FAPL Chapter 3 - Surface Prep

8/14/2019 FAPL Chapter 3 - Surface Prep

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Fundamentals of ApplyingFundamentals of Applying

Protective LiningsProtective Linings

Part 3: Surface PrepPart 3: Surface Prep

Presented by:Doug Dutton; Ron LoPresto


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IntroductionIntroduction

Purpose for RL protective linings is toprovide:

oAbrasion resistance

o Chemical resistance

o Impact resistance

o Slip resistance


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Basic PrinciplesBasic Principles

Remember SCAR for proper surface prep!!

Survey area

Clean contaminants

Abrade surface

Repair defects & Re-Clean.


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SubstratesSubstrates To be reviewed todayTo be reviewed today

Steel

Concrete/Masonry

Overview for other Materials


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SteelSteel Surface PreparationSurface Preparation

1. Survey1. Survey 1. Survey surface

Examine for rust, oil, grease, water, old paint

What is steel being exposed to?oAre there chemical contaminants present?

Mill Scale bluish, shiny oxide layer thatforms on steel during its manufacture (hot-rolling)


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2. Clean2. Clean 2. Clean Surface

Remove dirt, water, and other contaminants

before abrading surface

For oil and grease contamination, solvent

cleaning works best.


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For steel surfaces,recommend

Acetone

MEK

Citrus-based cleaners


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In some cases, steam cleaningand/or waterjetting is used.

Works well for large or difficultto clean areas

Does not create a rough

profile


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3. Abrade3. AbradeAbrade surfaceto create profile for lining to

bond to. For steel, SSPC (Society for Protective

Coatings) has created specific surface prepstandards.

SSPC Standards cover varying levels ofcleanliness for the steel surface.


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SSPC Surface Prep StandardsSSPC Surface Prep Standards

SP-2 Hand Tool Cleaning Removes loosely bondedcontaminants

SP-3 Power Tool Same as SP-2 but faster

SP-11 Power Tool to Bare Metal

SP-14 Industrial Blast Allows 10% level ofcontaminants such as rust, mill

scales, etc.SP-6 Commercial Blast 66% free of all visible residue

with only staining permittedon the remainder

SP-10 Near-White Blast 95% free of all visible residue

SP-5 White Metal Blast 100% free of all visibleresidue


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AbrasionAbrasion -- RecommendationsRecommendations

For Rhino products,abrasive blasting

proven best; Producesconsistent roughprofile.

Want a 2 3 milsurface profile for best

results.


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SP-11 is acceptable for light dutyapplications.

For immersion service or heavy duty, want

minimum SP-10 (near-white) or SP-5 (whitemetal).

bAb i


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Common aggregate forcorrect 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.


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Flash Rust: may become a problem in humidareas. Consider only blasting what you can coat within

24 hours.

Prime blasted areas quickly to avoid flash rust.

Containment of abrasives

o Must have plan on how to contain dust and overspray

S l S f


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4. Repair & Re4. Repair & Re--CleanClean 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


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Soluble SaltsSoluble Salts

In certain areas, steel can be contaminatedwith 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

R i S l bl S ltR i S l bl S lt


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Removing Soluble SaltRemoving Soluble Salt

ContaminationContamination

Chlor-Rid Soluble Salt Remover

Option 1: Add to pressure washer tank at a100:1 dilution and pressure wash at 3,000psi.

Option 2: Use Chlor-Rid DTS and apply directly

to the surface. Then rinse off with a gardenhose.

St lSt l S f P tiS f P ti


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ReRe--CleanClean Abrasion creates dust and contaminant

residue.

Sweep and vacuum area.

Consider a final solvent wipe to removeany dirt or oil tracked in.


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Examine results.

If necessary, measure surface profile.

Inspect twice, spray once.

Conc eteConcrete S face P epSurface Prep


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ConcreteConcrete Surface PrepSurface Prep



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1. Survey1. Survey Study surface many factors to consider with concrete

Age & Condition of concrete minimum cure time is 28 days

old concrete, greater likelihoodof contamination

strength: hard or crumbly?

Laitance: weak surface layer of cement

Efflorescence: white powdery residue created bylime in concrete leaching to surface.


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Moisture Vapor TransmissionMoisture Vapor Transmission

Concrete being porous, allowsmoisture to pass through

causing hydrostatic pressure.

Measure moisture level within

concrete with moisture meter. If greater than 7% moisture,

then test for vapor transmission.

Two methods of testing formoisture

Calcium Chloride

Test

vapor transmission



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ASTM Test MethodsASTM Test Methods Kit sold by Rhino Linings

Place weighed dish ofcalcium chloride onconcrete.

Cover and seal with aplastic dome

Leave for 60-72 hours.

Remove dish and weigh. Calculate transmission

rate (lbs/area/24 hours)

Tape 4-mil thick, 18 sq.

inch clear plastic sheet toconcrete with duct tape.

Make sure there are no

air leaks. Leave on for 16-24

hours.

Remove and check forwater droplets on plastic.


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Tackling MoistureTackling Moisture

If the moisture levels are high, i.e. >3 lbs, apply aconcrete treatment.

Treatment is applied at the end of surface prepprocedures.

Rhino CB1000 Prevents moisture from coming up and delaminating

Penetrates into concrete

Low viscosity liquid can be sprayed on.



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2. Clean2. Clean For oil, grease, or soiled areas:

1. Wipe, brush, or scrape away heavy deposits.

2. Use hot water with trisodium phosphate (TSP), orenzyme cleaner or steam cleaning.

Do not use solvents.

3. Rinse with clean water.



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2. Clean2. Clean

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

Water Bead test: Place a few drops of water onsurface and see if they bead up.

Heat Test: Heat a small area with a lamp; oil orgrease contamination will appear as a greasyfilm.

Treat mildew growth with bleach & watersolution.



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2. Clean2. Clean

For oily or organic chemical spots, can also

use a surface torch/weed burner to burnaway the contaminants.



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2. Clean2. Clean

For old coatings, tapes or laminates, useindustrial scraper.



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3. Abrade3. AbradeVariety of ways to

abrade concrete:

Abrasive blasting

Scarifying

HP water-jetting Grinding

Acid Etching

Steel Shotblasting Needle Scaling

b di CAb di C t


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Abrading ConcreteAbrading Concrete

For Rhino materials, recommend 3 options:

1. Disc Grinding

2. Abrasive (sand) Blasting

3. Scarifying

Consider sub-contracting out to a

professional.

GrindingGrinding


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GrindingGrinding

Pros: fairly quick and easy; good for largeareas;

Cons: minimal surface profile; creates fine dust(minimize with vacuum)



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Sand Blasting:

Pros: creates consistent profile; easy to reach

difficult areas Cons: creates a lot of dust

ScarifyingScarifying


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ScarifyingScarifying

Works well to remove excessive layers ofcontaminated concrete

Can remove older coatings

Can gouge easily & cause micro-cracking in concrete.

Ab di C tAb ading Conc ete


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ICRI - InternationalConcrete Repair Institute

established 9 levelsof surface profilesfor concrete.

RLUSA

recommends CSP 4or CSP 5.

EdgesEdges


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Edgesdges

Use hand grinders to roughen edges or areasthat are hard to reach.

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



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pp4. Repair4. Repair

Voids need to be filledand/or repaired.

Otherwise, expectblisters.

Bugholes &honeycombing

Use epoxy mortar (sandplus epoxy)



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4. Repair4. Repair

For larger areas, use concrete patch material

Rhino CRP

ConcreteConcrete -- Repair of CracksRepair of Cracks


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ConcreteConcrete Repair of CracksRepair of Cracks

Fill cracks with polyurethane caulk or TuffGrip 85-120 (slow version).

For cracks larger than , first placepolyethylene foam backer rod in crack



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pp

4. Repair & Re4. Repair & Re--CleanClean



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Abrading concrete should remove surfacesalts.

However, in some areas such as industrialplants or close to salt water, you may have

contamination from soluble salts. Use Chlor-Test to test for the presence of

soluble salts.



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pp

4. Repair & Re4. Repair & Re

--CleanClean

Sweep and vacuum

dust and contaminants.

Final solvent wipe maybe required.



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pp

Examine

results.

Prep for Other MaterialsPrep for Other Materials


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Principles of SCAR still apply.

Aluminum softer metal so use lessaggressive abrasion techniques; avoid

polishing.

Stainless Steel

hard material but same prep as steel



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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!!Rewards of Job Well Done!!


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Rewards of Job Well Done!!Rewards of Job Well Done!!

Time for a little rest !!Time for a little rest !!


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Time for a little rest !!Time for a little rest !!

SummarySummary


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SummarySummary

S urvey

Clean

A brade

R epair & Reclean

Documents

FAPL Chapter 3 - Surface Prep