Aerogel Blankets in Building Insulation: 2025 Perspective & Real Project Data

In 2025, out of the dozen Passivhaus and EnerPHit projects we handled, over 60% switched to externally applied aerogel blankets. Why? Because traditional materials often fail to meet the latest energy codes (like Australia's NCC 2022) without making walls impossibly thick.

1. Why Architects are Switching to Aerogel

Traditional 100mm rock wool or PIR boards often create "astronomical" thermal bridges in light steel frame calculations.

• The Space Problem: Increasing thickness exceeds planning limits.
• The Performance Problem: 10-20mm of aerogel can hit a U-value of 0.28-0.35, requiring only 1/5 the thickness of traditional solutions.

2. Measured Site Data (Not Lab Samples)

Case A: 1990s Double-Brick Renovation (Sydney)

• Before: U-value 1.94 W/m²·K
• After: 10mm Hydrophobic Aerogel Blanket + 50mm ventilated screen.
• Result: Verified U-value of 0.31 W/m²·K. Airtightness (n50) improved from 8.3 to 0.58.

Case B: Curtain Wall Cold Bridge (Brisbane)

• Problem: Aluminum frames causing condensation at 11°C.
• Solution: 10mm self-adhesive aerogel blanket.
• Result: Surface temperature rose to 17.8°C, completely eliminating condensation.

3. Selection Criteria for Construction-Grade Aerogel

Not all aerogel is suitable for buildings. In 2025, we only specify blankets that meet:

• Fire Rating: A1/A2 (Mandatory for commercial).
• Hydrophobicity: ≥99% (Crucial for humid climates like Queensland).
• Tensile Strength: ≥300kPa (To withstand wind pressure on exterior walls).

4. Pro Installation Tips: Avoiding the Pitfalls

1. Cutting: Never use a utility knife (dust issue). Use electric scissors or a dedicated saw table.
2. Surface Prep: The base must be 100% dust-free or the adhesive will fail within days.
3. Mechanical Fastening: Screws must have thermal-break washers to prevent new thermal bridges.

5. 2025-2027 Market Outlook & Pricing

With three new production lines opening next year, we expect the 10mm A1-rated aerogel price to drop significantly.

• Current Average: ¥280-350/m²
• 2026 Forecast: Below ¥220/m²
• Bulk Projects (>5000m²): Negotiable down to ¥180-200/m².

Download Technical Resources: Need detailed CAD node diagrams, PHPP files, or 3rd-party test reports? Leave a comment below or message Ruibin An directly for the full technical pack.