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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
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
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