Carbotherm® 551 Thermal Barrier

Durable Insulative Coating Energy Savings

Carbotherm 551

An insulative, liquid-applied, water-based epoxy coating that provides the following:

1. Protective thermal protection for workers 2. Resistance to solar (thermal) radiation 3. Insulation for heat efficiency 4. Durable insulative coating for industrial uses 5. Minimizes corrosion under insulation (CUI) 6. Eliminates condensation from cold surfaces

Carbotherm 551

Feature Benefit Epoxy based Durable; chemical resistant

Water-based Safe to use

High film build Fewer coats; faster application

Temperature resistance -60 to 350°F (-51 to 177°C)

Low density; low “k” value Excellent insulation properties

82% solids Excellent coverage

Carbotherm 551 – How it works

• Unique insulative filler package – Like most insulation; air/void

spaces are trapped within the material and reduces the density/mass of the insulation

• Double-pane windows • Rock wool insulation • Polyurethane foam • Styrofoam

Thermal Conductivity (k value)

• Units are: – W/m-°K – BTU/hr-ft-°F (or BTU-in/hr-ft2-°F)

• All materials have a thermal conductivity value – The higher the number; the better heat conductor – The lower the number; the better insulator

Thermal Conductivity of Common Materials

Material k value*

Air 0.0432

Styrofoam/PU foam 0.0519

Carbotherm 551 0.0550

Rock wool insulation 0.0778

Calcium silicate 0.0865

Material k value*

Drywall 0.294

Concrete 1.730

Stainless steel 52

Carbon steel 93

Copper 694

* BTU/hr-ft-°F

Thermal Conductivity

Polyurethane Foam

Carbotherm 551

Steel

Copper

Calcium Silicate

Concrete Insulators

Conductors

Rock Wool

R-Value

• In the consumer or commercial markets the “R-Value” is often used to represent insulation properties.

• It is expressed as a “number” per inch – Fiberglass insulation @1” has R = 3.8 – Polyurethane Foam Board @1” has R = 7 – Carbotherm 551 @1” has R = 1.29

• Units are: hr-ft2-°F/BTU

Epoxy versus Acrylic

• Increased durability – Hardness – Strength

• Greater adhesion • Increased chemical resistance • Comparable thermal conductivity (insulation

value) • Higher film build with faster recoat times

Epoxy versus Acrylic “General Properties”

Property Carbotherm 551 Insulative Acrylics*

Solids by Volume 82% 74-80%

Thermal Conductivity 0.055 BTU/hr-ft-°F 0.038-0.160 BTU/hr-ft-°F

Temperature Resistance 350°F 350°F

Topcoating Optional Recommended

Chemical Resistance Excellent Poor - Fair

*Average range for four commercially available products

Epoxy versus Acrylic “Application Differences”

Property Carbotherm 551

Standard Insulative Acrylics

High Build Insulative Acrylics

Film Build/Coat 40 mils (1 mm)

20 mils (0.5 mm)

45 mils (1.1 mm)

Recoat Time @75°F 5 hours 4 hours 16 hours

# Coats to Apply 160 mils (4 mm) 4 coats 8 coats 3 coats

Time to Apply 160 mils (4 mm) 2 days 4 days 3 days

Epoxy versus Acrylic “Physical Property Differences”

Property Carbotherm 551

Insulative Acrylics*

Adhesion 1000 psi (cohesive)

250 psi (cohesive)

Tensile Strength 800 psi 40 psi

Hardness 55 Shore D 34 Shore D

Pencil Hardness B 6B

*Values are typical

PRIMARY USES

Worker protection Solar Reflectance Provides Insulation for Processes Minimizes Corrosion Under Insulation

Thermal Barrier: Protection of Workers

• OSHA Requirement: – Protect workers from first degree

burns for 5 seconds on steel substrates

– Normally this is at or above 140°F (60°C) for steel. Steel has a very high “k” value (conducts heat very well).

Structural Steel and Blanket are at Same Temperature 140°F (60°C) Why do we burn ourselves on the steel but not the blanket?

Steel versus Blanket

• Answer: • The heat flux is different between the two

materials. The “mass” of the steel is far greater than the mass of the blanket and transfers more heat into your hand … even though the surface temperature of the blanket (Carbotherm 551) can be much higher than 140°F(60°C).

Low Thermal Conductivity

• Carbotherm 551 protects workers from surfaces operating up to 350°F (177°C) by dramatically reducing the heat transfer through its film

Steel

551

Worker Protection Thickness? The hotter the surface, the thicker the material needed to protect workers.

# Coats Thickness Temperature

1 20 mils (0.5 mm) Up to 65°C (150°F)

1 40 mils (1.0 mm) Up to 93°C (200°F)

1 40 mils (1.0 mm) Up to 121°C (250°F)

2 60 mils (1.5 mm) Up to 149°C (300°F)

2 80 mils (2.0 mm) Up to 177°C (350°F)

PRIMARY USES

Worker protection

Solar Reflectance Provides Insulation for Processes Minimizes Corrosion Under Insulation

Outstanding Thermal Radiation Reflectivity and Resistance

• 84.7% solar reflectivity • Can reduce the thermal

increase caused by solar radiation by up to 20-30 degrees Fahrenheit

Just a single coat of 40 mils (1 mm)

provides protection from solar radiation

Solar Thermal Insulation

• Minimizes solar radiation on vessels and storage tanks – Reduces petrochemical “evaporation”

• Production or profit losses due to commodity losses

PRIMARY USES

Worker protection Solar Reflectance

Provides Thermal Insulation Minimizes Corrosion Under Insulation

Provides Thermal Insulation Conserves Energy – Saves Money

Minimizes heat loss from vessels/piping

Insulates buildings/rooms; Warmer in the winter and cooler in the summer

Thickness vs Heat Efficiency

Data in chart assumes horizontal tank with ambient temperature of 75°F (24°C) and no wind.

Carbotherm 551 Thickness/# Coats

Heat Efficiency @ Process Temperature

250°F 350°F

120 mils/3 coats 30% 33%

160 mils/4 coats 36% 40%

200 mils/5 coats 42% 46%

Insulation and “R” Values

• R-Values are normally referenced in the consumer market for walls/ceilings

• R = 1/U – where U is the heat transfer coefficient

• U = measures the rate of heat transfer through a material over a given area; and thickness under static conditions

• For insulation purposes; most materials have to be installed very thick; – Fiberglass insulation @1” has R = 3.8 – Polyurethane Foam Board @1” has R = 7 – Trapped air (double pane) @1” has R = 45

Sweating Surfaces

• Insulates cold substrates from warm moist ambient air – Condensers – Cold vessels – LP tanks

• Prevents “drips” – Minimizes slippery surfaces – Reduces corrosion

PRIMARY USES

Worker protection Solar Reflectance Provides Insulation for Processes

Minimizes Corrosion Under Insulation

Minimizes CUI

While NACE and Carboline recommends an appropriate coating system for steel

substrates under insulation for long term corrosion control; Carbotherm 551 greatly

minimizes the threat of CUI due to its excellent barrier properties compared to

classical insulation.

Minimizes CUI

Classical Insulation • Classical insulation methods

are not adhered to the substrate.

• Classical insulation methods utilize a two-step/two material process incorporating a jacket material that often allows water to infiltrate and remain trapped

Carbotherm 551 • Better barrier

– Carbotherm 551 is applied to and directly adheres to the substrate.

• Single product for insulation and protection – Carbotherm 551 provides

insulation and prevents excessive moisture from getting to the substrate and initiating corrosion

Carbotherm 551

Physical Properties Application Properties

Corrosion Testing

Carbotherm 551 Physical Properties

Property Value Importance

Thermal Conductivity 0.055 BTU/hr-ft-°F Outstanding insulator

Solar Reflectivity 84.7 Prevents steel from excessive solar

thermal heating

Flame Spread

Flame Index: 0 Smoke Index: 5

Class A Rated Does not contribute to a fire

Tensile Strength Adhesion

800 psi 1000 psi Durable/Strong tenacious coating

Hardness Shore D 55 Toughness/Impact resistant

Application Properties

• High build (35-40 mils/coat) • Excellent high coverage

– Film has minimal collapse/shrinkage

• Low odor; water based • May be applied to hot surfaces up to 250°F • Outstanding smooth appearance • Extremely safe – contains no chlorides, low

VOC, no heavy metals

Easy to Install

• High film build properties (35-40 mils) – Applies more thickness per coat

• Acrylics typically applied @15-20 mils/coat – Fewer coats needed for higher temperature

applications • Quicker recoat times (5 hours) • Paint-like application

– Can insulate any complex geometry easily – Less labor required compared to other hand-applied,

pipe-wrap, casting, or board stock insulation methods with protective coverings

Carbotherm 551 – Corrosion Testing

Corrosion Testing Result

Cyclic Corrosion Test* (QUV-A/Prohesion) 2016 hours

No Effect

Humidity Exposure* 2016 hours

No Effect

*Samples were left untopcoated. Three separate primers were tested: Carbozinc 859, Carbozinc 11 HS, and Carbomastic 15

WHERE CAN IT BE USED? Examples

LP Tanks / Boiler Skins and Ductwork

Hot Process Piping

Steam Generators

Heat Exchangers

Boilers

Oil/Gas Separators or Crew Quarters

Storage Tanks (cryogenic, ethanol storage, LPG)

Sweating (condensation) Surfaces

Carbotherm 551 “Best fit” applications:

As a personnel barrier against hot surfaces To minimize solar radiation heat effects on pressure

vessels and process tanks To reduce emissions for exterior tanks storing

evaporative chemicals To provide 25-46% heat efficiency insulation To reduce or eliminate condensation on cold

surfaces Provides all the above in a more durable coating

system ideal for industrial applications