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| 1. Fitness for purpose |
Unique Polymer Systems offer a PAS (Product Application Survey) form for a guide to the correct product specification. This also allows alternative solutions that can be based upon further relevant
information; Cost - Effectiveness - Preferential Requirements.
Please see TECHNICAL INFORMATION DOWNLOADS for details.
Choice of product is essential, and will revolve around - Product Involved To Be Protected against - Temperature Of That Product & Abrasion/Corrosion Characteristics Of That Product.
Other essential information will also be Availability of the Application & Weather Conditions.
NEW!!
We have now introduced a feature called: ON-LINE APPLICATION ANALYSIS. If you provide the details of a proposed polymer application or repair/coating problem, then our technical experts will use that information to provide you with advice on which Advanced IPN Polymers are best suited to your requirements.
This service is online - and it's FREE!
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| 2. Joint design |
When making repairs to damaged equipment, it is essential that some thought be given to how this repair can be carried out by the use of a IPN Polymer Material.
IPN Polymer products are so versatile that "NEW" materials can be developed as needed by the end-user. Rather than "Make" end-users buy materials that are not designed specifically for their application, end-users can develop their own. An example may be where "Extreme" abrasion is being experienced. The product selected may be IPN GEL CERAMIC with ADDED Silicone Carbide Particles to act as a further deterrent against "Extreme" abrasion.
| Reinforced | Scarf | Overlap | Butt |
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Where 
designates the Polymer material being used
| Some practical examples: |
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| An example of the rubber repair of a conveyer belt, using Kevlar reinforced fabric to support the repair. |
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| 3. Surface Preparation |
A method should be chosen that:
- Will provide the required Standard of Preparation
- Will meet any of the limitations (dust free, no sparking, etc)
- Is appropriate for the Area and the Environment
CLEANING PROCESSES
BURNING: Torch is used to burn out impregnated oils from surface.
CONCERNS: Naked flame hazard.
DETERGENT / EMULSIFIER WASH: Solution is used to wash away Greases, Fats, Oils (normally impregnated). Machines are available that also "vacuum" the solution to aid drying.
CONCERNS: Disposal of washings. Moisture saturation of substrate.
SOLVENT DEGREASE: Solvents used to remove surface contamination, such as oil, fats, greases, chemicals and dust. This is normally a manual process.
CONCERNS: Solvent hazards (Fire & Toxic).
HARD SURFACE CLEANER DEGREASE: Solution used to remove surface contamination, such as oil, fats, greases, chemicals, and dust. This is normally a manual process.
STEAM CLEANING & PRESSURE WASHING: In pressure washing, solutions can be added to the reservoir tank, such as Fungicides and Degreasers.
Used to remove surface contamination such as oil, fats, greases, chemicals, and dust. May also remove rust and non-adherent coatings. Steam cleaning will also aid the release of soluble salts in steel.
CONCERNS: Disposal of washings. (If chemicals have been added to the reservoir). Moisture saturation of Substrate. (If porous). Moisture saturation of the atmosphere. (In enclosed environments). Splashing.
CHEMICAL STRIPPING: Non-abrasive method used to remove coatings. Such as paint stripper.
CONCERNS: Chemical hazards (Fire & Toxic). Disposal of washings.
ABRASIVE PROCESSES
Most of these abrasive processes create dust or debris, which will need to be removed afterwards. Some of the machines can be fitted with vacuum devices which limits the amount of dust left of the surface, and stops dust and debris effecting the working environment. Any excessive surface contamination such as grease, oil, or fats, should be removed prior to abrading. Otherwise the contamination will simply be driven further into the substrate.
WIRE BRUSH: Removes loose rust and dirt. Manual or Mechanical wire brush is a "Minimal" preparation method, (only removes loose debris and rust).
SANDING: Removes dust and scarifies softer surfaces. Hand held machines available such as Disc Abrasion (DA) machines. Very slow in scarifying hard metals.
ANGLE GRINDERS: Removes rust and coatings, and scarifies hard metals.
NEEDLE GUN: Mechanical device where a series of small rods are used to rapidly hammer at the surface creating a pitted profile. Removes rust and loosely adhered coatings. Tends to be slow.
ABRASIVE BLASTING: "Blast Media" is fired at the surface at high speed. Many types of Blast Media are available, such as:
Chilled Iron Grit
Aluminium Oxide
Steel Shot
Glass Beads
Plastic Media
Ceramic Beads
Sand
Quartz
Sponge Media
The choice of media depends upon the Material being prepared and Standard of Preparation required. Can be used over a wide variety of substrates.
Removes rust, dirt, and coatings, and provides a "Blast Profile", even on hard metals.
Many different forms are available:
Enclosed Cabinets
Automatic Units
Hand Held With Extraction - Etc.
CONCERNS: Flying debris or Blast Media.
ABRASIVE PROCESSES - FLOORING
Abrasive Techniques that are used on floors warrant their own section, as there are numerous pieces of equipment that have been specifically designed to prepare the large areas that are commonly involved in flooring work. The equipment is also often manufactured in a smaller scale version for use on smaller areas or areas where access is difficult. Some of thee modified machines can be used on walls and roofs also.
BLASTING: "Blast Media" is shot onto the surface at high speed. This is a popular type of preparation. The Blast Media tends to be Steel Shot. Can be sued to prepare for practically all coatings, over a wide variety of substrates.
Removes rust, dirt and coatings, and provides a "Blast Profile".
CONCERNS: May have difficulties preparing certain substrates, or removing certain coatings, when the surface is "Rubberised".
Equipment supplier can advise on use of blast media for specific work.
PLANER (SCABBLER): Cutting Teeth are used to gauge way the top layer of the substrate. Used over most substrates, except on Float Screeds and Flag Stones.
Very efficient at removing coatings and preparing floors which are highly contaminated. Creates a GROOVED surface in the substrate. Cutting Cylinders (Barrels) with different Shaped and Sized teeth are available.
CONCERNS: The pattern left behind will remain evident after applying thin film or high build coatings. Only screed will easily disguise this grooved pattern.
GRINDING: High-speed rotary Grinding Disks scrape away top layer of substrate. Used on most substrates, except for Steel. Removes coatings and adhesives. Leaves a smooth surface, but may leave some shallow circular marking. Machine is moved from side to side as machine travels across surface. Assortment of disks available.
CONCERNS: Difficult for Grinding Disk to make contact with total surface area on floors that are uneven.
STRIPPING (PEELING): "Chisel" head scrapes away top layer of substrate. Efficient removal of most coatings, linoleum, carpets, bitumen. Limited use in preparing the surface of the substrate.
CONCERNS: Difficult for cutting tool to make contact with total surface area on floors that are uneven. After removing linoleum and carpets, the adhesive will be left behind.
RELATIVE WORKING RATES
The working rates of these machines vary greatly depending upon substrate type, substrate quality, and the level of preparation required.
| RELATIVE WORKING RATES | ||
| Preparation Equipment | Concrete | Steel |
| Floor Blasting - 250mm width | 80 - 120m2/hr | 20 - 40m2/hr |
| Floor Diamond Grinder - 250mm head | 15 - 30m2/hr | - - |
| Floor Planer - 200mm width | 10 - 30m2/hr | - - |
| Hose Vacuum Blast | - - | 3 - 5m2/hr |
| Open Hose Blasting | 15 - 20m2/hr | 7 - 10m2/hr |
| Open Hose Wet Blasting | 15 - 20m2/hr | 7 - 10m2/hr |
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Abrasive blasting (Aluminum Oxide is better than sand) - Angular Blasting Material Only.
| < - - not acceptable - - > | ||
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| Steel where mill scale has started to rust and flake | Brush off cleaning - SA-1 | Commercial blast cleaning - SA-2 |
| ACCEPTABLE | BEST |
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| Near-white blast cleaning - SA-2-1/2 | White metal blast cleaning - SA-3 |
A SMOOTH surface is NOT the REQUIREMENT.
Select abrasives that can achieve the necessary standard of minimum depth of PROFILE at 3 mils (75 microns). The standards used by the industry are ISO 8501-1 Sa 2 1/2 = VERY thorough BLAST Cleaning. (US Standard NEAR WHIT FINISH SSPC SP10 - Swedish Standard Sa 2 1/2 SIS 05 5900)
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SALT WATER APPLICATIONS
Metal surfaces that have been immersed for any periods in SALT SOLUTION (i.e. Sea Water), should be blasted to the required standard, left 24 hours to allow ingrained SALTS to sweat to the surface and then WASHED prior to a further BLAST to remove these. This process may be needed to be REPEATED to ensure the REMOVAL of ANY SALTS.
CONCRETE
Blast clean or MECHANICALLY scarify the surface to remove ALL loose materials and surface laitance. All old coating / paint / tar etc should be removed. Finished surface must be CLEAN & DRY. Wash old concrete down with detergent to remove any remaining OIL / GREASE / DUST. Use CLEAN water to wash away detergents &/or ACID from ETCHING the surface.
If NEW concrete application, allow 28 days to cure or until the MOISTURE content is below 6%.
Other methods of preparation that can be used if BLAST Cleaning is not available:
- Grinding
- Acid Etching (Hcl @ 4/1 with water - spread @ 1 liter per m2 - RINSE & DRY)
- Hand Cleaning
NOTE:
No STANDING water on application PRIOR to coating. DAMPNESS on substrate can decrease the physicals of the coating material.
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| 4. Mixing the Product |
Always check the labels on the containers to verify BASE:SOLIDIFER volume ratios.
If PART using BASE:SOLIDIFER - ENSURE that the mixing implements (Spatula) do NOT come into contact with EACH other in the product containers as this will cause a reaction and make the reaming product un-usable.
Double mixing - after initial mixing on either mixing board or container - move mixed product to new board / area on board and re mix with clean mixing implements. If being mixed in a container, pour into new container and re mix with new mixing implements. This ensure that ALL product is mixed and that there is no UNMIXED material left on either the mixing medium or mixing implements.
A common source of error: Un-mixed material left on container wall / bottom. Un-mixed material on the blade of mixing implement.
When mixing the PASTE type products, then when asked for a ratio of say 3:1, eyeball assessment is satisfactory.
Solidifier is always a ratio of :1.
| RATIO OF 1 : 1 |
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| RATIO OF 3 : 1 |
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| Mixing with a spatula |
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| 5. Application |
Always use IPN CLEAN AID to wipe re-blasted surfaces before applying Advanced Polymer IPN PRODUCTS.
This will also be the case if you have to RE-PREPARE a previously coated surface that has cured.
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When applying TWO coats, the second coat is applied when the first coat is TACKY to the touch. If the first coat has cured then BRUSH BLAST and use CLEAN AID as above.
Gloves should be worn in all applications to avoid product on hands as well as to preventive grease from unprotected hands getting in contact with the coating material.
Every effort should be made to apply the first coat within 1 hour (as soon as possible) after wiping with CLEAN AID - this to prevent flash rusting on metal equipment.
EXCEPTION to second coat onto WET surface is IPN ELASTIC MEMBRANE. The SECOND and any subsequent coats are applied onto a DRY surface.
Care should be taken when planning the application to ensure that timing is relevant to your working conditions as well as POT LIFE of the product being used.
ALL INFORMATION IN DETAIL is supplied on the Advanced Polymer ENGINEERING and APPLICATION DATA SHEETS. Please see TECHNICAL INFORMATION DOWNLOADS.
Recommended product thickness - number of coats recommended and coverage per packaged unit are available form the above detailed sheets that will accompany your product. Please consult with your Advanced Polymer sales specialist / application engineer for further information.
Thickness Measurements
1 Inch = 1000 mils = 25.4 mm
1 mil = 25 microns
4 mils = 100 microns = 0.1 mm
8 mils = 200 microns = 0.2 mm
16 mils = 400 microns = 0.4 mm
1/16" = 62.5 mils = 1.6 mm
1/8" = 125 mils = 3.2 mm
1/4" = 250 mils = 6.35 mm
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| 6. Curing |
The curing of product can be split into three categories as follows:
Normal - Post - Shock
Normal cures are carried out at room temperature (15oC - 35oC) check in the Advanced Polymer Engineering and Application data sheets.
Post application of high heat ALWAYS AFTER NORMAL CURE AT ABOVE TEMPERATURES has been established.
Shock high heat to early. NEVER apply HIGH HEAT until NORMAL cure AT ambient temperatures has been achieved.
How to POST CURE
Seal the object to be POST CURED from the surroundings as follows:
1. Close all doors and windows etc - if it is a room. Close the gates, valves, hatches, lids etc. - if it is the interior of a piece of equipment. Erect a make shift tent around it, if it is the exterior of a piece of equipment, or use other such techniques as make themselves available.
2. Apply heat in a stepwise manner:
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12 + hours @ ambient temperature +
4 hours @ 50oC +
4 hours @ 70oC +
4 hours @ 90oC
Or if you do not have the capability of stepwise heat build up, and have only say 70oC available, then apply this heat for a longer period of time: 24 hours.
WHY WE NEED TO POST CURE
Post cure energizes the molecules and causes the polymer chains to weave a tighter network via cross-links. All of this increases the heat resistance and chemical resistance of the polymer. Post cure is good for you, though not always required or even justified. So go on a case by case basis or ask your local distributor for more information.
BENEFITS OF POST CURE
Increased performance (10-50% depending on type of post cure and property).
WHEN TO CONSIDER POST CURE
When service temperature or chemical resistance requirements are "Borderline cases.
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| 7. Service Conditions |
It is important for long service life to NOT exceed the design specifications of the polymer product.
One of the ADVANTAGES of using IPN POLYMER is that they far exceed the competition when it comes to both CHEMICALS and TEMPERATURE.
ALL IPN products, unless specified, will take you to the following: Further applications involving temperatures well in excess of the below are coated with UPS S.M.A.R.T. High / Low temperature products.
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WET temperature limits of Polymer: 93oC (Example - interior of pipe)
DRY temperature limits of Polymer: 204oC (Example - exterior of pipe)
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| 8. Inspection and Touch Up |
Advanced Polymer IPN products can all be repaired if required after initial service use. If you are repairing then all the applications steps should be carried out as if a new application on the area that you want to repair.
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