Get “high” heat protection that surpasses conventional insulation with HPC® Coating. HPC® Coating is a ceramic based, water-borne insulating coating designed to insulate in high temperature situations. Use HPC® Coating as an insulation to block heat loss or for employee protection.
HPC® Coating – single component water-based coating designed to insulate hot pipes or surfaces that load up to 260°C (500°F). The coating is not a reflective coating, but works to block the loading of higher heats and to resist the transfer of heat through the coating to the cooler side.
Holds heat on the surface in which it covers. Always ask what the temperature inside the unit is and not the heat on the surface. Once coated, the surface will be equal to the interior temperature which could be 93-148°C (200-300°F) higher than what is registering on the exterior. Learn More SPI >
Video above shows HPC® Coating being applied in 2011 at Gazprom (Russia’s largest LPG Energy supplier to Europe) and shows a 550°C hot pipe insulated down to less than 40°C in just minutes…all without a shutdown or hot permit. Manufactured by Superior Products International (SPI), Hot Pipe Coating (HPC) is available from NEOtech Coatings Australia.
This insulation method is much different than the traditional “wrap” insulation materials that only slow down the loss of heat (known as an R-rating or “heat transfer”). The eight ceramic compounds create a barrier to catch and hold heat on the surface of the unit, e.g. pipe, furnace surface, boiler, etc.
Unlike wraps that use air as the insulation component, the ceramic compounds in HPC® Coating resist absorbing heat trying to come off the surface to escape. This traps and holds the heat onto the surface for more effective insulation performance.
HPC® Coating test
A test on a heating pipe showing the powerful properties of ceramic insulation technology. Part of the pipe is painted with our Superior Products ceramic coating to show the comparison of the thin insulative film. Footage shows pipe reducing from 232°C (450°F) to 35°C (95°F) during application.
Additional benefits of HPC® Coating include:
Easy to Apply: Apply directly to hot pipes while operating. Spray with hopper guy or Graco 1500 TexSpray. Apply thin coats first, and after surface reduces heat level, thicker coats can be applied.
Increased Insulation: Additional coats immediately reduce surface temperature and loss of heat. 25mm (1 inch) over a 232°C (450°F) pipe allowed someone to touch the surface safely at 60°C.*
Long Lasting: Does not absorb humidity or lose insulation value with overcoat of Super Therm®.
Safe: Non-flammable and non-toxic.
Coverage: Can be sprayed to fit over any configuration or shape.
|ROCKWOOL/FIBERGLASS WITH METAL JACKET||HPC® COATING|
|Must shut down operation to install||HPC® COATING is installed without a shutdown|
|Deteriorates rapidly and loses insulating value when moisture is present plus elbows & valves can not be wrapped effectively so heat losses are significant in these areas||Non-Deteriorating and does not lose insulating value when moisture is present plus can be sprayed on elbows and valves reducing the significant heat losses through these areas|
|When a pipe cracks, the entire Jacket and RockWool or Fiberglass must be removed and repaired which requires downtime||When a pipe cracks, it can be inspected directly on the spot without removal and easily repaired by spraying or trowel application|
|CONDENSATION – DEWPOINT CHART OR DEW POINT CALCULATOR|
|High due to the air trapping characteristics of RockWool/Fiberglass||No condensation due to complete surface bon|
|CORROSION UNDER INSULATION (CUI)|
|High due to condensation problem||No condensation thus no corrosion|
|Must shut down operation to repair||No repair is necessary for HPC® COATING|
|High due to frequent maintenance required for condensation & corrosion control plus high down time, labour and material costs||Low as HPC® COATING is directly sprayed without plant shut down plus the labour and material cost are much lower|
|Lasts about 6 months||Several years|
- HPC® COATING ambient temperature thickness Chart 8°C, 21°C, 34°C for touch as per OSHA requirements.
- Research on Wrap Insulation vs Pipe Coating By Dr. Ir. Aniello Palmieri
For more information and documentation on HPC Coating, visit SPI Coatings
HPC for Cool Room Condensation – 30°C variation
The Challenge: A client was looking to stop condensation on a wall that was an office and the room was 22°C. The other side of the wall was a cool room at -15°C with panelling. Both walls are interior to the building however for this conversation the office wall is the exterior wall.
HPC Solution from SPI Coatings
When you get over a 30 degree difference between the interior and exterior of a wall, you need some thickness, so you are only interested in the exterior side of the wall.
Why, because the hot moisture air is only on the exterior wall.
When the warm air hits the wall and sets, it cools and when it cools, it cannot hold the moisture and it shows as condensation on the side of the warm air. As warm air cools, it drops out it’s moisture.
The interior is cold and no moisture as the air conditioning unit pulled all the excess moisture out of the air and cool air does not hold moisture. You must prevent the warm moist air from setting on the cold common wall between interior and exterior.
To do this, you must apply HPC for thickness to 13mm dry thickness and over coat with Super Therm®.
This blocks the warm air from setting on the surface of anything cool, the Super Therm® helps to throw off the radiation by using emissivity to release the warmth off the surface.
You must have the thickness of the HPC to prevent the wall surface with Super Therm® on it to ever being cool that would cause the warm air still covering the exterior wall during the warm air laying on the wall and then being thrown off by Super Therm®. You would still have some condensation without HPC.
HPC® and Top Coat Protection
If a durable protective finish is required because of the surrounding environment, such as physical, mechanical abuse or over pipes subject to vibration, apply as follows. After the last coat is applied but before it dries, wrap polyester or fiberglass mesh around the pipe with the edges slightly overlapping to provide complete coverage. Allow this to dry. Topcoat with Super Therm®.
For exterior applications subjected to WEATHERING apply Super Therm® at 2.5m2 per litre giving 425 mils WFT or 250 microns DFT. Allow to dry and cure over night.
For applications with HIGH HUMIDITY or SUBMERGED UNDER WATER allow the HPC® COATING to dry then apply Moist Metal Grip.
Information needed prior to application of HPC or HPC HT
To make a right choice of products to use HPC or HPC HT we need to know:
- What is the maximum temperature inside the pipes and valves
- Dimensions (outside diameter and lengths) of pipes/valves/vessels or approximate square meters of insulating area
- Location (indoor/outdoor: in this case looks like indoors)
- What is the average ambient temperature in the location of equipment and if there is any air ventilation