TRADE OF

Industrial Insulation
PHASE 2

Module 4

Insulation – Materials, Science and Application

UNIT: 15

Finishing Materials & Cladding

 Produced by

In cooperation with subject matter expert:

Michael Kelly

© SOLAS 2014
Module 4 – Unit 15 Finishing Materials & Cladding

Table of Contents
Introduction .................................................................................................................. 1 
Unit Objective .............................................................................................................. 2 
1.0  Finishing Materials and Cladding ................................................................. 3 
1.1  Materials .......................................................................................................3 
1.2  Reinforced Aluminium Foil.......................................................................3 
1.3  Mastic and Coating Finishes......................................................................3 
1.4  PVC Sheet ....................................................................................................4 
1.5  Sheet Metal Cladding ..................................................................................4 
1.6  Polyisobutylene Sheet (PIB) ......................................................................6 
1.7  Roofing Felt .................................................................................................6 
1.8  Self Setting Cement ....................................................................................7 
2.0  Materials and Their Applications ................................................................. 8 
2.1  Applications .................................................................................................8 
3.0  Fixings ............................................................................................................ 10 
3.1  Identification and Use of Fixing Products ............................................10 
3.2  Self-Tapping Screws and Rivets..............................................................10 
3.3  Bands, Wire and Wire Netting ................................................................10 
3.4  Mechanical Fasteners................................................................................11 
3.5  Aluminium Foil Tape ...............................................................................11 
3.6  Self-Adhering Laps ...................................................................................11 
3.7  Reinforcing Mesh ......................................................................................11 
3.8  Adhesives ...................................................................................................11 
3.9  Mastics ........................................................................................................12 
4.0  Selection of Suitable Finishing Materials for a Range of Applications . 13 
4.1  Mechanical Abuse Coverings ..................................................................13 
4.2  Corrosion and Fire Resistant Coverings................................................13 
4.3  Fire Resistance ...........................................................................................13 
4.4  Appearance Coverings and Finishes ......................................................13 
4.5  Hygienic Coverings or Finishes ..............................................................13 
4.6  Properties of Protective Coverings or Finishes ....................................14 
Summary ...................................................................................................................... 15 

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 Module 4 – Unit 15 Finishing Materials & Cladding

Introduction
Finishing materials including metal cladding are designed to enhance and
protect the integrity of the insulating material they are covering. There are
many finishing materials on the market which cover every possible system
design and specification. In this unit we will look at the materials available ,
their applications and installation guidelines to ensure that the materials are
applied and installed according to the job specification.

Module 4
Insulation –
Materials,
Science &
Application

Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 Unit 7 Unit 8

Basic Insulation Insulation Insulation – Glass Mineral Cellular Glass Calcium Sprayed or
Insulation Materials & Thickness, Terms, Fibre & or Foamed Silicate & Blown Fibre
Science & System Thermal Definitions & Rockwool Glass Magnesia & Ceramic
Principles Design Conductivity Formula Fibre
& (Blanket)
Performance
Criteria

Unit 9 Unit 10 Unit 11 Unit 12 Unit 13 Unit 14 Unit 15

Vermiculite Nitrile Polystyrene, Asbestos Fire Acoustics/ Finishing
Rubber Phenolic Foam Protection Noise Materials &
& Abatement Cladding
Polyisocyanurate
Foam

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Module 4 – Unit 15 Finishing Materials & Cladding

Unit Objective
By the end of this unit each apprentice will be able to:
 Recognise and state the uses of materials and cladding.
 Select suitable finishing materials for a range of applications.

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1.0 Finishing Materials and Cladding

Key Learning Points
 Identification of cladding and finishing materials.
 Reinforced aluminium foil. Mastic and coating finishes.
 PVC sheet.
 Sheet metal cladding.
 Polyisobutylene sheet.
 Roofing felt.
 Hard setting cements and compounds.

1.1 Materials
 Reinforced aluminium foil.
 Mastic and coating finishes.
 PVC Sheet.
 Sheet metal cladding.
 Polyisobutylene Sheet (PIB).
 Roofing felt.
 Self-setting cement.

1.2 Reinforced Aluminium Foil

Plain aluminium foil or reinforced aluminium foil laminates can be pre-applied
to insulation material by the insulation supplier or manufacturer. These facings
should not normally require further finishing and are used as dust and/or
vapour barriers in areas where there is little risk of mechanical damage, e.g. on
pipe-work at high level or in service ducts. Where the use of aluminium foil is
essential to the proper functioning of the system, the foil should be protected
from mechanical damage.
Longitudinal overlaps on pipe sections and all joints between abutting slabs and
mats should be sealed with matching self adhesive tape. Care should be taken
on chilled or cold-water services to ensure the integrity of the vapour barrier.

1.3 Mastic and Coating Finishes

The technique of application, e.g. by brush, hand or spray, depends on size,
location, risk of overspray and any possible need to permit evaporation of a
solvent. The contractor should consult the manufacturer of the material on the
details of the procedure be followed, on any special equipment required and
safety precautions to be taken.
Mastic and coating finishes based on ingredients such as bitumen’s, resins of
polymers can be of three types: water based (emulsions), solvent based or
solvent free. Selection of the type should depend on whether it can be applied

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direct to the insulant, or whether it has to be used in conjunction with open-

weave glass cloth, cotton scrim or canvas and the degree of protection required.
Water based materials should be protected from frost during storage and it is
essential that they should not be applied when the ambient or surface
temperature is below 5ºC, or when freezing conditions are expected within 24
hours of application. These materials are non-flammable during application.
However, some water based mastics are available with special antifreeze
ingredients, allowing application in freezing conditions.
Solvent-based mastics and coatings can withstand freezing, but for best results
they should not be applied at temperatures below 5ºC. Most of them thicken
considerably at low temperatures, rendering application by spraying particularly
difficult; for winter use, enclosed storage at a minimum of 10ºC should
facilitate easy application. Many contain highly flammable solvents and
precautions should be taken. Solvent vapours in fairly low concentrations can
cause narcosis, therefore adequate ventilation should be ensured whenever
solvent based materials are applied.
Solvent-free materials, such as epoxies or urethanes, are recommended where,
for example, particular chemical resistance is necessary.

1.4 PVC Sheet

Where rigid plastics (PVC) sheeting is used, it is usually pre-curled to facilitate
fitting over pipe sections and should not be less than 0.35mm thick.
Longitudinal and circumferential joints should be overlapped by 50mm and
longitudinal overlaps should be neatly secured every 150mm centre’s with
plastic rivets.
Alternatively, for cold work, or where a hygienic finish is required, the joints
can be continuously bonded with special formulated solvent. They can be
finished with matching PVC tape, if desired.
Where hot work is involved, care should be taken to see that the plastics sheets
are not subjected to excessive temperatures where the equipment is in use.
Bends and tees can be finished with purpose made fittings, which are usually an
integral part of the finishing system.

1.5 Sheet Metal Cladding

Sheet Metal is very widely used over both pre-formed and flexible insulating
materials for its resistance to mechanical damage and for its attractive
appearance when correctly applied. Corrosion is often a problem and for this
reason aluminium can be preferred for some applications. It is essential that
the aluminium should be isolated from dissimilar metals.
N.P. Aluminium (plain and stucco), Galvanized mild steel, Aluminium-Zinc
coated steel sheet (Aluzinc) and Stainless Steel are the standard sheet metals
used for cladding.

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Aluminium
Aluminium being relatively soft, should not be used for protection in areas
where it is likely to be exposed to substantial mechanical damage, particularly,
when it is applied over flexible insulating material.
As flat sheets of polished aluminium, through reflection of light, tend to
emphasise areas of minor damage, the reflecting surface, particularly with large
flat areas should preferably be broken up by the use of ribbed sheet or material
with an embossed “stucco” finish. Sheets with box or ribbed profile have
greater intrinsic resistance to deformation than flat sheet.
Profiled aluminium sheet has the advantage of scatter of reflective light as well
as increased resistance to deformation in the direction of the corrugations
while, in the direction across the corrugations, the sheet confirms easily round
uniform curved surfaces.
Aluminium sheet can develop irregular white areas of oxide film after a period
of exposure to outdoor weather conditions, but this can be avoided by the use
of material that has received a chemical treatment or an electrolytic, e.g.
anodized surface treatment. Aluminium should be isolated adequately from
direct contact with dissimilar metals to avoid galvanic corrosion.
Under certain conditions, aluminium cladding can constitute a hazard in the
event of fire in large process plants or the immediate vicinity, when it is
possible for the aluminium to melt and ignite adjacent materials. In a major
fire, hot molten aluminium can be scattered over a wide area of a plant leading
to many fires.
The thickness of flat aluminium used for cladding is usually between 0.7mm
and 1.6mm. The 1.6mm metal would be used for large flat areas over flexible
insulation for extra strength and support. The thickness of profiled aluminium
used is usually 0.9mm.

Galvanised Mild Steel

Galvanised Mild Steel is used in cladding for its appearance, good mechanical
strength and fire resistance. It is relatively cheap compared to stainless steel
and should be used in preference to aluminium where there is a risk of
development of fires due to the low melting point of aluminium.
The thickness of flat galvanised sheets used is usually between 0.6mm and
1.2mm.
For all materials, precautions should be taken against electrolytic corrosion,
particularly for plant within 10km of the sea. Where necessary precautions
should be taken to avoid direct contact between dissimilar metals.

Stainless Steel
Stainless steel (various grades) is used for cladding because of its excellent
appearance, excellent mechanical strength, corrosion resistance, mildew and
bacteria resistance, as well as excellent resistance to fire. These qualities make it
an ideal material to use in pharmaceutical, brewing and chemical, food
processing plants etc, where a high class finish is required coupled with high
levels of hygiene and resistance to fire.

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The cost of stainless steel is high compared to aluminium and galvanised mild
steel, however, in applications where galvanised may last only a number of
years, stainless steel will last indefinitely. Because of its almost complete
resistance to corrosion, the high cost of stainless does not necessarily mean it is
the most expensive metal to use, since its long life often makes it the cheapest
material to use in the long run. The thickness of flat stainless steel used is
usually between 0.5mm and 1.0mm.

Aluminium – Zinc Coated Steel Sheet (Alu-zinc)

Alu-zinc is used in cladding work for its excellent corrosion resistance, very
attractive appearance and excellent thermal and light reflectivity. With this
material you have the combination of three metals – the strength of steel, the
protection of zinc and the stability of aluminium.
Aluzinc has an ability to repair itself which makes the material resistant to
corrosion caused by scratches. The aluminium-zinc coating provides the steel
sheet with a double protection against corrosion. The first protection factor is
the coating on the steel sheet that forms a passivating barrier against general
corrosion. The other protection factor involves the formation of a galvanic
element when the sheet is exposed to moisture (electrolyte), resulting in zinc
ions flowing over the protecting the exposed steel against corrosion in
scratches or trimmed edges.
Aluzinc can be used in considerably more corrosive environments that for
instance hot dip galvanised sheets.

1.6 Polyisobutylene Sheet (PIB)

When insulated pipe work or ductwork is installed outdoors it can be finished
with Polyisobutylene (PIB) sheeting to protect it against the weather.
Minimum thickness is usually 0.8mm.
When fitting PIB over pipe work insulation for example it is important to
ensure that all joints are well butted together.
Longitudinal overlaps should be securely bonded by welding together with
white spirit or other suitable solvent. Circumferential joints should be
overlapped by typically 50-70 mm and securely bonded in the same way as the
longitudinal seams.
All overlaps must be arranged to shed water and special care taken when
sealing joints in order to prevent the ingress of moisture.

1.7 Roofing Felt

Applied directly to the external surface of the insulation, with all joints lapped
“weather-wise”, secured and sealed by suitable adhesive. All longitudinal and
circumferential overlaps should be a minimum of 50mm. Finish with two coats
of black bituminous paint. All such jointing, sealing materials and methods of
application should follow the recommendations of the sheet material
manufacturer. Secure in position with galvanised wire netting of 25mm mesh.
The netting joints should be secured with a lacing of 1mm galvanised wire.

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1.8 Self Setting Cement

Normally these finishing materials are based on Portland cement, but can be
gypsum plaster as a base. Supplied in loose, dry form, they are mixed on site
with water and trowelled as an armouring to the insulating sub-coat. They will
dry in-situ without the application of heat and give a much harder finish than
the hard setting compositions.

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2.0 Materials and Their Applications

Key Learning Points
 Effect of environmental conditions on finishing and cladding
materials.
 Factors governing the application of different finishes.

2.1 Applications
Aluminium Foil
Aluminium foil is used in areas where there is little risk of mechanical damage
e.g. on pipe work at high level or in service ducts.

Mastic and Coating Finishes

Generally used to provide a more robust vapour barrier or to provide an
appropriate surface for decorative surfaces. Water-based materials should not
be applied when the ambient or surface temperature is 5ºC or when freezing
conditions are expected within 24 hours of application.

PVC Sheet
PVC cladding is usually designed to last a very long time and requires little
maintenance. Due to pvc’s durability, high thermal insulation, excellent
weathering performance and good resistances to UV light and ozone. PVC
cladding can remain in place for many years. It is hygienic and can be easily
cleaned.

Sheet Metal Cladding

Sheet metal is very widely used for its resistance to mechanical damage and for
its attractive appearance when correctly applied. It is readily available and
inexpensive and is also available in alloys and with special coatings and finishes
that makes it a very versatile material that is used for many applications in the
thermal insulation industry.

Polyisobutylene Sheet (PIB)

Polyisobutylene or PIB is a good outdoor weather resistant finish that is used
to cover pipe and ductwork insulation. It is easily applied and the
manufacturer’s instructions/recommendations should be adhered to for proper
installation. It is very cost effective compared to metal cladding but would not
offer the same protection against mechanical damage or abrasion. To prevent
bellying, particularly on large ducts, the PIB covering can be wrapped with
galvanised wire netting secured with 1mm galvanised wire.

Roofing Felt
Like PIB, roofing felt is cost effective compared to sheet metal cladding and
can be easily applied. For proper installation, manufacturer’s recommendations

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should be followed. Roofing felt is secured with galvanised wire netting and
lacing wire.

Self-Setting Cement
Self-setting cement can be exposed to outdoor weather conditions without
further protection, but it is important to note that it is not impervious to water.
It is easily mixed with water and applied but it is important that the
manufacturer’s instructions are adhered to, so as to achieve a satisfactory
outcome. Whey dry, self-setting cement can be painted with various finishes.

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3.0 Fixings
Key Learning Points
 Identification and use of fixing products.
 Fixing techniques.
 Manufacturer’s catalogues or brochures.
 Personnel attitude towards finish.

3.1 Identification and Use of Fixing Products

As most insulations are not structural materials they must be supported,
secured, fastened or bonded in place. Fixings or secure-ments must be
compatible with insulation and jacketing materials. Some of the possible
choices include:
 Self-Tapping Screws and Rivets
 Bands, Wire, Wire Netting
 Mechanical Fasteners
 Aluminium Foil Tape
 Self-Adhering Laps
 Reinforcing Mesh
 Adhesives
 Mastics

3.2 Self-Tapping Screws and Rivets

Both of these types of fixings are used to secure sheet metal cladding in place
over insulated pipe work, ductwork or other equipment.
Precautions should be taken to prevent electrolytic corrosion developing
between dissimilar metals for example between aluminium ‘pop’ rivets and
galvanised mild steel cladding. Galvanised mild steel should be secured with
cadmium-plated or stainless steel fixings and aluminium cladding can be
secured with either aluminium or stainless steel fixings

3.3 Bands, Wire and Wire Netting

Unless the insulating material can be secured directly to the surface to be
insulated, e.g. by means of adhesives some form of mechanical accessory
should, if necessary, be used to secure it to the permanent attachments on the
tank or vessel etc. Banking, Tie Wire or Lacing Wire are some of the ways to
secure the insulation in place or the insulation can sometimes be covered with
wire netting with the edges laced tightly together. Banding is also used to
secure the outer cladding in place without the need for fixings such as self-
tapping screws or rivets.

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Lacing Wire or other securing device that is likely to be in direct metallic

contact with a final cladding of aluminium sheet, should be coated with a
plastics material in order to avoid bimetallic corrosion in the locations of
contact. Alternatively, it can be convenient to use aluminium or stainless steel
securing materials.

3.4 Mechanical Fasteners

When slab insulation products are used on square or rectangular ductwork, they
can be installed securely with adhesive which may be supplemented by
insulation hangers which are stuck to the ductwork with the insulation material
secured by a lock washer fixed on the hanger. These fastenings should be
spaced at regular intervals as recommended by the insulation suppliers and
should finish flush or below the surface of the simulation.

3.5 Aluminium Foil Tape

Plain aluminium foil or reinforced aluminium foil laminated can be pre-applied
to insulation material by the insulation supplier/manufacturer.
These facings should not normally require further finishing and are used as dust
and/or vapour barriers in areas where there is little risk of mechanical damage,
e.g. on pipe work at high level or in services ducts.
When foil faced pipe sections or slabs are installed they should be tightly butted
together and the joints covered with aluminium foil tape (supplied in rolls,
width 50mm or 75mm) to seal the joint and maintain the integrity of the
vapour barrier.

3.6 Self-Adhering Laps

These are available on the longitudinal seams of foil faced pipe sections and
make the installation and sealing of the joints easy and effective.

3.7 Reinforcing Mesh

One of the most commonly used reinforcing material is galvanised wire netting.
The main uses for the metallic reinforcement are with spray-applied fibrous
insulation, wet-applied finishing compositions and wet-finishing cements.

3.8 Adhesives
Adhesives are used to form a bond between adjacent insulation elements or the
insulation and the surface to be bonded. Most adhesives form a bond by
evaporation of solvents which can be flammable and toxic; water-based
adhesives are slow drying. Adequate “open time” should be allowed for
evaporation of the solvent before making a bond between materials of low
permeance.
Many adhesives do not continue to operate effectively at very low
temperatures. If they are used as an aid to erection, mechanical support should
also be provided. The manufactures advice on the effective temperature range
of the adhesive should be sought. Wherever possible, additional mechanical
support should be used in the form of banding, insulation pins or self-adhesive
tapes.

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Module 4 – Unit 15 Finishing Materials & Cladding

When using adhesives it is very important to consult all available safety

information before individual products are used.

3.9 Mastics
Refer to section 1.3 above.
Note: For further information on the above products including fixing
techniques, health and safety etc., please refer to the manufacturer’s catalogues
and brochures.

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4.0 Selection of Suitable Finishing

Materials for a Range of
Applications
Key Learning Points
 Selection of suitable finishing materials for a range of applications.
 Professional attitude towards finish.

Insulation finishes are applied over the insulation itself to provide, depending
upon type used, a vapour barrier, weather protection, chemical resistance,
protection from mechanical damage or improved aesthetics. The choice of
finish may be dependent upon the type of insulation used and the cost
implications for both materials and installation. Wet applied finishes will usually
require a firmer base than self-supporting metal coverings which can be used
with softer insulation materials. It is important that the installation of these
materials is carried out according to the manufacturer’s instructions and that a
professional approach is taken towards the use of such materials.

4.1 Mechanical Abuse Coverings

Rigid Jacketing provides the strongest protection against mechanical abuse
from personnel, equipment machinery, etc. The compressive strength of the
insulation material should also be considered when designing for mechanical
protection.

4.2 Corrosion and Fire Resistant Coverings

Corrosion protection can be applied to the insulation by the use of various
jacket materials. The corrosive atmosphere must be determined and a
compatible material selected. Mastics may be used in atmospheres that are
damaging to jacketing materials.

4.3 Fire Resistance

Fire resistant finishes can be applied to insulation systems by the use of
jacketing and/or mastics. Fire resistant materials are determined by flame
spread and smoke generated.

4.4 Appearance Coverings and Finishes

Various coatings, finishing cements, fitting covers and jackets are chosen
primarily for their appearance value in exposed areas.

4.5 Hygienic Coverings or Finishes

Coatings and jackets must present a smooth surface which resists fungal or
bacterial growth in all areas. High temperature steam or high pressure water
wash down conditions require jackets with high mechanical strengths and
temperature ranges.

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4.6 Properties of Protective Coverings or

Finishes
The properties of jacketing and mastic materials that must be considered to
meet the aforementioned functions are:
1. Chemical Compatibility – must be compatible with the insulation material
over which they are applied and to the elements in the environment such
as industrial chemicals, salt, air and ultraviolet or infrared light.
2. Resistance to Internal or External Movement – This property is significant
if the covering or finish must absorb or compensate for thermal expansion
and contraction of the insulation it covers i.e. (shrinkage of high
temperature insulation) or if the system vibration must be considered.
3. Temperature range of the finish or covering – The temperature range must
be compatible with the surface temperature of the insulation surface.
4. Vapour Permeability – The covering or finish should prevent the passage
of moisture vapour into or through the insulation.

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Summary
Insulation finishes are applied over the insulation itself to provide, depending
upon type used, a vapour barrier, weather protection, chemical resistance,
protection from mechanical damage or improved aesthetics. The choice of
finish may be dependent upon the type of insulation used and the cost
implications for both materials and installation. Fixings, adhesives and
mechanical secure-ments are used in conjunction with the insulation finishes
and cladding to ensure a secure overall assembly.

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