From curtain wall thermal bridges to entire building EnerPHit renovations: 5 reasons why architects will truly start using aerogel blankets in 2025.

In 2025, out of the dozen or so Passivhaus and EnerPHit projects I worked on in Australia, eight ultimately switched to using externally applied aerogel blankets. Below, I'll explain the pitfalls we encountered, the data we collected, and the questions architects care about most.

1. Why is everyone suddenly starting to use aerogel blankets?

Simply put: traditional materials collectively failed to meet the requirements of the 2022 NCC and the latest NSB (National Construction Code).

Using 100mm rock wool or PIR boards in light steel frame walls, the thermal bridge penalty in PHPP calculations was simply astronomical.

Want to increase the thickness? The total thickness of the exterior wall immediately exceeds the planning regulations, and the interior partition walls take up too much space.

Rock wool absorbs water, PIR ages, XPS is not breathable... the old three materials all failed in Australia's humid climate.

A 10-20mm aerogel blanket can reduce the effective U-value of the entire wall to 0.28-0.35 (including all thermal bridges), with a thickness only 1/5 of traditional solutions. This is what truly appeals to architects.

2. Actual measured data (not manufacturer samples)

2024 EnerPHit renovation of a 1990s double-brick house in inner Sydney:

Original wall U-value: 1.94 W/m²·K

Externally applied 10mm hydrophobic aerogel blanket (λ=0.018) + 50mm ventilated rain screen cavity

Effective U-value after third-party heat flow meter + infrared measurement: 0.31 W/m²·K

All linear thermal bridge Ψ values ​​in PHPP were reduced to below 0.01, and air leakage n50 decreased from 8.3 to 0.58

2025 Cold bridge treatment of a curtain wall in a commercial office building we just completed in Brisbane:

Aluminum alloy frame + double-glazed LOW-E triple silver glass, original cold bridge surface temperature was only 11℃ in winter

After applying a 10mm self-adhesive aerogel blanket, the surface temperature at the coldest point rose to 17.8℃, completely eliminating condensation.

3. What does a truly effective aerogel blanket look like in 2025? Not all aerogel blankets are suitable for construction! We currently only use these types:

A1/A2 fire rating (mandatory for commercial buildings in Australia)

Hydrophobicity ≥99% (Non-hydrophobic materials in Melbourne and Queensland typically lose 30% of their performance after one year)

With PE film or aluminum foil as a permanent vapor barrier (eliminates the need for an additional AVCL, saving 3-5 days of construction time)

Tensile strength ≥300kPa (must withstand wind pressure and the weight of the rainscreen when applied to exterior walls)

Currently, only Aspen Spacetherm A2, the domestic Nanoporous A1-Pro series, and OEM products from a few European manufacturers meet all four of these requirements.

4. Installation Pitfalls Guide (Hard-earned Experience)

Never cut with a utility knife; the dust will make you regret being born. You must use electric scissors or a dedicated saw table.

The base layer must be clean; if oil and dust are not removed, the adhesive will peel off in three days.

Corners and window openings must be cut at a 45° angle and overlapped, otherwise the airtight layer will be broken.

It's okay for the rainscreen framing to press on the aerogel blanket, but the screws must have washers, otherwise the local compression will immediately double the thermal bridging.

5. What will the market be like in 2025-2027?

NCC 2025 has clearly stated the 7-star energy rating requirements for existing buildings, and the demand for renovations of light steel and steel-concrete frame old buildings will explode.

The current average price of aerogel blankets is approximately ¥280-350/m² (10mm A1), and it is expected to fall below ¥220 in 2026 (three new domestic production lines will be put into operation next year).

Some developers have already started purchasing for entire buildings, and for projects over 5000 square meters, the price can be negotiated down to ¥180-200.

Finally, a frank statement:

Aerogel blankets are not a panacea; they still can't compete with VIP and foamed glass for cold radiation roofs and floor insulation. However, for walls and curtain wall nodes where space is limited, thermal bridging is complex, and Passivhaus/EnerPHit standards are required, there really won't be another comparable material in 2025. If you'd like to see detailed node diagrams, PHP files, or third-party testing reports, please leave a comment or send me a private message, and I'll send them to you for free.