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Back to Basics: R-Value and U-Value

The R-value of an insulation product is a thermal resistance rating that tells us how well a material resists heat flow. The higher the R-value, the better the insulation restricts heat transfer. Most insulation manufacturers use the ASTM C518 test to measure a material’s resistance to heat flow. Established by the American Society for Testing and Materials (ASTM), the ASTM C518 test is a standardized method that assesses the steady-state thermal transmission properties of a material using a heat flow meter apparatus. In addition to serving as an essential tool for many industries, ASTM C518 is a building code requirement for insulation.

R-values for metal building insulation range from R-8 to R-30. The most common fiberglass metal building insulation R-values include:

  • 2” (R-8, before lamination)
  • 3.4” (R-10)
  • 3.7” (R-11)
  • 4.3” (R-13)
  • 5.3” (R-13)
  • 6.3” (R-19)
  • 8.0” (R-25)
  • 9.25” (R-30)

It should be noted that thicknesses are nominal, as manufacturers produce different thicknesses to meet R-values. Commercial energy code requirements dictate the minimum R-value necessary for all new construction, additions, and alterations performed in the United States.

Once the R-value is determined, designers can use this data to better understand how a material will perform in an assembly. Heat flow through a material is driven by the temperature difference on each side of the material or assembly. Most construction types and code tables leverage the R-value table as a guide to code compliance. However, it is important to remember that the R-value table should not be mistaken as a reference for the total performance of an assembly. Metal-framed walls, wood-framed walls, and metal building walls and roofs undergo testing that determines the U-value of the entire assembly. The result of that testing can be found in the U-value table.

A U-value, also called a U-factor, measures heat transfer, or loss, through the assembly over time. While the R-value measures a single product’s ability to resist heat, the U-value measures the entire assembly’s resistance to heat transfer. The lower the U-factor, the better the insulation. Mathematically, R-values and U-values are reciprocals of one another: U-value = 1/R-value, R-value = 1/U-value. ASTM C1363 is the standard test method of U-values and includes a hot box apparatus. See Figure 1 and Figure 2.

NIA Sites > Insulation Outlook Magazine > Global

Metal Building Insulation Special Issue: An Introduction to Fiberglass Metal Building Insulation

Metal building systems (you may call them pre-engineered metal buildings) have long been favored for their strength, durability, and cost-effectiveness. However, one crucial aspect that often goes unnoticed is the insulation system. Proper insulation is essential for reducing energy consumption, maintaining comfortable indoor temperature, and ensuring the longevity of these metal structures. Among various insulation materials, fiberglass insulation stands out as a reliable and cost-effective choice. In this comprehensive article, we will explore why fiberglass insulation remains relevant and efficient for metal building systems.

Evolution – Where It Began

The evolution of fiberglass insulation use has progressed significantly since its inception, transitioning from basic single-layer applications with low R-values to sophisticated, multilayered systems that offer enhanced thermal performance and energy efficiency. Initially, fiberglass insulation was available in the form of batts or rolls, designed to be sandwiched between framing members and the roof or wall panels. While this is still a primary method of insulating a metal building, today’s energy codes have required the development of different solutions.

Over time, advancements in manufacturing and material science have led to the development of higher density fiberglass insulation products and more efficient installation techniques. Innovations include the introduction of multilayered systems, in which the installer utilizes two layers of fiberglass to further enhance performance. Modern fiberglass insulation systems often incorporate vapor barriers, reflective coatings, and other materials to address issues such as moisture control and radiant heat transfer. These systems are designed to maintain their R-value over a wider range of temperatures and conditions, ensuring consistent performance throughout the year. Unlike the single-layer fiberglass mentioned in the previous paragraph, these systems utilize the framing cavity, filling it with fiberglass to improve thermal performance.

Code Requirements

The American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) and the International Code Council (ICC) play crucial roles in developing energy codes in the United States. ASHRAE develops standards like ASHRAE Standard 90.1, which sets minimum energy efficiency requirements for commercial buildings and large multifamily housing. This standard is continuously updated through a consensus process involving industry experts, government representatives, and other stakeholders. The ICC publishes the International Energy Conservation Code (IECC), which includes energy efficiency requirements for both residential and commercial buildings. The IECC is updated every 3 years through a public consensus process, allowing for broad participation from various stakeholders. These organizations ensure that energy codes evolve to improve energy efficiency, reduce environmental impact, and promote sustainable construction practices.

Code agencies continue to value and require the properties of fiberglass insulation as a viable solution for achieving energy efficiency goals. The great news is that fiberglass insulation systems are able to meet all current energy codes.

As states adopt new codes, you will begin to see more requirements around air infiltration. This topic is becoming more relevant with each new code cycle. You should know that fiberglass insulation systems have been put to the test and perform to the current code requirements.

Benefits

Here are some of the benefits of fiberglass insulation and why it is a practical choice for metal buildings.

  • Fiberglass insulation is budget friendly, making it an attractive option for metal building projects. Although it is budget friendly, you are not sacrificing performance.
  • Fiberglass stands out for its low installed cost per R-value. R-value measures the material’s thermal resistance.
  • With the shortage of skilled labor and escalating labor costs, fiberglass insulation could be considered “user-friendly,” with its specific product markings and the general ease of handling. Its flexibility allows it to fit into irregular spaces (allowing for a filled cavity). The flexibility and ease of handling helps minimize installation costs.
  • Its durability is almost unprecedented. Unlike some materials that are prone to absorbing moisture, fiberglass insulation remains unaffected. It does not promote mold or mildew growth, ensuring a healthier indoor environment. Properly installed fiberglass insulation can last for decades without significant degradation, underscoring its cost-effectiveness over time.

Fiberglass insulation can contribute significantly to achieving, or exceeding, energy efficiency goals. The thermal performance of fiberglass insulation effectively reduces heat transfer, keeping indoor spaces warmer in winter and cooler in summer. A metal building system’s insulating properties help maintain a consistent temperature, enhancing occupant comfort, and can lead to reduced heating and cooling costs.

Tested

Metal building insulation must be tested for a myriad of safety and performance characteristics. The American Society for Testing and Materials (ASTM) is a primary agency for the development of standards that help enhance the performance of products and foster the confidence in those products that you, as both a consumer and/or architect/engineer/specifier, buy and use.

A couple of examples are:

  • ASTM E84 is the “Standard Test Method for Surface Burning Characteristics of Building Materials.” This standard should be used to measure and describe the properties of materials, products, or assemblies in response to heat and flame under controlled laboratory conditions. Fiberglass by nature is noncombustible; however, when you add a facing and some sort of adhesive material, it is important to test the final produced product.
  • ASTM C991 is the “Standard Specification for Flexible Fibrous Glass Insulation for Metal Buildings.” This specification covers the classification, composition, and physical properties of flexible fibrous glass insulation for use in metal building roofs and walls.

NIA 404 Standard

NIA and its Metal Building Laminator Committee* understand the importance of safety and performance characteristics related to the products we provide the market. The committee meets regularly and recently published a revised standard, “NIA Certified Faced Insulation Standard (Version 404.2–2024).” The specifics of the standard can be found at 404.2–2024

Metal building systems continue to be a popular choice for the one- and two-story commercial and industrial construction markets, since these projects require materials that are engineered to keep pace with constantly evolving design concepts and aggressive energy codes. As a committee, we are committed to providing a fiberglass insulation solution that meets the industry safety and quality requirements, as well as the most stringent energy efficiency codes.

This issue contains articles on the various aspects of metal building insulation systems and their benefits. If you need more information or have questions on utilizing certified faced fiberglass insulation solutions on your next project, reach out to NIA and our Metal Building Laminator Committee members at membership@insulation.org.

* A committee that meets within NIA, which is a not-for-profit service organization dedicated to meeting the needs of mechanical and specialty insulation contractors, distributors, fabricators, manufacturers, and metal building insulation laminators.

NIA Sites > Insulation Outlook Magazine > Global

Where Is this Water Coming From?

Walking through a mechanical room, you are surprised to find a small puddle on the floor  in front of you. “How did that get there?” you wonder, as you start looking around for the source. Something catches your eye, and you see a drop of water falling from above you. Does the roof have a leak? Did someone spill something above you?

Wait, is that pipe sweating?

Water vapor is part of the air around you, as water moves through the water cycle, and it is an important part of transferring heat and energy around the world.1 All air has some water vapor in it, meaning it is always present in the air around your mechanical systems. Given the right conditions, this water vapor will condense into a liquid and will greatly affect the performance of your system.

To determine whether the conditions will lead to condensation, knowledge of the relative humidity and dew point are key. The amount of moisture in the air can be measured by the relative humidity (sometimes abbreviated “RH”), defined as the percentage of water vapor in the air compared to the maximum amount of water vapor that air at that temperature could hold. For instance, in Las Vegas, Nevada, the most arid of the major cities in the United States, the average relative humidity is only 30%, meaning that, on average, only 30% of the maximum amount of water vapor at that temperature is held in the air. Most major U.S. cities average about 70% relative humidity. See Figure 1 for a sample.2

The dew point is the temperature at which water vapor in the air condenses into a liquid. The higher the relative humidity, the closer the dew point will be to the temperature of the air. Conversely, the lower the relative humidity, the cooler the dew point temperature is. For instance, at 68°F and 70% relative humidity, the dew point is 58°F, while at that same 68°F temperature and only 30% relative humidity, the dew point is a crisp 35°F.3

If a surface is below the dew point temperature, the air around it will cool, and the water vapor will condense into a liquid on the surface. Thus, maintaining the surfaces of below-ambient mechanical systems above the dew point temperature is paramount to controlling the formation of condensation.

Condensation: Raining Indoors

Below-ambient systems—such as chilled water, refrigeration, and cool air duct systems—are highly susceptible to the formation of condensation on their surfaces. With surface temperatures far below the average indoor dew point, these systems can quickly perspire and create enough condensation to form indoor rain.

Take, for example, the conditions in Figure 2: a 40°F chilled water pipe in a warm, humid space with relative humidity of 75%. The water vapor molecules in the 80°F air will condense into a liquid, as the surface temperature (Ts) of 40°F is far below the dew point of 72°F of the space.

This is obviously not an acceptable condition for a system, but what can be done to prevent it from happening?

Preventing Condensation: Use Insulation!

Keeping the surface temperature above the dew point, 72°F in the example, is of the utmost importance in preventing condensation. Adding insulation in the proper thickness to the system not only saves energy by preventing heat gains throughout the system, but it also raises the surface temperature above the dew point (Figure 3). However, if the insulation is porous, the water vapor can still find its way through the insulation and will condense on the cold surface of the pipe, regardless of the insulation thickness. If using a porous insulation material, a vapor retarder is necessary to prevent the water vapor from passing through the insulation and condensing.

These principles also hold true for duct systems. As air-conditioning systems not only cool the space but also remove humidity, condensation control is important with duct systems. The correct insulation thickness, with vapor retarder, if necessary, will prevent condensation formation on the duct surfaces, just like the below-ambient piping systems.

Why Is Condensation Forming, Even with Insulation?

Even after a system is insulated, condensation may still form as a result of a miscalculation or poor installation. If the mechanical system designer does not take the extreme humidity conditions of the space into account, or the system functions outside the normal design parameters, the insulation thickness will not be enough to make up for the increase in water vapor in the air, and condensation will form as the surface temperature falls below the dew point. The insulation also must be installed correctly: Any gap in insulation, or any small opening in the vapor retarder, will lead to condensation and must be sealed immediately.

In order to control condensation within a below-ambient system, an insulation material with low water vapor permeability must be chosen to prevent water vapor from passing through the material and condensing on the system. The proper thickness must be determined from the worst-case conditions in the space and can be confirmed with industry or manufacturers’ calculation tools. With the right thickness, low water vapor permeability, and proper installation, a system will be protected from the effects of condensation.

The Problem with Condensation

Condensation in a mechanical system does not just bring the nuisance of dripping water; it can also lead to devastating effects to the insulation or system itself. Moisture ingress is the absorption of water in a porous material that leads to an increase in thermal conductivity and the deterioration of the insulation system. Corrosion under insulation (CUI) can form when water gets trapped between the system and the insulation, heavily corroding the metal underneath. With the presence of water and a food source, mold is apt to follow any condensation that forms in the system.

Moisture Ingress: Soaking up Water Like a Sponge

Porous insulation materials rely on a vapor retarder to protect from water vapor accumulation. Unfortunately, these vapor retarders are not completely impenetrable and often get nicked or torn open during the regular maintenance process, or they are not completely sealed during installation due to difficult configurations or space constraints. With any gap in the vapor retarder, water vapor will start accumulating between the voids like a sponge soaking up water. For every 1% increase in moisture content in the material, a 7.5% loss in thermal value can be expected. After all the voids are filled, condensate will start to accumulate on the exterior surface of the insulation and the system itself, forming a thermal bridge with a thermal conductivity of water (4.1 Btu/(hr. °F. ft2/in) at 75°F mean
temperature). This thermal bridge causes large heat gains within the below-ambient system as the wet insulation allows heat to conduct to the system. When this occurs, the insulation that was used to prevent heat gain is now accelerating it, dropping the system efficiency precipitously. The water being held in close proximity of the system also can lead
to other issues, affecting the material you were trying to protect in the first place (see Figure 4 through Figure 6).

Corrosion Under Insulation

As alluded to earlier, one issue that can result from moisture ingress is CUI, or the formation of corrosion on the system surface when water is trapped between the surface of the system and the insulation. While CUI can form because of a system failure (leaks) or improper weather protection, it can also occur when condensation finds its way to the surface of a pipe through a break in the vapor barrier. Moisture ingress in porous materials can lead to CUI, as the insulation holds onto the water right next to the system itself, wrapping the metal with a wet covering and providing the means to form corrosion. CUI also can form if the water vapor finds a gap in the vapor barrier and proceeds to condense under the insulation. Any system that is subjected to corrosion will not operate as expected, as the metal starts degrading, and the maintenance cost of replacing the damaged system increases. Left alone long enough, this corrosion may lead to a complete failure of the system and the potential for catastrophic events.

Mold

Mold is various types of fungi that can grow on almost any surface that stays between 32°F and 120°F (optimally between 70°F and 90°F) with no air flow and that is damp with moisture.4 If condensation forms within the insulation and the insulation stays damp, it creates the perfect environment for mold growth to begin, often without any trace on the outside of the insulation. The mold can then propagate throughout the insulation and start to form on the surface, where it can travel throughout the air space and cause overall poor air quality within the space, potentially leading to allergies, rashes, and asthma attacks.

Conclusion: Do it Right the First Time

With below-ambient systems, condensation formation is always a risk. If the system is not insulated correctly, moisture ingress, CUI, and mold will soon follow the first drop of condensation. Not only will the insulation have to be replaced if the condensation formation is not identified in time, but the system piping, ductwork, or other components—along with any surrounding equipment that the condensation was dripping on—will have to be replaced as well. It is important to make sure the system is insulated with the right thickness of insulation so that the surface temperature is always above the dew point, and to use a complete vapor barrier to avoid condensation risks.

References
1. https://earthobservatory.nasa.gov/global-maps/MYDAL2_M_SKY_WV
2. Relative Humidity Averages in US Cities – Current Results
3. http://www.dpcalc.org/
4. Michael Pugliese, The Homeowner’s Guide to Mold, Reed Construction Data, Inc ©2006

NIA Sites > Insulation Outlook Magazine > Global

NIA Contractor Member Kerco 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, in 2023 we unveiled the first-ever NIA Insulation Project Art Gallery Showcase and Competition. We invited all NIA insulation contractors to submit photographs and a brief description of projects representing their most creative and artistic efforts. At 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. As a new regular column, we will profile the projects submitted, focusing this month on Kerco, Inc. We encourage NIA Contractor members to participate in the 2024 Insulation Project Art Gallery Showcase and Competition to possibly be featured in future articles.

PROJECT SNAPSHOT

Insulation Contractor: Kerco, Inc. (www.kercoinc.com)
Industry Segment: Industrial
Type of Plant/Facility: Cold Storage Warehouse
Temperature Range: Below-Ambient System (-40°F to 25°F)
Region: Southwest
System Designed/Application Type: Ammonia Refrigeration System
Insulation Materials (in Process Room and Engine Room):
  • Type–Polyisocyanurate
  • Manufacturer–DUNA-USA
  • Fabricator–Insul-Therm
  • International, Inc.
Jacketing:
  • Interior–PVC (in various colors)
  • Exterior (on roof)–.024 white aluminum with 3/4” stainless steel banding (no screws or staples)
Vapor Barrier: 
  • Type–Mylar Vapor Barrier
  • Brand–Childers

Project Description and Goals

The project involved insulating a refrigeration system for a new cold storage warehouse/process facility operating at below-ambient temperatures ranging from -40⁰F to 25⁰F. Pipes and equipment to be insulated run ammonia (-40⁰F and -25⁰F) and glycol (25⁰F), with temperatures on the piping schedule as follows:

  • Blast and cell freezer at -35⁰F,
  • Freezer at -10⁰F,
  • Dock at 10⁰F, and
  • Glycol at 25⁰F.

Goals of the project were to achieve energy savings by optimizing process efficiency (minimizing heat loss/gain in the system) and to control condensation. In addition, the customer sought to make the complex refrigeration system easier for maintenance personnel to work with by clearly delineating different process lines and temperatures, which offered the additional benefit of enhancing personnel safety.

Challenges

Sometimes the strengths of a project also present its greatest challenges. James Kerco, President of Kerco, Inc., has been in the commercial and industrial mechanical insulation industry for more than 45 years. He says, “The project was extremely well engineered, using colored PVC jacketing indoors to signify the temperature or type of system being insulated by color.” In the dock area, for example, colors were used to indicate the purpose of each pipe—condensate drain, hot gas line, refrigeration line, etc. (see Photo 1). If system repairs need to be made in the future, the colors will make it easy to isolate the line in question. While this simplifies things for facility maintenance personnel, it created a challenge for insulation installation: More than half a dozen colors were to be used, and the right color of jacketing needed to be applied to each pipe and piece of equipment insulated (along with the usual considerations, such as appropriate thickness, etc.).

System Design

Inside the facility, Kerco used polyisocyanurate insulation, with a mylar vapor barrier, applied to pipes and vessels. For condensation control, as well as process efficiency, Kerco personnel ensured insulation was installed at the correct thickness for the specific application, given the temperature of the individual pipes and the ambient temperature of the room where they were located. They used a staggered joint approach, with vapor barrier mastic applied to all seams and joints. Per specifications (and industry best practice), they applied vapor stops and expansion joints, and back-filled all voids with foam. MICA Plate 1-660 illustrates the approach they followed (see Figure 1). “We like to get [the MICA plate] on site to show how we will insulate and seal the pipe, and to educate the end user and the engineer,” James Kerco explains. “It is so important to insulate and seal particular types of insulation systems correctly. You miss one step, and you ruin the entire refrigeration system. The system can be completely destroyed within a year or two” because it was not insulated, or was not insulated properly. In contrast, Kerco adds, a sound insulation system will perform to expectations for so long that “by doing it correctly once, you don’t have to do it again.”

In both the process room and the engine room, pipes and vessels were color-coded using .030 PVC jacketing to indicate the temperature or type of system insulated (see Photo 2). The goal was for facility personnel to be able to walk into the engine room, for example, and know even from a distance what system/temperature each pipe or piece of equipment is.

As noted earlier, this feature presented a real test for the installation group, who had to “meet the challenge that all the PVC went on correctly on each system, making sure nothing was mislabeled,” James Kerco describes. To make sure the correct colors went on each piece insulated—while ensuring the correct insulation thickness was applied to each piping system—Kerco personnel insulated one system at a time, “working hand-in-hand with the refrigeration contractors” so everything was accurate.

Kerco also insulated exterior lines on the roof that provide service to the freezers, blast cells, and dock area (see Photo 3). They used .024 aluminum (painted white), with ¾ inch white stainless steel banding. The banding was essential. James Kerco notes, “You can’t use staples or screws in refrigeration jobs because you would violate the integrity of the vapor barrier. That’s the number one item that needs preservation. If that’s defeated, the system will fail.”

Table 1 offers an overview of insulation system components, listed by location.

The “Wow” Factor

James Kerco says that when facility personnel walked through the finished product, “Everyone was starstruck because of all the different colors—especially the refrigeration plant engineer and operating engineer for the refrigeration system.” Instead of the typical all-white system with labels indicating what ran inside each pipe, at what process temperature, “everything was color-coded, and they understood immediately what the colors meant.” In the end, while the use of color required that extra level of attention to detail during installation, the results were more than worth it in terms of immediate customer satisfaction and the long-term benefits of ease of maintenance and personnel safety.

Emphasis on Safety

James Kerco also stresses that completing a project on time, within budget, and achieving all the customer’s objectives is only part of the job. It is also vital that “we make sure all our employees go home safe at night.” In the pursuit of that mission, Kerco, Inc. is a 2023 NIA Safety Star™, awarded a Bronze Safety Excellence Award in April. As part of the company’s safety plan, in addition to attending regular general safety training and on-site project safety meetings, all Kerco field personnel are specifically trained on the equipment (e.g., forklift operation) and tasks they perform, and all are OSHA 10 certified; superintendents are OSHA 30 certified; and craftsmen and staff alike are trained in CPR. On this project, Kerco’s commitment meant that not only was the customer satisfied, but all Kerco employees were safe at the end of the day.

Project Takeaways

Many aspects of work performance contributed to the project’s success, but the takeaways listed below stand out as elements that are applicable to all insulation projects, whether new construction or upgrades.

  • Communication Is Key. While coordinating schedules among different trades often can be a challenge with new construction projects, James Kerco says that working with the general contractor/refrigeration contractor kept everything running smoothly on this job. He notes, “Communication went well. Everyone knew what had to be done, and we were able to apply the insulation quite well without interruption.”
  •  Start with a Sound Design and Install per Best Practices. A well-engineered, well-specified plan executed by well-trained, experienced personnel following industrybest practices virtually guarantees that project goals will be met or exceeded.
  • Planning Ahead Lowers Risk—and Stress. To ensure that all the materials were available in time, Kerco preordered those that typically require longer lead times, such as the white-painted jacketing used on the roof (which needed to be fabricated).
  • Strength in Numbers. This project offers a real-world example of NIA President Jack Bittner’s theme, Strength in Numbers, as Kerco coordinated with fellow NIA member Insul-Therm International, Inc. (www.insultherminc.com) for fabrication of the polyisocyanurate insulation for the pipes and fittings, which was manufactured by NIA Associate member DUNA-USA (www.dunagroup.com/usa).

Energy Savings

James Kerco observes that although insulation is often among the last products considered, it is one of the most critical parts of a project, especially when it comes to energy savings. He notes, “We’ve been the energy people since insulation began. We were at the forefront when we initially began insulating pipes. We were conserving energy from Day 1.” Now, as so many in government and industry are looking for ways to achieve sustainability, that is a message worth repeating.

About Kerco, Inc.

Kerco is an industry leader in effectively utilizing 21st Century technology to better serve its clients. Using the latest in computer technology, the company can produce fast, accurate, and detailed on-site bids that take into account individual requirements, applicable government regulations, and clients’ design objectives. Kerco’s seasoned craftsmen provide the highest levels of service and technical support in the installation and maintenance of energy retention systems that impede heat gain or loss. For more information, visit www.kercoinc.com.

 

NIA Sites > Insulation Outlook Magazine > Global

Energizing Tomorrow: Waste-to-Energy Initiatives Transforming America


In a world where taking care of our environment is becoming more crucial, the United States is at a crossroads. People worldwide are coming together to tackle big issues like climate change, extending resources, and managing waste.

This article dives into why sustainability matters and how waste-to-energy (WTE) plants could be a possible solution to the U.S. waste crisis.

The Waste Crisis in America

The trash situation in the United States has become a significant issue, contributing to a global challenge. Despite being home to only 4% of the world’s population, the United States produces more than 12% of the planet’s total trash, according to Environment America.

In 2018 alone, the United States disposed of a staggering 292 million tons of municipal solid waste (MSW), as reported by the U.S. Environmental Protection Agency. That number has only increased since.

This type of waste includes materials thrown away by households, businesses, and institutions like schools and libraries. To put it in perspective, each American discards about 4.9 pounds of trash every day, accumulating to nearly 1,800 pounds of waste per person annually.

The concerning part is that a substantial portion of this waste, about 62%, either ends up in landfills or is burned in incinerators. This means that a considerable amount of our waste is not being effectively managed or repurposed, contributing to environmental challenges.

Why is this a problem? The excessive generation of trash poses several issues for the environment.

Landfills take up valuable space, leading to deforestation and habitat loss. Additionally, burning waste in incinerators releases harmful pollutants into the air, impacting air quality and contributing to climate change. The sheer volume of discarded materials also highlights a wasteful use of resources, as many items that could be reused or recycled end up being disposed of in ways that harm the planet.

Addressing the trash crisis in the United States is essential for creating a more sustainable future. It involves not only reducing the amount of waste generated, but also adopting responsible waste management practices, such as recycling and WTE initiatives.

The Rise of Waste-to-Energy Plants

The need for sustainable energy in America goes beyond producing energy without emitting greenhouse gases from fossil fuels. It involves diversifying our energy sources, lessening reliance on imported fuels, and fostering economic development and job opportunities in various sectors. By prioritizing sustainable energy, we aim to create a cleaner environment, enhance energy security, and trigger economic growth through the expansion of job markets in crucial industries.

To address the dual challenge of managing our ever-increasing waste and reducing our dependence on fossil fuels, we must have an innovative solution. This is where the concept of WTE plants emerges as a beacon of hope. WTE plants are innovative facilities that turn waste into usable energy, offering a sustainable alternative to normal waste disposal methods.

In the United States, where a whopping 390 million tons of waste is produced each year, WTE plants offer a way to responsibly manage the leftover waste after recycling and composting.

Case Study: Reworld Waste’s Impact

Reworld Waste LLC, previously known as Covanta, a leader in the field, operates state-of-the-art WTE facilities that redirect waste from landfills, harnessing its energy potential through the combustion of MSW (Multiple Solid Waste). The innovative process transforms remaining waste, post-recycling, into electricity for homes and businesses, or steam exported to industries. This high-tech, advanced approach to waste disposal not only provides a viable energy source but also addresses environmental concerns by significantly reducing greenhouse gas emissions, particularly methane.

Landfills, as identified by NASA scientists, are recognized as significant methane emitters; and methane is 84 times more potent than CO₂ as a climate-warming gas.

Reworld’s WTE facilities make a substantial impact annually:

  • They reduce 21 million tons of greenhouse gas emissions.
  • They continuously power more than 1 million homes.
  • They recycle an impressive 600,000 tons of metal.

The process involves taking non-hazardous waste, otherwise destined for landfills, and combusting it to generate steam for electricity production. The ash produced undergoes processing to recover metal for recycling, while gases are carefully collected, filtered, and cleaned to minimize environmental impact. While it sounds simple, it is an intricate process that requires advanced technology and precision, and expertise mastered by Reworld.

The benefits of WTE extend beyond efficient waste disposal:

  • It is recognized as a technology that actively mitigates climate change.
  • WTE facilities are unique in reducing greenhouse gases, playing a crucial role in addressing climate change—e.g., for every ton of municipal solid waste processed, Reworld reduces greenhouse gases by up to 1 ton.
  • WTE facilities provide reliable energy to power more than 1 million homes 24/7.
  • The process recovers more than 600,000 tons of metal each year for recycling, equivalent to the steel needed for more than 450,000 automobiles.

Reworld’s commitment to sustainable practices and cutting-edge technology highlights a significant step towards a cleaner, more environmentally responsible future.

Environmental Benefits of Waste-to-Energy Plants

Utilizing WTE plants instead of landfills brings numerous advantages.

Reducing Landfill Waste: WTE initiatives play a crucial role in cutting down the amount of waste sent to landfills. Up to 80% of materials in landfills potentially could be reused or recycled. Diverting this material to WTE plants prevents it from causing harm by releasing toxic substances into water, soil, and air.

Generating Massive Energy: Well-planned WTE plants can generate significant amounts of energy, powering the creation of heat and electricity. Recognizing that waste cannot be entirely eliminated, these initiatives provide a second life to waste materials, transforming them into essential resources for human survival.

Environmentally Sound Process: The WTE process itself is environmentally friendly. It operates without relying on fossil fuels or non-renewable resources. WTE plants can even sustain themselves, producing energy while preventing the release of greenhouse gases. According to TRVST, an environmental organization, the power generated from WTE plants has the potential to save the use of 200,000 barrels of oil annually.

Mechanical Insulation’s Role in Waste-to-Energy Plants

In the journey toward a greener and more sustainable future in the United States, mechanical insulation companies like MC&I, Inc. play a crucial role by manufacturing energy-reducing storage tank insulation systems. One of the key ways MC&I, Inc. contributes to this mission is through insulating such tanks in the WTE sector. These storage tanks are utilized for a variety of applications, such as fire protection storage water that feeds a wet sprinkler system in the facility, or for cooling water used in the process.

Why is this important?

Mechanical insulation for storage tanks in WTE plants serves as a cornerstone for environmental responsibility. By providing efficient thermal protection from the atmospheric elements, products like MC&I’s RIDGLOK® Vertical Standing Seam Panel Insulation Systems contribute to the overall effectiveness of these plants, maintaining optimal temperatures and conditions within the storage tanks to make the process even more eco-friendly. Well-insulated tanks help optimize the energy production process, making it more efficient and environmentally friendly.

This commitment to insulation aligns with the broader goal of creating a sustainable America. It is not just about converting waste into energy, but doing so in a way that minimizes environmental impact and lowering energy costs.

The mechanical insulation industry—together with companies like MC&I, Inc. and Reworld—is shaping a future where innovation and environmental consciousness go hand in hand, creating a more sustainable and greener America.

Resources/References:
1. Environment American: https://environmentamerica.org/center/resources/trash-in-america-2/#:~:text=The%20U.S.%20produces%20more%20than,such%20as%20universities%20and%20libraries
2. U.S. Environmental Protection Agency: https://www.epa.gov/facts-and-figures-about-materials-waste-and-recycling/national-overview-facts-and-figures-materials#:~:text=The%20total%20generation%20of%20municipal,25%20million%20tons%20were%20composted.
3. Reworld’s Renewable Energy Recovery: www.reworldwaste.com/what-we-do/renewable-energy-recovery
4. Reworld’s Waste-to-Energy Virtual Tour: www.youtube.com/watch?v=RAXbohaBGt8
5. TRVST: www.trvst.world/renewable-energy/benefits-of-waste-to-energy/

NIA Sites > Insulation Outlook Magazine > Global

OSHA Heat Illness Rule & Industry Reactions

U.S. Department of Labor Announces Proposed Rule for Extreme Heat Protection

As reported in the June Insulation Outlook article “Heat Illness Prevention: 5 Steps for Employers to Take” by NIA Legal Counsel Gary Auman:

“As of May 2024, OSHA remained engaged in the rulemaking process to develop a standard to cover heat illness prevention. Acting Secretary of Labor Julie Su predicted that a proposed standard would be available for public review by October 2024. She also predicted that a final standard on heat illness prevention would be in place by the end of 2024.”

From OSHA:

On July 2, the U.S. Department of Labor released a proposed rule for Heat Injury and Illness Prevention in Outdoor and Indoor Work Settings.

The proposed rule would require employers to develop an injury and illness prevention plan to control heat hazards in workplaces affected by excessive heat. Among other things, the rule would require employers to evaluate heat risks and—when heat increases risks to workers—implement requirements for drinking water, rest breaks, and control of indoor heat. The rule would also require a plan to protect new or returning workers unaccustomed to working in high heat conditions.

Employers would also be required to provide training, have procedures to respond if a worker is experiencing signs and symptoms of a heat-related illness, and take immediate action to help a worker experiencing signs and symptoms of a heat emergency.

The public is encouraged to submit written comments on the rule once it is published in the Federal Register. OSHA also anticipates a public hearing after the close of the written comment period. More information will be available on submitting comments when the rule is published.

In the interim, OSHA continues to direct significant existing outreach and enforcement resources to educate employers and workers, and hold businesses accountable for violations of the Occupational Safety and Health Act’s General Duty Clause, 29 U.S.C. § 654(a)(1), and other applicable regulations. Record-breaking temperatures across the nation have increased the risks people face on the job, especially in summer months.

The agency continues to conduct heat-related inspections under its National Emphasis Program—Outdoor and Indoor Heat-Related Hazards, launched in 2022. The program inspects workplaces with the highest exposures to heat-related hazards proactively to prevent workers from suffering injury, illness, or death needlessly. Since the launch, OSHA has conducted more than 5,000 federal heat-related inspections.

From the Associated Builders and Contractors (ABC):

On July 2, ABC responded to OSHA’s Heat Injury and Illness Prevention in Outdoor and Indoor Work Settings proposed rule.

“ABC continues to believe employers should equip their employees and leadership teams to develop their own safety plans, unique to their jobsites, and we strongly encourage review of all applicable OSHA rules and guidelines,” said Greg Sizemore, ABC Vice President of Health, Safety, Environment, and Workforce Development. “We also provide tools to employers so that they can equip and empower supervisors to recognize the signs and symptoms of heat illness, as well as provide necessary rest, water, and shade that is dependent on local conditions. Our members work to ensure that jobsites are safe and implement the most appropriate practices for working in extreme heat conditions that focus on the individual worker, based on CDC recommendations.

“However, those protections must be flexible in response to the fluid nature of the construction environment, and unfortunately, some of the unworkable provisions in the proposed rule could weaken contractor efforts to prevent heat stress for workers,” said Sizemore.

ABC will continue to review and analyze the more than 1,000 pages of the proposed rule.

From Associated General Contractors (AGC):

On July 2, AGC CEO Jeffrey D. Shoaf responded to the release of OSHA’s new proposed federal heat safety rule.

“The proposed new federal heat safety rule codifies many of the heat safety practices the construction industry already uses to protect workers. Those measures, which broadly fall into the categories of water, rest, shade, and training, were crafted by construction firms as part of their general duty obligations to protect workers and keep them healthy.

“It is disappointing, however, that federal officials have not addressed the disparate impacts of heat in various parts of the country. In short, the impacts on worker safety of a 90-degree day in Mississippi are different than a 90-degree day in Alaska. The final version of the rule should take into account regional differences in weather patterns.

“The proposal also lacks any emphasis on the role workers must play to protect themselves from the heat. Heat safety does not begin at the job site and the rule should include measures designed to reinforce the role workers play in protecting themselves. These measures include self-hydrating, understanding how common health conditions and medications contribute to heat stress, and avoiding the excessive consumption of drinks containing caffeine and alcohol during periods of extreme heat. All of which the agency is aware.

“We appreciate the opportunities we have had to help federal safety officials learn about successful methods of protecting workers on job sites. That communication is one reason why so many of the measures outlined in the proposed new rule track with industry practices that are already in use. We are in the process of reviewing all the details of the new proposal with our members to ensure we can provide feedback to agency officials.

“Overall, this proposed new rule provides a starting point for creating measures to protect workers that are based on what the industry is already doing. We look forward to working with federal officials to craft a final rule that includes effective measures for firms and workers to follow. That final rule should also avoid the kind of one-size-fits-all approaches that will do more to hamstring firms than to protect workers.”

Visit www.osha.gov/heat for heat illness prevention resources and more information. Developments on the proposed rule will appear in future NIA communications.

NIA Sites > Insulation Outlook Magazine > Global

The Role of Technologies in Project Management in the Mechanical Insulation Industry

Cutting-edge technologies including video conferencing tools and mobile communication apps offer numerous benefits to the mechanical insulation industry, particularly in terms of project management and improved communication. Remote conferencing tools such as Microsoft Teams and Zoom have become essential for companies today to allow collaboration on projects. These platforms allow remote teams to work together and have face-to-face meetings to address issues and make decisions regardless of their actual location. Video conferencing on these platforms helps enhance stakeholder engagement. Apps such as Slack and Teams also provide the capability of quick and efficient communication between team members, with features like file sharing and direct messaging. This technology also allows project teams to collaborate and seek clarification.

These technologies improve communication and collaboration by allowing seamless coordination among team members (regardless of their physical location) with real-time sharing of documents and updates. Effective communication reduces any misunderstandings or delays, improving the efficiency of projects. Collaboration is enhanced even when working remotely, allowing users to effectively brainstorm ideas, discuss project details, and resolve any issues. Cloud-based platforms and project management software help to ensure that all tasks are assigned and tracked. Transparency is increased, as all project information and communication is available in one centralized channel, allowing all stakeholders to access updates and documents. This also reduces the risk of mistakes and miscommunication, as the correct information is always readily available.

Numerous communication technologies1 are now invaluable tools within the mechanical insulation industry, offering many benefits in project management, including improved team collaboration, increased transparency, effective stakeholder engagement, and enhanced project coordination. Successful companies will leverage these technologies to optimize team communication for higher quality decision-making.

The Evolution of Project Management Tools in the Mechanical Insulation Sector

The mechanical insulation industry has seen many advancements in the type of project management tools used to meet the unique demands of the sector. There has been an evolution from manual or paper-based documentation and physical filing systems to cloud-based or mobile communication technologies. These technologies have improved project efficiency significantly by allowing team members to collaborate effectively no matter where they are based, irrespective of local time zones. Team members can work remotely from home, connected via headsets to applications that provide access to real-time data and voice/video communication.

Advantages of Communication in the Mechanical Insulation Industry

One of the key benefits offered by communication headsets is the ability to have clear conversations even in noisy and dangerous environments. The mechanical insulation workplace can often involve loud machinery and noisy equipment. In this setting, clear communication is necessary for worker safety. Hands-free operation allows workers to perform tasks that require use of both hands safely while having clear, two-way communication. Allowing workers to communicate freely while keeping their hands free improves efficiency and enhances safety, as workers can focus completely on their tasks without distraction. Communication headsets can also facilitate teamwork, which is crucial for the success of all projects. Workers can stay connected regardless of their location, while real-time communication allows them to be aware of any problems and have all the information required to stay safe and make good decisions.

Minimizing Project Risks with Advanced Communication Technologies

Effective communication is crucial in industrial settings for ensuring the success of projects. Clear and efficient communication in warehouse2 or factory environments can minimize risk and improve productivity, and this is where advanced communication technologies can play a vital role. Communication is especially important in the mechanical insulation industry, which involves complex projects that require coordination and collaboration among various teams in potentially dangerous environments. Advanced communication headsets can help minimize risks on site, as workers can communicate instantly, eliminating potentially dangerous hand signals or misinterpreted shouted commands. A good headset with noise reduction can help filter background noise while protecting hearing and allowing for clear communication in environments with high background noise.

Key Features to Look for in Communication Headsets for the Mechanical Insulation Industry

In the mechanical insulation industry, effective communication is crucial for safety and efficiency. Good communication between team members is greatly enhanced by using communication headsets, but there are several key features to consider.

  • Noise reduction: Noisy environments are not uncommon in the mechanical insulation industry. Therefore, it is important to choose communication headsets that feature noise-reduction technology to filter out background noise.
  • Durability: Choose headsets that are durable and can withstand impact, vibration, and the sort of rough handling they can expect on the factory floor.
  • Long battery life: The last thing you want is for workers to be wasting time searching for fully charged headsets or batteries to maintain communication throughout the day. Headsets with a long battery life reduce the need for frequent recharging and allow workers to concentrate on their main tasks.
  • Reliability: To facilitate seamless communication between entire teams, ensuring that critical information is conveyed accurately and without any delay, reliability is crucial.
  • Comfort: Many workers will need to wear communication headsets for the entire workday, or at least for extended periods. Therefore, comfort is essential—otherwise there will be a temptation to remove headsets whenever possible, which could have safety implications. Choose headsets that provide a comfortable fit designed for all-day wear.
  • Hearing protection3: In any industry that may involve exposure to loud noise, there can be hearing damage. Select headsets that can safeguard hearing while providing clear communication. Also look for a noise-reduction rating (NRR) to ensure your headset can provide adequate protection for the noise levels.
  • Multi-channel options: In complex work environments where there may be multiple teams working on different projects, having the ability to set different channels for each team allows seamless communication.

Exploring the Future of Communications in Project Management Technology

The future of project management is likely to be heavily influenced by advanced communication technology that will revolutionize the way teams collaborate and communicate. Some key trends to look for include the increasing use of more powerful and intuitive mobile devices with project management tools that are optimized for team members to enhance flexibility and efficiency. These advanced communication technologies will continue to focus on improving collaboration and leveraging data to enhance decision-making.

References
1. https://www.forbes.com/sites/forbestechcouncil/2021/02/04/13-cutting-edge-technologies-that-may-soon-be-making-a-big-impact/?sh=e419c968ae84
2. https://www.plant-tours.com/blog/tips-for-communicating-effectively-in-warehouses/
3. https://www.cdc.gov/niosh/noise/about/noise.html?CDC_AAref_Val=https://www.cdc.gov/niosh/topics/noise/noise.html

NIA Sites > Insulation Outlook Magazine > Global

Corrosion under Insulation: Sources and Symptoms, and How to Safeguard Your Systems

Metal surfaces (like a pipe, tank, or piece of equipment) can corrode in the presence of moisture. When that moisture is trapped in or under insulation and against the surface of the metal, it creates conditions favorable to developing corrosion under insulation (CUI). CUI is a significant and very expensive problem in the oil, gas, chemical, and industrial sectors. Left unaddressed, CUI leads to worsening operational performance and efficiency, increased maintenance costs (accounting for up to 10% of annual maintenance costs in these industries1), and a serious risk to system integrity and personnel safety.

Unfortunately, CUI is often unaddressed or unnoticed until there is a problem. CUI is an invisible threat because, by its very nature, it exists under the insulation and is not easily visible. The key to preventing CUI is understanding the causes, knowing what to look for and catching it early, and—perhaps most importantly—knowing how to prevent it in the first place.

Causes and Contributors

Corrosion is the result of an electrochemical process that takes place when liquid water combines with oxygen on a metallic surface. Without the presence of moisture, corrosion cannot occur. To determine the cause of CUI, we first need to figure out how moisture is getting under the insulation.

One method by which water may be trapped between the insulation and the metal is moisture ingress. Moisture ingress is the term for the movement of moisture from the outside environment through the vapor barrier and insulation to the metal surface underneath.

Moisture ingress may start with condensation. Moisture will condense on any surface below the dew point temperature, including vapor retarders. If the insulation system is not not adequately protected with a vapor barrier, or the vapor barrier is compromised in some way, the water vapor will condense to liquid water. The moisture then passes through it or can be absorbed into some types of insulation and remain there, unable to escape or evaporate unless the system was designed with weep holes. Trapped moisture can lead to CUI.

Of course, condensation is only one potential cause of moisture ingress. Exterior sources of water, like rainwater, deluge, or liquid spillage, may get into the insulation if it is not properly protected with an adequate jacket or weather barrier.

Understandably, service (or operating) temperature is also a significant factor that can influence the development of corrosion. Low service temperatures are at risk of moisture ingress through condensation, but CUI is by no means limited to low temperatures. If moisture is already present, high temperatures can actually accelerate the chemical reaction of corrosion.

A metal surface may be most susceptible to CUI in higher temperatures, from 120°F to 350°F, due to factors like corrosion kinetics and stress corrosion cracking. The American Petroleum Institute (API) indicates the highest risk is in the temperate range
of 170°F to 230°F.2

Surfaces above 350°F are at lower risk from corrosion because at that temperature the moisture evaporates more readily, and subsequently the vapor drive acts to eject the moisture from the system. However, that is not to say that piping or equipment operating above 350°F is not at risk. There will be windows of time where the temperature will drop, such as during scheduled maintenance or other downtime.

Dual temperature or cycling temperature systems can be particularly challenging. Lower temperatures can create condensation and moisture, and higher temperatures can accelerate the rate of condensation in addition to pressure differences between the outside and the inside driving the moisture through the insulation.

Catch It if You Can

The best way to detect corrosion before it causes significant damage is to inspect the surface. An inspection with the sole purpose of determining the likelihood and consequence of corrosion is called a risk-based inspection (RBI).

The frequency, scale, and scope of the RBI will depend on factors like the likelihood of corrosion, historical rate of corrosion that has been observed in the past, and the consequence of a corrosion-related failure (minor maintenance costs versus major safety issue, for example).

An RBI may simply be a visual inspection. This would involve the physical removal of the jacketing and insulation to visually inspect and physically measure corrosion on a surface. This can be done fully or partially. Full removal of the insulation allows inspection of 100% of the surface but can be a very costly process. A partial inspection allows spot-checks on high-risk areas at a significantly lower cost, but there is the added risk of the insulation and jacketing not being properly replaced in that area. If insulation is incorrectly reinstalled, an area that previously passed inspection and showed little risk of future corrosion can quickly become a problem area. One method of addressing this risk in partial inspections is through the use of inspection ports and plugs, which involves creating a small area without jacketing and insulation, and attaching a watertight plug that can be easily removed to inspect the bare pipe and reapplied and resealed afterwards. That said, API warns that there is still a higher likelihood of CUI damage in areas with insulation plugs, or any areas where the insulation and jacketing is damaged or missing.3

With recent advances in technology, there are now “non- destructive” inspection techniques, which attempt to “see though” the jacketing and insulation to the metal surface below to look for any signs of corrosion. These include many of the same technologies that are used in healthcare, including radiographic/x-ray, ultrasonic/ultrasound, and pulsed-eddy-currents/magnetic resonance imaging.

An owner or operator should consider not only the labor costs but also the accuracy of the tests in the cost-benefit analysis to determine the method of inspection that is right for them.

Making Preparations

When installing and insulating a new system, some basic preparations should always be followed, such as ensuring that the surface is clean, dry, and at ambient temperature before any insulation is applied, making sure the insulation is properly sized for the job, and following the manufacturer’s installation instructions.

A critical step in mitigating CUI is the application of anti-corrosion coatings, sometimes called CUI coatings. Coatings applied directly to the metal can act as a physical barrier, preventing oxygen, moisture, and other contaminants from reaching the metal surface.

Inorganic, metal-based coatings, like thermally sprayed aluminum (TSA), offer an excellent vapor and moisture barrier to protect the underlying metal. There are also organic-based coatings newly available on the market—like epoxy phenolic, epoxy novolac, and high-build epoxy products—some of which may contain corrosion inhibitors.

Different coatings may have different temperature limitations and expected lifespans, depending on composition and application. Some are even recommended for use with specific insulation products.

It is important to think of CUI coatings as the last line of defense in the insulation system. Their barrier may not be impenetrable, and the vapor barrier may not be perfect; however, if the outer protective jacket is compromised, and the insulation underneath the jacket takes on moisture, the coating may provide the needed protection until the issue can be remedied.

The Role of Insulation

Proper installation of insulation can go a long way toward preventing CUI in the first place. There are many types of insulation to choose from, each with its own methods of mitigating the risk of corrosion. In deciding on the insulation product for a specific application, there are a few key questions to consider:

  • Are there any annular spaces or crevices that allow for the retention of water and other corrosive media?
  • By what mechanism is water prevented from being absorbed into the insulation?
  • How likely is the insulation to accelerate or decelerate the rate of corrosion?

The three types of insulation used in the mechanical insulation industry that are discussed in this article are fibrous, granular (including both rigid and flexible), and cellular.

Fibrous Insulation

Fibrous is just what is sounds like: a collection of small-diameter fibers dividing a space into many small air spaces. Examples of fibrous insulation include fiber glass and mineral wool. Fibrous insulation products are generally sold in batts, but they can also be preformed into pipe shells or segments sized to fit a pipe to help reduce annular space. A few contain water-repellant additives, which create a hydrophobic surface to prevent liquid water accumulation while still allowing water vapor to escape. Be aware that most of these water-repellant additives are temperature sensitive, and they may be damaged or destroyed in higher temperature applications.

A fibrous insulation product may also include a corrosion inhibitor, designed so that in the event of moisture ingress, the corrosion inhibitor washes out and travels with the water down to the bare metal, where a chemical reaction takes place to help counteract the effects of water on the metal surface.

Ideally, moisture ingress should be prevented from occurring in the first place, and the metal should have an anti-corrosion coating between it and the insulation.

Rigid Granular Insulation

Rigid granular insulation products like calcium silicate and perlite are rigid, high compression-strength materials, often silica-based, with a granular texture, containing small voids or hollow spaces in the material for air. Granular insulation products are also preformed, typically in blocks, pipe shells, or curved segments. As these products are naturally wicking, their manufacturers add hydrophobic coatings. Some manufacturers also offer corrosion inhibitors that are still effective at high temperatures. Similar to the inhibitors in fibrous products, if the insulation does take on water, the corrosion inhibitors will go with it and help mitigate the risk of corrosion. It is important to note that corrosion inhibitors, whether in insulation products, coatings, or both, can be beneficial when using any type of insulation with the potential to take on water, just as a precaution against the risks of moisture ingress.

Aerogel and Flexible Granular Insulation

Flexible granular insulation consists of microporous or aerogel granules in a fibrous medium, and it has distinct differences from both rigid granular insulation and fibrous insulation. Aerogel specifically is a relatively new technology: a man-made material with as the lightest weight and lightest density material on earth, with typically higher thermal resistance, in a given thickness, versus other non-vacuum based insulations. The aerogel is infused into a thin fibrous blanket for ease of installation. Whereas the air between the fibers is typically the insulator in a fibrous insulation, in this type of insulation, much of the air space in the blanket is replaced with aerogel, giving it higher thermal resistance in a smaller space. The installation of a flexible aerogel blanket involves wrapping it tight against the metal, with a metal jacket applied to the outside. The aerogel material within the blanket has inherent anti-corrosion properties, is hydrophobic to 600°F, and can withstand temperatures as low as -297°F and as high as 1,200°F.

Cellular Insulation

Cellular insulation materials are what is typically referred to as foam. There are open-cell and closed-cell foam products, but closed-cell is quite common when corrosion is of particular concern, as closed-cell materials create a natural barrier to water and water vapor. Rigid closed-cell insulation products, like cellular glass, are installed as pieces or in sections. The closed-cell nature of the foam can be an excellent vapor barrier, but a separate vapor barrier or jacket is still required to prevent moisture from getting in through the seams.

Flexible closed-cell insulation products, like flexible elastomeric foam (FEF), do not rely on an exterior vapor barrier or jacket as a first line of defense to keep out moisture because there are far fewer seams, and the adhesive used to seal them is at least as vapor tight as the insulation. As a result, one common method of installing flexible closed-cell foam insulation in areas of high corrosion risk is to completely adhere the foam insulation directly to the metal surface. This method fully eliminates any annular space between the insulation and the metal surface, so there is no physical space in which water can accumulate.

Hybrid Insulation Approach

In evaluating the pros and cons of different insulation types, including balancing their performance benefits against their material and labor costs, owners and operators have an important choice to make; but that does not mean they have to choose just one. Another industry-recognized practice is to take a hybrid approach, using two different products to get the best of both. Someone could, for example, marry the high compression strength of granular insulation, or the vapor barrier properties of closed-cell insulation, or the low cost of mineral wool, with the extreme hydrophobicity of aerogel.

When the International Association of Oil and Gas Producers (IOGP) released its Joint Industry Programme 33 specification document S-783 – Insulation for Piping and Equipment4, it recommended that for applications at high risk for corrosion, certain insulation products (specific fibrous and rigid products) not come into contact with the metal at all, and instead recommended the use of non-contact methods or aerogel applied directly to the metal piping or equipment as the primary insulation layer (see the aerogel photo on page 22).

Looking Ahead

The Association for Materials Protection and Performance estimates that corrosion currently costs the industry nearly $2.5 trillion. But by being smart and using industry best practices, insulation end users could cut the global cost of corrosion anywhere from 15% to 35%.5

You can do your part. Understand the causes of corrosion and recognize the signs. Use the RBI method to mitigate both costs and risks. Inspect smart and inspect often to catch any minor issues early, before they become major issues. Where possible, apply the optimum insulation system by using the right insulation and coating products for the right application, and making sure everything is properly sealed and insulated.

Be smart. When it comes to the high costs and high risks of CUI, insulate yourself.

References
1. NACE Impact Study, 2016, Annex D
2. API RECOMMENDED PRACTICE 583, 2021, Third Edition
3. ibid
4. IOGP Supplementary Specification to NORSOK M-004, S-783 Insulation for Piping and Equipment, 2020, Joint Industry Programme 33
5. NACE Impact Study, 2016, Annex D

Visit www.insulation.org/designguide to learn more about
product characteristics of thermal insulation materials.

NIA Classification of Materials

Cellular Insulations
• Elastomeric
• Cellular Glass
• Polystyrene
• Expanded Polystyrene (EPS)
• Extruded Polystyrene (XPS)
• Polyisocyanurate
• Polyurethane
• Sprayed Polyurethane Foam
• Poured-in-Place Polyurethane
• Phenolic
• Melamine
• Polyethylene/Polyolefin
• Polyimide

Fibrous Insulations
• Mineral Fiber (Fiberglass and Mineral Wool)
• Fiberglass
• Mineral Wool
• Mineral Fiber Pipe
• Mineral Fiber Blanket
• Mineral Fiber Block and Board
• Textile Glass
• High Temperature Fiber

Granular Insulations
• Flexible Granular
• Microporous
• Silica Aerogels
• Rigid Granular
• Calcium Silicate
• Molded Expanded Perlite

Reflective Insulation

NIA Sites > Insulation Outlook Magazine > Global

How to Pull 68 Million Metric Tons of CO2 out of the Atmosphere Each Year—Starting Tomorrow

Greenhouse gas emissions. Carbon credits. Green energy technologies. These are all hot topics, and as the world scrambles to figure out how to drastically reduce carbon emissions in the coming years, there is an already existing solution that could help make an impact.

Thermal insulation. For years, the insulation industry has highlighted the cost of under-insulated areas. We tout the dollar numbers ($2.5+ Billion a year lost in uninsulated or under-insulated systems), hoping the impact of such numbers will encourage more insulation installation.

We explain how insulation is often incorrectly viewed as an expense, not an asset. Expenses are incurred and do not provide any benefits in future accounting periods. Expenses also only provide a short-term benefit for a business. In contrast, assets help a business derive economic benefits in the future, and they can provide both short- and long-term benefits. Clearly, properly installed insulation is an asset, as it offers extremely attractive return on investment year after year.

Under-insulated piping and equipment at industrial facilities includes processes with no insulation, damaged insulation, or not enough insulation. Areas with no insulation typically include valves, flanges, and other high-traffic items that are not insulated due to the need for frequent access for required maintenance activities. Damaged insulation is just that—insulation that has been walked on, has damaged protective metal jacketing, or has otherwise been physically abused. Under-insulated systems often have insulation that was installed in the past, but current practices and codes require thicker insulation. All of these result in added cost of operations, more energy used than is necessary, and increased carbon emissions.

Unfortunately, industrial insulation seems to be a forgotten technology. There are no gauges, monitoring, or computer apps to “see” its success. The benefits are instantaneous and continuous, but because they are invisible, they are generally taken for granted, which is why we think it is time to change the narrative and entice people with carbon reduction statistics.

It is a well-known fact that the use of mechanical and industrial insulation reduces carbon emissions, but for years there was not much hard data on the subject—just anecdotal numbers describing the contribution of insulation. This changed when NIA published A Study on Insulation’s Positive Impact on Energy Efficiency and Emissions Reductions, which includes reported annual numbers from major manufacturers (see www.insulation.org/carbon).

The NIA study looked at commercial and industrial markets in the United States and Canada to determine how much energy is saved and the amount of greenhouse gas emissions reduced with the use of proper insulation. Conducted using 2022 data, the study includes under-insulated areas in high- temperature markets, giving solid numbers.

The study concludes that the cost of unnecessary CO2 emissions due to under-insulated systems is, conservatively, 68 million metric tons per year. By comparison, you would need to put 14,000 windmills into operation each year to offset those 68 million metric tons of carbon. Currently, there are only approximately 95,500 windmills operating today in the United States (90,000) and Canada (5,500).

Large countries around the globe have set carbon reduction goals. In the United States, the goal is a 45% reduction by the year 2030, to reach Net Zero by 2050. But the technologies to accomplish these goals do not exist yet, or the potential payoff from many of them is years in the future. The year 2030 is rapidly approaching, so there is no time to waste in getting a start on carbon emission reductions.

If the under-insulated systems were properly insulated, the savings in 2022 alone would have been 68 million metric tons (or 14,000 windmills’ worth). And while that by itself would not achieve the 45% reduction goal, it makes a good-sized dent. Because 68 million metric tons is an annual and compounding number, if you multiply that from 2024 to 2030, you are talking about 476 million metric tons over the next 7 years, which would be equivalent to adding another 98,000 windmills—doubling the amount in existence. (An important sidenote is that it can take up to 4 years to get a windmill installed and operational, given time for permitting, construction, etc. By insulating today, you will be receiving carbon reduction results for 4 years before the windmill is functional.

To further get people’s attention, we can put numbers into perspective regarding carbon credits. These were created by the government to limit the amount of greenhouse gases organizations can emit. A company that brings its overall emissions below what is required by law can sell its excess credits to other companies that are struggling to meet the limits.

As we approach the year 2030, it is likely that carbon credits will become a hotter and hotter commodity. One carbon credit equals 1 metric ton of CO2, so imagine the market for carbon credits for a company that has some to spare. All design thicknesses of insulation deliver reductions in CO2 and NOx emissions of 88 to 98%. Drastically reducing the amount of carbon emissions a company expels means that it will have more carbon credits to use or sell.

All these emissions savings, combined with the well-established and compounding cost savings that mechanical insulation provides, makes improving areas that are currently under-insulated (or not insulated at all) a no-brainer. There is no time to waste in reducing carbon emissions. Because the technology already exists, we can—and should—put insulation to work. Immediately.

NIA Sites > Insulation Outlook Magazine > Global

Heat Illness Prevention: 5 Steps for Employees to Take

In 2021, President Biden directed OSHA to develop a standard to cover heat illness prevention. Following this action, OSHA issued an Advance Notice of Proposed Rule Making (ANPRM) on October 27, 2021, and invited comments from the public. OSHA reportedly received 965 comments about this ANPRM. On May 3, 2022, OSHA held a virtual public stakeholder meeting and established a work group to move forward on a standard. On May 31, 2023, recommendations of the work group were passed on to OSHA. In August 2023, the Small Business Advocacy Review (SBAR) panel heard from Small Entity Representatives. As of May 2024, OSHA remained engaged in the rulemaking process, and Acting Secretary of Labor Julie Su predicted that a proposed standard would be available for public review by October 2024. She also predicted that a final standard on heat illness prevention would be in place by the end of 2024.

In the meantime, it is important to remember that OSHA has been mostly successful in enforcing heat illness prevention on employers under the General Duty Clause, Section 5(a)(1) of the Occupational Safety and Health Act, which requires all employers to provide their employees with a workplace free of recognized hazards causing or likely to cause death or serious physical harm.

Heat illness meets that criteria. In a decision in 2012, Judge Patrick Augustine of the Occupational Safety and Health Review Commission listed five parts of the criteria document that he felt were feasible steps for employers to take to prevent heat
illness. Some locations may be confronted with heat illness issues year-round, but we are entering a part of the year with warmer temperatures for most U.S. locations. Recently, OSHA went on television in Texas and warned employers of their responsibilities to provide heat illness prevention steps for their employees. In this televised notice, the OSHA Representative emphasized providing water, rest, and shade for employees when working in a high heat index environment. I believe that is an oversimplification of the problem. As I have reviewed safety programs in construction-related industries, many employers’ heat illness prevention program provides water, some shade, and some rest (the latter two are undefined) for employees. I feel that employers need to go well beyond water, rest, and shade in developing their heat illness prevention programs. Employers must understand that it is their responsibility to prevent heat illnesses for their workforce—and not the responsibility of their employees. Heat illness prevention is taking a front-and-center position for OSHA’s safety enforcement in 2024.

The five steps discussed by Judge Augustine begin with acclimatization and proceed through training. Remember that your heat illness prevention program is based on the heat index, not on temperature alone. I strongly suggest that you have your site supervisors download the OSHA–NIOSH Heat Safety Tool App (http://www.osha.gov/heat/heat-app) on their smartphones. This app will provide them with the heat index at their jobsite and reminders of actions they should take to prevent heat illness corresponding with the heat index they are experiencing.

Step 1: Acclimatization

Employers need to identify employees who are reporting to the high heat index environment for the first time or are returning to the high heat index environment after having been away from it for 1 or 2 weeks. Set a schedule for the gradual indoctrination of those employees to the heat index on the jobsite over a period of 1 to 2 weeks. With this step, as well as the others, you might want to consult with your company doctor for guidance on the best approach for your employees. If you are unsure about how to proceed in setting an acclimatization schedule, you should consult with your company doctor or an occupational medicine specialist for assistance.

Step 2: Establish a Work/Rest Regimen

This regimen will vary, depending on the heat index. For a low heat index, you might start with shorter rest periods with longer work periods between them. As the heat index increases, you will need to increase the length and frequency of rest periods. Again, guidance can be obtained from the OSHA–NIOSH Heat Safety Tool and/or from your company doctor or an occupational medicine specialist.

Step 3: Hydration

Employers need to be sure adequate cool water is provided on the jobsite. There should be sufficient water to provide up to a quart of water for each employee, each hour. Establish a hydration schedule at the start of the day and be prepared to modify it as the heat index increases. A rule of thumb is a cup (8 ounces) of cool water every 15 to 20 minutes in a moderate heat index. Again, consult the OSHA–NIOSH Heat Safety Tool and/or your company doctor for advice and ideas.

Step 4: Cooling-Off Areas

Employers should establish cooling-off areas in close proximity to the jobsite. These should be available for use by employees during rest breaks, especially as the heat index climbs during the day. Cooling-off areas should also be available to employees anytime they begin to feel the symptoms of any heat illness. An employee who needs to use a cooling-off area should never be permitted to find their own way to the area, especially if it is somewhat remote or removed from the active jobsite. Ideally, the cooling-off area should have an ambient temperature of 76°F.

Step 5: Training

Employers should train employees on the different types of heat illnesses, the symptoms of each, and how to recognize those symptoms in themselves and others. They should also be trained in the first-aid steps to take whenever they see the symptoms in themselves or others. Training also should include such things as staying away from alcohol, highly caffeinated beverages, and energy drinks during the entire period of time they will be working in a high heat index environment. Employees should be warned that anyone with underlying medical issues such as heart disease, diabetes, high blood pressure, etc., and/or a history of prior episodes of heat illness (especially heatstroke) is more susceptible to heat illness than other employees. Other related discussions include appropriate clothing for a high heat index environment. As you can see, training employees on this topic cannot be accomplished in a 5- to 10-minute toolbox talk.

Employers need to document all training as well as the steps taken each day to protect employees in a high heat index environment. Finally, your program has to be supervisor driven. You must ensure that supervisors know that this is NOT something they only tell their employees once and then leave up to the employees to comply or not. Site supervisors must understand that they are 100% responsible for ensuring that employees working for them fully comply with each part of all the steps. Start developing and implementing your heat illnessprevention program now. When OSHA does finalize a heat illness prevention standard, you should see specific steps in the standard that you will need to take to be in compliance. Until then, you should follow the outlined steps, or steps close to them, to meet the requirements of the General Duty Clause.