How to solve cold water piping challenges with a water pipe clamp

The installation of cold water pipework in building services projects can be a challenge.

If you have worked on chilled water systems, you will be already familiar with the challenges involved. 

Cold water pipe installation: why are they challenging?

The main issue with chilled or cold water pipework is condensation.

When the water temperature drops lower than the ambient temperature, moisture condenses on the pipe surface. If standard lined or unlined pipe clamps are installed directly onto the pipe before insulation is applied, these clamps eventually become hidden beneath the insulation layer.

Over time, condensation can lead to corrosion of threaded rods and support components, compromising the long-term reliability of the pipe support system.

Addressing the above, the pipe must be insulated first with pipe clamps fixed around the insulation, not around the pipe. The problem with this approach is the lack of clamping resistance: tightening the pipe clamp’s flange screws with the usual torque leads to squeezing the insulation material. Not using the required torque leaves the clamps prone to falling apart in the long term.

Traditional approach

Experienced chilled water pipe installer have solved this problem by using dense materials such as:

• Phenolic insulation blocks
• Polyurethane (PUR) blocks
• Wooden blocks
• Wood-rubber combination, locally known in New Zealand as 'the crocodile'

These materials provide the best of both worlds due to continuous insulation to prevent condensation but enough resistance to allow the pipe clamp to be fully tightened.

However, these types of pipe installation combines technical requirements that contradict one another and slow down the installation with:

• Multiple components: Insulation block and pipe clamp means two components instead of one. Since most insulation blocks are supplied in two halves, installers typically handle three components instead of one.
• Difficult installation: The installation of a support block and a pipe clamp while also tightening a pipe clamp can feel like a three-handed task, even though installers only have two.
• Limited flexibility: The block must be manufactured for a specific pipe outside diameter (OD). This means a separate block is required for each pipe size, reducing installation flexibility.
• Additional sealing requirements: For vapour-tight insulation, sealant often needs to be applied both around the pipe and between the two block halves. This adds further installation time and complexity.
• Reduced load capacity: Insulated support blocks are designed to minimise thermal bridging and maintain acceptable thermal conductivity. However, their load-bearing capacity is often significantly lower than that of the pipe clamp itself.
• Increased support requirements: For larger pipe diameters, the reduced load capacity may require shorter support spans. This means more support points, increased material usage and longer installation times.

A smarter solution: Chilled Water Pipe Clamp SKS TOP 2C

Key features:

• Polyurethan (PUR) block of high density (250 kg/m³ ) leading to high compression strength 0.7 N/mm²(for static loads)
• Stabil D3G pipe clamp pre-fixed to the PUR block with screws allowing installation in one piece
• Performing from -50°C up to +110°C whilst maintaining a high level of thermal conductivity at chilled water temperatures
• The blue elastomer layer adapts to different OD’s whilst blocking condense water without the need for a sealant
• Multi thread connection that can be combined with Sikla adaptors up to 1” for solid wall, floor or ceiling connections

Cutting the long story short:

What if there was a pipe support solutions that combined all of these benefits while being quick and simple to install as a standard pipe clamp?

The solution already exists as the Chilled Water Pipe Clamp  supplied as a single component, accommodates a range of pipe outside diameters (ODs), provides sufficient load-bearing capacity for the full pipe span, and eliminates the need for additional sealants. Such a solution would not only maintain thermal and mechanical performance but also significantly simplify installation.