This document summarizes the properties and benefits of Aerolon, a thermal insulating coating developed by Tnemec that features aerogel as a key ingredient. Aerolon offers superior thermal insulation and protection against corrosion under insulation compared to other coating and insulation options. It has an ultra-low thermal conductivity and high R-value, providing significant energy savings. Aerolon also improves worksite safety by reducing surface temperatures and preventing burns. It can be easily applied to pipes, tanks, and structures in industrial facilities.

1. AEROLON
THERMAL INSULATING COATING

2. 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.
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.
AEROLON
1
THERMAL INSULATING COATING
FEATURING AEROGEL

3. 2
WHAT MAKES
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.
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
AEROLON DIFFERENT?
Aerolon is the only coating
of its kind to effectively utilize
a key ingredient, aerogel – the
world’s best insulating solid.

4. 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.
3
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
ULTRA-LOW
HEAT TRANSFER
K-VALUE THERMAL EFFICIENCY COMPARISON
(AEROLON VS. OTHER INSULATION OPTIONS)
0 10 20 30 40 50 60
POLYURETHANE FOAM
AEROLON ACRYLIC
MINERAL WOOL
Btu-in/ft²-hr-°F
mW / mK
THERMAL INSULATING COATING A
THERMAL INSULATING COATING B
THERMAL INSULATING COATING C
70 80 90 100
0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70
The lower the K-Value, the better the insulating properties. This shows how
Aerolon compares with conventional insulation and other thermal insulating
coatings.

5. 4
BEFORE
AFTER
HOLDING TANK COATING PROJECT
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%.
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 water-
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
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.
138˚F
(59˚C)
75˚F
(24˚C)

6. 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.
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.
RESISTS CORROSION
UNDER INSULATION

7. PRIMER:
Series 1224 Epoxoline WB
6-8 mils (150-200 microns)
INTERMEDIATE:
Series 971 Aerolon Acrylic
40-50 mils (1000-1250 microns) per coat
TOPCOAT:
Series 1028T Enduratone
2-4 mils (50-100 microns)
6
INITIAL CUI
DAMAGE
REPAIR WITH
AEROLON
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.
Places that once required elaborate
installations can now be easily spray-
coated and protected. Ideal for
coating pipes, valves, vessels, and
hard-to-reach structural steel, the
Aerolon system provides corrosion-
resistance 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.
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
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 corrosion-
protection.
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.

8. 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
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 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.
7
WORKSITE SAFETY
AND PROTECTION
THERMESTHESIOMETER TEST RESULTS
EFFECT OF COATINGS ON CONTACT SKIN TEMPERATURE
(THERMAL INSULATING COATINGS VS. ACRYLIC PAINT)
The Aerolon coating out-performed
the others. Compared to the
alternate coatings, it reduced Tc
by
more than 32°F (18°C) at the 392°F
(200°C) surface temperature.5
The coatings with ceramic bead
additives still reduced Tc
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.
Tc
reductionvsAcrylicPaint(°C)
392°F (200°C) SubstrateTemperature
Acrylic
Paint
Thermal
Insulating
Coating 1
Thermal
Insulating
Coating 2
Thermal
Insulating
Coating 3
Aerolon
Acrylic
40°F
(22°C)
38°F
(21°C)
47°F
(26°C)
79°F
(44°C)
40 mils (1000 microns)
Lower Burn Risk
Higher Burn Risk

9. 8
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
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.
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.
WASTEWATER TREATMENT
BUILDING PROJECT
8
DURING
APPLICATION
COMPLETED
APPLICATION
302˚F (150˚C)
73˚F (23˚C)

10. 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.
9
Even though
traditional insulation
is built to protect
infrastructure from
condensation, over
time it can become
subject to CUI and other moisture-
related 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 condensation-
prone pipes and tanks have their
shortcomings. Most notably,
traditional forms of insulation
CONDENSATION
CONTROL
Because the Aerolon coatings
system can be applied directly to
the substrate, using a corrosion-
resistant 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.
Cladding
Insulation
Pipe
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.

11. 10
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
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.
PROCESSING PLANT
PROJECT
AEROLON
APPLICATION
ON CEILING

12. 11
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
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.
THERMAL BREAK
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. 12
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.
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.
STUDENT UNION
PROJECT SHOP
APPLICATION
COMPLETED
APPLICATION

14. 13
build of 50 mils (1250 microns) DFT,
making application time extremely
quick in comparison. By the time
conventional ceramic insulating
coatings have applied 12-16 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.)
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.
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
HIGHER BUILD &
FASTER APPLICATION
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.
MAXIMUM FILM BUILD ACHIEVED PER COAT
AEROLON VERSUS OTHER THERMAL INSULATING COATINGS
0 10 20 30 40 50 60
Mils 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.
Microns per coat (DFT)
0 254 508 762 1016 1270 1524
AEROLON ACRYLIC
THERMAL INSULATING COATING A
THERMAL INSULATING COATING B
THERMAL INSULATING COATING C

15. 14
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

16. 15
ULTRA-LOW HEAT TRANSFER
RESISTS CORROSION
UNDER INSULATION
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.
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.
PROJECT
SPOTLIGHT

17. 16
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
THERMAL BREAK
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.
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.

18. 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
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.
17
ULTRA-LOW HEAT TRANSFER
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.

19. 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.
WORKSITE SAFETY & PROTECTION
RESISTS CORROSION UNDER INSULATION
18
3E Plus®
is a registered trademark of the North American Insulation Manufacturers Association (NAIMA).
3E PLUS
®

20. 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
INNOVATION IN EVERY COAT ™
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.