How Thermaxx Became a Leader in Cut-to-Length Insulation

How it Started: A University Case Study

Back in 2010, Thermaxx was contracted by a large southeast university who was beginning the process of rehabilitating their 160+ steam pits. Thermaxx Jackets was tasked with insulating all steam OS&Y valves, flanges, expansion joints, and steam trap stations with removable insulation. Through the combined and coordinated efforts of these entities, the steam pits were completely stripped of old insulation, reinsulated, and fitted with removable Thermaxx insulation jackets. The final project resulted in a the following benefits for the university:

  1. A huge reduction in heat loss from each of the pits
  2. A significant increase in the temperature of the condensate that was returned to the steam plant
  3. Hundreds of thousands of dollars in saved BTUs for the university

Step 2: Testing Materials

The initial call was to help the university spec an insulation material and outer jacket covering that would withstand the harsh steam vault environment. The universities third party engineer had Thermaxx build 10 different types of fabricated removable insulation jackets for a steam pipe. After extensive testing, Pyrogel® was the clear winner.

Step 3: Develop Technology

In November of 2010, Thermaxx contracted an industrial hygienist firm to help design a negative pressure containment system in a section of our manufacturing plant where the Pyrogel® was being cut. Thermaxx then expanded that to the full manufacturing facility and placed 15,000 CFM HEPA filter machines strategically around the shop floor.

A vacuum based automated cutting table was procured and Thermaxx was soon cutting Pyrogel® to length and size. Our engineers worked with the cutting table manufacturer and modified the nesting software to maximize material usage, therefor increasing overall efficiency and reducing waste material.

Pyro 1

Step 4: Manufacture and Scale

Since 2010, Thermaxx has continued to manufacture cut to length insulation for numerous applications both internally and for external use. To date, Thermaxx has provided Cut to Length (CTR) Insulation and Pyrogel® for a variety of applications including the following:

Pyro 3
  • 2” Pipe
  • 3” Pipe
  • 4” Pipe
  • 6” Pipe
  • 8” Pipe
  • 10” Pipe
  • 12” Pipe
  • 24” Pipe
  • Elbows
  • Long Radius Elbows
  • Gate Valve
  • Steam Traps
  • Pressure Reducing Valves (PRV’s)
  • Vessels
  • Much More…


Please contact Thermaxx for all your Cut to Length Insulation Needs

Brian Bannon - Vice President of Thermaxx

Brian Bannon, Vice President of Thermaxx, started his career in construction, insulation & demolition. While performing undergraduate studies at the University of CT, Brian & family formed an environmental clean up company in New England. His vision, dedication & drive helped take this company from a garage startup in 1986 to a $25 million dollar a year CT icon. A life long entrepreneur, Brian has started and driven many companies to reach their revenue and performance goals.