Overview
MEGEL AC-300 is the industrial polyurethane specification within the MEGEL aerogel coating slurry range — a pre-dispersed aerogel coating with polyurethane (PU) binder, formulated for industrial airless spray application on process equipment, structural steel surfaces, and large-area industrial substrates. The slurry is 45–55% solids by weight — the highest solids content in the AC range — applied at 1.5–4 mm wet film thickness, drying to a 1.0–2.5 mm dry film with thermal conductivity 0.050–0.060 W/(m·K) at 25°C.
AC-300 trades a small thermal-conductivity penalty (0.050 vs 0.045 W/(m·K) for AC-100/AC-200) for three industrial-application advantages:
- Airless spray throughput. The higher solids content and PU binder rheology allow industrial-scale airless spray application at 800–1,000 m² per shift per spray gun, versus 200–400 m² for the lower-solids acrylic and silicone formulations. Required for cost-effective coating of storage tank exteriors, pipeline networks, and large structural-steel installations.
- Single-coat thick-film build. PU film building allows 2.5 mm dry film in a single application pass, versus 0.5–1.0 mm per pass for AC-100/AC-200. Reduces project labour cost on the dominant insulation-coating cost driver.
- Mechanical durability. PU binder retains film integrity under industrial mechanical-impact exposure — accidental tool contact, maintenance traffic, weather-rated outdoor service — where acrylic and silicone films may chip or abrade. Critical for industrial-plant service environments.
The PU binder is rated to 120°C continuous service — below silicone-bonded AC-200's 200°C limit — so AC-300 is positioned for ambient-temperature and moderately elevated industrial substrate service, not for high-temperature process equipment exterior surfaces.
Technical Specifications
| Property | Unit | Value |
|---|---|---|
| Binder type | — | Polyurethane (aliphatic) |
| Solids content | % w/w | 45–55 |
| Aerogel content (in solids) | % | 60–70 |
| Wet film density | kg/m³ | 420–460 |
| Dry film density | kg/m³ | 250–300 |
| Recommended wet film thickness | mm | 1.5–4.0 |
| Resulting dry film thickness | mm | 1.0–2.5 |
| Dry film thermal conductivity (25°C) | W/(m·K) | 0.050–0.060 |
| Service temperature range | °C | −30 to 120 continuous |
| Single-coat thick-film capability | mm dry film | up to 2.5 |
| Application throughput (per gun, 8h shift) | m² | 800–1,000 |
| Mechanical durability (impact resistance) | — | High |
| Standard packaging | — | 25 kg pail, 200 kg drum, 1000 kg IBC |
Applications
Storage Tank Exterior Insulation (Large-Area Industrial)
Above-ground bulk storage tanks at refineries, chemical plants, and bulk terminals — typical tank surface area 1,000–10,000 m² — use AC-300 for cost-effective insulation coating application via industrial airless spray. A 2 mm dry film delivers thermal-insulating performance equivalent to 30–40 mm of conventional polyurethane foam insulation, applied in a single-day shift on a typical 5,000 m² tank versus the 5–7 day install time for foam-and-jacket systems.
Pipeline Exterior Insulation
Steel pipeline transmission networks — gas pipelines, hydrocarbon transmission, industrial process piping — use AC-300 spray-applied to pre-cleaned pipeline exteriors at 1.5–2 mm dry film. The application equipment (airless spray rigs mounted on pipeline-following carts) delivers 100–200 m of pipeline coating per day at standard line speeds, replacing conventional weld-on jacket systems that require fabricated half-shells and specialist installation labour. CUI (corrosion-under-insulation) risk is reduced versus jacketed systems because the coating directly adheres to the pipeline surface without creating an interfacial water-residence layer.
Structural Steel Thermal Insulation
Industrial-building structural steel — process plant framing, refinery pipe rack columns, marine vessel superstructure — uses AC-300 to reduce thermal-bridging losses from interior heated spaces to exterior atmospheric conditions. The PU binder's mechanical durability and adhesion to grit-blasted carbon steel allow direct application without specialist preparation, and the coating is compatible with subsequent finish-coat application (epoxy, polyurethane, fluoropolymer) for cosmetic and corrosion-protection requirements.
Large-Area Building Envelope Retrofit
Commercial and industrial building envelope retrofit projects — warehouse exteriors, factory walls, distribution centre cladding — use AC-300 for spray-applied thermal upgrade. The single-coat thick-film capability and airless-spray throughput allow 5,000–10,000 m² envelope upgrades within a 7–10 day site-presence window, fitting within scheduled annual maintenance shutdowns. Combined with optional reflective topcoat (cool-roof topcoat or aluminium-pigmented finish), the system delivers measurable energy savings on solar-driven cooling load.
Packaging & Storage
AC-300 is supplied in three standard package formats, scaled for industrial airless-spray application:
- 25 kg sealed pail — pilot-project use, sample application
- 200 kg sealed drum — standard industrial application contractor
- 1000 kg IBC (intermediate bulk container) — large-area projects, dedicated pumping system supply
MOQ is 1 drum (200 kg); minimum order with IBC format is 2 IBC (2,000 kg). 40' container loads 24–28 drums or 20 IBCs depending on package mix. FOB Shanghai standard.
Store sealed at 5–35°C. The PU binder is moisture-cure — sealed packaging is critical to prevent premature surface skinning that would damage subsequent application. If part-drum surface skin forms, mechanical removal of the skin is possible and the residual product remains usable. Shelf life is 12 months in original sealed packaging.
Standard P100 respirator and chemical-resistant gloves for spray application; PU mist contains isocyanate precursor that requires NIOSH-rated PPE per US OSHA and EU REACH standards. Cleanup of equipment with PU-compatible solvents (acetone, MEK) before drying; cured film cleanup requires mechanical removal.
Related Products
- MEGEL® Silica Aerogel — parent hub
- MEGEL AC-100 — indoor acrylic variant
- MEGEL AC-200 — outdoor silicone variant, 200°C ceiling
- MEGEL AP-100 — raw aerogel powder for custom PU formulation
- MEGEL MG-650-IP — aerogel felt alternative for thicker section pipe insulation
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