Thermal Duty
Heat loss or gain, surface temperature, process stability, condensation, freeze protection and cooldown or warm-up behaviour.
Thermal · Cold · Cryogenic Engineering
Industrial Insulation System Design
ERATHERM develops project-specific insulation systems by coordinating thermal duty, operating envelope, material behaviour, moisture control, mechanical interfaces, maintainability and lifecycle cost within one design basis.
From concept selection and calculations to specifications, detail-design inputs, material supply, installation and performance verification.
Design Basis
Thermal Modelling
System Architecture
Lifecycle Verification
Design → Supply → Installation
1,000,000+m² Field Application Experience
Hot · Cold · CryogenicService-Specific System Architecture
Concept → IFCTraceable Engineering Development
One Integrated ScopeEngineering, Supply, Application and QA/QC
The System, Not a Stand-Alone Product
Why Insulation System Design Requires More Than Material Selection
Installed performance is created by the complete assembly: substrate preparation, insulation layers, joints, vapour control, supports, cladding, penetrations, drainage and maintenance details.
A material with excellent laboratory properties can still underperform if the design conductivity is used incorrectly, joints open during thermal cycling, water enters through a termination, a support creates an uncontrolled thermal bridge, or maintenance access destroys vapour-barrier continuity.
ERATHERM therefore designs insulation as a coordinated engineering system. Calculated thermal performance is developed together with constructability, exposure, mechanical behaviour, corrosion risk, inspection access and the expected operating life.
01 · Design Basis
Defining the Operating Envelope Before Selecting the System
The design basis records what the system must achieve, the conditions it must survive and the information that remains to be verified.
Equipment and geometry
Minimum, normal and maximum temperatures
Start-up, shutdown and cycling profile
Ambient temperature, humidity and wind
Indoor, outdoor, marine or chemical exposure
Heat loss, heat gain or process limits
Surface-temperature and contact criteria
Condensation and freeze-protection duties
Fire and acoustic requirements
Substrate, coating and corrosion strategy
Inspection and maintenance philosophy
Design life, codes and owner specifications
Controlled assumptions: Missing or uncertain inputs are listed in an assumptions and hold-point register instead of being hidden inside the design.
02 · Coordinated Design Decisions
Five Interdependent Decisions Define the Insulation System
Changing one decision can alter layer temperatures, material suitability, support geometry, vapour control, cladding and maintenance requirements.
Material Architecture
Design conductivity, temperature capability, layer arrangement, dimensional stability, compressive behaviour and compatibility.
Moisture & Corrosion Control
Substrate coating, vapour-retarder continuity, water shedding, drainage, sealed terminations and inspectability.
Mechanical Interfaces
Supports, shoes, rings, penetrations, cladding, fasteners, expansion or contraction zones and removable components.
Lifecycle Strategy
Constructability, planned maintenance, replacement logic, energy economics, spares, inspection access and end-of-life decisions.
Integrated decision chain
Operating Envelope→Performance Criteria→System Architecture→Interface Details→Verification Plan
03 · Performance Engineering
Calculations Establish the Required Performance—Not a Generic Thickness
The required analysis is selected from the actual service and project acceptance criteria.
Heat Loss or Heat Gain
Steady-state thermal duty for flat, cylindrical and spherical geometries under defined ambient conditions.
Surface Temperature
Outer-surface prediction for process, personnel-contact and condensation-related criteria.
Layer Temperatures
Temperature profile through multilayer systems to check each material, adhesive and membrane within its qualified range.
Dew Point & Vapour Control
Surface margin, vapour diffusion and system continuity assessment for cold-service conditions where applicable.
Thermal Bridges
Evaluation of supports, penetrations, metal paths and discontinuities that are not represented by one-dimensional field calculations.
Economic Thickness & LCC
Capital, energy, maintenance and replacement scenarios compared over the agreed study period and economic assumptions.
04 · Service-Specific Architecture
Different Operating Regimes Require Different Failure-Control Strategies
Heat Retention, Safe Surfaces and Water Management
- Design conductivity at operating mean temperature
- Single- or multilayer arrangement and joint staggering
- Thermal expansion and high-temperature interfaces
- Weatherproof cladding, drainage and CUI mitigation
Condensation Control and Vapour-Tight Continuity
- Dew-point and surface-temperature margin
- Low-permeance materials and continuous vapour control
- Sealed joints, penetrations and termination details
- Load-bearing thermal breaks at support locations
Heat-Leak Control Under Extreme Temperature Difference
- Contraction, differential movement and material compatibility
- Cellular, multilayer or vacuum-system architecture
- Penetration, support and boundary heat-leak control
- Drying, cleanliness, vacuum and test requirements
Repeated Access, Vibration and Thermal Cycling
- Movement-tolerant joints and fastening strategy
- Removable covers at valves, flanges and inspection points
- Identification, dismantling and reinstatement sequence
- Post-maintenance inspection and performance recovery
05 · Complete System Architecture
Designing Every Layer and Interface as One Assembly
The exact build-up changes by service, but the design review follows the full path from the process boundary to the external environment.
- 1Substrate & Coating
Surface condition, preparation, coating compatibility and corrosion-control basis.
- 2Primary Insulation
Product form, layer thickness, joints, interfaces and design-property basis.
- 3Vapour / Moisture Control
Retarder, membrane, sealant, joint and penetration continuity where required.
- 4Supports & Thermal Breaks
Load transfer, compression control, movement and local heat-flow management.
- 5Protective Cladding
Material, thickness, seams, overlaps, drainage, fastening and external exposure.
- 6Access & Verification Features
Removable areas, inspection ports, identification, hold points and reinstatement details.
06 · Material Selection Matrix
Selection by Verified Design Properties and System Compatibility
ERATHERM compares candidate systems using approved product data, relevant test methods and project conditions—not a universal “best material” ranking.
Thermal
- Design conductivity at mean temperature
- Service-temperature range
- Ageing and thermal-cycling behaviour
- Required thickness and layer count
Moisture
- Water absorption and wicking
- Water-vapour permeance
- Joint and seal compatibility
- Dry-out and recovery behaviour
Mechanical
- Compressive resistance
- Dimensional stability
- Vibration and impact exposure
- Fabrication and installation tolerances
Durability & Safety
- Substrate and chemical compatibility
- Reaction-to-fire requirement
- UV, weather and marine exposure
- Inspection, maintenance and replacement
Why no generic conductivity and temperature table?
Thermal conductivity and maximum-use temperature are product-specific. Density, mean temperature, ageing, moisture, orientation and test method can change the value used in design. Final selection is therefore based on the approved manufacturer data and the project acceptance criteria.
07 · Engineering Workflow
A Traceable Path from Requirements to Verified Installation
- 01
Input & Gap Review
Process data, equipment, environment, specifications, responsibilities and missing inputs.
- 02
Performance Basis
Thermal, condensation, safety, corrosion, maintenance and lifecycle acceptance criteria.
- 03
Thermal Analysis
Heat flow, surface and layer temperatures, vapour control and sensitivity cases as required.
- 04
Option Evaluation
Candidate materials and architectures compared on performance, risk, constructability and cost.
- 05
System Definition
Insulation, coating, vapour control, supports, cladding, joints and maintenance interfaces.
- 06
Design Package
Design basis, calculations, specifications, typical details, schedules and QA/QC requirements.
- 07
Field Verification
Submittal review, site support, inspections, testing, deviations and as-built close-out.
08 · System Design Deliverables
A Coordinated Engineering Package for Owner, EPC and Site Teams
The package is scaled to concept, FEED, tender, detail design, procurement, construction or brownfield-rehabilitation requirements.
Design Basis Memorandum
Operating envelope, performance criteria, assumptions, exclusions, interfaces and document hierarchy.
Thermal Calculation Report
Inputs, property basis, cases, heat flow, temperatures, condensation checks and sensitivities.
System Selection Report
Option matrix, technical risks, material architecture and documented selection rationale.
Insulation Class & Service Matrix
Line or equipment duty linked to insulation build-up, cladding, vapour control and accessories.
Technical Specification
Materials, qualification data, application requirements, tolerances, interfaces and acceptance criteria.
Typical Design Details
Joints, supports, penetrations, terminations, expansion zones, drainage and removable interfaces.
BOM / MTO Basis
Engineering quantity structure, material descriptions, accessories, allowances and traceability rules.
ITP & Verification Plan
Hold points, inspections, measurements, records, nonconformance control and close-out requirements.
Need fabrication-ready documents?
Explore Insulation Shop Drawing Preparation →
System design establishes the rules; the dedicated shop-drawing service converts approved inputs into project-specific fabrication and installation drawings.
09 · Technical Framework
Standards Applied Within Their Defined Scope
No single standard defines every insulation system. The governing edition, contractual hierarchy and project-specific acceptance criteria are confirmed in the design basis.
ASTM C1696-26
Industrial thermal-insulation guidance covering material selection, system design, protective coverings, application, inspection and maintenance.
ASTM C680-23aComputer-based estimates of heat gain or loss and surface temperatures for insulated flat, cylindrical and spherical systems.
ISO 12241:2022Calculation rules for heat-transfer-related properties of building equipment and industrial installations.
ISO 15758:2014Water-vapour diffusion calculation for cold-pipe insulation systems where its stated assumptions and temperature scope apply.
ISO 13732-1Assessment of human responses to contact with hot surfaces when touch-temperature criteria are required.
AMPP SP0198Systems approach to corrosion control under thermal insulation and fireproofing materials.
CINI ManualIndustrial insulation guidance, product specifications, system construction drawings and CUI-related practices.
Project Requirements
Owner specifications, equipment data, piping and pressure-equipment codes, fire criteria and manufacturer instructions complete the framework.
10 · Applications
Insulation System Design Across Critical Industries
Refining & Petrochemicals
Power Generation
LNG, Hydrogen & Cryogenics
Chemicals & Fertiliser
Cement & Metallurgy
Mining & Mineral Processing
Marine & Offshore
Nuclear & SMR
Defence & Aerospace
Data Centres & Critical Cooling
The ERATHERM Difference
System Engineering Informed by Real Fabrication and Site Behaviour
Material-Neutral Evaluation
Candidate products are compared against verified project duties and interfaces before the system is selected.
Design-to-Site Continuity
Field experience informs tolerances, access, water shedding, supports, sequencing and reinstatement requirements.
Integrated Delivery
Engineering, calculation, material supply, fabrication, installation, inspection and verification can be managed under one scope.
Traceable Decisions
Inputs, assumptions, selection rationale, revisions, hold points and acceptance records remain visible throughout the project.
Frequently Asked Questions
Industrial Insulation System Design
What is industrial insulation system design?
It is the coordinated engineering of the complete installed assembly, including the substrate and coating interface, insulation materials and layers, vapour or moisture control, supports, cladding, joints, penetrations, removable areas and verification requirements.
How is system design different from an insulation thickness calculation?
A thickness calculation predicts defined thermal results under stated conditions. System design uses those results together with material behaviour, environmental exposure, corrosion risk, mechanical interfaces, installation, maintenance and lifecycle requirements to define a buildable and verifiable assembly.
What information is required to start the design?
Typical inputs include equipment geometry, operating and design temperatures, ambient conditions, process limits, insulation objectives, substrate and coating data, exposure, supports, maintenance requirements, design life, project standards and owner specifications.
How does ERATHERM select an insulation material?
Candidate systems are compared using approved product properties at the relevant temperature, moisture behaviour, mechanical resistance, chemical and substrate compatibility, fire requirements, constructability, maintenance needs, availability and lifecycle cost.
Can ERATHERM design hot, cold and cryogenic insulation systems?
Yes. ERATHERM develops systems for hot service, cold and sub-ambient service, cryogenic and vacuum applications, cyclic equipment, heat-traced systems and combined thermal-acoustic duties. The calculation method and architecture are adapted to each service.
How is condensation controlled on cold insulation?
Condensation control combines an appropriate surface-temperature margin with low-permeance system selection, continuous vapour control, sealed joints and penetrations, thermally designed supports and installation QA/QC. Dew-point conditions and relevant diffusion assumptions are defined in the design basis.
How does system design address corrosion under insulation?
The design considers substrate coating, material compatibility, water-entry paths, cladding seams, weatherproof terminations, drainage, inspection access, removable sections and the operating temperature profile. These measures reduce risk but do not replace an owner-specific inspection and maintenance programme.
Can economic insulation thickness and lifecycle cost be evaluated?
Yes. Capital cost, energy value, operating profile, study period, discount assumptions, maintenance and replacement scenarios can be compared. The result is project-specific and should not be presented as a universal savings percentage.
Are cladding, supports and vapour control included in the design?
Yes, when included in the agreed scope. The system design can define cladding materials and performance, support and thermal-break concepts, vapour-retarder continuity, joints, penetrations, expansion or contraction zones, drainage and maintainability requirements.
Can ERATHERM provide engineering, materials, installation and verification?
Yes. ERATHERM can provide a complete solution covering input review, calculations, system design, specifications, drawings, material supply, fabrication, field installation, QA/QC, commissioning support and as-built close-out.
Start with the Operating Envelope
Request an Industrial Insulation System Design Review
Share your process temperatures, equipment list, drawings, environmental conditions and performance targets. ERATHERM will define the calculations, design package and delivery scope required for your project.