Sherwin-Williams launches coating to replace insulation and fight corrosion

Sherwin-Williams introduced Heat-Flex AEB, a sprayed thermal barrier designed to replace traditional insulation on hot assets and eliminate corrosion under insulation. The company says the coating can retain heat, speed installation and reduce maintenance, energy use and material waste.

Why it matters: - Corrosion under insulation is costly, hard to detect and dangerous because moisture can collect against hot metal and damage steel assets out of sight. - Heat-Flex AEB is designed to remove the insulation layer that creates those conditions, which could reduce maintenance, extend asset life and cut the environmental burden tied to repairs and replacement. - The product also aims to reduce the shutdown time, labor exposure and material handling tied to conventional insulation work.

What happened: - Sherwin-Williams introduced Heat-Flex AEB, or Advanced Energy Barrier, in Bolton, UK, on June 21, 2026. - The coating is a sprayed thermal insulative system for storage tanks, process vessels and piping. - Neil Wilds, Global Product Director for CUI at Sherwin-Williams Protective & Marine, said removing insulation removes the physical system needed for corrosion under insulation to occur. - The product is positioned as a more sustainable alternative to mineral-based insulation systems. - More information is available in the company's announcement.

The details: - Heat-Flex AEB is designed to retain operating temperatures up to 177°C, or 350°F. - The coating can handle excursions up to 204°C, or 400°F. - Sherwin-Williams says the coating maintains consistent thermal efficiency even as traditional insulation loses performance when moisture enters the system. - The product helps avoid increasing process heat and energy usage to maintain required operating temperatures. - Heat-Flex AEB is a single-component, or 1K, coating. - The coating is applied by spray as a single coat. - Sherwin-Williams says the single applied coat immediately reduces surface temperature and removes burn risk. - Assets can operate at up to 148°C, or 300°F, during application. - The spray method reduces the need for workers to wrap, band and cover bulky insulation around hot equipment. - New assets can be coated in pre-assembly yards instead of in place. - Heat-Flex AEB is typically applied over a primer on prepared steel. - Recommended primers include Heat-Flex 750 and Heat-Flex ACE.

Between the lines: - Sherwin-Williams is not just selling a coating. It is trying to replace an entire insulation stack that includes mineral wool, wiring, pins, banding and metal cladding. - That could matter for facilities trying to lower carbon footprints while also simplifying maintenance and installation. - The product also reflects a broader push to solve corrosion and energy-retention problems with coatings rather than heavier mechanical systems.

What's next: - Sherwin-Williams says the formulation was developed to keep process heat in place without affecting the flow of materials inside assets. - The company expects the product to support cost reductions and carbon-footprint improvements across facility applications. - Wider adoption will likely depend on how operators compare the coating’s performance, installation speed and lifecycle costs against traditional insulation systems.

The bottom line: - Heat-Flex AEB is Sherwin-Williams’ bet that a sprayed coating can do the job of insulation while also eliminating the conditions that cause corrosion under insulation.**