Fundamentals of Applying Protective Linings Part 3: Surface Prep

Presented by: Doug Dutton; Ron LoPresto

Introduction

Purpose for RL protective linings is to provide:

o o o o

Abrasion resistance Chemical resistance Impact resistance Slip resistance

Basic Principles

Remember SCAR for proper surface prep!!

Survey area Clean contaminants Abrade surface Repair defects & Re-Clean.

Substrates To be reviewed today

Steel Concrete/Masonry Overview for other Materials

Steel Surface Preparation

1. Survey

1. Survey surface

Examine for rust, oil, grease, water, old paint What is steel being exposed to?
o

Are there chemical contaminants present?

Mill Scale bluish, shiny oxide layer that forms on steel during its manufacture (hotrolling)

Steel Surface Preparation

2. Clean

2. Clean Surface

Remove dirt, water, and other contaminants before abrading surface For oil and grease contamination, solvent cleaning works best.

Steel Surface Preparation

For steel surfaces, recommend

Acetone MEK Citrus-based cleaners

Steel Surface Preparation

In some cases, steam cleaning and/or waterjetting is used. Works well for large or difficult to clean areas Does not create a rough profile

Steel Surface Preparation

3. Abrade

bond to. For steel, SSPC (Society for Protective Coatings) has created specific surface prep standards. SSPC Standards cover varying levels of cleanliness for the steel surface.

Abrade surface to create profile for lining to

SSPC Surface Prep Standards

SP-2 SP-3 SP-11 SP-14 Hand Tool Cleaning Power Tool Power Tool to Bare Metal Industrial Blast Allows 10% level of contaminants such as rust, mill scales, etc. 66% free of all visible residue with only staining permitted on the remainder 95% free of all visible residue 100% free of all visible residue Removes loosely bonded contaminants Same as SP-2 but faster

SP-6

Commercial Blast

SP-10 SP-5

Near-White Blast White Metal Blast

Abrasion - Recommendations

For Rhino products, abrasive blasting proven best; Produces consistent rough profile. Want a 2 3 mil surface profile for best results.

Abrasion - Recommendations

SP-11 is acceptable for light duty applications. For immersion service or heavy duty, want minimum SP-10 (near-white) or SP-5 (white metal).

Abrasion - Recommendations

Common aggregate for correct profile:

16 or 24 grit aluminum oxide 8/35 mesh silica sand G-25 or G-40 steel grit 16 mesh garnet

Generally best to out source blasting.

Abrasion - Recommendations

Flash Rust: may become a problem in humid areas.

Consider only blasting what you can coat within 24 hours. Prime blasted areas quickly to avoid flash rust.

Containment of abrasives
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Must have plan on how to contain dust and overspray

Steel Surface Preparation

4. Repair & Re-Clean

Repair any defects on steel

Grind down any protrusions or weld spatter Fill in any crevices or pits with polyurethane caulk Fix any rust holes or cracks in the steel

Soluble Salts
In certain areas, steel can be contaminated with soluble salts. Salts can cause blistering and delamination. Test for soluble salts. Chlor-Rid International; Chandler, AZ

800-422-3217; www.chlor-rid.com Chlor-Test Chlor-Rid Soluble Salt Remover

Removing Soluble Salt Contamination

Chlor-Rid Soluble Salt Remover

Option 1: Add to pressure washer tank at a 100:1 dilution and pressure wash at 3,000psi. Option 2: Use Chlor-Rid DTS and apply directly to the surface. Then rinse off with a garden hose.

Steel Surface Preparation

Re-Clean

Abrasion creates dust and contaminant residue. Sweep and vacuum area. Consider a final solvent wipe to remove any dirt or oil tracked in.

Steel Surface Preparation

Examine results. If necessary, measure surface profile. Inspect twice, spray once.

Concrete Surface Prep

Concrete Surface Prep

1. Survey

Study surface many factors to consider with concrete Age & Condition of concrete

minimum cure time is 28 days old concrete, greater likelihood of contamination strength: hard or crumbly?

Laitance: weak surface layer of cement Efflorescence: white powdery residue created by lime in concrete leaching to surface.

Moisture Vapor Transmission

Concrete being porous, allows moisture to pass through causing hydrostatic pressure. Measure moisture level within concrete with moisture meter.

If greater than 7% moisture, then test for vapor transmission.

Calcium Chloride Test

Two methods of testing for moisture vapor transmission

Moisture Vapor Transmission ASTM Test Methods

Tape 4-mil thick, 18 sq. inch clear plastic sheet to concrete with duct tape. Make sure there are no air leaks. Leave on for 16-24 hours. Remove and check for water droplets on plastic.

Kit sold by Rhino Linings Place weighed dish of calcium chloride on concrete. Cover and seal with a plastic dome Leave for 60-72 hours. Remove dish and weigh. Calculate transmission rate (lbs/area/24 hours)

Tackling Moisture

If the moisture levels are high, i.e. >3 lbs, apply a concrete treatment. Treatment is applied at the end of surface prep procedures. Rhino CB1000

Prevents moisture from coming up and delaminating Penetrates into concrete Low viscosity liquid can be sprayed on.

Concrete Surface Prep

2. Clean

For oil, grease, or soiled areas: 1. Wipe, brush, or scrape away heavy deposits. 2. Use hot water with trisodium phosphate (TSP), or enzyme cleaner or steam cleaning.

Do not use solvents.

3. Rinse with clean water.

Concrete Surface Prep

2. Clean

Check for oil or silicone (water repellants) contaminants with these simple tests:

Water Bead test: Place a few drops of water on surface and see if they bead up. Heat Test: Heat a small area with a lamp; oil or grease contamination will appear as a greasy film.

Treat mildew growth with bleach & water solution.

Concrete Surface Prep

2. Clean

For oily or organic chemical spots, can also use a surface torch/weed burner to burn away the contaminants.

Concrete Surface Prep

2. Clean

For old coatings, tapes or laminates, use industrial scraper.

Concrete Surface Prep

3. Abrade

Variety of ways to abrade concrete:

Abrasive blasting Scarifying HP water-jetting Grinding Acid Etching Steel Shotblasting Needle Scaling

Abrading Concrete

For Rhino materials, recommend 3 options:

1. Disc Grinding 2. Abrasive (sand) Blasting 3. Scarifying

Consider sub-contracting out to a professional.

Grinding
Pros: fairly quick and easy; good for large areas; Cons: minimal surface profile; creates fine dust (minimize with vacuum)

Abrading Concrete

Sand Blasting:

Pros: creates consistent profile; easy to reach difficult areas Cons: creates a lot of dust

Scarifying

Works well to remove excessive layers of contaminated concrete Can remove older coatings Can gouge easily & cause micro-cracking in concrete.

Abrading Concrete

ICRI

International Concrete Repair Institute

established 9 levels of surface profiles for concrete.

RLUSA recommends CSP 4 or CSP 5.

Edges

Use hand grinders to roughen edges or areas that are hard to reach.

For exposed edges, use a circular saw to create a key roughly 3/8 1/2 deep.

Concrete Surface Prep

4. Repair

Voids need to be filled and/or repaired.

Otherwise, expect blisters.

Bugholes & honeycombing

Use epoxy mortar (sand plus epoxy)

Concrete Surface Prep

4. Repair

For larger areas, use concrete patch material Rhino CRP

Concrete - Repair of Cracks

Fill cracks with polyurethane caulk or Tuff Grip 85-120 (slow version). For cracks larger than , first place polyethylene foam backer rod in crack

Concrete Surface Prep

4. Repair & Re-Clean

Soluble Salts
Abrading concrete should remove surface salts. However, in some areas such as industrial plants or close to salt water, you may have contamination from soluble salts. Use Chlor-Test to test for the presence of soluble salts.

Concrete Surface Prep

4. Repair & Re-Clean

Sweep and vacuum dust and contaminants. Final solvent wipe may be required.

Concrete Surface Prep

Examine results.

Prep for Other Materials

Principles of SCAR still apply. Aluminum softer metal so use less aggressive abrasion techniques; avoid polishing. Stainless Steel

hard material but same prep as steel

Prep for Other Materials

Wood

make sure it is dry use disk sanding for abrading surface

Fiberglass

hand or power tool sanding degreasing with detergent or solvent

Rewards of Job Well Done!!

Time for a little rest !!

Summary
S urvey C lean A brade R epair & Reclean