Insulation & Cladding

Thermal Insulation

Temperature under control. KAEFER excels in thermal insulation for complex, large-scale projects with tight deadlines. Using LEAN principles, we ensure timely and flexible responses to challenges.

We offer innovative, proprietary products and systems for a range of industries including refineries, power plants, food processing, LNG facilities, and chemical industries. Our expertise ensures efficient energy conservation and effective temperature control, addressing both environmental pressures and rising energy costs.

Our scope of work:

We carry out ther­mo­dy­namic calculations and di­men­sion­ing with our own pro­grammes as well as ded­ic­ated finite ele­ment methodologies. Our services include:

• Static and dynamic load calculations
• Dimensioning of insulation systems considering ecological and economic factors
• Development of high-temperature and cryogenic insulation concepts
• Planning and executing functional tests for complex insulation systems in our dedicated laboratories
• Designing insulation systems in 3D CAD programs
• Qualifying materials and systems

Areas of application – Thermal Insulation

• Refineries
• Chemical industry
• Food processing
• Wood and paper industries
• Heating, ventilation and air conditioning (HVAC)
• Natural gas storage tanks
• Biomass plants
• Environmental technology

Areas of application – Cold Insulation

• Cryogenic storage
• CO2 plants
• Gas liquefaction plants
• Piping
• Vessels
• Tanks

Cryogenic Insulation

The coolest job at KAEFER.
KAEFER has over 40 years of expertise in managing the extreme temperatures of -163°C for LNG. We offer comprehensive solutions across the LNG supply chain, including high-performance insulation for gas plants, pipelines, storage, and transportation tanks. Our dedicated LNG Solutions Centre, staffed by specialists, tackles complex scenarios and custom applications where mechanical and thermal stresses are significant.

Tech­nical Ex­pert­ise

The KAEFER LNG Solutions Centre delivers advanced solutions for major LNG projects, including a modular pre-insulation process for pipes. This method ensures high-quality insulation before on-site installation, reducing environmental impact, time, and costs. Our mobile system can be set up near large-scale projects globally, further decreasing transit times and expenses.

The LNG Solu­tions Centre cov­ers the entire LNG op­er­a­tions chain, from exploration to the re­ceiv­ing party:

• Liquefaction
• Storage
• Loading & Unloading
• Shipping
• Regasification

The KAEFER LNG Solutions Centre includes:

• Engineering
• Detailed design
• Project execution
• Purchase of materials
• Job site management
• Consultancy

Corrosion Under Insulation

Cor­ro­sion un­der In­su­la­tion (CUI) is the corrosion of metal surfaces that occurs under insulation. It’s often concealed and not immediately visible, making it difficult to detect until significant damage or integrity failures occur. This hidden corrosion can lead to serious plant issues, including reduced efficiency, unplanned shutdowns, and costly repairs.

CUI In­spec­tion and Remediation

KAEFER has extensive experience in assessing and remediating Corrosion Under Insulation (CUI) since 1918. Our service aims to reduce CUI identification costs, enhance plant efficiency, and prevent major failures and unplanned shutdowns. We use real-time radiography with our KAEFER Insulated Pipe Scanning (KIPS) equipment for precise inspection.

Our 4-step CUI process includes:

1. Thermal Imagery Surveys to identify CUI indicators.
2. Real-Time Radiography (RTR) and Moisture Content Measurement (MCM) based on survey results.
3. Non-Destructive Testing (NDT) for wall thickness verification where needed.
4. Remediation with the latest coatings and insulation technologies to prevent further issues.

We have served clients in the Oil & Gas, Power, and Chemicals sectors across Australia.

Remediation Solutions

Once CUI is identified, KAEFER offers remediation using various coating and insulation solutions tailored to environmental and process conditions, cost, safety, life expectancy, and quality requirements. Our dedicated R&D facility in Naval Base, Western Australia, simulates on-site conditions to test and refine these solutions.

Sheet Metal Cladding

From sheet metal fabrication to installation for durable insulation. KAEFER provides expert sheet metal cladding for insulation systems to ensure durability against weather and stress. Our precise fabrication and installation enhances insulation stability and longevity. We customise sheet metal solutions for high-demand components such as turbines, ensuring effective thermal insulation, corrosion protection, and sound absorption. Typical applications include boiler systems, flue gas ducts, container heads, pipe components, and tank roofs.

Durable Insulation Solutions

KAEFER offers comprehensive sheet metal cladding, including measurement, fabrication, and assembly, supported by workshops across Australia. Our services include:

• Fabrication for all insulation types
• Sound and heat insulation cassettes/enclosures
• Welding of specialist components

We use materials like stainless steel, aluminium, and galvanised sheet, tailored to insulation needs (thermal, cryogenic, acoustic) and client specifications. Equipped with advanced tools from Mabi, we streamline production and adhere to LEAN principles to deliver high-quality cladding efficiently and cost-effectively.

Pre-Insulation

KAEFER offers an advanced Pre-Insulation process that surpasses traditional methods. Our investment in research and development has led to a mechanised system delivering high-quality, cost-effective insulation, completed off-site and on-time.

Our modular facilities can be deployed globally to insulate pipes before on-site installation. This process uses multiple layers of polyurethane foam covered with a durable composite shell, ensuring robust, low-maintenance insulation.

Key Features:

• Cost-effective and efficient
• Reduces on-site installation time
• Predictable productivity and controlled conditions
• High-performance cryogenic insulation
• Robust, chemical-resistant, and non-corrosive
• Low maintenance and resistant to mechanical damage
• Accommodates thermal cycling stresses
• Significant cost and time savings

Acoustic Insulation

Sound solutions for noise and acoustics. Effective noise control for healthier environments.

KAEFER provides innovative solutions for managing noise and vibrations. Our process begins with precise measurement using advanced equipment, followed by tailored noise protection measures developed and tested in our acoustic laboratory.

We offer customised sound absorbers, acoustic enclosures, screens, and combined thermal insulation for various settings. In ships and offshore facilities, our team predicts noise and vibration levels based on designs and develops tailored solutions, such as linings, suspended ceilings, and silencers, meeting international standards.

Whether for industrial plants, buildings, or offshore facilities, KAEFER delivers expert, cost-effective acoustic solutions.

Ship and Offshore Acoustics

• Noise/vibration measurements and analysis
• Acoustic reports and predictions

Noise Protection Design

• Industrial acoustics: Noise/vibration measurements, planning, and simulations
• Development of noise protection measures

Room and Building Acoustics

• Noise measurements and analysis
• Acoustic reports and predictions
• Optimisation of room acoustics and sound absorption

Laboratory Services

• Development and design of noise protection measures