Pre-Insulated Pipe Systems

Thermacor Process

Thermacor is a leading provider of pre-insulated piping systems in the industrial, commercial, institutional, power generation, and military piping markets among others.

Thermacor manufacture superior systems for steam, condensate, chilled water, heating water, high temperature hot water, cryogenics, jet fuel, solvents, oil, and other domestic and industrial applications including those systems that require heat tracing or freeze protection. We also offer services for stress analysis, heat gain/loss calculations and infrared thermography of your piping system.

THERMACOR’S FUSION BONDED EPOXY (FBE) coated Class
A Steel Conduit System is Federal Agency Committee Approved for steam, condensate, and high temperature hot water systems. The system is professionally engineered as a complete system that is drainable, dryable, and air testable with total manufactured components: pipes, loops, elbows, tees, end seals, gland seals, and anchors. The system is built to withstand heavy traffic/ earth loads, high water tables, and the most corrosive of soils.

Thermacor Products and Services

High Temp

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Class “A” – FBE

THERMACOR’S CLASS A Steel Conduit systems are used for steam, condensate, and high temperature hot water system. The system is pre-fabricated and pre-engineered as a complete system that is drainable, dryable, and air testable with total manufactured components: pipes, loops, ells, tees, end seals, gland seals, and anchors. The system is built to withstand heavy traffic/earth loads, high water tables, and the most corrosive of soils.

FUSION BONDED EPOXY (FBE) is a primerless, one-part, heat curable, thermosetting powdered epoxy coating designed to provide maximum corrosion protection to pipeline systems.

Conduit Coating:
• Fusion Bonded Epoxy

Carrier Pipe:
• As Specified

Conduit:
• 6” ≤ c ≤ 26” – 10 Gauge
• 28” ≤ c ≤ 36” – 6 Gauge
• 38” ≤ c ≤ 42” – 4 Gauge

Carrier Pipe Insulations:
• As specified by engineer

​DUO-THERM “505”

THERMACOR’S DUO-THERM “505” is a factory-fabricated, pre-insulated piping system that incorporates polyurethane foam and a rugged, non-corrosive, High Density Polyethylene (HDPE) jacket with a Class A Steel Conduit System.

DUO-THERM is ideal for the distribution of high pressure steam, condensate, and high temperature hot water. The system is built around a typical Class “A”, steel-in-steel system, but is enhanced with an outside layer of polyurethane foam and a non-corrosive HDPE jacket. The HDPE jacket ensures watertight integrity of the insulation envelope, eliminating the need for cathodic protection. The system is pre-fabricated and pre-engineered as a complete system that is drainable, dryable, and air testable with total manufactured components: pipes, loops, ells, tees, end seals, gland seals, and anchors. The system is built to withstand heavy traffic/earth loads, high water tables, and the most corrosive of soils. An ERM leak detection system can be embedded in the foam insulation to detect groundwater intrusion.

Carrier Pipe:
• As Specified by Engineer

Conduit:
• 6” ≤ c ≤ 26” – 10 Gauge
• 28” ≤ c ≤ 36” – 6 Gauge
• 38” ≤ c ≤ 42” – 4 Gauge

Outer Jacket:
• High Density Polyethylene (HDPE)

Outer Insulation:
• Polyurethane foam

Carrier Pipe Insulations:
• As specified by engineer

CLASS “A” – NOVA

THERMACOR’S CLASS A Steel Conduit systems are used for steam, condensate, and high temperature hot water system. The system is pre-fabricated and pre-engineered as a complete system that is drainable, dryable, and air testable with total manufactured components: pipes, loops, ells, tees, end seals, gland seals, and anchors. The system is built to withstand heavy traffic/earth loads, high water tables, and the most corrosive of soils.

NOVACOAT is a two component, self-priming, chemically cured, polyurethane, high solids coating, designed to provide maximum durability, toughness, flexibility, and chemical resistance to pipeline systems.

Conduit Coating:
• Novacoat

Carrier Pipe:
• As Specified

Conduit:
• 6” ≤ c ≤ 26” – 10 Gauge
• 28” ≤ c ≤ 36” – 6 Gauge
• 38” ≤ c ≤ 42” – 4 Gauge

Carrier Pipe Insulations:
• As specified by engineer

HT-406

THERMACOR’S HT-406 is a factory-fabricated, pre-insulated piping system for above or below ground distribution of high temperature hot water (366°F), low pressure steam, and condensate. The system is designed with a steel carrier pipe as required, high temperature closed cell polyisocyanurate foam insulation, and a high density polyethylene (HDPE) jacket.

HT-406 utilizes the HDPE jacket in combination with molded fitting covers, electro-fusion welding, and pressure testable joint closures to create a seamless jacket and insure the watertight integrity of the system. ERM leak detection is incorporated into the system and can be utlized to detect groundwater intrusion if specified.

Carrier Pipe:
• As Specified by Engineer

Insulation:
• Polyisocyanurate foam

Jacket:
• High Density Polyethylene (HDPE)

Low Temp

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CHILL-TERM

THERMACOR’S CHILL-THERM is a factory-fabricated, pre-insulated piping system for the below ground distribution of chilled water. The system is designed with a PVC plastic pressure carrier pipe (type to be specified), polyurethane foam insulation, and a high density polyethylene (HDPE) or PVC jacket.

Carrier Pipe:
• Class 160 (SDR 26)
• Class 200 (SDR 21)
• C900/905
• Schedule 40/80 Solvent Weld

Insulation:
• Polyurethane foam

Jacket:
• High Density Polyethylene (HDPE)
• Type 1, Clas 1 PVC

FERRO-THERM

THERMACOR’S FERRO-THERM is a factory-fabricated, pre-insulated piping system for below ground or above ground distribution of hot water, chill water, low-pressure steam, condensate, oil and viscous fluids. The system is designed with a steel carrier pipe as required, polyurethane foam insulation (rated to 250°F) and a high density polyethylene (HDPE) jacket.

Carrier Pipe:
• Steel (type and grade specified, as required)

Insulation:
• Polyurethane foam

Jacket:
• High Density Polyethylene (HDPE)
• Type 1, Class 1 PVC

FIBER-THERM

THERMACOR’S FIBER-THERM is a factory-fabricated, pre-insulated piping system for the distribution of chilled water, low temperature hot water, steam and condensate up to 250°F. FIBER-THERM is designed with fiberglass reinforced plastic (FRP) pressure pipe, closed cell polyurethane foam insulation, and either a high-density polyethylene (HDPE) or PVC jacket.

Carrier Pipe:
• FRP – Fiberglass Reinforced Plastic per specification

Insulation:
• Polyurethane foam

Jacket:
• High Density Polyethylene (HDPE)
• Type 1, Clas 1 PVC

SPIRAL THERM

THERMACOR’S SPIRAL-THERM is a metal jacketed, factory-fabricated, pre-insulated piping system for above ground, shallow concrete trench, and tunnel piping applications. SPIRAL-THERM incorporates the insulation, or combination of insulations, of choice within a durable protective metal jacket (aluminum, galvanized steel, or stainless steel). The spiral lock seam, either internal or external, is air and watertight.

Carrier Pipe:
• As Specified

Spiral Wound Jacket:
• Aluminum, Galvanized Steel, or Stainless Steel
• Internal or External Seam
• Watertight rubber o-ring sealed seam

Insulation:
• Polyurethane foam

COPPER-THERM

THERMACOR’S COPPER-THERM is a factory-fabricated, pre-insulated piping system for below ground distribution of heating water, domestic hot water, chill water, condensate return, process fluids, and cryogenic services.

COPPER-THERM is designed with copper tubing (type to be specified), closed cell polyurethane foam insulation (rated to 250°F), and a high density polyethylene (HDPE) or PVC jacket. O-ring couplings are also available for joining straight lengths of pipe to compensate for thermal expansion.

Carrier Pipe:
• Type “K” Copper
• Type “L” Copper
• Type “M” Copper

Insulation:
• Polyurethane foam

Jacket:
• High Density Polyethylene (HDPE)
• Type 1, Class 1 PVC

FERRO-THERM D1

THERMACOR’S FERRO-THERM D.I. is a factory-fabricated, pre-insulated piping system for below and above ground distribution of chilled water or domestic hot water. The system is designed with ductile iron pressure pipe, closed cell polyurethane foam insulation, and a high density polyethylene jacket.

Carrier Pipe:
• Ductile Iron (as specified)

Insulation:
• Polyurethane foam

Jacket:
• High Density Polyethylene (HDPE)

POLYCOR™ PLATINUM™

THERMACOR’S POLYCOR™ PLATINUM™  is a factory-fabricated, pre-insulated piping system for hot water distribution up to 180°F.  POLYCOR™ PLATINUM™ is designed with PERT (Polyethylene-Raised Temperature) carrier pipe, closed cell polyurethane foam insulation, and a high density polyethylene jacket.

Carrier Pipe:
• PERT-High Density Polyethylene

Insulation:
• Polyurethane foam

Jacket:
• High Density Polyethylene (HDPE)

POLYCOR HDPE

THERMACOR’S POLYCOR HDPE is a factory-fabricated, pre-insulated piping system for distribution of chilled water, sewer, water main, force main, waste heat, etc…. POLYCOR is designed with high density polyethylene (HDPE) carrier pipe, closed cell polyurethane foam insulation, and a high density polyethylene jacket.

Carrier Pipe:
• High Density Polyethylene

Insulation:
• Polyurethane foam

Jacket:
• High Density Polyethylene (HDPE)

STEEL-THERM

THERMACOR’S STEEL-THERM is a factory-fabricated, pre-insulated piping system created by combining our popular FERRO-THERM line with Ductile Iron Couplings to seal the joints between lengths of pipe. The D.I. Couplings eliminate welding and provide compensation for expansion and contraction, thereby eliminating the need for expansion loops or expansion joints.

Carrier Pipe:
• d ≥ 2” – A53 ERW Grade B, Std. Wt. Black Steel
• d < 2” – A106 SML, Std. Wt. Black Steel • Seamless & Schedule 80 pipe are available for all sizes • Std. Wt. is the same as Schedule 40 through 10” • Ductile Iron Couplings Insulation:
• Polyurethane foam

Jacket:
• High Density Polyethylene (HDPE)