Insulation Manual

Application manual
Thermaflex insulation
products

Subject to changes and/or printing errors

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1. Thermaflex
General
guidelines
1.1 Tools for the application of Thermaflex
1.2 General application of Thermaflex
1.3 Use of Thermaflex for air conditioning, cooling and refrigeration applications
1.4 Suitable sealing techniques
1.5 Insulation of pipes with Thermaflex sheet material
1.6 Insulation of pipes with multi-layer Thermaflex tube/sheet material
1.7 Insulation of surfaces with multi-layer Thermaflex sheet material
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1.1 Tools for the application of Thermaflex

Thermaflex insulation products can be easily and smoothly applied with the aid of appro-
priate tools.
Make sure that you always use clean tools and that the knives have been sharpened!
Appropriate tools are:

Knife (short) Hollow punches

Knife (long) Scribing tools

Grinding stone Roller

Brush with short, sturdy hair Snap-off blade knife

Metal jointing rule Filling knife

Folding rule Scissors

Compass Blackboard chalk

Callipers

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1.2 General application of Thermaflex

Always use suitable tools, see paragraph 1.1 (page 2). Always use Thermaglue to seal
the material. See paragraph 1.4 (page 5) for further information.

Always work in properly ventilated work areas.

Only use clean Thermaflex material. It should be free of dust and grease. Use
Thermaclean to remove the dust and grease. Only apply dry material.

Always use the appropriate type of insulation material for the right application and with
the appropriate dimensions.

Oval tubes (large diameters) should always be cut on the flat side.

Never apply Thermaflex insulation material under stress. The sealed seams should
always be joined under pressure.

Only use Thermatape to secure the joints after the sealant is completely dry (minimum
24 hours, depending on the circumstances).

Never insulate installations that are in operation. The installations can only be used after
the sealant has completely cured.

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1.3 Use of Thermaflex

for air conditioning and refrigeration applications
Make sure that the insulation of each end joint is sealed around the medium pipe. This
also applies to each sealed seam when fitting the Thermaflex sheet material.

min. 2cm

The Thermaflex pipe support is used for the optimal vapour-tight insulation of systems
and the prevention of thermal bridges at the pipe hangers and anchor points (see para-
graph 2.1, page 10 for application).

For the insulation of several adjacent pipes, the opening between the insulated pipes
should be at least twice the wall thickness of the used insulation material.

Please visit: www.thermaflex.com to calculate the appropriate wall thickness by using

the calculation programme on the website.

Corrosion-sensitive surfaces should be protected with the appropriate materials prior to

insulation.

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1.4 Suitable sealing techniques

Thermaglue should not be applied at temperatures below +5°C and the storage tempe-
rature should be maintained between +5°C and +10°C (see the application instructi-
ons on the packaging).

The surfaces and materials should be clean and free of dust and grease prior to insula-
tion.

Shake and mix the Thermaglue well before use. Mix the sealant regularly during the insu-
lation work.

Apply a thin and even layer of Thermaglue on both sides of the material prior to insula-
tion. If two different types of material are used (for instance air ducts), the Thermaglue
should be first applied to the insulation material and then to the other surface.

Let the sealant dry (between 3 and 10 minutes depending on the conditions) until it no
longer creeps. Then join the sealed surfaces using light pressure.

Wet sealing techniques should be used to seal the seams under pressure. Apply the
Thermaglue evenly between the raised seam, and then join the seams under light pres-
sure.
The drying time does not have to be taken into account for this method and the seams
can be joined together immediately.

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Wet sealing techniques should also be used for sealing at high temperatures and in
draughty and humid areas. Smaller surfaces should also be sealed (depending on the
thickness of the material, maximum approx. 1 m2). As a result of the high temperature
and humidity, a film layer will form on the sealed surface, which prevents the use of dry
sealing techniques.

In order to absorb the stress on the sealed seam when using wet sealing techniques,
insulation tape can be placed at right angles to the sealed seam (every 20 cm).

Attention: Always use brushes with short, sturdy hair. An insulated installation may only be
used 24 hours after the work has been carried out.

1.5 Insulation of pipes with Thermaflex sheet material

Thermaflex sheet material is used for the insulation of pipes with a diameter of more
than 4” (114 mm). When securing Thermaflex sheet material, care should be taken to
avoid inadmissible high stress on the sealed seam caused by the bending of the sheet.

1. Determine the circumference of the pipe with the aid of a strip of insulation mate-
rial. Make sure that the circumference is always measured by using a strip with the
appropriate insulation thickness.

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2. Plot the circumference on the sheet and then cut to measure. Coat both surfaces
with sealant and let the sealant dry during the prescribed drying time.

3. Wrap sheet insulation around the pipe. First join the extremities and then the middle
part. Join the remaining parts using light pressure.

The stress depends on the diameter of the pipe to be insulated and the wall thickness.
If the pipes are covered with thick sheet insulation, it is recommended to apply these in
two layers. Turn the sealed seams 180 degrees in relation to each other when applying
two-layer insulation. (Also refer to paragraph 1.6).

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1.6 Insulation of pipes with multi-layer

Thermaflex tube / sheet material
Both tube and sheet insulation can be used for multi-layer applications.

Tube insulation: the inner diameter of the second layer should correspond to at least
the maximum outer diameter of the first layer (maximum tolerance).

Sheet insulation: after applying the first layer, the second layer should be applied in the
same manner. In order to reduce stress on the second seam as much
as possible, it is recommended to seal the second layer to the first
layer at seam level.

1.7 Insulation of surfaces with multi-layer

Thermaflex sheet material
For the insulation of surfaces with multi-layer Thermaflex sheet insulation, the first layer
should be fully sealed to the substrate. The second layer should be sealed to the first
layer at the level of the seams and the extremities of the sheet. Place a cross on the sheet
to prevent sagging. The second or additional layer should be applied in a staggered pat-
tern in relation to the underlying layer.

Also seal the seam of the first layer

Layer 2
Layer 1
Surface to be insulated

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2. Application
of Thermaflex
tube insulation
2.1 Self-sealing adhesive Thermaflex tube insulation
2.2 Push-on Thermaflex tube insulation
2.3 Cutting of Thermaflex tube insulation
2.4 Cutting of grooved and segmented elbows
2.4.1 90° elbow
2.4.2 45° elbow
2.4.3 Segmented elbow 1 coupling
2.4.4 Segmented elbow 2 couplings
2.4.5 Segmented elbow 3 couplings
2.5 Elbows with clamp fittings
2.6 Reducer
2.7 T-piece
2.8 Oblique T-piece
2.9 Straight pipe joint
2.10 Application of Thermaflex pipe support
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2.1 Self-sealing adhesive Thermaflex tube insulation

See the drawings below for the application of self-sealing adhesive Thermaflex tube
insulation.

Attention: Remove the protective foil on both sides prior to application

+35 ºC

+5 ºC

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Approx.20cm

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Cut through and seal

in order to avoid stress on the elbow.

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2.2 Push-on Thermaflex tube isolation

The insulation can be pushed onto pipes with smaller diameters.

Check during the fitting of the insulation material whether the insulation creases at the
elbows. In this case, the elbows have to be replaced with segmented elbows (see para-
graph 2.5).

Tip: Always work towards the insulated section to avoid material stress.

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2.3 Cutting of Thermaflex tube insulation

The following rule applies to the cutting of Thermaflex tube insulation:

Always cut the insulation on the flat side to minimise stress on the sealed seams as
much as possible.

Attention: Always use sharp and clean knives.

2.4 Cutting segments

For vapour-tight insulation we use whole segments that can be made by using the tem-
plate below. However, you should ensure a minimum void of 10 - 15 mm between the
segments at the inside of the elbow.
11,25º 11,25º
22,5º 22,5º
45º 15º 15º

The number of segments for vapour-tight insulation depends on the pipe diameter and
the wall thickness to be used. A void of 10 - 15 mm should be left at the inside of the
segments.

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2.4.1 90° elbow

45º

After cutting the segment, coat both sides with

Thermaglue and observe the drying time. Then
join both parts using slight pressure.

Subsequently, the inside of the segment should

be cut through. Attention: the sealed seam is
still weak!

Fit the segment on the pipe to be insulated and

seal the two insides together.

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2.4.2 45° elbow

The work sequence is the same as in 2.4.1.

22,5º

1/3 Ø

2.4.3 Segmented elbow 1 coupling

The work sequence is the same as in 2.4.1.

22,5º 22,5º

10-15mm
Ø

10-15mm

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2.4.4 Segmented elbow 2 couplings

The work sequence is the same as in 2.4.1.
22,5º 22,5º

2/3 Ø
10-15mm
Ø
2/3
Ø
2/3

10-15mm
10-15mm

2.4.5 Segmented elbow 3 couplings

The work sequence is the same as in 2.4.1.

1/2 Ø

10-15mm 10-15 10-15mm

11,25º 11,25º
11,25º 11,25º
Ø
1/2
Ø
2
1/
Ø
1/2

10-15

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2.5 Elbows with clamp fittings

Fit the tube insulation up to the clamp fitting and seal to the medium pipe. The diameter
of the segment should correspond to at least the outer diameter of the tube insulation.

Attention: The segment should overlap the tube insulation by at least 2 cm.

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2.6 Reducer

Cut the insulation on both sides (V-shape).

Seal both sides together.

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Cut the reducer to the right longitudinal size.

Cut the reducer in the longitudinal direction at right angles with the sealed seam.

Fit the reducer segment to the medium pipe and seal the cutting seam.

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21

2.7 T-piece
Attention: When sealing the T-piece, make sure that surface “A” has been properly cleaned
with Thermaclean.

Cut through the T-piece after the pipe branch has been sealed.

Then fit the T-piece on the medium pipe and seal both sides together.

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22

2.8 Oblique T-piece

See paragraph 2.7 for application.

2.9 Straight pipe joint

Min. 20mm

Attention: Minimum overlap 2 cm.

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2.10 Application of Thermaflex pipe support

Wrap the Thermaflex pipe support around the pipe and seal with the self-adhesive strip.
Make sure that the bracket is placed at the level of the PU segment. Press the insulati-
on against the pipe support and wrap Thermatape around the insulation.

Attention: Secure the pipe insulation across a minimal distance of 20 mm on the pipe at the
level of the pipe support.

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3. Application
of Thermaflex
sheet insulation
3.1 Insulation of surfaces
3.1.1 Self-sealing adhesive Thermaflex sheet insulation
3.2 Insulation of square ducts and spiral seam pipes
3.3 Two-part 90° elbow
3.4 45° elbow
3.5 90° T-piece
3.6 45° T-piece
3.7 Reducer
3.8 One-sided reducer (cone)
3.9 Valve
3.10 Tank/vessel
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3.1 Insulation of surfaces

See paragraph 1.7 for the application of multi-layer sheet material.

5m
m

Do not apply sealant on 30 mm

Push

Wet sealing

+5mm

1 2

+5mm +5mm

3 +5mm 4 +5mm 5 +5mm

+5mm

6 +5mm 7 +5mm

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3.1.1 Self-adhesive Thermaflex sheet insulation

Attention: The surfaces should be free of dust and grease prior to insulation.
Clean the substrate with Thermaclean.

+35 ºC

+5 ºC

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3.2 Insulation of square ducts and spiral seam pipes

Thermasheet sheet insulation
Insulation of square and round air ducts with Thermasheet AC and FR.

1. First clean the surface to be insulated with a degreasing agent (Thermaclean).

2. Coat or spray a thin and even layer of Thermaglue on the duct and the insulation
material. Let the sealant dry sufficiently (tacky and no creep, 3 – 10 min.). Apply the
Thermasheet sheet with a 2 cm overlapping width and press into place. This should
be done carefully, because the sheet can no longer be removed after it has been fitted.
There exist other methods for ducts with an insulation thickness of more than 20 mm.
(see Chapter ‘Alternative insulation methods for square ducts' on page 32).

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3. After the Thermasheet has been secured, both layers of the overlap should be cut
through so that the seams can interlock. The seams are joined while the sealant is
still wet.

4. Flanged seams are secured with strips of sheet insulation.

5. The seams are secured with Thermatape.

5. Seams can be finished with Thermatape.

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Thermasheet sheet insulation is also available as a self-adhesive version; it can be cut

to the required length and width.
If the self-adhesive version of Thermasheet is used, the butt joints of the longitudinal
seams should be sealed with Thermaglue according to the directions for use on the con-
tainer, i.e. by letting the sealant dry sufficiently (tacky, no creep, 3 - 10 min.) before the
sealed seams are joined. This is especially important in the case of round ducts in order
to absorb any possible material stress. The self-adhesive version of Thermasheet should
be applied to the surface without causing any stress. If stress is unavoidable, the adhe-
sive layer can only serve as an aid to apply the insulation. The surface should also be
coated with Thermaglue in that case. Thermaduct and Thermaduct elbows can be used
for round and spiral seam pipes (both with a quick-action closure).

Insulation of square and round air ducts with Alu stucco Thermasheet

1. First clean the surface with a degreasing agent (Thermaclean) before insulating.
2. Coat or spray a thin and even layer of Thermaglue on both surfaces in accordance
with the directions for use.
3. Let the sealant dry sufficiently (still a bit tacky, no creep).
4. Secure the Alu stucco Thermasheet with an overlapping width of 2 cm and press it
into place. This should be done carefully because the sheet can no longer be removed
after it has been fitted.
5. Cut through both layers of the overlap after the Thermasheet has been fitted. Remove
the overlaps so that the seams interlock. The seams are joined while the sealant is
still wet.
6. The longitudinal threads are secured with Alu stucco tape.
7. The flanged seams are secured with strips of Alu stucco sheet insulation and Alu
stucco tape.

8. Use blanked elbows for round air ducts and Alu stucco tape for longitudinal seams.

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Insulation of square and round air ducts with Thermasheet UV

(for outdoor installation)

1. First clean the surface with a degreasing agent (Thermaclean) before insulating.
2. Coat or spray a thin and even layer of Thermaglue on both surfaces in accordance
with the directions for use.
3. Let the sealant dry sufficiently (still a bit tacky, no creep).
4. Secure the Thermasheet UV plate with an overlapping width of 2 cm and press it into
place. This should be done carefully because the sheet can no longer be removed after
it has been fitted.
5. Cut through both layers of the overlap after the Thermasheet has been fitted. Remove
the overlaps so that the seams interlock. The seams are joined while the sealant is
still wet.
6. The longitudinal threads are secured with EDPM tape.
7. The flanged seams are secured with strips of Alu stucco sheet insulation and Alu
stucco tape.

Alternative methods for the insulation of square ducts

Sheet on sheet application:

1. This method is suitable for ducts with a larger wall thickness. The Thermasheet which
can be cut to the required width, is sealed to the four sides of the square duct.
Different types of Thermasheet can be used.

2. When using Alu stucco and UV Thermasheet, the sides should be cut at a 45° angle
so that the top layer fits the corners.

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3.3 Two-part 90° elbow

‘t 1/4 Ø
Thermaflex
strips

1/4 Ø

‘t
ir Ø ir 1/2 U

U = Pipe circumference
Thermaflex strips

C E J N P
‘t 6mm 9mm 13mm 19mm 25mm

Measure the circumference of the medium pipe with a strip of insulation material
(Attention: Use a strip with the same wall thickness as the insulation to be used).

Mark off the circumference with the aid of a compass on the sheet insulation and cut
the segment with a sharp and clean knife.

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Mark off the segment on the other half.

Apply Thermaglue to the outside.

Join both parts together by applying light pressure and let the seam dry a little bit.

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Subsequently, apply Thermaglue to the inside.

Fit the segment to the elbow and join both sides together by applying light pressure.

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36 45º

3.4 Elbow 45°

The work sequence is identical to the work sequence in paragraph 3.3.

Thermaflex
strips

U
1 /2
R= c
c

2U
c

1/
R=
c
1/2 1/2
U
Pipe circumference

Thermaflex strips

3.5 T-piece 90°

Attention: Make sure that surface “A” has been properly cleaned with Thermaclean before
sealing the T-piece.

Thermaflex
strips

Ø
a

1/4 1/4 1/4 1/4

A U
A
Pipe circumference a
Thermaflex strips

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37

3.6 45° T-piece

Attention: Make sure that surface “A”has been properly cleaned with Thermaclean before
sealing the T-piece.

Thermaflex
strips
1/4 Ø

a
t
b

1/2 1/2
A

a
Pipe circumference
A

Thermaflex strips

b
3.7 Reducer

d2

‘t ‘t

Thermaflex s
strips

1/2 d2

h
h

‘t
Thermaflex strips
‘t ‘t Ø= Ø Pipe 1/2 d1
d1 circumference

C E J N P
‘t 6mm 9mm 13mm 19mm 25mm

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3.8 One-sided reducer (cone)

D1
Thermaflex strips D2
d2
h h
Thermaflex
D2 strips
b

b
h

s Largest pipe s

1/4 d2
circumference

d1 ‘t
D1

C E J N P
‘t 6mm 9mm 13mm 19mm 25mm

3.9 Valve

B= Length incl. flange plate

A A Thermaflex
strips

Flange plate x

c a
B x
C

Reinforcement U
of synthetic sheet A= Circumference of flange and flange plate
Thermaflex strips

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Ø
Ø

Measure the diameter of the medium pipe and of the flange.

Plot the circumference with a compass on the sheet insulation and cut it out.

Fit the cut-out circumference on the outside of the flange.

Measure the length (outside of the flange/outside of the flange) “A”.

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Determine the circumference of the flange and plot the circumference (dimensions “B”).

Cut out the circumference.

Measure dimensions “A” on the bottom of the valve.

Plot these dimensions on the two extremities of the plate.

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Seal both surfaces on the pipe.

Fit the entire segment around the valve and join the surfaces lightly together.
A

Measure diameter “A” and “B” of the flange and plot the diameter.

Cut out the diameter and cut the diameter open on one side.

Seal both surfaces on the duct and fit the collar.

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C

Determine circumference “C” of the flange and cut the circumference out.

Distribute the circumference “C” across four equal surfaces.

B
A

Measure the highest and lowest point of the valve (dimensions A and B).

B
A

Mark off the highest and lowest point on the sheet material.

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Plot dimensions D with the aid of a compass on the intersection of the highest and lowest
point on the four dividing lines.

Cut this shape out at a slightly oblique inwards angle.

First seal surface “A” and press lightly together and then seal surface “B” using the wet
sealing technique.

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3.10 Tank / vessel

Length of arc

Thermaflex strip

*Approx. 5 cm
across the
welded seam

* These dimensions also apply to tanks with a diameter of max. ø 1.5 m and the dimen-
sions increase as the diameter increases.

Fully sealed

Length of Thermaflex
strip = ø circle

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4. Material
specifications of
Thermaflex products
4.1 Tube / sheet insulation AC
4.2 Thermaglue
4.3 Thermaflex pipe support
4.4 Thermaclean
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4.1 Tube / sheet insulation AC

Tube insulation is available to 114 mm and a wall thickness of 25 mm.
Sheet insulation is available with a 5 mm to 38 mm wall thickness and a standard 1
meter width.
For more information, visit: www.thermaflex.com

Technical characteristics
Thermal conduction coefficient (λ): 0,034 W/mK at 0ºC
0,038 W/mK at 40ºC

Water vapour diffusion resistance factor (μ): >7000

Temperature range: -80˚C tot +95˚C

UV resistance: > 10 years
Fire behaviour: Dutch NEN 6065 standard: Flame spread rating Class 1
Flame propagation rating Class 2
NEN standard: Smoke density: DL-max = 1.5 m-1

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4.2 Thermaglue
Thermaglue (Thermaflex Adhesive 474) is a contact adhesive. Thermaglue should not be
applied at temperatures below +5°C and the storage temperature should be between
+10°C and +25°C.
Contact your supplier for more information.

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4.3 Thermaflex pipe support

Available with a wall thickness of 13, 19 and 25 mm
and a pipe diameter of 10 to 14 mm.

4.4 Thermaclean
No information about Thermaclean available as of yet.

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Notes:

Thermaflex AC
 Accredited by the
ISO 9001 Dutch Council for
Certification

ISO 14001

Thermaflex Isolatie bv
Postbus 531 5140 AM Waalwijk
T 0416-567777
F 0416-567788
E sales.nl@thermaflex.com
I www.thermaflex.com

CODE: TF020407/1000