The document describes hot applied, hot cured ultra high build epoxy coatings called Interzone 954XS and Sigmasheild 880XS. It discusses their automatic application process which includes blasting, pre-heating steel, overlapping spray application and post curing to achieve full hardness in 10 minutes. The coatings provide improved performance through a LongKey process and have a track record of protecting structures for 15 years.
3. Interzone® 954XS / Sigmasheild 880XS
LongKey Process
+
• Automatic blasting to high standard
• Steel pre-heated prior to application
• Automatic mixing and overlapping spray application
• Accurate thickness control +/-7%, no defects
• Post cure to full hardness 10 minutes after application
• Same technology as Interzone 954HS / Sigmasheild 880
• Long track record for both products
• Harder, better performance as a result of LongKey process
Hot applied Hot cured ultra high build
epoxy coatings
4. • A two component, low VOC, high solids modified epoxy
barrier coat, single application
• Volume Solids : 85%
• Typical thickness : 200-500 microns
• Hard Dry Time : 8 hours @ 25oC
• Pack Size : 20kg
• Surface Preparation Requirements : SA 2.5 - SSPC-SP10
• Application : Conventional and Airless Spray
• Volatile Organic Content (VOC) :
• 255 g/ltr : UK PG6/23(92), Appendix 3
• 151 g/ltr : European SED
Interzone 954 HS
5. • A rapid cure, two component, ultra high solids modified epoxy barrier coat
designed to give long term protection in a single coat application. Designed
for application by automatic application plant using twin-feed plural pump
set-up only.
• Volume Solids : 98-99%
• Typical thickness : 500-1000 microns
• Hard Dry Time : 10 mins @110oC
• Pack Size : 200L or 1000L refillable tanks
• Surface Preparation Requirements : SA 2.5 - SSPC-SP10
• Application Method : Automatic twin feed application
• Volatile Organic Content (VOC) :
• 40 g/ltr : UK PG6/23(92), Appendix 3
Interzone 954 XS
6. • The XS versions were developed from the 954/880 technology
• Modified to allow fast curing at elevated temperatures (10 mins @ 110oC)
• Formulated to be applied at 50oC coating temperature through twin-feed
equipment
• Ultra-high solids at 98-99%
• Reduced environmental impact from solvents emissions
• No solvent entrapment
• More complete cross-linking of epoxy chains making the coating harder and
more impermeable to water
• 30-40% improvement in impact resistance
• 30-40% improvement in abrasion resistance
• 30-40% improvement in adhesion
• Greater CP resistance
Performance improvements
14. 1) 75% overlap on each spray pass and pile rotation
Excellent film distribution and no defects
Direction and turn
Each coat overlaps by 75%
15. 1) 75% overlap on each spray pass and pile rotation
2) 400% coverage, Excellent film distribution and no defects
Direction and turn
Gun moving for effect, actual
pile is moving and gun is stationary
Each pass is colour coded to show
Film build.
Four wet on wet overlapping coats
16. Post cure 2 Dust Removal
Blaster
Pre-heat 2
Spray
Cool
Heaters Heaters
Post cure 110Deg C + cooling to 80Deg C
17. Post cure 2 Dust Removal
Blaster
Pre-heat 2
Spray
Cool
Heaters Heaters
Hard cured piles up to 80M – 4600m2/day
18. Post cure 2 Dust Removal
Blaster
Pre-heat 2
Spray
Cool
Heaters Heaters
Post Cure, loadout for shipment, coated pipes
are handled once directly into ships hold
19. 600
620
640
660
680
700
720
740
760
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
DFT
No of readings x10
954XS DFT trace 28/11/09
Target DFT
Actual DFT
Upper control band
Lower control band
DFT control +/- 7%
Average DFT 707um
Target 700um
Minimum 680um (200 readings)
Maximum 750um (200 readings)
Maximum spread 70um
Manually applied coatings DFT +/-30%
Highly accurate Dry Film Thickness
24. 0
10
20
30
40
50
60
70
80
90
100
Interzone 954 700µ Interzone 954XS 700µ Interzone 954XSGF
700µ
Interzone 505 700µ
ShoreD
Hardness Shore D ASTMD2240Best
Worst
Shore Hardness D
Images & Tables courtesy of International Paints
25. 30 days in artificial sea water
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
Interzone
954 500µ
Interzone
954 700µ
Interzone
954XS
500µ
Interzone
954XS
700µ
Interzone
954XSGF
500µ
Interzone
954XSGF
700µ
mm
Cathodic Disbondment ASTMG8 30 daysWorst
Best
Cathodic Disbondment – 30 days
Images & Tables courtesy of International Paints
26. 0
1
2
3
4
5
6
Interzone 954 Interzone 954XS Interzone 954XSGF
CorrosionCreep(mm)
Best
Worst
Interzone 954XS Interzone 954XS GFInterzone 954
2000 hours
Hot Salt Spray Resistance – 2000 Hours
Images & Tables courtesy of International Paints
27. Interzone 954XS
Features Benefits
• Interzone 954 technology • Benefit of 15 year track record
• Great reputation with customers
• No re-approval needed
• Ideal blast standard • No compromise on surface
preparation
• Indoor application • Controlled environment
• Applied to heated steel • No dew point concerns
• Good flow of coating.
• Applied at elevated temperature • Cross-linking started sooner
• Smooth defect free appearance
• Automatic application • Smooth, even thickness control
• Very little wastage
• No mix ratio concerns
• Zero VOC • Reduced environmental impact
• No solvent entrapment
• Very fast curing • Speed of production increases
• Fully cured before exposure to
weather
• Fast cure at elevated temperature
by automatic plant
• Tighter more complete cross linking
• Better impact resistance
• Better abrasion resistance
• Better CP resistance
• Better adhesion
Benefits
Table courtesy of International Paints
