Selecting the Proper Coating/Lining System

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Selecting the Proper Coating/Lining System

• Kevin Morris
• Market Director Water Wastewater
• Sherwin-Williams

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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.

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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.

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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.

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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.

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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

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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?

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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

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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

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Surface Preparation Affects in System Selection

• ICRI Guideline No. 310.2, Selecting and
  Specifying Concrete Surface Preparation for
  Sealers, Coatings and Polymer Overlays

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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)

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Surface Preparation Affects on System Selection
The greater the DFT the greater the Surface
Profile
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Surface Preparation Affects on System Selection
The greater the DFT the greater the Surface
Profile
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Surface Preparation Affects on System Selection
The greater the DFT the greater the Surface
Profile
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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

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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.

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Aliphatic Polyurethanes

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

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Aromatic Polyurethanes

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

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Fluoropolymers

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

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Polysiloxanes

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

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Acrylics

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

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Alkyds

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

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Zincs

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

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Polyureas

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

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Novolac/Phenolic Epoxies

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

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Vinyl Esters / Polyesters

• Atmospheric and Immersion Service
• Excellent Chemical Solvent Resistance
• Fair Flexibility
• Good Abrasion Resistance
• Fast Cure
• Min Cure Temps Required

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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

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Thin Film Systems
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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

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Medium Film Coatings/Linings
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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

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Laminate Lining Systems
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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

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Mortar Systems
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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

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Self-Leveling Mortar System
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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

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Mortar Laminate Systems
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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

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Heavy Duty Mortar Laminate Lining Systems
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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

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Flexible Coating and Lining Systems
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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

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

• Any Questions