Thermoshield acknowledges our valued clients’ case studies. The following provide compelling evidence that Thermoshield provides the multitude of solutions our clients have depended upon.

It produces a large range of products which are stored in the company’s warehouses. Many of the products are temperature sensitive and must be stored at temperatures of less than 25°C. In order to satisfy Good Manufacturing Practice (GMP) requirements, the temperatures in the warehouses are continuously monitored in three zones: under the roof, mid warehouse, and near ground level.

The Problem

High summer temperatures resulted in the roof heating up, in turn heating up the air space underneath. This resulted in temperatures in the upper levels of the warehouses rising to 40°C in January 1998. The effect of this on the operation were:

  1. Temperature sensitive stock had to be re-allocated to cooler parts of the warehouse. This involved unnecessary movement of product and updating of warehouse records.
  2. Temperature activated extraction fans were installed in the roof to try and keep temperatures down.
  3. There was a risk of product spoilage if the temperature rose above 25°C.
  4. Heat transfer through the warehouse roof meant the air conditioning plant in the manufacturing and office areas contained within and adjacent to the warehouse consumed more electricity in order to keep these areas cool.

The Solution

In late April 1999 Pacific Pharmaceuticals decided to apply a Thermoshield Radiant Heat Barrier Coating to the warehouse which stores most of the heat sensitive product. The objective was to reduce the heat transfer through the roof, and lower the under-roof temperatures on hot summer days. The warehouse roof area was approximately 1,000 square metres. Thermoshield NZ Ltd was contracted to supply and apply the Thermoshield coating.

 

Thermoshield is a water-based emulsion of acrylic resins and ceramic beads. The ceramic beads give the product its heat barrier properties so that a 0.5 mm coating acts like a mirror to the heat of the sun. Additionally, Thermoshield will extend the life of a metal roof by converting rust into iron phosphate and preventing further corrosion.

 

After water-blasting the roof, the Thermoshield Heat Barrier Coating was applied in two coats with an airless spray gun to give a final coating thickness of 0.5 mm.

The Results

The benefits of coating the warehouse roof with Thermoshield have been dramatic. The extraction fans which would normally switch on when the underroof temperature reached 25°C have not operated at all since the application.There has been no need to move stock around the warehouse and disrupt normal operations.

Analysis of temperature records from April 1998 to April 2000 of the coated and uncoated warehouses shows the affect of the Thermoshield coating has been to reduce the peak roof temperature by 10.9°C. Prior to the Thermoshield application ( January 1999 ), monthly peak roof temperatures rose to 37.8°C. ie 8.4°C above the peak control temperature in the adjacent warehouse. After application ( January 2000 ) the monthly peak roof temperature was only 29.6°C. This was 2.5°C below the control temperature in the adjacent warehouse. Monthly average roof temperatures have been reduced by between 0.3°C and 15°C.

The benefits of the Thermoshield coating are greatest from November to February, the hottest time of the year. On the strength of the results from the first warehouse, Pacific Pharmaceuticals contacted Thermoshield to coat a second warehouse of similar size.

This research report has been commissioned by the Victorian Government Department of Sustainability and Environment (DSE) to compare the performance of two “6 Star” equivalent buildings which are identical in every way except for a cool roof coating on one. In this study, every variable has been either eliminated or fixed between the two study buildings, and this is the most accurate way of comparing the performance of the Cool Roof Paint (CRP) product directly.

The results of this study once again prove the effectiveness of CRP’s in reflecting heat and lowering both external roof surface temperatures as well as indoor temperatures. Most interestingly, this report also demonstrates a winter benefit to internal temperatures from the use of this particular product (Thermoshield).

This benefit is most clearly seen as warmer internal temperatures at the coldest part of the day ( usually at night ), which suggests the product is reducing heat transfer through the roof. Such a result significantly increases the potential of these products for certain building types that require extra heat during the winter time.

Methodology

This study is based on the field testing of two ½ scale buildings. These buildings have been constructed at the University of Melbourne’s Burnley campus in Melbourne, Australia.

The two buildings have identical properties with the exception of the roof surface coating. Building H has the Thermoshield cool roof product applied to the concrete tile roof and Building J has an untreated charcoal coloured concrete tile roof. Both have the same orientation, the same design, the same materials, and were constructed to a BCA 6 Star equivalent standard.

Design

Buildings H and J are 2000 x 2000 x 2250mm above ground, a single pitch roof, one window 600 x 600mm facing North and one door 600 x 1850mm facing South.

Field Results

The results of the onsite measurements conducted between December 2011 and May 2012 have been separated into a summer ( February 10 – 28 ) and winter ( May 20 – 29 ) set for ease of analysis. These sets are the most suitable for analysis for a number of reasons ( e.g. the periods are close to the warmest and coldest periods, as well as covering periods of dramatic outdoor temperature and radiation differences ) and allow a closer look at the performance of the tested product.

Test Building Calibration

 

The above graph uses the data collected from logtag mobile temperature recorders, which were logging both before and after the application of Thermoshield to building H.

Research commissioned by City of Melbourne and conducted by University of Melbourne used the products listed below to investigate the benefits of cool roofs.

The original study found a weakness in cool roofs, which is increased heating energy load during winter. The study showed Thermoshield “has an additional benefit typically unseen in other studies with other products. This benefit is the ability of the product to improve the retention of heat within the building during colder weather. It is noted that the marketing for Thermoshield claims the heat retention benefit of their product and these results support these claims”

Upon completion of the study, Thermoshield was the product chosen by Melbourne City Council to coat the historic Art Play building on the banks of the Yarra River. Art Play staff have said that they are able to use the building for longer periods of time in warmer months! Between 10-15% longer! (building without air conditioning)

Melbourne University senior lecturer Dominique Hes says white roofs are a low-cost solution to making buildings more sustainable.

Photo: Jason South The Age 25/01/2012 For the detailed findings of this research visit the 1200 Buildings webpage on the City of Melbourne website.