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Listed and Labeled: How Two Little Words Are Making Big Waves in Building Codes

As of 2024, every major mechanical building code now requires insulation for ducts and/or piping in a plenum to be “listed” and “labeled.” Owners, engineers, and other specifiers are making changes to their HVAC and plumbing insulation specifications, and building code inspectors are taking a closer look at insulation, while the contractor or installer is a bit caught in the middle. Installers need to understand what the new language means to ensure the right product is installed in the right application to follow the specification and meet building codes to the satisfaction of the inspectors.

What Do “Listed” and “Labeled” Mean, and Why Does it Matter?

An insulation product is expected to meet certain standards in the building and construction industry. Within organizations like ASTM and UL there are standard specifications, which list all the tests a product is expected to undergo as a minimum industry standard; and there are standard test methods, which describe the details of the tests themselves.

In the case of mechanical insulation, an insulation product could be tested to the “standard test method” per ASTM E84 or UL 723 for a flame spread rating and smoke developed rating, for example. The insulation sample would need to be mounted per ASTM practice ASTM E2231. If an insulation manufacturer wanted to show that their product met the minimum industry requirements, they would have a few ways of doing so.

One option is for the insulation manufacturer to test it internally— they may have a test chamber or test setup they can run themselves—and they would stand behind their own results. This would still be considered a test to the ASTM or UL standard as long as they followed the procedure outlined.

Another option is to obtain an independent third-party test, taking the testing out of the hands of the manufacturer and entrusting it to a testing lab. When going this route, manufacturers often look to labs that are accredited, meaning that that they have been recognized by OSHA as a nationally recognized testing laboratory (NRTL).

With either of these options, a manufacturer must only report the test results to show compliance with the standards. This is called self-reporting. How many times they test, or how often they test, is entirely up to the manufacturer.

Going a step further, the manufacturer can get the product “listed” and “labeled” by an NRTL, providing more confidence in the long-term performance of the product. “Listed” means that the NRTL will publish the test results publicly on its website and require regular testing to ensure that the product continues to meet the results listed. The product and associated materials will also be “labeled” with the corresponding test report number that links it to the test report and shows that the testing is continuously maintained.

What Exactly Are the New Building Code Requirements?

Updates to the International Mechanical Code
The International Code Council was an early adopter of the terms “listed” and “labeled” for insulation in plenums, including them in the International Mechanical Code (IMC) as early as 2012. For example, Section 602.2.1, entitled “Materials within Plenums,” requires, with few exceptions, that anything in a plenum either be noncombustible or be listed and labeled as having a flame spread of no more than 25 and a smoke developed index of no more than 50 when tested to ASTM E84 or UL723. The section for duct coverings and linings, like duct insulation, also included 25 flame spread and 50 smoke development requirements with the sentence, “Coverings and linings shall be listed and labeled.” Piping systems in a plenum would still be interpreted as falling under the broader category of “materials in plenums,” but neither piping nor piping insulation was specifically called out.

The IMC was again updated in 2015, and more clarification was given to exactly what did and what did not have to be “listed” and “labeled” to meet the flame spread and smoke developed requirements. The “Materials within Plenums” section remained unchanged, but new sections were added that covered specific materials and their requirements. For example, a new section was added in 602.2.1.7 for “Plastic Plumbing Pipe and Tube,” which clarifies that plastic piping itself must be listed and labeled to ASTM E84 or UL 723.

In the 2018 version of the IMC, a new section was added for 602.2.1.8 specifically addressing “Pipe and Duct Insulation within Plenums,” clearly stating that the insulation in plenums, whether for a pipe or duct, must meet the requirement of no more than 25 flame spread and 50 smoke developed per ASTM E84 or UL 723, and describing the mounting method and additional testing criteria. There is little ambiguity in the phrase, “Pipe and duct insulation shall be listed and labeled.”

The 2024 IMC brought in a lot of new, helpful language, including detailed descriptions of what qualifies as a plenum and the various types of plenums the section applies to. Section 602.3, “Materials within Plenums,” is reduced to just a single sentence, referencing the subsections below. The subsections call out each and every material likely to be found within a plenum. One exception is “materials listed and labeled for installation within a plenum and listed for the application.” Among the following subsections are “Plastic Piping and Tubing” and “Pipe and Duct Insulation within Plenums.” Just for good measure, a new Section 602.3.10, titled “Other Combustible Materials,” is included as a catch-all, simply stating that any combustible materials in a plenum not specifically mentioned in the sections above must be listed and labeled as having no more than 25 flame spread and 50 smoke developed per ASTM E84 or UL723.

Updates to the Uniform Mechanical Code
The IMC is not the only mechanical code adopted by states and municipalities across the United States. While most states have adopted some version of the IMC, there are some states and municipalities that have opted to use the Uniform Mechanical Code (UMC) as the reference for their code instead, like the State of California. Additionally, there are some cities or municipalities that have chosen to adopt the UMC even if the state has adopted the IMC. For example, the City of Houston uses the UMC, even though the State of Texas has adopted the IMC. For this reason, the different codes try to mirror each other, eventually using similar language to reduce chaos and confusion in the industry.

The 2024 UMC had the first mention of “listed” and “labeled” regarding insulation in plenums, adopting similar language to what was found in the IMC at the time. Similar to the IMC, Chapter 6 of the UMC also covers duct systems and plenums.

The UMC also has a Section 605, “Insulation of Ducts,” in which the final sentence clearly states, “The duct coverings and linings shall be listed and labeled.” Understandably, the chapter on “Duct Systems” focuses more on duct insulation than piping insulation, as seen in earlier editions of the IMC. So far, this is the only mention in the UMC of insulation needing to be listed and labeled.

As of 2024, the UMC does not specifically require listed and labeled for insulation on piping. Section 1201.2 states, “Where installed in a plenum, the insulation, jackets, and lap-seal adhesives, including pipe coverings and linings, shall have a flame-spread index not to exceed 25 and a smoke-developed index not to exceed 50…” So here we are told that the insulation must be tested to ASTM E84 or UL 723 and meet the same 25 and 50 ratings, but self-reported testing is acceptable.

That being said, a project specification might not rely solely on the IMC or UMC with regards to HVAC and mechanical systems—especially if the specifier does work in multiple jurisdictions. In addition to the requisite mechanical code, many local and state jurisdictions also require compliance with the standards set by the National Fire Protection Association (NFPA).

Updates to National Fire Protection Association Standards 90A and 90B
The NFPA has its own series of standards for the building and construction industry. Specifically, NFPA Standard 90A—the Standard for Installation of Air-Conditioning and Ventilating Systems—and NFPA 90B—Standard for the Installation of Warm Air Heating and Air-Conditioning Systems—are often cited regarding fire safety for HVAC systems.

In the committee to consider updates and changes for the 2024 edition, a suggestion was submitted through public comment that pipe and duct insulation should be listed and labeled so that NFPA codes and standards would agree with the other codes and standards. This also would be consistent with other items in plenums, like equipment and piping, that NFPA already required to be listed and labeled. The committee agreed and adopted the new language for the 2024 edition.

Section 6.4.1 is the section that specifically addresses pipe and duct insulation, calling for the insulation to have a maximum flame spread of 25 and maximum smoke developed of 50 when tested to ASTM E84 or UL 723. A subsection was added (6.4.1.1), with the single line, “Pipe and duct insulation shall be listed and labeled,” bringing the NFPA standard in line with the other major codes.

How Does the Change Affect Specifiers and Contractors?

Adding the words “listed” and “labeled” may seem like a simple change, but many separate project specification sections will be affected, including “Plumbing Piping Insulation,” “HVAC Piping Insulation,” “HVAC Equipment Insulation,” “Duct Insulation,” “Metal Ducts,” and practically any other mechanical or plumbing specification section that could conceivably have insulation in a plenum space.

Regardless of the section, project specifications generally list the flame spread and smoke developed requirements in the Quality Assurance paragraph. While some specifiers list one set of standards for insulation installed indoors and another standard for insulation installed outdoors—or inside plenums or outside of plenums—it is most common for specifiers to simply hold all mechanical and plumbing insulation to the highest standard and require all HVAC and plumbing insulation to be approved for use in plenums. Just as adding the words “listed” and “labeled” was a subtle but significant change to the recent codes, the words almost might go unnoticed by a contractor bidding on the project who is unfamiliar with the change.

It’s halfway down the paragraph, buried in a section so common it’s practically boilerplate. While “listed” and “labeled” can very easily be added to a specification, it is no good if the updates to the specification are completely missed by the contractor tasked with implementing it. There is a reason a specifier goes to the trouble of spelling everything out, rather than only stating something like, “product shall meet applicable building codes.” The specification change should do more to be noticed. Approaches like bolding, italicizing, underlining, or even highlighting important words in a different color may work, but a simpler solution may just be in the formatting. For example, consider adding a new sub-paragraph, or even just a single line, as in the update from NFPA 90A. See what such a formatting change does to the same example paragraph cited at left:

While simply adding the words “listed” and “labeled” might be enough to bring the project specification into code compliance, the contractor or installer needs to understand the change so as not to be blindsided by suddenly needing a different insulation product than the one originally bid—or, even worse, not realizing the wrong product was installed until the inspector reviews the work.

How Can We Help Building Inspectors Find What They’re Looking For?

Different states and cities have been operating on a patchwork of building codes and standards for years, making the job of the building inspector that much more difficult in trying to keep up with the codes and standards on a national, state, and even local level.

With the listed and labeled language update now in all major building codes and standards, there is more consistency in the industry—for example, eliminating the difficulty of not knowing whether to enforce an insulation requirement in the IMC that isn’t in the UMC or NFPA 90A. Just having the agencies in agreement on one more item, one more standard that is universally enforceable, makes the job easier. It’s no wonder the issue is getting more attention now!

Requiring a product to be listed and labeled is one thing, but expecting a building code inspector to read the fine print on a 1-inch tube of insulation hanging 20 feet in the air is quite another. The “labeled” part of “listed and labeled” means that the insulation itself should carry the seal, stamp, or other identifying mark from the nationally recognized laboratory that listed it. But, understandably, the insulation might be difficult to read.

It’s in the best interest of the insulation manufacturers to make their products easy to identify to ensure the right products are used in the right places. That might mean using dramatically different packaging, or a large, clearly identifiable label; or printing the label indicating the listing not just on every package, but on every brochure, invoice, product description, and other piece of literature in the contractor’s hands. One manufacturer has gone the extra mile by making the pipe and duct insulation approved for use in plenums a dramatically different color, easily identifiable from a distance.

What Do We Need to Do Now?

Not every product that has been used before can be used now. “Listed and labeled” is not simply a higher standard, but also higher accountability. Some legacy piping insulation may be perfectly fine for domestic plumbing running through a wall, or refrigerant piping in a variable refrigerant flow system, or underground buried lines; but if it’s not listed and labeled, it may not be permitted in a plenum. For insulated ducts, or any piping that could run through a plenum, it should be listed and labeled. So, what now?

The Role of Each Value Chain Player
Now, manufacturers need to rise to the challenge and make sure their insulation is up to the standards. Then, they must make sure the listed and labeled products are easily identifiable so they will not be confused with legacy products.

Specifiers need to make updates to their specifications—not just adding the listed and labeled requirements, but also ensuring the products they call out in the insulation schedule meet current code, verifying the building code requirements of the jurisdiction where the project is being performed with the authority having jurisdiction.

Contractors and insulation installers need to make sure they understand the changes to the specification language and are bidding and installing the appropriate products in plenum spaces.

Now, inspectors need to know how to identify the listed and labeled products. If the insulation isn’t easily identifiable at a distance, then they must know what else to look for (packaging, paperwork, etc.). Of course, there will still be times when a closer look is required.

Conclusion

At the end of the day, it is in everyone’s best interest to make sure that the insulation products that are installed in ducts and plenum spaces are up to the latest fire and smoke standards. The codes are evolving to meet higher standards, and no matter what your role is in the insulation industry—from manufacturer to specifier to contractor to inspector—it’s up to all of us to rise to the challenge.

NIA Sites > Insulation Outlook Magazine > Global

A Practical Guide to Industrial Sound Control

Sound can affect workers’ comfort, performance, and even health. Industrial noise poses a hearing threat to approximately 22 million workers in the United States each year.1 One in eight of those employees will experience hearing damage due to prolonged exposure to high sound level environments.2 Noise can also cause safety concerns, interfering with communication and masking notification sounds of hazards such as forklifts.

The most cost-effective time to address industrial noise is during design and construction. Understanding how sound is created and propagates, as well as evaluating the performance of different materials and assemblies, can help reduce noise at the source. Mitigating noise effectively requires a basic understanding of the science of sound and the tests that evaluate materials’ noise reduction performance.

The Science of Sound

Sound is created when a vibrating object excites the surrounding air. As air molecules collide and transfer energy away from the vibrating surface, a pressure wave travels throughout the surrounding space and reaches the ears. The wave then turns into an electrical signal within the middle ear, allowing your brain to recognize and process the sound. This basic interaction (vibration, wave, reception) is at the heart of everything acoustic.

Our ears can detect sounds across an enormous range. There is a difference in pressure of over 100,000 times between the softest hum and a loud industrial noise. Engineers rely on the decibel (dB) scale to quantify sound.

Introduced to measure signal loss over telephone lines, the decibel, named in honor of Alexander Graham Bell, is the standard for evaluating sound levels. Because the decibel is logarithmic, a seemingly small increase in decibels can represent a significant rise in sound energy and potential harm. To further quantify the relationship between what the ear hears and the measured sound level, a filter called A-weighting is applied to measured sound, resulting in measurements labeled dBA. This measure represents the sound that the ear senses, while considering the lack of sensitivity of the ear at lower frequencies.

A small change in decibels can represent a large change in actual sound energy. A 3 decibel reduction, just noticeable, requires cutting the emitted sound energy by half. To make the sound half as loud, you must reduce it by 10 decibels, which requires a 90% reduction in sound energy. Smart noise control should start early—it’s far easier to reduce sound at the source during the design stage.

Industrial Sound

Sounds below 85 dBA are regarded as safe for up to 8 hours of exposure, as outlined by the U.S. Occupational Safety and Health Administration (OSHA).3 Many common industrial machines operate at higher noise levels (see Figure 1).

A table saw typically reaches noise levels of 90 to 95 dBA. A hammer drill can reach almost 115 dBA. Unprotected exposure to levels above 85 dBA can result in permanent hearing damage. Industrial settings with higher than 85 dBA are required by OSHA to establish and maintain a Hearing Conservation Program. This adds a recurring cost to employers, and if hearing impairment affects workers, costs can be higher. It’s estimated that average U.S. occupational hearing loss claims cost businesses between $49 to $67 million each year.4

Common Methods of Industrial Noise Control

Engineers use three methods to analyze sound performance:

  • Sound absorption,
  • Transmission loss, and
  • Insertion loss.

Sound Absorption
Sound absorption represents how well a material reduces sound energy (see Figure 2). It is a function of how resistive a porous material is to airflow through it. Absorption performance is typically evaluated using ASTM C423 Standard Test Method for Sound Absorption and Sound Absorption Coefficients by the Reverberation Room Method, which assesses the bulk absorption of an acoustic material in a reverberation room. The result is often summarized and reported using the noise reduction coefficient (NRC), a single-number rating that reflects average absorption across several frequency bands. NRC ratings for many materials/products are published by multiple trade associations and building material companies.

A common misconception is that an NRC of a decimal value directly correlates to percent of sound absorbed by a material. For example, it is commonly thought that an NRC of 70 means a material absorbs 70% of sound. The NRC is determined by measuring the area of sound absorption provided by the material/product and then dividing that by the surface area of the material/product. So, the NRC is the percentage of the material/product that is fully absorbing sound. This comes into play when comparing the NRC of materials. There is little noticeable difference between an NRC of 0.70 and 0.75 when treating a small space. Adding a little more surface area of a slightly lower NRC material can make up that difference.

Thicker materials generally absorb more sound energy than thinner ones. Thickness is the easiest and most efficient way to increase sound absorption. If thickness cannot be increased, then density can be leveraged to gain absorption at lower frequencies. Higher frequency sound absorption will typically decrease as the material density increases. An alternative to increasing density could be to add a facing or scrim, which can be tuned to optimize the sound absorption of the material at a specific thickness.

Transmission Loss
Transmission loss refers to a sound’s energy reduction as it passes through a barrier typically a wall, floor, or ceiling assembly. Wall transmission loss is measured according to ASTM E90 Standard Test Method for Laboratory Measurement of Airborne Sound Transmission Loss of Building Partitions and Elements (see Figure 3). Sound is played and measured on the source side of a partition wall (source room) and measured on the receiving side (receiving room) at the same time. The amount of energy absorbed by the receiving room is determined and added to the measured amount in the receiving room. The logarithmic ratio is determined between the two sides, and the result is the transmission loss of the partition wall. The transmission loss is a characteristic of the partition wall assembly because it is a result of all the materials in the wall. Transmission loss of the partition wall is compared to a reference curve, per ASTM E413 Classification for Rating Sound Insulation, to develop a single-number rating called the sound transmission class (STC). The STC ratings for wall constructions are published by multiple trade associations and building material companies. Transmission loss is commonly used in architectural applications to meet minimum STC rating requirements.

Insertion Loss
A sound level is recorded in a space; then, a barrier or treatment is applied, and the sound level is measured again. The difference in sound level before and after is the insertion loss. The value represents the amount of sound reduced by the treatment. This type of measurement works well to compare products in the same setup. However, the measurements are both dependent on the material/product and the measurement location/setup. Multiple standards determine the insertion loss of products and systems to provide data for comparison of performance. There are subtle differences in how standards measure the insertion loss; however, the formula for calculating the insertion loss remains the same:

Untreated Sound Pressure Level (SPL) (dB) – Treated SPL (dB) = Insertion Loss (dB)

Industrial Noise Control
Interventions to reduce industrial noise from piping typically involve applying acoustic treatments to limit sound radiated from the pipe. ISO 15665 Acoustics – Acoustic Insulation for Pipes, Valves and Flanges and ASTM E1222 Standard Test Method for Laboratory Measurement of the Insertion Loss of Pipe Lagging Systems are two standards for measuring the insertion loss of pipe treatments (see Photos 1 and 2).

The ISO 15665 test mounts a pipe that runs through a test chamber where sound energy is applied to the interior of the pipe. It then runs from the test chamber through one wall, across the room, and out through the other wall. The sound radiated into the test chamber is measured before and after treatment, determining the insertion loss. The ISO 15665 standard provides a table to compare the results and identify a “class” rating. The rating is based on the pipe interior diameter and insertion loss at multiple frequency bands. These class ratings allow a design engineer to choose the amount of insertion loss for their application. The classification was recently expanded to include a Class D in an update to the ISO 15665 standard.5

Another option for determining insertion loss of pipe treatments, or lagging, is ASTM E1222. ASTM E1222 differs slightly from ISO 15665 in that the end of the pipe remains in the room. Theoretically, you should get the same result from each test, but in reality, the values can differ. ASTM E1222 insertion loss values are reported in a chart and/or table format by frequency band. There are no class ratings for this standard.

Insertion loss in air distribution systems is measured utilizing ASTM E477 Standard Test
Method for Laboratory Measurements of Acoustical and Airflow Performance of Duct Liner Materials and Prefabricated Silencers (see Photo 3). This test method measures the sound transmitted through a duct system with a 10-foot-long test section, first with an empty duct, and then with a treated duct or duct silencer with the same internal dimensions as the empty duct, providing values by frequency band for how much sound levels are reduced through the 10-foot-long test section. Results are presented as the overall insertion loss and the amount of reduction in dB/foot, giving information on the performance of the system as it will be operated. This test is especially relevant for treatment of HVAC system noise in spaces where quiet air delivery is crucial.

Some manufacturers only make available sound absorption data for their duct products following the ASTM C423 standard, providing only sound absorption coefficients. Unfortunately, the sound absorption results do not correlate to the material’s performance in use.6


Sound absorption following the ASTM C423 standard is useful for evaluation of duct wrap, though. Covering a duct with fiber glass duct wrap improves thermal efficiency of the duct and adds sound absorption to the space to which it is exposed. This is particularly useful for selecting insulation in areas where reducing background noise may help enhance focus and communication.

Together, data from these tests can help engineers design building spaces that reduce employee exposure to high sound levels.

Conclusion

The Centers for Disease Control and Prevention estimates that 22 million workers in the United States are exposed to hazardous noise.7 Industrial noise can affect safety, comfort, and long-term costs for any facility. Addressing noise early in the building process using sound absorption, transmission loss, and insertion loss measurement data can drive better noise control outcomes. Outsourcing this expertise is often a smart move. Bringing in the right help at the right time can make all the difference.

References

  1. OSHA.gov
  2. NIH.gov
  3. OSHA.gov
  4. Herreman, “Acoustic Measurements of Duct and Duct Liner Materials,” Proceedings Inter-Noise 2018, Chicago, IL, August 26–29, 2018
  5. Richard Pamley, “A Discussion of Changes to ISO15665:2023-12 Acoustics—Acoustic Insulation for Pipes, Valves, and Flanges,” Insulation Outlook, March 2025 www.insulation.org/io/articles/a-discussion-of-changes-to-iso156652023-12-acoustics-acoustic-insulation-for-pipes-valves-and-flanges)
  6. Herreman
  7. CDC.gov
NIA Sites > Insulation Outlook Magazine > Global

Bad Specs: When Numbers Miss the Mark

What numbers are good? Which ones are bad?

In our industry, we strive to eliminate confusion by crafting specifications tailored to the job or application at hand. One of our biggest challenges is balancing specificity with clarity by providing enough detail to be useful without overwhelming or diluting the intent of the specification.

Historically, specs were simple: weight, material composition, and dimensions. These were easy to measure, easy to communicate, and easy to compare. But as materials and applications evolve, so do product characteristics. Today, the numbers we rely on can be misleading if they’re not tied to performance.

Take the classic example of a 2” x 4” framing stud. In reality, it measures 1 ⅝” x 3 ⅝”. Structurally, that’s fine, since it still meets building code load requirements. Adjacent components, like pre-hung doors, have adapted accordingly. The actual dimensions don’t matter, as long as the wall is structurally sound. This is a perfect example of how performance beats precision in certain contexts.

We’ve seen similar shifts in our own space. Consider industrial mineral wool, which is sold by nominal, rather than actual, density. Over time, process improvements have removed much of the un-fiberized material, commonly referred to as “shot,” which reduces the product’s weight while maintaining the fiber content necessary for performance. To maintain consistency with legacy specifications, the nominal reference remains. But this raises a key question: Do we care about weight or performance?

Ultimately, customers are buying performance, not just a list of numbers. So how do we evaluate it? And more importantly, how do we write specifications that reflect it?

Building Better Specs: Key Considerations

Dimensions and Performance Requirements
Let’s revisit the wood stud example. Instead of specifying a material by its nominal size, ask, what performance is needed? If you’re considering different materials, what thickness is required for thermal or acoustic performance? What temperature range must be supported?

These questions help define performance requirements rather than locking in a product that may have changed over time. This approach allows for flexibility and innovation while still meeting the core need. For example, specifying a required R-value or decibel reduction gives manufacturers and contractors room to select the best material for the job—even if the product itself evolves.

Resources such as NIA’s Insulation Materials Specification Chart (www.insulation.org/about-insulation/system-design/techs-specs) offer valuable insights into how different materials perform under various conditions. Specs should reference these kinds of performance benchmarks rather than static product attributes.

Single-Number Ratings versus Spectrum Data
Single-number ratings simplify material selection. Flame spread and smoke development ratings (25/50), R-values for insulation, and pass/fail combustibility tests are easy to understand and compare. But they don’t always tell the full story.

Some performance metrics—like thermal conductivity or acoustic absorption—are better represented as curves across a range. For example, thermal conductivity changes with temperature, and acoustic absorption varies by frequency. These nuances are often lost in a single-number summary.

In acoustics, the noise reduction coefficient (NRC) is a single-number rating derived from spectrum data. Higher NRC values mean better sound absorption, making it easier to compare materials. But if you’re designing for a specific frequency range—say, low-frequency industrial noise—you’ll need to look beyond the NRC and examine the full absorption curve.

For thermal applications, tools like the North American Insulation Manufacturers Association’s 3E Plus® (www.insulation.org/training-tools/3e-plus) or NIA’s Simple Insulation Calculators (www.insulation.org/training-tools/designguide/simple-calculators) help determine the required insulation thickness based on a material’s thermal conductivity data. These tools rely on spectrum data to provide accurate, application-specific recommendations.

System versus Component Ratings
Specifications often focus on individual components, but real-world performance depends on systems. A system typically includes multiple components such as insulation, coverings, fasteners, and sometimes structural elements, each contributing to the final performance.

For example, insulation may reduce heat flow, but a covering might add durability, aesthetics, or resistance to environmental conditions. When it comes to fire resistance or acoustic performance, the entire system matters, not just the insulation.

Customers often ask about the hourly fire rating or sound transmission class (STC) of a specific insulation product. But insulation alone doesn’t carry these ratings: They’re system-level metrics. A 2-hour fire rating or an STC of 55 is achieved through a combination of materials, installation methods, and design details.

And remember, performance isn’t always additive. Doubling insulation thickness doesn’t guarantee double the fire resistance, or half the sound transmission. Specs should define system-level goals, such as a 2-hour fire rating or a target STC/insertion loss, rather than relying on assumptions about individual components.

Good Specs Focus on Outcomes

Specifications should guide users on what to use and what selections are supposed to do. Good specs define the goal, allowing for multiple solutions. This approach encourages innovation, accommodates evolving materials, and ensures that the end result meets the intended performance.

For example, specifying a 2-hour fire rating for a 12” schedule 40 pipe exposed to hydrocarbon fire is more useful than naming a specific insulation product without context. The same applies to acoustic ratings, which vary by pipe size, insulation thickness, and wall thickness.

It’s easy to get lost in the numbers. Sometimes small numbers are good, like thermal conductivity, flame spread, and smoke development. Other times, bigger is better, like hourly fire ratings or acoustic sound transmission results. But when you focus on what the insulation system needs to do, the specs start to make sense.

Conclusion: Move from Numbers to Needs

Bad specs happen when we confuse numbers with needs. Good specs start with a clear understanding of the problem to be solved, whether it’s thermal control, sound attenuation, fire resistance, or durability. From there, we can define performance requirements that guide product selection without locking ourselves into outdated or overly rigid criteria.

In a world of evolving materials and applications, performance-based specifications are not just helpful, they’re essential. They ensure that we’re building systems that work, not just checking boxes. And that’s a spec worth writing.

NIA Sites > Insulation Outlook Magazine > Global

Mitigating Corrosion under Insulation while Reducing Carbon Emissions—A Winning Combination

This article was written before King passed away, and it originally appeared in the June 2025 issue of Materials Performance, a publication of the Association for Materials Protection and Performance (AMPP).

As reported in Insulation Outlook, NIA and AMPP are working together on establishing a mechanical insulation standards program. This collaboration is a step forward in our mutual commitment to sustainability, energy efficiency, safety, decarbonization, and enhancing the value insulation brings to the global market. Together, we are setting a new benchmark for quality and performance, ensuring that our industries not only meet but exceed the expectations of today and the demands of tomorrow. To read the latest on the standards development, see “Bridging the Gaps: New AMPP/NIA Mechanical Insulation Standards Aim for Industry-Wide Solutions” on page 35.

Achieving sustainability goals is complex and requires addressing multiple aspects of decarbonization. NIA commissioned a study to examine the impact mechanical insulation systems can have on reducing energy demand, reducing greenhouse gas emissions, and increasing energy efficiency.

The study points out the obvious savings but, most importantly, highlights what could be saved if mechanical insulation was viewed as a proven decarbonization technology that is immediately available.

The study conservatively examined the emissions savings and losses for 1 year, 5 years, and cumulatively over an 11-year period. More than 7.5 million metric tons were saved, but more than 751 million metric tons of carbon reduction opportunity was lost due to under-insulated areas (see Figure 1).

Defining Mechanical Insulation

All insulation systems deliver energy savings and emission reductions, so why should mechanical insulation be looked at differently? The answer is related to temperature differential and heat loss/gain.

Mechanical insulation encompasses all thermal, acoustic, and personnel safety requirements for mechanical piping and equipment, and HVAC applications. The operating or service temperatures for those applications can range from cryogenic levels (for example, -300°F [-184°C]) to over 1,000°F (538°C).

Other insulation industry segments typically focus on building envelope applications and heating/cooling requirements for residential and commercial buildings. Piping and equipment requiring insulation in these applications usually range from 40°F (4°C) to 250°F (121°C). The greater temperature differentials in mechanical insulation applications yield much more significant energy and emission savings. Accordingly, mechanical insulation is utilized heavily in markets that experience corrosion under insulation (CUI).

Decarbonization

Decarbonization has two fundamental aspects. The first entails reducing the greenhouse gas emissions produced by the combustion of fossil fuels. The second is energy efficiency, which reduces the demand for energy.

As decarbonization efforts continue to be developed and implemented, energy efficiency becomes more critical than ever. The impact insulation industry segments can contribute to that effort should not be overlooked or underappreciated.

Impact of Under-Insulated Areas

Mechanical insulation is highly subject to damage from various sources, from outdoor weather events to indoor personnel and mechanical abuse. Potential damage also occurs due to improper installation, lack of repair, or removal of part of the insulation in a system without replacement.

For purposes of the study, “under-insulated mechanical insulation systems” was defined to include the following:

  • Items left uninsulated that could have been insulated (e.g., unions, flanges, valves);
  • Items not updated to be compliant with the most current model energy or building codes;
  • Items that are not specification compliant;
  • Items with poor installation quality;
  • Cases where insulation was removed for maintenance or other purposes without replacement, thus exposing the remaining insulation system to potential damage;
  • Parts with improper or untimely maintenance;
  • Damaged insulation as a result of:
    • Other trades and facility or maintenance personnel;
    • Weather-related events (e.g., wind, hail, flooding);
    • Moisture or other contaminants’ intrusion (e.g., product, oil, grease);
    • Mechanical equipment (e.g., forklifts, scaffolding, ladders);
    • Removal for maintenance without replacement, thus exposing the remaining insulation system;
    • Environmental elements (corrosive or contaminant environment);
    • System penetration (destructive testing) for inspection purposes without proper, timely repairs; and
    • Wash down or similar occurrences.

Examples of these issues are shown in Figure 2.

The question is, how much is under-insulated and, over time, does the problem manifest as a much bigger number?

Most facilities will acknowledge the problem, but they generally do not have a formal estimate of the magnitude—only general estimates, which can vary greatly depending on whom you ask. Each facility or project would need to determine its estimated percentage of under-insulated areas.

As with all facility systems, mechanical insulation systems should have regular inspection and timely, proper maintenance or the problem will become worse. What today may be a simple repair could be a major problem tomorrow. Additionally, other potential consequences, such as personnel and process safety concerns, process control, and CUI, need to be considered.

Industrial Versus Commercial Market Segment

The industrial segment represents a larger percentage of under-insulated areas than the commercial segment. Many of the insulated piping systems in the commercial segment are located in wall cavities or above ceilings and, accordingly, are not exposed to weather elements or potential mechanical or personnel abuse on a regular basis.

Because the breakdown between market segments is unknown, through a series of estimates, assumptions, and extrapolations, the total savings was allotted between the two market segments. On average, based on the variable percentages of under-insulated areas, the potential loss equates to 10%. For the commercial market, 1.7% was allocated, and for the industrial market segment, it was 8.3%, or an approximate ratio of 1 to 5. More than 751 million metric tons of carbon reduction opportunity was lost due to under-insulated areas (see Figure 3).

Recognizing that mechanical insulation is highly subject to damage from various sources provides the bridge to the discussion of mitigating CUI.

Corrosion Under Insulation

One of the most common concerns about mechanical insulation systems is the risk of CUI. The 2013 NACE Impact Study estimated the cost of CUI in the U.S. industrial market segment alone above $300 billion. On a global scale, across all economic sectors, the cost of CUI was estimated at more than $2.5 trillion in 2013.

It is important to understand that insulation does not cause corrosion. CUI is an electrochemical process. For CUI to start and continue, a combination of the following conditions must be present:

  1. Oxygen,
  2. Corrosive chemicals or compounds – pH < 7,
  3. A temperature at the metal surface between 50°F and 350°F (or a cyclic system that passes through this range at regular frequency), and
  4. An electrolyte (liquid water) to “close” the anode/cathode pathway.

Most industry experts agree that the primary cause of CUI is moisture/water ingress into the insulation system that migrates to the exposed metal surface beneath. Those same experts also believe that moisture/water will eventually get into the metal/insulation interface.

How does water get into a mechanical insulation system? Look back at the list of under-insulated areas and consider the following:

  • Mother Nature—rainwater, including flooding conditions;
  • Surrounding environment—cooling towers, as an example;
  • Condensation development—on or in the insulation system;
  • Sprinkler and/or fire control efforts;
  • Wash water and/or deluge system water; and
  • Pipe or equipment leakage.

To mitigate CUI, you have to keep the moisture out or get it out. You also have to think about mechanical insulation as a system, starting with a coating of the substrate and the design and selection of all materials within the insulation system, ensuring the initial installation is correct and followed by timely and proper maintenance.

We look back at the degree of potential conflicting specifications, lack of accepted application standards, improper installations, and the amount of under-insulated areas, and we ask why or how this happened. That answer comes to a few basic topics for most applications.

  1. Understanding and appreciating that mechanical insulation systems require continual inspection and maintenance.
  2. Capital cost is the primary focus of new construction, often at the expense of future operational and maintenance cost considerations.
  3. The consequences of improper installation and maintenance is only fully appreciated once problems occur.
  4. The investment aspect (financial and emission return on investment components) of maintaining an insulation system is not considered, potentially creating barriers to change.
  5. Hurdles are continuously created by conflicting business and decarbonization/sustainability objectives.
  6. Lack of knowledge and education about all aspects of mechanical insulation systems.

The solutions are complex; there are many opinions as to the best paths to follow, and effective change will take time. But the one change that can happen immediately is to view mechanical insulation as a proven technology and investment that will help achieve a company’s and our country’s decarbonization and sustainability objectives while taking a big step in mitigating CUI.

The challenge for business, finance, and policymakers is identifying how best to use the time and resources—and, especially, solutions—that are available now to advance the changes needed.

Next Steps

While each business or company may have unique circumstances, structures, and procedures to consider, a few common next steps should be considered in determining how and to what level mechanical insulation can help achieve the respective decarbonization goals while helping mitigate CUI.

  1. Commit to investigating and developing a better understanding of the benefits of mechanical insulation and the consequences of not having up-to-date specifications, improper installation, or insufficient or improper maintenance.
  2. Complete a thorough and objective review of current project or company specifications or standards and develop recommended changes, if any.
  3. Develop and implement specific mechanical insulation energy efficiency and emission reduction appraisals/audits and assessments of existing mechanical insulation with inspectors and appraisers certified in those fields.
  4. Determine the internal and external hurdles or barriers to implementing mechanical insulation energy and carbon reduction initiatives.
  5. “Inspect what you expect”—not only in monitoring and recording progress of specific plans, but during the initial installation and maintenance processes.
  6. Develop an annual inspection and maintenance program for existing facilities. This will benefit short- and long-term operational and capital budget planning, and the information could be used in internal and external climate change/sustainability programs, and to mitigate CUI.
  7. Ensure you have transition plans to transfer the mechanical insulation expertise and technology to your personnel. So often, knowledge is lost by right-sizing, downsizing, attrition, changes in responsibility, change of ownership, or mergers.

The technology known as mechanical insulation is available now, and it impacts every state, county (province), city, labor group, direct or indirect related business, and this and future generations.

That is potentially the industry’s greatest challenge. It is hoped that articles like this can be the nucleus of impacting change.

NIA Sites > Insulation Outlook Magazine > Global

NIA Member Fit Tight Covers Discusses System Design

Project Snapshot

NIA Member Company: Fit Tight Covers (FTC)
Industry Segment: Industrial
Type of Plant/Facility: Renewable Natural Gas Facility
Temperature Range: High-Temperature System
Region: Midwest
Insulation Materials: Piping – Alpha FCF-1650, Texo Type E Glass Mat Vessels – Owens Corning L-3.7 Utilicore
Jacketing: Alpha FCF-1650
Other: 12-gauge stainless steel lacing anchors, 2” Nomex Velcro, Braided Kevlar Drawstrings

Project Description and Goals

This new construction project was completed at a renewable natural gas landfill site in the Midwest. Capture and processing of natural gas is a growing sector in sustainable energy, and this project is one of more than a dozen sites FTC’s customer is bringing online across the United States.

The facility owner/operator, who also served as the construction manager, had both short- and long-term goals for the project. For the construction phase, the goals were to get the facility up and running as quickly and efficiently as possible, with a solution that would meet the long-term goals as well. Those long-term, post-construction goals included energy savings, process control, and personnel protection/safety.

Challenges

One challenge of working on a project within an ongoing, larger rollout of multiple facilities is that any difficulties encountered on an early job like this one could have a negative ripple effect on other sites as well. For example, failure to meet the aggressive schedule on this project, or being slow to adapt to last-minute design changes, had the potential to disrupt the customer’s construction and operations schedule on a much larger scale, as FTC was responsible for fabrication and hiring the contractors to install the insulation systems on all the sites.

FTC Vice President and General Manager Calvin Brasel explained how the company met this challenge: “We were able to measure, design, and fabricate a solution to help the customer get their plants online faster [including this one]. By using CAD [computer-aided design] and automated cutting tables, we were able to reproduce each part exactly. In the process, we reduced any errors or repairs that would have delayed construction.” Being able to prefabricate the covers for vessels and piping enabled FTC to shorten the project’s duration—not a common occurrence on new construction efforts, and certainly a boost for the customer.

The next challenge came from Mother Nature, as weather threw the project team something of a curve: brutal winter temperatures caused the design team to refine how much of the equipment (instrumentation in particular) needed to be insulated. FTC worked up a modified “winterization” package to accommodate the harsh conditions and kept the project on track.

Perhaps the greatest challenge resulted from the nature of starting up a new facility like this. The customer sought to begin operations as soon as possible, with all the insulation installed to achieve the energy savings and process control—not to mention personnel safety—beginning Day 1. At the same time, facility personnel would need direct access to much of the equipment during the startup phase, when bolts on piping items required retorquing and systems would be adjusted to optimize performance.

While these seemingly competing priorities would pose a trial for non-removable insulation, FTC’s custom-designed covers facilitated removal and replacement of the insulation during this critical phase. Over the long term, the solution also will make it easy to remove and replace insulation when facility equipment undergoes maintenance and repair. Even the adsorber vessels and loop piping were insulated with the removable covers, providing an additional layer of protection. This strategic choice will help prevent potential damage and reduce repair needs during the routine replacement of the media contained within the vessels, ultimately contributing to the overall durability and efficiency of site operations. As an added benefit, the covers require no personnel training to remove and replace. As Brasel notes, those working at this type of facility—many of whom have worked all over the world, including the Middle East—know the equipment well, so “working high-temperature Velcro and D-rings with straps, depending on the system,” is certainly within their skill set.

Photos 1 through 4 show the finished product.

FTC’s Solution

FTC recommended, and the owner/operator selected, removable insulation covers for all flanges, valves, and equipment to address concerns about startup costs and maintenance efficiency. The solution has the additional benefit of reducing waste—a critical consideration at a facility whose mission is sustainability. While hardcover conventional insulations must be discarded and replaced after being removed so plant personnel can perform inspections or maintenance, FTC’s removable blankets are designed to be easily reinstalled, which saves both landfill space and money for the facility owner.

For efficiency and quality assurance, FTC worked from component skids, fabricating and installing covers on the actual equipment before the components were shipped to the site. The skids included metal platforms containing all the piping to be mounted atop the vessels, as well as some of the smaller vessels. The project team took measurements from the skids, fabricated the removable covers, brought on installers, and shipped the skids out to the project site pre-insulated. Brasel notes, “The schedule is important to a client. When they start a site, they’re trying to condense the schedule to get the site operating as quickly as possible. An advantage of this approach is that a lot of the equipment shows up already insulated. With the exception of just a few parts—like large vessels—the site kit is already built. They don’t have to wait on a contractor to cut jacketing material or insulation.”

As alluded to earlier, the approach also provided quality assurance at the fabrication stage, as the CAD and automated cutting provided accurate, repeatable results. Because FTC sews its covers in the actual shape of the equipment—from a single valve to an entire piping system—the products fit the system perfectly. Finally, FTC performed quality control prior to releasing the skids, thoroughly inspecting each piece of equipment to ensure durable seams and complete insulation coverage.

Table 1 offers an overview of insulation system components, as well as product types and brands used. All materials and product types were selected for the temperature, weather, and chemical resistance properties. In addition to the ease of using Velcro for plant personnel, FTC’s covers require no wiring. Brasel notes, “Wiring can be a safety hazard—cutting it, it goes into the skin—and on the ground, it gets stuck in people’s boots.” Personnel protection is critical to this customer—which made insulating all the small pressure skids vital. Brasel explains, “The piping gets hot, and site personnel have to get around it to work on it, take the piping apart.”

Project Takeaways

Brasel says this project exemplifies a few themes common to most successful FTC projects.

Getting Insulation Experts Involved Early Saves Time and Money
FTC wrote the specifications for the entire insulation package—to include this site and all the others this customer is rolling out. This not only ensured an effective solution to meet all the short- and long-term performance objectives, but it also allowed seamless execution of the fabrication and installation. If a site required a slight change—e.g., if a bracket was moved to accommodate specific site conditions—FTC was able to adapt quickly.

Be Open to Good Ideas from All Sources
Calvin Brasel emphasizes that having an open mind and constantly learning and adapting is good for business—your own and your customers’. In this case, he says, “With industrial plants utilizing prefab skids to reduce cost and construction timelines, why not do the same thing with insulation?” As an added benefit, because FTC was capable of fabricating everything for the skids at its 20,000+ square foot facility in Evansville, Indiana, Brasel notes, “Our costs to fabricate the removable insulation covers for multiple sites did not vary or increase across the United States.”

Work with People You Trust
One theme that seems to run across all projects, when you have a job as important as this—remember, this project was just one of many sites for this customer, all with aggressive construction schedules—calling on companies you know you can count on is vital. FTC worked with several other NIA members to install this and similar projects:

  • Caldwell Insulation, Inc.
  • Gribbins Insulation & Scaffolding
  • Insco Industries, Inc.
  • Irex Contracting Group

FTC’s own project managers, CAD designers, and design engineer also deserve recognition for the company’s success on this project. Brasel says, “without everyone working on it, this would not have been a successful completion.”

Plan for Future Growth
One takeaway that may not immediately come to mind when one thinks of why a mechanical insulation project was successful is a company’s commitment and ability to plan to meet future requirements. The construction industry at large has been dealing with a labor shortage for years, and FTC has innovative strategies to grow the company’s personnel pipeline to keep pace with corporate growth. An internship program that draws from a local technical school, as well as local high schools, provides more potential talent each summer than the company can typically use. For students attending college, FTC brings interns in during school breaks, in addition to the summer. Brasel adds, “For full-time students in training, we work around their college class schedule.”

According to Brasel, “It takes 3 years training a fabricator to get to their full potential.” He adds, “We just hired a manufacturing engineer that we’re training in estimating.” The program is clearly paying off: Of six interns FTC has brought on board, all but one have stayed with the company while attending college and post graduation.

Pride in a Job Well Done

A second-place win in the NIA competition with highly qualified peers is extremely satisfying, and Calvin Brasel also takes tremendous pride in a job well done. “When you see the vessels, all the parts going together perfectly, 24 to 30 pieces assembled that fit that well, that’s what stood out on this project. You can see lots of blankets on piping systems, but those vessels, the tops of the vessels are like 32 feet up,” he marvels, concluding, “If it doesn’t fit right, it’s not Fit Tight.”

About Fit Tight Covers

FTC manufactures removable and reusable thermal insulation covers for commercial and industrial mechanical piping and equipment. The company is proud to be an insulation cover fabrication shop in the Midwest capable of servicing nationwide demand with the highest grade of removable insulation covers. With over 20,000 square feet of space and an experienced team of full-time fabricators, FTC can quickly and accurately produce any type of removable cover.

Please review their application pages for a sampling of some of the company’s work, as well as the materials available for certain specs and temperature requirements.

NIA Sites > Insulation Outlook Magazine > Global

Cause and Effect: Condensation Control and Mold Prevention

Air contains water vapor. Water vapor originates from our environment—rain and evaporation from open water, groundwater, etc. The amount of water vapor that air can hold is dependent on the air temperature (ambient temperature). As the temperature rises, air can retain higher levels of water vapor.

Relative humidity (RH) refers to the percentage of water vapor present in the air at a specific temperature compared to the maximum amount of water vapor that the air could hold at the same temperature. RH is referenced as a percentage (current/maximum).

Dew point is defined as the air temperature at which water vapor in the air condenses into liquid form. Dew point indicates how much moisture is present in the air and determines RH. For example, an air temperature of 70°F at 35% RH equals a dew point of 41.1°F. At the same temperature with RH at 60%, the dew point increases to 55.5% RH. The outer surfaces of insulation must be maintained above the dew point to prevent condensation.

Air with higher levels of moisture will migrate to areas of lower moisture content. Once air becomes saturated with water vapor, water vapor will migrate to air with lower concentrations of water vapor. When water vapor migrates to a cold surface, it loses energy and condenses. Condensation occurs when humidified air contacts a surface that is below the dew point temperature.

The reality is that building mechanical systems—such as HVAC/R and plumbing piping, equipment, and ductwork—are susceptible to the effects of the trio of ambient temperature, RH, and dew point. Since water vapor will always be present within the building envelope, it is imperative to adequately protect building mechanical systems from its undesirable effects. Left unchecked, uncontrolled water vapor can create a domino effect: vapor drive, condensation, decreased energy efficiency, and the potential for mold growth, corrosion, damage to expensive equipment and building components, slip/fall hazards, and eventual system failure/shut down.

Mechanical insulation is a proven and effective solution that addresses the trio mentioned above (ambient temperature, RH, and dew point). There are many commercially available insulation products and accessories that provide system protection. Due to the variety of mechanical systems and their operating requirements, it is common for multiple insulation types and accessories to be specified and installed on a single project.

Each insulation application is always a system, regardless of its size and complexity. At a basic level, there will always be a substrate, insulation, and vapor barrier (dependent upon the application). Additional insulation components could include adhesives, fasteners, tapes, sealants, and coatings. These systems can become more complex with the addition of insulation layers, fittings, valves, flanges, vapor stops, expansion/contraction joints, slip joints, and other system components.

Design Considerations for Below-Ambient Systems

Let’s dive into the design considerations for mechanical insulation to confidently prevent condensation and mold growth on systems that operate at below-ambient (cold) temperatures with an insulation system. Table 1 provides an overview of design elements and considerations for such systems.

Mold Prevention

Mold and condensation are intertwined. Without a water source (condensation), microbes cannot survive on organic food sources alone. When condensation is effectively controlled, mold prevention is achieved.

Like water vapor, it’s not a matter of if, but when mold spores enter a building through openings such as windows and doors, pipe penetrations, open seams in the building envelope, outdoor air intakes, and roof leakage. Additionally, mold typically grows at ambient temperatures ranging from 40°F/4°C to 100°F/38°C with RH above 55%.

With a source of food and moisture, mold spores can grow on any surface, including impervious objects such as glass, metal, and tile. Limited or uncontrolled mold growth in buildings poses a significant liability and real costs to building owners, so it is critical to factor a mold-resistant insulation strategy into building mechanical systems during the design stage.

Because mold spores can digest most organic matter, moisture control is the determining factor, since they cannot live without water. Sources of moisture in buildings include roof leaks, condensation on building mechanical systems, pipe leaks, deferred maintenance, malfunctioning humidification systems, and uncontrolled humidity, to name a few.

Since mechanical insulation is often installed in areas that are not easily accessible for maintenance, insulation material selection is critical. It may be next to impossible to keep organic food sources such as drywall dust, dust, and dirt off the insulation surface, but controlling condensation can be achieved with the proper insulation type, thickness, and vapor barrier (if required).

Insulation and accessory manufacturers report compliance with ASTM and UL standards for mold growth and mildew resistance. Insulations can be naturally microbial-resistant, meaning that the insulation does not contain any food sources such as oils, binders, and resins within and on the insulation surface. Other insulations are available with added EPA registered antimicrobial protection, published in manufacturer technical data sheets and websites.

Sources

NIA Sites > Insulation Outlook Magazine > Global

Vacuum Insulation Panels: High-Performance Building Envelope Insulation, Ideal for Retrofit Upgrades

Vacuum insulation panels (VIPs) are a thermally efficient insulation technology that has been in use for decades in specialty industries such as refrigeration, pharmaceuticals, and medical, and are now increasingly being considered for building envelope applications—particularly when maximizing insulation performance within a limited-thickness wall is critical.

About Vacuum Insulation Panels

VIP Construction

A VIP is essentially a highly insulating core material, sealed within an airtight, multilayer barrier film, with the air inside removed to create a deep vacuum. Each component plays a role in its exceptional performance (see Figure 1).

  • Core Material
    Typically made of pyrogenic silica or fine glass fibers, the core has an extremely fine pore structure (under 60 nanometers). This structure limits the ability of air molecules to transfer heat, even before the vacuum is applied. The core is also designed to resist compression under the high loads it will encounter when the vacuum is applied.
  • Barrier Film
    The barrier is a multilayer laminated plastic film with thin metal coatings that block the passage of gases and moisture. It is engineered to have both low gas permeability and the ability to be heat sealed.
  • Vacuum Environment
    During manufacturing, the air inside the panel is evacuated to a pressure of less than 0.07 PSI (5 millibar)—about 1/200th of normal atmospheric pressure. This drastically reduces air conduction and convection through the core.
  • Edge Protection
    VIP edges, where the barrier film seams exist, are then sealed by heat-welding, leaving folded “flaps.” These are folded flat or taped to minimize heat transfer at the edges (called “edge effects”), which is higher than through the panel’s center.

The result is an insulation product with thermal conductivity as low as 0.027 BTU-in/hr-ft2°F (0.004 W/m·K) in fresh, undamaged panels—about one-fifth that of common foam insulations. In practical terms, a 1-inch VIP can deliver R-35 or more.

Benefits

VIPs offer several advantages in building applications.

  • High Thermal Performance in Minimal Thickness
    This is particularly valuable where space is constrained—for example, in retrofits where thickening the walls can complicate finishing of window and door openings.
  • Significant Energy Savings Potential
    By raising the effective wall R-value dramatically, VIPs can cut heating and cooling demand in both new and existing buildings.
  • Applicability in Continuous Insulation Systems
    Continuous insulation on the exterior side of the structure minimizes thermal bridging from studs and other framing members.
  • Long Service Life
    With proper design and installation, VIPs can maintain superior performance for 25 years or more.

Applications

VIPs are already used in many applications.

  • Buildings—for walls, roofs, and floors in high-performance designs
  • Appliances—refrigerators, freezers, and specialty coolers
  • Cold-Chain Logistics—insulated packaging for perishable goods
  • Specialized Sectors—medical, laboratory, and defense applications

Challenges

While VIPs have impressive performance, they also present certain challenges.

  • Higher Cost
    On a per-R-value basis, VIPs currently cost more than traditional insulation. Costs may come down with new materials and production technologies.
  • Handling Fragility
    If the barrier film is punctured, the vacuum is lost, and thermal performance drops (though the core still insulates slightly better than rigid foam).
  • Standardized Sizing Available Only
    Panels cannot be cut to fit on site, so designs must accommodate fixed panel dimensions.
  • Gradual Aging
    Over time, small amounts of air may leak in, slowly reducing thermal performance over many years.

Retrofit Building Application Potential

Approximately 48% of buildings in the United States were built before 1980, often with insulation levels far below current energy codes. Retrofitting these structures can have a large impact on reducing overall energy consumption, particularly in climates with high heating or cooling loads.

Exterior continuous insulation is one of the most effective retrofit strategies because it:

  • Covers structural elements, reducing thermal bridging;
  • Improves the effective R-value of the whole wall assembly; and
  • Can be installed without major disruption to interior spaces.

VIP-based retrofit systems combine high performance with minimal added thickness. For example:

  • Adding just 3.5 inches of a VIP/foam composite can triple or quadruple the thermal resistance of a typical 2×4 wall assembly.
  • Even modest thickness systems can meet or exceed Passive House wall performance targets.

One practical approach is a VIP-foam sandwich panel system, mounted to the exterior over existing sheathing, or direct to studs, and secured using pultruded fiber glass z-girts. These girt members are much less conductive than steel, greatly reducing heat loss at attachment points. The z-girts also allow the attachment of exterior cladding systems without puncturing the VIPs with fasteners.

Performance and Durability Testing

A National Research Council of Canada (NRC) study1 tested a steel stud wall fitted on the exterior with a VIP- and foam-based composite insulation system to evaluate both performance and durability. Thermal performance testing was conducted using a guarded hot box apparatus in accordance with ASTM C1363, “Standard Test Method for Thermal Performance of Building Materials and Envelope Assemblies by Means of a Hot Box Apparatus.”

Wall Construction

The test wall consisted of:

  • Interior Layer—3.5-inch steel studs filled with mineral wool
  • Exterior Layer—3.5-inch VIP/extruded polystyrene (XPS) foam sandwich panels
  • Attachment System—fiber glass z-girts, spaced 24 inches apart, holding the cladding and insulation

This buildup created a total wall thickness of 7.75 inches yet delivered R-38—far above typical code-minimum values.

Thermal Performance

  • Testing was conducted at extreme temperature differences: interior at 70°F (21°C) and exterior at -4°F and -31°F (-20°C and -35°C).
  • A 3D finite element analysis (FEA) computer model was also created of the tested wall construction. The wall’s tested thermal performance (overall R-value) matched computer simulations within 2.5%, validating the modeling method.
  • The protective foam layers not only prevented accidental VIP damage during installation, but also contributed to thermal resistance.

Figure 2 shows a cross section of the tested wall assembly and the computer model. The cross section shows the VIP and the XPS foam layers, along with the z-girt support. The system used two layers of XPS to sandwich and protect the VIP. A ½-inch (12.7 mm) layer was used against the steel studs to prevent puncture of the barrier film by any sharp edges of the steel studs. A 2-inch (51 mm) layer was applied outboard of the VIP, which allowed the use of screws to attach cladding to the z-girt supports without penetrating the VIP. The VIP edges were covered with thin, puncture-resistant films for additional protection during assembly.

Durability Testing

The NRC subjected the wall to a wind-load aging protocol, then retested the wall’s thermal performance in the hot box apparatus. The protocol included sustained, cyclic, and gust loads. The wall retained its high R-value, demonstrating that properly protected VIPs are suitable for long-term building applications. The results of the performance testing before and after the wind loading are shown in Table 1.

Variable Construction Modeling

With the validated simulation model, multiple alternative designs were analyzed to see how thickness, VIP coverage, and attachment materials affected performance.

Thickness Performance

Three exterior insulation thicknesses were modeled:

  1. 2 inch (51 mm)—compact, minimal intrusion on openings, but only moderate gains over foam alone, with a 1-inch (25 mm) VIP yielding R-25 versus R-18 with foam alone.
  2. 3.5 inch (89 mm)—balanced solution with a 1-inch (25 mm) VIP, achieved R-38 and suitable for most retrofits.
  3. 5 inch (127 mm)—high-performance option with a 2-inch (50 mm) VIP; achieved up to R-57, ideal for Passive House or very cold climates.

The simulations showed that as insulation thickness increases, thermal bridging from girts becomes less significant relative to the total wall performance, but only if low-conductivity girts are used.

Coverage Impacts

Because VIPs can’t be cut to fit irregular areas, foam alone is used in gaps around openings and edges. Additionally, even with foam protection, an improperly driven nail or screw could compromise an isolated VIP’s vacuum. Modeling showed:

  • 25% non-VIP coverage area could reduce R-value by up to 20 to 23% in high-thickness VIP designs.
  • Damaged VIPs (loss of vacuum) still insulate as well or slightly better than foam, mitigating worst-case losses.

Table 2 shows the effects of a 25% reduction in VIP coverage in the event of damaged VIPs or poor fit of VIP shapes around the building fenestration. Two exterior insulation thicknesses were analyzed with different ratios of VIP thickness to foam thickness.

Effect of Support Materials

Changing the attachment system from pultruded fiber glass z-girts to steel z-girts had a dramatic impact:

  • In high-performance walls, R-value dropped by almost 60% due to thermal bridging.

This confirms the importance of low-conductivity structural supports in any high-R-value wall system.

Comparison to Conventional Walls

A standard 3.5-inch steel stud wall with mineral wool (or fiber glass) and OSB sheathing has an effective R-value of about R-8.4. The R-value is much less than the fiber-based insulation alone due to the thermal bridging of the structural elements.

  • Adding 0.5 inches of XPS foam sheathing raises it to an R-value of R-11.7.
  • Adding a 3.5-inch VIP/foam composite system instead can boost it to R-38—more than tripling thermal resistance.
  • A 5-inch VIP/foam system can reach R-57, a nearly five-fold improvement.

Figure 3 compares models of the two extremes: a 3.5-inch steel stud wall with mineral wool insulation, OSB sheathing, and no external insulation (R-value 8.4) versus the same wall with no OSB and a 5-inch VIP-and-foam composite external insulation system (R-value 57). Especially visible is the difference at the steel studs, where high levels of heat bridging occur in walls with no external insulation. The VIP and foam wall is just over twice as thick (4.25 inches versus 9.25 inches) but provides seven times the insulating value.

Conclusion

VIPs bring lab-grade thermal performance into the realm of building construction. In retrofit applications, they offer the rare combination of:

  1. High R-value in minimal thickness;
  2. Long-term durability and performance, when properly protected; and
  3. Flexibility in combination with other insulation types.

Key takeaways from this VIP performance study are as follows.

  1. Validated Modeling—simulation results matched full-scale hot box tests within 2.5%.
  2. Thickness Matters—optimal retrofit performance is achieved with 3.5 to 5 inches of an exterior VIP/foam composite system.
  3. Support Systems Are Critical—low conductivity girts are essential to preserve gains from high-performance insulation.
  4. Coverage Gaps Reduce Performance Slightly—areas without VIPs can reduce overall wall efficiency in high-VIP designs but still perform well above conventional assemblies.

As manufacturing costs decrease and designs improve, VIP systems are likely to become a standard tool for architects and engineers aiming for net-zero and Passive House performance standards in both new and existing buildings.

NIA Sites > Insulation Outlook Magazine > Global

NIA Contractor Member Performance Contracting, Inc. Discusses System Design

NIA is proud of the professionalism, creativity, and artistry of our Contractor members. To celebrate the craftsmanship of NIA mechanical and industrial insulation contractors, NIA established the Insulation Project Art Gallery Showcase and Competition in 2023. Last year, we again invited all NIA insulation contractors to submit photographs and a brief description of projects representing their most creative and artistic efforts. At our Fall Summit, we posted all the submissions anonymously, and attendees voted for the top three projects in terms of number of parts insulated, aesthetics, difficulty of installation, and well-installed application. We will profile the projects submitted, focusing this month on second-place (tie) winner Performance Contracting, Inc. (PCI). We encourage NIA Contractor members to participate in this year’s competition and possibly be featured in a future article. After this year’s competition, the next chance to compete will be in 2027, as the Contractor Showcase moves to a biennial schedule.

Project Description and Goals

This project involved the renovation of an existing data center in Birmingham, Alabama, which was built in the early 2000s. The project focused on upgrading the cooling and emergency power systems, which included the replacement of 8 chillers, 8 cooling towers, 24 chilled-water pumps, 10 emergency generators, and several computer room air conditioning (known as CRAC) units.

The enhancements aimed to improve the efficiency and reliability of the data center’s infrastructure, ensuring optimal performance and minimizing downtime. The project also included the implementation of advanced monitoring and control systems to provide real time data on the performance of the new equipment. This comprehensive upgrade not only enhanced the data center’s operational capabilities, but it also will contribute to ongoing energy savings and reduced environmental impact. For details about the insulation system products used, see Table 1.

Challenges

Access and scheduling were two large challenges for this 2-year renovation project. Regarding access, because this jobsite was an active data center for a bank, everyone who visited the site underwent a background check, which took time. To meet the tightly controlled schedule, the PCI team focused on planning and coordination to avoid delays, with attention to scheduled freeze periods that coincided with high banking transaction activity, such as the end of the month and around holidays, as well as unscheduled periods when the facility deemed it necessary to close access to the jobsite.

In addition, the mechanical systems could only be shut down for limited amounts of time due to the facility’s operations, so the PCI team had strict timelines. According to PCI Project Manager/Estimator Jene Johnson, “We had a certain amount of time to get our scope done, as our customer had to continue operations. We were informed when the systems needed to come back online, and we had to be done. Not completing the scope within the schedule was not an option.”

Project Takeaways

Assemble a Great Team for a Project that Will Shine

Johnson shared, “On many of our projects, a majority of our work is above ceilings and behind walls, and you never see it. For this project, with the two large mechanical rooms and all the colored PVC jacketing, this was truly a showcase project. We wanted to make these mechanical rooms shine. Our customers, engineers, and facilities personnel are in and out of these rooms, and they can see the craftsmanship of this custom work. Our guys knocked it out of the park, and I was incredibly proud of our work on this project. Our customers were pleased, giving us a few pats on the back and some ‘atta-boys,’ especially when it came to our care in matching the PVC colors.” He added, “The color PVC not only looks pristine, but it will also help the facility’s engineering teams during future maintenance work with identifying supply and return lines.” (See Photos 1 and 2.) The removable insulation pads designed in-house by PCI for the Y-shaped exhaust ports on the backup generators will also allow for maintenance access. (See Photos 3 and 4.)

Photo 1. Color-coded PVC supply and return for the chilled water pumps
Photo 2. Color-coded PVC supply and return for the chilled water pumps
Photos 3 and 4. RPR Aluminum Jacketing with removable insulation pads, fabricated by PCI, for the generator muffler exhaust, which can reach 800° to 1,000°F

Remain True to Your Core Values

Safety is PCI’s number one core value. Johnson noted that the PCI team had all the equipment, lifts, scaffolding, and anything else they needed to complete the project. The team had no safety incidents during this 2-year project.

Meet Tough Challenges Head on

When looking back on this project, Johnson noted, “You can always learn something from every single project you complete, and even the most complicated projects are within our abilities. The scheduling intricacies were huge with this project. We had a great customer, a dedicated team, and we delivered a beautifully functioning project all while dealing with the complicated intricacies of working in an existing data center. The system was expertly designed and installed, and works flawlessly.”

PCI recognizes the team members who played a vital role in this project.

  • Jene Johnson, Estimator/Project Manager
  • Randy Watson, Superintendent
  • Steve Cagle, Foreman
  • Charlie Hereford, Project Engineer

About PCI

As a top-tier specialty contractor in the United States, PCI delivers exceptional services and products to industrial, commercial, and nonresidential sectors. Offering a wide range of related services, PCI has established itself as a true “one-stop-shop” contractor, ensuring its customers receive comprehensive solutions tailored to their specific needs. Headquartered in Lenexa, Kansas, PCI is an employee-owned company with a nationwide network of more than 40 offices. For more information, visit www.performancecontracting.com.

NIA Sites > Insulation Outlook Magazine > Global

Bad Specs: Lost in Insulation—A Survival Guide to the Acronym Jungle

In the world of mechanical insulation, acronyms fly faster than fiber glass in a wind tunnel.

For mechanical engineers, facility managers, and building owners who regularly interact with insulation contractors and specifications, fluency in this abbreviated language isn’t just helpful—it’s essential for effective communication, accurate procurement, and proper system performance. Understanding these terms ensures you can confidently discuss projects, evaluate proposals, and make informed decisions about your facility’s insulation needs.

Let’s face it: In this industry, we don’t just love acronyms—we insulate ourselves with them. So, buckle up, grab your SDS (safety data sheet), and prepare to decode the alphabet soup of insulation lingo.

The Acronym Avalanche

You might think PIR is a pirate-themed insulation product. Alas, it’s just polyisocyanurate—a word so long, it needed an acronym just to survive in polite conversation.

Then there’s CUI—which sounds like a trendy new app but actually stands for corrosion under insulation. Not nearly as fun as an app,but understanding CUI -prevention strategies and material selections can save on significant long-term maintenance costs and prevent catastrophic system failures.

And don’t get us started on FSK (foil, scrim, kraft) and PSK (poly, scrim, kraft), which sound like a Scandinavian heavy metal band, but are actually common insulation facings. Rock on.

The Jacket that Does it All

ASJ stands for all service jacket, which sounds like something James Bond might wear. In reality, it’s a vapor barrier and insulation cover. Less glamorous, but still essential especially if you want to keep your insulation dry and your maintenance team happy.

Moisture, Meet Your Match

Moisture is the arch nemesis of insulation, which is why we have WVTR (water vapor transmission rate). No, it doesn’t have anything to do with keeping your car running. Low WVTR values are crucial for preventing moisture-related problems in refrigeration and below-ambient temperature applications, so just nod knowingly when someone brings them up.

Sounding off

Want peace and quiet? You’ll need to know your STC (sound transmission class) and NRC (noise reduction coefficient), which help you figure out how much sound your insulation can block—because nobody wants to hear the HVAC system’s greatest hits on repeat.

Fire, Fiber, and Fancy Titles

PFP (passive fire protection) is your silent guardian, your watchful protector. More reliable than your local power company, PFP insulation can be counted on to protect a facility’s assets in the event of a fire.

Meanwhile, FRP and GRP (fiber- and glass-reinforced plastic) are the unsung heroes of durability—the bodybuilders of the insulation world. Like a respirator during a chemical spill, someone needs to protect the insulation from damage.

Industry Standard Bearers

And let’s not forget the organizations that keep us in line: NIA (National Insulation Association), ICC (International Code Council), AMPP (Association for Materials Protection and Performance), API (American Petroleum Institute), ASTM (American Society for Testing and Materials), ISO (International Organization for Standardization), ASHRAE (American Society of Heating, Refrigerating, and Air-Conditioning Engineers), and others. Their acronyms are longer than some of their bylaws.

Final Thoughts from the SSL

SSL might sound like a secure internet protocol, but in insulation, it’s the self-sealing lap—a feature that helps insulation wrap itself up tighter than your aunt’s leftovers at Thanksgiving. It’s the duct tape of your ASJ: strong, sticky, and surprisingly satisfying to apply.

Bonus Round: More Acronyms that Deserve a Laugh

NPS (Nominal Pipe Size)

No, NPS doesn’t stand for “not particularly straight” or “needs professional supervision,” though both might apply on a rough install day. It actually refers to the standard sizing system for pipes. The catch? The number doesn’t always match the actual diameter. It’s like buying a “large” T-shirt that fits like a medium and shrugging because, hey, it’s nominal. In insulation, knowing your NPS is crucial for getting the right fit—because nobody wants to wrestle a pipe wrap that’s two sizes too small.

BTU (British Thermal Unit)

The BTU measures how much heat it takes to raise one pound of water 1°F. In insulation terms, it’s the unit that tells you how hard your insulation is working to keep the heat out (or in). Think of it as the calorie count for your building—except instead of burning fat, you’re burning less money on energy bills. Fewer BTUs escaping = happier accountants.

Are You thoroughly Lost yet?

Mastering these acronyms transforms confusing conversations into productive discussions about system performance, material selection, and project requirements. This knowledge enables more accurate specifications, better vendor communication, and informed decision-making that ultimately protects your facility’s mechanical systems while optimizing energy performance. When you speak the same language as insulation professionals, projects run smoother, specifications become clearer, and long-term system performance improves significantly.

NIA Sites > Insulation Outlook Magazine > Global

2025 North American Engineering and Construction Outlook—Third Quarter Edition

Amid sustained economic headwinds, including elevated interest rates, a challenging labor market, and growing uncertainty around federal policy, total U.S. engineering and construction spending is forecast to increase by just 1% in 2025, down from 7% growth in 2024.

This slowdown is primarily driven by broad-based weakness in the residential sector, where affordability constraints, rising costs, and tight credit continue to limit activity. Nonresidential building and infrastructure segments are expected to deliver mixed results, with several segments—such as manufacturing—shifting from high growth to more stable or less impressive rates of expansion.

The single-family residential market remains constrained but is showing signs of stabilization, as pricing adjusts and sales volumes begin to improve in disaster-affected and more affordable regions. Residential improvements are projected to hold flat in 2025, supported by aging housing stock and targeted renovation activity. Multifamily development, by contrast, continues to decline, with vacancy rates rising, rent growth slowing, and construction starts falling in oversupplied markets, especially across the South and West.

Nonresidential building activity is holding steady, though the pipeline of new work has begun to slow in response to elevated costs and longer lead times. Public funding, while still significant, faces increased scrutiny under the newly passed spending and tax bill, which includes reductions to several long-standing federal programs. The legislation shifts more responsibility for infrastructure and energy projects to states and the private sector, while narrowing federal support for programs across various areas including clean water, housing, health care, and education.

Infrastructure spending, however, remains comparatively resilient. Segments such as power, water, sewage, and transportation continue to benefit from previously authorized funding, though new awards have slowed. Road and bridge work is holding firm, supported by strong project pipelines and growing urgency around the 2026 reauthorization of the Surface Transportation Reauthorization Act. Notable new commitments were also made this quarter in transmission, nuclear energy, and freight rail, signaling continued interest in long-term grid, transportation, and logistics modernization.

Manufacturing and data center investment remain essential contributors to future construction demand. Strategic project announcements continue in these sectors, though labor shortages, tariffs, and power availability are beginning to impact timelines and delivery. Meanwhile, emerging trends such as flexible and fractional warehousing, along with modular infrastructure design, are expanding rapidly in response to changing retail and logistics needs.

The construction industry is entering a slower and more selective phase of expansion. While advances in artificial intelligence, digital delivery, and automation are driving greater efficiency, elevated costs, political/geopolitical uncertainty, and tight credit conditions are expected to weigh on growth through at least mid-2026. Over the next several years, owners, developers, and public agencies will need to reassess project priorities, funding strategies, and long-term planning to navigate volatility and shifting market conditions.

U.S. Key Takeaways

  • Total U.S. engineering and construction spending is forecast to increase by just 1% in 2025, a notable slowdown from the 7% growth recorded in 2024.
  • Growth in 2025 is expected to stall, primarily due to persistent weakness in the residential sector, driven by ongoing declines in multifamily construction and limited gains in single-family and residential improvements. While both single- family and residential improvement investment are expected to see modest rebounds in activity in 2026, the overall residential sector is expected to remain under pressure over the forecast period, due to persistent affordability constraints.
  • Nonresidential segments are expected to deliver mixed but resilient performance through 2025 and 2026. Short-term growth will be supported by strength in segments such as office, amusement and recreation, religious, transportation, power, sewage and waste disposal, and water supply. Longer-term growth will be led by lodging, office, and water infrastructure, each with a 5-year compound annual growth rate exceeding 5.5%. Nonbuilding structure investment is forecast to outperform nonresidential buildings over the next 5 years, driven by a mix of public and private infrastructure-focused needs.
  • The latest Nonresidential Construction Index improved to 49.8 from the previous quarter’s 43.5, signaling a rebound in contractor sentiment. This optimism reflects greater confidence in both economic and business conditions compared to last quarter, supported by stronger backlogs and improved construction outlooks. However, the index remains just below the neutral threshold of 50, suggesting stabilization rather than expansion of future engineering and construction opportunities.

Excerpted with permission from FMI’s (www.fmicorp.com) “2025 North American Engineering and Construction Industry Overview.” The full report is available for downloading at: https://tinyurl.com/ykuz4deb.