Everything You Need To Know To Find The Best Phenolic Foam Slab

Everything you need to know about Phenolic Insulation

What is Phenolic insulation?

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Phenolic insulation is manufactured by a process in which a plastic foam forms an insulating core between two flexible tissue faced layers. It has a high closed cell content and fine cell structure. Rigid phenolic insulation is produced by mixing high solids and phenolic resin with a surface acting agent.

Is Phenolic insulation combustible?

The first indicative test looked at the behaviour of 25mm Xtratherm Safe-R SR Phenolic PIR, a phenolic, fibre-free rigid thermoset material, recognised as "combustible". The second test looked at the behaviour of a rock mineral fibre insulation with a density of 40kg/m3 + 100kg/m3, recognised as "non-combustible".

What is the difference between PIR and Phenolic insulation?

As with the PIR/PUR boards above, phenolic insulation boards also have a closed cell structure. Phenolic Board has a slightly higher r-value (higher is better, unlike u-values) and a slightly thinner profile than PIR/PUR boards due to the manufacturing process.

How is phenolic made?

Phenolic sheet is a hard, dense material made by applying heat and pressure to layers of paper or glass cloth impregnated with synthetic resin. ... When heat and pressure are applied to the layers, a chemical reaction (polymerization) transforms the layers into a high-pressure thermosetting industrial laminated plastic.

Key Facts

FIRE PERFORMANCE The fire performance of Phenolic Foam is exceptional. It combines zero or very low flame spread with negligible smoke emission and a very low level of toxic gas emission

ENVIRONMENT Phenolic foam has very low embodied energy per unit thermal performance compared to other insulation materials • Significant CO2 savings can be achieved compared to other insulation materials

MOISTURE RESISTANCE Phenolic foam has been used successfully in insulation systems where moisture resistance is a key issue. The reasons for this excellent performance are: • Phenolic foam has a low water vapour permeance and is therefore highly resistant to the passage of water vapour • Phenolic foam has low water absorption which takes place predominantly in the cut/broken surface cells of the foam

STRUCTURAL STRENGTH Phenolic foams have an excellent strength/density relationship being lightweight but strong. Higher density phenolic foams are typically used for: • Pipe supports • Duct supports • Steel faced composite panels (including walk-on ceilings

THERMAL PERFORMANCE Phenolic foams offer a range of thermal conductivity performance. The closed cell type offers the lowest thermal conductivity available from any insulation material resulting from: • Closed cell structure • Extremely small cell diameter • Low thermal conductivity gas permanently encapsulated in cells.

Conclusion

Phenolic foam is used in many building applications, typically continuously laminated phenolic board is used in roofing, cavity board, external wall board, plasterboard dry lining systems, Wall Insulation, Floor Insulation and as a sarking board.

The superior fire performance of phenolic foam is being recognised and this is leading to increased market share in these areas. Phenolic foam is used in factory engineered composite panels. These composite panels comprise of a high density structural phenolic foam core with steel facings both sides and an appropriate jointing system. These panels are used in a range of applications including food processing factories, cold stores, semi conductor clean rooms and hospitals. These panels are structurally sound and fit for purpose for use in walk-on ceilings.

The excellent fire performance provided by the phenolic foam core gives both good insulation and integrity performance in the 3m furnace fire resistance test. Phenolic foam is used in process/petrochemical applications for the insulation of pipework, tanks, vessels etc. Phenolic foam is also used in a number of highly specialised applications including fire doors, highly fire resistant panels and for insulation in surface ships, off-shore installations and submarines.

It is clear that phenolic foam is a very versatile material being suitable for a large range of applications where thermal performance, moisture resistance, fire performance and in certain cases structural strength are key performance criteria. Phenolic foam is the only material that can provide this unique range of benefits.

All Pipe Insulation Types & Options Explained

Pipe Insulation Types

There is a wide range of Pipe Insulation Types available.  This guide will explain the most suitable types of insulation for the most common applications.

Before you choose the type of Insulation, you'll need to know two crucial factors - your pipe bore (the diameter) and the thickness of the insulation you require ("the wall thickness")

1. Pipe Bore (Diameter)

The pipe diameter (or bore) can be measured in imperial sizes (in inches) or metric sizes (in mm).  For insulation purposes, both measurements refer to the outside diameter (O.D) of the pipe.

When measuring steel pipe, it is important to remember that the OD measurement will be higher than the actual internal bore size - this is because the steel pipe has a substantial thickness of several mm.  For instance, a steel pipe with a 25 mm bore, will have an outside diameter (OD) of 34 mm. This method does not apply to copper pipe.

2. Insulation Thickness (Wall Thickness)

All of our pipe insulation products are available in some different thicknesses (also referred to as wall thickness).  As a rule of thumb - thicker insulation = less heat loss from pipes and greater protection from freezing temperatures.

For outdoor pipework, we recommend a minimum insulation thickness of 19mm.

Insulation Types:

Grey Foam Insulation 

Our most economically priced Insulation.  Tubolit is made from grey polyethene foam, the insulation is ideal for use in domestic pipework and plumbing.  It is available in all of the standard internal pipe sizes and is available in several wall thicknesses.  The insulation is supplied in either one or two-metre lengths and comes semi-split for ease of installation.  This insulation is not suitable for outdoor use.

Class O Nitrile Foam Rubber Insulation 

Class O Insulation is a flexible, closed cell, elastomeric, nitrile rubber insulation that offers reliable protection against condensation and effectively prevents energy loss. It is available in some formats including 2-metre unsplit tubes, long coils, sheets and also as a pre-slit self-seal tube that reduces installation times by up to 30%. The insulation is very versatile and can be used in a wide range of applications including domestic, plumbing and air conditioning.  Class O insulation (The class O refers to the fire standard) can be used on hot pipes up to a temperature of 105 degrees Celsius.  For temperatures above this (up to 150 degrees), an EPDM rubber insulation would be more suitable (see below).

*Class O insulation can be used outdoors but will require further protection from UV exposure, such as one of the Armafinish Paints.  Without additional protection, the insulation will eventually crack and crumble.

EPDM Foam Rubber Insulation 

EPDM rubber insulation is ideal for outdoor, high temperature and solar pipework use.  The insulation has an in-built UV protective layer, meaning it can be installed outside without any further treatment or coverings.  This insulation is also suitable for high-temperature pipework (up to 150 degrees Celsius), making it ideal for use on solar heating systems.  The insulation is available in 2 metre unsplit tube lengths, long coils and flat sheets in a range of wall thicknesses.  For outdoor use, we recommend a minimum insulation wall thickness of 19mm.

Mineral Fibre Insulation - Foil Coated 

Rockwool Insulation is designed for use in heating, ventilation and air conditioning applications; mineral fibre insulation can withstand temperatures of up to 700 degrees Celsius.  The insulation is provided as mineral fibre insulation sections which have a factory applied foil covering with an integral adhesive overlap.  This feature dramatically speeds up installation times.  The insulation can be used either indoors or outdoors.  *If used outdoors, however, an additional protective covering sheet known as Polyisobutylene (PIB) needs to be applied.

Phenolic Foam Insulation - Foil Covered 

Phenolic foam insulation is the most energy efficient insulation available for any given thickness.  It is typically used in industrial applications in the heating, ventilation, air conditioning and the petrochemical and maritime sectors.  The pipe insulation is supplied in foil-faced sections for a range of pipe diameters.  In addition, the material is available in slab and sheet form and can be used as roofing and wall insulation. Phenolic foam insulation can be used at temperatures up to +120 degrees Celsius and as low as -50 degrees Celsius.   As with mineral wool Insulation, phenolic insulation can be used outdoors * but will require additional covering with Polyisobutylene (PIB) sheeting.

How to Pick the Right Thermal Pipe Insulation

Pipe insulation is not the same across the board, with many choices available. It only performs its best when applied correctly, which includes using the right material for the right project. 

Will it be fiberglass or mineral wool? Polyurethane or phenolic insulation? Learn about the different types of thermal pipe insulation and how to pick the right one for your needs.

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Phenolic pipe insulation is known for its unmatched thermal resistance, superior performance and more. It has been a go-to pipe insulating product among laggers for some time now.

But, for those who are still debating about using Kingspan kooltherm phenolic pipe insulation or phenolic pipe lagging of other brands, we have put together a comprehensive guide that should help you make a decision. 

In this article, we will cover all you need to know about phenolic pipe insulation, including its composition, thermal qualities, installation technique, maintenance, fire resistance, comparison to other insulation materials, and environmental effect. At the end of this article, you will have a thorough grasp of phenolic pipe lagging

What is Phenolic Pipe Insulation?

As the name suggests, the phenolic pipe lagging is constructed of phenolic resin, a plastic created by combining phenol and formaldehyde. To create the insulating material, the phenolic resin is cured and foamed.

A firm foam core is sandwiched between two layers of facing material to form phenolic pipe lagging. Several materials, such as kraft paper or aluminium foil can make the face material. 

The phenolic pipe foam core is normally closed-cell, which means the foam cells are shut off from one other, limiting air and moisture infiltration. This feature contributes to the material's improved insulation performance and lowers the danger of corrosion on the surface of the pipe or equipment being insulated. Since phenolic pipe insulation is available in several diameters and thicknesses, it may be used in various applications

One of the finest examples of phenolic pipe insulation is Kingspan kooltherm insulation. The pipe insulation supplied is 1M long and is manufactured in a range of thicknesses and diameters to suit various applications. Kingspan kooltherm phenolic foam pipe lagging has been one best-selling insulation products here at Buy Insulation Online!

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Advantages of phenolic pipe insulation

Some of the crucial advantages of Phenolic pipe include the following:

• High thermal insulation properties: Since phenolic pipe insulation has low thermal conductivity, it resists heat flow well. This feature makes it a good candidate for use when energy efficiency is a concern.

• Lightweight and simple to install: This can assist in minimising installation costs and increase overall project efficiency. Phenolic insulation is easy to cut and shape to fit around pipes and other equipment, making it a practical choice for installers.

• Long life: Since phenolic pipe insulation has a long life. It may provide long-term insulating performance while reducing the need for regular replacement.

• Fire resistance: Phenolic insulation gives excellent fire and smoke performance, as its made of a densely cross-linked structure, which makes it difficult to ignite. The outer surface of this Class O rated pipe insulation develops a thick carbonaceous layer that limits heat generation and retards further flame spread. 

Disadvantages of phenolic pipe insulation

Some of the drawbacks of Phenolic pipe insulation include the following:

• Costlier: Phenolic pipe insulation can be more costly than other forms of insulation, such as fibreglass or mineral wool lagging

• Installation requirements: Installation of phenolic pipe insulation necessitates using specific tools and equipment, which can raise installation costs and necessitate more trained workers.

• Environmental impact: Because the phenolic resin is derived from petrochemicals, phenolic pipe insulation may have an environmental impact.

Thermal Properties of Phenolic Pipe Insulation

The thermal conductivity of phenolic pipe insulation is normally between 0.020 and 0.030 W/m*K. Because of its low thermal conductivity, phenolic pipe insulation effectively reduces heat transfer and conserves energy.

A material's heat capacity is the quantity of heat energy necessary to increase its temperature by a specific amount. The heat capacity of phenolic pipe insulation ranges between 1.4 and 1.7 kJ/kg*K. This implies that heating the insulating material consumes relatively little energy, which can increase energy efficiency.

Depending on the product and application, phenolic pipe insulation can normally tolerate temperatures ranging from -180°C to 150°C (-292°F to 302°F). Nevertheless, the maximum temperature that phenolic pipe insulation can take varies based on parameters such as insulation thickness, facing material utilised, and application.

Installation of Phenolic Pipe Insulation

What tools are needed during installation? 

The installation of phenolic pipe insulation necessitates the use of no specific tools and materials. You will need:

• Phenolic pipe insulation: This is the main material in this case.

• Protective gear: While working with phenolic pipe insulation, installers should use suitable protective equipment such as gloves, masks, and eye protection.

• Adhesive Or Foil Tape: Foil tape of the appropriate size or pipe insulation adhesives can be used to install and secure phenolic insulation around the pipework.

Steps of Installation? 

Below are the steps you need to follow while installing Phenolic Pipe Insulation:

1. Before applying the insulation, ensure the installation area, especially the pipework that needs insulating is clean and dry.

2. When working with phenolic pipe insulation, wear suitable safety equipment.

3. Wrap the Kooltherm phenolic foam pipe section around the pipework, being the ends of the lagging together and seal with foil tape. 

4. Ensure no gaps or voids exist between the pipe section and the pipe or equipment.

5. Seal all insulating joints to ensure there are no holes through which heat can escape.

6. Check the finished installation to confirm that it fulfils the standards and has no insulation gaps. Complete the installation by adding pipe identification labels of the appropriate type to help identify the pipework.

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Maintenance of Phenolic Pipe Insulation

The following are some maintenance procedures that can aid in the preservation of phenolic pipe insulation:

• Maintenance and repair: Keep phenolic pipe insulation clean to avoid accumulating dirt, dust, or other impurities that might reduce efficiency. If there is any damage to the insulation, it should be addressed as soon as possible to prevent heat loss.

• If you plan on using Kingspan kooltherm pipe insulation to insulate outdoor pipes, cover them with appropriate pipe insulation cladding materials 

• Inspection and monitoring: Frequent inspections and monitoring of phenolic pipe lagging can aid in the early detection of possible issues. Inspecting for indicators of deterioration, such as cracks or holes in the insulation, and ensuring that the insulation is correctly sealed around joints and fittings are all tasks for inspectors.

• Maintenance records: Maintaining precise records of the maintenance conducted on phenolic pipe insulation will ensure that it is properly maintained and that any possible problems are discovered and treated promptly.

Comparison of Phenolic Pipe Insulation with Other Insulation Materials

When comparing phenolic pipe insulation to other insulation materials, numerous considerations should be considered:

Phenolic pipe insulation provides outstanding fire safety. It is class O rated and has low smoke production. Compared to other insulation materials, such as foam pipe insulation, which can be combustible, phenolic insulation is a safer alternative for fire safety.

Compared to other types of insulation, phenolic pipe insulation has a much lower K-value compared to other pipe insulating options, which means it may give a high level of thermal performance

Phenolic Foam Pipe Insulation Manufacturers

Phenolic foam is a popular choice for pipe insulation in the UK and Europe due to its high performance and energy-saving properties. There are several manufacturers of phenolic foam pipe insulation in the region Like Kingspan, Supahphen etc. 

Kingspan offers a wide range of phenolic foam insulation products for various applications, including pipe insulation. Kingspan phenolic foam lagging comes in a range of thicknesses to fit different pipe sizes. It does not contain any CFC or HCFC making it an environmentally friendly option.

It is a high performance pipe insulation known for its excellent thermal insulation properties, fire resistance, and durability.

Frequently Asked Questions

1. What is phenolic insulation?

Phenolic insulation is a type of insulation made from phenolic foam. It is a highly effective and efficient insulating material that is commonly used in the construction industry for its excellent thermal performance.

2. Is phenolic a good insulator for pipes?

Yes, phenolic insulation is an excellent choice for insulating pipes. It has a high thermal resistance, which can help to keep pipes at the desired temperature while minimizing heat loss. Phenolic pipe insulation is also lightweight, easy to install, and provides excellent fire resistance.

3. Does phenolic insulation come in different sizes?

Yes, phenolic insulation is available in a wide range of sizes to fit pipes of different diameters. The most common sizes for phenolic pipe insulation are 15mm and 50mm, but other sizes are also available.

4. Is phenolic insulation moisture resistant? 

Yes, since phenolic insulation is a closed cell it usually does not allow the entry of moisture. Moreover, Kingspan pipe insulation is a foil backed pipe lagging, where the factory applied foil-facing, form an effective vapour barrier. 

However, it is important to state that Phenolic insulation is not waterproof. If it is affected by moisture for a long time, its insulating properties could be affected. 

5. What is the price of phenolic insulation?

The price of phenolic insulation can vary depending on factors such as the thickness, size, and quantity of insulation needed. It is best to contact an insulation supplier or manufacturer for pricing and ordering information.

Here at Buy Insulation Online, we stock phenolic pipe lagging and boards. We stock Kingspan pipe insulation supplied in a wide range of thicknesses to suit your application. 

6. Is phenolic insulation easy to install?

Yes, phenolic insulation is easy to install and can be cut to fit around pipes of different sizes and shapes. However, it is recommended to seek professional installation for the best results. For installing boards, you can refer to the manufacturer guidelines and videos on respective the product pages

7. What is the thermal performance of phenolic insulation?

Phenolic insulation has a high thermal resistance, which can help to minimise heat loss and reduce energy costs. It is one of the most effective types of insulation available for both residential and commercial applications.

8. Can phenolic insulation be used as part of a pipe insulation system?

Yes, phenolic insulation can be used as part of a pipe insulation system to help maintain the temperature of pipes and prevent heat loss. Moreover, it is Class O rated and complies with the required building regulation in the UK. It can also be used with other insulation materials for added performance.

9. What is the density of phenolic insulation?

Phenolic insulation has a relatively high density compared to other types of insulation, which can help to provide excellent thermal performance. The density can vary depending on the specific product and application but generally ranges from around 30-100 kg/m³.

Conclusion:

Ultimately, phenolic Pipe insulation is essential for mitigating heat loss and overheating issues. When installed and maintained properly, phenolic pipe insulation may offer excellent thermal insulation for many years, lowering energy expenditures and enhancing overall system efficiency.

Hopefully, this article has given you a better picture of how to install and maintain phenolic pipe insulation. If you are looking to purchase Kingspan Koolterm insulation online, there is no better place than Buy Insulation Online. We stock varying thicknesses and sizes, not commonly found online, which could be just what you are looking for. Also, if you need more information on Kingspan kooltherm phenolic foam pipe insulation, our experts are just a call away!

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