Corrosion Under Insulation (CUI):

NEW

PRODUCT
NAMES

CorrosionUnder
Insulation(CUI):

IndustrialTechnicalOverview

CONROCK® Excellencein
industrialinsulation
2 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.That’swhyyoushouldalwayscheckthatthe
informationyouhaveisuptodate.Ifyouhaveanyquestions
aboutspecificapplicationissues,workingmethodsorproduct
properties,pleasevisitourwebsiteatwww.roxul.com.

CONROCK® Tableofcontents 5

The best solutions, built on solid expertise It’s all about conditions …

ROXUL® insulationisabletodrawonin-depthexpertiseto 1. Insulation is everywhere 6
ensurethatendusersinthepetrochemicals,powergeneration,
marine,offshoreandtheprocessindustriesaregiventhebest 2. The Issue: Insulation and Corrosion 7
andmostadvancedinsulationsolution.Bothintheprocess
industryasinthemarine&offshoreindustry,ourstonewool
productsofferthebestpossibleprotectionagainstheatalong
withenergyloss,fire,noiseandotherunwantedinfluences.Our
salesteamwillbedelightedtoassistyouindevelopingtechnical
andprojectspecifications.

Our people, your profit 3. Preventing corrosion 8
8
Thekeytooursuccessisthecombinationofexcellentinsulation Protectingsteelwork 10
productsandoutstandingpeoplewhoknowexactlywhattheyare Design&planningoftheinsulationwork 11
talkingabout.Thankstotheirexpertiseandextensiveexperience, Insulationselection 12
wecanofferexceptionalstonewoolsolutionsandanimpeccable Maintenance&Inspection
service.Withtechnicalsupportonahighlevelwearepreparedto 13
helpyoutochoosetheoptimalsolutionsandsecurethe 4. ROXUL & corrosion prevention
necessarydocumentation. 15
5. Norms & standards 15
Part of the ROCKWOOL Group 16
Corrosion-relevantteststandards
ROXULInc.isasubsidiaryofROCKWOOLInternationalof Corrosionteststandards 18
Denmark,theworld'sleadingproducerofstonewool,whichisa 19
stonefiberbasedinsulationmadefromnaturalstoneand 6. Frequently asked questions
recycledcontent.ROCKWOOL Internationaloperatesworldwide
withmorethan9,800employeesand28factories. ROXULCertificationandStandardsTable

ROXUL has a melting point above 2000°F

Ourstonewoolproductsmeetthestrictestfireprotection
requirementsandmakeanactivecontributiontothefiresafetyofa
buildingorinstallation.Otherinsulationmaterialsmayfailat
muchlowertemperaturesandoftenreleasedangerous
substancesduringcombustion.Stonewoolisnon-combustible
withameltingpointof2150°F(1177°C).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.

3

CONROCK® NEW

One World. One Brand. PRODUCT
NAMES
Globalizationismovingfasterthaneverand,intheworldofinsulation,ROXUL®

isleadingtheway.Withbusinessesfromdifferentcountriescollaboratingtoengineer

newindustrialandpowergenerationfacilities,ROXULhaslaunchedproductbrandingthat

speaksthesamelanguageanywhereintheworld.It’sastrategythatbringsuniformityto

specifying,matchesproductstoperformanceandstreamlinescommunication.

Introducing ProRox® and SeaRox®.OurProRoxproductsprovide Structure: Ouridentificationsystemlinkstoaproductand

insulationsolutionsforindustrialprocessandpowergeneration. performancecharacteristicsselector.Theexamplebelow

SeaRoxproductsdothesameformarineandoffshore illustratestheadvantagesofthissimpleyethighlyefficient

applications. structure.

Clarity: Ournamingstructureallowsyouto e.g.: ProRox® SL 960 RFFNA
quicklyfindtherightproductfortheright

application.ItalsoalignsROXULwithother Product Range Local market specifications
participatingROCKWOOLcompaniesto
provideatrueglobalproductoffering. Facing Options
Performance: ROXULproductsprovide
superiorthermalandacousticalvalueandare RFF = Reinforced Foil Facer
BM = Black Mat
WHM = White Mat
WH = White Polypropylene

fireresistant,waterrepellent,non-corrosive Product Identifier Application Code

andresistanttomold.Ourtechnicalexpertise SL = Boards/Slabs 300 Series = Acoustics
andglobalapproachtoproductspecifications FSL = Flexible Boards/Slabs 400 Series = Industrial Fabrication Insulation
willhelptakeyourbusinesstoanewlevelof PS = Pipe Insulation 500 Series = Compression
performance. MA = Wrap/Mat 600 Series = Fire Resistance
700 Series = Comfort/Multi-Purpose
900 Series = Thermal Insulation

Sun Exploration, drilling and production

Waste

Coal
Gas

Solar Power Plant Processing industry
Oil

Flow of energy Gas Processing Power Plant Consumption
Petroleum Refining Processing Marine Non-residential
Industrial
Petrochemicals Residential

Offshore

ProRox® End Products
SeaRox®

CONROCK®

It’sallaboutconditions…

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

Itiscommonly,butwronglyassumedthatopenorclosedcell ROXUL® and CUI
insulationalsoprotectsagainstcorrosion.Ifsteelworkisnot
protectedwithasuitablecoatingandinsulationisnotinstalled ROXULinsulationproductsforindustrialusecomplywith
underdryconditionsandprotectedbyadequateweather-
resistantcladding,corrosionunderinsulation(CUI)isastrong mechanicalinsulationstandardsandareconsideredbymanyto
possibility.CUInecessitatesrepairsandreplacements,alongwith
higherthanexpectedheatlossesinthedesignphase. beoneofthemostcost-effective,thermallyefficientinsulation

Preventing CUI (Corrosion Under Insulation) productscurrentlyonthemarket,withexcellentsustainability

Makingtherightdecisionstofindtherightsolutionisacomplex credentials.
process.Withthisinmind,preventingcorrosionisaserious
concern,whichmustbeaddressedinthedesignphase.  ROXULindustrialinsulationishydrophobic,providing
 Pipeworkandequipmentmustbedesignedproperlyto effectiveprotectionagainstmoisturepenetrationacrossthe
entireinsulationthickness.
ensuresupportsandfittingsarepositionedtoshedwateras
muchaspossible.  ROXULindustrialinsulationhasafibrousopen-pore
 Therightanti-corrosionsurfacetreatmentmustbeappliedto structurethatisvaporopen.SoROXULproductsreducethe
pipeworkandequipmentandregularlycheckedaspartofa riskofsurfacewettingbyallowinganybulkwatertodrain
robustmaintenanceplan. andthestructuretodryoutnaturally.
 Therightinsulationlayermustbeselectedtoensurethe
productisfitforpurposeandwillnotbethesourceof  ROXULproductsarepermeable,sotheydonotabsorb
additionalcorrosion. water.
 Therightweatherprotectionsystemmustbechosen.It must
befitforpurpose,compatiblewiththeu nderlyinginsulation  ROXULinsulationischemicallyinerttosteelworktomitigate
andregularlycheckedaspartofapreventativemaintenance riskofcorrosion.ItmeetstherequirementsoftheNorth
plan. AmericanandEuropeancorrosionstandardsforuse.

5

CONROCK®

1.Insulationiseverywhere

Industrialplantinsulationiseverywhere.Amedium-sizedoilrefinerycontains356miles
ofinsulatedpipingandmorethan25footballfieldsworth1.4millionft²ofinsulated
equipment,vesselsandtanks.Theplanttemperaturecaneasilyexceed1100°F,making
insulationessentialtoprotectpeopleandmaintainoperationalefficiencies.

Prompt and proper maintenance Heat losses from damaged insulation
can be up to 8x greater
Inmanycases,insulationisnotpromptlyorproperlymaintained,
simplybecauseitisnotconsideredtobearisk.Foryears, Heatloss (BTU/hr/ft) Reduction 43%
industryhasestimatedthat10%to30%ofexposedinsulation 12000
becomesdamagedormissingwithinonetothreeyearsof Reduction 97%
installation.Thatpercentageislikelytoriseovertime,depending 10000
ontheoperatingenvironmentandexposuretotheelements. Heat Loss Heat Loss
Manyplantoperatorsknowthatsteam-generatingcapacitymust 8000
beincreasedwhenitrainstocontinuetoprovidetheheatthe ROXUL® insulated (damaged insulation)
plantneedstooperateefficiently. 6000

Damaged insulation leads to increased heat 4000
losses and corrosion costs
2000
Theimpactofdamagecanbesubstantial.Inmanycases,the
actualreductioninheatlossisupto40%morethanexpected. 0
Damagedinsulationcladdingoftenallowswatertopenetrateinto Heat Loss
theinsulation,whichcancausecorrosion.Costsduetocorrosion,
downtimeandadditionalunanticipatedenergylossesare (bare un-insulated)
substantial.Thecostsofinspectionandrepair,whichcanoften
becarriedoutduringoperation,arenegligiblecomparedtothe Design Conditions: Steam Pipe, T 608°F, 8 inch (NPS),
potentialsavings. ambient temperature 50°F, 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

Heat losses from damaged insulation
can be up to 8x greater

Mining 1% ($0.1 billion) 1%
Petroleum Refining 21% ($3.7 billion)
Mid-Size Refinery (150.000 Chemical, Petrochemical,
Pharmaceutical 10% ($1.7 billion)
Chemical plant barrels per day) Pulp and Paper 34% ($6 billion) 8% 21%
Agricultural 6% ($1.1 billion) 9%
Insulationdamage 19.2% 21.3% Food Processing 12% ($2.1 billion)
Home Appliances 9% ($1.5 billion)
Corrosion 250,000USD 500,000USD Oil and Gas Exploration and 12% 10%
Additionalenergy annually annually Production 8% ($1.4 billion) 6%

1,766,622USD 10,300,307USD

loss(0.0159USD/kWh) annually annually

Source:Steamdigestvol.IV,insulationmanagementanditsvaluetoindustry 34%

Thereportedannualcostofrepairs,replacementandproduction Annual cost of corrosion in the production & manufacturing category
lossesrunintomillionsofdollarseveryyear.TheNational
AssociationofCorrosionEngineers(NACE)estimatestheannual Source: http://events.nace.org/publicaffairs/images_cocorr/ccsupp.pdf
costsofcorrosioninproductionmanufacturingintheUSAtobe Corrosion costs and preventive strategies
aroundUS$17.6billion.

6

CONROCK®

2.TheIssue:InsulationandCorrosion

Corrosionoccursinthepresenceofwaterandoxygensoifthesteelworkunder
insulationremainsdryitminimizestheriskofcorrosion.Keepinginsulationdrycanbe
challenginganditisessentialthateveryeffortismadetokeepitdryduringstorageand
installation.Failuretodosoleadstowateringressintotheinstallationwhichcanleadto
steelworkcorrosion,commonlyreferredtoascorrosionunderinsulation(CUI).In
practiceCUIcommonlyappearsinthetemperaturerangebetween55°Fand395°For
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
of55°Fto395°F.

Thecorrodedsurfaceismostlyhiddenbytheinsulationsystem
andwillnotbeidentifieduntiltheinsulationisremovedfor
inspectionorintheeventofmetalfailureleadingtohealthand
safetyincidents.Thenecessityofprotectionagainstcorrosion
mustbedeterminedforeachindividualplant.Thisbrochurewill
helpyouaddressthemostimportantCUIissues.

Acommonbutincorrect CorrosionUnderInsulation(CUI)referstotheexternalcorrosion
assumptionisthatinsulationalso ofpipingorequipmentthatoccursunderneathexternallycladded
protectsagainstcorrosion.If insulationduetowaterormoisturepenetration.
steelworkisnotprotectedwitha
suitablecoatingandtheinsulation
isnotinstalledinadrystateunder
dryconditionsandprotectedby
adequateweather-resistant
cladding,CUIisastrongpossibility.

7

CONROCK®

3.Preventingcorrosion

Makingtherightdecisionstofindtherightsolutionisacomplexprocess.Withthisin
mind,preventingcorrosionisaseriousconcern,whichmustbeaddressedinthedesign
phase.Numerousfactorsareinvolvedincausingorpreventingcorrosionunder
insulation.Temperatureandambientconditionsareaninevitablepartoftheprocessplus
thesurroundingenvironmentandcannotbecontrolled.Otherfactorscanbecontrolled
effectivelyandthreeissuesshouldbeaddressed:
 Protectingsteelwork
 Designingandplanninginsulationwork
 Inspectionandmaintenance

Protecting steelwork ASTM C795: Thermal Insulation for Use in Contact
with Austenitic Stainless Steel
Thenecessityofprotectionagainstcorrosionmustbedetermined Thisspecificationcoversnon-metallicthermal
foreachindividualplantandtheappropriatemeasureshavetobe insulationforuseincontactwithausteniticstainless
identified.Generally,thedesignoftheinsulationsystemand steelpipingandequipment.Therequirementsofthis
corrosionprotectiondependsonthefollowingparameters. standardincludetestsasperC692andC871.
 Operationoftheplant:continuousorinterrupted/intermittent.
 Operatingtemperatures. ASTM C665: Corrosiveness to Steel
 Metalsused(non-alloy,lowalloysteel,austeniticstainless Thisspecificationcoversthecompositionandphysical
propertiesofmineral-fiberblanketinsulation.Thetest
steelorcopper). ensuresthatthecompositionoftheinsulatingmaterial
 Externalfactors. doesnotcreateapotentialforcorrosiononcertain
metalsinthepresenceofwaterorwatervapor.
Beforeapplyingthecorrosionprotectioncoating,thesurface
mustbefreefromgrease,dustandacidplustheprimingcoat
shouldberoughenedforbetteradhesion.Blastingisthe
recommendedsurfacepreparationmethod(foraustenitic
stainlesssteel,useaferritefreeblastingabrasive).Followthe
coatingmanufacturer’sprocessingguidelines.

8

CONROCK®

Watch out for electrochemical corrosion!

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

Material Combinationmaterial
Surfaceratioinproportion
Metal Zinc Aluminium Ferritic Lead Austenitic Copper
tocombinationmaterial
Zinc Small steel stainlesssteel
Large
Aluminum Small —MM HH H
Large
Ferriticsteel Small —L L LL L
Large
Lead Small L—L HH H
Large
Austenitic Small L—L ML H
stainlesssteel Large
Copper Small L L—HH L
Large
L L—LL L

L L L —H H

L L L —M M

L L L L—M

L L L L— L

L L L LL—

L L L LL—

L-Lightorlittlecorrosiontomaterial
M-Moderatecorrosiontomaterial,forexample,inveryhumidatmospheres
H-Heavyelectrochemicalcorrosiontomaterial

NOTE:Thetableshowsthecorrosionofthe“material”,andnotthatofthe“combinationmaterial”.
“Light”means:“small-scaleinproportiontothecombinationmaterial”and“heavy“means:“large-scaleinproportiontothecombinationmaterial”.

Example1:Materialisazincgalvanisedscrewincombinationmaterialwithacladdingmadefromausteniticstainlesssteel:Row“zincsmall”:“H”-heavycorrosionofthescrew.

Example2:Materialisacladdingmadefromausteniticstainlesssteelsecuredwithascrewgalvanisedwithcombinationmaterialzinc:Row“austeniticstainlesssteellarge”.
“L”-thecorrosiveattackupontheausteniticsteelislight.

BasedonGermanDIN4140standard.

9

CONROCK® Note
Walkingoninsulatedpipeswithlowcompressive
Design & planning of the insulation work strengthshouldbeavoidedifpossible,asthiscan
damagetheinsulation.Damagecausedbyfoottraffic
Therequirementsoftheplannedinsulationworkmustbe includesdentedsheetcladdingandgapsatthesheet
factoredinduringtheindustrialplantdesignandconstruction seams.Watercanpenetratetheinsulationthrough
phase.Itisthereforeadvisabletoinvolveallprojectmanagersat thesegapsandcauselastingdamagetotheentire
anearlystagetoprecludeunnecessaryandunanticipated insulationsystem.Theresultisoftengreaterheatloss
problemsduringinsulationwork. andcorrosion.Ifthisisnotpossiblethentheinsulation
shouldbedesignedinsuchawaysothatitisresistant
Allpreparatoryworkmustbecompletedinaccordancewiththe tofoottraffic.ROXUL® ProRox® PS980NA offersa
relevantinsulationstandardandifnecessary,applycorrosion solutiontodamagefromfoottrafficduetoitshigh
protection.Insulationmaterialshouldbestoredandinstalledin compressivestrengthanddurability.
dryconditions.Variousconditionsmustbefulfilledtoensurethe
insulationdoesnotcontributetothecorrosionofthesteelwork Illustration 1: Pipe Insulation resistant
lateron. to foot traffic

Note
Aninsulationsystemresistanttofoottrafficmustnot
becomepermanentlydamagedifapersonweighing220
lbsorgreater(weightincludinganytoolsandequipment
beingcarried)walksonit.Itisnotdesignedtobear
additionalloads,suchastheplacingofheavy
equipment.Forthepurposeofthesafetyregulations,a
durableinsulationisnotconsideredtobeawalkable
surface.

Ready to go: Allpreparationshavebeenmadesosubsequent 1.Pipe-2.Insulation-3.Cladding-4.Sheet-metalscreworrivet-
insulationdamage/removalisnotnecessary. 5.Thicknessofcladding
 Tracingandtechnicalmeasurementequipmenthavebeen

installed.
 Weldingandbondingworkhasbeencarriedoutonthe

object.Thesurfacedisplaysnocoarseimpurities.

Design
 Mountingsupportshavebeeninstalledtoaccommodatethe

supportstructure.
 Collarsandsealingdiscshavebeenfitted.
 Linetapsarelongenoughtoensurethatflangeslieoutside

theinsulationandcanbescrewedonwithouthindrance.
 Supportsaredesignedsoinsulation,vapourretardersand

claddingcanbeproperlyinstalled.
 Wherenecessary,ladders,bridgesandsoonhavebeen

installedtopreventanyonefromwalkingorclimbingonthe
insulation.Ifthisisnotpossible,theinsulationshouldbe
designedtoberesistanttofoottraffic.

10

CONROCK® Note
Makingtherightdecisionstofindtherightsolutionisa
Insulation selection complexprocess.Buterrorsofjudgmentcanprovevery
costly,suchasoptingforamanufacturer’ssystemthat
Whenmakingaconsideredinsulationselection,itisimportantto offersnorealguaranteeoflong-termperformance.
thinkaboutnotonlyobviousproperties,suchasthethermal Successdependshugelyonthedesignoftheinsulation,
conductivityormaximumservicetemperatureofaproduct.To anticorrosioncoating,thetypeofinsulationmaterial,
minimiseriskofCUI,itisalsoimportantthattheinsulationdoes the skilloftheinstallerandweatherconditionsduring
notaffectthesteelwork,doesnotabsorbanywaterandisopen installation.Themostconsideredapproachistolookat
tovapour,sothatmoisturecaneasilyegresstheinsulation. thebigpictureandthinkaboutamorecost-effective
Theserequirementsarelaiddowninthefollowingstandardsand insulationtype.Youalsohavetoensuretheinsulationis
testmethods. installedinadrystate,protectedfromtheweatherand
 Chemicallyinert:Steelcorrosionacceleratesrapidly, properlymaintained.

particularlyifacidiccompoundscanbeextractedfromthe
insulationmaterial.Anaqueousextractoftheinsulation
materialshouldbeslightlyalkaline,sothedangerof
corrosionofunprotectedsteelisdiminished.
 Chloridecontent:Chloridesininsulationmaybeleachedout
andcancauseexternalstresscracking.Thewaterleachable
chloridecontentofinsulationmaterialshouldbein
accordancewithASTMC871.
 Waterrepellency:Theconcentrationofextractedchlorides
andacidiccompoundsinwaterstronglyinfluencesthescale
ofcorrosiveattackonthesteelwork.
 Watervapourresistancefactordefinedasμshouldbeclose
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® Insulation of valves should be designed with
removable coverings or hoods
Maintenance & Inspection

Toavoidunnecessarilycomplicatingroutinemaintenanceand
inspectionwork,high-maintenanceareasmustbetakeninto
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)

4”

4”

a=distanceflangetonormalinsulation
a≥2"
x=boltlength+1.2"
s=insulationthickness

12

CONROCK®

4.ROXUL® &corrosionprevention

ROXULindustrialinsulationoffersawiderangeofhighqualitystonewoolproductsfor
theinsulationofmechanicalequipment.Allproductsaredesignedandengineeredwith
thefollowingfeaturesthatwillminimizetheriskofcorrosionunderinsulation.

 ROXULofferingincludesrigidinsulationthatallowsfor  Isfibrousandwaterrepellentallowingwatertodrain
easyinstallation,routinemaintenanceandprotection awayandforvaportodry.
againstdamagefrommechanicalloads.
 Ischemicallyinertwhichminimizescorrosionpotential
 Iscompatiblewithanti-corrosionsurfacetreatments. causedbychloridecontents.

 Canbesuppliedwithscrimandfoilfacingstofacilitate  Compliestorelevantcorrosionstandards.
theuseofanappropriateweatherprotectionsystem.

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
2150°F(1177°C),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  ASTM C795 “Thermal Insulation for Use in Contact with
Austenitic Stainless Steel”.
Inert to steel Thisspecificationcoversnon-metallicthermalinsulationfor
Thecorrosionofthesteelisrapidlyaccelerated,especiallyif useincontactwithausteniticstainlesssteelpipingand
acidiccompoundscanbeextractedfromtheinsulationmaterial. equipment.Inadditiontomeetingtherequirementsofthis
Anaqueousextractoftheinsulationmaterialshouldbeslightly standard,theinsulationmaterialsmustpassthe
alkalinetoreducetheriskofcorrosionofunprotectedsteel.The preproductiontestrequirementsofASTMC692,forstress
pHvalueshouldbemeasuredinaccordancewithASTMC871. corrosioneffectsonausteniticstainlesssteel,andASTM
C871forqualitycontrolchemicalrequirements.ASTMC795
Water-leachable chloride content showstheresultsofASTMC871toillustratearangeof
Thecorrosionresistanceofsteelisincreasedbyaddingalloying acceptablechlorideconcentrationsinconjunctionwith
elementssuchaschromium,nickelandmolybdenum.Alloying sodiumplussilicateconcentrations(seegraphbelow).
producesanaustenitic(face-centredcubic)atomicstructure.
Thesetypesofsteelarealsocalledausteniticsteels.Despite ASTM C795 acceptability of insulation material on the basis of the
theirgeneralhighresistancetocorrosion,thesesteelstendto plot points of the Cl- and the Na+ an SiO32- analyses
exhibitstresscorrosionundertheinfluenceofchlorideions.An
insulationmaterialwithanextremelylowwater-leachable 10.000
chloridecontentmustthereforebeusedtoinsulateobjectsmade
fromausteniticstainlesssteel.Forthisapplication,onlythose Water-leachable content Chloride (Cl-) (ppm) Unacceptable analysis
insulationmaterialsmanufacturedwithalowwater-leachable
chloridecontentcanbeused.Theclassificationcriteriawill 1.000
dependonthestandardfollowed.Ingeneral,adistinctioncanbe
madebetweenUSASTMstandardsandEuropeanENstandards. 100

 AS-Quality (AGI Q135 – EN 13468) Acceptable analysis
Thefollowingacceptancecriteriaapplytoinsulation
materialsofAS-Quality.Theaverageofsixtestsamplesmust 10
exhibitawater-leachablechloridecontentof≤10mg/kg.
ROXUL®
 ASTM C871 “Chemical analysis of thermal insulation stone
materials for leachable chloride”. wool
Thisstandardcoversthelaboratoryproceduresforthe
determinationoftheions,whichacceleratestresscorrosion 1
ofstainlesssteel.Iftheresultsofthechemicalanalysisfor
theleachablechloride,sodiumandsilicateionsarewithin Water-leachable content Sodium and Silicate
theacceptableareaofthegraphinASTMC795andalsopass (Na+ an SiO32-) (ppm)
ASTMC692,theinsulationmaterialshouldnotcausestress 1
corrosioncracking. 10
100
1.000
10.000
100.000

15

CONROCK® Corrosion test standards

Water repellency Thereisnosingletestmethodthatcanbeusedtopredictor
Thermalconductivityandproductperformanceisconsiderably measuretheamountofCUIthatwilloccurwhenaninsulated
impairedbythepenetrationofmoistureintothematerial.Wet pipeorequipmentisexposedtoenvironmentalconditions.
insulationmaterialcanalsocontributetocorrosion.Soinsulation Therearesimplytoomanyvariablesandtoomanydifferent
materialsmustbeprotectedagainstmoistureduringstorageand combinationsofexposurepossible.Thereforeseverallaboratory
installation,aswellaspost-installation. testmethodshavebeendevelopedtodeterminethepotentialrisk
ofCUI.
 ASTM C1104 / 1104M
“DeterminingtheWaterVapourSorptionofUnfacedMineral Quantitative accelerated evaluation ASTM C1617
fiberInsulation” “QuantitativeAcceleratedLaboratoryEvaluationofExtraction
Thisstandardcoversthedeterminationoftheamountof SolutionsContainingIonsLeachedfromThermalInsulationon
watervapoursorbedbymineralfiberinsulationexposedtoa AqueousCorrosionofMetals”.TheprimaryintentofASTMC1617
high-humidityatmosphere.Thetestsamplesarefirstdriedin istotesttheaqueouscorrosionofcarbonsteelunderinfluence
anovenandthentransferredtoanenvironmentalchamber ofthermalinsulationmaterial.Thisisdonebydeterminingthe
maintainedat120°Fand95%relativehumidityfor96hours. MassLossCorrosionRate(MLCR)causedbyexposureofthe
Thewatervapoursorptioniscalculatedusingtheweight metalcouponstotheinsulation.Thestandardusescontrolled
differencebeforeandaftertestingandisexpressedinweight amountsofcorrosivereferencesolutionscomparedtothe
percentageorvolumepercentage. corrosionresultingfromtheinsulationmaterialsolutionstothat
ofknowncorrosivesolutions.

Test procedure

 Threesamplesoftheinsulationmaterialareextractedin
accordancewithASTMC871.Thesolutionisplacedwithina
PVCtubeonaheatedflatplate(230°F)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® 8 76

ASTM C692: Contribution to external stress corrosion cracking 3 5
“EvaluatingtheInfluenceofThermalInsulationsonExternal 4 2
StressCorrosionCrackingTendencyofAusteniticStainless
Steel”.Thisstandardcoverstheproceduresforthelaboratory 1
evaluationofthermalinsulationmaterialsthatmayactively
contributetoexternalstresscorrosioncracking(ESCC)of 1.Hotplate-2.Testcoupon-3.PVCtube-4.O-ring-5.Siliconesealant-6. Tubing-
austeniticstainlesssteelduetosolublechlorideswithinthe 7.Barbedconnector-8.Straw
insulation.Inthiscorrosiontest,insulationspecimensareused
totransferdistilledordeionisedwaterbywickingfromdripping
toanoutsidesurfacethroughtheinsulationtoahotinnersurface
ofstressedstainlesssteelforaperiodof28days.Ifleachable
chloridesarepresent,theywillconcentrateonthehotsurfaceby
evaporation.Attheconclusionofthe28-daytestperiod,the
stainlesssteelcouponsareremoved,cleanedandinspectedfor
stresscorrosioncracks.Topassthetest,nocracksmaybefound
onthesurfaceofthecoupons.

Storagetanks Columns
Pipework
Vessels

17

CONROCK®

6.Frequentlyaskedquestions

Can wet insulation material be What type of protection should be used for pipe
reused after drying? and equipment conservation?

ROXUL® insulationistreatedtobewaterrepellentanditsthermal Protectivecoatingsorpaintsplayavitalroleinpreventingcorrosion
propertieswillberestoredafterdrying,providedthereisno underinsulation.Therearemanytypesofcoatingsandpaints
physicalandchemicaldegradation.However,whentheriskof basedonorganicorinorganiccompounds.Eachoneisdesignedto
contaminationwithchloridescannotbeavoided,theinsulation protectaspecificmetalinaspecifictemperaturerange.
shouldberemovedandreplacedbydryinsulation.
Can aluminum foil protect austenitic steel
Does specially inhibited insulation reduce the surfaces?
risk of stress corrosion cracking?
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 Why is it important to use water repellent
timeofwateringress. insulation?

Can ROXUL products be used in Theuseofwaterrepellentadditivesreducesthewatercontent
heavily diluted areas? insidetheinsulation.Moistureininsulationmaterialshasa
numberofnegativeimpacts.Thethermalconductivityofwateris
ROXULinsulationishighlywaterrepellentbutitcannotwithstand substantiallygreaterthanthatofair,whichistrappedbetween
themechanicalimpactofe.g.waterhosesanditwillnotprotect thefibers.Anincreaseinmoisturecontentthereforeresultsinan
thesteelagainstingressingwater.Iftheinsulationhastobe increaseinthethermalconductivityoftheinsulationand,
pressurecleanedorwillcomeintocontactwithseawater(marine correspondingly,adecreaseintheinsulationefficiency.A
oroffshoreapplications),applicationofarigidwatertight moisturecontentofeven1%canincreasethethermal
insulationprotection,suchasimperviousmaterialand conductivityby25%.Ahighermoisturecontentalsosignificantly
impermeablejacketingsystemsarerecommended. increasestheweight,which,asarule,isnottakenintoaccountin
thestaticdesignofaninsulationsystem.Moisturecausesmany
typesofcorrosionthatalmostneverdevelopinadrysystem.

18

C547 - Pipe COMPLIANCE

New C547 E136 S114 S102 / E84 C411 C447 C356 C1104 C165 C585 C800 C795
Name Linear Wicking
ProRox® PS960NA MineralFibrePreformed Behaviour Non- Surface Hot Maximum Shrinkage Moisture Compressive Diameters Corrosiveness
ProRox® PS980NA Sorption Strength forNominal tosteel
Old Nominal PipeInsulation at Combustibility Burning Burning Surface <1.3% PipeSizes
Name Density <0.6%
750°C Characteristics Characteristics Performance
TECHTON® 1200 8lbs./ft.3 I II IV V
STURDIROCK® 11.25lbs./ft.3
••• • • • • • <0.1% • • •
<0.1% • • •
•••• • • • • • 1102psf@10%

C612 - Board

COMPLIANCE

C612 E136 S114 S102 / E84 C411 C356 C1104 C518 (C177) C165 C665 C795
Moisture
MineralFibreBoard Behaviour Non- Surface Hot Linear Sorption Thermal Compressive Corrosiveness Corrosiveness
Insulation at Resistance Strength
New Old Nominal Combustibility Burning Burning Shrinkage 0.02% tosteel tosteel
Name Name Density IVA IVB 750°C 0.03%
Characteristics Characteristics 0.01%
ProRox® SL920NA RHT® 30 3lbs./ft.3 • • 0.04%
ProRox® SL930NA RHT® 40 4lbs./ft.3 • • • • • <1% 0.04% •• •
ProRox® SL940NA RHT® 60 6lbs./ft.3 • • • • <1% 0.01% • 63psf@10% • •
ProRox® SL960NA RHT® 80 8lbs./ft.3 • • 0.28%
ProRox® SL540NA RHT® 100 10lbs./ft.3 • • • • • <1% 0.03% • 104psf@10% • •
ProRox® SL560NA RHT® 120 12lbs./ft.3 • • • • • <1% 0.01% • 167psf@10% • •
ProRox® SL590NA RHT® 150 15lbs./ft.3 • 0.03%
ProRox® SL460NA NewProduct 9 lbs./ft.3 • • • • • <1% 0.02% • 313psf@10% • •
ProRox® SL450NA NewProduct 12lbs./ft.3 • •
ProRox® SL430NA NewProduct 4lbs./ft.3 • • • • • <1% • 418psf@10% • •
ProRox® SL760NA NewProduct 3.5lbs./ft.3 • • • • • <0.38% • 1220psf@10% • •
• • • • <0.4% • 720psf@10% • •
• • • <1% • 418psf@10% • •
• • • <0.35% • 71psf@10% • •
• • • <1% •• •

C553 - Blanket

COMPLIANCE

C553 E136 S114 S102 / E84 C411 C356 C1104 C518 (C177) C665 C795

New Old Nominal MineralFibreBlanket Behaviour Non- Surface Hot Linear Moisture Thermal Corrosiveness Corrosiveness
Name Name Density ThermalInsulation at Combustibility Burning Surface Shrinkage Sorption Resistance tosteel tosteel
Characteristics Characteristics
VII 750°C

ENERWRAP® MA960NA ENERWRAP® 80 8lbs./ft.3 • • •• • 1.49% 0.01% • • •
ProRox® FSL920NA RHT® 30Flex 3lbs./ft.3 • 0.02%
ProRox® FSL930NA RHT® 40Flex 4lbs./ft.3 • • •• • <1% 0.05% • • •
ProRox® FSL940NA RHT® 60Flex 6lbs./ft.3 • • •• • 1.49% 0.02% • • •
ProRox® FSL960NA RHT® 80Flex 8lbs./ft.3 • • •• • 1.68% 0.03% • • •
ProRox® MA930NA RHT® 40Wrap 4lbs./ft.3 • • •• • 0.68% 0.05% • • •
ProRox® MA940NA RHT® 60Wrap 6lbs./ft.3 • • •• • 1.49% 0.02% • • •
• •• • 1.68% • • •

Fortechnicaldatasheets,pleasevisitwww.roxul.com TS-TB-.0.001-0214©ROXULINC2014

A Global Leader Environmentally Sustainable

ROXULInc.ispartofROCKWOOLInternational,thelargest Ourstonewoolproductionprocessutilizessomeofthemost
producerofstonewoolinsulation,whichismadefromnatural advancedtechnologyavailable.Thelastdecadehasseenanew
basaltrockandrecycledmaterial.ROCKWOOLInternationalwas generationofROXULmanufacturingfacilitiesthataredesigned
foundedin1909andtodayoperatesworldwidewithmorethan tolowerourenvironmentalfootprint.Theseendeavorshave
9,800employees,with28factoriesacrossthreecontinents. includedthecaptureandrecyclerainwater,reductioninenergy
consumption,andzerowastetolandfillbytherecyclingofraw
ROCKWOOLhasover75yearsintheinsulationbusinessandfor materialsbackintotheproductionprocess.ROXULfacilitiesalso
25yearsROXUL® hasbeenservingtheNorthAmericanmarket, usenaturallightingandre-purposewaterusedduringthe
manufacturingstonewoolinsulationproductsforresidential, manufacturingprocesstominimizetheimpactonthe
commercial,industrialandOEMapplications. environmentandsurroundingcommunityresources.

ROXUL is the Better Insulation ROXULinsulationiscreatedusingnaturallyoccurring,inorganic
rawmaterialsandreuseswastefromothermanufacturersas
ROXULisaninnovativeinsulationofferingaworldofgreen wellasfromourplants.Stonewoolinsulationisnoncombustible
features.WhenROXUListhespecifiedinsulation,companieswill andachievesitsthermalperformancewithouttheuseofblowing
receiveasuperiorproductalongwiththetechnicalexpertiseof agents.Theproductsthereforedonotoff-gasovertime,
theROXULteamtomeetallinsulationrequirements. 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. ROX-IND-1113
420BronteStreetSouth,
Suite105,
Milton,ONL9T0H9
T:18002656878
www.roxul.com

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