Gilsulate® 500XR
1. Product Name
Gilsulate®500XR
U.S. Patent No. 4,231,884
Engineered Thermal Insulation and
Corrosion Protection System for
Underground Pipes, Tanks & Structures
2. Manufacturer
Gilsulate International, Inc.
P.O. Box 802650
Santa Clarita, CA 91380
Phone: (661) 299-5907
(800) 833-3881
Fax: (661) 298-9091
Contact: Laura Duncan, Owner
laura@gilsulate.com
www.gilsulate.com
66 years made only in U.S.A.
3. Product Description
Basic Use
Gilsulate®500XR is the ONLY patented
& engineered “green” formulation
which is uniquely manufactured to min-
imize energy use, reduce carbon foot-
print, insulate and protect underground
systems for applications where product
temperatures range from 35°F to
800°F. Gilsulate®500XR is the MOST
thermally efficient granular product
available. It is placed and consolidated
around pipes to isolate, insulate and
protect them from harsh underground
conditions. Specific examples include
steam and condensate lines buried in
the permafrost of Alaska to chilled
water lines buried in the hot desert
sands of Saudi Arabia. Other exam-
ples include district heating and cool-
ing systems, domestic water, superheat-
Steam pipelines thru an
environmentally protected park
Chevron Burnaby • Vancouver, Canada
SPECIFICATION DATA SHEET
ed hot water, fuel oil, hot
water, petrochemical, molten
sulfur, asphalt, compressed &
hot air. Gilsulate®500XR has
a long history of installations
solely to provide corrosion
protection including; hot oil
piping at road crossings in
refineries and sensitive pip-
ing systems in DOE nuclear
waste facilities like the
Savannah River site.
Engineered Composition
Gilsulate®500XR is comprised
primarily of two inert, inorganic,
non-toxic minerals: calcium carbonate
and sodium potassium aluminum sili-
cate which are all coated to be
hydrophobic. The particles of this dry,
free-flowing granular material are multi-
sized & multi-faceted, providing the sta-
bility required by soil engineers for a
load-bearing product
Gilsulate®500XR is consolidated prior
to backfill ensuring that envelope
dimensions and designed system effi-
ciencies will not change
Innovation & Reliability
Gilsulate®500XR has a proven track
record of performance and reliability,
insulating and protecting more piping
systems and tanks, for more years, than
any other granular/powder insulation.
From particulate engineering to pack-
aging, virtually every technological
innovation in the poured-in-place under-
ground pipe insulation and protection
system market can be directly attributed
to the continual product improvement of
Gilsulate®.
Markets
Educational, chemical, food & bever-
age, pulp & paper, refining, pharma-
ceutical, industrial, military, govern-
ment and power.
Limitations
Underground areas with flowing water
or a positive underground water source
should be avoided when designing or
installing an underground piping sys-
tem. For specific project recommenda-
tions, contact our office.
Gilsulate® is a registered trademark of Gilsulate International, Incorporated. ©2004 Gilsulate International, Inc. All Rights Reserved
Consolidated prior to backfill, the Gilsulate envelope will not
shrink or settle. This assures that envelope dimensions and
thermal efficiencies are sustained as designed.
Advantages
• Lowest average total installed cost
insulation system providing corrosion
protection.
• The most efficient, highest CO2
reduction, and lowest operational cost
granular insulation available. Typical
systems are 30% more efficient than
pre-insulated systems.
• Quicker installation due to reduced
weight and increased cubic foot pack-
aging.
• Because of it's unique properties, 4-6
mil Poly-film is not required. Bags can
be placed on top of insulation envelope
to reduce waste sent to landfill.
• It is designed to be consolidated
prior to backfill. This feature eliminates
loss of coverage due to “shrinkage” or
settling during backfill operations.
Assures energy design will not change
• Failures in conduit, concrete trench,
direct burial, or other systems are easi-
ly repaired with Gilsulate®500XR. Tie-
ins and extensions are made with ease.
• No limit on the number or tempera-
ture of pipes within system envelope.
Not affected by “thermal shock” on
startup or shutdown.
• Allows Thermal Pipe Expansion
movement and is absorbed by a miner-
al fiber cushion surrounding the pipes
at expansion loops and 90° bends. The
cushion is enclosed and protected by
the Gilsulate®500XR envelope. No
complicated vaults or internal cavities
are required.
• Chilled water BTU's are expensive.
They can be conserved and water tem-
perature stabilized by insulating chilled
water pipes with Gilsulate®500XR.
U.S. Patent No. 4,231,884
Gilsulate® 500XR
4. Technical Data
•Temperature Range: 35 °F to 800 °F
. is manufactured in Dalton, Georgia
•Use Density: 40-42 lb./cu.ft. consoli-
dated or compacted - the lower the
density the higher the thermal efficiency
•Load Bearing Stability: 12,000 p.s.f.
(58,600 Kg/M3) - multi-sized & multi-
faceted particles make the most stable
product
•Resistance to Moisture Penetration:
Product is certified 100% hydrophobic
(will not absorb water). Equal to or
greater than 48” hydrostatic head for
30 days (S-249 Test)
•Electrical Resistivity: Greater than
1012 ohm-cm. - Galvanic action
between piping and the soil is prevent-
ed
•Thermal Conductivity: ASTM C 177
consolidated or compacted
Expressed as BTU/hr/ft2/°F/in.
100 °F K=0.53
175 °F K=0.60
300 °F K=0.65
5. Installation
Installation of Gilsulate®500XR is quick
and easy; however, it is critical that cor-
rect placement procedures are fol-
lowed. Additional materials supplied
by other manufacturers are required.
Refer to GII's current 24 page “Design
And Installation Manual” for complete
details and requirements of the installa-
tion process. Gilsulate®500XR is
stocked at our plants and strategically
located warehouses, our network of
Manufacturers Representative's ware-
houses and stocking distributors
throughout the USA and Canada.
Immediate shipments are available
from a location economically conven-
ient to your project.
Gilsulate®500XR has always been
packaged and sold per cubic foot at its
consolidated/compacted density to
make estimating the volume and cost of
your project quick and easy. It is not
sold in loose bulk density. Additional
material consideration for “yield loss-
es” due to loose bulk density pricing
isn't required when purchasing
Gilsulate®500XR.
Gilsulate® is a registered trademark of Gilsulate International, Incorporated. ©2004 Gilsulate International, Inc. All Rights Reserved
SPECIFICATION DATA SHEET
6. Availability & Cost
Gilsulate®500XR's patented formulation
and North Hollywood, CA.
Gilsulate®500XR is packaged in multi-
ply, bilingual paper bags, 40-42 lbs.
net weight, containing one cubic foot of
insulation at the recommended use den-
sity, shipped on pallets with stretch
wrap, 60 bags per pallet, 18 pallets
per truckload (1080 cubic feet total).
Gilsulate®500XR is also available in
our innovative bulk bag. It contains the
largest volume in the industry, saving
time and money in the placement of the
material. Each reinforced polypropy-
lene bulk bag contains 2,400 lbs. net
weight or 60 cubic feet of material, at
the recommended use density.
Gilsulate®500XR has the lowest labor
cost to install compared to field applied
jacketed insulation systems or compli-
cated mechanical systems. A standard
steam-condensate system insulated with
Gilsulate®500XR will have the lowest
operational cost.
7. Warranty
Gilsulate International, Inc. warrants
that this product will meet the specifica-
tions set forth under the heading
“Material Specification” as found in the
“Design and Installation Manual” pub-
lished by the company for the term of
one year, provided that the use of and
installation of the product conforms to
the specifications and directions set
forth in the “manual”. Refer to the
Gilsulate International, Inc. “Design
and Installation Manual” for complete
warranty information.
8. Maintenance
Gilsulate®500XR is maintenance-free
Contact GII for operating temperatures 601°F-800°F or for tank, structure or special design projects
AL - Coverage for Large Pipe Diameter
AS - Coverage for Small Pipe Diameter
B - Selected for Small Pipe Diameter
C - Coverage for Large Pipe Diameter
The example above shows how to determine
proper dimensions for the insulation envelope
using the table below. Additional quantities
(thickness) are required at expansion loops and
90° bends where fiber cushion is used to accom-
modate pipe expansion. Refer to the “Design
and Installation Manual” for additional detail
requirements.
when installed according to the manu-
facturer's published recommendations.
No costly sacrificial anodes are
required to maintain.
9. Technical Services
Upon request Gilsulate International,
Inc. will assist customer technical per-
sonnel during design. Gilsulate
International, Inc. will review drawing
and specifications submitted prior to
bid or installation.
Gilsulate International, Inc. may be
available for on-site installation training
and project start up, to assure a suc-
cessful installation of Gilsulate®500XR.
Contact GII for more information.
10. General & Technical Data:
Additional product information is avail-
able from the manufacturer upon
request.
U.S. Patent No. 4,231,884