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Thermal insulation shell of expanded polystyrene

JV “PANELPLAST” proposes a molded insulation for pipe lagging, the polystyrene “shell” (rigid foam) of ПСБ-С - 15 and 25 (GOST 15588-86).  This “shell” is a new and effective type of insulation for pipes, which is widely used in industrial and civil engineering in the developed countries.  The product consists of two or more (depending on pipe diameter) semi cylinders/segments of 2 meters long and of 2 - 10 centimeters thick, which makes the insulation works most efficient and economical.  


The “shell” is made with side locking connection of «spike-and-groove» type, which is tightly closed, providing a comfortable, secure fit and prevents the formation of "cold bridge".  The assembled “shell” forms a one-piece insulating sheath for pipelines transporting liquids and gases within the temperature range of -188° to +85°C, both in the aerial and underground transportation links.  This “shell” could be applied to pipelines transporting high temperature products (up to 120 degrees).  To provide this, a layer of compressed mineral wool of 2-3 cm thick should used as a pad.  The “shell” could be applied using outer covering (fiberglass, aluminum foil, Poliizol, Bikrom or galvanized metal), and without any coating.  Works on thermal insulation of pipelines could be also done without preliminary laying of concrete bottom, and that significantly reduces the material costs.  


 Advantages of Shell Application

  • The pipes insulated with “shell” are less subject to corrosion, the service life of thermal insulation increases up to 10-25 years.  The insulation works using “shell” are implemented several times faster than using fiberglass and other materials.  There is an ability of applying of rust-preventing agent in the process of pipe preparation; 
  • The “shell” is very simple in assembling and disassembling, not requiring additional skills or equipment. Reusability, fast access to the damaged areas of pipeline; 
  • Heat losses in pipes are decreased by 2-3 times versus the normative ones.  The “shell” does not require any special protection.  It absorbs very little water, and this can only occur due to water pressure.  Water absorption for 24 hours on volume is 0.5%.  Expanded polystyrene shows a high resistance to organic substances. 
  • Insulating material is a 100% dielectric.  Safe to the environment.  Expanded polystyrene is a rot-resistant, non-toxic material, not evolving harmful substances.  
Prefabricated insulation component consists of a set of half-cylinders or segments of expanded polystyrene fastened to the pipe with tightening belts, the geometric dimensions of these half-cylinders and segments depend on the pipe diameter.  


Assembling of the “shell” segments of the pipeline can be performed at the temperatures range of -40° to + 50° C.  Mounting is performed by means of metal polymer tapes, mounting tape or wire.  

“Shell” segments of appropriate size are put on the tube with a 100-200 mm offset.  Vertical joints can be glued with self-adhesive tape.  Then, if necessary, the “shell” covers with the selected protection material (fiberglass, aluminum foil, Poliizol, Bikrom or galvanized metal).  


Dimensions of thermal insulation products (“shell”):

  • Thickness: 20 to 100 mm, Length: 1000 to 2000 mm;
  • Inner diameter: 15 to 1023 mm.


Thermal insulation of pipelines is implemented using “shell” and waterproofing coating “POLIIZOL”.  Waterproof materials POLIIZOL and BIKROM are produced by LLC "ALES-POLIZOL SINTEZ", a partner of JV “PANELPLAST”.