacket is an ideal option for steam pipe insulation. These jackets are easily installed and removed when necessary without requiring specialized skills, and the insulation types used are determined by your specific requirements. We offer Thermaxx jackets in numerous normal pipe sizes, ranging from 2 to 24 inches. Our jackets are designed have a touch temperature of 120 degrees or less to reduce energy loss and be more skin-friendly.

Finally, our jackets are the best for steam pipe insulation because they are customizable. If you have a pipe that is larger than a standard size, oddly-shaped or otherwise non-standard, we can design and manufacture one specific for your system. Our jackets help to keep moisture out, improving the lifetime of the insulation and underlying pipes, resulting in increased cost-effectiveness.

Mineral Wool vs. Fiberglass

Mineral wool and fiberglass are two common types of thermal insulation. Mineral wool is made from steel slag and basalt, making it more eco-friendly than other insulation types. A manufacturer makes it by spinning molten rock quickly while blowing cool air on it. Characteristics of mineral wool insulation include the following:

• It is heavier and denser than fiberglass, giving it a higher R-value.
• Mineral wool can be challenging to install and often requires professional assistance.
• It is more resistant to fire, mold, fungus, and moisture than some other materials.
• Mineral wool can often be more expensive.
• It is often more durable than materials like fiberglass.

Fiberglass is made by using fine glass fibers from materials like soda ash, borax, silica sand, and limestone. Check out these fiberglass characteristics:

• It can be more flexible, making it easier to accommodate obstructions.
• It is often easier to install with professional assistance.
• Fiberglass is also highly fire-resistant.

Fiberglass and mineral wool have advantages and disadvantages, making it crucial to weigh all the factors.

Fiberglass vs. Cellulose

Cellulose is another type of pipe insulation. It is made with recycled newspapers, cardboard, and magazines, will not itch during installation and comes in several R-values. Cellulose works as thermal insulation and has a high resistance to mold and mildew. Cellulose also has the benefit of being fire retardant.

Fiberglass offers improved protection against mildew and mold compared to cellulose and has an easier installation process. That said, cellulose has a more in-depth R-value.

Cellulose may settle after installation, which can cause it to lose its R-value. On the other hand, fiberglass is known for retaining its original form and can last longer.

Finally, cellulose is fire retardant like fiberglass, but it can pose other safety risks because it starts turning to dust over time. As a result, the chemicals used to make the cellulose are released into the air and can be harmful.

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Traditional vs. Advanced Pipe Insulation

Traditional steam pipe insulation is often made from fiberglass. You have to use it with an all-service jacket, which is a reinforced paper that is laminated to a layer of lightweight foil. These conventional materials offer some benefits, such as being lightweight and low-cost. However, traditional insulation can present challenges like:

• Increased risk of moisture: Since you have to cut a hole in fiberglass insulation, you have a greater risk of water entering the pipe system, raising the risk of corrosion under insulation (CUI).
• Time-consuming inspections: As mentioned above, you will need to cut into the fiberglass insulation to get to the pipe and perform an inspection. This process is more time-consuming than removing an insulation jacket quickly.
• Decreased performance: Aside from cutting into the fiberglass, which already decreases its performance, the material can also settle or become compacted, reducing the thickness and altering performance.
• Negative environmental impacts: Fiberglass cannot be reused or recycled, unlike a thermal jacket that can be removed.

When we say “advanced pipe insulation,” we are referring to removable thermal jackets. Thermal insulation jackets offer numerous benefits that make them one of the best choices for pipe insulation. Advantages of using our Thermaxx jackets include:

• Lowered energy costs: Thermaxx insulation jackets reduce the cost of energy, allowing them to pay for themselves in as little as a year.
• Easier maintenance and inspection: You can easily remove our thermal jackets to perform routine inspection or maintenance on your pipes.
• Less waste: Unlike other materials that you must cut into and replace when you do inspections, you can simply remove our jackets whenever necessary. Put them back on to reduce overall waste.
• Improved equipment life: Your pipes remain protected beneath Thermaxx insulation jackets, reducing their exposure to weather, elements, and accidental damage, which can prolong their life.
• Better workplace safety: Thermal jackets help improve workplace safety by preventing workers from coming in direct contact with high-temperature pipes.
• Increased corrosion prevention: We offer Thermaxx jackets for wet and dry applications and water drainage solutions, helping prevent CUI.

What to Consider When Choosing Your Pipe Insulation

When choosing pipe insulation, it’s crucial to consider all the factors. Everything from the materials and costs to where you plan to use the insulation play essential roles in the type of insulation you will need for your pipes. Factors to consider include:

• Material: As discussed above, different types of insulation offer unique benefits and disadvantages. Consider which ones would work best for your application. Thermaxx insulation jackets are useful for many applications, making them a top material choice.
• Cost: Cost is another factor to consider. Some materials for pipe insulation have higher initial costs but pay for themselves over time. Others are low-cost installations, which can be useful if you’re on a budget. Finding the right insulation that is the most cost-effective for your operations and budget is the ideal solution.
• Thickness: The thickness of your pipe insulation is something else to consider. Are you insulating pipes indoors or outdoors? Will they be exposed to extreme temperatures or weather? You need pipe insulation that is thick enough for how you intend to use it.
• Measurement: How large are the pipes you need to insulate? This measurement will play a role in how much you need and influences the thickness you need, affecting the materials you can use and their costs.

Insulation is rarely installed as a stand-alone item. Instead, insulation material is part of a system that includes the insulation; the securement; a vapor barrier, in the case of low-temperature applications; and an outer layer that might be referred to as the cover, jacket or lagging.

Each component plays an important part in the overall function of the system. The insulation material itself is the primary barrier to the flow of energy, while the securement holds the insulation in place. The function of the vapor barrier is to prevent the passage of moisture into the insulation. The most multi-functional component in the insulation system is the outer covering, referred to here as the jacket. It has a variety of functions, including protecting the insulation from mechanical damage, providing support, preventing moisture penetration and establishing the system emissivity and appearance. This article will examine the high points of insulation jackets.

To a casual observer, the most obvious characteristic of an insulation system is its appearance. Appearance is dominated by the characteristics of the jacket chosen for the system. In the chemical process industry (CPI), where most insulation is located outside, exposed to the elements, metal is the most commonly used material. For a metal to be useful in this situation, it must first have sufficient corrosion resistance to withstand exposure to both the elements and to the chemicals present in a typical chemical processing environment. Aluminum and stainless steel are the most commonly used jacket materials in the CPI because, among many other desirable characteristics, they have sufficient corrosion resistance to meet a basic low-maintenance, high-durability requirement. Both are available in a range of thickness, finishes and corrugations.

Metal Jackets

Aluminum has many advantages that make it attractive as a jacket material. Its low density and excellent formability allow it to be used in thicker sections that improve its damage resistance and make it more installer friendly. Metal jacketing that is used at low thickness such as 0.010 inch is difficult for the installer to handle because of the risk of injury from sharp edges. Thinner jacket materials are used safely every day; they just require more care than thicker materials.

Aluminum’s formability gives the designer choices in surface finish that include smooth, embossed and corrugated. Each of these serves a specific purpose. A smooth surface is easily cleaned and provides what many consider to be a more attractive appearance. A disadvantage of the smooth finish is its tendency to show imperfections such as mechanical damage to the surface. The rougher appearance of the stucco-embossed finish tends to hide minor imperfections and is often chosen for that reason. The downside of the embossed finish is its greater ability to hold surface contamination.

Another significant option when choosing aluminum is corrugation. Corrugation is available in a variety of sizes and adds stiffness to the jacket material. A concern is that when corrugated metal is used on horizontal surfaces, water collects on the top surface that might subsequently penetrate the jacket or cause corrosion or fouling of the jacket material.

A disadvantage of aluminum is its poor durability when exposed to fire. Because aluminum melts at 660 C, it does not take long for an aluminum jacket that is less than one-sixteenth of an inch thick to lose its integrity. When this happens, the fire has direct access to the underlying insulation material, with potentially disastrous results.

Fire-Resistance

When fire is a concern, the jacket material will often be stainless steel. Stainless steel melts at a much higher temperature and will remain in place much longer than aluminum. This greater durability protects the contents of the insulated asset and prolongs the time of exposure before a pressure relief will occur. This is a significant benefit that can be taken advantage of when designing relief systems. Other jacket materials such as galvanized steel can be used in the same way as stainless steel; however, the zinc coating on galvanized steel will most likely melt in a fire and poses a risk of liquid metal embrittlement to any nearby stainless steel surface. This is one reason that stainless steel is more often specified for fire-resistant installations. Thermoplastic jacket materials such as polyvinyl chloride (PVC) have even less resistance to fire and should never be used on equipment where fire resistance is a consideration.

When metal jacketing first came into common use it was all metal with no liner installed. With time, it was discovered that if the insulation material became wet, the metal jacket would corrode from the inside. This problem was solved by the introduction of the bonded craft paper liner. A continuous paper liner is bonded to the inside surface of the jacket to prevent corrosion of the metal by acting as a barrier between the wet insulation and the vulnerable metal jacket.

Later, the use of thermoplastic sheet material, such as surlyn, replaced the paper. The primary benefit of this approach is the improved water resistance of the surlyn plastic. The paper deteriorates when exposed to water and will eventually no longer provide an effective barrier. Surlyn does not absorb a significant amount of moisture and thus provides more effective protection against corrosion of the jacket.

Stainless steel, both 304 and 316, is readily available, has a clear advantage in corrosion resistance over aluminum and, along with its better fire resistance, is generally chosen instead of aluminum. Aluminum has a cost advantage over stainless so there must be a functional reason to choose stainless instead of aluminum if a metal jacket is to be used. Although stainless is not usually used at a thickness as great as aluminum for weight and cost reasons, it can be. Stainless is also not made with an inner corrosion barrier since it is not typically subject to corrosion caused by wet insulation.

Other Types of Jackets

Metal is not the only material used as insulation jacket; thermoplastics and fabrics are also important jacket materials. There are a wide variety of fabric materials that are used in an equally wide variety of ways. A common application is to combine fabric with a mastic material to create a jacket over a complicated shape. Often this might be a valve or fitting. The advantage of this approach is that it is easier to cover an unusually shaped item than it is with metal. A disadvantage, especially in outdoor applications, is reduced durability when compared to metal jacket. Fabrics are also used to provide the outer surfaces of flexible, removable-reusable insulation. Clearly, without fabric, these would not be possible. The type of fabric specified for these applications depends on the use temperature and the type of environment to which the insulation will be exposed.

Thermoplastic jackets are made from a variety of thermoplastic materials that include PVC and Saran, among others. Most often these materials are used for low-temperature applications. They have poor resistance to fire and should not be used in situations where there is significant risk of fire. They are used as smooth sheet material and are often selected in applications where cleanliness is important because they typically have better release properties than metal and are thus more easily cleaned. The plastics also have good resistance to a wide variety of chemicals and are not damaged by water. They are not used as commonly in industrial applications as the metals.

The jacket material plays an important role in the overall thermal performance of the system because it establishes the system emissivity. NAIMA’s computer program, 3E Plus®, contains a list of materials and their emissivity, used by the program to calculate heat transfer. New, shiny aluminum has an emissivity of 0.04, which changes to 0.1 after the aluminum oxidizes in service. Stainless steel has an initial emissivity of 0.13 that rises to 0.3 after it becomes dull in service. By comparison, the thermoplastic PVC and the colored mastics that would be used with fabric have an emissivity of 0.9. How does this impact performance? For a 4-inch diameter steel pipe operating at 350 F in an exterior environment with no wind and an ambient temperature of 75 F, with an oxidized aluminum jacket over mineral fiber insulation the energy loss at 1.5 inches is 650,500 Btu/ft/yr and the surface temperature is 128 F. If the jacket is changed to PVC or fabric and mastic, the heat loss rises to 704,700 Btu/ft/yr but the surface temperature falls to 104 F at the same 1.5-inch thickness of mineral fiber. This shows that if the primary purpose of the insulation is personnel protection, then a high-emissivity jacket will allow a reduced insulation thickness.

What about low-temperature systems? Change the example to a process operating at –50 F with 50-percent relative humidity and an ambient dewpoint of 55 F with cellular glass. With oxidized aluminum jacket, the heat gain at the 2.5 inches of thickness required to prevent condensation is 220,200 Btu/ft/yr. Using PVC, the thickness required to prevent condensation drops to less than 1.5 inches, but at that thickness the heat gain rises to more than 332,300 Btu/ft/yr. To achieve the same heat gain as obtained with aluminum jacket, the thickness must be more than 3 inches. Again, that jacket choice has a clear influence on thermal performance and should be made with a good understanding of why the insulation is being used. At low temperatures, if condensation control is all that matters, then a high-emissivity jacket should be chosen.

Summary

This article has just scratched the surface of insulation jacketing for industrial applications. Clearly, there are more materials available than are described here, and many more factors that influence jacket selection than one could cover in a brief article. Jacket selection is not a trivial matter. It effects many aspects of system design and performance and should be made by a knowledgeable designer with well-defined design criteria for each project. A one-size-fits-all solution to jacket selection fails to take advantage of the wide variety of excellent materials available in today’s marketplace.

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