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Free Vendor Highlight:
About Advanced Polymer Coatings
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CASE STUDYParticipating Vendors:
Project: Automotive Phosphate
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Scope of Work On June 26, 2010 the contractor Ultimate Corrosion Control Inc. commenced the job at 7PM and completed the job July 3, 2010 at 7AM. The scope of their work was to abrasive blast and line two tanks and the housings over those tanks. This report describes the Stage 2 Alkaline Cleaner tank, the more technical and critical portion of the job. Ultimate Corrosion Control (UCC) furnished workers that performed quality work at the plant previously and who are experienced and knowledgeable in the surface preparation and application of high performance industrial coatings.
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 Ultimate Corrosion Control provided extemely quick and efficient turn around by effectively staging the project. |
Top row, left to right: Removal of existing fittings; water-jet swirls on tank walls shows the many layers and coatings being removed; protective cover over tank during blasting/coating.
Lower photos, left to right: air bag for collecting blasting debris; debris collection and removal system.
Cleaning & Abrasive Blasting
All surfaces to be lined surface prior to abrasive blasting were cleaned by with a hydro-jet at 30,000 psi. All surfaces were free from contamination from grease, oils or salts.
After cleaning, the surface was abrasively blasted to SSPC-SP5 (NACE #1, SA3) white metal finish with 3 mil profile. Black Beauty 1240 was used in accordance to specification of the coating manufacturer, Advanced Polymer Coatings. The blasting debris was collected in vacuum boxes and the airborne contaminates collected in large dust bags.
The tank was cleaned and primed in a fashion that did not compromise the abrasive blast. Humidity was monitored and was 65% or lower during coating operations and the substrate temperature was within the range 10º to 40º C and 3º C of the dew point.
Primer Coating Applied
UCC applied the first spray coat of ChemLINE 784-32 (red) to the floors and walls of the dip and weir tanks and the suspended stairs at 6-8 mils (150-200) microns wet film thickness in accordance to the specification.
UCC allowed the (red) prime coat to cure to the B Stage and applied one coat of mixed clear Siloxirane resin and hardner and pressed one layer of fiberglass mat into the wet basecoat and fully saturated the fiberglass reinforcement.
The fiberglass coves, fiberglass couplings and eductor header outlets were installed using thickned ChemLINE 784-32. This was allowed to cure to B Stage.
Added between the primer coating and the final coating, fiberglass reinforcement improves the lining’s resistance to damage.
Fiberglass Reinforcement Applied
Once the prime coat was completed in both tanks, UCC applied fiberglass reinforcement prior to the full coat application. With fiberglass reinforcement the lining will be resistant to scrapes, and gouges from parts falling, dragging and piling up in the tank bottom and sides
About ChemLINE 784-32 Final Coating
The Advanced Polymer Coating called ChemLINE 784-32 was specified because the vinyl ester lining had failed in this tank and a more durable heat resistant lining was desired. ChemLine 784/32 will significantly improve lining performance for the Alkaline Cleaner Stage over the vinyl ester installed previous.
ChemLine 784/32‘s Higher Cross-Link Density (shown in the graphic above) as compared to the vinyl ester will provide:
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Left, A top coat was applied using ChemLINE 784/32. |
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A second full coat of ChemLINE 784/32 (Gray) at a wet film thickness of 7-8 mils was applied to achieve 6-7 DFT top coat. The tank was covered with 2” of ceramic insulation and held in place using Unistrut placed perpendicular to travel.
A temperature probe and chart was installed by PW at the roof level to insure that housing temperature did not activate the sprinkler system in the plant. At no time did the temperature exceed 75º F.
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The size of heating equipment and number of heaters used by UCC were adequate for the job. Indirect forced air heating was used using propane. The soak temperature used was 185º F for six (6) hours. A chart of the cure schedule results verified the post cure schedule.
In addition to unique application products and techniques, the project also offered several innovations, some requiring fabrication by Chemical Containment.
Fiberglass Coves - The fabricated fiberglass coves where assembled onsite and custom fitted.
1. Fiberglass Inserts - The fiberglass inserts shown in the fabricating process and installed.
2. Pipe Supports - Shown with adjustable chain.
3. Fiberglass Handrail, Ladder and Gratting - Traditional equipment was replaced with fabricated fiberglass. Shown right, the area before replacement.
Additional Areas of Interest
The refurbished Stage 2 Weir is shown with fiberglass insert, note the pipe supports with adjustable chains.
In conclusion, Ultimate Corrosion Control performed the task at hand in accordance to Advanced Polymer Coatings specification. The client is assured to receive long term service life for the tank lining plus the cleaning of the Stage 2 will be easier because of the low surface energy of the very dense coating applied in the tank.
For more information please contact:
Paul Turner
Tel: 586-792-3325
Fax: 586-792-2711
Email: info@chemicalcontainment.com
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After the complete ChemLINE 784/32 coating system was applied, a 70º F dry air was blown into the tank to promote material to release solvent and to be ready for soak post cure.
