Corrosion of plant & equipment is an inevitable occurrence at some point during operations of a company involved in mining, power generation, water or oil and gas. For Maintenance Engineers, the challenge has always been how to mitigate the impact of corrosion on production and plant up-time. One thing for sure is that the loss of productivity, incurred as a result of equipment down time due to corrosion or component wear and tear, translates into an irretrievable revenue loss.
Corrocoat Southern Africa is aware that some organisations, experiencing reduction of revenue due to the impact of COVID-19, may be tempted to cut costs when selecting products used in corrosion protection applications. Considering this, the company’s Johannesburg Branch Manager Richard Collins, is reminding maintenance managers to be aware of inferior products which may appear to available at bargain prices, underlining the importance of using quality products like Plasmet ZF.
SO, WHAT IS PLASMET ZF?
PLASMET ZF is a glass-flake reinforced, re-coatable & surface tolerant Epoxy Primer / coating manufactured by Corrocoat, incorporating a rust inhibitor, passivator and micaceous iron oxide (MIO) as well as glass-flake platelets for increased barrier protection and is manufactured according to ISO: 9001:2008 Standard.
The PLASMET ZF Epoxy coating is superior to many epoxy primers and coatings available in the market, as the product also contains micro-glass flake which improves the product’s permeation resistance to moisture vapour by creating a tortuous path within the coating as well as offering superior surface tolerance and outstanding abrasion resistance. The surface tolerant epoxy coating can also tolerate residual moisture.
Owing to its surface and moisture tolerance, PLASMET ZF can be applied on rusted, damp steel as well as previously galvanised surfaces. In addition, the passivator in the resin system converts any existing rust into a passive film which inhibits further rusting, as well as offering barrier protection against diffusion of corrosive vapours or liquids into the coating and down to the substrate. PLASMET ZF can also be used to offer superior chemical resistance for atmospheric and some immersed corrosion conditions; does not contain sacrificial bulking pigments such as aluminium which degrade over time and most existing firmly bonded coatings can be tolerated and overcoated with PLASMET ZF.
PLASMET ZF can be sprayed with conventional (pressure pot) equipment, airless-spray equipment and can also be hand-applied with a brush and roller. PLASMET ZF can be applied over substrates with minimum surface preparation, and also on flash-rusted or water-jetted surfaces, on its own or over-coated with a wide range of topcoats.
It is a tough, durable coating which can handle high atmospheric humidity during application and is tolerant of vehicular traffic. It is not necessary to overcoat PLASMET ZF, except for aesthetic purposes and is available in a limited range of colours. The surface is protected from excessive UV degradation by the refracting and reflecting properties of the micro glass platelets embedded in the resin system. However, as with all epoxies and albeit much slower, it will chalk when exposed to UV light over an extended period of time.
In terms of future maintenance and flexibility, PLASMET ZF remains overcoatable for extended periods, and can often be over-coated years later by merely water scrubbing and degreasing the surface. The resin is protected against UV attack by the glass flakes, which prevent deterioration of the resin binder after the surface layers have chalked.
PLASMET ZF is normally applied at DFT’s of 100 – 150 µm per coat, for light atmospheric duty, or 2 coats at 100 – 150 µm per coat in aggressive atmospheric or immersed conditions.
HOW GOOD IS IT REALLY? (NORSOK APPROVAL)
PLASMET ZF has been exceeding industry expectations in terms of product performance for 30 years.
The NORSOK standards were developed by the Norwegian petroleum industry to ensure the safest and most cost-effective products in engineering, manufacturing and maintenance of structures in the oil and gas industry. To achieve the NORSOK 501 standard, a coating system must demonstrate particularly high levels of protection with a minimum need for future maintenance and low environmental impact.
After six-month long exposure tests for cyclic ageing, seawater immersion and cathodic disbondment, the PLASMET ZF coating performed extremely well, passing all tests prescribed to meet or exceed the NORSOK 501 Standard.
PLASMET ZF was tested against System 1 – use on carbon steel with a max operating temperature of <120 °C – structural steel, equipment exteriors, vessels, pipework and valves (including in tidal and splash zones); and System 3B – internal surfaces of carbon steel vessels – ballast water tanks/internal seawater filled compartments.
The NORSOK testing was conducted by SGS, an independent inspection and testing organization. SGS commented that the results on the cathodic disbondment tests were “exceptional” reporting that they could not even get a knife blade between the coating and the steel after 175 days on test.
“Corrocoat specialist paints and coatings have been used for years in demanding corrosion protection applications throughout the world,” said Sales Director Rob Cole. “NORSOK approval is unbiased confirmation of PLASMET ZF’s performance and confirms our position as a leading provider of corrosion protection and engineering services to the offshore and marine as well as mining, water and power generation industries. Our customers now have an added level of confidence that PLASMET ZF will meet their toughest requirements.”
SO WHAT’S NEXT?
The Corrocoat range of glass-flake corrosion protection materials has a global reputation for excellence and as a world-wide Company Corrocoat certainly takes pride in holding the mantle for innovation in Corrosion Protection.
As a global ‘first’, Corrocoat are very proud to announce that the twin-pack PLASMET ZF epoxy coating is now available in an ‘all-in-one’ 400ml aerosol spray can, aimed at offering superior corrosion protection with easy application in difficult to access areas and for precise touch-up work.
Application with PLASMET ZF aerosol takes much less time when compared to traditional hand-application; it also ensures that every inch of the surface is covered – even deep areas and hard to reach nooks and crannies which might otherwise be missed.
Other key benefits include even coverage, minimal surface and material preparation; there is no longer a need to mix components on-site from separate containers, and no clean-up requirement afterward. In addition, once opened, the aerosol has a long pot life – at least 24 hours, meaning the user has time to complete a number of jobs across a site or installation.
With so many ease of use and convenience benefits, a PLASMET ZF aerosol will soon have a place in every service engineer’s tool bag – giving fast, effective corrosion protection… in an instant.