8/19/2018 Mechanical Insulation - Types and Materials

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Mechanical Insulation - Types and Materials

Any surface which is hotter than its surroundings will lose heat. The heat loss depends on many
factors, but the surface temperature and its size are dominant.
Putting the insulation on a hot surface will reduce the external surface temperature. By
insulation, the surface will increase on objects, but the relative effect of temperature reduction
will be much greater and heat loss will be reduced.
A similar situation occurs when the surface temperature is lower than its surroundings. In both
cases some energy is lost. These energy losses can be reduced by laying the practical and
economical insulation on surfaces whose temperatures are quite different than the surrounding
one.

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Categories of Insulation Materials

INSULATION MATERIALS OR SYSTEMS MAY ALSO BE CATEGORIZED BY SERVICE
TEMPERATURE RANGE.
There are varying opinions as to the classification of mechanical insulation by the service
temperature range for which insulation is used. As an example, the word cryogenics means "the
production of freezing cold"; however the term is used widely as a synonym for many low
temperature applications. It is not well-defined at what point on the temperature scale
refrigeration ends and cryogenics begins.
The National Institute of Standards and Technology in Boulder, Colorado considers the field of
cryogenics as those involving temperatures below -180°C. They based their determination on
the understanding that the normal boiling points of the so-called permanent gases, such as
helium, hydrogen, nitrogen, oxygen and normal air, lie below -180°C while the Freon
refrigerants, hydrogen sulfide and other common refrigerants have boiling points above -180°C.
Understanding that some may have a different range of service temperature by which to classify
mechanical insulation, the mechanical insulation industry has generally adopted the following
category definitions:

CATEGORY DEFINITION
Cryogenic Applications -50°F & Below
Thermal Applications:

Refrigeration, chill water and below ambient applications -49°F to +75°F

Medium to high temp. applications +76°F to +1200°F

Refractory Applications +1200°F & Above

CELLULAR INSULATIONS are composed of small individual cells either interconnecting or

sealed from each other to form a cellular structure. Glass, plastics, and rubber may comprise
the base material and a variety of foaming agents are used.

CELLULAR INSULATIONS are often further classified as either open cell (i.e. cells are
interconnecting) or closed cell (cells sealed from each other). Generally, materials that have
greater than 90% closed cell content are considered to be closed cell materials.

FIBROUS INSULATIONS are composed of small diameter fibers that finely divide the air space.
The fibers may be organic or inorganic and they are normally (but not always) held together by
a binder. Typical inorganic fibers include glass, rock wool, slag wool, and alumina silica.
Fibrous insulations are further classified as either wool or textile-based insulations. Textile-
based insulations are composed of woven and non-woven fibers and yarns. The fibers and
yarns may be organic or inorganic. These materials are sometimes supplied with coatings or as
composites for specific properties, e.g. weather and chemical resistance, reflectivity, etc.

FLAKE INSULATIONS are composed of small particles or flakes which finely divide the air space.
These flakes may or may not be bonded together. Vermiculite, or expanded mica, is flake
insulation.
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GRANULAR INSULATIONS are composed of small nodules that contain voids or hollow spaces.
These materials are sometimes considered open cell materials since gases can be transferred
between the individual spaces. Calcium silicate and molded perlite insulations are considered
granular insulation.

REFLECTIVE INSULATIONS and treatments are added to surfaces to lower the long-wave
emittance thereby reducing the radiant heat transfer to or from the surface. Some reflective
insulation systems consist of multiple parallel thin sheets or foil spaced to minimize convective
heat transfer. Low emittance jackets and facings are often used in combination with other
insulation materials.

Some Insulation Type Examples

Cellular Insulations
ELASTOMERIC
Elastomeric insulations are defined by ASTM C 534, Type I
(preformed tubes) and Type II (sheets). There are three grades in the
ASTM standard which are widely available.

Elastomeric insulations

Grade Basic description Temp. Flame Spread Index / Smoke

Limits Developed Index
1 Widely used on typical -297°F to 25/50 through 1½in
commercial systems 220°F thickness.
2 High temp. uses -297°F to Not 25/50 Rated
350°F
3 Use on stainless steel -297°F to Not 25/50 Rated
applications above 125 °F 250°F

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All three grades are flexible and resilient closed-cell expanded foam
insulation. The maximum water vapor permeability is 0.10 perm-inch
and the maximum thermal conductivity at 75°F temperature is 0.28
BTU in/(h ft2 F) for grades 1 and 3 and grade 2 is 0.30 BTU in/(h ft2
F). Grade 3 formulation does not contain any leachable chlorides,
fluorides or polyvinyl chloride or any halogens.
The preformed tubular insulation is available in ID sizes from 3/8" to 6
IPS and in wall thickness from 3/8" to 1.1/2" and in typical length of 6
feet. The tubular product is available with and without pre-applied
adhesive. The sheet insulation is available in continuous lengths of 4
feet widths or 3' x 4' and in wall thicknesses from 1/8" to 2". The sheet
product is available with and without pre-applied adhesive.
These materials are normally installed without additional vapor
retarders. Additional vapor-retarder protection may be necessary
when installed on very-low-temperature piping or where exposed to
continually high humidity conditions. All seams and termination points
must be sealed with manufacturer recommended contact adhesive.
For outdoor applications a weatherable jacket or manufacturer
recommended coating must be applied to protect against UV and
ozone.

CELLULAR GLASS
Cellular Glass is defined by ASTM as insulation composed of glass
processed to form a rigid foam having a predominantly closed-cell
structure. Cellular glass is covered by ASTM C552, "Standard
Specification for Cellular Glass Thermal Insulation" and is intended for
use on surfaces operating at temperatures between -450 and 800°F.
The Standard defines two grades and four types, as follows:

Cellular Glass insulations

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Type Form and Grades Available

I Flat Block, Grades 1 and 2

II Pipe and Tubing, Fabricated, Grades 1 and 2
III Special Fabricated Shapes, Grades 1 and 2
IV Board, Fabricated, Grade 2

Cellular glass is produced in block form (Type I). Blocks of Type I

product are typically shipped to fabricators who produce fabricated
shapes (Types II, III, and IV) that are supplied to distributors and/or
insulation contractors.

The maximum thermal conductivity is specified, by grade, as follows

(for selected temperatures):

Temperature,°F Grade 1 Grade 2

Type I, Block
-150°F 0.20 0.26
-50°F 0.24 0.29

50°F 0.30 0.34

75°F 0.31 0.35
100°F 0.33 0.37
200°F 0.40 0.44

400°F 0.58 0.63

Type II, Pipe
100°F 0.37 0.41
400°F 0.69 0.69

The standard also contains requirements for density, compressive

strength, flexural strength, water absorption, water-vapor permeability,
combustibility, and surface burning characteristics.

Cellular glass insulation is a rigid inorganic non-combustible,

impermeable, chemically resistant form of glass. It is available faced
or un-faced (jacketed or un-jacketed). Because of the wide
temperature range, different fabrication techniques are sometimes
used at various operating temperature ranges.
Typically, fabrication of cellular glass insulation involves gluing multiple
blocks together to form a "billet" which is then used to produce pipe
insulation or special shapes. The glue or adhesives used vary with the
intended end use and design operating temperatures. For below-
ambient applications, hot melt adhesives such as ASTM D 312 Type
III asphalt are usually used.
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On above-ambient systems, or where organic adhesives could pose a

problem (i.e., LOX service) an inorganic product such as gypsum
cement is often used as fabricating adhesive. Other adhesives may be
recommended for specific applications. When specifying cellular glass
insulation, include system operating conditions to ensure proper
fabrication.

Fibrous Insulations
Fibrous insulations are composed of small diameter fibers that finely
divide the air space. The fibers may be organic or inorganic and they
are normally (but not always) held together by a binder. Typical
inorganic fibers include glass, rock wool, slag wool, and alumina silica.

Fibrous Insulations

MINERAL FIBER PIPE

Mineral Fiber Pipe insulation is covered in ASTM C 547. The standard
contains five types classified primarily by maximum use temperature.

Type Form Maximum Use

Temp,°F
I Molded 850°F
II Molded 1200°F
III Precision V-groove 1200°F
IV Molded 1000°F
V Molded 1400°F

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The standard further classifies products by grade. Grade A products

may be "slapped-on" at the maximum use temperature indicated,
while Grade B products are designed to be used with a heat-up
schedule.
The specified maximum thermal conductivity for all types is 0.25 Btu
in/(hr ft2 °F) at a mean temperature of 100°F.
The standard also contains requirements for sag resistance, linear
shrinkage, water-vapor sorption, surface-burning characteristics, hot
surface performance, and non-fibrous (shot) content. Further, there is
an optional requirement in ASTM C 547 for stress corrosion
performance if the product is to be used in contact with austenitic
stainless steel piping.
Fiberglass pipe insulation products will generally fall into either Type I
or Type IV. Mineral wool products will comply with the higher
temperature requirements for Types II, III, and V.
These pipe insulation products may be specified with various factory-
applied facings, or they may be jacketed in the field. Mineral fiber pipe
insulations systems are also available with "self-drying" wicking
material that wraps continuously around pipes, valves, and fittings.
These products are intended to keep the insulation material dry for
chilled water piping in high-humidity locations.
Mineral fiber pipe insulation sections are typically supplied in lengths
of 36 inch, and are available for most standard pipe and tubing sizes.
Available thicknesses range from ½in to 6in.

Granular Insulations
CALCIUM SILICATE
Calcium Silicate thermal insulation is defined by ASTM as insulation
composed principally of hydrous calcium silicate, and which usually
contains reinforcing fibers.

Calcium Silicate Pipe and Block Insulation are covered in ASTM C

533. The standard contains three types classified primarily by
maximum use temperature and density.

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Calcium Silicate thermal insulation

Type Maximum Use Temp (°F) and Density

I Max Temp 1200°F, Max Density 15 pcf

IA Max Temp 1200°F, Max Density 22 pcf
II Max Use Temp 1700°F

The standard limits the operating temperature between 80°F to

1700°F.
Calcium Silicate pipe insulation is supplied as hollow cylinder shapes
split in half lengthwise or as curved segments. Pipe insulation sections
are typically supplied in lengths of 36 inch, and are available in sizes
to fit most standard pipe sizes. Available thicknesses range from 1" to
3" in one layer. Thicker insulation is supplied as nested sections.
Calcium Silicate block insulation is supplied as flat sections in lengths
of 36", widths of 6", 12", and 18" and thickness from 1" to 4". Grooved
block is available for fitting block to large diameter curved surfaces.
Special shapes such as valve or fitting insulation can be fabricated
from standard sections.

Calcium Silicate is normally finished with a metal or fabric jacket for

appearance and weather protection.
The specified maximum thermal conductivity for Type 1 is 0.41 Btu-
in/(h ft2 °F) at a mean temperature of 100°F. The specified maximum
thermal conductivity for Types 1A and Type 2 is 0.50 Btu-in/(h ft2 °F)
at a mean temperature of 100°F.
The standard also contains requirements for flexural (bending)
strength, compressive strength, linear shrinkage, surface-burning
characteristics, and maximum moisture content as shipped.

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Typical applications include piping and equipment operating at

temperatures above 250°F, tanks, vessels, heat exchangers, steam
piping, valve and fitting insulation, boilers, vents and exhaust ducts.

Reference(s):
https://www.wbdg.org and http://www.roxul.com

MORE ABOUT MECHANICAL INSULATION

Part 1:
Mechanical Insulation - Types and Materials

Part 2:
Mechanical Insulation - Space Requirements of Insulation
Part 3:
Mechanical Insulation - Insulation of Piping

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