A&E SYSTEMSHIGH PERFORMANCE

ANTI-CORROSION TOOLBOX

A&E SYSTEMSHIGH PERFORMANCE ANTI-CORROSION TOOLBOX

EUROPEEUROPE

NORTH AMERICANORTH

AMERICA

A&E has offices in four major centres

AUSTRALASIA

AUSTRALASIA

MALAYSIAMALAYSIA

Alocit coatings have a long history of problem solving around the world • HARD WEARING• EASY TO APPLY• ON WET & OILY SURFACES• CONCRETE OR STEEL• RESIST MIC & ALWC• LAST UP TO 30 YEARS

In a wide variety of industries

• ON AND OFFSHORE• MARINE INSTALLATIONS• GOVERNMENT & UTILITIES• MILITARY

When we say ‘wet surfaces’, we really mean it! This diver is applying Alocit 28.15 to a submerged pipeline in salt water, using a pumped plural component system, feeding through a specially designed short-bristled brush attachment

In the Mediterranean on a gas platform in the splash zone

In the Pacific along sweating pipes on an oil rig

Under the Pacific by Argentinian divers

In Taiwan on 40,000 sq yards of piles

In Malaysia under the Petronas Towers

In Germany on tunnels and floors

In Holland on ballast tanks and hulls

In Britain on sheet piles and floors

In Singapore on the Rapid Transit System

Applications around the World

In Malaysia on wet surfaces after water-jetting

Large SBM in tropical marine conditions requiring complete refurbishment used Alocit primer and second coat with PU topcoat above waterline

Water jetting with garnet was used to prepare surfaces – with painters following immediately after – Shell engineers estimated 30% cost saving using Alocit

A full testing regime was carried out. Pull off showed 1200 p.s.i. adhesion after w/jetting

And in the United States …

In Alabama and New York Harbour on sheet piles

Chosen by contractors because Alocit 28.15 adheres so strongly and is surface tolerant, with no need to worry about oil or water contamination

Alocit coatings have been in use by the Port Authority of New York and New Jersey for many years – on tunnels, airports and sheet piles in the harbour

The video shows a short extract from underwater footage taken by a contractor

Shell in Texas on sweating pipes

Competitive testing by Shell to find the most suitable coating for application on to cold pipes (34°F), streaming with water in the warm Gulf climate, found Alocit 28.15 to be the most suitable coating for such situations. Following testing, Alocit was given global approval by Shell

US Army Corps of Engineers

Alocit is one of only three coatings listed by USACE as meeting its criteria for application on wet areas – and it’s the only one of the three that can be applied underwater!

Dupont

Used for encapsulating PCBs and other harmful contaminants in concrete. Tested by United Power Services using EPA protocols, following coating with Alocit, PCB levels at the surface were below detectable limits

National Oceanic and Atmospheric Administration

On the Oregon ll in Louisiana, on ballast tank, bilge areas and the machinery room deck.

Preparation was by machine tools and blasting followed by coating with 28.15 gray, white and red

Alocit coatings have zero VOCs and paint inspectors commented on the odor-free atmosphere during coating works on the Oregon

USS Detroit

Full scale test application in the Port Shaft Alley Bilge completed in 2000 as part of the NAVSEA approval process. Follow up inspection by CES for NAVSEA in 2001 found the Alocit 28.15 coating to be ‘performing flawlessly in severe service’

The finished Port Shaft Alley bilge

area

Bilge Preservation – ALOCIT 28.15

Surface preparation: SSPC SP-11 Power Tool Cleaning to bare metal.

Coating Application: (All material is ALOCIT 28.15 in 3 colors)

Bilge area:Prime coat White 5-7 mils WFT/DFTStripe coat Gray 5-7 mils WFT/DFTFinish coat Terracotta 5-7 mils WFT/DFT

Above Bilge:Prime coat Gray 5-7 mils WFT/DFTStripe coat White 5-7 mils WFT/DFTFinish coat White 5-7 mils WFT/DFT

The subcontractor, UCC, was tasked to provide the in-process OA. Since the CES representative was on hand throughout the process, the OA became a joint effort that produced very satisfying results with no surprises. SUPSHIP attended all checkpoints and validated the results. The test application was successfully completed with the Shaft Alley turned over to Ship's Force in April 2000.

The shaft alley was surveyed May 2001 while USS Detroit was at home port at NWS Earle, NJ.

The Alocit Aquacoat coating system is in immaculate condition with no deterioration of any kind noted

There is standing salt water in the sump area and some mold and mildew growing (the ventilation in this space is poor). There was no corrosion of any type noted. Much of the steel in this space (bilge) is heavily pitted and without this re-preservation would be holed through (some steel replacement was accomplished in conjunction with the re-preservation in 2000).

Bilge Preservation – ALOCIT 28.15

Surface preparation: SSPC SP-11 Power Tool Cleaning to bare metal.

Coating Application: (All material is ALOCIT 28.15 in 3 colors)

Bilge area:Prime coat White 5-7 mils WFT/DFTStripe coat Gray 5-7 mils WFT/DFTFinish coat Terracotta 5-7 mils WFT/DFT

Above Bilge:Prime coat Gray 5-7 mils WFT/DFTStripe coat White 5-7 mils WFT/DFTFinish coat White 5-7 mils WFT/DFT

The subcontractor, UCC, was tasked to provide the in-process OA. Since the CES representative was on hand throughout the process, the OA became a joint effort that produced very satisfying results with no surprises. SUPSHIP attended all checkpoints and validated the results. The test application was successfully completed with the Shaft Alley turned over to Ship's Force in April 2000.

The shaft alley was surveyed May 2001 while USS Detroit was at home port at NWS Earle, NJ.

The Alocit Aquacoat coating system is in immaculate condition with no deterioration of any kind noted

There is standing salt water in the sump area and some mold and mildew growing (the ventilation in this space is poor). There was no corrosion of any type noted. Much of the steel in this space (bilge) is heavily pitted and without this re-preservation would be holed through (some steel replacement was accomplished in conjunction with the re-preservation in 2000).

What make Alocit so great?

You can apply it on the wettest of surfaces

As you can see from these flange bolts, from an application to pipework running at 38°F on an industrial cooling system, underground at KLCC in Malaysia

It gives fantastic adhesion

Tests on the Detroit showed adhesion beyond the ability of the testing equipment they were using (above 1000 p.s.i.)

Use it straight after water-jetting

Independent comparative testing, using coatings on surfaces exclusively prepared using ultra-high pressure water-jetting, showed Alocit to be have nearly twice the adhesion of its nearest rival. NAVSEA PPIs allow Alocit 28.15 to be used without drying surfaces

What make Alocit so great?

It can be used on oily surfaces

Oil-soaked bund areas, which might otherwise have to be rebuilt, can be coated with Alocit, preventing escape into the environment. On the right is the floor of a railroad maintenance tunnel in Switzerland, covered in oil before being coated with Alocit. The video shows Alocit being applied to oily concrete – underwater!It is very hard wearing and long-lasting

The Dutch Navy use Alocit because it last so well in its tanks – even where constant high pressure flows would abrade lesser coatings. In Germany, on water treatment plants, case histories show more than 30 years constant use in aggressive waste water without deterioration

Testing

For MIL-SPEC 23236C

• Gloss • CP Compatibility • Drying or cure time • Flash point • Brush & Rolling Application • Dedicated seawater service • Sag resistance • Edge coverage• Resistance to condensing water • Ultraviolet fluorescence • Adhesion-surface tolerant coating • Adhesion-bilge coating • Pot Life • Hazardous pigments

Testing by DNV gave Alocit the highest possible rating (B1). This included application on pre-rusted and steel wire brushed/high pressure washed, pre-rusted & hydro-jetted as well as moist test panels

Testing

For use with Cathodic Protection

By DNV on test plates in Norway and Zinga in Korea on round steel piles. Alocit has been used in conjunction with CP systems for many years with no reported failures

Long-term immersion following underwater coating

By German State testing agency on samples in the North Sea, coatings performed underwater on steel panels at two year intervals. Inspection after 6 years immersion showed no deterioration, despite the need to chip off extensive marine growth

On test plates coated underwater for Brazilian National Oil Company (PetroBras):

480 hour salt fog (ASTM B117-73): No corrosion - no penetration of corrosion from scribe

Exposure to environment with an air humidity 85% (underwater and in the range air/water) for 1000 hours (NBR 7351): no corrosion

40°C salt water immersion (ASTM D1308): 360 hrs - no corrosion,1000 hrs - no corrosion

Testing for use in tropical marine conditions

Testing

LPM Swiss Testing

Many tests have been performed by LPM for Alocit over the years, those shown are a summary of standard tests

Testing

Alocit primer based system on fresh pre-cast concrete

Undertaken by the contractor for the Singapore MRT in order to show that, using an Alocit primer, steam-cured concrete casting sections for the MRT tunnel could be coated within minutes, without waiting for the concrete to dry.It would normally be necessary to wait for the moisture content of the concrete to fall below recommended levels in order to coat. Removing the waiting and consequent storage and extra handling brought major cost savings.

Practical matters

The Alocit System

Alocit 28.15 is a two-component epoxy coating. 100% solids and VOC free, it can be applied using brush, roller or spray (airless or using dual-component pump)

It is supplied as standard in 1.2 kg and 3 kg packs, supplied as kits with hardener and base pre-measured for mixing

Standard White, Black and Gray are available from stock plus Fed Std 595 Green, Gray, White, Red, Light Gray & Black RAL and other international standards to orderA high standard of quality control, monitoring color consistency and application quality, is at the heart of Alocit’s ability to outperform its rivals. Uniquely engineered to adhere on the most challenging substrates, while at the same time maintaining a level of usability without sacrificing environmental standards

QUALITY CONTROLCOLOR CONSISTENCYAPPLICATION QUALITY

Where you can use it

Dry, wet or moist surfaces

On steel or concrete

On oily surfaces

In fresh or salty water

Down to temperatures of 4°C

There is no limit to the amount of water that can be on a surface to which Alocit 28.15 can be applied

From an operator’s point of view, excess water may affect his or her ‘comfort zone’ but coating adhesion will be unaffected

There is no limit to the amount of water that can be on a surface to which Alocit 28.15 can be applied

From an operator’s point of view, excess water may affect his or her ‘comfort zone’ but coating adhesion will be unaffected

Actually, Alocit can be applied to steel, concrete, plastic, wood and many other substrates, but is normally used on steel for corrosion protection and on concrete as a finishing coat, sealant and moisture barrier

On concrete, more than 30 years coating performance has been achieved and on steel, a ten-year life expectancy would normally be expected

Actually, Alocit can be applied to steel, concrete, plastic, wood and many other substrates, but is normally used on steel for corrosion protection and on concrete as a finishing coat, sealant and moisture barrier

On concrete, more than 30 years coating performance has been achieved and on steel, a ten-year life expectancy would normally be expected

Alocit being applied to a very

wet surface!

Alocit has been used here to coat

an old concrete floor!

Although Alocit can be applied on to steel surfaces with residual oil, this is unusual because it is quite easy to remove from steel

On concrete, however, steel will soak into the substrate, making it impossible to remove with normal cleaning and preparation techniques. Using Alocit, surfaces, such as gas station and factory floors, that have years of ingrained oil, can still be recoated

Although Alocit can be applied on to steel surfaces with residual oil, this is unusual because it is quite easy to remove from steel

On concrete, however, steel will soak into the substrate, making it impossible to remove with normal cleaning and preparation techniques. Using Alocit, surfaces, such as gas station and factory floors, that have years of ingrained oil, can still be recoated

Despite the terrible conditions in this

rail tunnel – oil-soaked concrete as

well as damp and cold, Alocit was

applied successfully

Although salt is usually thought to be a problem for coating performance – with Alocit, whether there is salt in the water or not, it makes no difference. And, of course, Alocit can be applied underwater and in the splash zone as well as it can above water – even straight from the can!

Although salt is usually thought to be a problem for coating performance – with Alocit, whether there is salt in the water or not, it makes no difference. And, of course, Alocit can be applied underwater and in the splash zone as well as it can above water – even straight from the can!

As long as the temperature is above freezing, Alocit will cure, but, for practical purposes, 3 or 4 degrees extra are needed for sensible curing times and application quality – especially when using underwater

As long as the temperature is above freezing, Alocit will cure, but, for practical purposes, 3 or 4 degrees extra are needed for sensible curing times and application quality – especially when using underwater

A typical problem substrate requiring Alocit’s

applicability in low-temp, damp conditions. On

pipework carrying ice-cold cooling system water in the

tropics, suffering from extensive under-insulation

corrosion

Application

General guidelines

Above water, Alocit 28.15 can be applied using brush, roller or spray equipment. Spraying can be either by airless sprayer (Graco King) or dual-component pump (Hydra-cat)

Below water a brush must be used but powered brush systems are available for covering large areas, these can be either single or dual-component units

Wet substrates

Particular attention must be given to providing a suitable profile during preparation for wet surface application with a minimum 2 mil profile. Brush strokes, preferably using a round short-bristled brush, should be firm, using a circular motion.

The material will cure underwater at the same speed as it does above – the main criterion being temperature.

The video show NZ Navy divers applying Alocit to a damaged prop shaft

Application

Contaminated substrates – oil & salt

As with all coating systems, Alocit requires that the substrate be sound and free from poorly adherent coatings or loose material. The same general principles apply to coating on oily or salty substrates. Residual oil is acceptable, but if you try to coat over pools of oil you will not succeed – a wash to remove these is just common sense.

The same applies to salt contamination, surfaces that have been in contact with salt water, even for long periods will not be too salty to coat with Alocit, providing they meet other normal preparation standards – profile etc. Salt crystals and other loose solids should be removed in the normal way – in most cases normal preparation will reduce salt to perfectly acceptable levels without any special consideration being given for their reduction before coating with Alocit.Conclusion

No coating can be all things to all men, but, if you want a hard-wearing coating with outstanding adhesion, low odor and exceptional surface tolerance – then Alocit 28.15 fits the bill perfectly. 100% solids, with zero VOCs, it meets the highest environmental standards without compromising on performance or usability.

HARD WEARING • SURFACE TOLERANT • COST-EFFECTIVE • ENVIRONMENTALLY FRIENDLY

The Enviropeel system is a very simple concept, designed to solve a very complicated problem – corrosion in complex steel systems, such as flanges and valves.

Rather than deal individually with the many causes of such corrosion, it takes a whole system approach, providing both a barrier to corrosion and an environment in which corrosion cannot take place.Enviropeel uses a unique, corrosion-inhibiting thermoplastic which encapsulates the target substrate in a perfectly-fitting protective outer layer.

Not only will Enviropeel prevent corrosion taking place, but it will also stop any corrosion that happens to already be in the system being coated. It is easy to remove and can be re-used without waste.

PROTECTS EVERY PART OF THE FLANGE

Here is a sorry example of what can happen despite the best efforts of engineers to provide protection.Although caps have been used to protect the bolts - they are not protecting anywhere else - and they are not even possible to use on all the boltsCaulking has been used to try and protect the flange faces – but it has shrunk back, creating the perfect environment for moisture to get in and corrosion to accelerate!And you have to feel sorry for the allen bolts at the base – they have no chance. Streaming rust from the structure above, galvanic corrosion from the various metals in the system – and a perfect collection point in the top of each bolt, apparently designed to collect water and generate corrosion!THERE IS A BETTER WAY!

Moisturepenetrate

s

Differentmetals

Corrosiontakes hold

Corrosiontakes hold

The Problem

Bolted systems are vulnerable to galvanic corrosion because they contain a variety of components, often of quite different materials – stainless steel flanges with carbon steel bolts, for example. Gaps and voids bring pitting corrosion, assembly damages coatings - and washers often fail.

Moisturepenetrate

s

Differentmetals

Corrosiontakes hold

Corrosiontakes hold

Bolted system constructed from dissimilar metals

Enviropeel coating prevents ingress of moisture

Built-in inhibitors penetrate all surfaces preventing any corrosion

The Problem

Bolted systems are vulnerable to galvanic corrosion because they contain a variety of components, often of quite different materials – stainless steel flanges with carbon steel bolts, for example. Gaps and voids bring pitting corrosion, assembly damages coatings - and washers often fail.The Solution

Enviropeel isolates and encapsulates, depriving corrosion of the moisture it needs and bathing the entire system in corrosion inhibitor, actively preventing rust.

Keep flanges good as new …

If you’d prefer your bolted systems to stay serviceable, never need to cut away a rusted bolt again and keep your assets intact - then you need to protect the whole system with Enviropeel.What not to do …

It seems obvious to say – don’t let your valves get into the same state as the example pictured here!This is an example, taken from a rig in the North Sea run by an international and well-respected oil company. Because there has been no simple solution for such problems, they are quite frequently left until replacement is required. Then, the bolts are cut away, the old component is discarded and a new one fitted, only to suffer the same fate.

You need Enviropeel!

Coat the whole system …

For maximum protection (yet with full access at any time – don’t forget how easy it is to remove and replace Enviropeel), you can encapsulate the complete structure – this valve, for example, will be as good as new if you ever have to remove the coating

Or protect the most vulnerable areas …

Sometimes it may only be necessary to protect those areas most likely to suffer from corrosion – threads, bolts and flange faces – areas that may never be successfully painted once the flange is assembled.

A perfectly fitting active barrier …

Enviropeel wraps itself round every contour and flows into every crevice - while active corrosion inhibitors are released on to every surface. Bolts, threads and washers are preserved, whatever their size and no matter how close they are to each other.

These flanges are completely protected – sealed away from their environment in a corrosion-inhibiting cocoon of Enviropeel.

Enviropeel is applied using a specially designed heating and pumping unit. Here we can see a standard Enviropeel unit being used on gas lines in Canada- the 35-foot hose allows easy access to all areas.

How the unit works

The diagram shows a simplified layout of the Enviropeel unit. The unit consists of three main elements: the chassis, the melting unit and the hose. The melting unit, made up of the microprocessor, heating tank and pump, controls the whole system. The hose and spray gun also contain heating elements controlled by the central microprocessor.

Material is entered into the heating tank, where it becomes a liquid. Once heated, new material can be added to the tank as it is used without interrupting the spraying operation.

How the unit works

The diagram shows a simplified layout of the Enviropeel unit. The unit consists of three main elements: the chassis, the melting unit and the hose. The melting unit, made up of the microprocessor, heating tank and pump, controls the whole system. The hose and spray gun also contain heating elements controlled by the central microprocessor.

The liquid Enviropeel material is pumped through the heated hose and gun and on to the substrate where it immediately

cools to a solid. The video shows the basic process – adding material, spraying, recycling waste material and how simple it is to strip away for access

How the unit works

The diagram shows a simplified layout of the Enviropeel unit. The unit consists of three main elements: the chassis, the melting unit and the hose. The melting unit, made up of the microprocessor, heating tank and pump, controls the whole system. The hose and spray gun also contain heating elements controlled by the central microprocessor.

Enviropeel material is supplied chipped in resealable containers. It is placed in the heating tank, melted, then sprayed on to the substrate, where it immediately forms a perfectly fitting, long-lasting barrier to all corrosion.

Surface preparation needs only to be a wire-brush removal of loose and flaking material – existing rust can be safely coated as Enviropeel’s built-in inhibitors will stop any further corrosion taking place.

Spraying starts at the bottom, working up, to be sure of completely sealing in the substrate. Note the collecting trays – waste Enviropeel can be reused in the heating unit.

Originally conceived as a repair unit for existing applications, the Slugger 170 has proved itself equal to a number of tasks. A rugged and capable performer, the ‘Slugger’ has been used on US Coastguard vessels, in the outback of Australia and on small projects in many other parts of the world

Making your own bolt caps is easy!

THE SLUGGER 170 HAND UNIT

The ‘Slugger’ is seen here protecting new

bolts after an Enviropeel protected bearing housing has

been installed

After 3000 hours in a hot salt fog, it is no wonder the unprotected mild-steel test flange is so corroded. Yet, when the Enviropeel was removed, the substrate was completely unaffected – no rust, with bolts and nuts as shiny as when they were first assembled!

AMAZING PROTECTION!

On the right, after years of exposure to the harsh, tropical marine atmosphere of the West Australian coast, this gear shaft emerges from its Enviropeel coating without a blemish

CASE HISTORIES – OFFSHORE NORTH SEA

Offshore in the North Sea, oil and gas platforms face the worst possible conditions. For three years now, Enviropeel has played its part in protecting flanges and valves throughout the Britannia platform, a large gas platform off the north British coast.As a result of its experience here and on other asset maintenance projects, Enviropeel has developed a tagging system that collects individual data for each application. Data collection on the Britannia is also part of the joint Enviropeel, BP, ConocoPhilips and DNV bolt testing program.

CASE HISTORIES – US COASTGUARD

Over the past few years a number of trials have been undertaken for the US Coastguard, using both the small handheld Slugger 170 unit and the full-size unit. The USCGC Kukui undertook a full scale sea trial employing a wide range of applications in Hawaii – the trial was 100% successful.

CASE HISTORIES – HONG KONG

An unusual request was received by Enviropeel for assistance on a new bridge in Hong Kong. Problems with galvanic corrosion in the bridge’s bearing bolts needed an innovative solution to prevent further deterioration. Enviropeel was chosen for its ability to provide direct corrosion inhibition in the targeted areas.Although access was difficult – more than 1000 machine movements were required – the project was successfully completed.

CASE HISTORIES - AUSTRALIA

In West Australia Enviropeel has transformed the mining industry’s approach to maintenance and storage. For BHP Billiton and Rio Tinto, using Enviropeel eradicated failures in stored equipment and increased the life of conveyor bearings in extremely aggressive conditions from 9 months to more than four years.

The old and the new – and how they look after using Enviropeel protection!

On stored conveyor pulleys• Return for replacement without Enviropeel 44.5%• Failure rate with full Enviropeel protection 0%

On operational pulleys – No bearing has failed since Enviropeel applied, previous average only 9 months!• Average bearing life in original trial location: 9 months• Current bearing life in original trial location with Enviropeel applied: 48+ months• Resulting component life increase: 500+%• Resulting saving in pulley changeout costs: 500+ %• Reduction in maintenance costs: 95 %• Percentage of Enviropeel costs to rebuild costs: 10-15 %• Percentage of Enviropeel costs to pulley change out costs: 5-7 %• Resulting percentage reduction in risk exposure: 90+ %• Anticipated increase in component lifetime: 500 %

AMAZING RESULTS

The innovation and cost-savings achieved by the use of Enviropeel for BHPB and Rio Tinto won the WA Engineers Australia Engineering Excellence Award in 2005

COMPARING SYSTEMS - Painting

Paint has no answer for a problem like this – although it has been tried many times as you can see in the picture on the right!

COMPARING SYSTEMS - Painting

A typical capping and sealing process might involve 11 separate labour-intensive stages:

1. Surface preparation2. Corrosion resistant paint application3. Wrap flange with pipeline tape4. Prepare injection and overflow vents in tape5. Heat and inject synthetic wax6. Extract excess wax7. Remove tape8. Spray bolts and nuts with anti-corrosion fluid9. Prepare and fill rust-converting compound10. Allow to cure11. Fix caps to nuts and studs

The Enviropeel process has only 2 stages:

1. Surface preparation2. Encapsulation

11SEPARATE

STAGES

ONLY 2 STAGES

COMPARING SYSTEMS

The tape wrap system on these stored conveyor pulley bearing shafts has clearly failed – and doesn’t offer protection to the whole system. Even if it had worked on the shaft, the corrosion on the unprotected housing shows that it could not protect everywhere it was needed.

COMPARING SYSTEMS

Petrolatum Tapes

Evidence of corrosion was clear on the shaft face and along the threads.

The sticky tape residue could only finally be removed using high VOC cleaning fluids and a considerable amount of time.

On a similar pulley to the example in the previous slides, Enviropeel has been applied to bearing and shaft. Enviropeel, however, protects the shaft AND the housing – and is very easy to remove without using solvents.

What about Enviropeel?

Enviropeel is easy to remove, with no mess – and no waste! You can seal the removed material back on to the substrate – or recycle it through the application unit.

• ENVIRONMENTALLY FRIENDLY - NO VOCS - NO WASTE

• EASY TO REMOVE FOR ACCESS & SERVICING

• PROTECTED BOLTS EASY TO UNDO

• REMOVED MATERIAL CAN BE RE-USED AGAIN & AGAIN

• PROVIDES REACTIVE AND PRO-ACTIVE SOLUTION

• ACTIVE AS WELL AS PASSIVE ACTIVE PROTECTION

• STOPS ALL KINDS OF CORROSION

• USED BY MAJOR MINING & OFFSHORE COMPANIES

• SMALL, COST-EFFECTIVE APPLICATION TEAMS

• REDUCED RISK OF ACCIDENTS & SYSTEMS FAILURE

• COST EFFECTIVE

Why you should use Enviropeel …