Title: Selecting the Proper Coating/Lining System
1Selecting the Proper Coating/Lining System
- Kevin Morris
- Market Director Water Wastewater
- Sherwin-Williams
2Learning Objectives
- Primary substrates for application
- Protection mechanisms
- Selecting the proper surface preparation based on
the selected system and substrate - Proper selection of the system.
3Primary 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.
4Protection 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.
5System 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.
6System Selection(Factors to Consider)
- 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
7System 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?
8Surface 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
9Surface 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
10Surface Preparation Affects in System Selection
- ICRI Guideline No. 310.2, Selecting and
Specifying Concrete Surface Preparation for
Sealers, Coatings and Polymer Overlays
11Surface 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)
12Surface Preparation Affects on System Selection
The greater the DFT the greater the Surface
Profile
13Surface Preparation Affects on System Selection
The greater the DFT the greater the Surface
Profile
14Surface Preparation Affects on System Selection
The greater the DFT the greater the Surface
Profile
15Surface 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
16Epoxies
- 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.
17Aliphatic Polyurethanes
- Atmospheric Service
- Good Chemical Solvent Resistance
- Good Flexibility
- Excellent Color and Gloss Retention
- Excellent Abrasion Resistant
- Low Temperature Application
18Aromatic Polyurethanes
- Atmospheric and Immersion Service
- Good Chemical Solvent Resistance
- Good Flexibility
- Good Abrasion Resistant
- Good Film Build
- Low Temperature Applications
19Fluoropolymers
- Atmospheric Service
- Good Chemical Solvent Resistance
- Good Flexibility
- Ultimate Color and Gloss Retention
- Excellent Abrasion Resistance
20Polysiloxanes
- Atmospheric Service
- Good Chemical Solvent Resistance
- Good Flexibility
- Excellent Color and Gloss Retention
- Good Abrasion Resistant
21Acrylics
- Atmospheric Service
- Fair Chemical Solvent Resistance
- Good Flexibility
- Good Color and Gloss Retention
- Good Abrasion Resistance
22Alkyds
- Atmospheric Service
- Fair/Poor Chemical Solvent Resistance
- Good Flexibility
- Fair/Poor Color and Gloss Retention
- Good Abrasion Resistant
23Zincs
- Atmospheric and Immersion Service
- Poor Resistance to Alkali and Acidic Environments
- Excellent Corrosion Protection
- Some Formulations Shop Applications Only
24Polyureas
- Atmospheric and Immersion Service
- Fair Chemical Solvent Resistance
- Ultimate Flexibility
- Ultimate Abrasion Resistance
- Excellent Film Build
- Low Temperature Applications
25Novolac/Phenolic Epoxies
- Atmospheric and Immersion Service
- Excellent Chemical Solvent Resistance
- Fair/Poor Flexibility
- Good Abrasion Resistant
- Good Film Build
- May require heat curing
26Vinyl Esters / Polyesters
- Atmospheric and Immersion Service
- Excellent Chemical Solvent Resistance
- Fair Flexibility
- Good Abrasion Resistance
- Fast Cure
- Min Cure Temps Required
27Thin 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
28Thin Film Systems
29Medium 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
30Medium Film Coatings/Linings
31Laminate 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
32Laminate Lining Systems
33Mortar 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
34Mortar Systems
35Self-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
36Self-Leveling Mortar System
37Mortar 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
38Mortar Laminate Systems
39Heavy 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
40Heavy Duty Mortar Laminate Lining Systems
41Flexible 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
42Flexible Coating and Lining Systems
43Flexible 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
44Flexible Basecoat Laminate System
45Technologies That Improve Performance
Crystals of MIO are fractured into thin flakes.
Flakes then align in parallel fashion.
46Technologies That Improve Performance
Topcoat Holiday Blue crescent is prime coat
fluorescence.
White Light Inspection
Fluorescent Inspection
47Thank You!