solvent free glass fiber reinforced epoxy tank -re re

Edition 07.2014 Identification No. P - 24

1 .Description:

A two component solvent -free epoxy reinforced with glass fiber mat to be used for lining and re-bottoming of storage tanks .its resistant to chemicals, oils petroleum also it can be produced as a heat resistant lining which can withstand temperature up to 170° C under the trade name PROLINE CERAMIC EP.

2 .Scope:

Steel storage tanks containingcorrosive fluids need to be internally lined to prevent corrosion of the substrate and contamination of the liquid stored within. There are many reliable organic lining systems available, typically epoxy based, which can be used at new building; however, in general, these will need to be maintained to ensure the tank achieves its design life. These same systems can also be used for maintenance painting. But what if corrosion has started in the tank base, leading to thinning of beneath steel plate or even the development of holes? The owner has two options: to replace the corroded steel, which is expensive and involves a long shutdown of the tank, or to use a reinforced lining. There are a host of different types of reinforced tank-lining systems that can greatly influence the duration of shutdown time required to apply the lining, financially benefit the end user in the long run, and allow linings to be applied to tanks that have suffered significant amounts of corrosion damage.

Solvent Free Glass Fiber Reinforced Epoxy Tank

-RE Bottoming System RE- Guide


5. How to use:

5.1. Surface preparation: The tank is desludged and cleaned with detergents to remove all the traces of the content.

The area to be coated is sandblasted to the clean metal, and then vacuum cleaned (Swedish

standard SIS 05.59.00-1967:Sa 2,5-3).

The Pits are either patched by welding, followed by sand blasting Of weld area , or they are

patched with a putty conveniently system with some dry and clean Quartz flour.

Welded Tanks Dry sand – blast the tank floor and the tank wall (shell plates) to a height of about 1-1.5

meter. A dull grey metal finish. Swedish standards Associations SIS 05 59 00 grade Sa 2 ½

or steel structures paint council, USA standards SP 6-63 , is suitable.

The height up to which the treatment of walls is

carried depends on the particular use of the tank.

In dehydration tanks or others containing water

bottom, it may be necessary to apply the laminate

depth of water likely to be encountered in service.

Remove blast-cleaning products and apply a

conventional two-pack EPOXY resin/amine adduct

or polyamide curing agent primer immediately after

sand-blasting. The manufacturer's instructions on mixing, thinning, application rates and

working life of the paint should strictly followed.

The use of clean brushes and a vacuum cleaner to remove dust ,ect.

Application of the primer is recommended. the freshly sand-blasted surface should be

primed as soon as possible , especially in humid conditions , preferably no more than 4 to 6

hours after blasting to prevent further corrosion .

Under no conditions should the sand-blasted surface be left uncoated overnight.

Metallic pigmented primers (Zinc-rich or lead –rich)

are not recommended, they are intended for different

services conditions over coated with paint.

Under the thicker and more rigid layer of a laminate

than when a conventionally pigmented EPOXY resin

primer is used.

Ventilate the tank adequately during the application

and drying of the primer to remove solvent vapors.

Edition 07.2014 Identification No. P – 24

Any holes greater than about 1 cm diameter in the bottom of the tank should be covered with

a sand-blasted and primed steel plate which can be stuck down using the laminating resin

system as an adhesive. Holes smaller than 1 cm diameter and any pitted areas should be

filled with an EPOXY resin based putty (EPOXY PUTTY).

Fill all overlap welds with the EPOXY resin based putty to give a smooth surface

on which to apply the laminate without bridging.

Fill the curb angle between floor and plates with a sand-filled EPOXY resin

system , again to give a smooth surface on which to apply the laminate without

bridging over an air gap.

A tack coat of unfilled resin mix can be applied to the areas of plate on which the Filler is to

be applied shortly before the sand-filled mix is trowelled into place, this facilitate application

of the filler mix and improves it's adhesion , any

other fixed

Protuberances should be treated similarly.

Patch any severely pitted and holes areas by

applying a laminate consisting of an EPOXY resin

system, reinforced with two layers of chopped strand

mat.

Apply laminate over the whole of the tank floor and

the cleaned and primed part of the tank wall. This laminate consists of one or two

layers of chopped strand glass.

Ensure that the primed steel is grease and dust free before applying the laminate. Abrade

the surface of any patches applied. Typically laminate would consist of two layers of 300

g/m² chopped strand mat or one layer of 450 gm/m² chopped strand mat, although

circumstances may arise where a thicker mat 450 g/ m² is considered desirable , a glass

surfacing tissue 300 micron is generally used.

A minimum overlap between adjacent strips of

mat of 5 cm is desirable. However to avoid ridges

and simplify the laying procedures, it is better to

have a 50% overlap.


In laying the laminate, apply a layer of resin mix by brush or roller and onto this place one

layer of chopped strand mat reinforced.

Compact by rolling with split washer rollers this displaces the air in the mat out wards, apply

further resin mix, then the second layer of chopped stand mat and consolidate as before

repeat for the surfacing tissue.

Typically the weight of resin mix required per unit area in a hand layup laminate is roughly 3

times the total weight of reinforcement per unit area plus about 300 gm/m² for the surfacing

tissue

The laminate applied to the shell plates may either be applied before or after the main

laminate onto the tank floor. The technique used is the same as for floor laminate but the

resin may be suitably modified to reduce resin drainage on the vertical surfaces. For

convenience the mat is generally applied vertically then horizontally.

In floating roof tank where legs are attached to the underside of the roof the legs should be

jacked up and the laminate applied underneath them in the usual way. While the resin

system is still wet, a sand blasted and primed steel plates a 45 cm square by about 12 mm

thick should be placed on the laminate under leg, then the leg is lowered.

When the resin system cures, the steel plates are firmly bonded to the laminate and prevent

the legs curing into the laminate each time the tank is emptied.

Once the laminate is hard enough to walk on (about 24 hours). Check for Porpoises

using a spark tester (holiday detector) or similar equipment, with high voltage spark testing

equipment, a voltage in the region 10-12 kv. is recommended. If a higher voltage is used

there is a danger of creating holes in the laminate.

It porous areas are found, roughen the surface of the cured laminate over an appropriate

area and remove all dust. Apply a further laminate consisting of one or two layers of chopped

strand mat and surface tissue.

Where a pigment overseal is required. This should be applied after the laminate has been

checked for pinholes and, if necessary made good. The overseal should either be based on

the amine adduct cured system of suitable quality.

If the required tank is to be used for fuels, the overseal must of course have approval for

this service.

Allow a minimum cure time of one week before putting the tank into service.


Riveted Tanks

In riveted tanks where leakage is only occurring along the seams and through loose rivets, only

a seam repair is necessary. If, however, the floor plates are hold and pitted the complete tank

bottom should be repaired.

The tank should be structurally sound and there must not be relative movement between plates

that is the plates springing or sliding relative to one another.

Seam Repairs Only,

Sand-blast the rows of rivet heads and

about 30 cm on either side,

to a dull grey finish grade

Sa 2½ Swedish Standard Association

SIS 05 59 00.Remove all sand and dust by brush

and vacuum cleaner.

Apply a conventional two-pack EPOXY resin primer (KEMPRIM M) immediately after

sand blasting as before, a zinc primer is not recommended under a laminate.

Apply an EPOXY resin based putty or a sand-filled EPOXY resin system (EPOXY

PUTTY)over all the rivet heads, to give a smooth surface on which to apply the

laminate. A tack coat of unfilled resin mix may be first applied to improve adhesion

and facilities application of filled mix.

Apply a laminate consisting of EPOXY resin

Laminating repair system with either two layers

of chopped strand mat plus surfacing tissue or

two layers or woven glass tape plus surface

tissue. Over the whole of smooth filled surface

and extending to about 10 cm on either side.

On vertical surfaces, a modified resin mix

containing a suitable thixotropic agent may be

necessary to prevent resin drainage.


Typically two layers of 300 g/m² chopped stand mat plus a 300 micron surfacing

tissue are used or one layer of 450 gm/m² glass mat is used

The laminating resin mix is applied by brush or roller to the part to be preparation the

first layer of glass

reinforced is laid on

this and consolidate

with a split washer

roller.

Further resin mix is

applied. Followed by the second layer of glass which is again rolled with a split-

washer roller. Repeat for the surfacing tissue.

The whole laminate is then fully consolidated by rolling to displace all the air

outwards. Providing sufficient resin system has been applied the laminate should

have a resin rich surface.

Check for porosities in the laminate using a spark tester or similar equipment after

the resin has cured for 24 hours. Repair any porous areas by roughening the cured

dust and applying a

further one or two

layers of

reinforcement plus

.surfacing tissue

A pigmented over seal may be applied if desired.

Shell plate shell flood coat with SF epoxy@20-50mils DFT

100%Solids Epoxy grout/caulk trowel applied toraduis weld and seal edges of 3D glass fabric

Fabrication Welds 3D glass fabric &Sf epoxy cut at 45 degree adjacent to weld

3layers 1OZ.chope strand mat wetted out with Sf epoxy

Steel substrate

"1/2 or3/8 " NPT Stainless steel threaded fitting welded to be conicalk machined stainlesssteel plate

Sf epoxy topcoat

3D Glass fabric

3D Glass Fabric

Steel substate

laminate, remove all stitch mat Sf epoxy topcoated

Steel substate


Total Floor Area Repair Essentially the repair procedure in this case is a combination of the procedure for welded tanks

with the preparation of the riveted seams.

Sand-blast the floor of the tank and about 1 meter up the tank wall to a dull grey finish and

primed as described under welded tanks, ensuring that the area around the rivet heads is

thoroughly cleaned.

Apply an EPOXY resin based putty (EPOXY PUTTY) or a sand filled EPOXY resin system

over all the rivet heads to give a smooth surface on which to apply the laminate a

preliminary tack coat of unfilled resin mix may be desirable to improve adhesion of the

filled mix and facilitate application.

Unless filler is applied around rivet heads difficulty will be experienced in applying a

bubble free laminate with no hollow patches. Hollow areas under into laminate are a

potential source of failure.

Continue as under welded tanks section.

Mixing

All ingredients in any container of lining or coating material shall be thoroughly

mixed before use and shall be agitated frequently during application to keep the

materials in suspension. Dry shipment which are separately packed shall be

uniformly blended into lining or coating component.

Thinner shall not be added to any lining or coating component unless required by

the manufacturer’s instructions, and then only of the type and the quantity

recommended. If required, thinner shall be added to the required component

during the mixing process.

Dryers catalyst in addition to those incorporated by the manufacturer shall not be

added to the lining coating materials unless specifically required and called for in

written field instructions for application.

Material should be applied before the expiration of the pot life time. Storage of

unused materials should be according to manufacturer's recommendation.


Prime Coating

The cleaned and repaired area is then protected with a thin layer of conservation

primer. The dry film thickness of this primer must be between 50-75 microns

To preserve the rough pattern of sand-blasting .This to ensure the best possible

adhesion between primer and laminate .

For this application we recommend conventional epoxy primer, as long as its

viscosity permits the obtaining of the thickness specified.

We recommend the primer to be applied by spray-gun spray application will ensure

particularly even distribution.

Laminating

After the primer has properly cured, the laminating can start.

The first batch of the chosen laminating system is mixed. Batches should preferably not

exceed a total of 10 kg, as time must not suffice to apply greater amounts at elevated

temperatures

Immediately after the mixture each batch is applied by a paint of the vertical surface and

then pass on to the adjoining floor area.

Immediately after the first application of the liquid system, place one layer of glass

mat(450 g/m²) on to using it and work the resin mix well through the glass mat using a

metal disc or other laminating roller. This is to avoid entrapping of air in laminate. An

overlapping of 3-5 cm between mat strips gives optimal results.

Immediately after applying the laminate layer cover it with a surfacing tissue (ca. 25

gm/m²) and work it well into the wet laminate, using a metal disc roller. Surfacing tissue is

to prevent glass fibers of the mat from protruding through the surface coat.

Ideal recoating time in hours, i.e minimum and maximum curing time the coating must

have, in order to achieve ideal interlayer adhesion to next coat. After maximum time has

elapsed, coat must be roughened (sand-paper) to assure inter-layer adhesion.

At 20 degree C 65% relative humidity 20-40 h

At 40 degree C7-15 h


After this last layer has cured roll on an ultimate abundant surface coat of the liquid

laminating system.

Curing Allow the whole laminated lining to cure thoroughly for at least 3 days before refilling the

tank.

Cleaning Flush equipment with manufacturer's approved solvents before and after use.

Job conditions

Primer or paint shall not be applied when any of the following conditions prevail:

When it is wet.

When heavy fog or mist are present.

When the relative humidity will cause condensation on carbon steel surfaces operation at

ambient temperature.

Minimum and maximum temperature and relative humidity for application of the materials

shall be within the following table.

When the surface temperature are less than 3 degree C (5 degrees F) above the ambient

dew point.

Thinners are to be approved for field use according to manufacturer's recommendations.

Cleaning solvents are to be provided by paint applications.

Tank should be equipped with fans of sufficient capacity to keep solvent vapors below 20%

of the lower explosive limit (LEL).

Explosion proof lights and electrical equipment shall be used.

Non-sparking shoes and tools for workers shall be used.

Theoretical Coverage KEMPRIM M : 0.15 kgm/M² (D.F.T 125 microns)

EPOXY PUTTY: 0.3-0.5 kgm/ M²

Epoxy Laminating (KEMCOAT E81,KemCoat E43,CermicCoat ):2 kgm/ M² (D.F.T 1250

microns)Glass Mat Or KemFelt :(450 gm/ M²): 0.5 kgm/ M²

Finish Coat (KEMCOAT E81 KemCoat E43,CermicCoat): 0.3-0.5 kgm/ M² (D.F.T 250 microns)


Packaging 1,5 kgm. cans( A&B) KEMCOAT E81- KemCoat E43-CermicCoat

100 LM rolls Glass Mat Or KemFelt

Shelf life & Storage PROLINE EP has a shelf life of 12 months if kept in original packs in a dry condition.

solvent free glass fiber reinforced epoxy tank -re re

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