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Global Environmental Regulations have driven many coatings developments over the last decades. Today´s regulations around worker safety and environment protection are seen as important drivers in new product development. More recently such regulations are spreading widely, as people want to live on a planet where everyone can enjoy a better quality of life, breathe clean air, where rivers and oceans are preserved, and the impact of humans on wildlife is reduced.
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Two component Epoxy polymer systems have been used as the basis for high performance protective coating systems since the 1950s. Numerous Epoxy resin types and ambient condition curing agents are available today which allow great flexibility in the formulation of coating products. This has led to the development of a wide range of applications ranging from simple anticorrosive systems to high performance heat and chemical resistant coatings and linings.
CLTWater is one of the largest water entities in the Southeast region, managing a total of ten water and wastewater treatment plants serving a population of approximately one million. The MCWWMF is the largest wastewater treatment plant of five wastewater facilities owned and operated by CLTWater, rated at a 64 MGD treatment capacity and accounting for over half of CLTWater’s wastewater treatment system.
Corrosion mitigation by the use of barrier coatings relies on polymers and other substances to minimize the permeation of corrosive agents to the substrate. To achieve good barrier properties, most protective coatings rely on high crosslinking density and special fillers to increase the tortuosity of the film. However, this approach usually leads to highly viscous and brittle coatings that take too long to cure. In contrast, flexible and tough coatings typically do not have the requisite barrier properties for enhanced corrosion prevention.
Bis-Phenol A epoxy resin-based coatings are known for excellent corrosion and chemical resistance. Limitations of this class of coatings are poor flexibility, thermal stability and weather resistance. Traditional siloxane resins are commonly used in the industry to improve the thermal and weather resistance of bis-Phenol A epoxy coatings. In addition, organo-functional silicone polymers have been used to provide improved flexibility, but create recoatability issues.
Epoxy-based coating used in the ships and marine structures can be quickly degraded after only a short period of exterior exposure. The weathering defects such as discoloration, chalking and gloss reduction are originated from a photo-oxidation of aromatic group in the epoxy resin under the UV light. Weather resistance coatings such as polyurethane and polysiloxane require more work due to the short over-coating interval and low compatibility with primer coating layers.
Coatings designed for heavy duty applications in the Maintenance and Protective Coatings market are exposed to aggressive environments such as aggressive chemical solvents, marine atmospheres, UV light, abrasion, among others. In the US as well as other areas of the world, coatings designed for these applications have been primarily solvent borne.
Many protective coatings markets have recently seen high demand for higher performing coatings or linings. For example, with enhanced oil recovery, many more assets are now used throughout these processes from the oil / water separation tanks to the acid injectors. The temperatures are higher and corrosive environments are more severe. Formulation chemists are working hard at trying to push the extent of the performance of typical resin systems, but it seems that most of the development has been done and the extent of the performance available has been maximized.
The Passaic Valley Sewerage Commission (PVSC) in Newark, New Jersey is one of the most extensive modern wastewater facilities in the Eastern United States and is the sixth largest in the country. Established in 1902, PVSC began operating the Newark Bay Treatment Plant in 1924 to mitigate pollution in the Passaic River. The sprawling facility contains miles of access roads, utility tunnels, sewers, storm drains, and process pipes.
Over the past 40 years, three-coat systems consisting of zinc-rich primer, epoxy intermediate and polyurethane topcoat (ZEU) have been the preferred coating system for steel bridge structures in highly corrosive environments due to their proven performance and cost effectiveness.1-6 Each layer serves a different function: galvanic protection is supplied by the zinc-rich primer, while the epoxy intermediate coat provides barrier to water and salts, and the polyurethane topcoat resists against ultraviolet degradation, abrasion, and chemicals.
HISTORICAL DOCUMENT. Ordering, cleaning, coating, inspecting, handling, transporting & installing steel reinforcing bars. Fusion-bonded epoxy powder coatings by electrostatic spray. For owners, architects, engineers & contractors.
HISTORICAL DOCUMENT. Defines the Thorough Cleaning (WJ-3) degree of surface cleanliness - one of four levels (WJ- 1,2,3,4) achieved by the use of waterjet cleaning.