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Until recently heavy metal-based corrosion inhibitors were widely accepted as the best materials that could provide the corrosion protection needed in coatings. Corrosion inhibitors provide an indispensable function in protective coatings. The performance of a coating under corrosive conditions requires that corrosion inhibitors provide sustainable protection during the coating’s lifetime.
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An important segment of the high-performance protective coatings market is weatherable, direct-to-metal coatings. Coatings that weather well and provide corrosion protection are recommended for direct-to-metal applications, due to the dual benefits of ease of application and good asset protection. However, performance can vary widely based on the coating type and substrate preparation, with performance often rated by accelerated corrosion testing.
Currently the shipbuilding industry is seeking to minimize to improve corrosion protection provided to the structures which comprise the Water Ballast Tanks (WBT’s) of a vessel. At the design stage two factors could reduce the carbon footprint of the coating process through life material selection and optimizing the structural design to facilitate the coating process and maintenance processes. Thus, the design stage exerts considerable influence on these two elements and can determine the through life costs and environmental penalties of maintaining the structure.
A two-year FHWA in-house study was launched in November 2006 to evaluate various coating materials that can be applied as one-coat systems to steel bridges. A total of eight test materials plus a 3-coat system and a 2-coat control system were applied over near-white steel test panels (SSPC-SP10). Their performance is being monitored using electrochemical impedance spectroscopy, various surface failures, rust creepage at scribe, adhesion, and change of color and gloss.
According to the international surface preparation standard for welds (ISO8501-3), the preparation grades before the application of paints are divided into 3 levels, P1, P2 and P3. These grades are described with rough qualitative representations, not description of surface treatment methods or measurable conditions. Because of the ambiguous wordings on the standard, there have been a lot of arguments for the surface preparation grades and abraded condition during the construction.
The objective of surface preparation is to create proper adhesion of a coating over the substrate. Proper surface preparation is vital to the long life and effectiveness of a coating applied in corrosive service. In some projects, the owners ask for the additional water jet cleaning prior to blasting work.
Feathering is the process of tapering or blending-in an existing intact coating in preparation of applying a new repair coating. This industry common practice is intended to ensure good adhesion of the repair coating to the legacy coating, and to provide a seamless aesthetic transition for areas where maintenance painting is performed. There are no industry standard requirements for performing feathering, resulting in most specifications having their own unique definition.
Coating performance and longevity is highly dependent on the quality of substrate surface preparation. The effect of profile height, profile type (e.g., type of tool used to perform the prep, angularity of profile, etc.), extent of cleanliness, and amount of chloride contamination on coating performance were all studied to determine the correlation between these factors in an attempt to identify the primary factor in coating failure due to improper surface preparation.
For decades, waterproofing has been a major concern and a widely researched topic by building scientists and forensic engineers. Elastomeric coatings have been broadly used in different applications since the early 1950s. Manufacturer’s recommendations for the proper application of elastomeric coatings are often based on laboratory conditions (75oF and 50% RH) rather than extreme conditions posed by the real world. This study examines the failure of elastomeric roof coating exposed to conditions of high temperature (150°F) and water pooling caused by precipitation.
The protection of commercial buildings from the elements is a major function of the coatings used in new build and maintenance applications. Waterborne elastomeric acrylic coatings represent an important category of coatings used in both residential and commercial architectural painting.
Due to their excellent performance properties, epoxy coatings are commonly used over metal and concrete substrates in applications where corrosion protection and chemical/solvent resistance are key requirements. One weakness of these epoxy coatings is their poor UV durability. Epoxy coatings typically have poor gloss and color retention as well as poor resistance to chalking on exterior exposure.
Tank lining products are necessary for protection of infrastructure and commodities to ensure daily business operations continue smoothly. They are expected to protect the tank from corrosion and chemical attack while maintaining the purity of the tank’s contents; ultimately keeping people and the environment safe from an accidental discharge. Rigorous laboratory testing programs and field trials are conducted to instill confidence the right product is recommended for each task.