Ceramic Insulation

Ceramic Insulation Coatings are a Unique Spray Applied Coating with Revolutionary Insulating and Protection Properties

Delta T & Protective Products introduced Ceramic Insulation Coatings, a unique spray applied coating, to the Canadian market. The term “ceramic insulation coating” is generic. It introduces a unique, revolutionary product that is used in conjunction with a variety of conventional insulation systems, or in many cases, as a stand-alone replacement product.

Blowtorch on hands protected by ceramic insulationThe ceramic insulation crystals in the hand reflect the heat from the blowtorch and protect the hand from serious burns. The picture demonstrates dramatically the isulative properties of ceramic insulation. Ceramic Insulation Coatings significantly reduces surface temperature and controls radiant heat by up to 95%.

There are numerous formulations and specifications involved including our own made in Canada CCC100 Ceramic Insulation, DTC Rust Direct , and Albi Clad fireproofing products for various applications. Contact Delta T & Protective Coatings for information relating to the products that are best suited for your specific project requirements.

A Laymans Guide to Heat Energy and Insulating

Heat is energy and has been defined through the ages by many great physics and scientists from Isaac Newton to Albert Einstein. So first we should understand the scientific Laws we will be working with. The first Law of Thermodynamics states in part, “heat is a form of energy transfer. The second rule of Thermodynamics states again in part that “heat energy will always move from hot to cold”, or simply stated from a higher to a lower temperature area. It will do this to establish a state of thermal equilibrium. To understand the full complexity of these two rules you can visit Wikipedia. As an example the Second Law of Thermodynamics we might state on a cold winter day,”close the door you are letting the cold in”. In actual fact the heat is moving out of the house (hot) to the outside air (cold). It wants to go out there and heat the countryside up and establish a state of equilibrium making the temperature outside the same as the inside of the house. Of course your furnace can’t keep up and the heat energy just gets swallowed up by the winter weather.

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A very important fact is introduced by the example of opening the door and the heat rushing out. The larger the temperature difference between the inside of the house and the outside the greater the movement of heat there will be. If the house thermostat was way up, like some people like, you could stand in the doorway and feel the warm breeze on your face as the heat heads outside. The same would be true for a hot day with the air conditioner on full blast, opening the door you would feel hot air from outside coming into the house. So we introduce the term Delta T. If you take the temperature at one spot, for instance the inside of your house and then take a temperature reading in another spot say outside on the porch you will get two different temperatures. Subtract these two temperatures and you have a Delta T. This is a common term in mathematics and simply means “the change” and has the mathematical symbol Δ (Greek alphabet letter D). So it would appear as ΔT. In this dissertation I shall just say Delta T. If the number is large then a lot of heat energy must be moving. A hot house at +200C, with a cold day outside at 00C produces a large DeltaT of 200C. Standing in the open doorway you would feel the rush of hot air heading outside. So the higher the Delta T the more heat is moving from (hot) to (cold). The lower the Delta T the less the heat is moving.

Now we will discuss insulating. To insulate you are putting up a wall or a barrier to stop the heat from moving. Remember that we are dealing with Energy, that magical stuff that makes up our universe. In our example we close the door and it stops the heat energy from moving outside. And how does the door insulate or stop the heat from moving outside? The heat energy in your house is basically warm air so the door does form a barrier to stop the heat from moving outside. We will discuss how some forms of heat can get right through the door later in this article. It is still colder on the outside of the door than it is inside the house so there is a high Delta T. The energy will be “attracted” to this area trying to get outside (hot to cold). Insulation consultants use a special infrared camera to show “cold” spots in your house that heat will be attracted to. In the case of the door, the warm air can’t penetrate the door but it can find open spots around the casing to move through (cold spots). In other words the heat energy is trying move to that colder region and will use any means at its disposal to do so. Filling the cracks around the door with insulation will make the door a better barrier to the heat energy trying to move out. But energy is the basis of our universe and has ways of getting through our insulation or barrier that we erect; it is a lot smarter than a door. Heat energy still wants to move outside where it is nice and cool. Follow me on the next section as I explain the three methods that heat energy uses to move from its hot spot to a cooler climate.

There are three ways that Heat Energy moves. They are called conduction, convection and radiation. With conducted heat two solid objects must touch each other and Heat Energy is transferred from the hot object to the colder object by molecular movement. Convection heat is scientifically stated as “the movement of heat through a fluid.” In real life air is considered a fluid so convection is heat movement by heating the air. A furnace has a firebox surrounded by an air chamber. The firebox heats the air and a blower (fan) pushes the warm air through the house through ductwork and vents in the floors. Radiant heat is scientifically stated as “movement of electromagnetic waves emitted from a black body”. Wow that is some statement! A person near a raging bonfire will feel the radiated Heat Energy of the fire even if the surrounding air is freezing cold. Radiant heat doesn’t require a medium in order to move. For convection heat a fluid is needed (air in most cases for dwellings), and two solid objects must be in contact for heat conduction. Radiant energy movement is the most complex and as luck would have it CCC100 only works only on this form of Energy movement and forms the best Radiant Barrier possible. With this in mind I will explain a little more on the properties of radiant heat.

Electromagnetic waves could be visualized similar to radio waves transmitted by your favorite radio station, they are emitted from the radio tower and travel through the air to the antenna in your radio. To see what a waveform is and how it gets from one place to another just look up radio “transmission” on the internet. To recap, radiant heat does not need a medium to travel through as convection and conduction heat energy does as it is an Electromagnetic waveform. One of the factors with radiant heat is that it only has so much power and is directly dependant on the source of the heat. For instance if you sit too close to a campfire or the woodstove you get extremely hot and have to move back. If you go to the kitchen for a cup of coffee the kitchen will be cold. Of course a woodstove will also heat the air in the room and you do get heat moving by convection. But if you don’t move the warm air with a blower to the other rooms it will be raging hot near the stove and colder in other parts of the house that are away from the stove. Radiant heat moves in a straight line from the source out. Pioneers had an ornate Pot Belly Stove in main gathering areas like the living room or in the corner of the local general store. This pot belly stove with its ornate designs was also practical in that the radiant heat from the stove would be “spread out” pointing in different directions to heat more area. The wonderful sun of ours is the largest source of radiant heat and contains many other sources of heat such as UV (ultra violet) and IR (infra red). As luck would have it CCC100 ceramic insulation works only on radiant heat and has no effect on heat conduction and heat convection.

Now that you have a picture of how Heat Energy works let’s discuss more on the topic of insulation and stopping the heat energy from moving. In reality you are putting up a barrier to it travelling from the hot spot to a colder spot. You know that heat energy is moving because there will be a large Delta T. One spot is hotter than the other. A perfect wall that would stop heat energy in its tracks would have a Delta T of 0 Degrees the temperature on either side of the wall would be equal (energy has reached equilibrium).

What are the methods of insulating? Conventional insulation puts up its wall by using a material such as fiberglass or Styrofoam with many air pockets. It is sometimes called bulk insulation and the thicker the better. The air inside the material heats up by convection and equals the temperature of the moving heat and forms a Delta T of 0 Degrees. The confusing part is that if you measured the temperature inside your house then went outside and measured the outside temperature of the wall you would have a large Delta T. This should mean the heat energy is moving outside. The answer is that the heat energy is in the insulation material itself and it is not moving because it is trapped. Bulk insulation works excellent and is time tested, simple and documented with an R-Rating, the bigger the R Value the more bulk. Bulk insulation is best for housing and working with the warm air of convection heat transfer.

But what about insulating from radiant heat? For instance a house with a metal roof on a hot sunny day needs to have a radiant heat barrier. Bulk insulation in the ceiling works for convection heat but doesn’t work well with the radiant heat coming off the metal roof. The sun is heating the metal roof up and the metal roof is radiating that heat into the attic. The attic thus acts like a woodstove in the ceiling of the house, not a pretty picture. Metal pipes and duct work in industrial areas are often hot, and sometimes hot enough to cause serious burns to personnel around them. The heat coming off of these metal surfaces is radiant heat. And naturally there is our mighty sun the biggest source of radiant heat known to mankind. Sometimes we want to keep the heat of the sun out of our houses. The suns heat contains invisible UV and IR radiation heat. Bulk insulation just doesn’t fit the bill for this type of barrier. We need a radiant barrier.

CCC100 from Delta T and Protective Products provides a radiant barrier that is up to 90% effective as a radiant barrier. The coating at only 20mils DFT is spray applied meaning no shutdowns or disassembly of equipment is required. Adhesion is phenomenal to most materials like metal, wood, cement and even Plexiglas. Moisture and condensation control is built in as the radiant barrier is solid polymer material that doesn’t promote moisture pockets. Explore our Web Site for applications and more details on CCC100 coating working as a radiant barrier.

We hope this primer on heat energy will be informative. We cannot stress enough the importance of having knowledge on a product and its uses. One cannot simply start spraying our CCC100 on everything and expect insulation results. Feel free to use out contact form for questions that you may have.

A Few Examples of the Formulations and Applications Performed

A white liquor tank at a Pulp MillA White Liquor Tank at a Pulp Mill
Ceramic coatings provide better insulation relating to radiant energy transfer than fiberglass or other conventional systems. Ceramic Insulation Coatings can be applied on a surface with temperatures up to 3600F. Shutting down operations is not required. (A white liquor tank at a Pulp Mill)

Oil Field Tank InsulationOil Field Tank Insulation
Insulative ceramic coatings provide not only a thermal barrier, but also a waterproof membrane that prevents water buildup caused from condensation between the substrate and the coatings. (Oil Field Tank Insulation)

Rusted Metal RoofsRusted Metal Roofs
Rusted surfaces do not require sand blasting when using DTC RUST DIRECT. The proprietary solvent and polymers are uniquely designed to penetrate and “wet” the surface. These polymers react with moisture in the air, out-gassing resin into the pores, and anchoring the coating to the surface. An incredible, durable, aluminum-reinforced urethane film is produced that is metallized, encapsulates, and regalvanizes. The more pitted and deteriorated (rusted) the substrate, the better anchoring properties the coating will exhibit. (Piping, tanks, shipping, metal roofs)

Pasteurizing Control ValvePasteurizing Control Valve
Breweries and Food processing industrys can benifit by using our coatings.This Pasteurizing Control Valve had Ceramic Coatings applied to 80 mils, for temperature control and personnel protection against accidental burn injury. (Labatts Brewery)

The coatings applied on Plexiglas skylightsThe Coatings Applied on Plexiglas Skylights
The coatings can be applied to cement, wood, metal and even plexiglas. Ceramic Coatings adhesion test conducted after full cure, pull-tested in excess of 200 psi. The coatings applied on Plexiglas skylights to control expansion and contraction (thermal shock) saved in excess of $75,000.00.