B08.02 Attachment - Appendix B2 -RLUSA Application Standard -Galvanized Steel Substrates.pdf

RLUSA Application Standard - Galvanized Steel Substrates Issue Date: 2-24-2012

Revised Date: NEW

PART 1. General Information

1.1 Scope

1.2 References and Standards

1.3 Quality Control

1.4 Storage and Handling of Materials

1.5 General Safety

PART 2. Products

2.1 Selection of Protective Lining

2.2 Primers

2.3 Topcoats

2.4 Solvents

2.5 Patch Compounds, Caulks and Crack Fillers

2.6 Equipment

PART 3. Execution

3.1 Site Examination

3.2 Site Prep

3.3 Surface Prep

3.4 Application of Rhino Lining products

3.5 Relining & Repair

3.6 Lining Inspection

PART 1: GENERAL INFORMATION

1.1 Scope

This application standard is designed to provide pertinent information and recommendations on the correct application of Rhino Linings protective linings onto galvanized steel surfaces. The standard covers the requirements for the materials, equipment, surface prep, application work, and inspection of the lining. It also reviews other important information such as safety requirements, storage and handling, and references.

1.2 References and Standards

The Society for Protective Coatings (SSPC)

International Steel Repair Institute (ICRI)

American Society of Testing and Materials (ASTM)

Rhino Linings Technical Reference Manual

Rhino Linings Safety Manual

Rhino Product Material Safety and Data Sheets

Rhino Product Data Sheets

1.3 Quality Control

1.3.1 Qualifications:

The project supervisor must be trained and should have at least one year experience on the use of Rhino

Linings Corporation products and equipment. The applicators and workers should be trained and knowledgeable on safety and application procedures for high performance protective linings.

1.3.2 Project:

A. Conduct a job-site conference to determine job requirements and responsibilities. This information should be placed in the job quote to avoid misunderstandings.

B. Conduct a site survey to determine the conditions of the jobsite, utilities available, surface prep required, and other relevant factors affecting the successful completion of the project.

1.3.3 Product Quality:

The Rhino Linings protective lining product to be applied for the application should be tested prior to the actual spray application for quality assurance purposes. This testing assures the user that the product sprays and cures as expected. This quality can be tested in several ways.

A. Perform reactivity and cure test via a cup test as outlined in the RL Tech Manual. The cup test involves mixing by hand the isocyanate and resin components at the correct weight ratio. The cure of the material is measured with a stopwatch and should match the expected profile of the product. This test only applies to chemicals with gel times of 12 seconds or greater when tested at 80 degrees F. The hardness and flexibility of the cured product should also be evaluated to make sure it matches the typical characteristics of the product.

Note that the chemical temperatures have a significant impact on the reactivity and cure of these products. These chemical systems have been designed to be sprayed within certain temperature ranges which are specified by Rhino Linings.

B. On the low pressure equipment, perform a ratio test to ensure the machine is proportioning the components at the correct ratio. This test is described in the RL Tech Manual.

C. On the high pressure equipment, check that the pressures during spraying are balanced between the iso and resin sides and are maintained above 1,500 psi minimum. Ideally spray pressures should be maintained above 1800 psi. Also the iso and resin pressures should stay within 200-400 psi of each other during the spraying of material. A sprayed sample can be checked for cure by using of a tongue depressor touching the wet sample until it dries. The gel time should be in 10 to15 seconds. The flexibility and hardness can also be checked once the sample has had 1 hour to cure.

D. Samples should be sprayed at the beginning and intermittently during a project to maintain a quality record of the application. A small 1-2 square foot sample should be sprayed and kept so that if there is any question as the quality of the product sprayed onto the substrate, the sample can show any signs of product defects. Small sprayed samples should also be saved at each change in drums or lot of product.

It is recommended that when spraying with the high pressure equipment the data recorder be used as a means of providing information on spray temperatures, pressures and amount of material applied.

1.4 Storage and Handling of Materials

1.4.1 Storage:

A. Store all Rhino Linings isocyanate, resin, and primer products at 60 – 90 oF in closed, well-sealed containers. It is best if the products are stored indoors in a dry protected area. These materials are hygroscopic and absorb water from ambient humidity. Therefore, sealing all containers, hoses and equipment is very important. This water absorption is not desirable and can lead to product quality problems such as foaming and delamination. Please note that this temperature range is not necessarily the temperatures at which the products are sprayed but only the appropriate storage range.

B. In addition, the isocyanates react with water and form carbon dioxide gas. In a closed container, this reaction can build a lot of pressure and cause an explosion. If you suspect that an isocyanate drum has been exposed to water or if you are decontaminating an empty iso drum, leave the small bung off or very loosely sealed to allow the drum to relieve any pressure build-up.

1.4.2 Handling:

A. Observe all safety precautions when handling chemicals (see below and RL Safety Manual).

B. If the isocyanate and/or resin drums are inadvertently allowed to get cold or frozen, they can be brought back up to the proper temps using band heaters. Using these heaters at medium heat will slowly bring the chemical temperature back to the recommended range. For the resin drums, it is best if the material is being agitated while heating. If the iso material has frozen, it will require higher heat for a prolonged period of time to liquefy the chemicals. The chemical requires from 120 to 150 degrees F.

bringing it back to liquid state and you should loosen the ¾ inch bung on the drum to avoid any pressure build during the process.

C. Do not subject RL isocyanates and resins to repeated cooling and heating as this promotes side reactions in the chemicals.

1.5 General Safety

1.5.2 Safety Procedures – observe all Rhino Linings safety guidelines and procedures provided in training as well as the Rhino Safety Manual.

1.5.3 Ventilation & Overspray Control – If spraying the Rhino products, proper ventilation needs to be established to eliminate overexposure to chemical vapors during spraying. This is especially true when spraying indoors. Adequate air flow should be established so that chemical vapors are exhausted to the outside and away from unprotected people in the area. If spraying, be aware of wind conditions which may track vapors downwind to other workers in the area.

1.5.4 Applying Rhino Linings products requires proper personal protective equipment. If spraying the products, full-face supplied air respirators are strongly recommended.

II. Products

2.1 Selection of Protective Lining

Please see product data sheets and consult with your Rhino Linings representative to determine the right lining product for your application.

Rhino Tuff Grip

Rhino HardLine

Rhino SolarMax

Rhino Hi Chem

Rhino Hybrid

Rhino Extreme

2.2 Primers

Primer 251

Primer 101 - Epoxy Primer

Primer 161

Primer 1500

Primer 1 K Bonding Agent

2.3 Topcoats

Rhino Shine Ultra – water based coating to revive color and gloss

UV Topcoat – 2K solvent based urethane coating

Rhino Fast Floor – 2K Polyaspartic

2.4 Solvents

Acetone

Denatured Alcohol

2.5 Caulks and Bridging Compounds

2.5.1 Bridging Compound – in order to transition welds and uneven joints, use of a urethane caulk or joint fill material is recommended.

2.5.2 Caulks – Use a polyurethane or polyurea caulk for filling cracks and joints. Rhino provides two products for this purpose. Consult your Rhino Linings catalog or customer service representative for these products.

2.6 Equipment

Low Pressure – RhinoPro LP-21 or Hi Flow-21 or Cartridge Gun

High Pressure – RhinoPro HP-21 or Graco Reactor 1 to 1 Equipment

III. Execution

3.1 Site Examination

Perform a site survey to determine the specific conditions you will face on the project. A site survey form is provided in RLUSA Tech Manual.

3.2 Site Prep

3.2.1 Masking – All surrounding areas and equipment that is not to be lined will need to be masked with masking paper or plastic.

3.2.2 Containment – Overspray and chemical vapors will need to be contained to prevent contaminating nearby areas and exposing people in the vicinity of the spray work.

3.2.3 Ventilation – If working indoors or in enclosed areas, ventilation will need to be provided to evacuate vapors created during the spray process.

3.3 Surface Prep

The following steps must be followed to ensure that the surface of the area to be sprayed is properly prepped to receive the RL protective lining. There are four suitable methods for galvanized steel preparation.

3.3.1 All welds shall be continuous and ground smooth or filled. Weld spatters, burrs, gaps, skip welds, slag, etc. shall be removed. Sharp edges shall be ground smooth.

3.3.2 Cleaning - Prior to surface preparation, the entire area to receive the lining shall be inspected for oil, grease, rust, dust, or any other deleterious substances. Any areas where such contaminants are present shall be cleaned in accordance with the condition of the lining. Solvent cleaning with acetone works well to lift contaminants and clean the surface. Degrease as necessary using high pressure water and biodegradable detergents. The cleaning process may have to be repeated for heavily soiled areas.

Rinse thoroughly.

3.3.3 For galvanized steel that may have been subjected to or exposed to chemicals or salts, the surface should be checked for soluble salt contamination such as chlorides, sulfates, and/or nitrates. Use Chlor-

Rid test kits for detecting soluble salts. If present, the chlorides must be neutralized with proper agents sold by Chlor-Rid or equivalent.

3.3.4 Abrasive Blast Method: After cleaning, all areas to receive the lining shall be abrasive blasted to a clean, consistent finish as described in SSPC-SP10 or SP-5 for heavy duty or immersion applications with an angular profile of 2-3 mils or SP-6 for light duty applications with an angular profile of 1-2 mils.

The cleaning abrasive can be either sand, steel grit or other angular medium and shall be selected to achieve the required surface anchor pattern.

3.3.4.1 T- Wash method for New Galvanized metal: T-Wash is still generally considered to be the best pre-treatment method for painting galvanized steel. T-Wash is a modified zinc phosphate solution which contains a small amount of copper salts. When applied, a dark grey or black discoloration of the zinc surface will result. T-Wash must not be allowed to pool on horizontal surfaces or this will prevent maximum paint adhesion. Any excess should be removed by water. T-wash is most suitable for application to new galvanizing and should not be used on weathered galvanizing. The constituents of T-

Wash are phosphoric acid (9.0%), ethyl cellusolve (16.5%), methylated spirit (16.5%), water (57.0%) and copper carbonate (1.0%). Variations to this composition may exist and so it is wise to consult the supplier if a successful result is to be achieved. Sufficient time must be allowed for the T-Wash to react and dry thoroughly before the first coat of paint is applied. (Suppliers' information will give recommended time intervals). While research has shown that T-Washed surfaces can be left for up to 30 days before painting and good paint adhesion can still result, it is advisable to minimize the time between pre-treatment and paint application. Any white salt formed by the exposure of the T-Washed surface to moisture must be removed before painting, using a stiff brush. If the T-Washed surface has become contaminated it must be cleaned in accordance with the suppliers' recommendations.

3.3.4.2 Etching Primer: Etch primers have also been used successfully. Their major disadvantage is the absence of any visible color change as is the case with T-Wash. Therefore, there can never be complete confidence that all surfaces have reacted with the primer. Etch primers are most suited to application on older, weathered galvanizing.

3.3.4.3 Weathering: This process only becomes fully effective after a galvanized surface has been exposed to the atmosphere for a period of at least six months. The surface is prepared using either abrasive pads or a stiff brush to remove all loose adherent materials and making sure that the bright zinc surface is not restored. This is followed by a hot detergent wash and rinsing with fresh clean water. The surface must be fully dry before any primer is applied. Weathering should not be used as a method of surface preparation in marine environments with high chloride levels.

3.3.4.4 TSP Cleaning: Tri Sodium Phosphate used in a proportion of 1 cup TSP to 1 Gallon of potable water will clean and prepare up to 40 square feet. If mildew or staining needs to be removed add 1 part bleach to 4 parts solution during the cleaning process.

3.3.5 Use clean, dry, oil free air to blow the dust, grit or other foreign matter from the substrate in a manner that does not affect the cleaned surface that is to be coated. Vacuum cleaning or other methods may be used in place of compressed air. The metal shall be 90% or greater dust free and dry.

3.3.6 All surfaces should be primed and coated within 8 hours of chosen surface preparation method to avoid surface contamination. Any galvanized steel that is not coated during that time period needs to be inspected for contaminants. If contamination is observed, it must be decontaminated and re-prepped according to the method chosen.

3.3.7 Apply steel wire tape to all edges of lined areas requiring clean straight lines.

3.4 Application of Rhino Linings products

3.4.1 Apply primer to a thickness of 2 - 3 mils using brush, roller, or spray. If spraying with an HVLP gun, the primer can be thinned with 5-10% acetone or other evaporative solvent.

3.4.2 Apply Rhino system within 12 hours of the primer becoming tack free.

3.4.3 Spray Equipment - The Rhino lining shall be applied by a plural component, heated high pressure airless spray machine approved for such use by the lining manufacturer. Perform product quality tests as outlined in section 1.3.3.

3.4.4 Environmental Conditions

3.4.4.1 Humidity and Dew Point. In order to avoid moisture contamination of the galvanized steel, the temperature of the substrate surface must at least 10 o F above the dew point temperature and rising after blasting and before the application of the lining material. High humidity may cause surface condensation in the form of dew or frost which will affect bonding of the lining. Therefore, the Applicator shall exercise caution if relative humidity exceeds 50% for urethanes and 75% for Hybrids and 80% for polyureas. Heating of the surface may be required to meet the requirements of the above dew point temperature restriction.

3.4.4.2 Temperature. The surface temperature of the galvanized steel should be between 60 o F and 130

F (55

C) for proper application. For colder temperatures, use of polyurea or hybrid products such as

Rhino Hybrid or Rhino Extreme is recommended. These products allow application temperatures below

F. Consult your Rhino Linings Technical Department when working in these conditions.

3.4.5 Application - The lining shall be applied according to the manufacturer’s application instructions.

Apply Rhino system within 12 hours of the primer becoming tack free. If the primer is allowed to cure more than 12 hours, a solvent wipe followed by an additional light application of primer of 1-2 mils will be necessary before applying the Rhino materials.

3.4.6 Thickness

3.4.6.1 Standard Thickness. The applied thickness of the lining shall be determined according to the application requirements. Please consult with Rhino Linings technical department for recommendations.

The owner may specify a greater thickness if so desired.

3.4.6.2 Minimum Thickness. The Applicator should not apply the lining to any thickness below 60 mils

(1.5mm) when being used as a flooring or abrasive resistant surface.

3.5 Relining

3.5.1 Recoat Window: The Rhino material can be re-coated without further surface prep if within 4 hours of application as long as the surface is without contamination.

3.5.2 Relining Past Recoat Window. Relining over new lining (of the same formulation) that has cured for more than the recoat time specified by the lining manufacturer shall be permitted. The existing lining shall be thoroughly sanded, followed by blow-off cleaning using clean, dry, high pressure compressed air or a wipe down with clean acetone. The surface then needs to be primed with Rhino Primer 251 at a thickness of 1-2mils.

3.5.3 Relining Over Old Linings/Linings. Relining over existing linings of a different type or formulation such as primer or epoxy shall not be permitted without the approval of both the owner and the lining manufacturer.

3.5.4 Removal of Old Lining. Completely remove damaged or improperly applied lining by scraping, and/or scarifying. Uncured lining that is sticky or gooey may have to be removed by solvent washing.

Ensure that any lining that is not being removed from the surrounding area to be repaired is well adhered. Remove additional surrounding lining if necessary until good, sound, well adhered lining is reached. Note it is not necessary to remove lining that is well adhered and well cured.

3.5.5 Repair of Thin Lining. To increase the lining thickness for areas that have been determined to have inadequate material thickness refer to section 3.5.1 and 3.5.2. Note that it is not necessary to remove well adhered, properly applied existing lining.

3.6 Lining Inspection

3.6.1 All sprayed lining applications require inspection to insure the project has been applied successfully. There should be inspections during the surface cleaning, preparation profiling, priming and lining application. There are many types of inspection tools available to the contractor for performing these tests. We recommend the customer and applicator determine the main criteria for inspection and methods to be used to perform the inspections. For immersion applications such as tank linings, we recommend holiday testing to check for pinholes in the lining. We also recommend testing the hardness of the lining using a Shore testing gauge. The hardness will indicate proper cure and ratio of the lining.

Thickness of the lining should also be measured in various locations to ensure the proper lining thickness has been achieved.