Corrosion prevention technology

General Technical Requirements

Corrosion prevention technology

General Technical Requirements

CORROSION

PREVENTION TECHNOLOGY

Corrosion prevention technology

General Technical Requirements

Contents General guidelines.................................................................................................3 2 Specification of the environment categories appertaining to the corrosion stresses.....................................................................................................................3 2.1 Categories for ground and water........................................................................3
1
2.2 Atmosphere

corrosion categories........................................................................3

Selection of coating systems suitable for corrosion categories according to EN ISO 12944-5 : 2000.........................................................................................4 4 Implementing of surface protection...................................................................4 4.1 Mechanical preparation, acceptance of metalwork.........................................4
3
4.2 Preparation
4.2.1 4.2.2

of the surface according to EN ISO 12944-4 : 2000...................5

Removal of sticking contaminations........................................................5

Removal of originating contaminations..................................................5 4.3 Data of coating materials.....................................................................................6

4.4 Completion

of painting work according to guidelines of EN ISO 12944-7:

2000..........................................................................................................................8 General specifications.................................................................................8 4.4.2 Execution.......................................................................................................8 4.4.3 Inspection of the painting work................................................................9 5 Paint coat system specification form, container inside. New task................9 6 Paint coat system specification form, container outside. New task............11
4.4.1

Corrosion prevention technology

General Technical Requirements

1 General guidelines
Steel structures in the atmosphere, in the water and in the ground without any protection are exposed to corrosion resulting in damages. Therefore steel structures are usually protected to avoid corrosion damages, that the structures are resistant in their whole lifetime against corrosion effects occurring. The EN ISO 12944 standard series deal with the protection of structures of 3 mm minimum thickness made from unalloyed, or slightly alloyed steel by means of paint coat systems, or coatings, with all its characteristics, which are important to achieve a suitable protection. When selecting the external and internal coating system of the containers it has been a fundamental consideration to provide the suitable protection against different stresses by a minimal number of coating systems. Essentially two kinds of corrosion stresses are discerned for the containers: The internal surface of containers for water storage. The external surface of containers being in contact with the air.

2 Specification of the environment categories appertaining to the corrosion stresses

2.1 Categories for ground and water
The standard EN ISO 12944-2 : 2000 specifies the categories listed in Table 1. for structures submerged in water and laid in the ground. Category Im1 Im2 Im3
Table 1

Environment Sweet water Sea, or mixed water Ground

Example River plants, water power plants. Structures of harbor areas, sluice gates, piers, coastal structures. Underground containers, steel pipelines.

We have selected the stricter category Im2 to specify the internal coating system of the containers, since chemicals are fed into the containers both for water treatment and maintenance, thus its content can not be considered as sweet water.

2.2 Atmosphere corrosion categories

The EN ISO 12944-2 : 2000 standard classifies the atmosphere environment in six corrosion categories, which are, as follows: C1 C2 C3 C4 very low low medium high

C5-I very high (industrial) C5-M very high (sea) We have selected the properly strict category C4 to specify the coating system of the external surface of the containers (being in contact with the air), also considering the arrangement and operation conditions of the containers.

Corrosion prevention technology

Category

General Technical Requirements

Corrosion rate ^.m/year (unprotected carbon steel)

Typical environment example in temperate zone External Internal

C4

50 to 80

Industrial and coastal areas with Chemical plants, salt content. swimming pools.

Table 2

3 Selection of coating systems suitable for corrosion categories according to EN ISO 12944-5 : 2000
The following coating system types are suitable for protection of internal surfaces of containers submerged in water: epoxy primer, epoxy intermediate layer, polyurethane cover, epoxy primer, 2 layers of solvent free epoxy resin, 3 layers of solvent free epoxy resin.

We have selected from the above types the two-component, solvent free, epoxy resin base coating material SIKACOR EG of 3 layers (see Chapter 5). For the protection of the external surface of the containers we have selected from the coating systems suitable for the corrosion category C4. The coating system consisting of the epoxy primer containing corrosion preventing pigments, the intermediate layer with epoxy resin cement and the cover containing polyurethane cement. The specified coating system (see Chapter 6): SIKACOR EG-phosphate SIKACOR EG 1-Rapid intermediate layer with iron mica

- SIKACOR EG 5 cover varnish colour (K) Of course, coating systems set up on the basis of similar cement material base from other manufacturers can be used in addition to the selected coating system; however their application references must be examined.

4 Implementing of surface protection

4.1 Mechanical preparation, acceptance of metalwork
After completion of welding, but prior to filling up with water the weld seams must be arch grinded off, in order to avoid sharp corners, weld knobs and filler rod ends. The methods of improper and proper finishing are shown in Figure 1.

Corrosion prevention technology

General Technical Requirements

Figure 1: Improper and proper finishing of weld seams

The metal pearls stuck to the surface when welding must also be removed, since protruding out from the surface, the effective coating thickness is reduced resulting in premature deterioration of the coating system.

4.2 Preparation of the surface according to EN ISO 12944-4 : 2000

Object: Removal of sticking (grease, oil, preserver) and originating (rust, scale) contaminations from the surface prior to painting.

4.2.1 Removal of sticking contaminations The oil, grease, preservers, salts and similar contaminations must be removed with an appropriate method prior to further surface preparation. The methods are: - Emulsion degreasing, rinsing with clear water, drying by blow off. - High-pressure water jet cleaning with a suitable detergent, then rinsing with clear water, drying by blow off. - Wiping off be means of a cloth saturated with organic solvent. The cloth must often be exchanged. After completion of drying off the internal surface the solidity of welds must be inspected and the possible corrections be carried out prior to grit blasting. 4.2.2 Removal of originating contaminations The object is, to remove the rust, the rolling scale from the surface and to roughen the surface to ensure an adequate sticking of the coating system to be created. The method: The surface must be cleaned by means of compressed air dry grit blasting to achieve a cleanliness and roughness rate required for the primer. The dust is removed from the surface by compressed air. The returning fine dust is removed by means of a brush vacuum cleaner and the surface cleanliness should be inspected. The surface must be wiped off with solvent prior to painting. The ordinary standard preparation rates of the grit blasting process and the features of the prepared surface are shown in Table 3.

Corrosion prevention technology

General Technical Requirements

Rate Sa 2 Sa 2 y2

Features of the prepared surface Most part of scale, rust, paint coating and foreign materials is removed. Any remaining contaminations must firmly stick. The scale, rust, paint coating and foreign materials are removed. Any remaining contamination traces occur only as small stains, dots, or stripes. The scale, rust, paint coating and foreign materials are removed. The surface has a uniform metallic color.

Sa 3
Table 3

The roughness of the internal surface of the container submerged in water is determined by measuring, or according to the standard EN ISO 8503. The cleanliness of the surfaces is appraised according to EN ISO 8502-3 : 1992.

4.3 Data of coating materials

Technical data of application of the selected coating materials are shown in Tables 4 to 7. Coating material Color Cement Storage time Surface preparation Epoxy resin base, solvent free, two-component paint SIKACOR EG Phosphate RAL 1014 ivory and ginger brown Solvent free epoxy resin - polyamine 12 months in original packing Blasting: cleanliness rate Sa 3 roughness > 50 pm Mixing rate Pot life at 20 C Layer thickness Number of layers Drying at 20 C A : B = 100 : 35 mass ratio 20 to 40 minutes depending on the quantity 150 m/layer (wet layer thickness 150 m) 3 Hand-dry: 2 hours Re-paintable: 12 hours, max. 36 hours Loadable: 12 hours Stress: 7 days* Applying Applying temperature Brush painting/rolling Minimum + 10 C.

* Because of temperature changing 14 days are safer. Table 4: Data of coating material selected for the internal surface of the container submerged in water

Corrosion prevention technology

General Technical Requirements

Coating material Color Cement Storage time Surface preparation Mixing rate Pot life at 20 C Layer thickness Number of layers Drying at 20 C

Epoxy resin base, zinc phosphate, twocomponent primer SIKACOR EG Phosphate RAL 8012 rusty brown Solvent epoxy resin - polyamine-amide adduct 24 months in original packing Blasting: cleanliness rate Sa 2 ^ roughness normal A : B = 5 : 1 mass ratio 3 hours 80 m/layer (wet layer thickness 160 to 170 m) 1 or 2 (if it can not be applied without running off) Hand-dry: 2 hours Re-paintable: 5 hours Loadable: 8 hours Stress: 4 days

Applying

Brush painting/rolling Air spraying Airless spraying

Table 5: Data of primer selected for the external surface of the container

Coating material Color Cement Storage time Mixing rate Pot life at 20 C Layer thickness Number of layers Drying at 20 C

Epoxy resin base, iron mica, two-component coating material, SIKACOR EG 1 RAL 7032 grey Solvent epoxy resin - polyamine-amide adduct 24 months in original packing A : B = 5 : 1 mass ratio 3 hours 80 m/layer (wet layer thickness 150m) 1 or 2 (if it can not be applied without running off) Hand-dry: 2 hours Re-paintable: 5 hours Loadable: 8 hours Stress: 4 days

Applying

Brush painting/rolling Air spraying Airless spraying

Table 6: Data of the intermediate layer selected for the external surface of the container

Corrosion prevention technology

General Technical Requirements

Polyester base, two-component, polyurethane cover varnish color SIKAKOR EG 5 Any faults occurring on the paint coat, that could result in a reduced protection capacity of the coating, Color a significant effect on the RAL 5019 blue be repaired prior to applying the next layer. or have appearance must Mixing rate A : B the : 1 mass ratio (with 2K fast hardener) The next layers can be applied keeping = 5 appropriate repainting and drying time by means of rolling, but special care Pot life at 20 C is required when creating the coating in the corners, on the weld seams, on the brackets 6 hours welded in for retaining the internal fittings and the frameworks fastened with bolted joints. Layer thickness 35 m/layer (wet layer thickness 70m) When applying the wet coat material the creation of a uniform coat of the necessary thickness can be Number by layers 1 or 2 (if it can not be must be required from the painters. ensured of measuring the wet layer thickness, thus this applied without running off) In case of applying of several layers drying between the layers should The specified thickness of each layer must be controlled after drying of the layer. 4.4.3 be ensured) Drying at 20 C painting workHand-dry: 4 to 6 hours Dry: 24 to 30 hours Stress: 4 days Inspection of the The execution must be inspected in every stage of working. The inspections must be carried out by accordingly qualified and skilled experts. Basically Applying the contractor himself is responsible for the execution of the inspection, however it is also Brush painting/rolling (only with 2K fast hardener) Air expedient for the customer to check, or have checked the corrosion prevention work. spraying Airless spraying After finishing the work the coating must be inspected with respect to the compliance. 1. Visual inspection, Thinning for rolling for example unevenness, color, to 5 % + 2faults. KH - 140 thinner, 0 covering, % brush additive
Table 7: Data of cover varnish color selected for the external surface of the container 2. With instruments:

Coating material

Dry layer thickness (with a destruction-free method). Unless any other agreement, no single values less than 80 % of the nominal dry layer thickness can be accepted. It is recommended at the same time, that the greatest dry to guidelines should not 12944-7 : times 4.4 Completion of painting work accordinglayer thickness of EN ISOexceed three2000 the nominal layer thickness. 4.4.1 General specificationsmethod, then to be repaired); Acceptance: > 2 MPa. - Adhering (destruction The companies and their employees entering into the agreement for applying the paint coat system on 5 steel structure must be specification form, container the task. thePaint coat systemsuitable for accurate and safe execution ofinside. New task. If the contractor has a functioning quality management system, a quality plan must be created, including the general professional regulations and a statement concerning the methods must be made for each working stage. The EHS (environment, health and safety) regulations must be kept. The surface to be painted must be safely accessible and well illuminated. When using the coating materials the technical data sheet of the manufacturer must be considered. The applied processes depend on the type of the coating material, the surface, the shape and size of the structure and the local conditions, respectively.

4.4.2 Execution The first primer layer is applied by brush painting on the external and internal surfaces. Special care is required when creating the coating in the corners, on the weld seams, on the brackets welded in for retaining the internal fittings and the frameworks fastened with bolted joints. The primer layer must cover the whole surface profile of the steel surface.

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Corrosion prevention technology

General Technical Requirements

Corrosion prevention technology

General Technical Requirements

6 Paint coat system specification form, container outside. New task.

APPLYING IN THE WORKSHOP RATE OF SURFACE PREPARATION: Sa 3, Rz > 50 m TYPE OF WORKSHOP PRIMER (if any): Paint manufacturer: PAINT COAT SYSTEM Nominal dry layer thickness Layer 1: SIKAKOR EG phosphate Layer 2: SIKAKOR EG 1 Layer 3: SIKAKOR EG 5 IN ALL m 120* 120* 120* 360 Area: m2 Repainting interval Minimum hours 12 12 12 Maximum hours 36 36 36 Drying time at 20 C hours 8 8 8

NOTE: * Several working processes may be necessary.

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Corrosion prevention technology

General Technical Requirements

APPLYING IN THE WORKSHOP RATE OF SURFACE PREPARATION: Sa 2 % TYPE OF WORKSHOP PRIMER (if any): Paint manufacturer: PAINT COAT SYSTEM Nominal dry layer thickness Layer 1: SIKAKOR EG phosphate Layer 2: SIKAKOR EG 1 Layer 3: SIKAKOR EG 5 IN ALL m 80* 80* 40* 200 Area: m2 Repainting interval Minimum hours 5 5 24 Maximum hours Drying time at 20 C hours 8 8 24 to 30

NOTE: * Several working processes may be necessary.

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