Polyurethane foam shells for pipe insulation

It takes more than just keeping your heating system in check to keep your house warm and energy-efficient; adequate insulation is also necessary throughout. Pipe insulation is one area that is frequently disregarded. A well-insulated pipe can make a big difference, whether your hot water needs to get from your heater to the tap without losing heat or your cold pipes need to be protected from freezing. For this purpose, polyurethane foam shells present an appealing option because they combine good insulating qualities with ease of installation.

Because of polyurethane foam’s exceptional capacity to hold heat and avert condensation, it has become a popular option for pipe insulation. This kind of insulation is available as pre-formed shells that are made to snugly fit around different pipe diameters. By minimizing heat loss, these shells not only keep the water flowing through the pipes at the proper temperature, but they also help save energy costs. They also offer the added advantage of reducing pipe noise, which makes the house quieter.

Polyurethane foam shells are an attractive option for both new construction and renovation projects because they are easy to install. With a few easy instructions, homeowners can install these shells themselves, unlike some other types of insulation that need to be installed by a professional. For anyone wishing to improve the insulation in their home, polyurethane foam shells are a great option because of their affordability, durability, and ease of use.

What is this insulating material

The construction of PPU (deciphering polyurethane foam) half-cylinders, which are typically manufactured in lengths of one meter and have inner diameters that match the dimensions of the insulated pipes. The locks on the shells guarantee a very solid connection, making assembly tasks easier.

The FPU insulation material for pipes has an average density of 60.0 kg/m3, which makes assembly and transporting protective goods to the installation site much easier. The components of insulation are secured with steel ties or foam. To achieve thermal insulation for pipelines with bends, angular parts are manufactured to enable the insulation of pipe bends and turns.

Crucial! Molds are used in the production process to form the pipe insulation’s shell. They can be produced with specific coverings, such as fiberglass, aluminum foil, or galvanized steel, depending on the needs of the operation. The strength and longevity of heat protection products are reinforced by these safety layers.

Where used, features

Foam shells with Dn = 108/133 mm are used to insulate waste water discharge and drainage pipelines from heat.

Standard dimensions for DHW systems and heat supply thermal insulation:

1. Pipes located inside heat ducts Dn: 15/20/32/45/57 mm.
2. Strapping of elevator assemblies of in-house ITPs and TSPs, Dn: 89/108/133/159/219 mm.
3. Main heat networks Dn: 273/326/1020 mm.
4. Foil shell insulation is installed indoors, and with reinforced foil, both outdoors and indoors.
5. In the case when the shell for pipes is protected by fiberglass – it is applicable for any type of pipelines, including when laid directly into the ground.

Pros and cons of application

The FPU shell for pipes allows thermal energy losses to be drastically decreased. Pre-insulated pipes are made to meet the requirements of modern thermal routes, industrial, and civil construction. Using this method, polyurethane foam is inserted into the space between the pipe and a large-diameter, specially-designed formwork. After that, a finished pipe is produced, which already has a layer of polyurethane foam applied to its exterior for protection.

The pipe shell offers several noteworthy benefits that set it apart from alternative thermal insulation materials for pipelines. These advantages include:

• Efficient user characteristics.
• Increased resistance to rot and pests.
• High chemical resistance.
• Wide temperature range of installation.
• Heat and fire resistance.
• Reusability.
• Ecological safety.
• Low unit costs for repair and operation of pipelines.
• Easy and fast installation work.

Polyurethane foam shell drawbacks:

• Large external dimensions, which increase transportation costs.
• Inadmissibility of application at extremely high temperatures, e.g. for insulation of steam pipes.

Types and configuration

The design of trunk pipelines aims to minimize the number of bends. Nevertheless, auxiliary shaped components in the form of tees, bends, and branches are produced for the purpose of thermal insulation of pipe systems. Thermosections in the insulated pipeline are fixed using specialized tools. They employ twists, steel ties, adhesive compositions, and assembly foam in their format.

A coupling is a particular shaped component that is used to join units along a length. Its goal is to build a formwork structure. The empty space that results is then filled with foam to guarantee complete pipe sealing.

PPS pipe diameter inside. Pipelines vary in diameter depending on their intended use, so a heat-insulating shell of an appropriate diameter must be used for thermal insulation. Furthermore, multiple layers of insulation are frequently required around pipes to ensure a notable decrease in heat loss. This places unique constraints on the shell diameters of polyurethane foam.

Kindly take note! With diameters ranging from 15 to 1220 mm, the FPU-shell is realized in the trade network in the widest range. The commercial offer for the vast majority of manufacturers is restricted to internal diameters between 32 and 219 mm. Since many heat consumers prefer these sizes, they are the most popular.

Generally speaking, the diameter of the pipe covered in protective polystyrene foam does not provide precise information about the product’s ability to withstand heat. The thickness of the product is therefore a crucial FPU indicator. It is brought on by the part’s diameter and varies from 15 to 100 mm. The maximum FPU thickness for pipes measuring 32 mm is 30 mm, for pipes measuring 1220 mm it is 55 mm, and for pipes measuring 100 mm it is the largest thickness of the protective layer.

The segments are half segments with a maximum length of 100 cm in the template.

The kind and diameter of pipes used have an impact on the joining angle. The majority of Russian producers create goods with typical joint angles:

• 180 degrees for Dn from 32 to 750 mm;
• 120 degrees for Dn from 750 to 920 mm;
• 90 degrees for Dn from 920 to 1440 mm.

Technical characteristics of polyurethane foam shells for heating pipes

Technological characteristics of Russian manufacturers’ polyurethane foam shells:

• Density of insulation from 55.0 to 60.0 kg/m3.
• Number of closed cells, up to 92.0%
• Compressive strength – 30.1 kPa.
• Tensile strength – 0.16 kPa.
• Thermal conductivity of FPU at 0 C is less than 0.026 W/mK.
• Thermal conductivity of FPU at 10 C is less than 0.031 W/mK.
• Thermal conductivity at 50 C less than 0.033 W/mK.
• Water absorption volume of FPU during a day – not higher than 3.5%.
• Water vapor diffusion resistance factor "3m-factor.

• Stable temperature range from – 35 to + 140C.
• Maximum temperature regime + 150C.
• Fire safety class G2-G3.
• Environmental safety parameters – without chlorofluorocarbons.
• Corrosion resistance in aggressive media.
• Chemical safety – inert and non-toxic material.
• Nominal period of use – 30 years.

Shells made of polyurethane foam are a clever way to insulate pipes in your house. These shells fit snugly around pipes, acting as a barrier to keep heat inside in the winter and stop heat gain in the summer. Polyurethane foam shells are simple to install and can be molded to fit any pipe shape, providing maximum efficiency and complete coverage in contrast to traditional insulation methods. They not only lower energy consumption and utility costs, but they also keep pipes from freezing and bursting during the winter, saving expensive repairs. Polyurethane foam shells are an affordable method to extend the life and increase the energy efficiency of your home’s heating system because of their robust and adaptable qualities.

How to install

A well-known technique for installing polyurethane foam segments involves using lock assemblies. Fundamental steps for installing FPU shells:

1. On the eve of thermal insulation works it is necessary to perform all required calculations and determine the required number and operating parameters of FPU segments for the pipeline.
2. Markings are made and the parts are cut to the required length.

It is essential to consider every installation detail when installing FPU-shells:

• The products are quite rigid, so it will not be possible to similarly cylinders made of minwool – to press it at the connecting junction.
• If the welded joint is thickened and falls on the center of the shell – its edge will be able to extend by 10mm.
• All convexities that interfere with the installation should be removed from the shell so that they do not interfere with the firm adhesion.
• Before insulating the pipes, it is necessary to prepare their surfaces, clean them from dirt, degrease and primed.
• Installation of FPU-shells can be performed at any time of the year in the absence of natural precipitation.
• When joining segments to each other, it is necessary to lubricate the joints with one-component polymer adhesive to create better moisture insulation. The glue is applied to one of the segments, then the glue plane is wetted with sprayed water. After that, the shells are installed with technological fixation.
• For foil-covered shells, it is required to seal the joint areas with foil tape after the installation is complete.

Additional information. One crucial detail that needs to be considered during installation is the location of the joints. It is necessary to arrange them in accordance with a wristwatch’s hands, which stand for 9 and 3 o’clock. Should the installer consider this requirement, the structure will be adequately shielded from moisture intrusion. In the event that the insulating product is manufactured without grooves, wire or glue solution is used during installation. Since this type of system is the least dependable, a polyethylene film must be used to improve moisture protection.

For comfort and energy savings, it is essential that our homes have effective insulation and heating systems. Polyurethane foam shells provide an efficient and workable solution for pipe insulation. These adaptable insulation materials offer a shield that lowers energy usage and helps stop heat loss.

Shells made of polyurethane foam are renowned for having superior thermal insulation qualities. Homeowners can drastically reduce heat transfer by wrapping pipes in these shells, guaranteeing that hot water stays hot and cold water stays cold. By lowering the need for continuous heating or cooling, this improves comfort and also helps to save utility costs.

In addition to providing good thermal insulation, polyurethane foam shells have outstanding moisture resistance. This feature is especially helpful in humid environments or places where moisture accumulation is likely to occur. These shells contribute to the insulation’s long-term preservation by keeping moisture from penetrating the material and extending the pipes’ lifespan.

Polyurethane foam shells also have the benefit of being simple to install. In contrast to certain alternative insulation techniques, like conventional fiberglass wrapping, polyurethane foam shells are quickly and simply applied to pipes of different sizes and shapes. They are therefore a practical choice for both experienced installers and do-it-yourselfers.

Finally, polyurethane foam shells offer a strong pipe insulation option for both residential and commercial settings. They are an appealing option for homeowners trying to lower heating expenses and increase energy efficiency because of their superior thermal insulation qualities, resistance to moisture, and simplicity of installation. People can enjoy more comfort in their homes and contribute to environmental sustainability by using less energy by investing in polyurethane foam shells for pipe insulation.

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