Calcium Silicate Pipe and Board Insulation Resource Library
Over the last 30 years, North American high-temperature calcium silicate (cal sil) insulation has undergone a multitude of changes. Some of the changes were visible, such as the product’s color; it has been white, off-white, pink, blue, gold, had a green stripe, and had gold mica flakes – all to identify that is was asbestos-free. However, there have also been changes to the product that are not as visible to the eye. Did you know that in the last 30 years, Johns Manville's Thermo-1200® calcium silicate has added corrosion inhibitors, become water-resistant, and is now offered in a curved segment configuration for large diameter (30” – 126”) equipment? Each of these changes has redefined the toughness of calcium silicate insulation and should also influence specification and installation decisions.
- Thermo-1200® Calcium Silicate Insulation Superior Performance
- What is the XOX Corrosion Inhibitor®?
- The Benefits of Water-Resistant Calcium Silicate Insulation
- Installing Calcium Silicate Insulation
- Specifying Calcium Silicate Insulation
- Insulation Intel® Resources
Thermo-1200 is a water-resistant, Type I calcium silicate pipe and block insulation, with the XOX Corrosion Inhibitor®, designed for applications that operate at temperatures up to 1200°F (650°C). When properly installed and maintained, it’s superior physical strength and inorganic binders can provide an insulation lifespan of up to 25 years or more.
As of 2002, the XOX Corrosion Inhibitor is a proprietary corrosion inhibitor that is integral to the chemical makeup of Thermo-1200 calcium silicate. The corrosion inhibitors activate with water and help protect the steel surface from corrosion and is one of the least corrosive industrial insulations available (per ASTM C1617 test methods).
Thermo-1200 is a cementitious insulation with exceptional compressive strength (>100 psi/690kPa), making it ideal for applications where mechanical abuse is likely and further protecting against conditions that contribute to CUI. When properly installed and maintained, it’s superior physical strength and inorganic binders can provide an insulation lifespan of up to 25 years or more.
The most recent innovation is a product expansion: curved segments (Curved Segs) for large diameter vessels, piping and equipment. Curved Segs are 6” wide and 36” long segments with sides angled to fit specific diameters. Installation is with bungee cords, just like typical scored block. The advantage is that the fit is custom and exact, so the finishing work that is typically required with scored block (mudding and pointing up small open joints and cracks) is significantly reduced.
As of 2002, the XOX Corrosion Inhibitor is a proprietary corrosion inhibitor that is integral to the chemical makeup of Thermo-1200 Calcium Silicate. The corrosion inhibitors activate with water and help protect the steel surface from corrosion and is one of the least corrosive industrial insulations available (per ASTM C1617 test methods).
As of 2017, Thermo-1200 calcium silicate insulation is water-resistant and redesigned to absorb less than 15% water by weight (maximum ASTM specification allows for 20%) in a 20-minute, typical rainstorm (1¼” of rain/hour). By comparison, traditional calcium silicate can absorb close to 100% of it's weight in water in a 20-minute typical rainstorm. This is where Thermo-1200 can offer significant benefits to contractors.
While insulation systems can provide significant benefits to the end user, systems that are not properly installed or maintained can result in conditions that promote CUI. Installing cal sil is a valued skill in the industry, here are a few resources to support installation methods.
VideoCompare: Installing Thermo-1200® Calcium Silicate vs. Silica Aerogel Thin Blanket InsulationHere is a head-to-head video comparing the installation time of caclium silicate and silica aerogel insulation.
VideoProduct Demo: The Benefits of Water-Resistant Thermo-1200® Calcium SilicateThermo-1200 is the only calcium silicate manufactured in North America that is water-resistant. It is engineered to withstand a heavy rainfall (1¼” of rain/ hour) for up to 20 minutes without absorbing more than 15% of its weight in water allowing contractors more time and flexibility in the installation process than has traditionally been available. Watch the demo to learn more.
Project ProfileProject Profile: Thermo-1200® Calcium Silicate in Power PlantThe construction of the Newark Energy Center gas-fired power plant in Newark, New Jersey called for an aggressive construction schedule and several specific insulation requirements for the pipe and vessel application. The insulation had to provide high-compressive strength, optimize corrosion defense, be readily available and cost-effective.
Inspection ProgramNIA’s Thermal Insulation Inspector Certification™Learn how to verify that the insulation system has been installed in accordance with the mechanical insulation specifications.
BlogInsulation Disaster Recovery: Restarting Your Refinery or Petrochemical PlantLearn what to look for and what to do if your plant has been damaged or shut down by a natural disaster.
AccessoriesAdhesives, Finishing Cements and CoatingsJohns Manville's accessory offerings include a variety of adhesives, finishing cements and coatings which are specifically designed to complement JM's insulation materials.
WebinarMechanical Integrity Considerations for Your Insulation SystemHosted with Inspectioneering: Learn more about how insulation plays a role with Corrosion Under Insulation (CUI) and Risk-Based Inspection (RBI) programs.
WebinarMitigating CUI: A Two-Pronged ApproachDive into the details of how to combine jacketing and insulation to create a robust system that can limit the risk of Corrosion Under Insulation (CUI).
WebinarKnow the Code: Industrial Standards & SpecsDiscussing industrial standard specifications and what can force your spec out of compliance.
WebinarCUI Research - The Critical Components & FindingsSouthwest Research Institute (SwRI) and Johns Manville partnered for corrosion testing. Find out the results.
WebinarHow Hydrophobic Insulation Impacts CUIDive into key details to optimize your CUI protection strategy utilizing water-repellent insulating materials.
WebinarJM Industrial ProductsAn Overview of JM Industrial Insulation Products