Protective Coating & Linings
 
 

Protective Coatings & Linings II
5-Day Classroom Course

Description
This course provides training on the different types of specialized protective coatings and linings, the application of these coating systems, and general information on the use of these systems in relation to corrosion control.

Who Should Attend
Anyone involved in corrosion that needs a basic understanding of protective coatings and linings, as well as professionals involved in selecting and specifying coatings including: coating project specifiers, maintenance and project engineers in all industries, and marketing representatives of coating materials or equipment.

Prerequisites
No prior training is required.

Course Highlights (include but are not limited to)

  • Review of Corrosion Theory and Coating Fundamentals
  • Maintenance Planning and Execution Including Coating Project Management
  • Special Applications (Electroplating, Cladding, Thermal Spray, Vitreous Coatings, Rubber Linings, Hot Dip Galvanizing)
  • Substrates Other Than Concrete and Carbon Steel (Frp, Aluminium, Stainless Steel, Fire Protective Coatings)
  • Nace Standard RP0198-Corrosion Under Insulation
  • Pipeline Coatings

ADVANCED PROTECTIVE COATINGS AND LININGS - II

Course Outline

I. Review of PC&L-Basic

 

A. Corrosion overview

 

B. Coating materials

1. Basic mechanisms of corrosion protection

2. Desirable properties of coatings

3. Chemistry of coatings

4. Curing mechanisms

5. Coating system selection

 

C. Application of coating systems

1. Coating specification

2. Safety

3. Pre-job conference

4. Surface preparation methods

5. Workmanship/application

6. Hot-dip galvanizing vs. other zinc coatings

7. Interior protective linings

8. Inspection and quality control

9. Reporting

 

D. Coating failures

1. Failure/defect causes

2. Types of failures/defects

3. Preventive measures

 

 

II. Pipeline Coatings

 

A. Pipeline overview

1. Pipeline uses, terrain/environment

2. Four types of pipe (seamless, ERW, DSAW, spiral weld)

3. Materials of pipeline construction (carbon steel, glass-reinforced pipe, ductile iron, concrete, plastic, special alloy steels)

 

B. Criteria for pipeline protection

 

C. Desirable properties of a pipe coating

 

D. Methods of pipe coating application

1. Stationary plant application

2. Field application

 


E. Fusion-bonded epoxy pipeline coatings

1. Composition/properties

2. Plant application process

3. Field application process

 

F. Coal tar coatings

1. Coal tar enamels

2. Coal tar epoxy

3. Coal tar pitch tapes

G. Extruded polyolefins

1. Cross-head extrusion

2. Side extrusion

3. Hard-adhesive extrusion

 

H. Abrasion-resistant pipeline coatings

 

I. Cold-applied tapes

1. Laminated polyolefin tapes

2. Co-extruded polyolefin tapes

3. Plant application

4. Field applications

5. Petrolatum tape

 

J. Shrink-fit sleeves

 

K. Weight coatings

1. Asphalt mastic

2. Concrete weight coating

•  Impingement

•  Form and pour

•  Compression coat

 

 

III. Concrete and Other Cementitious Surfaces

 

A. Introduction to concrete as a substrate and a coating

1. Concrete properties

2. Reactive nature

 

B. Concrete composition

 

C. Types of concrete and cementitious surfaces

1. Poured

2. Block

3. Special concrete surfaces (gunite, asbestos cement, glass-fiber)

 

D. Reasons for coating concrete

 

E. Surface preparation of concrete/cementitious surfaces

 

F. Smoothing concrete surfaces, filling voids, treating cracks/expansion joints

 

G. Coating systems for concrete

1. Categories of concrete coatings (waterproofing, waterproofing and

dampproofing, decoration, protective barrier)

2. Penetrating primers

3. Types of coating systems (thin film, thick film, elastomeric, laminate,

mechanically-bonded thermoplastic liners, sheet liners, bag liners,

brick and tile linings)

 

H. Coating selection

 

I. Methods for applying coating to concrete

 

J. Concrete as a coating

1. Weight coating

2. Rebar coated with concrete

3. Fire-protection coating

 

K. Concrete failures

 

 

IV. Hot-Dip Galvanizing

 

A. Galvanizing definition and benefits

 

B. Continuous and after-fabrication galvanizing

 

C. Hot-dip safety

 

D. Hot-dip process

1. Surface preparation

2. Fluxing

3. Dipping

4. Inspection

 

E. Hot-dip galvanized alloy layers

F. The effect of silicon-killed steels on galvanizing

 

G. Quality issues related to hot-dip galvanizing

1. Alteration of substrate properties

2. Workpiece design

3. Coating thickness and service life

4. Adhesion

5. Appearance

 

H. Visual inspection of hot-dip galvanized article

 

I. Field erection of galvanized structures

1. Bolting of galvanized steel

2. Faying surfaces

3. Welding, grinding, cutting of galvanized steel

4. Safety and health factors associated with welding galvanized steel

 

J. Corrosion resistance of galvanized coating

1. Barrier vs. sacrificial protection

2. Atmospheric corrosion

3. Aqueous corrosion

4. Soil corrosion

5. Chemical resistance

 

K. ASTM standards pertinent to hot-dip galvanizing

 

L. Coating galvanized surfaces

1. Reasons for coating galvanized surfaces

2. Synergy of duplex systems

3. Surface preparation and application related to age of galvanized

structure

4. Application methods

5. Coating systems

6. Maintenance painting of galvanized steel

 

 

V. Thermal Spray

 

A. Definition of thermal spray

B. Thermal spray techniques

1. Combustion (gas flame)

2. Electric arc

3. Plasma arc

4. Specialized thermal spray processes (HVOF)

 

C. Advantages of thermal spray coatings

D. Thermal spray aluminum and thermal spray zinc coatings

E. Metals used in thermal spray for corrosion control

 

F. Thermal spray application process

1. Surface preparation

2. Coating deposition

3. Finishing

4. Inspection

 

G. Health and safety considerations related to thermal spray processes

 

 

VI. Rubber Linings

A. Types of natural and synthetic rubber applications

 

B. Methods of curing (vulcanizing) rubber

1. Autoclave

2. Internal steam

3. Atmospheric steam

4. Hot-water cure

5. Chemical cure

 

C. Categories of natural rubber

1. Soft

2. Semi-hard

3. Hard

4. Triflex construction

 

D. Synthetic rubbers

1. Butyl rubber

2. Chlorobutyl rubber

3. Neoprene

4. Nitrile rubber

5. Hypalon

 

E. Chemical resistance of rubber linings

F. Critical service conditions

 

G. Application process for rubber linings

1. Surface preparation

2. Adhesive application

3. Rubber lining application

4. Inspection and repair before cure

5. Cure

6. Inspection after cure

7. Repair (if required)

 

H. Rubber lining of pipe

I. Rubber lining of concrete surfaces

J. Rubber lining safety

K. Rubber lining failures

L. Repairs to rubber-lined equipment

M. Quality assurance for rubber linings

 

VII. Special Applications

 

A. Electroplating

1. Electroplating applications

2. Corrosion protection mechanisms of elecroplated coatings

3. Surface preparation

4. Electroplating process

5. Advantages and disadvantages of electroplating

6. Specific electrodeposited coatings (nickel, nickel-phosphorus,

cadmium, zinc, chromium, tin, lead, copper, gold, nickel-chromium)

7. Electroless nickel process

B. Cladding

1. Definition

2. Reasons for cladding

3. Cladding processes (rolling, explosion)

4. Bonding mechanism in cladding

5. Clad metal systems (noble metal, corrosion barrier, sacrificial,

transition, Complex multilayer)

 

C. Sherardizing

1. Advantages of sherardizing

2. Sherardizing process

D. Vapor deposition

1. Thermal decomposition

2. Cathode sputtering

3. Evaporation of molten metals

 

 

VIII. Coatings for Non-Ferrous Substrates

 

A. Fiberglass-reinforced plastic (FRP)

1. FRP composition

2. Surface preparation

3. FRP lining application

4. FRP lining inspection

5. FRP as a substrate

1. Surface preparation

2. Coating system

 

B. Wood

1. Sealing

2. Stabilizing

3. Preservation

4. Flame retardance

5. Seasoning

6. Hardwoods vs. softwoods

 

C. Aluminum

1. Reasons for coating aluminum

2. Types of coating systems for aluminum

a. Organic coatings

b. Anodizing

c. Conversion coatings

d. Electroplating

e. Porcelain enamels

f. Preventive oils

g. Temporary protective coatings

h. Polyvinyl chloride dispersions

3. Surface preparation methods

4. Anodizing process

5. Chemical conversion process

 

D. Stainless steel

1. Basic types of stainless steel

2. Surface preparation methods

3. Reasons for coating stainless steel

4. Coating systems

 

 

IX. Vitreous Coatings

 

A. Definition and examples of vitreous coatings

B. Porcelain enamels

C. Ceramic coatings

D. Glass linings

 

 

X. Fire-Protective (Intumescent) Coatings

 

A. Definition of intumescent coating

B. Protection mechanism

C. Benefits of intumescent coatings in addition to fire protection

D. Surface preparation methods for steel, galvanized steel, and galvanized

luminum surfaces

E. Application process

F. Failures associated with intumescent coatings

 

 

XI. Maintenance Planning and Execution

 

A. Definition of maintenance coating

B. Maintenance coating selection considerations

C. Controlling costs associated with a maintenance-coating program

D. Reasons for coating maintenance

E. Considerations in designing cost-effective maintenance coatings program

F. Planning

G. Waste disposal and safety considerations

H. Implementation of a Total Quality Management coating program

I. Material testing

J. Quality assurance for maintenance coating

K. Key steps of a successful maintenance coating operation ("From Coating

Selection to Installation")

•  Define the project

•  Plan the details

•  Develop project schedule

•  Project controls

•  Reporting

L. Computer-assisted maintenance painting programs

 
       
Designed & Maintained by Anis Chief