Containment Systems & Chemical Resistant Coatings
Who It’s For
This session is useful for:
Maintenance Manager
Maintenance Supervisor
Maintenance Technician
Reliability Engineer
Reliability Manager
Plant Engineer
Facilities Manager
Facilities Maintenance Manager
Asset Integrity Manager
Mechanical Maintenance Planner
Today, we’re diving into containment systems and chemical-resistant coatings. In the next 10 minutes, we’ll cover how to choose the right containment system and the appropriate chemical-resistant coating for your specific needs. We’ll wrap up with a Q&A session at the end, so thank you for joining us!
The first step in selecting chemical-resistant coatings and containment solutions is to identify your complete stress stack. While chemical resistance is crucial, it’s just one aspect of the overall equation. A coating that performs well in one situation may not be suitable in another, so understanding the total stress stack is essential.
We need to determine what the coating will be required to endure. This includes the chemistry involved—what chemicals are present—as well as temperature considerations. Additionally, we must consider whether this will be an immersion system or if it will experience splashes. Is it secondary containment? All these factors significantly impact chemical resistance and the coatings you choose.
We also need to evaluate any potential abrasion or impact the container may face. What full conditions will the container be subjected to? Finally, consider the substrate and any preparation limits.
Lastly, think about downtime and the cure window. How long can the asset be out of service, and how long will it take to return it to service?
When building out your stress stack, it’s crucial to gather detailed operational specifics—not just the chemical name or pH. While it’s tempting to rely on that information, understanding the specific chemicals involved and their blends is vital for making informed decisions.
Does this system undergo a cleaning cycle? Remember, those cleaning agents are also chemicals, so it’s crucial to ensure protection against them. Additionally, consider any byproducts that might be generated in this environment. You’ll want to discuss concentration levels—what’s your worst-case scenario or peak concentration compared to your normal operating range?
Temperature is another factor to keep in mind. What’s your typical operating temperature, and do you have systems that experience peak operating temperatures? Don’t forget about thermal shock, which occurs when temperatures change rapidly.
Contact type is also essential. Are we dealing with immersion, splashes, fumes, or secondary containment? When discussing secondary containment, it’s important to consider its placement. For instance, if it’s located under a structure where people will walk, you’ll need to think about abrasion resistance from foot traffic or even equipment.
Lastly, consider the frequency of exposure. Will there be continuous immersion, or will it involve batches? Is it a wash-down situation, or could there be emergency exposure in the case of secondary containment? All these factors contribute to the overall stress considerations.
This could involve abrasion, UV exposure, or pressure. Does the container need to be flexible? Is it mobile, and will there be traffic over it? All these factors play a role in determining whether we’re selecting the right coating and how to make that decision.
Understanding your asset and substrate is crucial. Your selection may vary depending on the substrate type. There are excellent primers available that allow various coatings to be applied to different surfaces. For steel, it’s essential to ensure the correct blast profile and to test for soluble salts. You’ll also need to address any existing pitting or corrosion, smooth out welds, and consider edge conditions. The type of steel will influence your product choice as well.
When it comes to concrete, consider its typical moisture level and pH. Are there cracks or potential outgassing issues? You might also need to ask if it’s embedded in a wall or underground, where it could be subjected to hydrostatic pressure. There are solutions for all these challenges, but they’re vital for achieving the best results for your asset.
Regarding existing coatings, it’s generally not advisable to apply a new coating over a severely damaged one. Identifying compatibility is important; many systems come in two colors—a base color, like blue or red, and an overcoat, usually gray. This design allows for easy inspection; if you can see the underlying color, it may indicate damage and signal the need for recoating.
These systems are designed for easy recoating; we know the product inside, and we can prepare the surface by roughening it up before applying a new coat. If the coating has been in place for an extended period and shows significant damage, you may need to strip the entire coating off. Lastly, don’t forget to consider the geometry of the asset, including its edges, pits, seams, bolts, and any confined spaces.
What does access look like? This factor will influence our product selection, as there are many excellent products suitable for spraying, while others are designed specifically for brushing or rolling. If your space has complex geometry, we’ll need to focus on the sprayable options.
I came across a saying that I can’t quite place, but it resonates: great chemistry can overcome poor surface preparation. It’s crucial to pay attention to our Technical Data Sheets (TDS) and adhere to the outlined surface prep steps.
Typically, we begin with an inspection. This includes conducting soluble salt tests, moisture checks, and pH assessments where necessary. If there are cracks in concrete, they need to be repaired. For damaged steel structures, it’s essential to address those issues as well. We offer some excellent epoxy repair solutions to fix cracks and pitting, helping to restore any wall loss effectively.
Before applying your coating, the next step is preparation. It’s vital to follow all the necessary preparation steps, especially if you want a long-lasting solution. Most coating failures stem from improper surface preparation.
Once you’ve prepared the surface, you move into the application stage. Here, it’s essential to adhere to all application steps, but an important final step is verification. There are many inspection tools available, and skilled inspectors can ensure there are no holidays or pinholes in your coating, confirming that you’re ready to put it into service.
The last step is to schedule your first maintenance inspection once you return to service. This is crucial for quickly addressing any issues that may arise and for establishing a routine inspection process. Sometimes, you’ll circle back to earlier steps, as illustrated in the triangle setup. All these factors are important for ensuring a durable asset in any environment.
At USI, we focus on product selection, offering a wide range of solutions suitable for various environments. While I can’t list all our brands, the right choice depends on your specific situation—pressure, temperature, and the chemical mix involved, as well as whether the environment will experience heavy abrasion.
We also provide exceptional high-temperature, chemical-resistant products. It’s important to remember that there isn’t a one-size-fits-all solution; every detail matters. Consulting with an expert who understands these products and can ask the right questions when assessing your asset is essential.
Now, let’s open the floor for questions. You can either chat them in or speak them out loud. I see we have a question in the chat: “How do you address existing cracks or damaged concrete before applying a chemical-resistant lining?” Bobby, that’s a great question! Typically, you’ll want to remove any loose materials from those cracks. We have excellent repair products that are more chemical-resistant than the surrounding concrete.
Our lightweight concrete repair systems allow you to build up on a wall without needing forms, and we have options designed for heavy traffic. The approach will depend on the specific environment you’re dealing with, similar to selecting a chemical-resistant coating.
Be sure to clear out any loose concrete, scuff up the surface, and apply a repair patch before putting on the lining. Doug, do you have anything to add?
Doug Klingensmith: One thing to keep in mind, Bobby, is to saw cut around the edges to about a quarter inch deep. This helps create a solid bond for the repair. Whenever possible, opt for a concrete repair system that includes a primer to penetrate the existing concrete, ensuring strong adhesion.
Christopher Williams: Any other questions for us today regarding chemical-resistant coatings or linings, or anything else?
Doug Klingensmith: Chris, one aspect to consider with steel tanks is the importance of stripe coating. It’s best to apply a stripe coat first with a brush to ensure good penetration at the welds and sharp edges, and then follow up with your first coat of chemical-resistant lining before the overcoat window closes.
Christopher Williams: I’ve heard that with stripe coating, you don’t wait for the cure window, right? You apply the stripe coat and then almost immediately proceed to add that extra film thickness around those irregular geometries.
Doug Klingensmith: Yes, that’s typically the best practice. You don’t wait for it to fully cure; just allow it to tack up a bit.
If you have any more questions, we’ll be sending out a survey to everyone who attended to ensure we’re providing maximum value with these discussions. You can also reach out to us at 248-735-7000 or via email at office@usigroups.com.
