Thermobreak Installation Instructions

Thermobreak Tube and Sheet for Pipework

PREFACE
This document covers installation instructions for Thermobreak Tube and Sheet around pipework with
operating temperatures less than 100C.
Installation of Thermobreak for cold or chilled water applications requires additional instructions.
These instructions must be read along with the General Installation Instructions Section in this document.
Installation of Thermobreak for outdoor applications requires additional instructions. These
instructions must be read along with the General Installation Instructions Section in this document.
For all outdoor applications, cladding over Thermobreak Tube and Sheet is recommended.
These installation instructions are one of a series that cover various Thermobreak applications:
Insulation of general pipework: Thermobreak Tube and Sheet for Pipework.
Insulation of ductwork: Thermobreak Sheet for Ductwork.
Insulation of AHUs: Thermobreak Sheet for Air Handling Units (AHUs).
Insulation of fittings: Thermobreak Sheet and Tube Fittings.
Insulation of vessels: Thermobreak Sheet for Vessel Insulation and Cladding.
Insulation of under-slab: Thermobreak Sheet for Under-Slab.
Insulation of raised floors: Thermobreak Sheet for Raised Floors.
Insulation of pipework used in solar applications: Thermobreak Solar.
Sound absorbing insulation for duct liners: Thermobreak Acoustic.
Pre-insulated pipework: Thermobreak Thermacoil for Refrigeration Piping.
Pipe supports: Thermobreak Thermaloc.
Fire-stopping of wall/floor penetrations: Thermobreak Fi-Block.
Thermobreak products are very easy to install. However, since they are based on closed cell foam, they
require different techniques to those experienced in fibrous and beaded insulations. It is important to
note the following:
1. Review the Engineers specifications in conjunction with this document.
2. Read the installation instructions pertinent to the type of system to which Thermobreak will be
installed. This may include other Thermobreak installation instructions as listed above.
3. Should there be any doubt on how to install Thermobreak it is advisable to contact Sekisui Foam
International and speak to a sales representative who will advise as to the best method of
installation.

Safety Equipment
Thermobreak is dust and fibre free and will not cause itchiness when used. Gloves and dust masks are
not required when using Thermobreak; however one should consult the OH&S requirements specified on
site.

Exposure to Heat
Closed cell foams will expand when heated. The expansion is small and predictable for service
temperatures up to 100C but needs to be taken into account. The thicker the foam used, the more one
must accommodate for any expansion of the foam.
With the installation of Thermobreak Tube it is essential that the insulation is cut 15mm 20mm longer
than the space into which it should fit. This ensures a very tight fit and allows for any potential
dimensional change that can occur with Thermobreak Tube should the pipe be heated.

Installation Instructions Thermobreak Tube and Sheet for Pipework

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GENERAL INSTALLATION INSTRUCTIONS

Preparation for All Installations

Review Installation requirements of Engineers specifications.

Check that the insulation complies with the local building codes.
Check that the insulation is of sufficient thickness to prevent surface condensation. Sekisui Foam
International has developed software (Thermacalc) to provide guidance on determining this
thickness.
Ensure that scale, rust, grease, flaking paint and the like has been removed from the pipe
surface.
Ensure that the pipe surface is clean, dry and at ambient temperature prior to installation.
(Applicable only in Australia) Ensure that all steel pipe work has had one coat of zinc phosphate
primer applied before insulation commences.
Ensure all hangers, brackets and pipe clamps are in place.
Do not begin to apply insulation until all pipe work pressure testing is complete.

Installation of Thermobreak Tube around Pipes and Fittings

Unlike other insulation materials Thermobreak Tube can easily be compressed and then expand
out again. This property can be used to create airtight joins.
Use full length pipe sections to complete the run, avoid using off-cuts butted together.
Cut the sectional pipe 15 mm 20 mm longer than that measured, as this will ensure the pipe
remains tightly butted against clamps, blocks, supports and at the joins between sections (Figure
1).
When forming elbows for angle joins cut each section slightly larger than normal, compress it
into the join and the foam will then expand out to form a tight seal.
Mitre elbow/bend segments using a sharp knife or blade, following the instructions in the
document Thermobreak Installation Instructions for Fittings.
For fittings, valves and flanges, the insulation should be cut with a sharp knife and profiled to
fit, following the instructions in the document Thermobreak Installation Instructions for Fittings.
Apply aluminium foil tape to all joints as per instructions provided in the Taping Instructions
Section.

Figure 1. Illustration of Thermobreak Tube to be installed between pipe supports.

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Installation of Thermobreak Sheet around Large Pipes

Thermobreak Tube is available preformed tube up to 12 IPS. For larger diameter pipe, Thermobreak
Sheet must be used. Sheets are available up to 25mm single thickness for this purpose. For higher
thicknesses, multi-layer installation must be used. Thermobreak Sheet can be supplied with factory
applied adhesive.

Determine the circumference of the pipe. While the

circumference formula is given on the Thermobreak Tube
Information sheet, it is recommended that a small strip is cut
from the Thermobreak Sheet (same thickness as used in the
installation) to determine the exact circumference and sheet
length required.
Cut the sheet with a sharp knife to exact length as determined
in the above step. A 45o angle should be used.
Remove the adhesive liner where applicable, and slowly apply
the insulation to the pipe.
Seal the longitudinal joints with Thermobreak Supa Seal,
rubber/neoprene based contact adhesive or low VOC water
based construction glue.
Apply aluminium foil tape to all joints as per instructions
provided in the Taping Instructions Section.
Continue section by section until the pipe is completely insulated.
Glue all sectional joints, followed by reinforced aluminium foil
tape.
Temporary straps, or bands may be used if necessary.

Length
required

Thermobreak
Sheet strip

Pipe

Installation of Multi-Layer Sheet Insulation

In case of thick insulation required on large pipes (greater than 25mm thickness), it is advisable to use 2
layers of insulation. This will ensure a better finish on the insulation and avoid gaps in the joints due to
the large thickness. The two layer insulation system performs as well as a single layer.
Follow the installation instructions as above for the first layer of insulation.
Determine the new circumference of the pipe with the first layer insulation layer using the same
method.
Cut the sheet to the required length at 45 angle, and then follow the installation instructions as
above.
Ensure the joints between the first and second layer are staggered at a 90 angle (Figure 2).
The joints between the first layer of insulation and second layer should be staggered along the
pipe length (Figure 3).
Apply aluminium foil tape to all joints as per instructions provided in the Taping Instructions
Section.

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Figure 2.

Figure 3.

Pipe Supports or Ferrules

Sekisui Foam International recommends the use of pipe supports based on high density closed cell foam
that does not absorb moisture. Ferrules that absorb moisture will lose their thermal resistance. In the case
of wooden products, absorption of moisture can lead to rotting of the wood over time.
Check that the thickness of the pipe support corresponds with the insulation being used or to
specifications.
Follow instructions provided by the ferrule supplier.
Thermobreak Thermaloc pipe supports can be used for this application.
Use of Thermobreak Thermaloc ferrules will significantly reduce the chances of moisture
absorption happening due to its closed cell nature.
The interlocking design ensures an airtight fit, preventing any air moving in or out.
When covered with fire-rated aluminium foil tape, Thermobreak Thermaloc retains its thermal
properties under the most extreme conditions, over the life of the installation.
Installation Instructions are provided in the document Installation Manual Thermobreak Thermaloc.

Taping Instructions All Installations

Use 50 mm or greater width of recommended or specified aluminium foil tape. For outdoor
installations, use outdoor recommended/specified aluminium foil tape.
It is important that the insulation surface to which tape is to be adhered is free from dust and
dirt. If uncertain, clean the surface with a clean rag. In the case of any oil or silicone
contamination, wipe the surface with a clean rag and suitable cleaning agent, then wait to dry
before applying tape.
Aluminium foil tapes must be applied using pressure. The more pressure applied, the more
surface contact is achieved and the better the result.
The best way to apply this pressure is to repeatedly rub the tape external surface with a flat
blunt object.
The vapour barrier should be continuous wherever there is a break in the Thermobreak foil
facing; i.e. no foam surfaces must be exposed after installation.
When applying tape, follow the contours of the material. Do not try to flatten the contours out
with the tape. Let the tape relax into and conform to the irregularities of the surface, then rub
down (refer to Figures 4 and 5) to eliminate air bubbles.

Figure 4.

Figure 5.

Fix tape over all joints, ensuring the vapour barrier is continuous over all fittings and flanges.

Installation Instructions Thermobreak Tube and Sheet for Pipework

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Where possible, the length of the tape should not only exceed the length of the joint, but
continue around the next edge to provide an anchor point. There should be at least 50mm
overlap.

Additional Taping Instructions - Thermobreak Tube

After the pipe insulation is installed, the laps should touch each other at the face, allowing easy
taping. If they do not touch, apply gentle hand pressure to squeeze the insulation together so
the gap is closed, whilst applying the tape (refer to Figures 6 and 7).

PIPE

THERMOBREAK

PIPE

THERMOBREAK

Figure 6. Do not apply tape over this gap.

Figure 7. Apply hand pressure to

close the gap and simultaneously
apply tape.

For horizontal pipe sections, whenever possible, position the insulation so that the longitudinal
gap (and tape join) faces upwards.
Use tape to seal all longitudinal laps and circumferential butt joins (Figure 8).
Apply additional banding around the circumference of the insulation at maximum 500mm
intervals along the pipework (Figure 8). Ensure the tape is wound around the full circumference
of the insulation with a 50mm overlap to provide an anchor point.
Longitudinal gap

Circumferential butt join

Maximum 500mm gap between circumferential bands

Thermobreak Tube

Taping of gaps and joins

Figure 8. Illustration of taping over longitudinal gaps and butt joins, and positioning of
circumferential bands.

Fix tape over all other joints, ensuring the vapour barrier is continuous over all fittings, flanges
and valves. Cover with tape any remaining surfaces with exposed foam.
Wider tapes should be used for larger pipes.

INSTALLATION INSTRUCTIONS FOR COLD WATER & REFRIGERATION

PIPING
The following instructions are in addition to the general installation instructions detailed above and must
be read in conjunction with them.
It is recommended that all gaps and joins are sealed, including those between the insulation and the
pipe supports/blocks. This can be achieved either using the Thermobreak Supa Seal system or with
sealant/glue. This will prevent any possibility of cold air or moisture tracking down the pipe and should
the vapour barrier be compromised in any way, this will restrict cold water/air tracking beyond the
block or butt join.

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Using Thermobreak Supa Seal

Thermobreak Supa Seal is a soft foam sheet material with a pressure sensitive high-tack adhesive
bonded to both sides. Either strips or discs can be cut from the sheet using a sharp knife. Longitudinal
and circumferential joins should be sealed by the Thermobreak Supa Seal Strips & Thermobreak Supa
Seal Discs (Figure 9).
Peel backing paper from one side of a strip and apply sticky foam to one side of longitudinal
slit (Figure 10).
Apply insulation to pipe, peel backing paper from remaining side and close the slit, applying
pressure to achieve a complete seal (Figures 11 and 12).
Apply foil tape around the full circumference of the insulation near the butt end, with a 50mm
overlap to provide an anchor point (Figure 13).
Peel backing paper from one side of a disc and apply sticky foam to a butt edge (Figure 14).
Peel backing paper from remaining side and press butt end of adjacent insulation onto the
disc, ensuring all edge surfaces come into contact with the adhesive (Figures 15 and 16).
Apply aluminium foil tape to seal all longitudinal laps and circumferential butt joins as per
instructions in the Taping Instructions Section. (Figure 17).
Apply Thermobreak Supa Seal Discs to the faces of the insulation ends and blocks to ensure full
adhesion between insulation and pipe support/block. Then apply aluminium foil tape as per
instructions.

Figure 9. Supa Seal strips

and discs cut to shape.

Figure 10. Supa Seal strip

applied to one side of
longitudinal slit.

Figure 11. Thermobreak

Tube & Supa Seal strip
installed around pipe.

Figure 12. Supa Seal strip

sealed to both sides of
longitudinal slit.

Figure 13. Foil tape

applied around insulation
near butt edge.

Figure 14. Supa Seal disc

applied to one butt end.

Installation Instructions Thermobreak Tube and Sheet for Pipework

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Figure 15. Supa Seal disc

and adjoining butt end.

Figure 16. Both butt ends in

contact with Supa Seal
disc.

Figure 17. Completed

installation with applied
foil tape.

Using sealant/glue

A sealant /glue should be applied to:

1. All mating surfaces of the insulation between adjacent pipe sections.
2. Longitudinal joint.
3. To the faces of the Insulation and the pipe supports at the joints.
Either rubber (neoprene) based contact adhesive or low VOC water based construction glue is
recommended. Glue should be applied to both surfaces.
Follow instructions provided by the glue supplier.
Ensure the glue does not come into contact with the pipe.

INSTRUCTIONS FOR OUTDOOR INSTALLATIONS

This section is applicable for all outdoor installations of Thermobreak Tube and Sheet.
Sekisui Foam International recommends that cladding is used over Thermobreak whenever it is installed
outdoors. Although the Thermobreak reinforced aluminium foil facing can withstand many years of UV
exposure, it can be compromised through the effects of salt water, chemicals or mechanical damage. For
further information, refer to the Technical Information Bulletin Expected Service Life of Thermobreak.
The General Installation Instructions can be followed for outdoor installations (prior to cladding). If
cladding is not used, the following additional instructions must be observed:
Prior to installation, store Thermobreak indoors in its packaging.
Remove Thermobreak from its packaging just before cutting/installation to ensure all surfaces
remain clean and free from dust/moisture.
Avoid installing the insulation during times of the day when the pipe surface may be very hot,
when it is raining or when condensation has occurred.
Use outdoor recommended aluminium foil tape. Take extra care to fully seal the tape onto
Thermobreak and eliminate air bubbles.

Installation Instructions Thermobreak Tube and Sheet for Pipework

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ENQUIRIES
If you require any further information, please consult your local distributor or contact us at
SEKISUI PILON
1-5 Parraweena Road
Taren Point
NSW 2229
AUSTRALIA

YOUNGBO AUSTRALIA
15/853 Nudgee Road
Northgate
QLD 4013
AUSTRALIA

Tel : +61 2 9525 9880

Fax : +61 2 9525 8004
Email: info@pilon.com.au

Tel: +61 7 3267 7100

Fax: +61 7 3267 7166
Email: sales@youngbo.com.au

This information on Sekisui Foam International products is presented to the best of our knowledge. All product
data is based on average values and is for guidance only. As these products are subject to constant research and
development, we reserve the right to update the contents without notice.
Recommendations as to methods of post fabrication, application and use of Sekisui Foam International products
are based on our experience and knowledge of the characteristics of our products and are given in good faith. As
producer of the material we have no control over the application of Sekisui Foam International products and no
legal responsibility is accepted for such recommendations. In particular, no responsibility is accepted by us for any
system in which Sekisui Foam International products are utilised or for any application.
Softlon and Thermobreak Registered trademarks of Sekisui Chemical Co. Ltd or its subsidiaries.
Date of Publication: June 2012.

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