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.
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.
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)
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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.
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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Contact us to discuss your requirements of floor phenolic foam board. Our experienced sales team can help you identify the options that best suit your needs.