CoatingsPro Magazine

MAR 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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60 MARCH 2018 COATINGSPROMAG.COM on the aesthetics of the system. "e specified coating was certainly a functional coating system, but the owner of the utility didn't want the plant's 'crown jewels' coated in an alumi- num coating that was not at all pleasing to look at," said Philipp. e CUI team worked with Kiewit and the Sherwin-Williams technical services department to engineer a high-temperature coating system to solve this problem. e team ultimately decided to install Sherwin-Williams' Heat-Flex Hi Temp 1000, a specially engineered silicon hybrid resin that is high-temperature resistant that can be applied directly to shop-applied inorganic zinc and has a low overspray risk. "is product can withstand tempera- tures from 500 degrees Fahrenheit [260.0 °C] to 1,000 degrees Fahrenheit [537.8 °C], as well as severe thermal cycling. It also provides excellent corrosion protection over the shop-applied inorganic zinc. e owner was very pleased because the Heat-Flex 1000 also comes in multiple packaged colors," said Philipp. e color options gave the owner more flexibility to showcase their major investment in clean energy technology. Active Jobsite W hen the 10-man CUI crew set out to begin the coating work, it became very clear that the low overspray risk of the Heat-Flex 1000 would be a huge asset in maintaining the schedule and keeping the other trades on the jobsite happy. One of the characteristics of Heat-Flex 1000 is that it dries very quickly. According to Philipp, it almost dry falls. is allowed the crew to speed up the schedule by spray applying the coating but without incurring the risk of overspray. "ere were many, many other trades onsite and lots of equipment. e last thing we wanted to do was get overspray on construction vehicles and sensitive equipment, like cranes and lifts," stated Philipp. Given the fast-drying property of the Heat-Flex coating, the crew was able to work more easily around the other trades, and they did not have to extend the schedule by roller and brush applying the coating to the 300,000 square feet (27,870.9 m²) of surface area. e crew worked on the job over a one-year period. A ll intakes, stacks, and HRSGs were brand-new carbon steel shop-coated with zinc. According to Philipp, although the crew had to take some breaks during the warmer months on the job due to wet weather — the humidity in the south affected the application process — cold winter weather did not stop progress on the job. "We were lucky that, for the most part, the weather was cooperative. at coupled with being able to spray apply the Heat-Flex 1000 really helped us keep on schedule," said Philipp. All About the Prep On an active construction site, surface preparation can be a huge challenge. e CUI team took this into account and worked with Graco to come up with a surface prep plan that would not inter- fere with the other construction trades but would provide the proper anchor for the Heat-Flex 1000. According to Philipp, the carbon steel needed to be in compliance with NACE No. 2/Society for Protective Coatings (SSPC) Surface Preparation (SP) 10: Near-White Blast Cleaning. And even though they were prepping only the weld seams in the field, a strategy was still necessary. To achieve this, the CUI team brought in two of Graco's EcoQuip 2 EQ Elite vapor blasting machines. "e EcoQuip 2 EQ Elite units generate little or no dust versus dry abrasive blasting or mechanically prepping substrates. ey also use less water than traditional water-based wet blasting. We used garnet supplied by BlastOne as the media," explained Philipp. HoldTight 102 solution was added to the media mix. is solution removes all salts and contaminants from substrates and helps prevent flash rust. Using the vapor blasting equipment increased productivity and created an angular profile on the steel, all the while keeping the crew — and the other trades — from being exposed to dust and debris. "ese units proved themselves beneficial not only on the carbon steel but also in helping CUI comply with the OSHA [Occupational Safety and Health Administration] silica exposure standard when preparing concrete surfaces in other areas, such as concrete containments, sumps, and trenches," said Philipp. ere were areas on the intakes, stacks, and HRSGs, though, where power tool cleaning was required. e CUI team used an MBX Bristle Blaster to prepare the welds that were near It took a 10-person crew from Coatings Unlimited, Inc. a year to prep and coat the 300,000 sq. ft. (27,870.9 m²) of steel on the new intakes, stacks, and generators at an active combined-cycle power plant. The crew complied with all safet y standards and rules. They wore respirators and protective suits when necessar y, and they were tied off when working at heights. The crew also used a third-party safety consultant. Steel Surfaces

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