Professional Documents
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3. Controlling Corrosion
The corrosion cell comprises four basic elements: anode, cathode, electrolyte,
and closure path (Fig. 3-2).
The anode is the metal that corrodes—that is, metal ions leave its surface and
enter the electrolyte solution. The cathode is a metal from which no metal
ions enter the solution. The electrolyte may be any solution, such as drinking
water, that is capable of conducting electricity. The closure path, also called
the return current path, is the electrical conductor (usually metal) that
connects the anode and the cathode. If any one of these elements is missing,
corrosion does not occur. For example, coating stops corrosion from
occurring by providing a barrier to the current that flows between the metal
and the electrolyte.
Figure 3-1. How electrical potentials of various metals compare.
A dry-cell battery is a corrosion cell. When the battery’s anode (zinc) and
cathode (carbon) are connected through a closure path (the lightbulb), the
potential difference between the zinc and the carbon produces a current
flow. The current continues to flow until the zinc anode is consumed by the
corrosion process.
It is important to consider why the current flows in the direction it does. The
direction of flow is determined by the metals selected for the dry-cell
battery’s case and center post. If the center post was magnesium instead of
carbon, the current flow would be reversed: The magnesium center post
would be the anode (which corrodes), and the zinc base would be the cathode
(which does not corrode).
The current can also be forced to flow in the opposite direction if the
standard carbon/zinc battery is connected to an outside current source
instead of the lightbulb. In this situation, the anode and the cathode would
also be reversed—that is, the battery case would become the cathode and
would be protected from corrosion.
In a steel water-storage tank, some portion of the metal will be the anode and
some portion will be the cathode (Fig. 3-3).
Cathodic protection systems are used to prevent or retard the corrosion that
would naturally occur in a steel water tank. These systems prevent or slow
corrosion by altering the electrochemical environment so that the submerged
tank shell becomes the cathode of a corrosion cell. Since the cathode of a cell
does not corrode, the submerged metallic tank shell is protected. There are
two basic types of cathodic protection systems: impressed-current systems
and galvanic systems.
When holes are cut in the roof, the finished installation must be watertight to
eliminate openings for insects and runoff to enter the tank.
For tanks subject to icing, either vertical anode systems with extensible
elements or horizontal suspension systems designed to minimize ice damage
to the anodes should be considered. These suspension systems can provide
year-round protection and may eliminate the need for annual anode
replacement due to ice damage.
Active solvent : An active solvent is a true solvent for the resin (binder)
portion of the formula. It dissolves the resin and keeps it in solution.
Diluent : Although not a solvent for the resin portion of a particular paint
formula, a diluent can still be used in conjunction with a true (active)
solvent, without causing precipitation or incompatibility (“kick-out”).
Latent (auxiliary) solvent : This is not a true solvent, but combined with an
active solvent, it increases the strength (solvency power) of the active
solvent.
Evaporation rate Some solvents are more volatile than others: The greater
the volatility, the faster the evaporation rate. Because of its effect on
application properties, it is important to consider the evaporation rate when
selecting a solvent or solvent blend for a coating formula. For example, the
use of a “fast” solvent may be appropriate if the coating is typically spray
applied, but the result may not be a smooth, continuous film if the coating is
applied by brush or roller.
Flash point Flash point is defined as the temperature at which the vapor
directly above a liquid will ignite when exposed to a spark or an open flame.
The faster the evaporation rate of the solvent, the lower the flash point. The
U.S. Department of Transportation defines paints with a flash point below
100ºF (38ºC) as flammable and paints with a flash point above 100ºF (38ºC) as
combustible. A label picturing a red flame must be affixed to containers
holding flammable liquids with a flash point below 100ºF (38ºC).
Ketones This family of organic solvents has very high solvency power for
most generic paints. Acetone, often used for cleanup in organic chemistry
labs, is the base molecule for this family. Ketones most often used in paint
formulas are MEK (methyl ethyl ketone), MIBK (methyl isobutyl ketone), MNPK
(methyl normal propyl ketone), and MAK (methyl amyl ketone).
Esters Esters, like ketones, have high solvency power for most generic
paints and are used most often in lacquers and furniture finishes. They have
limited use in industrial coatings because of their high cost and reactivity
with certain resins. Ester solvents most often used in paints are ethyl
acetate, butyl acetate, isobutyl acetate, and amyl acetate.
Alcohols Alcohols are not true (active) solvents for most generic paints.
Exceptions are found in vinyl wash primers and ethyl silicate inorganic zinc
–rich primers. Certain water-soluble alcohols are also used as co-solvents in
water-based paints and in water-emulsion paints. Alcohol solvents found in
paints include ethyl alcohol (drinking alcohol), isopropyl alcohol (rubbing
alcohol), butyl alcohol, and amyl alcohol.
Glycol ethers and glycol-ether acetates Glycol ethers are unusual in that
several are water soluble yet also have high solvency power. Because of their
water solubility, they are often used as co-solvents in water-based paints.
Glycol-ether acetates are strong solvents that are often used in urethane
paint formulations.
Nearly all paints contain pigments. Exceptions are certain high-gloss clear
coatings. Unlike dyes, pigments used in protective coatings are essentially
insoluble in water and organic solvents. Their chemical structure can be
either organic or inorganic depending on the pigment type. Most inorganic
pigments are derived from minerals that are mined from the earth. Organic
pigments are made synthetically and are typically much more expensive than
inorganic pigments.
Paint manufacturing would be a fast, simple process if it was not for the need
to include one or more pigments in most paint formulas. Considerable energy
and time are required to disperse pigments into the liquid components of any
paint formula. During initial manufacturing, the pigment suppliers grind
pigments to a very small particle size. Regrettably, these small pigment
particles agglomerate before they are added to protective coatings. When
dispersing pigments during paint manufacture, the intent is to break apart
the pigment agglomerates into the individual particles originally produced by
the pigment manufacturer. The amount of energy and time required to
accomplish this depends on the type of pigment. In general, organic pigment
agglomerates are much more difficult to disperse than inorganic. Most
inorganic pigments can be dispersed using high-speed dispersion equipment,
which is generally the fastest and the most economical method of pigmented
paint manufacture. More time and energy are required to disperse most
organic pigments; other manufacturing methods such as sand milling or ball
milling are required.
Prime pigments Prime pigments provide color and hiding power and can be
either organic or inorganic. Red iron oxide, yellow iron oxide, titanium dioxide
(TiO 2), lead molybdate (toxic), and lead chromate (toxic) are examples of
inorganic prime pigments. Carbon black, phthalocyanine blue,
phthalocyanine green, and quinacridone violet are examples of the more
expensive organic prime pigments.
Extender pigments Most extender pigments provide little, if any, color and
hiding. All extender pigments are inorganic minerals that are mined from the
earth. These pigments are used in paint formulas to provide a variety of
desirable properties including gloss reduction, primer surface roughness for
better topcoat adhesion, higher solids, film reinforcement, lower moisture
vapor transmission (MVT), and thixotropy (sag resistance). Magnesium
silicate (talc), barium sulfate (barytes), mica, aluminum silicate (clay), calcium
silicate (wollastonite), and silica (sand) are examples of extender pigments
used in paint.
3.4.3. Resins
With only a few exceptions, resins (binders) are organic polymers. Depending
on molecular weight and resin type, these paint constituents can be either
liquid or solid before they are added to the batch.
The physical properties and performance of a cured paint film are related
more to the types of resins used in the paint than to any of the other
ingredients. This is why most paints are classified according to the resins
(binders) they contain. Single-component paints can sometimes contain more
than one type of resin, but these paints are usually classified by the resin
that is present in the formula at the higher percentage, with the other resin
identified as a modifier. For example, a paint that contains 80 percent alkyd
resin solids and 20 percent acrylic resin solids would be classified as an
acrylic-modified alkyd. Two-component paints are generally classified using
both types of resins. For example, a two-component paint that consists of
epoxy resin in one component and polyamide resin in the second component
would be identified as a polyamide epoxy.
Coal tar pitch solution : Coal tar pitch is produced from the destructive
distillation of bituminous coal. A protective coating can be made by simply
dissolving hot pitch in xylene. The cured film has low MVT and good
chemical resistance. Coal tar pitch solutions can be formulated with a
higher solids content (lower VOC) than the other lacquer coatings. These
coatings have excellent adhesion to steel and concrete and are typically
used for sewage and wastewater immersion service. They are only
available in black and have poor resistance to direct sunlight.
Oil-based paints At the turn of the 20th century, the choice of generic
paints was very limited. Most paints were based on vegetable oils such as
linseed oil. These “oil-based” paints exhibited excellent wetting and adhesion
to marginally prepared steel substrates and provided long-term weathering
and corrosion resistance when exposed to many atmospheric conditions. The
biggest disadvantage was very slow dry time.
Alkyds Alkyd technology was developed in the late 1920s. It was discovered
through laboratory testing that by combining a trifunctional alcohol with an
acid salt and reacting them at high temperature, an ester-type resin could be
formed that had very fast dry time. However, the film was too brittle to be
considered as a paint binder. It was then discovered that by incorporating a
vegetable oil such as linseed oil in the same reaction, resins could be
produced that dried more quickly than straight linseed oil, yet had good
enough film properties to be considered as paint binders. This development
revolutionized the paint industry at that time.
Further testing revealed that film properties and dry times could be adjusted
depending on the type and amount of oil included in the reaction.
Terminology that came out of this discovery included alkyd, which stands for
an alcohol/acid reaction, and short-oil, medium-oil, or long-oil alkyd resins.
The short–medium–long terminology designates the amount of oil the alkyd
resin contains. Short-oil alkyds dry more quickly than medium- or long-oil
alkyds, but are generally less flexible and do not produce paints with as good
weatherability and corrosion resistance.
In general, paints that exhibit this curing mechanism produce paint films with
a wide variety of properties depending on the type and amount of oil in the
resin. Overall, alkyd and oil-based paints are less expensive than other
generic types and can provide long-term corrosion protection of steel as long
as the exposure environment is not too severe. Chemical resistance and color
and gloss retention are considered fair to good, depending on the
formulation. Alkyd paint formulations can be modified with other resins, such
as acrylics and silicones, to upgrade color- and gloss-retention properties.
Epoxy esters Epoxy esters are epoxy resins that have been “esterified”
with fatty acids, resin, and so on. Epoxy-ester paints have better chemical
resistance than oil-based or alkyd paints, but they chalk more readily when
exposed to direct sunlight.
Two-component epoxies can be modified with coal tar pitch, producing coal
tar epoxy coatings. The coal tar pitch is usually added to the polyamide or
polyamine curing agent. Properly formulated, these coatings can be applied
up to 20 mil (508 μm) dry film thickness (DFT) in a single coat. They typically
cost less than unmodified two-component epoxies and have low MVT and
good chemical resistance. They are most often used for protecting steel and
concrete substrates from immersion in sewage and wastewater.
Aromatic polyurethanes generally have better adhesion to steel and are less
expensive, but they tend to yellow when exposed to direct sunlight. They are
often used as direct-to-steel or direct-to-concrete stand-alone coating
systems. Some formulations can be used for immersion service.
Because they are 100 percent solids and exhibit an extremely fast cure
response, these coatings can be spray applied in one coat at very high film
thickness. Depending on formulation, a wide range of performance
properties can be achieved using this technology. Rigid or elastomeric
(greater than 100 percent elongation) formulas are possible. Chemical
resistance is generally very good, and some formulations are suitable for
immersion service. One hundred percent solids, two-component polyurethane
coatings are also available. Although their properties are generally similar to
those of the polyureas, they are less flexible and have better chemical
resistance.
Baking enamels These are coatings with two co-reacting resins packaged
in the same container. One resin is typically a polyester or acrylic containing
one or more hydroxyl groups. The other resin is usually a melamine or urea
formaldehyde. Cross-linking of the resin molecules only takes place at high
temperatures (generally above 250ºF [121ºC]). Home appliances such as
stoves, refrigerators, washers, and dryers have metal substrates that are
protected with baking enamels. Components are painted in the shop and
then sent through ovens, where the coating cures (usually in 10 to 15
minutes) at high temperature. Pot life is not a concern, since cure (co-
reacting) will not take place at ambient temperatures.
3.4.3.1.2. COALESCENCE
The polyesters form hard, dense, chemical- and water-resistant films. They
are used primarily as laminating resins and gel coats for the manufacture of
fiberglass boats, shower stalls, bathtubs, bowling balls, and so on.
The vinyl esters have excellent acid resistance and are used primarily as
fiberglass-reinforced and nonreinforced linings for steel and concrete
substrates that come in contact with strong acids. Because of their reactive
nature, vinyl esters have poor package stability, resulting in short shelf life,
especially at high storage temperatures.
Hydrolysis The primary use of ethyl silicates and polysilicates, which are
among the few resins that are not based on organic polymers, is in the
formulation of inorganic zinc-rich primers. The curing mechanism is similar to
the curing mechanism for concrete (cement). An inorganic zinc-rich primer
contains considerable metallic zinc dust, typically more than 70 percent by
weight in the cured film. When the liquid paint is applied and the solvent
evaporates, moisture from the surrounding air is absorbed into the film,
setting up the hydrolysis process. In the case of ethyl silicates, complex
chemical reactions occur, forming a silicon oxide (SiO) matrix in which a small
amount of resin binder holds together a large amount of metallic-zinc
pigment. Upon complete hydrolysis (curing), the applied film is very hard,
dense, and resistant to abrasion and solvents. Inorganic zinc-rich primers
protect steel from corrosion by galvanic action. The zinc becomes the anode
in the corrosion battery and the steel becomes the cathode. The zinc
sacrifices itself to protect the steel in a process that is similar to that
exhibited by galvanized-steel substrates. Inorganic zinc-rich primers are
resistant to high temperatures (up to 750ºF [399ºC]), are difficult to topcoat,
and have poor acid resistance.
Driers : For driers, metallic soaps are added to oil-based or alkyd paints to
accelerate the oxidation and polymerization process.
Pigment wetting agents : These additives are usually silicone based and
are incorporated into paint formulas to assist the resin in surrounding and
wetting out each of the dispersed pigment particles.
If a gallon or liter of paint contains volatile and its percentage of total volume
solids is known, its spreading rate, wet-to-dry film ratio, and cost per applied
mil per square foot (per applied micron per square meter) can be calculated
as follows:
Theoretical spread rate @ 1.0 mil DFT = Percent of volume solids × 1,604 ft 2
Spread rate @ DFTs other than 1.0 mil = Percent of volume solids × 1,604 ft
2 /specified DFT
Cost per mil per sq ft = Cost per gallon/spread rate @ 1.0 mil DFT
3.5.1. Example
Let us assume we have one gallon of paint that is 50 percent volume solids.
The specified DFT is 5 mil and the cost per gallon is $22. With this
information, we can make the following calculations:
2
Theoretical spread rate @ 1.0 mil DFT = 0.50 × 1,604 ft = 802 ft 2/gal
Spread rate at specified 5.0 mil DFT = 0.50 × 1,604 ft 2/5 = 160 ft 2/gal
D102 is the AWWA standard for painting the interior and exterior of steel
water tanks. The objective of this standard is to provide information about
various coating systems for coating and recoating the interior and exterior of
steel tanks used for potable water storage. Coating systems for new bolted-
steel tanks are not covered by this standard.
The first edition of this standard was approved by the AWWA Board of
Directors on February 11, 1964. The second edition was approved on January
28, 1978, and subsequently withdrawn on June 23, 1991. The standard was
reissued and subsequently approved by the AWWA Board of Directors on
February 2, 1997. The third edition was approved in 2003.
Following are the primary reasons that substantial changes have been made
to inside and outside coating systems over the years:
Advances in coatings technology
Inside and outside coating systems contained in future editions of D102 will
be further restricted by the continued implementation of more stringent VOC
regulations for both shop- and field-applied protective coatings. Future
editions of D102 will most likely only contain inside and outside coating
systems that are very high solids based or water based.
Together, these two organizations have issued joint standards that are
commonly referenced by those who need to specify proven surface
preparation methods. For example, AWWA D102–03 Standard for Coating
Steel Water-Storage Tanks cites four SSPC/NACE surface preparation
standards (SP10/NACE 2 Near White Blast Cleaning, SP6/NACE 3 Commercial
Blast Cleaning, SP7/NACE 4 Brush-Off Blast Cleaning, and SP11 Power Tool
Cleaning to White Metal). Surface preparation methods vary and may not be
appropriate for all materials of construction. Methods may use abrasive blast
cleaning (SP10/NACE 2, SP6/NACE 3, and SP7/NACE 4, for example), hand or
power tools (SP2, SP3, SP11, and SP15, for example), or water under pressure
(SP12/NACE 5, for example).
The surface preparation standards listed previously are primarily used for
steel surfaces. Methods such as SP13/NACE 6 Surface Preparation of
Concrete exist for cementitious substrates. In addition, SP13/NACE 6 further
identifies surface preparation practices developed by ASTM International,
formerly the American Society for Testing and Materials. Organized in 1898,
ASTM International is one of the largest voluntary standards development
organizations in the world. ASTM International is a not-for-profit organization
that provides a forum for the development and publication of voluntary
consensus standards for materials, products, systems, and services. Surface
preparation is so important to the successful completion of a water tank
project that members of AWWA, ASTM, and other organizations donate time
to review and update industry standards and methods and to develop new
standards and methods as to surface preparation equipment improves and
changes.
AWWA D102–03 Section 1.2, Surface Preparation, paragraph 4.5.2.1 states for
outside surfaces of new tanks:
For outside surfaces of existing tanks, AWWA D102–03 Section 1.2, paragraph
4.5.2.2, states:
When the…coating system will adhere to the existing coating, all corrosion
products and deteriorated coatings shall be removed by spot cleaning to
SSPC SP11 or SSPC SP6/NACE 3 and the remainder of the exterior surfaces
shall be cleaned by SSPC SP7/NACE 4 or by washing with an alkaline
cleaner…to remove all dirt, dust, coating/paint chalk, and foreign matter.
When the new coating system is not compatible with the existing coating,
all existing coatings shall be removed and the surfaces blast cleaned to
SSPC SP6/NACE 3 or, if specified, to SSPC SP10/NACE 2.
For interior surfaces of new tanks, AWWA D102–03 Section 1.2, paragraph
4.5.3.1, states:
When existing coatings have not deteriorated extensively and the new
coating system will adhere to and is compatible with the existing coating,
all corrosion products and deteriorated coatings shall be removed by spot
blasting to SSPC SP10/NACE 2 and the remainder of the interior surfaces
shall be cleaned by SSPC SP7/NACE 4. When existing coatings have
deteriorated extensively or the new coating system is not compatible with
the existing coating, all existing coatings shall be removed and the
surfaces cleaned to SSPC SP10/NACE 2. Blast-cleaned surfaces shall have a
surface profile that is appropriate for the specific primer and coating
system in accordance with the coating manufacturer’s recommendations.
Steel plate for bolted tanks may be prepared by first cleaning and rinsing in
a hot alkaline solution followed immediately by hot-air drying. This process
removes not only dirt but also hydrocarbon contaminants that will prevent
future coating adhesion. Thereafter, these plates are sent through a
centrifugal blast machine where an approximately 2-mil-deep (51-μm-deep)
profile is made on the surface in accordance with SSPC SP10 Near White Blast
Cleaning procedures.
AWWA D103 Standard for Factory-Coated Bolted Steel Tanks for Water
Storage recommends that tank components to be protected with glass
coatings receive either Near White Blast Cleaning (SSPC SP10) or, as an
alternative, Pickling (SSPC SP8).
that water tanks constructed of concrete are without their own surface
preparation requirements.
Even though most concrete tank surfaces may need little to no roughening,
they do require cleaning. The SSPC SP12 standard for low-pressure water
cleaning, WJ4, will accomplish this. This procedure usually removes loose
shotcrete clusters and may remove debris left behind by, or concrete
escaping through, placement forms. Placement forms are coated with release
agents or compounds to prevent adhesion of concrete to these forms and
thereby allow placement forms to be removed cleanly. These compounds may
act as contaminants, however, and prevent adhesion of paints and coatings.
WJ4 may be specified for this purpose. If non–water soluble or non–water
dispersible form-release compounds are used, low-pressure water cleaning
will not remove them, and abrasive blast cleaning through the use of ASTM
D4259 may be required.
Concrete surfaces, because they are porous, also absorb moisture. Whether
because of rain or the use of water when cleaning equipment for surface
preparation, these surfaces must be allowed to dry before coating. The
length of, and need for, time to dry are influenced both by the temperature
and humidity at the tank site and by the type of coating to be applied to the
tank.
An interior coating system in the wetted areas of the tank must withstand
constant immersion; it must be able to resist alternate wetting and drying in
the upper portion of the operating range and high humidity above the top
capacity level; it must be resistant to the actions of ice abrasion in cold
climates; and, in some geographic areas, it must be able to withstand
extreme temperature fluctuations. In addition, interior coating systems must
be able to be both shop-applied and field-applied, must be cost-effective, and
must meet the minimum requirements of ANSI/NSF 61 Standard for Drinking
Water System Components.
For interior surfaces of tanks, ANSI/AWWA D102 lists five interior coating
systems (Table 3-2). Such coatings “shall have been evaluated for long-term
fresh water resistance and the system shall have demonstrated satisfactory
service in fresh water for at least 18 months. Any coating that cannot meet
these requirements, whether or not included in this standard, shall not be
used.”
1 Two-coat, two-
component epoxy
2 Three-coat, two-
component epoxy
3 Three-coat,
zinc/epoxy/epoxy,
interior nonimmersed
surfaces above TCL
4 One-coat polyurethane
or polyureas
5 Three-coat
zinc/epoxy/epoxy,
interior surfaces
above and below TCL
Glass coating systems may begin with a primer coat of catalytic nickel oxide
prior to the application of 6 to 19 mil (152 to 482 μm) of the glass coating,
firing, and fusion of the glass coating to the substrate in a furnace operating
at temperatures above 1,200ºF (649ºC).
Thermoset liquid (epoxy) coating systems are generally applied in two coats.
The first coating is applied and heated to create a tacky, partially cured first
coat followed by additional coating to achieve a minimum 5-mil (127-μm) DFT.
It is subsequently baked at 425 to 525ºF (218 to 274ºC), to thermally cross-
link the complete coating system.
As mentioned earlier, the exterior coating attracts more attention and may
cause more concern than any other aspect of a tank project because it is all
that the neighboring community sees.
2 Three-coat moisture-cured
urethane
4 Three-coat zinc
primer/urethane/fluorourethane
5 Three-coat epoxy
primer/epoxy/urethane
6 Three-coat zinc
primer/epoxy/urethane
For exterior surfaces of tanks, ANSI/AWWA D102–03 lists six outside coating
systems (Table 3-3). According to the standard, “[p]roprietary formulations
will be acceptable provided the coating is of the same generic type and that
the performance of the formulation offered meets or exceeds the
performance of the formulation defined in the referenced coating standard
and also is suitable for the specified service conditions.”
In some instances, the entire protective coating system is applied in the shop
—for example, with bolted tanks. The steel panels are generally coated
following roll forming and bolt-hole punching. In this situation, a thermoset
liquid coating may be applied and then baked at a prescribed temperature,
or a thermoset powder coating may be applied and then baked according to
the manufacturer’s instructions. Depending on the type of interior lining
system, the bake temperatures can vary between 425ºF (218ºC) and (in the
case of a glass lining)
Although coating and/or lining systems applied in the field share many of the
considerations we reviewed under shop-applied coatings, other factors
specific to field painting need to be evaluated. Among these items are the
type of lining that is environmentally compliant, tank heating and ventilating,
dehumidification requirements, the landscape surrounding the tank, and the
type of environment that the tank is subject to during the preparation,
application, and cure of the lining and coating systems (e.g., chloride sources
in a marine environment).
Generally speaking, the interior of the tank requires the highest degree of
surface cleanliness and preparation. Many of the protective lining systems
surface cleanliness and preparation. Many of the protective lining systems
require a minimum surface cleanliness equaling an SSPC SP-10/NACE 2 Near
White Metal Blast. In an effort to achieve this, painting contractors typically
blast the bottom of the tank first and then begin to blast the wall section by
section. Each section (called a drop) is blasted and coated during the work
shift unless an environmental control such as dehumidification is needed.
The abrasive used in the cleaning process is allowed to fall to the floor of the
tank and accumulate there. This abrasive provides an insulation of sorts from
the environment so that the initial blast on the floor is held or maintained. If
the blast is lost, the contractor reblasts the floor area and coats it as he is
finishing the interior of the tank. Special care needs to be taken to ensure
that spent blast media is not billowed and deposited into the freshly coated
surface. Although this is a common approach to lining the inside of storage
tanks, it is not the only correct way to perform this task.
When a primer has been applied in the shop and the contractor is only
applying finish coats to the tank in the field, the surface preparation
specification is usually a bit different than that just described. Two concerns
must be addressed: (1) the condition of the shop primer and its preparation
before receiving any topcoats and (2) the weld seam preparation. Typically,
the shop primer is swept blast according to SSPC SP7/NACE 4 Brush-Off Blast
Cleaning, while the weld seams are prepared according to SP10/NACE 2 Near
White Metal Blast. In some cases the primer is reapplied, while in others only
the finish coat(s) are applied. Proper ventilation of the tank’s interior is
critical to ensure a thoroughly cured lining.
When coating the outside of the tank, the consequences of over-spray, dry
spray, and ambient conditions must be considered. Adverse conditions
during surface preparation, coating application, and curing can (and most
often do) lead to premature catastrophic failure of the coating system.
Specifiers and contractors should also be aware of the areas surrounding the
tank and the environment to which the coating system will be subjected. For
example, an elevated water tank in a congested urban area may require
coating materials that can only be roller applied or that tend to “dryfall” if
applied by a sprayer. By way of environmental considerations, coastal
regions may require a coating system that has a higher film build and more
barrier protection to protect the tank from a chloride-rich environment.
Depending on the tank and the contractor, the coating process is completed
in different ways, but completing drops is still the most common way to
ensure that a properly cleaned surface is maintained. Typically, the specified
cleanliness for the exterior of the tank would be an SSPC SP6/NACE 3
Commercial Blast. For a shop-applied primer, the primer is swept blast
according to SP7/NACE 4, while the weld seams require SP6/NACE 3. Again, a
primer may be reapplied if specified or the finish coats may be applied over
the prepared existing primer.
Many shops that use liquid coatings apply them with spray equipment, which
has undergone many improvements since the introduction of conventional
spray units. This section briefly describes methods and equipment for
applying protective coating and lining systems in both shop and field. In the
field, paint contractors typically use rollers or airless spray systems.
However, because of new coating technology and new environmental
concerns and legislation, plural-component spray equipment is increasingly
showing up on tank coating projects. The use of brushes and rollers in a
shop environment is mostly limited. Brushes and rollers are typically used for
touch-up or to coat difficult or complexly designed areas.
3.8.3.1. BRUSHES
Brushes are not as high tech as sprayers, and many consider them an
outdated way to apply paint. However, many situations still require their use.
A “stripe coat,” often specified for added protection of edges,
3.8.3.2. ROLLERS
Rollers have earned a bit more respect than brushes, but their production
results still pale in comparison with results of spray application. Application
by roller is faster than application by brush, but is not quite as fast as
application by spraying. Because the roller cover holds considerably more
coating than a brush, a much larger area can be covered with one load.
Rollers are excellent for large, flat areas—for example, the tops or sidewalls
of tanks. Rollers can be used wherever the skill of a brush or spray
application is not called for. Rollers can also be used if spray applications are
prohibited due to overspray concerns.
The procedure for using the roller is to immerse it in the coating tray or
bucket and roll it back and forth on either a tray ramp or bucket grid on the
inside of the bucket. This removes the excess coating from the roller and
prevents excessive drip and spatter. Continue spreading the liquid coating
onto the surface in the form of a W or an M over an area that one roller’s
worth of coating will cover. After initially spreading the coating by this
method, fill in the area by rolling the roller back and forth over the entire
surface being covered. Finish by rolling the coating in one direction. This is
called laying off, and it aids in developing a uniform finished appearance.
Spraying and backrolling is another example where the roller is used to
ensure a uniform application and finish.
Many shops apply the protective coatings with what is termed conventional
air spray equipment. This method uses compressed air to atomize the paint
as it exits the spray gun. In other words, air is injected into a stream of paint
through the air nozzle in front of the gun, creating the mist that is propelled
out. The basic components needed to apply paint by air spray are an air
compressor, paint pot or cup, oil and moisture separators, air supply hoses,
material hose, regulators, and air spray paint gun (Fig. 3-11).
Figure 3-11. Components needed to apply paint by air spray.
(Courtesy of Spray-Quip, Inc., Houston, TX.)
Because of the low transfer efficiency and slow production time associated
with conventional spray equipment, airless spray equipment was developed
and introduced (Fig. 3-12). Airless sprayers work by pressurizing paint fluid.
The paint travels through a supply hose to an airless spray gun tip, and the
coating atomizes into fine droplets as it exits the tip. In airless spray, as the
name suggests, air is not used to atomize the paint. The basic components of
an airless spray system are a power source, a pressure pump, a paint
container, high-pressure fluid hose, an airless spray gun, and an airless
spray tip. The paint is pressurized by the pump and forced through high-
pressure hose to the airless spray gun. When the stream of high-pressure
coating reaches the airless tip, it is atomized and shaped by the specific size
of the tip. The only adjustment to an airless spray gun is to change the tip.
Coating manufacturers specify the correct tip size and proper atomizing
pressures needed to produce the best-quality applied film.
Although the airless spray applicator does not have the control that a
conventional spray system affords, the trade-off is that greater speed and
greater transfer efficiency value (35 to 50 percent) are possible.
Some have found a way to combine the best features of conventional air
spray with airless spray equipment and have created a new spray finishing
capability. The process has been termed as air-assisted airless spray. This
equipment (Fig. 3-13) uses a standard airless pump and an airless spray tip
to atomize the coating and shape it into a fan pattern. However, in contrast to
normal airless operations, the fluid pressure in an air-assisted airless spray
system is relatively low. As expected, a low fluid pressure (usually below
1,000 psi [6,894 kPa])
fails to produce an acceptable spray pattern, and the resulting pattern has
heavy edges called tails. To eliminate the tails and assist in the atomization
process, air is added at a low volume, typically 1 to 3 cfm (0.47 to 1.41 L/s),
and at a low pressure between 10 and 20 psi (69 and 138 kPa). To this coating
stream, assisting air is directed into the airless pattern through horns on a
special air cap. This results in a good appearance, very good transfer
efficiency (50 to 65 percent), reduced overspray, less tip wear, and longer
pump life due to the lower pressures.
The mixing manifold, when required, is critical for properly blending and
mixing the materials before they leave the spray gun. The manifold usually
contains a static in-line mixer that works by splitting the coating stream and
rotating it to 90 degrees. This is done numerous times so that the
components are mixed thoroughly when they exit the spray gun.
Many tests can be performed after the coating has been applied. It is often
difficult to find deficiencies in the coating system, however. Once the job is
finished, a poor job may look the same as a high-quality job. Therefore, it is
important that inspections occur not only at the conclusion of a project, but
also during coating operations. This will help determine that the coating
specification was met.
During the application, the inspector may need to conduct a wide array of
key tests and observations:
Ensure that the surface is free of dust, dirt, or any abrasive residue from
the blast cleaning operation.
Ensure that coatings have been properly thinned ahead of time. This
includes being certain that the recommended thinner has been used in the
recommended amount.
Ensure that the wet film is of the proper thickness. This can be determined
by conducting mathematical calculations of the surface area coated and/or
by periodically taking direct readings while the coating is being applied.
Ensure that the coating is applied evenly, that the passes are overlapped,
and that there are no thin spots, discontinuities, dry spray, and so on.
The more often problems during application are addressed immediately, the
greater the likelihood that runs, sags, and discontinuities can easily be
brushed out and corrected.
Dry film thickness measurements: Type I, Type II, or Tooke Gage method
WFT gauge : The wet film thickness gauge is used to measure the
thickness of paint being applied at the point of application. Two common
gauges used are the interchemical gauge and a notch-type gauge.
DFT gauge : The dry film thickness gauge is used to measure the
thickness of paint after it has been applied and, preferably, cured.
Eddy current gauge : The eddy current gauge (Fig. 3-17) measures
nonconductive coatings over a nonferrous surface. It operates by emitting
an eddy current and measuring the difference between the emitted signal
and the return signal. This difference in time is affected by the coating
thickness. Calibration assurance in the field according to the gauge
manufacturer’s instructions is strongly recommended.
Mirrors and telescoping mirrors : Mirrors are helpful when the applicator
needs to check behind hard-to-reach areas such as nuts and bolts
—wherever direct viewing is impossible.
Replica tape and spring micrometers : Replica tape and micrometers are
often used to determine surface profiles.
Tooke Gage : Commonly called a paint inspection gauge, the Tooke Gage is
known as “the referee,” so named for its ability to examine individual
coatings within a multicoat system as well as the system in its entirety. It is
highly accurate in determining film thicknesses up to coating films of 50
mil (1,270 μm). Testing with the Tooke Gage is destructive, so repairs will
be required.
In the swabbing method, the salts are extracted by using distilled water
and medicinal-grade wool or cotton swabs. A defined surface area is then
swabbed with the cotton swabs that have been saturated with the distilled
water solution and dried with additional dry cotton swabs. The wet and
dry swabs are then placed back into the beaker containing the distilled
water and stirred for several minutes.
In the Bresle patch method, the salts are extracted by using distilled water
in conjunction with a plastic patch self-adhesive cell and syringe. Distilled
water is injected into the cell, allowed to dwell for 20 seconds, and then
drawn back into the syringe. The same solution is then reintroduced into
the cell, and the process is repeated. This process is conducted a total of
three times.
Conductivity test
QuantoFix test
Bibliography
Citation
EXPORT
Steve Meier; American Water Works Association: Steel Water Storage Tanks: Design,
Construction, Maintenance, and Repair. Controlling Corrosion, Chapter (McGraw-Hill
Professional, 2010), AccessEngineering
This product incorporates part of the open source Protégé system. Protégé is
available at http://protege.stanford.edu//