Thermal Covers | Custom Insulation Solutions for Industrial Machinery

Thermal covers

Why Choose Our Thermal Covers?

Our thermal covers are designed for durability, thermal performance, and a custom fit, providing a protective barrier to minimise fire risk from oil, fuel, or hydraulic oil leaks. We offer solutions that insulate engine parts, exhaust piping, and industrial machinery to meet stringent safety standards.

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Benefits

Locally Manufactured Quality
Our covers are fabricated locally with quick turnaround times, ensuring compliance with local safety regulations.
Quality Design & Fit
Precisely engineered for each machine, our covers maximize coverage and prevent hot spots with the highest-grade materials.
High Thermal Capacity
Our covers reduce touch surface temperatures by up to 85%, lowering ambient heat in engine bays.
Innovation
Innovations like embossed foil linings enhance thermal cooling, and unique designs like lobster-back ensure seamless coverage on bends.
Cost-Effective Solutions
We offer high-quality products to suit any budget, saving up to 25% compared to competitors while ensuring effective heat control and fire mitigation.

Cover Composition

Our thermal covers are crafted using advanced manufacturing technologies and premium materials for optimal protection and performance. Designed for durability, they mitigate fire risks and heat damage, meeting the highest safety standards.

Hot Face Barrier
Constructed from heavy-duty stainless steel, the hot face barrier provides exceptional resistance to direct-contact heat, ensuring maximum durability and protection.
Inner Layer
The inner layer is made of high-performance silica fabric that is both flexible and durable, offering superior thermal protection even in extreme conditions.
Insulation
Our non-combustible and non-flammable silica needlemat insulation delivers exceptional heat absorption capabilities, withstanding temperatures exceeding 1000°C to provide reliable safety.
External Layer
The robust external layer safeguards the cover from tears, abrasions, spills, and leaks. Made with a double silicone-coated fabric and reinforced with stainless-steel mesh, it effectively disperses heat and prevents fluid absorption, enhancing overall cover integrity.

Thermal Cover Designs

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Lobster Back
A unique design that fits perfectly around bends, reducing joints and maintenance needs. Ideal for seamless insulation in complex areas.
Reduces joint count for a cleaner system layout
Lowers pressure on joints to enhance durability
Ensures joint seams are consistently insulated for optimal safety
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Turbo Wings
Additional protection around turbo and pipework joints to prevent hot spots and enhance system safety.
Creates an additional heat barrier
Prevents hot spots for improved system safety
Designed for areas around turbo and pipe work
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Clamshell
A hinged design for easy inspections and maintenance without compromising insulation integrity.
Hinged design for easy access and inspection
Simple installation and removal process
Fits snugly within limited engine spaces
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Retention Springs
Custom stainless steel springs ensure consistent tension and fit, adapting to various environments.
Provides constant tension for a secure fit
Flexibility to adapt to varied environments
Unique spring design ensures durability and fit

Leading the Way in Thermal Cover Innovation

Committed to product innovation, our thermal covers are recognised for their safety, cost-effectiveness, and reliability. We use non-toxic materials to minimise fire risks and protect against leaks.

Enhanced Safety

Mammoth’s thermal insulation covers are specifically designed to reduce fire risks, using durable, non-toxic materials. They provide a robust protective barrier against oil, fuel, and hydraulic leaks, ensuring safety in high-risk environments.

Adaptable and Easy to Use

Our covers are tailored to meet diverse industrial requirements and come in various specifications suitable for any setting and budget. They are designed for easy installation and maintenance, featuring identification plates for straightforward operation.

Cost-Effective Protection  

Engineered for optimal performance, our covers reduce fluid ingress and thermal stress, effectively lowering touch temperatures to meet stringent safety standards. They offer an economical solution to safeguard equipment and personnel in high-temperature environments.

Certified Thermal Covers. Proven Performance and Reliability.

FAQs

What Caterpillar models do you make Thermal Covers for?

We supply Thermal Covers for the following Caterpillar models:

120H, 120K2, 12G, 12H, 12M, 140G, 140H, 140K, 140M, 14G, 14H, 14M, 14M3, 160H, 160M, 16G, 16H, 16M, 18M

226B, 24H, 24M, 262D

308E, 320D, 320D2, 325D, 325L, 329DL, 336D, 336FL, 345B, 345D, 3516B, 3516C, 374D, 385B, 385C

416F2

6020B, 621G, 623G, 627G, 631E, 631G, 637G, 651E, 657E, 657G

740B, 740C, 769D, 773B, 773D, 773E, 773F, 773G, 775D, 775E, 775F, 775G, 777C, 777D, 777E, 777F, 777G, 784C, 785B, 785C, 785D, 789B, 789B-C, 789C, 789D, 793B, 793C, 793D, 793F, 794AC, 795F, 797A, 797B, 797F

824G, 824H, 824K, 825G, 826G, 834H, 836H, 844H, 854G, 854K

924G, 928G, 930G, 930H, 930K, 938H, 938K, 950H, 950K, 962K, 962M, 966G, 966GII, 966H, 966L, 980G, 980H, 980K, 988F, 988G, 988H, 988K, 990K, 992C, 992G, 992K, 992K[H4C1-UP], 993K, 994D, 994F, 994H, 994K

AD40, AD55B, C18, C27, C32, C9.3, D10N, D10R, D10T, D10T2, D11, D11N, D11R, D11T, D11T[C32], D6R, D7R, D8R, D8T, D9R, D9T, G3612, IT28G, IT38G, IT62G, M322D, MD5125, MD5150, MD6250, MD6290, MD6310, MD6420, MD6540, R2900, RH170, TH255C

What Komatsu models do you make Thermal Covers for?

We supply Thermal Covers for the following Komatsu models:

1BD5, 630E, 685E, 730E, 7LD, 830E, 830E-1AC, 930E-2, 930E-4SE, 960E, 960E-1K, 980E

BADGER

D155AX-6, D275A-5, D375-6, D375-EO, D475-5E0, D475-5EO, D575, D85EX-15E0

GD655-5, GD825A-2

H185S, HD1500-7, HD325-7, HD465-5, HD465-7, HD605-5, HD605-7, HD605-8, HD785-5, HD785-7, HM400-2

LT-650

MT400

PC1250-7, PC1250-8, PC138US-2E1, PC2000-8, PC3000-1, PC3000-6, PC300-8, PC4000, PC4000-6, PC450-8, PC5500-6, PC8000-6, PC8000-6[QSK60]

WA1200-3, WA1200-6, WA250, WA320, WA470, WA500-6, WA500-7, WA600-6, WA900-3, WA900-8R, WD600-3, WD900-3, WEASEL, WX07

What Hitachi models do you make Thermal Covers for?

We provide Thermal Covers for a range of Hitachi models, including:

AH400D

EH3500AC-2, EH4000, EH4000AC-2, EH4000AC-3, EH4500, EH5000, EH5000AC-3, EH5000AC3[QSKTTA60], EH5000ACII, EX1200-6, EX1900-5, EX1900-6, EX2500-5, EX2500-6, EX2600-6, EX3600-5, EX3600-6, EX5500-5, EX5500-6, EX5600-6, EX8000-6

ZX290, ZX870-3

For additional models or custom solutions, please contact us to discuss your specific requirements.

Do you make Thermal Covers for models not listed above?

Yes, Mammoth provides a wide range of thermal covers for various OEMs. We also offer custom-designed thermal covers tailored to your specific machinery, with on-site consultation available. Contact us to learn more about our custom solutions.

How do Thermal Covers reduce the fire risks due to exhaust lagging wraps?

Unlike traditional exhaust lagging wraps, Mammoth’s Thermal Covers are form-fitted, allowing easy installation around clamps and obstructions. They offer enhanced protection by preventing moisture and oil ingress, significantly reducing fire hazards.

How do Thermal Covers reduce the fire risks due to oil leakage?

Our form-fitted Thermal Covers completely enclose machinery components, preventing oil leaks from encountering hot surfaces. The covers also feature a protective foil layer that blocks fluid ingress, further reducing the risk of fire.

What Personal Protective Equipment (PPE) is required for fitment of a Thermal Cover?

The required PPE includes general protective clothing, steel cap boots, a hard hat, safety glasses, and cut-resistant gloves.

Consult your Mammoth Solutions Expert today!

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Featured work in the field

All case studies

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Case Study

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Thermal Solutions

Thermal Assessment Capabilities

In Q1 2022 a North American Gold Mine had a fire event on site. To mitigate the risks of fires from occurring, the site’s mobile maintenance team engaged Mammoth to carry out thermal audits across their Load, Haul and Ancillary fleet.
The deliverables included; identifying potential fire risks and recommending controls to reduce touch surface temperatures below the flash point of flammable fluids.
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Case Study

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Equipment Solutions

EX3600 Digger Full Deck Refurb

The client engaged Mammoth to supply airboxes and other exhaust parts for a full rebuild of their EX3600 digger. Our sales rep communicated that our vast service and parts capabilities meant we could undertake the full refurbishment of the upper deck.
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Case Study

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Sound Attenuation

Komatsu 930E grid box and exhaust attenuation

The client operated an open cut coal mine in NSW. The sound power target for its fleet of Komatsu 930E trucks was set at 120 dB(A) to meet the boundary noise requirements. The current noise level was recorded at 124 dB(A), 4 dB(A) louder than the prescribed limits.
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Case Study

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Sound Attenuation

Hitachi EH5000 Sound Suppressed Exhaust System

A site running Hitachi EH5000 trucks that were fitted with standard sound suppression mufflers was having issues with them due to high back pressure, cracking and falling apart prematurely. The current mufflers were not meeting the sound reduction requirements the site was seeking to achieve. The client was exceeding boundary noise limits due to upscaling of fleet size and required noise reduction to be achieved on existing trucks to continue mining at night.
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Case Study

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Equipment Solutions

Custom-Engineered Tail Pipe Extensions

A mining operation faced recurring issues with their fleet’s tail pipe extensions. The harsh operating environment caused rapid wear and damage, leading to frequent downtime and high replacement costs. The client needed a durable and reliable solution that could withstand the demanding conditions while meeting compliance standards.

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Why Choose Our Thermal Covers?

Locally Manufactured Quality

Quality Design & Fit

High Thermal Capacity

Innovation

Cost-Effective Solutions

Cover Composition

Lobster Back

Turbo Wings

Clamshell

Retention Springs

Leading the Way in Thermal Cover Innovation

Enhanced Safety

Adaptable and Easy to Use

Cost-Effective Protection

Thermal Assessment Capabilities

EX3600 Digger Full Deck Refurb

Komatsu 930E grid box and exhaust attenuation

Hitachi EH5000 Sound Suppressed Exhaust System

Custom-Engineered Tail Pipe Extensions