History of Telstar INSULRAP

    Telstar INSULRAP has gone through many stages since we did our first ST7.5. Our first machines were done using three basic components. T-Braid-2, PT-5 and Pyrosil Tape. We would start by wrapping the complete exhaust in a spiral direction butting edge to edge with T-Braid-2. We would secure it at both ends with mechanics wire. We would then wrap over top with PT-5. Once again we would wrap in a spiral direction butting the material edge to edge as much as possible. Next we would temporarily secure the PT-5 in place using the Pyrosil-Tape. Once everything was in place we would take a damp rag and wipe down the entire exhaust system. The reason for wiping the system down is as follows. Pyrosil-Tape is a silicone based tape that is the same as the coating on the PT-5. There is no adhesive on this tape and we rely on it to bond to itself. It is for this reason that we must ensure that the surface of the PT-5 is as clean and free of lint as possible. Finally, we would make a couple of wraps around the beginning of the PT-5 and then follow the seam in the same spiral direction as before. We would remove the protective cellulose and stretch the tape as we smooth it in place. We finish up at the end as we started by making a couple of wraps around the PT-5. We take care not to apply the Pyrosil-Tape directly to the bare exhaust as it has a much lower flash point than the other materials.
    During this period of time, we would also make up a manifold boot for use on Deutz engines. In some cases, we would wrap them in the same ways as the rest of the exhaust. For the eight, ten and twelve cylinder engines, we would make up this boot. We would use a light weight silicone coated glass fiber material as an outer layer. We combined this with a 1" glass fiber matting and a stainless steel mesh liner. These three products were then stitched into a boot that could be slipped onto the manifold and held in place with a wire fed through a series of grommets. This procedure remains the same to this date. As new materials became available, we were able to change our methods. With the introduction of Pyro-Jacket-XL we were able to cover straight lengths of pipe as well as mufflers, silencers and purifiers with a single sheet of material. Since Pyro-Jacket-XL comes in a roll 40" wide, we were able to cover some very large pieces. At this time, we started covering the exhaust components with 1" Insulmat (a 1" thick glass fiber blanket) and temporarily securing it in place with mechanics wire. We would put hooks on the Pyro-Jacket-XL and we would lace the cover over the exhaust as you would lace a skate. The PT-5 would be used only to cover the elbows of the system and we would seal the joints and seams once again with the PST-24 (Pyrosil-Tape). There was however, one drawback, to the use of the hooks. There was the potential for someone to injure themselves on the exposed hooks. For this reason, we went to eyelets and started lacing the cover as you would a boot. This system worked very well, but I was not satisfied. I searched until I found a buckle that we could put on the Pyro-Jacket-XL that would be easy to buckle and unbuckle. It also had to give us a bit of adjustment because of variances in material sizes as well as the placement of clamps, etc. Up until a couple of months ago, this was the best system that we could provide. It went together fairly easily and provided a way that the end user could take it apart to make repairs and put it back together with a minimal cost.
    We did not stop there, however. We felt that there was still room for improvement and we started looking back at the boots that we were making for the manifolds. At this point, we went to the people who were stitching the boots for us, and had them make up a blanket for us with Pyro-Jacket-XL, Insulmat, the Stainless wire mesh and the buckles. This worked well enough that we went out and bought an industrial sewing machine. We are now doing blankets for straight lengths of pipe, as well as covers for purifiers and mufflers. Whenever possible, we also make covers for the elbows. We currently use a high heat silica cloth as a liner instead of the stainless wire mesh. It is easier for us to sew, have less waste, and we will not have the random wire barbs protruding through the surface of the cover. This happens as a result of the needle hitting the wire, and pushing it through with the thread.
    As you can see, we have made some considerable changes since we first started in 1992, and we will keep on making changes as long as we, or our customers, feel that there is room for improvement.top

The Telstar Insulrap System came about as the resulf of customers looking for a good, quality heat protection system. They came to us because they were experiencing problems with extreme heat affecting their dash wiring, gauges, etc. We started looking and came up with a series of products that would do the job, and we are consistently looking for new, improved and better products for our applications. Following is a list of the products and a brief description of their uses:top

T-Briad Sleeving - Used mainly as the primary insulator or underlay on hoses, wiring, small diameter piping, etc. When used in these applications, you would apply it by sliding it over the medium that you want to protect. When used on larger diameter applications, ie. exhaust pipes or mufflers, you would flatten the sleeving and wrap the pipe as described in our installation instructions.top

Pyrojacket Sleeving - Used as a light-duty heat protection for hoses, wiring, etc. It can be applied by itself or in conjunction with the T-Braid Sleeving. Pyrojacket Sleeving is basically T-Braid Sleeving coated and impregnated with high heat silicone. Once again, it is applied by sliding it over the hose, wiring, or pipe that you wish to protect or insulate.top

Pyrotape - Used as an insulating, protective cover, applied over T-Braid Sleeving or Ceramic Mat (described further on). Pyrotape consists of varying widths of glass fiber woven strips, coated and impregnated with high heat silicone. It is supple and stretchy and when pulled taught, it will conform to uneven surfaces.top

Pyroblanket - Used as a protective covering for large areas such as firewalls, manifold boots, or long lengths of straight pipes. It is made up of a thin sheet of woven glass fiber coated and impregnated with high heat silicone on both sides - approximately 1/32" thick. It can be sewn with reasonable ease as is done with manifold boots and firewall blankets.top

Pyrojacket-XL - Used as a heavy-duty protective cover for large areas or long, straight lengths of exhaust. It can also be used for covering large mufflers or purifiers, but must be custom designed to fit. This blanket would normally be applied over ceramic mat. We have been experimenting with different ways of fastening it and have found that the best way seems to be using hooks & ladders. As long as there is about an inch of overlap, and the hooks and ladders are placed roughly 2" apart, facing the outside of the machine, or away from the direction of any hoses or fuel lines, there should be no problems with fuel or oil entering the blanket.top

PyroSealant - Used in conjunction with all of the above products, it seals the open ends of Pyrojacket and the spiral seams formed when using the Pyrotape. It is also used to seal the joint where Pyrotape and Pyrojacket / Pyrojacket-XL meet. It is the binding, so to speak, that holds the whole wrap together. PyroSealant is a high heat silicone that bonds itself to the silicone coating of our other products. For proper adhesion, all surfaces must be clean and dry. If you find that the surfaces of the pyro products listed above, become soiled or show visible signs of fibers on the surface, then use a clean, damp rag to clean the surfaces and dry thoroughly with a clean dry rag.top

Ceramic Mat - Used as an insulating barrier in areas of high to extreme heat. It is a ceramic fiber matting, available in 3/4" thickness. We recommend its use on large areas, in manifold boots or firewall blankets. It also acts as a sound deadener in closed operator compartments.top

    It is suggested that P.F.T.B be applied to the engine compartment side of the firewall. Panels should be covered individually, and P.F.T.B should be held in place by three or four 1/8 x 1" pieces of flat bar fastened across the width of the panel.
    It is also suggested that P.F.T.B be applied to the underside of the floor as well as heat tends to rise, making it hot on the operator's feet.
    For the additional heat displacement from the engine compartment, we suggest the use of the manifold boot. This boot is just slipped on and tied with stainless steel wire to secure it in place.

By following the above application procedures, you should be able to reduce the amount of heat in the operator's compartment, making it much more comfortable on the operator.top

        We recommend that all pipe joints be welded. If bands clamps are being used, they should be inspected for tightness and leaks. Tighten or replace clamps as required. Periodic inspections should be made to confirm the condition of the clamps. Our liner and insulation are rated to approx. 1800-2000° F. The outer cover is rated continuous to 500° F. and intermittent to 3000° F. The insulating materials that we use bring the operating temperatures within the required parameters of the cover. The main purpose of the outer cover is to provide protection against contamination of the insulating materials by combustibles as well as providing a rugged protection against high pressure washing, abrasion and wear.
    We express no warranties or liabilities should a clamp loosen or a pipe fail, allowing the direct exhaust to penetrate the insulation or even break through the outer cover. This could create its own fire! As the flash point of diesel fuel is approx. 680° F., and hydraulic oil is approx. 700° F., the presence of either on the surface of the covering when this happens could create a flash fire (as it would if there was no wrap at all or even a metal cover). This scenario is the main reason for the covering to be checked at the start of every shift. If any contamination is found, the wrap should be cleaned properly or replaced before the machinery goes back into service.
    Minor damage can be repaired using PLT-310 High Heat Silicone Sealer. Major repairs may require the use of T-Braid sleeving and PT-3 or PT-5 bands, or may require replacement altogether.
    If there are any concerns as to whether Insulrap is suitable for your application, we recommend testing before using.top

    The INSULRAP system is a very straightforward application.
    Most parts are currently being made to custom fit. The inner lining is made up of silica cloth (Omnisil). The insulating material is ceramic matting (TB 1260). The protective cover is glass-fiber cloth coated with approximately 1/16" of special high heat silicone (Pyro-Jacket-XL). These three components are stitched together to form a blanket. Elbow, purifier, and muffler covers are done in the same manner. Adjustable hook and ladder buckles secure covers in place. All seams are stitched and sealed with a special high heat silicone sealer (PLT 310).
    Application of exhaust wrap to the exhaust system is usually very simple. First, the elbows are put in place and buckled. Once all of the elbows have been put in place, the blankets can be positioned so they overlap the elbows a little bit. A small amount of insulation can be tucked into the joint between the elbow and blanket. Then stretch a strap of Pyro-Tape (2", 3", or 5" as required) around the joint and fasten it. The next step is to seal both exposed seams on either side of the straps with the PLT 310. Finally, using a wet cloth on your finger, smooth out the silicone to insure that a complete and proper seal has been made. If necessary, this procedure can be performed to seal the overlapping seam where the buckles are.
    If you are doing a repair on a system or another application, regardless of size, follow the instructions for the application of T-Braid and Pyro-Tape.top

    A) T-Braid (Insulation applied directly to bare exhaust)
            1) Use a light wire to tie off flattened T-Braid to bare exhaust pipe at starting position.
            2) Firmly wrap flattened T-Braid, edge to edge in a spiral pattern along exhaust pipe. Do NOT overlap.
            3) Tie off the trailing end of the T-Braid to hold in place.

    B) Pyro-Tape (Do not apply directly to bare exhaust pipe)
                  (Protective insulating cover applied directly over T-Braid)
            1) Tie off end of Pyro-Tape at starting point of T-Braid.
            2) Firmly wrap Pyro-Tape, edge to edge in a spiral pattern, covering the T-Braid. You shouldn't have to overlap, but if overlapping
                    is required, overlap by at least 1/2" to prevent slipping.
            3) Tie off the trailing end of the Pyro-Tape to maintain tightness and to prevent unraveling.

    C) PLT-310 (Do not apply directly to bare exhaust pipe)
                  (Silicone sealant to prevent fluids from entering insulation)
            1) Apply to seam of Pyro-Tape and smooth out with a damp cloth ensuring complete sealing of spiral edges.
            2) Allow PLT-310 proper curing time, of approximately 1 hour, before putting exhaust pipe back into service.

CAUTION: Do not apply Pyrotape or Pyrosealant directly to the bare pipe, as this could create a fire.

Once Telstar Insulrap has been installed on your exhaust system, there are a few things that you should watch for:

Our Customized Applications Deliver Superior Heat Protection INSULRAP can be used in practically any specialized application, whenever heat or safety is a concern. We have provided INSULRAP for a variety of customized applications including exhaust manifolds and pipes, firewalls, scrubbers and turbos, hydraulic hoses, wiring, blast furnace water jackets, and many others
BEFORE & AFTER INSULRAP The following photos illustrate the 'before and after' effect of INSULRAP heat protection. For improved operator safety, the operating temperature of this Deutz V-8 diesel engine manifold had to be greatly reduced:
	With INSULRAP heat protection, the manifold temperature dropped to a safer temperature of 178° F. ( A temperature drop of 341°F.
Without heat protection, the infrared heat sensor indicated the manifold temperature at 519° F.

HIGH HEAT WRAP - KEEPS HEAT IN OR OUT Easily slips over Hose Assemblies, Exhaust Systems, Wiring Harnesses, Pipes, etc. Expands over fittings and connectors -65° F to +500° F continuous, 3000° F intermittent Non-Asbestos 1/4" to 4 1/2" diameter	In Other Words... "Our goal is the development of reliable, quality products for heavy industry - mining, forestry, construction, etc. Since we began our research into heat protection, INSULRAP has shown great potential as a leading product. I think you'll find INSULRAP meets or exceeds your expectations ... and I believe there is no better heat protection." Al Viita, President, Telstar Hydraulics Ltd.
	"I first tried Telstar's INSULRAP on an ST8B about a year ago. It works so well, I use it to wrap the exhaust system on my airplane to prevent burns and any possibility of a fuel leak fire." Myles Bruce, Blackwood Hodge Equipment Limited
Performance results of INSULRAP Insulation "On Friday, November 25th, 1994, I was able to obtain heat measurements from two identical models of dump trucks. The unit numbers were #755 serial 1917 and #822 serial 1553. These were Eimco Jarvis Clark 30 ton trucks. Unit #755 has been equipped with a INSULRAP exhaust manifold boot and had the firewall re-insulated with INSULRAP Pyroblanket. Both units were hauling rock from 950-5190 to 600-1800. This consisted of a one way tram of 3100 feet, 1600 feet of which was up a 20% incline. Measurements were taken on 600 level. The results are as follows... 755 822 Top of Hood 103 140 Firewall between knees 101 140 Floor between feet 122 132 Firewall between ankles 105 136 ... all measurements are in °F. All operators who have driven #755 notice the difference and Mining Dept. has asked to have all U/G dump trucks equipped the same way." Jim Rousselle McCreedy West Mine INCO Ltd.	"When Telstar's INSULRAP was tested at our plant on a Deutz F8L413FW engine, the external temperature drop at the exhaust manifold, under full load conditions, was an impressive 341° F... This dramatic temperature reduction is sure to improve operator comfort and reduce fatigue. A definite consideration with today's environmental concerns." Edward Bayford, Henninger's Diesel
Contact us for consultation regarding your heat protection requirements, as well as detailed application instructions.