The short answer
Most heat loss in a poorly insulated boiler comes from discontinuities — penetrations, supports and joints — not from insufficient thickness. Detailing beats specification.
Insulation is usually the last package awarded and the first one compressed when the schedule tightens. It is also where a surprising amount of operating cost is decided.
Thickness is the easy part
The specification states a thickness and a material, and meeting it is straightforward. What actually determines performance is how the discontinuities are handled.
- Support penetrations — every bracket through the insulation is a thermal bridge
- Access doors and manways — often left poorly finished because they feel temporary
- Expansion joints — must accommodate movement without opening a gap
- Terminations — where insulation stops is where water gets in
Cladding keeps water out, not heat in
The cladding's structural job is weatherproofing. Wet insulation loses most of its value and corrodes the surface underneath. Lap direction, sealing and drainage matter more than appearance.
Sequence it properly
Insulation cannot start until the hydro test is complete and the surface is dry. Compressing it means insulating over damp steel or delaying handover. Build the duration into the plan from the start.
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