Chapter V

COATING SYSTEMS FOR VARIOUS

STRUCTURES
 Chapter V

COATING SYSTEMS FOR VARIOUS STRUCTURES

From the visit to certain structures and factory visit it has been
observed that the methods adopted earlier to prevent the structures from
corrosion was not scientific and adequate, it was trial & error techniques

only. Also it has been seen that method adopted was not effective to
prevent the corrosion for important structures. Study has been made to

find out the method adopted earlier and why it was not effective. And what
should be the proper methods to arrest or minimize the corrosion ^form
existing system.
Before studying the high performance coating, it is necessary to
know the methods used earlier. Following methods of painting or coating
Vwas adopted for the steel structures. Also it was observed that in earlier

methods most of the places concrete structures were not coated

Structural steel:
Earlier method for coating the structural steel, -

After Procurement of structural steel,-

Step 1: Application of Red Oxide as a primer without any surface
preparation. Without monitoring the environmental parameters.

Step 2: Application of Finish paint (mostly synthetic enamel was applying

as finish paint).

Findings on the above method,-

When structural steel brought from market, it is in the form of

adherent rolling mill-scale on the bare steel surface, it is uniform layer
through out the surface. ^considering the new steel peoples applying red

oxide on it directly. But mill scale appears adherent, which needs not to be

138
completely adherent, and it is a temporary barrier on the surface. If such
steel exposed to weather, mill scale will (starts rusting, If this mill-scale

embedded in the coating. Coating tends to fail because red oxide primer is

not impervious and is not arresting vapour transfer, resulting into rusting of
mill-scale & eventually failure of coating. Hence require frequent

maintenance, if not failure of structures cannot be avoided.

Conclusion:- {(
In all cases, even though the mild exposure pr dry weather, it is
always recommended to remove all mill scale by mechanical means or
grinding for better performance of any painting to reduce the maintenance

cost. But other than the mild exposure, exposure conditions as explained
earlier, this system is not adequate to sustain tee structures in aggressive
environment. For this, ‘High Performance Coating’ is tee only solution.

As studied earlier, high performance coating like epoxy,

polyurethane, etc are available in tee market. But only the good product is
not sufficient, it requires proper selection of coating depends or exposure
conditions, type of substrate, proper application, proper environmental
parameters control, etc. Each and every conditionj^nentioned above is

equally important for the performance of coating. Therefore using ‘costly’

coating is not solution but to ‘understand’ and ‘perform’ accordingly as

explained in earlier chapters, is the only solution to prevent tee structure
from corrosion.

In this project, study has been made on the following structures

highlighting the types of coating, methods of application, performance tests

etc. The candidate had chance to work in Dabhol Power Project with

Bechtel International Inc., and also visited few industries. Based on

observations & discussion with tee authorities tee coating system
suggested in this chapter tor various structures have been tried in Dabhol
Power Project and performance was observed for more than a year (for

various temperatures & weather conditions). It was found that tee coating
systems adopted was satisfactory.
, / f

139
THE DIFFERENT STRUCTURES STUDIED ALONG WITH THE EARUER
METHODS OF COATINGS ARE,-

A) STEEL STRUCTURES:
1. Storage Tanks
I. Water storage tanks
II. Add & Alkali storage tanks
lil.Naphtha & Distillate Storage Tank

2. Chimney (Stacks)
I. Dual wall (Insulated)

3. Pipelines
I. Water supply line
II. Heat resistance pipes

4. Body Accessories of Equipments

B) CONCRETE STRUCTURES:
1. RCC Cooling Tower: Following are the sections of Cooling
tower, -
I. Hot water basin (Part of cooling tower situated at top),
II. Circulating water (C. W.) channel (Area between Cold
water basin and Circulating water pump house.),
III.Cooling water pump sump
IV. Cooling tower Super structure

A) STEEL STRUCTURES:
1. STORAGE TANKS
I) Water Storage Tank:
• Purpose of tank:
Storage of raw water before treatment.

140
• Material used for fabrication:
Structural steel i.e. MS plates, angles, channels, pipes
for connections.
• Dimensions:
Internal diameter 24.4 m I / D
Height: 16.2 m
• Type of roof:
Cone Roof Tank
• Atom covered under coating including supporting
structure:
External surfaces:
Tank Shell, Cone Roof, Curb Angles, Hand Rails,
Outside pipes, staircase.
Internal Surfaces:
Tank Shell, Bottom, Cone Roof, Roof Structure, Inside
Pipe Connections.
• Type of Exposure:
External surfaces exposed to salty weather due to
coastal area.
Internal Surfaces: Under Immersion services, water
pH between 6 to 7 (Potable water)
• Earlier methods of coating on such type of tank:
Internal surfaces:
In earlier method it was found that no coating was
applied.
External surfaces
External surfaces were found painted with Red oxide
as a primer, it was applied without any surface
preparation and synthetic enamel as a finish paint.
• Observation:

141
 i-\i : £

It was observed that most of the surfaces >vas rusted

very badly, internal surfaces were also found rust
flakes all over surfaces.
Drawv backs of material as above or alternative
method:
Major Tanks were of concrete tanks, it is time
consuming and space consuming. Also found lots of
leakage from the connections due to composite
material i.e. concrete tanks and pipe connection were
of MS steel.

• Suggested effective coating for storage tank:

High performance coating is the best solution to
protect the structure from its aggressive environment,-
Following are the systems for better performance,
Internal Surfaces:
Condition is Fresh I Waste Water immersion
This includes areas that remain underwater for longer
than a few hours at a time. The water may be potable,
non-potable, sanitary sewage and many industrial
waste liquids.
Tank lining is the most difficult of any coating work. It
must only be done by experienced workers and should
be inspected at frequent intervals.
One important distinction to make is the lining of a tank
or pipe that will contact or contain potable (drinking)
water. The first systems suggested, two coats of
epoxy (System L) is frequently used for this service,
make sure the material selected meets the necessary
standards and is approved for use by your local health
department. Also it was tested for performance after 1
14 year and was found satisfactory.

142
System Suggested are:
System D - Aluminium Epoxy Mastic + Aluminium
Epoxy Mastic
System J - Epoxy Mastic + Epoxy Mastic
System L - Epoxy + Epoxy (Potable Water)
System L - Epoxy + Epoxy
Features-
Offers two coat, high build protection with ease of
application. We suggest the use of the same product
for both coats. Corrosion inhibitors are not necessary
in immersion service. A third coat may be added for
additional protection.
System-
For Potable Water 2 coat Super Hi-Gard 891 Epoxy
@ 4-6 mils daft (100-150microns)
Surface Preparation-SSPC-SP 5- White Metal Blast.
External Surfaces:
Exposure needs to be analyzed, here with consider the
case of resistance to salty weather & Fresh Water
Spray,-
Frequently wet by fresh water, involves condensation,
splash or spray. This would include interior or exterior
areas that experience frequent cleaning or washing
including stem cleaning.
This group of systems includes the use of inorganic
zinc as a primer. It is generally recognized that
inorganic zinc is the best coating that can be applied
to steel and that it offers the longest term of protection.
Systems using inorganic zinc have been known to last
for over 20 years. In some cases you may need to
substitute organic zinc. This will affect the overall

143
protection quality of the system but only by a small
amount.
System Suggested are:
System B - Inorganic Zinc + Epoxy Primer +
Polyurethane Finish
System C - Inorganic Zinc + Acrylic Latex Finish
System E - Aluminum Epoxy Mastic + Polyurethane
Finish
System G - Aluminum Epoxy Mastic + Acrylic Latex
Finish
System R - Acrylic Latex Primer + Acrylic Latex
intermediate + Acrylic Latex Finish

The procedure of the system B was tried and works

very effectively. The details are,-
System B - Inorganic Zinc + Epoxy Primer +
Polyurethane Finish
Features-
Outstanding corrosion resistance and undercutting
resistance afforded by the primer. -■
The Inteimediate epoxy coal forms a barrier protect the
primer.
The polyurethane finish gives excellent colour gloss
retention.
System-
1 coat of Carboline Make-Carbo Zinc 11 HS Inorganic
Zinc @ 2-3 mils DFT (50-75 microns) or equivalent
approved of other make i.e. Berger, Amron, etc.
1 coat Carboline 893 Epoxy Primer @ 4-6 mils DFT
(100-150microns) or equivalent other make i.e. Berger,
Amron, etc.

144
1 coat Carbothane 134 HS Polyurethane @ 2-4 mils
DFT (50-100 microns) or equivalent other make i.e.
Berger, Amron, etc.
Surface preparation: For both the surfaces: Surface
Preparation-SSPC-SP 10 Near White Blast.
Monitoring of Environmental parameters
Monitored the environmental parameters as explained
in earlier chapter i.e. Dew Point temp., surfaces Temp
of substrate, Relative Humidify.
Application methods
Application done by Spray Method & for touch up
Brush application.
Curing / overcoat Interval:
As per data given by the manufacturer.
Performance Test Conducted:
Internal surfaces: X
Visual Inspection is theNmandatory for every course of
action (as, per guidelines explained in earlier chapters)
for visual defects.
Surface profile after surface preparation by replica tape
method and by Comparator, Wet film thickness during
the application of coating, DFT after completion of
coating, adhesion test of finish paint by Knife test,
holiday test.
External surfaces
Visual Inspection is the mandatory for every course of
action (as per guidelines explained in earlier chapters)
for visual defects.
Surface profile after surface preparation by replica tape
method and by Comparator, Wet film thickness during
the application of coating, DFT after completion of
coating, adhesion test of finish paint by Knife test

145
 • Review of performance test after one year:
External Surfaces:
Reviewed the same for complete performance through
out the period more than one year but did not find any
defects, which can be concluded that system applied
was OK
Internal Surfaces:
Reviewed the same for complete performance during
the period of shutdown till completion of one year but
did not find any defects, which can be concluded that
system applied was OK

II) ACID & ALKAU STORAGE TANK:

• Purpose of tank:
Storage of Acid & Alkali for use in the chemical
process of treatment of water in the industries.
• Material used for fabrication:
Structural steel i.e. Mild steel plates, angles, channels,
pipes for connections.
• Shape of Tank:
Capsule Shape
• Areas covered under coating including Supporting
structure:
External surfaces:
Tank Shell, Curb Angles, Tank cover external surface,
Hand Rails, Outside pipes, staircase.
Internal Surfaces:
Talk Shell, Tank covers, Inside Pipe Connections.
• Type of Exposure:
External surfaces exposed to salty weather due to
coastal area.

146
 Internal Surfaces: Under Immersion services, Acid &
Alkali.
• Earlier methods of coating on such type of tank:
Internal surfaces:
In a earlier method it was found that Acid or alkali
----- "s

stored in the tank(who lining was done with acid proof

lining.
External surfaces
N/A
• Observation:
Application of Acid proof lining is the time consuming
method and very costly also if annual maintenance
cost was very high. Therefore use of high performance
coating is the solution for storage of acid & alkali.
• Suggested effective coating for Acid & Alkali
storage tank:
High performance coating is the best solution to
protect the structure from its aggressive environment
and storage of Add & Alkali,- Following are the
systems for better performance,-
ACID STORAGE TANK:
• Type of Exposure:3E Extreme pH Exposure
Indudes oxidizing chemicals, strong solvents, extreme
pH’s or combinations of these with high temperatures.
Epoxy Phenolics, high build Polyurethanes and Epoxy
Novalacs are the general choice for coating these
areas. Also consider special coatings such as vinyl-
esters and reinforced polyesters.
• System Suggested are:
System H - Epoxy Phenolic Primer + Epoxy Phenolic
Finish + Epoxy Phenolic Finish

147
 System I - Epoxy Phenolic Primer + Epoxy Phenolic
Lining + Epoxy Phenolic Lining
System P - Epoxy Novalac + Epoxy Novalac
System U - Solventless Elastomeric Polyurethane
System suggested is System P>
System P - Epoxy Novalac + Epoxy Novalac
Features-
Outstanding chemical and physical abuse resistance.
One of the finest industrial coatings for a wide range
chemical resistance.
Higher temperature resistance than a standard J400
°F continuous).
System-
1 coat Thermaline 450 Epoxy Novalac @ 6-8 mils DFT
(150-200 microns)
1 coat Thermaline 450 Epoxy Novalac @ 6-8 mils DFT
(150-200 microns)
Surfaces-
Normally Steel or Concrete.
Surface Preparation-
White Metal Blast -SSPC-SP 5

ALKALI STORAGE TANK:

• Type of Exposure: 3E Extreme pH Exposure -Alkali
Immersion
• System suggested is:-
(Exposure -Alkali Immersion
System suggested is:
Vinyl Ester printer- 75 microns + Vinyl Ester Finish
filled with glass flake - 625 microns to 750 microns.
• Rest of tiie parameters are same as above.

148
• External Surfaces:
Coating system for external surfaces is same as Water
Storage Tank, External Surface, since exposure
conditions are the same.
• Monitoring of Environmental parameters
Monitor the environmental parameters as per chapter
i.e. Dew Point temp., surfaces Temp of substrate,
Humidity.
• Application methods
Application done by Bruch) roller & Trowel method.
• Curing / overcoat Interval:
As per data given by the manufacturer.
• Performance Test Conducted:
Internal surfaces: ^
Visual Inspection is! the mandatory for every course of
action (as per guidelines explained in earlier chapters)
for visual defects.
Surface profile after surface preparation by replica tape
method and by Comparator, Wet film thickness during
the application of coating, DFT after completion of
coating, adhesion test of finish paint by Knife test,
holiday test.
External surfaces ^
Visual Inspection is the)nandatory for every course of
—__

action (as per guidelines explained in earlier chapters)

for visual defects.
Surface profile after surface preparation by replica tape
method and by Comparator, Wet film thickness during
the application of coating, DFT after completion of
coating, adhesion test of finish paint by Knife test
• Review of performance test after one year:
External Surfaces:

149
 Reviewed the same for complete performance through
out the period more than one year but did not find any
defects, which can be concluded that system applied
was OK.
Internal Surfaces:
Reviewed the same for complete performance during
the period of shutdown till completion of one year but
did not find any defects, which can be concluded that
system applied was OK

HI) NAPHTHA & DISTILLATE STORAGE TANK :

Purpose of Naphtha or Distillate storage tank:
Purpose of this tank is to store the Distillate or Naphtha
storage. These tanks were built to store the above fuel
as a bulk before treatment. Those fuels were used to
run the turbine.
Type:
Naphtha Storage Tank :Self supporting type steel
structure with Fixed roof.
Distillate Storage Tank : Self supporting type steel
structure with floating roof.
Material used for fabrication:
Structural steel i.e. MS plates, angles, channels, pipes
for handrails, gratings.
Dimensions:
Internal diameter 57.5 m I / D
Height: 20 m
Areas covered under coating including Supporting
structure:
External surfaces:

150
 Tank Shell including supporting structure, which will
include channels stiffeners etc., roof top and top
ladder, Girder, stairway, outside pipes etc.
Internal Surfaces:
Tank Bottom, one meter of shell above tank bottom,
and 2 meter of shell from top, inside pipe connection,
* Type of Exposure:
External surfaces:
Exposed to salty weather due to coastal area.
Internal Surfaces:
Under Immersion services, coated only, Tank top 2
meter and bottom 1 meter. Because when distillate /
Naphtha comes in^raw tt contains the some amount of
water. Due to it’s heavier than fuel it settles down at
bottom and tends to corrosion of plates.
- SUGGESTED EFFECTIVE COATING FOR
DISTILLATE & NAPHTHA STORAGE TANK:
High performance coating is the best solution to
protect the structure from its aggressive environment,-
Following are the systems for better performance, -
INTERNAL SURFACES:
The systems suggested, two coats of epoxy (System
L) is frequently used for this service, make sure the
material selected meets the necessary standards and
V*'

is approved for use by your local health department.

v.....'.
System Suggested are:
System D - Alumine'Epoxy Mastic + Aluminum Epoxy
"N

Mastic
System J - Epoxy Mastic + Epoxy Mastic
System L - Epoxy + Epoxy (Potable Water)
System L - Epoxy + Epoxy
Features-

151
Offers two coat, high build protection with ease of
application^ We suggest the use of the same product
for both coats. Corrosion inhibitors are not necessary
in immersion service. A third coat may be added for
additional protection.
System-
2 coats of Berger Epilux 610 @ 30 microns per coat
i.e. 60 microns as a primer.
2 coats of Berger Epilux 78 HB @ 100 microns per
coat i.e. 200 microns.
Surface Preparation -
SSPC-SP 5-White Metal Blast.
EXTERNAL SURFACES:
Exposure needs to be analyzed, here with consider the
case of resistance to salty weather & Fresh Water
Spray,-
Frequently wet by fresh water, involves condensation,
splash or spray. This would include interior or exterior
areas that experience frequent cleaning or washing
including stem cleaning.
This group of systems indudes the use of inorganic
zinc as a primer. It is generally recognized that
inorganic zinc is the best coating that can be applied
to steel and that it offers the longest term of protection.
Systems using inorganic zinc have been known to last
for over 20 years. In some cases you may need to
substitute organic zinc. This will affect the overall
protection quality of the system but only by a small
amount.
System Suggested are:
System B - Inorganic Zinc + Epoxy Primer +
Polyurethane Finish

152
System C - Inorganic Zinc + Acrylic Latex Finish
System E - Aluminum Epoxy Mastic + Polyurethane
Finish
System G - Aluminum Epoxy Mastic + Acrylic Latex
Finish
System R - Acrylic Latex Primer + Acrylic Latex
intermediate + Acrylic Latex Finish
It was proved that the following systemjs worked very
effectively,-
System B - Inorganic Zinc + Epoxy Primer +
Polyurethane Finish
Features-
Outstanding corrosion resistance and undercutting
resistance afforded by the primer.
The intermediate epoxy coat forms a barrier protect the
primer.
The polyurethane finish gives excellent colour gloss
retention.
System-
1. 1 coat of Carboline Make-Carbo Zinc 11 HS
Inorganic Zinc @ 2-3 mils DFT (50-75 microns) or
equivalent appoved of other make i.e. Berger, Amron,
etc.
1 coat Carboline 893 Epoxy Primer @ 4-6 mils DFT
(100-150microns) or equivalent other make i.e. Berger,
Amron, etc.
1 coat Carbothane 134 HS Polyurethane @ 2-4 mils
DFT (50-100 microns) or equivalent other make i.e.
Berger, Amron, etc.
Surface preparation:
Internal Surface: SSPC SP10 -Near White Metal Blast
Cleaning

153
 External Surfaces: SSPC SP 10 - Near White Metal
Blast Cleaning
" Monitoring of Environmental parameters
Monitor the environmental parameters as per chapter
i.e. Dew Point temp., surfaces Temp of substrate,
Humidity.
• Application methods ^y
Application can be doneany of the methods explained
earlier; small portion can applied by brush or roller
(preferably Roller) and large portion by spray method.
• Curing / overcoat Interval:
As per data given by the manufacturer.
• Performance Test Conducted:
Internal surfaces:
Visual Inspection is the mandatory for every course of
action (as per guidelines explained in earlier chapters)
for visual defects.
Surface profile after surface preparation by replica tape
method and by Comparator, Wet film thickness during
the application of coating, DFT after completion of
coating, adhesion test of finish paint by Knife test,
holiday test.
External surfaces
Visual Inspection isthe mandatory for every course of
action (as per guidelines explained in earlier chapters)
for visual defects.
Surface profile after surface preparation by replica tape
method and by Comparator, Wet film thickness during
the application of coating, DFT after completion of
coating, adhesion test of finish paint by Knife test
• Review of performance test after one year:
External Surfaces:

154
 Reviewed the same for complete performance through
out the period more than one year but did not find any
defects, which can be concluded that system applied
was OK
Internal Surfaces:
Reviewed the same for complete performance during
the period of shutdown till completion of one year but
did not find any defects, which can be concluded that
system applied was OK

2) STACK (CHIMNEY):
* Purpose of Stack:
Coating system for 98.17 m height steel stack, which
will be constructed for 1552MW, combined cycle power
plant
* Type:
Self-supporting type duel wall insulated steel stack.
■ Material used for fabrication:
Structural steel i.e. MS plates, angles, channels, pipes
for hand rails gratings.
■ Dimensions:
Internal diameter 6.5 m I ID
Height: 98.17 m (From Ground)
■ Thickness of plate Used:
22 mm thk, 16 mm thk, 12 mm thk, 8 mm thk MS plate
varying form TOP (8 mm tfik) to BOTTOM (22 mm
thk).
■ Areas covered under coating including supporting
structure:
External surfaces:
Stack Shell, Supporting channels, Curb Angles, Hand
Rails, ladders with cage.

155
 Internal Surfaces:
No coating done on internal surface.
* Type of Exposure:
External surfaces exposed to salty weather due to
coastal area. Due to emission of heat temp of shell rise
up to <300 degree centigrade.
Internal Surfaces: Due to continuous emission of heat
no coating is required.
■ Earlier methods of coating on such type of tank:
In earlier method it was found that Chimneys were
constructed of RCC with no coating. And steel without
adequate coating techniques because found lots of
rusting on it and increased maintenance cost.
■ Observation:
' r-

Due ease of construction and speedy erection it is

always recommended to fabricate and erect the steel
tanks. But need proper coating to protect the steel
from the aggressive environment.
■ Suggested effective coating for Stacks:
High performance coating is the best solution to
protect the structure from its aggressive environment,-
Following are the systems for better performance, -
Internal Surfaces:
No coating system required.
External surfaces:
External surface is heated due to emission of heat up
to 300°C therefore to resist the heat, need heat

resistance coating.
Suggested Coating system:
Primer - Inorganic Zinc Silicate + Finish coat- Hi.
Temp. Silicone Finish
Primer:

156
 1 coat of Carboline Make-Carbo Zinc 11 HS Inorganic
Zinc @ 2-3 mils DFT (50-75 microns) or equivalent
approved of other make i.e. Berger, Amron, etc.
Finish Coat:
Hi. Temp. Silicone with or without Aluminum finish
Silicone aluminum top coat with a total Vol. Solids
content of not less than 35 Vol.%@ 1-1.5 mils DFT (25
- 35 microns)
Surface preparation:
External surface: SSPC SP 10-Near to white Metal
• Monitoring of Environmental parameters
Monitor the environmental parameters as explained in
earlier chapter i.e. Dew Point temp, surfaces Temp of
substrate, Humidity.
• Application methods
Application done by Spray & Roller.
* Curing / overcoat interval:
As per data given by the manufacturer.
* Performance Test Conducted:
External surfaces
Visual Inspection is the mandatary fa* every course of
action (as per guidelines explained in earlier chapters)
for visual defects.
Surface profile after surface preparation by replica tape
method and by Comparator, Wet film thickness during
the application of coating, DFT after completion of
coating, adhesion test of finish paint by Knife test
■ Review of performance test after one year:
External Surfaces:
Reviewed the same for complete performance through
out the period more than one year but did not find any

157
 defects, which can be concluded that system applied
was OK

3. PIPE UNES:
I) WATER SUPPLY UNES:
• Type of Exposure:
Internal Surface:
Coating Not required
External surface:
For Exposure of resistance to salty weather & Fresh
Water Spray,-
• System Recommended is:
Inorganic Zinc silicate + 2 coate of High Build
Epoxy

1 coat of In-organic Zinc silicate Zinc Anode 304 of

Berger Make of DFT 50-100 microns.
2 coats of High build Epoxy Carboline 890 of Carboline
make of DFT 100 -150 microns.
Other parameters are same as Water storage tank
(external surfaces).

II) HEAT RESISTANCE PIPE:

• Type of Exposure:
Internal Surface: Not required
External surface:
For Exposure of Heat resistance up to 300 degree
centigrade
• System Recommended is:
Inorganic Zinc silicate + 2 coats of high temp
Silicone of DFT 25-35 microns.

158
 1 coat of In-organic Zinc silicate Zinc Anode 304 of
Berger Make of DFT 50-100 microns.
2 coats of High Temp Silicone of Carboline make of
DFT 25 - 35 microns for each coat.
Other parameters are same as Stacks.

4. BODY ACCESSORIES OF EQUIPMENTS (IN GENERAL):

• Purpose of Equipments:
There are lots of equipments and its body cover needs
to protect from aggressive environment. Most of the
equipments are coated by the manufacturer has its
own coating system based on following guidelines as
per the requirements. But it is necessary to
understand the procedure of touch-up & repair at job
site without affecting the performance of the exiting
coating.
• Type:
Mostly thin sheet of metal used for preparation of
equipment cover, equipment top & supporting
structures.
• Material used for fabrication:
Structural steel thin plates + sheets, angles, channels,
etc including base frame.
Depends on model and type of equipment
• Thickness of plate Used:
Up to 4 mm
i. Areas covered under coating including Supporting
structure:
External surfaces:
Body cover
Internal Surfaces:
Inside of body cover and equipment body cover.

159
• Type of Exposure:
External surfaces:
Exposed to salty weather due to coastal area.
• Suggested effective coating for General type of
equipment:
High performance coating is the best solution to
protect the structure from its aggressive environment
also given the repair & touch up coating system.
Following are the systems for better performance,-
External Surfaces & Internal surfaces:
Exposure needs to be analyzed, here with consider the
case of resistance to salty weather & Fresh Water
Spray,-
Most of the cases it is recommended not use abrasive
blasting. Normally surface of sheet is smooth
therefore for better adhesion primer should be such
that which will adhere to plate and same time it should
be compatible to finish paint.
• System Suggested are:
System U: wash primer + polyurethane finish.
Features-
Outstanding adhesion on smooth surface & The
polyurethane finish gives excellent colour gloss
retention & corrosion resistance.
System-
2 coats of Bison wash primer of Berger make @ DFT
10 to 15 microns or equivalent approved of other make
i.e. Carboline, Amron, etc.
2 coat Carbothane 134 HS Polyurethane @ 2-4 mils
DFT (50-100 microns) or equivalent other make i.e.
Berger, Amron, etc.
Surface preparation:

160
 External Surfaces & External surfaces:-Solvent
cleaning SSPC-SP-1
• Monitoring of Environmental parameters
Monitor the environmental parameters as per chapter
i.e. Dew Point temp., surfaces Temp of substrate,
Humidity.
• Application methods
Application of primer shall be possible by brush only
since very fast drying of primer. Finish paint applied by
spray for uniform finish.
• Curing / overcoat Interval:
As per data given by the manufacturer.
• Performance Test Conducted:
External surfaces / Internal surfaces:
Visual Inspection is done as per guidelines explained
in earlier chapters for visual defects.
DFT after completion of coating, adhesion test of finish
paint by Knife test
• Review of performance test after one yean
Reviewed the same for complete performance through
out the period more than one year but did not find any
defects, which can be concluded that system applied
was OK.
\ • For Touch up and repair method of coating:
Initially: tails advised to collect the data of exiting the
1r V. -'

coating system. For compatibility of primer to be used

for touch up. If no data available use rust tolerant self
priming epoxy paint as primer and finish paint as usual
polyurethane to match with exiting colour.
Coating system:

161
 Rust tolerant self priming epoxy mastic Berger make
protestomastic of DFT 60 to 100 microns. + Bison
wash primer of Berger make DFT 10 to 15 microns.
Finish paint-
Polyurethane of any standard brand.
Surface preparation:
SSPC-SP 1-Solvent cleaning, SSPC-SP 2-Hand tool
cleaning.
Control of all other parameters will be the same as
above.

B) CONCRETE STRUCTURES:
Concrete structures are more durable than Structural steel work, but in
some 'Ip aggressive environment like where continuous flash of salty

water or continuous immersion of salt water, concrete structure shall be

protected by High performance coating. But selection and application
of high performance coating is very much important. Following is one of
the typical case considered for study point of view and which is tested
for hill proof coating system.
ROC Structural Elements:-
This covers the requirements for surface preparation and application of
Elastomeric polyurethane lining system on concrete surfaces intended
for immersion service in sea water cooling tower, pump sump & cooling
tower super structure. Approximate surface area to be coated with this
coating shall be to the tune of 13000 m2. Following portion of cooling
tower was coated
I. Cold water Basin: Part of cooling tower situated at Bottom.
II. Hot water basin: Part of cooling tower situated at top.
III. Circulating water (C. W.) channel: Area between Cold water
basin and Circulating water pump house.
IV. Cooling water pump sump
V. Cooling Tower Super structure

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I. TO IV.rCOATING SYSTEMS FOR ABOVE STRUCTURES:
• Purpose of coating System:
To ensure the proper and complete installation of the
specified polyurethane lining systems on the specified
concrete surfaces.
Hie application procedure is based upon the specification
and technical information provided in the material
manufacturer’s technical data for the specific material.
• UNING SYSTEM -COATING MATERIALS
Geothane-520, consisting of Surfacer + Sealer-Futura-Bond-
320 Gel-(For filling of bug-holes and other concrete surface
defects)
Primer + Sealer- Futura - Bond 415 (over all surfaces at 3-5
DFT (75-125 microns)
Elastomer caulk- Future - Caulk 5705 (Filling of cracks.)
Elastomer lining - Geothane 520 (over all surfaces at 50-60
mils DFT (1.26-1.50mm)
• SURFACE PREPARATION FOR CONCRETE:
Note: New concrete shall be cured minimum of 28 days prior
to coating.
Thoroughly clean all surfaces to be primed and coated,
effectively removing all traces of contamination, i.e: oil,
grease, release, agents, surfaces, dirt, etc.
Wash at high pressure water jetting (1500 psi or greater) with
10% TSP (Tri Sodium Phosphate ) in hot water solution.
Immediately rinse washed areas with clean water removing
all traces of detergent and contaminants.
Repeat the cleaning procedures as required to ensure
complete removal of all contamination. Remove all standing
or ponding water from horizontal surfaces.

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Grind ail surface irregularities flush with surrounding surface
areas removing all ridges, spurs protrusions, etc.
Prepare all cracks which have opened to width of 1/6 inch
(1.6 mm) or greater (if required).
Open all cracks to a width of 34 inch(6.35) and depth of 34
inch (12.7 mm) using diamond tipped router bits or circular
saw blades or grinders.
Abrasives grit blast ail surfaces to the coated, effectively
removing all surfaces laitance, old coatings and loose spalled
surfaces, and providing a surfaces, and providing a surfaces
texture similar to medium-coarse sand paper approximate
surface profile of 3.0-6.0 mils (75-125 microns).
Required Operation ConcNtions:-
The compressed air supply shall be completely free of oil,
water and jprticuls^contaminants, and provide the required
volume of air at 100 psi or greater pressure.
The abrasive grit or steel shot shall be a clean, uniform grade
of appropriate size particles to obtain the specified surface
finish and profile. Do not use contaminated grit or hot.
Direct the abrasive grit blast onto the concrete surfaces at a
45 degree angle for best results. Move the blast nozzle with
rapid sweeping motions (“brush - blast*) and uniformly strip -
away the surface laitance, old coatings and spalled surfaces
to a clean profiled appearance.
Thoroughly clean all blasted surfaces to remove all dust and
debris after dry blasting.
(Dry) Sweep -down and./or blow-down all surfaces and
remove excess dust and debris.
(Wet) High pressure wash-down all surfaces and remove
excess dust debris and standing water. Thoroughly dry all
surfaces prior to final dealing procedures with vacuum-clean

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all surfaces to be coated, effectively removing all remaining

dust.

LINING APPLICATION

FUTURA-BOND 320 GEL

This product used to fill up hairline and shrinkage

cracks upto 3mm width:
Fill with Futura-Bond 320 Gel or equivalent material

and strike flush with concrete surface prior to the

application of the elastomeric polyurethane coating

system.
FLOOR TO WALL JOINT IN C.W. BASIN,

PUMPSUMP:-

A coat shall be made with Futura-Bond 320 Gel /

Elastomeric Caulk material using a putty knife.
APPLICATION TEMPERATURE RANGE :
Minimum 45 °F (7 °C)

Maximum 110 °F (44 °C)

MIXING
Thoroughly mix components A and B together utilizing

an air powered mixer with impeller.

Mix ratio : 1:1 A: B components.

Mixed Pot Life : 1-2 hours at 75 °F (24°C)

Trowel or putty knife apply to effectively fill all “ non­

moving" cracks less than 1+16 inch wide (1.6mm.),

all bug-holes and other surface defects % inch

diameter or greater (6.36 mm), and bug-holes 1/8 inch

diameter (3.18 mm) which are visually deep to % inch

or greater (6.36 mm)

Allow the applied Futura-Bond 320 Gel to cure to a

dry-to touch maximum recoat time.

Minimum cure : 4-6 hours at 70-90 °F (21-32 °F)

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 Maximum Recoat: 72 hours at 70 °F (21 °C)

FUTURA-BOND 415- CONCRETE PRIMER / SEALER

Application Temperature Range:
Minimum: 45 °F (7 °C)
Maximum :110 °F (44 °C)
Thoroughly mix components A and B together utilizing
an air powered mixer with impeller. Slowly add the
required amount of Thinner#70* (15-25% by volume)
while mixing, to provide the proper sprayable viscosity.
Mix Ratio : 1:1 A:B Components, plus Thinner # 70*
Mixed Pot Life: 1-2 hours at 75 °F (24 °C)
Spray-apply a single uniform, wet coat of primer at 5-8
mils WFT (125-200 microns) over ail concrete surfaces
to be lined, including previously sealed soots or areas.
Immediately following the spray application, back-roll
the wet coat into the concrete surface, utilizing a
medium-nap roller and effectively sealing all surfaces
with a uniform coat of primer at 3-5 mils DFT (75-125
microns). Also immediately following the spray
application, brush-apply a wet, coat of primer into all
opened and prepared cracks.
Allow the applied Futura-Bond 415 to cure to a dry-to-
touch and non-marring condition before walking upon
to apply the caulk to joints and cracks. (Do not exceed
the maximum recoat time prior to application of the
polyurethane coating as shown below.
Minimum cure : 5-6 hours at 70-90 °F (21-32 °C)
Maximum Recoat: 48 hours 70 °F (21 °C)

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FUTURA-CAULK K 5705* POLYURETHANE ELASTOMER
CAULK
This product used to fill up cracks more than 3mm
width:
Application Temperature Range:
Minimum: 45°F(7°C)
Maximum: 110 °F (44 °C)
Thoroughly mix components A and B together utilizing
an air powered mixer with impeller.
Mix Ratio : 9:1 A:B components
Mixed Pot Life: 30-45 minutes at 75 °F (24 °C)
Allow the applied Futura-Caulk 5705 to cure to a dry-
to-touch condition before over-coating with the
polyurethane coating.
Minimum cure : 1 -2 hours at 70-90 °F (21 -32 °C)

GEOTHANE 520:
Elastomer lining - Geothane 520 (over all surfaces as
finish coat.
These are 100% solids, zero V. O. C. polyurethane
elastomeric linings. Hie Geothane 520 must be batch
mixed, and requires airless spray equipment.
Application Temp. Range :
Minimum 45 °F (5 °C)
Maximum 120 F (49 °C )
Relative Humidity Conditions: Maximum 85%
Thoroughly mix components A and B together utilizing
an air powered mixer with impeller.
Mix Ratio : 1:1 A:B components
Mix Pot Life: 40 minutes at 75 0 (24 0C)

GEOTHANE 520 LINING -

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 (Minimum thickness 50 Mils in two coats of 25-30 Mils
each)
Coat 1 of Geothane 520 - The gap between
successive applications of different material / coats
shall be maintained as shown in sketch no. 3 in
enclosed annexure.
Ambient temperature records have to be maintained
during application of each and every coat of Primer,
surfacer / Geothane 520 to determine minimum cure
time and maximum cure time.
Maximum re-coat time exceeded by less than 24
hours: The surface reactivation will be done by
spraying MEK.
The each coat of Geothane 520 shall be applied by
uniform multiple pass spray. This shall be performed
in 3-4 passes, with each pass applied using a 50%
overlap of the previous pass aid applied in a cross-
hatch pattern to provide the most uniform and
consistent thickness.
Allow tie first coat of Geothane 520 to cure to a dry-
to-touch condition before over coating with the second
coat. Do not exceed the maximum recoat time.
Minimum cure : 3-4 hours at 70-90 °F (21-32 °C)
Maximum Recoat: 72 hours at 70 °F (21 °C)
Preferable Recoat: 4-24 hours at 70 °F (21 °C)

Allow the applied Geothane 520 to folly cure prior to

use.

• INSPECTION AND QUALITY ASSURANCE

Inspect visually for all steps involved in coating for
defects.

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 Random Elcometer Adhesion Tests will be performed
by representatives of the owners to verify compliance
to: (a) lining thickness specification (b) lining adhesion
specification.

• ACCEPTANCE CRITERIA
Inspected for following Defects, -
BLISTERS- All blisters greater than 3/8 inch diameter (
9.53 mm) shall be cut out and repaired. Groups of
blisters of any size shall be repaired
PINHOLES- No pinhole will be permitted. The pinhole
area shall be identified and shall be cut out and
repaired as blistered area.
DELAMINATIONS- Any delaminations of the lining
shall be removed and repaired.
ADHESION- 0-99 psi adhesion will be considered
unacceptable and 100 psi or greater will be
considered acceptable. Areas showing adhesion
below 100 psi may require removal and replacement of
coating.
• DRY FILM THICKNESS -
The polyurethane lining exclusive of the surfacer and
primer, shall be no less than 50 mils DFT (1.25 mm),
nor greater than 60 mils DFT (1.50mm).

V. COATING SYTEM FOR COOLING TOWER SUPER STRUCTURE

(RCC)
• EXPOSURE CONDITION:
Super Structure Concrete surfaces of cooling tower
basin subject to constant salt-water splash & spillage
during the operation.

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 • COATING MATERIAL:

Polyurea - DFT applied -0.5-1 mm- Siloxane-PSX 700-

100% solids spray grade polyurea.
• SURFACE PREPARATION:
Coating performance is, in general, proportional to the
degree of surface preparation. Prior to coating the
surface will be cleaned, dry, undamaged and free from
all contaminants including salt deposits, all loose dust,
grease or other contaminants would be removed by
water blasting (Jetting) method.
• ENVIRONMENTAL CONTROL:
TEMPERATURE °C
AIR 4 TO 49
SURFACE 4 T049

REL. HUMIDITY MINIMUM 40

Surface temperature of concrete must be at least 5 °F

(3 °C) above dew point to prevent condensation during
application and initial dry through.
• APPLICATION PROCEDURE
i. Spray painting equipment will be flushed with thinner-
Amercoat 12 everyday before use and after use.
ii. Paint as required will be brought from stores and the
batch No., Shelf life etc. Will be checked and recoded.
iii. Also the humidity, dew point at the work area will be
checked and recorded.
iv. The required paint i.e. PSX 700 resin will be mixed
uniformly using pneumatic agitator.
v. Once uniform consistency is formed, the paint will be
sprayed on the surface area to achieve a thickness of

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 6 to7 mils in a coat. Before applying on clear areas,
the comers and edges shall be smoothen.
vi. The mixed paint will be used within its pot-life, i.e., only
the quantity of paint, which can be spread within pot-
life only, be mixed.
vii. The thickness of paint applied will be checked with
WETFILM THICKNESS GAUGE along with application
of paint.
• COATING INSPECTION:
i. Surface temperature and humidity readings shall be
taken prior to application of each coat.
ii. The Dry Film thickness shall be measured with an
ELCOMETER. The testing method shall be in
accordance with SSPC PA - 2.
iii. Defective or damaged coating that have been repaired
and replaced shall be reinserted to the original
requirements.
iv. The coatings applied over concrete surfaces will be
visually inspected to ensure they are free of pinholes /
voids.
v. The Moisture Content of surfaces shall be determined
using an electronic moisture meter or acceptable
equivalent method. We will not apply paint when
moisture content of concrete is above 12%.
vi. Ensure that cementations surfaces are prepared as
specified, void & rock pockets are filled flush with
compatible patching /filler materials, and incompatible
liquid airing membrane is removed.
vii. The coating shall be visually inspected for application
defects such as over spray, runs, sags etc.
viii. /Ml Inspection gauges / Instruments shall be
calibrated.

171
 REVIEW OF PERFORMANCE, TOUCH-UP AND
REPAIR:
While inspection shut down, it was observed that the
coating in the basin was in good condition with few
exceptions of application related defects (such as bug
holes, pinholes between coats, runs, missed / skips,
etc. which could account for 2-4 percent of coated wall
surface area in the applied coating). There was no
indication provide continued acceptable service for the
design life of the coating system. How long a coating
will last depend on the user’s approach to and
philosophy of maintenance coating program: Proactive
approach or deferred maintenance. First maintenance
painting should take place wAien initial breakdown of
the coating occurs or is detected. Once significant
coating break down occurs, it is more costly to repair
and the effectiveness of the protection is greatly
reduced.

PROBLEM ON THE INTERIOR SURFACE OF THE TOWER

STRUCTURE:
The coating on all accessible areas of superstructure
in cooling tower numbers was found to be in good
condition except that excessive amount of bug holes or
voids was noted on the coated surface. The existing
coating found to be intact and properly bonded to the
substrate with no signs of the coating failure or
degradation.
Other abnormalities identified during the visual
inspection were surface defects or non-compliant
conditions that require repair or corrective action.

172
 These include exposed rebar or tie wire, exposed
nails, cracked grout, exposed concrete surfaces,
damaged concrete surfaces, rough areas with
inadequate coating, etc.

METHODOLOGY FOR FUTURA GT 520 COATING REPAIR

COOLING TOWER BASIN, HOT WATER BASIN & PUMP HOUSE
STRUCTURE

• REPARING OF PINHOLES BETWEEN THE COATS

Using coarse grit (36-80 grit) sandpaper, roughen or
grind the lining surface area surrounding the pinhole at
a diameter of approximately 30-50 mm. Remove loose
paint dust, sand + grit particles or other loose
contaminants prior to the coating repair.
Wipe the roughened area with a dean cotton doth
saturated with Methyl Ethyl Ketone (MEK) to adivate
the GT 520 surface. Allow the MEK to dry for no
longer than 10 minutes before applying the primer.
Brush-apply a coat of FB 610 / 613 primer to the
prepared surface. Do not overlap onto unprepared
areas.
Allow the GT 520 to cure to the minimum full cure as
specified on the Tech Data Sheet prior to putting in
service.

METHODOLOGY FOR REPAIR OF COOLING TOWER SUPER

STRUCTURE:
• PURPOSE
Purpose of this methodology is to fill bug holes,
blowouts, voids, or other such defects or defidency on
the coated surface with AMERON AMERLOCK 400 to

173
 essentially restrict the entry of saline water in to

concrete.

• BUGHOLES, BLOWOUTS, VOIDS ETC.

Using coarse grit (36-80 grit) sandpaper thoroughly

roughen or grind the coated surface to be repair. Use

of either Hand or power sanding method is acceptable.

Remove loose dust, sand + grit particles and other

surface contaminants prior to proceeding with the

repair. It is not necessary to roughen the filler coat
prior to the application of AMERLOCK 400 finish coat
application.
Mix AMERLOCK 400 in accordance with the product
data sheet Do not thinner or solvent during the mixing

of AMERLOCK 400 until desired level of paste like

consistency is obtain. Add between 20-60 percent by
volume filler material. Do not add more filler material
once the mixing is complete.

Fill bug holes, blowouts, voids, etc. with the paste with
putty knife or other suitable means. Wipe excess putty
from the coated surface, if required. Allow the fill coat
to dry for a minimum recoat period as specified on the

AMERLOCK 400 product data sheets.

Apply by brush, roll, or spray coat (s) of AMERLOCK

400 (without filler) to the patched or filled surface to

achieve a wet film thick ness of 125-175 micron. Allow

the AMERLOCK 400 to cure to the minimum full cure

as specified on the Tech Data Sheet prior to putting in

service.

The conclusions based on the present study are given in the next Chapter.

174