AEROLON

THERMAL INSULATING COATING

 AEROLON
THERMAL INSULATING COATING
FEATURING AEROGEL
The marriage of Tnemec’s time-
tested coatings technology and the
world’s best insulating solid, aerogel,
has produced an advanced coatings
system featuring Aerolon – a fluid-
applied, 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.
1
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.
 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 ceramic-
or 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 ultra-
low thermal conductivity of approx.
12mW/mK, (vs. 50-200mW/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
 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.
3
These values are often confused as mineral wool and polyurethane
with one another or completely foam. Each coat of Aerolon will
switched in the coatings industry. have its own R-Value that will
Because the math is complicated exceed those of other thermal
and their applications are similar, insulative coatings, while its K-Value
the confusion is understandable. will remain the same. Series 971
However, what must be designated Aerolon Acrylic maintains a K-Value
is this: at a single temperature of 35mW/mK, making it more
point, K-Value is the measure of efficient, and less conductive, than
a product’s conductivity, and it is mineral wool. Its R-Value is also
constant; R-Value is the measure of impressive, at 4.1 per inch, which is
resistance and it is proportional to twice as efficient as other insulative
thickness. coatings and comparable to most
other forms of insulation.
Whichever one you consider,
Aerolon has the thermal value that
rivals conventional insulation such
K-VALUE THERMAL EFFICIENCY COMPARISON
(AEROLON VS. OTHER INSULATION OPTIONS)
mW / mK
0 10 20 30 40 50 60 70 80 90 100
POLYURETHANE FOAM
AEROLON ACRYLIC
MINERAL WOOL
THERMAL INSULATING COATING A
THERMAL INSULATING COATING B
THERMAL INSULATING COATING C
0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70
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.
 138˚F
(59˚C)

75˚F
(24˚C)

During a laboratory evaluation, The tanks were run continuously

Aerolon’s insulation value was for multiple days and test results
compared with an untreated surface. were compiled and evaluated. The
Two 5-gallon tanks were coated tank coated with Aerolon (Tank B)
and setup to simulate a typical hot consistently delivered an average
process: Tank A was coated with a of 45% energy savings over the
standard primer and topcoat; Tank B non-insulated Tank A at ambient
was coated with a standard primer, conditions. When the air movement
150 mils (3800 microns) of Aerolon, simulating wind was introduced, the
and then the same standard insulated tank, Tank B, showed even
topcoat. Submersible heaters were greater savings, greater than 60%.
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.

HOLDING TANK COATING PROJECT BEFORE

Sometimes energy savings are The coatings system featuring
difficult to picture. The before- and Aerolon has physical characteristics,
after-photos (at right) show not only such as high-film build, excellent
the aesthetic enhancement possible adhesion, and low thermal
with a few coats of Aerolon, but conductivity, which help to create
also the difference of labor between an ideal combination of attributes.
applying an insulating coating versus These characteristics improve
traditional insulation and cladding. thermal efficiency, reduce the rate
These are pictures of the same of heat transfer, and can decrease
holding tank in a plant. A water- energy losses in the process.
based 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 spray-
applied using a single-component AFTER
spray gun with attached hopper.

4
 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.
5
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.
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 corrosion-
resistant Tnemec primer is applied.
Whether a zinc-rich primer or barrier-
coat 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.
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 water-
based 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.
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
Places that once required elaborate Even protrusions that once created
installations can now be easily spray- issues, like brackets, nozzles, or
coated and protected. Ideal for valves, can be easily avoided or
coating pipes, valves, vessels, and coated. And because the Aerolon
hard-to-reach structural steel, the coatings system can be applied
Aerolon system provides corrosion- to substrates with a surface
resistance where conventional temperature of 200°F (93°C),
insulation most often fails. In spots it allows equipment to stay in
where cladded mineral wool or service, and limits costly production
blanket insulation becomes too downtime.
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.
TOPCOAT:
Series 1028T Enduratone
2-4 mils (50-100 microns)
INTERMEDIATE:
Series 971 Aerolon Acrylic
40-50 mils (1000-1250 microns) per coat
PRIMER:
Series 1224 Epoxoline WB
6-8 mils (150-200 microns)
panels were submitted to ASTM INITIAL CUI
G85 Standard Practice for Modified
Salt Spray (Fog) testing. After 5000 DAMAGE
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 corrosion-
protection.
REPAIR WITH
AEROLON
6
 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 work-
related, 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
7
a thermesthesiometer, which uses The Aerolon coating out-performed
an internal, temperature-controlled the others. Compared to the
mass of silicone rubber and a alternate coatings, it reduced Tc by
thermocouple buried beneath the more than 32°F (18°C) at the 392°F
surface to simulate human dermal (200°C) surface temperature.5
layers – a surface’s burn potential The coatings with ceramic bead
can be evaluated by allowing direct additives still reduced Tc at this
measurement of skin contact surface temperature, but by a much
temperature. smaller margin.
Aerolon Acrylic and three other When it comes to work-place safety,
coatings were laboratory tested this differential presented by Aerolon
with the thermesthesiometer. shows a significant margin and
They were all evaluated against an advantage in protecting personnel.
acrylic control for Tc 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
Higher Burn Risk
Tc reduction vs Acrylic Paint (°C)
40°F
(22°C)
38°F
(21°C)
47°F
(26°C)
79°F
(44°C)
Lower Burn Risk
Acrylic Thermal Thermal Thermal Aerolon
Paint Insulating Insulating Insulating Acrylic
Coating 1 Coating 2 Coating 3
40 mils (1000 microns)

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
WASTEWATER TREATMENT
BUILDING PROJECT
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.
COMPLETED
APPLICATION
302˚F (150˚C)
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.
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.
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.
DURING
APPLICATION
8
8
 CONDENSATION
CONTROL
Even though have some amount of gap – Because the Aerolon coatings
traditional insulation often unnoticeable – between system can be applied directly to
is built to protect the insulation and the substrate. the substrate, using a corrosion-
infrastructure from Insulation materials with this void resistant primer, it starts protecting
condensation, over can absorb moisture and create the substrate right away - eliminating
time it can become an ideal spot for corrosion. Failed gaps that cause corrosion by laying
subject to CUI and other moisture- cladding/jacketing intended to a contiguous corrosion-resistant
related deterioration. Aerolon combat this condensation can barrier layer around the spots of
provides proven moisture reduction also cause leaks that will not only condensation concern.
by insulating cool metal substrates deteriorate the insulation, but cause
from warm, moist air. extreme degradation to its thermal
properties. This problem created
Condensation is caused by a by condensation can become even
difference in temperature between more prevalent when intricate
two sides of a surface; when one shapes and cut-and-form insulation
side of the surface becomes lower covers are required.
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 Cladding
Gap
the more likely you are to see drops
of condensed water develop on the
surface. Excessive condensation
in a facility can cause safety issues, Insulation
manufacturing deficiencies, and
corrosion.

Preventing contact with moisture is

the best way to prevent corrosion
on a surface, but traditional systems
used to insulate condensation-
prone pipes and tanks have their
shortcomings. Most notably,
Pipe
traditional forms of insulation

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

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.
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.
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
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
10
 THERMAL BREAK
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 third-
party, Series 971 Aerolon Acrylic
applied directly to steel controls
condensation more effectively than
other options.
11
In a controlled setting, a model was has achieved a Class A result
created to simulate steel beam for flame spread and smoke
structures during the winter months. generation per ASTM E 84.
Using four 4’ I-beams, half of each This system, especially when
beam in a freezer and the other half combined with a zinc- or MIO-filled
exposed to ambient temperatures, primer, bonds to the substrate to
various thermal break solutions prevent undercutting and provides
were tested at the same time: one exceptional resistance to corrosion
beam was the control (not coated), under insulation (CUI).
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 Above (from left): Control I-beam (not coated);
no condensation and the steel beam I-beam equipped with structural thermal break
coated with Aerolon on the cold pad; I-beam coated with Aerolon on the ambient
side exhibited surface temperatures end; I-beam coated with Aerolon on the exterior
almost 15° higher than the control. (cold) end.
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
Above: A thin strip of Aerolon was applied to
sealants, select fireproofing, and
the warm end of the control beam to better
demonstrate the coating’s thermal efficiency using
an infrared (IR) camera.

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
COMPLETED
APPLICATION
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 (Aerolon-
coated) 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.
SHOP
APPLICATION
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.
12
 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, The Aerolon coatings system has
making application time extremely the unique ability to be applied to
quick in comparison. By the time substrates in service, too. Because
conventional ceramic insulating it can be applied to equipment with
coatings have applied 12-16 coats surface temperatures of up to 200°F
to reach the desired thickness, the (93°C), it helps to further eliminate
Aerolon system would already be costly downtime.
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.)

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
MAXIMUM FILM BUILD ACHIEVED PER COAT
coatings system, combat these
AEROLON VERSUS OTHER THERMAL INSULATING COATINGS
typical occurrences and are easier
to install. Since it is spray-applied, Mils per coat (DFT)

there is no cutting, shaping, cladding 0 10 20 30 40 50 60

of the tank; this makes preparation

AEROLON ACRYLIC
and installation easier.
THERMAL INSULATING COATING A

Other thermal insulating coatings THERMAL INSULATING COATING B

lack the build available with Aerolon. THERMAL INSULATING COATING C
Most acrylic ceramic coatings said
0 254 508 762 1016 1270 1524
to have similarities to Aerolon have
Microns per coat (DFT)
a maximum single coat film build of
20 mils (500 microns) DFT. Aerolon
can be applied more than double
The ability to achieve higher, single-pass film build can significantly shorten
that thickness, with a maximum film application times (often by several days) to greatly minimize facility downtime
and substantially save on application labor costs.

13
 Aerolon is single-component, gun, or a thick-film and mortar
meaning there is no mixing of pump. This equipment is readily
multiple parts, and it can be applied available and can be used without
with a variety of texture sprayers modifications.
with the single attachment of a
hopper gun. This will complete Applicators are always welcome to
smaller projects without any contact Tnemec technical service for
drawbacks or issues, but using a specific equipment information.
recommended model for larger
projects will result in a more
efficient application. Tnemec
recommends using a texture spray

EASY TOUCH-UP
1. APPLY AEROLON
Touch up of the system is easily
administered when needed. It TO DAMAGED AREA
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.

2. SMOOTH AND
FINISH APPLICATION

14
 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 30-40 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
 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 water-
based 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

ULTRA-LOW HEAT TRANSFER
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 90-97 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.
CONDENSATION CONTROL
HIGHER BUILD & FASTER APPLICATION
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.
 RESISTS CORROSION UNDER INSULATION

WORKSITE SAFETY & PROTECTION

Aerolon has been modeled using

3E PLUS
®
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
 1. “Aerogel for Highly Thermally Insulative Coatings.” CoatingsTech. June 2012
2. “New Thermal Insulation Coating Systems Utilize Properties of Silica Aerogel.” Banda, Hilary. Materials Performance. October
2012.
3. “Is There a Cure for Corrosion Under Insulation?” Lettich, Michael. Insulation Outlook. November 2005.
4. “Can We Better Address CUI and Energy Loss?” Srinivasan, Sridhar. Materials Performance. Jan. 2013.
5. “Aerogel Insulative Coatings: New Coating Technology Offers Personnel Protection.” Koravos, Norwood, Pescatore, and Pidhurney.
PCI Magazine. July 2013.
6. “The Next Generation of Condensation and Corrosion Protection.” Pescatore, Peter. PCI Magazine. March 2013.

INNOVATION IN EVERY COAT ™

Tnemec Company Inc. 6800 Corporate Drive Kansas City, Missouri, USA 64120-1372 1-800-TNEMEC1 816-483-3400 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 www.tnemec.com or contact your Tnemec technical representative. Printed in USA. © Tnemec Company, Inc. 2015 HW5M915 BROAERO