ISOPARTNER : Insulated Pipe Supports: More Complex Than You Think 

Pipe supports rarely grab headlines, yet they play a critical role in the performance, safety, and sustainability of modern mechanical systems. At ISOPARTNER we are acutely aware that for contractors and consultants working on complex pipe networks in Data centres, factories, schools, hospitals, and large commercial buildings, the selection of pipe support materials has become a far more significant issue than it once was.

Today, we see a large increase in construction of data centres, and this has put a huge focus on process piping technology. The millions of litres of cooling fluid flowing through data centres providing cooling solutions enable quadrillions of operations per second and allow facilities to handle millions of user requests. As power densities rise and thermal tolerances tighten, the reliability and efficiency of these piping systems become critical to maintaining uptime and performance. Any failure or inefficiency in cooling infrastructure can have immediate and costly impacts on both operational stability and energy consumption.

Sustainability is also a critical consideration in modern data centre design, particularly as cooling systems account for a significant portion of overall energy and water consumption. Efficient piping layouts, low-loss materials, and the integration of water-saving and heat-recovery technologies can substantially reduce environmental impact while lowering operating costs. By embedding sustainability into the design phase of process piping systems, data centres can meet performance demands while aligning with regulatory requirements and long-term environmental responsibility.

A Decision Made Early – With Long- Term Consequences

In most projects, the choice of pipework and associated supports is determined by design engineers during the early stages of system design. These decisions are typically informed by high-level thermodynamic and fluid dynamic calculations, focusing on flow rates, pressures, and operating temperatures.

However, the sustainability implications of getting this choice wrong can be significant. Pipe supports form a direct thermal bridge between the pipe and the building structure. Poorly specified supports can increase heat loss or gain, introduce condensation risk, and contribute to corrosion under insulation (CUI), all of which drive higher energy consumption and maintenance costs over the life of the building.

Fire safety is an increasingly important consideration, particularly in healthcare, education, and high-occupancy buildings. Non-combustible pipe support materials such as Phenolic foam, calcium silicate, Foamglas, and microporous insulation offer clear advantages in meeting regulatory and insurer requirements.

The complexity increases further when pipe support system design is added to the equation. Supports must be capable of carrying the dead load of the pipe, the fluid, and the insulation, while also accommodating thermal expansion and absorbing vibration from pumps and fluid movement.

Crucially, changes in mechanical support performance can influence fluid and thermal performance. Excessive vibration can disrupt flow characteristics, while insulation compression at support points can significantly reduce thermal efficiency. In chilled water systems, this can lead to condensation; in steam systems, it can result in increased heat loss and reduced system efficiency.

Material Choice: More Than Just Strength

To address these challenges, designers can choose from a wide range of pipe support materials, each available in different density grades. The main objective of the support material is twofold: to safely carry the mechanical load and to minimise heat transfer between the pipe and the support structure.

Density plays a crucial role. Higher-density materials generally offer greater load-bearing capacity, but this often comes at the expense of increased thermal conductivity. In some materials, higher density can also increase the risk of cracking or damage under thermal cycling or vibration. As a result, selecting the “strongest” material is not always the optimal solution.

– Phenolic foam is widely used in chilled water and refrigeration systems due to its exceptionally low thermal conductivity and good compressive strength. It is easy to machine into custom shapes and sizes, making it well suited to complex installations. The addition of a passivation layer on the inside removes the risk of corrosion under the insulation. Operating temperature range is ~ -50°C to +110°C.

– Foamglas, or cellular glass, offers a unique combination of high compressive strength, non-combustibility, and complete resistance to moisture. It performs well in cryogenic and wet environments and is often specified where CUI risk is high. Operating temperature range is ~ –260°C to +430°C

– PIR (polyisocyanurate) remains popular in general HVAC applications, offering good thermal performance and moderate strength. Fire performance and temperature limits must be carefully considered, particularly in occupied buildings. Operating temperature range is ~ –180°C to +120°C

– Calcium silicate is widely regarded as the industry standard for steam and high-temperature process piping. It offers excellent compressive strength and fire performance, making it ideal for demanding industrial environments. Moisture protection, however, is essential to maintain long-term performance Suitable for temperatures up to 850°C.

– Monolux and other microporous insulation materials sit at the premium end of the market. They combine very low thermal conductivity with extreme temperature resistance, often up to 1,000°C. Their use is typically reserved for space-constrained or specialist applications where performance justifies the cost.

– Mineral wool has a long history in high-temperature applications. High-density grades are non-combustible and capable of withstanding temperatures up to 650°C. However, mineral wool is not inherently load-bearing and typically requires inserts or saddles to support heavy pipework. Operating temperature range is +10°C to 250°C.

Rethinking the “Hidden” Component

As mechanical systems become more complex and performance expectations rise, pipe supports can no longer be treated as a secondary consideration. Material selection must be informed by a balanced understanding of load, temperature, thermal performance, fire risk, and long-term durability. For designers and contractors alike, rethinking pipe supports is an opportunity—not only to improve system performance but also to deliver more resilient, efficient, and sustainable buildings. Sometimes, it is the components you never see that make the biggest difference.

About ISOPARTNER Ireland

ISOPARTNER Ireland specialises in the distribution and conversion of a very wide range of insulation solutions. With a focus on professional advice, standard and customised insulation solutions and excellent logistics, ISOPARTNER is the perfect partner for every project.

We provide customers from the building sector, industry and specialised trade with products in the areas of thermal insulation, high temperature insulation, acoustic insulation, fire prevention and fire rated insulation. In addition, we are specialists in customisation for a range of insulation applications. We remain under the umbrella of the successful IPCOM Group because ISOPARTNER is the name of the business unit within IPCOM specialising in Technical Insulation. ISOPARTNER is already active in several European countries. Being part of this group of progressive companies, all sharing the same values, has many advantages. This international network allows us to further distinguish ourselves in expertise, service and know-how. This allows us to anticipate faster in times of change and continue to offer and guarantee quality-oriented, distinctive solutions. This is how we create noticeable economic synergies.

Contact us, we are ready to help! sales@isopartner.ie  fire@isopartner.ie +353 1 8829990 www.isopartner.ie