Insulation

The insulation industry has played a pivotal role in enhancing energy efficiency, fire safety, and temperature regulation in residential, commercial, and industrial settings. From the late 19th century through much of the 20th century, asbestos was a dominant material in insulation products due to its exceptional thermal and fire-resistant properties. Asbestos-containing insulation was widely used in applications such as pipe lagging, boiler insulation, spray-on coatings, and building materials like wallboards and ceiling tiles. Its versatility made it a staple in construction, shipbuilding, and industrial facilities, where managing heat and preventing fire hazards were critical concerns.

The use of asbestos in insulation peaked during the mid-20th century, particularly during and after World War II, when the demand for durable and effective insulation materials surged. However, as the health risks associated with asbestos exposure became evident, its use in insulation products began to decline. Today, asbestos-containing insulation is largely banned or heavily regulated in many countries, though it remains present in older buildings and industrial sites, requiring careful management during renovations or demolitions.

Why Asbestos Was Used in the Insulation Industry

Asbestos was extensively used in the insulation industry because of its unique ability to withstand extreme temperatures while providing excellent thermal and acoustic insulation. Its natural resistance to fire, heat, and chemical degradation made it an ideal material for insulating pipes, boilers, and other high-temperature equipment. Additionally, asbestos fibers could be easily combined with other materials to create lightweight, durable, and cost-effective insulation products that were easy to install and maintain.

Another key reason for asbestos’s popularity in insulation was its ability to prevent the spread of fire, making it a critical component in fireproofing applications. Its fibrous structure also contributed to its effectiveness in soundproofing, further broadening its appeal in construction and industrial settings. Despite these advantages, the discovery of serious health risks associated with inhaling asbestos fibers, particularly during the installation, maintenance, or removal of insulation, led to its decline. Safer alternatives, such as fiberglass and mineral wool, have since replaced asbestos in most insulation applications.

Types of Asbestos Used in the Industry

The insulation industry extensively utilized several types of asbestos fibers, each selected for its unique properties that enhanced the performance and safety of insulation materials:

Chrysotile (White Asbestos): Chrysotile was the most commonly used type of asbestos in the insulation industry due to its flexibility, durability, and excellent thermal resistance. It was widely incorporated into pipe insulation, boiler insulation, and spray-on insulation products. Chrysotile’s ability to be woven and combined with other materials made it ideal for applications requiring both heat resistance and structural reinforcement.

Amosite (Brown Asbestos): Amosite was highly valued in the insulation industry for its superior heat resistance and strength. It was frequently used in thermal insulation boards, pipe lagging, and insulating panels for high-temperature environments. Its durability and resistance to heat made it a preferred choice for industrial and commercial insulation applications.

Crocidolite (Blue Asbestos): Crocidolite was used in specific insulation applications where exceptional resistance to chemicals and high temperatures was required. It was often found in spray-on insulation and insulation for industrial equipment exposed to harsh conditions.

The insulation industry relied on asbestos for its unparalleled ability to provide thermal insulation, fireproofing, and durability. However, due to the significant health risks associated with asbestos exposure, its use has been discontinued in favor of safer alternatives in modern insulation practices.

Common Types of Asbestos Products in the Insulation Industry

The insulation industry heavily relied on asbestos due to its exceptional heat resistance, fireproofing capabilities, and insulating properties. Asbestos was a key component in various insulation products designed to protect buildings, machinery, and equipment from heat and fire. Common types of asbestos products used in the insulation industry include:

Asbestos Pipe Insulation: Asbestos pipe insulation was designed to wrap around hot water and steam pipes to prevent heat loss and protect against burns. It was often pre-formed into half-cylinder shapes or applied as a flexible wrap. Widely used in residential, commercial, and industrial settings, particularly in power plants, factories, and shipbuilding, this insulation was effective in maintaining energy efficiency and protecting workers from high-temperature surfaces. Its durability and resistance to heat, moisture, and corrosion made it a preferred choice for pipe insulation. Amosite asbestos insulation, such as “Unibestos,” was specifically developed for this purpose and could withstand temperatures up to 1,200°F.

Asbestos Block Insulation: Asbestos block insulation consisted of rigid blocks or slabs made from asbestos fibers mixed with binders, designed to insulate high-temperature equipment. It was commonly applied to boilers, furnaces, heat exchangers, and other industrial equipment to prevent heat loss and improve energy efficiency. Frequently used in power plants and manufacturing facilities, its rigid structure allowed for easy installation on flat or curved surfaces, and its high thermal resistance made it suitable for extreme temperatures. High-temperature insulation blocks developed by companies like Philip Carey Manufacturing Co. were widely used in industrial applications.

Asbestos Spray-On Insulation: Asbestos spray-on insulation was a mixture of asbestos fibers and a binding agent, applied using a spray gun to create a fireproof and thermally insulating layer. It was used extensively in commercial and industrial buildings to insulate steel beams, walls, ceilings, and other structural components. Shipbuilding and large-scale construction projects also relied on spray-on asbestos insulation for fireproofing and thermal control. The spray-on application allowed for coverage of irregular surfaces and hard-to-reach areas, providing seamless insulation and fireproofing. The “Limpet” spray process, developed by Turners Asbestos Cement Co., was a notable example of this method.

Asbestos Insulating Cement: Asbestos insulating cement was a pliable, paste-like material made from asbestos fibers mixed with other ingredients. It was commonly applied to pipe joints, valves, and fittings in industrial and commercial settings, often used to seal and insulate joints, gaps, and irregular surfaces. This material was also used to repair or reinforce existing insulation. Its flexibility and ease of application made it ideal for sealing complex shapes and ensuring a tight, heat-resistant seal. Asbestos cement finishes were often reinforced with wire mesh for added durability and applied to large equipment like ducts and breechings.

Asbestos Blanket Insulation: Asbestos blanket insulation consisted of flexible sheets or rolls of asbestos fibers, often reinforced with wire mesh or kraft paper. These blankets could be wrapped around equipment or pipes for thermal protection and were widely used in shipbuilding, locomotive lagging, and industrial settings to insulate large surfaces or irregularly shaped equipment. Additionally, asbestos blankets were used in residential settings for attic and wall insulation. Their flexibility allowed them to conform to various shapes, and their lightweight nature made them easy to handle and install. Asbestos cloth jackets filled with loose asbestos wool were commonly used for ship hull insulation and steam pipe wrapping.

Companies That Manufactured Asbestos Insulation Products

Several companies were prominent in producing asbestos-containing insulation materials. These include:

Johns-Manville Corporation: Johns-Manville Corporation was one of the largest and most influential manufacturers of asbestos-containing products in the 20th century. The company produced a wide range of insulation materials, including pipe insulation for steam and hot water pipes in industrial and commercial settings, block insulation for boilers and industrial equipment to improve energy efficiency, and spray-on insulation for structural steel and fireproofing applications in construction and shipbuilding. Johns-Manville’s products were widely used due to their durability, fire resistance, and thermal insulating properties. However, as the health risks of asbestos exposure became widely recognized, the company faced significant legal challenges, ultimately filing for bankruptcy in 1982 due to asbestos-related lawsuits.

Owens-Corning Fiberglas Corporation: Owens-Corning Fiberglas Corporation was another major player in the asbestos insulation market, manufacturing pipe coverings designed to insulate pipes in industrial, commercial, and residential applications, as well as insulating cements used to seal and insulate joints, fittings, and irregular surfaces. These cements contained asbestos to enhance heat resistance and durability. Owens-Corning’s products were widely used in construction and industrial settings, but as asbestos-related health concerns grew, the company faced mounting lawsuits and liabilities, leading to its own bankruptcy filing in 2000.

Eagle-Picher Industries: Eagle-Picher Industries was well known for its asbestos-containing insulation products, particularly block insulation used in industrial applications to insulate equipment such as boilers, furnaces, and tanks. The company also produced insulating cements that provided thermal insulation and sealed gaps in industrial systems. Eagle-Picher’s products were valued for their ability to withstand high temperatures and effectively reduce heat loss. However, as asbestos litigation increased, the company struggled under the financial burden of legal claims and ultimately filed for bankruptcy in 1991.

Armstrong World Industries: Armstrong World Industries was a significant manufacturer of asbestos-containing insulation materials, particularly those designed for pipes and boilers. The company’s insulation products provided thermal efficiency and fire resistance and were widely used in industrial and commercial settings. Despite their effectiveness, Armstrong World Industries faced substantial legal and financial challenges as the dangers of asbestos became apparent, eventually leading to its bankruptcy filing in 2000 as it sought to manage its asbestos-related liabilities.

Keasbey & Mattison Co.: Keasbey & Mattison Co. was a prominent producer of asbestos insulation products, including pipe coverings used in various industrial and commercial applications and spray-on insulation applied to structural components for fireproofing and thermal insulation. The company was an early adopter of asbestos in its products and played a significant role in popularizing its use in insulation materials. However, like other manufacturers, Keasbey & Mattison faced significant liabilities as the health risks of asbestos exposure became widely known, ultimately contributing to its decline.

The widespread use of asbestos in the insulation industry was driven by its effectiveness and affordability. However, the health risks associated with asbestos exposure have led to strict regulations and the development of safer, non-asbestos insulation materials in modern construction and industrial practices.

Insulation Workers are at Risk of Asbestos-Related Diseases

Insulation workers, particularly those involved in the installation, maintenance, and removal of insulation materials, face a significant risk of asbestos exposure. Historically, asbestos was extensively used in the insulation industry due to its exceptional heat resistance, fireproofing capabilities, and durability. Medical research has conclusively demonstrated that asbestos exposure can lead to the following health complications:

Mesothelioma – Insulation workers are at an elevated risk of developing mesothelioma, a rare and aggressive cancer, due to inhaling airborne asbestos fibers. These fibers were often released during the cutting, shaping, or removal of asbestos-containing insulation materials, which were widely used in industrial equipment, commercial buildings, and ships .

Lung Cancer – The installation and removal of insulation frequently involved disturbing asbestos-containing materials, such as sprayed-on insulation, pipe lagging, and boiler insulation. This disturbance released asbestos fibers into the air, significantly increasing the risk of lung cancer for workers who inhaled them. For decades, the industry relied heavily on asbestos without fully disclosing its dangers, leaving workers vulnerable .

Throat Cancer – Inhalation or ingestion of asbestos fibers during tasks such as cutting or removing insulation could lead to cancers of the larynx and pharynx. Insufficient protective measures in the past further exacerbated this risk for insulation workers .

Stomach Cancer – Workers could inadvertently ingest asbestos fibers, particularly if they ate in contaminated areas or failed to clean up properly before meals. This exposure has been linked to an increased risk of stomach cancer. Poor hygiene practices and inadequate dust control measures in insulation work contributed to this risk .

Colon Cancer – Known as colorectal cancer, this condition may result from ingesting asbestos fibers. Insulation workers were often exposed to asbestos, which could contribute to the development of this type of cancer .

Asbestosis – This chronic lung disease, caused by the inhalation of asbestos fibers, leads to scarring of lung tissue and significant breathing difficulties. Asbestosis is a direct result of prolonged exposure to asbestos in the workplace, particularly during the handling of asbestos-containing insulation materials .

Insulation workers played a critical role in ensuring the energy efficiency and safety of buildings and industrial equipment. However, the nature of their work placed them at significant risk of asbestos exposure. Modern safety protocols, including the use of personal protective equipment (PPE), proper ventilation, and strict adherence to asbestos abatement regulations, are essential to protect workers from the long-term health effects of asbestos exposure.

Learn more about the diseases asbestos can cause.

Worker Tasks and Asbestos Exposure in the Insulation Industry

The insulation industry historically relied heavily on asbestos due to its exceptional heat resistance, durability, and insulating properties. Workers in this industry were frequently exposed to asbestos during the manufacture, installation, maintenance, and removal of asbestos-containing insulation materials. These tasks often released hazardous asbestos fibers into the air, putting workers and those nearby at significant risk.

Key tasks that exposed insulation workers to asbestos included:

Prefabrication: Cutting and shaping insulation materials, often using hand or power saws, either on-site or in a contractor’s shop. This process generated asbestos dust, especially when working with materials containing high asbestos content.

Application: Fitting, hammering, carving, and attaching insulation materials to surfaces such as pipes, boilers, and industrial equipment. These tasks often involved wiring, gluing, or spraying asbestos-containing materials, which released fibers into the air.

Maintenance and Repairs: Removing or replacing damaged or worn-out insulation during routine maintenance or emergency repairs. This often required scraping, cutting, or tearing apart asbestos-containing materials, creating significant exposure risks.

Demolition and Renovation: Stripping old insulation from industrial equipment, commercial buildings, or ships during renovation or demolition projects. These activities disturbed asbestos fibers embedded in the insulation, releasing them into the environment.

Mixing and Spraying: Preparing and applying asbestos-containing spray insulation, which was commonly used in the past for fireproofing and soundproofing. This process generated high levels of airborne asbestos fibers.

Even workers not directly handling asbestos-containing materials, such as those working nearby or cleaning up debris, were at risk of secondary exposure due to the widespread contamination of the work environment.

The risk of take-home exposure was a significant concern for insulation workers. Asbestos fibers often clung to workers’ clothing, shoes, and tools, allowing them to unknowingly bring these hazardous fibers into their homes. Family members could be exposed through activities such as shaking out or laundering contaminated work clothes, which released asbestos fibers into the air. This secondary exposure placed workers’ loved ones at risk of developing serious asbestos-related diseases, such as mesothelioma and asbestosis, underscoring the far-reaching dangers of asbestos in the insulation industry.

Our Law Firm Assists Insulation Industry Workers with Asbestos-Related Conditions

Insulation workers faced significant asbestos exposure while installing, removing, and handling asbestos-containing insulation materials in buildings, industrial facilities, and ships. Asbestos was widely used in insulation for its fireproofing and heat-resistant properties, but prolonged exposure to airborne fibers has led many workers to develop serious diseases like mesothelioma, lung cancer, and asbestosis. If you or a loved one has been diagnosed with an asbestos-related illness, you may be entitled to compensation. Our law firm is committed to guiding insulation workers and their families through the legal process, providing comprehensive support in the following areas:

Asbestos Trust Claims
Many manufacturers and suppliers of asbestos-containing insulation products have set up trust funds to compensate workers diagnosed with asbestos-related diseases. Filing a claim with these trusts does not require a lawsuit and can provide financial relief for medical expenses, lost wages, and other costs. Our legal team can help determine your eligibility and guide you through the claims process.

Asbestos Lawsuits
Companies that produced, supplied, or installed asbestos-containing insulation can be held accountable through legal action. Insulation workers exposed to asbestos while working in homes, commercial buildings, refineries, and industrial sites may be eligible to file a lawsuit. Compensation from these lawsuits can help cover medical bills, lost wages, pain and suffering, and other damages. Our experienced attorneys are dedicated to fighting for the rights of insulation industry workers.

Asbestos Disability Claims
Workers diagnosed with asbestos-related conditions may qualify for Social Security disability benefits if their illness prevents them from working. Additionally, veterans who were exposed to asbestos while installing or removing insulation on military bases, ships, or defense-related projects may be eligible for veterans’ disability benefits. These claims can provide essential financial support for affected individuals and their families.