Selecting PROPERCOATING SYSTEM-Lining System Rev Kla 7_11 (1)

Selecting the Proper Coating/Lining System

Kevin MorrisMarket Director Water & WastewaterSherwin-Williams

Learning ObjectivesPrimary substrates for applicationProtection mechanisms Selecting the proper surface preparation based on the selected system and substrateProper selection of the system.

Primary SubstratesSteelCarbon 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.

Protection MechanismsBarrier 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.

System SelectionSystem 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.

System Selection(Factors to Consider) SteelCommodity (Name, CAS#, Percentage)Storage Temperature Movement / FlexibilityType of StructureLocation and Use ofStructure Agitation (% of SuspendedSolids)Design (Welded, Bolted orRiveted)Inaccessible AreasNew Construction, Repaintor Structural Repairs

ConcreteCommodity (Name, CAS #, Percentage)Storage Temperature Location 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

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?

Surface Preparation Affects on System SelectionSSPC-SP 1 Solvent CleaningSSPC-SP 2 Hand Tool CleaningSSPC-SP 3 Power Tool CleaningSSPC-SP 11 Power Tool Cleaning to Bare MetalSSPC-SP 7/NACE No. 4 Brush-Off Blast CleaningSSPC-SP 6/NACE No. 3 Commercial Blast Cleaning

Surface Preparation Affects on System SelectionSSPC-SP 10/NACE No. 2 Near White Metal Blast CleaningSSPC-SP 5/NACE No. 1 White Metal Blast CleaningSSPC-SP 12/NACE No. 5 Surface Preparation and Cleaning of Metals by Waterjetting Prior to CoatingSSPC-SP 13/NACE No. 6 Surface Preparation of Concrete

Surface Preparation Affects in System SelectionICRI Guideline No. 310.2, Selecting and Specifying Concrete Surface Preparation for Sealers, Coatings and Polymer Overlays

Surface Preparation Affects on System SelectionWhen 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)

Surface Preparation Affects on System SelectionThe greater the DFT the greater the Surface Profile

Surface Preparation Affects on System SelectionThe greater the DFT the greater the Surface Profile

Surface Preparation Affects on System SelectionThe greater the DFT the greater the Surface Profile

Surface Preparation Affects on System SelectionMinimum DFTs to fill surface profiles:CSP 1 = 13.5 mils +/- 2.5 milsCSP 2 = 16 mils +/- 2.5 milsCSP 3 = 19 mils +/- 2.5 milsCSP 4 = 25 mils +/- 2.5 milsCSP 5 = 33 mils +/- 2.5 milsCSP 6 = 63 mils +/- 2.5 milsCSP 7 = 87.5 mils +/- 5 milsCSP 8 = 105 mils +/- 5 milsCSP 9 = 107 mils +/- 5 mils

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.

Aliphatic Polyurethanes Atmospheric ServiceGood Chemical & Solvent ResistanceGood FlexibilityExcellent Color and Gloss RetentionExcellent Abrasion ResistantLow Temperature Application

Aromatic PolyurethanesAtmospheric and Immersion ServiceGood Chemical & Solvent ResistanceGood FlexibilityGood Abrasion ResistantGood Film BuildLow Temperature Applications

FluoropolymersAtmospheric ServiceGood Chemical & Solvent ResistanceGood FlexibilityUltimate Color and Gloss RetentionExcellent Abrasion Resistance

PolysiloxanesAtmospheric ServiceGood Chemical & Solvent ResistanceGood FlexibilityExcellent Color and Gloss RetentionGood Abrasion Resistant

AcrylicsAtmospheric ServiceFair Chemical & Solvent ResistanceGood FlexibilityGood Color and Gloss RetentionGood Abrasion Resistance

AlkydsAtmospheric ServiceFair/Poor Chemical & Solvent ResistanceGood FlexibilityFair/Poor Color and Gloss RetentionGood Abrasion Resistant

ZincsAtmospheric and Immersion ServicePoor Resistance to Alkali and Acidic EnvironmentsExcellent Corrosion ProtectionSome Formulations Shop Applications Only

PolyureasAtmospheric and Immersion ServiceFair Chemical & Solvent ResistanceUltimate FlexibilityUltimate Abrasion ResistanceExcellent Film BuildLow Temperature Applications

Novolac/Phenolic EpoxiesAtmospheric and Immersion ServiceExcellent Chemical & Solvent ResistanceFair/Poor FlexibilityGood Abrasion ResistantGood Film BuildMay require heat curing

Vinyl Esters / PolyestersAtmospheric and Immersion ServiceExcellent Chemical & Solvent ResistanceFair FlexibilityGood Abrasion ResistanceFast CureMin Cure Temps Required

Thin Film Coatings/LiningsGenerally 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

Thin Film Systems

Medium Film Coatings/LiningsGenerally 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 cargoUsed for containment areas with pedestrian and light vehicular traffic, trenches and sumpsHighest permeation resistance per mil

Medium Film Coatings/Linings

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 flow Limited crack bridging capability

Laminate Lining Systems

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 trafficGood thermal shock resistanceImproved wear resistance Skilled mechanics required for installation

Mortar Systems

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

Self-Leveling Mortar System

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

Mortar Laminate Systems

Heavy Duty Mortar Laminate Lining SystemsGenerally 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 resistanceGood thermal shock resistanceHighest cost, most skill required

Heavy Duty Mortar Laminate Lining Systems

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

Flexible Coating and Lining Systems

Flexible Basecoat Laminate SystemsGenerally 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 resistanceHighest crack bridging capabilityMost versatile

Flexible Basecoat Laminate System

Technologies That Improve Performance

Crystals ofMIO arefracturedinto thinflakes.Flakesthenalign inparallelfashion.

Technologies That Improve PerformanceWhite LightInspectionFluorescentInspectionTopcoat Holiday:Blue crescent is prime coat fluorescence.

Thank You!Any Questions

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