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Solution vinyl resin coatings are an effective coating system that have been used on raw water hydraulic steel structures since the 1940’s, including many of the nation’s hydroelectric and lock and dam facilities. The high performance of the vinyl coating is at the cost of releasing high amounts of volatile organic compounds into the air. This study evaluates polysiloxane coating systems as greener alternatives to solution vinyl systems.
Solution vinyl resin coatings are an effective coating system that have been used on raw water hydraulic steel structures since the 1940’s, including many of the nation’s hydroelectric and lock and dam facilities. The high performance of the vinyl coating is at the cost of releasing high amounts of volatile organic compounds into the air. This study evaluates polysiloxane coating systems as greener alternatives to solution vinyl systems. Laboratory experiments were executed to simulate immersion and cyclic weathering conditions that the infrastructure may endure. The analysis also included physical testing of the coating resistance to impacts, abrasion, and erosion. Electrochemical analysis included cathodic disbondment testing to evaluate compatibility with cathodic protection systems and electrochemical impedance spectroscopy to determine barrier and degradation properties.
Third Generation Polysiloxane (TGPS) ambient curing CUI mitigation coatings have been used in the petrochemical industry for over five years since the “third generation” concept was introduced at NACE Corrosion 2017. These coating technologies have demonstrated positive results in both shop and field application for asset management in elevated temperature, cryogenic and cyclic applications across -196 to 650o C/ -321 to 1200o F operational temperatures. TGPS coatings have also demonstrated effective use of a two-step (primer-insulation) CUI mitigation coating approach operating up to 400o C/750o F, when compared to the traditional (CUI coating-fibrous insulation-cladding) systems.
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Substrate preparation which includes the removal of contaminates, abrading or etching to create a surface profile via mechanical or chemical methods have a major impact on the adhesion performance of applied coatings. For coatings, a primary performance characteristic is adhesion after exposure to corrosive environments. One of the consequences of corrosion forming under a coating is the loss of adhesion or delamination of the coating.
The electroplating of aluminum has represented a challenge for the coatings industry for decades. The reactivity of aluminum metal leads to a very negative reduction potential. This leads to abundant gas evolution instead of aluminum reduction in water. Current aluminum deposition technology overcomes this limitation by excluding oxygen and water from the process with rigorously dry solvent and airtight plating tanks.