Presentation on theme: "Selecting the Proper Coating/Lining System"— Presentation transcript:
1 Selecting the Proper Coating/Lining System Kevin MorrisMarket Director Water & WastewaterSherwin-Williams
2 Learning Objectives Primary substrates for application Protection mechanismsSelecting the proper surface preparation based on the selected system and substrateProper selection of the system.
3 Primary Substrates Steel Concrete 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.ConcreteConcrete - used more than any other man-made material in the world and is easily attacked when placed in chemical environments.
4 Protection Mechanisms Barrier ProtectionThe coating/lining isolates the electrolyte from the anode, cathode, and metallic pathway.Rust InhibitiveThe slightly water-soluble pigments permeate to steel/coating interface and passivate the substrate.SacrificialThe coating/lining contains pigments that are more active than the metal and sacrifice themselves to protect the substrate.
5 System SelectionSystem selection for coatings/linings is not as simple as providing a coating that will resist a given commodity andSystem selection must consider a multitude of factors for a successful application.
6 System Selection (Factors to Consider) SteelConcreteCommodity (Name, CAS#, Percentage)Storage TemperatureMovement / FlexibilityType of StructureLocation and Use ofStructureAgitation (% of SuspendedSolids)Design (Welded, Bolted orRiveted)Inaccessible AreasNew Construction, Repaintor Structural RepairsCommodity (Name, CAS #, Percentage)Storage TemperatureLocation and Use of StructureType of Traffic (Foot, Cart or Vehicular)Agitation (% of Suspended Solids)Mix Design, Placement and FinishingJoints, 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 PreparationRegulationsWhat 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 , “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
16 EpoxiesEpoxies 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 ServiceGood Chemical & Solvent ResistanceGood FlexibilityExcellent Color and Gloss RetentionExcellent Abrasion ResistantLow Temperature Application
18 Aromatic Polyurethanes Atmospheric and Immersion ServiceGood Chemical & Solvent ResistanceGood FlexibilityGood Abrasion ResistantGood Film BuildLow Temperature Applications
19 Fluoropolymers Atmospheric Service Good Chemical & Solvent Resistance Good FlexibilityUltimate Color and Gloss RetentionExcellent Abrasion Resistance
20 Polysiloxanes Atmospheric Service Good Chemical & Solvent Resistance Good FlexibilityExcellent Color and Gloss RetentionGood Abrasion Resistant
21 Acrylics Atmospheric Service Fair Chemical & Solvent Resistance Good FlexibilityGood Color and Gloss RetentionGood Abrasion Resistance
22 Alkyds Atmospheric Service Fair/Poor Chemical & Solvent Resistance Good FlexibilityFair/Poor Color and Gloss RetentionGood Abrasion Resistant
23 Zincs Atmospheric and Immersion Service Poor Resistance to Alkali and Acidic EnvironmentsExcellent Corrosion ProtectionSome Formulations – Shop Applications Only
24 Polyureas Atmospheric and Immersion Service Fair Chemical & Solvent ResistanceUltimate FlexibilityUltimate Abrasion ResistanceExcellent Film BuildLow Temperature Applications
25 Novolac/Phenolic Epoxies Atmospheric and Immersion ServiceExcellent Chemical & Solvent ResistanceFair/Poor FlexibilityGood Abrasion ResistantGood Film BuildMay require heat curing
26 Vinyl Esters / Polyesters Atmospheric and Immersion ServiceExcellent Chemical & Solvent ResistanceFair FlexibilityGood Abrasion ResistanceFast CureMin 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 equipmentDifficult to cover rough concrete
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 containmentWill tolerate moderate abrasion from turbulent flow and low solids cargoUsed for containment areas with pedestrian and light vehicular traffic, trenches and sumpsHighest permeation resistance per mil
31 Laminate LiningsGenerally 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 LaminateWill tolerate moderate solids, agitation and turbulent flowLimited crack bridging capability
33 Mortar SystemsGenerally are 125 to 250 mil dft systems designed for the protection of concrete in more harsh environments and tolerate moderate to heavy industrial trafficGood thermal shock resistanceImproved wear resistanceSkilled mechanics required for installation
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 installVertical applications will require modifications to eliminate the self-leveling propertiesGood wear resistanceLimited thermal shock resistance
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 containmentWill tolerate turbulent flow and agitationGood permeation resistanceGood thermal shock resistanceRequires skill and experience
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 flowGood permeation resistanceGood thermal shock resistanceHighest cost, most skill required
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 resistanceHigh crack bridging capabilityRelatively easy to install at a moderate price range
43 Flexible Basecoat Laminate Systems Generally are 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 resistanceHighest crack bridging capabilityMost versatile