Insulation board foam spray pipe home wall roof | Wedge India

Wedge India is leading Insulation brand company good quality manufacturer, contractor, importer, exporter of thermal, acoustic, electrical insulation good quality products at low price boards, foam, spray, pipe tubes for wall roof floor door green home sound and thermal barrier, solving heat problems oven van furnaces. Buy good quality Insulation Board Products for heat, cold, fire, and noise reduction applications at Wedge India. We have strong manufacturing bases in more than 12 countries and capable to offer wide range of Insulation Boards and Materials for various applications in Building Insulation, Industrial Insulation, Noise Control, Cold Storages, Cold Chain Insulation, Prefabricated Building, Railways Insulation, Pipe Insulation, and Fire Protection Insulation.

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Benefits of Insulation | Why to use Insulation?

  • 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 

High Temperature Insulation
Van Insulation
Construction Crane

What is Insulation?

Insulation is a property of any material that explains the resistance to transfer or transmit any form of energy it could be sound, heat, electricity, fire, cooling, vibrations. In general term Insulation is used to describe material that creates barriers for transmission of electricity, heat, moisture, shock or sound.

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What is thermal or heat Insulation?

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.

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Heat insulating materials are products for the refractory lining of thermal industrial plants with the objective of reducing heat losses. Here the low thermal conductivity and the thermal capacity of air is used. Heat insulating materials usually have a total porosity of at least 45%, in practice

mostly from 60 to 90%, and in extreme cases up to 99%. Besides low thermal conductivity, high porosity causes reduced mechanical strength, high gas permeability and low corrosion resistance. The thermal conductivity not only depends on the total porosity of the material, but also on the pore size and shape, the structure composition and the mineralogical composition. Depending on temperature, the factors responsible for the flow of heat solid state conduction, convection and radiation vary in influence. Maximum pore diameters of < 1 mm are necessary. Wedge Micro Silica Aerogel Microporous FSMP insulating materials with pores < 0.1 μm have the lowest thermal conductivity. The thermal shock resistance of lightweight construction materials has a large influence on applications. High temperature wool products usually resist severe

thermal shocks. Other lightweight construction materials are sensitive to thermal shock.

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The term “heat insulating bricks” covers those heat insulating materials which are applied up to 1000°C and which are often mistakenly referred to as rear insulation materials. These products are manufactured on the basis of naturally occurring lightweight raw materials (kieselguhr, vermiculite, perlite). They are assigned to the group of lightweight refractory bricks which are made out of refractory raw materials.

 

In furnaces and plants with low mechanical load and without corrosion stress, a design with lightweight heat insulating materials has almost completely eliminated heavy designs with dense, refractory materials. High temperature insulation technology must make economic use of the properties of insulation materials and systems, while observing the laws of physics and chemistry.

Heat Insulation
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)

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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.

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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.

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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.

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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).

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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

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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

types of Insulation

Types of Insulation

The most common insulation materials are fiberglass, cellulose and foam. Home insulation types include any of the above materials in the form of loose-fill, batts, rolls, foam board, spray foam and radiant barriers. 

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Building Insulation Blanket Batts Rolls Flexible Sheets

These type of Insualtion products are made of Fiberglass, Mineral Wool, Rockwool, 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 Insulation

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.

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Spray Foam Building Insulation

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.

 

A two-component mixture composed of isocyanate and polyol resin comes together at the tip of a gun, and forms an expanding foam that is sprayed onto roof tiles, concrete slabs, into wall cavities, or through holes drilled in into a cavity of a finished wall.

Spray foam is also an informal term used to refer to various plastic foam materials that are used in building construction to provide thermal insulation and minimize air infiltration. Polyurethane and polyisocyanurate are two types of foam used in this application. 

 

Benefits of Spray Foam Insulation

  • Best for hard-to-reach or oddly shaped areas and already insulated areas. 

  • Can be used to fill small gaps and cracks or to insulate large spaces. 

  • Ideal for sealing around doors, windows and vents. 

  • Sets quickly and can be trimmed, painted or stained. 

  • Has two types: open-cell foam and closed-cell foam.

  • Closed-cell foam is denser and thus has a higher R-value.

  • Closed-cell foam is usually more expensive than open-cell foam.

  • Open-cell foam has an approximate R-value of R-3.7 per inch of thickness. 

  • Closed-cell foam has an approximate R-value of R-6.2 per inch of thickness.

  • Sheathing reduces heat conduction through structural elements like wood and steel studs. 

  • Great insulation choice for cold climates. 

  • DIY-friendly. Typically more expensive per square foot than other insulations.

  • R-values range from R-4 to R-6.5 per inch of thickness.

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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.

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Wall insulation

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.

 

Roof insulation

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.

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Window and door insulation

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.

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Floor insulation

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.

 

Wedge mineral wool floor insulation is made from premium stone wool and can improve a building's thermal and acoustic performance. Not every wall does. A vapour retarder is a material used to prevent water vapour from diffusing into the wall, ceiling or floor during the cold winter. In an average home, approximately 10% of the heat loss is through the ground floor. Therefore, insulation as a means of reducing heat loss is typically installed on the ground floor. However, it may also be provided in upper-floors between heated and unheated areas. In comparison with wall insulation or roof insulation, savings associated with floor insulation are more modest, but under some circumstances, installation costs can be lower.

  • The installed performance of an insulation product is dependent on:

  • The performance characteristics of the insulation material.

  • The suitability of the insulant to its installed location.

  • Adherence to manufacturer’s instructions.

  • Quality of workmanship.

  • Defects, gaps in insulation, thermal bridging and moisture penetration. 

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Most Commonly used floor insulation materials are:

  • Cellulose.

  • Wedge Aerogel Sheet

  • Cork board.

  • Hempcrete.

  • Woodfibre.

  • Mineral wool.

  • Extruded Polystyrene (XPS).

  • Expanded Polystyrene (EPS). 

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Vapour Barrier Insulation

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.

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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

Wedge Steel Plant Insulation.png

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 insulation products

​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

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Markets for High Temperature Insulation

​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

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Insulation Thermal Conductivity Comparision.png
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Mechanical Insulation 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.

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What is Cellular insulations?

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.

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Fibrous insulations

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 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.

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Flake insulation

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.

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Granular insulation

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.

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Reflective Insulation

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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