Many industrial processes generate significant heat, require hot commodities to move through piping, or would benefit from a reduction of outside temperature influences. In these environments, surface temperatures can reach very high values resulting in unsafe working conditions for personnel which can cause worker discomfort or in cases of contact with the surface, permanent skin damage. Traditionally, conventional insulation and jacketing or the use of metal gratings was used as protection. Thermal insulative coatings have also been used but current products require up to five, 500-micron (20 mils) coating layers to give adequate protection. We have developed a next generation waterborne, thermally insulative coating that has low thermal conductivity and is designed to provide protection from surface contact burns via a single coat application. The coating insulates elevated temperature processes and lowers the surface temperature of the process vessels or pipes. Additionally, this product reduces solar radiant heat gain, a significant contribution of unwanted temperature increases in high solar exposure environments, thereby keeping commodities’ temperatures from rising too high. In addition, since the product is directly bonded to a primer substrate, corrosion under insulation is eliminated as there is no corrosion zone unlike traditional insulation. The single coat differentiates this product from the competition and eases the burden on site owners in keeping their workers safe and meeting safety requirements. In this paper, we will discuss the relevant testing procedures that were performed as well as the data gathered to prove that thick film, waterborne insulative coatings can be made and achieve viable results.