Pre-Insulated Pipe Systems
Pre-insulated piping systems are essential across modern buildings, industrial facilities and infrastructure projects where temperature control, durability and installation efficiency are critical. A pre-insulated pipe combines an inner carrier pipe, high-performance insulation and a protective casing into a complete system that arrives on site ready for installation. This reduces labour costs, maintains thermal performance and supports long-term reliability for a wide range of fluids and gases.
Total Insulation designs and manufactures pre-insulated pipe systems for projects across Australia, New Zealand and the Pacific Rim. All systems are produced in our controlled factory environment and tailored to your precise specifications to ensure consistent performance, compliance and dependable results over many years of use.
WHAT IS Pre-Insulated Pipe Systems
A pre-insulated pipe system consists of a carrier pipe – commonly carbon steel, stainless steel, steel, copper, HDPE or PVC – surrounded by high-performance insulation such as PUR or PIR polyurethane foam. The insulation is then enclosed within a durable casing made from aluminium, stainless steel, high-density polyethylene (HDPE) or PVC.
This factory-produced layered system reduces heat loss or gain, prevents condensation, supports corrosion control and offers excellent long-term performance. Because the system arrives ready to install, it minimises on-site fabrication time and ensures consistent thermal results across large and complex industrial projects.
Where Pre-Insulated Pipe Systems Is used
Pre-insulated pipes are used across a wide range of industrial and commercial applications where temperature stability, durability and reliability are essential.
HVAC
Used throughout chilled and hot water networks to maintain stable temperatures and improve system efficiency in modern buildings.
Oil and gas industries
Pre-insulated pipes are designed to withstand chemical exposure, temperature extremes and demanding process conditions common in oil applications.
Chemicals and pharmaceuticals
Maintains controlled conditions for sensitive fluids, helping facilities meet strict process and compliance requirements.
Marine vessels
Designed to suit harsh marine environments, providing stability against saltwater, vibration and temperature fluctuations.
Refrigeration
Ideal for ammonia, glycol and low-temperature lines, providing consistent performance and preventing heat gain and condensation.
Mining industries
Durable construction suits above-ground and ground-level installations, withstanding vibration, moisture and dust exposure.
Cryogenics
Suitable for extremely low-temperature transport, minimising external heat gain and ice formation.
Infrastructure and construction
Used across major commercial and industrial project developments to deliver efficient, low-maintenance temperature-controlled pipe networks.
Chilled water systems
Pre-insulated pipe systems support reliable cooling for data centres, commercial towers and industrial plants by reducing thermal losses across long pipe runs.
Food processing
Maintains precise temperature control for wash-down lines, process fluids and cooling networks.
Heating and cooling
Suitable for high-temperature and low-temperature transfer, helping mechanical systems meet energy and comfort requirements.
Buried applications
HDPE-cased systems offer strong moisture barriers, corrosion resistance and mechanical durability for underground installation.
Heating and cooling
Suitable for high-temperature and low-temperature transfer, helping mechanical systems meet energy and comfort requirements.
Breweries and wineries
Supports glycol loops and fermentation cooling lines where consistent temperatures are essential for product quality.
Cooling networks
Often used in district heating and district cooling systems to ensure efficient transport of chilled or heated media across large distances.
Mechanical services
Protects critical pipework across industrial and commercial sites, reducing corrosion risk and ensuring long-term performance.
Abattoirs and dairy farms
Provides robust, corrosion-resistant insulated pipe solutions for chilled and heated water supply.
Water treatment
Provides reliable thermal protection for process lines, pumps and distribution systems.
WHAT MATERIALS WE USE
Total Insulation manufactures custom pre-insulated pipe systems using high-quality materials selected for temperature performance, long-term durability and compatibility with project conditions.
Insulation Materials
We use high-performance products such as polyurethane foam, PIR and phenolic foam. These insulation materials provide strong thermal resistance, low water absorption and excellent results over long installation distances. Depending on temperature and media, we also use mineral wool or cross-linked polyethylene to ensure optimal system performance.
Outer Casings and Jacketing
Our outer casing options include aluminium, stainless steel, Colorbond, PVC and high-density polyethylene. These casings protect the insulation from mechanical damage, UV exposure and weathering, and are designed to suit both above-ground and buried conditions. HDPE jackets are commonly selected for underground use due to their strong corrosion resistance and ability to withstand moisture exposure.
Carrier Pipe Compatibility
Systems can be manufactured to incorporate carbon steel, stainless steel, steel, copper, HDPE or PVC carrier pipes. This flexibility allows us to tailor each system to the intended temperature range, application, environmental exposure and site-specific conditions.
All systems are produced in our controlled factory environment, ensuring consistent quality and durability across fittings, reducers, tees, bends, valves and pipe lengths.
Benefits
Reduces on-site labour costs
Because each insulated pipe is manufactured off-site, installation time is significantly reduced. This helps large commercial and industrial projects maintain tight schedules and reduce labour expenditure.
Lowers total lifecycle costs
Reduced maintenance, improved system longevity, and fewer temperature-related issues lead to lower long-term operational costs and a better overall result for asset owners.
Maximises insulation efficiency
Factory-applied insulation eliminates gaps and inconsistencies, providing a continuous protective layer that delivers long-term thermal stability and reliable system performance.
Provides condensation and corrosion control
The sealed outer casing prevents moisture ingress and reduces the risk of corrosion, protecting both the insulation and the carrier pipe beneath it.
Has excellent thermal insulation qualities
High-quality insulation materials, such as polyurethane foam, deliver reliable thermal resistance, reducing both heat loss and gain, and supporting efficient operation across all environmental conditions.
All About Us
Our Process
- Assessment and design – We assess project requirements, temperature ranges, environmental exposure and layout needs.
- Material selection – We choose the appropriate insulation, carrier pipe material and casing to suit the application.
- Fabrication – All components are produced in our controlled factory, including fittings, reducers, tees and bends.
- Supply and installation support – Systems are delivered to the site ready for installation, with guidance available to ensure correct handling and efficient completion.
Frequently Asked Questions
It is a complete pipe system that includes a carrier pipe, insulation and outer casing to maintain temperature, reduce heat loss and improve efficiency.
Yes. HDPE-cased systems are designed to withstand moisture, soil loads and corrosion for long-term underground applications.
Depending on materials, they can support cryogenics, chilled water, heating networks and medium- to high-temperature industrial systems.
Yes. We supply a complete system including tees, bends, reducers, valves and all compatible components.
They are used in HVAC, refrigeration, oil and gas, mining, water treatment, chemical processing, food manufacturing, district heating and major infrastructure projects.
Request a Quote
Speak with our technical team to discuss your project. We will help you select the right materials, configure the correct system design and achieve excellent results for your installation.
Total Insulation Locations
Total Insulation has locations across both Australia and New Zealand. From our humble Brisbane beginnings, we’ve since expanded to have offices in both Perth and Auckland, and provide our services all across Australia, New Zealand, and the Pacific Rim.
Get in touch with your local Total Insulation team to learn more about how we can assist you with your insulation needs.
Brisbane office: (07) 3277 9785
Perth office: (08) 9356 2175
Auckland office: (09) 263 5657
Talk To The Leading Industrial Insulation Team in Australia & New Zealand
Speak to one of our trained specialists and get an industry-leading solution to your commercial insulation needs which will be done right, first time, with no hassle.
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Brisbane office: 07 3277 9785 |
Perth office: 08 9356 2175 |
Auckland office: 09 263 5657
Brisbane office: 07 3277 9785 |
Perth office: 08 9356 2175 |
Auckland office: 09 263 5657