3rd Edition of the Mascoat Messenger

4rd Quarter 2011

In this Issue

Editor's Box

Senior Editor...Will Conner
Managing Editor...Vargo Williams
Associate Editor...Katy Wendell
Design & Production...AMG Creative

Why Don't Thermal Insulating Coatings Use R-Value to Measure Insulation Value?

R-values of thermal insulating coatings explained.

During my past 17 years of selling insulation coatings, the two most common questions I hear from clients are, “What is the R Value for the coating?” and, “How much coating will I need to replace my existing foam insulation?” When I hear these questions, my response is, “What is important about R Value or insulation thickness to you?” The reason I present this question is so that I can better understand exactly what the client’s needs or expectations are, versus just analyzing what has been done the in past. Defining expectations is critical to understanding their problems and how they can be solved.

In most cases, our customers' knowledge of insulation is based upon what has been done in the past. A typical mindset is: "We specified two inches of blanket insulation because that is what we have always used." This approach is understandable, but does it really provide the best solution?

When defining a customer’s needs and expectations, I find that a brief education of insulation and heat transfer is sometimes needed. (Mascoat even offers classes on these subjects.) Typically, most conventional insulation systems use thermal conductivity to slow down heat/cold flow. Thermal conductivity is the transfer of heat/cold via a solid pathway. Things that transmit heat/cold quickly are said to be good conductors and therefore have high thermal conductivity. (The term "high" refers to a faster rate of flow.) Things that transmit heat/cold slowly are said to be bad conductors and have a low thermal conductivity (which is actually good in the case of insulation.) Confused yet? Hopefully the following definition will help:

Thermal conductivity is defined as the flow rate of heat/cold through a solid surface and expressed typically in units of BTU or Watts per a specific thickness and a specific area.

In the late 1940's, Everett Shuman from the Penn State University Building Research Institute proposed a new way of expressing a material's ability to insulate in layman’s terms. In the past, insulation was defined in a term called U Value, but it described the heat/cold transfer in complex terms, such as watts/m/ Kelvin, or BTU/ft/hr/F, loaded with decimal-laden numbers that were difficult to remember. Shuman felt there needed to be an easier way.

Shuman came up with the term "R-value", defined as the thermal resistance of a material using the inverse of thermal conductivity. He felt that the inverse, which is a whole number, would be far easier to remember than a fraction or decimal system. The above definition only applies when expressed in the units of BTU-in/F/ft2/hr and is most commonly defined by one inch of a given material; however, the total R-value takes into account additional layers of insulation above one inch.

So what does this mean in regard to insulating coatings? And, more importantly, how does this help define needs and expectations for the customer? The performance of an insulating coating is typically hard to define by thermal conductivity alone. R-value (the inverse of thermal conductivity) does not give an accurate description of thermal coating performance across a wide range of temperatures. This is due to the way in which radiant reflection and a few other thermal blocking agents work within the coating. These additional thermal blocking agents don't measure well in standard conductivity tests. The National Association of Corrosion Engineers (NACE) and the American Society for Testing and Materials (ASTM) are aware of these issues, and are now looking for a better means of measurement. Members of our company sit on panels with these groups working to better define performance standards for insulating coatings. The most important objective is to correctly define the heat flow rate for prediction means and not to confuse the public or engineers with the antiquated R-value nomenclature.

So, when I am asked about R-values for our coatings, I have found that the discussions above become vitally important in meeting the client’s needs and expectations. Mascoat’s in-house engineering department plays a vital role at this stage. Our calculations employ very complex algorithms that allow us to effectively predict heat flow, thereby getting to the root of the customer’s concerns. By providing accurate feedback regarding expected heat flow (and temperature) a customer’s expectations or needs can be properly identified. This invaluable tool allows the client to know exactly how our coatings will perform in their specific application.

Our goal is to educate our clients from both a practical standpoint and an engineering perspective to determine whether their expectations can be met. If we cannot meet a customer’s expectations, we let them know it is not the right application for an insulating coating and try to help steer them towards a workable solution. This is far better than having an unhappy customer due to miscommunication of the product’s abilities, or to try and meet unachievable expectations.

Customer education and establishing realistic expectations are paramount at Mascoat. By always being upfront about the performance of our products and how they will positively affect our customers’ bottom line, we can get past restrictive R-value evaluations and the need to compare our products with conventional insulation methods.


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Smooth Sailing with Mascoat Lightweight Coatings

J-Class sailing vessels, popular in the yacht racing circuits of the 1920s, were originally designed for use in the America’s Cup Race – a prestigious international sailing event that attracts top vessels from all over the world. J-Class yachts fell out of use in the late 1930s, but reemerged in the early 2000s when J-Class enthusiasts formally met to reestablish new rules and guidelines to promote and protect the class for future generations. J-Class vessels regained their popularity, and new designs began to emerge.

In an effort to keep the vessels as light and fast as possible, a number of weight-saving measures are integrated into the design of every J-Class sailing yacht. Realizing insulation is important to protect a vessel’s interior environment, J-Class yacht designers found that conventional insulation is heavy, bulky and difficult to install. Designers saw this as a major dilemma and reached out to Mascoat for a solution to protect the crafts without adding a great deal of weight.

Mascoat determined that Mascoat Marine-DTM insulating coating offered the perfect solution. Mascoat Marine-DTM is a rapidly applied, extremely thin coating that provides thermal insulation and condensation protection in harsh marine environments. Shipyards using the coating have reported insulation weight reductions in vessels of up to 60%. Mascoat Marine-DTM is a water-based, low-VOC coating that applies like paint and cures quickly to hasten vessel delivery time.

 

Applied up to 2.0 mm thickness in a series of 0.5 mm coats, Mascoat Marine-DTM provides the same protection as up to 50 mm of thermal blanket insulation when applied in conventional wall and bulkhead construction. In addition to the insulating benefits, the coating helps prevent corrosion, eliminates radiant transfer into the ship’s interior and meets IMO/SOLAS guidelines.

An application of Mascoat Sound Control-dB sound damping coating is a great addition to protect vessels against unwanted structural-borne noises and vibrations caused by waves slapping against hulls.

Thanks to Mascoat, it looks like smooth sailing ahead for J-Class vessels.


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Mascoat's Stelmach Voted President of CSHA, Appointed NACE Conference Program Chair

Mascoat Business Development Associate Michael Stelmach was recently honored by two highly-respected industry organizations. After many years of service, Stelmach was voted President of the Coating Society of the Houston Area (CSHA). The CSHA is a non-profit organization comprised of facility owners, contractors and manufacturers located around the Houston area. The organization’s goal is to promote the use of protective coatings and educate people in the industry about their benefits. Along with their education and awareness programs, the CSHA runs a scholarship fund that benefits 10-15 college students every year.

Stelmach was also asked to be a Program Chair at the National Association of Corrosion Engineers (NACE) 2012 Bring on the Heat Conference in Houston, TX, June 19-21. The conference will be attended by industry leaders from around the country providing three days of highly-informative educational programs about different types of coatings, including fireproofing, high-temperature and insulating coatings. Highly regarded for his knowledge in the coatings industry, Stelmach will present a program on the use of Personal Protective Equipment (PPE) and the application of insulating coating in relation to various substrates and environments.


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Mascoat Saves School District $130,000; Ends Mold Risk

Mascoat recently helped four schools in the Northside Independent School District (NISD) in San Antonio, TX that were experiencing condensation on their air conditioning units due the high temperatures and high humidity in South Texas. The air conditioners were experiencing a particularly large amount of condensation from mid-spring until mid-fall. The NISD found the risk of mold, mildew, and corrosion associated with condensation unacceptable and contacted Mascoat for a solution.

Before making a recommendation, our Mascoat representative asked the school district to identify the most extreme condition they would encounter. The NISD estimated that at the height of summer, the area around the air conditioning units would reach a dew point of 74˚F (23.3˚C). After contacting the manufacturer of the units, it was determined that 100 mils (2.5 mm) of Mascoat anti-condensation insulating coating would be required to stop the condensation from forming.

The School District decided to conduct a test on a single unit before proceeding with the entire project. A small unit at Clark High School was selected for the test. Paradise Painting of San Antonio, TX was contracted for the job. In January of 2011, after thoroughly cleaning the unit with water, Paradise Painting applied five coats of Mascoat, in 20 mil coats, directly to the aluminum surface of the air conditioner. To ensure the coating application eliminated the condensation issue, NISD waited until June when the ambient temperature reached 74˚F. When the unit arrived at that temperature, there was no condensation to be found.

The NISD immediately decided to coat all 12 of their units with 100 mils of Mascoat Industrial-AC. According to the district, Mascoat was able to save the schools $130,000 in materials and application costs compared to traditional insulation. Eliminating the condensation problem ended the concerns over mold and mildew, to which children are especially susceptible. All 12 air conditioners are currently in service, and the schools have not experienced any condensation, mold or mildew on any of the units.


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Mascoat Brings Holiday Cheer to Family in Need

For many families in our area, the joy and awe of the holidays are overshadowed by overwhelming hardship. To address this heartbreaking situation, Mascoat rallied its 35 employees to contribute to the Westside Homeless Partnership (WHP) Adopt-A-Family program this holiday season. At Mascoat, we feel that it is important that families in crisis know there are people in the community who care.

"When our adopted family sees images of perfect families having perfect holidays, we want them to be able to experience the warmth and joy of the holidays as well," said Belia Loredo, Mascoat’s program coordinator. "This is the second holiday season that we have adopted a family through the WHP, and it feels great to know that our contribution will give them a holiday to remember."

Mascoat's donations came at a critical time when their chosen family's resources barely covered necessities. Mascoat provided the family with much needed clothes, toys, books, games, grocery gift cards, and even an MP3 player. The mother of the family was invited to a staff luncheon where she was showered with even more gifts. "Our employees were very generous," said Loredo. "We made her day and helped her family tremendously. This is the kind of heartwarming cheer we like to spread at Mascoat."

Like Mascoat's adopted family, many families in the Houston area rely on the generous support from the community and the Westside Homeless Partnership to make it through the holidays. To learn more about what you can do to help families in need and create a special memory during difficult times, please visit www.westsidehomeless.org.


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