Workers in the Rio Tinto Nammuldi Mine lean-to workshop building faced major challenges due to excessive temperatures. The tremendous heat accumulation inside the building not only hampered employee comfort but also affected operating efficiency. CharCoat Passive Fire Protection was called upon to develop a unique thermal insulation solution to address this issue.
What’s the solution?
CharCoat CTI is a cutting-edge ceramic-based insulation coating that provides exceptional thermal performance while also protecting industrial infrastructure over time.
The Challenge: Excessive Heat in the Workshop Building
Mining operations frequently encounter difficult climatic conditions, with high outside temperatures resulting in substantial heat transfer to metal buildings. At Nammuldi Mine, the roof of the lean-to workshop building absorbed too much heat, making working conditions uncomfortable for personnel.
The key obstacles included:
- Steel Surface Overheating: The metal roof absorbed and radiated heat, resulting in high inside temperatures.
- Employee Discomfort: High temperatures made working conditions unpleasant and dangerous.
- Energy Inefficiency: Without proper insulation, cooling systems (if available) had to work harder, leading to increased energy consumption.
The goal: Find an efficient, durable, and cost-effective way to reduce heat absorption and improve working conditions.
The Solution: CharCoat CTI – A High-Performance Thermal Insulation Coating
Bennco Group addressed the issue by applying 1mm of CharCoat CTI ( Ceramic Thermal Insulation Coating) to the top of the lean-to workplace. Unlike standard insulation materials, CharCoat CTI is a high-solid, thin-film ceramic coating with superior thermal insulation and reflective qualities.
Why CharCoat CTI?
✅ Thin-Film Insulation: Provides insulation without bulking up the structure.
✅ Reflective Properties: Reduces heat absorption, keeping surfaces much cooler.
✅ Durability: Provides long-term protection in severe industrial conditions.
✅ Anti-Corrosion Protection: Prevents rusting, extending the lifespan of steel.
✅ Non-Flammable: Meets safety standards for industrial and mining facilities.
The Results: Temperature Reduction & Improved Comfort
The outcomes of using CharCoat CTI were immediate and significant:
????Morning Temperature Comparison:
- Uncoated Area: 33°C * Coated Area: 25°C
- Temperature Reduction: 8°C lower in the morning.
- Peak Daytime Temperature Comparison:
- Uncoated Area: High heat buildup
- Coated Area: 20°C lower than the uncoated metal surface.
????Employee satisfaction: Workers in the lean-to shed reported significant increases in comfort, which led to increased productivity.
????Energy Savings: Reduced heat transmission led to lower cooling costs and more sustainable operations.
Client Feedback
“The temperature difference was immediately noticeable. The coated areas were much cooler, making it significantly more comfortable for our team working inside the shed.” – Rio Tinto Mine Personnel
What Makes CharCoat CTI Different?
CharCoat CTI is not just reflective paint—it insulates by using ceramic bead technology that traps and dissipates heat, providing:
- Up to 20°C Surface Temperature Reduction
2. R3 Insulation Performance at Just 0.5mm DFT - Protection for Metal, Stainless Steel, and Other Industrial Surfaces
- Long-Term Durability in Extreme Weather Conditions
With CharCoat CTI, Rio Tinto successfully implemented a low-maintenance, highly effective insulation solution, improving worker safety and energy efficiency.
A Smart Investment in Thermal Insulation
Rio Tinto used CharCoat CTI to reduce excessive heat accumulation, improve worker safety, and provide a cost-effective and sustainable insulating solution.
