Industrial thermal insulation is about much more than controlling heat transfer. A well-designed insulation system contributes to personnel safety, asset protection, process reliability, energy efficiency and sustainability throughout the lifetime of an installation.
Flexible aerogel insulation blankets combine an exceptional set of material properties that enable these objectives to be achieved simultaneously. Their extremely low thermal conductivity, mechanical robustness, flexibility, hydrophobicity and fire performance make them particularly suitable for demanding industrial applications where traditional insulation systems reach their limits.
At Insulcon, we supply aerogel thermal insulation solutions from leading manufacturers, including Aspen Aerogels and Armacell. Rather than promoting a single product family, we help our customers select the most appropriate aerogel solution based on operating temperature, available installation space, mechanical requirements, maintenance strategy and project specifications.
Protecting people and installations is one of the primary objectives of thermal insulation. Aerogel insulation helps to create safe to touch surface temperatures, limits radiant heat and contributes to safer working environments. Depending on the selected product and complete system configuration, aerogel insulation can support demanding fire performance requirements.
“Corrosion under insulation (CUI) refers to the external corrosion of piping and vessels that occurs underneath externally clad/jacketed insulation as a result of the penetration of water.”
EFC Corrosion Under Insulation Guidelines, 3rd Edition
Moisture ingress is one of the major causes of insulation system degradation and Corrosion Under Insulation, CUI. The hydrophobic nature of aerogel insulation helps minimise water absorption while maintaining thermal performance over time. Combined with its mechanical durability and flexibility, aerogel insulation can contribute to longer equipment life and reduced maintenance requirements.
Learn more about Corrosion Under Insulation
Stable thermal performance helps maintain consistent process temperatures under demanding operating conditions. Aerogel insulation remains effective during thermal cycling and mechanical movement, reducing the likelihood of insulation damage and helping to minimise process disruption and unplanned downtime.
Aerogel offers one of the lowest thermal conductivities available for industrial thermal insulation products. This enables equivalent thermal performance with significantly reduced insulation thickness, creating valuable space around piping, equipment and complex installations. Alternatively, the available space can be used to increase the level of insulation, further reducing heat transfer and improving the overall thermal performance of the insulation system.
Reducing energy consumption directly contributes to lower CO₂ emissions and improved operational efficiency. Combined with long service life, reduced maintenance requirements and the possibility of reusing insulation during maintenance activities, aerogel insulation supports sustainable asset management throughout the entire lifecycle of an installation.
A flexible aerogel insulation blanket consists of nanoporous silica aerogel integrated into a flexible fibre reinforcement batting.
Its value lies in the combination of:
Together, these properties deliver reliable thermal performance in a safer working environment, while reducing installation complexity, maintenance requirements and total lifecycle costs.
The most appropriate aerogel solution depends on the operating conditions and the requirements of the complete insulation system
Operating temperature, available space, thermal cycling, mechanical loading, moisture exposure, vapour control, fire performance and maintenance strategy all influence product selection. Insulcon therefore evaluates aerogel solutions by application and project specification rather than by manufacturer alone.
Flexible aerogel insulation blankets for hot service applications help control heat loss and surface temperatures in piping, vessels and industrial equipment.
Their low thermal conductivity enables high thermal performance with reduced insulation thickness. Their flexibility, mechanical robustness and hydrophobic performance make them particularly relevant where available space, thermal cycling, moisture exposure, CUI risk or maintenance access influence the insulation design.
Flexible aerogel insulation blankets for cryogenic and dual temperature applications are designed to limit heat gain and maintain reliable thermal performance during cooling, normal operation and thermal cycling.
Effective vapour control is an essential requirement in cold and cryogenic insulation systems. Flexible aerogel insulation blankets combine low thermal conductivity, hydrophobic performance and an integrated vapour barrier to fulfil an integral role within the vapour control strategy.
Relevant industries
Available product solutions
View products and technical documentation
ASTM C1728 provides a recognised technical reference for specifying and comparing flexible aerogel insulation blankets. Project specifications may require a specific ASTM type and grade, depending on the intended service and performance requirements.
Insulcon can help identify which available aerogel solutions meet the required classification and verify the supporting technical documentation.
Does your project specification require a specific ASTM C1728 type or grade?
Talk to an aerogel specialist
Selected aerogel insulation blankets can be used in demanding fire protection applications. In specific tested configurations, aerogel can also form part of a Passive Fire Protection system designed to protect critical pipework, vessels and process equipment against severe thermal exposure for a specified period.
For selected products, thermal insulation and passive fire protection can be combined within one flexible insulation system. The suitability of a system depends on the relevant fire scenario, required protection period, operating temperature and complete tested configuration.
Reaction to fire classification of an individual material should not be confused with the proven fire resistance of a complete tested system.
Material performance alone does not determine the performance of an insulation system. Product selection, engineering, conversion, installation, weather protection and maintenance all influence the final result.
As an independent technical system partner, Insulcon helps translate project requirements into an appropriate aerogel insulation solution. We combine material knowledge, engineering support, prefabrication and project assistance from initial evaluation through to implementation.
Engineering and product selection
Evaluation of operating conditions, thermal targets, available space, mechanical requirements, maintenance strategy and project specifications.
Thermal calculations
Thermal calculations can support:
Conversion and prefabrication
Aerogel blanket material can be converted into project-specific components, including:
CNC cutting and prefabrication under controlled conditions can improve consistency, reduce cutting, handling and waste on site, shorten installation time and help reduce exposure to installation related risks.
Installation and project support
Correct installation is essential to the performance of the complete insulation system. Insulcon supports contractors, engineers and project teams with installation guidance, technical clarification, application-specific recommendations and project documentation. This can help reduce rework, installation complexity and unnecessary time on site.
Available documentation can include:
Product values, classifications and approvals depend on the selected grade and system configuration. The latest validated documentation should therefore be used during technical evaluation and specification.
Insulcon supports customers in developing aerogel insulation solutions that contribute to safety, asset protection, process reliability, energy efficiency and lifecycle performance.
Pipe supports are critical points within an industrial insulation system. The support must transfer mechanical loads while limiting changes in insulation thickness, unwanted heat transfer and interruptions to the weather or vapour control system.
As an addition to the Insulcon aerogel portfolio, Rilco offers engineered pre insulated pipe supports for hot and cryogenic applications.
PyroWrap® pipe supports are designed to match systems insulated with Pyrogel XTE. They are available as resting, guided, anchor and hanging supports. Rilco specifies PyroWrap systems for high temperature environments up to 650°C.
CryoWrap® pipe supports combine Rilco support engineering with Cryogel Z insulation for cryogenic piping. The supports can be configured for different loads and movement requirements and are used in applications such as LNG, LPG and ethylene systems.
The Rilco support range helps maintain a consistent insulation system through the support location while combining thermal performance with the required mechanical support function.
We do this in cooperation with our sister company which has more than 40 years of experience in this.
The benefits of this for the customer are:
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