AEROLON THERMAL INSULATING COATING

Transcription

1 AEROLON THERMAL INSULATING COATING

2 AEROLON THERMAL INSULATING COATING FEATURING AEROGEL The marriage of Tnemec s timetested coatings technology and the world s best insulating solid, aerogel, has produced an advanced coatings system featuring Aerolon a fluidapplied, thermal insulating coating. Aerolon offers protection that combats deficiencies found with conventional insulation and it can be applied in areas where traditional installations are problematic. Part of a complete coatings system that also includes specialty primers and topcoats Series 971 Aerolon Acrylic exhibits superior adhesion and protects infrastructure in several ways. Ideal for coating pipes, valves, tanks, and structural steel, its thermal properties are more efficient than other thermal insulating coatings and it posts similar values to materials such as polyurethane foam and mineral wool. In side-by-side comparisons, Aerolon s protective characteristics represent a more effective solution than virtually all other available options. And when applied in industrial facilities, manufacturing plants, water treatment plants, on architectural steel or storage tanks, it provides a long list of additional benefits including ultra-low heat transfer, resistance to corrosion under insulation (CUI), worksite safety and protection, thermal break and condensation control, while offering higher build and faster application. Aerolon s multiple benefits rise to a level of performance that offers viable solutions - delivering innovation in every coat. 1

3 WHAT MAKES AEROLON DIFFERENT? When it comes to insulative coatings, manufacturers commonly use ceramic or glass spheres as additives. By adding these small beads to paint resins, manufacturers have created a way to use the trapped gas inside the beads to lower the thermal conductivity of the coating. One of the problems with ceramicor glass-infused coatings is that the thermal conductivity is not nearly as efficient as traditional forms of insulation; and if the spheres break during mixing or application, the thermal properties are altered even further.1 This is an issue that has paved the way for the next generation of thermal insulating coatings a problem solved by Aerolon. Aerolon is the only coating of its kind to effectively utilize a key ingredient, aerogel the world s best insulating solid. The thermal performance of aerogel is defined on the nanometer scale, so particle breakage is not a concern. Even if aerogel was to fracture during application, the porosity is maintained since it is at an extremely small scale. The nanoporous microstructure of each aerogel particle makes it lightweight 20 times lighter than sand and its pore size helps reduce energy transfer. Because of these factors, aerogel particles produce an ultralow thermal conductivity of approx. 12mW/mK, (vs mW/mK for ceramic spheres) and have proven to serve a long and consistent service life in architectural daylighting, subsea oil and gas pipelines, and insulative blanket products.2 2

4 ULTRA-LOW HEAT TRANSFER Protecting equipment from external temperature is a concern for any industry. When trying to eliminate the transfer of heat between two sides of a surface, and reduce costly discharge of energy, there are many possible choices in insulation. Aerolon has equal, or better, thermal efficiencies than other forms of insulation, so it can be applied to equipment with a tendency to release valuable energy and help to reduce its loss. Heat transfer by conduction is determined by Fourier s Law for Heat Conduction, where thermal conductivity (W/(m-K)) is an intrinsic material property that defines the ability of a material - any specific material, regardless of density or weight - to conduct heat. This thermal conductivity, as defined above, is a measurement often called K-Value; a term analogous to electrical conductivity. Conversely, an R-Value which is a value used commonly in the construction industry is a measurement of thermal resistance. It is inversely proportional to thermal conductivity and proportional to thickness. R-Values, unlike K-Values, are relayed in terms of thickness, and therefore can vary when other factors change. These values are often confused with one another or completely switched in the coatings industry. Because the math is complicated and their applications are similar, the confusion is understandable. However, what must be designated is this: at a single temperature point, K-Value is the measure of a product s conductivity, and it is constant; R-Value is the measure of resistance and it is proportional to thickness. Whichever one you consider, Aerolon has the thermal value that rivals conventional insulation such as mineral wool and polyurethane foam. Each coat of Aerolon will have its own R-Value that will exceed those of other thermal insulative coatings, while its K-Value will remain the same. Series 971 Aerolon Acrylic maintains a K-Value of 35mW/mK, making it more efficient, and less conductive, than mineral wool. Its R-Value is also impressive, at 4.1 per inch, which is twice as efficient as other insulative coatings and comparable to most other forms of insulation. K-VALUE THERMAL EFFICIENCY COMPARISON (AEROLON VS. OTHER INSULATION OPTIONS) POLYURETHANE FOAM AEROLON ACRYLIC MINERAL WOOL THERMAL INSULATING COATING A THERMAL INSULATING COATING B THERMAL INSULATING COATING C mw / mk Btu-in/ft²-hr- F The lower the K-Value, the better the insulating properties. This shows how Aerolon compares with conventional insulation and other thermal insulating coatings. 3

5 138 F (59 C) 75 F (24 C) During a laboratory evaluation, Aerolon s insulation value was compared with an untreated surface. Two 5-gallon tanks were coated and setup to simulate a typical hot process: Tank A was coated with a standard primer and topcoat; Tank B was coated with a standard primer, 150 mils (3800 microns) of Aerolon, and then the same standard topcoat. Submersible heaters were inserted into water in each tank to maintain a temperature of 130 F (54 C). Thermocouples were applied to each tank and the heaters were connected to a meter that recorded energy use. After several hours, each tank would be introduced to airflow, simulating real-world wind. The tanks were run continuously for multiple days and test results were compiled and evaluated. The tank coated with Aerolon (Tank B) consistently delivered an average of 45% energy savings over the non-insulated Tank A at ambient conditions. When the air movement simulating wind was introduced, the insulated tank, Tank B, showed even greater savings, greater than 60%. HOLDING TANK COATING PROJECT BEFORE Sometimes energy savings are difficult to picture. The before- and after-photos (at right) show not only the aesthetic enhancement possible with a few coats of Aerolon, but also the difference of labor between applying an insulating coating versus traditional insulation and cladding. These are pictures of the same holding tank in a plant. A waterbased epoxy primer was used as a corrosion-resistant foundation for the Series 971 Aerolon Acrylic coating. Then a high performance topcoat was added. Rather than the time-consuming process of cutting, shaping, wrapping and cladding the tank, the Aerolon system was sprayapplied using a single-component spray gun with attached hopper. The coatings system featuring Aerolon has physical characteristics, such as high-film build, excellent adhesion, and low thermal conductivity, which help to create an ideal combination of attributes. These characteristics improve thermal efficiency, reduce the rate of heat transfer, and can decrease energy losses in the process. AFTER 4

6 RESISTS CORROSION UNDER INSULATION While delivering excellent thermal efficiency, Aerolon also bonds tightly to substrates, forming a durable, water-resistent barrier that limits the deteriorative process known as corrosion under insulation, or CUI. This moisture-caused attack is a widespread concern, one of the most destructive and costly issues impacting industrial facility infrastructures today. 3 The key contributor to CUI is moisture ingress into the insulation system. This moisture intrusion that starts the corrosion process is caused by improper installation, material damage, or both. Moisture can accumulate inside the product, and then become trapped between the substrate and insulation, creating corrosion cells that perpetuate the degenerative process. Since the metallic surface is covered by insulation, this process can go unnoticed for years. Wet insulation causes another problem significant economic impact. Moisture ingress causes convection cells to form within the insulation where water vapor is generated on the steel surface and is driven outward. It condenses on the inside of the cooler jacket wall and then is reabsorbed by the insulation in a process known as refluxing; leading to concentration of corrosive species in the insulation. And because water has 10X the thermal conductivity of dry thermal insulation, this absorption affects the insulation s efficiency. Absorption of water, as little as 4% by volume, into dry insulation can increase its thermal conductivity by 70%. 4 This creates considerable energy economic loss. 5

7 The Aerolon coatings system, featuring Series 971 Aerolon Acrylic, starts protecting corrosion-prone areas from the moment the prime coat is laid down. After appropriate surface preparation, a corrosionresistant Tnemec primer is applied. Whether a zinc-rich primer or barriercoat primer, the system will adhere tightly and help block corrosion cells from forming on the substrate. After the necessary coats of Aerolon are applied, for further protection from water infiltration and for added aesthetic appearance, a finish coat is then applied. The resulting bond to the substrate, and the barrier qualities of the system, restrict moisture from contacting the substrate. Places that once required elaborate installations can now be easily spraycoated and protected. Ideal for coating pipes, valves, vessels, and hard-to-reach structural steel, the Aerolon system provides corrosionresistance where conventional insulation most often fails. In spots where cladded mineral wool or blanket insulation becomes too complicated, Aerolon remains easy to install with its high-build and fast application; providing an equal and even layer of protection on every bend, bolt, and flange. Even protrusions that once created issues, like brackets, nozzles, or valves, can be easily avoided or coated. And because the Aerolon coatings system can be applied to substrates with a surface temperature of 200 F (93 C), it allows equipment to stay in service, and limits costly production downtime. TOPCOAT: Series 1028T Enduratone 2-4 mils ( microns) INTERMEDIATE: Series 971 Aerolon Acrylic mils ( microns) per coat PRIMER: Series 1224 Epoxoline WB 6-8 mils ( microns) WATER TREATMENT PLANT BOILER LINE PROJECT Flooding at a water treatment plant led to the discovery of extreme corrosion under insulation on the boiler lines, which otherwise may have continued to go unnoticed. Instead of reinsulating the boiler lines with conventional materials, and possibly allowing the situation to continue, the plant s coating consultant recommended the Aerolon coatings system. A waterbased corrosion-resistant epoxy primer, Series 971 Aerolon Acrylic, and a high-performance topcoat were applied to the pipelines in order to prevent future incidence of corrosion and economic loss. panels were submitted to ASTM G85 Standard Practice for Modified Salt Spray (Fog) testing. After 5000 hours of testing, the panels showed no signs of blistering, cracking, rusting or delamination of film. The results were equivalent to other Tnemec coatings systems that are designed specifically for corrosionprotection. INITIAL CUI DAMAGE REPAIR WITH AEROLON The Aerolon coatings system has been subjected to many of the same testing protocols other Tnemec coatings are required to endure. Like other high-performance primers and topcoats, Aerolon-coated 6

8 WORKSITE SAFETY AND PROTECTION Just one coat of Aerolon provides enough protection to well-exceed specified safety standards. Because Aerolon slows heat transfer from one side of a material to the other, it stands as a safeguard from potential hazards preventing workrelated, contact-burn accidents and injuries. The American Society for Testing and Materials (ASTM) C1055 defines acceptable limit in industrial environments for skin contact exposure to be 140 F (60 C) at 5 seconds. A thermal burn, which occurs as a result of a rise in tissue temperature above a threshold value for a period of exposure time, cannot occur during this finite time frame. Therefore, this means that for any surface to pass the ASTM C1055 standard for skin contact, a person s skin temperature must never rise above the 140 F (60 C) threshold while pressed against the surface for 5 seconds or less. ASTM C1057 recognizes potential tissue damage is often a result of energy transference and therefore demonstrates a mathematical model and alternate method for determining safe-touch. When using this alternate method called a thermesthesiometer, which uses an internal, temperature-controlled mass of silicone rubber and a thermocouple buried beneath the surface to simulate human dermal layers a surface s burn potential can be evaluated by allowing direct measurement of skin contact temperature. Aerolon Acrylic and three other coatings were laboratory tested with the thermesthesiometer. They were all evaluated against an acrylic control for T c at 5 seconds. This graph (below) shows the performance of each coating at 40 mils (1000 microns) thickness above a 392 F (200 C) substrate. THERMESTHESIOMETER TEST RESULTS EFFECT OF COATINGS ON CONTACT SKIN TEMPERATURE (THERMAL INSULATING COATINGS VS. ACRYLIC PAINT) 392 F (200 C) Substrate Temperature T c reduction vs Acrylic Paint ( C) Acrylic Paint 40 F (22 C) Thermal Insulating Coating 1 The Aerolon coating out-performed the others. Compared to the alternate coatings, it reduced T c by more than 32 F (18 C) at the 392 F (200 C) surface temperature. 5 The coatings with ceramic bead additives still reduced T c at this surface temperature, but by a much smaller margin. When it comes to work-place safety, this differential presented by Aerolon shows a significant margin and advantage in protecting personnel. 38 F (21 C) Thermal Insulating Coating 2 47 F (26 C) Thermal Insulating Coating 3 79 F (44 C) Aerolon Acrylic Higher Burn Risk Lower Burn Risk 40 mils (1000 microns) 7

9 302 F (150 C) A panel was coated with Aerolon and held at a constant temperature of 300 F (149 C). Using an infrared camera, pictures were taken of a hand touching the hot plate for 5 seconds. After removing the hand, the resulting picture (above) showed a lower temperature where the fingers had touched the plate. Even though the surface temperature is 73 F (23 C) lowered by just 10% - far from a temperature considered safe it feels much cooler. The fingers themselves act as a heat exchanger, cooling the Aerolon-coated surface faster than the substrate heat can pass through the coating. And the fingertips, with only a slight increase in temperature, were far from being burned. Another way to think of this is to relate it to cooking. Just about everyone has subjected their skin to 300 F (149 C)+ temperatures. When you place your food in the oven, the air inside the oven is extremely hot, but you are not immediately burned. This is because still air has low thermal potential, due to a combination of factors including low density and low thermal conductivity. If you touch the racks in the oven, the result will be vastly different. This is because the high thermal conductivity of steel allows for heat to transfer easily to your skin. So when you coat a highly conductive substrate like steel with Aerolon, you reduce its thermal potential, resulting in a surface that behaves similar to air. WASTEWATER TREATMENT BUILDING PROJECT DURING APPLICATION When infrastructure at municipal wastewater treatment buildings needed maintenance, they turned to Tnemec to cover their floors, walls, ceilings and everything in between. Part of the project s scope included how to coat five hot air blowers and their complicated-shaped piping. The city needed a coating that would combat corrosion and assist in protecting personnel from the hot temperatures of the exposed equipment. After being hand-sanded and primed with a water-based epoxy coating, Aerolon was spray-applied while the blowers were still hot, as high as 180 F (82 C), and then was followed by a finish coat of an acrylic polymer. The resulting surface was more durable and safe, less likely to create any work-related accidents. COMPLETED APPLICATION 8 8

10 CONDENSATION CONTROL Even though traditional insulation is built to protect infrastructure from condensation, over time it can become subject to CUI and other moisturerelated deterioration. Aerolon provides proven moisture reduction by insulating cool metal substrates from warm, moist air. Condensation is caused by a difference in temperature between two sides of a surface; when one side of the surface becomes lower than the dew point. So when the ambient temperature falls below the dew point, and water vapor changes to liquid, this results in condensation. The higher the humidity level, the closer the air temperature is to the dew point, and the more likely you are to see drops of condensed water develop on the surface. Excessive condensation in a facility can cause safety issues, manufacturing deficiencies, and corrosion. Preventing contact with moisture is the best way to prevent corrosion on a surface, but traditional systems used to insulate condensationprone pipes and tanks have their shortcomings. Most notably, traditional forms of insulation have some amount of gap often unnoticeable between the insulation and the substrate. Insulation materials with this void can absorb moisture and create an ideal spot for corrosion. Failed cladding/jacketing intended to combat this condensation can also cause leaks that will not only deteriorate the insulation, but cause extreme degradation to its thermal properties. This problem created by condensation can become even more prevalent when intricate shapes and cut-and-form insulation covers are required. Insulation Cladding Pipe Because the Aerolon coatings system can be applied directly to the substrate, using a corrosionresistant primer, it starts protecting the substrate right away - eliminating gaps that cause corrosion by laying a contiguous corrosion-resistant barrier layer around the spots of condensation concern. Gap This image represents a traditional insulation and cladding system. Even when installation is done properly, a gap can be left between the insulation and the pipe. 9

11 Another area of concern regarding condensation is window framing. The difference in temperature, and dew point, between two sides of a window can create excess water on the inside portion of the frame. When this condensation forms, it can produce, or perpetuate, common concerns including corrosion, moisture damage, and the potential for slips and falls. To demonstrate how Aerolon can combat this concern, a window frame display piece was constructed and applied with two different coatings systems; one side applied with a primer and topcoat (A), the other with an added intermediate coat of Aerolon (B) applied at 80 mils (2000 microns). A cooling loop was attached to the back side of the window frame to simulate cold exterior conditions while the inside of the frame was left open, exposing it to room-temperature air. The result was an obvious difference in condensation; with beads of water dripping down from the side without Aerolon, while the side with the Aerolon system remained condensation-free. 6 PROCESSING PLANT PROJECT In one process facility, this type of condensation was causing excess humidity, processing issues, and concerns of slips and falls. Just above a warm, heat-filled room was a cold storage room and, because of their proximity, the ceiling in the warmer processing room was covered in drops of condensation so much that it appeared to be leaking. The owner was informed of Tnemec s Aerolon and it was applied to the ceiling. The resulting space no longer is subject to the condensation and the processing room has improved efficiency and performance, limited the potential for work-related accidents, and will resist any potential corrosion under insulation. With this next-generation product, industries can now consider insulating surfaces that have been difficult to insulate or coat due to location, humidity, environmental exposure, and/or maintenance and space requirements. Whether it is process piping or structural steel, Aerolon provides condensation control and minimizes corrosion caused by water infiltration. AEROLON APPLICATION ON CEILING 10

12 THERMAL BREAK 11 With the ability to control condensation by slowing the transfer of exterior temperatures into the building envelope, Aerolon acts as an effective fluid-applied, non-structural thermal break. The product helps keep surface temperatures above the dew point because of its low thermal conductivity thus inhibiting moisture buildup on and inside walls, preventing corrosion and mold formation. When applied to steel or concrete, Aerolon has the ability to address the most common thermal bridging areas. Other products used to reduce thermal bridging, like structural thermal break pads, must be considered in the design phase of a project and engineered before construction even begins. During construction, these products require special attention from the fabricator and accessories are required for their assembly. Because Aerolon can be spray-applied on- or off-site, this solution provides greater flexibility and can limit application time and overall labor and material expenses. It can also provide additional thermal benefits when compared with structural thermal breaks or other insulating materials. Using Aerolon to address thermal bridging is an all-around easier solution. Based off of research conducted by Tnemec and a thirdparty, Series 971 Aerolon Acrylic applied directly to steel controls condensation more effectively than other options. In a controlled setting, a model was created to simulate steel beam structures during the winter months. Using four 4 I-beams, half of each beam in a freezer and the other half exposed to ambient temperatures, various thermal break solutions were tested at the same time: one beam was the control (not coated), one was coated with Aerolon on the ambient side, one coated with Aerolon on the exterior (cold) end, and the other was equipped with a structural thermal break pad. The freezer was kept at -10 F (-23 C) and the exterior temperature remained at approx. 65 F (18 C). Under these conditions, the Aerolon-coated beams consistently showed the highest surface temperatures and the least amount of condensation. The control and the beam attached to the structural thermal break showed condensation as high as eight inches up on the warmer side. The beam coated with Aerolon on the warm side showed no condensation and the steel beam coated with Aerolon on the cold side exhibited surface temperatures almost 15 higher than the control. Even though these results were proven on steel, Aerolon is not limited to exposed I-beams. This fluid-applied thermal break solution can also be beneficial for fins, canopies, or wall ties; roof davits, parapets, or shade louvers; and interior or exterior window frames, spandrel glass and concrete. Wherever applied, the Aerolon system is compatible with ABV sealants, select fireproofing, and has achieved a Class A result for flame spread and smoke generation per ASTM E 84. This system, especially when combined with a zinc- or MIO-filled primer, bonds to the substrate to prevent undercutting and provides exceptional resistance to corrosion under insulation (CUI). Above (from left): Control I-beam (not coated); I-beam equipped with structural thermal break pad; I-beam coated with Aerolon on the ambient end; I-beam coated with Aerolon on the exterior (cold) end. Above: A thin strip of Aerolon was applied to the warm end of the control beam to better demonstrate the coating s thermal efficiency using an infrared (IR) camera.

13 The photo at left shows an I-beam running through a container filled with ice, replicating a cold exterior environment. The right side is Aerolon coated at 100 mils. The left side, which is unprotected, serves as a control. The infrared (IR) image (bottom left) shows a significant temperature variance from point 3 (51.4 F) on the left (uninsulated) side to point 2 (60.6 F) on the right (Aeroloncoated) side. It demonstrates how Aerolon works as an effective thermal break to reduce condensation by preventing the surface temperature of the beam from lowering below the dew point. STUDENT UNION PROJECT The project architect for the new student union building on a central Pennsylvania campus originally planned to utilize thermal break pads to limit condensation in the building envelope. Local Tnemec coating consultants introduced the firm to a more efficient way to combat this problem and the team decided to substitute the pads for the innovative, fluid-applied thermal insulating coating, Series 971 Aerolon Acrylic. The coating was applied in the shop. Steel members for the building s canopy first received a coat of Tnemec s single-component, moisture-cured MIO/zinc-filled polyurethane primer at 3.0 mils dry film thickness (DFT). The prime coat was followed by two coats of Aerolon and, because the beams would be hidden, no finish coat was applied. Once delivered to the jobsite, some minor touch-up was done in the field before the building was completed. SHOP APPLICATION COMPLETED APPLICATION 12

14 HIGHER BUILD & FASTER APPLICATION Even though Aerolon can be applied in a high-build coat, a much lower overall thickness is required due to its low thermal conductivity. These two characteristics make application times faster, resulting in quicker return to service and decreased labor cost. The high-build qualities of the system, combined with the low thermal conductivity, will result in overall savings during and after application. build of 50 mils (1250 microns) DFT, making application time extremely quick in comparison. By the time conventional ceramic insulating coatings have applied coats to reach the desired thickness, the Aerolon system would already be back in service after only needing 3 coats to achieve the same performance. Plus, each coat of Aerolon is more efficient with an R-Value of 0.21 per 50 mil (1250 microns) coat keeping the energy of the equipment where it needs to be. (See graph below.) The Aerolon coatings system has the unique ability to be applied to substrates in service, too. Because it can be applied to equipment with surface temperatures of up to 200 F (93 C), it helps to further eliminate costly downtime. Conventional insulation materials take time to install and can leave infrastructure unusable during downtime. The inconvenience of this disruption can create a setback in production time and, overall, cause costly delays. Thermal insulating coatings, like the Aerolon coatings system, combat these typical occurrences and are easier to install. Since it is spray-applied, there is no cutting, shaping, cladding of the tank; this makes preparation and installation easier. Other thermal insulating coatings lack the build available with Aerolon. Most acrylic ceramic coatings said to have similarities to Aerolon have a maximum single coat film build of 20 mils (500 microns) DFT. Aerolon can be applied more than double that thickness, with a maximum film MAXIMUM FILM BUILD ACHIEVED PER COAT AEROLON VERSUS OTHER THERMAL INSULATING COATINGS AEROLON ACRYLIC THERMAL INSULATING COATING A THERMAL INSULATING COATING B THERMAL INSULATING COATING C Mils per coat (DFT) Microns per coat (DFT) The ability to achieve higher, single-pass film build can significantly shorten application times (often by several days) to greatly minimize facility downtime and substantially save on application labor costs. 13

15 Aerolon is single-component, meaning there is no mixing of multiple parts, and it can be applied with a variety of texture sprayers with the single attachment of a hopper gun. This will complete smaller projects without any drawbacks or issues, but using a recommended model for larger projects will result in a more efficient application. Tnemec recommends using a texture spray gun, or a thick-film and mortar pump. This equipment is readily available and can be used without modifications. Applicators are always welcome to contact Tnemec technical service for specific equipment information. EASY TOUCH-UP Touch up of the system is easily administered when needed. It can be spot-repaired using just a trowel. Any surface damage to the system will only require a few steps. After preparing the problem area of the substrate, according to SSPC- SP2 or SP3, Hand or Power Tool Cleaning, and priming if needed, the applicator applies Aerolon directly to the damaged area, then smoothes and finishes the. The ability to simply and very cost-effectively restore the coating s integrity with a simple touch-up is a big advantage in extending life cycles. 1. APPLY AEROLON TO DAMAGED AREA 2. SMOOTH AND FINISH APPLICATION 14

16 PROJECT SPOTLIGHT ULTRA-LOW HEAT TRANSFER Greater Little Rock, Arkansas Located near a cooling tower and uncovered, this sulfuric acid tank in Arkansas was exhibiting accelerated corrosion and severe pitting on the interior and exterior steel. The owner needed to repair the tank and find a way to guard the tank s steel and contents from the harsh exterior conditions. Rather than build a cover or install costly insulation, the facility utilized Tnemec s thermal insulating coating, Aerolon. The exterior steel was prepared and primed and then two coats of Series 971 Aerolon Acrylic were applied at mils dry film thickness (DFT) per coat. Following Aerolon, the tank received a topcoat of Tnemec s innovative acrylic polymer in Safety Yellow. RESISTS CORROSION UNDER INSULATION Boston, Massachusetts Chiller tanks in the ground floor of this office building were using foam insulation to control the surface temperature and condensation. However, the insulation was allowing moisture to penetrate and cause pitting on the steel surfaces. To combat this issue, the building s owner utilized Tnemec s Aerolon coating system on one of their tanks instead of their traditional insulating approach. Aerolon provided a thick, continuous system without gaps or seams and, even through the hot summer months when condensation and associated CUI issues are most common, the Aerolon system has performed exceptionally well. 15

17 WORKSITE SAFETY AND PROTECTION Southern California When a modern energy facility needed a solution to protect personnel from hot process piping, the facility chose to utilize an Aerolon coating system. The piping received a coat of Tnemec s waterbased epoxy primer followed by one coat of Series 971 Aerolon Acrylic. All coatings used in the system were water-based, low VOC and low odor, and all products, including Aerolon, conform to the strict regulatory requirements of California s air district. CONDENSATION CONTROL West Point, Pennsylvania Ground water tanks and their piping on this company s campus were being painted every two years due to excess condensation on the painted surfaces. This condensation was accelerating corrosion, and creating puddles on the floor, so the engineers needed a more effective solution than that of a typical paint system. Furthermore, the piping could not be wrapped with conventional insulation because of its complex shapes with multiple flanges and valves. The Aerolon coating system was the most viable solution; the system was applied to all problem areas and it has controlled the condensation issue since its installation. THERMAL BREAK Needham, Massachusetts With sustainable building design in mind at every turn, the architect for this new building specified an innovative solution to reduce thermal bridging. Following a prime coat of Tnemec s MIO/zinc-filled primer for perimeter steel, Series 971 Aerolon Acrylic was spray-applied to steel in the shop as a non-structural thermal break. The steel members were then shipped to the jobsite and touched up in the field before being installed. By slowing the thermal transfer between the interior and exterior temperature, Aerolon helped reduce the formation of condensation and assisted in providing additional energy efficiency. 16

18 CONDENSATION CONTROL ULTRA-LOW HEAT TRANSFER HIGHER BUILD & FASTER APPLICATION INNOVATION IN EVERY COAT When Series 971 Aerolon Acrylic is applied to a substrate, it s protected by a coatings system which includes a specialty primecoat and topcoat; tailored to the needs of any project. Whether you need a zinc-rich primer, like Series Tneme-Zinc, or a water-based primer, like Series 1224 Epoxoline WB, Aerolon Acrylic can be applied atop a variety of products. It can be top-coated with several options, too, from an aliphatic polyurethane to a HDP acrylic polymer. Every coat of Aerolon is backed by a tradition of producing innovative, performance-driven coatings for industrial environments. Tnemec has been researching 17 and formulating high-performance coating technologies since 1921, when founder Albert C. Bean, Sr. discovered that the alkaline conditions of cement inhibited rust and used this information to create a revolutionary coatings formula. For nearly a century, this tradition of innovation has been put into every bucket of Tnemec coatings; with all formulations focused on performance. Even the name, Tnemec, created by reversing the letters of the word, cement, is a reminder of this investigation. Our product line of nearly 150 coatings is backed by this quality process, and supported by outstanding technical support in the field and in the lab during all steps of a project. Aerolon s benefits from low heat transfer to CUI resistance, condensation control to faster application are combined with the excellent adhesion and corrosion protection found in other Tnemec coatings systems. Application possibilities continue to grow as Aerolon s versatile nature creates new solutions to common industrial situations. Please contact your local Tnemec representative, or visit tnemec.com/aerolon for more information about how to protect your infrastructure.

19 RESISTS CORROSION UNDER INSULATION WORKSITE SAFETY & PROTECTION 3E PLUS Aerolon has been modeled using the NAIMA (North American Insulation Manufacturers Association) application 3E Plus an energy management tool developed to simplify the task of determining necessary insulation for different projects. 3E Plus calculates what product will best address several factors, given the associated mean temperatures and thermal conductivity of a product. When Aerolon s thermal information is entered, the program clearly displays the benefits available with this coatings system. 3E Plus is a registered trademark of the North American Insulation Manufacturers Association (NAIMA). 18

20 1. Aerogel for Highly Thermally Insulative Coatings. CoatingsTech. June New Thermal Insulation Coating Systems Utilize Properties of Silica Aerogel. Banda, Hilary. Materials Performance. October Is There a Cure for Corrosion Under Insulation? Lettich, Michael. Insulation Outlook. November Can We Better Address CUI and Energy Loss? Srinivasan, Sridhar. Materials Performance. Jan Aerogel Insulative Coatings: New Coating Technology Offers Personnel Protection. Koravos, Norwood, Pescatore, and Pidhurney. PCI Magazine. July The Next Generation of Condensation and Corrosion Protection. Pescatore, Peter. PCI Magazine. March INNOVATION IN EVERY COAT Tnemec Company Inc Corporate Drive Kansas City, Missouri, USA TNEMEC tnemec.com Published technical data, instructions and pricing are subject to change without notice. Contact your Tnemec technical representative for current technical data, instructions and pricing. Warranty information: The service life of Tnemec coatings will vary. For warranty, limitation of seller s liability and product information, please refer to Tnemec Data Sheets at or contact your Tnemec technical representative. Printed in USA. Tnemec Company, Inc HW5M915 BROAERO