Dry Tech Aerogels (Pty) Ltd RUST GRIP® 27-82-5862811 Rust Grip® Presentationdrytechaerogels.co.za/assets/dry-tech-aerogels-rust-grip... · 2018-06-14 · Dry Tech Aerogels (Pty)

Dry Tech Aerogels (Pty) Ltd Willie Coetzee

27-82-5862811

Rust Grip®

Presentation

RUST GRIP®


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What is Rust Grip®?

• Rust Grip® is a patented, one-part, single component, penetrating moisture cure polyurethanecoating, that combines with atmospheric moisture to cure.

• Rustgrip provides long term corrosion remedy without the need of sandblasting to new or nearnew metal during surface preparation ( No SP5 or SP10).

• Rust Grip® is not a sacrificial rust inhibitor such as a zinc enriched primer that will wear out overtime, but in fact, a long term corrosion solution that is collectively a primer, intermediate coatand top coat, all in one.

• Both USA patented and ASTM E1795 certified & approved for encapsulation of biohazardmaterials (Lead based paint , Asbestos, etc).

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Competitive 3 coat 2 part systems

• Require sandblasting to new metal or near new metal (requires a SP5 or SP10)

• Must use glue for adhesion

• Flash Rust will reappear of the metals surface shortly after blasting

• Contractors often apply the zinc primer over flash rust

• Overtime, the glue gives away, resulting in coating failure from within

• Labor intensive as 3 separate coatings must be applied. Requires a minimum of 6-8 passes

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Rust Grip® - The difference

• Rust Grip® does not require sandblasting to new or near new metal (no Sp5 or SP10)

• Rust Grip® only require loose milscale and pack rust removed (must be apply to a firmlybonded surface)

• Rust Grip® is designed to be applied directly over existing flash/surface rust (which isthe preferred surface profile for Rust Grip®) or firmly bonded paint without use of Glue.

• Made with proprietary additive designed to penetrate into the pores of the metalswhere is locks in and becomes one with the metal from the inner pores to the outersurface.

• Rust Grip’s permeability is 0 (ASTM E 1795). Once within the pores of the metal surface,the metal’s surface cannot not breath and is devoid of moisture. (Essentially removingthe electrolyte that is required for corrosion). Rustgrip is able to do this as a one coat,single component system with a surface tensile strength of 12,000 psi after 21 days.

• Patented for encapsulating bio- hazardous material such as lead based paint andasbestos (ASTM E1795 certified)

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Surface Prep Rust Grip®?

• Loose milscale and pack rust must be removed. Firmly bonded paint and rust on the metal’s surface isok. ( NO SP5 0r SP10 required). Saves money, time and provides a benefit to the environment.

• Can use power tool (Use a Power Brush – No Needle gun), Wire brush, UHP, Commercial blast.

• Surface must be completely dry before applying Rustgrip.

• If not sure that the surface is dry, wipe the surface with a acetone prior to applying Rustgrip.

• Require 4 dry mils of Rustgrip over the surface profile of the metal.

• Is applied in 2-3 passes.

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Rust Grip® PREFERED SURFACE PROFILE IS FLASH RUST

RUST GRIP®

The largest US Coast Guard approved gaming vessel, Blue Chip Casino ship ,allowed new metal to flash rust, then the metal was power washed and overcoated with Rust Grip® and Enamo Grip as a topcoat. This client saved more than 2 million dollars by avoiding sandblasting to a SP5 or SP10.


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Rust Grip® Over coating Corrosion on Metal Roof Structures

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Rust Grip® - Economic Benefits of Using Rust Grip®

Imagine the bottom line financial savings when:

1. The costs associated with blasting or UHP of the surface to a new ornear new metal (SSPC-SP10 or SP5) is eliminated.

2. Eliminating the excessive labor, material, equipment and rentalscost associated with the application of three coatings (the zinc primer,the epoxy and urethane topcoat as prescribed in a traditional 3-coatsystem) versus one, with Rustgrip (1 coat, single component system)

3. The high costs associated with containment and disposal ofhazardous waste from abrasive blasting is eliminated. Rustgrip cansimply be painted over lead based paint and asbestos coatedsurfaces. Patented and has passed the USA required ASTM 1795.

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Rust Grip® Cost Advantages (Example: comparing remedy of corrosion on 200 sq.ft)

RUST GRIP®

X = Quantity of Input

RI & CI = Category of Input Rustgrip vrs Conventional 3 coat 2 part system

Input Rust Grip Description Rust Grip RI(x) Conventional Description Conventional CI(x) R{C} with placeholder

Labour

1 Supervisor, 1 Day 1 1 Supervisor, 3 Days 3 3

Not Applicable 0 1 Blaster, 3 Days 3 3

Not Applicable 0 1 Painter, 3 Days 3 3

Not Applicable 0 1 TMA, 3 Days 3 3

Not Applicable 0 1 Mechanic, 1 Day 1 1

Equipment

Not Applicable 0 1 Blast Pot, 1 Day 1 1

1 Power Washer, 1 day 1 1 Power Wahser, 3 Days 3 3

1 Extra Hose, 1 day 1 1 Extra Hose, 3 Days 3 3

Not Applicable 0 1 Blasting Set, 1 Day 1 1

Not Applicable 0 1 Exra Hose, 1 Day 1 1

Not Applicable 0 1 Blasting Whip Line, 1 Day 1 1

Not Applicable 0 1 3/4" Air Hose, 1 Day 1 1

Not Applicable 0 1 Dead Man Hose, 1 Day 1 1

Not Applicable 0 1 Bull Hose, 1 Day 1 1

Not Applicable 0 1 Breathing Air Hose, 1 Day 1 1

Not Applicable 0 1 ALG10 and Air Analyser, 1 Day 1 1

Not Applicable 0 1 Blasting Mask, 1 Day 1 1

1 Paint Pump, 1 Day 1 1 Paint Pump, 3 Days 3 3

1 Extra Hose, 1 Day 1 1 Extra Hose, 3 Days 3 3

1 Inspection Kit, 1 Day 1 1 Inspection Kit, 3 Days 3 3

Materials

1 Base Coat Rust Grip 1 1 Base Coat 1 1

1 Intermediate Coat Rust Grip 1 1 Intermediate 1 1

1 Top Coat Enamo Grip 1 1 Top Coat 1 1

Not Applicable 0 15 Bags Grit 1 1

1 Day Consumables 1 3 Days Consumables 3 3

1 Gallon Acetone 1 1 Gallon Acetone 1 1

3rd Party Rental

1 Compressor, 1 Day 1 1 compressor, 3 Days 3 3

1 Hiab, 2 Trips 2 1 Hiab, 4 Trips 4 2

1 Pick-up Van, 1 Day 1 1 Pick-up Van, 3 Days 3 3

Average Multiple 1.9

For Every 1 Unit of activity required by R to remedy corrosion, C requires 1.9 Units or more, on Average.

In this comparison, an additional gallon of Rustgrip and a gallon of Enamogrip topcoat was added to the comparison and Rustgrip still required less.

Analysis is based on requirement to remedy corrosion on 200 square feet. The larger the surface area, square footage wise, the greater the savings when Rustgrip is used.


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Rust Grip®

Validation

RUST GRIP®

• Rust Grip® Testing:

• ASTM TESTING:

B117 Salt Fog corrosion testing (15,000 hours with a perfect score of 10 and no failure)

ASTM D5894 salt fog corrosion testing (10,000 hours with a perfect score)

D4541, D3273, D3274, D2486, D3359,D522,D2794, D1653, C411,D3359,D6904,D7088, E-108, G20, D5894,

G85, D4060, D522,D1308,E84,D2369,D4017,D3960,D1475,D2370

E1795 ( testing designed specifically for Encapsulation ability of Bio Hazardous Material).

• CHINA SHIPBUILDING TESTS:

• GB/T 1771-91 Salt Fog Resistance (2000 Hrs)

• GB/T 1866-88 Manual Aging (2000 Hrs)

• GB/T 10834-88 Salt Water Resistance (1000 Hrs)

• GB/T 5219-85 Pulling Apart Adhesion (4.07 MPa)

• GB/T 1733-93 Boiling Water Immersion (8 hrs)

• MARITIME APPROVALS:

• DNV (Det Norske Veritas) – Certified and approved

• ABS (American Bureau of Shipping) – Certified and approved

• IMO (Internat’l Marine Organization) – Certified and approved

• US Coast Guard – Certified and approved

• The Society For Protected Coatings (SSPC) 2011 E.Crone Knoy Award (Highest Award given by SSPC for Rust Grip use on Hoover Dam)

Dry Tech Aerogels (Pty) LtdWillie Coetzee

27-82-5862811Rust Grip


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Rust Grip® Testing:

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Rust Grip® conforms to all the requirements for Non-Reinforced Liquid Coatings Encapsulation Products for Leaded Paint in Buildings, Exterior and Interior.

Rust Grip® has been issued a patent as a “Method for Abating Bio-Hazardous Materials found in Coatings, including lead-based paint and asbestos.

15,000 hour Salt Fog Corrosion Test with perfect score of 10


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Army Corps of Engineers Rust Grip® Reports:

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Results:Please note Rust Grip was tested as a one coat systemapplied to direct metal. Other products were multiplecoat applications.

• Rust Grip met all requirements of the specificationfor stray stability, mixing properties and sprayingproperties.

• Rust Grip exceeded the minimum requirements foradhesion to the substrate.

• Rust Grip exceeded the impact requirement forintrusion testing.

• Rust Grip exceeded the requirements for blisteringand rust undercutting at the scribe.

• Rust Grip was the only primer/topcoat system thatpassed the rust evaluation requirement of thespecification.

Final Assessment:The final assessment is based on the results achieved atSimmons Army Airfield at Fort Bragg, Fayetteville, NCand was part of demonstration of smart coatings beingperformed.

“The overcoating process does not require extensivepreparation, and can be significantly less expensivethan other maintenance practices, particularly whenthe existing coating contains lead or other hazardousmaterials.

The overcoating procedure was demonstrated on twotypes of structures: steel tanks and corrugated steelhangars. It is recommended that these technologies beimplemented as standard practice for coating of steelstructures for the Army and DoD.”


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Corrosion & Lead-Based Paint Projects at Simmons Army Airfield:

RUST GRIP®

In 2007, RUST GRIP® was applied to corroded, lead-based painted deluge tanks and airport hangar. A visualinspection in March 2010 found the paint system intact and no signs of atmospheric corrosion.

The hangar could not be abrasive blasted because blasting creates dust that is incompatible with the functions of thehangar. Assuming production rates in the range 80 to 100 ft2/h, the added labor cost of complete coating removal onthe hangars would have been $0.11/ft2 to $0.24/ft2. Additional costs associated with the mobilization/demobilization,equipment, health and safety, containment, water filtering, and waste disposal would add an estimated $6-8/ft2. Theestimated cost of repainting the hanger using UHP water blasting and a similar two coat paint system would be about$9-11/ft2 as compared to the overcoating cost of $2.85/ft2.

The deluge tanks could have been contained and dry abrasive blasted to remove the existing coating prior torepainting. Assuming production rates in the range 150 to 200 ft2/h, the cost of complete coating removal on thetanks would have been about $0.40/ft2 to $0.80/ft2 less in terms of production labor. However, the additional costs ofmobilization/demobilization, equipment, materials, containment, worker protection, and waste disposal would haveincreased the cost by about $6/ft2 to $8/ft2. Overall the cost of abrasive blasting and repainting would have beenabout $8/ft2 to $10/ft2 as compared to an overcoating cost of $1.89/ft2.

According to the CERL/ERDC TR-09-31 report, the average cost of using Rust Grip® to eliminate blasting and toencapsulate on the tanks and hangar was $2.36/ft2 compared to $9.50/ft2, for traditional methods. The averagesavings is $7.14/ft2.


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Rust Grip® Corrosion & Lead-Based Paint Projects at Fort BraggSimmons Army Airfield:

RUST GRIP®

Corrosion and Lead-based painted structures, power washed to remove dirt, oils and loose paint flakes; flakes trapped in perforated tarp and water released back into the environment; Rust Grip®/Enamo Grip paint system applied. No safety or environmental violations on this project.


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Rust Grip® & Lead-Based Paint on Concrete Surfaces at Simmons AAF

RUST GRIP®

Rust Grip®/Enamo Grip paint system applied to the concrete portions of the hangar with the same procedures as applied to the Metal tanks and hangars. Rust Grip® can be applied to wood, metal, and masonry surfaces with the same successful results.


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Project Army Corps of Engineers & Offshore Oil Platform

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102-year old bridge with Corrosion and Lead-based paint onbridge in Gadsden, AL. Army Corps of Engineers approvedcontainment system of perforated tarp, allowing power washwater to be released back into the environment safely.

Rust Grip on valve and associated piping.

• Rust Grip to stop corrosion on the entire platform and give a tough, long lasting corrosion protection even under abusive conditions (475 bar tensile) on the entire platform

• Single coat. Single component. Easy to brush, roll or spray using airless sprayers

Rust Grip


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USE RUST GRIP TO PROTECT THE ENTIRE PLATFORM

BEFORE


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PEMEX Nohoch Platform Mexico


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Pemex impact adhesion test 200 Kilo drop on Rust Grip coated panels


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PEMEX impact adhesion test 65 Kilo drop of RustGrip


27-82-5862811PEMEX torch test. No burn out!

Rust Grip


27-82-5862811Rustgrip Meshing System


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Recap of Rust Grip® 1. Rust Grip will not crack or peel when applied per Manufacturer’s specification.

2. 60 % or more on average, cost savings when total cost is compared to competitive 3 coat 2 part corrosions systems.

3. Validated by more than 28 independent Certified ASTM test by USA accredited laboratories.

4. Applies easily without extensive surface preparation. No sandblasting to new metal required.

5. Application friendly. Simply clean surface, remove loose mils scale & pack rust, stir and apply.

6. Apply as a one-coat single component system directly over surface rust after removal of mil scale and pack rust.

7. Designed to penetrate through surface rust deep into the pores of the underlying substrate .

8. Rustgrip expands and swell in the metal pores and recesses to anchor lock. No glue adhesion.

9. 0 permeability, once within the pores of metal, no air & moisture can infiltrate = no rusting.

10. 6,780 psi Surface tensile strength when it dries. Fully curing at 12,000psi after 21 days

11. Has durability and strength to last Fifteen to Twenty years in the harshest environments.

12. Withstand abrasion and direct impact.

13. Withstand acid rain and chemical splashes.

14. NO Mud Cracking and NO pot life.

15. Class A Non Combustible Flame spread rating.

16. Ship time by ocean 4-6 weeks on average.

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Rust Grip® VIDEO LINKS

https://www.youtube.com/watch?v=3APSkTtDHG4 (Slide# 20)(Pemex Oil, the national oil company of Mexico, drops 100 kilo anvil on panel coated with Rustgrip to see the impact, abuse and adhesion capacity of Rustgrip, Rustgrip did not crack or dis-bond)

https://www.youtube.com/watch?v=pnD3dCnAOr0 (Slide # 22)

(Pemex uses a torch to cut metal panel that have been coated with Rustgrip to see if burn off, how far it burned back and if flammable. If pipe had to be cut they wanted to know how a Rustgrip coated pipe would be impacted. Rustgrip showed no impact)

https://www.youtube.com/watch?v=t-aDPlqeL_0 (Slide# 23)

https://www.youtube.com/watch?v=4i9Kf3-0yqE

(Video showing how Rustgrip can be used to patch holes (large and small )on metal while at the same time remedy corrosion without sandblasting to new metal.

https://www.youtube.com/watch?v=skLo4bJUwZs(Use of Rustgrip on US DOT Highway Bridges)

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https://www.youtube.com/watch?v=3APSkTtDHG4

https://www.youtube.com/watch?v=pnD3dCnAOr0

https://www.youtube.com/watch?v=t-aDPlqeL_0

Documents

Dry Tech Aerogels (Pty) Ltd RUST GRIP® 27-82-5862811 Rust Grip® Presentationdrytechaerogels.co.za/assets/dry-tech-aerogels-rust-grip... · 2018-06-14 · Dry Tech Aerogels (Pty)