Lloyd Insulations India Limited is THE largest organization in Industrial Thermal and Acoustic Insulation contracting company in this part of the world. We have been associated with every major project executed in India in the Industrial and commercial sectors for over 50 years. Our Leadership status and Industry Expertise in this is responsible for our being Market Leaders with over 70% market share.

• We are an All-India organization with seven dedicated Insulation supply points, four full service regional offices, 24 branch offices and over 110 customer contact centers to handle assignments at any location in India presenting a reservoir of resources to handle Thermal Insulation contracts country wide.
• Over 20000 insulation and cladding workmen trained to deliver quality work under all conditions with specialization in insulation of large industrial projects.
• Countrywide infrastructure for logistics, supply chain management and commercial interface of all kind.

We are an ISO 9000 Company known for our commitment to deliver total performance to our client. For this purpose, we are equipped to provide design of systems, manufacture and supply of specialty materials and their scientific application. Almost always, we measure the performance of the applied system in actual service and ensure delivery of total customer satisfaction.

Large database generated over the years have equipped us to face any application challenge in the Indian environment.

We are actively serve on Standards bodies like ISO, Bureau of Indian Standards (BEE) and others.

Thermal Insulation plays an important role in every Process / Manufacturing plant from view point of "Energy Conservation". In applications like hot / cold insulation properly designed "Insulation System" can achieve any of the targets set through a focused "Energy Conservation" program implementing the designed insulation system through scientific erection practices at actual work site is the key to achieving these goals. Our experience of more than 50 years in this field has taught us a number of Do's and Don'ts imparting unbeatable application expertise to our site personnel.

Assisting various organisations right from Basic Engineering i.e. Design of Insulation system, Preparation of Material Specifications, Preparation of Quality Manuals for materials as well as Site Erection practices and, last but not least, correct Application at site is the major aspect of our business model. We have extended these services to a number of our clients where they have achieved targeted results. We also offer Annual maintenance service to most of our larger clients.

Applications handled by us range from -200°C upto 1450°C and can provide you all the necessary Technical back-up in regard to selection of materials and ancillaries which are most important for a proper "Insulation System". We provide these technical back-ups as part of our turnkey solutions, which include supply and application and guarantee the applied systems for performance.

Our commitment towards assisting industry to arrest of energy loss has been one of the spearheading causes to place us in the leading position. Today the company offers a wide range of services coupled with the state of the art products (Insulation & Allied) to meet the most varied and stringent demands of the Industry at large.

The company specializes in carrying out site works with high importance to

• Maintaining Project Specifications,
• Following the highest Safety norms,
• Ensuring the highest Quality Standards,
• Ensuring overall Economy to Users

Hot and cold insulation work in Turbines, Boilers, Pressure Vessels, chemical processes in Refineries / Petrochemicals, Pharma and metallurgical Industries for equipment, Piping & critical Cryogenic processes constitute major part of our offerings.

Lloyd insulations have the comprehensive competence to execute industrial Thermal Insulation projects on turnkey basis to International standards. We have the expertise to design, fabricate, supply, and install advanced insulation and allied systems strictly keeping with the special requirements that individual projects call for. We are the first company to offer our valued customers an advanced thermal insulation audit service.

ROCKLOYD, the company's flag bearer for over 3 decades has been in continuous development to meet and exceed performance expectations of large projects as they have come up. At the same time, the company has built into this product, features like certified fire barrier properties and ecological features like bio solubility, negligible binder contents (to limit phenol formaldehyde contents to the lowest levels) and encouraging recycle contents in its manufacture.

Lloyd Insulations have been closely involved with the development of advanced insulation products and systems that have set new Industrial standards including SUPERCERA Spun Ceramic fiber for High temp service upto 1450°C and Isoloyd & LloydFoam Rigid urethane foam insulation for low temperature insulation down to cryogenic temperature (both preformed or in-situ produced), for ultimate Thermal efficiency of tanks, process plants and pipelines.

Specialty products like SUPERTHERM Low Temp Pipe supports. Fire barrier grade and Water Repellant grade of ROCKLOYD Stonewool Slab, Mattress and Pipe Section Industrial insulation products are the first choice of major project specifies.

Each of our products are tested for all critical qualities in dedicated labs equipped with all the required equipment and manned by experienced personnel. Quality of each product is audited closely through an interactive process between engineers is the field and the professionals at the manufacturing plants.

Instant, we provide a comprehensive range of turnkey insulation services, such as high temp, cryogenic, acoustic and fire protection insulation featuring best available ancillary materials. We are constantly innovating by evaluating and developing the use of new materials and application techniques. This allows us to offer forward-thinking, intelligent solutions, which reduce whole life costs. Our customers obviously think so, as we receive a great deal of repeat business. We care for the environment and products offered by us meet and exceed all current environmental norms. We encourage use of insulation to thicknesses calculated to reduce harmful CO2 emissions from our clients' plant.

Our fabrication services include sheet metal fabrication and fire protection cladding along with a specialist department offering fire tested mattresses and thermal mats. Special areas of expertise are marine applications and hazardous application (Like Hydrocarbon, Ethylene / Propylene oxide systems).

We are currently involved in a number of large insulation contacts for almost all corporate houses in India apart from public sector undertakings like:

• Essar
• Reliance
• Adani Power / Tata Power
• Petronet LNG
• Indian Oil Corporation Limited (IOCL)
• Hindustan Petroleum Corporation Limited (HPCL)
• Bharat Petroleum Corporation, in all their refineries Limited (BPCL)
• Oil & Nature Gas Corporation (ONGC)
• National Thermal Power Corporation (NTPC)

We have worked with many of the well known consultants, like:

• Bechtel International.
• Wall Bridge Brown & Root International
• Shell Global Solutions International BV
• Samsung Engineering Co. Ltd. South Korea
• ThyssenKrupp (Uhde India Limited)
• Engineers India Limited.
• Toyo Engineering India Limited
• Aker Kvanerner Powergas India Ltd.
• Mott MacDonald
• Jacobs H&G Limited.
• Siemens
• Stone & Webster Inc.
• ABB Lummus Global
• Lurgi AG
• Linde AG
• UOP
• MW Kellogs
• And many more...

Our Insulation services are available for all over India and in neighboring countries.

 

Energy efficiency in buildings is achieved through a multi - pronged approach involving adoption of architectural principles responsive to the climate of the particular location by combining efficient insulation with robust structural design. Implementation of energy-efficiency in building systems is almost entirely dependent on effective Thermal Insulation of the building envelope.

India is quite a challenge in this sense since there are as many as six major climate zones:

1. Cold and sunny
2. Cold and cloudy
3. Warm and humid
4. Hot and dry
5. Composite and
6. Moderate

Translation of optimum architectural design in the Indian context therefore poses a major challenge in proper choice and deployment of Insulation, Vapour retarder, Weather protection and aesthetic finishing.

Design of energy efficient envelope is a matter of deep understanding of Building Physics and thorough knowledge of Materials Sciences. Lloyd Insulations have led from the front in these branches of science.

Thermal insulation in buildings plays an important part in achieving thermal comfort for its occupants. Insulation reduces unwanted heat loss or gain and can decrease the energy demands of heating and cooling systems.

In addition to a wide choice of Thermal envelopes, Lloyd Insulations provide complete solutions for scientific thermal Insulation of HVAC system elements like chilled water Refrigerant lines, supply and Return air ducting and Air Handling units a hot water plumbing to provide comprehensive energy efficiency to the built environment.

We have joined major players in the Building Sector in India, in co-ordination with energy experts, to draw up ENERGY CONSERVATION BUILDING CODE (ECBC). This aims to specify norms for insulation resistance requirements for buildings servicing various specific functions in various climate zones.

Whether in Industry, commerce or in residential environment, thermal comfort has become a vital necessity. Employee productivity is directly linked to his workplace environment.

Enclosures which operate without any cooling systems are totally dependant on Insulation coupled with adequate ventilation for achieving thermal comfort.

In spaces which are air-conditioned to face summer conditions, high heat ingress greatly increases the load required on the HVAC equipment to remove the above ingress of heat - which means:-

• High energy cost for running the HVAC system and
• Higher running time and, hence wear and tear of the HVAC equipment
• Insufficiently or poorly insulated building would also mean necessity to install HVAC equipment of much higher capacity than what would be adequate if proper thermal insulation had been provided. This would mean higher first cost of the project itself.

In other parts of the year, insulation duty would also include extreme winter ambient conditions and the concurrent need for achieving thermal comfort in the building interior by heating.

Under winter conditions, a major hazard is the risk of condensation within the system itself or on the inner surfaces of un-insulated or insufficiently insulated building elements. Detailing the Insulation system design would involve proper placement of Vapour Retarder and very careful attention to potential heat bridges and Cold spots.

Major contributors to energy balance in buildings are the roofs. Roofs are composed of Reinforced Cement Concrete (RCC), sheets of fiber Reinforced Cement sheets or Plain / Coated Metal profiles. Apart from addition of insulation value to such elements, it is necessary to add thermal capacity as well - to be able to dampen the effect of cyclical temperature variations so very common over a typical Indian summer day.

Thermal insulation, by retarding heat flow, delivers the following benefits to a building enclosure:

1. Helps maintain temperatures as perceived by the occupant to be within his limits of tolerance.
2. Reduces over-all cost of heating or cooling by cutting down energy consumption.
3. Reduces capacity of capital equipment to be installed for HVAC duty by cutting heat loss or heat gain to be compensated.
4. Keeps the temperature of the inner surfaces of buildings within acceptable limits to reduce possibility of their acting as “Radiators” causing added thermal discomfort in summer and possible condensation in winter.
5. Provides fire protection to metal structures.
6. Reduces break-in of external noises and absorbs internally generated Noise.

Thermal insulation is specified and applied to fulfill any one or combination of the above functions.

Materials- Importance of physical & chemical properties

As can be appreciated, the most important single requirement is that the materials deployed in the insulation system should remain in place and continue performance of their assigned role over the expected life of the building. This stipulation would require that each material should be unaffected by exposure to the environmental media for the entire life span of a building.

Lloyd insulations offers a wide range of materials, each of them developed, tested and validated to deliver the best value to the end user.

The ROCKLOYD range of bonded mineral wool combines excellent insulation value with total fire safety. Its fibrous matrix affords excellent acoustical and Noise control properties as well. It is offered in all possible forms - Slabs, flexible Mattress, performed Pipe Section or sprayable formulations.

ISOLOYD NILFLAME, SUPERFOAM, LLOYD FOAM and SUPERTHEM represent the higher end of thermal efficiency, while delivered excellent structural strength properties. These closed cell Rigid Urethane Foam insulating materials resist vapour migration and water ingress.

LLOYD PANEL Systems provide the ultimate value in building insulation. They provide a one step solution towards excellent Insulation Value, Extraordinary Structural Strength and the highest levels of aesthetic finish to a building. Exciting opportunities are offered to Architects and designers to extract maximum benefit to the end user in applications like commercial complexes, large Industrial buildings and public buildings like Airports, stadia and convention centers.

Lloyd Insulations manufactures each of the above materials in a network of plants, located in different parts of India to service customer requirements promptly and economically.

Each of the plants is equipped with relevant laboratory and testing facilities to assure quality at each step.

Having met and exceeded specified requirements of some of the most demanding users and consultants, our products enjoy the benefit of acceptance by every leading specifier in the field.

Our list of clients reads virtually like a “Who - is -Who” in each of the major sectors, some of them being,

Acoustics is the science of study of SOUND - its generation, propagation and finally its receipt by a listener. Unwanted sound is defined as NOISE. Noise is a result of activities such as loud talking, operation of machinery or vehicles in the neighborhood. In today`s world, noise has assumed an important area of study since it affects our way of life, our health and our psychology.

In architectural acoustics, Lloyd Insulations has handled Noise control projects and in size and complexity ranging from Aero Engine Test Beds, Automotive Engine and vehicles test cells, Enclosures for very large steam Turbines and for very noisy Gas Turbine. In these assignments, acoustical enclosures housing very noisy mechanical equipment have been treated by us to ensure that the operational areas in the immediate neighborhood experience acceptable levels of disturbance either as prescribed by codes or in line with what is optimum for the activity on the quieter side.

Control of noise, usually termed as "Noise Reduction" is the subject covered by Acoustical Engineering. Design of interiors, however falls within the area of expertise covered by the Architect and the Interior Designer. There is need for close interaction between the two disciplines to evolve technically correct & functionally sound interiors for the modern man.

Acoustical performance of enclosed spaces such as Office areas is important in that we expect the persons occupying these areas to perform efficiently for fairly long periods. High level of importance is given to ease of voice communication -whether between individuals in the same space or over of telephones, inter- communication equipment or others.

These human activities make a big demand on the nature of the environment in which they are performed. A noisy work-place is considered undesirable for mental tranquility of the occupants, quality of work and hence their Productivity. LLOYD INSULATIONS have a large range and absorption materials and systems for optimum treatment of all enclosures including auditoria.

Protecting communities from excessive outside noise arising from traffic on highways and busy city traffic requires well rounded solutions covered by an interactive process of various between engineering disciplines.

General principles of control of noise produced internally

In this section, we deal with the aspects of noises produced within the space as contrasted to those from the adjoining areas.

Any mechanical equipment or a loud talker is a highly localised source of noise. When many such sources combine together, the overall Noise Level builds up to a high "ambient". When a person needs to communicate in this ambient, he would raise his voice instinctively. This gives rise to further increase in the ambient level and so on.

In public spaces, like airports, precise delivery of message through the P A system is possible only if the interior is treated for optimum acoustical absorption.

This is the main reason why it s very important to avoid a scenario which would promote build-up of noise level. The major culprit in building up the level is the reflectivity of the surrounding surfaces like the ceiling, walls and the floor. In addition, if furniture is constructed of hard panels (as in most cases), the situation is further aggravated.

In Industry, Zoning of noisy equipment and providing enclosures around them would prevent their contributing to the general noise buildup in a larger production or process hall. This is an aspect to be kept in mind during layout of the premises.

Provision of acoustically absorptive surfaces, particularly in the ceilings and walls is the first step in proper interior design.

In any acoustical work providing acoustical absorption economically is a necessary function.

ROCKLOYD Insulation has been engineered to provide optimum Acoustical Absorption by offering the highest “Noise Reduction Co-efficient,” to the designers and architects. They helps in judicious use of absorptive surfaces in the interior design.

Acoustics of Ventilation & Air-Conditioning system

When we talk about mechanical equipment which we deploy for tasks such as ventilation or air handling, any sound produced by them could be termed as "unwanted" and hence, requiring reduction - if not total elimination. This subject is quite diverse and it is not possible to cover all aspects briefly. However, an attempt is made here to cover the basics and open out the minds of the designers to the significant parameters that influence acoustical performance of mechanical equipment like ventilation or air-conditioning installations.

As can be readily seen, this function involves mechanical machinery, some featuring both rotating and reciprocating movements, while others handle large volumes of air through narrow passages such as ducts and deliver through restricted areas of cross sections such as grilles to produce aerodynamic noise.

All these elements are potential areas of Noise Generation. Acoustical treatment steps are totally dependent on study of these specific subjects scientifically.

A significant area concerns duct silencing where free flow of air is to be permitted while trapping noise at source. It would be important to know where & why - silencers are to be deployed.

Duct silencers are frequently applied in air-conditioning systems at the intake or discharge of system fans to reduce or eliminate fan noise on the return and supply sides. Silencers may also be required after branch takeoffs or elbows, after pressure reducing valves, and after mixing boxes. In short, silencers allow movement or air as the Air-conditioning Engineer may want but, act as traps to cut off unwanted noise transmission through duct passages. Today, packaged duct silencers incorporating ROCKLOYD are capable of performing to the precise degree demanded by the user while working within specified parameters of space and pressure loss.

Performance of requirement of silencing equipment can be calculated, after an acoustic design criterion has been set, for each noise generator in an Air Conditioning system.

Silencers used in HVAC systems belong to the family of "dissipative" silencers which predominantly rely on absorption in a "straight through" device. In all cases, these silencers incorporate a fairly low resistance air flow channel duly lined with ROCKLOYD acoustical absorptive material having precise specific airflow resistance, the parameter that determines silencer efficiency.

 

While designing dedicated silencers to perform noise attenuation in ducts, what we look for are:

1. High acoustical efficiency vis-a-vis space occupied - All dimensions are important in building design and there is high premium on compactness.
2. High acoustical efficiency with least resistance to flow i.e. with least pressure drop encountered in passage. If the silencer offers too high a resistance, the air supply fans may have to be oversized with higher Power consumption.
3. Sound rugged construction ensuring long service life without any deterioration/corrosion. This is important since most silencers are not accessible once the work is completed. In addition, silencers should be so constructed as to prevent dislodgment of particles of acoustical medium itself during use.

Often, it is mistakenly believed that an ad-hoc provision made in the duct system is more than adequate to handle the acoustical duty.

Review has shown that such an approach has always resulted in a very expensive post treatment.

Step-by-step selection procedures are to be adopted to ensure acoustical and aerodynamic adequacy.

Lloyd Insulations specialise in precise design of Acoustical systems to meet any duty requirement. With very large capacity for many plants distributed across the country and with the dedicated fabrication plant located at Baddi, H.P to manufacture enclosures, Silences and lived ducts, We provide economical solutions for every duty.

It is to be realised that it is important to remove annoyances that may be caused by noise - whether by the activities within the space or due to the provision of Air-conditioning and Ventilation Systems which are essentially provided for improving comfort conditions to the occupants of an enclosure and to improve Productivity. At times, the equipment deployed for the purpose of providing comfort to one set of persons may, in effect cause disturbance to the neighboring persons. Conscious design of equipment and careful design of noise control provisions would render the installations acceptable for the entire community.

Some of Acoustic Job references are...

Force Motors Limited
Bajaj Auto Limited
Bajaj Tempo Limited
Larsen & Taubro Ltd
Reliance Engineering Associates Pvt. Ltd.
The Automotive Research Ass. Of India (ARAI)
Beckay Engineering Corporation
Tata Power Ltd
Reliance Industries Limited
Hazira LNG Pvt. Ltd. and many more...

Lloyd Traffic Noise Barrier System

Barrier design for traffic noise attention (control) requires a number of concurrent requirements such as robustness in construction, to withstand all external forces including wind loads, ability to resist environmental exposure conditions, aesthetics, proof against pilferage and vandalism and highest level of cost effectiveness.

 

Needless to state all these can be built is to the system through a “tailor made” design featuring an interdisciplinary design approach.

Pre-engineered buildings have become an essential option for a number of buildings such as warehouses in infrastructure projects and production shops for every conceivable manufacturing activity. With the large, clean floor area free of columns or obstructions, afforded by this concept, PEB's find favour with organisation who have very dynamic plans related to products and process handled by them over a period of time. In warehouses, the pre-engineered building allows for more storage and stacking than the conventional concepts such as concrete and site fabricated structural steel. PEBs permit end user to optimise column free space to suit racking arrangements and internal logistical requirements.

Pre-Engineered Buildings, are best constructed as stand-alone buildings precisely engineered to specific user requirements. PEB components are totally shop fabricated require bolting of components together of the same on site connected to previously completed foundations and sub structures. They feature a structural steel framework of primary and secondary members (rigid frame, beams, purlins and girts, trusses, and columns) on to which cladding and roofing components are attached. In short, pre-engineered buildings can be as unique as your needs.

Buildings intended for commercial, industrial or institutional occupancies can be built precisely, economically & speedily using this concept.

PEB steel Lloyd

We have established facilities in India to design, detail and manufacture Pre-Engineered Buildings of any size and nature, with full capability to execute projects of any volume all over India. We are known for maintaining time schedule of projects, which is the prime requirement of today's building industry.

We specialize in providing turnkey solutions in Pre Engineered Buildings in respect of insulation and Noise control. As well to acquaint our capability, we are pleased to present various details including those related to manufacturing of Pre Engineered Buildings, their complete field erection coupled with necessary Roofing and Cladding.

LII has been in the business of turnkey contracting services for the Indian Industry for 52 years now and have always made available relevant updated technologies and materials for Infrastructure development and providing total solutions to projects.

LII, have association with PEB group of companies based in Europe, having extensive Design, and erection manufacturing unit at Vietnam and experience of over 3,200 PEBs in China, Vietnam, Thailand, Myanmar, Laos, Bangladesh, Qatar, Sri Lanka and Cambodia.

PEB Steel Lloyd offices are staffed with talented and experienced engineers who would be very pleased to offer you a completely free consultation and a comprehensive quotation including proposal drawings, in the shortest possible time frame.

Our installed capacity for Design, Engineering and Manufacture of Pre Engineered Building structures in India is 60,000 MT per Year. Our plant is located at Pithampur, near Indore, M.P.

Design for total safety - availability of Code

Any structure that is built, apart from delivering all functional needs of the end user, must provide highest levels safety against all loads and exposure conditions that are expected to be imposed during construction as well as service phases of a building.

PEB, as a concept, finds its strength in its innovative design process. This process derives its strength from optimization by which metal is deployed to its required extent exactly matched to the loads that are incident on that element.

Conventional structural engineering standards, (which are all based on rolled steel components with fixed cross section), sometimes, fail to capture this unique feature available to the end user.

Heartening development in this respect is revision in the Code of Practice for structural steel design (IS: 800-2007) which has been modified substantially in line with this concept. However, new standardization work is needed for covering materials such as composites (like sandwich panels), and codes for fire safety.

Highly researched fire safe panels incorporating polyisocyanurate and Mineral Wool cores with excellent fire rating are available from the company to meet all fire safety codes.

Today's PEB structures incorporate panels having steel facings with proven advanced metallurgical protection like aluminium + zinc coatings.

Exterior finishes like organic coating (paint systems) are available having a wide array of colour and shades as colour coated products. India is a country with diverse climatic and environmental conditions and metal exterior surfaces needed are engineered precisely to meet the aggressiveness of the environment in which they have to perform

Our PEB designs follow the latest IBC Codes as well as IS Codes featuring best grades of steel (high tensile or otherwise).Complete design work is carried out in our dedicated design center at Pithampur. Our Design team is well equipped with trained and experienced design engineers along with design drafting facilities like AutoCAD, STADPRO,TEKLA Structures and special Customised software which are capable to deliver the best of the Pre Engineered Building products to any user.

Today's building projects are large and require to be commissioned in the shortest possible time. Roofing and Cladding of the buildings of the past have featured the use of various materials like asbestos cement sheets (since prohibited by Health and Safety reasons) shallow circular corrugated aluminium Galvanised Steel sheets, GI sheets, FRP and PVC sheets etc.

Today, coated steel roofing made from a variety of profile have virtually occupied the whole space, with special aluminium profile making their presence felt.

Lloyd Insulations is committed to serving the construction industry by manufacturing high quality, competitive roofing and siding products and by providing expert technical service. Our commitment is based upon a policy of working closely with Architects, designers and customers, applying quality assurance practices to all our activities, and achieving technical excellence through close interaction with vendors of

• Primary metals
• Product development and
• Capital investment.

We feature basic colour coated metals sourced from vendors having years of experience in manufacturing organic coated steels, in partnership with leading paint manufacturers. Any product from Lloyd Insulations would have been tested and proven at laboratory by specialist manufactures.

Steel as a profile material

Steel, with its combination of flexibility, durability, strength-to-weigh ratio, and economy, is an ideal material for profiled cladding

The ability of any cladding profile to meet the required structural design criteria depends on the mechanical properties and thickness of the material, and the profile shape.

Steel is the strongest and stiffest of the various materials used to make cladding sheets. Steel cladding is therefore thinner (normally 0.4mm - 0.7mm) than cladding made from other materials.

Although the deflection of a steel profiled sheet is not affected by the choice of steel grade, its resistance to plastic deformation and web buckling is. For this reason, it is often worthwhile using high tensile steels. They can markedly improve the resistance to accidental denting caused by concentrated impact loads. However, it is important to check whether high tensile grade are compatible with the specific profiles and field jointing (Seaming) operation.

Base Metal:

The basic material is cold rolled steel sheets in appropriate thickness to specific duty. Steel is available having various yield strengths, from 240 MPa to 550 Mpa for roofing and cladding applications.

Base Metal Protection:

The steel sheets used for building applications are corrosion protected with metallurgical coating of 180 GSM to 275 GSM galvanising. "Zincalume" / "Galvalume" sheets have metallurgical protection of 55% hot dipped coated Aluminium, 43.5% Zinc and 1.5% silicon. The coating density these is either 150 GSM or 200gsm. The Zinc - Aluminium alloy coating provides excellent corrosion resistance coupled with sacrificial protection provided by the Zinc in the alloy.

Organic Coatings:

Organic coatings provide aesthetic finish to Galvanised/ Zincalume coil stock. Choice of coating depends on the environmental conditions at the point of end use. Architectural Polyester coating is provided by indigenous manufacturers as standard products and Modified Polyester, PVF2 coatings, etc. are available on special order. Protective coatings are available in aesthetically appealing shades, whose durability without chalking or fading can be guaranteed for known exposure conditions.

Profiles

Different types of profiles are available by using continuous Roll forming technique.

TYPES OF ROOFING AND CLADDING SYSTEMS

LLOYDECK profiled sheets are fixed to the purlins/ girts with carefully engineered self drilling and self tapping screws provided with EPDM washer and matching colour coated UV stabilized caps. Trapezoidal, Hi-rib LLOYDECK profile with anti siphoning flute which drains the water entering through the capillary action, are being widely used in the industrial buildings. Profiled sheets are available in lengths upto 12 M (limited only by transportation considerations).

These systems are widely used in our country and offer the most cost effective solutions to industrial roofing requirements.

Lloyd Klip-fix Concealed Fixing System

This system features a patented concealed clip, which is fixed to the purlins with special fasteners, and the profiled sheets are clipped on to the concealed clips. The profile design and champing system have been designed to provide excellent resistance to wind uplift. Details have been so worked out as to make the total system projects water tight.

This system was basically developed to cater to the buildings having shallow slopes (as low as 2°)

An extraordinary feature of Lloyd Klip-fix system is that it is possible to roll form at site to any length and make it possible to have a single sheet from eave to ridge without any end laps. It is also possible to provide an "end to end" continuous length of joint-free roofing where shallow curved roofs are involved. For more details CLICK HERE

INSULATED ROOFS

Built up Roofing & Cladding System:

Roofing and cladding can be built up, layer by layer, with insulation to meet the requirements of Thermal comfort as well as noise control. Combination of LLOYDECK and LLOYD KLIP FIX systems is effectively utilised today in many building roofs. Double skin LLOYDECK Roofing and Cladding systems are commonly used for economical solutions thermal where reasonable efficiency building envelopes are designed. For more details CLICK HERE

Decking sheets having high rib profile are used in industrial buildings as permanent shuttering and also in insulated built up roofing, with a second profiled metal skin on the weathering side and insulation material deployed between the two sheets. For more details CLICK HERE

Composite Roofing & Cladding System:

Prefabricated sandwich panels with PUF/ Rockwool or Polyisocyanurate as core are available today for the most robust solutions in roofing, Wall cladding for buildings and insulated envelopes for cold rooms, D.G. set rooms to reduce the heat ingress and in DG set enclosures for noise transmissions. These composite panels essentially comprise of two metal skins with PUF/ Rockwool core offered as a one-step structural panel with weather tightness and almost the highest thermal efficiency.

Pre-fabricated sandwich panels with PUF core and with profiled sheet on the weather side and slightly ribbed plain sheets on the inner side are now the first choice for high efficiency insulation for roofings / Claddings in prestigious industrial and commercial buildings. For more details CLICK HERE

Special Roofing System:

Lloydtile type profiled sheets are available for resorts and other buildings where importance is given to aesthetic acceptance. It is common to see designers featuring these very attractive roofs in single storey units in an industrial site to break the monotony. For more details CLICK HERE

ANCILLARY MATERIALS FOR ROOFING AND CLADDING SYSTEMS

Lloydeck system utilises large quantity of self-drilling self tapping fasteners and there are many type of screws available from various manufacturers. Careful selection of screws is very important for roofing, since any weakness or proneness to corrosion of these items can cause complete breakdown of the system.

Profiled HDPE end closures, Flashings, cappings of adequate width, Sky-lighting with Poly Carbonate /FRP sheets etc have to be carefully designed and installed to make the building water tight.

Thermal Insulation/ Acoustic insulation to the buildings are provided with bonded Rockwool rolls having a standard density ranging from 48 kg/m3 to 144 Kg/m3 both bare and with aluminium foil facing. Superior density and thermal damping afforded by Rockloyd and similar rockwool's are preferred for certain special situations.

Metal roofing and cladding concepts developed by Lloyd Insulations have carved for themselves an enviable position in the Construction Industry in view of their being ideally suited to the situation and needs of the modern Engineering Industry. It would be very difficult to imagine how we could have met requirements for large enclosures with thermal and acoustical features demanded by the users of today without these concepts. The major advantage of the high speeds of design and construction afforded by metal roofing and cladding has contributed to the premier position occupied by them in the industrial Building sector today. Needless to state, Roofing and cladding work require correct installation at site to deliver performance to full potential. Lloyd Insulations provide complete field services of planning detailing supervision and installation as a turnkey offering. The single point guarantee offered is Valued very highly by all discriminating customers.

Some of Roofing & Wall Cladding project references...

Imsofer Manufacturing Co. Pvt. Ltd. Baramati (A Division of M/s. Ferrero Rocher)
Balewadi Sports Complex, Pune - Common Wealth Games
Adani Power Ltd., Mundra.
Volkswagen (I) Pvt. Ltd. Chakan Pune.
General Motors India Pvt. Ltd., Pune
Mumbai International Airport Limited T1C. Terminal 2
Nagpur Airport
Indira Gandhi Indoor Stadium, New Delhi - XIX Common Wealth Game, 2010.
Wrestling Stadium, New Delhi - XIX Common Wealth Games, 2010.
Jawaharlal Nehru International Stadium, Kochi.
TCS Siruseri, Chennai
Infosys IT Park at Pune
Delhi Metro Rail Corporation
Petroleum retail Outlets for M/s. Reliance Industries Limited 
Mahindra & Mahindra Limited Nasik, Pune, Haridwar
Bechtel International Inc., Dabhol Power Project, Dabhol
Metro Cash & Carry (India) Pvt. Ltd., Bangalore
Safal Fruit and Vegetable Auction Market, Bangalore, A/c. Larsen & Toubro Limited.
National Thermal Power Corporation Bangalore.
Ford Car Factory, Chennai
Roofing for Cidco Railway Station Turbhe, Ghansoli Railway Station, Rabale Railway Station and many more...

Buildings of all types require external fabrics which are capable of facing external exposure conditions while resisting various loads that are incident on them. External conditions include high or low ambient temperatures, high incidence of solar radiation (including ultraviolet rays), attack by environmental media (some of which can be corrosive) and seasonal exposure to rain, snow or sandstorm situations. Loads incident on external fabrics include wind loads, seismic loads, live loads faced during usage of the building and many collateral loads such as loads due to mechanical equipment and services directly mounted on the building fabric.

Metal faced pre-insulated sandwich panels combine every feature required to meet the above exposure conditions while offering high thermal insulation value extraordinarily high structural strengths to span large distances between supporting structural members.

Apart from external Walls and roofs, every building would require partitioning of internal spaces. Metal faced sandwich panels provide simple and easy-to-erect solutions for all such applications.

Many special facilities like Cold Stores require high level of thermal and structural integrity coupled with high thermal insulation values to meet specific low temperature conditions.

Many manufacturing facilities (in Pharma, Electronics, Precision machining, Paint shops) demand temperature controlled interiors. Thermally insulated envelopes have become a necessity for all such applications.

Lloyd Insulations (India) Ltd. has a comprehensive range pre-insulated sandwich panels with a variety of outer finishes and insulating cores ranging from high efficiency polyurethane / polyisocyanurate to totally fire-safe Rock Wool insulation.

To meet aggressive conditions, metal facings are pre-painted with a variety of finishes over hot dip galvanized / galvalume steel. Architectural coatings include polyester, poly vinyl di fluoride (PVDF/PVF2) many other options in a wide range of colours.

In the latest manufacturing unit of LLOYDS, these panels are produced in extended lengths featuring continuous production processes which are probably the most advanced in the world. The rigid urethane foams featured in this plant are 100% free from CFC or HCFC, which are known Ozone depleting substances.

Rockwool core incorporated in these special panels are of structural grade and have the unique “lamella” construction to offer extraordinarily high compressive strengths while building in highest fire safety among all panel systems.

Lloyd Insulations (I) Ltd. have a system of providing total solutions including complete responsibility for detailing and installation in field. All connected activities like design, detailing and ancillary material selection are done to result in easy and fast realization of panel work with every small detail taken into account.

Lloyd Insulations (I) Ltd. have made it a practice to keep upgrading manufacturing technologies so that speed, cost and high functionality are built into every system offered to its customers.

Polyurethane Sandwich Panel production processes and their effect on Cold Store panel performance- A brief overview.

Polyurethane Sandwich Panels are specified and used in a variety of applications-

1. Insulated roofs in commercial and Industrial buildings feature where an external profiled sheet and internal plain sheet with an integral insulation core. In Between joints of panels, precisely details lapping system in profiled facing is designed to prevent water and vapour leaks. The external sheet is similar to the profiled sheets normally used in metal roofing arrangements. The inner sheeting, although referred to as plain, does have a minor profile- featuring what are known as 'light cutting grooves'.
2. Siding systems for walls where the facings are selected according to the architectural elevation design follow the same configuration as the one featured for the roof in its simplest form. However, as per designers, choice various external skin of the panel are offered to various aesthetical Designer profiles.
   Normally, spaces are air conditioned in building application for comfort and hence temperature difference between the two faces is nominal. Importance is given to water and air tightness of the external face in all cases.
3. Technical facilities like Cold Storages, and Frozen Chambers demand larger temperature differences between the two faces of panels than in building applications. Metallic faces for these applications are generally flat with joints in insulation featuring a 'male and female' profiled jointing system. Joints are either positively interlocked or with liquid injected integrity . Very high importance is given to sealing - both in the butt joint between the PU insulation of adjoining panels as well as the vapour tight joint of the external steel.

In cold and frozen store applications, these features become very important, apart from the requirement of higher thermal efficiency of insulation per se.

In the Western World, in terms of millions of square meters of panels produced and used, the market is dominated by building roof and siding applications, In India, use of sandwich panels is evenly balanced between the two end uses presently. However, with the advent of Electronic, Pharma and precision manufacturing activities, sandwich Panels are assuming high relevance in building construction.

Production Processes:

Sandwich panels with rigid facings are produced using two variants in production techniques, viz:

1. Continuous production process and
2. Semi Discontinuous production process.

Production aspects in either process are aimed at producing products with similar end-use features. Although equipment may look drastically different, the basic foaming techniques and process steps featured in foam production are very similar.

1. Continuous Panel Production:

Continuous panel making process involves all operations starting from forming sheet metal profiles required for both faces, creation of Polyurethane foam (or Lamella Rockwool), creation of the panel to panel joining profile detail, curing of the composite and final cutting of product to length all along a continuous conveyorised line.

Two separate Roll formers for the two metal facings start from coils of sheet metal and issue out the two facings, which move to the moulding area. A pair of moving side belts of a flexible material on either side creates the side closures for retaining the liquid chemicals and for the rigid foam to fill. These side belt also acts as moulds to generate the edge profile. The top and bottom sheets are supported continuously by a slat and side chair conveyor precision with plattens keeping the sheets pressed against the side belts. Thickness of the panel is determined by the gap between the two platten forces and the vertical height of the side belt featured in each case. The two sheets and the two side belts enclose and create the moving hollow space, which is the 'mould'.

Urethane chemicals which are carefully selected are injected as precisely metered individual streams, blended into one streams and distributed evenly. Where needed, the inner surface of profiled metal is given a 'CORONA' treatment to improve bonding strengths. The chemical system is delivered in to the 'mould' by an oscillating manifold on which delivery nozzles are mounted at equal spacing. These lines of the liquid chemical mixture slowly find their level over the bottom sheet evenly. They start reacting after the 'cream time' is reached. The foam then starts to rise, till the 'rise time' is completed. The top surface of the foam starts to adhere to the bottom surface of the top sheet after the 'tack-free' time is attained. All these reactions proceed even as the whole 'mould' is moving along.

The Pressure platten conveyors over the two sheets along with the side belts are long enough to keep the “Sandwich “ in closed state for a sufficiently long duration so that the finished panels is fully curved in all respects before it leaves this crucial section of the line.

It is to be noted that the density of foam selected for all sandwich panel making processes are sufficiently higher than the free-rise density of the foams. This is required to ensure that the foam fills all the nooks and corners of the 'mould'. The finished panel is cut to length by microprocessor controlled cross cut saws- cutting the sandwich assembly two sheet facings and the foam together.

The above is the brief process used, which is specifically tailor made for production of building and cold store panels of extra ordinary uniformity at very production speeds.

2. Discontinuous Panel making process:

In this production process, the principle of panel production is exactly similar to the above continuous process. However, all the activities are conducted in a stationary single station, as against a moving arrangement described above.

The equipment used is known as the 'Panel Press', which features a vertical hydraulic ram of the length and width of the layest panel desired to be produced.

Profiling of the two faces of metallic facing (or any other facing like FRP, PVC etc) is done as an 'off line' processes and brought to and stacked on either end of the press. The 'mould' is created as follows:

The base on which the bottom facing is placed is a precisely machined flat Platten equipped with a built in heating system. Sides of the mould are made of machined Aluminum extrusions (jigs), profiled to the male and female joint features desired. These jigs are specific to each thickness of panel being produced. Jigs also feature accurately positioned fixtures to mount “CAMLOCK” components, which get embedded in to the foam later. When the pre-profiled top and bottom facing sheets are placed in this mould with special spacers, we create a hollow space which is ready for chemical injection complete.

This complete pre-assembly is moved laterally into the 'daylights' of the press by a positioning actuator. A heavy ram, which is a precision machined guided block, closes the mould tightly and holds the 'mould' firmly. The temperature controlled heated plattens keep the mould at the optimum reaction temperature.

Through many nozzles provided on the sides of the 'mould', PU chemicals mix is injected to precise volume as per settings in the microprocessor controlled delivery head. The liquid mix finds its level well before the 'cream time' of the chemicals is reached. The foaming reaction starts and the foam rise gradually to fill the nooks and corners of the mould. The rising of the foam is complete well before the 'tack-free' time, when the adhesion to the sheets starts- i.e., well after the foam has filled the 'mould'. The assembly is held in position, in the preheated mould till after the 'mould release' time has elapsed.

Maintenance of each of the time elements of the process is achieved using the microprocessor assisted control system.

The above describes a 'single panel' manufacturing process. However, our modern panel presses feature 'multiple daylight', double acting machines involving creation of two, four, six or more panels in one operation.

As explained earlier, each of the above processes are engineered to result in optimum finished product features. However, there are differences in respect of some features and limitations in each. These are discussed as follows:-

1. As the name implies, Continuous panel plants produce panels continuously, with highest uniformity of properties and dimensions which can be cut to longer lengths. However, transportation limitation may restrict the length to 12 mtr. (Discontinuous panel plants are also able to deliver such lengths.)
2. The main aspect of a continuous plant is the speed of production- being continuous; the manufacture of panels can be theoretically speeded up using faster conveyors. The longer process lines employed in our plants ensure that the panel moulds retains the panels together till the various process times are ensured comfortably before reaching the cooling curing section of the plant, even at the fastest speed.
3. Panels made in continuous plants show higher uniformity in foam qualities and better architectural flatness.
4. Older Panel presses, which had limited lengths of 6mtr (max), have now been replaced by machines with a mould length of 12.5 m. Hence, these machines manufacture panels to the longest transportable lengths today, thereby removing this limitation.
5. Multiple daylight and double acting panel presses have greatly increased the overall production speeds and capacities. Multiple daylights permit more than one panel pre-assembly to be closed at a time. Double acting arrangement features a central ram, which can move up to close and hold the top array of moulds, and in its movement downwards, to close and hold the bottom arrays. Precision machined platterns have improved the aesthetics of these panels as well. 
   This process is described as 'semi discontinuous', and, in terms of speed of production, very closely match with that of some of the continuous lines, within a more compact production shop.
6. Semi discontinuous panels press concept facilitates production of panels featuring “Cam Locks” to interlock panels together for additional integrity. This is also gives the advantage of producing panels of widths which may be non standard in a mix of sizes as may be required.

Panel manufacturing capability available to us in the LLOYDPANEL system meets and exceeds the duty requirements of all building designs and those of any scientifically designed and constructed cold storage. The most versatile discontinuous plants at Pithampur and Baddi along with arguably the most modern continuous panel plant in the world at cheyyar, Tamil Nadu give the company a very large and geographically distribution base. All the facilities also incorporate in-house 'state of art' laboratory facilities for testing all significant properties, including Thermal conductivity, Compressive / Shear / Flexural strengths, Thermal stability and all relevant PU foam tests.

Our plants are ISO 9000 accreditated and produce products to meet all International Standards. We have had the privilege of meeting and exceeding the standards prescribed by UNILEVER, BECHTEL, MICHELIN, BROWN & ROOT, FERRARO ROCHER, NDDB, and many such international users.

Needless to state, we have the largest experience in Field erection and finishing of Lloyd panel System country-wide through dedicated crews to take full responsibility for correct implementation, finishing and commissioning, speedily and to prescribed standards.

Our technical and contracting capabilities are well known to important customers and we normally spare no efforts to place them totally at their disposal of project implementing teams.

 

As a part of 50 years of business in this part of the world, we have been associated with more than 20,000 Industrial, Infra-structure, Post Harvest Management Projects.

As a pioneer and market leaders for specialized construction solutions to major Projects, LII has continuously made available relevant technologies and required infra-structure to provide total service demanded by large Projects.

Our Accent on Energy Conservation at every stage and our expertise in Resource Management has shaped our position in the Insulation Industry. Our Leadership status and Industry Expertise has made us Market Leaders with over 70% market share.

Our association with Cold Chain Projects
Right from inception of our company i.e. in the year 1956, we have been involved in Cold store insulation work. Initially, we were employed by our various clients for insulation of Conventional Cold Stores. With the help of this experience we always upgraded construction practice for Cold Chains and introduced various new concepts in India.

As of today, we have a separate division to work on Post Harvest Management of Horticultural includes Design Solutions, Supply, and Execution of various Cold Chain Projects including:

1. Pre-cooling System, with mobile pre-cooling where needed.
2. Refrigerated Infrastructure required at Rural Markets - various State Agriculture Marketing Board assignments.
3. Transit Cold Storage / Storage Facilities.
4. Refrigerated Transport System.
5. Refrigerated Railway Wagons.
6. Refrigerated Cargo Containers.
7. Cold Storages / CA Storages / ULO Storages.
8. Refrigerated Retail Outlets.

In Indian market, we are known as Total Solution Company with single point responsibility for Design, Manufacturing, Supply, Application and field Erection. The forward integration programme of our company implemented during last 50 years has evolved the different business lines which are complementing to our activities in Cold Chain Sector. We offer comprehensive solution including Pre-engineered Buildings to our clients.

With Metal Roofing and Cladding, Sorting and Grading Lines, Insulated Sandwich Panels, Cold Rooms, Ripening Rooms, CA Stores and other special Enclosures.

We have been associated with various companies for different systems which forms a complete Cold Chain.

Following are our associates:

M/s.Greefa Machinebow, Holland	Sorting and Grading Line specialists for various fruits and vegetables
M/s.Van Amerongen, Holland	For Controlled Atmosphere (CA) Gas supply and monitoring systems
M/s.Von der Heiden, Holland	Airflow control through TARP system for Ripening Chambers
M/s.Mistech Inc., USA	For precise humidification projects
M/s.BG Doors	Upsliding Doors of all sizes
M/s.Salco Holland	Special doors for Gas Tight and Frozen Stores
M/s.Polaris Technologies, Spain	Ethylene Metering and Management in Ripening Rooms.
M/s.Termolog, South Africa	Data Logger for temperature and RH Monitoring M/s.Bio Conservacion, Spain - Ethylene Absorption.
M/s.Bitzer, Ms.Helpman,	Refrigeration Systems - both Evaporating and M/s.Guntner, Germany Condensing Units

We are member of International Association of Refrigerated Warehouses.

The only two facilities in India which are accredited by IARW, USA, both are constructed by us.

Lloyd & Distribution Centres
Lloyd Insulations leads the industry when it comes to refrigerated distribution facilities. Unlike other construction companies who do a little bit of everything, LII focuses all of its attention on building and improving refrigerated distribution facilities.

With knowledge gained as Contractor for various types of refrigerated warehouse spaces, LII can help solve refrigerated distribution issues right down to the last detail. We know what it takes to run these facilities day in and day out, because we have experience of each & every situation.

• Distribution centres for MSAMB,UPSIDC & APMC.
• CFS / ICD Warehouses for CWC, KWC, CONCOR etc.
• Had privilege of constructing India's first multi temperature Food Distribution centre for Radhakrishna Foodlands and India's Biggest Fruit & Vegetable Auction Market A/c. M/s. Safal, Bangalore.

We have constructed complete facility and Distribution of foods and associated products to foodservice establishments such as hotels, restaurants, caterers, flight kitchens, fast food chains, etc.

We have been associated with the only ORGANIZED foodservices distribution company in India ensuring product integrity throughout the supply chain.

The customer's facility has been designed by international experts, USDA approved and is built to Codex Standards integrating HACCP solutions. This facility is first of several. This Distribution Centre procures, value ads, stores and distributes over 700 tons per day of perishable and non-perishable food products and operating supplies.

The designs are scalable and replicable to handle diverse environments in India and overseas.

The facility has post harvest infrastructure for grading, sorting, portioning and packaging of produce.

We have constructed the largest and most advanced cold storage complex, run and managed by a private entrepreneur in India.

State of the art multi-product, multi-temperature cold storage facility of 2 million cu. ft. for storing 25,000 MT goods from +25 to 0 degree centigrade. Deep freeze facility for storing 1,500 MT goods at 0 till -20 degree centigrade. This is the only cold storage in India to be granted license for operating as a "Privately Owned Custom-Bonded Warehouse" under the Indian Customs Act.

This pioneer in the country in providing facilities like grading, sorting, repacking, dry warehousing, trans-shipment and container stuffing facilities etc within single premises is a valued Lloyd's customer.

 

Lloyd & Retail Outlets

• Metro Cash & Carry Pvt. Ltd., Bangalore
• Shoprite SA, Mumbai
• Ivory Properties, Malad (Hypercity)
• Kalpataru Megapolis Mall, Thane
• Inorbit Malls (I) Pvt. Ltd., Mindspace, Malad.

 

Post Harvest Management -Reference Highlights

1. Supply And Execution Of Complete Pack House For Mangoes On Turn-Key Basis At Maharashtra State Agro Marketing Board (Msamb), Jalna, Tal & Dist., Jalna
   
   Description: Aforesaid facility executed at MSAMB consists of -
   • 1.5 MT per hour Sorting and Grading Line
   • Pre-cooling Room
   • Cold Store.
   • Ripening Chamber
2. Supply And Execution Of Complete Pack House For Mangoes On Turn-Key Basis At Maharashtra State Agro Marketing Board (Msamb), Jalna, Tal & Dist., Jalna
   • Thermal Insulation using Lloyd-PUF Panels for Walls, Flooring and Ceiling of existing pre-built chambers
   • Hinged doors - insulated
   • Intricate refrigeration system: evaporator, condenser & controls
   • Ripening system: ethylene generator, ventilator and controls
   • CO2 scrubber including CO2 and O2 gas analysers
3. Supply And Execution Of Complete Pack House For Mangoes On Turn-Key Basis For Maagrita Exports Ltd At Nilakottai
   
   Description: Aforesaid facility executed at MAAGRITA consists of -
   • 3.0 MT per hour Sorting and Grading Line for mangoes and 1 MT per Hour sorting and grading line for vegetables.
   • 2 Nos Pre-cooling Room 12 MT.
   • 2 Nos Cold Store 50 MT.
   • 2 Nos Ripening Chamber 12 MT.
4. Supply And Execution Of Complete Pack House For Mangoes On Turn-Key Basis For Maagrita Exports Ltd At Nilakottai
   • Thermal Insulation using Lloyd-PUF Panels for Walls and Ceiling.
   • Vertically opening doors for ripening, sliding doors insulated from M/s BG doors.
   • Intricate refrigeration system: Evaporator, Condenser & Controls from M/s Bitzer and M/s Helpman
   • Ripening system: ethylene generator, ventilator and controls from M/s Polaris.
   • Humidification system from M/S Miatech.

Apart from this, we have constructed one facility for export of grapes in Sangli District of Maharashtra for Euro Grapes which is been approved to existing European Norms.

 

Lloyd and Pack Houses

• Integrated Mango Pack House including CA Cold Store at UPSIDC, Lucknow.
• Integrated Pack House including Ripening Rooms for various kinds of fresh fruit & vegetables at the second plant of MAAGRITA EXPORTS LIMITED, NILLAKOTTAI
• Centralised CA Facility for storage of apples at Kundli, Haryana- near Delhi
• Packhouse for mangos for M/s Galla Foods Chittoor.
• Cold Store for Grapes for M/s Euro Fruits
• CA Storage for apples valued Rs. 26 crores for M/s Adani Exports in Himachal Pradesh

 

Benefits to our client

• Streamlined Project Cycle
• Single-Point of Accountability
• Deep Knowledge of construction of Distribution Centres
• Experience Gained Over History Of Successful Projects
• Tight Integration Between Design, Engineering, Execution and Personnel
• Measurable Results … Faster

 

Core Strength
Lloyd Insulations is committed to

• Quality
• Maintaining and Improving on project specifications &
• To complete assignments to prescribed time schedules.
• The company is proud of its excellent safety record and safe working practices at site.
• Lloyd Insulation is an ISO 9001-2000 Organisation.

Simply put, we have 50 years of general contracting experience and we have leaved by the simple business philosophy of meeting and exceeding customer expectations. Our contracting work has been to build on time and within budget. This core philosophy has allowed us to maintain lasting relationships with leading Corporate Houses that span decades, and helped us to grow since 1956. Our construction practice, safety awareness has received special mention by International Companies like Stellar - USA, Shoprite - S.A., Metro Cash and Carry - Germany, Bechtel Inc. USA, Shell Global, Wall Bridge Brown and Root, Foster Wheeler and many others.

Current Scenario in Cold Chain Business in India

In India we have been associated with number of Projects which are part of partial Cold Chains. In fact, we have experience of construction of all the important sections of Cold Chain but unfortunately in India there is not a single example of a complete Cold Chain.

Cold Chain Present Status in India can be described as below,

• Large numbers of obsolete cold storages - There is no correlation between growing areas and cold storage locations, India has almost 20m tons of cold storage capacity, over 80% dedicated to potato
• Little or no pre cooling
• Limited reefer transport - Large logistics providers like Crystal Roadways & Radhakrishna Food Land have less than 100 reefers
• Limited number of Refrigerated Distribution Centers

After entry of number of big Corporate Houses in Retail business, we had great expectations that presence of these Corporate Houses will initiate complete Cold Chain activities on PAN India basis. Unfortunately, nothing has happened for last two years may be because of change in thinking process of these Corporate Houses to sell the perishables at minimum price. Unawareness of consumers like hygiene and condition of the perishables is also other reason to restrict growth of Cold Chains in India. Apart from above following are other reasons of non viability of cold chains,

• Cold Chain adoption in India is product centric and fragmented
• Since most small and medium sized farmers need cash soon after harvest, they evacuate their produce to the nearest mandi immediately to try and reduce product risk, obviating the need for cold storing
• Non-availability of quality and reliable power in rural areas. Power outages necessitate the use of generators which makes cold storing financially unviable
• Farmers know about cold storing, but most are unaware of the benefits of pre-cooling and reefer transport
• High capital costs compounded by high instance of excise / customs duty on equipment
• Existing capital subsidy schemes of the government are not adequate
• Significant expenditure on power
• Low utilization on account of lack of awareness and seasonality
• Not enough quality human capital to manage the cold chain
• No cadre of post harvest managers who can provide know how on treatment and handling of various F&V produce

This is however changing with the advent of major retail chains like Reliance, Bharti, Godrej, ITC, Future Group, AV Birla Retail who are demanding quality produce. Foreign players like Wal-Mart, Carrefour, etc, are waiting in the side liners.

 

Market Potential for LII
The total production of storable fruits in cold stores in India is around 9 million ton and storable vegetables are around 42.5 million tons. Around 35% of the storable produce (18 million ton) is consumed in fresh form during harvest season. Remaining 65% i.e. 33.5 million ton needs storage capacity out of which present cold store capacity in the country is around 20.5 million ton. Hence the gap of 13 million ton needs to be created. Production of F & V in the year 2011 is going to be double which would require creation of additional cold storage capacity. In terms of numbers presently 5500 cold storages are existing and 9000 more are required to cope up this demand.

The government agencies like National Horticulture Board and State Agricultural Produce Marketing Boards are promoting various Cold Chain Projects in India to decrease the unnecessary wastage of F & V products which is around 35-40% of the total production with value of Rs.50000/- crores. These Boards constantly promoting export of various fruits, vegetables and flowers with necessary inputs to the India farmers.

In coming years Modern format retailing may require distributed sourcing, centralized holding and dispatch followed by de-centralised sales. In this case, Cold Chains will become inherent part of retailing for maintaining the quality of the produce through this process. With growth rates of 25-30% organized retail in India looks extremely promising and is already outpacing to non-organised sector which is growing at around 8%.

The export of F & V products calls for long distance moment of perishables along with long term storage. This factor will again help to increase the number of Cold Chains in India.

Export, Processing and Retail are exerting a strong demand pull on Cold Chain Infra-structure and the pull will aggravate in future.

As stated earlier, LII has already set up a Post Harvest Management Department to tap maximum share of opportunities available in Cold Chain sector during forth coming years. We strongly believe in providing total solutions to customer under one roof with detailed technical back up which helps us in turn to develop long lasting relation and repeat business. To cope up with future demands of Cold Chain Industry, we have already amended our manufacturing facility by doubling the capacity and have short-listed appropriate team members who will provide us necessary system integration backups.

The existing contracting capability and vast experience in executing complex contracts will definitely compliment our above preparations to fulfill demands of this industry.

Lloyd Telecom Shelters / Pre-Fabricated Enclosures:

• Lloyd Insulations the first Indian company to provide 'Ready to Erect' Telecom Shelters in India with in-house Design, Engineering, Manufacturing and Erection / Installation capability all across India for efficient and cost effective operations of telecom equipment. {Dust Weather proof Insulated Cabin for Housing GSM/ CDMA Transmission equipment base station.}
• Our units were designed and perfected to provide 100% Weather integrity under all environmental conditions, high thermal efficiency to minimize energy consumption with superlative ability to withstand Wind loads as prevailing in all parts of the country.
• Lloyd Insulations commenced supply and installation of Shelters to Indian Telecom Operators in 1998 with 'Birla AT & T' as first customer.
• During the course Lloyd Insulations have serviced all operators, Services provider & infrastructure provider & have installed in excess of 1 Lacs such enclosures.

Salient Features

• Corner panels - Lloyd shelter has a unique design of “tied down” corner panels which define shelter co-ordinates & are able to substain wind load of 180 kmph.
• Floor panel - Floor panels of 19 mm marine ply as inner skin and embedded in the sandwiched foam duly strengthened with structural square tubing are designed to withstand the floor loading of 2500 kg/m3. Panel to panel joint is Tongue & Groove / Camlocks for mechanical robustness.
• Tie Rods - as a special feature tie rods are provided through the corner/wall panels joining ceiling and floor panels and are tied down to the base structure to make the shelter as a whole unit.
• Base Structure - Lloyd shelter is installed on roof tops & ground on suitable base structure consisting of beams & channels (ISMB & ISMC) are provided for requisite floor loading in excess of 2500 kg/m2. Each arrangement is designed to suit specific building.
• Secondary Roof - Profiled Secondary roof is provided to shed rain water with features. Boxed edges prevent in gress of driven water under all intensities of rainfall.
• Elastomeric Rubberised Polyurethane based material (ISOTHANE EMA/EMB) is applied to result in a “NO LEAKAGE “ Shelter.

Lloyd Telecom Shelter comes with

• Air Conditioner with Free Cooling Unit ( Make : Shulz, Italy)
• PCM Energy Storage Emergency Cooling Unit with energy storage System (including 2 Nos. of DC fans) (Make: PCM Energy, India)
• Diesel Generator (Make : Powerica)
• Power Management Unit ( Make : Selvon / Lloyd)
• Alarm System with Audio Hooters (Make : Lloyd)
• Battery bank (Make : Amarraja)
• Enclosure with PUF Sandwich Panels with
  • 2 side sloping roof or Slant Roof
  • FRP Outer Facing / PPGI inner facing
  • Tongue & Groove Joint / Cam lock, Corner panel or without corner panel
  • Expandable in either directions
  • Door, Cable Trays etc.
• Electricals : Siemens / Philips and others (ISI approved)

Lloyds have the set up to manufacture the largest number of Telecom shelters, deliver them to sites “on time” and deploy erection teams to any corner of India for which has helped Indian Telcos to roll out phenomenal number of towers country wide.

LLOYDPLUS is a 'one-step' system providing a comprehensive solution for thermal insulation of buildings and waterproofing requirements.

The system comprises high efficiency LLOYDFOAM for thermal insulation and monolithic and elastomeric ISOTHANE for waterproofing.

Some conspicuous features of LLOYDPLUS system are:

1. The component raw materials are in liquid form which is relatively stable with acceptable shelf life
2. The process of application does not involve melting of bitumen etc (needed for applying Expanded Polystyrene) or use of torches etc needed for felt waterproofing. This eliminates fire, smoke and pollution hazards.
3. Components of both insulation foam and waterproofing membrane being Urethane based have excellent compatibility with each other, affording cohesion between themselves and excellent adhesion to any substrate.
4. The inherent adhesive nature of the system lends itself to effective bond while conforming to any shape and curvature of roofs including vertical features like parapets.
5. Ensures a joint-free and monolithic structure both in insulation and the Waterproofing layers, which is so essential for trouble -free performance.

Though this system can be extremely efficient and cost-effective, it involves carrying out foaming at site, under site construction environment. Hence, there is need for use of proper equipment operated by skilled personnel along with adequate inspection as well as regular collection and testing of test samples from various stages during the actual foaming operation, to ensure that the same degree of quality control is obtained. The standard Quality Assurance Plan document is intended to cover all such points to result in an efficient and reliable application.

Lloyd Insulation under takes these works as a 'one-stop' agency to ensure full compliance with all requirements. Complete recommended specifications and specific details suited to specific applications are available from the company.

ISOTHANE EMA - Elastomeric Waterproofing

ISO THANE EMA elastomeric membrane is a liquid applied coating based on urethane perpolymers which cure by reaction with atmospheric moisture to give a continuous film which is elastic. It contains leafing aluminium which gives excellent U.V. resistance.

ISOTHANE EMA curves to a permanently flexible seamless membrane which, by virtue of its chemical reactivity in the wet state has good adhesion to a wide ranges of substrates (given proper preparation) such as roofing asphalt, slates, tiles, asbestos, concrete, brick, wood, glass and metals. Unlike more traditional bitumen based product ISOTHANE EMA does not readily embrittle with age, exposure to ultra violet radiation or weathering and hence it does not crack or craze.

Since it is elastomeric ISOTHANE EMA is not adversely affected by extremes of temperature, consequently it does not crack at low temperatures or suffer thermal flow at elevated temperatures.

Application

ISOTHANE Elastomeric Membranes are designed to bond to many types of substrate particularly those commonly used as roofing, such as felt, asphalt, slate, tiles, asbestos, concrete, brick, wood, glass and metals. They can also be applied to sprayed polyurethane (PU) foam insulation. However, it is essential that substrate and structures are properly prepared, and stable.

Technical Data: Typical Properties

Specific Gravity	1.18
Solids	95 % min
Abel Closed cup flash point	56°c
Application limits	0-70°c
Approximate Dry time	12-20 hours touch dry, 7 days full cure
Tensile Strength	2.07 MN/m2
Accelerated Weathering	No appreciable deterioration
U/V Resistance	Excellent
Water Resistance	Excellent
Resistance to Industrial Environments	Excellent
Resistance to Mechanical Damage	Good
Storage Stability (Temperate Climate)	9 month

Thermoplastic Polyolefin (TPO) membrane waterproofing System

TPO is a heat-weldable single-ply thermoplastic polyolefin sheet designed for new roof construction and reroofing applications. TPO membrane waterproofing System is based on advanced polymerization technology that combines the durability and weatherability of ethylene-propylene (EP) rubber with the heat weldability of polypropylene. The membrane is specifically formulated for long-term weather resistance without the use of either polymeric or liquid plasticizers. Physical properties of the membrane are enhanced by a strong, polyester fabric that is encapsulated between the TPO based top and bottom plies. The combination of the fabric and TPO plies provide Sure-Weld reinforced membranes with high breaking strength, tearing strength and puncture resistance. The membrane is environmentally friendly and safe to install. TPO membrane waterproofing System are LEEDTM (Leadership in Energy and Environmental Design) compliant. (The U.S. Green Building Council (USGBC) re the originators of the LEED Green Building Rating System).

FEATURES:

• Wide window of weldability
• Outstanding puncture resistance
• Chlorine-free with no halogenated flame retardants
• Plasticizer-free, does not contain liquid or polymeric plasticizers
• Excellent low temperature impact resistance
• Excellent chemical resistance to acids, bases, and restaurant exhaust emissions
• Exceptional resistance to solar UV, ozone, and oxidation
• Low water vapour Permience and water absorption
• Hot melt extrusion processed for complete scrim encapsulation
• Warp knitted fabric (not woven) for smooth surface and greater thickness-over-scrim
• Polyester reinforcing fabric which is resistant to degradation by bacteria, mildew and fungi

TPO membrane Waterproofing from Lloyds is provided either directly over building structures or over insulated roof systems in a Variety of configurations. Please contact us for an optimum design solution to meet specific Insulation, Noise control or Fire resistance objectives.

Some of our major waterproofing projects are...
Mumbai International Airport Ltd, Terminal 2, Mumbai.
Tata Power Company Limited, Trombay Power Station
Larsen & Toubro Limited, (ECC Construction Group) Jamnagar, Gandhinagar, Npcl Kudam Kulam
Reliance Industries Limited, Worli, Patalganga
Department Of Space Ahmedabad,
Essar Projects Limited. Refinery Plant Building At Vadinar 
Gujarat State Fertilizers & Chemicals Ltd
Nicholas Piramal India Limited.
Indian Petrochemicals Corp. Ltd. Baroda, Nagothane
Central Public Work Dept (CPWD)

Introduction

Piping systems involve heat sinks such as valves, pipe supports and instruments, which along with residual loss through insulation which accounts for loss of heat in large amounts whenever there is sufficient difference between the pipe and ambient temperatures. Variation in ambient temperatures from freezing winter nights to scorching summer days affect the extent of heat loss . (There can be situations when there can be a heat gain as well.)

Heat tracing is a way of maintaining the temperature variation in a pipe within acceptable limits. Trace heating is used for the purposes of

• Heat maintenance
• Frost Protection
• Heat recovery

The combination of trace heating and insulation may be described as the creation of an artificial to surround a process pipeline, container or instrument. Many industrial products and processes environment are prone to a variety of undesirable effects if they are not maintained and pumped at the correct temperatures. Some of the effects our products are listed below

• Waxing
• Solidification
• Clouding
• Precipitation
• Crystallisation
• Discoloration

Process materials have different optimum operating temperatures, some of which are required to be maintained at certain temperature band to avoid any of the aforesaid states.

Lloyd Insulations specialize in providing technically best suited and most economical package integrating a well matched combination of optimum Tracer conductor with correct temperature rating and heat output and correct choice of Insulating material and the thickness. The precise design is carried out to deliver end performance at the lowest first cost of installation and the most economical running cost.

Type of Heat Tracing

Heat tracing can be accomplished by any of the following methods

• Steam Heat Tracing
• Electric heat tracing

(A) Steam Tracing

Steam tracing cane be done using any of the following methods

(a) External Pipe Jacket Method

In this method of tracing, heating or cooling is accomplished by running a small line (Pipe or Tubing) containing the heating medium either parallel or spiral wound around the pipe or vessel.

(b) Internal tracing method.

In this method, the tracer with heating medium is fitted inside the process pipe and runs parallel to it.

Advantages

1. This is a very reliable and simple method of heat tracing. The hot spot and over heating problems cannot come up because the maximum temperature is limited by the pressure of the steam. Depending on the temperature requirements the pressure can always be adjusted.
2. In the past when the cost of energy was low, steam was treated as a free commodity and hence the proliferation of steam tracing systems.
3. Steam is usually available in most industries and does not require additional arrangements for production. Being produced at the site, the problem of unreliability in quantity and quality does not exist.
4. Even if the system has steam leaks and faulty traps, it continues to work although at a higher energy cost.

(B) Electric Heat Tracing

In recent years electric tracing has enjoyed increasing applications in the industry. This is mainly due to -

1. Proliferation of a large number of new types of heat tracing systems.
2. Increase in cost of steam due to oil price hike.
3. Very serious housekeeping problem in Steam Tracing including heavy Corrosion in process pipes caused by steam leaks.

As the impedance type and skin effect current type electric tracing systems have limited application, the discussion that follows is focused on the pros and cons of resistance type electric tracing systems.

The resistance type systems could also be classified as 'Constant wattage type' and 'Variable wattage type'. The advantages and disadvantages of the Mineral Insulated Cable (MI) and Zoned Series Resistance Wire type in the constant wattage category are as follows:

Advantage of MI Cable

1. It can tolerate brief periods of over heating
2. It can be used for high temperature applications (as high as 800°C)
3. It has good impact resistance
4. It has relatively low cost per feet length

Disadvantages of MI Cables

1. The greatest disadvantage with MI Cable is that it must be factory fabricated to length to deliver exact wattage to the system and cannot be cut or sliced to desired length in the field. This makes design, installation and maintenance more difficult than other types of electric tracers.
2. It is also not flexible and is therefore, difficult to be installed over complicated shapes.
3. Because of the series circuit design, failure of the heating element at any point causes the entire circuit to fail.
4. Generally it uses non standard voltages and a transformer may be necessary to produce required voltages.
5. It requires skilled personnel and techniques to seal ends and exclude moisture.

Additional Advantages of Zoned Series Resistance Type Tracers

The Zoned Series Resistance wire type tracing systems are an improvement over the MI Cable because a few of the problems associated with MI Cable have been overcome in this type and hence it offers the following additional advantages:-

1. The main advantage of this tracer is that it can be cut to length in the field because of the parallel circuit design.
2. It operates on standard voltages.

Advantages of Auto-Trace Self Regulating & Self Limiting Type Tracers

The most promising electric tracing system is the self-limiting type. Because of the unique principle which is adopted in this type of tracing system for generating heat, almost all the disadvantages of the other type of electric tracing systems have been overcome.

In addition it uses energy at very high efficiency levels compared to steam tracing. The salient advantages of the self-limiting type heat tracing systems can be summarized as follows:-

High Energy Efficiency

The energy efficiency of self regulating type heat tracing system is very high because of the unique self-regulating feature built in the tracers. The tracer resistance varies as a function of its temperature. As temperature increases, the resistance of the polymer, constituting the core of tracer, increases which causes a decrease in the power output. The energy output, therefore, always matches the requirements of the system.

Safety Aspects

Self-regulating type electric tracers are intrinsically safe and can be used in hazardous areas. In fact, it has been given an unconditional T-rating in several countries.

Again, because of the self-regulating feature, at no point can the tracer create high surface temperature and there are no chances of any fire hazard even in the presence of inflammable gases/liquids in and around the pipes. Even if the tracer crosses over itself, as in case of tracing of pipe elbows, valves and fittings, there will not be any local hot surface temperatures.

Ease of installation

It can be installed on any contour such as pipe elbows, valves and different fittings due to its flexibility. The tracer can be cut-to-length in the field and precise measurements at manufacturing stage are not required. The heater strip is very flexible and can be mounted on any shape.

Precise Temperature Control

The tracer maintains uniform temperature profile throughout the pipeline which results in greater energy economy.

The temperature variation in pipe is automatically controlled due to its self regulating feature hence there is n temperature fluctuation in the pipe

The temperature at the hot and cold zone in the same pipe can be controlled by the tracer itself hence provision for separate thermostat at different zones is eliminated.

Higher Life

The self regulating type tracers are guaranteed for more than 40 years of working life. This results primarily from the absence of any hot spot at a particular point and also due to the absence of any corrosive material in the tracer. In fact, the tracer once installed, generally does not require any replacement for the entire life of the plant.

Easy Maintenance

The self regulating type electric tracer hardly requires any maintenance work during its entire life period. But for minor circuit defects, which are unavoidable in any electrical system, practically nothing goes wrong with the tracer. It has been the experience of industries using such tracers for a number of years that absolutely no maintenance is called for as far as the tracing system is concerned.

SKIN EFFECT CURRENT HEAT TRACING:

Skin Effect Current Heat Tracing is the most cost effective heat tracing design for long runs of pipe. The design can be furinished as a single end power feed or mid fed power feed design on preinsulated pipe or field insualted pipe applications.

Skin Effect Current Heat Tracing combines the engineering principles of skin effect and proximity effect design that offers an economical solution to heat tracing problems in long pipelines by providing a single or mid-fed power point. LLOYD INSULATIONS specialize in design, supply and installation of a complete system that includes the engineering, material selection, and insualted pipe system for any application.

LLOYDS have been associated with some of the longest heat traced lines for hot oil featuring Skin Effect current Heat Tracing system even in totally buried lines. Special insulation and external cladding system have been developed and perfected to face the most adverse and aggressive soil and terrain situations.

Some of our EHT clients are

Indian Oil Corporation Limited (IOCL)
Indian Petrochemicals Corporation Ltd (IPCL)
Hindustan Petrochemical Limited (HPCL)
Gas Authority of India Limited (GAIL)
Engineers India Limited (EIL)
Bharat Heavy Electricals Limited (BHEL)
McNally Bharat Engineering Company Limited
Reliance Industries Limited (RIL)
Uttar Pradesh State Electricity Board
Punjab State Electricity Board
Tamil Nadu Electricity Board
Haryana State Electricity Board
Gujarat Electricity Board
Indian Explosives Limited
Asian Paints
Mukund Limited
Nirma Limited and many more...

Lloyd Insulations is an ISO-9001 certified engineering and contracting organization with specialization in providing active & passive fire protection facilities/solutions for various critical/fire prone areas. We at LLOYD INSULATIONS are fully geared to provide total design, manufacture and erection service for an almost limitless range of Active & Passive fire protection facilities for a vide range of industrial and commercial environments.

One of our major strength is our vast experience in installing such fire protection systems & our ability to innovate, develop and provide effective fire protection solutions in order to meet the specific requirements of our clients.

We provide two type of Fire protection Service viz.

• Passive Fire Protection Services
• Active Fire Protection Services

PASSIVE FIRE PROTECTION SERVICES

• Cable Fire Protection Systems
• Bus-Duct Firestop Barrier System
• Fire Proofing of Steel structures
• Fire Proofing of hydrocarbon vessels and structures
• Lloyd Fire safe Enclosures-Fire Proofing of Actuators for remote/motor operated control valves
• Fire Doors

ACTIVE FIRE PROTECTION SERVICES

We provide design, installation & commissioning of the following active fire protection systems:

• Fire detection and alarm system
• Fire hydrant system
• Water/foam sprinklers/spray system
• Co2/Foam flooding system
• Gas detection system
• Water foam monitors
• Jumbo Water curtains
• Fire extinguishers
• Linear heat detection systems

A) Passive Fire Protection Services

1.0 CABLE FIRE PROTECTION SYSTEMS

• Lloyd Firestop Systems for Sealing of Cable Penetration Openings in walls, floors and under electrical panels (RTV Silicone Foam, Mortar, Panel type sealing systems)
• Lloyd Fire retardant Cable Coating systems
• Lloyd Protect Duct Fireproofing System for Control & Instrument cables/cable trays
• Lloyd Bus Duct Fire Barrier System

The above systems are in operation in more than 475 power generating units, steel plants, refineries, fertilizer plants etc. The system details Brief details of the cable fire protection are given as;

1.1 LLOYD FIRESTOP:-

Unsealed openings in compartment walls & floors for routing of cables are hazardous as fire; smoke, gases & degradation products from combustion can spread rapidly into adjacent rooms or other parts of the building.

A safe counter measure is to seal the openings with Lloyd Firestop. These have been tested for fire resistant ratings upto 4 hrs. As per national & international standards and have a record of successfully preventing fire spread in actual fires in power stations. We have RTV silicone foam, mortar and panel type firesealing systems in our product range.

The Firestop are installed in-situ tailored to suit individual penetration opening. For more details CLICK HERE

1.2 LLOYD FR-NILFLAMME FIRE RETARDANT COATING:-

Lloyd FR-Nilflame is a fire retardant coating compound for preventing spread of flame through cables installed in groups/trays/racks. It has a high limiting oxygen index and high degree of flame retardancy. When applied to the cable sheath, the compound forms a flame retardant layer, which shields the cable from oxygen, which is required for combustion. Application of Lloyd FR-Nilflame coating on cables prevents spread of flame upto 30 mts. in case of a fire hazard. For more details CLICK HERE

1.3 LLOYD PROTEC DUCT SYSTEM:-

The Lloyd Protecduct system protects control/instrumentation cables enabling them to maintain circuit integrity and continue functioning when engulfed in flames upto 45 minutes. The metallic jacket also protects the cable runs from combustible/hazardous dust and chemicals.

When installed intermittently on cable runs, the duct system functions as an effective fire break and delay flame spread.

The Protect ducts are installed in-situ tailored to suit individual cable run. For more details CLICK HERE

1.4 BUS-DUCT FIRE BARRIER SYSTEM

The busduct fire barrier system provided by us gives fire rating upto 2 hours. This system is installed inside the bus ducts at the points wherever the duct crosses over the walls and floors to prevent spread of flames, fumes, hot gases, smoke etc. from one area to others through the ducts. For more details CLICK HERE

2.0 FIRE PROOFING

1. On shore installations:

a) Fire Proofing of Steel structures.

• Materials:


• Subliming/intumescent type coatings.
• Vermiculite Cementitious premixed coating
• Fibrous encapsulation blankets/slabs

b) Fire Proofing of hydrocarbon storage vessels, equipments & piping

• Materials:


• Subliming/intumescent type's coatings and Cementitious/Vermiculite based coating conforming to UL: 1709, UL: 263, ASTM E-119, BS: 476, BAM, DOT Standards

2. Offshore Installation

Fireproofing of riser pipes and other facilities using subliming/ intumescent types coatings.

3.0 FIRESAFE ENCLOSURES

In the event of a fire occurrence in hydrocarbon processing/storage plants, to ensure that the control valves remain operational till the safe shut down of the plant is achieved, the valve actuator mechanism must be protected from exposure to heat/flames for a specific period. Lloyd Fire safe enclosures are engineered and factory built to suit individual valve actuator assembly and can be custom built to provide protection upto 60 minutes.

4.0. FIRE DOORS:-

Insulated Fire doors upto 2 hours rating (4 hours -double door system) are installed for prevention of fire spread from one area to another. It restricts heat smoke and fire from the exposed side, maintain compartmentation to contain fire spread, allow the passage of people or goods from one compartment to another in fire conditions & allow smoke free access to escape routes without any loss to the structure forming these routes i.e. Corridors and shafts.

B) Active Fire Protection Services:

We are also providing our services for total design, engineering, supply and installation of fire detection, alarm and fire fighting systems which includes smoke ionization detectors, heat detectors, alarms, fire water pumps, remote controlled long range tower/base mounted water/foam monitors, control valves, hydrants, laying of hydrant lines, water curtains, gas detection system, public address system, related electrical and instrumentation works including control panels, enunciation panel etc.

FIRE DETECTION & PROTECTION WORK

BHEL (Pan India)
NTPC (Pan India)
IPCL (Pan India)
IOCL (Pan India)
GAIL (Pan India)
L&T (Pan India)
Lurgi India Co. Ltd. A/c. Haldia Petrochemicals Limited.
TOYO Eng. India Ltd, Mathura
ILFS, Mumbai
Mazagon Dock Limited (MDL), Mumbai
Reliance Petrochemicals Limited (Pan India)
Technimont ICB Pvt. Ltd.
EIL Panipat.
UP Rajya Vidyut Utpadan Nigam Limited

Fire seal in penetrations, ducts etc to protect ship structure from fire and to prevent risk to life caused by occurrence of fire by providing insulation to Bulkhead / Deckhead & partitions of compartments. Fire barrier insulation is also deployed to reduce the risk of damage caused by fire to the ship structure, its cargo and the environment.

This helps contains, control and suppress fire and explosion in the compartment of origin.

Fire barrier Insulation is the major element in ship construction for "Safety of Life At Sea (SOLAS)" by separating accommodation spaces from the remainder of the ship by precisely designed Thermal and structural boundaries. Fireseals in pipe / duct/ cable penetrations require adequate insulation to prevent fire migration through annular space CLICK HERE (Fire Proofing & Fire Insulation Link)

Functions

Thermal & acoustic Insulation of partitions, structural members to reduce energy required for space heating and cooling, to provide an acceptable thermal environment for occupants and to prevent moisture condensation on the interior surfaces. Norms applicable are very similar to what is applicable for building insulation. For more details CLICK HERE (Building Insulation Link)

Cold and cool rooms, freezer compartments or board ships depend on efficient thermal insulation to eliminate spoilage of food products. For more details CLICK HERE (Cold Store & Cold Room Link)

Insulation is also deployed is chilled water tanks and pipes, steam lines, Gas Turbine exhaust ducts other areas, where the norms are similar to those applicable to Industrial Insulation. For more details CLICK HERE (Insulation Link)

Product Forms

Our products are offered in a wide range of specially developed and approved products for specific applications such as comfort insulation, floating floors and technical insulation in various product forms like Blankets, Bulk Fibers, Boards, Preformed Pipe Sections, Papers, Mastics to facilitate the application of an efficient sound and thermal insulation system.

Main Characteristics:

Our products are ideally suited to use in passive fire protection applications due to the following attributes:

• Blanket product forms are flexible and are easy to install around profiled structures.
• Blanket products are inorganic and non-combustible and will not contribute to any fire. Other forms are low in organic content and contribute little heat in fire situations.
• All product forms are excellent insulators which result in lightweight and thin systems, characteristics particularly important in marine and offshore situations.
• Wide range of fire certificates ranging from non combustibility certificates to Type Approved fire rated deck and bulkhead fire resisting systems and structural steel protection systems.
• Statutory approvals from “Directorate General of Shipping (DGS)”, Government of India, MED certification for European countries are called for.

Typical Applications:

The requirements for insulation work on ships differ from those for onshore jobs especially with regard to the working conditions. Installations onboard ships are often very compressed making access rather difficult. Therefore insulation and accommodation work onboard ships must be carefully planned and carried out by specially trained personnel.

LII expertise includes insulation and cladding of complicated engine room plants, exhaust pipes from main and auxiliary engines, fuel oil pipes, boiler systems and condenser tubes from compressors with specially designed insulation system to limit the heat loss to minimum & efficiency to maximum.

Furthermore, we carry out all types of fire and conventional insulation work on bulkheads and ceilings etc.

Our expertise is in following areas,

• Ships & offshore oil installations: Blanket for lining steel and aluminium bulkheads and decks. Rating from A15, A30, A60 and H120.
• Fire Doors: Blanket and Boards for infill of fire doors for building and marine use.
• Intumescent Paint: Engineering fibers for reinforcement of fire protection intumescent paints.
• Gas Turbines: Blanket for fabricating into insulation mattresses.
• Duct Work Systems: Blanket and modules for lining hot gas ducts, turbine exhaust ducts and diffusers.
• Silencers: Acoustic Blanket for infilling silencer splitters in gas turbine systems and co-generation plants.
• Pipe Protection: Blanket for wrapping hot water and steam pipes in co-generation and conventional power plants.

ISOLOYD NILFLAME
Rigid Polyisocynurate foam insulation, a specialist low temperature and cryogenic insulation which has low thermal conductivity, closed cell, moisture resistance and enhanced compressive strength at low temperature, whilst not comprising its elasticity so as to avoid cracking.

CFC FREE
Isoloyd Nilflame is the only CFC FREE polyisocynurate Insulation product, designed within the guidelines of the Montreal protocol, 1987 for the protection of the Ozone layer.

BETTER EXTREME- TEMPERATURE PERFORMANCE
Unlike most thermoplastics, Isoloyd Nilflame has low smoke & Toxic gas emission, and will not melt or drip in fire. It has low flame spread and and is not easily is not easily ignitable.

It also has a higher hot surface performance Temperature of 150°C. This makes it ideal for use directly over steam or electrical tracing. Its fire classification meets even the stringent requirements of the British Board of Trade for shipboard insulation as per BS 5608, the Indian Navy, and those of the US Bureau of Mines.

INSULATION PERFORMANCE
ISOLOYD Nilflame is amongst the most thermally efficient insulation materials available and retains its thermal insulation materials available and retains its thermal efficiency under the moat sever operating condition due to its closed cell structure resistance to moisture absorption. With ISOLOYD Nilflame insulations thickness can be reduced as compared to other materials like polystyrene foam cellular glass. Lower thickness exposes lower surface area for expensive vapour barrier and outer cladding.

EASE OF APPLICATION
Resistant to almost all solvents, Isoloyd Nilflame is compatible with cold applied adhesives, sealants and vapor -barrier mastics.Isoloyd Nilflame is available in boards, pipe sections, radiused and bevelled lags, with or without factory laminated facings.

buildings. It is provided with a precisely engineered “Rib and Flute” design to ensure wide spanning and quick recovery after being subjected to excessive load.

Lloydtile, in addition to Superdeck, offers new dimensions to architectural aesthetics and frees the designer of monotonous standard Trapezoidal design.

Lloyd Kliplock and Lloyd Standing Seam are laterally trapezoid profile with wide spanning and excellent water shedding capacities. The bold and broad flat outline makes a strong and striking appearance.

Lloyd Superdeck is a high depth roofing metaldeck profile.

Lloyd light groove is a lightly grooved sheet that can be used for plain facings.

Availability

Lloyddeck, Superdeck, Lloydtile, Lloyd Light Groove, Lloydkliplock & Standing Seam profiles are available in following standard finishes:-

• Pre-painted zincalume / galvalume steel with super Polyester, Silicon Polyester or Fluropolymer (PVF₂) coating.
• Pre-painted galvanized steel with polyester coating (SMP / RMP).
• Bare zincalume / galvanized finishes.

Profile

Lloydeck and Lloydtile sheets are available in a profile depth of 28-30mm at 195-200mm pitch and for Superdeck profile depth of 44mm and 130mm pitch. Lloydtile has steps of 200-300mm with height of 12-15mm . Lloyd Kliplock has a profile depth of 41-47mm at 218-250mm pitch. Lloyd Standing Seam has a profile depth of 62mm at 350-550mm pitch. In between 2 profiles, there are two small ribs in all the above profiles.

Base Zincalume / Galvalume Steel

Zincalume / galvalume steel us a zinc aluminium alloy coated steel offering high corrosion resistance.

This alloy coating comprises of 55% aluminium, 43% zinc and silicon. This coating offers a superior barrier protection against coastal atmosphere conditions. The coating class is AZ:1397, which means 150gms/m² minimum coating mass total of both sides. Zincalume / galvalume steel are available in tensile strength of 300, 345 & 550 Mpa.

Galvanized Steel.

Galvanized steel comprises of galvanized zinc coating over mild steel of minimum coating mass 175 gms/m² IS: 277 and tensile strength of min. 240Mpa.

Standard Conformance

As: 2728, AS: 1397
IS: 14246, IS: 513, IS: 277

ISO THANE EMA elastomeric membrane is a liquid applied coating based on urethane perpolymers which cure by reaction with atmospheric moisture to give a continuous film which is elastic. It contains leafing aluminium which gives execellent U.V. resistance.

ISOTHANE EMA is a very high solids coating designed to give a high build film. It can be brush or spray applied (with airless spray equipment) but it has a higher viscosity than a conventional paint and should not be diluted.

ISOTHANE EMA curves to a permanently flexible seamless membrane which, by virtue of its chemical reactivity in the wet state has good adhesion to a wide ranges of substrates (given proper preparation) such as roofing asphalt, slates, tiles, asbestos, concrete, brick, wood, glass and metals. Unlike more traditional bitumen based product ISOTHANE EMA does not readily embrittle with age, exposure to ultra violet radiation or weathering and hence it does not crack or craze.

Since it is elastomeric ISOTHANE EMA is not adversely affected by extremes of temperature, consequently it does not crack at low temperatures or suffer thermal flow at elevated temperatures.

ISOTHANE EMA can be applied by brush, airless spray or roller without the need to mix, stir or heat before application.

APPLICATION
ISOTHANE Elastomeric Membranes are designed to bond to many types of substrate particularly those commonly used as roofing, such as felt, asphalt, slate, tiles, asbestos, concrete, brick, wood, glass and metals. They can also be applied to sprayed polyurethane (p.u) foam insulation. However, it is essential that substrate and structures are properly prepared, and stable.

Surface previously treated with silicon based materials will inevitably be difficult to overcoat and this should not be attempted with IOSTHANE products.

Substrates with poor adhesion to the underlying structure (e.g. blistered roofing felt) may also cause problems in providing sound over-coating.

Preferential vapour drive in building must also be borne in mind when over coating the roof and it may be judged expedient to employ ventilation to cope with transmission of high levels of moisture vapour.

METHOD OF APPLICATION
The dry film thickness(DFT) of ISOTHANE EMA, should not be less than 0.5mm or more than 1.0mm for each coat. Rough or textured surfaces will reduce the coverage rate and consequently more material must be allowed to achieve the minimum D.F.T. IOSTHANE EMA is a membrane coating, not a paint and as such protection is only achieved with a high film build, i.e. 1mm minimum. It is therefore essential that this is achieved. The membrane can be applied in one 1mm or two 0.5mm coats. Two coats are recommended on uneven and jointed surfaces to minimise the possibility of thin patches, missed areas and pinholing. In case of two coat application, it is important to recoat within 24 hours of the coat becoming sufficiently curved to allow operator access.

DO not dilute ISOTHANE EMA

Method

1. Remove all loose material by vigorous brushing. Wire brush if necessary.
2. Treat any remaining fungal growth with proprietary fungicide as recommended.
3. Allow surface to dry thoroughly and any moisture contained in the structure to evaporate. Isothane special primer and EMA should not be applied to damp substrates.
4. Fill cracks and voids with a mastic sealant.
5. Prime with Isothane special primer (6-10 m2/lt) depending on substrate texture and porosity) when cures to a slightly tacky film in 2-4 hours. Overcoat with Isothane EMA as sson as possible after this time and certainly within 48 hours. If delay exceeds this, re-priming is advised.
6. Apply Isothane EMA at a maximum film thickness of 0.5mm for two coat applications and 1mm for one coat.
7. In the case of two coat application, the first coat should be touch dry in 12-48 hours (in some conditions this might be delayed) and the second coat should be applied within 24 hours of this stage to ensure good adhesion.
8. Second coat delay:- if more than 24 hour elapse after the touch dry stage of the first coat, prime the entire surface with special with special primer and allow to dry before recoating within 4-8hours.
9. Day-work joints- where application extends over more than a working day, an overlap of 15mm should be used.
10. Aromatic hydrocarbon solvent should be used to clean equipment etc.

     

    Spray application
    Only airless spray should be used
    Graco king 60 to 1 ratio or similar
    Compressor: 100psi, 60cft min.
    Tip Siz: 28/30 thou. 60° Angle.

    APPLICATION RATE
    ISOTHANE EMA is easily and quickly applied manually at a rate of 40m2 per man hour or up to 600 m2 per day by spray application.

    REPAIRS
    Minor damage to ISOTHANE EMA, can be repaired by removing loose membrane, cleaning the surrounding area with aromatic hydrocarbon solvent overlapping by 150mm, priming the area with special primer and finishing with two coats of IOSTHANE EMA.

    COVERAGE
    Coverage rate may vary with surface texture and porosity. The information given is based on average usage. A site trial is recommended.
    
    ISOTHANE special primer 6-10m2/lt
    
    ISOTHANE EMA 1kg (0.8lt)/ m2 on a smooth surface will provide and adequate film thickness of approx 1mm. Any surface texture will increase the surface area which must be allowed for when calculation usage- e.g. on a chipping embedded surface the actual area will be approximately doubled.

    STORAGE
    Store in a cool place and avoid unnecessary opening of cans. In very cold conditions inside before using - do not attempt to thin.
    
    Once opened ISOTHANE EMA will start to cure and a skin will form, even on re-sealed cans. This can be removed if material is used within approximately a month.

    HEALTH & SAFETY
    The recommendations in our material safety data sheet (MSDS) ref. 05 should be followed at all times.

    1. • Paints products UN 1263.
       • Keep out of reach of children.
       • Keep away from sources of ignition.
       • No smoking.
       • Do not breathe vapour / spray.
       • Ensure good ventilation during application and drying.
       • In case of eye contact- wash with plenty of clean water and seek medical advice.
       • Avoid prolonged skin contact; wear suitable protective clothing and gloves.
       • Remove from skin with mild solvent / hand cleanser and wash with warm soapy water.
       • Contains isocyante, specific information available on request.
    2. Note: More details on the above are available in lidquid polymers publication "A Guide to the safe Handling of polyurethane Resins." This document should be consulted before use of any ISOCYANATE based materials.

Boards & Blocks
Supercera Boards and Blocks are made from superspun Supercera fibres by multi component organic / inorganic bonding process.

Supercera Blocks and shapes are obtained by vacuum suction of a mixture of Supercera ceramic fibres with organic and mineral binders. These vacuum formed products can be moulded and cured into a wide variety of shapes to have a smooth inside surface and a rougher outside, as demanded by the application.

Supercera Fibre Boards, Blocks and shapes can be rendered machinable- to be sawed, drilled or machined, when required.

Application (Vacuum Formed Shapes)

• Combustion Chambers
• Domestic boiler doors
• Peep holes, Pipe Seals
• Special furnace lining parts
• Radiant element supports in vitroceramic hotplates (Either electric resistance or halogen)

 

Application (Boards and Blocks)

• Lining of : Furnaces including electric Furances; Flue and chimney of furnace and kilns; Hot gas ducts; combustion chamber in central heating boiler;
• Glass tank side, ends walls, and port neck, low and high temperature driers.
• Trough and distribution lining for conveying molten metal
• Refractory backup for bricks and castables.
• Pouring forms for non ferrous castings
• High temperature baffles and muffles
• Heat shield for personnel protection
• Rigid high temperature gaskets and seals
• Expansion joints.

 

Availability (Boards)

Grade	Size (mm)	Available Thickness (mm)
HTZ, RTZ	1000 x 500 and 915 x 610	10-50 (in increments of 5)

 

Availability (Boards)

Density *	260 - 320 kg/m3
Dimensions (mm)	915 x 610 and 1000 x 500

* Higher Density products offered on request.

 

Physical Properties

Melting temperature (°c)		1700-1760
Specific Heat (KJ / Kgk)		1.07
Fibre Diameter (Mean)		2.8µ
Linear shrinkage (%) after 24 hrs Firing / Soaking	1000°c	1.5
	1100°c	2.2
	1200°c	3.0
Bulk Density (per m3) 260 - 320
Max Service Temp. (°c) 1260

 

Supercera Anchored Modules and Veneereing Modules

Anchored Modules are made from folds of Supercera Ceramic fibre - the only superspun double-needled fibre in the country. The module is held in compression by removable strapping. Each module has an integral anchoring system- the result of continuous R & D and advanced design.

Fixing of the module to metal shell is achieved by welding specially designed studs, supplied integral with the module, resulting in efficient, fast and error free installation,

Advantages

• Fast and efficient installation
• Lesser down time
• No gap between the casing plate and the module
• Faster cycling with increased plant utilization
• Higher fuel economy
• Lower installed cost
• Lower maintenance cost

 

Application

• Reheating furnaces
• Bell Annealing Furnaces
• Soaking pit seals and covers
• Laddle Preheaters
• Chemical precoess Heaters
• Kilns
• Incinertors
• Reformers, etc.

 

Typical Physical and chemical properties*

Grade	Classification temp (°c)	Chemical Analysis (%)
		Al2 O3	SiO2	ZrO2	Fe2O3
HT	1425	32-36	44-48	16-18	Trace
RT	1260	46-48	52-54	-	Trace
RTZ	1300	40-44	50-54	4-6	Trace

Fibre diameter (micron): 2-3
Fibre Length (mm): 150-200
These are indicative only.

 

Availability Densities and Thickness

Types of Modules	Grade	Densities** (kg/m3)	Available Thickness (mm)
Anchored	HT, RT	128, 160	100-300
Veneering	HT, RT	128, 160	5075

**Higher Densities are available on request.

 

Speciality Products

A. Supercera Cermic Fibre Cloth/ Tape

Supercera cloth/ tape is a high temp. specially fabric used for variety of industrial applications. It contains 15-20% organic carrier fiber to facilitate the carding process, which may burn off at a lower temperature. This however does not change the mechanical features including strength. It exhibits excellent chemical stability, resistance attack from most corrosive agents. Available in standard thickness of 3mm. Other thicknesses available on request.

Technical Details
Size / Packing
Cloth: 3mm x 300mm x 10RMT
Tape: 3mm x 50mm x 25 RMT

B. Supercera Twisted Rope/ Braids

Supercera Twisted Rope is a three-ply rope manufactured from supercera long fibres. It contains 15-20% organic carrier fibre to facilities the carding process which may burn off at a lower temperature.

Supercera Twisted Rope is a dense, resilient high temperature refractory possessing excellent thermal properties, chemical stability and high mechanical strength.

Supercera Braids: Supercera Braided Rope is available with SS 304/ SS 310 Braiding.

Technical Details

Size	6mm Dia. to 40mm Dia.
Density	300 kg/m3 (Min.)
Diameter Tolerance	-15% to + 30%
Length Tolerance	-0, Excess Permitted.
Tensile Strength	1kg/cm2
Packing	10/25 RMT- Coils

C. Supercera paper

 

Supercera Ceramic paper is manufactured from high temperature Supercera ceramic fibre product containing 20-25% organic material to give it an extra ordinary pliability. If wet by water, steam or oil, its thermal and physical properties are restored up on dying.

Technical Data

Size	1000mm x 500mm (other sizes on request)
Standard Thickness	1mm to 6mm
Dimension Tolerance	-0, Excess Permitted
Density	240 kg/m3 (-155 to 30%)
Tensile Strength	0.4 kg/cm2
Linear shrinkage	3.5% maximum at 1260°c for 24 hours

Rockloyd is a precisely engineered Resin Bonded Fibrous Insulation to offer maximum resistance to heat passage. Rockloyd fibres are spun from selected rocks, melted at 1600°c and blended to a carefully adjustment chemical composition. Its centrifugally spun fibres have a diameter 1/20^th that of human hair which are felted using State of the Art Technology into bonded and cured mattress to optimum density and resilience. Over 25million sq.mts. of Rockloyd Insulation are in services in prestigious projects within the country saving millions of tones of fuel year after year.

Rockloyd, like all scientifically processed fibrous insulants is composed of fibres which are laid in the optimum configuration to offer maximum resistance to heat flow. To retain these exceptional properties up to the point of end-use, fibres are interlocked by lightly bonding them together using a thermosetting binder. Subsequently, matts are factory stitched to specified wire mesh using a continuous stitching machine to permit a ready-to-use configuration.

Salient Feature

• Higher Thermal Performance, as it is made out of Rockwool and not slagwool.
• Eliminated setting and sagging.
• Longer Life, permitting reuse after removal during maintenance.
• Environment Friendly, as there is no chicken feathering (Which normally pollutes the environment). It is ECO friendly to personnel due to the chemistry of fibres.
• Uncontaminated, as manufacturing is totally a DRY Process.
• Application Friendly, as it permits very fast installation.
• Can feature Resistance to capillary if needed

 

Specification conformance
Rockloyd mattress manufactured from select rocks to state of Art Specification fully conform to local & International Standards such as.

IS	8183-1993
BS	3958 Part-3
ASTM	C 592

Approved for A-60 Class insulation*
* The only product in India.

 

Technical Specifications

Standard Densities	100, 120 & 150 Kg/m3
Application Temperatures	-100°c to +800°c
Standard Thickness*	25, 40, 50, 60, 65, 75mm
Standard Size	1520 x 1220 mm

* Other thickness from 20 to 100 mm in steps of 5mm can also be made available.

 

Corrosion Protection
Rockloyd fibres, in the first place, are devoid of impurities like Halides (Chlorides & fluorides) and Sulphides which are commonly found in other materials such as Calcium Silicate. This is due to the fact that Rockloyd fibres are manufactured by a dry manufacturing process and its faint alkalinity actually fight against corrosive reactions. It meets various critical specifications including ASTM C 795 requirements where specified.

This feature is responsible for its exclusive selection for critical applications such as Nuclear Power plants, ship building and Railways coaches where corrosion resistance is of vital significance.

Fire Resistance
Incombustible when tested as per IS:3144 Melting point of fibres is above 1000°c (1825°F)

Compression Resistance & Sound Absorption
Excellent compression resistance & sound absorption by virtue of its scientific fiber lay pattern which ensures controlled dispersion of air pockets.

Inhibited Rockwool
Where stress corrosion is there on austenitic stainless steel, inhibited Rockwool Mattressess are used. Inhibition is done by spraying sodium silicate of adequate quantity in order to lower chloride content as low as 2ppm.

Water Repellent Grade
It is special grade Rockwool materials wherein special type of chemical is added during its manufacturing process to make it water repellent grade. For this property it is tested as per BS:2972 with partial immersion in water for 48hrs. which exhibits superior results as compared to normal grade Rockwool.

Thermal Conductivity
Resin Bonded Rockloyd material is the only one to offer the LOW THERMAL CONDUCTIVITY to weight ratio among all industrial insulants thus minimizing the total load on the applied equipment.

Rockloyd Slab - Resin Bonded, Rockwool Slabs
Rockloyd is a precisely engineered Resin Bonded Fibrous Insulation to offer maximum resistance to heat passage. Rockloyd Fibres are spun from selected rocks, melted at 1600°c and blended to a carefully adjusted chemical composition. Its centrifugally spun fibres have a diameter 1/20^th that of human hair which are felted using state of art Technology into bonded and cured slabs to optimum density and resilience.

Over 25 million sq. mts. Of Rockloyd Insulation are in service in prestigeous projects within the country saving millions of tones of fuel year after year.

Specification Conformance
Rockloyd Slabs manufactured from select rocks using state of the art technology conforms to and exceeds requirements specified in local & international standards such as

IS 8183: 1993
BS: 3958 Part-5
ASTM C 612

IMO for A15, A-30& A-60 class fire barrier insulation. **
** The only product to carry this certification in India.*

Physical Data for Standard Products
 

Slab Grade	Slab Density kg/m3	Optimum Temperature Limits °c	Thickness (mm)**	Size (m)
300	48	250	25,40,50,60,65 & 75	1.0x0.50, 1.0x0.60 or 1.2 x 0.75
400	64	300	25,40,50,60,65 &75	1.0x0.50, 1.0x0.60 or 1.2x 0.75
600	96	400	25,40,50,60,65 &75	1.0x0.50, 1.0x0.60 or 1.2x 0.75
900	144	550	25,40,50,60&65	1.0x0.50, 1.0x0.60 or 1.2x 0.75

** Can be made available with increments in thickness of 5mm against special orders.

 

Water & Moisture Repellence
Rockloyd Slabs by virtue of fiber surface treatment and lay pattern has an angle of contact exceeding 90°c which result good resistance to water and moisture ingress and hence does not promote capillary action. When tested as per IS, BS and ASTM standards the material exhibits excellent resistance to moisture absorption and is superior to materials like Calcium Silicate and Glasswool which are inherently hygroscopic in nature.

* All insulation materials degrade in their properties when water or moisture enters their body.

Sound Absorption
Excellent sound Absorption by virtue of its scientific fibre lay pattern ensuring controlled dispersion of air pockets and prices air flow resistance.

Sound absorption co-efficient of Rockloyd Slabs 48 Kg/m³ are furnished below:
 

Thickness in mm		25*	50*	25**	50**
Frequency	125	0.13	0.23	0.16	0.28
	250	0.32	0.58	0.41	0.68
	500	0.82	0.85	0.84	0.98
	1000	0.95	0.96	0.96	0.97
C/S	2000	0.94	0.98	0.96	0.95
	4000	0.76	0.94	0.92	0.94
NRC			0.84	0.79	0.89

* With rigid backing ** with 1" air gap

 

Fire Resistance
Totally Incombustible when tested as per IS: 3144 (Melting point of fibres is above 1000°c [1825°F])

Corrosion Protection
Rockloyd Fibres, in the first place, are devoid of impurities like Halides (Chlorides & Fluorides) and Sulphides which are commonly found in other materials such as Calcium Silicate. This is due to the fact that Rockloyd fibres are manufactured by a dry manufacturing process and its faint alkalinity, actually fights against corrosive reactions. It meets various critical specification including ASTM C795 requirements where specified.

This is feature is responsible for its exclusive selection for critical application such as Nuclear Power Plants. Ship building and Railways coaches where corrosion resistance is of vital significance.

Thermal Conductivity
Resin Bounded Rockloyd material is the only one to offer the LOW THERMAL CONDUCTIVITY to weight ratio when compared t block type insulants like Clacium Silicate. This minimizes the total load on the piping and equipment while maximizing thermal efficiency with a given thickness of usage.

ROCKLOYD PIPE SECTION
Rockloyd is a precisely engineered Resin Bonded Fibrous Insulation to offer maximum resistance to heat passage. Rockloyd Fibres are spun from selected rocks, melted at 1600°c and blended to a carefully adjusted chemical composition. Its centrifugally spun fibres have a diameter 1/20^th that of human hair which are felted using state of art Technology into bonded and cured pipe section to optimum density and resilience.

Over 25 million sq. mts. of Rockloyd Insulation are in service in prestigeous projects within the country saving millions of tones of fuel year after year.

Mandrel wound and concentrically formed form fitting Pipe sections, Precisely made to fit standard pipe diameters offer uniform maximum resistance to passage of heat along and around the entire 360degrees of the pipe axis. Superior density of this product enhances compression resistance in services. These sections are easy to fit and hence afford speedy application to site.

Specification Conformance
Rockloyd Pipe sections manufactured from select rocks using state of the art technology conforms to local & international standards such as

IS: 9842
BS: 3958 Part-5
ASTM C547-95

Thermal Conductivity
 

Standard Densities	144, 150 & 160 Kg/m3
Application Temperatures	-100°c to +8000°c
Standard Thickness*	25, 40, 50, 60, 65, 75mm
Diameter Range**	12.5mm to 350mm Nominal Bore.
Standard length	0.5, 0.75, 1.0 mts.
Facings (if specified)	Kraft {Paper, Scrim cloth, Canvas or Aluminium Foil.

* Other thickness from 20 to 100 mm in steps of 5mm can also be made available.
** Outer Diameter of Pipe to be specified.

 

Water & Moisture Repellency *
Rockloyd Pipe sections, by use of special additives and fibre lay pattern has an angle of contact exceeding 90°c which make it totally resistant to ingress of water wherever called for. When tested as per IS, BS and ASTM standards the material exhibits excellent resistance to moisture as compared to materials like Calcium Silicate and Glasswool which are inherently hygroscopic in nature.

* Insulation materials loose their properties when water or moisture enters their body.

Corrosion Protection
Rockloyd fibres, in the first place, are devoid of impurities like Halides (Chlorides & fluorides) and Sulphides which are commonly found in other materials such as Calcium Silicate. This is due to the fact that Rockloyd fibres are manufactured by a dry manufacturing process and its faint alkalinity actually fight against corrosive reactions. It meets various critical specifications including ASTM C 795 requirements where specified.

This feature is responsible for its exclusive selection for critical applications such as Nuclear Power plants, ship building and Railways coaches where corrosion resistance is of vital significance.

Fire Resistance
Incombustible when tested as per IS: 3144 (Melting point of fibres is above 1000°c (1825°F)).

Sound Absorption
Excellent sound Absorption by virtue of its scientific fibre lay pattern ensuring controlled dispersion of air pockets and prices air flow resistance.

Thermal Conductivity
Resin Bounded Rockloyd material is the only one to offer the LOW THERMAL CONDUCTIVITY to weight ratio thus minimizing the total load on the applied pipelines or equipment.

Inhibited Rockwool
Where the stress corrosion is there on austenitic stainless steel inhibited Pipe sections are used. Inhibition is done b spraying sodium silicate of adequate quantity in order to lower chloride content as low as 2ppm.

SUPERTHERM PIPE SUPPORTS
A heavy duty easy to install prefabricated pipe support system of truly revolutionary proportions Supertherm Pipe Supports are made from specially formulated chemical systems that result in high density rigid polyurethane foam. The very nature of the material immediately yields several advantages.

Property	Advantages
Wide density range possible	Higher densities enable higher loads without increase in surface area.
Pre-engineered at our factory	No sawing and Shaping at site. The support precisely matches pipe's OD. Installation time dramatically reduced.
Material has a closed cell structure	Does not permit water penetration. No wet rot. No dry rot.
Excellent 'K' value	Provides vastly superior insulation as compared to timber and other materials. No condensation at support point. So no drips, puddles or energy wasted.
Good fire resistance	Improved safety at site. Improved durability.
Close dimensional tolerance	Pipe Support thickness precisely matches insulation thickness, resulting in neat finish at support location.
Supplied in assembled condition, complete with all metal attachment	Improved speed of installation. Joint-free in the load bearing area, even for larger diameters of pipe.
Special sizes, shapes and finishes	On request Non-standard sizes and shapes can be manufactured to suit specification. Supports can be supplied with a factory-applied coat of fire-resistive mastic, which also serves as a vapour barrier, on the exposed surface.

Physical Properties for different Densities

Density (kg/m3)	% Closed Cells	Water Vapour Transmission (gms/m2/24hrs)	Compression strength (Kpa)	Tensile Strength (Kpa)
80	93	50	900	1200
120	94	45	1500	1600
180	94	30	2900	2500
250	96	25	4900	3100
320	96	15	8200	5000
This system is 'CFC FREE' and has been designed within the Guide lines of the Montreal Protocol, 1987, for the protection of the Ozone layer.

Comparison with Wood

Wood	Density (kg/m3)	'K' Value at 10°c	Max. Temp °c	Min. Temp °c	Fire Rating
Oak	740	0.159	65	0	Poor
Mahogany	560	0.144	65	0	Poor
Supertherm	80	0.023	110	-185	Class P as per BS: 476 Part-5 for ignitability
	120	0.031	110	-185
	160	0.033	110	-185

Supercera Blankets
Supercera Blanket is a refractory fibre needled mat made without binder from Supercera fibres the only super-spun double needled fibre in the country today. Supercera RTZ and HTZ Blankets are zirconoca stabilized and are suitable or use upto 1260°c and 1425°c respectively.

Both blankets have excellent resistance to most chemicals. If wet by oil or water, thermal and physical properties are fully restored upon drying.

Out Standing Advantage

• Excellent Thermal Stability.
• Low Shrinkage at elevated temperature - due to their excellent Thermal Stability.
• Low Heat Storage Both blanket store approximately 95% less heat than dense firebrick and approximately 75% less heat than insulating firebrick a property of significant importance in the operation of periodic kilns / furnaces.
• Good Cold strength.
• Excellent Hot strength.
• Thermal stock Resistance due to the flexible matrix of Supercera, extreme temperature change do not alter its ability to physically stay in place and perform at higher levels.
• The products are not wetted by molten non-ferrous metals. If wet by oil, water or steam, Thermal and physical properties will be fully resorted after burn out or drying.

 

Applications

• Normalising Annealing furnaces and glass lehrs.
• Reformers & Ducts in petrochemical, fertiliser and Boiler Linings Industry
• Fexible high temperature pipe insulation.
• Low velocity HRSG and stack linings
• Glass Furnace crown insulations
• Trundish cover, Transfer cars in steel plants
• Soaking pit seals and expansion joint
• Kilns, klin cars for ceramic industry
• Annealing cover bottom seals
• Reusable insulation blankets for field stress relieving of welds
• Removable Insulation blankets for steam and gas turbines and fire protection.
• Insulation wrap on investment casting moulds
• Furnace door seals, linings and gaskets
• Temporary repair of refractory furnace linings and roofs
• High temperature filter media / gaskets
• High temperature sound absorption and Nuclear Insulation applications.

 

Availability (for all grades)

Density (kg/m3): 64, 96, 128
Thickness (mm): 6, 12, 20, 25, 50
Roll Dimension: 7620 mm x 610mm
Other sizes available on request.

They conform to IS: 15402-03 & ASTM C 892-00

Supercera Boards & Blocks

Supercera Boards and Blocks are made from superspun Supercera fibres by multi component organic / inorganic bonding process.

Supercera Blocks and shapes are obtained by vacuum suction of a mixture of Supercera Ceramica fibres with organic and mineral binders. These vacuum formed products can be moulded and cured into a wide variety of shape to have a smooth inside surface and a rougher outside, as demanded by the application.

Supercera fibre boards, blocks and shapes are self supporting with excellent stability at high temperatures, having high resistance to thermal shock and chemical attack. Supercera fibre boards, blocks and shapes can be rendered machinable to be sawed, drilled or machined, where required.

Density	260 - 320, 720 kg/m3
Size	915 x 600 mm & 1000 x 500mm
Thickness	10-50 mm

 

Applications (Vacuum formed shapes)

• Combustion chambers
• Domestic boiler doors
• Peep holes, pipe seals
• Special furnace lining parts
• Radiant element supports in vitroceramic hotplates (either electric resistance or halogen)

 

Applications (Boards and Blocks)

• Linning of : Furance including electric furnaces: Flue and chimney of furnaces and Hot gas ducts: combusting chamber in heating boilers: Glass tank side, end walls, and port neck; Low and high temperature driers
• Trough and distribution linings for conveying molten metal
• Refractory backup for bricks and castables.
• Pouring forms for non ferrous castings
• High temperature baffles and muffles
• Heat shield for personnel protection
• Rigid high temperature gasket and seals
• Expansions joints.

 

Supercera Anchored Modules and Veneering Modules
Supercera anchored modules are made from folds of Supercera ceramic fibre the - only superspun doubled-needed fibre in the country. The module is held in compression by removable strapping. Each module has an integral anchoring system - the result of continuous R & D and advanced designing. Fixing of the module to metals shell is achieved by welding specially designed studs, supplied integral with the module, resulting in efficient, fast, and error-free installation. Supercera Modules are ideal for full thickness lining for new furnaces as well as conversion into fibre lining incase of old furnaces. They enhance the furnace life and performance.

Density: 128, 160kg/m3
Thickness: 100- 300mm for anchored and 50- 75mm for veneering.

Supercera veneering Modules improve the thermal efficiency of old brick linings with minimum downtimes for repairs.

Applications

• Reheating Furnaces
• Bell Anneling Furnaces
• Soaking pit seals and covers
• Ladle preheaters
• Chemical process heaters
• Incinerators
• Reformers, etc.

 

Specially Products
Supercera cloth / tape is a high temp. specially fabric used for a variety of industrial applications. It contains 15 - 20% organics carrier fibre to facilitate the carding process, which may burn off at a lower temperature. This however does not change the mechanical features including strength. It exhibits excellent chemical stability, resisting attack from most corrosive agents. Available in standard thickness of 3mm. Other thickness available on request.

Cloth sizes: 3mm x 300mm / 1000mm x 10m
Tape sizes: 3mm x 50mm x 25mm

Supercera twisted Rope is a three-ply rope manufactured from Supercera long fibres. It contains 15 - 20% organic carrier fibre to facilitate the carding process which burn off at a lower temperature. It is dense, resilient high temperature refractory possessing excellent thermal properties, chemical stability and high mechanical strength . Size 6 to 40mm dia, 10/25m coils & 300 kg.m3 density (min.)

Supercera Braids Supercera braided rope is available with SS304/ss310 braiding Supercera ceramic Paper is manufactured from high temperature. Supercera ceramic fibre product containing 20-25% organic material to give it an extra ordinary pliability. If wet by water, Steam or oil, its thermal and physical properties are resorted up on drying.
 

Size	1000mm x 500mm
Thickness	1 to 6mm
Density	240 kg/m3

Supercera Bulk Fibre
Supercera is a high temperature insulating refractory fibre processed from high purity alumina and silica constituent specially selected for high strength refractoriness and stability even under severe conditions.

Supercera spun texture gives it the added extra of exceptionally long fibres and superior mechanical properties essential to meet service conditions.

Supercera bulk fibres provide superior acoustical benefit in addition to high thermal performance a relevant benefit in process furnaces. Supercera can be handled and worked into expansion joints, wall penetrations and other areas with nominal skills. In specific cases, our application engineers would be happy to assist with heat loss. Surface temperature and heat storage computations.

Salient features

• Low heat storage
• Light weight
• Very low thermal conductivity.
• Resistance to high temperature
• High resilience
• Excellent corrosion resistance
• Resistance to thermal shock
• Excellent resistance to chemical attack (with the exceptions of hydrofluoric and phosphoric acids)

 

Applications
As a resilient fill or packing material in high temperature areas like:

• Burner Openings
• Kiln Insulations
• Furnace patch sealings
• Emergency repairs in refractory
• Glass tanks and glass processing
• Furnace repairs
• Expansion joints
• Fibre boxes.

 

Specifications

Chemical Composition	RT	RTz	HTZ
Al2 O3 (%)	46 - 48	41 - 43	33 - 36
SiO2 (%)	52 - 54	50 - 54	44 - 48
ZrO2 (%)	-	4 - 6	16 - 19
Leachable Chlorides	< 10ppm	<10ppm	<10ppm

Physical Properties		RT	RTz	HTZ
Melting Temperature (°c)		1760	1700	> 1650
Specific Heat (KJ / kgK)		1.07	1.07	1.07
Fibre Diameter (Mean)		2.8µ	2.8µ	2.8µ
Linear Shrinkage (%) After 24 hrs Firing / Soaking	1000°c	1.5	1.5	-
	1100°c	2.2	2.2	-
	1200°c	3.0	3.0	2.7
	1300°c	-	-	3.5
	1400°c	-	-	4.0
Max Service Temp. (°c)		1260	1206	1425

Availability (For all grades)
Supercera Bulk fibre is available in standard packs of 10kg.