Frequently Asked Questions About InsulThin™ HT

InsulThin HT is a new, high-temperature blanket insulation from IIG, a Johns Manville company.

Q. InsulThin HT is referred to as “microporous.” What does that mean?

A. “Microporous” material is formed from compacted powder with an average interconnecting pore size that is equal to or below the mean free path of air molecules at standard atmospheric temperature and pressure. This “air-enhanced” insulation contains fibers to add integral strength and an opacifier to slow radiant heat passing through it. The powdered microporous material is encapsulated in between two high-temperature glass fiber blankets and then stitched together. InsulThin HT can be compared to a quilt.

Q. What temperature range is InsulThin HT suitable for?

A. 150°-1200°F (66° – 650°C).

Q. What are the product’s main advantages?

A. It has extremely low thermal conductivity, it is hydrophobic, it has excellent thermal stability in high-humidity conditions (unlike silica aerogel), and is both thin and flexible – making it ideal for pipes as small as 1” IPS and projects where space is limited or dead loads are restricted. Additionally, InsulThin HT offers potentially better Corrosion Under Insulation performance than silica aerogels.

Q. What is the main drawback of using thinner insulations such as microporous or silica aerogel blankets?

A. Compared to traditional pre-formed insulations such as calcium silicate, expanded perlite and mineral wool, all thin blanket materials have higher material and installation labor costs. For any given pipe size and operating temperature to achieve safe-to-touch standards (i.e., 140° F), the material-only costs are 2-3 times more expensive. Labor costs are always higher because a typical application requires between 3-10 layers of thin blankets compared to 1-3 layers of pre-formed. More layers to measure, cut and install mean higher installed costs on every project.

Q. What are some typical industrial applications for InsulThin HT?

A. InsulThin HT is ideal for refinery and petrochemical facilities, power plants, offshore oil equipment, marine vessels and commercial steam tunnels. Within these segments, it is advantageous in any area where limited space is more important than higher cost.

Q. I’ve read that Johns Manville has held multiple patents for high-temperature thin blanket insulations for over 25 years. Why did IIG choose now to offer this material into the industrial market?

A. Johns Manville has been in business since 1858, and we know insulation. Microporous blankets have been performing well in the aerospace industry for three decades because space and weight considerations take precedence over higher cost. The industrial pipe and vessel insulation market has long been dominated by traditional pre-formed materials like calcium silicate and perlite because they provide the right balance of performance, low installed cost and a broad base of experienced contractors.

Thin blanket insulations like silica aerogel have made inroads into the industrial market in the last 10 years due largely to marketing efforts by certain manufacturers. IIG developed InsulThin HT for one reason: to offer a competitive product that provides facility owners an alternative material to foster organic market competition in a more contractor-friendly configuration, with shorter lead times and sold through a well-established industrial supply chain.

Q. How do the physical properties compare to traditional pre-formed insulations?

A. Due to extremely low k-values, thin blankets will provide the thinnest and lightest section on any given project. That is all. Unfortunately, other companies that market silica aerogel blankets are making claims in regard to improved corrosion under insulation (CUI), as well as thermal and fire resistance that may not be validated by accepted ASTM test methods. (Among thin blankets, our outside lab test data indicate that microporous blankets can outperform silica aerogels on CUI.) Thin blankets do not provide any additional performance characteristics beyond thinner, lighter sections.

Q. What are the available sizes?

A. Unlike silica aerogel blankets, which offer only rolls that weigh nearly 600 pounds and require a forklift to handle, InsulThin HT rolls weigh less than 55 pounds.   InsulThin HT is available in 60” and 36” wide rolls shipped from our Calcium Silicate plants in Fruita, CO and Ruston, LA. The 5mm rolls are 50’ long and the 10 mm rolls are 25’ long and shipped in cardboard boxes. The idea with the smaller configuration is one person can handle one roll and can use the same installation practices that they do when installing 36” long sections of pre-formed insulation.

Q. When will it be available?

A. Orders will begin shipping August 1, 2014.

Q. What is the minimum amount I have to order?

A. Unlike silica aerogel blankets that require a $125k- $250k investment for a half or full truckload, InsulThin HT will be readily available in LTL quantities through our established industrial supply chain (5mm is readily available). The selected distribution outlets need purchase only 1 pallet (9-18 rolls) minimum, and it will ship on the same truck as their calcium silicate orders. During the opening rollout, IIG is offering broken pallet quantities to allow owners/contractors to run trials without making a significant investment.

Q. How can I get more information about InsulThin HT?

A. Visit the web page on jm.com also visit the technical resource library to compare with other products.