MICA Industry News | Technical Resources
By Darrell Peil | Originally published November 2020
Industrial facility owners and managers face an evolving list of priorities when selecting mechanical insulation systems. From corrosion prevention and personnel safety to energy efficiency and operating costs, the demands placed on these systems continue to change.
As regulations, technologies and operating practices evolve, so do expectations for industrial insulation. Some longstanding concerns remain essential, while emerging priorities create new challenges for engineers, contractors and facility managers.
One principle remains constant: the performance of a mechanical insulation installation depends on the entire system, not simply one material or component.
Insulation materials, protective finishes, accessories and installation methods must work together to deliver the desired performance. Focusing on a single component as a solution to a complex problem can overlook important factors affecting durability, safety and long-term costs.
Industrial facilities encompass a broad range of operations involving the production, processing, storage and transportation of materials and finished products.
Mechanical insulation serves important functions across industries including:
Although operating environments differ, facility owners share many of the same concerns regarding mechanical insulation performance.
Their decisions often balance capital expenditures (CapEx), ongoing operating expenses (OpEx), regulatory compliance, safety and the expected service life of the installation.
The following priorities represent major considerations identified for industrial mechanical insulation systems.
Corrosion under insulation remains one of the most significant concerns for industrial facility owners and managers.
CUI can occur when moisture and contaminants enter an insulation system and contribute to deterioration of the underlying piping or equipment.
Beyond the financial consequences of damaged equipment, corrosion can create serious safety hazards. Deteriorating piping and equipment may lead to leaks, pressure-related failures, chemical exposure, burns and other injuries.
Preventing corrosion requires careful evaluation of both insulation materials and the complete system design.
Important considerations include:
Effective CUI prevention depends on selecting compatible components and installing them as a complete protective assembly.
Moisture control is closely connected to corrosion prevention, but its importance extends beyond protecting metal surfaces.
All insulation materials can retain moisture to some degree. A properly designed insulation system must address the potential movement of both liquid water and water vapor.
Unwanted moisture can contribute to several problems, including corrosion, biological growth, energy losses and reduced process efficiency.
Moisture intrusion can create conditions that support microbiological growth and microbiologically influenced corrosion (MIC).
These conditions may damage piping and equipment while creating additional concerns for workplace health and safety.
Moisture can also contribute to slip-and-fall hazards. Condensation dripping from inadequately protected cold systems may create puddles, while moisture accumulation in freezer environments can result in ice formation.
Wet insulation can experience a substantial reduction in thermal performance.
As moisture increases heat transfer through the insulation system, additional energy may be required to maintain process temperatures.
Temperature fluctuations can also affect production quality, increase waste and reduce the efficiency of industrial operations.
Proper moisture-resistant system design helps preserve insulation performance and avoid unnecessary energy and operational costs.
Industrial insulation systems are frequently exposed to physical forces that can compromise their performance.
Damage may occur when maintenance personnel step on insulated piping, use ductwork as a temporary support surface or lean access equipment against insulated components.
Additional risks exist in high-traffic areas where forklifts, vehicles, equipment and material-handling operations may strike insulation systems.
When insulation is crushed or permanently compressed, its effective thickness decreases, potentially increasing heat transfer and reducing system efficiency.
Repeated damage also creates repair and replacement costs. Reinstalling the same materials without addressing the original cause can lead to recurring maintenance problems.
Compression resistance should be evaluated at the system level rather than by insulation material alone.
Depending on the application, an effective design may use a lower-compressive-strength insulation material with a highly durable protective finish, or a stronger insulation substrate with a different finishing system.
The objective is to select the combination of components that provides the necessary resistance to expected loads while maintaining thermal performance and controlling lifecycle costs.
Fire resistance is another major priority for industrial facility owners, particularly in environments involving combustible materials, high-temperature processes or potentially hazardous operations.
Industrial fires can cause significant property damage, production interruptions and serious injuries.
When evaluating mechanical insulation systems, designers and facility managers must consider how individual components and complete assemblies behave when exposed to fire.
Important characteristics include:
Materials that contribute less fuel to a fire or produce lower levels of smoke and hazardous gases can support broader facility fire-safety objectives.
In certain applications, insulation systems may also help protect structural or mechanical components from excessive heat exposure.
These considerations are especially important in facilities that manufacture, process or store flammable products.
Industrial facility owners continually seek opportunities to reduce capital investment costs without compromising required performance.
Mechanical insulation is part of the overall capital investment in a facility, making its initial cost an important consideration during project planning.
Advances in insulation materials, protective finishes and installation methods can create opportunities to improve efficiency and reduce installation expenses.
Examples include factory-fabricated components, preassembled systems, improved installation practices and materials that provide the necessary performance at a lower total installed cost.
However, lower initial costs should be evaluated alongside expected durability, maintenance requirements and operating expenses.
A system that costs less to install but requires frequent replacement or performs inefficiently may ultimately prove more expensive over its service life.
Noise control has become an increasingly important consideration in industrial environments.
Industrial equipment and processes can generate significant sound levels, creating concerns about employee hearing protection, regulatory compliance and noise affecting surrounding communities.
Mechanical insulation can contribute to acoustical control by reducing noise transmission from piping, equipment and other industrial systems.
Engineered acoustical insulation assemblies and sound enclosures can help facilities address process-generated noise while supporting safer working environments.
Effective acoustical solutions require consideration of the complete assembly, including insulation materials, coverings, enclosure construction and installation details.
As awareness of workplace noise exposure and community sound concerns increases, acoustical performance is becoming another important factor in insulation system selection.
Although corrosion resistance, moisture control, compression resistance, fire safety, cost and acoustical performance are distinct priorities, they share a common requirement: thoughtful system design.
Standardized test methods can help evaluate individual material characteristics, but the performance of a complete mechanical insulation system depends on how its components interact.
Engineers, contractors and facility managers should evaluate the insulation material, protective finish, accessories and installation methods as a coordinated assembly.
This approach allows designers to balance competing priorities and develop solutions tailored to specific operating environments.
Continuing to use an insulation system that repeatedly fails to meet performance expectations can create unnecessary expense when alternative materials and installation methods may be available.
Industrial facility owners and managers will continue to face changing expectations for safety, reliability, efficiency and cost control.
Fortunately, the mechanical insulation industry offers a broad range of materials, technologies and installation approaches that can address these challenges.
The key is recognizing that no single insulation product can solve every problem. Successful installations require careful evaluation of the entire system and a willingness to consider different combinations of materials and methods.
By focusing on complete-system performance, industrial facilities can achieve more durable installations, improve operating efficiency, reduce risk and support long-term investment value.
Darrell Peil is a longtime mechanical insulation industry professional with experience in contracting, distribution, manufacturing, product development and technical standards. At the time of the original publication, he served as Business Development Manager, Commercial & Industrial, for Knauf Insulation. He has participated in technical committees associated with ASHRAE, ASTM and the National Insulation Association, and contributed to the National Commercial and Industrial Insulation Standards manual (MICA Manual).
Originally published in Insulation Outlook, November 2020, by Darrell Peil. Copyright © 2020 National Insulation Association. Reprinted and adapted with permission.