http://www.engineeringnews.co.za
  SEARCH
Login
R/€ = 14.23Change: -0.09
R/$ = 11.03Change: -0.12
Au 1220.93 $/ozChange: -15.19
Pt 1345.00 $/ozChange: -17.00
 
 
Note: Search is limited to the most recent 250 articles. Set date range to access earlier articles.
Where? With... When?








Start
 
End
 
 
And must exclude these words...
Close Main Search
Close Main Login
My Profile News Alerts Newsletters Logout Close Main Profile
 
Agriculture   Automotive   Chemicals   Competition Policy   Construction   Defence   Economy   Electricity   Energy   Environment   ICT   Metals   Mining   Science and Technology   Services   Trade   Transport & Logistics   Water  
What's On Press Office Tenders Suppliers Directory Research Jobs Announcements Contact Us
 
 
 
RSS Feed
Article   Comments   Other News   Research   Magazine  
 
 
Aug 03, 2012

Insulation specialist introduces new developments to SA

Back
Natal|Allied Products|Cement|Components|Eskom|Fire|Gas|IPC Industries|IPC Industries Supplies|Pipe|Pipes|PROJECT|Projects|Sasol|Turbines|Waste|Europe|The Netherlands|Kusile Power Station|Cement|Manufacturing|Pipes|Product|Products|Thermal Applications|Barry Collins|Power|Turbines|Waste|Foamglass|Insulation|Pipe|Proximity
|Cement|Components|Eskom|Fire|Pipe|Pipes|PROJECT|Projects|Turbines|Waste||||Manufacturing|Pipes|Products||Power|Turbines|Waste|Insulation|Pipe|Proximity
natal|allied-products-company|cement-company|components|eskom|fire|gas-company|ipc-industries|ipc-industries-supplies|pipe-company|pipes|project|projects|sasol|turbines-company|waste-company|europe|the-netherlands|kusile-power-station|cement|manufacturing|pipes-industry-term|product|products|thermal-applications|barry-collins|power|turbines-person|waste|foamglass|insulation|pipe|proximity
© Reuse this



Hot and cold insulation specialist IPC Industries has started manu- facturing prefabricated dome heads for vessels from rigid polyurethane foam (PIC).

The company focuses on developing new products and technologies from four core materials – PIC, Rockwool, Foamglass and cement, says IPC Industries MD Barry Collins.

PIC is used for cold insulation and the company previously cut pipe sections and vessels from this material; however, at the beginning of this year, it also started producing several new components from the material.

“Usually, a skilled labourer had to bend a dome head from a sheet of material, which would take days. With this new development, customers provide us with the size of the dome they need, and we supply a prefabricated dome head that simply needs to be fitted.

“The manufacturing of the PIC dome takes about five hours. This eliminates the need for a skilled labourer and saves our clients time and money,” says Collins.

IPC Industries also manufactures pre- fabricated PIC elbows, bends and tees.

“The bends are made to fit, so there is minimum heat loss.

“The time it takes to complete a job is a major cost factor for any contractor and these new products allow for time savings of up to three hours for each bend,” adds Collins.

IPC Industries manufactures the products in sizes from half an inch to 48 inches.

Collins notes that there has been demand for these products from the insulation industry, with clients, such as contractors to fuel giant Sasol, using them.

“With many projects, the insulation is the final task to complete. This usually means there is pressure on the contractors to finish quickly, as other sections of the project may have taken longer than expected. These preformed products allow contractors to save time without compromising on quality,” he points out.

Rockwool
IPC Industries is also the South African agent for the Rockwool brand, which is imported from Holland. The material is imported in the form of wire-backed mattresses and is used for hot insulation.

“We use computer numerical control (CNC) cutting machines to cut pipe sections from the Rockwool in any thickness and in sizes ranging from half an inch to 48 inches,” says Collins.

He states that the thermal value of Rockwool pipe sections is superior to that of other mattress and preformed pipe materials, adding that it has been used on projects like State-owned Eskom’s Kusile power station.

“We cut the pipe segments with lips, so there is no direct heat-loss channel. Rockwool has high compressor strength, is easy to work with and there is no waste with the material. We recycle any leftover material, making it an environment-friendly form of insulation,” he says.

The company uses the material to manufacture bends, elbows, tees, boilers, heat exchangers and vessels.

“Rockwool is also used as a fire-protec- tion measure for vessels and boilers, as well as for workers on site who work with the machines, to prevent them from being burnt,” says Collins.

Recently, IPC Industries used the material to manufacture roof panels for soundproofing and thermal applications – an area where the company hopes to see more demand.

“Rockwool gives us an advantage in the industry, as we are able to cut pipe sections quickly and to the exact size required by the customer. Usually they would have to buy a certain length of piping, like 5 m, but if they need 4 m, we cut that exact amount, so there is no waste,” he explains.

Foamglass
The company’s third core product is Foamglass, which is made from recycled glass and is suitable for hot and cold insulation applications.

The raw material is imported by IPC Industries from Europe, in the form of blocks or billets. It is used to manufacture pipe sections, vessel segments, vessel head segments and vessel dome heads.

The material is noncombustible, has a high compressor strength and is able to withstand temperatures ranging from –220 ºC to 482 ºC.

Preformed pipe sections made from Foamglass have previously been avail- able on the market. Now IPC Industries has started manufacturing preformed bends, tees, elbows and vessel dome heads from this material.

It also produces specialised vessel cutouts and segments for heat and gas exchangers from Foamglass.

“We go on site and assess the specialised cut that is needed, measure it and manufacture it according to client specifications,” says Collins.

The company has been developing its Foamglass product range since 2005.

“We have developed our own specifications for South African products that conform to Foamglass special applications for anti-abrasives, joint sealers and membranes, among others.

“All products and tools used with Foamglass are locally sourced, so we are developing the market to be equal to those that comply with European standards,” he says.

Cement
The company also manufactures its own cement which it calls thermal plaster.

The THP 300 thermal insulating plaster can withstand temperatures of up to 300 ºC and is used to cover vessels and pipes on site where Rockwool has been applied in the blanket form, acting as an outside skin.

It acts as a vapour and thermal protection barrier, as well as an insulator that can be painted.

The THP 1000 is a thermal finishing plaster, which is finer than the THP 300 plaster. It is able to withstand temperatures of between 800 ºC and 1 000 ºC.

IPC Industries also produces a specialised plaster called Limpet, which is applied as a spray to insulate turbines. It contains a significant proportion of Rockwool and can be used for fireproofing applications.

Collins points out that Limpet has been used in many of Eskom’s plants.

All three products are asbestos-free.

Allied Products
IPC Industries supplies insulation materials and related tools to clients.

“As a service, right from the tender stage of a project, we go on site and assess exactly what the clients will need. We then supply them with a full kit, containing insulation material, as well as all the related tools and parts, right down to hammers and pop rivets, which are all locally sourced,” says Collins.

The company opened a branch in Secunda, in 2008, that stocks parts and tools should a client need any extras. Collins notes that Secunda was chosen owing to its close proximity to the Sasol plant.

Future Outlook
The company plans to continue the growth it has experienced over the last three years.

“We have gone from one premises to five in the last three years and are now looking to expand into Lephalale and KwaZulu-Natal,” says Collins.

The company is developing preformed valve boxes and covers made from PIC, which it plans to complete by the end of August.

“We are also developing an automated production line to produce bends, elbows, tees and dome heads using metal sheets for the heating, ventilation and air conditioning industry. This should be ready for launch by the end of September,” he says.

Collins points out that IPC Industries spends a large portion of its yearly budget on research and development. On average, it releases six new products or product lines a year.

“We were one of the first companies to combine insulation manufacturing with CNC computerised cutting machines and processes. We had to build our own machines and had to design our own computer-aided design and computer- aided manufacturing programmes, which was a challenge.

“Our research and development made it easier for us to speed up our processes and expand our product range. We plan to continue advancing not only our business, but also the industry at large,” he says.

Edited by: Chanel de Bruyn
© Reuse this Comment Guidelines (150 word limit)
 
 
 
 
 
 
 
 
Other Pipes and Tubes News
Pump specialist Australian Pump Industries announced in May that it offers a simple guide for the use of hydrostatic testers, which it makes available free of charge. Locating leaks and proof-testing gas and oil pipelines is made easier with portable hydrostatic...
Marley Pipe Systems is the leading manufacturer and supplier of plastic pipe systems, serving the needs of the mining and industrial segment with superior quality products and turnkey solutions to improve efficiency, solve key industry challenges, and ensure safe and...
WATER WAY The R150-million first phase of the Northern Aqueduct project is scheduled for completion in the third quarter of 2015
Municipal water and sanitation services eThekwini Water and Sanitation (EWS) says construction of the Northern Aqueduct Augmentation, which forms part of the eThekwini strategic master plan to deal with the increasing demand for water in the northern regions of...
Article contains comments
More
 
 
Latest News
President Jacob Zuma
Updated 4 minutes ago National government was committed to supporting all struggling municipalities to become functional and efficient, President Jacob Zuma said on Thursday, opening the 2014 Presidential Local Government Summit (PLGS), in Midrand. Also speaking at the PLGS, Cooperative...
Updated 32 minutes ago Uganda is hoping to secure an $8-billion loan from China to build a railway network to revamp the country's transport infrastructure as it prepares to start oil production. As in other areas of Sub-Saharan Africa, China has become a major investor in Uganda. It has...
Herman Mashaba
Updated 46 minutes ago A minimum wage discussion paper released by the Durban Chamber of Commerce and Industry (DCCI) outlined that minimum wage laws posed a significant inflationary risk to the macroeconomy, but acknowledged that sectoral minimum wages might yield positive results. This...
More
 
 
Recent Research Reports
Road and Rail 2014: A review of South Africa's road and rail infrastructure (PDF report)
Creamer Media’s Road and Rail 2014 report examines South Africa’s road and rail transport system, with particular focus on the size and state of the country’s road and rail network, the funding and maintenance of these respective networks, and the push to move road...
Real Economy Year Book 2014 (PDF Report)
This edition drills down into the performance and outlook for a variety of sectors, including automotive, construction, electricity, transport, steel, water, coal, gold, iron-ore and platinum.
Real Economy Insight: Automotive 2014 (PDF Report)
This four-page brief covers key developments in the automotive industry over the past 12 months, including an overview of South Africa’s automotive market, trade figures, production and the policies influencing the sector.
Real Economy Insight: Construction 2014 (PDF Report)
This five-page brief covers key developments in the construction industry over the past 12 months. It provides an overview of the sector and includes details of employment in the sector, infrastructure and municipal spending, as well as insight into companies’...
Real Economy Insight: Electricity 2014 (PDF Report)
This five-page brief covers key developments in the electricity industry over the past 12 months, including details of State-owned power utility Eskom’s generation activities, funding and tariffs, independent power producers and prospects for the sector.
Real Economy Insight: Road and Rail 2014 (PDF Report)
This six-page brief covers key developments in the road and rail industries over the past 12 months, including details of South Africa’s road and rail network and prospects for both sectors.
 
 
 
 
 
This Week's Magazine
The board of UD Trucks Southern Africa (UDTSA) has announced the resignation of MD Jacques Carelse.   Long-time UD employee, corporate planning and marketing GM, Rory Schulz, has been appointed as acting MD while the process started to appoint a new MD. The Japanese...
There is a need to start planning another pumped storage scheme in South Africa. Much work has already been done at a site in the Limpopo province and the project was very close to being put out to tender at one stage. In 2008/9 the National Energy Regulator of South...
The Coega Development Corporation (CDC) is preparing to leverage its strategic coastal position to develop the Eastern Cape economy through proposed aquaculture development zones (ADZs), with a proposed R2-billion project aiming to contribute $278-million to the...
Completion of the ongoing construction of the 102 km Zomba–Jali–Phalombe–Chitakale road, in southern Malawi, has been extended from June  to December 15 because of persistent rains and difficulties in paying the contractor. The project is being undertaken by Kuwait's...
The Malawi government has awarded South African firm  Fischer Consortium the  contract to upgrade the Malawi Road Traffic Information System. The Directorate of Road Traffic and Safety Services at Malawi's Ministry of Transport and Public Works says Fischer...
 
 
 
 
 
 
 
 
 
Alert Close
Embed Code Close
content
Research Reports Close
Research Reports are a product of the
Research Channel Africa. Reports can be bought individually or you can gain full access to all reports as part of a Research Channel Africa subscription.
Find Out More Buy Report
 
 
Close
Engineering News
Completely Re-Engineered
Experience it now. Click here
*website to launch in a few weeks