International Journal of Engineering Research and DevelopmentIJERD Editor
Electrical, Electronics and Computer Engineering,
Information Engineering and Technology,
Mechanical, Industrial and Manufacturing Engineering,
Automation and Mechatronics Engineering,
Material and Chemical Engineering,
Civil and Architecture Engineering,
Biotechnology and Bio Engineering,
Environmental Engineering,
Petroleum and Mining Engineering,
Marine and Agriculture engineering,
Aerospace Engineering.
Casting Defects Analysis in Foundry and Their Remedial Measures with Industri...AVINASH JURIANI
In this current scenario of globalization, foundries play a key role for manufacturing industries as they are the major source of castings. As a key industry a foundry's performance should be effectively high in terms of production with minimum number of rejections. Castings are the major inputs for most industrial products hence foundry industry is most indispensable. Casting is an integrated process considered as an artwork with experienced professionals for high quality yield, even then in highly controlled environment defects are dominant to take place leading to rejections, contrary to rejections a foundry's key attempt is to satisfy the demands neglecting quality levels.
Structural Damage and Maintenance Day 2tti-sharmila
The aim of this presentation is to provide a consistent test/fail guideline for light and heavy vehicle inspections that are in line with the RTA Guide.
How to reduce hot forging costs through innovative techniques?Srikar Shenoy
This presentation gives successful industrial case studies of cost reduction in hot forging by the use of:
1. Anti-scale protective coatings to prevent rejections due to scaling, reduce or eliminate shot blasting, reduce decarburization in heat treatment, hot rolling and hot forging.
2. Environment friendly die lubricants that eliminate pollution and increase die life.
3. Zero maintenance die lubricant spraying systems that ensure maximum uptime and no unplanned downtime during hot forging.
International Journal of Engineering Research and DevelopmentIJERD Editor
Electrical, Electronics and Computer Engineering,
Information Engineering and Technology,
Mechanical, Industrial and Manufacturing Engineering,
Automation and Mechatronics Engineering,
Material and Chemical Engineering,
Civil and Architecture Engineering,
Biotechnology and Bio Engineering,
Environmental Engineering,
Petroleum and Mining Engineering,
Marine and Agriculture engineering,
Aerospace Engineering.
Casting Defects Analysis in Foundry and Their Remedial Measures with Industri...AVINASH JURIANI
In this current scenario of globalization, foundries play a key role for manufacturing industries as they are the major source of castings. As a key industry a foundry's performance should be effectively high in terms of production with minimum number of rejections. Castings are the major inputs for most industrial products hence foundry industry is most indispensable. Casting is an integrated process considered as an artwork with experienced professionals for high quality yield, even then in highly controlled environment defects are dominant to take place leading to rejections, contrary to rejections a foundry's key attempt is to satisfy the demands neglecting quality levels.
Structural Damage and Maintenance Day 2tti-sharmila
The aim of this presentation is to provide a consistent test/fail guideline for light and heavy vehicle inspections that are in line with the RTA Guide.
How to reduce hot forging costs through innovative techniques?Srikar Shenoy
This presentation gives successful industrial case studies of cost reduction in hot forging by the use of:
1. Anti-scale protective coatings to prevent rejections due to scaling, reduce or eliminate shot blasting, reduce decarburization in heat treatment, hot rolling and hot forging.
2. Environment friendly die lubricants that eliminate pollution and increase die life.
3. Zero maintenance die lubricant spraying systems that ensure maximum uptime and no unplanned downtime during hot forging.
DONIT 4 AS Specially designed anti-stick coatingdonitmarketing
Removing gaskets from the flange connection can be
a tedious and labour intensive task which can result
in flange surface or equipment damage. When using
hammer and chisel to remove a gasket from the flange
surface, one can damage the latter. The amount of time
spent on cleaning flanges can be significant, and in
many cases, the plant must remain off-line while the
gaskets are being removed, creating a loss of valuable
production time. It has an important impact on maintenance
costs and plant efficiency. To avoid these problems
using gasket materials with a proper anti-stick
coating is recommended.
Increasing die life, reducing rejections by the use of japanese cold welding ...Srikar Shenoy
1. Die, mould and tool wear are major reasons for production downtime and increased costs in most industries. Apart from using suitable alloy steels for making dies, a few effective treatments like nitriding, PVD & CVD can be administered to increase die life. Such treatments are not feasible for all metal forming units. Carbide coating to protect only the wear-prone areas of dies using Japanese cold-welding technology is a practical and economical technique that has proven to increase die life. This technique, though similar to welding, does not need pre and post-weld heat treatment and skilled labour. The process does not emit smoke. It can also be carried out on the die or tool without unloading it from the casting press or such equipment, without need of a weld shop.
2. Die spray units are used to effectively spray lubricant on the dies. During the pressure die casting process, it is mandatory to keep die and plunger well lubricated. Die protective coating cum lubricant is used to achieve these objectives. Until recently, pressure feed tanks have been used to spray-lubricate dies. However, these conventional pressure-feed tanks are proving to be a hazard on the shop floor. Pressurised equipments on shop floor always pose a risk of explosion. They also cause production downtime during re-filling. Better alternatives are now available for dispensing die lubricants.
Here is a “Solvent Based Coating Technical Datasheet“. TDSmaker offer you free Datasheet/ Specsheet/ Techsheet. Visit to ( https://www.tdsmaker.com ) to get start with free template.
Experimental Study on Surface Roughness by Using Abrasive ParticlesIJERA Editor
New advancement of technology and never satisfying demands of the civilization are putting huge pressure on the natural fuel resources and these resources are at a constant threat to its sustainability. Surface finish has a vital influence on functional properties such as wear resistance and power loss due to friction on most of the engineering components. Voltage, mesh number, revolutions per minute (rpm) of electromagnet, and percentage weight of abrasives has been identified as important process parameters affecting surface roughness. The experiments were planned using response surface methodology and percentage change in surface roughness (ΔRa) was considered as response. Analysis of experimental data showed that percentage change in surface roughness (ΔRa) was highly influenced by mesh number followed by percentage weight of abrasives, rpm of electromagnet, and voltage. The process has been investigated extensively in the finishing of cylindrical surfaces. The surface finish was found to improve significantly with an increase in the grain size, relative size of abrasive particles vis-à-vis the iron particles, feed rate and current. Super finishing is a micro-finishing process that produces a controlled and smooth surface condition on work pieces. It is not primarily a sizing operation, its major purpose is to produce a surface on a work piece capable of sustaining uneven distribution of a load by improving the geometrical accuracy. The wear life of the parts micro finished to maximum smoothness is extended considerably. According to the design of experimentation, mathematical model for Lapping operation on advance ceramic material is proposed. In order to get minimum values of the surface roughness, optimization of the mathematical model is done and optimal operation of the examined factors is going to be determined. The obtained res
Investment casting is one of the archaic Investment casting procedures, with lost wax procedure being one of the most oldest metal framing techniques. From 5000 years prior, when honey bees wax shaped pattern, to today's high innovation waxes, recalcitrant materials and specialist alloys, the castings guarantee brilliant segments are created with the key advantages of precision, repeat ability, flexibility and integrity.
PEB Steel specializes in the Design, Fabrication and Erection of pre-engineered steel buildings (PEBs), steel structures for factories, warehouses, showrooms, commercial/ trade centers, supermarkets, sport stadiums, exhibition halls, aircraft hangars, etc.
(www.indiamart.com/goodrichgasket) We are involved as the manufacturer and exporter of API Ring Type Joint Gasket, Spiral Wound Gasket, Rubber Gasket, Bridgeman Gasket, Kammprofile Gasket, Metal Jacketed Gasket, PTFE Gasket and many more. These products are highly acclaimed for their utmost quality.
This lecture describes the important factors governing weldability of aluminium, such as influence of alloying elements, combinations of base material and filler materials and edge preparation for welding. Basic knowledge in metallurgy of aluminium is assumed.
The design and manufacture of precast refractory shapes has become a specialized field within the refractory industry in recent years. As the demands increase for greater refractory lining performance and lower maintenance costs, refractory users are finding that one effective way to achieve those goals is to incorporate a broader use of precast refractory shapes into their lining systems.
Investment casting is also a manufacturing technique with a ceramic metal or material is coated by the wax pattern with a refractory material of ceramic. visit know more information: http://goo.gl/59JMaF
Mechanical face Seals are designed to be employed in
most abusing working conditions, accepted worldwide
to use in extremely harsh environments under enormous
stresses, sand, dirt, mud, dust and earth material.
DONIT 4 AS Specially designed anti-stick coatingdonitmarketing
Removing gaskets from the flange connection can be
a tedious and labour intensive task which can result
in flange surface or equipment damage. When using
hammer and chisel to remove a gasket from the flange
surface, one can damage the latter. The amount of time
spent on cleaning flanges can be significant, and in
many cases, the plant must remain off-line while the
gaskets are being removed, creating a loss of valuable
production time. It has an important impact on maintenance
costs and plant efficiency. To avoid these problems
using gasket materials with a proper anti-stick
coating is recommended.
Increasing die life, reducing rejections by the use of japanese cold welding ...Srikar Shenoy
1. Die, mould and tool wear are major reasons for production downtime and increased costs in most industries. Apart from using suitable alloy steels for making dies, a few effective treatments like nitriding, PVD & CVD can be administered to increase die life. Such treatments are not feasible for all metal forming units. Carbide coating to protect only the wear-prone areas of dies using Japanese cold-welding technology is a practical and economical technique that has proven to increase die life. This technique, though similar to welding, does not need pre and post-weld heat treatment and skilled labour. The process does not emit smoke. It can also be carried out on the die or tool without unloading it from the casting press or such equipment, without need of a weld shop.
2. Die spray units are used to effectively spray lubricant on the dies. During the pressure die casting process, it is mandatory to keep die and plunger well lubricated. Die protective coating cum lubricant is used to achieve these objectives. Until recently, pressure feed tanks have been used to spray-lubricate dies. However, these conventional pressure-feed tanks are proving to be a hazard on the shop floor. Pressurised equipments on shop floor always pose a risk of explosion. They also cause production downtime during re-filling. Better alternatives are now available for dispensing die lubricants.
Here is a “Solvent Based Coating Technical Datasheet“. TDSmaker offer you free Datasheet/ Specsheet/ Techsheet. Visit to ( https://www.tdsmaker.com ) to get start with free template.
Experimental Study on Surface Roughness by Using Abrasive ParticlesIJERA Editor
New advancement of technology and never satisfying demands of the civilization are putting huge pressure on the natural fuel resources and these resources are at a constant threat to its sustainability. Surface finish has a vital influence on functional properties such as wear resistance and power loss due to friction on most of the engineering components. Voltage, mesh number, revolutions per minute (rpm) of electromagnet, and percentage weight of abrasives has been identified as important process parameters affecting surface roughness. The experiments were planned using response surface methodology and percentage change in surface roughness (ΔRa) was considered as response. Analysis of experimental data showed that percentage change in surface roughness (ΔRa) was highly influenced by mesh number followed by percentage weight of abrasives, rpm of electromagnet, and voltage. The process has been investigated extensively in the finishing of cylindrical surfaces. The surface finish was found to improve significantly with an increase in the grain size, relative size of abrasive particles vis-à-vis the iron particles, feed rate and current. Super finishing is a micro-finishing process that produces a controlled and smooth surface condition on work pieces. It is not primarily a sizing operation, its major purpose is to produce a surface on a work piece capable of sustaining uneven distribution of a load by improving the geometrical accuracy. The wear life of the parts micro finished to maximum smoothness is extended considerably. According to the design of experimentation, mathematical model for Lapping operation on advance ceramic material is proposed. In order to get minimum values of the surface roughness, optimization of the mathematical model is done and optimal operation of the examined factors is going to be determined. The obtained res
Investment casting is one of the archaic Investment casting procedures, with lost wax procedure being one of the most oldest metal framing techniques. From 5000 years prior, when honey bees wax shaped pattern, to today's high innovation waxes, recalcitrant materials and specialist alloys, the castings guarantee brilliant segments are created with the key advantages of precision, repeat ability, flexibility and integrity.
PEB Steel specializes in the Design, Fabrication and Erection of pre-engineered steel buildings (PEBs), steel structures for factories, warehouses, showrooms, commercial/ trade centers, supermarkets, sport stadiums, exhibition halls, aircraft hangars, etc.
(www.indiamart.com/goodrichgasket) We are involved as the manufacturer and exporter of API Ring Type Joint Gasket, Spiral Wound Gasket, Rubber Gasket, Bridgeman Gasket, Kammprofile Gasket, Metal Jacketed Gasket, PTFE Gasket and many more. These products are highly acclaimed for their utmost quality.
This lecture describes the important factors governing weldability of aluminium, such as influence of alloying elements, combinations of base material and filler materials and edge preparation for welding. Basic knowledge in metallurgy of aluminium is assumed.
The design and manufacture of precast refractory shapes has become a specialized field within the refractory industry in recent years. As the demands increase for greater refractory lining performance and lower maintenance costs, refractory users are finding that one effective way to achieve those goals is to incorporate a broader use of precast refractory shapes into their lining systems.
Investment casting is also a manufacturing technique with a ceramic metal or material is coated by the wax pattern with a refractory material of ceramic. visit know more information: http://goo.gl/59JMaF
Mechanical face Seals are designed to be employed in
most abusing working conditions, accepted worldwide
to use in extremely harsh environments under enormous
stresses, sand, dirt, mud, dust and earth material.
This is an introductory presentation into the world of linings that are used in various industries. We will review what a lining is and what types of linings exist in the market place. We will also discuss how to choose or specify a lining system which includes surface preparation, proper application, repairs to lining defect and how fast a lining will be ready for service.
If you have any questions Contact us at:
http://info.international-pc.com/Solutions
Our main goal is to cover our customer needs in terms of quality, performance and product lifetime. How important are the treatments and processes that our canopies suffer? Check it in this technical article.
Adhesives for • Design • Manufacturing • Assembly • Maintenence • Repair & Overhaul
Permabond’s history of developing and manufacturing engineering adhesives spans four decades and three continents.
Today, Permabond Engineering Adhesives Ltd (Europe & Asia) and Permabond LLC (Americas) provide technological solutionsto engineers all over the world, with officesand facilities in America, Asia and Europe, backed by a high-tech ISO 9001:2008 certified production plant in Europe.
This brochure contains information on our most popular products, if you don’t see exactly what you need, or
would like assistance in selecting the best product for your application, please contact us:
Metals tend to corrode very fast. To prevent corrosion various methods are used. Once such method is galvanization. Hot Dip Galvanizing is used to prevent machines from corroding. You can read along the document and get more details regarding the process.
2011 CTM Session 2: Terminology for Productsnovacsi
Focus on Division 07 to understand what happens when specifications terminology requires significant interpretation by the contractor or mixes up terminology, and the potential impact to prices, contracts, and project success.
Mastering Multi-Touchpoint Content Strategy: Navigate Fragmented User JourneysSearch Engine Journal
Digital platforms are constantly multiplying, and with that, user engagement is becoming more intricate and fragmented.
So how do you effectively navigate distributing and tailoring your content across these various touchpoints?
Watch this webinar as we dive into the evolving landscape of content strategy tailored for today's fragmented user journeys. Understanding how to deliver your content to your users is more crucial than ever, and we’ll provide actionable tips for navigating these intricate challenges.
You’ll learn:
- How today’s users engage with content across various channels and devices.
- The latest methodologies for identifying and addressing content gaps to keep your content strategy proactive and relevant.
- What digital shelf space is and how your content strategy needs to pivot.
With Wayne Cichanski, we’ll explore innovative strategies to map out and meet the diverse needs of your audience, ensuring every piece of content resonates and connects, regardless of where or how it is consumed.
When most people in the industry talk about online or digital reputation management, what they're really saying is Google search and PPC. And it's usually reactive, left dealing with the aftermath of negative information published somewhere online. That's outdated. It leaves executives, organizations and other high-profile individuals at a high risk of a digital reputation attack that spans channels and tactics. But the tools needed to safeguard against an attack are more cybersecurity-oriented than most marketing and communications professionals can manage. Business leaders Leaders grasp the importance; 83% of executives place reputation in their top five areas of risk, yet only 23% are confident in their ability to address it. To succeed in 2024 and beyond, you need to turn online reputation on its axis and think like an attacker.
Key Takeaways:
- New framework for examining and safeguarding an online reputation
- Tools and techniques to keep you a step ahead
- Practical examples that demonstrate when to act, how to act and how to recover
Financial curveballs sent many American families reeling in 2023. Household budgets were squeezed by rising interest rates, surging prices on everyday goods, and a stagnating housing market. Consumers were feeling strapped. That sentiment, however, appears to be waning. The question is, to what extent?
To take the pulse of consumers’ feelings about their financial well-being ahead of a highly anticipated election, ThinkNow conducted a nationally representative quantitative survey. The survey highlights consumers’ hopes and anxieties as we move into 2024. Let's unpack the key findings to gain insights about where we stand.
Come learn how YOU can Animate and Illuminate the World with Generative AI's Explosive Power. Come sit in the driver's seat and learn to harness this great technology.
Mastering Local SEO for Service Businesses in the AI Era is tailored specifically for local service providers like plumbers, dentists, and others seeking to dominate their local search landscape. This session delves into leveraging AI advancements to enhance your online visibility and search rankings through the Content Factory model, designed for creating high-impact, SEO-driven content. Discover the Dollar-a-Day advertising strategy, a cost-effective approach to boost your local SEO efforts and attract more customers with minimal investment. Gain practical insights on optimizing your online presence to meet the specific needs of local service seekers, ensuring your business not only appears but stands out in local searches. This concise, action-oriented workshop is your roadmap to navigating the complexities of digital marketing in the AI age, driving more leads, conversions, and ultimately, success for your local service business.
Key Takeaways:
Embrace AI for Local SEO: Learn to harness the power of AI technologies to optimize your website and content for local search. Understand the pivotal role AI plays in analyzing search trends and consumer behavior, enabling you to tailor your SEO strategies to meet the specific demands of your target local audience. Leverage the Content Factory Model: Discover the step-by-step process of creating SEO-optimized content at scale. This approach ensures a steady stream of high-quality content that engages local customers and boosts your search rankings. Get an action guide on implementing this model, complete with templates and scheduling strategies to maintain a consistent online presence. Maximize ROI with Dollar-a-Day Advertising: Dive into the cost-effective Dollar-a-Day advertising strategy that amplifies your visibility in local searches without breaking the bank. Learn how to strategically allocate your budget across platforms to target potential local customers effectively. The session includes an action guide on setting up, monitoring, and optimizing your ad campaigns to ensure maximum impact with minimal investment.
SMM Cheap - No. 1 SMM panel in the worldsmmpanel567
Boost your social media marketing with our SMM Panel services offering SMM Cheap services! Get cost-effective services for your business and increase followers, likes, and engagement across all social media platforms. Get affordable services perfect for businesses and influencers looking to increase their social proof. See how cheap SMM strategies can help improve your social media presence and be a pro at the social media game.
In this presentation, Danny Leibrandt explains the impact of AI on SEO and what Google has been doing about it. Learn how to take your SEO game to the next level and win over Google with his new strategy anyone can use. Get actionable steps to rank your name, your business, and your clients on Google - the right way.
Key Takeaways:
1. Real content is king
2. Find ways to show EEAT
3. Repurpose across all platforms
Top 3 Ways to Align Sales and Marketing Teams for Rapid GrowthDemandbase
In this session, Demandbase’s Stephanie Quinn, Sr. Director of Integrated and Digital Marketing, Devin Rosenberg, Director of Sales, and Kevin Rooney, Senior Director of Sales Development will share how sales and marketing shapes their day-to-day and what key areas are needed for true alignment.
5 big bets to drive growth in 2024 without one additional marketing dollar AND how to adapt to the biggest shifting eCommerce trend- AI.
1) Romance Your Customers - Retention
2) ‘Alternative’ Lead Gen - Advocacy
3) The Beautiful Basics - Conversion Rate Optimization
4) Land that Bottom Line - Profitability
5) Roll the Dice - New Business Models
First Things First: Building and Effective Marketing Strategy
Too many companies (and marketers) jump straight into activation planning without formalizing a marketing strategy. It may seem tedious, but analyzing the mindset of your targeted audiences and identifying the messaging points most likely to resonate with them is time well spent. That process is also a great opportunity for marketers to collaborate with sales leaders and account managers on a galvanized go-to-market approach. I’ll walk you through the methods and tools we use with our clients to ensure campaign success.
Key Takeaways:
-Recognize the critical role of strategy in marketing
-Learn our approach for building an actionable, effective marketing strategy
-Receive templates and guides for developing a marketing strategy
It's another new era of digital and marketers are faced with making big bets on their digital strategy. If you are looking at modernizing your tech stack to support your digital evolution, there are a few can't miss (often overlooked) areas that should be part of every conversation. We'll cover setting your vision, avoiding siloes, adding a democratized approach to data strategy, localization, creating critical governance requirements and more. Attendees will walk away with actions they can take into initiatives they are running today and consider for the future.
Influencer marketing isn't just for big brands or consumer products anymore. In 2024, marketers face hurdles like escalating paid channel costs, diminishing organic reach, and building trust in their ideal customer accounts. This session offers practical ways to bring influencer marketing into your organization, to provide cost-effective access to niche audiences, countering budget constraints and rising CPMs. We'll discuss the impact of social algorithms on reach, the trust deficit in traditional advertising and how influencer partnerships offer genuine connections with audiences. Attendees will gain actionable insights to integrate influencer marketing into their strategies, leveraging influencers for impactful campaigns in both B2B and B2C environments. Join us to unlock the potential of influencers in navigating the evolving marketing landscape of 2024 and driving meaningful business growth.
Key Takeaways:
- Educate on the various types of influence we can use as marketers
- Establish the problems that make influencers a priority
- Walk through some practical tactics on HOW to run a program leveraging several of these influence channels
Core Web Vitals SEO Workshop - improve your performance [pdf]Peter Mead
Core Web Vitals to improve your website performance for better SEO results with CWV.
CWV Topics include:
- Understanding the latest Core Web Vitals including the significance of LCP, INP and CLS + their impact on SEO
- Optimisation techniques from our experts on how to improve your CWV on platforms like WordPress and WP Engine
- The impact of user experience and SEO
When most people in the industry talk about online or digital reputation management, what they're really saying is Google search and PPC. And it's usually reactive, left dealing with the aftermath of negative information published somewhere online. That's outdated. It leaves executives, organizations and other high-profile individuals at a high risk of a digital reputation attack that spans channels and tactics. But the tools needed to safeguard against an attack are more cybersecurity-oriented than most marketing and communications professionals can manage. Business leaders Leaders grasp the importance; 83% of executives place reputation in their top five areas of risk, yet only 23% are confident in their ability to address it. To succeed in 2024 and beyond, you need to turn online reputation on its axis and think like an attacker.\
Key Takeaways:
- New framework for examining and safeguarding an online reputation
- Tools and techniques to keep you a step ahead
- Practical examples that demonstrate when to act, how to act and how to recover
AI-Powered Personalization: Principles, Use Cases, and Its Impact on CROVWO
In today’s era of AI, personalization is more than just a trend—it’s a fundamental strategy that unlocks numerous opportunities.
When done effectively, personalization builds trust, loyalty, and satisfaction among your users—key factors for business success. However, relying solely on AI capabilities isn’t enough. You need to anchor your approach in solid principles, understand your users’ context, and master the art of persuasion.
Join us as Sarjak Patel and Naitry Saggu from 3rd Eye Consulting unveil a transformative framework. This approach seamlessly integrates your unique context, consumer insights, and conversion goals, paving the way for unparalleled success in personalization.
Mastering Local SEO for Service Businesses in the AI Era is tailored specifically for local service providers like plumbers, dentists, and others seeking to dominate their local search landscape. This session delves into leveraging AI advancements to enhance your online visibility and search rankings through the Content Factory model, designed for creating high-impact, SEO-driven content. Discover the Dollar-a-Day advertising strategy, a cost-effective approach to boost your local SEO efforts and attract more customers with minimal investment. Gain practical insights on optimizing your online presence to meet the specific needs of local service seekers, ensuring your business not only appears but stands out in local searches. This concise, action-oriented workshop is your roadmap to navigating the complexities of digital marketing in the AI age, driving more leads, conversions, and ultimately, success for your local service business.
Key Takeaways:
Embrace AI for Local SEO: Learn to harness the power of AI technologies to optimize your website and content for local search. Understand the pivotal role AI plays in analyzing search trends and consumer behavior, enabling you to tailor your SEO strategies to meet the specific demands of your target local audience. Leverage the Content Factory Model: Discover the step-by-step process of creating SEO-optimized content at scale. This approach ensures a steady stream of high-quality content that engages local customers and boosts your search rankings. Get an action guide on implementing this model, complete with templates and scheduling strategies to maintain a consistent online presence. Maximize ROI with Dollar-a-Day Advertising: Dive into the cost-effective Dollar-a-Day advertising strategy that amplifies your visibility in local searches without breaking the bank. Learn how to strategically allocate your budget across platforms to target potential local customers effectively. The session includes an action guide on setting up, monitoring, and optimizing your ad campaigns to ensure maximum impact with minimal investment.
1. ABCDE
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Coating Work in the Fabricating Shop
by Daniel Griffin
International Protective Coatings
Houston, TX. USA.
Painting structural steel at the steel fabricator’s shop offers some real advantages over field painting. Since
painting can usually be done indoors, weather conditions are less of a factor, and the coatings application and
inspection process can be more easily controlled. Well-designed steel fabrication shops have used these
advantages to become sources of high quality protective coatings work .
With the advent of high production, centrifugal shot or grit blasting equipment, some shops have combined the
process of fabricating, blast cleaning, and painting all under one roof. The resulting cost savings and continuity
have led to millions of tons of structural steel arriving at their end-use destinations fully painted and ready for
erection with minimal field touch up required.
Successful fabricator shop painting depends upon many factors that must be controlled to ensure quality
coatings work. Comments on some of these factors follow.
Steel Design Considerations
Back-to-back angles should be designed out of a project because they create surfaces inaccessible for coating,
or, if the angles are set flush and tack-welded, crevice corrosion may occur. If back-to-back angles must be
used, the surfaces should be blast cleaned to a minimum commercial blast (SSPC-SP 6), and the fabricator
should apply at least one coat of primer prior to bolting up the angles. Normally, a zinc-rich or rust inhibitive
polyamide epoxy primer is recommended.
Whenever it is cost-efficient, continuous welding of structural members is preferred. Discontinuous, tack, or stitch
welding often creates areas of crevice corrosion that lead to problems in aggressive environments. The owner
and structural engineer must do a cost-benefit analysis to determine the point at which continuous welding
becomes necessary or cost-efficient, since it does add to the cost of the fabrication process.
Surface Preparation
Proper surface preparation is of great importance in assuring a clean, smooth coating system with good
adhesion. The first step in surface preparation is to degrease and solvent-clean the steel prior to abrasive blast
cleaning.
When centrifugal blasting machines are used, the abrasives themselves must be kept totally free of grease and
oil. Once the metallic abrasives become contaminated, they impart a thin film of oil and metal fines to the blast-cleaned
surface. This contamination of the surface may result in adhesion failures of the coating system.
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The proper size and blend of aggregate must be used and maintained to develop the specified blast profile for
the primer being applied. An efficient practice is to measure the blast profile periodically to ensure that proper
size and blend of aggregate is being used. Generally accepted methods include use of replica tape or
comparators.
A description of procedures necessary to maintain quality control in the centrifugal blast cleaning process is
available from the Steel Structures Painting Council in the monograph, Guidelines for Centrifugal Blast Cleaning
(1984), by A. W. Mallory.
Considerations about the selection and use of metallic abrasives, including the critical importance of maintaining
an effective "operating mix" of abrasive, are described in "Controlling the Centrifugal Blast-Cleaning Process" by
Einar A. Borch in this issue on pp 28-33.
Coatings fail first on prominences such as sharp edges, burrs, welds, and weld spatter. Laminations (slivers) in
the steel may not be easily visible until after blasting. These laminations, burrs, and weld spatter should be
removed and any rough welds smoothed by hand or power tool cleaning. Sharp edges should be ground to a
radius where subsequent coatings systems must perform in highly corrosive atmospheres. When grinding is
required, it should be clearly stated in bid documents.
Even the painting "bucks" or supports are crucial to the quality of a coating system. If allowed to become dirty or
coated with overspray, they can contaminate freshly blasted or painted steel during the turning operation. Bucks
should be made of angle stock, laid with single point up for minimum impingement on the structural member, and
kept clean.
After being spread out on the bucks, and just prior to painting, the steel should be blown with clean, dry air to
remove residue, dust, and aggregate. Other contaminants, such as oil from overhead cranes, should also be
removed.
The steel should be spaced to allow easy access to each member so that the painter is not required to reach or
stretch during the painting operation. Sufficient layout space should be available so there is not an excessive
rush to keep up with the flow of steel that passes through a centrifugal blastmachine. Rushing reduces the
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quality of application, and can result in damage or failure from handling or topcoating before sufficient cure is
achieved.
Storage and Mixing Of Coating Material
Proper handling, storage, and mixing of coating products are equally important to a coating system’s success.
Maintaining materials within specified temperature limitations is vital. Manufacturers generally recommend
protected storage in the range of 40° F (4° C) to 100° F (38° C). For optimum application properties, it is also a
general practice to recommend that material temperatures range from 70° F (21° C) to 80° F (27° C) prior to
mixing and application.
Power agitation for mixing a coating, whether it is a single- or multiple-component material, assures even
dispersal and smooth blending of ingredients. The motor and agitator blade should be properly sized to mix the
material uniformly.
Coatings should always be mixed in whole unit sizes as supplied by the manufacturer. Attempting to mix a partial
unit of a multiple-component zinc-rich primer, for example, may lead to premature failure of the system because
of an incorrect ratio of components.
If thinning is required after the coating is mixed, the manufacturer’s recommended thinner should be used.
Thinning should be kept to a minimum because excessive thinning can increase cost and reduce film build. Only
the amount of thinner required to attain the proper spray fan pattern and film formation should be used. The
manufacturer’s recommended clean up solvent should also be used at prescribed intervals (e.g., breaks, lunch)
during the application process and at the end of the work day.
Application Equipment
Many manufacturers test various types of application equipment with their products to recommend the
equipment that gives the most desirable results with their coatings. For this reason, the application equipment
recommended on the coating manufacturer’s written application instructions should be used.
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All coatings can cause wear of spray tips, but when abrasive material such as a zinc-rich primer is applied by
airless spray, the abrasive ingredient will wear and enlarge the spray tip orifice quite rapidly. Good application
practice, then, includes periodic inspection and replacement of tips that become excessively worn. Tip wear can
be recognised by changes in the spray pattern or by film build problems such as sagging.
Conventional air spray equipment, particularly the gages, must be maintained in proper functioning condition.
However, when gages break, as they frequently do, it is possible to adjust the spray pattern as follows: turn off
the regulators to the fluid and atomisation pressures. Hold the gun at your hip. With the atomisation pressure off,
gradually increase the fluid pressure until triggering the gun yields a material flow stream that falls approximately
4 ft in front of you. Then adjust the atomisation air to break up the material flow, spreading it into a satisfactory
fan pattern.
Effective Work Procedures
Prior to spray application of the primer, the steel should be inspected for areas that will be difficult or tight to
spray paint (for instance, end clips, gussets near a flange, or nuts and bolt heads). These tight areas should
receive a brush coat prior to the spray application.
Both primer and topcoat should be specified with minimum and maximum thicknesses, and those targets should
be consistently reached. Too little coating usually causes premature failure in service, while excessive
thicknesses may lead to "mudcracking," associated with zinc-rich primers, or to coating delamination due to
curing stresses. Fabricators who are painting structural steel must be careful to avoid too much film thickness on
flat and web areas of structural pieces and too little thickness on the vertical and flange areas. The minimum and
maximum limits for the specific coating being applied should be determined by the coating manufacturer. This
information should be clearly stated in the specifications.
Sometimes, the turning and spraying technique used when T-braces are coated leaves uncoated areas on the
edges. This occasionally occurs on the outside edges of flanged steel. The painter should be made aware of this
potential problem so that the edges will be properly coated. Other practices to avoid include dragging material
lines over freshly coated steel, walking on freshly coated steel, or handling steel coated with uncured paint (even
with gloved hands).
An interesting phenomenon is that the first and last few feet of I-beams or other structural members tend to have
lighter or lower coating thickness than the midsection. This is a problem created by the method of application.
Generally, a painter will coat the first 5 ft to 6 ft, then move down the beam. At the beginning of the next
sequence of passes, he will over lap some of the previously coated area. Because the first and last few feet do
not receive an over lap, they obviously will have a lower coating thickness. An extra pass over these areas can
eliminate this problem.
Topcoating
Where topcoats are applied in the fabricating shop, special considerations must be taken into account. They
include assuring that the appropriate cure of the primer has been achieved before topcoating, setting up the
physical layout and work flow of the paint shop to allow for holding steel between priming and topcoating, and
improving the care in handling and storage of topcoated steel to minimise damage that must be repaired
subsequent to erection.
Assuring cure of the primer before topcoating can be accomplished by following the coating manufacturer’s
recommendations on recoat intervals and on the ambient conditions necessary for recoating.
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Advice on the care necessary in handling, shipping, and storing topcoated steel is available in Tinklenberg and
Culp, "Michigan’s Answer: Total Shop Painting," JPCL, June 1984, and in Bayliss, "The Handling, Transport, and
Storage of Coated Items," JPCL, August 1984.
After the steel is coated, it must be allowed to sit undisturbed for the specified time prior to handling. The
minimum time depends upon shop and surface temperatures when the finish coat is sprayed, but is usually in
the range of eight to 24 hours. When the steel is handled, care must be exercised to avoid excessive damage to
the coating, since the coatings have not reached their ultimate toughness during this period. Nylon slings work
well, though they may cause wider abrasions than chains do, if the steel is handled too rapidly after coating.
Chains can be used effectively if only one piece of steel is moved at a time, and the hooks are placed in the end
clips, not wrapped around the steel.
Stacked steel should be protected with dunnage to minimise metal-to-metal contact from damaging the coating
system. In transportation, coated steel needs the same careful stacking with dunnage and secure anchoring to
truck or railcar bed to prevent damage from load shifting. Steel temporarily stored outside the fabrication shop
also requires careful handling and stacking so that ponding of water and dirt entrapment is kept to a minimum.
Recent Trends In Fabricator Shops
As the trend to in-shop application grows, some fabricator shops are beginning to insulate and heat their painting
areas to facilitate movement and handling of painted steel. A few have also installed misting or fogging devices
to elevate the humidity in the painting shop and induce faster curing of some inorganic zinc primers.
Many fabricators are upgrading their equipment to enable them to apply high performance coatings. The more
experienced applicators are also using larger equipment versatile enough to handle a wide range of products.
The Coating Manufacturer
Coating manufacturers are responding to fabricators’ needs by developing new products that dry and cure in
much less time and at lower temperatures than standard coatings. They are also developing products to meet
another trend affecting not only the steel but all industry – increasing government regulation of pollution caused
by solvent emission. To fulfil needs brought about by this trend, manufacturers are developing water-based and
higher solids coatings to eliminate or reduce the emission of volatile organic compounds (VOC’s).
Conclusion
Many fabricating shops are beginning to recognise and accept that painting is an integral and essential part of
the steel fabricating industry. It can no longer be dismissed as a nuisance or hindrance to the demands of high
throughput of steel. These fabricators have accepted the challenge of applying high quality coating systems and
of protecting the coatings to the final field-site destination.
6. Disclaimer
The information given in this sheet is not intended to be exhaustive and any person using the product for any purpose other than that specifically recommended in this sheet without first
obtaining written confirmation from us as to the suitability of the product for the intended purpose does so at his own risk. Any warranty, if given, or specific Terms & Conditions of Sale are
contained in International’s Terms & Conditions of Sale, a copy of which can be obtained on request. Whilst we endeavor to ensure that all advice we give about the product (whether in
this sheet or otherwise) is correct we have no control over either the quality or condition of the substrate or the many factors affecting the use and application of the product. Therefore,
unless we specifically agree in writing to do so, we do not accept any liability whatsoever or howsoever arising for the performance of the product or for any loss or damage (other than
death or personal injury resulting from our negligence) arising out of the use of the product. The information contained in this sheet is liable to modification from time to time in the light of
experience and our policy of continuous product development.
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