Corrosion and mechanical protection, EPC-S systems with epoxy resins
Corrosion and mechanical protection at under-crossings is for the pipe thread, for the watch pipes and for the protection tubes.
Epoxy composite coating systems and reinforcing tapes have been developed to respond to extremely aggressive agents (e.g. rocky terrain, sloping terrain combined with landslides) or special uses such as pipelines laid by forced draught in tunnels made by horizontal drilling (undercutting of watercourses, roads, railways) or ballasted pipelines.
Epoxy composite insulation systems and reinforcing tapes have been created to respond to extremely aggressive agents (eg rocky terrain, sloping terrain combined with landslides) or special uses such as pipelines placed by forced pulling in tunnels made by horizontal drilling.
The epoxy composite gives these insulation systems a very high chemical resistance, excellent mechanical resistance, typical of reinforced epoxy resins, and very good dielectric properties.
The reinforcing strips are made of glass fiber fabric (EPC-S insulation systems).
Due to the extraordinary adhesion to steel, these systems are also suitable for the repair of storage tanks and cracked pipes.
Areas of application
- Corrosion protection of metal pipes under plaster or buried tanks, bends, flanges or any body with irregular geometry.
- Corrosion protection and mechanical protection of buried metal pipes.
- Additional mechanical protection layer of pre-coated pipes with cold applied bands or extruded polyethylene in conditions where these pre-coated pipes do not meet very hard stress conditions (e.g. forced pulling in horizontal drilling tunnels).
EPC SYSTEM STRUCTURE - S
| Characteristic | UM | System code | Value |
| Adhesion to steel (tensile method) | Kgf/ cm2 | EPC – S | ≥ 50 |
| Test voltage | KV | EPC – S | > 35 |
| Penetration resistance | mm | EPC – S | 0.15 ÷ 0.20.1 ÷ 0.15 |
| Cathodic discharge* | mm | EPC – S | 1.91 |
BICOMPONENT EPOXY ANTICORROSIVE PRIMER
Epoxy bicomponent anti-corrosive primer is a film-forming anti-corrosive protection product, cross-linkable with polyamide amine oligomers.
Component A contains epoxy resins, very chemically stable salts, compatible with epoxy resin, titanium dioxide, thixotropic agents and dyes where appropriate.
Component B is the hardener made of polyamide-amine oligomers, additives and pigments.
The two-component primer is made in accordance with SR EN 10289:2002.
Fields of application
If the transport environment raises particular corrosion conditions (wastewater, acid or alkaline environments, oil, etc.) the pipes are protected on the inside with a two-component epoxy anti-corrosion primer.)
Technical characteristics
- Binder type: epoxy - polyamide
- Product type: bicomponent - base mixture: hardener 2:1 - 4:1
- Solid % by volume: min. 100%
- Shelf life in hermetically sealed packaging: 12 months
- Drying at 20o C and 65% hygrometry - wet film: 100 microns
| Surface drying | Deep drying | Total curing |
| 12 h | 24h | 7 zile |
Drying times are prolonged by changes in film temperature.
Lack of air or poor air circulation, excessive humidity, interfere with drying and cause drying to be slower and possible deterioration of film performance.
Drying according to substrate temperature - 100 micron wet film.
Support temperature | Surface drying | Deep drying | Total curing |
5oC | 16h | 36h | 14 days |
10oC | 12h | 24h | 14 days |
15oC | 8h | 16h | 14 days |
23oC | 6h | 12h | 7 days |
35oC | 4h | 8h | 7 days |
The product is not required before it is fully cross-linked. After this and especially in the case of pipes for the transport of drinking water, they are filled twice with fresh water and left for 24 hours each time, after which they are rinsed with a jet of water.
Implementation:
- Average temperature: 5 - 30o C
- Average relative humidity: max. 65%.
- Temperature support: 15 - 40o C
- Product temperature: min. 15o C
In case of application at temperatures below 5o C and hygrometers above 65%, the drying and recoating time values are increased by 2/3 times (depending on the actual temperature).
Temperatures above 15o C are required for complete curing.
Support preparation
Degreasing and sandblasting is mandatory. The primer must be applied within 4 hours of sandblasting.
Product preparation
- Before opening the packaging, wipe off any traces of water, oil or other impurities to prevent contamination of the product.
- Condition at 15 - 30o C.
- Remove any crusts from the surface.
- Homogenize the contents in order to perfectly redisperse any sediment using a suitable mechanical mixer.
- Carefully combine and mix the two components in strict compliance with the gravimetric ratios indicated in the analysis report accompanying each batch. Mixing ratios must be maintained as accurately as possible, otherwise chemical reactions are altered and lead to improper hardness, filming, poor resistance to weathering and chemical agents.
Weighing and not volumetric dosing is recommended as this gives errors due to the varying densities of the components in different deliveries. After perfect mechanical homogenization, the mixture of the two components must be kept for a pre-reaction time of 10 minutes at 23 ± 2oC, which must be observed before dilution. The mixture has a pot life of maximum 1 hour at 20oC.
Only the amount possible to use within the viability period of the mixture shall be prepared. The pot life of the mixture decreases with increasing temperature and amount of mixture due to acceleration of chemical reactions due to the temperature released from the polyamide epoxy reaction.
- Wet film thickness per layer: 100 microns
- Dry film thickness per layer: 100 microns
Corrosion and mechanical protection, EPC-S systems with epoxy resins
Mechanical protection with UV crosslinking tapes provides an effective solution to protect surfaces exposed to wear and tear. These tapes are designed to withstand mechanical impact, thus protecting surfaces from scratches, impacts or damage. Their abrasion and tensile resistance provides a durable barrier against tearing or cracking. Also, mechanical protection with UV crosslinking tapes provides resistance to corrosion, extreme temperatures and UV radiation. These strips are easy to apply and can adapt to various surfaces and shapes.
Additional mechanical protections
For rocky soil: rubber or special HDPE/PP foils.
Additional mechanical protections, such as the use of rubber or special HDPE/PP films, are ideal solutions to protect rocky soil in different environments and applications. By using impact-resistant rubber or HDPE/PP films, an effective barrier is created against scratches, cracks or other damage caused by rough rocks or hard objects. These additional protections provide abrasion resistance and superior mechanical strength, preventing soil erosion and maintaining surface integrity. They are durable, easy to install and can be adapted to various configurations and shapes of rocky ground. The use of these additional mechanical protections helps to extend the life of the soil and maintain the stability of the ground.
Corrosion and mechanical protection of tubes
Our team of experts provides customized and innovative solutions to prevent corrosion and ensure the durability of industrial tubes. We use advanced technologies and high-quality materials, such as special coatings, paints and protective layers, to provide an effective barrier against corrosion factors. Our products include various mechanical protection systems such as supports and fasteners that help prevent tube damage during handling and operation. Whatever your project needs, we are the ideal choice for corrosion and mechanical protection services and products for pipes.