SPI PP Short 2014

Superior Products for Superior Results | Copyright © 2012 Superior Products International II | All rights reserved.

Joseph E. PritchettPresidentSuperior Products International II, Inc.10835 W 78th StreetShawnee, Kansas 66214 [email protected]

SPI COATINGSThermal Insulation Coating and Corrosion Controls

Handling Corrosion

• Sandblast• Primer• One or multiple top coats

Currently being handled the same way as always for the past 50 years

• Blast is made• Coating application is delayed• Surface is bloomed or flash rust has developed before application –100% of the time

Why is there only limited success?

What Does SPI Do?Provide Thermal Insulation to all surfaces of any building material

- stop heat load

Provide Fire Protection to all surfaces of any building material - up to and beyond 7 hours

Provide Corrosion Protection with a

single coat system - replace sandblast and 3 coat systems

Save Energy Usage and Costs - 20% up to 60%

Save Maintenance, Repair and Replacement

costs

Reduce or eliminate CUI (Corrosion Under Insulation)

SPI Performance Coatings

• Solvent based, single component• Applied by spray, brush or roller

• Encapsulates existing rust, asbestos and Lead-based paint without removal

• 6780 psi (475 bar) surface tensile strength

• Maintains flexibility and can bend to 90° without cracking

• Surface rust is the profile for best adhesion

• Penetrates deep into the pores, anchors, swells and encapsulates

• RUST GRIP® tested Water barrier against hydrostatic pressure and wind driven rain

Stop Corrosion Development Quick and Easy With Rust Grip®

Heat, Insulation, Fire, Corrosion Protection (CUI)

• Penetrated through 16 existing coats of lead-based paint

• RUST GRIP® pull testing ranges from 1400 psi (98 bar) up to 4600 psi (322 bar) over existing rust. Three coat systems average 150 psi

• Certified for Bridge Structures passing 7,000 hours of accelerated salt spray/UV testing with perfect 10 score and going to 10,000 hours

• No sandblast and single coat

SPI Performance Coatings

Offshore Rigs

• Rust Grip decking to stop corrosion and give a tough, long lasting corrosion protection even under abusive conditions (475 bar tensile)

• Single coat. Single component. Easy to brush, roll or spray using airless sprayers

Rust Grip

• Stops the heat load on the surface of the metal. Reduces the surface heat that workers are standing over

• Reduces the sound from lower machine areas up through other levels

• Brings living quarters to ambient temperatures for better rest of workers

Super Therm

SPI Applications

• Blue Chip Casino II, 2006 Michigan City, Indiana

• The Largest US Coast Guard Approved Casino Vessel Ever Built In US

• $163 Million - Cost Of Construction

• Rusted Surfaces were power-washed at approximately 3,500 PSI and then primed with RUST GRIP®.

• No Sandblasting Required

Marine Applications

• 5 mile long bridge in Baton Rouge, Louisiana using standard blast and three coat system was bid at $72 million.

• With the Rust Grip System, of water blast and one coat system the same bridge cost only $29 million.

• The result was a 60% cost savings in materials and labor

Infrastructure Applications

• Rust Grip Steel Encapsulation for FAA (Federal Aviation Administration facilities, equipment, concrete foundations, towers and antennas.

• One-coat encapsulation product to protect steel.

• One coat system, serving as the primer and topcoat

• Rust Grip provides superior encapsulation technology

• 60% less costly than the traditional 3 part zinc rich primer-epoxy-urethane systems being used over bridges and steel structures

SPI New Technology Solution

Corrosion Under Insulation (CUI)

Underneath externally clad/jacketed

insulation as a result of the penetration of water or absorption of

moisture into insulation material

Moisture ingress into conventional insulation usually results in

accelerated corrosion of the underlying steel surface which can result in

structural failure of the pipe, vessel or other insulated item

The corrosion may be more severe because the

insulation will not allow evaporation and will act as a sponge

Moisture occurring in one area moves through the insulation to another area causing the corrosion to spread more rapidly

Undetected until the insulation and cladding/jacketing is removed to allow inspection or when leaks occur

Replacement of pipes is very expensive, with substantial down time

Corrosion Under Insulation (CUI)

• In 2001, U.S. Congress reported the direct cost of corrosion to be $276 billion per year, with that number potentially doubling when indirect costs are also considered.

• A study done by ExxonMobil Chemical in September 2003 indicated that between 40 and 60 percent of piping maintenance costs are related to CUI

• E.I. DuPont de Nemours and Company estimated that the direct cost of CUI repairs and replacements exceeds $10 million per year, which does not include normal preventative maintenance costs and indirect costs

“R” VALUE – not for real world

• STUDY RESULT FROM MAJOR USA ENGINEERING UNIVERSITY. “Released in 2012”

• In testing to prove the value of SUPER THERM to block initial heat load to reduce heat absorption and conduction through roofing, it was discovered that “R” rated materials are “only” effective in Steady State Environments or a Laboratory, due to wind moving air through standard insulation materials, changes in humidity and sudden changes in ambient temperatures. R value materials work on absorption and rate of conduction and cannot be effected by changes in ambient conditions to effectively measure performance.

• SUPER THERM is not affected by ambient conditions.

Stop CUI with SPI

• Rust Grip, HPC and Super Therm over hot pipes to control CUI• Up to 170 C, RUST GRIP® applied to surface of pipes, tanks or valves can block and stop corrosion development

• Apply HPC ® as the insulation and then SUPER THERM® to seal the surface with RUST GRIP® to block moisture and air flow from reaching the surface

• Stop moisture loading into the insulation material• Stop the free air flow into the insulation material• Stop the condensation that release foam insulation• Provides a 100% seal to block air, moisture and chemicals from attacking the surfaces

• Stop CUI from forming

Blocking Heat with SPIReduce evaporation by 90%

Drop temperature

inside of tanks

Reduce interior temperatures on storage tanks to within 5 degrees of ambient

Reduce heat load over surface

from 108 watts per sq.m/hour down to 1 watt per sq.m/hour

Prevent moisture from causing

heat gain

• Replace metal jacketing for a moisture and air tight system with a simple spray that covers 100% of all surface from elbows to valves.

• Covers all configurations

How Standard Insulation Works

Materials absorb 100% of heat load from surface

R or K value is the measurement of how fast this heat transfers through the material

R K

Moisture absorbs into the material and speeds the transfer rate which dramatically reduces

the R or K value after it is installed

Air flow into and through these materials cancels out

the R or K valueAfter the fiber material is fully loaded with heat, does it have any insulation value? The resistance is finished

ASHRAE (American Society of Heating, Refrigerating and Air Conditioning Engineers) has the 90.1 Code with a chart showing R 19- R21 over any metal

structure tested to only R 7.4

Super Therm, HPC, HSC

SUPER THERM blocks initial heat load from ever happening that begins the insulation process

SUPER THERM protects surfaces from weathering

SUPER THERM is a tested water

barrier

SUPER THERM is a “0” flame

spread/fire retarder

SUPER THERM is a tested sound barrier -50%

HSC – HPC holds heat inside a tank or pipe at the surface level and resist the “heat transfer” of heat through a material to escape to the

atmosphere

Methods of Heat Transfer

Conduction Convection• Radiation is the transfer of heat, in the form of electromagnetic energy, through a space

Radiation• Convection is the transfer of heat through the movement of a fluid, such as water or air. Heat is blocked by SUPER THERM

• Once a material LOADS HEAT, the heat passes through the material at a calculated speed. Heat is blocked by HSC and HPC

* What each heat wave to total heat load

• 3% of total energy• Responsible for sunburn

Ultraviolet• 40% of total energy

• Visible light

Visible• 57% of total energy

• Feels as heat

Infrared

SuperTherm Blocks 97% of UV because

it is white (*3%)

SuperTherm Blocks 96% of Short Wave or Visual Light

(*40%)

SuperTherm Blocks 99% of Long Wave or

Infrared (*57%)

SuperTherm

• 91% emissivity to repel heat build up on the surface back into the atmosphere.

• Blocks 96% solar and 99% of IR waves

• Works for interior as well as exterior.

• Tested and proven Water Barrier for hydrostatic pressure and 108 kilometer wind driven rain

• Tested against Fiberglass 75 mm thick board and outperformed the heat conduction by 68% with one coat and 148% with two coats.

• ASTM C 1326 Guarded Hot Box test. SUPER THERM® applied at 250 micron dry thickness

Characteristics• UL, FM, ABS, ENERGY STAR• California Bureau of Home Furnishings and Thermal Insulation

• ICC (International Code Council #21-25)

• CRRC (Cool Roof Rating Council - Emissivity of 0.91)

• JIS (Japanese Institute of Standards) A 5759

• US GREEN BUILDING COUNCIL- Certified, LEED program

• MBDC Cradle to Cradle Program – Silver Certificate for LEED and Environment USDA approval letter and US Consumer Council approved

Certifications

SuperTherm for Storage Tanks

Steel Double Deck

Roof

Radiation

Heat LoadProduct Liquid

Heat LoadProduct Liquid

88F(31C)Air Air

79F(26C)

88F(31C)

85F(29C)

Super Therm

Super Therm

155F(46C)

155F(46C)

Steel Single Deck Roof

• Metal surface not coated allowed 367.20 (108 watts) to enter a storage tank per sq.m per hour

• Metal coated with one coat of SUPER THERM® allowed only 3.99 BTU (1 watt) to enter per sq.m per hour

SuperTherm for Storage Tanks

• 39 tanks coated with Super Therm at Hokko Terminal

• Super Therm eliminated the use of electricity and water for cooling

• SuperTherm substantially reduced VOC emissions into the atmosphere

• Insulation performance of Super Therm has not deteriorated after 14 years

• Mitsubishi is promoting the use of Super Therm for exceptional insulation performance and for protection of environment

Mitsubishi Related Tank TerminalDaiko Shakai Co., LTD

Osaka, Japan

SPI for Roofing Applications

40º

35º

30º

25º

20º

40º

35º

30º

25º

20º11/19 11/20 11/21 11/22 11/23 11/24 11/25 11/26 11/272/9 2/10 2/11 2/12 2/13 2/14 2/15 2/16 2/17

¥8,500,000 worth of energy was calculated to be saved after the temperature reduction. However, in a few months’ time, actual electricity savings were already more than that amount. After the application of SPI, there was no need for an air-conditioning system which the plant had budgeted for.

Rohm Apollo Electronics Co., LTD. (Thailand)

Outside Air

Attic Temperature

Before the Application

After the Application


• Slate Roof Insulation Coating Project• Application Area – 165,000 m2

Nissan Motor Co., LTD

Before Cool Therm Application After Cool Therm Application


Energy Performance Field TestingSony Koda Factory

May 1994 (Before Application)3,767KWMay 1995 (After Application)519KWJune 1994 (Before Application)

5,647KWJune 1995 (After Application)1,869KW

Hitachi ElectronicUncoated (Before Application) 82ºCCoated (After Application)

47ºC


Apartment Buildings in Munich, Germany

• Only 3 sides of the building were coated with Super Therm

• 3 apartment buildings with common heating system

• Water heating savings against previous year – 6,000ltr

• Total energy savings – 20%

Hot Pipe Coating (HPC)

0.0700

0.0650

0.0600

0.0550

0.0500

0.0 10.0 20.0 30.0 40.0 50.0NEW RUSSIAN TESTING : RESULTS: W/mK is 0.025.

Relation between the thermal conductivity of Hot Pipe Coating and

its average temperature

Ther

mal Co

nducti

vity

Thermal conductivity at different mean temperatures

Mean Temperature ºC

Thermal Conductivity (W/m,K)

-10010203050100200300400

500

0.0590.0600.0610.0620.0630.0660.0710.0830.0940.1060.117

HSC® – Hot Surface Coating

• Single component and water based• Applied over surfaces that are small in size and difficult to get to

• Single component and water based

• Applied over surfaces that are small in size and difficult to get to

• Smoother in appearance than HPC®• Goes over surfaces up to 170C• Can be sprayed with a standard airless 7900HD spray machine

PEMEX TURBINE IN GULF OF MEXICO. 500C down to 80C, HPC applied at 1.5” or 37mmAnd applied in one effort at the unit. Spray on in thin coats while operating and allowSteam to escape, then with additional coats, increase thickness and apply to full thickness.

PEMEX rigs, Gulf of Mexico, RUST GRIP for a single coat corrosion protection and HPC as theInsulation for the hot pipes, replacing wrap and jacketing, then OMEGA FIRE as the fireProtection for the Fiberglass water pipes for fire control. Coating directly over the pipes.

HPC sprayed directly over cleaned hot surface pipes without corrosion primers. BecauseOf the heat level, HPC is applied first to contain the heat and then RUST GRIP is appliedOver the HPC as the corrosion protection to seal air and moisture from entering the HPC.

Enamo Grip / 5000

• Solvent two-part polyurethane• Finish coat in any color and also clear gloss or matte

Enamo Grip• Solvent two-part polyester.• Designed to withstand acids and chemical splash or vapors in any environment.

• UV controlled to be used on the exterior to protect tanks, pipes or equipment from chemical and UV deterioration

• Used over all metal surfaces.• Used on concrete flooring to protect concrete in the environment from splash and acid drips that deteriorate the concrete and cause cracking

Enamo Grip 5000

Lining Kote UHS

• High molecular weight two-part epoxy• Used to coat the interior of acid or chemical tanks• Used in oil fields and petrochemical areas• Used for coating the interior of drilling mud tanks and frac tanks to contain drilling liquids and protect the interior of the tanks

• Used by Haliburton Oil in Australia and some tanks have performed for 8 years without deterioration.

• Most tanks deteriorated within 1 year before Lining Kote UHS came into use

Return of Investment

Cost Effectiveness of SPI3 Part System Steps

Sandblast$4.50/sqftPrimer $0.30/sqftIntermediate $0.30/sqftTop coat$0.30/sqftLabor $1.50/sqft

Rust Grip System

Total $6.90/sqft

Power Wash$0.75/sqftRust Grip$0.75/sqftLabor $0.50/sqftTotal $2.00/sqft

• DOE (Dept of Energy) study and SONY study shows SUPER THERM provides 13 month up to 2 year return on investment

• DROP BTU or Watt heat load from 108 watts down to 1 watt per sq.m per hour over the tank surface

• Replace sandblasting and 3 coat system.• Encapsulates Lead Based Paint Without Removal or Exotic Containment• Save 60% of total cost and time now used over conventional systems• RUST GRIP is 20 years old with testing and field proven


One Coat Paint System• Eliminate Sandblasting: Reduced surface preparation costs (SSPC-SP2 vs. SSPC-SP10)

• Encapsulate lead based paint: with its ability to encapsulate lead-based paint, existing rust or Asbestos

• Rust Grip® will dramatically reduce the need to monitor and maintain rigs, pipes or tanks coated with the traditional overcoat method

Replace Jacketing• Current Metal Jacket is not air tight and not moisture tight• Moisture and air blows into the insulation• HPC® to insulate over all configurations• SUPER THERM® to seal off from air and moisture• RUST GRIP® to give a 0.24 permeability to block moisture, air flow, chemicals and salts with a 6780 psi (475 bar) surface tensile strength that covers 100% of the pipe surface, including valves and odd configurations

• RUST GRIP® acts a monolithic metal jacket with no seams, no air leaks and no moisture absorption


Effectiveness of SPI products

• Replace the wrap and jacket system that can cost up to $65 per linear foot

• HPC®, SUPER THERM® and RUST GRIP® system can cost up to or less than $25.00 per linear foot subject to thickness used

• Another option: Keep existing insulation wrap, but remove the metal wrap and replace with a coat of SUPER THERM® to seal and RUST GRIP® to be the monolithic air and moisture tight jacketing that prevents CUI

• Easy to apply, then easy to repair and reapply saving millions in time and materials

• Reduce the replacement schedule for pipes, tanks and equipment

• This amounts to millions and billions in savings over a single year up to 10 or 20 year life expectancy for the equipment and facilities

•Before application, the room temperature on the 2nd floor exceeded 37-40ºC in summer, after the application, the room temperature was kept around 33ºC

Toshiba Logistics CorporationKyushu Branch

•After the application, the room temperature had decreased by 5 to 7ºC. With the comparison of the same outside air temperature, the coating maintained same insulation effect in 2004, even after 10 years after it was applied


Temperature ResultBefore After 10 years

33.5ºC 32.5ºC 34.3ºCOutside39ºC 32ºC 33.5ºCRoom

Temperature ResultBefore After 10 years

35.5ºC 36ºC 35ºCOutside39.2ºC 32.9ºC 33ºCRoom

KOKUYU CO., LTDNagoya Distribution Center

SPI Performance

• Passed 15,000 hours (625 days) of UV, Salt Spray and Weathering cycles without dropping from a perfect 10 score. Single coat at 150 microns (6 mils) dry thickness

• Passed 7,000 hours and running until 10,000 hours on latest ASTM D5894 UV, Salt Spray, dry sun cycles

Rust Grip• Lab tested and field tested for 18 years. Losing only 8% of reflective ability and only losing 37 microns from 200 micron dry film thickness when first applied

• Passed 5,000 hours of ASTM D5894 UV, Salt Spray and dry sun cycles – just to see how it would weather. Good results

Super Therm

• Advantages:• SUPER THERM saves energy, reduces condensation inside

storage tanks and evaporation. Reduces surface temperature of surfaces facing the sun to within two degrees of ambient. Reduces the “initial heat load” which is the purpose of insulation, to reduce the amount of heat transferring to the cool side.

• RUST GRIP replaces three coat systems with a single application. Time, reduced or no blasting and longevity (performs longer) because it encapsulated the surface by anchoring deep into the pores of the surface rust or metal, expanded and sealed to a 6780psi surface tensile strength.

• HPC/ HSC replaces wrap and jacketing that never did work well and everyone agreed. The only coating recognized in the world market (expressed by Pemex and Aramco) to coat over surfaces above 300F and provide the insulation to save heat loss and increase the heat inside the unit to realize a very large jump in efficiency which can pay for the coating in 8 days (Aramco) to less than a year. No need to strip off wrap and jacketing, but the valves and areas not wrapped can be coated and a savings can be realized immediately. New construct or rehab can be coated instead of using the wrap and jacketing. Cost: 6” pipe with 3” of wrap and jacketing is $58.48 per foot and 500 mils of HPC (mtl only) is $29.00/ linear foot. (From local insulation company that handles wrap and jacketing.)

The SPI Family of Performance Coatings

Insulation/Fire Control

Top Coats

Super Therm® Enamo Grip 5000Epoxotherm Enamo Grip SAS

HPC® Coating SP LIQUID MEMBRANEHSC® Coating SP SUPER SIL

(Silicone)Omega FireTM Sealants/Roofing

Super Base HSCorrosion Control Total Seal

Rust Grip® / RG 1000Moist Metal Grip Stucco SystemLining Kote UHS iSTUCCOTM

Emano Grip

Contact

• 10835 W. 78th Street• Shawnee, Kansas 66214• Phone: 913-962-4848• Fax: 913-962-6767 • www.spicoatings.comContacts: Tim Cappel (VP Sales) 913-669-2550 –[email protected]

BJ Ray (Sr. Project Supervisor) 816-225-5748 – [email protected]

Jacob Ray (Project Supervisor) 816-352-1039 – [email protected]

Craig Smith (Technical Mgr) 816-807-3556 – [email protected]

Boris Minasov (Heat Transfer Eng) 913-226-2090 – [email protected]

mailto:%E2%80%[email protected]

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SPI PP Short 2014

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