When people ask me what I do for a living my response is, “Go inside any commercial building or garage and look up.” It may not be glamorous, but it is extremely important. The primary reason for insulated pipe supports is to support the weight of the pipe. The secondary reason is to provide continuous insulation throughout the system. In addition, many pipes expand and contract as the temperature becomes hotter or colder. Without an insulated pipe support, this expansion and contraction may stress the pipe and may cause damage. Insulating a complete system is key to maintaining insulation’s benefits. The insulated pipe support is essential to the proper functioning of the entire hanger assembly.
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The most important thing that we have learned from listening to our customers for more than 26 years is that when it comes to insulated pipe supports, a seamless and integrated system design is vital to the success of the installation, function, and long-term viability of the product. This creates a functional support and also adds aesthetic value to the overall installation.
There are 3 distinct market segments within the contracting community for utilizing insulated pipe supports. They each have unique requirements and needs specific to the installation.
The mechanical trade installs the hanger assembly. This includes steel, cast iron, and stainless steel, copper, and plastic pipes.
The plumbing trade installs 3 types of pipe, with supports required for all 3. This includes copper, cast iron, and thermoplastic.
Per ASTM C-585, the dimensional standard for pre-formed thermal insulation for pipes and tubing, insulated pipe supports must match the outside diameter of the pipe and installation. This is important because each support needs to fit the pipe without being too loose or tight. Without a proper fit, the pipe has unnecessary stress that could cause it to crack or break.
In addition to controlling temperature and saving energy, 2 of the great advantages of insulated pipe supports in this industry are ease and time savings. Insulated pipe supports installed on a clevis hanger are incredibly simple to install. The contractor doesn’t have to work directly with the pipe hanger and the installation process only requires making a butt joint between the pipe insulation system and the insulated support.
When utilizing insulated pipe supports, there are many important considerations to weigh.
Flame/Smoke Rating per ASTM E84—This test measures both a flame spread index and a smoke developed index of the flat material being tested. Various factors, including location within a building, determine the flame/smoke indices required. In plenums, pipe insulation must meet a flame/smoke index no greater than 25/50.
Vapor Retarders—Vapor retarders greatly reduce the flow of moisture from the ambient environment into the insulation system. This is important to prevent mold and pipe corrosion, to reduce the likelihood of surface condensation on the insulation system, and to improve the longevity of the insulation system. The standard is a maximum of a 0.02 perm rating for the vapor retarder.
Insulation within the Support Must Carry the Weight of the Pipe—Many factors must be considered related to supporting the weight of the pipe. These include the span between supports, shield length, safety factors, pipe size and schedule, pipe contents, and more. Remember that you are not just supporting the pipes, but the fluid as well. Taking shortcuts to save time or money by placing supports further apart without using commensurately higher strength insulation at the supports can cause deterioration and breakage of the insulation at the support locations.
Seismic Conditions—Seismic conditions must be addressed. You must make sure the hanger assembly has the ability to maintain its integrity in an earthquake.
Not all insulated pipe supports are equal. Here are some important facts to consider.
Fire Rating—Make sure the product you are using is tested by the manufacturer per ASTM E84. The product must be tested for fire rating.
We often run across products that are foam based or use wood blocks. Keep in mind that foam-based products have widely varying flame/smoke ratings and wood blocks are not a fire-rated product. Even worse, wood blocks provide a food source for mold.
Vapor Retarder—Another critical consideration is the insulation vapor retarder. Insulation vapor retarders are generally stressed on systems that run below ambient temperature. A sealed vapor retarder is the first line of defense against water vapor intrusion and corrosion under the insulation. These would be most prevalent on systems operating between 100˚F and 300˚F. The best solution is a full sealed vapor retarder through the hanger. It should extend past the protection shield so that it seals the entire insulation system.
Different types of effective vapor barriers include:
You will sometimes see PVC jacketing and galvanized metal offered as a vapor barrier. Keep in mind that these products are not vapor retarders and should not be used for this purpose.
One of the advantages of using calcium silicate is that this product is dense and provides a great deal of structural support with a compressive strength of 100 PSI. The dense nature of this product means that the pipe support doesn’t have to be as long because it provides structural strength. We recommend the use of this product in the majority of our hot applications and cold applications with a vapor barrier.
Polyisocyanurate is a good option for cold and cryogenic applications. This product is closed cell, which is beneficial because it limits the moisture intrusion. Some grades of PIR have 25/50 flame/smoke ratings and most grades meet a flame/smoke rating of Class A/Class 1. Also keep in mind that in an installation, you must match the density of the foam used in the supports to the forces exerted at these locations. Larger spans between supports usually will require greater compressive strength from the insulation so this must be considered. The larger the pipe span, the more you must increase the density to support the weight of the pipe. Density ranges from 2 ½ to over 30 pounds.
This product is a good option for cold applications such as refrigeration and chilled water. Up to 3 inches thick phenolic, which is the most that would be needed in these applications, has a flame/smoke rating of ≤25/50, so it can be used as pipe insulation in commercial building areas.
While I do not often use it, cellular glass is a closed-cell non-combustible foam of glass. It is used in both above- and below-ambient systems as insulated pipe supports for small- to medium-diameter piping.
There are multiple governing bodies within this industry that we rely on for building or pipe support standards.
ASHRAE publishes standards and guidelines that relate to HVAC systems and issues. These standards are part of many building codes.
ANSI is a nonprofit organization that oversees many of the standards that we use. ANSI does not develop standards but works with those developing standards to ensure the procedures used are solid. ANSI accreditation indicates that the procedures used meet requirements for openness, balance, consensus, and due process.
ASTM develops over 12,000 voluntary consensus standards, many of which apply to the pipe-support industry. These are referenced frequently and many become mandatory by corporation and government contracts.
The American Welding Society maintains code and certification procedures, which help to provide industry standards for the welding and joining of metal, plastics, and other materials.
The MSS of the valve and fittings industry references all of the pipe support standards when outlining procedures for manufacturing components and systems for the field.
These standards have been a driving force in our industry for nearly 60 years since they were first set in . Here are some key components of the standards that apply to the insulated pipe support industry.
In , the MSS standards were updated to allow for an alternative type 40 shield. They require:
Insulated pipe supports in the industrial market are unique and special in many ways. The majority of applications are highly customized and engineered. We rarely see “off the shelf” products for this market. Some of the considerations for the industrial market include:
In the higher-temperature industrial market, denser materials are made from high temperature, calcium silicate (Type II, Grade 5 and 6) board material. Boards start at a compressive strength of 450 PSI and go as high as PSI. Pipe loads determine the length of insulated pipe support. The larger the pipe, the longer the support must be in order to properly hold the weight. The MSS sets the standards for minimal allowable loads between hangers.
In applications that produce incredibly low temperatures, another unique set of requirements is presented. The density of poured urethane foam starts at 2 pounds per cubic foot (PCF) and goes to 30 PCF. Multilayer and low permeance vapor retarders are required in order to keep ice from forming and to minimize moisture intrusion into the insulation system.
For hot and cold industrial applications, insulation thickness varies widely depending on many factors. It can be as little as ½ inch to nearly unlimited thickness depending on the project.
For a contractor, one of the biggest advantages of utilizing an insulated pipe support is cost savings. Whether the application is for mechanical or plumbing, the presence of the insulated pipe supports reduces the amount of labor required by the contractor. Depending on the size of the project, this can result in large cost savings or the ability to lower your bid and win projects.
As a building or facility owner, insulated pipe supports help to conserve energy. They will continuously help to reduce heating and cooling costs in the buildings where they are installed. A properly insulated system means equipment doesn’t have to work as hard, therefore reducing maintenance costs. This also helps avoid down time and extends the life of the equipment and the insulation system.
For a successful outcome, make sure to partner with companies that have deep expertise in this industry. Know the markets you serve and make sure to be knowledgeable about the relevant standards that apply.
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Piping systems can be deceptive. When they’re running smoothly, it’s hard to see the wear, danger, and deterioration subtly creeping in. However, they’re up against powerful natural hazards.
Pipes carry corrosive materials and often face extreme external climates. Movement and vibrations are inherent, and as heavy metallic structures move, they wear down, corrode, and risk breaking open.
At the same time, changes in temperature stand as another foe to piping systems. Temperature changes can cause heat transfer, promote damaging friction, and create destructive ice formation.
With pipes strained by so many forces, piping systems are up against the constant danger of ruptures and on-site disasters. The good news? Pipe supports can protect pipes from many of the most menacing issues. And as soon as you understand how to fight off the most common destructive forces, you can begin to protect them, too.
Galvanic corrosion is an electrochemical process by which one metal causes another metal to corrode and break down. This type of corrosion requires three things: an anode (one metal), a cathode (a second metal), and an electrolyte (usually water, bacteria, or grime).
Simply put, metals have different physical properties. A more noble metal (the cathode) has a tendency to hold on to its electrons and pull electrons from other sources, whereas more basic metals (the anodes) are eager to give their electrons away. That means that when you connect these dissimilar metal types in an electron-heavy environment, the more basic metal will give its electrons to the more noble metal. When a metal gives up its electrons, galvanic corrosion begins, and the metal will rust.
Pipe restraints and fittings can help reinforce systems and stop destruction. However, it’s possible to put too much pressure on these tools, and that can cause more serious problems. Sloppy installation can easily lead to worn parts and broken fittings, which can set off a chain reaction that snaps or collapses other parts within your piping system.
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It’s important to get past the common belief that stopping pipe movement altogether is always the best option. Instead, fittings should promote natural, axial movement and reduce friction whenever possible. At the same time, supports need to be able to hold up to vibrations, pressure, and pipe weight.
Pipe supports are built to counter these forces, and quality piping solutions will lengthen the lifespan of your whole piping system.
First, supports should reduce corrosion. This usually means adding insulation that discourages metal-on-metal corrosion. Because galvanic corrosion occurs when two dissimilar metals interact, supports can stop this destruction by insulating pipes.
Pipe supports can also strengthen systems by physically reinforcing them. In some instances, they can add a protective barrier between the pipe’s surface and surrounding harsh surfaces. In this way, supports can prevent ruptures and tears.
At the same time, an efficient support will reduce friction and the wear that results. When a pipe rubs against surrounding surfaces, it becomes vulnerable to cracks, tears, and corrosion. With every small opening that forms, corrosive materials are able to seep in and cause damage. Pipe supports also help pipes move more fluently so they can avoid ruptures or fitting failures.
Wondering how pipe shoes fit into this equation? Pipe shoes should have the same broad goal as other pipe supports. However, they accomplish these goals in a unique way.
For instance, your pipes may be made up of carbon steel. If the surrounding I-beams are made of a more noble metal, like stainless steel, then resting bare carbon pipes directly on beams is dangerous. In time, the electrons from your carbon pipes will pass into the more noble stainless-steel beam. This results in a carbon pipe that’s eaten away or weakened. In this case, pipe shoes lift carbon pipes off of the dissimilar metal of the beam and protect them.
Even if metals are compatible, shoes can prevent destruction. Pipes can move for any number of reasons. Vibrations can cause pipes to shift, heat changes can cause pipes to swell or contract, and sloshing liquids inside pipes can create movement. As pipes move, pipe shoes keep different materials from grinding against each other. In the same way, they minimize the movement and direct wear that comes with temperature changes.
This is especially apparent in systems that face extreme cold, like liquid natural gas (LNG) plants. In these cases, even if the connected metals get along, they encourage damaging ice formation. Because metals are conductive, the metal of the beam will encourage heat transfer in pipes. Heat naturally wants to flow between metals. This means metals that touch encourage thermal contraction, ice formation, moving pipes, and surface damage. Well-insulated pipe shoes will help stabilize pipe temperatures and keep heat from exiting or entering pipes.
Regardless of temperature and external conditions, bare pipes that rest on surrounding objects are subject to grinding, friction, and wear. Temperatures and corrosive environments amplify damage. In turn, pipe shoes keep pipes from grinding, tearing, and leaking.
Finally, and most importantly, pipe shoes can allow for a safer working environment because they make it possible to install insulation and personal protection cages on pipe that is too dangerous for workers to be exposed to or touch. By elevating the pipe, the line can be fully encapsulated—creating a safer working environment and reducing the risk of injury.
Overall, by lifting pipes off of other surfaces, pipe shoes help pipes maintain their integrity. They prevent metal-on-metal contact and reduce friction damage. Essentially, they can insulate pipes, give them structural support, and promote natural movement.
Although the advantages of pipe shoes outweigh the disadvantages, there are still some things to look out for. When looking at the potential disadvantages of pipe shoes, it’s good to remember that materials matter. Unprotected metal shoes have the potential for corrosion if they’re not paired with the right insulation.
At the same time, there are natural concerns to consider when pipe shoes are welded directly to supporting beams. Anytime welding occurs, there is potential for stress cracking, especially in chloride-heavy environments like sea air. This means it’s usually well worth making sure that all welds are heat treated and welded by professionals.
Traditional metallic pipe shoes have been common in the industry for decades. In the past, manufacturers have designed metallic pipe shoes using structural shapes from cost-effective materials. For instance, manufacturers might use I-beams or channel beams to form a shoe. Right away, it’s easy to see the benefits of using these simple materials to form a pipe shoe. They’re made of materials that are easy to access and a wide range of suppliers can make them. They also tend to be fairly low cost and aren’t overly complex to install or produce.
However, there are some disadvantages to these traditional shoes. First, using any type of unprotected metal for a shoe can be dangerous. Pairing up dissimilar metals can lead to corrosion underneath the welded shoe. They also aren’t ideal for systems that undergo heavy temperature changes because metal-on-metal pairing can encourage ice formation and wear
Beyond these relatively simple traditional shoes, there are more advanced T-style metallic pipe shoe designs. Often referred to as T-slides, some of these metallic shoe options feature cradles and U-bolts, or two clamps to hold the pipe in place.
Beyond having a slightly more intentional design than that of traditional shoes, these metallic shoes have advantages of versatility. Many T-style pipe shoes can be paired with wear pads or other liners. This eliminates metal-on-metal contact, allows for better control of a shoe’s movement, and can provide greater protection to the piping system.
Other metallic shoes can be built from other channel material or plate to any custom dimensions. The major advantage of this is that you get exactly what you want. But as is the case with anything custom, you will have to pay for that flexibility, and the price can become prohibitive when compared to that of other options.
Metallic shoes can be welded directly to the pipe in a pipe fabrication shop or in the field. When installing, it’s always a good idea to use professionals and welders who uphold industry standards such as MSS SP-58. Additionally, using U-bolts or clamps to install piping is no more complicated than using a wrench.
Composite pipe shoes offer a corrosion-resistant alternative to metallic shoes. Still, composite materials are often misunderstood. Because they don’t have the same rigid makeup of metal, it’s common for some to assume that composites are weak. However, they can actually be extremely durable. Here’s a look at some popular composite pipe shoes that are available today:
The ProTek composite pipe shoe is a UV-resistant, non-metallic pipe support that is built to withstand heavy pressure and especially hot and cold temperatures. It has 150,000 pounds of compressive strength, a temperature range of -320 to +400 degrees Fahrenheit, and is resistant to chemical attack. Because of its makeup, it has become a popular option for corrosion-heavy systems such as onshore and offshore refineries and plants.
They also offer an advantage in the way they fit against pipes. They fit against piping snugly, with their inner diameter crafted to fit the pipe’s outer diameter precisely. This essentially keeps corrosive elements from sneaking in between the pipe and the support. With a precise fit, the shoe seals off vapors and stops corrosive materials from settling on pipes.
ProTek shoes don’t require specialized installation. They’re lightweight and don’t require welding. The installation process includes simply fixing the shoe to the pipe using steel bands and silicone.
CryoTek composite pipe shoes have quickly become a popular item in cryogenic piping systems that involve gas liquefaction, LNG terminals, carriers, and ethylene plants.
They have the same corrosion protection and operating temperature advantages as ProTek shoes (-320 to +400 degrees Fahrenheit). However, CryoTek shoes are a sturdy option that can handle a bit more of an axial load than ProTek shoes can. In fact, they have a maximum compressive strength of 27,500 pounds per square inch. They include well-defined insulation that protects piping. Their design also makes them a sturdy option for a stop or anchor. Despite their robust design, these supports are also easy to transport.
Additionally, they offer an advantage in their ability to eliminate heat sync. Their insulation features banding slots inside the shoe, which stay inside the insulation and prevent any heat from entering or escaping.
Because both CryoTek and ProTek shoes are much lighter than their metallic counterparts, they offer an installation advantage over traditional metal shoes. Installation also doesn’t require welding or specialized labor.
CryoTek shoes are installed using a powerful epoxy. They can be bonded using a static epoxy mixer, which takes the guesswork out of mixing two-part epoxy. From there, the bonded shoe is reinforced with steel metal bands.
Pre-insulated pipe shoes generally consist of hefty stainless steel bodies and an encapsulating insulation foam between the pipe and the stainless steel body to keep the line insulated.
The biggest advantage of pre-insulated shoes is that they come installed and ready to go.
However, with their size and makeup comes some disadvantages. On jobs that require transportation, they can be difficult to maneuver, and setting them in place requires specialized lifting equipment. They also generally come with a relatively hefty price tag.
Pre-insulated pipe shoes need to be installed by professionals on-site or pre-fabricated and moved. They generally require heavy, specialized equipment, precise procedures, and professional welders.
When considering your budget, it’s a good idea to keep total costs in mind. Of course, that starts with the price of each unit. However, it also means deciding how many units you’ll need, the cost of installation, and the long-term costs that may result down the line. Here’s a general look at the costs of pipe shoes:
Metal T-style shoes can be some of the most cost-effective shoes out there. However, some low-end T-styles can run the risk of corrosion on their own. Countering that disadvantage leaves room for creativity. It’s a good idea to factor in corrosion protection options when weighing this shoe’s overall costs.
The price of metal T-style shoes with clamps can vary, especially depending on which liners you decide to pair them with. However, as a whole, they tend to have a midrange cost, plus the ability to make upgrades by pairing them with things like wear pads or slide plates.
At the composite end, ProTek shoes tend to be the more affordable option. In fact, they often come in under or close to the price of their metallic counterparts. CryoTek prices can vary, but they tend to be a good deal more expensive than their ProTek counterparts.
This is the simplest application for pipe supports and its objective is simply to support the load of the pipe and allow for the free movement of the piping system.
In both resting and guided supports, pipe shoes can be used in conjunction with slide plates fastened to the underside of the shoe’s base. These plates are generally sodium-etched PTFE that’s bonded to 10-gauge carbon or stainless steel. The PTFE is usually paired with a polished stainless steel plate that’s attached to the beam to allow for one of the lowest coefficients of friction possible. At the same time, it promotes more natural movement and less wear.
These supports are used when you want to restrict most, if not all, pipe support movement. These can be fixed to a point—preventing movement in the axial, lateral, and vertical directions.
Beyond costs, there are several other factors to weigh when making your final pipe shoe selection. First, always think about how well the shoe’s composition, design, and features will fit into your specific system.
For instance, if you’re operating an offshore rig that’s exposed to salt-heavy conditions, you may want to place more emphasis on corrosion-resistant materials. At the same time, if your system is fairly calm and protected from the elements, it may be smarter to focus on shoes with a lower upfront cost.
With those factors in mind, here are some helpful questions to ask in order to get more out of your pipe shoes:
As soon as you’ve picked out the right shoe, you can start to benefit from its unique advantages. For instance, metallic shoes with clamps can be enhanced by adding specialized liners or wear pads. These additions stop metal-on-metal contact and help both pipes and supports last longer.
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