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Resimac Ltd Engineered Polymer Solutions

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WHAT WE DO. REPAIR Metallic surfaces subject to abrasion, wear and corrosion
PROTECT Metallic components, equipment and structures subject to erosion, corrosion and chemical attack
UPGRADE The performance of metallic components and equipment
FULL RANGE OF PRODUCTS COVER - Metal Repair - Ceramic enhanced coatings for abrasion and wear environment - High temperature protective coatings - Thermal Insulation coatings - Chemical protective coatings - Anti corrosion coatings - Waterproofing and roof coatings

Resimac customers worldwide

Resichem 530 HA100 Fluid epoxy
Stand alone corrosion coating
Being tested as a replacement for FBE
Tested and applied as part of a flame sprayed system Being tested as part of a 3 Layer system
Pipe coating systems on the market

Product characteristics. Single pack heat activated epoxy novalac Activated at temperatures in excess of 100C Applied by spray to hot surfaces - Pipework, process vessels, reactors etc Dry temperature resistance of 240C Chemical composition of the product. Low functionality epoxy novalac, 2.15 Polyamine curatives blended with the novalac Hazard Class 8 Application details Apply to mechanically abraded, hydroblasted or abrasive blast surfaces 2 x 250microns (10mil) is the system recommendation Applied by airless spray, product heated to 70C Typical equipment GRACO EXTREME, 3000psi pressure +

Test Data. (In house) Corrosion Resistance Tested to ASTM B117 Minimum 1000 hours salt spray resistance.
Hardness Shore D to ASTM D2240 20C 90 100C 86 150C 80 200C 72
Cure Times Cure times are dependent on the cure temperature as indicated in the table below. Temp Touch dry Light loading 100C 50 mins 2 hours 110C 35 mins 70 mins 120C 25 mins 50 mins 130C 15 mins 30 mins 140C 7 mins 15 mins 150C 3 mins 7 mins
Adhesion Tensile Shear to ASTM D1002 on abrasive blasted mild steel with 75 micron profile and cured at 120C. 197 kg/cm (2800 psi)
Mechanical Properties Adhesion Tensile Shear to ASTM D1002 on abrasive blasted mild steel with 75 micron profile and cured at 120C. 197 kg/cm (2800 psi)

Test Data. (Doosan Babcock/ Chevron Chevron Texaco looking at HA100 for subsea pipeline, high temp riser protection Product applied on site at DOOSAN BABCOCK in prep for bend tests 2 x 350 microns applied, cured at 150C
PREPARED SURFACE SA2.5 HEATED TO 100C APPLIED 1st COAT 300MIC
APPLIED 2nd COAT 300MIC HEATED TO 100C JACKED TO GET 150C

Test Data. (Doosan Babcock) Product tested on test rig, PASSED bend test set at 20%

Test Data. (Doosan Babcock) Follow on testing approved by Chevron Samples at ELEMENT product passed all tests Cathodic disbondment testing 28 days - 20C, ISO 21809 Peel test ISO 21809, Water Immersion Test

Test Data. Plascoat Systems Corrib Pipeline - Shell On site trial performed by COATSOL System used is HA100 with flame sprayed PP from PLASCOAT HA100 used as the primer layer PP Flock sprayed onto wet film Heated to 150C to cure HA100 and to fuse the PP Cathodic Disbondment test performed at PLASCOAT Labs
Test Results Test Sample Required Performance Test Result Sample 1 7 mm

Test Data. Plascoat Systems Corrib Pipeline - Shell Photos of CD testing for Corrib Pipeline

Test Data. Plascoat Systems Corrib Pipeline - Shell Cathodic Disbondment 28 days @ 90C CAN/CSA-Z245.20 12 N/mm Peel Strength @ 90C (over Novalac) ISO 21809-3: Annex D >5 N/mm Hardness @ 25C ASTM D-2240 Shore D >60 Flexibility @ 0C CAN/CSA-Z245.20 No cracks @ 3C PDD Impact resistance @ 23C DIN 30670 >20 Joules Tensile Elongation (at break) of topcoat @ 25C (after flame spraying) ASTM D-638 10% Taber Abrasion topcoat ASTM D-4060/84, H18 500Gm load 1000 cycles 55 mg weight loss

Field Qualification. Plascoat Systems Coatsol South America On site trial performed by COATSOL System used is HA100 with flame sprayed PP from PLASCOAT HA100 used as the primer layer PP Flock sprayed onto wet film Heated to 150C to cure HA100 and to fuse the PP Cathodic Disbondment test being performed at PLASCOAT Labs

Test Data. BSR Ramco External Pipecoating Pipe coating mill looking to use HA100/ HA80 as external pipe coating Use as part of a 3 layer system PP Use as a primer for insulation Seawater Immersion Test in accordance with ISO 20340 using the method described in ISO 2812 2 (to include full test report). Two versions of the product to be tested. Details to be discussed: HA70 HA100 Please note that if a document/test is not referenced in this offer then it is not applicable to Tata Steels scope of work and will not be a contractual requirement of any Order placed.

Advantages over existing coating systems Single pack heat activated epoxy novalac High temperature resistance up to 240C Compatible with a range of existing 2/3 layer systems Excellent CD resistance Simple to apply for pipe mills of in field coating High build coating, 200-300 microns per coat Fast curing at elevated temperatures Based on existing epoxy coating technology Cured coating has good flexibility on blast cleaned surfaces Will fuse with 3 layer systems for increased inter layer adhesion

HSE GUIDANCE FACTS AND FIGURES
BURNS AND SCALDS At 44C it takes up to 6 hours to get a 1st degree burn At 60C it takes less than 6 seconds At 100C it takes less than a second
HSE GUIDELINES METAL Surfaces above 60C must be protected Approximately 1.5% of all reported incidents concerned thermal burns Median days off was 4 By law employers are required to protect employees and ensure there safety
AREA ALSO COVERED BY ASTM C1055 -92

ADVANTAGES AND DISADVANTAGES OF EXISTING SYSTEMS
MINERAL WOOL INSULATION

ALTERNATIVE SYSTEMS AVAILABLE ON THE MARKET WATER BASED THIN FILM COATINGS Acrylic technology Water Based Thin film coverage 100-200 microns per coat Based on glass bead technology Proven track record in industry 55 shore hardness Multi coat systems approx 8-10 coats to achieve protection Restricted by weather conditions on outside applications 10C - 30C
EPOXY HIGH BUILD COATINGS Based on proven epoxy technology Solvent free 100% solids High build system 0.5mm 1mm per coat Based on innovative filler technology New to industry 18 months track record Suitable up to 160C Good corrosion resistance Can be applied to damp, cold surfaces (condensation) Can be applied to hot surfaces up to 120C

Resimac High Temperature Coatings 561 Thermal Barrier
561 THERMAL BARRIER application features Applied by Standard airless spray Applied in 5 coats up to 1mm per coat Can be applied to surfaces up to 110C Manual surface prep, hydroblast, abrasive blast clean Slump resistant upto 3mm in a single coat
561 THERMAL BARRIER product features Two pack epoxy system Standard Bis A/F resin Lightweight Solvent free 100% solids Reduces surface temperature of metallic surfaces Reduces heat loss by up to 40%

THERMAL CONDUCTIVITY OF MATERIALS k value Carbon Steel 43 W/mK Mineral wool 0.04 W/mK Water based 0.15 W/mK Epoxy based 0.10 W/mK
HOW DO INSULATION COATINGS WORK?
Definitions.. K-value thickness matters because the thicker something is, the slower heat will pass through it. The thermal conductivity is a measure of how easily heat passes through the material and is called the k-value . k-value is measured in W/mK. Thermal conductivity is an inherent property of a material, like stiffness or density
U-value is measured in W/m2K that is, Watts per square metre per degree Kelvin (1 degree Kelvin is the same as 1 degree Centigrade, but with a different zero). So if a wall has a U-value of 1.0, then 1 m2 of wall will let 1 Watt pass through it when there is a temperature
difference of 1 degree between the inside and outside.
HEAT LOSS OF MATERIALS u value Carbon Steel 8600 W/mK Mineral wool 8.0 W/mK Water based 30.0 W/mK Epoxy based 20.0 W/mK
BASED ON 50MM OF ROCKWOOL, 5MM THICKNESS OF CARBON STEEL, WATER BASED AND EPOXY BASED COATINGS.

WHAT THIS EQUATES TO IN SURFACE TEMPERATURE REDUCTION USING STANDARD DEFINITIONS AND TESTING EQUIPMENT
Based on the graph, if you apply 5mm of epoxy high build the temperature will be reduced from 118C to 60C
* Blue line on the graph

Resimac High Temperature Coatings 561 Thermal Barrier
561 THERMAL BARRIER testing Independently tested by Gearing Scientific Conforms to ISO 8301 Proven to reduce surface temperature Proven to have insulating qualities Reduces heat loss by 40% compared to bare steel pipe
Test
No
:
Pla
te N
o:
Mat
eri
al
thic
kne
ss
(mm
)
Lower
temperature
set (C)
Actual
Temperature
Recorded (C)
Lambda Value
@ C Mean
Steel
Plate
Temperature
(C)
8 6 3.93 35.0 38.

resimac · pdf fileresichem 530 ha100 – fluid epoxy product characteristics. •...

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