1. Corrosion costs the Indian economy heavily per annum in the form of
- Premature equipment deterioration or failure resulting in the need for
maintenance, repair & replacement of damaged equipment.
- Industrial leakages, contamination & accidents.
- Lost of production & increased downtime.
- And in some cases even investment in additional standby equipment.
Today corrosion is in fact the single largest maintenance cost over the lifespan of
an equipment & is a constant charge to a companies capital bank. Estimated to be
in-between 4-10%, of the cost of plant & machinery /structures… per annum.
WHY CORROSION ?
5. High Temperature Corrosion – Bowl Mills High Temperature Corrosion – ESP Domes
High Temperature Duct Corrosion
Galvanised Surface Corrosion
6. Why Coating Failures ?
Blistering Cracking /Flaking Peeling
Efflorescence Heavy Corrosion Due to Acidic Fumes
7. Questions: Why is corrosion taking place
in India, when every industrial customer,
is regularly spending on anti corrosion
coatings, paints... being bought from the
world’s leading brands ?.
WHY CORROSION ?
9. Conventional Technologies Require :-
– Clean Surface (Free of Rust /Dust /Oils…)
– Dry Surface (Free of moisture)… Rust = Hydrated iron oxide…
– Anchoring Profile - 30-50 microns external
- 50-70 microns immersion
Today’s technologies are NOT designed to adhere to metal surfaces that are not clean, dry & without
a profile. Present primers do not adhere well on rusty /wet… ST2 /ST3 surfaces & therefore for
performance all manufacturers today ask for:-
- For external use : SA 2.5 Blasting
- For immersion use : SA 3.0 Blasting
Sa2.5 – Near white
metal
Sa3 – White metal
St2 – Hand tool
cleaning
St3 – Power tool
cleaning
Today’s Coatings Need…
…But are Being Applied on
PROBLEM NO 1: ADHESION ISSUES
10. SURFACE PREPARATION STANDARDS
SSPC—THE SOCIETY FOR PROTECTIVE COATING.
NACE—NATIONAL ASSOCIATION OF COROSSION ENGINEERS.
NACE No. 4/SSPC-SP 7 /SWEDISH Sa.1---Brush-Off Blast Cleaning.
NACE No. 3/SSPC-SP 6/ SWEDISH Sa.2-- Commercial Blast Cleaning.
NACE No. 2/SSPC-SP 10/ SWEDISH Sa.2.5--Near-White Metal Blast
Cleaning.
NACE No. 1/SSPC-SP 5/ SWEDISH Sa.3 --White Metal Blast Cleaning.
A brief description of each of the four levels of cleanliness is as follows:
Brush Off - Loose mill scale, loose rust and foreign particles are removed.
Commercial - Mill scale, rust and foreign particles are substantially
removed and grey metal is visible.
Near White Metal - Mill scale, rust and foreign particles are removed to the
extent that only traces remain in the form of spots or stripes. The cleaned
surface will show varying shades of grey.
White Metal - Visible mill scale, rust and foreign particles are entirely
removed. The cleaned surface should have a uniform metallic colour but
may show varying shades of grey when viewed at different angles.
11. HIGH SURFACE TOLERANCE COATING ARE THE SOLUTION.
Coatings that have high surface tolerance, compared to other modified epoxies, have lower
surface tension into the substrate, adhesion is superior and they are moisture tolerant. They can
be applied faster and more easily on less well prepared surfaces delivering real savings in time
and money.
Apply even on firm aged coatings, flash rust,
moist…. surfaces
Excellent flow & wetting due to low surface
tension
Ultimate in adhesion & corrosion preventionPenetrates deep
13. •Rust-tolerant: Surpasses any so called “Surface-tolerant materials” hence it is called Rust-tolerant. Ideal for poorly and
hand prepared surfaces (ST2 or WJ-4).
•Wet-tolerant: Surpasses any so called “Moisture-tolerant materials” hence it is called Wet-tolerant. The product can be
applied in any humidity and on really wet surfaces. No dew point restrictions.
•Any surface preparation method: Choose the most convenient/cost effective system, e..g.grit-blast, wet-blast, HP
water jetting (500-800 bar), UHP or mechanical (ST 2 /ST 3).
•Durable protection: Superb corrosion resistance (new MIO-Zinc technology).DFT >150 microns protects the substrate
in excess of 10 years in field conditions (independent test certificates available).Needs minimal surface preparation, yet
provides long term protection. Can be used as a primer or primer-finish or over coated with a color finish.
•U.V. Tolerant. Ideal as a “stand-alone” system for large structures and pipe work in harsh or exposed environments.
Does not require PU top coating.
•Unique combination of high flexibility as well as high surface adhesion: Tensile
•elongation values are in excess of 7%. Product does not crack in flexural testing or in 180° Conical Mandrel Bend
testing… yet exhibits >1200 psi Pull – Off adhesion values, on rusty /wet steel surface. Will thereby exhibit superior crack
/de-lamination resistance. Will not chip-off, despite surface damage. Will perform excellently on surfaces exposed to high
stress /strains… where generally epoxy coatings tend to detach /peel – off.
•Excellent acid resistance: With--stands >7days immersion in 50% H2SO4, 33% HCL… ideal for protecting metallic &
concrete structures against acidic fumes & even intermittent acid spillages.
•Unlimited over-coating: Ultimate product for start/stop maintenance projects. Can be applied on rusty/wet/sweating
substrates, excellent adhesion (>1200 Psi). Easy touch-up /refresh coating.
.Good edge coverage: Reduces need for stripe coating.
•High solids: VOC compliant.
•Unique high density formulation: Specific gravity >2.
•Suitable for new, aged or rusty galvanized steel.
•Oil tolerant: Can even be applied over oily surfaces, e.g. oil soaked concrete, where thorough oil removal is not
possible.
Requirements of a Good Anti-Corrosive Coating
23. Epoxy Coating Capable of application on
Damp, Water Saturated, Green, Concrete…..
As well as for “Negative Pressure” Water
Proofing.
CONCRETE PROTECTION
24. Why Concrete Damage ?
Water Saturation & Re-Bar Corrosion; Acid Attack; Loss Of Alkalinity & Spalling
Severe Concrete CorrosionConcrete Cancer – Loss of Alkalinity; Spalling ;
Re-Bar Corrosion;
Sulfuric Acid Attacked Concrete
Severe Corrosion in Concrete Catastrophic Concrete Corrosion & Failure
25. 1. Water ingress leads of corrosion of steel reinforcements, As lead to
expansion as corrosion products develop.
2. Expansion leads to tension between reinforcements & concrete
cover.
3. Leads to spalling of concrete cover.
WHY CONCRETE DAMAGE ?
26. Applications:
1. Cooling towers.
2. Containment areas.
3. DM plants.
4. Water treatment plants.
5. Dams & irrigation.
6. Tunnels and subway.
7. Concrete Tanks & Pits.
8. Basement flooring and wall coating
• A complete Negative pressure water proofing system…
THE SOLUTION = “BREATHABLE” TECHNOLOGY
27. Niche Market Industrial Coating
Manufacturer Product Name Product Cost
Per Sq. M
Application
Cost Per Sq. M
Application
BELZONA-NICCO R METAL/ S METAL/1341 20-25 K INCLUDED Condenser Tube Plate
& End cover. /CW
pump coating
ITW –DEVCON TITANIUM PUTTY/BRUSHABLE
CERAMIC
25-35 K INCLUDED --DO—
STANVAC 1170/1180/1190/1195 15-20 K INCLUDED --DO--
