surface preparation and application guide

TABLE OF CONTENTS
Introduction...........................................................................1
Products & Packaging...............................................................1
General Requirements for the Work Site....................................1
Steel Surface Preparation....................................................1-2
Mixing....................................................................2-3
Application & Equipment........................................................3
SURFACE PREPARATION
AND APPLICATION GUIDE
SERIES 350 TANK ARMOR
TNEMEC COMPANY I NCORPORATED
6800 Corporate Drive, Kansas City, MO 64120
1-800-TNEMEC1 www.tnemec.com
Published technical data, instructions, and pricing are subject
to change without notice. Contact your Tnemec technical
representative for current technical data, instructions, and
pricing. Warranty information: The service life of Tnemec’s
coatings will vary. For warranty, limitation of seller’s liability,
and product information, please refer to Tnemec’s Product Data
Sheets at www.tnemec.com or contact your Tnemec Technical
Representative. 7/2015
Curing Time........................................................................3
Inspection.............................................................3-4
R e p a i r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 4
Health & Safety................................................................4
entrance of the tank where clean footwear, or disposable overshoes,
can be put on prior to entering the tank.
1.0 INTRODUCTION
The purpose of this guide is to acquaint contractors and applicators
with the basic information necessary for properly ordering and installing Tnemec’s Tank Armor. Prior to starting work, please read this
entire guide carefully. If you have questions, contact your Tnemec
representative or call 1-800-TNEMEC1. It is important that you obtain
answers to any questions before work begins.
Please review all pertinent Product Data Sheets as well as the Tank
Armor Plural Component Equipment Recommendation Guide prior to
starting. Also, reference the project specifications and compare them
with this guide and the Product Data Sheets. Resolve any inconsistencies prior to starting work.
This application guide cannot cover every issue that may be
encountered in the field. If issues arise that are not addressed in
this guide or the Product Data Sheets, please contact your Tnemec
representative or call 1-800-TNEMEC1 for assistance.
2.0 PRODUCTS AND PACKAGING
3.2 MATERIAL STORAGE
Minimum storage temperature for the product is 20°F (-7°C)
and maximum is 110°F (43°C). Prior to application, the material
temperature will need to be between 70°F and 80°F (21°C and 27°C).
It is suggested that the material be stored at the aforementioned
temperatures at least 48 hours prior to use.
3.3 DEHUMIDIFICATION
The surface should be clean, dry, and contaminant free, and
be at least 5°F (3°C) above the dew point. Do not apply when
humidity exceeds 80%. For tanks, dehumidification equipment is
recommended if humidity exceeds 80%.
If dehumidification equipment is not used, the surface to be coated
should be abrasive blasted within twenty four (24) hours prior to
the application of the lining material.
3.4 VENTILATION
When used as a tank lining or in enclosed areas, provide adequate
ventilation during application and cure.
2.1 SERIES 350 TANK ARMOR
3.5 HEATING
A high-build tightly cross-linked high performance epoxy with
excellent resistance to a broad range of chemicals, solvents and
petroleum over a wide range of temperatures.
Series 350 may be installed only when steel temperatures reach
above the minimum temperature that is indicated on the Series
350 product data sheet. Necessary heating, as specified, should be
by means of a heat exchange system that is incorporated into the
dehumidified air supply. Air admitted into the tank should not pass
directly through a combustion chamber.
2.2 SERIES 350 PACKAGING
KIT SIZE
PART A
PART B
YIELD
( M IXED)
3.6 LIGHTING
Large Kit †
3 - 55 gallon drums
1 - 55 gallon drum
(partial fill)
200 gallons (757.0 L)
Reference SSPC-Guide 12 for more information.
Medium Kit † 3 - 6 gallon pails
1 - 6 gallon pail
(partial fill)
20 gallons (75.7 L)
Small Kit
1 - 1 gallon can
4 gallons (15.1 L)
( PA RT I A L LY FI L LED)
1 - 5 gallon pail
† Configured for plural-component applications only.
Note: Series G390-1232 TK can be used for repair or touch-up.
Reference the Series 390 product data sheet for packaging and mixing
information.
2.3 SERIES 350 COVERAGE RATES (THEORETICAL)
DRY MILS
(MICR ONS)
WET MILS
(MICRONS)
SQ.FT./GAL
(M 2 /GAL)
Suggested
30.0 (762)
30.0 (762)
53 (5.0)
Minimum
20.0 (508)
20.0 (508)
80 (7.5)
Maximum
40.0 (1016)
40.0 (1016)
40 (3.7)
Allow for overspray and surface irregularities. Application of coating
below minimum or above maximum recommended dry film thickness
may adversely affect coating performance.
4.0 STEEL SURFACE PREPARATION
4.1 P R I O R T O B L A S T I N G S T E E L
Before work can commence on tanks previously in service, it is
vital that all internal tank surfaces are clean, dry and in suitable
condition for surface preparation and lining system application. The
following minimum requirements apply:
• Tanks must be structurally sound and free of chemical fumes
(gas-free).
•
Mill scale or other debris attached to the tank’s surfaces, must
be removed. For heavily scaled or contaminated surfaces,
sweep blasting may be required.
•
If hydrostatic testing is carried out using salt or brackish water
in the tank, then this test must be followed by fresh water
washing. The maximum allowed total soluble salt contamination
before application of Series 350 is 3 µg cm-2.
•
The surface should be clean, dry, and contaminant free, and
be at least 5°F (3°C) above the dew point. Do not apply when
humidity exceeds 80%. For tanks, dehumidification equipment is
recommended if humidity exceeds 80%.
•
If dehumidification equipment is not used, the surface to be
coated should be abrasive blasted within twenty four (24) hours
prior to the application of the lining material and before flash
rusting occurs.
3.0 GENERAL REQUIREMENTS FOR THE WORK SITE
3.1 CLEANLINESS
Prior to and during surface preparation and the lining application,
cleanliness must be maintained to avoid contaminants compromising
the performance of the lining system. To prevent contamination from
being tracked into the work area, establish a clean area around the
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4. 2 W E L D S
Remove weld spatter, burrs, or protrusions; remove and/or round
sharp edges; and smooth rough welds and gouges prior to abrasive
blasting. Welds should be ground to remove any irregularities and
are considered ready for painting when a minimum finishing level
of a C designation, as defined by NACE SP0178 latest revision, has
been achieved.
4. 3 C O N TA M I N AT E D S U R FA C E S
Unlined tanks or previously-lined tanks require checking for
contaminant presence that require complete removal prior to
abrasive blasting. Water soluble contaminants such as chlorides,
sulfates, acids, alkalies, etc. are not readily visible when present in
small quantities on the surface of the metal. These surface contaminants
can be embedded into blast profile if not removed and cause extensive,
persistent corrosion and blistering under the protective coating system.
4.4 P R E PA R AT I O N O F S T E E L - A B R A S I V E C L E A N I N G
All steel surfaces to receive Tnemec’s Tank Armor materials should
be abrasive blasted to a white metal cleanliness in accordance with
SSPC-SP5/NACE 1 White Metal Blast Cleaning or ISO Sa 3 Blast
Cleaning to Visually Clean Steel with a minimum angular anchor
profile of 3.0 mils (75 microns).
The abrasive used should be clean, dry, bagged material that has
a hard, angular cutting surface, such as aluminum oxide. Abrasive
materials should be selected to produce the required 3.0 mils (75
microns) minimum angular anchor pattern and no evidence of a
polished or peened surface will be accepted. Depth of anchor pattern
is suggested to be measured by using HT Testex-Replica profile tape
prior to the application of the prime coat. Profile readings should be
recorded on HT Testex-Replica tape and retained by the applicator
for verification as part of the Quality Assurance file (reference NACE
SP0287 and ASTM D4417).
The compressed air used for blasting should be free of water and oil.
Adequate traps and separators should be used to ensure elimination
of all contaminants. Cleanliness of the air supply may be checked
by operating the line without abrasive media through a clean white
cloth for 20 seconds. If oil or water appear on the cloth, the traps and
separators should be cleaned until subsequent 20 second tests prove
satisfactory (reference ASTM D4285).
Blasting should not be performed when the surface temperature is less
than 5°F above the dew point to prevent the formation of rust bloom.
Dew point and surface temperature readings should be taken prior to
blasting to ensure this condition. In addition, application of the prime
coat should be scheduled so as to immediately follow blasting and
cleaning operations. Painting over flash rust or other contaminants
is not acceptable. Care should be exercised by all personnel to avoid
hand or clothing contamination of the freshly-blasted surface.
All dust and blasting debris must be removed by vacuuming. Cloths
should not be permitted for cleaning blasted surfaces because of
possible lint contamination. Brushing or blowing the surface should
not be permitted as these methods will not dislodge all particles
embedded in the surface profile.
4. 5 S U R FA C E I M P E R F E C T I O N S
Abrasive blasting may expose surface imperfections in steel surfaces
that may previously have gone unnoticed. If practical, these
imperfections must be repaired immediately and blasted to duplicate
the surrounding area. If immediate repair is not feasible (due to loss
of blast), the affected area is to be masked off and repaired following
application of the first coat. If welding is involved in the repair
procedure, the masked area must measure 6” in any direction from
the weld. The edges of all masked repair areas should be feathered
using an abrasive cloth or wheel. Prepare the repaired area for coating
using the surface preparation procedures for steel outlined previously
in Sections 3 and 4. Any contamination resulting from the repair must
be removed by solvent wiping prior to abrasive blasting.
A record should be kept of all repaired areas using a coordinate
system. The repaired area must be spot-blasted and remain free of
voids, undercutting and weld spatter and exhibit a minimum 3.0 mil
anchor pattern.
5.0 MIXING
Do not mix part A with part B. CAUTION: Do not reseal mixed
material. Exothermic temperature can reach in excess of 250°F
(121°C). An explosion hazard may be created.
5.1 D RU M S E T S
Place blanket heaters on drums and set to medium heat. Recirculate
the material through the primary heaters set to the highest setting
back into the drums. Remove the center 2” bung on the drum and
insert the drum agitator. The material should be 80°-90°F (27°-32°C)
before the drum agitator is turned on. Agitate the material for 30-60
minutes before use or until the material in the drums reaches 110°120°F (43°-49°C).
5. 2 M E D I U M K I T S
To aid in mixing this material, place it in a 70°F to 80°F (21°C to
27°C) heated area for 48 hours prior to its use. Then mechanically
mix the entire contents of Part A and Part B separately. Use a
minimum 10 amp, 3/4” heavy-duty drill with a PS Jiffy blade and
mix the components for a minimum of two minutes. Note: Product
must be heated to 110°-120°F (43°-49°C) prior to and during
application.
5. 3 S E R I E S 3 9 0 T O U C H - U P K I T
Series G390-1232-TK can be used for touch-up or repair of the
Series 350 Tank Armor lining. The Series 390 touch-up kit consists
of six (6) tubes along with twelve (12) static mixers.
Equipment: A dispensing applicator with a 26:1 thrust is required
and can be ordered separately (F100-TKAP).
Usage: Material tube must be used in conjunction with provided
static mixer in order to ensure proper mixing. Unscrew retaining
ring and remove plug. Save plug in case entire tube is not used.
Install static mixing element, replace retaining screw ring, and place
tube in applicator. Point assembly up and slowly pull the trigger to
de-air the mixer. Dispense approximately 1 fluid ounce of material
to waste and continue to pump until material is of uniform color
with the Part A completely blended with the Part B. Use a putty
knife or spatula to ensure adequate coverage and mixing.
6.0 APPLICATION & EQUIPMENT
6.1 A P P L I C AT I O N C O N D I T I O N S
The minimum surface temperature is 50°F (10°C) and maximum is
120°F (49°C).
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The surface should be dry and at least 5°F (3°C) above the dew point.
Do not apply when humidity exceeds 80%. For tanks, dehumidification
equipment is recommended if humidity exceeds 80%.
Under certain environmental conditions, this coating may develop an
amine blush during cure. While this condition will not adversely affect
the performance of this coating, amine blush must first be removed and
then the coating aggressively sweep blasted prior to applying additional
coating. Please contact Tnemec Technical Services for more information.
6. 2 R E S U R FA C I N G, F I L L I N G A N D S T R I P E C O AT I N G ( W E T O N W E T )
Welds, seams and repaired areas should be given an initial brush
coat of Series 350 prior to a full spray application to work the
material into the surface. This should also apply to all areas
inaccessible by spray gun and as necessary to achieve the specified
dry film thickness and a surface free of imperfections.
For added protection against chemical attach or to protect the
chime areas of a tank from movement, Series 351 should be applied
to seams, bolted or riveted tanks and chime areas prior to
topcoating.
6.3 TANK ARMOR - PLURAL COMPONENT EQUIPMENT
RECOMMENDATION
Tank Armor is applied using a Graco XP70 heated plural component
airless spray unit or equivalent. Contact Tnemec Technical Services
for recommended equipment modifications.
GRACO XP70 HEATED PLURAL COMPONENT AIRLESS SPRAY
PUMP SIZE
Graco XP70
GUN
Graco XTR-7
TIP ORIFICE
0.021” - 0.029”
ATOMIZING PRESSURE
4500 - 5000 PSI (DYNAMIC)
PAINT LINE
50’ - 3/8” (9.5 mm)
STATIC MIXERS
Two - 3/8” x 12 Fold SST Static Mixers
One - 1/4” x 6 Fold SST Static Mixer
WHIP LINES
6’ - 10’ X 1/4”
PRIMARY HEAT (PRT A)
120ºF - 130ºF
PRIMARY HEAT (PRT B)
110ºF - 120ºF
HOSE HEAT
140ºF - 160ºF
MATERIAL TEMP AT GUN
115ºF - 120ºF
FILTERS
30 MESH WYE
PURGE TIME
Less than one minute
COMPONENT RATIO
3 (Epoxy) to 1 (Amine)
7.0 CURING
TEMPE RATURE
TO TOUCH
TO HANDLE
IMMERSION
75ºF (24ºC)
3 Hours
4 Hours
24 to 36 Hours
These times are based on a 20.0 mil (500 microns) dry film
thickness. Higher film thicknesses, insufficient ventilation or cooler
temperatures will require longer cure times. This coating commonly
develops an amine-blush during cure. While this condition will not
adversely affect performance of the coating, this blush must be
removed by aggressive sweep blasting before applying additional
coats. During high humidity conditions, it is recommended that the
application be done while temperatures are increasing. Cure time
to achieve a minimum Shore D Hardness of 77 or Barcol GYZJ 935
hardness of 55 for immersion service is 24 to 36 hours. In order to
obtain an accurate reading, the minimum DFT must be 30 mils.
8.0 INSPECTION
8.1 B L A S T P R O F I L E (S T E E L )
Refer to Section 4.4-Preparation of Steel for more information.
8. 2 W E T F I L M T H I C K N E S S M E A S U R E M E N T
Wet film thickness readings for successive coats should be taken as
soon as possible at a frequency of at least one per 100 sq. ft. and
should be taken so as to avoid surface irregularities that could
distort the readings. Readings on corners and in areas of intricate
geometry should be taken every 10 sq. ft. to ensure proper wet
coverage.
8. 3 F I N A L I N S P E C T I O N - H I G H V O LTA G E D I S C O N T I N U I T Y (S PA R K )
TESTING
If required by the contract specifications, high voltage discontinuity
(spark) testing may be used to determine the presence and number
of discontinuities in the nonconductive Tank Armor coating system
applied to a conductive surface.
All high voltage discontinuity (spark) testing should be performed
in accordance with NACE SP0188 and the procedures outlined
herein. NACE SP0188 recommends AGAINST spark testing liners
that have been placed in service.
The Series 350 coating system should be applied and allowed to
cure within the parameters of the corresponding Product Data Sheet.
Sufficient curing time of the coating system should allowed prior to
conducting a holiday test, as indicated by the, “Immersion,”
duration on the Product Data Sheets. Curing time will vary with
surface temperature, air movement, humidity and film thickness.
If the substrate is incompatible or if thickness constraints are not
applicable for a non-destructive dry film thickness gauge,
measurements of the coating system thickness are to be performed
during application of each system component using a wet film
gauge, feeler gauge or other measurement device that can
accurately measure the coating wet film thickness. These coating
measurements are to be tabulated to determine the total system
thickness.
The high voltage discontinuity (spark) testing voltage can be
calculated using the tabulated total coating system thickness (in
mils) multiplied by 100 volts DC. Never exceed the recommended
100 volts DC per mil, for excessive voltage may produce a holiday
in the coating film. All high voltage discontinuity (spark) testing
should be performed using a Tinker & Rasor model AP/W Holiday
Detector.
To perform holiday testing, attach a ground wire from the
instrument ground output terminal to the conductive substrate and
ensure proper electrical contact. Test conductivity by attaching the
instrument ground wire to rebar or other metallic ground
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permanently installed in the concrete and touch the electrode to the
bare concrete. If metallic ground is not visible, the ground wire can
be placed directly against bare concrete surface and weighted with
a damp cloth and paper sand-filled bag. Make contact with the
exploring electrode on the conductive substrate to verify the
instrument is properly grounded. If the test proves negative,
determining discontinuities with a high voltage spark test will be
ineffective. Under no circumstances should the voltage be increased
above the recommended voltage potential.
8.4 R E C O M M E N D E D V O LTA G E S F O R H I G H V O LTA G E S PA R K
T E S T I N G W I T H T I N K E R & R A S O R M O D E L A P/ W
TOTAL DRY FILM THICKNESS (MILS)
VOLTAGE (V)
20-24
2,500
25-29
3,000
30-39
3,500
40-47
5,000
48-59
6,000
60-69
7,500
70-79
8,500
80-99
10,000
100-124
12,500
125-134
15,000
135-159
16,000
160-174
17,500
175-214
20,000
215-269
27,000
270-299
31,000
300-350
35,000
A record should be kept of all repaired areas using a coordinate system. The repaired area must be spot-blasted and remain free of voids,
undercutting and weld spatter and exhibit a minimum 3.0 mils (75
microns) angular anchor profile pattern.
If film defects are suspected to involve a significant void
or holiday, or if the film has been damaged to the substrate,
repairs may be made using Series 390 touch-up and repair. Please refer
to the Series 390 product data sheet for details.
10.0 HEALTH & SAFETY
Tank Armor is for industrial use only and must be installed by qualified
coating and lining application specialists only. Paint products contain
chemical ingredients which are considered hazardous. Read container
label warning and Material Safety Data Sheet for important health and
safety information prior to the use of this product. Keep out of the
reach of children.
More detailed health and safety requirements for Series 350 are available in the Material Safety Data Sheet. Contact your local Tnemec
representative for more information.
Holiday testing of repaired areas should be performed using the same
testing procedures as outlined above.
If utilizing alternate high voltage DC holiday detectors, never exceed
the recommended 100-125 volts DC per mil or contact Tnemec
Technical Services for recommended voltage settings. Excessive
voltage may produce a holiday in the coating film.
9.0 REPAIR
Where imperfections, discontinuities or surface defects are present, or
if a coating is damaged during inspection, the area in question should
be masked and mechanically abraded to provide a consistent finish.
Application of an additional brush coat may be necessary.
If immediate repair is not feasible (due to loss of blast), the affected
area is to be masked off and repaired following application of the
first coat. If welding is involved in the repair procedure, the masked
area must measure 6” in any direction from the weld. The edges of
all masked repair areas should be feathered using an abrasive cloth
or wheel. Prepare the repaired area for coating using the surface
preparation procedures for steel previously outlined in section 4. Any
contamination resulting from the repair must be removed by solvent
wiping prior to abrasive blasting.
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