What is aerogel insulation? Technical guide for engineers
Aerogel insulation achieves a thermal conductivity (λ) of 0.012–0.020 W/m·K — 3 to 5 times lower than glasswool or rockwool at the same thickness. It is a nanostructured silica material in which more than 90% of the volume is air, held within pores smaller than 50 nm. Used across oil and gas pipelines, building envelopes, cold chain systems, and EV battery packs, it is the highest-performing thermal insulation material available in commercial blanket and board formats.
How aerogel achieves 0.012–0.020 W/m·K: the Knudsen effect
Aerogel’s thermal conductivity is lower than still air (approximately 0.025 W/m·K at ambient conditions) — a counterintuitive result that follows directly from its pore geometry.
The silica matrix that forms aerogel contains mesopores in the 2–50 nm range. Air molecules at atmospheric pressure have a mean free path of approximately 70 nm — the average distance a molecule travels before colliding with another. When pore size falls below this mean free path, gas molecules collide with pore walls more frequently than with each other. This suppresses gaseous conduction — the dominant heat transfer mechanism in conventional insulation. The effect is described by the Knudsen number and is the reason aerogel outperforms materials with far larger pore structures.
Solid conduction is equally constrained. The silica skeleton constitutes only 1–10% of aerogel’s total volume. The heat conduction path through the solid phase is tortuous and minimal. Radiative heat transfer is partially attenuated by the silica network at low and mid temperatures, though its contribution increases above 300°C.
Applied implication for specifiers: Aerogel’s performance advantage over conventional insulation is most pronounced at low to mid temperatures — ambient to approximately 300°C. Above 600°C, radiative transfer increases in significance and the gap over mineral wool narrows. For full temperature-dependent performance data, see Aerogel insulation temperature range.
Thermal conductivity and R-value specifications
λ values by operating temperature
| Operating temperature | λ (W/m·K) | Notes |
| Ambient (25°C) — best-in-class silica aerogel | 0.012–0.013 | Near-ambient, low-density monolithic aerogel |
| Ambient (25°C) — industrial blanket (typical) | 0.013–0.020 | Composite blanket with fibre reinforcement |
| 200°C | ~0.017–0.025 | Varies by product and density |
| 400°C | ~0.025–0.035 | Higher radiative contribution |
| 600°C | ~0.035–0.042 | Approaches upper limit for silica aerogel |
Source: Published datasheets, ASTM standards (2025–2026).
R-value (thermal resistance) by thickness
Thermal resistance (R-value) = thickness (m) ÷ λ (W/m·K).
| Thickness | At λ = 0.015 W/m·K | At λ = 0.020 W/m·K |
| 5 mm | R 0.33 m²·K/W | R 0.25 m²·K/W |
| 10 mm | R 0.67 m²·K/W | R 0.50 m²·K/W |
| 20 mm | R 1.33 m²·K/W | R 1.00 m²·K/W |
| 25 mm | R 1.67 m²·K/W | R 1.25 m²·K/W |
Thickness equivalence: A 10 mm aerogel blanket at λ = 0.015 W/m·K delivers the same R-value as approximately 20–30 mm of glasswool (λ = 0.030–0.045 W/m·K). On space-constrained industrial pipework, in retrofit scenarios where wall build-up is fixed, or on elevated structures where insulation weight is a structural input, this difference is a design variable — not a minor optimisation.
For a complete breakdown of λ values across product formats, thicknesses, and temperature conditions, see the Aerogel thermal conductivity and R-value guide.
Operating temperature range: −200°C to 650°C
| Application class | Operating range | Product format |
| Cryogenic | −200°C to −50°C | Blanket with vapour barrier system |
| Ambient / cold | −50°C to +100°C | Standard blanket or board |
| Medium temperature | +100°C to +300°C | Industrial blanket (standard grades) |
| High temperature | +300°C to +650°C | High-temp blanket (e.g. Pyrogel XTE, ArmaGel HTL) |
| Ultra-high temperature | Up to 1000°C+ [VERIFY per product] | Speciality composite — confirm rated temp with supplier |
ASTM C1728 covers aerogel blanket for continuous exposure from −196°C (−321°F) to 649°C (1200°F).
Critical specification note: Above approximately 650°C, standard silica aerogel undergoes sintering — structural densification that degrades thermal performance. Do not specify standard aerogel blankets for sustained operation above the product’s confirmed rated temperature without written supplier confirmation. For applications above 650°C (industrial furnaces, kilns, high-temperature reactors), specialist composite products exist — see [/resources/technical/temperature-range] and confirm the specific product datasheet.
Aerogel insulation formats: blanket, board, granule, and composite
Aerogel blanket (flexible sheet)
The standard commercial format. A silica aerogel composite reinforced with glass fibre or ceramic fibre, supplied in rolls or cut panels. Blanket is flexible and conforms to pipes, vessels, and complex geometries without custom fabrication. Available in standard thicknesses of 5, 10, 15, 20, and 25 mm; multiple layers can be applied for higher total thickness requirements.
This is the primary specification format for pipe and vessel insulation in oil and gas, petrochemical, power generation, and process industries. Density: typically 150–220 kg/m³ for industrial grades (e.g. Pyrogel XTE nominal density ~200 kg/m³, ArmaGel HTL ~150 kg/m³).
Aerogel board (rigid panel)
Aerogel bound into a rigid format, typically with a facer. Used for flat surfaces — building walls, floors, ceilings, and flat equipment faces. Density typically 180–300 kg/m³. Compressive strength is higher than the blanket format; board is specified where the insulation must carry surface loads. The primary building envelope format for applications where wall thickness is constrained and Energy Conservation Building Code (ECBC) 2017 U-values must be met.
Aerogel granules and loose fill
Free-flowing aerogel particles for cavity wall fill, irregular void filling, and as a feedstock component in aerogel paint formulations. Bulk density 60–120 kg/m³. Used where pour-in-place installation is preferred over cut-and-wrap, or where the cavity geometry does not suit sheet formats.
Aerogel composite and speciality formats
Aerogel combined with metal foil, ceramic fibre, or intumescent layers for fire-rated assemblies, removable insulation jackets, and extreme-temperature applications. Vacuum insulation panels (VIPs) use an aerogel or fumed silica core under vacuum, achieving λ approximately 0.004–0.008 W/m·K [VERIFY per specific product datasheet] — but they are puncture-sensitive and significantly more expensive. VIP applications in India are primarily confined to pharmaceutical cold chain packaging and temperature-controlled medical logistics.
Aerogel paint and coatings
Aerogel particles suspended in a paint binder. Coverage approximately 1–2 sqm/litre at useful application thickness. Performance is substantially lower than blanket or board formats. Used as a surface treatment on building walls and HVAC ducts where sheet installation is not feasible — not as a standalone primary insulation layer in any application with meaningful thermal requirement. Indicative India pricing: ₹400–₹900/litre [VERIFY].
For a full format selection guide, see Types of aerogel insulation: blanket, board, granule, composite.
Fire safety rating: Class A1 non-combustible
Most premium aerogel blanket and board products carry a non-combustible (Class A1) fire classification — the same category as rockwool and calcium silicate, and sharply different from polyurethane foam (PUF) and polyisocyanurate board (PIR), both of which are combustible.
| Standard | Classification | Verified product example |
| ASTM E84 | Flame Spread Index ≤5, Smoke Developed Index ≤10 (Class A surface burning) | Pyrogel XTE |
| EN 13501-1 | A1 (Non-combustible) | ArmaGel HTL and equivalent high-temp blankets |
| ISO 1182 | Non-combustible | International benchmark |
| DIN 4102 | Class A1 | European-spec products |
| IS / BIS (India) | [VERIFY: likely IS 1353 or relevant BIS standard — confirm with Bureau of Indian Standards before project specification] | — |
PUF, the dominant insulation in Indian cold storage and building panel applications, is rated B2–B3 under DIN 4102 (flammable) and produces toxic smoke during combustion. PIR achieves B–C under EN 13501-1 with suitable facings — better than PUF, but still combustible. In oil and gas, pharmaceutical, and public building projects in India, non-combustible specification is often a mandatory project requirement or affects insurance classification. Aerogel meets this requirement; PUF and PIR do not.
For a full comparison of fire ratings across insulation types and applicable Indian standards, see Fire safety ratings for aerogel insulation.
What is aerogel insulation used for? Primary applications in India
Oil and gas pipelines and process plant. Pipe insulation, vessel insulation, and heat tracing protection from cryogenic (LNG, −160°C) to high-temperature process service (to 650°C). Aerogel’s hydrophobicity addresses corrosion under insulation (CUI) — a critical concern on carbon steel pipework in India’s coastal refinery and terminal locations (Gujarat, Maharashtra, Odisha coastlines). For sector-specific guidance, see Aerogel insulation for oil and gas in India.
Building envelopes. Wall, roof, and floor insulation in commercial, industrial, and residential construction. Board and blanket formats achieve ECBC 2017-mandated U-values at 20–50% less thickness than rockwool or PUF alternatives — enabling compliance in renovation projects where wall or floor build-up cannot increase.
Cold chain and cryogenic storage. Blanket systems for cryogenic storage vessels and LNG tanks (to −200°C with vapour barrier), refrigerated transport containers, and pharmaceutical packaging. The temperature range extends further below ambient than PIR (limited to −50°C) without the moisture ingress risk that affects glasswool in cold service.
EV battery thermal management. Aerogel pads installed between battery cells limit heat propagation during thermal runaway events — a fire safety and pack protection application growing rapidly in India’s EV manufacturing sector. DARQ Industries (Gurugram) stocks EV battery pad formats.
Industrial furnaces and high-temperature process equipment. High-temperature blanket products for kiln walls, furnace external insulation, and process vessel wrap, within the product’s confirmed temperature rating.
For a comparative evaluation of all insulation materials available in the Indian market, see All insulation materials compared — India guide and Aerogel vs PUF insulation — India comparison.
Aerogel insulation in India — availability, pricing, and climate relevance
Suppliers and distributors
Aerogel insulation is commercially available in India, though it remains less ubiquitous than glasswool, rockwool, or PUF. Known active distributors as of 2025–2026:
- DARQ Industries Pvt. Ltd. (Gurugram) — aerogel blankets, boards, EV battery pads; pan-India distribution; indicative pricing from approximately ₹1,614/sqm (~₹150/sqft) [VERIFY current pricing]
- Wedge India — WedGel blanket range; building and industrial grades; rated −170°C to +1200°C [VERIFY product confirmation]
- BM Insulations Pvt. Ltd. (Chennai) — aerogel blanket supply; ₹2,350/sqm quoted for 6 mm/220 kg/m³ product [VERIFY — IndiaMart listing, may be outdated]
- S.K. Trading (Mumbai) — aerogel blanket supply; ₹3,500/sqm quoted [VERIFY — IndiaMart listing]
Indian manufacturer: DashamLabs produces silica aerogel domestically, with published λ ~0.016 W/m·K and temperature range −50°C to 650°C.
Most aerogel core material sold in India is imported — manufactured in China (Aspen-licensed facilities), South Korea, or Europe. Global brands available through Indian distributors include Aspen Aerogels (Pyrogel, Spaceloft) and Armacell (ArmaGel). Import HS code and applicable basic customs duty (BCD): [VERIFY with a licensed customs broker — likely classified under HS 6806 or 3824; check CBIC portal for current tariff].
For current supplier listings, contact details, and stocking locations, see Aerogel suppliers and distributors in India.
Indicative pricing in India (2025–2026)
| Format | Indicative range (₹/sqm) |
| Standard industrial blanket (5–10 mm) | ₹1,600 – ₹2,500 |
| High-temperature blanket (to 650°C) | ₹2,000 – ₹3,500 |
| Building-grade board | ₹1,800 – ₹3,000 |
| Aerogel paint / coating | ₹400 – ₹900 per litre |
Sources: IndiaMART listings, DARQ India, Wedge India (2025–2026). All prices indicative — bulk and project pricing typically 20–40% lower than list price. Always obtain a formal quotation.
Aerogel costs more per sqm than glasswool (₹80–₹250/sqm), rockwool (₹200–₹500/sqm), or PUF panels (₹250–₹600/sqm). The cost case rests on total installed system economics: a thinner insulation section at equivalent R-value reduces material volume, structural support load on pipework, and jacketing cost; non-combustibility can affect insurance classification and project approval timelines; and hydrophobicity sustains performance in India’s humid coastal environments where glasswool and untreated rockwool degrade over time.
For a full India pricing breakdown by format, thickness, and application, see Aerogel insulation price in India.
India climate relevance
India’s five composite climate zones — hot and dry, warm and humid, composite, temperate, and cold — each present specific insulation challenges. In warm and humid coastal environments (Maharashtra, Gujarat, Odisha, and Kerala coastlines), conventional insulation materials absorb moisture and lose R-value progressively. Glasswool and standard-grade rockwool in industrial settings in these regions often require inspection and replacement within 5–10 years of installation due to moisture-related degradation. Aerogel’s hydrophobicity — water vapour sorption ≤5% by weight per ASTM C1104/C1104M, hydrophobicity ≥99% for industrial grades — maintains R-value in these conditions without requiring additional protective jacketing.
For process plant in the major Indian industrial clusters (Gujarat petrochemicals, Maharashtra refineries, Odisha and Jharkhand steel and power), aerogel’s simultaneous Class A1 fire rating and performance to 650°C addresses requirements that PUF (limited to 120°C, combustible) and glasswool (limited to 350°C) cannot meet.
ECBC 2017 mandates minimum U-values for building envelopes across all five climate zones. Aerogel board formats can achieve these U-values at 20–50% less wall thickness than rockwool or PUF in many configurations — a material advantage in renovations where existing structure limits wall build-up. Green Rating for Integrated Habitat Assessment (GRIHA) and Indian Green Building Council (IGBC) schemes award energy efficiency credits that aerogel specifications can contribute to [VERIFY specific credit pathways with GRIHA/IGBC assessor].
Sources: IndiaMART listings, DARQ India, Wedge India (2025–2026). All prices indicative — bulk and project pricing typically 20–40% lower than list price. Always obtain a formal quotation.
Aerogel costs more per sqm than glasswool (₹80–₹250/sqm), rockwool (₹200–₹500/sqm), or PUF panels (₹250–₹600/sqm). The cost case rests on total installed system economics: a thinner insulation section at equivalent R-value reduces material volume, structural support load on pipework, and jacketing cost; non-combustibility can affect insurance classification and project approval timelines; and hydrophobicity sustains performance in India’s humid coastal environments where glasswool and untreated rockwool degrade over time.
For a full India pricing breakdown by format, thickness, and application, see Aerogel insulation price in India.
India climate relevance
India’s five composite climate zones — hot and dry, warm and humid, composite, temperate, and cold — each present specific insulation challenges. In warm and humid coastal environments (Maharashtra, Gujarat, Odisha, and Kerala coastlines), conventional insulation materials absorb moisture and lose R-value progressively. Glasswool and standard-grade rockwool in industrial settings in these regions often require inspection and replacement within 5–10 years of installation due to moisture-related degradation. Aerogel’s hydrophobicity — water vapour sorption ≤5% by weight per ASTM C1104/C1104M, hydrophobicity ≥99% for industrial grades — maintains R-value in these conditions without requiring additional protective jacketing.
For process plant in the major Indian industrial clusters (Gujarat petrochemicals, Maharashtra refineries, Odisha and Jharkhand steel and power), aerogel’s simultaneous Class A1 fire rating and performance to 650°C addresses requirements that PUF (limited to 120°C, combustible) and glasswool (limited to 350°C) cannot meet.
ECBC 2017 mandates minimum U-values for building envelopes across all five climate zones. Aerogel board formats can achieve these U-values at 20–50% less wall thickness than rockwool or PUF in many configurations — a material advantage in renovations where existing structure limits wall build-up. Green Rating for Integrated Habitat Assessment (GRIHA) and Indian Green Building Council (IGBC) schemes award energy efficiency credits that aerogel specifications can contribute to [VERIFY specific credit pathways with GRIHA/IGBC assessor].
Frequently asked questions
What is the thermal conductivity of aerogel insulation?
Industrial aerogel blankets achieve 0.013–0.020 W/m·K at 25°C. Best-in-class silica aerogel reaches 0.012–0.013 W/m·K. Conventional alternatives — glasswool and rockwool — achieve 0.030–0.045 W/m·K at ambient, making aerogel 2 to 5 times more thermally efficient per millimetre of thickness. Conductivity increases with operating temperature: approximately 0.025–0.035 W/m·K at 400°C and 0.035–0.042 W/m·K at 600°C.
How does aerogel insulation work?
Aerogel’s pores measure 2–50 nm — below the mean free path of air molecules (~70 nm at atmospheric pressure). This geometry suppresses gaseous conduction via the Knudsen effect: molecules collide with pore walls rather than each other, inhibiting heat transfer. The silica skeleton constitutes only 1–10% of total volume, minimising the solid conduction path. The result is a material with lower thermal conductivity than still air, without requiring a vacuum.
What is aerogel insulation used for?
Primary Indian applications are oil and gas pipe and vessel insulation, building envelope insulation for ECBC 2017 compliance, cold chain and cryogenic storage (to −200°C), EV battery thermal management, and high-temperature industrial process equipment (to 650°C). The common specification driver across these applications is space constraint, fire rating requirement, moisture resistance, or operating temperature beyond what conventional materials can handle.
What is the difference between aerogel blanket and aerogel board?
Aerogel blanket is a flexible composite sheet reinforced with glass or ceramic fibre. It conforms to curved surfaces — pipes, vessels, and complex geometries — without custom fabrication. Aerogel board is a rigid panel for flat surfaces: building walls, floors, and ceilings. Blanket is the standard format for industrial pipe and vessel insulation; board is used in building envelopes and flat equipment applications where compressive load or surface flatness is required.
Is aerogel insulation fire resistant?
Most premium aerogel blanket products are classified non-combustible — Class A1 under EN 13501-1 and Class A surface burning under ASTM E84 (Flame Spread Index ≤5, Smoke Developed Index ≤10, verified for Pyrogel XTE). This is the same fire classification as rockwool and calcium silicate. PUF — the most widely used alternative in India — is rated B2–B3 (flammable) and produces toxic smoke. Indian BIS fire standard applicability: [VERIFY IS 1353 or equivalent before project specification].
Is aerogel insulation available in India?
Yes. Aerogel insulation is stocked by distributors including DARQ Industries (Gurugram), Wedge India, BM Insulations (Chennai), and S.K. Trading (Mumbai). DashamLabs manufactures silica aerogel domestically. Global brands — Aspen Aerogels (Pyrogel, Spaceloft) and Armacell (ArmaGel) — are available through Indian distributors. Most core material is imported. Current supplier listings and contact details are at /india/aerogel-suppliers-india.
What does aerogel insulation cost in India?
Standard industrial blanket (5–10 mm) is priced at approximately ₹1,600–₹2,500/sqm from Indian distributors. High-temperature blanket runs ₹2,000–₹3,500/sqm; building-grade board is ₹1,800–₹3,000/sqm. Bulk and project pricing is typically 20–40% lower than list price. These figures are indicative as of 2025–2026 — for current pricing, see Aerogel insulation price in India.
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