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Selecting the Proper Coating/Lining System

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Title: Selecting the Proper Coating/Lining System


1
Selecting the Proper Coating/Lining System
  • Kevin Morris
  • Market Director Water Wastewater
  • Sherwin-Williams

2
Learning Objectives
  • Primary substrates for application
  • Protection mechanisms
  • Selecting the proper surface preparation based on
    the selected system and substrate
  • Proper selection of the system.

3
Primary Substrates
  • Steel
  • Carbon Steel Easily attacked by the environment
    in which it is placed and will begin to revert
    back to iron ore.
  • Stainless Steel - Stainless steel does not stain,
    corrode, or rust as easily as ordinary steel.
  • Concrete
  • Concrete - used more than any other man-made
    material in the world and is easily attacked when
    placed in chemical environments.

4
Protection Mechanisms
  • Barrier Protection
  • The coating/lining isolates the electrolyte from
    the anode, cathode, and metallic pathway.
  • Rust Inhibitive
  • The slightly water-soluble pigments permeate to
    steel/coating interface and passivate the
    substrate.
  • Sacrificial
  • The coating/lining contains pigments that are
    more active than the metal and sacrifice
    themselves to protect the substrate.

5
System Selection
  • System selection for coatings/linings is not as
    simple as providing a coating that will resist a
    given commodity and
  • System selection must consider a multitude of
    factors for a successful application.

6
System Selection(Factors to Consider)
  • Steel
  • Concrete
  • Commodity (Name, CAS
  • , Percentage)
  • Storage Temperature
  • Movement / Flexibility
  • Type of Structure
  • Location and Use of
  • Structure
  • Agitation ( of Suspended
  • Solids)
  • Design (Welded, Bolted or
  • Riveted)
  • Inaccessible Areas
  • New Construction, Repaint
  • or Structural Repairs
  • Commodity (Name, CAS , Percentage)
  • Storage Temperature
  • Location and Use of Structure
  • Type of Traffic (Foot, Cart or Vehicular)
  • Agitation ( of Suspended Solids)
  • Mix Design, Placement and Finishing
  • Joints, Cracks,Vapor Barriers, etc.
  • New Construction or Rehabilitation

7
System Selection(Factors to Consider)
  • Do any of these place restrictions on system
    selection for Steel and Concrete?
  • The reason for coating?
  • Allowable methods of Surface Preparation
  • Regulations
  • What else?

8
Surface Preparation Affects on System Selection
  • SSPC-SP 1 Solvent Cleaning
  • SSPC-SP 2 Hand Tool Cleaning
  • SSPC-SP 3 Power Tool Cleaning
  • SSPC-SP 11 Power Tool Cleaning to Bare Metal
  • SSPC-SP 7/NACE No. 4 Brush-Off Blast Cleaning
  • SSPC-SP 6/NACE No. 3 Commercial Blast Cleaning

9
Surface Preparation Affects on System Selection
  • SSPC-SP 10/NACE No. 2 Near White Metal Blast
    Cleaning
  • SSPC-SP 5/NACE No. 1 White Metal Blast Cleaning
  • SSPC-SP 12/NACE No. 5 Surface Preparation and
    Cleaning of Metals by Waterjetting Prior to
    Coating
  • SSPC-SP 13/NACE No. 6 Surface Preparation of
    Concrete

10
Surface Preparation Affects in System Selection
  • ICRI Guideline No. 310.2, Selecting and
    Specifying Concrete Surface Preparation for
    Sealers, Coatings and Polymer Overlays

11
Surface Preparation Affects on System Selection
  • When specifying surface cleanliness it should be
    noted that surface profile is as important.
  • Surface profile promotes mechanical bond of the
    coating/lining system to the substrate.
  • Steel (This is commonly specified in mils)
  • Concrete (This is commonly specified as a CSP
    (1-9) Concrete Surface Profile)

12
Surface Preparation Affects on System Selection
The greater the DFT the greater the Surface
Profile
13
Surface Preparation Affects on System Selection
The greater the DFT the greater the Surface
Profile
14
Surface Preparation Affects on System Selection
The greater the DFT the greater the Surface
Profile
15
Surface Preparation Affects on System Selection
  • Minimum DFTs to fill surface profiles
  • CSP 1 13.5 mils /- 2.5 mils
  • CSP 2 16 mils /- 2.5 mils
  • CSP 3 19 mils /- 2.5 mils
  • CSP 4 25 mils /- 2.5 mils
  • CSP 5 33 mils /- 2.5 mils
  • CSP 6 63 mils /- 2.5 mils
  • CSP 7 87.5 mils /- 5 mils
  • CSP 8 105 mils /- 5 mils
  • CSP 9 107 mils /- 5 mils

16
Epoxies
  • Epoxies are two component products consisting of
    an epoxy resin which is cross-linked with a
    co-reactant or hardener. Epoxy coatings are
    formulated based upon the performance
    requirements of the end product. When properly
    catalyzed and applied, epoxies produce a hard,
    chemical and solvent resistant finish. They are
    typically used on concrete and steel to give
    resistance to water, alkali and acids.

17
Aliphatic Polyurethanes
  • Atmospheric Service
  • Good Chemical Solvent Resistance
  • Good Flexibility
  • Excellent Color and Gloss Retention
  • Excellent Abrasion Resistant
  • Low Temperature Application

18
Aromatic Polyurethanes
  • Atmospheric and Immersion Service
  • Good Chemical Solvent Resistance
  • Good Flexibility
  • Good Abrasion Resistant
  • Good Film Build
  • Low Temperature Applications

19
Fluoropolymers
  • Atmospheric Service
  • Good Chemical Solvent Resistance
  • Good Flexibility
  • Ultimate Color and Gloss Retention
  • Excellent Abrasion Resistance

20
Polysiloxanes
  • Atmospheric Service
  • Good Chemical Solvent Resistance
  • Good Flexibility
  • Excellent Color and Gloss Retention
  • Good Abrasion Resistant

21
Acrylics
  • Atmospheric Service
  • Fair Chemical Solvent Resistance
  • Good Flexibility
  • Good Color and Gloss Retention
  • Good Abrasion Resistance

22
Alkyds
  • Atmospheric Service
  • Fair/Poor Chemical Solvent Resistance
  • Good Flexibility
  • Fair/Poor Color and Gloss Retention
  • Good Abrasion Resistant

23
Zincs
  • Atmospheric and Immersion Service
  • Poor Resistance to Alkali and Acidic Environments
  • Excellent Corrosion Protection
  • Some Formulations Shop Applications Only

24
Polyureas
  • Atmospheric and Immersion Service
  • Fair Chemical Solvent Resistance
  • Ultimate Flexibility
  • Ultimate Abrasion Resistance
  • Excellent Film Build
  • Low Temperature Applications

25
Novolac/Phenolic Epoxies
  • Atmospheric and Immersion Service
  • Excellent Chemical Solvent Resistance
  • Fair/Poor Flexibility
  • Good Abrasion Resistant
  • Good Film Build
  • May require heat curing

26
Vinyl Esters / Polyesters
  • Atmospheric and Immersion Service
  • Excellent Chemical Solvent Resistance
  • Fair Flexibility
  • Good Abrasion Resistance
  • Fast Cure
  • Min Cure Temps Required

27
Thin Film Coatings/Linings
  • Generally systems up to 20 mils DFT designed for
    corrosion protection of concrete and steel from
    immersion and atmospheric exposure.
  • Do not tolerate abrasive conditions (high solids,
    agitation, turbulent flow)
  • Least expensive alternative (price sensitivity)
  • Usually spray applied, simple equipment
  • Difficult to cover rough concrete

28
Thin Film Systems
29
Medium Film Coatings/Linings
  • Generally are systems from 20 to 40 mils DFT
    designed for the protection of concrete and steel
    from more harsh environments in immersion and
    secondary containment
  • Will tolerate moderate abrasion from turbulent
    flow and low solids cargo
  • Used for containment areas with pedestrian and
    light vehicular traffic, trenches and sumps
  • Highest permeation resistance per mil

30
Medium Film Coatings/Linings
31
Laminate Linings
  • Generally are 55 to 120 mil dft systems designed
    for the corrosion protection of concrete and
    steel in immersion conditions, secondary
    containment, and steel tank bottom renewal.
  • Single or double Laminate
  • Will tolerate moderate solids, agitation and
    turbulent flow
  • Limited crack bridging capability

32
Laminate Lining Systems
33
Mortar Systems
  • Generally are 125 to 250 mil dft systems designed
    for the protection of concrete in more harsh
    environments and tolerate moderate to heavy
    industrial traffic
  • Good thermal shock resistance
  • Improved wear resistance
  • Skilled mechanics required for installation

34
Mortar Systems
35
Self-Leveling Mortar Systems
  • Generally are 70 to 125 mils dft designed for the
    corrosion protection of concrete in more harsh
    environments and can include a broadcast
    aggregate for a textured finish.
  • Easiest mortar system to install
  • Vertical applications will require modifications
    to eliminate the self-leveling properties
  • Good wear resistance
  • Limited thermal shock resistance

36
Self-Leveling Mortar System
37
Mortar Laminate Systems
  • Generally are 90 to 125 mil dft systems designed
    for the corrosion protection of concrete and
    steel in immersion and secondary containment
  • Will tolerate turbulent flow and agitation
  • Good permeation resistance
  • Good thermal shock resistance
  • Requires skill and experience

38
Mortar Laminate Systems
39
Heavy Duty Mortar Laminate Lining Systems
  • Generally are 125 to 190 mil dft systems designed
    for the protection of concrete and steel in
    immersion and secondary containment.
  • Best for high solids, agitation, and turbulent
    flow
  • Good permeation resistance
  • Good thermal shock resistance
  • Highest cost, most skill required

40
Heavy Duty Mortar Laminate Lining Systems
41
Flexible Coating/Lining Systems
  • Generally 25 to 125 mil dft systems designed for
    the corrosion protection of steel, concrete, and
    masonry in atmospheric or immersion conditions.
  • High thermal shock resistance
  • High crack bridging capability
  • Relatively easy to install at a moderate price
    range

42
Flexible Coating and Lining Systems
43
Flexible Basecoat Laminate Systems
  • Generally are 45-65 mil dft systems designed to
    be installed prior to the application of a
    topping system for crack bridging capability in
    atmospheric exposure on concrete.
  • Highest thermal shock resistance
  • Highest crack bridging capability
  • Most versatile

44
Flexible Basecoat Laminate System
45
Technologies That Improve Performance
Crystals of MIO are fractured into thin flakes.
Flakes then align in parallel fashion.
46
Technologies That Improve Performance
Topcoat Holiday Blue crescent is prime coat
fluorescence.
White Light Inspection
Fluorescent Inspection
47
Thank You!
  • Any Questions
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