Insulating Coatings for Energy Efficiency

Solutions applied directly onto metallic surfaces to reduce surface temperature, prevent contact burns, and optimize energy performance in demanding industrial environments.

In plants where extreme temperatures are inherent to the process, maintaining thermal control on exposed equipment is an operational necessity—not a luxury. Aplika Control Corrosion supplies coatings with insulating properties capable of:

• Reducing surface temperature to levels safe for human contact, in accordance with ASTM C1055 criteria, protecting personnel from accidental contact burns.
• Mitigating energy losses due to thermal conduction, especially in continuous-service lines.
• Preventing condensation formation on cold surfaces, avoiding persistent moisture and reducing the risk of corrosion under insulation (CUI).

These coatings are applied directly onto the metallic substrate—often without dismantling equipment and, depending on the system, under controlled operating conditions—adapting to complex geometries, hard-to-access areas, and assets subject to frequent maintenance.

Why Use Thermal Insulating Coatings?

• Operational Safety: Prevents contact burns and complies with thermal protection criteria established by international standards.
• Energy Efficiency: Reduces heat loss in hot lines, heat exchangers, tanks, and other critical process assets.
• CUI Protection: Acts as a functional barrier against moisture ingress on cold or insulated surfaces, reducing the risk of corrosion under insulation.
• Technical Simplicity: No need for metal structures, fasteners, cladding, or additional loads.
• Inspection and Maintenance Compatibility: Allows visual inspections and NDT without dismantling, facilitating integrity control.

System Design Based on Operating Environment

Each solution is defined using an applied engineering approach, considering:

• Operating temperature (high or low).
• Personnel exposure and contact frequency.
• Ambient humidity, ventilation, and condensation risk.
• Geometry, accessibility, and maintenance frequency.
• Equipment criticality within the process.

Systems Are Selected and Validated in Accordance with Standards Such As:

• ASTM C1055 / ASTM C1057: Criteria for safe human contact.
• AMPP SP0198: Guidance for corrosion under insulation (CUI) prevention.
• ISO 12944: Anti-corrosion performance of the metallic substrate.
• ASTM D2485, ASTM D4060, ASTM D2247, among others: Testing for thermal resistance, abrasion, humidity, and adhesion.

Technical Support and In-Service Validation

Our specialized team provides end-to-end support from diagnosis through commissioning, including:

• Initial thermal assessment of the asset.
• Technical system selection based on required performance.
• Application supervision, thickness control, environmental conditions, and curing.
• Performance verification through surface temperature measurements and in-service validation.

Results That Impact Operations

• Reduced risk of burn-related accidents.
• Improved energy efficiency in active lines.
• Elimination of condensation points on cold surfaces.
• Reduced CUI risk without replacing conventional insulation.
• Savings in maintenance, inspection, and replacement of damaged insulation.