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PHC LINER, anti-acid, anti-osmotic, eco-friendly, and washable for protection coatings on porous materials 22-12-2010 IBIX Agents EOY Meeting AUTHORS: Engineer MARGHERITA PRIOLO Mr. MATTEO RAVA Slide 2 2 Liner: the cutting-edge coating solution for porous materials INTERNATIONAL PATENT New frontiers.. PHC LINER Slide 3 PHC Liner: the cutting-edge coating solution for porous materials WHAT IS PHC LINER? It is synonymous of a 100% self-supporting, perfect coating anti-osmotic barrier isolate A perfect coating has to be an anti-osmotic barrier in order to isolate substrates against the external agents the coating is exposed to. concrete, fiberglass and porous materials in general. For this product specifically, the substrates to be protected generally consist of concrete, fiberglass and porous materials in general. 3 Slide 4 PHC Liner: the cutting-edge coating solution for porous materials Concrete - Typical Characteristics Concrete 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. surface morphology Other peculiar and negative characteristics of concrete are a non- uniform, changing surface morphology as well as the typical porosity of the finished body. 4 Slide 5 PHC Liner System compared with Coating Resins COATING RESINS such as polyureas and epoxies DO NOT guarantee a long-lasting protection when applied on concrete substrate since they present both application and intrinsic problems. Productive systems have flaws such as: no control over ambient conditions when product is applied (air moisture, wet substrate, air and substrate temperature, etc.). Application cycles are hard to control (flash period, drying, weathering, etc.) Unchanging thicknesses in surface morphology cannot be guaranteed (pitting, roughness, etc.) Therefore, this coating DOES NOT guarantee anti-osmotic properties as gases and liquids can pass through it. When these elements reach concrete, the result is early corrosion. 5 Slide 6 SOLUTION THE PHC LINER OFFERS The SOLUTION THE PHC LINER OFFERS: 6 In theory, the main aim of any coating is to create an impermeable barrier that protects the substrate against any kind of aggression. The chose coating must guarantee adhesion, resistance to chemicals and physical agents, elasticity, and long-term stability. PHC LINER: The idea finds its roots in the proof that traditional painting systems (using liquid varnishes) CANNOT GUARANTEE lasting performance, especially when used on porous substrates such as concrete. Slide 7 PHC Liner: Key Factors to Success Highly flexible and versatile system Several PHC Liner models The avant-garde production technology applied allows offering a wide variety of copolymers. A vast choice of products are available to meet the requirements of various market segments Special versions: Cuspidal version (with pre-shaped cusps suitable for the hook to be buried in concrete and to be installed at the concrete casting stage); Version with metal reinforcement (also suitable for providing the hook to be buried in concrete and to be installed at the concrete casting stage); Non-slip version Photo-luminescent version Anti-bacterial version Abrasion-resistant version 7 Slide 8 8 IBIX PHC Liner, non-slip version. Repairable. IBIX PHC Liner, cuspidal version, ready to be installed during the concrete casting stage. Viable LINER versions Slide 9 PHC LINER: Product Description Chemical & Physical Characteristics : Resistance to penetration of liquids (anti-osmotic characteristics) Enhanced smooth fluidity ('waxed' effect); Excellent resistance to chemicals (acids, alkali, solvents) Excellent resistance to adverse weather conditions Excellent behaviour in case of fire (material that would not easily catch fire) Anti-bacterial and anti-fouling properties (special formulations) 9 Slide 10 10 Mechanical Properties: Abrasion-resistant (Taber ASTM 60mg/500g) Remarkable elastic properties (ultimate at break: 500%) Resistance to cold (-70C) Technical Characteristics: Leak-tight joints and connections Easy to repair if accidentally damaged (THERMOplastic) No porosity Slide 11 11 Colour range Our colours are: 695 Ral 7045 (grey) 536 Ral 5017 (blue) 110 Ral 9016 (white) 700 Ral 9005 (black) Natural (transparent) Other colours can be made upon customer's request Slide 12 12 Let's see how to apply the product in detail Sub-base inspection: First, take a close look at the surface where the coat will be applied. The substrate should show no friable, fragile, or loose parts. It should be intact, firm and solid; any potential deformation should be foreseen before applying the coating. Slide 13 13 Any substrate deformation or unevenness, warping or irregularity should be solved before the adhesive is applied. Do not use the adhesive to compensate for these faults. Carefully check that there are not any release agents such as release oils or any other element that can adversely affect adhesion. Slide 14 14 Finishing coats Apply a skim coat of mortar if concrete is irregular. We recommend Kerabuild, a monocomponent cement-based mortar formulated for deep filling, to restore or repair damaged or missing sections in cement and masonry. Excellent product workability to fill surfaces, even if imperfections are deep, when the coat is spread and finally laid by trowel. Moisture: Due to the characteristics of the adhesive, the substrate where it is applied should be dry and free of rising damp. Damaged concrete Slide 15 15 Once you have checked that the sub-base is solid, measure the moisture content. It should not exceed 3%, the same as for laying any other flooring. If over 3%, use any specific equipment that can adequately warm up or dry the floor Recommended glue: bi-component SLC PU70 glue Slide 16 16 BASIC LAYING CONDITIONS REQUIRED Clean and firm sub-base Negative roughness 3-4 mm max Max moisture: 3% Minimum room temperature: 13C Slide 17 PUMP TO APPLY IBIX SUPERGLUE 17 An effortless task Single-phase supply Slide 18 18 Applying glue using the pump Slide 19 19 How to lay the plates Follow the same steps as for any other resilient flooring. How to apply the glue: use a pump spraying system if the area is very large (about 1sq.m / min), or spread by hand (with a saw-toothed scraper, 1 mm) Plates are to be laid head to head. Standard sizes: 1x2 m or 1x1m, different thicknesses depending on the customer's request, from 1.5mm to 2mm; 2.5mm thick for the anti-slip version. Slide 20 20 ROLLING: Once the plates are laid (should coincide with one another; maximum deviation allowed: one millimetre), they should be rolled using a specific loaded floor roller. Purpose: The roller presses the liner onto the surface underneath so as to improve adhesion and eliminate any air that may be trapped Slide 21 21 WELDING: Once the 24-hour drying period has elapsed (do not walk on the surface during this time), weld the plates one to the other. Welding Methods Used: Extrusion welding gun Hot-air welder, once plates are milled. Floor uniformity (for both welding technologies) is given by a weld bead of the same material (PHC) and colour. The final result is a seamless floor. Slide 22 22 This extrusion system joins PHC Liner sheets by applying the same material (PHC) via extrusion. Suitable for welds that have to endure continuous stress. Welds are tear resistant and have the same flexibility to breaking stress as the original PHC Liner sheets. Automatic fan to blow hot air, suitable for preparing PHC Liner sheets to receive the extruded material Double check for fan and extrusion chamber temperatures Teflon tip that can turn 360 Extrusion welding gun R-SB 50 to weld PHC Liner Slide 23 23 Welding material in several colours This is how the extrusion-welded Liner plates look like Slide 24 24 Welding using a hot-air welder Manual milling machine that drills a groove where the weld bead is melted Automatic welder that melts the weld bead in the groove Slide 25 25 Examples of works performed Slide 26 26 Codelco Norte - Chuquicamata Chemical processing plant for raw minerals Chemical processing plant for raw minerals Area of belt elevators Acid environment Slide 27 27 Concrete conditions in an acid environment Liner application: protection coating and insulation for the switchgear rooms. Ref. Roofing and cladding of the SwitchGear room, Codelco Teniente. Protection against acid attack and molybdenite concentrations highly polluted environment Slide 28 28 Examples of areas attacked by acids Traditional protection systems (epoxy resins) do not withstand acid attack because they do not offer an adequate barrier The PHC Liner is made using thermoplastic anti-acid copolymers, 2mm-thick layers, that offers a total anti-osmotic protection barrier Slide 29 29 SWITCHGEAR ROOM - CODELCO TENIENTE SANTIAGO REGION - CHILE Previous state: chemical corrosion Previous state: chemical corrosion Slide 30 30 SWITCHGEAR ROOM - CODELCO TENIENTE (DET) SANTIAGO CHILE PHC- Protection roofing and coating in PHC Liner PHC- Flame-spraying coating for steel parts Ambient conditions: Weather: Winter: snows from May to September ; Summer: marked thermal gradient Thermal gradient: Summer: +5 C at night; +55 C during daylight (temperature measured on coated roof) Winter: -15 C at night; + 15C during daylight Slide 31 31 SWITCHGEAR ROOM - CODELCO TENIENTE (DET) SANTIAGO CHILE PHC- Protection roofing and coating in PHC Liner PHC- Flame-spraying coating for steel parts Conditions at DET: Highly polluted environment, occasional paraffin spills, accidental material spills pedestrian walkway Winter with permanent snow; very high temperatures in Summer Accidental material spills when pipes carrying minerals break Treated material is deliberately discharged 4 times a year. Permanent contact 1 - 2 weeks each time. Components: acids, copper concentrate, float reagents Slide 32 32 SWITCHGEAR ROOM - CODELCO TENIENTE (DET) SANTIAGO CHILE PHC- Protection roofing and coating in PHC Liner PHC- Flame-spraying coating for steel parts Results after one year: No damage to coating No signs of moisture PHC Liner coating and flame- spraying coating - September 2008 Pictures one year later (September 2009) after washing Slide 33 33 SWITCHGEAR ROOM - CODELCO TENIENTE (DET) SANTIAGO CHILE PHC- Protection roofing and coating in PHC Liner PHC- Flame-spraying coating for steel parts No damage to coating and no sign of moisture Slide 34 SWITCHGEAR ROOM - CODELCO TENIENTE (DET) SANTIAGO - CHILE PHC- PROTECTION ROOFING AND COATING SWITCHGEAR ROOM - CODELCO TENIENTE (DET) SANTIAGO - CHILE PHC- PROTECTION ROOFING AND COATING Roof coated in September 2008; acid environment April 2010, 20 months later Perfectly sealed. Excellent results. No acid spray or acid rain seepage in the building Slide 35 Section of a concrete pipe directly placed into the die, using IBIX PHC Liner, cuspidal version Slide 36 PHC LINER & IBIX SuperGlue to obtain enhanced adhesion to concrete 36 Damaged concrete fixed using Kerabuild Presto PHC Liner applied on IBIX SuperGlue Slide 37 Chemical attack on concrete floor in an electrolytic line (CuSx Factory) 37 Concrete floor made in January 2010 damaged already by acid fumes and drops falling from the acid tanks installed on the floor See Figure, bottom left Slide 38 Special epoxy varnish already degrading after 3-4 months Sulphuric acid spills PHC Liner will be applied over 12 months after the tests made in constant contact with H2SO4 Slide 39 Future projects coating for water tanks for fireproof systems and concrete flooring 39 Slide 40 40 PHC Liner: practical examples PHC LINER PHC: anti-acid, anti-osmotic, eco-friendly and washable PHC for protection coatings on porous materials PATENTED PHC LINER SYSTEM PATENTED PHC LINER SYSTEM Concrete tank in galvanising plant - resistance to acids - Italy PHC Liner coating performed in December 2002 Excellent condition after about 7 years Slide 41 41 Liner applied in Bergamo, in a cold storage anteroom Alimentari Moretti Initial condition Final condition Slide 42 42 Work-with Ambient Conditions: Thermal gradient: - 0 inside the anteroom - Rooms at controlled temperature - work-with temperature was about 10 C; this temperature was obtained by keeping the anteroom door open the whole night before the product was applied. Floor underneath: - Ceramica tiles Area to cover: 28 sq.m Slide 43 43 Laying and glueing Slide 44 44 Despite the low work-with temperatures, using a hot-air blower we managed to minimise the floor rising damp and to increase the room temperature so that the glue can adhere. Welds were made 24 hours after the product was applied Slide 45 Application 45 Slide 46 MILLING BEFORE WELDING 46 Slide 47 47 Finished job Slide 48 48 LINER CLEANING Cleaning the Liner is easy and simple- just wash it on a regular basis with floor scrubber and regular floor detergent. You can also wash it with a high pressure water jet cleaner. Never use steam or hot water to wash it; in case you need to use hot water, water temperature should never be over 40. If dirt has caked onto the Liner, wash using an IBIX9 H2O sand-blaster and bicarbonate, and the Liner will not be affected. Slide 49 49 Anti-acid applications in pre-galvanising pre-processing plants (hydrochloric acid tanks) Hydrochloric acid dissolves almost any metal, and it is also the cause for concrete weakening as calcium ions are removed from the silicate hydrates that form the main concrete binders. And so, concrete becomes decalcified. On the contrary, in metals such as steel, the action of these gases leads to continuous corrosion, also inside the metal core. Over time, the floor or the supporting metal structures will undergo a slow but significant thinning process. Slide 50 50 Solution suggested Our solution is to apply a protection coating/lining, 100% insulating and acid- resistant, on the floor and the internal walls of the building. We recommend PPA571 coating to be applied on metals using a fire-spraying system, and a panel pattern (Liner) on floors. If applied on floors (PHC Liner system with gluing, once the substrate is clean). Slide 51 51 Liner applied at FRIGO GENOVA The solution suggested is a protection coating/ lining, 100% insulating and resistant to heavy traffic of forklift trucks and staff. Resistant to sudden temperature changes and that 'moves' together with the floor underneath, that does not crack or get spoiled as traditional resins. Slide 52 52 Liner applied in veterinary clinic in S.Biagio The solution suggested is a protective coating, totally insulation and resistant. Slide 53 53 Slide 54 54 DETAIL OF SKIRTING HEALTH Slide 55 55 Liner PHC Photoluminescent is proposed and used;. Reports of safety in corrosive environments. Marking of escape routes. Report any possible obstacles It has two possible versions: Smooth or slip version This pigment absorbs sunlight or artificial light and releases the fluorescent effect for several hours LINER PHC PHOTOLUMINESCENT VERSION Slide 56 52 PICTURE OF PHOTO-LUMINESCENT LINER The PHC Liner Photo-luminescent Version can be used in:. Safety signs in corrosive environments. Signs for evacuation routes. Signs warning about potential obstacles Two models available: Smooth and non-slip versions This pigment absorbs sun or artificial light, and the photo-luminescent effect lasts several hours PHC LINER - PHOTO-LUMINESCENT VERSION Slide 57 53 THE MARKET PHC Liner can be used in a wide range of applications : Chemical industries (anti-acid waterproofing coatings; safety areas non-slip anti-acid photo-luminescent version, etc.) Sewage treatment plants Textile industries where there are chemicals (textile dyes) Pharmaceutical industries Tanneries Food industries, distilleries, cellars Food storage industries Cold storage anterooms and rooms Industrial kitchens Large workshops Coatings for industrial flooring in compliance with the regulations on safety at work. Coatings on terraces, swimming pools, solariums, and any kind of surface that requires total insulation. Slide 58 54 QUESTION TIME