North American Headquarters For Low Pressure, Portable … · 2019. 6. 12. · standard Coatings • Increased service life – No cracking on bending – No chipping on impact –

North American Headquarters For Low Pressure, Portable Blasting and

Coating Systems

www.IBIXUSA.com

Our Coverage

•  Canada •  USA •  Mexico •  Puerto Rico •  Caribbean •  and •  Peru / SA •  Trinidad and

Tobago

IBIX North America services the following Countries:

Corporate Location Tampa Bay Florida

Corporate Headquarters: 2075 Lake Ave SE Largo, FL 33771 United States

Markets Served Building Restoration

Historical Preservation

Concrete

Marine

Transportation

Plant Maintenance

Oil and Gas

Thermoplastic Flame Spray

powder coating For

ON-SITE projects

The Contractors Coating systems

POLY-Steel

or POLY- Concrete

protection

for the next generation

Thermoplastic •  Conventional coatings dry by evaporation of solvents and

oxidisation. •  High performance solvent free PU/Epoxy dry by reaction (base and

hardener) •  FBE powder is thermosetting, one time cure set

(heat causes reaction) •  Polyolefin is a thermoplastic, heat melts the powder and then

hardens (cures) by cooling (no chemical reaction takes place). Can be immediately put into use. No down time on site. Water or air can be used to cool down coating

Advantages of our Polyolefin to standard Coatings

•  Increased service life –  No cracking on bending

–  No chipping on impact –  Thicker coating with

excellent coverage over sharp edges and welds

–  Flexible to -70 °C

–  Superior salt, sea and sand resistance

•  Repairable

•  Vandal resistant –  Graffiti can be wiped clean

–  Coating cannot be peeled off

•  Safety –  TGIC and heavy metal free

•  No requirement for cross-linking

–  reduced rejects

–  extended shelf life –  reduced energy usage

Application principle : Heat applied through gun direct on steel and concrete Spartacus 5th Generation

B Benefits of long term Protection

•  IBIX has been teaching and performed successful Thermal spray operations throughout many industries including:

•  Power, OIL / GAS Refining, Plant Steel Structures, , Pipe, railing, Marine structures , chemical and Wastewater Treatment Facilities, and Leisure equipment, Parks.

Why coat and spray with Thermoplastics?

• Barrier Properties • Vapor •  Liquids • Chemical Resistance

•  Electrical Insulation • Anti-corrosion

Why Use Thermoplastics?

!  Barrier Properties

◦  Vapour ◦  Liquids

◦  Chemical Resistance

!  Electrical Insulation

◦  Anti-corrosion

!  Flexibility ◦  500-800% elongation

!  No cracking or chipping

!  Thicker coatings ◦  Barrier properties

◦  Edge and weld coverage

◦  “Grip” and “warmth”

◦  Impact resistance

◦  Fluid dip, flame and flock spraying

"  250 -1000 micron ◦  Electrostatic spray

"  150 -300 micron !  Food Contact

◦  Low Toxicity

Further benefits of using our Flame spray system with our thermoplastics coatings

Functionalised Polyolefin Alloys Poly-Steel Long term adhesion without need of a primer

–  Excellent UV and salt spray resistance –  Contain only C, H, O

•  Food/water contact approvals •  Low smoke/toxicity on burning

–  Elastomeric / very flexible •  Ductile impact properties •  No cracking/chipping

–  Temperature range -70°C to 70°C (100°C)) –  Good chemical resistance –  Minimum recommended thickness - 300 micron

Benefits extend with Chemical and Bacteria Resilience

Ferric chlorides and sulphuric acid

Swimming Pool Containment Tanks

Antibacterial coatings Aggressive Environments such as heavy traffic, pollution, etc.

Flame spray to protect against the elements

Spartacus with Hercules gun: •  Compact; •  Portable and easy to carry; •  Easy to use; •  The application process can be easily controlled by

means of fast settings. SYSTEM DESCRIPTION AND TECHNICAL DATA: •  Mobile unit with large wheels for easier transport on

rough terrain; •  Quick connect, colour coded hoses to machine; •  Just requires LPG and compressed dry air.

The most efficient portable technology to prevent surface corrosion on-site

Flame Spray Thermoplastic Coating System

Spartacus flame spray system Features

•  Three application gun sizes with different flow rates and available in different

versions (featuring straight flow or wide spray pattern), fully interchangeable. •  New CENTURION gun, the most powerful gun of its time, powered by IBIX® Srl –

Wider Spray Pattern (over 10 cm with the Large CENTURION gun) offering:

•  Faster spraying and more uniform layers; •  Easier overlapping of passes and better powder flowing out; •  No powder "lines" or "stripes”; •  Minimizes the risk of un-molten powder with air trapped in the

coating.

Spartacus Flame Spray Thermoplastic Coating System Guns

NEW EXTRA-COOLING SYSTEM with heat exchanger for

prolonged flame spraying HERCULES.

Small Medium

Large

Super-heater as additional pre-heating system for thick metals, large surfaces, special round tube shapes….

Spartacus Gladiator Accessories: To assist with Pre-Heat surface

N o n c o n t a c t I n f r a r e d Temperature measuring device with laser pointer to check pre-heating temperature and for coating cycle control

QNix® Thickness g a u g e f o r n o n d e s t r u c t i v e t h i c k n e s s measurement of coatings on metal a n d n o n m e t a l substrates

Spartacus Gladiator : Control Instruments coating thickness and temperature, for consistent results

N o n d e s t r u c t i v e thickness gauge for a w i d e r a n g e o f appl icat ions which require the ultrasonic technology (wood, c o n c r e t e , p l a s t i c , metals, etc.)

Typical Applications & Case Histories

CONCRETE Coating

Flame Spray Applications Concrete Substrates

Concrete – Typical Characteristics

•  Concrete is a composite material that deteriorates when exposed to normal environmental conditions.

•  At the casting stage, concrete is sensitive to climatic changes and absorbs gases present in the atmosphere.

•  We should not overlook the fact that concrete “breathes”, so it expands and shrinks with seasonable moisture and temperature variations, and this often causes cracking problems.

•  Other peculiar and negative characteristics of concrete are a non-uniform, changing surface morphology as well as the typical porosity of the finished body.


Concrete and Corrosion Carbonation •  Carbon Dioxide in air reacts with calcium hydroxide in

concrete to form calcium carbonate: •  Increases mechanical strength of Concrete; •  Changes the pH of the concrete from alkaline (pH10+) to

acidic. •  Below pH10 the passivation layer on steel R-bars dissolves

and corrosion will start to occur.

Chlorides: Can be used to shorten setting time but can leach calcium hydroxide leading to loss of strength. Sulphates: Can lead to chemical changes in concrete and loss of strength. Leaching: Water flows through cracks in concrete dissolving minerals in the concrete.

Example of flat piece of concrete having d i s l o d g e d w i t h c o r r o d e d R - b a r underneath.

Example of secondary efflorescence in parking garage exposed to diluted road salt from vehicles entering the garage during winter. .


SYSTEM COATINGS

What is Polyfusion? •  Polyfusion is a coating providing an anti-osmotic barrier used

to insulate porous substrates against the external agents the coating is exposed to.

•  Generally speaking, the substrates to be protected are porous materials such as concrete, fiberglass, etc.


Polyfusion Vs Coating Resins such as polyureas and epoxies

Conventional Coatings:

•  They do not guarantee a long-lasting protection when applied on concrete substrates since they present both applications and intrinsic problems;

•  They have no control over ambient conditions when product is applied (air moisture, wet substrate, air and substrate temperature, etc.);

•  They do not guarantee anti-osmotic properties as gases and liquids can pass through them (when these elements reach concrete, the result is early corrosion).

Flame Spray Applications Concrete Substrates – Polyfusion System

Chemical & Physical Characteristics •  Resistance to penetration of liquids

(anti-osmotic characteristics);

•  Enhanced smooth fluidity; •  Excellent resistance to chemicals (acids,

alkali, solvents*); •  Excellent resistance to adverse weather

conditions; •  Outstanding UV protection;

•  Excellent behaviour in case of fire (material that would not easily catch fire);

•  Stain resistance, there are no pores for calcium, rust or other staining agents to grab or imbed into;

•  Anti-bacterial properties (special formulations).

*Contact IBIX® for specific chemical resistance requirements.

Mechanical Properties •  Excellent Adhesion; •  Abrasion-resistance (Taber ASTM 60mg/500g); •  Remarkable elastic properties (elongation at break:

500%); •  Excellent resistance to blistering, chalking, peeling,

cracking and other signs of deterioration in normal use;

•  Excel lent f lex ib i l i ty, even at very cold temperatures;

•  Resistance to cold (-50°C). Appearance and Technical Characteristics •  Smooth, durable and long-lasting coating; •  Antislip version available; •  Colour and pattern uniformity which will last for

many years to come; •  Easy to repair i f accidental ly damaged

(Thermoplastic); •  Eco Friendly; •  No porosity.

Flame Spray Applications Concrete Substrates – Polyfusion System

Application Procedure •  Removal of existing coating; •  Surface Preparation: Inspect the surface for any

delamination or hollow spots. If hollow spots are found they must be chopped out and repaired using appropriate repairing material;

•  Sand and/or smooth existing surface to a flat finish with a sanding disc and/or a cement-based product.

•  Blast to clean the surface; •  Apply a first layer of the bi-component sealing

primer Polyres (A+B). •  Apply a second layer of Polyres and wait until it

dries (it should not cure, hence it should still be tacky);

•  Apply Polyfusion System through Hercules Flame Spray System.

Flame Spray Applications Concrete Substrates - Flooring




Switzerland – St. Gallen Coating of a private garage.


Mauritius – MFD logistic centre Ex- salt deposit to switch into sugar cane warehouse - 1080 mq. Problems: •  Salt efflorescence - highly visible on

floors and walls. •  Rising damp coming up from the

expansion joints.

Solutions: •  Joints – opened and re-sealed with epoxy primer + quartz sand + silicone on the top. •  POLYFUSION cycle:

!  POLYRES-N epoxy primer applied overall the surface in 2 coats, in order to seal the substrate from rising damp and salt and to improve the adhesion of POLYFUSION (2nd coat – “tacky status” as usual).

!  POLYFUSION GREY 7001 flame spraying with No. 3 Hercules systems at work: "  1st coat - applied over 300 sq m per time "  2nd coat - 80 sq m per machine in 2, 5 h in total. Notes: 2 layers for 600 µ instead of 3 – gas supply working at 3 constant bar + powder supply at 3,7 bar = wider flame spray.

Flame Spray Applications Concrete Substrates - Flooring Mauritius – MFD logistic centre Ex- salt deposit to switch into sugar cane warehouse - 1080 mq.




Flame Spray Applications Concrete Substrates - Flooring Mauritius – Coating of a terrace flooring

PRIMER APPLICATION


COATING PHASE


RESULT

Varese (ITALIA) Coating of an Industrial Garage (Chemical Resistance)

BEFORE AFTER

Flame Spray Applications Concrete Substrates - Chemical Industry


GNOSIS, Pharmaceutical Company Switzerland – Repairing and coating of a 40sq m concrete flooring due to the chemicals corrosion.

BEFORE


AFTER




BEFORE


FINAL RESULT

•  HMC produces copper cathodes. •  PHC Flame Spray Coating of concrete containment

tank for H2SO4 tanks. •  Desert climate; area subject to marine salt spray. •  Thermal gradient -10°C +35°C. •  Surface subject to the following conditions:

•  Resistance to 95 % - 100 % sulphuric acid flow.

•  Kind of surface coated: new concrete.

HMC Haldeman Mining Company La Cascada - 120 km da Iquique - Región de Tarapacá, Norther Chile (Sept. ’09)

Flame Spray Applications Concrete Tanks

Coating thickness 1200 microns: first coat 1000 microns of PHC Black and 200 microns PHC Green topcoat. Thickness control by weight and witness; metal plate and certified thickness gauge.

Test period: 12 months.


HMC Haldeman Mining Company La Cascada - 120 km da Iquique - Región de Tarapacá, Norther Chile (Sept. ’09)


Albini Cotton Factory – Albino (BG) Coating of a concrete tank meant for containing a fiberglass tank to restrain

caustic soda 30% at ambient T°.

BEFORE

Final Result: Plascoat PPA571 – POLYFUSION version coating



Saudi Arabia Coating of concrete tanks in a ready mix concrete factory.


Saudi Arabia Coating of concrete tanks in a ready mix concrete factory.

FINAL RESULT

Flame Spray Applications Concrete Coating - Polyfusion: luminescent version

Flame Spray Applications Concrete Coating - Polyfusion : anti-slip version Jan 2016 Slaughterhouse GAVAZZA, Asti. Making of anti-slip flooring for for allowing the cattle to walk down the hallways without slipping.

ORIGINAL STATUS AFTER THE APPLICATION OF ARDEX A 46

APPLICATION OF POLYFUSION – ANTI-SLIP VERSION

FINAL RESULT

Flame Spray Applications Concrete Coating – Polyfusion : anti-slip version

Jan 2016 Slaughterhouse GAVAZZA, Asti. Coating of a tiled flooring using Polyfusion, in order to guarantee an easier cleaning procedure (it eliminates the problems related to the tiles grout-lines). Available in the antimicrobial version too.

BEFORE AFTER

Flame Spray Applications Concrete Coating – Polyfusion : antimicrobial version

Refrigerating Room, Asti. Coating of flooring and walls in a confined and closed area using Polyfusion. The new coating will eliminate all the hygienical problems related to the tiles of the floor.

Flame Spray Applications Concrete Coating - Polyfusion : antimicrobial version

Flame Spray Applications Concrete Coating – Polyfusion : antimicrobial version

Refrigerating Room, Asti. BEFORE COATING

Refrigerating Room, Asti – FINAL RESULT

Flame Spray Applications Concrete Coating - Polyfusion : antimicrobial version

METALS Coating with Spartacus flame system

The Flame Spray technology is particularly suitable for coating of metal substrates, since it provides the following benefits:

•  No need for a primer: –  PolyHotCote powders adhere directly to the prepared substrate.

•  Anti-osmotic barrier: –  For outdoor structures such as buildings / constructions, bridges, off-shore sector, nautical applications.

•  Continuous dielectric insulation: –  Protective coating against stray currents for articles to be buried; –  Electrical and marine corrosion protection.

•  Abrasion resistance: –  Abrasion-resistant coatings, high mechanical strength; –  Coatings for ducts to discharge mineral waste, process water, etc.

•  Chemical resistance: –  Anti-acid coating for tanks, containers, fittings, industrial plants, etc.

Flame Spray Applications Metals

Application Procedure

•  Surface Preparation: The substrate must be cleaned. Sandblasting is the preferred pre-treatment method, using a grain size which provides a 40-50 microns profile and SA 2.5 cleaning standard.

•  Preheating: The substrate is preheated to approx. 100°C-150°C (normally the melting point of the thermoplastic coating powder used) using the gun of the flame spray coater (flame only, no powder).

•  Powder Application: The powder flow is started by turning on a switch located on the gun itself or by pressing the gun trigger. Now the powder is propelled through the gun by dry compressed air and hits the preheated substrate and immediately melts adhering to the substrate.

•  The coating thickness is dependent on the number of passes. The minimum recommended coating thickness is 300 microns.

•  Additional coating or repairing will always be possible in time: while coating, after coating is complete, after some time or later.

•  The flame spray coating cycle is now complete. •  Usually, the substrate is air cooled. If needed, you can water quench the coated

substrate.


Flame Spray Applications with Spartacus flame system various Metal applications



Oil tank mounted on a mining equipment, suffering filtration in the welding seams, due to constant vibrations

BEFORE

Flame Spray Applications Metal Box, protection acid with Polyolefin powder and our Spartacus flame system


Thanks to the impressive elongation of PHC (800%), the seams have been sealed successfully.

PHC for Chemical Resistance

Catwalks in Copper Sulphate Plant - Santiago

Painting after 8 months Completely corroded

PHC after 8 months Like New!

Mining in Chile Chemical and electrical corrosion

PHC for Chemical Resistance

Copiapo Mine, Chile Metal structure carrying a conveyer beld in a acid plant

Flame Spray Coating of structural steel on cat-walk running around and over sulphuric acid tanks

Thermoplastic Flame Spray in MINING Cominco Mines, British Columbia (Canada)

Flame Spray Coating of supporting piling

Thermoplastic Flame Spray in MINING Cominco Mines, British Columbia (Canada)

Pipes for acid waters in a mine in Chile

Thermoplastic Flame Spray Coating of Pipes for Mining

Flame Spray Coating with PHC of Metal Structures of Hydro-electric Power Stations replacing wet painting

ENEL: internal coating of water pipes

ENEL: Carpentry

EBB - NORWAY Flame Spray Coating of Fumes from aluminium extrusion plant at Hydro in Norway

Flame Spray Coating for Corrosion Protection and Electric Insulation of Pipes

HYDRO ALUMINIUM Factory Haugesund – Norway •  Job: coating of fume exhaust pipes

from aluminium extrusion ovens; •  Carbon Steel pipes - 5 Km.; diam. from

500 mm to 3 m; •  Operating temperature 40-70°C; •  Previous System: fiberglass-reinforced

epoxy paints.

Problem: •  Electrical corrosion (very strong magnetic

fields); •  Very strong environmental corrosion (the

plants are cooled down by sea water spraying on top of the roofs -> dripping from the roof – 7/8 m high – of contaminated, salty water on the pipes).

Hydro - Norway – Flame Spray

1°Test 2003 – PHC White

•  Test area after 2 years (2005): white area – after washing;

•  After 4.5 years (inspection June ’07): coating like new whereas the previous epoxy paints were faulty after 4 months;

•  2005: coating of the first 1070 sq m job – grey colour;

•  August 2007: starting of the second job – colour grey;

•  May 2008: starting of the third job – colour grey (2000 sq m).

!  High Pressure Washing; !  Sand blasting; !  Flame Spray Coating (first the welds for -pinhole-free

coating + coating of a pipe section, overcoating of welds); !  Damaged Areas (holes in the steel): ◦  Washing + sandblasting; ◦  “sealing” coating with PHC in the surrounding area; ◦  Closing of the holes using UV - cured polyester films (by

means of UV lamps; ◦  Overspraying with polyurethane paint.

Job phases

Benefits offered by the Flame Spray Technology

•  Long Term Anticorrosion Protection (antiosmotic protection; electric insulation; chemical resistance): final solution to the problem for Hydro;

•  System usable in any weather condition (hot – cold weather – rain – if the item is protected against direct rain – in this case with the scaffolding);

•  One-step application cycle; •  Fast turnaround: immediate use of the coated items; •  No overspray -> no need to protect equipment, vehicles etc.; •  No risk to damage plants, vehicles, pedestrians; •  Ecologic system (no VOC, TGIC, plastifiers, Isocyanates, Halogens

etc.); •  Easy touch up; •  Easy repair.

# Three colour Thermoplastic Flame Spray Coating to easily check and control abrasion and damage

# The damaged part can be repaired promptly thus restoring the coating to its original state

BLASTING

HALF-PIPE BEFORE BLASTING

COATING OF SLURRY HALF-PIPES MINING - CHILE

Anticorrosion Sealing Coating with PHC Green

Additional Wear-Resistant and Wear Control PHC-H Black Top Coat

ANTICORROSIVE AND ANTIABRASIVE COATING WITH WEAR-CONTROL PHC SYSTEM

Half-pipes ready to be installed in a Thickening Plant for mineral slurry

Half-Pipe ready for delivery

Thermoplastic coating is highly resistant to impact and shocks during installation

PHC – COATED PIPES INSTALLED

Combined system to apply PHC to unreachable or restricted areas, into holes. Coating of complex structures, complicated shapes.

New Development

•  CUSTOMER: Cia. Explotadora de Minas •  Mining Site: Dos Amigos - Localidad: Domeyko CHILE •  COATING JOB:

•  Coating thickness: 1100 micron 1.1 mm, min. •  Coating :Thermoplastic Thermal Spray Powder PHC (Italy). •  Coating process: By thermal spraying after IBIX Blasting to white metal. •  Corrosion protection against acid attack due to H2SO4 fumes.

Coating of acid plant absorption towers

PHC Flame Spray Coating after blasting with Ibix-Garnet System.

•  PHC coatings offer improved release properties. •  More efficient high pressure washing to remove

wet paint drops during painting process. •  Coating life: 2 months (8 high pressure washing

operations @ 2000 bar).

Ford Painting Shop Grating - Turkey

Pipe coated with PHC

Internal coating at 900-1000 microns Pipe 1 m long – diameter 500 mm Time: 50”

External coating at 1.5 mm

KOREA – anticorrosion society

PHC-A Flame Spray Thermoplastic Coating of a Tank - KOREA

KOREA – anticorrosion society

UK Engineering Co. At the biggest mill in the UK Coating resistant to hopper’s corrosion and abrasion

Coating of a Tank - India

USA – Metal Structure

2075 Lake Ave SE – Largo, FL 33771 (727) 322-4611

[email protected] www.IBIXUSA.com

Thank you!

Documents

North American Headquarters For Low Pressure, Portable … · 2019. 6. 12. · standard Coatings • Increased service life – No cracking on bending – No chipping on impact –