Insulation Price, Cost, Thickness, Heat Loss, R U Value Calculation | Wedge India

Get best r13 r19 r21 r30 r38 r49 best types of thermal heat insulation thickness r value chart insulated board materials store companies contractors. Insulation materials for furnace spray foam home attic garage door kit mineral wool board Insulated water bottle bags pipe blow in cellulose fiberglass batt roof sound proof wall window price diy r13 r19 r30 vermiculite ceiling elastomeric mineral wool duct glass. Wedge India is leading Insulation Materials, Products, and Systems manufacturer, contractor, importer, and exporter. Our product range includes thermal, acoustic, cryogenic good quality products at low cost board, foam, spray, pipe tubes for wall roof floor door green homes.

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What Insulation I should use?

Materials Type, Thickness, Cost Calculation

Send details of your required application and goals to reduce heat loss or wall, roof temperature, pipe insulation thickness our team will send you best combination of insulation materials with most commercially feasible thicknesses to achieve target objectives and goal at ver low cost.

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What is insulation?

Insulation refers to a material or substance that is used to slow down or prevent the transfer of heat, sound, or electricity. It is commonly used in buildings, electrical systems, and various industrial applications to improve energy efficiency, provide thermal comfort, reduce noise, and enhance safety.

Thermal insulation is perhaps the most well-known type of insulation. It is used to reduce the heat transfer between the inside and outside of a building, helping to maintain a comfortable temperature and reduce energy consumption for heating or cooling. Common thermal insulation materials include fiberglass, mineral wool, cellulose, foam boards, and spray foam.

Sound insulation, also known as acoustic insulation or soundproofing, is used to reduce the transmission of sound between different spaces. It is often applied in buildings, particularly in areas where noise control is important, such as recording studios, theaters, or residential units near busy roads or airports. Sound insulation materials can include mass-loaded vinyl, acoustic foam, or specialized panels.

Electrical insulation is crucial for ensuring the safety and efficiency of electrical systems. It prevents the flow of electricity to unintended pathways and protects against electric shocks. Insulating materials for electrical applications include rubber, plastic, ceramics, and specialized coatings.

Insulation materials can vary in their properties, such as thermal conductivity, sound absorption coefficient, or dielectric strength, depending on the specific application requirements. The choice of insulation material depends on factors like the desired level of insulation, cost, environmental impact, fire safety regulations, and local building codes.

Proper installation and maintenance of insulation are essential to ensure its effectiveness over time. It is important to follow manufacturer guidelines and building codes when installing insulation to achieve optimal performance and safety.

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Types of Insulation

There are several types of insulation available, each with its own characteristics and applications. Here are some common types of insulation:

Fiberglass Insulation: Fiberglass insulation is made from tiny glass fibers that are spun into a fluffy material. It is widely used for thermal insulation in residential and commercial buildings. Fiberglass insulation is available as batts, rolls, or loose-fill, and it is relatively affordable.
Cellulose Insulation: Cellulose insulation is composed of recycled paper products, such as newsprint, and treated with fire retardants. It is an eco-friendly option and is often used in attics and wall cavities. Cellulose insulation is effective at reducing air infiltration and has good sound absorption properties.
Spray Foam Insulation: Spray foam insulation is a versatile option that is sprayed into place using a special gun. It expands and hardens, creating an airtight seal and providing excellent thermal insulation. Spray foam insulation is commonly used in areas with irregular shapes or hard-to-reach spaces.
Mineral Wool Insulation: Mineral wool insulation, also known as mineral wool or slag wool, is made from natural minerals like basalt or slag. It is available as batts, boards, or loose-fill. Mineral wool insulation has good fire resistance properties and provides effective thermal and sound insulation.
Polystyrene Insulation: Polystyrene insulation comes in two main forms: expanded polystyrene (EPS) and extruded polystyrene (XPS). EPS is a lightweight and cost-effective option, often used for insulation in walls, roofs, and foundations. XPS is denser and offers higher compressive strength, making it suitable for applications like insulating below-grade foundations.
Polyurethane Insulation: Polyurethane insulation is commonly used in spray foam form. It expands when applied, creating a tightly sealed barrier that provides excellent thermal insulation. Polyurethane insulation has a high R-value (a measure of thermal resistance), which means it offers a high level of insulation in a relatively thin layer.
Reflective Insulation: Reflective insulation is typically made of aluminum foil laminated onto paper or plastic backings. It reflects radiant heat, helping to keep the space cooler. Reflective insulation is often used in attics and can be combined with other types of insulation for enhanced thermal performance.

It's important to note that the choice of insulation type depends on factors such as the application, local climate, budget, and building codes. Consulting with a professional or understanding specific requirements for your project is recommended to determine the most suitable insulation type.

The most common types of insulation materials are fiberglass, cellulose, foam aerogel, vermiculite, calcium silicate, ceramic fiber, millboards, non asbestos millboards, bricks, perlite, mineralwool, xlpe foam, rubber etc. Here is a list of type of Insulation Products manufactured, fabricated, and supplied by Wedge India.

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Benefits of Insulation?

Insulation is property of any material to resist any form of energy transfer it could be heat, fire, sound, electricity, etc from one side to other side of the applications. Insulation products are designed to prevent heat or sound from being transmitted from one area to another. In general term Insulation is used to describe material that creates barriers for transmission of electricity, heat, moisture, shock or sound.

Insulation Materials are used in wide range of applications some applications are listed here:

Home Insualtion: Wall, Roof, Door, Window, Floor, Duct, Pipe, etc.
Industrial Equipment, Construction
Exhaust Pipes, Furnaces, Ovens, Storage Tanks
EV battery Insulation, Partitions, etc.

Thermal insulation of any material (organic or inorganic) is the resistance to heat transfer or transmission. To understand insulation materials we need to understand the physics of heat transfer. Heat transfer can occur through conduction (solid & gaseous), convection and radiation. Usually the overall heat transfer comes from a combined effect of all of them. The driving force in this process is the temperature difference.

A house with no insulation loses around 33% of its heat through walls and 25% of heat through the roof.

High Thermal Comfort in Homes
Energy Cost Reduction, Heat Loss Reduction, High Cold Storage Efficiency
Home and factory buildings sound noise pollution reduction.
Fire Protection, Effective heat shield, Energy Saving, Environment Protection
High Acoustic Insulation, Better Home Insulation, Green Building Construction
Sound Control, High Strength with Light Weight, Building Life Enhancing
Industrial Heat Loss Reduction, Equipment Life Increase

Insulation Materials are used in wide range of applications some applications are listed here:

Home Insualtion: Wall, Roof, Door, Window, Floor, Duct, Pipe, etc.
Industrial Equipment, Construction
Exhaust Pipes, Furnaces, Ovens, Storage Tanks
EV battery Insulation, Partitions, etc.

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What is Heat transfer?

The heat energy transfer rate through a body is proportional to the temperature gradient across the body and its cross sectional area. In the limit of thickness and temperature difference, the fundamental law of heat transfer is:

Q = λA x dT / dx

Q is the heat transfer (W)

A is the cross-sectional area (m2)

dT/dx is the temperature/thickness gradient (K/m)

λ is defined as the thermal conductivity value (W/m.K)

Even the very best thermal insulation will not block heat completely. Every material will transfer some heat if a temperature gradient exists across its thickness. According to the known laws of thermodynamics, heat will always fl ow from a region of high temperature to one of lower temperature. This is simple physics. The effectiveness of a material as a thermal insulator can be expressed in terms of its thermal conductivity.

Solid Conduction Heat transfer

In a solid, a liquid, or a gas, as individual molecules heat up they vibrate more and more. In solid conduction heat energy is transferred from one adjacent molecule to another by this vibration. The transfer rate is related to the material’s density or mass. The higher the mass, the higher the

conduction will be. It is also related to the length and cross section of the conduction path. The rate of solid conduction is directly proportional to the cross sectional area of the conduction path, and inversely proportional to the length of that conduction path.

Convection Heat transfer

Convection is heat transfer by bulk movement within a heated fluid such as a liquid or a gas. Free convection is caused by expansion of gas or fluid when heated, causing hot regions to become less dense and buoyant and to rise. Circulation occurs as the hot fluid cools and sinks down again. Free convection systems can be very large and convey massive amounts of heat, for instance in weather systems and the circulation

of molten rock inside the earth. The gas or liquid particles may be energised when passing by a warmer solid mass. A classic convector heater is a perfect example (hot air rises, and as it cools down, it falls). Convection currents are avoided by the inability of the air molecules to flow inside the microporous structure. Since a microporous material consists mostly out of entrapped air (> 95%), it cannot act as an intermediary solid material to allow convection of the surrounding air.

Radiation Heat transfer

All objects absorb and emit thermal radiation. Also called infrared radiation, the heat is transferred by the emission of electromagnetic waves.

No particles are involved, unlike in the processes of conduction and convection, so radiation can even work through the vacuum of space. This is why we can still feel the sun’s heat, although it’s 150 million km away from the earth. The hotter an object is, the more infrared radiation it emits.

The radiation rate is proportional to the fourth power of temperature, resulting in rapidly increasing heat loss when temperature rises.

Gaseous Conduction Heat transfer

All materials whether solid, liquid, or a gas, have mass and a thermal conductivity and can therefore conduct heat. When gas molecules are heated, the heat energy is converted to kinetic energy and they start moving faster. Gaseous conduction occurs when adjacent gas molecules collide and transfer their kinetic energy. The mean free path of a gas molecule is the average distance it will need to travel before it collides with another molecule. The mean free path of an air molecule at STP is around 93 nm (3.66 x 10-6 inches).

What is Thermal conductivity λ Lambda value?

Thermal conductivity is the rate at which heat passes through a specified material, expressed as the amount of heat that flows per unit time through a unit area with a temperature gradient of one degree per unit distance. The thermal conductivity of a material is a measure of its ability to conduct heat. It is commonly denoted by k, \lambda, or \kappa. Heat transfer occurs at a lower rate in materials of low thermal conductivity than in materials of high thermal conductivity. A good high temperature insulator has a very low thermal conductivity at high temperatures. Not all materials transfer heat equally and the thermal conductivity (λ value) of a material is a physical property which describes its ability to transfer heat. The lower the thermal conductivity value, the more resistant a material is to the heat transmission. An insulator therefore has a low thermal conductivity, while a conductor has a high thermal conductivity. Examples of the thermal conductivity of some common materials or substances at ambient temperatures.

Formula to calculate Thermal Conductivity of any material.

K or λ = Qd / A (T1 - T2)

K = thermal conductivity

Q = amount of heat transferred

d = distance between the two isothermal planes

A = area of the surface

T1-T2= difference in temperature

λ value Copper = an excellent conductor 401 W/m.K

λ value Carbon steel = 54 W/m.K

λ value Glass = 1.05 W/m.K

λ value Air 0.026 = W/m.K

λ value Wedge Microporous insulation = 0.021 W/m.K

λ value Wedge HVIP (High Vaccum Insulation Boards) = < 0.0035 W/mK

λ value of Wedge Aerogel WAG650 = 0.015 W/m.K

Building Blanket Batts Rolls Flexible Sheets

These type of Insualtion products are made of Fiberglass, Mineral Wool, Slag wool, Plastic fibers, Natural fibers. Main applications are Unfinished walls, including foundation walls, Floors and ceilings, Fitted between studs, joists, and beams. Flexible type insulation materials are low cost and very easy to install and suited for standard stud and joist spacing that is relatively free from obstructions.

Foam Board Rigid Concrete block Building

Foam boards are various types of rigid insulation structures made of wide range of materials Polystyrene, PIR Polyisocyanurate, PUR / PUF Polyurethane, Phenolic. These type of insulation materials are most suitable for unfinished walls, including foundation walls, new construction or major renovations walls (insulating concrete blocks), floors and ceilings, Unvented low-slope roofs, Interior applications: must be covered with 1/2-inch gypsum board or other building-code approved material for fire safety. For exterior applications these boards must be covered with weatherproof facing. These boards provide high insulating value for relatively little thickness and can block thermal short circuits when installed continuously over frames or joists.

Spray Foam

Spray foam building insulation is a polyurethane foam that expands and hardens to fill gaps. Spray foam is a chemical product created by two materials, isocyanate and polyol resin that reacts when mixed with each other and expand up to 30 to 60 times its liquid volume after it is sprayed in place. For large insulating jobs, professionals spray this insulation into place with special equipment. For small sealing jobs, spray foam is available in spray cans. Spray foam insulation or spray polyurethane foam (SPF) is an alternative to traditional building insulation such as fiberglass.

Spray polyurethane foam (SPF) insulation can be categorized into two different types: light-density open-cell spray foam insulation and medium-density closed-cell spray foam insulation. Both types of SPF are thermoset cellular plastics comprising millions of small cells.
Open cell spray polyurethane foam insulation being applied in wall cavities. Open cell insulation can be crushed in your hand and has a lower insulation value. Closed cell is rigid to the touch and each air cell is completely sealed. While closed cell foam has a higher R-value, it is more costly to buy.

Wall Application

Wall insulation is most efficient way of saving energy and reducing cooling or heating cost inside your home or building. Wall insulation can be done on both and exterior or interior walls. Wall insulation also gives best acoustic properties and reduces noise sound. Depending on the type of wall you have, you can use:

1. Cavity wall insulation a gap between the inner and outer leaf. Insulation material is inserted to the wall through drilling holes which are then refilled with cement.
2. Solid wall insulation (no cavity inside them). External insulation typically covers the entire facade of the property while internal is generally applied to inner rooms. Download Catalog for Wall Insulation.

Roof Application

One of the most common and effective ways to insulate your roof is with perlite insulation boards or powder if you are looking for external insulation. For internal insulation polyurethane spray foam is most common material is used for Roof Insulation. This spray-applied plastic is known to be highly effective for sealing any cracks as well as resisting wind and heat.

The foam is applied to the underside of your roof deck and directly onto the slates and tiles.

1. Warm loft, insulating immediately under the roof. This is more expensive than cold loft but usually is a better insulator.
2. Cold loft, insulating immediately above the ceiling of the top storey.

Window and door

If your windows don't seal properly, one of the options to solve this problem is a weather-seal tape. You can choose among different types to insulate windows, but foam strips are the most popular, easy to use, and cheap. The best insulation for stopping drafts around windows will be a material that keeps air from leaking around the frame. The most commonly used insulation materials are fiberglass and window spray foam insulation. Make sure you have double glazed windows and doors made of Wedge Vacuum Insulation Glass. This is, having at least two panels of glass some millimetres apart instead of a single glass. Double glazing will also protect you from outer noise, keeping your home warm and silent. If you can access the area behind the window or door trim, adding batt insulation or spray foam insulation is one of the best ways to insulate doors and windows for winter because it can keep cold air from coming through the window.

Floor Uses

EPS sheets, fully known as expanded polystyrene sheets, are one of the best floor insulation materials. This might be very expensive, make sure if you really need it depending on the type of floor you have. They are easy to install and they have a high insulation value. Insulation boards have to be fixed on an even ground and they are pressure-resistant, so the floor won't crack or collapse Usually, modern houses have insulators under the concrete floor surface, but older houses with suspended floors will need some investment. After the insulation is in place you will want to add a vapour barrier or retarder, sometimes called a vapour barrier, if you need one.

Most Commonly used floor insulation materials are:

Cellulose.
Wedge Aerogel Sheet
Cork board.
Hempcrete.
Woodfibre.
Mineral wool.
Extruded Polystyrene (XPS).
Expanded Polystyrene (EPS).

Vapour Barriers

Vapour barriers prevent water vapour from travelling through your home’s ceiling and walls when it’s cold outside. Even if you already have an insulation system, moisture can still build up around it both inside and outside of your home, causing the insulation’s R-value to lower.

Vapour barriers, typically large sheets made of plastic or foil, can prevent this by reducing the amount of moisture that passes through the insulation. Not measured in R-value, this system is both DIY- and budget-friendly and is best suited for homes in humid climates that experience cold weather.

Benefits of Home or Building Insulation

Reduces energy costs
Prevents moisture condensation
Reduces capacity and size of new mechanical equipment
Enhances process performance
Reduces emissions of pollutants
Safety and protection of personnel
Acoustical performance: reduces noise levels
Maximizes return on investment (ROI)
Improves Appearance
Fire Protection

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High Temperature Insulation

High temperature insulation materials also known as Industrial Thermal Insulation materials market is driven by growing demand in various end-use industries, such as petrochemical, ceramic, glass, aluminum, and iron & steel. High-temperature insulation materials operate at high-temperature ranges such as 600°C-1100°C. Petrochemical is the largest and fastest-growing end-use industry of high temperature insulation materials. High temperature insulation materials such as ceramic fibers, insulating firebricks and calcium silicate, which are used in high-pressure steam piping, flanges, boilers, dryers, furnaces and turbines. The upward growth trend of the petrochemical industry is due to the increasing use of petrochemical products in energy systems, such as turbines, electric vehicle parts, and solar panels, especially in developing countries. This is expected to encourage petrochemical manufacturers to add new capacities, which is likely to boost the demand for high temperature insulation materials in this industry.

Types of High Temperature applications

The product segment is classified into ceramic fiber, calcium silicate, insulating firebrick, and others. Ceramic fibers are the leading segment worldwide

Ceramic fibers
Insulating firebricks
Calcium silicate
Perlite
Vermiculite
Microporous materials

Markets for High Temperature

high-temperature insulation materials market is fragmented based on application, type, and geography. The global market is segmented based on the application as aluminum, ceramics, iron & steel, petrochemicals, powder metallurgy, glass, refractory, cement, and others. The geographical segmentation of the global market includes North America, Europe, Asia-Pacific, Latin America, and the Middle East & Africa.

Petrochemicals
Ceramics
Glass
Cement
Iron & Steel
Refractory
Powder Metallurgy
Aluminum

Mechanical Materials

Insulation materials or systems may also be categorized by service temperature range. There are varying opinions as to the classification of mechanical insulation by the service temperature range for which insulation is used. As an example, the word cryogenics means "the production of freezing cold"; however the term is used widely as a synonym for many low temperature applications. It is not well-defined at what point on the temperature scale refrigeration ends and cryogenics begins.

What is Cellular?

Cellular insulation is composed of small individual cells either interconnecting or sealed from each other to form a cellular structure. Glass, plastics, and rubber may comprise the base material and a variety of foaming agents are used.

Cellular insulations are often further classified as either open cell (i.e. cells are interconnecting) or closed cell (cells sealed from each other). Generally, materials that have greater than 90% closed cell content are considered to be closed cell materials.

Fibrous

Fibrous insulation is composed of small diameter fibers that finely divide the air space. The fibers may be organic or inorganic and they are normally (but not always) held together by a binder. Typical inorganic fibers include glass, rock stone mineral wool, slag wool, and alumina silica.

Fibrous insulations are further classified as either wool or textile-based insulations. Textile-based insulations are composed of woven and non-woven fibers and yarns. The fibers and yarns may be organic or inorganic. These materials are sometimes supplied with coatings or as composites for specific properties, e.g. weather and chemical resistance, reflectivity, etc.

Flakes

Flake insulations are composed of small particles or flakes which finely divide the air space. These flakes may or may not be bonded together. Vermiculite, or expanded mica, is flake insulation.

Granular

Granular insulations are composed of small nodules that contain voids or hollow spaces. These materials are sometimes considered open cell materials since gases can be transferred between the individual spaces. Calcium silicate and molded perlite insulations are considered granular insulation.

Reflective

Reflective Insulations & treatments are added to surfaces to lower the long-wave emittance thereby reducing the radiant heat transfer to or from the surface. Some reflective insulation systems consist of multiple parallel thin sheets or foil spaced to minimize convective heat transfer. Low emittance jackets and facings are often used in combination with other insulation materials.

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