CoatingsPro Magazine

NOV 2018

CoatingsPro offers an in-depth look at coatings based on case studies, successful business operation, new products, industry news, and the safe and profitable use of coatings and equipment.

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COATINGSPRO NOVEMBER 2018 41 experience w ith Belzona products. Having so much support onsite was ver y helpful. A ny questions we had about the products and the application process were answered right away, and this really kept the project moving," stated Vera. T here was also a NACE Level III inspector onsite to inspect for holidays in the coating system. T he f irst step in the application process was for the crew to insta l l Belzona 1511 Super HT ( high temperature) Meta l. T his heat-resistant, paste-g rade meta l epox y is used for rebui ld ing meta l loss. It is a t wo -par t repair composite based on a solvent-f ree epox y resin reinforced si licon w ith steel a l loy. T he product prov ides excel lent cor rosion and chemica l protection, and under immersion, Belzona 1511 Super HT Meta l is suitable for applications up to 160 °C (320.0 °F). It can a lso be over-coated w ithout the need for add itiona l sur face prep, sig nif icant ly reducing operationa l dow ntime as wel l as cost. 'e application was done by hand using a spatula and plastic applicator supplied by Belzona. "No brushes or rollers were used at all in the application of the material. It was all hand-applied, and the thickness of application depended on the depth of the metal loss," said Vera. On top of the •rst layer, the crew applied two coats of Belzona 1593, a two-part hand-applied epoxy coating designed to provide long-term corrosion and chemical resistance to equipment operating in continuous immersion. According to information from the manufacturer, it withstands a steam- out process up to 210 °C (410.0 °F) and rapid depressurization. Belzona 1593 has excellent adhesion to metal surfaces and high retention of adhesion at elevated temperatures. In addition, downtime is reduced because of the material 's post-cure mecha- nism activated at service temperatures. "We hand-applied each coat at a thickness of 15 to 20 mils [381.0–508.0 microns]," stated Vera. 'e crew again used a spatula and plastic applicator to apply those two layers. The topcoat was Belzona 1593, applied in the same manner in two layers at 15–20 mils (381.0–508.0 microns) each. The crew wore Ty vek suits, gloves, shoe covers, and eyewear when coating. JOB AT A GLANCE PROJECT: Rebuild metal loss and coat interior liner of a deaerator tank at a New York state power plant COATINGS CONTRACTOR: Tower Maintenance Corp. 1 Plaza Rd., Ste. 102 Greenvale, NY 11548 (516) 305-5100 www.towermaint.com SIZE OF CONTRACTOR: 40–50 employees SIZE OF CREW: 6 crew members PRIME CLIENT: Westchester Department of Public Works and Transportation 148 Martine Ave. White Plains, NY 10601 (914) 995-2548 https://publicworks.westchestergov.com SUBSTRATE: Steel CONDITION OF SUBSTRATE: Severe metal loss and rust over the entire surface; wall thickness was not compromised SIZE OF JOB: 500 sq. ft. (46.5 m²) DURATION: 1 week UNUSUAL FACTORS/CHALLENGES: » The schedule was extremely tight as the tank was needed back in opera- tion before winter temperatures hit. » The coatings were originally applied as a temporary fix, but they performed well and became the permanent solution. » It was the first experience for Tower Maintenance Corp. with working with the Belzona coatings. A Belzona New York representative was onsite for the duration of the job to advise. MATERIALS/PROCESSES: » Abrasive blasted to NACE No. 3/Society for Protective Coatings (SSPC) Surface Preparation (SP) 6: Commercial Blast Cleaning, had it inspected and repaired, and reblasted to NACE No. 2/SSPC-SP-10: Near-White Blast Cleaning » Applied Belzona 1511 Super HT (high temperature) Metal by hand using a spatula and plastic applicator supplied by Belzona New York; thickness of product applied depended on the depth of metal loss » Applied Belzona 1593 using a spatula and plastic applicator at 15–20 mils (381.0–508.0 microns) each SAFETY CONSIDERATIONS: » Trained and certified for confined spaces » Wore full helmets/face mask with independent air supplies and ear protection during abrasive grit blasting » Wore Tyvek protective suits, latex gloves, shoe coverings, and protective eyewear during coating applications

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