1. Selecting the Proper Coating/Lining System
Kevin Morris
Market Director Water & Wastewater
Sherwin-Williams

2. Learning Objectives Primary substrates for application
Protection mechanisms
Selecting the proper surface preparation based on the selected system and substrate
Proper selection of the system.

3. Primary Substrates Steel Concrete
Carbon Steel – Easily attacked by the environment in which it is placed and will begin to revert back to iron ore.
Stainless Steel - Stainless steel does not stain, corrode, or rust as easily as ordinary steel.
Concrete
Concrete - used more than any other man-made material in the world and is easily attacked when placed in chemical environments.

4. Protection Mechanisms
Barrier Protection
The coating/lining isolates the electrolyte from the anode, cathode, and metallic pathway.
Rust Inhibitive
The slightly water-soluble pigments permeate to steel/coating interface and passivate the substrate.
Sacrificial
The coating/lining contains pigments that are more active than the metal and sacrifice themselves to protect the substrate.

5. System Selection
System selection for coatings/linings is not as simple as providing a coating that will resist a given commodity and
System selection must consider a multitude of factors for a successful application.

6. System Selection (Factors to Consider)
Steel
Concrete
Commodity (Name, CAS
#, Percentage)
Storage Temperature
Movement / Flexibility
Type of Structure
Location and Use of
Structure
Agitation (% of Suspended
Solids)
Design (Welded, Bolted or
Riveted)
Inaccessible Areas
New Construction, Repaint
or Structural Repairs
Commodity (Name, CAS #, Percentage)
Storage Temperature
Location and Use of Structure
Type of Traffic (Foot, Cart or Vehicular)
Agitation (% of Suspended Solids)
Mix Design, Placement and Finishing
Joints, Cracks,Vapor Barriers, etc.
New Construction or Rehabilitation

7. System Selection (Factors to Consider)
Do any of these place restrictions on system selection for Steel and Concrete?
The reason for coating?
Allowable methods of Surface Preparation
Regulations
What else?

8. Surface Preparation Affects on System Selection
SSPC-SP 1 “Solvent Cleaning”
SSPC-SP 2 “Hand Tool Cleaning”
SSPC-SP 3 “Power Tool Cleaning”
SSPC-SP 11 “ Power Tool Cleaning to Bare Metal”
SSPC-SP 7/NACE No. 4 “Brush-Off Blast Cleaning”
SSPC-SP 6/NACE No. 3 “Commercial Blast Cleaning”

9. Surface Preparation Affects on System Selection
SSPC-SP 10/NACE No. 2 “Near White Metal Blast Cleaning”
SSPC-SP 5/NACE No. 1 “White Metal Blast Cleaning”
SSPC-SP 12/NACE No. 5 “Surface Preparation and Cleaning of Metals by Waterjetting Prior to Coating”
SSPC-SP 13/NACE No. 6 “Surface Preparation of Concrete”

10. Surface Preparation Affects in System Selection
ICRI Guideline No , “Selecting and Specifying Concrete Surface Preparation for Sealers, Coatings and Polymer Overlays”

11. Surface Preparation Affects on System Selection
When specifying surface cleanliness it should be noted that surface profile is as important.
Surface profile promotes mechanical bond of the coating/lining system to the substrate.
Steel (This is commonly specified in mils)
Concrete (This is commonly specified as a CSP (1-9) “Concrete Surface Profile”)

12. Surface Preparation Affects on System Selection
The greater the DFT the greater the Surface Profile

13. Surface Preparation Affects on System Selection
The greater the DFT the greater the Surface Profile

14. Surface Preparation Affects on System Selection
The greater the DFT the greater the Surface Profile

15. Surface Preparation Affects on System Selection
Minimum DFT’s to fill surface profiles:
CSP 1 = 13.5 mils +/- 2.5 mils
CSP 2 = 16 mils +/- 2.5 mils
CSP 3 = 19 mils +/- 2.5 mils
CSP 4 = 25 mils +/- 2.5 mils
CSP 5 = 33 mils +/- 2.5 mils
CSP 6 = 63 mils +/- 2.5 mils
CSP 7 = 87.5 mils +/- 5 mils
CSP 8 = 105 mils +/- 5 mils
CSP 9 = 107 mils +/- 5 mils

16. Epoxies
Epoxies are two component products consisting of an epoxy resin which is cross-linked with a co-reactant or hardener. Epoxy coatings are formulated based upon the performance requirements of the end product. When properly catalyzed and applied, epoxies produce a hard, chemical and solvent resistant finish. They are typically used on concrete and steel to give resistance to water, alkali and acids.

17. Aliphatic Polyurethanes
Atmospheric Service
Good Chemical & Solvent Resistance
Good Flexibility
Excellent Color and Gloss Retention
Excellent Abrasion Resistant
Low Temperature Application

18. Aromatic Polyurethanes
Atmospheric and Immersion Service
Good Chemical & Solvent Resistance
Good Flexibility
Good Abrasion Resistant
Good Film Build
Low Temperature Applications

19. Fluoropolymers Atmospheric Service Good Chemical & Solvent Resistance
Good Flexibility
Ultimate Color and Gloss Retention
Excellent Abrasion Resistance

20. Polysiloxanes Atmospheric Service Good Chemical & Solvent Resistance
Good Flexibility
Excellent Color and Gloss Retention
Good Abrasion Resistant

21. Acrylics Atmospheric Service Fair Chemical & Solvent Resistance
Good Flexibility
Good Color and Gloss Retention
Good Abrasion Resistance

22. Alkyds Atmospheric Service Fair/Poor Chemical & Solvent Resistance
Good Flexibility
Fair/Poor Color and Gloss Retention
Good Abrasion Resistant

23. Zincs Atmospheric and Immersion Service
Poor Resistance to Alkali and Acidic Environments
Excellent Corrosion Protection
Some Formulations – Shop Applications Only

24. Polyureas Atmospheric and Immersion Service
Fair Chemical & Solvent Resistance
Ultimate Flexibility
Ultimate Abrasion Resistance
Excellent Film Build
Low Temperature Applications

25. Novolac/Phenolic Epoxies
Atmospheric and Immersion Service
Excellent Chemical & Solvent Resistance
Fair/Poor Flexibility
Good Abrasion Resistant
Good Film Build
May require heat curing

26. Vinyl Esters / Polyesters
Atmospheric and Immersion Service
Excellent Chemical & Solvent Resistance
Fair Flexibility
Good Abrasion Resistance
Fast Cure
Min Cure Temps Required

27. Thin Film Coatings/Linings
Generally systems up to 20 mils DFT designed for corrosion protection of concrete and steel from immersion and atmospheric exposure.
Do not tolerate abrasive conditions (high solids, agitation, turbulent flow)
Least expensive alternative (price sensitivity)
Usually spray applied, simple equipment
Difficult to cover rough concrete

28. Thin Film Systems

29. Medium Film Coatings/Linings
Generally are systems from 20 to 40 mils DFT designed for the protection of concrete and steel from more harsh environments in immersion and secondary containment
Will tolerate moderate abrasion from turbulent flow and low solids cargo
Used for containment areas with pedestrian and light vehicular traffic, trenches and sumps
Highest permeation resistance per mil

30. Medium Film Coatings/Linings

31. Laminate Linings
Generally are 55 to 120 mil dft systems designed for the corrosion protection of concrete and steel in immersion conditions, secondary containment, and steel tank bottom renewal.
Single or double Laminate
Will tolerate moderate solids, agitation and turbulent flow
Limited crack bridging capability

32. Laminate Lining Systems

33. Mortar Systems
Generally are 125 to 250 mil dft systems designed for the protection of concrete in more harsh environments and tolerate moderate to heavy industrial traffic
Good thermal shock resistance
Improved wear resistance
Skilled mechanics required for installation

34. Mortar Systems

35. Self-Leveling Mortar Systems
Generally are 70 to 125 mils dft designed for the corrosion protection of concrete in more harsh environments and can include a broadcast aggregate for a textured finish.
Easiest mortar system to install
Vertical applications will require modifications to eliminate the self-leveling properties
Good wear resistance
Limited thermal shock resistance

36. Self-Leveling Mortar System

37. Mortar Laminate Systems
Generally are 90 to 125 mil dft systems designed for the corrosion protection of concrete and steel in immersion and secondary containment
Will tolerate turbulent flow and agitation
Good permeation resistance
Good thermal shock resistance
Requires skill and experience

38. Mortar Laminate Systems

39. Heavy Duty Mortar Laminate Lining Systems
Generally are 125 to 190 mil dft systems designed for the protection of concrete and steel in immersion and secondary containment.
Best for high solids, agitation, and turbulent flow
Good permeation resistance
Good thermal shock resistance
Highest cost, most skill required

40. Heavy Duty Mortar Laminate Lining Systems

41. Flexible Coating/Lining Systems
Generally 25 to 125 mil dft systems designed for the corrosion protection of steel, concrete, and masonry in atmospheric or immersion conditions.
High thermal shock resistance
High crack bridging capability
Relatively easy to install at a moderate price range

42. Flexible Coating and Lining Systems

43. Flexible Basecoat Laminate Systems
Generally are mil dft systems designed to be installed prior to the application of a topping system for crack bridging capability in atmospheric exposure on concrete.
Highest thermal shock resistance
Highest crack bridging capability
Most versatile

44. Flexible Basecoat Laminate System

45. Technologies That Improve Performance
Crystals of
MIO are
fractured
into thin
flakes.
Flakes
then
align in
parallel
fashion.

46. Technologies That Improve Performance
Topcoat Holiday:
Blue crescent is prime coat fluorescence.
White Light
Inspection
Fluorescent
Inspection

47. Thank You!
Any Questions