What Are Insulative Water-Based Coatings?

Insulative water-based coatings are advanced, fluid-applied technologies formulated to reduce heat transfer, control surface temperatures, and mitigate moisture-related issues — all while using water as the primary carrier instead of traditional solvents.

Unlike conventional insulation systems (think bulky wraps, rigid boards, or cladding), these coatings form a seamless, bonded layer of insulation directly on the substrate. This eliminates gaps, seams, and common failure points where moisture intrusion, corrosion, and thermal inefficiencies often begin.

At their core, these coatings are designed to:

• Limit heat gain or loss
• Reduce surface temperatures
• Control condensation formation
• Minimize thermal bridging
• Help prevent corrosion under insulation (CUI)

Tnemec’s Aerolon line of products takes this concept further by combining water-based resin systems with some of the world’s most effective insulating solids, resulting in a high-performance, multifunctional coating system.

Aerolon: Fluid-Applied Insulation

Tnemec’s Aerolon technology is built to solve the real-world challenges that traditional insulation often can’t.

What sets it apart:

• Fluid-applied versatility – Conforms to complex geometries like valves, flanges, and tight spaces
• Reliable protection – Bonds directly to substrates, eliminating pathways for moisture intrusion
• CUI resistance – Reduces the risk of corrosion caused by trapped moisture
• Thermal performance – Low thermal conductivity helps stabilize surface temperatures
• Safety benefits – Helps protect personnel from extreme hot surfaces of up to 250ºF (121ºC)

Aerolon is a proven solution with a long track record across industrial, commercial, architectural, municipal, and marine environments worldwide. From reducing condensation on chilled water lines to creating effective thermal breaks and improving jobsite safety, Aerolon has been specified and applied in some of the most demanding conditions.

Where Insulative Water-Based Coatings Excel

Insulative coatings are particularly valuable in these industrialized scenarios:

• Condensation control on cold surfaces
  Controls dripping, pooling, and moisture-related hazards.
• Surface temperature reduction
  Creates safer environments by reducing burn risk on hot equipment.
• Complex or irregular geometries
  Ideal for valves, fittings, and intricate structures where insulation is difficult to install.
• Fast-track projects
  Aerolon has twice the efficiency of regular spray-applied systems and can be applied with twice the thickness per coat, reducing installation complexity, labor time, expenses, lifecycle costs, and asset downtime.

Meet the Aerolon Lineup

Aerolon’s capabilities and specific performance areas can be summed up into three categories: condensation control, thermal bridging mitigation, and thermal efficiency. Each of the following Aerolon products plays a role in those applications.

Series 971 Aerolon Acrylic

A fluid-applied acrylic insulation coating enhanced with insulative particles for exceptional thermal performance.

Best suited for:

• Pipes, tanks, and structural steel
• Applications requiring both thermal improvement and personnel protection
• Eliminating CUI risk by bonding directly to the substrate
• Acting as a thermal bridge, omitting the need for a thermal break

Series 971 forms part of a durable, corrosion-resistant system that bonds directly to substrates.

Series 972 Aerolon Marine

A hybrid silicone-acrylic, anti-condensation coating engineered for harsh marine environments.

Best suited for:

• Bulkheads, overheads, and vessel interiors
• High-moisture environments prone to condensation and corrosion
• Shipyards, offshore platforms, and marine vessels

This water-based system reduces condensation-related hazards, such as dripping and wet surfaces, while also providing safe-touch heat protection. Built-in biocides prevent condensation-related mold and mildew growth — supporting cleaner, safer environments.

Series 972 Aerolon Marine is ABS-certified, IMO-compliant, and USCG-approved.

Series 975 Aerolon

sA high-performance, fluid-applied acrylic insulation coating designed for maximum thermal efficiency and durability.

Best suited for:

• Applications requiring enhanced thermal performance
• Projects prioritizing thermal efficiency and sustainability
• Environments where condensation control and personnel protection are essential
• Applications that require high-build capabilities per coat

With exceptionally low thermal conductivity and strong adhesion, Series 975 delivers long-term performance while supporting sustainability initiatives, including LEED and WELL Building standards.