560 Thermal Barrier XF.

560 Thermal Barrier XF is an insulative epoxy coating that reduces surface temperatures and prevents condensation build-up. Designed to reduce heat transfer and prevent corrosion under insulation (CUI).

560 Thermal Barrier XF insulative epoxy coating.

560 Thermal Barrier XF is a solvent free, high build insulative epoxy coating formulated to reduce heat transfer and minimise surface temperatures on metallic surfaces. This low emissivity coating helps to prevent burns from personal contact by reducing surface temperatures from 140°C (284°F) to below 55°C (130°F).

In addition to thermal protection, 560 Thermal Barrier XF effectively prevents condensation build-up, reducing the risk of corrosion under insulation (CUI), moreover, it is designed for use on offline process surfaces between 5-45°C (41-113°F) and can be applied to external pipework, tanks, heat exchangers and other industrial equipment.

Industrial equipment operating at elevated temperatures often presents two critical challenges: excessive surface heat that can pose a safety risk to personnel, and condensation build-up that can lead to corrosion under insulation (CUI). 560 Thermal Barrier XF is specifically engineered to address both issues simultaneously, providing an advanced thermal insulation coating that protects equipment, personnel, and long-term asset integrity.

560 Thermal Barrier XF is a solvent-free, high build insulative epoxy coating designed to significantly reduce heat transfer on metallic surfaces. By lowering surface temperatures and limiting thermal conductivity, the coating helps create safer working environments while also improving energy efficiency across industrial systems.

This advanced coating incorporates low emissivity technology, allowing it to reduce surface temperatures from 140°C (284°F) to below 55°C (130°F). By lowering the external temperature of hot surfaces, it helps prevent accidental burns caused by personal contact with pipes, vessels, or equipment exposed to high operating temperatures.

In addition to providing thermal protection, 560 Thermal Barrier XF effectively prevents condensation from forming on equipment surfaces. Condensation is one of the primary causes of corrosion under insulation (CUI), a costly and often hidden form of corrosion that can compromise infrastructure over time. By preventing moisture build-up, this coating reduces the likelihood of corrosion damage and helps extend the service life of critical equipment.

Advanced Thermal Insulative Protection for Industrial Equipment.

Thermal management is a major concern across industries such as oil and gas, petrochemical processing, chemical manufacturing, power generation and general industrial production. Equipment operating at elevated temperatures can radiate heat into surrounding environments, increasing energy losses and creating hazardous working conditions.

560 Thermal Barrier XF acts as a protective insulating layer that significantly reduces surface heat transfer. Once applied, it creates a durable thermal barrier that limits heat loss from hot equipment while lowering the surface temperature that personnel may come into contact with.

The coating’s high-build formulation allows it to be applied in multiple layers, enabling operators to achieve the desired insulation thickness depending on the operating temperature and environmental conditions. This flexibility makes it suitable for a wide variety of applications where traditional insulation materials may be difficult to install or maintain.

Because the product is 100% solids and solvent free, it provides a durable and environmentally responsible solution that can be applied safely during maintenance operations.

Preventing Corrosion Under Insulation (CUI) and Condensation using 560 Thermal Barrier XF.

Condensation forms when warm air comes into contact with cooler equipment surfaces, creating moisture accumulation that can lead to corrosion over time. In many industrial environments, this phenomenon occurs beneath insulation systems, making it difficult to detect until significant damage has already occurred.

560 Thermal Barrier XF helps eliminate this risk by maintaining controlled surface temperatures that prevent condensation from forming. By reducing moisture accumulation on external surfaces, the coating plays a key role in preventing corrosion under insulation, one of the most expensive and difficult maintenance issues in industrial facilities.

This makes the product particularly valuable for equipment exposed to varying temperatures, humidity fluctuations or outdoor environments where condensation is common.

What are the key features and benefits of 560 Thermal Barrier XF?

560 Thermal Barrier XF offers a combination of thermal insulation, safety improvement and corrosion prevention benefits:

Reduces surface temperatures to protect personnel from burns.
Prevents condensation build-up, reducing moisture related damage.
Helps prevent corrosion under insulation (CUI) for long-term asset protection.
Minimises heat transfer, improving energy efficiency and process stability.
High build epoxy coating that allows for flexible insulation thickness.
Solvent-free formulation for safe and environmentally responsible application.
Excellent durability and adhesion on metallic surfaces.

These features make the coating an effective alternative or supplement to traditional insulation systems in many industrial maintenance programs.

What are the typical Industrial Applications for Thermal Barrier XF?

Due to its versatility and thermal insulation properties, 560 Thermal Barrier XF can be applied across a wide range of industrial equipment and infrastructure. It is particularly useful in areas where heat exposure, condensation and corrosion are ongoing concerns.

Typical applications include:
External pipe surfaces.
Tank externals.
Process vessels.
Separators.
Fan housings.
Mixing vessels.
Heat exchangers.
Ovens and high temperature equipment.

By applying the coating to exposed surfaces, maintenance teams can create a protective thermal barrier that improves safety and operational efficiency.

Insulative epoxy coating performance and mechanical properties.

560 Thermal Barrier XF has been engineered to deliver reliable performance in demanding industrial environments.

The coating demonstrates excellent resistance to mechanical wear and environmental exposure, including:
Abrasion resistance: Tested using Taber CS17 wheels with a 1 kg load, showing minimal material loss after extended cycles.
Corrosion resistance: Tested to ASTM B117, achieving a minimum of 5000 hours in salt spray testing.
Flexural strength: Measured at 522 kg/cm² (7400 psi), providing strong structural durability.
Thermal conductivity: Low thermal conductivity values help maintain effective insulation performance.
Hardness: Shore D hardness of 51 provides a balance between durability and flexibility.
These properties ensure that the insulative epoxy coating remains stable under operating conditions while continuing to deliver thermal protection and corrosion resistance.

What is the surface preparation and application 560 XF?

Proper surface preparation is essential to ensure optimal adhesion and long-term performance.
Metallic substrates should be thoroughly cleaned to remove all oil, grease, and surface contaminants before application. Surfaces may then be prepared using abrasive blasting, mechanical abrasion or hydro-blasting depending on site conditions and project requirements.

Typical preparation steps include:

1. Remove oil and grease using a suitable cleaning solvent.
2. Abrasive blast surfaces to ISO 8501 SA2.5 or mechanically abrade to ISO ST3 standards.
3. Clean the prepared surface again to remove debris or contaminants.
4. Apply the coating before oxidation or surface contamination occurs.

Following proper preparation ensures maximum adhesion and performance of the coating system.

Mixing and Application Process.

560 Thermal Barrier XF is supplied as a two-component system consisting of a base and activator.
Before application:
Ensure the base component is between 15–25°C.
Confirm the ambient and surface temperature is above 10°C.

The activator is poured into the base container and mixed using a slow-speed electric paddle mixer until a uniform consistency is achieved. Once mixed, the material should typically be used within 30 minutes at 20°C.
The coating can be applied using a brush, roller, or squeegee. Each layer is typically applied at a wet film thickness of 1–2 mm, with additional coats added until the required insulation thickness is achieved.

Packaging and Availability.

560 Thermal Barrier XF is available in multiple pack sizes to accommodate both small maintenance jobs and large industrial projects:

• 1 litre (0.25 US gallon)
• 4 litres (1.1 US gallons)
• 13 litres (3.5 US gallons)

This range of packaging options allows maintenance teams to efficiently manage material requirements for projects of varying scale.

560 Thermal Barrier XF: Protect Equipment, Improve Safety and Reduce Energy Loss.

In industrial operations where high temperatures are unavoidable, protecting equipment and personnel is essential. 560 Thermal Barrier XF provides a reliable solution that reduces heat transfer, prevents condensation and prevents corrosion under insulation CUI.

By combining thermal insulation, corrosion protection and personnel safety into a single high-performance coating, additionally it helps facilities reduce maintenance costs, extend equipment life and maintain safe operating conditions.

For industries seeking a durable and efficient way to manage heat and moisture challenges, 560 Thermal Barrier XF insulative epoxy coating delivers long-lasting protection where it matters most.

560 Thermal Barrier XF insulative epoxy coating. MSDS, TDS, Brochure, Application Instructions .PDF downloads.

560 Thermal Barrier XF insulative epoxy coatings Product Data Sheet

560 Thermal Barrier XF Activator SAFETY DATA SHEET

560 Thermal Barrier XF Base SAFETY DATA SHEET

Resimac 560 and 561 Thermal Barrier Thickness to heat reduction correlation chart

560 Thermal Barrier XF insulative epoxy coating Technical Data Sheet. Click here.

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