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 ?

Corrosion Effects.

Corrosion Caused Leakages

Floating Tank Corrosion Weld Joint Corrosion

Pipeline Catastrophic Failure Gas Pipeline Corrosion Leakage

Corrosion under coating

Paint Disbondment & Corrosion Structural Support Base Corrosion Pipe Support Corrosion

Fastener Corrosion Wet Surface Corrosion Equipment Corrosion

Corrosion Effects.

Pipeline Corrosion Under Insulation

Corrosion – Under Insulation ?

High Temperature Corrosion – Bowl Mills High Temperature Corrosion – ESP Domes

High Temperature Duct Corrosion Galvanised Surface Corrosion

Why Coating Failures ?

Blistering Cracking /Flaking Peeling

Efflorescence Heavy Corrosion Due to Acidic Fumes

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 ?

ANSWER

1. Adhesion Issues

2. Inadequate Barrier Impermeability

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

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.

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

FOCUSED AREAS

• 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

Tank Externals (UHP surface preparation)

Corrosion prevention on highly “Rusted Surfaces”BEFORE

SURFACE PREPARATION

FINAL COAT

SURFACE PREPARATION

ST2/ST3

Wet Surface Corrosion Prevention Manhole Hatch – Hydel Power Plants

Before After application .

Application on hot power station exhaust ducts operating at 150OC

Before After application.

Corrosion Prevention – ESP Domes

Before Application After Application.

Corrosion Prevention – Outdoor Installed Equipments

Before Application After Application.

Before Application After Application

Transformer Completely Coated with Long Term Anti-Corrosion Solutions

Before Application

After Application

Tank Firm Applications.

Loading /unloading of acids & hazardous chemicals floor coating

Acid storage area bund linng

Battery room floor coating

Acid Spillage Protection

Epoxy Coating Capable of application on Damp, Water Saturated, Green, Concrete….. As well as for “Negative Pressure” Water Proofing.

CONCRETE PROTECTION

Why Concrete Damage ?Water Saturation & Re-Bar Corrosion; Acid Attack; Loss Of Alkalinity & Spalling

Severe Concrete Corrosion Concrete Cancer – Loss of Alkalinity; Spalling ; Re-Bar Corrosion;

Sulfuric Acid Attacked Concrete

Severe Corrosion in Concrete Catastrophic Concrete Corrosion & Failure

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 ?

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

Niche Market Industrial Coating Manufacturer Product Name Product Cost

Per Sq. MApplication Cost Per Sq. M

Application

BELZONA-NICCO R METAL/ S METAL/1341 20-25 K INCLUDED Condenser Tube Plate & End cover. /CW

pump coatingITW –DEVCON TITANIUM PUTTY/BRUSHABLE

CERAMIC25-35 K INCLUDED --DO—

STANVAC 1170/1180/1190/1195 15-20 K INCLUDED --DO--

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