Calcium Silicate Pipe Cover
A Calcium Silicate (CS) Pipe Cover is a rigid, pre-formed insulation product manufactured from a blend of silica, lime (CaO), and reinforcing inorganic fibers. It is hydrothermally molded and autoclaved into two semi-cylindrical halves designed to precisely fit industrial piping. CS Pipe Cover is the industry standard for load-bearing, high-temperature pipe insulation due to its exceptional compressive strength, low thermal conductivity, and structural rigidity up to its maximum service temperature (MST).à
Main Components and Structure
The material’s physical strength and thermal efficiency derive from its micro-porous structure based on Calcium Silicate Hydrate (CSH) phases.
| PROPERTY | DESCRIPTION | PRIMARY ADVANTAGE |
| Form | Pre-formed semi-cylinders (two halves) | Allows for quick, snug fit onto existing and new piping. |
| Compressive Strength | HIGH | Can support the weight of metallic jacketing and personnel traffic without crushing. |
| Thermal Conductivity (k) | LOW | Efficient insulation through a high volume of microscopic air pores. |
| Non-Combustible | EXCELLENT | Purely inorganic; safe for process environments. |
| CLASSIFICATION | MAXIMUM SERVICE T | PRIMARY USE |
| Standard Grade | ~650°C (1200F) | Medium-temperature steam and process piping. |
| High-Temp Grade | ~1000°C (1832 F) | High-pressure steam and extreme process lines. |
Advantages and Key Characteristics
CS Pipe Cover is the preferred insulation solution for large industrial piping systems that require a robust, long-lasting, and structurally sound thermal barrier.
- Durability and Load-Bearing: Unlike flexible materials, CS sections are rigid and highly resistant to mechanical abuse, making them ideal for pipes that require frequent maintenance access or are in areas with personnel traffic. They are critical for supporting the outer metal jacketing.
- Excellent Thermal Performance: Provides reliable insulation, reducing heat loss from pipes and ensuring stable process temperatures while keeping the outer surface safe to touch.
- Corrosion Under Insulation (CUI) Mitigation: The material is non-corrosive to the underlying metal, and its inherent resistance to moisture helps prevent the accumulation of water on the pipe surface, significantly reducing CUI risk.
- Speed and Ease of Installation: The pre-formed sections are simply placed around the pipe and secured with bands or wire before the outer jacketing is applied, offering a faster installation process than cutting large flat boards.
Typical Industries and Applications
CS Pipe Cover is a staple in energy and process industries:
- Oil and Gas / Petrochemical: Insulation for process pipes, especially steam lines and hot utility lines in refineries and plants.
- Power Generation: Insulation for main steam lines, high-pressure feedwater lines, and auxiliary piping in power plants.
- Chemical Industry: Insulation for chemical transport lines and reactors requiring precise temperature control.
Key Data Sheet Properties to Consider
Selection is based on the pipe size and required mechanical/thermal performance:
- Maximum Service Temperature (MST): CRITICAL VALUE. Must exceed the pipe’s operating temperature.
- Pipe Diameter and Wall Thickness: The cover must match the outer diameter (OD) of the pipe to ensure a snug fit.
- Compressive Strength: High compressive strength is required to resist crush damage during installation and maintenance traffic.
Technical Guidance: Pipe covers must be installed in a staggered-joint configuration (joints in the inner layer should not align with the joints in the outer layer, if multi-layer) to break the heat path and prevent heat loss. A vapor barrier must be applied over the CS to prevent moisture from the atmosphere from condensing and compromising the insulation value in cold or fluctuating environments.
✨ Customization Services
We offer product customization services, allowing you to tailor the appearance, dimensions, or specific markings of items like refractory shapes or bricks. This includes options for incorporating specific geometric requirements to ensure seamless integration into your process systems.
🔬 Sampling for Testing & Validation
Free product samples are available for thorough testing and validation. This allows you to confirm the quality, compatibility, and performance of our materials—such as specific bricks, castables, or raw materials—before committing to a full order.
💡 Expertise in Refractory Solutions
Leverage our deep expertise to receive detailed, application-specific refractory solutions. We move beyond just selling products by providing comprehensive plans that encompass material selection, installation guidance, and performance optimization to maximize the lifespan and efficiency of your high-temperature processes.
Rabatec products are exclusively manufactured in facilities that have achieved rigorous ISO certifications across Quality (ISO 9001), Environmental Management, and Occupational Health & Safety. This commitment ensures every product, from refractory bricks to specialized equipment, meets the highest global benchmarks for performance, sustainability, and workplace safety.
📦 Logistics Excellence: Shipping, Packaging, and Marking
Minimizing Risk: We manage all logistics to minimize handling touchpoints and transit shock. Our carriers are pre-vetted for their experience in transporting heavy, fragile, and sensitive industrial materials.
Traceability: Every shipment includes comprehensive documentation and tracking information, providing end-to-end visibility and ensuring precise delivery coordination for your site.
Protection is Paramount: Our packaging strictly follows industry standards to prevent damage, corner chipping, and moisture absorption—especially critical for materials like Basic Refractory Bricks and Refractory Mortars & Mixes.
Robust Palletization: Products are secured on fumigated, high-strength export pallets (e.g., 1100x950mm or similar sturdy dimensions) using heavy-duty strapping and durable protective wrapping (polyethylene sheeting, cardboard, etc.) to withstand long-distance travel and multiple loadings.
Moisture Control: Sensitive materials are protected with appropriate sealing and, where necessary, desiccants or moisture-vapor proof enclosures to maintain the product's integrity until installation.
Clear Identification: All outer packaging is clearly marked on multiple sides with large, legible text for immediate identification and safe handling.
Full Traceability: Markings include all essential data points: Product Name, Quality Grade, Batch Number, Quantity, Net/Gross Weight, Order Number, and the Final Destination/Construction Area. This ensures every pallet can be accounted for and correctly staged upon arrival.
Safety & Compliance: We adhere to all regulatory requirements for marking, labeling, and placarding—especially for any items classified as Dangerous Goods—to ensure full compliance with international and domestic transport regulations.
❓ Frequently Asked Questions (FAQ)
Question | Elaborated Answer |
Q: What is the Refractoriness Under Load (RUL) of your refractories? | A: Refractoriness Under Load (RUL) is a critical property that defines the maximum temperature our materials can withstand while under compressive stress before deforming (softening). Since we offer a wide range of materials—from Alumina-Silicate Bricks to high-performance Silicon Carbide Bricks—the RUL varies significantly. For specific product data, please refer to the product data sheet or submit a quote request for the material you are interested in. |
Q: Where are the Rabatec refractories and materials produced? | A: Our products are primarily sourced from specialized manufacturing plants in China. Crucially, these facilities have all undergone rigorous audits and achieved comprehensive ISO certifications (Quality, Environment, and Safety), ensuring that production adheres to the highest global standards for consistency and performance. |
Q: What refractory materials does the company offer? | A: We supply a comprehensive portfolio of advanced refractory solutions, including: Shaped Products: Alumina & Silica Bricks, Basic & Specialized Bricks (e.g., Magnesia), SiC & Structural Ceramics, and Precast Shapes. Monolithic Products: Refractory Castables, Mixes & Mortars. Insulation: Insulation Fibre and High-Performance Insulation Products. |
Q: How should I choose the appropriate refractory material for my application? | A: Selecting the correct refractory is paramount to process efficiency. The choice depends on three key factors: 1. Operating Environment: Maximum process temperature and thermal cycling (shock). 2. Chemical Attack: Type of slag, molten metal, or corrosive gas being handled (acidic, neutral, or basic). 3. Mechanical Stress: Abrasion, erosion, and static load requirements. We recommend utilizing our detailed refractory solutions service to consult with our engineers for an optimized, application-specific recommendation. |
Q: Which monolithic material should I choose when patching an existing lining? | A: For patching and minor repairs, the ideal monolithic material depends on the parent lining material, the patching depth, and the need for a rapid return to service. Common choices include: Refractory Mortars & Mixes (for minor joints/surfaces) or Plastic Refractories (for areas requiring physical compaction). Always choose a patch material chemically compatible with the existing lining to ensure proper bonding and service life. |
Q: Can I receive product samples before placing a major order? | A: Yes. We gladly provide product samples for your internal testing and validation purposes. This ensures you can confirm the quality, composition, and fit of the material—such as our Refractory Castables or Alumina-Silicate Bricks—in your specific operational environment before committing to a bulk purchase. |
Q: Do you provide certifications to verify material quality? | A: Absolutely. We provide product-related inspection certificates and quality assurance documentation upon request. This verifies that your order has passed all internal quality control checks and meets the required material specifications and industry standards. |
Q: What measures are taken for product protection during transport? | A: We ensure quick, reliable transport by using robust, industrial packaging that strictly follows industry standards. This includes high-strength palletization, heavy-duty strapping, and weather-resistant wrapping to protect fragile items like bricks and mixes from corner chipping, mechanical damage, and moisture during transit. |
