NEDW

UCT
PRO
N AM ES

CorrosionUnder
Insulation(CUI):
IndustrialTechnicalOverview

CONROCK

Excellencein
industrialinsulation
solutions
ROXUL developsinnovativeindustrial
insulationsolutionsfortheprocess
industryalongwiththemarineand
offshoremarket.Throughourvast
productlines,weofferafullarrayofhigh
temperaturesolutionstomeetyour
industrialinsulationrequirements.Our
75+yearsofglobalexperienceisreflected
inacompletesetofhigh-gradeproducts
andexpertadvice.Today,weremainfully
committedtoprovidingtheverybest
serviceinthemarketandatotalrangeof
cutting-edgeinsulationsolutions.
Your highest quality is our minimum demand
Allindustrialinsulationsolutionswithinourofferingmeet
stringentqualityandsafetystandards.Allproductsand
constructionshavebeentestedaccordingtothelatest
regulationsandapprovedbyallmajorclassificationgroups.As
aninnovation-drivencompanywedemandexcellence.Inevery
segmentwekeepsearchingfornewsystems,methodsand
solutions.Weendeavourtodevelopmoreefficientproductsand
toconstantlyoptimizeproductionprocessesandprocessing
technologies.

Our knowledge delivers the right solutions!

Asahighlyskilledprofessionalyouarealwayslookingforthe
bestpossibleendresult.Thequickestwaytoachievethatiswith
ROXULinsulationproductsandthedetailedinformationthat
comeswiththem.Thatswhyyoushouldalwayscheckthatthe
informationyouhaveisuptodate.Ifyouhaveanyquestions
aboutspecificapplicationissues,workingmethodsorproduct
properties,pleasevisitourwebsiteatwww.roxul.com.

CONROCK

The best solutions, built on solid expertise

ROXUL insulationisabletodrawonin-depthexpertiseto

Tableofcontents

ensurethatendusersinthepetrochemicals,powergeneration,
marine,offshoreandtheprocessindustriesaregiventhebest

Its all about conditions

1. Insulation is everywhere

2. The Issue: Insulation and Corrosion

3. Preventing corrosion

andmostadvancedinsulationsolution.Bothintheprocess
industryasinthemarine&offshoreindustry,ourstonewool
productsofferthebestpossibleprotectionagainstheatalong
withenergyloss,fire,noiseandotherunwantedinfluences.Our
salesteamwillbedelightedtoassistyouindevelopingtechnical
andprojectspecifications.

Our people, your profit

Thekeytooursuccessisthecombinationofexcellentinsulation
productsandoutstandingpeoplewhoknowexactlywhattheyare
talkingabout.Thankstotheirexpertiseandextensiveexperience,
wecanofferexceptionalstonewoolsolutionsandanimpeccable
service.Withtechnicalsupportonahighlevelwearepreparedto
helpyoutochoosetheoptimalsolutionsandsecurethe

Protectingsteelwork
Design&planningoftheinsulationwork
Insulationselection
Maintenance&Inspection

8
10
11
12

necessarydocumentation.

Part of the ROCKWOOL Group

4. ROXUL & corrosion prevention

13

5. Norms & standards

15

ROXULInc.isasubsidiaryofROCKWOOLInternationalof
Denmark,theworld'sleadingproducerofstonewool,whichisa
stonefiberbasedinsulationmadefromnaturalstoneand
recycledcontent.ROCKWOOL Internationaloperatesworldwide
withmorethan9,800employeesand28factories.

Corrosion-relevantteststandards
Corrosionteststandards

15
16

ROXUL has a melting point above 2000F

Ourstonewoolproductsmeetthestrictestfireprotection
requirementsandmakeanactivecontributiontothefiresafetyofa
buildingorinstallation.Otherinsulationmaterialsmayfailat
muchlowertemperaturesandoftenreleasedangerous

6. Frequently asked questions

ROXULCertificationandStandardsTable

18
19

substancesduringcombustion.Stonewoolisnon-combustible
withameltingpointof2150F(1177C).Asaresult,ROXUL
insulationinhibitsthespreadoffire,ultimatelysavinglivesand
protectingpeople,systemsandbuildings.

Stone wool protects people and the

environment
ROXULproductsoffereffectiveprotectionandoptimal
performancefortheentirelifecycleoftheinsulationsystem.
ROXULisoneofthemostdurableproductsavailablewithan
unequalledcombinationinthefieldofenvironmental
improvement,energysavings,CO2 reduction,acousticinsulation
andfiresafety.Thefireresistantcharacteristicsofourstonewool
productsdeliversuperiorprotectiontopeople,propertyandthe
environment.

CONROCK

NEW

One World. One Brand.

PRODUCT
NAMES

Globalizationismovingfasterthaneverand,intheworldofinsulation,ROXUL
isleadingtheway.Withbusinessesfromdifferentcountriescollaboratingtoengineer
newindustrialandpowergenerationfacilities,ROXULhaslaunchedproductbrandingthat
speaksthesamelanguageanywhereintheworld.Itsastrategythatbringsuniformityto
specifying,matchesproductstoperformanceandstreamlinescommunication.
Introducing ProRox and SeaRox.OurProRoxproductsprovide

Structure: Ouridentificationsystemlinkstoaproductand

insulationsolutionsforindustrialprocessandpowergeneration.

performancecharacteristicsselector.Theexamplebelow

SeaRoxproductsdothesameformarineandoffshore

illustratestheadvantagesofthissimpleyethighlyefficient

applications.

structure.

Clarity: Ournamingstructureallowsyouto
e.g.:

quicklyfindtherightproductfortheright

ProRox SL 960 RFFNA

Local market specifications
Facing Options

application.ItalsoalignsROXULwithother
Product Range

participatingROCKWOOLcompaniesto

RFF
BM
WHM
WH

provideatrueglobalproductoffering.
Performance: ROXULproductsprovide
superiorthermalandacousticalvalueandare
Product Identifier
SL = Boards/Slabs
FSL = Flexible Boards/Slabs
PS = Pipe Insulation
MA = Wrap/Mat

fireresistant,waterrepellent,non-corrosive
andresistanttomold.Ourtechnicalexpertise
andglobalapproachtoproductspecifications
willhelptakeyourbusinesstoanewlevelof

lor

atio

Sun

n, d

rill

ing

and

pro

duc

Reinforced Foil Facer

Black Mat
White Mat
White Polypropylene

Application Code
300 Series = Acoustics
400 Series = Industrial Fabrication Insulation
500 Series = Compression
600 Series = Fire Resistance
700 Series = Comfort/Multi-Purpose
900 Series = Thermal Insulation

performance.

Exp

=
=
=
=

tion

Waste
Coal
Gas

Pro

Solar Power Plant

Oil

Flo

Gas Processing

of

en

er

ces

sin

g in

dus

try

Power Plant

gy

Con
Petroleum Refining Processing
Industrial

Non-residential
Residential

Petrochemicals

Marine

Offshore

ProRox

SeaRox

End Products

sum

ptio

CONROCK

Itsallaboutconditions
Corrosionisundoubtedlyoneofthecostliestproblemsfacingindustrytoday.
Duetocorrosionofpipingandequipmentunderinsulationmanycompanieshaveto
repairand/orreplacemajorpartsataconsiderablecost,reportedtorunintobillionsof
dollarsannually.Clearlythisconsiderablyreducesthepotentialservicelifeofindustrial
facilities.Morefrequently,essentialshutdownsandoverhaulsimpairplant
efficiency,drivingupoperatingcosts.

Itiscommonly,butwronglyassumedthatopenorclosedcell

ROXUL and CUI

insulationalsoprotectsagainstcorrosion.Ifsteelworkisnot

ROXULinsulationproductsforindustrialusecomplywith

protectedwithasuitablecoatingandinsulationisnotinstalled

mechanicalinsulationstandardsandareconsideredbymanyto

underdryconditionsandprotectedbyadequateweather-

beoneofthemostcost-effective,thermallyefficientinsulation

resistantcladding,corrosionunderinsulation(CUI)isastrong

productscurrentlyonthemarket,withexcellentsustainability

possibility.CUInecessitatesrepairsandreplacements,alongwith

credentials.

higherthanexpectedheatlossesinthedesignphase.

ROXULindustrialinsulationishydrophobic,providing
effectiveprotectionagainstmoisturepenetrationacrossthe
entireinsulationthickness.

Preventing CUI (Corrosion Under Insulation)

Makingtherightdecisionstofindtherightsolutionisacomplex
process.Withthisinmind,preventingcorrosionisaserious
concern,whichmustbeaddressedinthedesignphase.
Pipeworkandequipmentmustbedesignedproperlyto
ensuresupportsandfittingsarepositionedtoshedwateras
muchaspossible.
Therightanti-corrosionsurfacetreatmentmustbeappliedto
pipeworkandequipmentandregularlycheckedaspartofa
robustmaintenanceplan.

ROXULindustrialinsulationhasafibrousopen-pore
structurethatisvaporopen.SoROXULproductsreducethe
riskofsurfacewettingbyallowinganybulkwatertodrain
andthestructuretodryoutnaturally.
ROXULproductsarepermeable,sotheydonotabsorb
water.
ROXULinsulationischemicallyinerttosteelworktomitigate
riskofcorrosion.ItmeetstherequirementsoftheNorth
AmericanandEuropeancorrosionstandardsforuse.

Therightinsulationlayermustbeselectedtoensurethe
productisfitforpurposeandwillnotbethesourceof
additionalcorrosion.
Therightweatherprotectionsystemmustbechosen.Itmust
befitforpurpose,compatiblewiththeunderlyinginsulation
andregularlycheckedaspartofapreventativemaintenance
plan.

CONROCK

1.Insulationiseverywhere
Industrialplantinsulationiseverywhere.Amedium-sizedoilrefinerycontains356miles
ofinsulatedpipingandmorethan25footballfieldsworth1.4millionftofinsulated
equipment,vesselsandtanks.Theplanttemperaturecaneasilyexceed1100F,making
insulationessentialtoprotectpeopleandmaintainoperationalefficiencies.
Prompt and proper maintenance
Inmanycases,insulationisnotpromptlyorproperlymaintained,

Heat losses from damaged insulation

can be up to 8x greater

simplybecauseitisnotconsideredtobearisk.Foryears,
industryhasestimatedthat10%to30%ofexposedinsulation
becomesdamagedormissingwithinonetothreeyearsof
installation.Thatpercentageislikelytoriseovertime,depending

Heatloss (BTU/hr/ft)
12000
10000

ontheoperatingenvironmentandexposuretotheelements.

8000

Manyplantoperatorsknowthatsteam-generatingcapacitymust

6000

beincreasedwhenitrainstocontinuetoprovidetheheatthe

4000

plantneedstooperateefficiently.

2000
0

Damaged insulation leads to increased heat

losses and corrosion costs
Theimpactofdamagecanbesubstantial.Inmanycases,the
actualreductioninheatlossisupto40%morethanexpected.
Damagedinsulationcladdingoftenallowswatertopenetrateinto
theinsulation,whichcancausecorrosion.Costsduetocorrosion,

Reduction 43%
Reduction 97%
Heat Loss
(bare un-insulated)

Heat Loss
ROXUL insulated

Heat Loss
(damaged insulation)

Design Conditions: Steam Pipe, T 608F, 8 inch (NPS),

ambient temperature 50F, ROXUL insulation: ProRox PS 960NA

Between 10% to 30% of the insulation becomes

damaged or missing within 1 to 3 years
Source: National Insulation Association and ROXUL calculations

downtimeandadditionalunanticipatedenergylossesare
substantial.Thecostsofinspectionandrepair,whichcanoften
becarriedoutduringoperation,arenegligiblecomparedtothe
potentialsavings.

Heat losses from damaged insulation

can be up to 8x greater
Mining 1% ($0.1 billion)

Mid-Size
Chemical plant
Insulationdamage
19.2%
Corrosion
250,000USD
annually
Additionalenergy
1,766,622USD
loss(0.0159USD/kWh)
annually

Refinery (150.000
barrels per day)
21.3%
500,000USD
annually
10,300,307USD
annually

Source:Steamdigestvol.IV,insulationmanagementanditsvaluetoindustry

1%

Petroleum Refining 21% ($3.7 billion)

Chemical, Petrochemical,
Pharmaceutical 10% ($1.7 billion)
Pulp and Paper 34% ($6 billion)

8%
9%
12%

10%

Agricultural 6% ($1.1 billion)

Food Processing 12% ($2.1 billion)
Home Appliances 9% ($1.5 billion)

21%

6%
34%

Oil and Gas Exploration and

Production 8% ($1.4 billion)

Thereportedannualcostofrepairs,replacementandproduction
lossesrunintomillionsofdollarseveryyear.TheNational
AssociationofCorrosionEngineers(NACE)estimatestheannual
costsofcorrosioninproductionmanufacturingintheUSAtobe
aroundUS$17.6billion.

Annual cost of corrosion in the production & manufacturing category

Source: http://events.nace.org/publicaairs/images_cocorr/ccsupp.pdf
Corrosion costs and preventive strategies

CONROCK

2.TheIssue:InsulationandCorrosion
Corrosionoccursinthepresenceofwaterandoxygensoifthesteelworkunder
insulationremainsdryitminimizestheriskofcorrosion.Keepinginsulationdrycanbe
challenginganditisessentialthateveryeffortismadetokeepitdryduringstorageand
installation.Failuretodosoleadstowateringressintotheinstallationwhichcanleadto
steelworkcorrosion,commonlyreferredtoascorrosionunderinsulation(CUI).In
practiceCUIcommonlyappearsinthetemperaturerangebetween55Fand395For
wherethereiscyclicoperationoftheequipment.CUIisfoundunderneathalltypesof
insulationwhenyouhaveinstallationissuesordamageasstatedabove.
Types of corrosion
Whenapplyinginsulation,thecorrosionresistanceofthemetal
surfacetobeinsulatedisanimportantfactor.Themost
frequentlyoccurringtypesofCUIare:
Generalandpittingcorrosionofcarbonsteel,whichmay
occurifwetinsulationcomesintocontactwithcarbonsteel,
particularlyifacidicproductcanleachfromtheinsulation
materialitself.
Externalstresscorrosioncracking(ESCC)ofaustenitic
stainlesssteel,whichisaspecifictypeofcorrosionmainly
causedbytheactionofwater-solublechloridesfrom
rainwaterorinsulationthatdoesnotmeetmaterial
standards.Austeniticstainlesssteelisgenerally
susceptibletothistypeofattackinthetemperaturerange
of55Fto395F.

Thecorrodedsurfaceismostlyhiddenbytheinsulationsystem
andwillnotbeidentifieduntiltheinsulationisremovedfor
inspectionorintheeventofmetalfailureleadingtohealthand
safetyincidents.Thenecessityofprotectionagainstcorrosion
mustbedeterminedforeachindividualplant.Thisbrochurewill
helpyouaddressthemostimportantCUIissues.

Acommonbutincorrect
assumptionisthatinsulationalso
protectsagainstcorrosion.If
steelworkisnotprotectedwitha
suitablecoatingandtheinsulation
isnotinstalledinadrystateunder
dryconditionsandprotectedby
adequateweather-resistant
cladding,CUIisastrongpossibility.

CorrosionUnderInsulation(CUI)referstotheexternalcorrosion
ofpipingorequipmentthatoccursunderneathexternallycladded
insulationduetowaterormoisturepenetration.

CONROCK

3.Preventingcorrosion
Makingtherightdecisionstofindtherightsolutionisacomplexprocess.Withthisin
mind,preventingcorrosionisaseriousconcern,whichmustbeaddressedinthedesign
phase.Numerousfactorsareinvolvedincausingorpreventingcorrosionunder
insulation.Temperatureandambientconditionsareaninevitablepartoftheprocessplus
thesurroundingenvironmentandcannotbecontrolled.Otherfactorscanbecontrolled
effectivelyandthreeissuesshouldbeaddressed:
Protectingsteelwork
Designingandplanninginsulationwork
Inspectionandmaintenance
Protecting steelwork
Thenecessityofprotectionagainstcorrosionmustbedetermined

ASTM C795: Thermal Insulation for Use in Contact

foreachindividualplantandtheappropriatemeasureshavetobe

with Austenitic Stainless Steel

identified.Generally,thedesignoftheinsulationsystemand

Thisspecificationcoversnon-metallicthermal

corrosionprotectiondependsonthefollowingparameters.

insulationforuseincontactwithausteniticstainless

Operationoftheplant:continuousorinterrupted/intermittent.

steelpipingandequipment.Therequirementsofthis

Operatingtemperatures.

standardincludetestsasperC692andC871.

Metalsused(non-alloy,lowalloysteel,austeniticstainless
steelorcopper).
Externalfactors.
ASTM C665: Corrosiveness to Steel
Beforeapplyingthecorrosionprotectioncoating,thesurface

Thisspecificationcoversthecompositionandphysical

mustbefreefromgrease,dustandacidplustheprimingcoat

propertiesofmineral-fiberblanketinsulation.Thetest

shouldberoughenedforbetteradhesion.Blastingisthe

ensuresthatthecompositionoftheinsulatingmaterial

recommendedsurfacepreparationmethod(foraustenitic

doesnotcreateapotentialforcorrosiononcertain

stainlesssteel,useaferritefreeblastingabrasive).Followthe

metalsinthepresenceofwaterorwatervapor.

coatingmanufacturersprocessingguidelines.

CONROCK

Watch out for electrochemical corrosion!

Electrochemicalcorrosionisariskwhenmetalswithdifferent
electrochemicalpotentials,suchasaluminumandcopper,come
intocontactwithoneanother.Thiscanbeavoidedusing
intermediateisolatinglayers,suchasnon-metallicstraps.The
presenceofmoisturewillintensifyelectrochemicalcorrosion.
Thefollowingtableshowstheinitialriskofelectrochemical
corrosionwhendifferentcombinationsofmetalsareused.

Metal
Zinc
Aluminum
Ferriticsteel
Lead
Austenitic
stainlesssteel
Copper

Material
Surfaceratioinproportion
tocombinationmaterial
Small
Large
Small
Large
Small
Large
Small
Large
Small
Large
Small
Large

Zinc

Aluminium

L
L
L
L
L
L
L
L
L
L

M
L

L
L
L
L
L
L
L
L

Combinationmaterial
Ferritic
Lead
steel
M
H
L
L
L
H
L
M

L
L

L
L
L
L
L
L
L
L

Austenitic
stainlesssteel
H
L
H
L
H
L
H
M

L
L

Copper
H
L
H
H
L
L
H
M
M
L

L-Lightorlittlecorrosiontomaterial
M-Moderatecorrosiontomaterial,forexample,inveryhumidatmospheres
H-Heavyelectrochemicalcorrosiontomaterial
NOTE:Thetableshowsthecorrosionofthematerial,andnotthatofthecombinationmaterial.
Lightmeans:small-scaleinproportiontothecombinationmaterialandheavymeans:large-scaleinproportiontothecombinationmaterial.
Example1:Materialisazincgalvanisedscrewincombinationmaterialwithacladdingmadefromausteniticstainlesssteel:Rowzincsmall:H-heavycorrosionofthescrew.
Example2:Materialisacladdingmadefromausteniticstainlesssteelsecuredwithascrewgalvanisedwithcombinationmaterialzinc:Rowausteniticstainlesssteellarge.
L-thecorrosiveattackupontheausteniticsteelislight.
BasedonGermanDIN4140standard.

CONROCK

Design & planning of the insulation work

Therequirementsoftheplannedinsulationworkmustbe

Note

factoredinduringtheindustrialplantdesignandconstruction

Walkingoninsulatedpipeswithlowcompressive

phase.Itisthereforeadvisabletoinvolveallprojectmanagersat

strengthshouldbeavoidedifpossible,asthiscan

anearlystagetoprecludeunnecessaryandunanticipated

damagetheinsulation.Damagecausedbyfoottraffic

problemsduringinsulationwork.

includesdentedsheetcladdingandgapsatthesheet
seams.Watercanpenetratetheinsulationthrough

Allpreparatoryworkmustbecompletedinaccordancewiththe

thesegapsandcauselastingdamagetotheentire

relevantinsulationstandardandifnecessary,applycorrosion

insulationsystem.Theresultisoftengreaterheatloss

protection.Insulationmaterialshouldbestoredandinstalledin

andcorrosion.Ifthisisnotpossiblethentheinsulation

dryconditions.Variousconditionsmustbefulfilledtoensurethe

shouldbedesignedinsuchawaysothatitisresistant

insulationdoesnotcontributetothecorrosionofthesteelwork

tofoottraffic.ROXUL ProRox PS980NA offersa

lateron.

solutiontodamagefromfoottrafficduetoitshigh
compressivestrengthanddurability.

Note
Aninsulationsystemresistanttofoottrafficmustnot
becomepermanentlydamagedifapersonweighing220
lbsorgreater(weightincludinganytoolsandequipment

Illustration 1: Pipe Insulation resistant

to foot traffic

beingcarried)walksonit.Itisnotdesignedtobear
additionalloads,suchastheplacingofheavy
equipment.Forthepurposeofthesafetyregulations,a
durableinsulationisnotconsideredtobeawalkable
surface.

Ready to go: Allpreparationshavebeenmadesosubsequent

insulationdamage/removalisnotnecessary.
Tracingandtechnicalmeasurementequipmenthavebeen
installed.
Weldingandbondingworkhasbeencarriedoutonthe
object.Thesurfacedisplaysnocoarseimpurities.
1.Pipe-2.Insulation-3.Cladding-4.Sheet-metalscreworrivet-
5.Thicknessofcladding

Design
Mountingsupportshavebeeninstalledtoaccommodatethe
supportstructure.
Collarsandsealingdiscshavebeenfitted.
Linetapsarelongenoughtoensurethatflangeslieoutside
theinsulationandcanbescrewedonwithouthindrance.
Supportsaredesignedsoinsulation,vapourretardersand
claddingcanbeproperlyinstalled.
Wherenecessary,ladders,bridgesandsoonhavebeen
installedtopreventanyonefromwalkingorclimbingonthe
insulation.Ifthisisnotpossible,theinsulationshouldbe
designedtoberesistanttofoottraffic.

10

CONROCK

Insulation selection
Whenmakingaconsideredinsulationselection,itisimportantto

Note

thinkaboutnotonlyobviousproperties,suchasthethermal

Makingtherightdecisionstofindtherightsolutionisa

conductivityormaximumservicetemperatureofaproduct.To

complexprocess.Buterrorsofjudgmentcanprovevery

minimiseriskofCUI,itisalsoimportantthattheinsulationdoes

costly,suchasoptingforamanufacturerssystemthat

notaffectthesteelwork,doesnotabsorbanywaterandisopen

offersnorealguaranteeoflong-termperformance.

tovapour,sothatmoisturecaneasilyegresstheinsulation.

Successdependshugelyonthedesignoftheinsulation,

Theserequirementsarelaiddowninthefollowingstandardsand

anticorrosioncoating,thetypeofinsulationmaterial,

testmethods.

theskilloftheinstallerandweatherconditionsduring

Chemicallyinert:Steelcorrosionacceleratesrapidly,
particularlyifacidiccompoundscanbeextractedfromthe
insulationmaterial.Anaqueousextractoftheinsulation
materialshouldbeslightlyalkaline,sothedangerof
corrosionofunprotectedsteelisdiminished.

installation.Themostconsideredapproachistolookat

Chloridecontent:Chloridesininsulationmaybeleachedout
andcancauseexternalstresscracking.Thewaterleachable
chloridecontentofinsulationmaterialshouldbein
accordancewithASTMC871.

thebigpictureandthinkaboutamorecost-effective
insulationtype.Youalsohavetoensuretheinsulationis
installedinadrystate,protectedfromtheweatherand
properlymaintained.

Waterrepellency:Theconcentrationofextractedchlorides
andacidiccompoundsinwaterstronglyinfluencesthescale
ofcorrosiveattackonthesteelwork.
Watervapourresistancefactordefinedasshouldbeclose
to1.0.Thismeansthatthevapourresistanceisnegligible
andusuallyfeltsimilartoair.

Thepotentialcorrosivenessoftheinsulationtowardscarbonand
stainlesssteelisdeterminedbyquantitativeandqualitativetests
suchasASTMC1617andASTMC692.Themaincriteriaare:
Novisualcrackingofthestainlesssteelaftera28-day
corrosiontest.
TheMassLossCorrosionRateofthecarbonsteelshouldbe
lessthanareferencetest.

Note
Itiscommonly,butwronglyassumedthatclosedcell
insulationprotectstheinstallationagainstcorrosion.It
isimportanttonotethatifinsulationisnotcorrectly
installedinadrystateunderdryconditions,waterwill
leakintotheinsulationorcondensationwaterwillbe
trappedbetweeninsulationandsteel.

Theaboverequirementsmakeclearthatselectingthewrong
insulationcanexacerbatetheCUIissuebytrappingmoisture
againstthesteel.ROXUL industrialproductscomplywithallthe
aboverequirementsandareconsideredbysometobethemost
costeffective,thermallyefficientinsulationproductscurrentlyon
themarket,withexcellentsustainabilitycredentials.

11

CONROCK

Maintenance & Inspection

Toavoidunnecessarilycomplicatingroutinemaintenanceand

Insulation of valves should be designed with

inspectionwork,high-maintenanceareasmustbetakeninto

removable coverings or hoods

account,especiallyinthedesignphase.Removableinsulation,
suchascoveringsandhoods,couldbefittedinsuchareas.Easy
toremovecoveringsorsocalledinsulationhoodsare
recommendedtoallowrapiddisassembly.Botharegenerally
fastenedwithquick-releaseclamps,whichcanbeopened
withoutspecialtools.
Removablecoveringsorhoodsareusuallyinsulatedfromthe
inside.Thecoveringsarefastenedtotheobjectwithlever
fastenings,whicharefixeddirectlyontothecoveringoronto
straps.Takethefollowingsuggestedconditionsintoaccount
whendesigninginsulatedcoveringsforfittingsandflanges:
Theoverlapdistanceoftheinsulatedcoveringoverthe
insulatedpipeshouldbeatleast2".
Thepipeinsulationshouldendattheflanges,leavingagap
equaltotheboltlengthplus1.2"andshouldbeclosedoff
withalockwashersotheflangecanbeloosenedwithout
damagingtheinsulation.
Withvalves,anextendedspindleshouldpreferablybefitted
horizontallyorbelowthepipetopreventleakagealongthe
spindleshaft.
Thecladdingmustbefittedtopreventtheingressofmoisture
intheinsulation.Oninclinedorverticalpiping,forexample,
mountraindeflectorsabovetheremovablecoverings.Ifthe
ingressofmoistureintotheinsulationisunavoidable,make
0.4"diameterdrainholesintheremovablecovering.

Minimum distances within range of pipe flanges (dimensions in inches)

a=distanceflangetonormalinsulation
a2"
x=boltlength+1.2"
s=insulationthickness

12

CONROCK

4.ROXUL &corrosionprevention
ROXULindustrialinsulationoffersawiderangeofhighqualitystonewoolproductsfor
theinsulationofmechanicalequipment.Allproductsaredesignedandengineeredwith
thefollowingfeaturesthatwillminimizetheriskofcorrosionunderinsulation.

ROXULofferingincludesrigidinsulationthatallowsfor
easyinstallation,routinemaintenanceandprotection
againstdamagefrommechanicalloads.
Iscompatiblewithanti-corrosionsurfacetreatments.
Canbesuppliedwithscrimandfoilfacingstofacilitate
theuseofanappropriateweatherprotectionsystem.

Isfibrousandwaterrepellentallowingwatertodrain
awayandforvaportodry.
Ischemicallyinertwhichminimizescorrosionpotential
causedbychloridecontents.
Compliestorelevantcorrosionstandards.

Eachproducthasbeendesignedforaspecificapplication(pipework,boilers,storagetanks,etc.),andwhenproperlyinstalledina
completeoverallsystem,corrosionriskcanbemitigated.

ProRox PS 960NA and ProRox PS 980NA:

ROXULPipeSectionsaresupplied,splitandhingedforeasysnap-onassemblyand
aresuitableforthermalandacousticinsulationofindustrialpipework.ROXULPipe
Sectionsareavailableinawiderangeofdiametersandthicknesses.

ENERWRAP MA 960NA:
Availablewitheitherablackscrimorfoilfacing,ENERWRAP MA960NA isaflexible
stonewoolblanketinsulationthatisnon-combustibleandengineeredforhard-to-fit,
high-temperaturesurfacessuchaslarge-diameterpipes,vessels,boilers,tanks,
furnacesandirregularlyshapedmechanicalequipment.

ProRox BOARD, FLEX, and WRAP:

ProRox isavailableinrigid,semi-rigidandwrap(mat)productsinavarietyof
densitiesanddimensions.ProRox issuitableforuseinpetro-chemical,power
generationplants,boilers,furnaces,towers,ovensanddryingequipment.

13

CONROCK

WhychooseROXUL industrialinsulation?
Fire Resistance

Moisture Management

ROXULisavailableinavarietyofsizesandthicknesses,aswell

ROXULdoesnotabsorbwaterorholdmoisture.Itsstonewool

ascustomlengthstoaccommodatefire-ratedindustrial

compositionhasanopenfiberweave,whichisidealforrepelling

insulation.ROXULisnon-combustiblewithameltingpointof

anddrainingwateraway.Plus,itsR-valuealwaysremainsthe

2150F(1177C),possessesexcellentfire-stoppingproperties

sameiftheproductbecomeswetandallowedtodry.ROXUL

anddoesnotdevelopsmokeorpromoteflamespreadwhen

doesnotrot,corrode,orpromotefungiorbacteriagrowth.

exposedtofire.
IndustrialequipmentinsulatedwithROXULoffersa
cost-effectivesolutiontofireandprovidesincreasedflexibility
comparedtomoretraditionalsolutions.ROXULindustrial
insulationisacompletesystem,whichmeanslessmaterial
requiredatthejobsite,aswellasareductioninoveralllabor
costswithfasterinstallation.

Acoustic Performance
ROXULindustrialinsulation demonstratessuperiorsoundcontrol
characteristics.Theuniquenon-directionalstructureisdenser
thantraditionalinsulations.Thiseffectivelyreducesairflowand
dissipatessoundtransmissionsforexcellentsoundreduction.
Thesedenserstructures,coupledwithtight,seamlessjoints,
createeffectivebarrierstonoiseandcontributetoamuchquieter
workenvironment.

Energy Saving Performance

ThelowthermalconductivityofRoxulproductsresultinenergy
savingsinareaswhereit'sneededmost.ROXULindustrial
insulationisdimensionallystableandnevershrinksorsagsto
deliveralongtermperformanceandcontributestoacomplete,
energy-efficientsystem.ROXULindustrialinsulationcontributes
toamaintenancefreeperformanceandlongerlifecycles.

Dimensional Stability
ROXULisarigidandsagfreematerial.Thehigherdensitykeeps
ROXULindustrialinsulation inplace.Thereisnoshrinkagedue
tooffgassingandnothermalexpansionorcontractiondueto
temperaturevariance.Theinsulatingintegrity isnever
compromisedtomaintainoptimumfireprotectionandthermal
performance.

14

CONROCK

5.Norms&standards
Therelevantteststandardsaregenerallydividedintoteststandardsforreactivityto
steelwork,water-leachablechloridecontentandwaterrepellency.Additionalqualitative
andquantitativestandardshavebeendevelopedtoevaluatetheimpactoftheinsulation
materialoncorrosionrateandexternalstresscracking.
Corrosion-relevant test standards
Inert to steel
Thecorrosionofthesteelisrapidlyaccelerated,especiallyif
acidiccompoundscanbeextractedfromtheinsulationmaterial.
Anaqueousextractoftheinsulationmaterialshouldbeslightly
alkalinetoreducetheriskofcorrosionofunprotectedsteel.The
pHvalueshouldbemeasuredinaccordancewithASTMC871.
Water-leachable chloride content

ASTM C795 Thermal Insulation for Use in Contact with

Austenitic Stainless Steel.
Thisspecificationcoversnon-metallicthermalinsulationfor
useincontactwithausteniticstainlesssteelpipingand
equipment.Inadditiontomeetingtherequirementsofthis
standard,theinsulationmaterialsmustpassthe
preproductiontestrequirementsofASTMC692,forstress
corrosioneffectsonausteniticstainlesssteel,andASTM
C871forqualitycontrolchemicalrequirements.ASTMC795
showstheresultsofASTMC871toillustratearangeof
acceptablechlorideconcentrationsinconjunctionwith
sodiumplussilicateconcentrations(seegraphbelow).

Thecorrosionresistanceofsteelisincreasedbyaddingalloying
elementssuchaschromium,nickelandmolybdenum.Alloying
producesanaustenitic(face-centredcubic)atomicstructure.

ASTM C795 acceptability of insulation material on the basis of the

plot points of the Cl- and the Na+ an SiO32- analyses

Thesetypesofsteelarealsocalledausteniticsteels.Despite
theirgeneralhighresistancetocorrosion,thesesteelstendto

10.000

AS-Quality (AGI Q135 EN 13468)

Thefollowingacceptancecriteriaapplytoinsulation
materialsofAS-Quality.Theaverageofsixtestsamplesmust
exhibitawater-leachablechloridecontentof10mg/kg.
ASTM C871 Chemical analysis of thermal insulation
materials for leachable chloride.
Thisstandardcoversthelaboratoryproceduresforthe
determinationoftheions,whichacceleratestresscorrosion
ofstainlesssteel.Iftheresultsofthechemicalanalysisfor
theleachablechloride,sodiumandsilicateionsarewithin
theacceptableareaofthegraphinASTMC795andalsopass
ASTMC692,theinsulationmaterialshouldnotcausestress
corrosioncracking.

100
Acceptable analysis
10
ROXUL
stone
wool

1
100.000

madebetweenUSASTMstandardsandEuropeanENstandards.

10.000

chloridecontentcanbeused.Theclassificationcriteriawill
dependonthestandardfollowed.Ingeneral,adistinctioncanbe

1.000

insulationmaterialsmanufacturedwithalowwater-leachable

Unacceptable analysis
1.000

100

fromausteniticstainlesssteel.Forthisapplication,onlythose

10

chloridecontentmustthereforebeusedtoinsulateobjectsmade

insulationmaterialwithanextremelylowwater-leachable

Water-leachable content Chloride (Cl-) (ppm)

exhibitstresscorrosionundertheinfluenceofchlorideions.An

Water-leachable content Sodium and Silicate

(Na+ an SiO32-) (ppm)

15

CONROCK

Water repellency

Corrosion test standards

Thermalconductivityandproductperformanceisconsiderably
impairedbythepenetrationofmoistureintothematerial.Wet

Thereisnosingletestmethodthatcanbeusedtopredictor

insulationmaterialcanalsocontributetocorrosion.Soinsulation

measuretheamountofCUIthatwilloccurwhenaninsulated

materialsmustbeprotectedagainstmoistureduringstorageand

pipeorequipmentisexposedtoenvironmentalconditions.

installation,aswellaspost-installation.

Therearesimplytoomanyvariablesandtoomanydifferent
combinationsofexposurepossible.Thereforeseverallaboratory

ASTM C1104 / 1104M

DeterminingtheWaterVapourSorptionofUnfacedMineral
fiberInsulation
Thisstandardcoversthedeterminationoftheamountof
watervapoursorbedbymineralfiberinsulationexposedtoa
high-humidityatmosphere.Thetestsamplesarefirstdriedin
anovenandthentransferredtoanenvironmentalchamber
maintainedat120Fand95%relativehumidityfor96hours.
Thewatervapoursorptioniscalculatedusingtheweight
differencebeforeandaftertestingandisexpressedinweight
percentageorvolumepercentage.

testmethodshavebeendevelopedtodeterminethepotentialrisk
ofCUI.
Quantitative accelerated evaluation ASTM C1617
QuantitativeAcceleratedLaboratoryEvaluationofExtraction
SolutionsContainingIonsLeachedfromThermalInsulationon
AqueousCorrosionofMetals.TheprimaryintentofASTMC1617
istotesttheaqueouscorrosionofcarbonsteelunderinfluence
ofthermalinsulationmaterial.Thisisdonebydeterminingthe
MassLossCorrosionRate(MLCR)causedbyexposureofthe
metalcouponstotheinsulation.Thestandardusescontrolled
amountsofcorrosivereferencesolutionscomparedtothe
corrosionresultingfromtheinsulationmaterialsolutionstothat
ofknowncorrosivesolutions.
Test procedure
Threesamplesoftheinsulationmaterialareextractedin
accordancewithASTMC871.Thesolutionisplacedwithina
PVCtubeonaheatedflatplate(230F)for4days.
Thetestcouponsaredrippedwith8.45oz.ofthesolutions
perdayduringfourdays.Duetotheheat,thesolution
evaporatesquickly,producinganair(oxygen)interfaceand
facilitatingthousandsofwet-drywetcycleswithinashort
timeframe.Attheendofthetestthecouponsarecarefully
cleaned,driedandweighed.
ThecalculationoftheMLCRperyearisbasedontheweight
lossofthesteelcouponsandiscomparedagainsttheMLCR
ofstandardreferencetests(usuallya5ppmchloride
solution)toestimatethecorrosivenessofthesolubleionsin
thesolution.

ASTM C665: Corrosiveness to Steel

Thisspecificationisaqualitativetestthatensuresthatthe
compositionoftheinsulatingmaterialdoesnotcreateapotential
forcorrosiononcertainmetalsinthepresenceofwaterorwater
vapor.Whentested,themetalplatesincontactwiththe
insulationshallshownocorrosiongreaterthanthatobservedon
thecomparativeplatesincontactwithsterilecotton.

16

CONROCK

ASTM C692: Contribution to external stress corrosion cracking

EvaluatingtheInfluenceofThermalInsulationsonExternal

StressCorrosionCrackingTendencyofAusteniticStainless
Steel.Thisstandardcoverstheproceduresforthelaboratory
evaluationofthermalinsulationmaterialsthatmayactively
contributetoexternalstresscorrosioncracking(ESCC)of
austeniticstainlesssteelduetosolublechlorideswithinthe

3
5

insulation.Inthiscorrosiontest,insulationspecimensareused
totransferdistilledordeionisedwaterbywickingfromdripping
toanoutsidesurfacethroughtheinsulationtoahotinnersurface
ofstressedstainlesssteelforaperiodof28days.Ifleachable
chloridesarepresent,theywillconcentrateonthehotsurfaceby
evaporation.Attheconclusionofthe28-daytestperiod,the
stainlesssteelcouponsareremoved,cleanedandinspectedfor

1.Hotplate-2.Testcoupon-3.PVCtube-4.O-ring-5.Siliconesealant-6.Tubing-
7.Barbedconnector-8.Straw

stresscorrosioncracks.Topassthetest,nocracksmaybefound
onthesurfaceofthecoupons.

Storagetanks

Columns

Pipework

Vessels

17

CONROCK

6.Frequentlyaskedquestions
Can wet insulation material be
reused after drying?

What type of protection should be used for pipe

and equipment conservation?

ROXUL insulationistreatedtobewaterrepellentanditsthermal

Protectivecoatingsorpaintsplayavitalroleinpreventingcorrosion

propertieswillberestoredafterdrying,providedthereisno

underinsulation.Therearemanytypesofcoatingsandpaints

physicalandchemicaldegradation.However,whentheriskof

basedonorganicorinorganiccompounds.Eachoneisdesignedto

contaminationwithchloridescannotbeavoided,theinsulation

protectaspecificmetalinaspecifictemperaturerange.

shouldberemovedandreplacedbydryinsulation.

Does specially inhibited insulation reduce the

risk of stress corrosion cracking?

Can aluminum foil protect austenitic steel

surfaces?
Ithasbeenproventhataluminumfoilappliedbetweenthe

Theassumptionwhenusingsodiummetasilicateinhibited

austeniticstainlesssteelsurfaceandtheinsulationlayerwill

mineralwoolinsulationisthatthewaterwillseepthroughthe

significantlyreducetheriskofstresscorrosionininsulated

insulation,leachingoutinhibitor(ie.chloride)toprevent

stainlesssteelsurfaces.Thefoilactsasaphysicalbarrier,which

corrosioncracking.However,thevastmajorityofmoisture

stopschloride-containingfluidsmigratingtowardsthestainless

whetherthatberainwater,seawater,runoffwaterordroplet

steelsurface.Butthemostimportanteffectisthatitprovides

condensationonthestainlesssteelsurfaces,iscommonly

cathodicprotectioninwetinsulationsystems,whichprevents

believedtoentertheinstallationwithoutpenetratingthe

pittingandcracking.Thefoilissimplywrappedaroundthepipe

insulationatall.Nothavingpassedthroughtheinsulation,the

orequipmentwithapproximately50%overlaytoshedwater

waterwillnotbeinhibited.Evenifwaterdoespenetratethe

alongverticallines.

insulation,theveryhighsolubilityofthesodiummetasilicatewill
causealmostalltheinhibitortoenterthesolutionatthefirst
timeofwateringress.

Why is it important to use water repellent

insulation?
Theuseofwaterrepellentadditivesreducesthewatercontent

Can ROXUL products be used in

heavily diluted areas?

insidetheinsulation.Moistureininsulationmaterialshasa

ROXULinsulationishighlywaterrepellentbutitcannotwithstand

substantiallygreaterthanthatofair,whichistrappedbetween

themechanicalimpactofe.g.waterhosesanditwillnotprotect

thefibers.Anincreaseinmoisturecontentthereforeresultsinan

thesteelagainstingressingwater.Iftheinsulationhastobe

increaseinthethermalconductivityoftheinsulationand,

numberofnegativeimpacts.Thethermalconductivityofwateris

pressurecleanedorwillcomeintocontactwithseawater(marine

correspondingly,adecreaseintheinsulationefficiency.A

oroffshoreapplications),applicationofarigidwatertight

moisturecontentofeven1%canincreasethethermal

insulationprotection,suchasimperviousmaterialand

conductivityby25%.Ahighermoisturecontentalsosignificantly

impermeablejacketingsystemsarerecommended.

increasestheweight,which,asarule,isnottakenintoaccountin
thestaticdesignofaninsulationsystem.Moisturecausesmany
typesofcorrosionthatalmostneverdevelopinadrysystem.

18

NA

ENERWRAP 80
RHT 30Flex
RHT 40Flex
RHT 60Flex
RHT 80Flex
RHT 40Wrap
RHT 60Wrap

ENERWRAP MA960NA
ProRox FSL920NA
ProRox FSL930NA
ProRox FSL940NA
ProRox FSL960NA
ProRox MA930NA
ProRox MA940NA

8lbs./ft.3
3lbs./ft.3
4lbs./ft.3
6lbs./ft.3
8lbs./ft.3
4lbs./ft.3
6lbs./ft.3

Nominal
Density

3lbs./ft.
4lbs./ft.3
6lbs./ft.3
8lbs./ft.3
10lbs./ft.3
12lbs./ft.3
15lbs./ft.3
9 lbs./ft.3
12lbs./ft.3
4lbs./ft.3
3.5lbs./ft.3

Nominal
Density

8lbs./ft.3
11.25lbs./ft.3

Nominal
Density

COMPLIANCE

VII

0.03%
0.05%
0.02%

0.68%
1.49%
1.68%

0.05%
0.02%

1.49%

0.02%

<1%
1.68%

0.01%

C1104
Moisture
Sorption

C518 (C177)
Thermal
Resistance

720psf@10%
418psf@10%
71psf@10%

418psf@10%
1220psf@10%

313psf@10%

167psf@10%

104psf@10%

63psf@10%

TS-TB-.0.001-0214ROXULINC2014

C795
Corrosiveness
tosteel

C795
C665
Corrosiveness Corrosiveness
tosteel
tosteel

C795
Corrosiveness
tosteel
C800
Wicking

C665
Corrosiveness
tosteel

C585
Diameters
forNominal
PipeSizes

C165
Compressive
Strength

1102psf@10%

C165
Compressive
Strength

C518 (C177)
Thermal
Resistance

<0.1%

<0.1%

C1104
Moisture
Sorption

1.49%

C356
Linear
Shrinkage

0.28%
0.03%
0.01%
0.03%
0.02%

<0.38%
<0.4%
<1%
<0.35%
<1%

COMPLIANCE

0.04%
0.01%

<1%
<1%

0.01%
0.04%

<1%

0.02%
0.03%

C1104
Moisture
Sorption

<0.6%

<1.3%

C356
Linear
Shrinkage

<1%

<1%
<1%

C411
Hot
Surface
Characteristics

C356
Linear
Shrinkage

S102 / E84
Surface
Burning
Characteristics

COMPLIANCE

C411
S102 / E84
Hot
Surface
Burning
Burning
Characteristics Characteristics

S114
NonCombustibility

S114
NonCombustibility

E136
Behaviour
at
750C

E136
Behaviour
at
750C

IVB

C553
MineralFibreBlanket
ThermalInsulation

IVA

C612
MineralFibreBoard
Insulation

C547
E136
S114
S102 / E84
C411
C447
MineralFibrePreformed Behaviour
NonHot
Maximum
Surface
PipeInsulation
Combustibility
at
Burning
Surface
Burning
Characteristics Characteristics Performance
750C
I
II
IV
V

Fortechnicaldatasheets,pleasevisitwww.roxul.com

Old
Name

RHT 30
RHT 40
RHT 60
RHT 80
RHT 100
RHT 120
RHT 150
NewProduct
NewProduct
NewProduct
NewProduct

New
Name

C553 - Blanket

ProRox SL920
ProRox SL930NA
ProRox SL940NA
ProRox SL960NA
ProRox SL540NA
ProRox SL560NA
ProRox SL590NA
ProRox SL460NA
ProRox SL450NA
ProRox SL430NA
ProRox SL760NA

New
Name

Old
Name

TECHTON 1200
STURDIROCK

ProRox PS960NA
ProRox PS980NA

C612 - Board

Old
Name

New
Name

C547 - Pipe

A Global Leader

Environmentally Sustainable

ROXULInc.ispartofROCKWOOLInternational,thelargest
producerofstonewoolinsulation,whichismadefromnatural
basaltrockandrecycledmaterial.ROCKWOOLInternationalwas
foundedin1909andtodayoperatesworldwidewithmorethan
9,800employees,with28factoriesacrossthreecontinents.

Ourstonewoolproductionprocessutilizessomeofthemost
advancedtechnologyavailable.Thelastdecadehasseenanew
generationofROXULmanufacturingfacilitiesthataredesigned
tolowerourenvironmentalfootprint.Theseendeavorshave
includedthecaptureandrecyclerainwater,reductioninenergy
consumption,andzerowastetolandfillbytherecyclingofraw
materialsbackintotheproductionprocess.ROXULfacilitiesalso
usenaturallightingandre-purposewaterusedduringthe
manufacturingprocesstominimizetheimpactonthe
environmentandsurroundingcommunityresources.

ROCKWOOLhasover75yearsintheinsulationbusinessandfor
25yearsROXUL hasbeenservingtheNorthAmericanmarket,
manufacturingstonewoolinsulationproductsforresidential,
commercial,industrialandOEMapplications.

ROXUL is the Better Insulation

ROXULisaninnovativeinsulationofferingaworldofgreen
features.WhenROXUListhespecifiedinsulation,companieswill
receiveasuperiorproductalongwiththetechnicalexpertiseof
theROXULteamtomeetallinsulationrequirements.

ROXULinsulationiscreatedusingnaturallyoccurring,inorganic
rawmaterialsandreuseswastefromothermanufacturersas
wellasfromourplants.Stonewoolinsulationisnoncombustible
andachievesitsthermalperformancewithouttheuseofblowing
agents.Theproductsthereforedonotoff-gasovertime,
contributingtoasustainableenvironment.
EachROXULplantusesavaryingcombinationofnewand
recycledcontentinordertoremainefficientandenvironmentally
friendly.ROXULiscommittedtoimprovingouroverall
efficiencieswhichfurthersolidifiesourcommitmentto
environmentalstewardshipwithintheorganization.
ForfurtherdetailscontactyourROXULsalesrepresentative.
Pleasevisitwww.roxul.com forthelatestinformation.

DISCLAIMER AND LIMITATION OF LIABILITY:ThestatementsanddatacontainedinthisbrochureareforgeneralinformationpurposesONLY.TheyareNOTspecific

technicalrecommendationsastoanyparticulardesignorapplicationandtheultimatedeterminationastoproductsuitabilityisthesoleresponsibilityoftheinstallerorend
user.Althoughtheinformationcontainedherein,includingROXULproductdescriptions,isbelievedtobecorrectatthetimeofpublication,accuracycannotbeguaranteed.
ROXULfullyreservestherighttomakeproductspecificationchanges,withoutnoticeorobligation,andtomodifyordiscontinueanyofitsproductsatanytime.Innoevent
shallROXULbeliableforanydirect,indirect,orconsequentialdamagesofanykindarisingfrominformationcontainedinthisbrochure,including,butnotlimitedto,claims
forlossofprofits,businessinterruption,ordamagestobusinessreputation.Thislimitationofliabilityshallapplytoallclaimswhetherthoseclaimsarebasedincontract,
tort,oranylegalcauseofaction.

ROXUL INC.
420BronteStreetSouth,
Suite105,
Milton,ONL9T0H9
www.roxul.com

/TM:US-ownerRockwoolInternationalA/Susedunderlicense;Canada-ownerRoxulInc.

ROX-IND-1113

T:18002656878