High-Temperature Coating Systems Simplified with Mitch Buchanan and Jim Kunkel
When considering coatings, it’s essential to understand the application methods. Questions to ask include whether the coating can be applied using airless spraying, if it requires plural component spraying, or if it needs to be heated.
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
About the Speakers
Mitch Buchanan is a protective coatings and MRO specialist with Henkel focused on asset integrity solutions for the general industrial and infrastructure market. Mitch is a US Navy veteran with industry experience in chemical plant maintenance and operations along with coatings, adhesive, and combination. composite formulation development expertise.
Jim Kunkel is a certified protective coding specialist and his work with Henkel is focused on midstream new pipeline construction, repair and rehab. Also, Jim is the SME or the subject matter expert on above ground storage tanks in the US
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Who is Henkel:
Henkel bought two, made two major acquisitions in this market in 2024, closed and fully integrated now. We’re all, you know, Henkel employees now legally, but they bought critical infrastructure, so ClockSpring NRI pipeline, and they bought SEAL for Life Industries. So SEAL for Life, main products we’re going to be talking about today was a coatings conglomerate focused on field joint coatings and infrastructure coatings. So Powercrete, CANUSA-CPS, Anodeflex, STOPAQ, Mascot, Highland International, lots of brands you recognize into this high temperature space and pipeline coatings. We’re now all part of the Henkel Adhesives technology right alongside LocTite, Teroson, Bonderite, and Nordbak, a lot of legacy product lines from Henkel as well.
And our shared vision is to build and maintain and protect your critical infrastructure. And we’re now part of what we call infrastructure protection and repair. So Henkel IPR, if you see that around, that’s Jim and I are part of that group. And we are the coding specialists and asset integrity specialists within Henkel. So when we talk about common codings, this is not by any means an exhaustive list of different chemistries, but it’s good to kind of get a baseline and understanding of how this all plays into high temperatures, because not every solution is going to be the correct solution for your asset. And while something like epoxies are ubiquitous and everywhere and it’s used all throughout every industry in our daily lives, they’re not the solution for everything.
Coatings can be broadly classified into three categories:
- Organic: These contain carbon bonds.
- Inorganic: This category includes materials like zincs, various metallizing agents, and certain silicones.
- Hybrid: These combine both organic and inorganic technologies. A good example is organic zinc, which features an inorganic filler combined with an organic binder or modified polymerics.
When considering coatings, it’s essential to understand the application methods. Questions to ask include whether the coating can be applied using airless spraying, if it requires plural component spraying, or if it needs to be heated.
This also leads to a discussion of 100% solids coatings versus solvent-borne coatings. Solvent-borne coatings encompass water-borne options, which are a subset, as well as oil-reducible alkyds. We often discuss these separately, but when we refer to solvent, we typically mean VOCs and hydrocarbons, including acetone and various alcohols. Water is usually mentioned separately due to its lack of VOC content.
There are many different chemistries to consider, such as epoxies (including coal tar epoxies), polyureas, and polyaspartics (the aliphatic subset of polyureas). Other options include alkyds, acrylics, nitriles, fluoropolymers, and thermal spray coatings.
Additionally, we have viscoelastics, such as visco attack or stow pack, which are cold-flow coatings that can be particularly effective in anti-corrosion applications.
When considering temperature, how do we define high-temperature coatings? While various definitions exist, this is my perspective on the matter. Different chemistries have varying temperature thresholds. For example, epoxies are a common organic coating. Basic epoxies, like JB Weld or mercaptan-cured types, usually have a maximum service temperature of around 250 degrees Fahrenheit.
As we progress to bisphenol F and Novolac epoxies, these typically allow for continuous operation, especially in immersion services, at about 350 degrees Fahrenheit. Then, we have specially formulated organics, such as BMI resins and multifunctional epoxies like glycidol amines and cyanide esters, which can achieve continuous operating temperatures of up to 300 degrees Celsius.
Many organic coatings are often cited as having upper limits around 180 to 200 degrees Celsius. This is generally accurate, particularly because viscosity can be an issue. However, if you’re working with plural component coatings or composite repair solutions, like our high-temperature pipe wrap, these organic resin binders can sustain continuous operating temperatures between 250 and 300 degrees Celsius.
Silicone hybrids, including silicone alkyds and silicone acrylics, typically fall within the 550 degrees Fahrenheit range. By increasing the threshold to 800 degrees Fahrenheit, you’ll primarily find modified silicones and some higher-temperature silicone polymers.
Beyond that, true high-performance coatings, such as modified polymeric silicones and multi-polymeric matrices, can sustain continuous operating temperatures up to 1200 degrees Fahrenheit. Many of these coatings can handle temporary peaks during start-ups and process interruptions up to 1500 degrees Fahrenheit without compromising adhesion, color, or gloss.
Once temperatures exceed the 1200 degrees Fahrenheit range, metallizing coatings, thermal sprays, and materials such as zinc, aluminum, and magnesium become the primary solutions. Additional options include thermal spray silicones or ceramic oxides, like aluminum oxide and various ceramics, rather than just pure zinc metallizing.
On the opposite end of the spectrum are cryogenic coatings, which are crucial in applications such as pipelines and aerospace. Many silicones that perform well at 1200 degrees Fahrenheit also excel at cryogenic temperatures. For environments reaching around negative 100 degrees Fahrenheit, specialized organic coatings like epoxies can be used, provided they include high-end cold temperature tougheners that maintain excellent flow properties below negative 50 degrees Fahrenheit.
As we explore what Henkel brings to the table, it’s clear that nearly every industry involves some degree of high-temperature applications. For instance, in the food and beverage sector, high temperatures might involve cookers operating around 300 degrees Fahrenheit, which can indeed be hazardous.
To effectively manage exposure, it’s essential to anticipate and mitigate potential issues. In terms of applications, virtually all types of surface equipment will include components that operate at extremely high temperatures. This includes pipes, tanks, vessels, and various process equipment, as certain chemical reactions require elevated temperatures. Your process vessels typically have high temperature ratings, along with flanges, valves, and other ancillary equipment.
When evaluating different products, consider essential features such as color stability, strong adhesion, and thermal shock resistance. Many high-temperature applications, except for those in the asphalt industry that operate continuously, experience fluctuations in temperature. For example, boilers undergo start-ups, shut-downs, and blowdowns daily, which influence the required thermal resistance and shock resistance in specific applications. Additionally, food-safe technologies must be taken into account.
For instance, if you are lining a cooker, the temperature ratings for food-safe materials differ significantly from those for ambient-cure coatings. Most potable water-rated coatings, like our LifeLast DuraShield, have a peak temperature limit for NSF certification. Exceeding this limit in tank applications can invalidate the potable water rating.
In high-temperature scenarios—up to 1200 degrees Fahrenheit—protection is crucial, especially regarding Corrosion Under Insulation (CUI). The “corrosion sweet spot” is typically between 120 and 320 degrees Fahrenheit, where corrosion rates accelerate rapidly. Above 320 degrees Fahrenheit, moisture in insulation tends to evaporate quickly. While absorbent insulation, such as mineral wool, may retain some moisture, the risk of corrosion decreases when equipment operates above 350-400 degrees Fahrenheit. However, during start-up and shutdown cycles, temperatures can drop below 300 degrees Fahrenheit, reintroducing rapid corrosion risks.
Dry fall coatings are vital in this context. We offer solutions that include dry fall coatings and can be hot-applied. For asset owners, especially those considering overcoating for preventive maintenance, these applications can be performed without extensive containment setups or abrasive blasting. This proactive approach can save substantial costs by addressing corrosion issues before they escalate.
I’d like to highlight some key products today, including the Highland 827, which serves as our primary option for high-temperature applications. For instance, Mascot insulative coatings can withstand temperatures up to 350 degrees Fahrenheit. This specialized acrylic binder allows for continuous operation at this temperature, and it can handle up to 375 degrees Fahrenheit comfortably. However, exceeding this threshold may lead to heat being reflected back, potentially raising temperatures to around 425 degrees Fahrenheit, at which point the acrylic binder may harden and delaminate. While this is a high temperature for acrylic coatings, standard acrylic latex paints will not perform well at 350 degrees Fahrenheit.
In the pipeline industry, most transmission pipelines operate below 100 degrees Celsius, although some can reach between 125 and 150 degrees Celsius. For these applications, consider using Canusa HBEHT or PowerCrete R150, which are ceramic-modified epoxies designed for such conditions.
We offer high-temperature pipeline coatings specifically designed for Atmospheric Release Outlets (AROs). Our coatings for chemical containment and Corrosion Under Insulation (CUI) include a single-coat, high-build solution, Grip Line 6700 HB. This coating is ideal for hot caustic environments, allowing application up to 20 mils in a single coat, which can significantly reduce processing costs for high-temperature needs.
For immersion services, depending on the chemicals involved, the coating can withstand temperatures up to 300 or 350 degrees Fahrenheit, while dry heat applications can reach 450 degrees Fahrenheit. This product utilizes epoxy Novolac chemistry.
Next in our lineup is ChemTemp 74 HF, which serves as both a CUI coating and a chemical-resistant liner. It supports dry heat applications up to 450 degrees Fahrenheit and immersion services up to 350 degrees Fahrenheit. Many aggressive acids are compatible, capping out at 250 or 300 degrees Fahrenheit, but we can discuss specifics with asset owners. This coating meets SP0198 specifications for CS3 and SS2. Moving to higher-temperature solutions, we transition from organic to inorganic coatings. Our silicone hybrid options offer best-in-class color and gloss retention, with continuous operation up to 600 degrees Fahrenheit. Additionally, the Temper Coat 888 presents a lower VOC alternative to the Temper Coat 850, capable of withstanding continuous temperatures of 850 degrees Fahrenheit, with a gloss finish for aesthetic appeal.
For applications involving exhaust pipes, barbecues, or exhaust stacks—where external corrosion is a concern but extreme conditions are not required—our Timber Coat 1000 and Stovemaster 1200 provide effective solutions, operating continuously up to 1200 degrees Fahrenheit without the need for excessive layering.
Finally, we highlight our premium product: Loctite 827 HB. This coating can handle excursions from -300 to 1200 degrees Fahrenheit and withstands temperatures up to 1500 degrees Fahrenheit. It meets various SP0198 CUI specifications and has undergone extensive testing for scribe creep, salt spray, thermal shock resistance, and CUI applications. This product is heavily utilized in continuous operating environments, such as asphalt plant firing drums and exhaust stacks, where insulation is essential for energy retention while protecting against CUI.
Questions:
Q. What types of failures have you encountered with HDPE pipe that you might need assistance with? For example, we’ve experienced issues with high concentration chlorine. We have Chemline for HDPE, so I’m curious if you have solutions that could address these problems, such as blistering. They are seeing the blistering from the outside of the pipe.
A. When specifying a lining or solution, one key factor is the substrate. If the substrate is plastic, bonding can be quite challenging. However, there are options for creating a pipe-in-pipe scenario where bonding isn’t as critical. The service environment and temperature will influence which system we recommend. There are likely solutions available, both within our portfolio and beyond, for relining HDPE.
Our concern was related to the concentration of chlorine, which we thought was within acceptable limits based on the ratings. However, it appears that this is not the case, as we’ve encountered failures. We suspect that the additional several hundred feet of the line underground may be experiencing similar issues. (Conversation taken offline)
Q. Have you encountered any instances of pipe failure? I believed that using HDPE was fairly standard, or at least common. It wasn’t your regular.
A. Absolutely, you raise a valid point. Blistering on pipes or assets generally indicates wall thinning. While coatings can offer some protection, their effectiveness has limits. Certain coatings with high tensile strength can help create a protective layer for non-pressurized hydrocarbon scenarios, but they don’t provide a structural repair. If you’re dealing with wall thinning, blistering, or, in the case of HDPE, micro-cracking or stress cracking, a composite solution would likely be more suitable for an in-place repair.
Q. What surface preparation is needed for Highland 827HB, and what is the maximum application temperature?
A. For most applications, we consider H27HB to be a surface-tolerant coating. This means there are varying levels of surface preparation: acceptable, better, and best. The best option involves a near-white metal blast or even a white metal blast, followed by a solvent wipe to remove all chlorides. This approach ensures the longest-lasting performance. If only a commercial blast is feasible, we’ve still achieved good results with that method.
For overcoat applications where blasting isn’t possible, using a water jet to remove tightly adhered rust, mill scale, contaminants, solvents, and oils is effective before applying the coating. Since H27HB is a silicone coating, it bonds differently than inorganic or acrylic coatings, relying more on ionic bonding rather than mechanical bonding like epoxies. Consequently, while it is more surface tolerant, the peak adhesion is generally lower. For epoxies, we typically expect adhesion levels of over 1,000 up to nearly 3,000 PSI, while acrylics and silicones range from about 300 to 500 PSI.
Regarding application temperatures, I need to confirm, but I believe the maximum temperature for H27HB is either 600 or 800 degrees Fahrenheit. We do reduce this with a slow-release solvent for hot applications. Additionally, our CUI code epoxy, the 74 HF epoxy, can be hot applied up to 400 degrees Fahrenheit.
I also noticed Bobby had a question about specifying high temperatures. A common mistake, especially in the pipeline industry, is failing to accurately measure the temperature of the asset. Jim has likely observed this issue as well. This is the biggest mistake owners make.
For instance, in a boiler system, you might have piping that operates at 350 degrees with high oil. If you apply a MOS code without considering the steam, which could cause the temperature to rise to 450 degrees, you risk a failure. When it comes to coatings, if you think you can save time and money by overcoating with a 600-degree Fahrenheit modified acrylic or silicone acrylic, you might run into trouble. During startup, that coating could actually experience temperatures of 1200 degrees Fahrenheit. Such a significant temperature swing from the continuous operating conditions is often where failures and issues arise.
Absolutely, I’ve witnessed that as well. It’s crucial to thoroughly research and qualify the products you want contractors to apply or consider using. Engaging with coating manufacturers and consulting subject matter experts is essential. This ensures that the systems you’re interested in, as Mitch mentioned, are appropriate and helps identify any potential issues, especially regarding temperature spikes.
One important point to emphasize is the necessity of adhering to all surface preparation instructions outlined in the technical data sheet. This is crucial for any coating project, not just high-temperature applications. I always stress the significance of following these steps correctly, as it greatly impacts the final results.
Now, regarding your question: do you have coatings that can be applied to hot surfaces while in operation, and what are their temperature limits?
Yes, most of our coatings, particularly our drywall coatings, can be applied hot. It really depends on the specific application. For instance, the Mass coat can handle continuous operating temperatures of 350 degrees Fahrenheit, while some of our epoxies can be hot applied at temperatures of 200, 300, or even 450 degrees Fahrenheit. As for silicone acrylics, they typically work at temperatures ranging from 400 to 800 degrees Fahrenheit.
For applications requiring peak operating conditions without a shutdown, we can discuss potential solutions and even conduct tests, as we have data and case histories supporting applications at high temperatures. Surface preparation is crucial in these scenarios; it raises questions about how to ensure cleanliness while the system is still operational. These are important conversations to have moving forward.
Q: Is there a particular application you’re considering that could assist Mitch and Jim? We occasionally have exchangers that we prefer not to take offline, especially those operating at temperatures between 250 and 300 degrees, where we’d like to apply a coating. We might be able to use water blasting or a similar method for preparation. Our hand prep them a little bit, but you know nothing that we can really take offline at the time to take care of.
A. Absolutely, that’s an excellent application for the Highland 74HF under Moscoat DTI. You’ll benefit from the corrosion protection provided by the epoxy, along with the insulative properties and personnel protection from the insulative coating. All this can be accomplished while the system is still running. Since Moscoat is a waterborne acrylic, applying it hot is actually advantageous; you can achieve 80 to 100 mils in just a couple of hours instead of taking a few days. This allows for significantly faster throughput if you can apply it while hot.
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.
