Silica Aerogel vs Mineral Wool vs PIR
Head-to-head comparison of the three materials behind this calculator — λ, temperature limits, cost and best-fit applications.
Home/Insulation Thickness & Heat Loss Calculator
Free estimation tool Insulation Thickness & Heat Loss Calculator
⚠️ Estimation tool only — based on simplified flat-surface conduction with typical λ values.
Real engineering design requires a formal thermal calculation with certified datasheet data.
Estimated heat loss through insulation — W — W/m²
Mineral wool, same thickness — W —×
Mineral wool needed for equal loss — mm —×
Aerogel blanket at the same thickness loses roughly half the heat of mineral wool; to match aerogel performance, mineral wool needs about twice the thickness.
How it works
Calculation principle & limits
The calculator applies Fourier’s law of steady-state conduction through a flat layer: Q = λ · A · ΔT / t, where λ is thermal conductivity (W/m·K), A the surface area (m²), ΔT the difference between hot-face and ambient temperature (K), and t the insulation thickness (m). Heat flux (W/m²) is Q divided by A.
Key simplifications: surface convection and radiation films are not modelled, λ is treated as constant over the temperature span, and joints, seams, compression and aging are ignored. That makes the output a screening estimate — deviations of ±20–50% versus a full heat-loss calculation are normal, especially at low ΔT or with thin layers.
Next steps
Need precise selection data?
Aerogel Insulation for Industrial Pipes
Why thin, flexible aerogel blankets replace thick mineral wool on pipes where space and CUI risk matter.
Measured λ vs Datasheet Values
What independent test data reveals about the gap between claimed and measured thermal conductivity.
FAQ
Common questions
What is the calculation principle?
Steady-state conduction through a flat layer: Q = λ × A × ΔT / t. The result is the heat flow (W) passing through the insulated surface once steady conditions are reached; divide by area for heat flux (W/m²).
How accurate are the results?
Indicative only. λ varies with mean temperature and product; surface films are excluded; installation factors are ignored. Expect ±20–50% deviation from a formal calculation — use it to compare materials and thicknesses, not to certify a design.
Which material should I choose?
Aerogel blanket (λ ≈ 0.018–0.023 W/m·K) where thickness, weight or CUI risk dominate; mineral wool (λ ≈ 0.035–0.045) where cost matters and space is free; PIR (λ ≈ 0.021–0.025) for flat panels in building and cold-chain work. For your exact operating temperature, request a datasheet and design λ from the supplier.