Thermolastic Exhaust Insulation Fitting Instructions

Thermal Insulation of wide bore diesel exhausts

Saveguard Thermolastic Tape has been specially developed to provide a highly efficient insulation medium in a simple to fit format. The product consists of a high temperature glass fibre textile bonded to a metal foil facing to provide a flexible tape with the elastic properties required to provide a snug fit and to accommodate bends.

Thermolastic tapes are applied in layers according to the temperatures involved in the application, normally 3 layers are sufficient for most diesel exhaust applications. The Thermolastic system consists of two components, inner reflective insulation layers, and a choice of outer protective layer of self bonding tape depending on the temperature resistance required (see data sheet).


Thermolastic Tapes	Tools required
There are no special tools required for installation only a tape measure a straight edge or ruler and a pair of scissors. These simple to follow, fully illustrated instructions are included with each pack

	fig.1
Step 1: Exhaust should as clean and dry as possible and free from oil and dust. Where a distinct finished edge is required, typically before pipe joints, first wrap the Thermolastic Insulation Tape loosely around the pipe to the thickness of insulation required, normally 3 layers and cut with scissors as in fig.1. Remove from pipe and fold in foiled edges to middle. fig.2

fig.2	fig.3
Step 2: Fix to pipe *fig.3* with self adhesive tape and wrap tightly, under tension to thickness. *fig.4* Fasten with self adhesive tape to hold and flatten edge with finger or suitable smooth object as in fig.6

fig.4	fig.5
Step 3: Measure the circumference of the exhaust pipe to be insulated *fig.7. Mark the same measurement on the front of the Thermolastic tape, (over the insulating section) at an angle as shown in fig.8. Cut with scissors as fig.9*

fig.6	fig.7


fig.8	fig.9
Step 4: Fasten the tapered cut end of tape to the exhaust to start. Spiral wrap the Thermolastic tape around the pipe keeping it under tension and overlapping the foil layers. The insulated section should butt up against the adjacent insulated section as in *fig.11. Fasten with adhesive tape to secure. Subsequent layers should be spirally wound in the opposite direction as fig.12*

fig.10	fig.11


fig.12	fig.13
Step 4: Tightly bind ends with HT self adhesive glass fibre tape and smear with Thermolastic High Temperature Silicone RTV. As in *figs.13 &14.* Apply Thermolastic protective layer, spirally winding under tension, removing the interleaving as you progress *fig.15.*

fig.14	fig.15

The Thermolastic protective layer should be overlapped by at least 20mm. This will allow sufficient area for self bonding. Smooth over the overlapping edges applying pressure in the direction of the wind. The bond strength will increase with age and any increase in temperature from the exhaust.