3rd Quarter 2011
In this Issue
- Mascoat Introduces Highly Reflective Coating to Reduce Solar Loading
- A Message about Different Insulations from George More
- Mascoat Expands into China to Help Reduce Carbon Footprint
- WeatherBloc-IC Helps Increase Honey Yield in Australia
- Mascoat Provides Insulation Solution for Modified Shipping Containers
- Case Study: NuStar Marine Fuel Tank Insulation
- Case Study: Seacor Vessel Sound Damping
Senior Editor...Will Conner
Managing Editor...Vargo Williams
Associate Editor...Katy Wendell
Design & Production...AMG Creative
Mascoat's new Industrial-HR is the ideal solution to reduce the effects of solar loading on tanks and pipelines while providing outstanding insulating qualities.
The ability to combat the effects of solar loading from the sun and keep tanks and pipelines at a constant temperature poses significant challenges in industrial environments. In response, Mascoat has formulated a new highly reflective insulating coating – Mascoat Industrial-HR (High Reflectivity).
MI-HR borrows its insulating ability from the widely used and industry-proven Mascoat Industrial-DTI (MI-DTI), a market leader for over 15 years. Along with its well-known insulating effects, MI-HR was specially formulated with additional highly reflective particles to help further its ability to reflect UV rays. It is used most commonly as a topcoat to complement the insulating effects of MI-DTI.
Mascoat clients have achieved great success with the MI-HR on a wide range of industrial applications, including gasoline storage tanks, potable water lines and chilled water tanks.
Gasoline storage tanks, in particular, need to be insulated against radiant heat gain to maintain temperature levels and product stability. Prolonged heating from the sun converts liquid gas into a vapor. This vapor is highly explosive and must be vented into the atmosphere regularly to ensure the integrity of the tank and the product within. By adding a top coat of MI-HR to a base coat MI-DTI, companies can save money on lost product and reduce harmful emissions.
Since its release, there has been a surge in demand for MI-HR, particularly in arid zones and desert climates affected by constant exposure from the sun. To learn more about Mascoat Industrial-HR, please inquire via e-mail: firstname.lastname@example.org.
Distributor and Customer Contacts
We invite you to drop us a line to discuss any questions, concerns or ideas you may have.
The Mascoat Team
George More (email@example.com) – technical questions about our products, thermal analysis and engineering
Gary Prasher (firstname.lastname@example.org) / Bill Herzog (email@example.com) – general business questions and concerns
Chad Davis (firstname.lastname@example.org) – questions about technical application and product pricing
Will Conner (email@example.com) / Vargo Williams (firstname.lastname@example.org) – questions regarding promotions, trade shows, printed materials, marketing, advertising and website
Erik Nillson (email@example.com) – orders, fulfillment and shipping questions
Victor Tsai (firstname.lastname@example.org) – thermal analysis requests and tracking
In my 16 years of making and selling insulating coatings, I have been asked countless times by customers how our products compare to conventional insulation. I wish there was a simple answer, but it's not always that straightforward. When I am posed with this question, the first thing I try to do is determine what the customer is really looking for when they use the term "insulation". What customers usually want to know is the amount of thermal loss that will occur, rather than an actual product comparison. It is the manufacturer's responsibility to provide accurate information regarding the expected thermal transference over time.
With conventional insulation, nomenclature like "R-value" and "K-value" are used; however, these definitions are based on theoretical values and not necessarily representative of actual values found in the field. So, when we are asked how our products perform, in order for there to be a fair evaluation, it is very important to not only understand what product we are being compared to, but also the environmental variables present. This information is critical because different types of insulation perform in different ways depending on the environment.
Performing an accurate comparison study of insulations is a difficult task, but Mascoat has taken great efforts to make this process as easy as possible for our customers. As many know, Mascoat has a highly experienced engineering department that can perform product comparison studies at no charge. We strongly recommend a product comparison analysis to all our customers. We have found that we can save them a great deal of time and money by making sure our product is suitable for their application. Because of the differences between insulating coatings and conventional insulation, we always try to look for a location in a plant or facility that has not been insulated due to potential problems. We typically find these areas in every plant we visit and, after testing, conclude that our product is usually perfect for these applications. Common areas for testing are tank tops and personnel areas that require removal or constant replacement of insulation, such as eye wash lines. These places, found to benefit from the use of Mascoat insulating coatings, usually have common themes of corrosion under insulation, lack of inspections and loss of energy. Customers are quickly satisfied with the application of Mascoat, as multiple issues are usually solved with just one application in a short period of time.
When conducting comparisons between insulating coatings and conventional insulation, we recommend taking the following steps: first, determine that the test area has not been insulated as a result of a potential or existing problem; second, allow for an impartial comparison of products; and third, remember that Mascoat’s engineering department is available to assist in the evaluation. We are here to help you every step of the way. All you need to do is ask.
Mascoat’s new business development team closely monitors the pulse of the industry, identifying trends and opportunities to introduce its products to new regions and markets. One of these new markets is China. An emerging leader in energy conservation, China continues to search for new and innovative ways to reduce its carbon footprint and conserve energy while expanding its manufacturing and refining capacity.
Recognizing that spray-applied insulating coatings provide outstanding energy retention value, several businesses in China have partnered with Mascoat to make their energy consumption cleaner, more efficient and sustainable. To support these efforts and further the company’s goal to become a worldwide energy saving solutions provider, Mascoat recently opened an office in Beijing, becoming the first North American insulating coatings company to open an office in China. Mascoat’s Beijing office will provide the same superior service and outstanding customer support provided by offices in the U.S. and The Netherlands.
"China is a huge market for us," stated Gary Prasher, vice president of business operations for Mascoat. "They have many fast-paced industries that are growing rapidly. We have made great strides to help companies reduce their energy needs and keep processes as efficient as possible."
Mascoat has already completed several successful applications in China, and the Beijing sales team is working with major petrochemical refiners, food processors and other industries to reduce their energy usage through the use of insulating coatings.
For more information about Mascoat's operations in China, or to request a quote, please e-mail Mascoat China's manager, Zheng Chaogang, at email@example.com.
Greg Owens, Mascoat's Australian distributor who is also a beekeeper hobbyist, found an innovative use for Mascoat WeatherBloc-IC while creating a replacement honey super for one of his hives. (A "super" is a special box used to hold honey storage racks.) The wooden framework of the super needed to be sealed to protect it from the elements. Owens had some Mascoat WeatherBloc-IC on hand and, being familiar with the product’s superior protective properties, coated both the super and the hive lid with it.
Bees are very temperamental creatures, especially when it comes to environmental conditions. They are known to beat their wings repeatedly near the hive’s openings to create an air conditioning effect when the temperature is too high. Other bees bring in water to further cool the interior. During the warm Australian summers, many bees that would otherwise be producing honey perform these tasks for the greater good of the hive.
During the following honey harvest, Owens discovered that, in addition to the weather sealing ability he originally intended, the application of Mascoat also provided a significant thermal insulating benefit.
Owens noted that the WeatherBloc-coated hive produced nearly 14 kg (30.86 lb) of honey, compared to the 12 kg (26.45 lb) produced by an uncoated hive during the same time period. The two hives were identical and located in the same space. He also noted that the coated hive needed fewer bees to maintain the internal temperature, freeing up more workers to forage for pollen and nectar.
The most amazing fact of this higher yield was that the uncoated super was already in use prior to the experiment. The WeatherBloc-coated super was started from scratch, meaning that the bees had to create all of the honeycombs before producing the larger amount of honey.
The bees also demonstrated the environmental friendliness of Mascoat. If WeatherBloc-IC contained any harmful substances, the bees' instinct would have been to vacate the hive and relocate.
Used shipping containers have become increasingly useful around the world. Purposes for the containers are only limited by one’s creativity. Common uses include working, living and storage spaces. Storage containers offer portability, solid construction and low building costs. Ideal for harsh climates, containers offer outstanding protection against the elements. As the demand for containers increase, one main challenge has risen – they are not energy efficient and need to be insulated to provide comfortable living and working environments.
Mascoat WeatherBloc-IC offers a solution to the challenge of insulating and reducing energy loss in containers. Mascoat WeatherBloc-IC is a superior insulating coating, attacking heat before it penetrates the substrate. A spray application of Mascoat at 20 mils (0.5 mm) per coat will offer complete protection against the elements compared to conventional insulation which starts at a thickness of 0.5 inches (12.7 mm). Because the surfaces of most containers are corrugated, the use of conventional insulation is space restrictive and difficult to apply. Mascoat’s rapid spray-on application is ideal for uneven surfaces and projects where space preservation is an issue. Another benefit is that Mascoat can be applied prior to shipping the containers, providing insulation during transport. The insulating coating is typically applied to interior walls, ceiling and floor spaces of the container. In harsh geographical climates subject to intense heat and sunlight, an additional exterior coat may be recommended for the roof and side walls of the container.
The performance of Mascoat WeatherBloc-IC thermal insulating coating has been well documented in unforgiving environments around the world. The product has been tested to American Society for Testing and Materials (ASTM) standards and exceeds most minimum criteria for resistance to weathering, adhesion, flexibility and UV resistance. Additionally, it is Class A fire rated, providing an added fire retardant benefit.
For more information regarding the application of Mascoat WeatherBloc-IC, please firstname.lastname@example.org.
? An angled plate was retrofitted to each tank to hold the existing insulation
Fuel supplier NuStar Energy was challenged with the task of re-insulating three of its marine fuel tanks in its Portland, Oregon, terminal without creating conditions that would encourage corrosion under insulation (CUI). The NuStar tanks required insulation for both energy retention and personnel protection. The tanks’ conventional insulation had been removed for a periodic routine inspection, representing a significant cost for the company. All three tanks had experienced CUI on the flat plates at the bottom of their welded vertical walls, known as the chime.
To combat the CUI, NuStar's Tank Maintenance Manager Michael Kelley chose to use Mascoat Industrial-DTI (MI-DTI) thermal insulating coating on the lower tank shells, while retrofitting the angled plates to support conventional insulation. A certified Mascoat applicator then applied 60 mils (1.5 mm) of MI-DTI coating in three 20-mil (0.5 mm) coats to the flat plate lower tank shells. By applying the MI-DTI directly to the substrate, it eliminated the physical gap for condensation and moisture to collect and develop corrosion.
This Mascoat insulation system now allows NuStar to easily monitor the condition of each tank’s substrate, particularly at the chime since it is no longer concealed by conventional insulation material and jacketing. Any leaks or problems can now be quickly identified and addressed before becoming a major problem.
? Lower shells of the NuStar marine fuel tanks were coated with 60 mils of Mascoat MI-DTI insulating coating
The application of Mascoat MI-DTI thermal insulation allowed NuStar to meet their energy retention goals and maintain an operating temperature of 120°F (49°C), as required by OSHA for personnel protection. The incidence of CUI was eliminated, prolonging tank operation and improving safety and reliability. The ability to perform visual inspections created additional cost savings. This use of existing materials in combination with MI-DTI demonstrates an innovative and economic solution to eradicate CUI damage at the tanks’ most vulnerable points.
"I thought this was a pretty slick system for addressing the issue of under insulation corrosion damage," said Kelley. "In the past I’ve used a coating system suitable for under-insulation service. But this way you still have a visual on the chime, and you don’t have to strip off insulation to perform an inspection."
? To reduce bow thruster noise, Mascoat Sound Control-dB is applied to Seacor new build projects, including their latest vessel, the Aaron S. McCall.
When offshore vessel provider Seacor Marine, based in Houma, Louisiana, began experiencing sound problems with one of its new build projects, they found a solution with Mascoat Sound Control-dB. The vessel, under construction at Gulf Craft shipyard in Patterson, Louisiana, was experiencing unwanted noise traveling throughout the boat from its bow thrusters. Mascoat Business Development Specialist Andrew Margarit met with representatives of Seacor and Gulf Craft to help find an answer to the problem.
Margarit discovered that bow thrusters in modern vessels put out a great amount of noise. There are two main issues that make the noise hard to control. First, it is extremely difficult to apply conventional types of damping systems to the areas of the vessels that experience the brunt of the sound. The second constraint is the high noise levels and frequency ranges the thrusters put off. Many traditional sound-damping products do not perform well against the extreme nature of this noise.
Maragarit met with Mascoat engineers and discovered that similar issues had been successfully resolved in the past on vessels by applying a sound-damping coating to the affected areas. Mascoat's engineers researched the project and calculated that applying Mascoat Sound Control-dB with a thickness between 80-120 mils (2-3 mm) to the forward machinery spaces and bow thruster area would dampen the noise to an acceptable level.
The vessel was completed at Gulf Craft in 2010 and released for sea trials. Holding crew comfort and safety as its highest priorities, Seacor was pleased to report that the application of Mascoat Sound Control-dB significantly lowered noise levels in the concerned areas, contributing to an all-around quieter vessel and more comfortable crew. Seacor continues to use Mascoat on its new builds. Their latest vessel, the Aaron S. McCall, was recently launched with Mascoat Sound Control-dB, and the reports have been positive.