Types and Materials of Insulation

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.

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 and 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 and 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.
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 & 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.

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 1.1/2in thickness.
commercial systems 220°F
2 High temp. uses -297°F to Not 25/50 Rated
350°F
3 Use on stainless steel applications -297°F to Not 25/50 Rated
above 125 °F 250°F

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

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.
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

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
1/2in 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.
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.
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: Types and Materials
Part 2: Space Requirements of Insulation
Part 3: Insulation of Piping