Posted at Friday, 18 June, 2021

How to protect your assets from abrasion, corrosion and chemical attack?

Paul Skade
By Jon Whitehouse
Director, Industrial MRO and Safety

Having started in the Electrical industry in 1995 my early career developed holding a variety of roles from technical support through to business development with...

Read full bio

Wear, abrasion, erosion, chemical attack, and corrosion are some of the most common causes of failure in process equipment, magnified even further in harsher industrial environments. One of the top performers in the protective compound range is LOCTITE® PC 7255...

How to protect your assets from abrasion, corrosion and chemical attack? (striking hands together)
How to protect your assets from abrasion, corrosion and chemical attack?

 

Often, this type of equipment is very expensive, therefore repairing and protecting these assets comes at a significant cost. However, traditional repair methods such as hard metal spraying or flame spraying are also costly and are limited to relatively small surface areas.

But what if we told you there was a more cost-effective, reliable, and flexible alternative?

The application of LOCTITE® protective coatings and compounds can be effortlessly applied on any surface – irrespective of size. Yes, you heard us right, no matter the size, LOCTITE is the solution. There’s no risk of heat stress during the application process, and they also provide the extra benefit of corrosion protection.

Typical applications include the treatment of air ducts, pumps, heat exchangers, centrifuges, impellers, fan blades, cyclones, pipes, tanks, and retention areas.

The compound formulations of LOCTITE’s innovative portfolio include ceramic fillers that provide excellent adhesion and wear resistance. The key advantage of this product range is the ability to create a sacrificial and renewable working surface that protects the structural integrity of the original substrate.

 

These compounds are complemented by protective coatings that are primarily designed to protect against corrosion and chemicals, and as they do not contain ceramic fillers, they can be applied by a wide variety of methods to create that smooth surface required.

In short, collectively, these products have the ability to restore worn surfaces, extend the lifecycles of both new and old components, increase efficiency, and minimise downtime. The application of such products will save you money by considerably reducing the need for part replacement and associated spare-part inventories.

Choosing the right product

Selecting the right product for the application is always the most crucial decision, and the first consideration you must make is particle size. In order to improve abrasion resistance, particle size of the abrasive material, and that in the protective compound, should be identified and matched similarly to the LOCTITE range, which offers grades from fine to course.

 

LOCTITE products are also suitable for a range of operating temperatures from -30°C to +120°C, with some grades capable of up to 230°C; but please note, that these special grades require post curing to achieve their ultimate high temperature performance.

Thanks to their special epoxy matrix, the products are resistant to most types of chemical aggression, and offer good protection against fresh and sea water, ammonium sulphate and sodium hydroxide, with many other special chemical requirements also being accommodated.

Preparing the surface

Following particle size identification, your next consideration is correct surface preparation. This process is vital to the successful application of LOCTITE products.

Similarly, to preparing a surface ready for painting, correct surface preparation will improve the compound or coating’s adhesion to the component, preventing unwanted and problematic corrosion between layers, thus extending maintenance intervals.

ERIKS Protective Coatings

PC 7255 in action

One of the top performers in the protective compound range is LOCTITE PC 7255 – a low-friction epoxy that is sprayed directly onto the substrate that is especially effective for coating large surface areas and complex structures.

Creating an ultra-smooth finish that is resistant to both acids and alkalis, PC 7255 strongly protects against abrasion, corrosion, and in particular, chemical attack.

ERIKS’ application of this product to the cover dome of a pelletiser gave a lifetime extension to the asset which plays a critical role at the start of the production process. With no spare machine as back-up, or any spare components to replace those that were damaged or worn, the LOCTITE compound was successfully utilised to repair the surface, to the highest standards and ensure production could continue, providing the perfect interim solution. Then, during a routine maintenance shutdown, the machine was restored to full working order.

Good enough for our customers, good enough for us

The durability of this ceramic-enforced, epoxy sprayable coating has also been demonstrated at Henkel’s very own manufacturing facility in Germany.

After more than five years, the usually detrimental effects of acid, corrosion, and intense heat have had minimal impact on a flue gas, whose inside surface was coated with PC 7255 to protect against aggressive sulphur and nitrogen compounds, as well as condensation water.

Prior to the application of LOCTITE PC 7255, it was common practice to shield the flue gas duct with sandwich panels – a method that was intricate, complicated, and costly. The process of rubberising the surface was time-consuming and very expensive as the material needed to be adapted to suit the design of that specific duct.

Loctite Epoxy Spray

This is precisely where the benefits of this innovative protective compound are found, proving to be extremely efficient, effective, and user-friendly.

It can be sprayed on quickly and easily to create a sacrificial layer that prevents wear and tear on the base material, delivering exceptional advantages. In Henkel’s case, maintenance engineers have expressed their delight in data that has shown that even with long-term exposure to extreme corrosion, the thickness of the coating, and its shore hardness, had changed only minimally over a sustained period of time.

For more information on LOCTITE PC 7255 or Henkel’s well-balanced and diversified portfolio of specialist coatings, please contact your local ERIKS representative, who will be happy to discuss the best options for your requirements. View the Loctite range.

 

#Loctite #Henkel #LOCTITEPC7255 #protectivesurface

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