CoatingsPro Magazine

NOV 2014

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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JOB AT A GLANCE PROJECT: Coat the concrete, and create a secondary containment in the pit, which was set up to collect and clean the solid waste (aka sludge and cuttings) from the oil liquids carried by the waste management trucks COATINGS CONTRACTOR: R&R; Oilfield Construction P.O. Box 2255 Graham, TX 76450 (940) 549-6907 www.rrocinc.com SIZE OF CONTRACTOR: 60 employees SIZE OF CREW: 4 crew members worked this job PRIME CLIENT: Trisun Energy Services, LLC 7501 Miller Rd. 2 Houston, TX, 77049 (281) 860-0900 www.trisun-energy.com SUBSTRATE: Concrete CONDITION OF SUBSTRATE: New SIZE OF JOB: 18,000 sq. ft. (1,672 m²) DURATION: 3 days UNUSUAL FACTORS/CHALLENGES: » The crew worked with the client to come up with a secondary containment for the oil pit that would not use high-density polyethylene (HDPD) liners. » The coatings system needed to be able to protect the concrete from trucks, abrasives, cuttings, saltwater, hoses, and tools. » The heat index ranged from 108° F to 110° F (42–43° C) every day. MATERIALS/PROCESSES: » Started work on the 3,000 psi (21 MPa) concrete once it had cured for 45 days » Abrasive-blasted the concrete in 12 hours using a Clemco blast unit and Black Beauty coal abrasives » Sprayed Perma-Crete 5400 to the entire surface at a rate of 200 square feet per gallon (19 m²/L) » Spray-applied Dow Chemical's Hyperlast LU 1047 Polyol mixed with Hyperlast LE 5011 Isocyante using a pressure pot, air assist spray tip, and 150-foot-long (46 m) hoses at 6–8 mils (152–203 microns) » Spray-applied Dow Chemical's 100 percent polyurea system, Vorastar HA 6440 Polyol/Vorastar HB 6042 Isocyanate at a thickness of 100 mils (2,540 microns) using a Graco HXP3 unit » Broadcast Black Beauty abrasives into the wet topcoat to act as anti-skid material SAFETY CONSIDERATIONS: » Wore flame-resistant clothing (mandated by the facility), Tyvek suits, and full face respirators » Used one truck as a "cool zone" to mitigate heat exhaustion COATINGSPRO NOVEMBER 2014 67 and still provide the abrasive protection from the slurry/cuttings was needed." For those keeping track, this polyurea needed to protect against trucks, abrasives, cuttings, saltwater, hoses, and tools. Luckily, for this coatings contracting company, it was an order they could fll. And, as it turns out, the chosen Dow system was the perfect solution for the client's myriad qualifcations. Work It! RROC's job started as soon as the pit was set up. Te 18,000 square feet (1,672 m²) of surface was created using 3,000 psi (21 MPa) concrete, which was new and included a fbermesh and " hi early" additive. Once the concrete pit had cured for 45 days, the coatings crew was able to get onsite and get right to work. Wearing fame-resistant clothing (mandated by the facility), Tyvek suits, and full face respirators, the crew abrasive blasted the concrete as prescribed in the standard NACE No. 6/Society for Protective Coatings (SSPC) Surface Preparation (SP) 13: Surface Preparation of Concrete. It took them 12 hours to blast the entire unit using a Clemco blast unit and Black Beauty coal abrasives. Te crew, which also depended on the expertise from appli- cator Courtney Ross, then sprayed Perma-Crete 5400, a PPG product, to the entire surface at a rate of 200 square feet per gallon (19 m²/L). Te Perma-Crete helped to eliminate any water vapor transmission through the concrete substrate. "It stops the gassing on the concrete to prevent pinholing," explained Rogers. Once that dried, his crew started in on the coatings applica- tion. Working their way in rows up the driveway-like pit, they spray-applied the two-part polyurethane primer to the entire substrate. Tis was Dow Chemical's Hyperlast LU 1047 Polyol mixed with Hyperlast LE 5011 Isocyante. Tey applied this 6–8 mils (152–203 microns) layer, which was cut with 10 percent acetone to help with the viscosity during application, using a pressure pot, air assist spray tip, and 150-foot-long (46 m) hoses. Te fnal layer for this secondary containment project was Dow Chemical 's 100 percent polyurea system, Vorastar HA 6440 Polyol/ Vorastar HB 6042 Isocyanate. Te crew spray-ap- plied this beige seamless topcoat at a minimum thickness of 100 Wearing flame-resistant clothing, Tyvek suits, and full face respirators, the crew then spray-applied Vorastar HA 6440 Polyol/Vorastar HB 6042 Isocyanate at a minimum thickness of 100 mils (2,540 microns). They used abrasives in the topcoat for anti-skid.

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