A particularly well thought-out and thorough question from longtime GBA reader Aaron Birkland on the pH of phenolic foam and its possible corrosive nature prompted me to follow up my original blog on Kingspan&#;s Kooltherm rigid insulation.
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Aaron has two main questions:
Phenolic foam rigid insulation was introduced in the U.S. in the s and sold by Beazer East and Johns Manville, but serious corrosion problems resulted in legal action and both companies ceased production in .
Kingspan, an Irish company with a completely new formulation for its phenolic foam insulation, has been producing and selling Kooltherm in Europe since , introducing it in the U.S. in .
In , Dow Building Solutions introduced a white paper, &#;Rigid Polymeric Foam Boardstock Technical Assessment,&#; at a Society of Plastics Engineers conference. This paper compares certain performance properties of two types of phenolic foam, one type of polyisocyanurate, and one type of extruded polystyrene (XPS) insulation. Here are the most important points from this paper:
Dr. Jan Kosny of Fraunhofer Institute (see last section of blog) is a widely respected building scientist and materials expert; Kosny characterized this Dow report as &#;marketing material.&#;
Kingspan provided me with a third-party pH test of their Kooltherm insulation conducted by Cardiff University, dated July 21, , following the test method for EN: &#;Thermal insulating products for building equipment and industrial installations &#; Determination of trace quantities of water soluble chloride, fluoride, silicate, and sodium ions and pH.&#; Two samples of the insulation yielded pH test results of 6.51 and 6.49.
Kingspan shared a test report with me prepared by BDA Keuringsinstituut (a division of Kiwa NV, a Netherlands-based testing laboratory), dated January 22, . I do not have permission to copy or post this full report, but below is information from the report.
For the BDA Keuringsinstituut tests, four types of rigid insulation &#; mineral wool, Kingspan phenolic foam, polyurethane (PUR), and expanded polystyrene (EPS) &#; were fastened with washers and screws to a profiled steel deck (see Image #1, above) and the insulation then covered with an EPDM roof membrane (see Image #2, below). These assemblies were then placed over a heated water tank such that the assemblies were subjected to 70°C (158°F) and 95% relative humidity for 28 days.
To see the condition of the fasteners after testing was complete, see Images #3, #4, and #5 below (all photos taken from the report).
From the &#;Results&#; section of the report: &#;&#;.[I]t appears as though there is no structural difference in the amount of corrosion after the test. All screws show on average the same amount of corrosion on the part of the screw that has been turned through the profiled steel deck. On that part that has not been turned through the profiled steel deck and therefore was in direct contact with the insulation material no corrosion was found.&#;
I tried to contact Dow Building Solutions to get their response to the above BDA Keuringsinstituut report on Kingspan&#;s Kooltherm, but did not hear back.
It dawned on me that I could go to the Kooltherm project right here in Brattleboro, climb into the unfinished attic, and back out some screws to see if there was any corrosion (see Images #6 and #7). The only problem is that those big bad-boy screws were protected by a baked enamel finish, and they have only been in place about 4 or 5 months.
I also remembered that for my blog on the X-Floc cellulose insulation installation system, we used Kooltherm in a wall mockup installed with plain old interior drywall screws (see Images #8 and #9). This wall mockup has been sitting in my quite damp garage for the last three months. There is still no fastener corrosion, so I decided to fill the drywall screw holes with water and put the screws back in (see Image #10). Image #11 shows the same screw a week later: no corrosion, for what it&#;s worth.
I was not aware of the DOE Buildings Technology Office project until Aaron let me know about it: Development of a Bio-based, Inexpensive, Noncorrosive, and Nonflammable Phenolic Foam for Building Insulation (see Image #12). I checked in with the project partner, Atlas Roofing. They reported that there has been no commercialization of this work, either on their part or as evidenced by any new patents they could find based on this project (a key indicator of any project commercialization).
Just before completing this blog, however, I did reach Dr. Jan Kosny, Director of Building Enclosures and Materials at the Fraunhofer Institute U.S.A. Kosny reports:
Not surprisingly, these images (and the testing they represent) put my &#;Wingnut-testing&#; to shame.
Kooltherm remains the &#;real McCoy&#; of currently available phenolic foam rigid insulation in the U.S.
Acidity concerns and corrosion issues have been resolved with Kooltherm phenolic foam rigid insulation. And while competitors to Kooltherm insulation may be several years out, Fraunhofer-led research and development could well mean serious competition in the years to come.
In addition to acting as GBA&#;s technical director, Peter Yost is the Vice President for Technical Services at BuildingGreen in Brattleboro, Vermont. He has been building, researching, teaching, writing, and consulting on high-performance homes for more than twenty years. An experienced trainer and consultant, he&#;s been recognized as NAHB Educator of the Year. Do you have a building science puzzle? Contact Pete here. You can also sign up for BuildingGreen&#;s newsletter to get a free report on insulation, as well as regular posts from Peter.
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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 !
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
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.
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.
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
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.
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.
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.
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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.
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:
Before applying the insulation, ensure the installation area, especially the pipework that needs insulating is clean and dry.
When working with phenolic pipe insulation, wear suitable safety equipment.
Wrap the Kooltherm phenolic foam pipe section around the pipework, being the ends of the lagging together and seal with foil tape.
Ensure no gaps or voids exist between the pipe section and the pipe or equipment.
Seal all insulating joints to ensure there are no holes through which heat can escape.
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.
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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Contact us to discuss your requirements of Phenolic Roof Insulation. Our experienced sales team can help you identify the options that best suit your needs.