High temperature coating protects steel surfaces from overheating
When a substrate is subject to heat and rapid temperature fluctuations, it can lead to surface breakage and corrosion. Electrical and engine components, chimneys and ovens, pipework and chemical plants, all these are exposed to possibly damaging temperatures and conditions. A high temperature coating (or thermal management coating) works to protect the substrate from variations and extremes of temperature without losing functionality. As well as protecting from heat, these coatings:
- Allow for higher operating temperatures while limiting thermal exposure; increasing efficiency
- Protect from corrosion under insulation (CUI): provide an extra layer of protection between the hot surface and insulation
- Resist temperatures up to 1000°C: Different types of high temperature coating provide resistance to temperatures from -196°C to 1000°C
- Abrasion resistant: Suitable for rough environments like industrial and offshore
- Reduce thermal fatigue: Heat resistant coating improves performance of machinery and extend component life
In this article we look at the different categories of high temperature coating, how to choose the right one for your project, and where to find products and contractors in Pakistan.
Towards the right choice – 3 factors to consider when choosing a heat resistant coating
As with any coating application, understanding the needs of your substrate and the application process is crucial for making the right coating choice. As well as knowing the substrate type, you need to know its environment, its use, the coating time parameters, and the likely ways it will fail. Here are some factors you need to consider before you can choose a high temperature coating:
Is the substrate insulated?
If you are choosing a high temperature coating for metal to combat CUI, that coating needs to be specially formulated for the purpose. It needs corrosion resistance, but it also needs to be able to be applied to hot substrates and deal with boiling water exposure.
For example, PPG HI-TEMP 1027 is designed to prevent CUI and can be applied to hot substrates
2. Maximum operating temperature
What is the maximum temperature of the substrate that you wish to protect?
One of the most common reasons for failure is expecting high temperature coatings to perform outside of the temperature range they were manufactured to tolerate. Each coating type has a specific temperature range, and outside it the functionality and efficacy fails. Make sure not to understate the maximum temperature.
For example, International Intertherm 50 is recommended for temperatures up to 540°C
3. Application temperature
What will the substrate temperature be during application?
There are high temperature coatings formulated for hot (up to 300oC) and ambient temperature application. A hot application may be required to avoid needing to shut down operations, spot coating problem areas, and generally not disrupting a facility.
For example, Jotun Epoxy HR can be applied on substrates up to 150oC
The different types of heat resistant coating
It is important to note that while high temperature coating does provide some protection from flames, it is not a fire resistant coating. Essentially, heat resistant coatings can be divided into four types:
1. Sprayed metal coatings from -50°C to +550°C
Of all the sprayed metal coatings, thermal spray aluminium (TSA) is the most common as it offers excellent corrosion protection in high temperatures. TSA and other sprayed metal coatings are usually applied on steel to provide protection from corrosion and high temperatures.
Thermal sprayed aluminium is particularly used as high temperature coatings for steel for CUI prevention in onshore and offshore platforms and processing plants.
2. Epoxy and silicone based liquid coatings up to +550°C
The liquid high temperature coatings are usually either epoxy or silicone based. The general rule is that the more silicone the coating contains the higher temperatures it can resist. These coatings exist as single and two component systems and are formulated on water or solvent base.
These coatings can be applied at new constructions, on-site or as maintenance coatings. The liquid coatings have the advantage of being able to be applied even on heated surfaces, meaning fast return to service time.
3. High temperature powder coatings from +200°C to +600°C
As well as being corrosion resistant, high temperature powder coatings have been developed for heat resistance to medium to high temperatures. The powders are usually epoxy and silicone-based (like the liquid paints), and silicone-based powders perform better at higher heats.
Powders are becoming more and more popular as heat resistant coating for metal and they can be applied instead of liquid heat resistant coating on ferrous metals (steel) offsite. The reasons why powders may be chosen over liquids include wide colour and finish range as well as zero VOC content.
4. High heat ceramic coatings from -196°C to +1000°C
The heat resistance properties of ceramic coating are well known, and some of the highest heat coatings available are ceramics. Ceramic coatings are known among car enthusiasts for manifold and engine component protection, but they also have a reputation as industrial heavy duty and offshore high temperature coating.
The high temperature ceramic coatings are widely used in industrial and offshore applications due to the fact that next to heat resistant they are also resistant to corrosion and a wide range of chemicals.
High temperature coating Pakistan – A product overview
Heat resistant coatings are used across a wide range of industries, as well as by homeowners and barbecue enthusiasts. As such, a wide range of products and services are available across the country, no matter your project. Below is a table outlining just a few of the products and their costs, as an indication. High temperature coatings should be applied by a trained professional. If you would like more information about heat resistant coatings, or would like to connect with one of our partners to coat your project, contact us! Our experts are here to help, just use the “Request a quote” button below the article and take advantage of our 100% free quote service.
|high temperature Coating Product||Product Description||Applications||Theoretical Coverage|
|PPG HI-TEMP 1027||One component, silicone-based ceramic coating for carbon steel and stainless steel||CUI prevention in chemical/petrochemical, power, and offshore market segments up to 650°C||5.8m2 per litre for 125 microns|
|International Intertherm 50||Single components, silicone-based high temperature coatings for steel||Corrosion protection in fire stacks, chimneys, exhausts, vents and pipework up to 540°C||18m2 per litre at 25 microns|
|Jotun Solvalitt Midtherm||Single component silicone acrylic heat resistant coating for metal; steel and aluminium||Corrosion protection for insulated and non insulated surfaces up to 260°C||11.3m2 per litre|
|Rust-Oleum 4200 Heat Resistant Topcoat||Silicone-based topcoat with an aluminium finish for bare steel or primed surfaces||Heat resistance up to 425oC||16m2 per litre|
Heat resistant paint manufacturers in Pakistan
In case you are looking for known heat resistant coating manufacturers present in Pakistan, we have compiled a list containing a few of them. For more information on high temperature coating and contact details feel free to contact us!
|Heat resistant coating manufacturer||Address (Pakistan)|
|Jotun Pakistan (Pvt.) Ltd.||2 KM Defence Road, off 9 Km Raiwind Road,، Defence Road, Lahore, Punjab 54770|
|AkzoNobel Pakistan||346, Ferozepur Road, P O Box 273, Lahore 54600|
|Hempel Marine and Commercial Services (Pvt) Ltd.||9C First Commercial Lane Zamzama,, Phase 5, D.H.A., Karachi 75600|
|Berger Paints Pakistan||Street 36, Quaid-e-Azam Industrial Estate Quaid e Azam Industrial Estate, Lahore, Punjab|
|Kansai Paint||11 – CCA, Phase V, Defense Housing Authority, Lahore|