Aerogel Coatings – Fast and Flexible
Aerogel coatings as high-performance thermal insulation for pipes, equipment and industrial surfaces
Aerogel coatings combine the outstanding thermal insulation properties of aerogel with the versatility of a coating system. They enable thermal insulation to be applied directly to surfaces and are particularly attractive for pipes, vessels, equipment and complex geometries.
By incorporating highly porous aerogel into a coating formulation, very good thermal insulation performance can be achieved with comparatively thin insulation layers. The coating conforms closely to the substrate and creates a continuous insulation layer without joints or gaps.
Aerogel coatings are especially suited to applications where conventional insulation systems are difficult to install, where available space is limited, or where a seamless insulation solution is preferred.
AIC Energy – Aerogel Thermal Insulation Coating
AIC Energy is our high-performance aerogel coating system for thermal insulation and improved energy efficiency in industrial applications.
The AIC Energy system combines a suitable primer with AIC Energy Core, the aerogel-containing thermal insulation layer, and AIC Energy Top, a smooth top coat and sealant.
AIC Energy Core contains a latest-generation aerogel component to provide high thermal insulation performance. It can be built up in several layers to achieve the insulation performance required for the respective application.
AIC Energy Top protects the insulation layer and forms a water-repellent, hydrophobic surface. The resulting seamless coating system provides reliable and consistent thermal insulation while helping to reduce the risk of corrosion under insulation (CUI).
Highlights
High energy efficiency – Low thermal conductivity for effective thermal insulation
Aerogel technology – Aerogel-containing core layer for high thermal performance
Seamless insulation – Conforms directly to the surface without joints
Hydrophobic system – Water-repellency protects the insulation system
Robust and durable – Designed for demanding industrial applications
Flexible application – Strong adhesion to a wide variety of suitably prepared surfaces
Wide temperature range – Suitable for a broad range of thermal insulation applications
Helps reduce CUI – The coating system helps protect the substrate against corrosion under insulation
The AIC Energy Coating System
The AIC Energy coating system consists of three functional layers:
Primer
An epoxy or zinc-silicate primer, selected according to the substrate and application, provides the basis for reliable adhesion and substrate protection.
AIC Energy Core
The main thermal insulation layer. AIC Energy Core is a water-based, two-component coating consisting of a liquid base and an aerogel component. Several layers can be applied to build up the required insulation thickness.
AIC Energy Top
A water-based top coat and sealant applied over AIC Energy Core. It forms a smooth, hydrophobic layer that helps prevent water penetration and maintain consistent insulation performance over the lifetime of the coating system.
Applications
AIC Energy is designed for thermal insulation and energy-saving applications in industrial environments, for example:
Hot pipes and piping systems
Tanks and vessels
Process equipment
Industrial surfaces and installations
Complex geometries where conventional insulation systems can be difficult to install
The coating is applied using suitable professional spray equipment. Surface preparation and correct application are essential for optimum performance and durability.
Typical Properties
| Property | AIC Energy Core | AIC Energy Top |
|---|---|---|
| Thermal conductivity at 10°C | approx. 33 mW/(m·K) | approx. 64 mW/(m·K) |
| Dry density | approx. 0.3 g/cm³ | approx. 0.6 g/cm³ |
| Wet density | < 0.4 g/cm³ | approx. 0.7 g/cm³ |
| Solid content | approx. 67% | approx. 70% |
| Hardness | 30–40 Shore A | 65–70 Shore A |
| Maximum layer thickness | 5–8 mm | 3–5 mm |
| Water-vapor permeability | 25 g/(m²·d) | — |
| sd value at 8 mm thickness | 0.76 m, Class V2 according to DIN EN 1062-1 | — |
| Fire class EN 13501-1 | E expected* | E expected* |
*According to the current AIC Energy Technical Datasheet.
Application
AIC Energy Core can be applied in several passes. For efficient processing, individual coats are typically built up in partial layers, allowing the required total insulation thickness to be achieved step by step.
AIC Energy Top is applied over the completed AIC Energy Core insulation layer as the final hydrophobic top coat.
Correct surface preparation, coating thickness and drying between layers are essential to achieve the intended performance. The AIC Energy coating system should therefore be applied by experienced and trained professionals in accordance with the technical documentation and application instructions.
