PROJECTS
INDUSTRIAL PROJECTS
Salt Plant, previously used mechanical Insulation. We removed all insulation, cleaned and ground areas to remove built up salt. Mechanical insulation does not work well in this environment because of constant wet and salt. Mechanical insulation does not have the characteristics like TC Ceramics to reduce energy costs. Also TC Ceramics still insulates as well as prevents corrosion.
Applied 60/1000 TC Ceramic to metal tank and pipes. TC Ceramic at this point will not allow the salt to break down the metal and corrode. Tank at this point is approximately 15 years old with no degradation. Customer says they feel over 50%+ savings-the tank operates at approximately 250°F. At this thickness anything in the plant coated with TC Ceramic is "Safe Touch" Safe for all human contact.
TC Ceramic Certification Salt spray-ASTM B117-19 Product test passed
Just shows you how good it looks-TC Ceramic reflects 98% Energy-brightens up every room. Everything coated, no manufacturing parts for fittings-easy to apply and TC Ceramic is a longevity coating. (Has lasted decades around the world)
ARENA'S
Applied TC Ceramic to the inside of arena and curling rink. The hockey arena was having problems with condensation forming on the ceiling and dripping on the ice forming bumps. Applied TC Ceramic to ceiling and all condensation stopped.
The curling rink was having similar problems as well as ice was softer then they cared for. Applying TC Ceramic to the inside walls the ice became crisper and the Energy costs reduced by 45%.
All cost savings tests were performed 3rd party-we were just given the results.
TC Ceramic is a highly reflective coating that performs exceptionally well in solar gain environments. The high reflectivity and emissivity of the TC Ceramic resists radiant energy, virtually eliminating energy transferred to the structure and dramatically reducing temperature fluctuations. In solar reflective environments, TC Ceramic's high reflectivity repels 98% of solar gain, allowing less than 2% of the sun’s heat to touch your roof or other external surfaces.
Coating the outside of dust collection system
Coating of industrial dust collection systems in manufacturing plants. These systems, are difficult to insulate with conventional insulation and difficult to have the conventional insulation to cover the large bag house and all of the ducting leading to the bag house. The conventional insulation does not cover everything, leaving cold or hot spots, and typically gets wet, thus ceasing to insulate properly allowing condensation inside the system which then causes the forming of material sticking to the sides of the system which now reduces the efficiency of the system and corrosive on the substrate. (Corrosion under Insulation, CUI) The accumulation of moisture and material on the inside then requires the system to be shut down and cleaned. This is very expensive, time consuming and in some cases, stops or slows down production of the plant. Failure to keep the inside of the system clean from buildup, causes increased Energy costs as the fan becomes more inefficient, the fire risk goes up and slowing of production can take place. Coating the dust collection system with 60 mils/1.2mm of TC Ceramic, insulates everything, is impervious to moisture, does not allow corrosion to form, no CUI and minimizes material buildup inside the system. This reduces the requirement to clean out the interior of the system and is about 40% cheaper in the original costs vs the cost of conventional insulation. Return on TC Ceramic costs are generally recovered in the first year of operating. The savings of not having to clean the dust collection system ever or even occasionally are significant in labor costs, but even more in increased production.
Hot water and steam pipes
The next three pictures show hot water/steam pipelines, which move hot water/steam to buildings for heating and hot water in the buildings.
These hot water/steam pipelines are coated with approximately 100 mils/2.5mm of TC Ceramic. For the most part, these hot water pipelines are typically above ground, insulated with asbestos and the insulation is falling off.
Other than coating many such hot water pipe lines and the fact the TC Ceramic Coating seems to be satisfactory, we have no additional information.
Steam systems – 250F to 450F
This picture and the next picture are a 350F steam pipe T section, which is difficult to insulated, is very expensive to insulate and historically, have severe corrosion under insulation (CUI) problems. Also, many of these sections are in manholes which might flood. When a manhole floods, all of the conventional insulation on the steam pipe or fittings, is ruined, water saturated and has to be replaced. (Note: generally, none of the flood damaged conventional insulation is ever replaced.) Very expensive to replace. With coating the steam pipe fitting with approximately 100 to 120 mils of TC Ceramic, the steam pipe is insulated, is impervious to water and requires no replacement due to flooding. Also, upon flooding, in a conventional insulated manhole, the water can be 180F to 200F. The water in a TC coated insulated manhole is about 100F and the TC Ceramic insulation has no need to be replaced because of the flooding. Additional benefits are the increase in personnel protection for employees working in the manholes, reduction in damage to pumps used in pumping the water out of the flooded manhole. You will notice the bare hand touching the surface with just 100 to 120 mils thickness of insulation.
Hot storage tanks-Refinery
The next five pictures show a variety of storage tanks coated with TC Ceramic in both Black and White. Black is generally used for above ground hot systems, to get the additional benefit of the solar heat. White is generally used for above ground cool or cold systems to get the benefit of solar heat reflection to help keep the system cool or cold. These systems are typically coated with 40 mils/1.0mm to 60 mils/1.5mm of TC Ceramic.
TC Ceramic out performs everything else regarding Frac tank water storage
TC Ceramic is used on the frac water storage tanks, with great success. A special system was designed by Capstone which out performs any other insulation for these tanks. It should be noted that wind chill has no impact on TC Ceramic’s performance in minus F or C environments. TC Ceramic coated frac tanks survived a propane tank explosion with TC still adhered to the tank.
Street Rod, Hot Rod cars
The coating of the inside of rebuilt hotrods or street rods with 30/1000 of TC Ceramic. The reduction in heat and noise was significant. A test was done with a 1937 Chevy, metal body construction for heat reduction and decibel reduction.
Before coating, the fire wall temperature was 110°F and the decibel level inside the car was 108 decibels. The whole inside was coated with 30 mils of TC Ceramic. After coating the fire wall, the temperature was 95°F and decibels were 96. After the TC Ceramic dried the temperature was 70°F inside the car. (37.5% decrease) the firewall temperature dropped to 95°F (13.6% decrease), and a decibel reading of 96 (11.11% decrease)
Very good results for the thickness of a business card!!
A Google earth satellite picture of a roof coated with 20 mils/0.5mm of TC Ceramic white. The roof is a concrete roof. Before the roof was coated with TC Ceramic, the air conditioning electrical panel was measured for two hours, from 1300 to 1500 hours. Two days after the roof was coated with TC Ceramic white, the air conditioning system electrical panel was again between 1300 and 1500 hours. The difference was a reduction of 63% of electricity used to power the air conditioning system. In 2004, all power for this building was provided by a large generator which was fueled by a separate fuel tank. Before the roof being coated with TC Ceramic, the fuel tank would last two days. After coating the roof with TC Ceramic, the fuel tank lasted three days. A 50% reduction in fuel consumption.
High angle picture of the concrete building roof.
Note:
it is important to also coat the insides for the parapets, otherwise they will transmit significant energy into the building, reducing the benefits of coating the roof.
Notice the air conditioning ducting on the roof of the building is coated. Before coating the ducting, the ducting, insulated with conventional insulation, was so hot because of the high solar heat, 180°F/83°C, the air conditioning system could barely keep the building comfortable. Also note all of the hand rails for stair and ladders are also coated for personnel protection. Before coating the rails, you had to be wearing gloves to keep from burning your hands on the hand rails.
Roof top water tanks coated with 40 mils/1.0mm thickness of TC Ceramic White. Before coating the tanks with TC Ceramic, the water coming out of the cold water tap inside the building, was 130°F/55°C. After coating the water tanks, the water coming out of the cold water tap inside the building was 80°F/27°C. Before coating the cold water was too hot to drink and too hot to use to take a shower.
Budweiser cold storage facility in Kauai, Hawaii. They coated only the cold storage sections of the building. Sections coated were the south wall, west wall and the roof. After one year, they reported an energy saving of 20% to 25%. (Note: Estimates based upon comparing prior years energy bills with after coating energy bills.) The return on capital, or cost of the coating, was approximately 18 months. Additional note: It was also determined about two years later, the severe condensation problem inside their walls, with water condensing on inside of the sheet rock interior wall because of the coldness of the wall (50°F) and air flow convention on the inside of the wall, had been eliminated. Because the space between the outside metal wall and inside sheet rock wall could not be sealed, there was constant moist air convection going up inside the wall which condensed on the inside of the sheet rock which was the cold storage wall at 50°F. The water would then run down the inside of the wall on to the floor of the cold storage warehouse making the warehouse floor slippery and dangerous. The coating of the outside metal wall with TC Ceramic all but stopped the between wall convection by stabilizing the temperate inside the wall. The outside wall no longer heated up, which had caused increased heat between the walls and the increasing rising of the moist hot air. A second Budweiser cold storage warehouse was also coated on the Island of Hawaii in Hilo with the same results.
48 foot refrigerated trailer roof
Picture coating the roof of 48 foot refrigerated trailers. Coating the roof with 15 mils/0.375mm of TC Ceramic White. Testing showed the reduction of fuel consumption between 10% and 26%. 10% fuel savings was older trailers (4 to 8 years old). The under roof and side wall insulation had been greatly reduced. The 26% fuel savings was in newer trailers (new to 3 years old) where the roof and side wall insulation was still intact. The recovery of the costs range between 6 to 12 months depending upon the age of the trailer, how the trailer was used and the price of diesel fuel. These results were only for local delivery trailers. Testing on long haul trailers showed a 1% to 2% reduction in fuel use. The difference was because the long haul trailers have wind flow across the top of the trailer. The wind flow has a significant cooling effect, keeping roof of the trailer cooler. Not subject to high solar heat of local delivery trailers.
RV ROOFS
Coating the roofs of RV’s is very effective for reducing solar heat through the roof. Reduction in use of air conditioning units has run from 50% to 75% for RV’s of 35 to 40 feet long.
Inside RV's
Coating the inside of RV’s, when being renovated, is a good way to insulate the inside of the RV, including insulate the ribs of the shell. Typically, the ribs are not insulated, thus there is about a 25% energy loss through the uninsulated ribs. With the ribs coated with 30 mils/0.75mm to 40 mils/1.0mm of TC Ceramic, the energy loss or gain through the ribs is almost all eliminated. Recovery of the cost, not counting the improvement in comfort and living space, is about 18 months. Coating the roof with 15 mils/0.375mm is also recommended to block the solar heat from heating the outside of the coach. With the roof and the inside coated with TC Ceramic, there is about an 80% reduction in energy consumption inside the coach.
Building before
Before – Coating glass exterior walls with TC Ceramic Travatan color.
These are pictures of a glass walled building in Las Vegas, before coating and after coating. This building was built in the late 1970’s and it had never been able to stay cool from about June 1 through October 1, every year. The air conditioning system would turn on about 0500 hours each morning and would run, non stop, up to about midnight. By 1500 hours each day, the building would be above 80°F and climbing. The air conditioning system would not cycle during this period as it would run 100% and not be able to keep up with the demand load.
After coating the outside surface (approximately 60,000 sq. ft.) of the black wall glass and the concrete superstructure, with 40 mils/1.0mm of TC Ceramic, in the Travatan color (desert sand color), the AC system cycles throughout the day and the building is consistently comfortable. The estimated reduction in energy use was 50%. Cost recovery estimate was 12 to 18 months. (Estimates by the Command Engineer.)
After – Coating glass exterior walls with TC Ceramic Travatan color.
50% reduction air conditioning costs during the summer.
Additional reduction in HVAC costs during the rest of the year.
Significant improvement in the look of the building.
Contact Us
TC Ceramic has many applications for use across the commercial and industrial sector.
If you have any questions you would like answered or are thinking of purchasing a TC Ceramic product then please get in contact with us.
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(306) 750-7762
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