Jotun Pipeline Coatings

CONTENTS
1. PRODUCT OUTLINE 4. PROCESSING

Stand Alone FBE Selection Chart . . . . . . . . . . . . . . . . . . . . . . . .1 Fusion Bonded Epoxy for Stand Alone Coatings . . . . . . . .117-121
Special feature grades – Corro-Coat EP-F 3000 series . . . . . . . . .2 Fusion Bonded Epoxy for Multi-layer Coatings . . . . . . . . .122-128
Multi-layer FBE Primer Product Range and Selection Guide . . . . . .3 FBE Coating Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . .129-130
InterCoat Timing Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 46F640 Coating Repairs . . . . . . . . . . . . . . . . . . . . . . . . .131-132
Girth Weld Coating with FBE . . . . . . . . . . . . . . . . . . . . . .133-137
2. PRODUCT INFORMATION
Corro-Coat EP-F 1003LD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 5. TRACK RECORD
Corro-Coat EP-F 1003HW . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8 Yadana Gas Pipeline project – Thailand . . . . . . . . . . . . . . . . .138
Corro-Coat EP-F 1010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10 Corro-Coat EP-F 1000 Series reference list . . . . . . . . . . . .139-143
Corro-Coat EP-F 1011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-12 Corro-Coat EP-F 2000 Series primer reference list . . . . . . . . . . .144
Corro-Coat EP-F 1020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-14 Corro-Coat EP-F 2004 reference list
Corro-Coat EP-F 2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-16 on projects where design temperature is 140°C: . . . . . . . . . . .145
Corro-Coat EP-F 2002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-18 PGU III Sector 2 & 3 & Loop 1 Petronas Gas Bhd. – Malaysia . .146
Corro-Coat EP-F 2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-20 Hindustan Petroleum Corporation – India . . . . . . . . . . . . . . . .147
Corro-Coat EP-F 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-22 Gulf of Suez Petroleum Company – Egypt . . . . . . . . . . . . . . . .148
Corro-Coat EP-F 3001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23-24 Esso Imperial Oil Resources – Canada . . . . . . . . . . . . . . . . . . .149
Corro-Coat EP-F 3002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Husky Oil – Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
46F640 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26-28 Amoco Petroleum – Canada . . . . . . . . . . . . . . . . . . . . . . . . . .151
HPL 100 – 75F650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29-31 Tunus/Steg Project – Turkey . . . . . . . . . . . . . . . . . . . . . . . . . .152
HPL 100 Brush Grade – 75F650R . . . . . . . . . . . . . . . . . . . .32-34 Ocensa Oleoducto Sentral S.A. – Columbia . . . . . . . . . . . . . . .153
SWCC Al Jubal – Riyadh Line C – Saudi Arabia . . . . . . . . . . . .154
3. HEALTH AND SAFETY SWCC Yanbu-Madina Pipeline Project – Saudi Arabia . . . . . . .155
Corro-Coat EP-F 1003LD Beige . . . . . . . . . . . . . . . . . . . . . .35-40 Sui Northern Gas Ltd. 1 – Pakistan . . . . . . . . . . . . . . . . . . . . .156
Corro-Coat EP-F 1003HW Blue . . . . . . . . . . . . . . . . . . . . . .41-46 Sui Northern Gas Ltd. 2 – Pakistan . . . . . . . . . . . . . . . . . . . . .157
Corro-Coat EP-F 1003HW Beige . . . . . . . . . . . . . . . . . . . . . .47-51 Goldfields Gas Transmission Joint Venture – Australia . . . . . . .158
Corro-Coat EP-F 1010 Grey . . . . . . . . . . . . . . . . . . . . . . . . .52-57 Beijing Natural Gas Transmission Company – China . . . . . . . .159
Corro-Coat EP-F 2001 Grey . . . . . . . . . . . . . . . . . . . . . . . . .58-62 Pilbara Pipeline – Australia . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Corro-Coat EP-F 2002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63-67 Imperial Oil Resources Limited (Esso/Exxon) – Canada . . . . . . .161
Corro-Coat EP-F 2002 HW . . . . . . . . . . . . . . . . . . . . . . . . . .68-72 Poland Country Market Polish Oil & Gas Client – Poland . . . . .162
Corro-Coat EP-F 2004 Beige . . . . . . . . . . . . . . . . . . . . . . . .73-77 Abu Dhabi National Oil Company – U.A.E. . . . . . . . . . . . . . . .163
Corro-Coat EP-F 2013 Beige . . . . . . . . . . . . . . . . . . . . . . . .78-82 Multi-layer H.D.P.E. Coating Projects . . . . . . . . . . . . . . . . . . . .164
Corro-Coat EP-F 3001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83-87 Gas Pipeline to Spur Development – Australia . . . . . . . . .165-167
Corro-Coat EP-F 3002 Blue . . . . . . . . . . . . . . . . . . . . . . . . .88-92 SWWC – Saudi Arabia . . . . . . . . . . . . . . . . . . . . . . . . . .168-170
46F640 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93-98
HPL 100 Curing Agent – Clear . . . . . . . . . . . . . . . . . . . . . .99-103 Continued
HPL 100 Brush Grade Base – Off White . . . . . . . . . . . . . .104-109
HPL 100 Spray Grade Base – Off White . . . . . . . . . . . . . .110-116
6. APPROVALS 10. ARTICLES
Saudi Arabian Oil Company . . . . . . . . . . . . . . . . . . . . . . . . . .171 ‘J D N’ MultiCoat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213-219
Transco (Corro-Coat EP-F 1003 LD, New Test Methods for Evaluating Pipeline Coatings . . . . .220-228
Corro-Coat EP-F 1003 HW) . . . . . . . . . . . . . . . . . . . . . . . . . . .172 High Temperature Performance of Three-layer Epoxy/
Transco (Corro-Coat EP-F 1010) . . . . . . . . . . . . . . . . . . . . . . .173 Polyurethane Coatings . . . . . . . . . . . . . . . . . . . . . . . . . .229-237
Coaters Reference list . . . . . . . . . . . . . . . . . . . . . . . . . . .174-175 Development of Three-layer High Density Polyethylene
Corro-Coat EP-F Spec/Client approvals list . . . . . . . . . . . .176-177 Pipe Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238-244
UK ISO Certificate of Approval . . . . . . . . . . . . . . . . . . . . . . . . .178 Polyethylene – Extrusion – Coating of buried steel pipe . .245-263
Polythene Coatings in Europe . . . . . . . . . . . . . . . . . . . . .264-276
7. TEST REPORTS Trilaminate as a pipe coating . . . . . . . . . . . . . . . . . . . . . .277-286
I.T.I. CSA. Laboratory Testing of Jotun FBE Products . . . . .179-194 Update on how to select mill applied pipe coatings . . . . .287-289
I.T.I. Test on Corro-Coat EP-F 1010 . . . . . . . . . . . . . . . . . .195-200 Designing the Ideal Pipeline Coating . . . . . . . . . . . . . . . .290-300
Environmental and Economical Aspects
8. GENERAL INFORMATION of Multilayer Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . .301-304
Cathodic Protection Design . . . . . . . . . . . . . . . . . . . . . . . . . . .201 Powder Coatings playing its part in the protection
Thermal Conductivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202 of pipelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305-307
Consumption of FBE in various systems . . . . . . . . . . . . . . . . . .203
Evaluation of Corro-Coat MOPS202- . . . . . . . . . . . . . . . .204-209
9. CONTACTS
Jotun Functional Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . .210
Pipe Coating Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
Girth Weld Coating Contractors . . . . . . . . . . . . . . . . . . . . . . . .212
Stand Alone FBE Selection Chart
Jotun Powder Coatings offers three Stand Alone Special application Stand Alone FBE grades.
grades of Corro-Coat EP-F designed to suit different
application conditions. Corro-Coat EP-F 1011
Corro-Coat EP-F 1010 Low application temperature grade ideal for heavy
wall pipe and field application.
A new generation of fusion bond epoxy with
enhanced tolerance to surface profile conditions.
Corro-Coat EP-F 1020
Corro-Coat EP-F 1003 LD For higher operating temperature conditions.
Standard product to cover most application

conditions.
46F640
Two pack epoxy repair compound.

Corro-Coat EP-F 1003 HW
Slower reaction product suited to slower application The key application property for powder selection
speeds where temperatures are maintained for is gel time.
longer period. Using the CSA Z240.20-M98 (12.2) method, these
product gel times are:
Product Gel Time
Corro-Coat EP-F 1010 15 seconds ±20%
Corro-Coat EP-F 1003 LD 15 seconds ±20%
Corro-Coat EP-F 1003 HW 21 seconds ±20%
1
Special feature grades – Corro-Coat EP-F 3000
series
Antislip epoxy overcoat to enhance the adhesion

between an FBE anticorrosion coating and a
concrete weight coat.
Mechanical protection epoxy for use over FBE to

provide effective mechanical protection for
handling, backfill and directional drilling.
2
FACT SHEET MINIMUM APPLICATION DELAY
In the case of extruded adhesive, a minimum time
MULTI-LAYER FBE PRIMER PRODUCT prior to application of the adhesive has to be
allowed. This is required to enable the mobility of
RANGE AND SELECTION GUIDE the FBE to be reduced through partial cure or
The product range manufactured and supplied by gelation in order to avoid skidding during
Jotun Powder Coatings for multi layer coatings application of the adhesive. For powder/powder
comprises several different grades to meet a variety application there is no minimum time.
of needs. The selection of the correct grade is
primarily dependent on two key factors: MAXIMUM APPLICATION DELAY
1. Plant conditions for application of the Adhesive has to be applied before all the reactivity and
FBE primer and Adhesive mobility has been removed from the FBE to ensure
optimum reactions between the two layers. The key
2. Thickness of FBE specified by the client
property of the FBE for evaluation of this is the gel
Selection due to plant conditions is the most time. Gel time is dependent on the application
important. Bonding between the FBE and the temperature and the epoxy film thickness.
Adhesive involves a chemical reaction in which the
From this combination and based on the nominal gel
epoxy groupings of the FBE and the anhydride
time for various grades, a maximum time before
groupings of the adhesive react together. For this
application of the adhesive can be estimated to aid
reaction to occur properly the reactivity of the FBE
selection of the best grade under any particular
primer has to be correct at the time of application of
plant conditions.
the adhesive.
PRODUCT CORRO COAT CORRO COAT CORRO COAT CORRO COAT

EPF1003HW EPF1003HW 2013 2001/2002
THICKNESS OF EPOXY 60–125µ 125–35Oµ 125–175µ 60–100µ
MAXIMUM INTERCOAT TIME
@ 180°C 25 sec
@ 200°C 12 sec
@ 220°C 6 sec 10 sec 20 sec 7 sec
@ 240°C 3 sec 5 sec 15 sec 3 sec
NOTE: These values are for guidance only and may vary depending on plant design and pipe characteristics. Tests should be carried out
to ensure the correct grade is selected for an individual plant.
Special application grade Corro-Coat EP-F 2004.

Specially designed for use as a primer in 3LPP
systems requiring higher operating temperatures.
3
InterCoat Timing Guide
60
50 Corro-Coat EP-F 1003 HW
40
Corro-Coat EP-F 2002 HW
Time (Sec)
30
20
10
0
170 180 190 200 210 220 230 240
Temperature (C)
4
temperatures and lower humidities are
Corro-Coat EP-F 1003LD recommended. A shorter shelf life is obtained at
higher temperatures. Do not exceed 92°F (33°C).
Corro-Coat EP-F 1003LD is a fusion bond epoxy Product should be evaluated through gel time
designed for use as a stand-alone anti-corrosion testing if aging exceeds 12 months beyond
coating suitable for application from 12 to 24 mils manufacture date.
(300 to 600 microns). Higher thickness may be used
for application under concrete weight coating. Corro-Coat EP-F 1003LD coatings are suitable for
operations at temperatures up to 212°F (100°C) in
Suitable for application temperature in the range of dry conditions. 285°F (140°C) would be acceptable
450°F to 488°F (232°C to 252°C). A shelf life of at for intermittent exposure. In wet conditions the
least twelve months is obtained when stored at 77°F maximum operating temperature is 176°F (80°C).
(25°C) and 65% Relative Humidity. Cooler
5
Corro-Coat EP-F 1003LD
*Typical Properties
Property Test method Result
Cure Time CSA-Z245.20-M98 (12.1) <30 seconds
Moisture Content CSA-Z245.20-M98 (12.3) Below 0.30% (at time of manufacture)
Density CSA-Z245.20-M98 (12.6) 1450±50 g/l
Theoretical Coverage N/A 134 Ft2/lb./mil (1.72m2/kg/400 microns)
Particle Size CSA-Z245.20-M98 (12.5) 99.8% below 250 microns
Shelf Life @ 77°F (25°C) or cooler 12 months (see previous page)
Flexibility CSA-Z245.20-M98 (12.11)
3.0°PPD@-30°C (-22°F) Pass
Strained Polarization CSA-Z245.20-M98 (12.13)
28 days Pass/No Cracking
Chemical Resistance CSA-Z245.20-M98 (12.9) No Change
Abrasion Resistance ASTM D 4060-95, CS-17, 1Kg weight
5K cycle 0.26g wt. Loss
Hardness Shore D ASTM D2240-97 Average of 90
Impact Resistance CSA-Z245.20-M98 (12.12) 1.5J (Pass)
Thermal Characteristics CSA-Z245.20-NI98 (12.7) Tg 1 = 50–66°C
Tg 2= 98–110°C
Delta H = 40-60j/g
Delta Tg =±5°C
C(%) = >96%
Adhesion CSA-Z245.20-NI98 (12.14)
165°F (75°C), 48hours # 1 or 2 rating
205°F(95°C), 24 hours # 1 or 2 rating
Cathodic Disbondment CSA-Z245.20-M98 (12.8)
48 hours,1.5v, 150°F(65°C) 4.0 mm radius avg. (Pass)
24 hours, 3.5v, 150°F(65°C) 4.0 mm radius avg. (Pass)
28 days, 1,5v, 68°F(20°C)±2° 5.5 mm radius avg. (Pass)
Electrochemical Impedance Max 13.3 logZ ohms/cm2
Dielectric Strength ASTM D149-95 >550v per mil (25 microns)
RECOMMENDED REPAIR SYSTEMS ARE JOTUN 46F640 TWO-PACK EPOXY AND JOTUN HPL EPOXIES.
English
6
Typical application temperature range is 230°C–
Corro-Coat EP-F 1003HW 250°C as a stand alone and 200–220°C as a primer.
Corro-Coat EP-F 1003HW is a fusion bond epoxy A shelf life of at least 12 months is obtained when
designed for use as a stand-alone anti-corrosion stored at 25°C and 65% relative humidity. However,
coating when applied at 300 to 600 microns. cooler temperatures and lower humidities are
Thicker coatings may be applied for used under recommended. A shorter shelf life is obtained at
concrete weight coating. higher temperature. Do not exceed 33°C.
Corro-Coat EP-F 1003HW can also be used as a Corro-Coat EP-F 1003HW coatings are suitable for
primer in a 3 layer coating system when it is typically operations at temperature up to 100°C in dry
applied at 80 to 500 microns. Especially formulated conditions. 140°C would be acceptable for
with slower reaction making it ideally suited for intermittent exposure. In wet conditions the
coating heavy wall pipe, and as a primer in 3-layer maximum temperature is 80°C.
coating systems.
7
Corro-Coat EP-F 1003HW
*Typical Properties
Cure Time CSA-Z245.20-M98(12.1) <60 seconds
Moisture Content CSA-Z245.20-M98 (12.3) Below 0.30 % (at time of Manufacture)
Density CSA-Z245.20-M98 (12.6) 1400±50g/l
Theoretical Coverage N/A 140 Ft2/lb./mil (1.79m2/kg/400 microns)
Shelf Life @77°F (25°C) 12 months (see previous page)
Flexibility CSA-Z245-20-M98 (12.11)
3.0°PPD0@ -30°C (-22°F) Pass
Strained Polarization CSAJ245.20-M98 (12.13)
Chemical Resistance CSA-Z245.20-M98 (12.9) No Change
Abrasion Resistance ASTM D 4060-95,CS-17,1Kg weight
Impact Resistance CSA-Z245.20-M98 (12–12) I.5J (pass)
Thermal Characteristics CSA-Z245.20-M98 (12.7) Tg 1 = 50–66°C
Tg 2= 98–110°C
Delta H = 40–60J/g
Delta Tg = ±5°C
C(%) = >96%
Adhesion CSA-Z245.20-M98 (12.14)
205°F (95°C), 24 hours # 1 or 2 rating
Cathodic Disbondment CSA-Z245.20-M198 (12.8)
28 days, 1.5v, 68°F(20°C)±3° 4.5 mm radius avg. (Pass)
Revision English
8
450°F to 488°F (232°C to 252°C). A shelf life of at
Corro-Coat EP-F 1010 least 12 months is obtained when stored at 77°F
(25°C) and 65% Relative Humidity. Cooler
Corro-Coat EP-F 1010 introduces a new generation temperatures and lower humidities are
of fusion bond epoxy with enhanced tolerance to recommended. Do not exceed 92°F (33°C). Product
surface profile conditions. should be evaluated through gel time testing if aging
Corro-Coat EP-F 1010 is designed for use as a stand- exceeds 12 months beyond manufacture date.
alone anti-corrosion coating suitable for application Corro-Coat EP-F 1010 coatings are suitable for
from 12 to 24 mils (300 to 600 microns). Higher
operations at temperatures up to 212°F (100°C) in
thickness may be used for application under
dry conditions. 285°F (140°C) would be acceptable
concrete weight coating.
for intermittent exposure. In wet conditions the
Suitable for application temperature in the range of maximum operating temperature is 176°F (80°C).
9
*Typical Properties
Cure Time CSA-Z245.20-M98 (12.1) < 30 seconds
Moisture Content CSA-Z245.20-M98 (12.3) Below 0.30 % (At Time of Manufacture)
Density CSA-Z245.20-M98 (12.6) 1500±50g/l
Theoretical Coverage N/A 131 Ft2/lb/mil (1.67m2/kg/400 microns)
Shelf Life @ 77°F (25°C) or cooler 12 months (see previous page)
3.O°PPD@-30°C (-22°F) Pass (> 3° PPD)
Strained Polarization CSA-Z245.20-M98 (12.13)

Chemical Resistance CSA-Z245.20-M98 (12–9) No Change
Abrasion Resistance ASTM D 4060-95, CS-17, 1Kg weight
Impact Resistance CSA-Z245.20-M98 (12.12) 3.0J (Pass)
Thermal Characteristics CSA-Z245.20-M98 (12.7) Tg 1 = 52–66°C
Tg 2= 98–110°C
Delta H = 40–60j/g
Delta Tg = ±5°C
C(%) = >96%
205°F (95°C), 24 hours # 1 or 2 rating
Cathodic Dishondment CSA-Z245.20-M98 (12.8)
48 hours, 1.5v, 150°F (65°C) 3 – 4 mm radius avg. (Pass)
24 hours,3.5v, 150°F (65°C) 3 – 4 mm radius avg. (Pass)
28 days, 1.5v, 68°F (20°C)±3° 4 – 5 mm radius avg. (Pass)
English
10
PROVISIONAL PRODUCT DATA SHEET
A shelf life of at least 12 months is obtained when
Corro-Coat EP-F 1011 stored at 25°C and 65% Relative Humidity. Cooler
Corro-Coat EP-F 1011 introduces a new generation recommended. A shorter shelf life is obtained at
of fusion bond epoxy with lower application higher temperature. Do not exceed 33°C.
temperature. Corro-Coat EP-F 1011 coatings are suitable for
Designed for use as a stand alone anti corrosion operations at temperatures up to 100°C in dry
coating suitable for application from 300 to 600µm. conditions. 120°C would be acceptable for
Higher thicknesses may be used for application intermittent exposure. In wet conditions the
under concrete weight coating. maximum temperature is 80°C.
Typical application temperature range is 185°C –
210°C.
Typical Powder Properties

Colour Grey
Moisture content CSA-Z245.20-M98 (12.3) Below 0.50% (at time
of manufacture)
Density CSA-Z245.20-M98 (12.6) 1.35 +/- 0.05g/cc
Particle Size CSA-Z245.20-M98 (12.5) 99.5% below 250m
Shelf life 25°C or cooler 12 months (see text
above)
Gel Time Hot plate method
180°C 12–18 s
Cure Time 200°C @ 50 s
(Time to Quench)
Differential Scanning Calorimeter Tg1(onset) 54 °C +/-10 %
(Mettler TA 3000 ∆H 82 J / gm +/-10 %
DSC20 Cell) Tg2 (onset) 100°C +/-5 %
∆Tg Max. +/-3 °C
The information on this product data sheet, is given to the best of our knowledge, based on laboratory testing and practical
experience. However, as the product is often used under conditions beyond our control we cannot guarantee anything but the
quality of the product itself.
11
Typical Film Properties

3.0°PPD @ -30 °C Pass (>3°PPD)
Strained polarization CSA-Z245.20-M98 (12.13)
28 days Pass / no cracking
Chemical resistance CSA-Z245.20-M98 (12.9) No change
Impact resistance CSA-Z245.20-M98 (12.12) Pass (3.0 J)
75°C, 48 hours #1 or 2 rating
Cathodic disbondment CSA-Z245.20-M98 (12.8)
65°C, 48 hours, 1.5v Pass (3 – 4 mm av.)
20°C, 28 days, 1.5v Pass (4 – 5 mm av.)
Notes:
Recommended repair systems are Jotun 46F640 two component epoxy and Jotun HPL coatings.
12
Corro-Coat EP-F 1020 introduces a new generation recommended. A shorter shelf life is obtained at
of fusion bond epoxy for use at higher operating higher temperature. Do not exceed 33°C.
temperatures. Corro-Coat EP-F 1020 coatings are suitable for
Designed for use as a stand alone anti corrosion operations at temperatures up to 120°C in dry
coating suitable for application from 300 to 600µm. conditions. 135°C would be acceptable for
Higher thicknesses may be used for application intermittent exposure. In wet conditions the
under concrete weight coating. maximum temperature is 100°C.

245°C.

Colour Grey
Moisture content CSA-Z245.20-M98 (12.3) Below 0.50% (at time
of manufacture)
Density CSA-Z245.20-M98 (12.6) 1.40 +/- 0.05 g/cc
Particle Size CSA-Z245.20-M98 (12.5) 99.5 % below 250m
Shelf life 25 °C or cooler 12 months (see text
above)
Gel Time CSA-Z245.20-M98 (12.2)
204°C 12 – 19 s
Cure Time CSA-Z245.20-M98 (12.1)
(Time to Quench) 232°C <60 s
Differential Scanning Calorimeter Tg1 52 °C +/-10%
(Mettler TA 3000 ∆H 90 J / gm +/-10%
DSC20 Cell) Tg2 123 °C +/-5 %
∆Tg Max. +/-3°C
13
3.0°PPD @ -30 °C Pass (>3 °PPD)
CSA-Z245.20-M98 (12.14) Modified
75°C, 7 Days #1 or 2 rating
20°C, 28 days, 1.5v Pass (4 – 5 mm av.)
CSA-Z245.20-M98 (12.8) Modified
Steel temp 110°C
48 Hours, 1.5v 3 – 4 mm
Notes:
14
4.2.1.1 PRODUCT DATA SHEET
Corro-Coat EP-F 2001 stored at 25°C and 65% Relative Humidity however,
cooler temperatures and lower humidities are
Corro-Coat EP-F 2001 is a series of fusion bond recommended. A shorter shelf life is obtained at
epoxies designed for use as primer coat in multi- higher temperature. Do not exceed 33°C.
layer coating systems for steel pipes typically for Corro-Coat EP-F 2001 coatings are suitable for
application from 50 to 120 microns but suitable for operations at temperatures up to 110°C in dry
a wide range of thicknesses. conditions. 140°C would be acceptable for
The series contains different reactivity materials to intermittent exposure. Dependent on the other
suit different coating plant conditions. components of the multi layer system.
220°C.

Colour Green, Grey
Particle Size Malvern Laser 2600 99.5 % below 250m
Density Liquid displacement method 1.53 +/-0.05 g/cc
Moisture content Below 0.50 % (at time
of manufacture)
Differential Scanning Calorimeter Tg1 62°C +/-10 %
(Mettler TA 3000 ∆H 62 J / gm +/-10 %
DSC20 Cell) Tg2 105°C +/-5 %
∆Tg Max. +/- 4 °C
180°C 38 – 50 s
200°C 22 – 32 s
220°C 7 – 12 s
Cure Time 180°C @ 90 s
(Time to Quench) 200°C @ 55 s
220°C @ 30 s
15

Hardness Buchholz > 90
ISO 2815 / DIN 53153
Impact resistance Modified ASTM D2794 > 80 lbs. inch
Flexibility Mandrel bend test < 5 mm
ISO 1519 / DIN 53152
Dielectric resistance ASTM D149 – 87 550 volts per 25 microns
Dielectric constant ASTM D150 – 74 2.7 @ 1 MHz
Volume resistivity ASTM D257 – 76 6.9 x 1015
Chemical resistance
Distilled water 30 days at 80 °C No visible signs of blistering
Sodium Hydroxide 30 days at 80 °C cracking or disbondment
Cathodic disbondment CSA-Z245.20-M98
65°C, 48 hours, 1.5v Pass (less than 5mm)
20°C, 28 days, 1.5v Pass (less than 5mm)
Note:
Hardness, impact and flexibility results are on lab samples on 0.8mm cold rolled steel at 60–80 microns.
16
Corro-Coat EP-F 2002 is a fusion bond epoxy recommended. A shorter shelf life is obtained at
designed for use as a primer coat in multi-layer higher temperature. Do not exceed 33°C.
coating systems for steel pipes, typical for Corro-Coat EP-F 2002 coatings are suitable for
application thicknesses from 50 to 500 microns operations at temperatures up to 110°C in dry
dependent on plant coating conditions. conditions. 140°C would be acceptable for
With enhanced anti-corrosion and adhesion intermittent exposure. Dependent on the other
performance, Corro-Coat EP-F 2002 is more components of the multi layer system.
tolerant to surface preparation and applied typically
within an application temperature range of 180°C –
220°C.

Colour Grey
Density Liquid displacement method 1.60 +/- 0.05 g/cc
Moisture content Below 0.50 % (at time
of manufacture)
Differential Scanning Calorimeter Tg1 62 °C +/-10%
(Mettler TA 3000 ∆H 62 J / gm +/-10%
DSC20 Cell) Tg2 107 °C +/-5%
∆Tg Max. +/- 3°C
180 °C 32 – 45 s
200 °C 19 – 27 s
220 °C 5 – 10 s
Cure Time 180 °C @ 90 s
(Time to Quench) 200 °C @ 55 s
220 °C @ 30 s
17

Hardness Buchholz > 90
ISO 2815 / DIN 53153
Impact resistance Modified ASTM D2794 > 80 lbs. inch
Flexibility Mandrel bend test < 5 mm
ISO 1519 / DIN 53152
Chemical resistance
Distilled water 30 days at 80°C No visible signs of blistering
Sodium Hydroxide 30 days at 80°C cracking or disbondment
Cathodic disbondment CSA-Z245.20-M98
65°C, 48 hours, 1.5v Pass (less than 5mm)
20°C, 28 days, 1.5v Pass (less than 5mm)
Note:
Hardness, impact and flexibility results are on lab samples on 0.8mm cold rolled steel at 60 –80 microns.
18
Corro-Coat EP-F 2004 recommended. A shorter shelf life is obtained at
higher temperature. Do not exceed 33°C.
Corro-Coat EP-F 2004 is a fusion bond epoxy Corro-Coat EP-F 2004 coatings are suitable for
designed for use as a primer coat in multi-layer operations at temperatures up to 150°C in dry
coating systems for steel pipes, suitable for conditions, dependent on the other components of
application from 50 to 500 microns. the multi-layer system.
Recommended application temperature in the
range of 200°C–250°C.
stored at 25°C and 65% Relative Humidity. Cooler

Colour Beige
Density Liquid displacement method 1.33 +/- 0.05 g/cc
Moisture content Karl Fischer Below 0.50 % (at time
of manufacture)
Differential Scanning Calorimeter Tg1(*) 54°C +/- 10 %
(Mettler TA 3000 ∆H 140 J / gm +/- 10 %
DSC20 Cell) Tg2 (**) 150°C +/- 5 %
180°C 36 – 50 s
200°C 18 – 30 s
240°C 12 – 22 s
Cure Time @ 200°C 90 s
(Time to Quench) @ 235°C 70 s
@ 243°C 50 s
Note
(*) Tg1 may be difficult to measure due to masking peaks present in the
same region.
(**) A Tg2 value of greater than 142°C indicates adequate cure
19
Hardness Rockwell E-Scale
1/8" ball 100Kg load 48 – 50
ASTM D2583 (Barcol) 50 – 60
Impact resistance Modified ASTM G14 – 72 > 80 lbs. inch
(direct) (*) @ 25°C 18.00 J
@ -18°C 9.00 J
@ -40°C 6.80 J
Flexibility Mandrel bend test
@ 25°C Pass 3.22 % strain
@ 0°C Pass 2.22 % strain
Cathodic disbondment CSA-Z245.20-M98 less than 8mm
65°C, 48 hours, 1.5v
British Gas CW6 less than 5mm
25 °C, 25 days
Note:
(*) Impact results are on lab samples on 3.00mm plate without multi-layer topcoat. Typical pipe
samples without multi-layer coat are 1.50J at 350 microns.
(**) Cathodic disbondment based on 350 microns on 3.00mm plate without multi-layer topcoat.
Bends and girth weld components can also be coated using Corro – Coat EP F 2004 in combination with
powder adhesive and powder topcoat.
20
PRODUCT DATA SHEET
However, cooler temperatures and lower humidities
Corro-Coat EP-F 2013 are recommended. A shorter shelf life is obtained at
higher temperature. Do not exceed 33°C.
Corro -Coat EP-F 2013 is a fusion bond epoxy Corro-Coat EP-F 2013 coatings are suitable for
designed for use as a primer coat in multi-layer operations at temperatures up to 100°C in dry
coating systems for steel pipes. Typically applied at conditions. 140°C would be acceptable for
thicknesses of 125 to 170 micron and in a intermittent exposure. In wet conditions the
temperature range of 190°C -250°C. maximum temperature is 80°C.
stored at 25°C and 65% Relative Humidity.

Colour Beige or Grey
Moisture content CSA-Z245.20-M98 (12.3) Below 0.50 % (at time

of manufacture)
Density CSA-Z245.20-M98 (12.6) 1.45 +/- 0.05 g/cc
Theoretical coverage N/A 1.72 m_ / Kg / 400m
Particle Size CSA-Z245.20-M98 (12.5) 99.5 % below 250m
Shelf life 25 °C or cooler 12 months (see text

above)
220 °C 22 – 30 s
240 °C 12 – 17 s
Cure Time 230 °C @ 80 s

(Time to Quench) 240 °C @ 60 s
Differential Scanning Calorimeter Tg1 58 °C +/- 10 %

(Mettler TA 3000 DH 40 J / gm +/- 10 %
DSC20 Cell) Tg2 102 °C +/- 5 %
DTg Max. +/- 3 °C
21

3.0 °PPD @ -30 °C Pass

Hardness Shore D ASTM 2583 90
Dielectric strength ASTM D149-95 >550v per 25µm
Notes:
22
lower humidities are recommended. A shorter shelf
Corro-Coat EP-F 3001 life is obtained at higher temperatures. Do not
exceed 92°F (33°C). Product should be evaluated
Corro-Coat EP-F 3001 is a fusion bond epoxy through gel time testing if aging exceeds six months
designed for use as an anti-slip overcoating for use beyond manufacturing date.
in conjunction with Jotun Fusion Bond Epoxy. The
coating is designed to improve adhesion between Corro-Coat EP-F 3001 is applied immediately after
the Fusion Bond Epoxy and a concrete weight coat. the primary coating to a thickness of approximately
This product is not a stand-alone corrosion coating. 3–4 mils (80 microns). It does not impair the
anticorrosive performance of the primary coating
Application Temperature is in the range of 430°F nor require any changes to the line speed or
(220°C) to 480°F (250°C). A shelf life of at least 6 application temperature of the primary coating.
months is obtained when stored at 77°F (25°C) and
65% Relative Humidity. Cooler temperatures and
23
*Typical Properties
Particle Size Alpine Air Jet Sieve 99.5% < 250 Micron
Gel Time Hot Plate Method
@355°F (180°C) 30–55 seconds
Cure Time @ 450°F(232°C) 70 seconds
(Time to Quench) @ 430°F(220°C) 80 seconds
@ 395°F(200°C) 90 seconds
Specific Gravity CSA-Z245.20-M98 (12.6) 1650±50g/l
10 March 2000 Revision 1 English

24
PRODUCT DATA SHEET
Typically applied within the temperature range of
Corro-Coat EP-F 3002 220°C – 250°C.
Mechanical protection epoxy for use over FBE to A shelf life of at least 6 months is obtained when
provide effective mechanical protection for stored at 25°C and 65% Relative Humidity. Cooler
handling, backfill and directional drilling. temperatures and lower humidity are
recommended. A shorter shelf life is obtained at
CORRO-COAT EP-F 3002 is a fusion bond epoxy higher temperature. Do not exceed 33°C
designed for use as an abrasion resistant overcoating
in conjunction with Corro-Coat EP-F Fusion Bond CORRO-COAT EP-F 3002 is applied immediately
Epoxy. The coating is designed to enhance the after the primary coating to a thickness of up to 500
physical protection of Fusion Bond Epoxy during microns.
directional drilling operations and back fill
operations.

PROPERTY TEST METHOD RESULT
Colour Dark Blue
Particle Size Alpine Air Jet Sieve 99.5% below 250 Micron
Gel Time CSA Z245.20-M98 Method
@ 204°C – Std grade 12 – 18 Seconds
HW grade 18 – 24 Seconds
Cure Time @ 232°C 70 Seconds
(Time to Quench) @ 220°C 80 Seconds
@ 200°C 90 Seconds
Specific Gravity CSA Z245.20-M98 Method 1.55±.05 g/cc
Gouge Test R-33 Carbide Burr Pass 50 Kg
No penetration at 500 micron
Flexibility CSA Z245.20-M98 Method
0 Deg C > 3 Deg PPD
-30 Deg C > 2 Deg PPD
25
FAST CURE EPOXY PATCHING COMPOUND, GREY
46F640
Features High quality. Fast setting. Accurate proportioning. No waste.
Typical Uses Pipe coating repairs.
Finish Gloss Color: Grey
Vehicle/Pigment/Solvent Epoxy Amine/Titanium Dioxide and Reinforcing Pigments
Flash Point (min) 102°C (215°F) Tag Closed Cup
Viscosity Smooth non-flowing paste.
% Volume Solids 100%
Dry Film Thickness 0.5–2.0 mm (20–80 mil).
Coverage (theoretical) 1 Kg. Covers 0.33 sq. meters at 2mm thickness.
Mix Ratio Components A:B = 2:1 by volume.
Recommended Primer Not required
Temperature To Inspect To Handle Full Cure
5°C(50°F) 8 Hrs. 16 Hrs. 5–7 Days
20°C(68°F) 2 Hrs. 5 Hrs. 24 Hrs.
5O°C(122°F) 18 Mins. 45 Mins. 2 Hrs.
90°C(195°F) 6 11ins. 10 Mins. 1 Hr.
120°C(248°F) 3 Mins. 5 Mins. 1 Hr.
Pot Life 20 Minutes at 25°C (77°F)
Performance Fumes Splash/Spill Immersion
Mineral Acids Very Good Very Good
Pot Life 20 Minutes at 25°C (77°F)
Solvents Excellent Good
0il & Fats Excellent Very Good
Water Excellent Excellent Excellent
Sea Water Excellent Excellent Excellent
Heat Resistance Sub-stained to 93°C (200°F). Intermittent to 121°C (250°F). Some
Color change elevated temperatures may occur.
Abrasion Resistance Very Good
Flexibility Fair
26
FAST CURE EPOXY PATCHING COMPOUND, GREY
46F640
Weathering Excellent, but chalks.
Impact Resistance Good
Caution For best results do not apply when temperatures are below 10°C (50°F).
Unusual temperature conditions can be accommodated with special procedures.
Package In 380ml cartridges, requires dispenser gun. 12 cartridges / box.
Shelf Life 2 years minimum.
Storage Temperature 4–43°C (40–110°F)
Application 1. Cartridge – Squeeze our desired amount near point of patch location. Mix well with
stiff spatula or knife. Allow the patch to heat to the same temperature as the pipe.
Spread the patch out to the desired thickness.
2. Bulk – Mix 2:1 by volume ratio. Mix well with stiff spatula or knife.
27
Product Data
46F640 FAST CURE EPOXY PATCHING COMPOUND, GREY
For making in-coating plant repairs (pinhole type faults detected when jeeping), it is recommended that about 10–20 cc’s be
dispensed into a small paper cup and mixed. The typical patch size for such repairs uses 1⁄2–1 cc of material. Therefore,
approximately 20–30 patches can be made with that mix.
For somewhat larger repairs (usually from mechanical damage) the same approach can he used but the patches may need a
little more material. As an alternative, the appropriate amount can be dispensed onto the surface near the repair site, mixed
and then transferred to the repair point.
For making large repairs an option exists to attach a small static mixer (disposable) to the dispensing nozzle which will mix
the 2 component while dispensing. This method may be particularly useful for use on cad-weld test lead connections.
The patching matenal will perform best when is it accurately proportioned, thoroughly mixed and spread out in a uniform
smooth film The optimum patch thickness is about 10–25% thicker than the original coating. ‘More’ is not better. In fact making
a thick blob of a patch is very poor practice as it is prone to getting ‘knocked off. Once way of helping to make a good, smooth
patch is with the help of a small patch of Polyethylene (can be from a garbage bag). The PE comes off easily when the repair
material has set.
The ‘Set’ and ‘Cure’ of the epoxy patching material can be accelerated with heat. At room temperature 46F640 will set in 1
hour and is fully cured after 24 hours. By externally applying heat the set and cure times can be much shortened. Good heat
sources are, for example, a ‘blow dryer’ or a gas torch fitted with a diffuser attachment. While preheating of the surface speeds
up the ‘set’ time, the most effective way to achieve fast setting is by holding the heat source close to the surface. A good patch
ready for handling can be achieved in as short a time as 2 minutes at 200°F with no sag.
Excessive direct heating above 230°F must be avoided. If the wet patch ‘bubbles’ the temperature is too high. An enclosed ‘hot
air box’ surrounding the pipe will he a good way to achieve fast curing of a large patch, including the weld seams, if necessary.
NOTICE: This product is for industrial use only and is not intended or suitable for use in or around a house hold or dwelling.
SAFETY INFORMATION: CONSULT MATERIAL SAFETY DATA SHEET for complete hazard and safety information.
WARNING: CONTAINS POLYAMINE EPOXY RESIN. Do not get in eyes. Avoid breathing vapors. Avoid contact with skin, and
clothing. Wash thoroughly after handling. Keep away from heat and open flame. Use with adequate ventilation. Use suitable
respiratory equipment, as necessary. Keep container closed.
FIRST AID: In case of contact, immediately flush eyes with plenty of water for 15 minutes while removing contaminated clothing
and shoes. Call a physician. Flush skin with water. Wash contaminated clothing before reuse. If inhaled, remove to fresh air.
If not breathing, give artificial respiration, preferably mouth-to mouth, and call a physician.
28
TECHNICAL DATA
HPL 100 – 75F650
PRODUCT DESCRIPTION : A 100% solids, two component modified urethane.

RECOMMENDED USE : For use in refurbishment of buried steel pipelines where down-time must be kept to a
minimum. For use with cathodic protection systems.
TECHNICAL INFORMATION :
Color : Gray
Solids (% by volume) : 100%
VOC : 0.0 lbs/gal (0 gms./ltr.)
Flash point : >215°F (100°C ) Water Resistance : Excellent
Gloss : High Solvent Resistance : Excellent
Flexibility : Excellent Abrasion Resistance : Excellent
Film thickness per coat Theoretical spreading rate
Dry Wet
Application Range : 20.0 – 30.0 mils 20.0 – 30.0 mils 1604 ft2/gal (39.1 m2/ltr.)
(500 – 750 µm) (500 – 750 µm) per dry mil (25 µm)
Typical : 25.0 mils (625 µm) 25.0 mils (625 µm) 64.1 ft2/gal (1.5 m2/ltr.)
APPLICATION DATA :
Application Methods : Plural component airless spray fitted with 3:1 ratio cylinders
Nozzle Tip : 0.023” – 0.035” (0.58 – 0.88mm)
Thinner: Do not thin.
Cleaner: 7T33
Mixing Ratio: 3:1 by volume with 75T608. Note: Do not premix components
29
TECHNICAL DATA
HPL 100 – 75F650
STORAGE: The product must be stored in accordance with national regulations. Preferred storage
conditions are to keep the containers in a dry space provided with adequate ventilation.
The containers should be sealed tightly.
HANDLING: Handle with care. Stir well before use.
HEALTH AND SAFETY : For detailed information on the health and safety hazards and precautions for use of
this product, refer to the Material Safety Data Sheet.
DISCLAIMER: The information in this data sheet is given to the best of our knowledge based on laboratory
testing and practical experience. However, as the product is often used under conditions beyond our
control, we can not guarantee anything but the quality of the product itself. We reserve the right to change
the given data without notice.
VERSION ISSUED MAY 2001, JOTUN PAINTS INC.
THIS DATA SHEET SUPERSEDES THOSE PREVIOUSLY ISSUED
31
TECHNICAL DATA
HPL 100 BRUSH GRADE – 75F650R
PRODUCT DESCRIPTION : A 100% solids, two component urethane designed for brush application on areas that by their
design are difficult to coat with a holiday free film using spray equipment.
RECOMMENDED USE : For use in refurbishment of buried steel pipelines where down-time must be kept to a
minimum. For use with cathodic protection systems.
TECHNICAL INFORMATION :
Color : Gray
Solids (% by volume) : 100%
VOC : 0.0 lbs/gal (0 gms./ltr.)
Flash point : >215°F (104°C ) Water Resistance : Excellent
Gloss : High Aliphatic Solvents : Excellent
Alkali Resistance : Excellent Abrasion Resistance : Excellent
Dry Heat : To 212°F (100°C) Sustained
To 260°F (125°C) Intermittent
Wet Heat : To 131°F (55°C) Sustained
To 176°F (80°C) Intermittent
Film thickness per coat Theoretical spreading rate

Dry Wet
Application Range : 20.0 – 30.0 mils 20.0 – 30.0 mils 1604 ft2/gal (39.1 m2/ltr.)
(500 – 750 µm) (500 – 750 µm) per dry mil (25 µm)
Typical : 25.0 mils (625 µm) 25.0 mils (625 µm) 64.1 ft2/gal (1.5 m2/ltr.)
APPLICATION DATA :
Application Methods : Use a stiff bristle brush. DO NOT APPLY BY ROLLER.
Thinner: Do not thin.
Cleaner : 7T12
Mixing Ratio : 3:1 by volume with 75T608
Pot Life @ 73°F (23°C) : 8-10 minutes per kit. Leaving material in can once mixed will shorten pot life.
32
TECHNICAL DATA
SURFACE PREPARATION : All surfaces to be coated must be dry and free of all dust, dirt, grease, wax, loose paint, and
other surface contaminants. For optimum performance, SSPC-SP 10 "Near White Metal Blast"
or SA 2.5 using steel grit is recommended. Performance will decline with lesser surface
preparation.
CONDITIONS DURING The temperature of the substrate should be a minimum of 5°F (3°C) above the dew point.
APPLICATION: For best results, apply when surface temperature is above 50°F (10°C) and the relative
humidity is not greater than 85%.
DRYING TIME: Drying times are generally related to air circulation, temperature, film thickness and
number of coats, and will be affected correspondingly. The figures given in the table
are typical with:
* Good ventilation (Outdoor exposure or free circulation of air)
* Recommended film thickness
* One coat on top of inert substrate
Dry to Recoat 1
Substrate Temp. Inspection Cured Minimum Maximum
35°F (1.6°C) 6 Hours 96 Hours 24 Hours
88°F (31°C) 3 Hours 24 Hours 24 Hours
104°F (40°C) 1 Hour 8 Hours 24 Hours
1. Recommended data given for recoating with the same generic type of paint.
The given data must be considered as guidelines only. The actual drying time/times before recoating may be
shorter or longer, depending on existing coating, generic type, film thickness, system chosen, number of
coats, ventilation, temperature, requirement for early handling and mechanical strength etc. A complete
system can be defined on a specification sheet, where all parameters and special conditions are included.
NOTE: This product is moisture sensitive. Keep containers closed until ready for use. Cover product with an inert gas blanket
when only partially used.
33
TECHNICAL DATA
STORAGE: The product must be stored in accordance with national regulations. Preferred storage
conditions are to keep the containers in a dry space provided with adequate ventilation.
The containers should be sealed tightly.
HANDLING: Handle with care. Stir well before use.
HEALTH AND SAFETY : For detailed information on the health and safety hazards and precautions for use of this
product, refer to the Material Safety Data Sheet.
DISCLAIMER: The information in this data sheet is given to the best of our knowledge based on laboratory
testing and practical experience. However, as the product is often used under conditions beyond our
control, we can not guarantee anything but the quality of the product itself. We reserve the right to change
the given data without notice.
VERSION ISSUED MAY 2001, JOTUN PAINTS INC.
THIS DATA SHEET SUPERSEDES THOSE PREVIOUSLY ISSUED
34
MATERIAL SAFETY DATA SHEET
EMERGENCY PHONE: 1-888-345-5732
PRODUCT NAME: CORRO-COAT EP-F 1003LD-BEIGE
PRODUCT CODE: A700500
1. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION

REVISION DATE: 01-17-2000
SUPERCEDES: None
Manufactured by: Jotun Paints, Inc.
9229 Highway 23, PO Box 159,
Belle Chasse, LA 70037
III. COMPOSITION/INFORMATION ON INGREDIENTS

CHEMICAL NAME/COMMON NAME % CAS# PEL
MODIFIED SOLID EPOXY BISPHENOL A TYPE 10–30 TRADE SECRET No PEL established
EPOXY RESIN
BISPHENOL I- (EPICHLOROHYDRIN) EPOXY 10–30 25036-25-3 No PEL established
RESIN / EPOXY RESIN
REACTION PRODUCT OF EPOXY RESIN/ 7–13 TRADE SECRET No PEL established
BISPHENOL A WITH FLOW MODIFIER AND
CURING ACCELERATOR / EPOXY CURING AGENT
BARIUM SULPHATE / BARYTES 7–13 13462-86-7 No PEL established
NEPHELINE SYENITE / NEPHELINE SYENITE 5–10 37244-96-5 No PEL established
TITANIUM OXIDE / TITANIUM DIOXIDE 1–5 13463-67-7 total dust: 15 mg/m3
TWA
Components not listed are not physical or health hazards as defined in 29 CFR 1910.1200
(Hazard Communication Standard).
IV. HAZARDS IDENTIFICATION

Routes of Entry: Inhalation; Absorption; Ingestion; Skin contact; Eye contact
Immediate (Acute) Health Effects:
Inhalation: Can cause minor respiratory irritation, dizziness, weakness, fatigue, nausea, and headache.
Harmful! Can cause systemic damage (see ‘Target Organs’)
Skin Contact: Can cause minor skin irritation, defatting, and dermatitis.
Eye Contact: Can cause moderate irritation, tearing and reddening, but not likely to permanently
injure eye tissue. Can cause mechanical irritation if dusts are generated.
Ingestion: Mildly irritating to mouth, throat, and stomach. Can cause abdominal discomfort. Small
amounts (a tablespoonful) swallowed during normal handling operations are not likely to
cause injury; swallowing amounts larger than that may cause injury.
Target Organ Acute Toxicity: No organs known to be damaged from exposure to this product.
35
Long-Term (Chronic) Health Effects:
Carcinogenicity: None of the substances have been shown to cause cancer in long term animal studies.
Not a carcinogen according to NTP, IARC, or 0SHA.
Reproductive and
Developmental Toxicity: No data available to indicate product or any components present at greater than 0.1%
may cause birth defects. Not likely to be a human reproductive hazard.
IV. FIRST AID

Inhalation: Remove to fresh air. If breathing is difficult, have a trained individual administer oxygen.
Eyes: Use an eye wash to remove a chemical from your eye regardless of the level of hazard. Flush
the affected eye for at least twenty minutes. Tilt the head to prevent chemical from transferring
to the uncontaminated eye. Seek medical advice after flushing.
Skin Contact: Wash with soap and water. Get medical attention if irritation develops or persists.
Ingestion: If swallowed, have a trained medical professional induce vomiting immediately. Never give
anything by mouth to an unconscious person.
V. FIRE FIGHTING MEASURES

Flammability Summary: Combustible at elevated temperatures.
Flash Point: 400 deg.F 204 deg.C
Fire Hazards: Material may be ignited only if preheated to temperatures above the high flash point, for
example in a fire. Dust explosions can occur under conditions of high dust concentrations in
the presence of an ignition source. Burning will produce irritating smoke.
Extinguishing Media: Use alcohol resistant foam, carbon dioxide, or dry chemical when fighting fires. Water or foam
may cause frothing if liquid is burning but it still may be a useful extinguishing agent if
carefully applied to the surface of the fire. Do Not direct a stream of water into the hot burning
liquid.
Fire Fighting Instructions: Do not enter fire area without proper protection including self-contained breathing apparatus
and full protective equipment. Dust explosions can occur under conditions of high dust
concentrations in the presence of an ignition source. Burning will produce irritating smoke.
Hazardous Combustion Carbon dioxide; Carbon monoxide
Products:
VI. ACCIDENTAL RELEASE MEASURES

Health Consideration for Exposure to the spilled material may be irritating or harmful. Follow personal
Spill Response: protective equipment recommendations found in Section VIII of this MSDS.
Additional precautions may be necessary based on special circumstances created by the spill
including; the material spilled, the quantity of the spill, the area in which the spill occurred.
Also consider the expertise of employees in the area responding to the spill. Clean up spills
immediately using Protective Equipment recommended in Section VIII at a minimum.
36
Spill Mitigation Procedures:
General Methods: Prevent the spread of any spill to minimize harm to human health and the enviromnent if safe
to do so. Wear complete and proper personal protective equipment following the
recommendation of Section VIII at a minimum. Dike with suitable absorbent material like
granulated clay. Gather and store in a sealed container pending a waste disposal evaluation.
Use an inert absorbent such as sand or vermiculite. Place in properly labeled closed container.
VII. HANDLING AND STORAGE
Handling: Toxic or severely irritating material. Avoid contacting and avoid breathing the material. Use
only in a well ventilated area. Irritating vapors, mists, or dusts may be released upon thermal
processing or during combustion. Avoid creating dusts as an explosive dust air mixture can be
created at high concentrations. If dusts are created, ensure no sources of ignition are present.
Take precautionary measures to prevent electrostatic discharges. Ground and bond containers
when transferring material. Follow all MSDS/label precautions even after container is emptied
because it may retain product residues. As with all chemicals, good industrial hygiene practices
should be followed when handling this material. Minimize dust generation and accumulation.
Storage: Store in a cool dry place. Isolate from incompatible materials. Store at ambient temperature
and atmospheric pressure. Store away from heat Prevent contact withmoisture. Moisture will
impact product performance. Keep away from heat, sparks, and flame Keep container closed
when not in use.
VIII. ENGINEERING CONTROLS AND PERSONAL PROTECTIVE EQUIPMENT

Engineering Controls: Local exhaust ventilation or other engineering controls are normally required when handling
or using this product to avoid overexposure. Engineering controls must be designed to meet
the OSHA chemical specific standard in 29 CFR 19 10.
Protective Equipment:
Respiratory Tract: Respiratory protection may be required to avoid overexposure when handling this product.
General or local exhaust ventilation is the preferred means of protection. Use a respirator if
general room ventilation is not available or sufficient to eliminate symptoms. Follow a
respiratory protection program that meets 29 CFR 1910.134 and ANSI Z88.2 requirements
whenever work place conditions warrant the use of a respirator.
Respirator Type(s): None required where adequate ventilation is provided. If airborne concentrations are above
the applicable exposure limits, use NIOSH/MSHA. approved respiratory protection.
Eyes: Wear chemical splash goggles when handling this product. Additionally, wear a face shield
when the possibility of splashing of liquid exists. Do not wear contact lenses. Have an eye
wash station available. Wear goggles if dusts can reach the exposure limit.
Skin: Avoid skin contact by wearing chemically resistant gloves, an apron and other protective
equipment depending upon conditions of use. Inspect gloves for chemical break-through and
replace at regular intervals. Clean protective equipment regularly. Wash hands and other
exposed areas with mild soap and water before eating, drinking, and when leaving work.
Wash hands and other exposed areas with mild soap and water before eating, drinking, and
when leaving work. Nitrile rubber and PVC are not suitable protective materials; Neoprene is
recommended.
Protective Clothing: Neoprene
37
Control Parameters:
CHEMICAL NAME ACGI11 TLV-TWA ACG111 STEL IDLI1
MODIFIED SOLID EPOXY BISPHENOL No TLV ND
A TYPE
BISPRENOL I- (EPICHLOROHYDRIN) No TLV ND
EPOXY RESIN
REACTION PRODUCT OF EPOXY No TLV ND
RESIN/ BISPHENOL A WITH FLOW
MODIFIER AND CURING
ACCELERATOR
BARIUM SULPHATE No TLV ND
NEPHELINE SYENITE No TLV ND
TITANIUM DIOXIDE 10 mg/m3 TWA Potential NIOSH carcinogen.
IX. PHYSICAL AND CHEMICAL PROPERTIES

Specific Gravity: 1.47
Solubility in Water: Not determined
Theoretical VOC (Ibs/gallon) 0.000
Theoretical VOC (grams/liter) 0.000
X. STABILITY AND REACTIVITY

Stability Information: Stable
Conditions to Avoid: Temperatures above the high flash point of this combustible material in combination with
sparks, open flames, or other sources of ignition. Contamination
Chemical Incompatibility: Acidic conditions; Amines; Caustics (bases); Metals
Decomposition Temp:
Hazardous Decomposition
Products:
Xl. TOXICOLOGICAL INFORMATION

Component Toxicology Data (NIOSH):
Chemical Name CAS Number LDSO/LC50
Sensitization: No data
Eyes (Draize score): This material is estimated to be moderately irritating to the eyes (Draize score is 25–50
[rabbits]).
Skin (Draize score): Likely to be non-irritating to skin based on animal data.
38
XII. ECOLOGICAL INFORMATION
Overview: This material is not expected to be harmful to the ecology.
Mobility: No data
Pesistence: No data
Bioaccumulation: No data. Based on the physical properties of this product, significant environmental persistence
and bioaccumulation. would not be expected.
Degradability: No data
XIII. DISPOSAL CONSIDERATIONS

Waste Description for Spent or discarded material is a hazardous waste.
Spent Product:
Disposal Methods: Dispose of by incineration following Federal, State, Local, or Provincial regulations.
Potential EPA Waste Codes: If discarded, this product is considered a RCRA ignitable waste, D001.
XIV. TRANSPORTATION INFORMATION

DOT Basic Description-Land Transportation: PAINT DRY NOIBN
Hazard Code-Land Transportation: 2A
UN Number-Land Transporation: NA
Hazard Class-Land Transporation: NOT REGULATED
DOT Basic Description-Air Transporation: PAINT DRY NOIBN
Hazard Code-Air Transportation: 2A
UN Number-Air Transporation: NA
Hazard Class-Air Transporation: NOT REGULATED
DOT Basic Description-Sea Transporation: PAINT DRY NOIBN
Hazard Code-Sea Transportation: 2A
UN Number-Sea Transporation: NA
Hazard Class-Sea Transporation: NOT REGULATED
XV. REGULATORY INFORMATION

Toxic Substances Control Act (TSCA): All components in this product are on the TSCA Inventory.
Chemical Name Regulation CAS# % Range
No 313–listed chemicals SARA 313 No CAS # 0.24
in this product
No 313–listed chemicals SARA 313 NoCAS# 0.01
in this product
39
XVI. ADDITIONAL INFORMATION
Disclaimer: IMPORTANT: WHILE THE DESCRIPTIONS, DATA AND INFORMATION CONTAINED HEREIN ARE PRESENTED IN GOOD FAITH AND BELIEVED TO BE ACCURATE,
IT IS PROVIDED FOR YOUR GUIDANCE ONLY. BECAUSE MANY FACTORS MAY AFFECT PROCESSING OR APPLICATION/USE, WE RECOMMEND THAT YOU PERFORM AN
ASSESSMENT TO DETERMINE THE SUITABILITY OF A PRODUCT FOR YOUR PARTICULAR PURPOSE PRIOR TO USE. NO WARRANTIES OF ANY KIND, EITHER EXPRESSED
OR IMPLIED, INCLUDING FITNESS FOR A PARTICULAR PURPOSE, ARE MADE REGARDING PRODUCTS DESCRIBED, DATA OR INFORMATION SET FORTH. IN NO CASE
SHALL THE DESCRIPTIONS, INFORMATION,OR DATA PROVIDED BE CONSIDERED A PART OF OUR TERMS AND CONDITIONS OF SALE. FURTHER, THE DESCRIPTIONS,
DATA AND INFORMATION FURNISHED HEREUNDER ARE GIVEN GRATIS. NO OBLIGATION OR LIABILITY FOR THE DESCRIPTION, DATA AND INFORMATION GIVEN ARE
ASSUMED. ALL SUCH BEING GIVEN AND ACCEPTED AT YOUR RISK.
40
PRODUCT NAME: CORRO-COAT EP-F 1003HW- BLUE
I. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION

SUPERCEDES: None
II. COMPOSITION/INFORMATION ON INGREDIENTS

MODIFIED SOLID EPOXY BISPHENOL A TYPE / EPOXY RESIN 15–40 TRADE SECRET No PEL established
BISPHENOL I- (EPICHLOROHYDRIN) EPOXYRESIN / 10–30 25036-25-3 No PEL established
EPOXY RESIN
REACTION PRODUCT OF EPOXY RESIN/ 10–30 TRADESECRET No PEL established
BISPHENOL A WITH FLOW MODIFIER AND CURING
ACCELERATOR / EPOXY CURING AGENT SUPPLIER
TRADE SECRET / EPOXY RESIN 5–10 TRADE SECRET No PEL established
TWA
Components not listed are not physical or health hazards as defined in 29 CFR 1910.1200 (Hazard
Communication Standard).
III. HAZARDS IDENTIFICATION

Harmful! Can cause systemic damage (see ‘Target Organs’)
Eye Contact: Can cause moderate irritation, tearing and reddening, but not likely to permanently injure eye
tissue. Can cause mechanical irritation if dusts are generated.
cause injury; swallowing amounts larger than that may cause injury.
41
Longterm (Chronic) Health Effects:
Not a carcinogen according to NTP, IARC, or OSHA,
Reproductive and
IV. FIRST AID


Fire Hazards: Material may be ignited only if preheated to temperatures above the high flash point,for
liquid.
Products:

Health Consideration for Exposure to the spilled material may be irritating or harmful. Follow personal protective
Spill Response: equipment recommendations found in Section VIII of this MSDS. Additional precautions may
be necessary based on special circumstances created by the spill including; the material spilled,
the quantity of the spill, the area in which the spill occurred. Also consider the expertise of
employees in the area responding to the spill. Clean up spills immediately using Protective
Equipment recommended in Section VIII at a minimum.
42
General Methods: Prevent the spread of any spill to minimize harm to human health and the environment if safe

because it may retain product residues. As with all chemicals, good industrial hygiene
practices should be followed when handling this material. Minimize dust generation and
accumulation.
and atmospheric pressure. Store away from heat Prevent contact with moisture. Moisture will
when not in use.
VIIII. ENGINEERING CONTROLS AND PERSONAL PROTECTIVE EQUIPMENT

the OSHA chemical specific standard in 29 CFR 1910.
general room ventilation is not available or sufficient to eliminate symptoms. Respiratory
protection may be required in addition to ventilation depending upon conditions of use.
Follow a respiratory protection program that meets 29 CFR 1910.134 and ANSI Z88.2
requirements whenever work place conditions warrant the use of a respirator.
the applicable exposure limits, use NIOSH/MSHA approved respiratory protection.
exposed areas with mild soap and water before eating, drinking, and when leaving work. Wash
hands and other exposed areas with mild soap and water before eating, drinking, and when
leaving work. Nitrile rubber and PVC are not suitable protective materials; Neoprene is
recommended.
Protective Clothing: Neoprene 43

Control Parameters:
CHEMICAL NAME ACGIH TLV-TWA ACGIH STEL IDLH
A TYPE
BISPHENOL I- (EPICHLOROHYDRIN) No TLV ND
EPOXY RESIN
MODIFIER AND CURING
ACCELERATOR
SUPPLIER TRADE SECRET No TLV ND


sparks, open flames, or other sources of ignition. Contamination.
Decomposition Temp:
Products:
XL TOXICOLOGICAL INFORMATION
Chemical Name CAS Number LD5O/LC50
[rabbits]).
44
Mobility: No data
Pesistence: No data
Bloaccumulation: Bioconcentration is not expected to occur. Based on the physical properties of this product,
significant environmental persistence and bioaccumulation would not be expected.

Spent Product:

DOT Basic Description- Land Transportation: PAINT DRY NOIBN
Hazard Code- Land Transportation: 2A
UN Number- Land Transporation: NA
Hazard Class- Land Transporation: NOT REGULATED
DOT Basic Description- Air Transporation: PAINT DRY NOIBN
Hazard Code- Air Transportation: 2A
UN Number- Air Transporation: NA
Razard Class- Air Transporation: NOT REGULATED
DOT Basic Description- Sea Transporation: PAINT DRY NOIBN
Razard Code- Sea Transportation: 2A
UN Number- Sea Transporation: NA
Hazard Class- Sea Transporation: NOT REGULATED

No 3 13 -listed chernicals in this product SARA 313 NoCAS# 0.15
45
ASSESSMENT TO DETERMINE THE SUITABILITY OF A PRODUCT FOR YOUR PARTICULAR PURPOSE PRIOR TOUSE. NO WARRANTIES OF ANY KIND, EITHER EXPRESSED
SHALL THE DESCRIPTIONS, INFORMATION,OR DATA PROVIDED BE CONSIDERED A PART OF OUR TERMS AND CONDITIONS OF SALE. FURTHER, THE DESCRIPTIONS,
ASSUMED, ALL SUCH BEING GIVEN AND ACCEPTED AT YOUR RISK.
46
PRODUCT NAME: CORRO-COAT EP-F 1003HW-BEIGE

SUPERCEDES: None
III. COMPOSITION/INFORMATION ON INGREDIENTS

MODIFIED SOLID EPOXY BISPHENOL A TYPE/EPOXY RESIN 10–30 TRADE SECRET No PEL established
BISPHENOL 1- (EPICHLOROHYDRIN) EPOXY 10–30 25036-25-3 No PEL established
RESIN / EPOXY RESIN
REACTION PRODUCT OF BISPHENOL 7–13 TRADESECRET No PEL established
A/EPICHLOROHYDRIN WITH CURING
ACCELERATOR / EPOXY CURING AGENT
SUPPLIER TRADE SECRET / EPOXY RESIN 5–10 TRADE SECRET No PEL established

Routes of Entry: Inhalation; Absorption; Ingestion; ; Skin contact; Eye contact
Inhalation: Can cause minor respiratory irritation, dizziness, weakness, fatigue, nausea, and
headache. Harmful! Can cause systemic damage (see ‘Target Organs’).
Eye Contact: Can cause moderate irritation, tearing and reddening, but not likely to pemianently injure eye
Ingestion: Mildly irritating to mouth, throat and stomach. Can cause abdominal discomfort. Small amounts
(a tablespoonful) swallowed during normal handling operations are not likely to cause injury.
swallowing amounts larger than that may cause injury.
47
Not a carcinogen according to NTP, IARC, or OSHA
Reproductive and
IV. FIRST AID

Ingestion: If swallowed, have a trained medical professional induce vomiting immediately.
Never give anything by mouth to an unconscious person.
Use process enclosures to control the level of dust in the air.
may cause frothing if liquid is burning but it still may be a useful extinguishing agent if carefully
applied to the surface of the fire. Do Not direct a stream of water into the hot burning liquid.
Fire Fighting Instructions: Do not enter fire area without proper protection including self- contained breathing apparatus
and fall protective equipment. Dust explosions can occur under conditions of high dust
Use process enclosures to control the level of dust in the air.
Products:

Spill Response: equipment recommendations found in Section VIII of this MSDS. Additional precautions may be
necessary based on special circumstances created by the spill including; the material spilled, the
quantity of the spill, the area in which the spill occurred. Also consider the expertise of
Equipment recommended inSection VIII at a minimum.
48

Handling: Toxic or severely irritating material. Avoid contacting and avoidbreathing the material. Use
because it may retain product residues. As with all chemicals, good industrial hygiene
practices should be followed when handling this material. Minimize dust generation and
accumulation.
and atmospheric pressure. Store away from heat Prevent contact with moisture. Moisture will
when not in use.

the OSHA chemical specific standard in 29 CFR 1910.
Follow a respiratory protection program that meets 29 CFR 1910.134 and ANSI Z88.2
requirements whenever work place conditions warrant the use of a respirator.
wash station available. Wear goggles if dusts can reach the exposure lin-lit.
recommended.
49
Control Parameters:
CHEMICAL NAME ACG1H TLV-TWA. ACG1H STEL IDLH
A TYPE
BISPHENOL I- (EPICHLOROHYDRIN) No TLV ND
EPOXY RESIN
REACTION PRODUCT OF BISPHENOL No TLV ND
AlEPICHLOROHYDRIN WITH
CURING ACCELERATOR
TITANIUM OXIDE 10 mg/m3 TWA Potential NIOSH carcinogen.


sparks, open flames, or other sources of ignition. Contamination.
Chemical Incompatibility: Acidic conditions; Amines; Causties (bases); Oxidizing materials; Metals.
Decomposition Temp:
Products:
XI. TOXICOLOGICAL INFORMATION

[rabbits]).
50
Mobility: No data
Pesistence: No data
Bioaccumulation: Bioconcentration is not expected to occur.Based on the physical properties of this product,

Waste Description Spent or discarded material is a hazardous waste.
for Spent Product:

XY. REGULATORY INFORMATION

No 313-listed chemicals in this product SARA 313 NoCAS# 0.27

Disclaimer: IMPORTANT: WHILE THE DESCRIPTIONS, DATA AND INFORMATION CONTAINED HEREIN ARE PRESENTED IN GOOD FAITH AND BELIEVED TO BE ACCURATE, IT
IS PROVIDED FOR YOUR GUIDANCE ONLY. BECAUSE MANY FACTORS MAY AFFECT PROCESSING OR APPLICATION/USE, WE RECOMMEND THAT YOU PERFORM AN
OR IMPLIED, INCLUDING FITNESS FOR A PARTICULAR PURPOSE, ARE MADE REGARDING PRODUCTS DESCRIBED, DATA OR INFORMATION SET FORTH. IN NO CASE SHALL
THE DESCRIPTIONS, INFORMATION,OR DATA PROVIDED BE CONSIDERED A PART OF OUR TERMS AND CONDITIONS OF SALE. FURTHER, THE DESCRIPTIONS, DATA AND
INFORMATION FURNISHED HEREUNDER ARE GIVEN GRATIS. NO OBLIGATION OR LIABILITY FOR THE DESCRIPTION, DATA AND INFORMATION GIVEN ARE
51
PRODUCT NAME: CORRO-COAT EP-F 1010 GREY

SUPERCEDES: None

CHEMICAL NAME / COMMON NAME % CAS# PEL
TITANIUM OXIDE / TITANIUM DIOXIDE 13463-67-7 total dust: 15 mg/m3
TWA
ALUMINUM HYDROXIDE / ALUMINUM HYDROXIDE 21645-51-2 No PEL established
AMORPHOUS SILICA GEL / SILICA 112926-008 No PEL established
MODIFIED SOLID EPOXY BISPHENOL A TYPE / 10–30 TRADE SECRET No PEL established
EPOXY RESIN
BISPHENOL I – (EPICHLOROHYDRIN) EPOXY 10–30 25036-25-3 No PEL established
RESIN / EPOXY RESIN
REACTION PRODUCT OF EPOXY RESIN / 7–13 TRADE SECRET No PEL established
BISPHENOL A WITH FLOW MODIFIER AND
CURING ACCELERATOR / EPOXY CURING AGENT
ZINC DUST PIGMENT / ZINC DUST PIGMENT 1–5 7440-66-6 No PEL established
IRON OXIDE BLACK / IRON OXIDE BLACK 1–5 1317-61-9 No PEL established

Routes of Entry: Inhalation; Ingestion; Skin contact; Eye contact; Absorption
Inhalation: Can cause minor respiratory irritation, dizziness, weakness, fatigue, nausea, and
headache. Harmful! Can cause systemic damage (see ‘Target Organs’)
52
cause injury; swallowing amounts larger than that may cause injury. Harmful if swallowed.
May cause systemic poisoning.
Target Organ Acute
Toxicity: No organs known to be damaged from exposure to this product.
Not a carcinogen according to NTP, IARC, or OSHA,
Reproductive and
Developmental Toxicity: No data available to indicate product or any components present at greater than 0.1 %
IV. FIRST AID

Eyes: Use an eye wash to remove a chemical from your eye regardless of the level of hazard.
Flush the affected eye for at least twenty minutes. Tilt the head to prevent chemical from
transferring to the uncontaminated eye. Seek medical advice after flushing.
Notes to MD: No additional first aid information available.

Flash Point: 400 deg. F 204 deg. C
example in a fire. Use process enclosures to control the level of dust in the air. Dust explosions
can occur under conditions of high dust concentrations in thepresence of an ignition source.
Burning will produce irritating smoke.
Extinguishing Media: Use alcohol resistant foam, carbon dioxide, or dry chemical when fighting fires. Water or foam may
cause frothing if liquid is burning but it still may be a useful extinguishing agent if carefully applied
to the surface of the fire. Do Not direct a stream of water into the hot burning liquid.
and full protective equipment. Use process enclosures to control the level of dust in the air.
Dust explosions can occur under conditions of high dust concentrations in the presence of an
ignition source. Burning will produce irritating smoke.
Hazardous Combustion
Products: Carbon dioxide; Carbon monoxide; Hydrogen; Metal fumes.
53
Health Consideration Exposure to the spilled material may be irritating or harmful. Follow personal protective
for Spill Response: equipment recommendations found in Section VIII of this MSDS. Additional precautions may
the quantity of the spill, the area in which the spill occurred.
Also consider the expertise of employees in the area responding to the spill. Clean up spills
granulated clay. Gather and store in a scaled container pending a waste disposal evaluation.

Handling: Toxic or severely irritating material. Avoid contacting and avoid breathing the material. Use only
in a well ventilated area. As with all chemicals, good industrial hygiene practices should be
followed when handling this material. Minimize dust generation and accumulation. Irritating
vapors, mists, or dusts may be released upon thermal processing or during combustion. Avoid
creating dusts as an explosive dust air mixture can be created at high concentrations. If dusts
are created, ensure no sources of ignition are present. Take precautionary measures to prevent
electrostatic discharges. Ground and bond containers when transferring material. Follow all
MSDS/label precautions even after container is emptied because it may retain product residues.
Storage: Store in a cool dry place. Isolate from incompatible materials. Keep container closed when not
in use Store at ambient temperature and atmospheric pressure. Store away from heat Prevent
contact with moisture. Moisture will impact product performance. Keep away from heat, sparks,
and flame Store this product in air-fight containers.

Engineering Controls: Local exhaust ventilation or other engineering controls are normally required when handling or
using this product to avoid overexposure. Engineering controls must be designed to meet the
OSHA chemical specific standard in 29 CFR 1910.
Respirator Type(s): None required where adequate ventilation is provided. If airborne concentrations are above the
applicable exposure limits, use NIOSHIMSHA approved respiratory protection.
54
recommended.
Protective Clothing: Impervious rubber Neoprene
Control Parameters:
CHEMICAL NAME ACGI11 TLV-TWA. ACGI11 STEL IDLI1
3
TITANIUM DIOXIDE 10 mg/m TWA Potential NIOSH carcinogen.
ALUMINUM HYDROXIDE No TLV ND
AMORPHOUS SILICA GEL No TLV ND
MODIFIED SOLID EPOXY
BISPHENOL A TYPE No TLV ND
BISPHENOL 1- (EPICHLOROHYDRIN) No TLV ND
EPOXY RESIN
MODIFIER AND CURING
ACCELERATOR
ZINC DUST PIGMENT No TLV ND
IRON OXIDE BLACK No TLV ND

Solubility in Water: Negligible; 0–1%

Chemical Incompatibility: Metals; Acidic conditions; Amines; Caustics (bases); Acids; Oxidizing materials; Water
Decomposition Temp:
Products:
55
Xl. TOXICOLOGICAL INFORMATION
Chemical Name CAS Number LD5011LC50
No data available 21645-51-2 No data available
[rabbits]).

Mobility: No data
Pesistence: No data
Bloaccumulation: No data. Based on the physical properties of this product, significant environmental persistence
and bioaccurnulation would not be expected.

Spent Product:

56
Toxic Substances Control Act (TSCA): This substance is listed on the TSCA Inventory of Existing Chemical Substances.
Zinc CERCLA NoCAS#
No 313-listed chemicals SARA 313 21645-51-2 124.85
in this product
Zinc SARA 313 NoCAS#
Zinc SARA 313 7440-66-6 4.77
Lead SARA 313 No CAS 0.00

Disclaimer: IMPORTANT: WHILE THE DESCRIPTIONS, DATA AND INFORMATION CONTAINED HEREIN ARE PRESENTED IN
GOOD FAITH AND BELIEVED TO BE ACCURATE, IT IS PROVIDED FOR YOUR GUIDANCE ONLY. BECAUSE MANY FACTORS MAY AFFECT PROCESSING OR APPLICATION/USE,
WE RECOMMEND THAT YOU PERFORM AN ASSESSMENT TO DETERMINE THE SUITABILITY OF A PRODUCT FOR YOUR PARTICULAR PURPOSE PRIOR TO USE. NO
WARRANTIES OF ANY KIND, EITHER EXPRESSED OR IMPLIED, INCLUDING FITNESS FOR A PARTICULAR PURPOSE, ARE MADE REGARDING PRODUCTS DESCRIBED, DATA
OR INFORMATION SET FORTH. IN NO CASE SHALL THE DESCRIPTIONS, INFORMATION,OR DATA PROVIDED BE CONSIDERED A PART OF OUR TERMS AND CONDITIONS
OF SALE. FURTHER, THE DESCRIPTIONS, DATA AND INFORMATION FURNISHED HEREUNDER ARE GIVEN GRATIS. NO OBLIGATION OR LIABILITY FOR THE DESCRIPTION,
DATA AND INFORMATION GIVEN ARE ASSUMED. ALL SUCH BEING GIVEN AND ACCEPTED AT YOUR RISK.
57
PRODUCT NAME: CORRO-COAT EP-F 2001- GREY

SUPERCEDES: 11-08-2000
Manufactured by: Jotun Powder Inc.
9203 Highway 23

CHEMICAL NAME/COMMON NAME % CAS # PEL
REACTION PRODUCT OF BISPHENOL 40–70 25036-25-3 No PEL established
A-(EPICHLOROHYDRIN)/EPOXY RESIN
BARIUM SULPHATE/BARYTES 7–13 13462-86-7 No PEL established
NEPHELINE SYENITE/NEPHELINE SYENITE 7–13 37244-96-5 No PEL established
TITANIUM OXIDE/TITANIUM DIOXIDE 1–5 13463-67-7 total dust: 15 mg/m3
TWA
IRON OXIDE BLACK/IRON OXIDE BLACK 1–5 1317-61-9 No PEL established

Harmful! Can cause systemic damage (see Target Organs)
Ingestion: Mildly irritating to mouth, throat, and stomach. Can cause abdominal discomfort. Small amounts
(a tablespoonful) swallowed during normal handling operations are not likely to cause injury;
Carcinogenicity: None of the substances have been shown to cause cancer in long term animal studies. Not a
carcinogen according to NTP, IARC, or OSHA.
58
Reproductive and
Developmental Toxicity: No data available to indicate product or any components present at greater than 0.1% may cause
birth defects. Not likely to be a human reproductive hazard.
IV. FIRST AID

Eyes: Use an eye wash to remove a chemical from your eye regardless of the level of hazard. Flush the
affected eye for at least twenty minutes. Tilt the head to prevent chemical from transferring to the
uncontaminated eye. Seek medical advice after flushing.

Flash Point: 400 deg. F 204deg.C
example in a fire. Dust explosions can occur under conditions of high dust concentrations in the
presence of an ignition source. Burning will produce irritating smoke. Use process enclosures to
control the level of dust in the air.
Fire Fighting Instructions: Do not enter fire area without proper protection including self-contained breathing apparatus and
full protective equipment. Dust explosions can occur under conditions of high dust concentrations
in the presence of an ignition source. Burning will produce irritating smoke. Use process
enclosures to control the level of dust in the air.
Products: Carbon dioxide; Carbon monoxide

quantity of the spill, the area in which the spill occurred. Also consider the expertise of employees
in the area responding to the spill. Clean up spills immediately using Protective Equipment
recommended in Section VIII at a minimum.
General Methods: Prevent the spread of any spill to minimize harm to human health and the environment if safe to
do so. Wear complete and proper personal protective equipment following the recommendation
of Section VIII at a minimum. Dike with suitable absorbent material like granulated clay. Gather
and store in a sealed container pending a waste disposal evaluation. Use an inert absorbent
such as sand or vermiculite. Place in properly labeled closed container.
59
Handling: Harmful or irritating material. Avoid contacting and avoid breathing the material. Use only in a
well ventilated area. Irritating vapors, mists, or dusts may be released upon thermal processing or
during combustion. Avoid creating dusts as an explosive dust air mixture can be created at high
concentrations. If dusts are created, ensure no sources of ignition are present. Take precautionary
measures to prevent electrostatic discharges. Ground and bond containers when transferring
material. Follow all MSDS/label precautions even after container is emptied because it may retain
product residues. As with all chemicals, good industrial hygiene practices should be followed
when handling this material. Minimize dust generation and accumulation. Storage: Store in a
cool dry place. Isolate from incompatible materials. Store at ambient temperature and
atmospheric pressure. Store away from heat Prevent contact with moisture. Moisture will impact
product performance. Keep away from heat, sparks, and flame Keep container closed when not
in use

general room ventilation is not available or sufficient to eliminate symptoms. Follow a respiratory
protection program that meets 29 CFR 1910.134 and ANSI Z88.2 requirements whenever work
place conditions warrant the use of a respirator.
applicable exposure limits, use NIOSH/MSHA approved respiratory protection.
Eyes: Wear chemical splash goggles when handling this product. Additionally, wear a face shield when
the possibility of splashing of liquid exists. Do not wear contact lenses. Have an eye wash station
available. Wear goggles if dusts can reach the exposure limit.
replace at regular intervals. Clean protective equipment regularly. Wash hands and other exposed
areas with mild soap and water before eating, drinking, and when leaving work. Wash hands
and other exposed areas with mild soap and water before eating, drinking, and when leaving
work. Nitrile rubber and PVC are not suitable protective materials; Neoprene is recommended.
Control Parameters:
A-(EPICHLOROHYDRIN)
TITANIUM OXIDE 10 mg/m3 TWA Potential NIOSH
carcinogen.
IRON DIOXIDE BLACK No TLV ND
60
Theoretical VOC (lbs./gallon) 0.000
Theoretical VOC (grams./liter) 0.000

Conditions to Avoid: Temperatures above the high flash point of this combustible material in combination with sparks,
open flames, or other sources of ignition. Contamination
Decomposition Temp:
Hazardous Decomposition Products:

Chemical Name CAS Number LD50/LC50
Eyes (Draize score): This material is estimated to be moderately irritating to the eyes (Draize score is 25–50 [rabbits]).

Mobility: No data
Pesistence: No data
and bioaccumulation would not be expected.

Spent Product:

UN Number- Land Transportation: NA
Hazard Class- Land Transportation: NOT REGULATED
DOT Basic Description- Air Transportation: PAINT DRY NOIBN
61
UN Number- Air Transportation: NA
Hazard Class- Air Transportation: NOT REGULATED
DOT Basic Description- Sea Transportation: PAINT DRY NOIBN
Hazard Code- Sea Transportation: 2A
UN Number- Sea Transportation: NA
Hazard Class- Sea Transportation: NOT REGULATED

Chemical Name Regulation CAS # % Range
No 313-listed chemicals in this product SARA 313 No CAS # 0.29
XVI. ADDITIONAL INFORMATION Disclaimer:

IMPORTANT: WHILE THE DESCRIPTIONS, DATA AND INFORMATION CONTAINED HEREIN ARE PRESENTED IN GOOD FAITH AND BELIEVED TO BE ACCURATE, IT IS
PROVIDED FOR YOUR GUIDANCE ONLY. BECAUSE MANY FACTORS MAY AFFECT PROCESSING OR APPLICATION/USE, WE RECOMMEND THAT YOU PERFORM AN
ASSESSMENT TO DETERMINE THE SUITABILITY OF A PRODUCT FOR YOUR PARTICULAR PURPOSE PRIOR TO USE. NO WARRANTIES OF ANY KIND, EITHER EXPRESSED OR
IMPLIED, INCLUDING FITNESS FOR A PARTICULAR PURPOSE, ARE MADE REGARDING PRODUCTS DESCRIBED, DATA OR INFORMATION SET FORTH. IN NO CASE SHALL
INFORMATION FURNISHED HEREUNDER ARE GIVEN GRATIS. NO OBLIGATION OR LIABILITY FOR THE DESCRIPTION, DATA AND INFORMATION GIVEN ARE ASSUMED. ALL
SUCH BEING GIVEN AND ACCEPTED AT YOUR RISK.
62
PRODUCT NAME: CORRO-COAT EP-F 2002

9203 Highway 23

REACTION PRODUCT OF BISPHENOL A- 30–60 25036-25-3 No PEL established
(EPICHLOROHYDRIN)/EPOXY RESIN
TWA
ZINC DUST PIGMENT/ZINC DUST PIGMENT 1–5 7440-66-6 No PEL established

63
Reproductive and
Developmental Toxicity: No data available to indicate product or any components present at greater than 0.1% may
cause birth defects. Not likely to be a human reproductive hazard.
IV. FIRST AID

in the presence of an ignition source. Burning will produce irritating smoke. Use process
enclosures to control the level of dust in the air.
Hazardous Combustion Carbon dioxide; Carbon monoxide; Hydrogen; Metal fumes
Products:

64
when handling this material. Minimize dust generation and accumulation.
Storage: Store in a cool dry place. Isolate from incompatible materials. Store at ambient temperature and
in use Store this product in air-tight containers.

Control Parameters:
A- (EPICHLOROHYDRIN)
TITANIUM OXIDE 10 mg/m3 TWA Potential NIOSH
carcinogen.
65

Chemical Incompatibility: Acidic conditions; Amines; Caustics (bases); Metals; Acids; Oxidizing materials; Water
Decomposition Temp:
Products:


Mobility: No data
Pesistence: No data

Spent Product:
66
Hazard Class-Air Transportation: NOT REGULATED
DOT Basic Description-Sea Transportation: PAINT DRY NOIBN
UN Number-Sea Transportation: NA
Hazard Class-Sea Transportation: NOT REGULATED

Zinc CERCLA No CAS #
Zinc SARA 313 No CAS #
Zinc SARA 313 7440-66-6 4.75
Lead SARA 313 No CAS # 0.00

67
PRODUCT NAME: CORRO-COAT EP-F 2002 HW

9203 Highway 23

REACTION PRODUCT OF BISPHENOL 15–40 25036-25-3 No PEL established
A-(EPICHLOROHYDRIN)/EPOXY RESIN
BISPHENOL 1-(EPICHLOROHYDRIN) EPOXY RESIN/ 5–10 25036-25-3 No PEL established
EPOXY RESIN
ZINC DUST PIGMENT/ ZINC DUST PIGMENT 1–5 7440-66-6 No PEL established
TWA
REACTION PRODUCT OF BISPHENOL A/EPICHLOROHYDRIN/ 1–5 TRADE SECRET No PEL established

68
Reproductive and
IV. FIRST AID


full protective equipment. Dust explosions can occur under conditions of high dust
concentrations in the presence of an ignition source. Burning will produce irritating smoke. Use
process enclosures to control the level of dust in the air.
Products: Carbon dioxide; Carbon monoxide; Hydrogen; Metal fumes

Health Consideration for Exposure to the spilled material may be severely irritating or toxic. Follow personal protective
Spill Response: equipment recommendations found in Section VIII of this MSDS. Personal protective equipment
needs must be evaluated based on information provided on this sheet and the special
circumstances created by the spill including; the material spilled, the quantity of the spill, the area
in which the spill occurred, and the expertise of employees in the area responding to the spill.
Never exceed any occupational exposure limits. Clean up spills immediately using Protective
such as sand or vermiculite. Place in properly labeled closed container. 69
in a well ventilated area. Irritating vapors, mists, or dusts may be released upon thermal
Storage: Store in a cool dry place. Isolate from incompatible materials. Store at ambient temperature and
in use Store this product in air-tight containers.

Control Parameters:
A- (EPICHLOROHYDRIN)
A TYPE
EPOXY RESIN
70
TITANIUM DIOXIDE 10 mg/m3 TWA Potential NIOSH
carcinogen.
A/ EPICHLOROHYDRIN


Chemical Incompatibility: Acidic conditions; Amines; Caustics (bases); Metals; Acids; Oxidizing materials; Water
Decomposition Temp:
Products:


Mobility: No data
Pesistence: No data

Waste Description for Spent or discarded material is non-hazardous according to environmental regulations.
Spent Product:
71
UN Number-Land Transportation: NA
Hazard Class-Land Transportation: NOT REGULATED
DOT Basic Description-Air Transportation: PAINT DRY NOIBN
UN Number-Air Transportation: NA
Hazard Class-Air Transportation: NOT REGULATED
DOT Basic Description-Sea Transportation: PAINT DRY NOIBN
UN Number-Sea Transportation: NA
Hazard Class-Sea Transportation: NOT REGULATED

Zinc CERCLA No CAS #
Zinc SARA 313 No CAS #
Zinc SARA 313 7440-66-6 4.76
Lead SARA 313 No CAS # 0.00

INFORMATION FURNISHED HEREUNDER ARE GIVEN GRATIS. NO OBLIGATION OR LIABILITY FOR THE DESCRIPTION, DATA AND INFORMATION GIVEN ARE ASSUMED.
ALL SUCH BEING GIVEN AND ACCEPTED AT YOUR RISK.
72
PRODUCT NAME: CORRO-COAT EP-F 2004- BEIGE

9203 Highway 23

MODIFIED SOLID EPOXY RESIN-BISPHENOL 60–90 TRADE SECRET No PEL established
A/EPICHLOROHYDRIN TYPE/EPOXY RESIN
TWA

Reproductive and
73
IV. FIRST AID

presence of an ignition source. Burning will produce irritating smoke.
in the presence of an ignition source. Burning will produce irritating smoke.
Products:

and store in a sealed container pending a waste disposal evaluation.

when handling this material. Minimize dust generation and accumulation. Storage: Store in a
74
cool dry place. Isolate from incompatible materials. Store at ambient temperature and
in use

Protective Clothing: No information available
Control Parameters:
MODIFIED SOLID EPOXY RESIN- No TLV ND
BISPHENOL A/EPICHLOROHYDRIN TYPE
carcinogen.

Stability Information: Stable Conditions to Avoid: Temperatures above the high flash point of this combustible material
in combination with sparks, open flames, or other sources of ignition. Contamination Chemical
Incompatibility: Acidic conditions; Amines; Caustics (bases); Metals
Decomposition Temp:
Products: 75

Mobility: No data
Pesistence: No data

Spent Product:


76
77
PRODUCT NAME: CORRO-COAT EP-F 2013 - BEIGE

9203 Highway 23

BISPHENOL 1-(EPICHLOROHYDRIN) EPOXY RESIN/EPOXY RESIN 10–30 25036-25-3 No PEL established
NEPHELINE SYENITE/ NEPHELINE SYENITE 7–13 37244-96-5 No PEL established
REACTION PRODUCT OF BISPHENOL A/EPICHLOROHYDRIN/ 5–10 TRADE SECRET No PEL established
TWA

Not a carcinogen according to NTP, IARC, or OSHA.
Reproductive and No data available to indicate product or any components present at greater than 0.1% may
Developmental Toxicity: cause birth defects. Not likely to be a human reproductive hazard.
78
IV. FIRST AID
affected eye for at least twenty minutes. Tilt the head to prevent chemical from transferring to
the uncontaminated eye. Seek medical advice after flushing.

Products:

quantity of the spill, the area in which the spill occurred. Also consider the expertise of

in a well ventilated area. Irritating vapors, mists, or dusts may be released upon thermal
79
Storage: Store in a cool dry place. Isolate from incompatible materials. Store at ambient
temperature and atmospheric pressure. Store away from heat Prevent contact with moisture.
Moisture will impact product performance. Keep away from heat, sparks, and flame Keep
container closed when not in use

when the possibility of splashing of liquid exists. Do not wear contact lenses. Have an eye wash
station available. Wear goggles if dusts can reach the exposure limit.
exposed areas with mild soap and water before eating, drinking, and when leaving work. Wash
leaving work. Nitrile rubber and PVC are not suitable protective materials; Neoprene is
recommended.
Control Parameters:
A TYPE
EPOXY RESIN
A/ EPICHLOROHYDRIN
carcinogen.
80

Chemical Incompatibility: Acidic conditions; Amines; Caustics (bases); Oxidizing materials; Metals
Decomposition Temp:
Products:

[rabbits]).

Mobility: No data
Pesistence: No data

Spent Product:
81


INFORMATION FURNISHED HEREUNDER ARE GIVEN GRATIS. NO OBLIGATION OR LIABILITY FOR THE DESCRIPTION, DATA AND INFORMATION GIVEN ARE ASSUMED.
ALL SUCH BEING GIVEN AND ACCEPTED AT YOUR RISK.
82
PRODUCT NAME: CORRO-COAT EP-F 3001

SUPERCEDES: None

LIMESTONE / CALCIUM CARBONATE 30–60 1317-65-3 total dust: 15 mg/m3
TWA; respirable fraction: 5 mg/m3 TWA
REACTION PRODUCT OF BISPHENOL A- 15–40 25036-25-3 No PEL established
(EPICHLOROHYDRIN) / EPOXY RESIN
REACTION PRODUCT OF BISPHENOL 5–10 TRADE SECRET No PEL established
ACCELERATOR / EPOXY CURING AGENT

Routes of Entry: Inhalation; Absorption; Ingestion;
Inhalation: Causes respiratory tract irritation.
Skin Contact: Can cause minor skin irritation, deflatting, and dermatitis. Causes skin irritation.
tissue. Can cause irritation.
Ingestion: Small amounts (a tablespoonful) swallowed during normal handling operations are not likely
to cause injury; swallowing amounts larger than that may cause injury.
83
Carcinogenicity: Contains a substance that is a probable cancer hazard based on animal studies using doses
likely to be encountered in the workplace. Possible cancer hazard based on tests with
laboratory animals.
Reproductive and
may cause birth defects.
IV. FIRST AID

Inhalation: This material does not present a hazard if inhaled. Remove individual to fresh air after an
airborne exposure if any symptoms develop, as a precautionary measure.
Skin Contact: Wash with soap and water. Get medical attention if irritation develops or persists. Wash with
soap and water.

liquid.
Products:

84

only in a well ventilated area. Ground and bond containers when transferring material. Follow
all MSDS/label precautions even after container is emptied because it may retain product
residues. Irritating vapors, mists, or dusts may be released upon thermal processing or during
combustion. Avoid creating dusts as an explosive dust air mixture can be created at high
concentrations. If dusts are created, ensure no sources of ignition are present. Take
precautionary measures to prevent electrostatic discharges.
Storage: Store in a cool dry place. Isolate from incompatible materials. Prevent contact with moisture.
Moisture will impact product performance. Keep away from heat, sparks, and flame Store at
ambient temperature and atmospheric pressure. Store away from heat.

Engineering Controls: Use local exhaust ventilation or other engineering controls to minimize exposures and
maintain operator comfort.
Eyes: Wear chemically resistant safety glasses with side shields when handling this product. Do not
wear contact lenses.
when leaving work.
Protective Clothing: Impervious rubber
85
Control Parameters:
CHEMICAL NAME ACG1H TLV-TWA ACG111 STEL IDLH
LIMESTONE 10 mg/m3 TWA (The ND
value is for total dust
containing no asbestos and
<1% crystalline silica)
A-(EPICHLOROHYDRIN)
ACCELERATOR

Theoretical VOC (Ibs.lgallon) 0.000
Theoretical VOC (grams.111ter) 0.000

sparks, open flames, or other sources of ignition.
Chemical Incompatibility: Acidic conditions; Amines; Caustics (bases); Oxidizing materials
Decomposition Temp:
Products:

[rabbits]).
86
Overview: This material is not expected to be harmful to the ecology
Mobility: No data
Pesistence: No data
Bioaccumulation: Bioconcentration is not expected to occur. Based on the physical properties of this product,

Spent Product:
Disposal Methods: Dispose of by incineration following Federal, State, Local, or Provincial regulations

UN Number-Land Transportation: NA
Hazard Class-Land Transportation: NOT REGULATED
DOT Basic Description-Air Transportation: PAINT DRY NOIBN
87
PRODUCT NAME: CORRO-COAT EP-F 3002 BLUE

SUPERCEDES: None
Manufactured by: Jotun Powder, Inc.
9203 Highway 23

SUPPLIER TRADE SECRET / SILICA-ALUMINA ALLOY 10–30 TRADE SECRET No PEL established
MODIFIED SOLID EPOXY BISPHENOL A TYPE / EPOXY RESIN 10–30 TRADE SECRET No PEL established
BISPHENOL 1- (EPICHLOROHYDRIN) EPOXY RESIN / 10–30 25036-25-3 No PEL established
EPOXY RESIN
REACTION PRODUCT OF EPOXY RESIN/ BISPHENOL A
WITH FLOW MODIFIER AND CURING ACCELERATOR /
EPOXY CURING AGENT 7–13 TRADE SECRET No PEL established
SUPPLIER TRADE SECRET / EPOXY RESIN 5–10 TRADE SECRET No PEL established
TWA


Causes respiratory tract irritation Harmful! Can cause systemic damage (see "Target Organs)
Eye Contact: Can cause severe irritation. Eye contact may result in corneal injury. Symptoms may include
discomfort or pain, excess blinking and tear production, with marked redness and swelling of the
conjunctiva. Temporary vision impairment (cloudy or blurred vision) is possible. Contact may
cause severe eye irritation, corneal damage, and may result in temporary or permanent loss of
vision. Can cause mechanical irritation if dusts are generated.
88
Reproductive and
birth defects.
IV. FIRST AID
Skin Contact: Wash with soap and water. Remove contaminated clothing and launder. Get medical attention if
irritation develops or persists.

Products:

Health Consideration Exposure to the spilled material may be severely irritating or toxic. Follow personal protective for
89
General Methods: Prevent the spread of any spill to minimise harm to human health and the environment if safe to

in a well ventilated area. Ground and bond containers when transferring material. Follow all
Irritating vapors, mists, or dusts may be released upon thermal processing or during combustion.
Avoid creating dusts as an explosive dust air mixture can be created at high concentrations. If
dusts are created, ensure no sources of ignition are present. Take precautionary measures to
prevent electrostatic discharges. As with all chemicals, good industrial hygiene practices should
be followed when handling this material. Minimize dust generation and accumulation.
Storage: Store in a cool dry ventilated location. Isolate from incompatible materials and conditions. Keep
container(s) closed. Prevent contact with moisture. Moisture will impact product performance.
Keep away from heat, sparks, and flame Store at ambient temperature and atmospheric pressure.
Store away from heat Keep container closed when not in use

protection may be required in addition to ventilation depending upon conditions of use. Follow a
Eyes: Wear chemically resistant safety glasses with side shields when handling this product. Do not
wear contact lenses. Wear goggles if dusts can reach the exposure limit.
90
Control Parameters:
MODIFIED SOLID A TYPE No TLV ND
EPOXY BISPHENOL
EPOXY RESIN
REACTION PRODUCT OF EPOXY RESIN/ No TLV ND
BISPHENOL A WITH FLOW MODIFIER
AND CURING ACCELERATOR
carcinogen.


Conditions to Avoid: Sparks, open flame, other ignition sources, and elevated temperatures. Contamination
Chemical Incompatibility: Strong oxidizing agents; Acidic conditions; Amines; Caustics (bases); Metals
Decomposition Temp:


Mobility: No data
Pesistence: No data
91
Bioaccumulation: Bioconcentration is not expected to occur. Based on the physical properties of this product,

Waste Description for Spent or discarded material is non-hazardous according to environmental regulations.
Spent Product:



92
PRODUCT NAME: JOTUN RP
PRODUCT CODE: 46F640

1401 Severn Street
Baltimore, MD 21230

PHENOL, 4,4’-(1-METHYL-ETHYLIDENE) BIS, POLYMER 10–30 25068-38-6 No PEL established
WITH (CHLOROMETHYL) OXIRANE/EPOXY RESIN
SILICIC ACID, ALUMINUM SALT (1:2)/CLAY 5–10 22708-90-3 No PEL established
NONYL PHENOL/NONYL PHENOL 5–10 25154-52-3 No PEL established
PHENOL, 4,4’-(1-METHYLETHYLIDENE) BIS-/BISPHENOL A 1–5 80-05-7 No PEL established
1-PIPERAZINEETHANAMINE/AMINOETHYLPIPERAZINE 1–5 140-31-8 No PEL established
BENZENEMETHANOL/BENZYL ALCOHOL 0.1–1 100-51-6 No PEL established
CYCLOHEXANEMETHANEAMINE, 5-AMINO-1,3,3- 0.1–1 2855-13-2 No PEL established
TRIMETHYL/IPD-ISOPHORONE DIAMINE
N,N-DIMETHYL BENZENEMETHANAMINE/ 0.1–1 103-83-3 No PEL established
BENZYLDIMETHYLAMINE

Inhalation: Can cause severe respiratory irritation, dizziness, weakness, fatigue, nausea, headache and
possible unconsciousness. Harmful! Can cause systemic damage (see Target Organs)
Skin Contact: Corrosive to skin tissue. Can cause chemical burns. May cause sensitization.
discomfort or pain, excess blinking and tear production, with marked redness and swelling of the
conjunctiva. Temporary vision impairment (cloudy or blurred vision) is possible. Contact may
cause severe eye irritation, corneal damage, and may result in temporary or permanent loss of
vision. Can cause mechanical irritation if dusts are generated.
Skin Absorption: Harmful if absorbed through the skin. May cause severe irritation and systemic damage.
93
Ingestion: Corrosive to tissue. Can cause severe and permanent damage to mouth, throat, stomach.
Aspiration may lead to lung damage. Harmful if swallowed. May cause systemic poisoning.
Target Organ Acute Toxicity: Nervous System
Carcinogenicity: Contains a substance that can cause cancer in laboratory animals at high oral doses. Not a
carcinogen according to NTP, IARC, or OSHA. There is no scientific evidence to indicate the
substance or this product is a human carcinogen.
Reproductive and
IV. FIRST AID

Inhalation: Remove to fresh air. If breathing is difficult, have a trained individual administer oxygen. If not
breathing, give artificial respiration and have a trained individual administer oxygen. Get medical
attention immediately.
Eyes: Immediately flush eyes with plenty of water for at least 20 minutes retracting eyelids often. Tilt
the head to prevent chemical from transferring to the uncontaminated eye. Get immediate
medical attention and monitor the eye daily as advised by your physician.
Skin Contact: Wash with soap and water. Remove contaminated clothing, launder immediately, and discard
contaminated leather goods. Get medical attention immediately.
Ingestion: Severely irritating. Do not induce vomiting. Seek medical attention immediately. Drink 2 glasses of
water or milk to dilute. Notes to MD: No additional first aid information available

Flammability Summary: Combustible.
Fire Hazards: Material may be ignited if preheated to temperatures above the flash point in the presence of a
source of ignition.
Extinguishing Media: Use alcohol resistant foam, carbon dioxide, dry chemical, or water spray when fighting fires.
Water or foam may cause frothing if liquid is burning but it still may be a useful extinguishing
agent if carefully applied to the fire. Do not direct a water stream directly into the hot burning
liquid.
full protective equipment. Fight fire from a safe distance and a protected location due to the
potential of hazardous vapors and decomposition products.
Products: Carbon dioxide; Carbon monoxide; Toxic fumes.; Toxic gases

Health Consideration for Exposure to the spilled material may be severely irritating or toxic. Follow personal protective
94

in a well ventilated area. Ground and bond containers when transferring material. Follow all
Wash thoroughly after handling. Remove contaminated clothing and wash before reuse. Avoid
contact with material. As with all chemicals, good industrial hygiene practices should be followed
when handling this material. Minimize dust generation and accumulation. “Empty” containers
retain product residue (liquid and/or vapor) and can be dangerous.

OSHA chemical specific standard in 29 CFR 1910. Facilities storing or using this material should
be equipped with an eyewash and safety shower.
Respiratory Tract: Respiratory protection will be required when handling this product. Use respirators only if
ventilation cannot be used to eliminate symptoms or reduce the exposure to below acceptable
levels. Respiratory protection not normally needed since volatility and toxicity are low. If vapors,
mists or aerosols are generated, wear a NIOSH approved respirator. Follow a respiratory
place conditions warrant the use of a respirator. Wear a NIOSH approved respirator if any
exposure is possible.
applicable exposure limits, use NIOSH/MSHA approved respiratory protection. A respiratory
protection program that meets OSHA’s 29 CFR 1910.134 and ANSI Z88.2 requirements must be
followed whenever workplace conditions warrant a respirator’s use
available. Wear goggles if dusts can reach the exposure limit. Wear goggles and a Face shield
Use impervious gloves.
95
Control Parameters:
PHENOL, 4,4’-(1-METHYL-ETHYLIDENE) BIS, No TLV ND
POLYMER WITH (CHLOROMETHYL) OXIRANE
SILICIC ACID, ALUMINUM SALT (1:2) No TLV ND
NONYL PHENOL No TLV ND
PHENOL, 4,4’-(1-METHYLETHYLIDENE) BIS- No TLV ND
1-PIPERAZINEETHANAMINE No TLV ND
BENZENEMETHANOL No TLV ND
CYCLOHEXANEMETHANEAMINE, No TLV ND
5-AMINO-1,3,3-TRIMETHYL
N,N-DIMETHYL BENZENEMETHANAMINE No TLV ND


Chemical Incompatibility: Strong oxidizing agents; Acids; Strong alkalies; Metals; Aluminum alloys; Oxidizing materials
Decomposition Temp:

Bisphenol A - Epichlorohydrin polymer 25068-38-6 SL6321000:Phenol, 4,4’-isopropylidenedi-, monomer with
1-chloro-2,3-epoxypropane (12/1/97); Oral LD50 Rat : >1
gm/kg; Oral LD50
Mouse : >500 mg/kg; SL6475000:Phenol, 4,4’-
isopropylidenedi-, polymer with 1-chloro-2,3-epoxypropane
(10/1/97); Oral LD50 Rat : 11400 mg/kg; Oral LD50
Mouse: 15600 mg
Phenol, nonyl- 25154-52-3 Oral LD50 Rat : 1620 mg/kg; Oral LD50 Mouse : 1231 mg/kg;
Dermal LD50 Rabbit: 2140 uL/kg
Phenol, 4,4’-isopropylidenedi- 80-05-7 Oral LD50 Rat : 3250 mg/kg; Oral LD50 Mouse : 2400 mg/kg;
Dermal LD50 Rabbit : 3 mL/kg
Piperazine, 1-(2-aminoethyl)- 140-31-8 Oral LD50 Rat : 2140 uL/kg; Dermal LD50 Rabbit : 880 uL/kg
96
Benzyl alcohol 100-51-6 Oral LD50 Rat : 1230 mg/kg; Oral LD50 Mouse: 1360 mg/kg;
Dermal LD50 Rabbit : 2 gm/kg
Benzylamine, N,N-dimethyl- 103-83-3 Oral LD50 Rat : 265 mg/kg; Dermal LD50 Rabbit : 1660 mg/kg
Ingestion (LD 50 mg/kg-rat): 1230 Not expected to be toxic if swallowed, however may be harmful.
Absorption: 2.000 Estimated to be > 5.0 g/kg; practically non-toxic Sensitization: No data
Eyes (Draize score): This material is likely to be slightly irritating to eyes based on animal data.
Skin (Draize score): Estimated to be non-irritating to skin (Primary Irritation Index is <0.5 [rabbits]).

Mobility: No data
Pesistence: No data
Bioaccumulation: Bioconcentration is not expected to occur.

Waste Description for Spent or discarded material may be a hazardous waste.
Spent Product:

DOT Basic Description- Land Transportation: PAINT
DOT Basic Description- Air Transportation: PAINT
Hazard Code- Air Transportation: C1
UN Number- Air Transportation: UN1760
Hazard Class- Air Transportation: 8
Packaging Group- Air Transportation: II
Technical Name- Air Transportation: CORROSIVE LIQUID, N.O.S.
DOT Basic Description- Sea Transportation: PAINT
Hazard Code- Sea Transportation: C1
UN Number- Sea Transportation: UN1760
Hazard Class- Sea Transportation: 8
Technical Name-Sea Transportation: CORROSIVE LIQUID, N.O.S.
Packaging Group - Sea Transportation: II
97
No 313-listed chemicals in this product SARA 313 25068-38-6 25.00
4,4’-Isopropylidenediphenol SARA 313 80-05-7 5.00

98
EMERGENCYPHONE: 1-888-345-5732
PRODUCT NAME: HPL 100 CURING AGENT - CLEAR
PRODUCT CODE: 75T608
1. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION

SUPERCEDES: None

CHEMICAL NAME/COMMON NAME % CAS PEL
ISOCYANIC ACID, POLYMETHYLENE 30–60 9016-87-9 No PEL established
POLYPHENYLENE ESTER / AROMATIC
POLYISOCYANATE
BENZENE, 1, V-MEETRYLENEBIS 2-ISOCYANATO- / 30–60 2536-05-2 No PEL established
DIPHENYLMETHANE DHSOCYANATE

Routes of Entry: Inhalation; Absorption; Ingestion
Medical Conditions
Aggravated: Kidney disease; Lung disease
Immediate (Mute) Health Effects:
Inhalation: Harmful! Can cause severe irritation or burns and lung inflammation. Central nervous system
effects such as dizziness, weakness, fatigue, nausea, headache, and unconsciousness are
possible, Other possible symptoms include; wheezing and coughing due to pulmonary edema
(fluid build-up in lungs). May cause allergic respiratory reaction.
Skin Contact: Causes skin irritation. May cause allergic skin reaction. May cause sensitization.
discomfort or pain, excess blinking and tear production, with marked redness and swelling of
the conjunctiva. Temporary vision impairment (cloudy or blurred vision) is possible. Contact
may cause severe eye irritation, corneal damage, and may result in temporary or permanent
loss of vision.
Ingestion: Severely irritating to mouth, throat and stomach. Can cause abdominal discomfort, nausea,
vomiting and diarrhea.
99
Target Organ Acute Toxicity: Kidneys; Lungs
Reproductive and
cause birth defects. No information available.
IV. FIRST AID
Inhalation: Remove to fresh air. If breathing is difficult have a trained individual administer oxygen. If not
breathing, give artificial respiration and have a trained individual administer oxygen. Get
medical attention immediately.
Skin Contact: Wash with soap and water. Remove contaminated clothing and launder. Get medical attention
if irritation develops or persists.
Ingestion: Do not induce vomiting and seek medical attention immediately. Drink two glasses of water or
milk to dilute. Provide medical care provider with this MSDS.

Flammability Summary: Combustible.
Flash Point: 200 deg. F 93 deg.C
Fire Hazards: Material may be ignited if preheated to temperatures above the flash point in the presence of
a source of ignition.
Extinguishing Media: Use alcohol resistant foam, carbon dioxide, dry chemical, or water spray when fighting fires.
Water or foam may cause frothing if liquid is burning but it still may be a useful extinguishing
agent if carefully applied to the fire. Do not direct a water stream directly into the hot burning
liquid.
and full protective equipment. Fight fire from a safe distance and a protected location due to
the potential of hazardous vapors and decomposition products.
Hazardous Combustion Carbon dioxide, Carbon monoxide
Products:

Health Consideration Exposure to the spilled material may be severely irritating or toxic. Follow personal protective
for Spill Response: equipment recommendations found in Section VIII of this MSDS. Personal protective
equipment needs must be evaluated based on information provided on this sheet and the
special circumstances created by the spill including; the material spilled, the quantity of the
spill, the area in which the spill occurred, and the expertise of employees in the area
responding to the spill. Never exceed any occupational exposure limits. Clean up spills
100
General Methods: Prevent the spread of any spill to minimise harm to human health and the environment if safe

only in a well ventilated area. Ground and bond containers when transferring material. Follow
all MSDS/label precautions even after container is emptied because it may retain product
residues.
Storage: Store in a cool dry place. Isolate from incompatible materials. Prevent contact with
moisture. Moisture will impact product performance. Keep away from heat, sparks, and flame

Engineering Controls. Use local exhaust ventilation or other engineering controls to minirni e exposures and
maintain operator comfort.
the applicable exposurelimits, useNIOSH/MSHA. approved respiratory protection.
wash station’ available.
Skin: Not normally considered a skin hazard. Where use can result in skin contact, practice good
personal hygiene, and wear a barrier cream and/or impervious surgical style gloves. Wash
leaving work. Wash hands and other exposed areas with mild soap and water before eating,
drinking, and when leaving work. Nitrile rubber and PVC are not suitable protective materials;
Neoprene is recommended.
101
Control Parameters:
CHEMICAL NAME ACGIH TLV-TWA ACG1H STEL IDLH
ISOCYANIC ACID, POLYMETHYLENE No TLV ND
POLYPHEMENE ESTER
BENZENE, 1,1’-METHYLENEBIS 2- No TLV ND
ISOCYANATO

Solubility In Water: Not determined
Theoretical VOC (lbs/gallon) 0.000
Theoretical VOC (grams/liter)0.000,

sparks, open flames, or other sources of ignition.
Chemical Incompatibility: Caustics (bases); Acids
Decomposition Temp:
Products:

Polymethylenepolyphenyl isocyanate 9016-87-9 Inhalation LC50 Rat: 490 mg/m3/4H; Oral LD50 Rat: 49 gm/kg;
Dermal 1,1350 Rabbit: >9400 mg/kg
Eyes (Draize score): This material is likely to be slightly irritating to eyes based on anirnal data.

Mobility: No data
Pesistence: No data
102
Waste Description Spent or discarded material may be a hazardous waste.
for Spent Product:

LTN Number- Land Transporation: NA
DOT Basic Description- Air Transporation: PAINT
Hazard Class- Air Transporation: NOT REGULATED
DOT Basic Description- Sea Transporation: PAINT
Hazard Code- Sea Transportation: IA
UN Number- Sea Transporation: NA

Polymeric diphenylmethane diisocyanate SARA 313 9016-87-9 55.00

SHALL THE DESCRIPTIONS, INFORMATION,0R DATA PROVIDED BE CONSIDERED A PART OF OUR TERMS AND CONDITIONS OF SALE. FURTHER THE DESCRIPTIONS,
103
PRODUCT NAME: HPL 100 BRUSH GRADE BASE - OFF WHITE
PRODUCT CODE: 75F65OR
I. CHEMICAL PRODUCT AND COMPANY IDENTMCATION

SUPERCEDES: None

SILICON DIOXIDE 1 AMORPHOUS, 15–40 7631-86-9 No PEL established
SYNTHETIC SILICA
ALUMINUM OXIDE / ALUMINA 10–30 1344-28-1 total dust: 15 mg/m3
TWA; respirable fraction:
5 mg/in3 TWA
POLY (OXY- (METHYL-1,2-ETHANEDIYL)), 7–13 25723-16-4 No PEL established
ALPHA-HYDRO-OMEGA-HYDROXY-ETHER
WITH 2-ETHYL-2—(HYDROXYMETHYL)1,3
PROPANEDIOL / POLY (OXYALKYLENE) POLYOL
CASTOR OIL, ESTER WITH PENTAERYTHRITOL 7–13 68459-68-7 No PEL established
POLYESTER RESIN
2-PROPANOL, 1.1’-((1- 3–7 116-37-0 No PEL established
METHYLETHYLIDENE)BIS(4,1-PHENYLENEOXY))
BIS- / POLYMERS OF BISPHENOL A, PROPYLENE
OXIDE
9-OCTADECENOIC ACID, 12-HYDROXY-,3- 3–7 78-22-8 No PEL established
HYDROXY-2,2-BIS(HYDROXYMETHYL)PROPYL
ESTER, (R-(Z))- / POLYOL
SUPPLIER TRADE SECRET / ADDITIVE, 1–5 TRADE SECRET No PEL established
PLASTICIZER
TWA
104
Inhalation: Can cause moderate respiratory irritation, dizziness, weakness, fatigue, nausea and
headache. Causes respiratory tract irritationHannful! Can cause systemic damage (see ‘Target
Organs’)
Skin Contact: Can cause minor skin irritation, defatting, and dermatitis. May cause sensitization.
may cause severe eye irritation, comeal damage, and may result in temporary or permanent
loss of vision. Can cause irritation. Can cause mechanical irritation if dusts are generated.
Skin Absorption: No data.Component(s) may be absorbed through intact skin, but it is unlikely that harmful
affects will occur unless contact is prolonged, repeated, and extensive.
Ingestion: Mildly irritating to mouth, throat, and stomach. Can cause abdominal discomfort. Harmful if
swallowed. May cause systemic poisoning.
Reproductive and
cause birth detects. Not likely to be a human reproductive hazard.
IV. FIRST AID

Inhalation: Remove to fresh air. If breadiing is difficult, have a trained individual administer oxygen. No
specific treatment is necessary since this material is not likely to be hazardous by inhalation.
Eyes: Flush eyes with plenty of water for at least 20 minutes retracting eyelids often. Tilt the head to
prevent chemical from transferring to the uncontaminated eye. Get immediate medical
attention.
Notes to MD: No additional first aid information available

Fire Hazards: Material may be ignited only if preheated to temperatures above the high flash point,
for example in a fire. Use process enclosures to control the level of dust in the air.
105
Products:

Spill Response: equipment recommendations found in Section VII1 of this MSDS. Additional precautions may
Equipment recommended in Section VIII at a minimum
General Methods: Prevent the spread of any spill to minimise harm to human health and the environment if safe
recommendation of Section Vlll at a minimum. Dike with suitable absorbent material like
Ensure clean-up measures are in compliance with OSHA (29 CFR 1910.120).

Handling: Harmful or irritating material. Avoid contacting and avoid. breathing the materiaL Use only in a
well ventilated area. Ground and bond containers when transfening material. Follow all
Empty drums should be completely drained, properly bunged and promptly returned to a drum
re-conditioner, or promptly disposed of as with all chemicals, good industrial hygiene practices
Moisture will impact product performance. Keep away from heat sparks, and flame Keep
container closed when not in use.

the OSHA chemical specific standard in 29 CF11 19 10.
106
Respiratory protection not normally needed since volatility and toxicity are low. If vapors,
protection program that meets 29CFR 1910.134 and ANSI Z88.2 requirements whenever
work place conditions warrant the use of a respirator.
the applicable exposure limits, use NIOSHIMSHA. approved respiratory protection. A
respiratory protection program that meets OSHA’s 29 CFR 1910.134 and ANSI Z88.2
requirements must be followed whenever workplace conditions warrant a respirator’s use.
wash station available. Wear goggles and a Face shield Wear goggles if dusts can reach the
exposure limit.
personal hygiene and wear a barrier cream and/or impervious surgical style gloves. Wash
Control Parameters:
CHEMICAL NAME ACGM TLV-TWA. ACGIH STEL IDLH
SILICON DIOXIDE No TLV 3000 mg/m3 IDLI-I
ALUMINIUM OXIDE as AI: 10 mg/m3 TWA ND
(The value is for total dust
<
1 % crystalline silica)
POLY (OXY- (METHYL-1,2- No TLV ND
ETHANEDIYL), ALPHA-HYDRO
OMEGA-HYDROXY-ETHER WITH 2
ETHYL-2-(HYDROXYMETHYL)Q
PROPANEDIOL
CASTOR OIL, ESTER WITH No TLV ND
PENTAERYTHRITOL
2-PROPANOL, No TLV ND
METHYLETRYLIDENE)BIS(4,1
PHENYLENEOXY) BIS
9-OCTADECENOIC ACID, 12- No TLV ND
HYDROXY-J-HYDROXY-2,2
BIS(HYDROXYMETHYL)PROPYL
ESTER, (R-(Z))
107
Theoretical VOC (Ibs./gallon) 0.000
Theoretical VOC (gramsAiter) 0.000

Chemical Incompatibility: Strong oxidizing agents; Metals
Decomposition Temp:
Products:

Component Toxicology Data (NIOSM:
Sensitization: No data No data

Mobility: No data
Pesistence: No data

Waste Description Spent or discarded material is not expected to be a hazardous waste.
for Spent
Product:
Disposal Methods: Dispose of in a landfill. Disposal is not likely to be regulated.
108
Hazard Code- Land Transportation: IA
UN Number- Land Transporation: NA
DOT Basic Description- Air Transporation: PAW
Hazard Code- Air Transportation: IA
Hazard Class- Air Transporation: NOT REGULATED
DOT Basic Description- Sea Transporation: PAINT
Hazard Code- Sea Transportation: IA
LTN Number- Sea Transporation: NA
Aluminum oxide SARA 313 1344-28-1 18.12
No 313-Ested chemicals in this product SARA 313 NoCAS# 0.14

Disclaimer: WORTANT: WHILE THE DESCRIPTIONS, DATA AND INFORMATION CONTAINED HEREIN ARE PRESENTED IN GOOD FAITH AND BELIEVED TO BE ACCURATE,
IT IS PROVIDED FOR YOUR GUIDANCE ONLY. BECAUSE MANY FACTORS MAY AFFECT PROCESSING OR APPLICAUON/USE, WE RECOMMEND THAT YOU PERFORM AN
ASSESSMENT TO DETERMINE THE SLTITABILITY OF A PRODUCT FOR YOUR PARTICULAR PURPOSE PRIOR TO USE. NO WARRANTIES OF ANY KIND, EITHER EXPRESSED
SHALL THE DESCRIPTIONS, INFORMATION,0R DATA PROVIDED BE CONSIDERED A PART OF OUR TERMS AND CONDITIONS OF SALE. FURTHER, THE DESCRIPTIONS,
109
PRODUCT NAME: HPL 100 SPRAY GRADE BASE - OFF WHITE PRODUCT CODE: 75F650B
I. CHEMICAL PRODUCT AND CONTANY IDENTIFICATION

SUPERCEDES: None

CHEMICAL NAME/COMMON NAME % CAS PEL
SILICON DIOXIDE / AMORPHOUS, SYNTHETIC 15–40 7631-86-9 No PEL established
SILICA
ALUMINUM OXIDE / ALUMINA 10–30 1344-28-1 total dust: 15 mg/m3
TWA; respirable
fraction:
5 mg/m3 TWA
CASTOR OIL, ESTER WITH PENTAERYTRUTOL 7–13 68459-68-7 No PEL established
POLYESTER RESIN
POLY (OXY- (METHYL-1,2-ETHANEDIYL)), 7–13 25723-16-4 No PEL established
ALPHA-HYDRO-OMIGA-HYDROXY-ETHER WITH
2-ETHYL-2—(HYDROXYMETHYL)1,3
PROPANEDIOL / POLY (OXYALKYLENE) POLYOL
2-PROPANOL, 3–7 116-37-0 No PEL established
METHYLETHYLIDENE)BIS(4,1-PHENYLENEOXY))
BIS- / POLYMERS OF BISPHENOL A, PROPYLENE
OXIDE
9-OCTADECENOIC ACID, 12-11YDROXY-,3- 3–7 78-22-8 No PEL established
HYDROXY-2,2-BIS(HYDROXYMETHYL)PROPYL
ESTER, (R-(Z))- / POLYOL
SUPPLIER TRADE SECRET / ADDITIVE, 1–5 TRADE SECRET No PEL established
PLASTICIZER
TITANIUM OXIDE TITANIUM DIOXIDE 1–5 13463-67-7 total dust: 15 mg/m3
TWA
Components not listed are not physical or health hazards as defmed in 29 CFR 1910.1200 (Hazard
110
Inhalation: Can cause moderate respiratory irritation, dizziness, weakness, fatigue, nausea and headache.
Causes respiratory tract irritationHarmful! Can cause systemic damage (see ‘Target Organs’)
Skin Contact: Can cause minor skin irritation, defatting, and dermatitis. May cause sensitization.
Eye Contact: Can cause severe irritation. Eye contact may result in comeal injury. Symptoms may include
may cause severe eye irritation, comeal damage, and may result in temporary or permanent
loss of vision. Can cause irritation. Can cause mechanical irritation if dusts are generated.
Skin Absorption: No data,Component(s) may be absorbed through intact skin, but it is unlikely that harmful
affects will occur unless contact is prolonged, repeated, and extensive.
Ingestion: Mildly irritating to mouth, throat, and stomach. Can cause abdominal discomfort. Harmful if
swallowed. May cause systemic poisoning.
Reproductive and
cause birth defects. Not likely to be a human reproductive hazard.
IV. FIRST AID
Inhalation: Remove to fresh air. If breathing is difficult, have a trained individual administer oxygen. No
specific treatment is necessary since this material is not likely to be hazardous by inhalation.
Eyes: Flush eyes with plenty of water for at least 20 minutes retracting eyelids often. Tilt the head to
prevent chemical from transferring to the uncontaminated eye. Get immediate medical
attention.
Notes to NID: No additional first aid information available

example in a fire. Use process enclosures to control the level of dust in the air.
111
liquid.
Products:
VI. ACCEDENTAL RELEASE MEASURES

employees in the area responding to the spill. Clean up spills; immediately using Protective
General Methods: Prevent the spread of any spill to minimize harm to human health and the enviromnent if safe
Ensure clean-up measures are in compliance with OSHA (29 CFR 1910.120).
well ventilated area. Ground and bond containers when transferring material. Follow an
Empty drums should be completely drained, properly bunged and promptly returned to a drum
re-conditioner, or promptly disposed of. As with all chemicals, good industrial hygiene practices
should be followed when handling this material. Minimi e dust generation and accumulation.

OSHA chemical specific standard in 29 CFR 19 10.
112
Respiratory protection not normally needed since volatility and toxicity are low. If vapors,
protection program that meets 29 CFR 1910.134 and ANSI Z88.2 requirements whenever
work place conditions warrant the use of a respirator.
the applicable exposure limits, use NIOSH/MSHA approved respiratory protection. A
respiratory protection program that meets OSHA’s 29 CM 1910.134 and ANSI Z88.2
requirements must be followed whenever workplace conditions warrant a respirator’s use.
wash station available. Wear goggles and a Face shield Wear goggles if dusts can reach the
exposure limit.
personal hygiene and wear a barrier cream and/or impervious surgical style gloves. Wash
Control Parameters:
CHEMICAL NAME ACGI11 TILV-TWA ACGM STEL IDLI1
SILICON DIOXIDE No TLV 3000 mg/m3 MH
ALUMINIUM OXIDE as AI: 10 mg/m3 TWA ND
(The value is for total dust
<
1% crystalline silica)
CASTOR OIL, ESTER WITH No TLV ND
PENTAERYTHRITOL
POLY (OXY- (METHYL-1,2- No TLV ND
ETHANEDM)), ALPHA-HYDRO
OMEGA-HYDROXY-EMER WITH 2
ETHL-2(HYDROXYMETHYL)1,3
PROPANEDIOL
2-PROPANOL, 1,1.-Q1- No TLV ND
METHYLETHYLIDENE)11IS(4,1
PHENYLENI1OXY)) BIS
9-OCTADECENOIC ACID, 12- No TLV ND
HYDROXY-,3-11YDROXY-2,2
BIS(HYDROXYMETHYL)PROPYL
ESTER, (R-(Z))
113
IX. PHYSICAL AND CHEARCAL PROPERTIES
Theoretical VOC (Ibs.lgallon) 0.000

Waste Description for Spent or discarded material is not expected to be a hazardous waste.
Spent Product:
IIV. TRANSPORTATION INFORMATION

DOT Basic Description–Land Transportation: PAW
Hazard Code–Land Transportation: 1A
UN Number–Land Transporation: NA
Hazard Class–Land Transporation: NOT REGULATED
DOT Basic Description–Air Transporation: PAINT
Hazard Code–Air Transportation: 1A
UN Number–Air Transporation: NA
Hazard Class–Air Transporation: NOT REGULATED
DOT Basic Description–Sea Transporation: PAINT
Hazard Code–Sea Transportation: 1A
UN Number–Sea Transporation: NA
Hazard Class–Sea Transporation: NOT REGULATED

Chemical Incompatibility: Strong oxidizing agents; Metals
Decomposition Temp:
Products:

Chemical Name CAS Number LD5011LC50
114
Sensitization: No data No data

Mobility: No data
Pesistence: No data

Waste Description for Spent or discarded material is not expected to be a hazardous waste.
Spent Product:

DOT Basic Description-Land Transportation: PAINT
DOT Basic Description-Air Transporation: PAINT
DOT Basic Description-Sea Transporation: PAINT
115
Aluminum oxide SARA 313 1344-28-1 18.3
No 313-listed chemicals SARA 313 116-37-0 6.59
in this product
No 313-listed chemicals SARA 313 NoCAS# 1.57
in this product
in this product
in this product

Disclaimer: IMPORTANT: WHILE THE DESCRIPTIONS, DATA AND INFORMATION CONTAINED HEREIN ARE PRESENTED IN GOOD FAITH AND BELIEVED TO BE
ACCURATE, IT IS PROVIDED FOR YOUR GUIDANCE ONLY. BECAUSE MANY FACTORS MAY AFFECT PROCESSING OR APPLICATIONIUSE, WE RECOMMEND THAT YOU
PERFORM AN ASSESSMENT TO DETERMINE THE SUITABILITY OF A PRODUCT FOR YOUR PARTICULAR PURPOSE PRIOR TO USE. NO WARRANTIES OF ANY KIND,
EITHER EXPRESSED OR IMPLIED, INCLUDING FITNESS FOR A PARTICULAR PURPOSE, ARE MADE REGARDING PRODUCTS DESCRIBED, DATA OR INFORMATION SET FORTH.
IN NO CASE SHALL THE DESCRIPTIONS, INFORMATION,OR DATA PROVIDED BE CONSIDERED A PART OF OUR TERMS AND CONDITIONS OF SALE. FURTHER, THE
DESCRIPTIONS, DATA AND INFORMATION FURNISHED HEREUNDER ARE GIVEN GRATIS. NO OBLIGATION OR LIABILITY FOR THE DESCRIPTION, DATA AND
INFORMATION GIVEN ARE ASSUMED. ALL SUCH BEING GIVEN AND ACCEPTED AT YOUR RISK.
116
Following are reviews of each step.
Processing Guide
1. PREPARATION of PIPE PRIOR to
Fusion Bonded Epoxy for Stand Alone ABRASIVE CLEANING
Coatings Proper attention to the pre-cleaning and
preparation of the raw pipe prior to abrasive
Introduction cleaning has a considerable effect on the eventual
This guide provides information for the application
quality of surface cleanliness. Efficiency and cost of
of fusion bonded epoxy pipe coatings for use in a
the cleaning process can also be adversely affected
stand-alone epoxy coating.
by poor preparation.
General
Fusion bonded epoxy coatings provide high quality The basic elements of pre-cleaning are:
protection of pipelines used for the transmission a) REMOVAL OF SURFACE
of oil, gas, slurry and water. The advantages of CONTAMINANTS
Fusion bond epoxy coatings can be gained through
controlled plant application. b) LOOSENING OF MILL SCALE
(on new pipe)
The expertise and quality control of the coating
operation will have a significant influence on c) REMOVAL OF FROST OR
achieving optimum coating performance MOISTURE
Raw pipe is often covered with contaminants such as
The critical steps that must be controlled are:
salts, soil, grease, oil, organic coating residue and
1. Preparation of pipe-prior to abrasive mill treatments. It is highly desirable that as much as
cleaning possible of these contaminants is removed prior to
the first abrasive-cleaning step. Failure to do this
2. Abrasive cleaning
may lead to excessive contamination of the abrasive
3. Final cleaning and final inspection media, which can greatly impair production
efficiencies and, worse, may cause performance
4. Surface conditioning
deficiencies of the subsequently applied coating.
5. Preheating of the pipe Deeply embedded salts and certain organic
6. FBE Coating Application contaminants, if not completely removed, can cause
bond failures and film forming deficiencies.
7. Post treating
Sometimes conditions may exist that require prior
8. Final Inspection and Quality Control removal of snow and ice from the inside and outside
9. Coating Repair Procedures the pipe. This is best accomplished in a staging area
with overhead or bottom heating devices. Another
10. Pipe Handling option is to immerse the pipe in hot water (75–85°C)
for 3–5 minutes, which effectively removes surface
salts, and dirt, and also preheats the pipe uniformly.
117
The best way to pre-clean pipe depends on the type The best overall cleaning is achieved by the
and degree of contamination. Salts and soil can be following sequence of operations.
removed effectively only with fresh water
a) The pre-cleaning and preheated pipe
(preferably high pressure, 1000–2000 psi), while
enters the first cleaning chamber. S-280
organic contaminants require a hydrocarbon solvent
abrasive medium should be used on pipe
such as Xylene or mineral spirits. Wire brushes are
that still has much mill scale present. If the
effective in removing loose scale and dirt.
pipe surface is mostly corroded. G-25 or
The next important stage of the preparation is to G-40 grit only should be used.
preheat the pipe, preferably by impinging flame Combinations of shot and grit may be
burners to loosen mill scale (if present), remove desirable.
frost and moisture, burn off organic matter, and
b) The first cleaning step will establish the
condition the pipe surface for easier abrasive
basic cleanliness and anchor pattern. It will
cleaning. The pipe temperature should be between
also uncover pipe defects such as slivers,
65°C and 82°C. Excessive skin heating must be
burrs, laminations, scabs and gouges. Disc
avoided.
grinding or other suitable methods must
Electrical induction heating is also acceptable for correct these defects. If serious defects
preheating. exist the pipe should be rejected at this
stage.
2. ABRASIVE CLEANING c) The next step is a second abrasive cleaning
The purpose of the abrasive cleaning is to achieve a process using G-25 or G-40 steel grit as
‘clean’ surface, having a slight angular anchor with medium, having a hardness of 50–60
an average profile depth of between 50 and 100 Rockwell C. The main purpose of this step
micron. The surface cleanliness should meet a is to achieve the final desired cleanliness
minimum of Near White Blast quality as described and the desired anchor pattern. Often only
under any of the following specifications: a ‘light’ blasting is necessary for best
SSPC – SP10 performance.
NACE No. 2 d) Abrasive residues should be removed from

the interior of the pipe with compressed
SA 21⁄2 air or by other suitable means.
This can be achieved most effectively with If only one abrasive cleaning unit is available, it is
centrifugal type blasting equipment using steel shot recommended that a blend of S-280 shot and G-25
and steel grit as the abrasive media in two cleaning grit abrasive in the ratio of 50:50 be used for good
chambers separated by an ‘inspection and grinding’ results. (The shot and grit must be of similar
station. The shot abrasive should not be larger than hardness when used as a blend or ‘grinding’ will take
S-330 and the grit not coarser than G18. place resulting in excessive fines, or rounding or the
grit particles.)
118
Regardless of the type of operation, the following important that the period between cleaning and
general conditions are important in order to achieve coating be kept as short as possible to avoid
high quality and efficient cleaning: deterioration of cleanliness.
The centrifugal wheels should have adequate
horsepower and be positioned strategically. 4. SURFACE CONDITIONING
To achieve the best possible surface wetting, with
A good quality abrasive medium should be used and
consequently superior coating adhesion, a surface
replenished regularly (Abrasive must be free of
treatment of the pipe surface is recommended.
sodium nitrate)
A weak Phosphoric acid solution in water (10% of
3. FINAL CLEANING AND INSPECTION 75% concentrated acid) has been found to perform
well. It is highly important and critical to the success
All abrasive dusts need to be removed and this can
of this pre-treatment that any free acid is removed
be checked periodically by tightly taping the surface
by thorough water washing immediately following
with adhesive tape, and examining the underside for
the treatment. It is important that the rinse water
dirt particles after removal of the tape.
contains no detrimental contaminants and has a
It is more difficult to check oil or organic matter maximum hardness of 200 ppm.
contamination. The use of surface tension
Other surface conditioning procedures may prove to
measurements, using Wetting Tension Solution of
be equally satisfactory. A 5% Oakite 33 or FOX
known values and characteristics, provide the best
BOND 1099 solution in water, for example, gives
information. However, for practical purposes
excellent results.
observing how well a drop of clean water will wet the
surface is a useful indicator. This treatment will be mandatory as raw pipe has
been undergoing corrosion in the presence of
The specification for pipe coating requires a ‘Near
chloride or sulphate ions prior to processing at the
White’ metal blast quality. In most cases, the skilled
coating plant. A common occurrence of this is due
operator can visually recognise the required
to salt-water exposure during ocean voyage of the
standard. Visual standards (NACE or Swedish
pipe from the steel mill to the coating plant or from
pictorial Standards) should be used if any doubt
stockpiling near salt water or SO2 atmosphere.
exists.
Under these conditions, ferrous salts will form which
It is very important that the required anchor pattern will be retained on the steel surface, particularly in
is achieved. The profile should be angular but pits, even after normal abrasive cleaning,
should not have ‘undercuts’ that can result from
A good test to establish the presence of ferrous salts
‘over blasting’, wrong abrasive or improper
is by using the potassium Ferricyanide or
positioning of the centrifugal wheels. The profile
Phenanthrolin tests. The tests and procedures are
can be measured by instruments such as: Tooke
described in a further information sheet,
Gauge, Elcometer Surface Profile Gauge or Testex
Press-O-Film Any pipe showing more than a trace of ferrous salts
must be appropriately treated or must not be coated
The specified surface cleanliness should exist at the
if optimum performance is desired. Proper surface
point of coating application it is therefore very
119
treatment ensures that the pipe surface will be free With induction heating it is important that the
of harmful contaminants arising from transportation appropriate frequency is used to ensure ‘deep’
or coating plant operations. heating. Intense skin heating must be avoided.
Additional coating performance enhancement can Uniform metal temperatures at the specified levels
be achieved by treating the ‘clean’ pipe surface with must be maintained for the best results. The,
a ‘chromate’ solution prior to the final preheats. temperature must be controlled at the entrance to
the coating chamber. TEMPILSTICKS and Infrared
An Accomet PC, Gardobond 4504, or equal
Pyrometers are satisfactory control tools, but must
treatment is particularly effective. A 10% solution in
be calibrated regularly to ensure their accuracy.
water is applied by spreading the solution uniformly
over the pipe surface. Care should be taken to keep The correct application temperature will depend on
any ‘run off’ to a minimum. It is also important that the type of powder, the line speed, the distance to
any waste material is collected for appropriate adhesive application, the adhesive type, the mass of
disposal as required by local regulations. steel and time to quench.
Recommended usage of Chromate is 0.3–0.7Kg of
concentrate per 100m2 of pipe surface. 6. FBE COATING APPLICATION
Powder application is best accomplished by
5. PREHEATING OF PIPE electrostatic spraying. It is important that a
fluidising powder feed and suitable reclaim systems
Proper heating of the pipe joints is one of the most
are used. When the guns are properly set up there
important steps in the successful application for
should be relatively little overspray in the powder
fusion bond pipe coatings. The steel must reach the
chamber.
appropriate temperature required for the particular
pipe size, line speed, intercoat time and coating Following are some of the more important points
specification. that should be in balance to achieve the best
At no time should the metal temperature exceed results:
275 °C as this may cause metallurgical or surface a) Pipe must be well grounded during its
defects. A strong ‘bluing’ or darkening of the pipe entire travel through the coating chamber.
surface is one indication of excessive heating.
b) Proper charge on the sprayed powder must
Acceptable heat sources are: be maintained. (Normally 50–100 kV.)
Amperage should be controlled at the
a) Gas fired radiant heat
electrode and should be 150–225
b) Gas fired direct flame impingement microamp.
c) Electrical Induction c) The guns should be positioned strategically
in the coating chamber to give a uniform
It is important that the gas fired heating systems are
powder deposition.
well adjusted so that no combustion products are
deposited on the steel surface.
120
The guns should be at such a distance from the pipe A test should be made to measure the necessary
surface to make optimum use of the electrostatic powder delivery for a given pipe size and speed. This
properties and give minimum overspray. This information can be used to determine deposition
distance is likely to be 5–10 inches from the surface, efficiency and effectiveness of equipment settings.
and is, to some extent, dependent on the pressure
It is important that all air used in the coating
necessary to uniformly transport powder through
chamber and supporting systems is clean and dry.
the line. As a starting point, position the guns at a
Moisture can cause both deposition problems and
distance of 8 inches from the pipe. Then adjust
coating deficiencies such as craters and pinholes.
according to film thickness requirements, pipe size
Worse problems will result from air contamination
and line speed. Powder delivery tubing should be of
with oil. In addition to causing coating defects oil
appropriate diameter (usually 12mm or greater) and
contamination is a major cause of impact fusion,
the length be as short as practical with minimum
which can cause system clogging and erratic spray
restrictions between the guns and fluidized bed.
patterns.
Avoid gravity effects on powder flow through the
tubing. A 60 or 80 mesh screen is recommended in recovery
systems to eliminate oversized particles. For
The most common errors in adjusting the
screening virgin powder a 50 or 60 mesh screen is
equipment are setting the guns too close or too far
most appropriate.
from the pipe and using excessive air pressure for
powder delivery. Both will result in excessive Magnetic separators should be used in the powder
overspray and inefficient powder deposition. feed system to help remove metallic contaminants.
Excessive electrostatic charge must also be avoided
The coating chamber must be equipped with
since this may cause back ionisation and possible
appropriate fire and explosion detection systems.
film defects.
Improper adjustments can also result in the more 7. POST TREATING
serious problem of gun clogging. This can also be To achieve optimum film and resistance properties,
caused by either the guns being too near the hot the curing reaction of the coating must he allowed to
surface, or partially cured overspray getting into the meet the minimum requirement prior to water
diffusers. Proper design and selection of diffusers quenching. The minimum requirement will, depend
will minimise problems. on the preheat temperature, the pipe size and the
The best positioning of the guns is on the side of mass of steel.
counter clockwise rotating pipe. This will minimise Wetting of the conveying wheels to minimise
detrimental effects of radiant heat or gun clogging ‘tracking’ may be done.
and reclaim powder. The guns should also be
positioned to give a steady build up of the required
film and not flooding the pipe.
121
10. Coating repair procedures
Processing Guide
11. Pipe handling
FUSION BONDED EPOXY FOR Following are reviews of each step with particular
MULTI-LAYER COATINGS reference to the fusion bonded epoxy.
INTRODUCTION 1. PREPARATION OF PIPE PRIOR TO

ABRASIVE CLEANING
This guide provides information for the application
of fusion bonded epoxy pipe coatings for use in a Proper attention to the precleaning and preparation
multi-layer coating system. of the raw pipe prior to abrasive cleaning has a
considerable effect on the eventual quality of
GENERAL surface cleanliness. Efficiency and cost of the
Fusion bonded epoxy coatings provide high quality cleaning process can also be adversely affected by
protection of pipelines used for the transmission of poor preparation.
oil, gas, slurry and water. The advantages of fusion
The basic elements of precleaning are:
bonded epoxy coatings can be used in the
multi-layer coating systems through controlled plant Removal of surface contaminants
application and the use of compatible adhesive
Loosening of mill scale (on new pipe)
coatings to bond the multi-layer systems together.
Removal of frost or moisture
The expertise and quality control of the coating
operation will have a significant influence on Raw pipe is often covered with contaminants such as
achieving optimum coating performance. The salts, soil, grease, oil, organic coating residue and
critical steps that must be controlled are as mill treatments. It is highly desirable that as much of
follows: these contaminants as possible be removed prior to
the first abrasive cleaning step. Failure to do this
1. Preparation of pipe prior to abrasive
may lead to excessive contamination of the abrasive
cleaning
media, which can greatly impair production
2. Abrasive cleaning efficiencies and, worse, may cause performance
deficiencies of the subsequently applied coating.
3. Final cleaning and final inspection
Deeply embedded salts and certain organic
4. Surface conditioning contaminants, if not completely removed, can cause
5. Preheating of the pipe bond failures and film forming deficiencies.
6. FBE coating application Sometimes conditions may exist that require prior
removal of snow and ice from the inside and outside
7. Intercoat timing of the pipe. This is best accomplished in a staging
8. Post treating area with overhead or bottom heating devices.
Another option is to immerse the pipe in hot water
9. Final inspection and quality control (75 to 85°C) for 3 to 5 minutes, which effectively
122
removes surface salts and dirt, and also preheats the The best overall cleaning is achieved by the
pipe uniformly. following sequence of operations.
The best way to preclean pipe depends on the type 1 . The pre-cleaning and preheated pipe
and degree of contamination. Salts and soil can be enters the first cleaning chamber. S-280
removed effectively only with fresh water abrasive medium should be used on pipe
(preferably high pressure, 1000 to 2000 psi), while which still has much mill scale present. If
organic contaminants require a hydro-carbon the pipe surface is mostly corroded, G-25
solvent such as Xylol or mineral spirits. Wire or G-40 grit only should be used.
brushes are effective in removing loose scale and Combinations of shot and grit may be
dirt. desirable.
The next important stage of the preparation is to 2. The first cleaning step will establish the
preheat the pipe, preferably by impinging flame basic cleanliness and anchor pattern. It will
burners to loosen mill scale (if present), remove also uncover pipe defects such as slivers,
frost and moisture, burn off organic matter, and burrs, laminations, scabs and gouges.
condition the pipe surface for easier abrasive These defects must be corrected by disc
cleaning. The pipe temperature should be between grinding or other suitable methods. If
65°C and 82°C. Excessive skin heating must be serious defects exist the pipe should be
avoided. rejected at this stage.
Electrical induction heating is also acceptable for 3. The next step is a second abrasive cleaning
preheating. process using G-25 or G-40 steel grit as
medium, having a hardness of 50-60
2. ABRASIVE CLEANING Rockwell C. The main purpose of this step
The purpose of abrasive cleaning is to achieve a is to achieve the final desired cleanliness
“clean” surface, having a slight angular anchor and the desired anchor pattern. Often only
pattern with an average profile depth of between 50 a “light” blasting is necessary for best
and 100 micron. The surface cleanliness should meet performance.
a minimum of Near White Blast quality as described 4. Abrasive residues should be removed from
under any of the following specifications: the interior of the pipe with compressed
SSPC - SP10; NACE No. 2; SA 21⁄2 air or by other suitable means.
This can be achieved most effectively with If only one abrasive cleaning unit is available, it is
centrifugal type blasting equipment using steel shot recommended that a blend of S-280 shot and G-25
and steel grit as the abrasive media in two cleaning grit abrasive in the ratio of 50:50 be used for good
chambers separated by an inspection and grinding results. (The shot and grit must be of similar
station. The shot abrasive should not be larger than hardness when used as a blend or “grinding” will
S-330 and the grit not coarser than G18. take place, resulting in excessive fines, or rounding
of the grit particles.)
123
Regardless of the type of operation, the following The specified surface cleanliness should exist at the
general conditions are important in order to achieve point of coating application. It is therefore very
high quality and efficient cleaning: important that the period between cleaning and
coating be kept as short as possible to avoid
The centrifugal wheels should have
deterioration of cleanliness.
adequate horsepower and be positioned
strategically.
4. SURFACE CONDITIONING
A good quality abrasive medium should be
To achieve the best possible surface wetting, with
used and replenished regularly (the
consequently superior coating adhesion, a surface
abrasive must be free of sodium nitrate).
treatment of the pipe surface is recommended.
3. FINAL CLEANING AND INSPECTION A weak Phosphoric acid solution in water (10% of
75% concentrated acid) has been found to perform
All abrasive dusts need to be removed and this can
well. It is highly important and critical to the success
be checked periodically by tightly taping the surface
of the pretreatment that any free acid is removed by
with adhesive tape, and examining the underside for
thorough water washing immediately following the
dirt particles after removal of the tape.
treatment. It is important that the rinse water
It is more difficult to check oil or organic matter contains no detrimental contaminants and has a
contamination. The use of surface tension maximum hardness of 200 ppm.
measurements, using Wetting Tension Solution of
Other surface conditioning procedures may prove to
known values and characteristics, provide the best
be equally satisfactory. A 5% Oakite 33 or FOX
information. However, for practical purposes,
BOND 1099 solution in water, for example, gives
observing how well a drop of clean water will wet the
excellent results.
surface is a useful indicator.
This treatment will be mandatory if the raw pipe has
The specification for pipe coating requires a “Near
been undergoing corrosion in the presence of
White” metal blast quality. In most cases, the skilled
chloride or sulphate ions prior to processing at the
operator can visually recognise the required
coating plant. A common occurrence of this is due
standard. Visual standards (NACE or Swedish
to salt water exposure during ocean voyage of the
pictorial standards) should be used if any doubt
pipe from the steel mill to the coating plant or from
exists.
stockpiling near salt water or SO2 atmosphere.
It is very important that the required anchor pattern Under these conditions, ferrous salts will form which
is achieved. The profile should be angular but will be retained on the steel surface, particularly in
should not have “undercuts” that can result from pits, even after normal abrasive cleaning.
“over blasting”, wrong abrasive or improper
A good test to establish the presence of ferrous salts
positioning of the centrifugal wheels. The profile
is by using the potassium Ferricyanide or
can be measured by instruments such as: Tooke
Phenanthroline tests. The tests and procedures are
Gauge, Elcometer Surface Profile Gauge, or Testex
described in a further information sheet. Any pipe
Press-O-Film.
showing more than a trace of ferrous salts must
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either be appropriately treated or must not be With induction heating it is important that the
coated if optimum performance is desired. appropriate frequency is used to ensure “deep”
heating. Intense skin heating must be avoided.
Proper surface treatment ensures that the pipe
surface will be free of harmful contaminants arising Uniform metal temperatures at the specified levels
from transportation or coating plant operations. must be maintained for the best results. The
temperature must be controlled at the entrance to
Additional coating performance enhancement can
the coating chamber. TEMPILSTICKS and Infrared
be achieved by treating the “clean” pipe surface with
Pyrometers are satisfactory control tools, but must
a “chromate” solution prior to the final preheat. An
be calibrated regularly to ensure their accuracy.
Accomet PC, Gardobond 4504 or equal treatment is
particularly effective. A 10% solution in water is The correct application temperature will depend on
applied by spreading the solution uniformly over the the type of powder, the line speed, the distance to
pipe surface. Care should be taken to keep “run off” adhesive application, the adhesive type, the mass of
to a minimum. It is also important that any waste steel and time to quench.
material is collected for appropriate disposal as
required by local regulations. 6. FBE COATING APPLICATION
Recommended usage of Chromate is 0.3 to 0.7 kg or Powder application is best accomplished by
concentrate per 100m2 of pipe surface. electrostatic spraying. It is important that a
fluidising powder feed and a suitable reclaim
5. PREHEATING OF PIPE systems are used. When the guns are properly set
up, there should be relatively little overspray in the
Proper heating of the pipe joints is one of the most
powder chamber.
important steps in the successful application of
fusion bond pipe coatings. The steel must reach the Following are some important points that should
temperature required for the particular pipe size, be in balance to achieve the best results:
line speed, intercoat time and coating specification.
1. Pipe must be well grounded during its
At no time should the metal temperature exceed entire travel through the coating chamber.
275°C as this may cause metallurgical or surface
defects. A strong “bluing” or darkening of the pipe 2. Proper charge on the sprayed powder must
surface is one indication of excessive heating. be maintained (normally 50 to 100 kv).
Amperage should be controlled at the
Acceptable heat sources are:
electrode and should be 150 to 225
gas fired radiant heat microamp.
gas fired direct flame impingement 3. The guns should be positioned strategically
in the coating chamber to give a uniform
electrical induction
powder deposition.
It is important that the gas fired heating systems are
well adjusted so that no combustion products are
deposited on the steel surface.
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The guns should be at such a distance from the pipe deposition efficiency and effectiveness of the
surface to make optimum use of the electrostatic equipment settings.
properties and give minimum overspray. This
It is important that all air used in the coating
distance is likely to be 5 to 10 inches from the
chamber and supporting systems is clean and dry.
surface, and is, to some extent, dependent on the
Moisture can cause both deposition problems and
pressure necessary to uniformly transport powder
coating deficiencies such as craters and pinholes.
through the line. As a starting point, position the
Worse problems will result from air contamination
guns at a distance of 8 inches from the pipe. Then
with oil. In addition to causing coating defects, oil
adjust according to film thickness requirements,
contamination is a major cause of impact fusion,
pipe size and line speed. Powder delivery tubing
which can cause system clogging and erratic spray
should be of appropriate diameter (usually 12 mm
patterns.
or greater) and the length be as short as practical
with minimum restriction between the guns and A 60 or 80 mesh screen is recommended in recovery
fluid bed. Avoid gravity effects on powder flow systems to eliminate oversized particles. For
through the tubing. screening virgin powder, a 50 or 60 mesh screen is
most appropriate.
The most common errors in adjusting the
equipment are setting the guns too close or too far Magnetic separators should be used in the powder
from the pipe and using excessive air pressure for feed system to help remove metallic contaminants.
powder delivery. Both will result in excessive
The coating chamber must be equipped with
overspray and inefficient powder deposition.
appropriate fire and explosion detection systems.
Excessive electrostatic charge must also be avoided,
since this may cause back ionisation and possible
film defects.
7. INTERCOAT TIME
In multi-layer coating the time between the
Improper adjustments can also result in the most application of the fusion bonded epoxy and the
serious problem of gun clogging. This can also be adhesive is crucial to obtaining good peel adhesion
caused by either the guns being too near the hot values.
surface, or partially cured overspray getting into the
diffusers. Proper design and selection of diffusers The adhesive should be applied before the epoxy
will minimise problems. coat gels to optimise the peel strength. This ensures
that sufficient reaction can take place between the
The best positioning of the guns is on the side of chemical groups on the epoxy and the adhesive.
counter clockwise rotating pipe. This will minimise
detrimental effects of radiant heat or gun clogging If the adhesive is applied too late, the peel strength
and reclaim powder. The guns should also be will be very low and the peel will reveal a smooth
positioned to give a steady build up of the required coat of epoxy with failure between the adhesive and
film and not flood the pipe. the epoxy.
The test should be made to measure the necessary If the adhesive is applied in powder form there is no
powder delivery for a given pipe size and line speed. minimum time before the application of the
This information can be used to determine adhesive. In the case of extruded adhesive however,
126
the epoxy has to have achieved a level of mobility to DSC evaluation of the glass transition temperature.
support the extruded film without “skidding”.
The peel test is important in assessing the cure and
The other components of the multi-layer system can the intercoat adhesion which in the process control
be applied by side extrusion, cross head extrusion or terms gives feedback on the intercoat timing of
powder spray depending on the final specification phase 7. Peel test methods may vary with the coating
for the project. specification being used but, in general, the failure
should be within the adhesive film, leaving some
8. POST TREATING adhesive attached to the epoxy and some attached to
To achieve optimum film and resistance properties, the outer coat.
the curing reaction of the coating must be allowed to Longer term tests should also be carried out
meet the minimum requirement prior to water periodically to assure that the system is performing
quenching. The minimum requirement will depend optimally.
on the preheat temperature, the pipe size, the mass
of steel and the specification of the multi-layer These include:
system. The specification of the multi-layer film Hot water soak
affects this phase as the insulation properties of the
outer layers will enable the epoxy to continue the Impact test
cure process after the water quenching has started. Bend test
Wet the conveying wheels to minimise ‘tracking”, if
desired. Cathodic disbondment test
9. FINAL INSPECTION and QUALITY 10. COATING REPAIR PROCEDURES

CONTROL A procedure for the repair of three layer systems is
described in a separate information sheet. However,
Thorough inspection and coordination of this
where the steel is exposed, it is strongly
function with the other application steps are
recommended that a 2 pack 100% solid epoxy repair
essential for optimum multi-layer coating. It is far
compound be used prior to the use of a heat shrink
more important to consider “inspection” as a means
sleeve or extruded material to complete the repair.
of process control rather than to simply pronounce
non-specification conditions or rejection. If each
processing step is done correctly, a high quality 11. PIPE HANDLING
coating will be a natural consequence.
A. BARE PIPE
Regular quality control tests to be carried out during
Bare pipe must not be stored in direct contact with
application include film thickness check, holiday
the ground. It should be placed on wooden runners.
detection (“jeeping”), peel testing and cure.
Wooden separators should also be used as a break in
Cure of the epoxy layer is usually assessed on a the pile to allow forklift trucks to pick-up from the
section of pipe which is coated without the outer pile.
layers at the start or end of the running period. The
test should be carried out using the MEK rub test of
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B. COATED PIPE
Careful handling of the coated pipe is essential to
avoid mechanical damage during stacking, loading,
transportation, stringing and “lowering”.
Multi-layer systems provide excellent mechanical
resistance properties. But the contact forces of pipe
against pipe or a stone between pipes can cause
puncture damage. The basic requirements are as
follows.
All contact points of handling must be
padded, and a load spreader beam should
be used for pipe lifting.
Separators must be used when stacking
joints (3/4” thick rubber pads, tire tread,
synthetic rope are suitable).
Load should be protected from Stone
Throws (plywood shielding, fenders or
tarpaulins are useful).
Pipe joints should always be “lifted” rather
than dragged.
Slamming together pipe ends should be
avoided.
Beveled ends should be protected with
suitable “caps”.
128
FBE COATING REPAIRS lowering in. For the initial repairs the 100% Solids
Liquid Epoxy 46F640 are the most suitable.
COATING REPAIRS – MAJOR DAMAGE OR Experience has shown that in most situations
enough time exists for cure prior. to handling the
LARGE PREVIOUSLY UNCOATED SURFACES. pipe again. The setting and curing of the
The following repair procedure is recommended two-component epoxy can be accelerated with
for areas larger than 1600mm2 (25 in2). application of heat. This may be an essential practice
1. Remove all loose coating and dirt by in cold climate applications.
‘sweep blasting’ (SSPC-SP7). Any Detailed repair procedures for both the 100% solids
corroded steel or bare steel surface must Epoxy is attached.
be blasted to a ‘Near White Metal’,
SSPC-SP10, quality. COATING OF FITTINGS AND
If ferrous salts were found to be present, a MISCELLANEOUS PUMP AND
thorough scrubbing with a chemical COMPRESSOR STATION COMPONENTS
treatment such as Oakite 33 or FOX
Most fittings used for pipeline construction have
BOND 1099 followed by fresh water
‘some type’ of coating applied at the factory, often a
rinsing must be done.
bituminous ‘mastic’ material or a ‘shop primer’.
Sound coating adjacent to bare metal must Since fittings may come from several suppliers, it is
be feathered at least 2 inches by ‘sweep quite possible that the coatings used from different
blasting’, or by abrading with 80 Grit sand suppliers and the coating composition may differ
paper. considerably.
2. Apply 20–30 mils DFT of Jotun HPL 100, Following are some general guidelines for making
75F650. For smaller repairs, the Brush field repairs and to suggest a simple, but effective
Grade version (75F650R) is more suitable. protective coating system which will accommodate
This should be applied by using a stiff most conditions that may exist in an NGL or oil
bristle brush. pipeline construction.
3. Back filling may be done as soon as the 1. Remove any contaminants from the fitting
product has hardened sufficiently to surfaces and the pipe connections, in
prevent mechanical damage to coating accordance with the surface preparation
(approximately 2–3 hours). recommendations made in Section A of
this Guide.
COATING REPAIRS – SMALL DAMAGE
2. Weld joints and other bare metal should be
Minor coating repairs in the field are usually done at abrasive blasted to a Near White Metal
2 stages of the pipe laying operation – the first time Blast, SSPC-SP10, while existing coatings
after sections have been welded together and the should be given a Brush Off blast,
field joint coating has been completed; the final SSPC-SP7, or abraded with 80 Grit
repair takes place immediately preceding the sandpaper.
129
3. Apply 500-625µ (20–25 mils) of 75F650, Some simple tests will help to make an
Jotun HPL 100, over all bare metal and assessment:
factory primed surfaces.
1. Check the adhesion of the coating with a
4. If the factory coating is the bituminous knife. Make a V cut and peel back from
type, it must be established whether of not the apex.
‘bleeding’ will occur when applying 75F650
2. With the aid of an 8–10 power magnifying
over it. Should this occur, a sealing
glass look at coating cross section, at the
operation must be carried out before
coating/substrate interface and if the
applying finish coats. For sealing, it is
coating comes off easily on the back of the
recommended that 75–100µ of 75-Al,
coating.
Alumapoxy, be used.
Film formation quality and surface
5. For any above ground piping and fittings, it
preparation quality can be judged from
is recommended that a 50–75µ (2-3 mil)
this.
coating of 40 Series Urethane is applied
over the 75F650 for long lasting good 3. Measure film thickness.
appearance.
4. Rub the coating with MEK to check for
cure. A cured coating will not soften or
REPAIR OF INSTALLED LINES wear significantly.
The first step in establishing the most appropriate 5. Check the bared pipe surface for ferrous
coating repair procedure is to find out WHY the salt contamination with Potassium
coating had failed: Ferricyanide Paper.
It is simply mechanical damage from
handling during installations?
Is the coating failing to resist the exposure
environment?
Was the coating properly applied and
cured?
Was the surface preparation done
properly?
130
FBE PIPE COATING REPAIRS 3. For making repairs, an option exists to
attach a small static mixer (disposable) to
46F640 (FORMERLY 46W640) the dispensing nozzle which will mix the 2
components while dispensing. This
In our search for better ways of making FBE pipe method may be particularly useful for use
coating repairs, we have developed a new cartridge on cad-weld test lead connections.
packaging and dispensing system. This system makes
it possible to use fast setting, 2-component 4. 46F640 is particularly well suited for
thermosetting repair materials. In addition to this application to hot surfaces (65–105°C).
important feature, the system has many other
advantages over existing methods: DIRECTIONS FOR USE OF 46F640 FAST
ACCURATE DISPENSING
CURE EPOXY PATCHING COMPOUND
A ‘good’ pipe coating repair always requires several
NO WASTE basic steps that include:
NO MESS 1) The surface that is to receive the patch
FAST SETTING must be properly prepared. Any existing
coating must be abraded with 80 grit
HIGH QUALITY sandpaper to remove the surface skin
ECONOMICAL along with any accumulated contaminants.
Any exposed metal must be treated to
The cartridge packaged system can be used in remove contaminants such as corrosion
different ways to suit particular needs. products, salts, and dirt. This step may
For example: entail the use of water or organic solvent.
In most instances, the use of 80 grit paper
1. For making in-plant coating repairs
is satisfactory, but the use of a power
(pinhole type faults detected when
grinder (with flexible medium support)
jeeping), it is recommended that about
may be appropriate in some cases.
10–20 cc’s be dispensed into a small paper
cup and mixed. The best patch size for It is important to remember the old axiom
such repairs uses 1⁄2–1cc of material. ‘if it ain’t broken, don’t fix it.’ For example,
Therefore, approximately 20–30 patches if a pinhole in the coating needs repairing,
can be made with that mix. just abrade the area surrounding the
pinhole with 80 grit paper and apply the
2. For somewhat larger repairs (usually from
patching material. if possible, work some
mechanical damage), the same approach
patching compound into the pinhole with a
can be used but the patches may need a
knife. DO NOT use a file or grinder to
little more material. As an alternative, the
inflict more damage than the original
appropriate amount can be dispensed onto
pinhole.
the surface near the repair site, mixed and
then transferred to the repair point. 2) The patching compound will perform best
131
when it is accurately proportioned,
thoroughly mixed, and spread out in a
uniformly smooth film. The optimum
patch thickness is about 10–50 % thicker
than the original coating. ‘More’ is not
better. In fact, making a thick blob of a
patch is very poor practice as the patch is
prone to getting ‘knocked off’ during
handling. One way of helping to make a
good smooth patch is with the help of a
small sheet of Polyethylene pressed over
the patch area. The PE comes off easily
when the repair material has set.
The ‘set’ and ‘cure’ of the Epoxy Patching
Compound can be accelerated with heat.
At room temperature, 46F640 will set in
one to two hours and is fully cured after 24
hours. By externally applying heat, the set
and cure times can be shortened
considerably. Good heat sources are, for
example: a ‘blow-dryer’ or gas torch fitted
with a special infrared diffuser attachment.
While preheating of the surface will also
speed up the ‘set’ time, the most effective
way to achieve fast setting is by holding the
heat source about 15cm (6 inches) away
from the surface. It is possible to achieve a
good patch ready for handling in two
minutes. Excessive direct heating must be
avoided. If the wet patch ‘bubbles’, the
temperature is too high.
An enclosed ‘hot air box’ surrounding the
pipe can be a good way to achieve fast
curing of large patches and, if necessary,
can be used to make girth weld repairs
effectively.
132
GIRTH WELD COATING WITH FBE 3. CLEANING PROCESS AND MATERIAL
DESCRIPTION
1. INTRODUCTION The most practical method for cleaning pipe or
This guideline describes surface preparation and related equipment in the field is by a manual open
application requirements and procedures, blast system using dry expendable abrasives.
inspection and safety recommendations related to
the field application of Corro-Coat EP-F to pipeline 3.1 The equipment should consist of a blast
girth welds. machine, air compressor, and abrasive
hopper mounted on a moveable trailer.
Suitable oil and water eliminators must be
2. SURFACE PREPARATION
used in the compressed air lines to ensure
2.1 The surface must be free of mill scale and dry and oil free air supply.
corrosion products and meet the ‘Near
White’ standard as stipulated by 3.2 The blasting abrasive should be of the
SSPC-SP10 or NACE No. 2, or BS Second proper size of hardness to most effectively
Quality and as pictorially represented by achieve the specified standard of
the Swedish Standards SA 21⁄2. cleanliness. The choice of abrasive will be
influenced by local supply conditions, and
2.2 The surface must be free of extraneous environment regulations. It is generally
matter and contaminants which includes: prudent to use proven abrasives of high
a) Welding residues and spatter, dirt, quality rather than locally found ‘cheap’
abrasive residues, masking tape materials.
remnants. Cost evaluations should be based on value
b) Organic contaminants such as grease received rather than cost per pound of
and oils. material.
c) Soluble salts, both unreacted and Suitable abrasives include the following:
those having reacted with iron during a) 16–35 Mesh Sand (salt and clay free);
the corrosion process.
b) Mineral Slag, such as Black Beauty;
2.3 The surface must have a suitable anchor
pattern. This should be angular and have a c) Metal Abrasives of proper size and
surface profile between 50µ and 100µ. The hardness, ie., GL-25 (Metal Abrasives
profile should be ‘open’ and folded peaks are usually used only in enclosed
and undercutting of the steel surface systems such as Vacu-Blast, because
should be avoided. of otherwise high cost.
133
NOTE: In remote construction locations where sand 4.3 During adverse weather conditions (ie.,
is abundant, it may be advantageous to use local snow, rain, high winds, fog), the cleaning
sand for blasting, provided that the following operation may only proceed if a
conditions are met: satisfactory shelter is provided for
protecting the work surface, materials and
a) Local regulations allow its use.
equipment.
b) The sand is salt free
4.4 SAFETY REQUIREMENTS
c) The sand is properly screened.
Operators should wear suitable protective
d) The sand will give the proper surface clothing and all operations should be
profile. carried out using sound working practices.
e) Special care is taken to remove All relevant local Safety and Health
residues from cleaned surface. regulations must be adhered to.
4. CLEANING PROCEDURE 5. HEATING

4.1 Remove extraneous contaminants, Proper heating of the girth weld is most important
including weld spatter, by chiseling, if for achieving a high quality coated joint. Electrical
necessary. If organic contaminants are Induction heating has proven to be the most
present, wipe the surface clean with effective method of heating and is strongly
hydrocarbon solvent, such as Xylol. Use recommended. (The use of gas fired infra red
lint free rags and change them frequently. heaters have not yet found successful applications,
For salt contamination, use a good but may be considered if shown to offer advantages).
scrubbing brush with fresh water. If ferrous
salts are deeply embedded in steel, a Following are typical equipment and operating
phosphoric acid solution in water directions as used by one successful field joint
treatment may be necessary. coating contractor:
4.2 Blast clean the metal surface and a narrow 5.1 EQUIPMENT DESCRIPTION
strip (2–3cm) of the factory applied Induction Heating Equipment comprises a
coating to the specified standard of mobile generator, power unit, control unit,
cleanliness. The factory applied coating cooling unit, and split heating coil. The
must be feathered from the edge of well generator, power unit, control unit and
adhering coating over a distance of cooling unit are mounted on a moveable
approximately 25mm (1 inch). This is best trailer with a boom which supports the
done by holding the cleaning nozzle at a induction coil and power cables. The coil is
distance of approximately 50cm (20
inches) from the surface and at a very
shallow angled blast.
134
a split type with manual clamps. The 5.4 SAFETY REQUIREMENTS
moveable trailer is completely shrouded The induction heating coil will operate at a
and weather-proofed with the shroud able maximum of 110 volts. All open ‘live’ contact areas
to be extended to cover the pipe for will be insulated. Safety notices will be displayed
weather ptotection. during the heating process and ‘Hot Pipe’ notices
after. All relevant sections of the Health and Safety
5.2 EQUIPMENT OPERATION Work Act will be adhered to.
Prior to heating, any particles of grit remaining on
the surface are to be brushed or blown off. 6. COATING APPLICATION
The induction coil will be lowered over the girth Pipes having a diameter of 12 inches (300 mm) and
weld area and clamped to the pipe so that it is larger should be coated with Automatic or
centrally positioned over the weld. Semi-Automatic Application Equipment.
The heating cycle can then commence. ‘Flocking’ by hand spray may be used for smaller
diameter pipes.
After the specified temperature has been reached,
the power will be switched off, unclamped, raised off 6.1 COATING SPECIFICATION
the pipe and moved out of the way. Jotun EP-F series powders should be
applied to a minimum film thickness of
5.3 400µ (16 mil). The coating must overlap
The application temperature must fall within the the factory applied coating by at least
limits of the specified FBE powder and typically will 25mm (1 inch).
be a maximum of 250°C (480°F) and minimum of
6.2 TYPICAL APPLICATION
230°C (445°F). Allowance must be made for the
EQUIPMENT DESCRIPTION
reduction in temperature due to time delay between
AUTOMATIC
coil ‘switch off’ and the coating start. Heating must
be uniform to achieve a constant temperature The coating equipment consists of a
around the circumstances of the weld area. Heating powder hopper and feed machine, control
must be within the tolerances allowed, and must cabinet, vacuum extraction machine, air
take into account that the pipe temperatures will compressor, rotary traversing machine and
already be affected by direct sunlight heating. spray heads. The powder hopper and feed
machine, control cabinet, vacuum
Temperature measurement will be carried out with
extraction machine and air compressor are
the use of TEMPILSTICK Crayons or a calibrated
mounted on the same trailer as the
contact temperature measuring device.
induction heating equipment. A boom
At least 3 temperature readings, equi-spaced around supports the air hoses, cables, and spraying
the circumference, must be taken to ensure uniform machine. This equipment is located
heating. Under no circumstances must the metal alongside the induction heating equipment
temperature exceed 300°C (575°F). and is thoroughly weather-proofed.
135
6.3 TYPICAL EQUIPMENT OPERATION 30°C (85°F). Any fluidized bed or material
feed or return hopper must also be kept
Immediately after the induction heating
below this temperature and not exposed to
coil is removed, the rotary traversing
sunlight.
machine will be lowered onto the pipe and
clamped to the pipe so that the spray heads
are located centrally over the weld. 7. COATING INSPECTION
Protective pads are to be used to prevent 7.1 Should be checked with an approved and
the coating machine clamps from correctly calibrated film thickness gauge
damaging the factory applied epoxy (such as Mikrotest or Elcometer). A
coating. minimum of 6 evenly spaced positions
around each joint must be measured.
The pipe temperature will then be
rechecked to ensure that the temperature 7.2 FILM INTEGRITY AND ADHESION
is still within the defined limits. Film formation and adhesion should be
Coating will then proceed obtaining the checked periodically by cutting the film in
required thickness in the minimum a V shape with a sharp knife. Assess
number of passes, normally two passes will coating adhesion and examine cross
be sufficient. After completion of coating, section of the coating as well as the
the rotary machine will be unclamped and steel/coating interface under
raised out of the way. Periodically, the magnification.
powder hopper will be checked to ensure 7.3 CURE
that there is always sufficient powder to
prevent the powder running out during the During the start-up of a field joint coating
application process. project, thorough cure testing should be
done while the application parameters are
After each application, the spray heads will being established. Tests should include
be checked for any clogging or Impact Resistance Testing, Adhesion,
contamination, and purged, if necessary. MEK Resistance and DSC measurements.
At the end of each day, all the powder Adherence to the preheat temperature
coating equipment shall be cleaned down and application setting which were found
completely and left empty until the to give satisfactory coating performance
following day’s use. during the cure testing will then be the best
Periodic checking of the air line, water/oil insurance for achieving good cure.
traps and filters, is required to prevent Adhesion testing and visible deviation
contamination of the powder during from ‘normal’ coating characteristics may
spraying. be used as indicators of cure. As a
The stored powder is to be kept dry at all safeguard, a once a week DSC check is
times, and out of direct sunlight. Powder recommended.
must be stored at a temperature below
136
7.4 HOLIDAY DETECTION
‘Jeeping’ of the coated weld joint is most
practically done in conjunction with the
completed pipeline jeeping.
Experience has shown that under normal
field joint coating conditions, holidays will
occur very infrequently.
Jeeping voltage should never exceed the
factory jeeping voltage used on the
coating. It is recommended that the field
jeeping voltage be 200V below the
specified factory jeeping voltage.
137
CASE HISTORY
Yadana Gas Pipeline project – Thailand HW (formally called Valspar D1003HW) product.
Bredero-Shaw’s plant in Thailand carried out the
Petroleum Authority of Thailand (PTT) have coating during 1996 and 1997. The pipe was then
commissioned the development of the 240 trucked to stockpile sites and double jointed prior to
kilometres Yadana gas pipeline in Thailand. being transported up the right of way. This
The 42 inch diameter line extends from the Burmese operation was carried out with the minimum of
border at Ban-I-Thong to Ratchburi, 100 kilometres damage.
southwest of Bangkok. At Ratchburi, the Electricity The coating was specified by OGP Technical
Generating Authority of Thailand (EGAT) plans to Services of Malaysia who had the contract for
build a 4,600 megawatt power plant to run on the engineering procurement and construction
Yadana gas. management.
The pipeline will be owned and operated by PTT. The Yadana pipeline is a critical component of
Scheduled for completion in mid 1998 it will deliver Thailand’s natural gas transportation infrastructure
525 million cubic feet of natural gas per day. The and will play an important role in increasing natural
estimated capital cost of the pipeline and associated gas utilisation in South East Asia. It is particularly
facilities is around $US400 million. important to Thailand where energy demand has
The pipeline is protected against corrosion by grown by roughly eight per cent per annum for the
Fusion Bond Epoxy. The Jotun factory based in past ten years.
Bangkok manufactured the Corro-Coat EP-F 1003
138
Jotun Functional Coatings
Corro-Coat EP-F 1000 Series reference list
Project Name or location Length Km Applicator Application Date Client
North Sea 36 Blome 1982 ELF.ATO
North Sea 8 MKS/Shaw 1982 Mobil
Africa 40 Rivico 1982 Gulf Oil
Holland 20 MKS/Shaw 1982/3 Mobil
South Africa 116 Blome 1983 Caltex
Iraq/SA 675 Rivestubi/ Isopipe 1984/5 SCOP
Holland 16 Blome 1985 Mobil
England 20 BPCL 1986 British Gas
England 8 Plast.ctgs 1986 British Gas
England 17 BPCL 1987 Phillips
England 60 BPCL 1987 Shell
Upper Beryl 3.5 BPCL 1987 Mobil
England 10 BPCL 1988 Amoco
Camelot 15 BPCL 1988 Mobil
England 50 BSC-Ramco 1988 BritOil
England 18 BSC-Ramco 1988 Arco
England 10 BSC-Ramco 1988 Amoco
England 6.5 BSC-Ramco 1988 Hamilton Bros.
Mobil Camelot 15 BSC-Ramco 1989 Mobil
Angola 6 Socomo 1989 Chevron
England 240 BSC-Ramco 1889/90 Petrafina
Phillips Moira 21 BSC-Ramco 1989 Phillips
Phillips Audrey 10 BSC-Ramco 1989 Phillips
Middle East 163 Blome 1989
Norway 20 Blome 1989
Germany 83 Blome 1989
Iraq 30 Blome 1989
Algeria 120 Blome 1989
Holland 18 Blome 1989
North Sea 6 Blome 1989
Holland 8 Blome 1989
Congo 14 Blome 1989
P12,North Sea 44 Blome 1989 Mobil
139
UK 20 Blome 1990
Iraq 120 Blome 1990
Norway 3 Blome 1990
UK 110 Blome 1990
BP Amethyst 21 BSC-Ramco 1990 BP
Ravenspur 27 BSC-Ramco 1991 Hamilton Bros
North West Ethylene Pipeline 450 BSC-Ramco 1991 Shell
Adnoc 166 NPCC, UAE 1991 ADNOC
UK 24 BSC-Ramco 1991 Allseas/Ranger Oil
UK 50 BSC-Ramco 1991 Kinetica
UK 70 BSC-Ramco 1992 British Gas
Strathspey 55 BSC-Ramco 1992 Texaco
Wei-Zhou 11-4 58 Bredero Price (M) Sdn Bhd 1992 HHI
Thapp Line 250 Bredero Price (M) Sdn Bhd 1992 John Brown
Sepang PGSP 29 Bredero Price (M) Sdn Bhd 1992 Petronas Gas
Malaysia 17 Bredero Price (M) Sdn Bhd 1992 Tioxide
Transmache 2 Balmoral Webco Pipeline Systems 1992 Transmanche
Strathspay Manifold Balmoral Webco Pipeline Systems 1992 Texico
Valdemar & Regnar 33 Balmoral Webco Pipeline Systems 1992 Maersk
UK 35 BSC-Ramco 1993 ARCO
Hyde Field 12 BSC-Ramco 1993 BP
Essex 1 BSC-Ramco 1993 Essex Water
Arun Field, Indonesia 4.6 Bredero Price (M) Sdn Bhd 1993 Mobil - SMI
Malaysia 8 Bredero Price (M) Sdn Bhd 1993 Shell Sarawak
Melaka Laterals 35 Bredero Price (M) Sdn Bhd 1993 IPCO
Griffin Field, Australia 71 Bredero Price (M) Sdn Bhd 1993 BHP
Papua New Guinea 95 Bredero Price (M) Sdn Bhd 1993 BHP-Chevron
140
France Isopipe 1993 ELF
Middle East Isopipe 1993
Bab Maqta - Taweelah 182 NPCC, UAE 1994 ADNOC
Holland 12 Isopipe 1994 Lasmo
Eurotube 19 BSC-Ramco 1994 Hamilton
Shell Galleon 85 BSC-Ramco 1994 EMC-Shell
Liverpool bay 160 BSC-Ramco 1994 Hamilton Oil
Onshore Gas 108 NPCC, UAE 1994 ADNOC
Knapton 37 BSC-Ramco 1994 Scottish Powder
Gudang Metering 4.5 Bredero Price (M) Sdn Bhd 1994 YTL PAKA
PGUIII 100 Bredero Price (M) Sdn Bhd 1994 Petronas Gas
Marathon Kakap 25 Bredero Price (M) Sdn Bhd 1994 P.T.McDermott
Guntong "D" 14 Bredero Price (M) Sdn Bhd 1994 EPMI
Pigas Eng Shah Alam Phase II 10 Bredero Price (M) Sdn Bhd 1994 Pigas Eng.
Sumitomo Indonesia 29 Bredero Price (M) Sdn Bhd 1994 Mobil Oil
Ho Hup Const. (Segambut) 26 Bredero Price (M) Sdn Bhd 1994 Ho Hup Const.
UK 60 BSC-Ramco 1994/5 Amoco
Fray 1.3 Balmoral Webco Pipeline Systems 1995 Elf
Brent South 5.2 Balmoral Webco Pipeline Systems 1995 Shell
Wytch Farm 3.1 Balmoral Webco Pipeline Systems 1995 BP
Thamama C&F 295 NPCC, UAE 1995 ADNOC
Andrew 45 BSC-Ramco 1995 BP
Longannet 9.1 BSC-Ramco 1995 Shell
Cormorant Alpha/Pelican 16 Balmoral Webco Pipeline Systems 1995 Shell
NGPS to Prestigi (Malaysia) 15 Bredero Price (M) Sdn Bhd 1995 Pi-Gas
NGPS to Kluang (Malaysia) 23 Bredero Price (M) Sdn Bhd 1995 MMCE
141
Lateral Lines 11 Bredero Price (M) Sdn Bhd 1995 Gas Malaysia
6102 SHLD Isopipe 1996 Shell
6137 MNGD Isopipe 1996
4134 CRUA Isopipe 1996 Shell
Birch South 40 Balmoral Webco Pipeline Systems 1996 Lasmo
Belfast Gas line 26 BPCL 1996
Derwood/ Dauntless 20 BSC-Ramco 1996 Amerada Hess
Captain Balmoral Webco Pipeline Systems 1996 Texico
Teeside Gas 7.5 BSC-Ramco 1996 Amoco
Erskine 30 BSC-Ramco 1996 Texico
Habsham - Jabeel Dhanna 115 NPCC, UAE 1996 ADCO
Usari BPCL 1996 Mobil
Usari Isotub 1996 Mobil
Caninba Area B & C (Algeria) 34 Bredero Price (M) Sdn Bhd 1996 Mitsubishi
Multi-Product Line Malaysia 130 Bredero Price (M) Sdn Bhd 1996 NKK-JV
KLCC stage II (Malaysia) 7 Bredero Price (M) Sdn Bhd 1996 Ho Hup
Various Arabian Pipe Coaters Ltd. 1997 Aramco
Pakistan 3.7 Cresent Steel 1997 Oil & Gas
Development Corp
Brega-Zueitina,Libya 120 Ilva,Italy 1998
British Gas, various Bredero Price Coatings Ltd, Scotland 1998 British Gas
Various Arabian Pipe Caoters Ltd 1998 Aramco
Asab gas gathering line 181 NPCC, UAE 1998 ADCO
Åsgard Thermotite, Norway 1998 Statoil
142

British Gas, various Britsh Steel Ramco, England 1998 British Gas
Mobil NSO Bredero Price Batam 1998 Mobil
Asab gas Development 194 NPCC, UAE 1998 ADNOC
Zueitina-Benghazi,Libya 142 Ilva,Italy 1999 Mann GHH for
Sirte Oil
OGDII 226 NPCC, UAE 1999 ADCO
new OGDII 246 NPCC, UAE 1999 ADCO
Pipeline Tube/Casing Ltd, Libya 11 Socoril, Argentina 2000 Sirte Oil
Maqta - Jebel Ali 120 NPCC, UAE 2000 ATHEER
North Carolina Gas 140 EB Pipe, USA 2000 North Carolina Gas
Gulf Sream EB Pipe, USA 2001 Williams
143
Corro-Coat EP-F 2000 Series primer reference list
Customer Projects Adhesive Top Coat
Eupec, Germany Various Various BASF
Isopipe, Dunkirk Portugal Line 200+Km Lotader 2100 NCPE 6060 Cj
Various
Isotub, Joeuf Turkey Water Line Borealis Adhesive Borealis
Various Various
Thermotite, Norway Various Various Various
Cresent Steel, Pakistan Bab Magia Mirfa Borealis Adhesive
Various Pakistan State Oil Fusabond 158
Fusabond 206 D
Various Sui Northern Gas Projects Fusabond 158
Various Sui Southern Gas Projects Fusabond 158
Gold Mine
S.E.R.T., Spain Various Polymer Europa Polymer Europa
Izostal, Poland PGNiG 26.5Km Fusabond MB 347 DG Sclair 35BP
Gazomontaz Wolomin Fusabond MB 347 DG Sclair 35BP
56.4Km Fusabond MB 347 DG Sclair 35BP
GOZG Zabrze 17 Km Fusabond MB 347 DG Sclair 35BP
Various Fusabond MB 347 DG Sclair 35BP
PSL, India Various Borealis NCPE 0420 Borealis
Panjin Hualong Tanjin Hualong China Fusabond 158 Sclair 35BP
Petroleum Corrosion Project Phase 1 100Km
Protection Co. Ltd.,China
Umran, Turkey Various BASF Lucalen 3110M Petmin LDPE G-03-5
Mannersman, Turkey Various BASF Various
Noksel, Turkey Various BASF Petmin LDPE
KPIOS, Kuwait Various Fusabond 158 Sclair 35BP
144
High Temperature References for
on projects where design temperature is 140°C:
Project Year Length (m)

Åsgard Phase 1 1998 83 663
Åsgard Phase 2 1999 24 696
Åsgard 2000 60 000
Åsgard Bends 1999 39 piece
The lines are 8, 10 and 12 inch diameters

Total system: FBE – adhesive – PP – PPfoam – PP
145
TEST RESULTS
PGU III SECTOR 2 & 3 AND LOOP 1

PETRONAS GAS BHD. MALAYSIA
Three Layer HDPE Exterior Coating System
System: Epoxy Primer: Minimum 50 microns Corro Coat EP-F 2001

Adhesive: Minimum 150 microns Fusabond® EMB 158D
Top Coat: 3000 microns HDPE Sclair® 35 BP (Black)
**Steel pretreatment using Chromate
Applicator: Petro-Pipe Socotherm Coating Sdn. Bhd.
Sungai Petani, Kedah, Malaysia
Steel Pipe product: 914.4 mm diameter x 13.06 mm wall thickness
914.4 mm diameter x 10.88 mm wall thickness
Steel Pipe manufactured by Hicom Petro-Pipe Sdn. Bhd.
170,000 meters
Girth Weld Coating: Shrink Sleeves
KEY TEST RESULTS

(Using Spec. CAN/CSA-Z/245.21-M92/ASTM G8-85)
CHARACTERISTIC RESULT
Adhesion Peel strength (N/mm) @ 20 +/- 3 deg. C > 150 N/mm
Elongation and Tensile Strength > 17.0 Mpa Tensile stress at yield
(ASTM D638) @ 20 +/- 3 deq. C > 300% Elongation at break
Cathodic Disbondment, 48 hours < 10 mm
C 65 +/- 5 deq. C, -1.5 volts
Cathodic Disbondment, 28 days < 15 mm
@ 20 +/- 5 deg. C, -1.5 volts
Melt flow index (before extrusion) 0.15 - 0.80 g/10 minutes
190 deg. C / 2.16 kg
Heat Aging > 65% of original tensile stress at
100 +/- 3 deg. C for 2,400 hrs +/- 24 hrs yield
> 150% of the original percentage
of elongation at break
February 1998
146
TEST RESULTS
HINDUSTAN PETROLEUM CORPORATION LTD.,

MUMBAI, INDIA
Black oil pipeline project (high temp. service), New Delhi
Three layer polyethylene coating system
System: 100 to 110 microns Corro Coat EP-F 2001

350 microns Fusabond® E MB 158 D Adhesive
3 to 3.2mm Sclair® 35 BP High Density Polyethylene
Applicator: PSL Holdings Limited, New Delhi, India
Pipe product: MS Seamless Pipe, 12.7” diameter, 7.1mm wall
thickness, 19561.11 meters coated
KEY TEST RESULTS

per DIN 30670 Standard
Peel Adhesion Pass
Impact Pass
Coating material performance: SATISFACTORY

Project Completed August 1996
147
TEST RESULTS
GULF OF SUEZ PETROLEUM COMPANY

CAIRO, EGYPT
High pressure gas transfer lines three layer HDPE anti-corrosion coating system
System: 200 microns of Corro-Coat EP-F 1003 HW

200 microns of Fusabond E MB 158
2000 microns of Sclair 35BP BK
Applicator: Precision Tube Technology, Houston, Texas, USA
Pipe product: 4.577 outside diameter, 0.250 wall using carbon steel
grade x 52 70,000 yield
27,076 meters coated
KEY TEST RESULTS

per CSA Z245.21-M92 Standard
Peel Adhesion 15.3kg
(must be < 10mm/min peel rate) PASS
Cathodic Disbondment
(-1.5v: 6.4mm holiday)
28 days @ 20°C 6.5 mmr
28 days @ 65°C 22 mmr
28 days @ 80°C 22 mmr
2 days @ 65°C 2.6 mmr
Hot Water Soak
(1000 hours @ 95°C) Adhesion Rating #1 (cannot be removed)
Coated test samples easily meet the CSA Specification
148
TEST RESULTS
ESSO IMPERIAL OIL RESOURCES

JUDY CREEK AND SWAN HILLS PRODUCTION FIELD,
ALBERTA, CANADA
Three Layer HDPE Coating System
Pipe product: 10”, 12” and 16” pipe size, total pipe length: 50,000 meters
System: Nova® Sclair 5135B Polyethylene (1100 micrometers)
Fusabond® Adhesive E MB 158 D (250 micrometers)
Applicator Garneau Inc., Nisku, Alberta, Canada
Pipeline Conditions: The field is characterized by high temperature (up to 90°C) and very
aggressive soil conditions. ESSO used several different coatings before selecting the three layer
polyethylene applied by Garneau Inc. All other coatings have failed and the pipe had corroded
and leaked. As a result the entire pipeline network had to be replaced at a large cost.
KEY TEST RESULTS

in accordance with CSA Z245.21 Standard
Peel Adhesion 200 to 250 N/25 mm
Cathodic Disbondment, 2 to 4 mm
48 hours @ 65°C, 1.5v
Shear Test (99°C, 18.6kg pressure, 0.5mm movement
7.8kg lateral)
Flexibility pass
@ -30°C 2.5 degree / pipe diameter
Impact pass
@ -30°C 3 J/mm thickness
Project completed between 1993 and 1995

New pipe coated with three layer polyethylene coating performs very well at the service conditions.
Excavation of bell holes after 2 and 3 years in service does not reveal any changes in the coating condition or
does not indicate any corrosion of steel.
SCLAIR® is a registered trademark of NOVA Chemicals Ltd. in Canada and of NOVA Chemicals (International) S.A. elsewhere.
FUSABOND® is a registered trademark of DuPont Canada Inc.
149
TEST RESULTS
HUSKY OIL
NORTH EASTERN ALBERTA HEAVY OIL RESERVOIR,
CANADA
Pipe product: 12” pipe size, total pipe length: 10,000 meters
System: Nova® Sclair 35BP Polyethylene (1500 micrometers)
Pipeline Conditions: The oil needs to be recovered by steam injection method. Husky
required a coating which could withstand the conditions of high
temperature and large temperature gradient.
KEY TEST RESULTS

Peel Adhesion @ 23°C 200 to 250 N/25 mm
Cathodic Disbondment, 4 to 6 mm
48 hours @ 65°C, 1.5v
Flexibility pass
Impact pass
Project completed in 1995

The coated pipe performs very well in service conditions. Consecutive testing by the corrosion engineers after
putting the line in service did not show any problems.
150
TEST RESULTS
AMOCO PETROLEUM (Canada) LTD.

NORTHERN ALBERTA PRODUCTION FIELD, CANADA
Pipe product: 10”, 12” and 16” pipe size, total pipe length: 25,000 meters
System: Nova® Sclair 35BP Polyethylene (1500 micrometers)
Pipeline Conditions: Permafrost, frozen in winter, turning to soft sticky clay and mud in
summer. Had experienced failures with other types of coatings
due to soil stress.
KEY TEST RESULTS

Peel Adhesion @ 23°C 200 to 250 N/25 mm
Cathodic Disbondment, 4.0 mm
48 hours @ 65°C, 1.5v
Flexibility pass
Impact pass
Project completed in 1993

During construction, the pipeline contractor was pleased with the toughness and very low level of physical
damage to the coating. The pipe works well in service. The soil stress has very little effect on the coating.
151
TEST RESULTS
TUNUS/STEG PROJECT, TURKEY

System: Sclair® 35BP

Fusabond® Adhesive 158
(average thickness: approx. 3 mm)
Applicator Mannesmann – Sumerbank
Pipe product: 20 inch diameter
TEST VALUES
Penetration Resistance 2.5 kg weight 0.11 mm
@ 25°C – 24 hour
@ 10 N/mm2 pressure
Peel Adhesion @ 25°C 180 N/cm
Elongation @ 50mm/min @ 25°C 380%
Impact Resistance @ 1.53 kg
1.0 m height, 30 blows okay
1993
152
TEST RESULTS
OCENSA OLEODUCTO SENTRAL S.A.

COLUMBIA, SOUTH AMERICA
CUSIANA/CUPIAGUA FULL FIELD DEVELOPMENT
System: Sclair® 35BP (2700 microns min.)

Fusabond® 206 (200 microns min.)
Pintuco Epoxy Primer D 2013 PR (150 microns min.)
Applicator Bredero Price Columbia BV, Santa Maria, Columbia
Pipe product: 30 and 36 inch diameter, 360 kms, 12 and 18 meter lengths
SAW x 65 steel pipe
TEST VALUES
Peel Adhesion 140 to 190 N/cm
@ 65°C, 48 hours, 1.5 volts < 4.0 mm
Hot Water Soak
@ 75°C, 48 hours no adhesion loss
Flexibility
@ 0°C, 2% strain pass
Impact > 150 in/lbs
June 1995
153
TEST RESULTS
SALINE WATER CONVERSION CORPORATION (SWCC)

SAUDI ARABIA
Project: AL JUBAL – RIYADH LINE C
System: 200 microns Corro-Coat EP-F100HW

225 microns Fusabond® Adhesive E MB 158
3480 microns Sclair® 35BP Black HDPE
(total minimum thickness 3.5mm)
Applicator Al Qahtani Pipe Coating Terminal
Dammam, Saudi Arabia
Pipe product: 80 inch diameter; WT 1.25”, 1.00” & 0.908”
KEY TEST RESULTS

(as per DIN 30670, 1991 spec)
CHARACTERISTIC CONDITIONS RESULT
Bond Strength (N/cm) @ 25°C > 40 N/cm
Impact resistance @ 25°C > 18 Joules
2
Indentation 24 hrs, @ 25°C, 10N/mm 0.06 mm
Elongation at break @ 25°C, 50 mm/min 654.0%
Cathodic Disbondment (ASTM-G8) @ 25°C, -1.5v, 90 days 4.82 mm (R)
154
TEST RESULTS
SALINE WATER CONVERSION CORPORATION (SWCC)

YANBU – MADINA PIPELINE PROJECT,
SAUDI ARABIA

Corro-Coat EP-F1003HW
Applicator Arabian Pipe Coating Company, Al Jubail
Pipe product: 52 to 60 inch diameter
TEST VALUES
Penetration Resistance 2.5 kg weight 0.007 inches
1.8mm stylus @ 25°c
Adhesion (per DIN 30670)
@ 23°C – 17.5 kg no peel off
@ 40°C – 10.0 kg no peel off
Peel Strength,
transverse direction SCM width @ 27°C 65 kgs
Melt Flow Index (Sclair 25BP) 0.36 DG/min
Breaking Elongation 497%
Impact Resistance, 25 mm diam. sphere
5 Nm/mm – tests, 25 ku holiday no holidays
Resistance to Aging by UV Light 0.38%
80 hours @ 60°C, 65% RH mi change
(modified ASTM G8-90)
30 days 0
60 days 0
June 1994
155
TEST RESULTS
SUI NORTHERN GAS LTD., PAKISTAN


Corro-Coat EP-F1003HW
Applicator Cresent Steel and Allied Products
Pipe product: 30 inch diameter, 14 mm wall
TEST VALUES
Elongation (per ASTM 638) 1040%
Tensile Yield (per ASTM 638) 30.3 N/mm2
(test terminated before failure)
Hot Water Soak
(modified BGS PS/CW6 PART 1; APP.E no delamination
tap water @ 85°C, immersed sample no loss of adhesion
100%, 7 days
(modified ASTM G8)
12mm holiday, -1.5 volts, 3% Nacl
@ 23°C, 28 days 1.1 mmR
@ 80°C, 28 days 8-10mmR
June 1992
156
TEST RESULTS
SUI NORTHERN GAS PIPELINE, PAKISTAN

System: Sclair® 35BP H.D.P.E. Black (2700 microns)

Fusabond® Adhesive E MB 158 D (250 microns)
Corro-Coat EP-F 2001 (70 microns)
Applicator Crescent Steel and Allied Products
Karachi, Pakistan
Pipe product: 30 inch diameter S.A.W. helical seam
made by Crescent Steel and Allied Products
TEST VALUES
(per DIN 30670 specification)
Impact @ 26°C > 5 joules/mm
Hot Water Soak
28 days @ 85°C no adhesion loss
Indentation per DIN spec. < 0.03 mm
Tensile stress at Yield
per ASTM D638 30.3MPa
Elongation (at break) 1040%
Cathodic Disbondment (ASTM-G8)
@ 25°C, 48 hours, -1.5 volts 0 mm
@ 25°C, 28 days, -1.5 volts 2 mm
@ 80°C, 28 days, -1.5 volts 10 mm
June 1995
157
TEST RESULTS
GOLDFIELDS GAS TRANSMISSION JOINT VENTURE (GGTV)

WESTERN AUSTRALIA
System: Novapol® HD-2079-BK H.D.P.E. (1200 microns)

Fusabond® Adhesive E MB 158 D (200 microns)
Corro-Coat EP-F 1003 LD (150 microns)
Applicator Shaw Pipe Protection Pty. Limited
Plants: Port Hedland, Western Australia;
Kembla Grange, New South Wales
Pipe product: 1400 kms, 14 and 16 inch diameter
Pipeline Conditions: Desert, extreme heat, 0°C to 50°C
42 year design life, soil temp @ 12°C – 36°C
KEY TEST VALUES

(Canadian CSA Z-245.21-M92)
U.V. Resistance to 80°C 12 months min.
Peel Adhesion
per CSA 12.4 / 12.5 150 N min.
per CSA 12.3 8mm max.
1995 project
NOVAPOL® is a registered trademark of NOVA Brands Ltd.
158
TEST RESULTS
BEIJING NATURAL GAS TRANSMISSION COMPANY, CHINA

System: Sclair® 35BP Black (2650 microns)

Fusabond® E MB 158 D (250 microns)
Corro-Coat EP-F 2001 (80 microns)
Applicator Panjin Hualong Petroleum Corrosion Protection Ltd.
Qing Zian, China
Plant equipment by Pipe Coating Systems, Canada
Pipe product: 100kms, 24 inch diameter, spiral welded steel pipe
TEST VALUES
(specification: China Q/B T 005 95 standard)
Impact per Q/G D 0151.7 > 5 joules/mm
Tensile @ Yield 18 MPa and 860%
Tensile @ Break 27 MPa and 860%
Flexibility (2.5°)
(per Q/G D 0151.6) no cracking
Peel Adhesion
@ 23°C > 200 N/cm
@ 65°C, 48 hours < 2mm
June 1996
159
TEST RESULTS
PILBARA PIPELINE, AUSTRALIA

KARRATHA TO PORT HEDLAND GAS PIPELINE
System: Sclair® 35BP Black (1200 microns min.)

Fusabond® Adhesive 158 (250 microns min.)
Corro-Coat EP-F 2001 (75 microns min.)
(plus chromate pretreatment to steel)
Applicator Bredero Price (Malaysia) SDN BHD
Kuantan, Malaysia
Pipe product: 215 kms x 18 inch diameter
seamless steel, made in Australia
12 kms to be concrete coated
pipe joints at 18 meter lengths
TEST VALUES
(Canadian CSA Z 245.21-M92 spec.)
Peel Adhesion
@ 30°C 450 N/25mm
@ 60°C 150 N/25mm
48 hours at 55°C 0 mm
6mm holiday; -1.5 volts
June 1996
160
TEST RESULTS
IMPERIAL OIL RESOURCES LIMITED (ESSO/EXXON)

ALBERTA, CANADA
System: Nova Chemicals H.D.P.E. (1.5mm thick)

Fusabond® Adhesive 158 (0.25mm thick)
Corro-Coat EP-F 1003HW Epoxy (0.25mm thick)
(plus chromate pretreatment to steel)
Applicator Pipe Coating Systems, Division of Garneau Inc.
Nisku, Alberta, Canada
Pipe product: 20,000 meters 6, 8, 12 inch diameter
Pipe Conditions: 85°C service; harsh and wet environment
KEY TEST VALUES
CHARACTERISTIC TEMPERATURE RESULT

Impact -30°C 5 joules/mm
Peel Adhesion 23°C 200 to 350 N/25mm strip
Cathodic Disbondment 48 hours @ 65°C 1 – 2 mm
6mm holiday; -1.5 volts
November 1994
161
TEST RESULTS
POLAND COUNTRY MARKET

POLISH OIL & GAS CLIENT, POLAND
System: Nova’s HDPE Sclair® 35 BP Black @ 1800 to 2500 microns

DuPont’s Fusabond® EMB 347 DG (powder) @ 250 microns
Corro-Coat EP-F 2001 @ 100 microns
Applicator Izostal S.A.; Zawadzkie, Poland
Pipe product: Various from 2 inches to 20 inches in diameter
300,000 Square Meters in 1995 – 1996
Pipe Conditions: DIN 30670 Standard
KEY TEST VALUES

Impact 25°C Pass
Peel Adhesion 25°C 70 N/CM
Heat Aging 100°C/100 days 4% change of M.I.
Penetration 25°C 0.03 mm
June 1997
® Nous
162
TEST RESULTS
ABU DHABI NATIONAL OIL COMPANY, UNITED ARAB

EMIRATES, BAB-MAQTA-TAWEELAH GAS PIPELINE
System: 175 microns Corro Coat EP-F 2013

250 microns Fusabond® Adhesive E MB 158
3,300 microns Sclair® 35BP Black HDPE
(total thickness: 3.73mm)
Applicator National Petroleum Construction Co., Abu Dhabi, U.A.E.
Pipe product: 36 inch diameter; 1.00 wall
KEY TEST VALUES

Bond Strength (N/cm) 25°C 386
Bond Strength (N/cm) 50°C 124
Impact 25°C > 20 joules
Indentation 25°C 0.05 mm
Peel Adhesion 25°C > 36.5 minutes
(per DIN 30670, 1980)
Cathodic Disbondment* 14 days @ 70°C < 1 mm
6mm holiday; -1.5 volts; 3% sol.
* Disbondmet test completed by independent lab, 1994

November 1995
163
MULTI-LAYER H.D.P.E. COATING PROJECTS
CUSTOMER YEAR LENGTH (m) SIZE (in) PROJECT LOCATION PIPE COATER
ADNOC 1994 365,000 16 Bab Habsan U.A.E. National Petroleum
20-42 Bab Magta Construction Company
24 Mirfa
Sui Northern 1994 75,000 30 Pakistan Crescent Steel
Various 1992 9.000 10-20 Various Pakistan Crescent Steel
Sui Southern 1993 42,000 18 Pakistan Crescent Steel
Tunus/ Steg 1993 20,000 20 Turkey Mannesmann
Sumerbank
Gas Authority 1992 94,000 6-12 Bombay India PSL Pipe Coater
India
Saline Water 93-94 365,000 12-60 Yanbu-Madina Saudi Arabian Pipe Coating Co
Conversion Arabia
Corp.
Pilbara 1994 215,000 18 Karratha-Port Australia Bredero Price Malaysia
Hedland
BPX 1993 137,000 3-20 Cuisana Columbia Energy Coatings*
Essar Guijarat 1995 270.000 14/16 Iron Ore Slurry India PSI- Holdings
Ltd P. L.
GGTV 1995 1,400,000 14-16 Goldfields Australia Shaw Pipe
Ocensa 1995 360,000 30-36 Cuisana/ Columbia Bredero Columbia
Cupiagua
Polish Oil & Gas 1995 60,000 6-20 Various Poland Izostal
Sui Northern/ 1995 90,000 6-30 Various Pakistan Crescent
Southern
Beijing Nat. Gas 1996 100,000 24 BNGT China Panjn
164
CASE HISTORY
Gas Pipeline to Spur Engineering marvel

Construction of the pipeline was a massive
Development in Western engineering feat. Its 857 mile length exceeds the
Australia distance from New York to Chicago, yet it took just
one year and six days to complete.
The Goldfields Gas Transmission pipeline Construction began in August 1996 and was
completed in September 1996 has brought an completed September 1997. During that time,
abundant supply of clean, lower-cost energy to the temperatures ranged from just below freezing to a
resource-rich interior of Western Australia. Fed by sizzling 50°C (122°F), and construction sites were on
gas from offshore fields, the pipeline runs from near occasion struck by cyclones that caused extensive
the coast to Kalgoorlie in the interior, a distance of flooding.
857 miles (1380 km).
Total construction cost was 450 million Australian
Buried along its entire route, the pipeline’s steel dollars, equivalent to about U.S. $350 million.
pipe is protected against corrosion by a rugged
threelayer coating system consisting of Corro-Coat CMPS & F of Sydney had overall responsibility for
EP-F, adhesive and high density polyethylene. engineering and procurement management. The
main construction contractor was Saipem Australia.
The pipeline is already feeding gas to six power A team of about 600 people worked on the project.
stations with a combined generating capacity of 370
megawatts along the route. Electrical power costs to
huge iron, gold, nickel and other mining and mineral
processing operations in the interior region served
by the pipeline are expected to drop 30 to 60 percent
in the future. The pipeline will also furnish gas fuel
to homes and businesses in Kalgoorlie and other
towns in the region.
Currently operated with two compressor stations,
the pipeline can deliver 82 terajoule of energy daily,
but it has been designed for a daily capacity of 160
terajoule.
Goldfields Gas Transmission Pty Ltd. (GGT) of
West Perth manages the pipeline for a consortium of
subsidiaries of three large mineral resource New pipeline transports gas originating in offshore fields to mining and
companies, WMC Resources Ltd., Normandy mineral-processing industries in the interior
Mining and BHP Minerals.
165
CASE HISTORY
The construction required 78,000 lengths of pipe The epoxy component provides a high degree of
each measuring 18 meters long by up to 16 inches in protection against corrosion with its excellent fusion
diameter. Tubemakers of Australia supplied the pipe bond to steel and resistance to cathodic
used for the southern portion from a plant in New disbondment.
South Wales. Pipe for the northern portion came
The majority of the epoxy resin used for the project
from overseas sources.
was supplied by Jotun Powder Coatings from its
plant in Thailand. The grade used was EP-F
Effective corrosion protection 1003LD.
To protect the pipe against corrosion, Bredero-Shaw
During shipping and handling, the black high
Australia (formerly Shaw Pipe Protection Pty Ltd.)
density polyethylene outer layer provided resistance
coated the pipe using its state-of-the art trilaminate
to UV and mechanical damage. In this case, coated
system. It combines fusion-bonded epoxy, a
pipe was transported up to 1000 km, much of the
powerful interlaminar polyolefin adhesive and an
distance over gravel-surfaced roads. The outer
outer layer of high density polyethylene.
coating thus had to provide protection against added
The coating was applied at two plants. potential for damage by vibration and stones thrown
Bredero-Shaw’s plant at Kembla Grange in New up from the roadway. In addition, the coated pipe
South Wales coated the pipe produced by was exposed to extreme desert heat with
Tubemakers of Australia. To coat pipe arriving from temperatures up to 50°C (122°F).
overseas, Bredero-Shaw set up a plant at Port
Hedland on the coast of Western Australia. This
plant was dismantled for use elsewhere after its part
of the coating job was done.
The three-layer pipe
coating system
consisted of:
150 micron (min.) of
Corro-Coat
200 micron (min.) of
adhesive resin
1000 micron (min.) Adhesive
of black high density
polyethylene.
166
CASE HISTORY
The coating specifications established by CMPS & F
were based on Canadian Standard CSA
Z-245.21-M92. The standard establishes rigorous
test values for minimum adhesion peel resistance of
150 Newton and a maximum cathodic disbondment
radius of 8 mm.
A leader in pipe coating

The Bredero-Shaw Group was formed in 1996,
uniting the operations two world leaders in pipe
coating technology, Shaw Pipe Protection and
Bredero-Price.
The Bredero-Shaw Group of companies has 35
plants in 18 countries plus a global project plant
capability. The Group offers a wide range of
products for pipeline coatings, linings, insulation
systems and concrete weight coating.
For additional information, please contact the
Houston, Texas, office of Bredero-Shaw.
Tel: +713-974-7211 Fax: +713-260-4500
167
Saudi Water Pipeline
Gets Triple Protection
Against Corrosion
168
CASE HISTORY
Rugged 3-Layer System Protects ever made with an extrusion-applied coating. Each
15 m length of it weighs 7 tons.
Water Pipeline APCO has successfully met the challenge of
handling and coating such large-diameter pipe with
An advanced three-layer anti-corrosion pipecoating consistent on-time delivery and compliance with
system is playing a key role in the expansion of SWCC’s rigorous engineering specifications. The
potable water supplies in Saudi Arabia. company began coating pipe in late 1993 under a
20 month contract.
Using pipe protected with a layer each of Corro-
Coat EP-F, adhesive polymer and high density
polyethylene (HDPE), contractors are laying a
370-km high-capacity pipeline to deliver desalinated New pipeline traverses
water from Yanbu on the Red Sea to Medina in the rugged, mountainous terrain
to deliver water from
interior. Construction began in late 1994 and is desalination plant on the
scheduled for completion in early 1996. Red Sea to the Medina area.
The pipeline is part of the first phase of a huge water

development project coordinated by Saline Water
Conservation Corp. (SWCC), Riyadh. Later stages
of the project will involve additional pipelines and
expansion of an existing desalination plant at Yanbu.
Arabian Pipecoating Co. (APCO) of Al Khobar
coated the pipe for the Yanbu-Medina line. In
competing for the contract, APCO ran coating trials
of 36- and 42inch diameter pipe for evaluation by
SWCC and its engineering consultants. The
company also documented the three-layer system’s
major advantages over sintered polyethylene
coatings previously used for such projects. The
advantages include improved adhesion, greater
resistance to cathodic disbondment, lower
maintenance costs over the life of the pipeline and
superior durability under severe field conditions.
The steel pipe used for the project was supplied by
National Pipe Co. Ltd., of Al Khobar. Diameters
range from 12 to 60 inches (305 to 1524 mm). About
40% of the pipe used is 60-inch, possibly the largest
169
CASE HISTORY
The pipe is coated at APCO’s plant in Al Jubayl on Fusion-bonded epoxy provides excellent adhesion to
the Persian Gulf, then trucked across the entire the steel pipe, resistance to cathodic disbondment
width of Saudi Arabia to Yanbu on the Red Sea, and chemical resistance. The powder epoxy resin
about 1600 km by road over rugged desert terrain. In used is produced in Dubai.
Yanbu, the pipe is lined with 1/2 inch (13 mm) of
The HDPE outer layer has two functions. It guards
cement by Ramond Arabia Ltd. It is then
against the penetration of moisture, and
transported out to the pipeline route.
helps protect the epoxy coating from abrasion
Under these severe conditions, the epoxy adhesive damage during handling and installation.
HDPE coating has demonstrated exceptional
resistance to damage. Of the first 5000 joints of 15m
pipe delivered, only two suffered minor damage
during transport and handling.
Maximum
protection
The corrosion
protection provided Adhesive
by the combination
of epoxy, adhesive
and polyethylene
used for the
Yanbu-Medina
projects relies on
the unique
properties of each.
Pipe’s three-layer anti-corrosion coating
system offers good resistance to damage
during handling and installation.
170
SAUDI ARABIAN OIL COMPANY
(SAUDI ARAMCO)
Room 2239, Admin. Building
Dhahran 31311, Saudi Arabia
December 30, 1995
IDD (KIM)-1096-95
Corro-Coat Saudi Arabia Co. Ltd.

P. 0, Box 10830
Dammam 31442
Dear Sirs:
We are pleased to inform you that your company is now an approved supplier to Saudi
Aramco under Vendor Code DC-1 253-01 for the following products:
C C CODE PRODUCT
N/A Thermoset Powder Coatings
You are advised that this approval is dependent upon adherence to Saudi Arabian and
Saudi Aramco standards and specifications for the products you manufacture. This
approval, however, should not be construed as a commitment by Saudi Aramco to
purchase from you, but you will be given an equal opportunity to compete with other
approved suppliers.
We would like to thank you for your interest in Saudi Aramco, and take this opportunity
to reiterate that it is Saudi Aramco’s policy to encourage the use of locally manufactured
materials.
For any further information or assistance, please contact the Industrial Development
Division on 875-5596.
With kind regards.
Sincerely yours,
FAREED S. AL-ASALY, Co-ordinator
Industrial Development Division
171
Transco Approval
GBE/CW6, Part 1 (January 1993) and
Amendment No 1
(December 1993)
Corro-Coat EP-F 1003 LD (formally Valspar
D1003LD) and Corro-Coat EP-F 1003 HW
(formally Valspar D2003DV) are included in the
Transco, List of Approved Coating Materials for the
Corrosion Protection of Steel Line Pipe.
172
173
Coaters Reference list
Product Coater Supplied since

Corro-Coat EP-F 1003 LD Bredero Price (Lieth) 1986
Bredero Price (Kuantan) 1989
APCO (Saudi Arabia) 1998
Shaw Pipe (Australia) 1994
Bredero Price (Indonesia) 1996
Bredero Shaw (Thialand) 1996
Bredero Price (UAE) 2000
Bredero Shaw (USA) 2000
Eupec France (Dunkurque) 1990
Isotub France (Gravlines) 1990
Petro Pipe (Malaysia) 1993
Balmoral (UK) 1992
British Steel/Ramco 1992
Ilva 1998
Socotherm (Italy) 1999
Socoril (Argentina) 2000
Orion (Italy) 2000
Ormac (UK) 1989
Primeline (UK) 1990
Barrier Coatings (UK) 2000
PIH (UK) 1990
Commercial Resins (Tulsa) 2000
CCSI (Conroe) 1999
PT Indal Pipe (Indonesia) 1999
Corro-Coat EP-F 1003 HW Bredero Price (Lieth) 1991
Bredero Price (Kuantan) 1992
Bredero Shaw 2000
APCO 1991
Thermotite 1990
Precision Tube (UK) 1995
Precision Tube (USA) 1998
Ilva 2000
EB Pipe (USA) 1998
NPCC (Abu Dhabi) 1997
Ormac (UK) 1996
174
Coaters Reference list
Product Coater Approved

Barrier (UK) 2000
CCSI (Conroe) 1999
Corro-Coat EP-F 1010 Bredero Shaw (Australia) 2000
EB pipe (USA) 2000
Commercial Resins (Tulsa) 2000
Ilva 2000
Corro-Coat EP-F 2001 Eupec France
Cresent Steel (Pakistan)
Sui Northern (Pakistan)
Umran (Turkey)
Noksel (Turkey)
Middle East Tube (Israel)
Petropipe (Kuantan)
PSL
Kuwait Pipe Industries & Oil 2000
Corinth Pipe Works 1998
PT Indal Steel 1999
SAW India
Langfang Anti Corrosion China
Corro-Coat EP-F 2002 Eupec Germany 2000
Ilva (Italy) 2000
Socotherm (Italy) 2000
Northpoint (UK) 2000
Corro-Coat EP-F 2002 HW Ilva (Italy) 1999
Corro-Coat EP-F 2004 Thermotite 1996
Bredero Price (Indonesia 1998
Corro-Coat EP-F 3001 NPCC (Abu Dhabi)
175
Corro-Coat EP-F Spec/Client approvals list
Product Approval When

Corro-Coat EP-F 1003 LD British Gas CW6 Part 1 (based on D1003LD) 1986
Williams 15.03.04.05/0 (based on D1003 LD) 2000
Mobil (Buckland field Spec) 1998
CSA Z245.20-M98 by ITI (Thailand Produced) 2000
CSA Z245.20-M98 by ITI (UK Produced) 2000
CSA Z245.20-M98 by TISI (UK Produced) 2000
BP Amoco PCI 01/99 1999
Conoco revision 9/95 1995
Qatar General Petroleum (based on D1003LD) 1998
Italian Water by Istituto Scientifico Breda 2000
BS 6920 by WRc 1988
BS 6920 by WRc 1998
Chevron (Cabinda Spec) 1995
Sitre Oil (Lybia) 1997
Shell (USA) 2000
CNPC 1999
Corro-Coat EP-F 1003 HW British Gas CW6 Part 1 (based on D1003HW) 1992
ARAMCO SAMMS 089
ARAMCO SAMMS 089 (Hot Subkha) (APCS 104) 2000
BP Amoco PCI 02/99 1999
Conoco revision 9/95 1995
Corro-Coat EP-F 1010 CSA Z245.20-M92 by Bodycote 1998
CSA Z245.20-M98 by Charter Coating Services
(UK produced) 1999
AS 3862 –1991 by Bredero Shaw Australia 2000
British Gas CW6 Part 1 1999
176
Corro-Coat EP-F Spec/Client approvals list
Williams 15.03.04.05/0 (EB pipe application) 2000

British Gas CW6 part 2 (Ilva) 2000
North Carolina Gas 2000
El Paso Gas 2000
Shell (USA) 2000
Colorado Interstate 2000
Corro-Coat EP-F 1010 HW Italian Water by Istituto Scientifico Breda 2000
Corro-Coat EP-F 2001 DIN 30670 by Polish Oil and Gas Institute
(with Fusabond 158/Lupolen 2453D) 1998
EIL India
CNPC (China) 1999
177
178
Final Report
on
Laboratory Testing of Jotun Fusion Bond Epoxy Products
Prepared by Gary Cox
Report No. 00-1120

I.T.I. Contract No. 6425
May 12, 2000
I.T.I. Anti-Corrosion, Inc.

10175 Harwin * Suite 110
Houston,Texas 77036
Telephone: (713) 771-0688
Facsimile (713) 776-9634
179
Coating Material I.D. Jotun EP-F 1010 Batch No. 2 Color Grey
Manufacturing Location: Flixborough, England Plant

Test Results
1. Thermal Characteristics
1.1 Test Instrument: DuPont Instruments Model 910 Differential Scanning Calorimeter
Tg 1: 61.53°C; Tg 2: 99.73°C; Tg 3:105.08°C; Tg 4:105.02°C; ∆Tg: 0.06°C
∆H: 55.32 J/g; ∆H1: 0.6481 J/g; % Conversion: 98.8
2. Short Term Cathodic Disbondment Tests
Specimen Test Test Test Disbonded Acceptance Pass/
No. Temp. Duration Potential radius, mm Criterion Fail
1 65°C 24 hrs. -3.50 VDC 3.48 8 mm Maximum Pass
Average 3.53 Pass
Average 3.34 Pass
3. Long Term Cathodic Disbondment Tests

Specimen Test Test Test Disbonded Acceptance Pass/
No. Temp. Duration Potential radius, mm Criterion Fail
1 23°C 28 days -1.50 VDC 5.75 10 mm Maximum Pass
2 23°C 28 days -1.50 VDC 5.25 10 mm Maximum Pass
3 23°C 28 days -1.50 VDC 1 4.88 10 mm Maximum Pass
Average 5.29 Pass
180
4. Chemical Resistance (90 Day immersion at 23°C)
Immersion Specimen Evaluation Parameter

Reagent No. Bleaching Swelling Softening Blisters Cracks Delamination Loss of
Adhesion
HCI in distilled H20 1 0 0 0 0 0 0 0
pH 2.5–3.0 2 0 0 0 0 0 0 0
3 0 0 0 0 0 0 0
10% NaCI w/H2S04 1 0 0 0 0 0 0 0
in distilled H20 2 0 0 0 0 0 0 0
pH 2.5–3.0
3 0 0 0 0 0 0 0
10% NaCI in distilled 1 0 0 0 0 0 0 0
H2 0 2 0 0 0 0 0 0 0
3 0 0 0 0 0 0 0
Distilled H20 1 0 0 0 0 0 0 0
2 0 0 0 0 0 0 0
3 0 0 0 0 0 0 0
5% NaOH in distilled 1 0 0 0 0 0 0 0
H2 0 2 0 0 0 0 0 0 0
3 0 0 0 0 0 0 0
MgCO3: CaCO3 1 0 0 0 0 0 0 0
1:1 in distilled H20 2 0 0 0 0 0 0 0
Sat’d Sol’n.
3 0 0 0 0 0 0 0
181
5 & 6. Porosity Ratings

Rating Acceptance Criterion Pass/Fail
5. Cross-Section: 1 1–4 Pass
6. Interface: 1 1–4 Pass
7. 3° Flexibility at -30°C
Specimen Cracking Acceptance Pass/Fail
No. Immediate After 2 hrs @ 23°C Criterion
1 0 0 No Cracking Pass
Note: Two straps were intentionally overbent to: 4.78°/p.d. No cracking was observed on any specimen, either immediately or
after 2 hours.
8. 1.5J Impact Resistance at -30°C

Specimen Impact Impact Acceptance Pass/Fail
No. No. Force J Criterion
1 1 1.5 No Holidays at ≤ 1.5J Pass
2 1.5 No Holidays at ≤ 1.5J Pass
182
9. Strained Coating, 28 day Cathodic Disbondment

No. Criterion
1 0 No Cracking Pass
10. 24 or 48 hour adhesion (Hot Water Immersion)
Specimen Test Test Adhesion Acceptance Pass/Fail

No. Duration Temperature Rating Criterion
1 24 hours 95°C 1 1–3 Pass
2 24 hours 95°C 1 1–3 Pass
3 24 hours 95°C 1 1–3 Pass
4 48 hours 75°C 1 1–3 Pass
5 48 hours 75°C 1 1–3 Pass
6 48 hours 75°C 1 1–3 Pass
183
Coating Material I.D. Jotun EP-F 1003 HW Batch No. 2 Color Blue
Test Results
Tg 1: 63.37°C; Tg 2: 100.29°C; Tg 3: 101.30°C; Tg 4: 103.40°C; ∆Tg: 2.10°C
Specimen Test Test Test Disbonded Acceptance Pass/Fail

No. Temperature Duration Potential Radius mm Criterion
1 65°C 24hrs -3.50 VDC 2.45 8mm Maximum Pass
Average 2.48 Pass
Average 4.43 Pass

1 23°C 28 days -1.50 VDC 8.25 10mm Maximum Pass
Average 8.08 Pass
184

Adhesion
pH 2.5–3.0 2 0 0 0 0 0 0 0
3 0 0 0 0 0 0 0
10% NaCI w/H2S04 1 0 0 0 0 0 0 0
in distilled H20 2 0 0 0 0 0 0 0
pH 2.5–3.0
3 0 0 0 0 0 0 0
H2 0 2 0 0 0 0 0 0 0
3 0 0 0 0 0 0 0
Distilled H20 1 0 0 0 0 0 0 0
2 0 0 0 0 0 0 0
3 0 0 0 0 0 0 0
H2 0 2 0 0 0 0 0 0 0
3 0 0 0 0 0 0 0
MgCO3: CaCO3 1 0 0 0 0 0 0 0
1:1 in distilled H20 2 0 0 0 0 0 0 0
Sat’d Sol’n.
3 0 0 0 0 0 0 0
185

after 2 hours.

186

No. Criterion

1 24 hours 95°C 2 1–3 Pass
2 24 hours 95°C 1 1–3 Pass
3 24 hours 95°C 2 1–3 Pass
4 48 hours 75°C 1 1–3 Pass
5 48 hours 75°C 1 1–3 Pass
6 48 hours 75°C 1 1–3 Pass
187
Coating Material I.D. Jotun EP-F 1003 LD Batch No. 355 Color Beige
Test Results
Tg 1: 64.18°C; Tg 2: 100.04°C; Tg 3: 103.19°C; Tg 4: 103.91°C; ∆Tg: 0.72°C

Average 2.53 Pass
Average 3.26 Pass

Average 5.17 Pass
188

Adhesion
pH 2.5–3.0 2 0 0 0 0 0 0 0
3 0 0 0 0 0 0 0
10% NaCI w/H2S04 1 0 0 0 0 0 0 0
in distilled H20 2 0 0 0 0 0 0 0
pH 2.5–3.0
3 0 0 0 0 0 0 0
H2 0 2 0 0 0 0 0 0 0
3 0 0 0 0 0 0 0
Distilled H20 1 0 0 0 0 0 0 0
2 0 0 0 0 0 0 0
3 0 0 0 0 0 0 0
H2 0 2 0 0 0 0 0 0 0
3 0 0 0 0 0 0 0
MgCO3: CaCO3 1 0 0 0 0 0 0 0
1:1 in distilled H20 2 0 0 0 0 0 0 0
Sat’d Sol’n.
3 0 0 0 0 0 0 0
189

after 2 hours.

190

No. Criterion

1 24 hours 95°C 2 1–3 Pass
2 24 hours 95°C 2 1–3 Pass
3 24 hours 95°C 2 1–3 Pass
4 48 hours 75°C 2 1–3 Pass
5 48 hours 75°C 2 1–3 Pass
6 48 hours 75°C 3 1–3 Pass
191
TESTING EQUIPMENT & QUALITY CONTROL
INSTRUMENT SOURCES
The following list identifies sources of testing equipment for Quality Control/Assurance
Laboratories plus independent test labs:
1. Paul N. Gardner Company Inc. (Coating test instruments, etc.)
316 NE, 1st.
Pompano Beach, Florida Telephone: 1-305-946-9454
U.S.A. 33060 Fax: 1-305-946-9309
2. Testing Machines Inc. (Testing Machines)
400 Bayview Avenue
Amityville, New York
U.S.A. 11701 Telephone: 516-842-5400
3. Tinuis Olsen Testing Machine Co. Inc. (Testing Machines)
Easton Road, Box 429,
Willow Grove, PA Telephone: 1-215-675-7100
U.S.A. 19090-0429 Fax: 1-216-441-0899
4. Instron Corporation (Tensile Testing Machines)
100 Royal Street
Canton, Mass. Telephone: 1-617-828-2500
U.S.A. 02021-1089 Fax: 1-617-575-5725
5. Erichsen Instruments Inc. (USA Distributor)
TJ. Bell Inc.
1340 Home Ave.
Akron, Ohio Telephone: 1-216-663-36M
U.S.A. 44310 Fax: 1-216-633-1977
6. S.G. Pinney & Assoc. Inc. (Coating Test Instruments)
P.O. Box 9220
Port St. Lucie, Florida Telephone: 1-407-337-3080
U.S.A. 3498519220 Fax: 1-407-337-0294
7. K-TA-TATOR, Inc. (Coating Instruments for testing &
115 Technology Drive measurement)
Pittsburgh, PA Telephone: 1412-788-1300
U.S.A. 15275 Fax: 1-412.788-1306
192
8. Ontario Die Company Ltd. (Die Stamping Forms)
(ODC International Inc.)
119 Roger Street, P.O. Box 70
Waterloo, Ontario Telephone: 1-519-576-8950
Canada, NU 3Z6 Fax: 1-519-576-3670
9. TA Instruments Inc. (Thermal Analyzers)
Box 311, 10 Lukens Drive
New Castle, Delaware Telephone: 1-302-427-4000
U.S.A. 19720-0311 Fax: 1-302-4274001
10. SSPC (Surface Prep. Specifications)
Steel Structures Painting Council
4400 Fifth Avenue
Pittsburgh, PA
U.S.A. 15213-2683
11. ASTM (Testing Standards)
100 Barr Harbour Drive
West Conshocken, PA Telephone: 1-610-832-9585
U.S.A. 19428-2959 Fax: 1-610-832-9555
12. I.T.I Anti-Corrosion, Inc. (Independent Test Laboratory)
10175 Harwin, #110
Houston, Texas Telephone: 1-713-771-0688
U.S.A. 77036 Fax: 1-713-776-9634
13. Harding & Neal (Q.C.1QA Laboratory Consultants)
10 Wild Oak Circle
Houston, Texas Telephone: 1-713~8405
U.S.A. 77055-4724 Fax: 1-716-464-4532
14. Ceast U.S.A. Inc. (Testing Instruments for plastics)
Box 30785 (European based company)
Fort Mill, SC Telephone: 1-803-548-6093
U.S.A. 29715 Fax: 1-803-548-1954
15. Atlas Electric Devices Company (Weather-o-meter Testing)
4114 North Ravenswood Ave.,
Chicago, Illinois Telephone: 1-312-327453
U.S.A. 60613 Fax:1-312-327-5787
193
16. Bodycote Materials Testing Ltd.
North West Laboratory
Jefferson House
5 Washington Centre
Broadway
Salford M5 2UW Telephone: +44 (0) 161 876 0277
UK
17. Mettler Toledo GmbH

CH-8606 Greifensee
Switzerland Telephone: (01) 944 22 11
www.mt.com
194
Technical Report No. 99-1042
Mr. Denis Grimshaw

JOTUN POWDER COATINGS, LTD.
2nd Avenue
Flixborough Industrial Estate
Scunthorpe DN15 8SD
Laboratory Testing of Corro-Coat EP-F 1010
October 12, 1999
Prepared by Gary Cox
I.T. I. Contract No. 6193
195
LABORATORY TESTING OF ‘CORRO-COAT EP-F 1010’
Introduction:
As authorized by Mr. Denis Grimshaw of Jotun Powder Coatings, Ltd., I.T.I.
AntiCorrosion, Inc., has conducted laboratory testing to evaluate performance
characteristics of “Corro-Coat EP-F 1010”.
Test Procedures
1. Cathodic Disbondment in accordance with CAN/CSA Z245.20-M98 with
modifications as indicated below.
1.1 Duration: 28 days Temperature: 20°C Modification: None
1.2 Duration: 28 days Temperature: 65°C Modification: 28 day
1.3 Duration: 28 days Temperature: 80°C Modification: 28days; 80°C
1.4 Duration: 48 hours Temperature: 65°C Modification: None
Note: All above procedures were conducted at -1.50 VDC potential in a 3%
weight percent sodium chloride electrolyte.
2. Adhesion (hot water soak) in accordance with CAN/CSA Z245.20-M98 with

modifications as indicated below.
2.1 Duration: 28 days Temperature: 65°C Modification: 28 days
2.2 Duration: 28 days Temperature: 80°C Modification: 28 days; 80°C
3. Impact Resistance in accordance with CAN/CSA Z245.20-98 at six (6)

temperatures: -30°C, 0°C, 20°C, 65°C and 75°C.
4. Flexibility in accordance with CAN /CSA Z245.20-98 at six (6)
temperatures: -30°C, -10°C, 0°C, 20°C, 65°C and 75°C.
5. Hardness, Shore “D”, in accordance with ASTM D2240 at six (6)

temperatures: -30°C, -10°C, 0°C, 20°C, 65°C and 75°C.
6. Abrasion resistance in accordance with ASTM D4060
6.1 Wheels: CS-17 Load: 1kg Cycles: 1000
6.2 Wheels: CS-17 Load: 1kg Cycles: 5000
196
7. Electrochemical Impedance Spectroscopy (EIS).
Electrolyte: 0,01 M Na2 SO4
Immersion Electrolyte Temperature: 65°C±2°C
E I S Measurements intervals: 0, 1, 4,7,14,21 and 28 days.
8. Gouge Test (a modification of ASTM D2197 using a balance beam scrape

adhesion tester).
Modifications: 1. Phillips Head Screw driver point for stylus.
2. Loads: 25, 30, 35, 40, 45 and 50 Kg (55, 66, 77, 88, 99
and 110 lbs.)
Test Results
1. Cathodic Disbondment
Test Conditions Disbonded radius, mm

Duration, Test Potential Specimen Specimen Specimen Average
Days/hours Temperature °C VDC No 1 No 2 No 3
48 hours 65 -1.50 3.5 1.9 1.9 2.3
28 days 20 -1.50 5.9 4.8 4.6 5.1
28 days 65 -1.50 7.0 7.7 6.6 7.1
28 days 80 -1.50 6.4 6.9 6.4 6.6
2. Adhesion, (Hot water soak)
Test Conditions Adhesion Ratings

Duration, Temperature No 1 No 2 No 3 Average
28 days 65°C 1 1 1 1
28 days 80°C 2 2 2 2
Adhesion Ratings:
Rating 1: Coating cannot be removed cleanly.
Rating 2: Less than 50% of the coating can be removed.
Rating 3: More than 50% of the coating can be removed, but the coating
demonstrates a definite resistance to the levering action.
Rating 4: The coating can be easily removed in strips or large chips.
Rating 5: The coating can be completely removed as a single piece.
197
3. Impact Resistance
Specimen DFT Temp Impacts at 1.50 Joules (13.28 in-lbs), Pass/Fail

No mils °C No 1 No 2 No 3
1 21 -30 Pass Pass Pass
2 20 -10 Pass Pass Pass
3 19 0 Pass Pass Pass
4. Flexibility
Specimen Test Angle of Cracking

No Temp °C Deflection Yes/No
1 0 2.5° No
2 0 2.5° No
3 0 2.5° No
4 -30 3.0° No
5 -30 3.0° No
6 -30 3.0° No
5. Hardness, Shore “D”
Specimen DFT, Test Hardness Measurements

No. milss Temp °C 1 2 3 4 5 6 7 8 9 10 Average
1 21 -30 86 87 92 87 85 87 85 87 90 86 87.2
2 20 -10 88 87 86 85 85 84 86 87 86 88 86.2
3 19 0 85 86 85 85 85 85 85 85 86 86 85.3
4 21 20 82 82 81 84 85 85 84 84 84 85 83.6
5 19 65 80 82 81 83 82 82 84 83 83 84 82.4
6 19 75 84 82 83 82 83 82 83 82 81 82 82.4
198
6. Abrasion Resistance
Specimen Load, No. Weight Taber Thickness Wear

No. Kg Cycles loss, g wear index loss, mils cycles/mil
1 1 1,000 0.0610 0.0610 0.58 1724
2 1 5000 0.2619 0.0524 3.30 1515
7. Electrochemical Impedance Spectroscopy
Average Dry ilm Thickness in Mils,

Sample No. Thickness
1 15.5
2 16.0
3 23.0
4 16.5
Electrochemical Impedance Spectroscopy
11.20
No. 1
No. 2
11.00
No. 3
No. 4
10.80
Log Z, Ohms/cm2
10.60
10.40
10.20
10.00
0 5 10 15 20 25 30
Time – Days
199
8. Gouge Test
Specimen DFT, Load, Surface scrape Penetration*

No. mils Kg or groove to steel (Holiday)
1 12.3 25 Yes No
2 14.0 30 Yes No
3 15.0 35 Yes No
4 16.3 40 Yes No
5 20.8 45 Yes No
6 21.5 50 Yes No
*Holiday detection: 67.5 volt DC with wet sponge.

Conclusion:
The test results reported herein either meet or exceed the minimum acceptance criteria as
stated In Table 2 of CAN/CSA Standard Z245.20-98 “External Fusion Bond Epoxy
Coating for Steel Pipe”.
99-1042/RFIT
200
FACT SHEET
Cathodic Protection Design - note from Valspar - Reference #017

From Mr. Toni Pfaff (retyped for JDN)
“The design of most CP systems is based on expected current demand after 20 years of
service. (It is generally believed that the systems have stabilized by then and no further
increase in current draw will take place after 20 years.)
My contact with CP designers clearly established that FBE coated pipelines use less CP
current than most other coating systems. Tape and Asphalt/Coal tar systems, for example,
have shown to draw as much as 5 times more current than FBE.
Nova’s actual experience is that Tape and Asphalt coatings use double the current
compared to FBE. Actual consumption averages 7 uA per sq. ft. for FBE and 14 uA per
sq. ft. for Tape or Asphalt. On this basis new lines coated with FBE are designed for a draw
of 7 uA per sq. ft.
For an offshore pipe in Nigeria, Mobil Oil’s design criteria had Coal Tar Enamel requiring
4 times the current compared to FBE.
I know that a great deal of controversy exists about coating systems selection for North Sea
projects. There is a strong bias in favor of Coal Tar. For many reasons I do not agree that
CTE is a better choice than FBE.
As you know, Mobil’s Beryl Project did go with FBE after considerable discussions and
souls searching.”
Signed: Toni Pfaff

Note: For DuVal** I would suggest to use the same values as for regular service FBE.
Signed: Toni Pfaff (1 to 2 microAmps per sq. ft. is expected)
**DuVal is a Multi-Layer Coating System of a combination of FBE and Polyolefin where
the FBE thickness is a minimum of 300 microns.
P.S. RL (Leaking Resistance) = 100,000 ohm. sq. m. for a pipeline/soil potential range
from 1.0 -3.0 volts.
September 15, 1993
201
FACT SHEET
THERMAL CONDUCTIVITY (K)

QUESTION: What thickness of 3 layer HDPE coating is needed to achieve a R value of 3.81 ?
UNITS: watts • m/m2 • °C

GIVEN: K1 EPOXY==0.01070 K2 MDPE==0.02390 K3 PP==0.00836
WHERE: total thermal resistance (R) watts / m2 • °C
1 == T1 + T2 + .... T3
R k1 k2 k3
epoxy thickness T1 7 mills 0.000178 meters

Fusabond thickness T2 7 mills 0.000178 meters SO
MIDPE thickness T3 ??
Calculations to determine an “R” value of 3.81 watts / m2 • °C :

1 == 0.000178 + 0.000178 + T3
3.81 0.0107 0.0239 0.0239
SO T3 == 220 mils
Thus the coating system would be:

7 mils of epoxy + 7 mils of adhesive + 220 mils of MDPE or Sclair 35 BP
NOTE: if PP is used instead of MDPE, then T3 == 78 mils
Thus the coating system would be:

7 mils of epoxy + 7 mils of adhesive + 78 mils of PP
Kingston Research
July 22, 1996
202
FACT SHEET
CONSUMPTION OF FBE IN VARIOUS SYSTEMS

VARIOUS PIPE DIAMETERS
Surface Per EP-F 1003LD EP-F 1003HW EP-F 2001
Inches 0D mm OD Linear Metre usage per Km at usage per Km at usage per Km at
M2 360 micron 200 micron 100 micron
1 25.4 0.0798 41 Kg 23 Kg 12 Kg
2.375 60.325 0.1895 98 Kg 54 Kg 29 Kg
2.875 73.025 0.2294 118 Kg 85 Kg 36 Kg
3.5 88.9 0.2793 144 Kg 80 Kg 43 Kg
4 101.6 0.3192 165 Kg 91 Kg 50 Kg
4.5 114.3 0.3591 185 Kg 102 Kg 56 Kg
6.625 168.275 0.5287 273 Kg 151 Kg 82 Kg
8.625 219.075 0.6883 355 Kg 196 Kg 107 Kg
10.75 273.05 0.8579 443 Kg 244 Kg 134 Kg
12.75 323.85 1.0175 525 Kg_ 290 Kg 158 Kg
16 406.4 1.2768 659 Kg 364 Kg 199 Kg
22 558.8 1.7556 906 Kg 500 Kg 273 Kg
36 914.4 2.8728 1,483 Kg 818 Kg 447 Kg
42 1086.8 3.3516 1,730 Kg 955 Kg 522 Kg
48 1219.2 3.8304 1,978 Kg 1,091 Kg 596 Kg
56 1422.4 4.4688 2,307 Kg 1.273 Kg 696 Kg
203
EVALUATION of Corro-Coat MOPS
Introduction
Physical damage has for a long time been regarded as a weakness of fusion bond
anticorrosion systems. The use of mechanical overcoat protection systems is a method to
reduce this weakness and take full advantage of the anticorrosion properties for fusion
bond epoxy without many of the concerns of shielding raised with other coating systems.
Mechanical protection of anticorrosion fusion bond epoxy means a reduction in the
damaged caused to the anticorrosion layer during handing and laying operations for the
linepipe
The areas of operation which are vulnerable are in handling and laying of a fusion bond
coated pipeline. During these operations the pipe may be subjected to a variety of
conditions which, in order to assess the effectiveness of the MOPS system, need to be
understood and suitable laboratory tests established.
Back Fill Damage

During the backfill operation the most arduous mechanical forces are placed on the
coating. During this stage the coating is subjected to many impacts from falling stones as
the trench is filled and the pipe buried. For this operation it is frequently required that a
special backfill to be carried to the pipeline to reduce the damage. To study the effect of
The MOPS system in this environment a Stone drop test is utilised.
Stone Drop Test – ASTM G13.

This test reflects stone chips during transportation and also the effects of backfill. In this
test a known weight of stone chips of crushed river bed aggregate grades to 25mm (7.5Kg)
are dropped down a tube of 10cm diameter from a known height (2 Mtr) onto a panel
coated in the protective coating held at 45 Degree. The Stone chip is repeatedly dropped
onto the test panel. Between drops the coating is tested for holidays.
Thickness No. Drops to holiday

200 micron of EP-F1000 series 1
400 micron of EP-F1000 series 2
800 micron consisting 400 micron EP-F 1000 >5
series and 400 micron EP-F 3002
The performance clearly shows the benefit of having the MOPS system to protect the pipeline.
204
Directional Drilling and dragging of Coated pipe.
The forces exerted on a pipe during the positioning of pipe by dragging or in a directional
drilling operation as such that considerable damage can result. A gouge test can be used
to assess the relative damage which could result from this event.
Gouge test
In this test a loaded contact point of known geometry is dragged over the coated test piece
and the resultant damage assessed for breakthrough of the coating by holiday detection
and the depth of the gouge is assessed.
Using A R-33 bit.
Coating Thickness Load Holiday test Gouge Depth

400 micron EP-F 24 kg Fail 300 micron
1000 Series
800 micron EP-F 44 Kg Pass 500 micron
1000 series
MOPS–500 micron 40 Kg Pass 300 micron
consisting 200
micron EP-F 1000
series and 300
micron EP-F 3002
MOPS–800 micron 50 Kg Pass 400 micron
consisting 400
micron EP-F 1000
series and 400
micron EP-F 3002
Clearly a higher loading can be endured when MOPS is utilised and less damage is
sustained.
205
Flexibility
During the lay operation pipes may require bending in the field therefore it is important
to understand the bending capabilities of the MOPS system.
Evaluated using the Canadian Standard CSA Z245.20-98 the MOPS system complies with
the 0°C flexibility requirement of 3°/pipe diameter
Anticorrosion performance
It is obviously essential that the use of MOPS does not reduce the anticorrosion
performance of the base coat. The traditional methods to evaluate these are Cathodic
Disbondment and Hot water soak.
Cathodic Disbondment and Hot Water Adhesion
Using the Canadian Standard CSA Z245.20-98 as the evaluating procedure a comparison
of an EP-F 1000 series coating (EP-F 1010) and the same used as a base coat with EP-F
3002 was carried out.
Corro-Coat EP-F 1010 MOPS

with EP-F 1010
and EP-F 3002
Cathodic Diisbondment 4–5mm 4–5mm
28 days @ 20ºC
Cathodic Disbondment 4–5mm
14 days @ 65ºC
Cathodic Disbondment 3–4 mm
2 days @ 65ºC
Hot Water Adhesion Rating 1–2 Rating 1–2
48 Hours @ 75ºC
Hot Water Adhesion Rating 1–2 Rating 1–2
24 Hours @ 95ºC
It is clearly seen that the anticorrosion performance is not impaired.
Conclusion
The use of mechanical overcoat protection improves the handling and lay characteristics
of fusion bond epoxy ensuring a greater reliability to the anticorrosion performance of
fusion bond epoxy when installed and in operation as the preferred anticorrosion coating
on a pipeline.
206
Corro-Coat EP-F Mechanical Overcoat Protection System
Corro-Coat EP-F 1000 series
And Corro-Coat EP-F 3002
Overcoat thermoset systems enhancing the mechanical protection offer by Fusion Bond
epoxy and an excellent way to provide damage resistance in harsh environments including
river/road crossings and rocky terrains.
The excellent impact and chip resistance combine to offer excellent protection during the
construction phase of a project.
Application
The overcoat system is applied in the same manner as stand alone Fusion Bond Epoxy.
Requiring the same preparation of substrate to give a near white (NACE#2) or Swedish
Standard Sa21/2 grit blasted surface with an angular profile.
Preheated to a temperature of about 232°C and 250°C depending on pipe size and
application speeds.
The EP-F 1000 series anticorrosion layer is applied by spraying methods followed
immediately by the Corro-Coat EP-F 3002.
After sufficient time to ensure cure the coating is water quenched typically this would be
90 seconds at 230°C
Typical Film Properties of Applied System Corro-Coat MOPS
Recommended Thickness Corro-Coat EP-F 1000 series 250–500 micron

(EP-F 1003 LD EP-F 1003 HW
or EP-F 1010)
Corro-Coat EP-F 3002 300–700 micron
Selected thickness depends on the pipe sizes and the environment in which the pipe is to be handled
and laid.
207
Corro-Coat EP-F Mechanical Overcoat Protection System
Typical Film Properties of Applied System Corro-Coat MOPS
Flexibility CSA-Z245.20-M98 at 0°C Pass

3°/pipe diameter (12.11)



65°C, 14 days, 1.5v 4-5 mm
20°C, 28 days, 1.5v Pass (4 – 5 mm av.)
Gouge Test R33 bit 50Kg No penetration

Smooth LS-1 bit 93 Kg No penetration
Stone Drop Test Modified ASTM G13, 5 drops No holiday
Notes:
The information on this product data sheet, is given to the best of our knowledge, based on laboratory
testing and practical experience. However, as the product is often used under conditions beyond our control
we cannot guarantee anything but the quality of the product itself.
Data sheet revised: March 2001

208
Table 1
PERFORMANCE TESTS ON D–1003LD
TEST RESULTS
ASTM
TEST NAME DESIGNATION VALSPAR RESULTS
1. Cathodic Disbondment G8-M Disbonded equivalent
@ 145°F Diameter Circle = 1.037 Inches.
Cathodic Disbondment Disbonded eqIvalent
@ room temperature Diameter Circle = .43 inches.
2. Impact Resistance G14-88 Did not fail @ 325 inch
@ room temperature pounds.
Impact Resistance G14-88 Did not fail @ 325 Inch
@ -50°F pounds.
3. Penetration Resistance G17-88 Penetrated 3.1% of total coating thickness,
4. Alyeska Shear TP206 NONE Total Displacement =
@ 145°F 0.0025 inches.
5. Water Permeation E-96 28.76 x 10-5
@ 145°F - g/hr/mil
6. Water Absorption D570 @ 80°F = 2.80
% absorbed @ 100°F = 4.40
@ 120°F = 4.0
@ 145°F = 5.30
7. Bend Test - Tension NONE @ 80°F -.39,
inches deflection w/o failure @ -40°F = .39
Bend Test - Compression NONE @ 80°F = .5 inches
Inches deflection w/o failure @ -40°F -.5 inches.
8. Adhesive Strength D1002-72 Peel rate of .1 in/min =
@ 145°F 40% adhesive failure @
2600 psi. Peel rate of
.05 in/min = 100%
adhesive failure @ 2625 Psi.
9. Abrasive Resistance D4060 Grams loss/cycle - 2.00
@room temperature x 10-5
Volume (cc) loss/cycle =
1.47 x 10-5
10. Dielectric Strength G149-87 550 volts/mil
@ room temperature
Dielectric Strength G149/87 581 volts/mil
@ 145°F
11. Coefficient of Friction D1894-78 Static =.291
Kinetic =.259
209
Global contacts
Corporate: Jotun Powder Coatings (N) AS Middle East: Jotun Powder Coatings UAE
P.O. Box 2130 Stubberød (LLC)
3255 Larvik P. O. Box 51033
Norway Dubai
Tel: + 47 33 16 40 00 United Arab Emirates
Fax: + 47 33 16 41 32 Tel: + 971 4 34 72 515
Email:gry.saether@jotun.no Fax: + 971 4 34 72 815
Email:powder@jotun.co.ae
Asia Pacific: Jotun Powder Coatings (Malaysia)
Sdn. Bhd. United States: Jotun Powder Coatings Inc.
P. O. Box 7057 11245 Highway 225
40702 Shah Alam Laporte
Selangor Darul Ehsan Houston
Malaysia Texas 77571
Tel: + 60 3 55 190 898 United States
Fax: + 60 3 55 104 108 Tel: + 1 281 219 37 47
Email:melvin.devadass@jotun.com.my Fax: + 1 281 219 35 43
Email:houstonoffice@jotun.com
Europe: Jotun Powder Coatings Ltd.
Second Avenue
Flixborough Industrial estate
Scunthorpe
North Linconshire DN15 8SD
United Kingdom
Tel: + 44 1724 86 12 26
Fax: + 44 1724 28 06 15
Email:powder@jotun.co.uk
210
PIPE COATING STANDARDS
A. CANADIAN/CSA - Z245.20 - M98 F. NACE RP0394-94

CSA NACE International Membership Services Dept.
178 Rexdale Blvd. P.O. Box 218340
Rexdale, Ontario Houston
CANADA M9W 1R3 Texas 77218-8340
Tel: 416-747-4044 Fax: 416-747-2475 Tel: +1 (281) 228-6200
www.csa.ca www.nace.org
B. CANADIAN/CSA - Z245.21 - M98 G. AWWA C213-96
CSA American Water Works Association
178 Rexdale Blvd. 6666 West Quincy Avenue
Rexdale, Ontario Denver
CANADA M9W 1R3 www.awwa.org
Tel: 416-747-4044 Fax: 416-747-2475 H. AS 3862
www.csa.ca Standards Australia
C. GERMANY DIN 30670 P.O. Box 1055
Beuth Verlag Gmbh Strathfield
Burggrafenstrabe 6 NSW 2135
D - 10787 Berlin, Germany www.standards.com.au
Tel: 49-30-2601-2260 Fax: 49-30-2601-1231
www.din.de
D. FRENCH NFA49-710
L-Association Francaise de Normalisation
(AFNOR)
Tour Europe Cedex 7
92080 Paris La Defense
www.afnor.fr
E. BRITISH GAS BGC/PS/CW6
British Gas Corp.
Standards Department
National Westminster House
326 High Holborn
London WC 1V 7PT
www.transcoe.uk.com
211
GIRTH WELD COATING CONTRACTORS
There is a variety of coating systems for pipeline girth welds when field applied. The most
common is the use of multi-layer shrink sleeves.
The major global suppliers for multi-layer shrink sleeves are:
The major global suppliers for multi-layer shrink Major field girth-weld and fitting contractors are:
sleeves are:
Pipeline Induction Heat Limited (PIH)
CANUSA The Pipeline Centre, Farrington Road
A division of Shaw industries Ltd. Rossendale Road Industrial Estate
25 Bethridge Road Burnley, Lancaster BB11 5SW United Kingdom
Rextiale, Ontario, Canada Tel: 44-1282-415323
M9W 1 M7 Fax: 44-1282-415326
Tel: (416) 240-21301 E-Mail: sales@pih.co.uk
Fax: (416) 241-6890 Website: http://www.1pih.co.uk
Internet site – www.shrinksleeves.com Attn: Ian Lancaster
Services Offered: – FBE field joint coating
Contacts: Ron Dunn, General Manager – Europe, Middle East,
Africa, Russia – Polypropylene field joint coating
Richard Lewellan, General Manager – Americas – Onsite specialist coatings contractors for Onshore
or Offshore Pipeline Construction/Rehabilitation
Fred Wutschert, Regional Manager – Asia/Australia
– ISO 9002 QA/W accreditation
Canusa is a supplier of a full range of heat shrink sleeves for onshore,
offshore and rehab applications; specialty pipeline coatings for
bends/fittings; and is a certified ISO 9002 manufacturer. C.C.S.I. (Commercial Coating Services Inc.)
Box 3296, Conroe, Texas, U.S.A. 77305-3296
Raychem Tel: (409) 539-32941
Fax: (409) 539-3073
Please contact:
Cantech Pipe Protection Attn: John Pfieffer or Dennis Graham
1916 – 27th Avenue N.E.
Calgary, Alberta, Canada T2E 7A5 National Coating Co. Ltd.
Tel: (403) 250-9910 Box 11146, Pueblo, CO, U.S.A. 81001
Fax: (403) 291-4990 Tel: (719) 561-67241 Fax: (719) 561-6135
Attn: Cec Milburn
Attn: Tom Ball
212
‘J D N’ MULTI-COAT
COMPARING BENEFITS
of HIGH DENSITY POLYETHYLENE COATINGS
for ANTI-CORROSION PROTECTION
of PIPELINES using the CSA / Canadian Standard Z 245.21
DUPONT CANADA INC

GLOBAL PIPECOATING SYSTEMS
JAMIE W. COX:DENIS GRIMSHAW
MIKE JONES
213
ABSTRACT INTRODUCTION
Higher Density Polyethylene’s are seeing a major Plant applied extruded Polyethylene for exterior
growth shift in usage for exterior pipeline coatings in coatings of pipelines have an excellent track record
the Multi-Coat type system. This paper will examine in 2 or 3 layer coating systems over the past 30 years.
the benefits of this polymer and its value in purpose The industry today has shifted to tailor-made higher
designed coating systems for both off-shore and density grades ( from low density grades ) for the
on-shore pipelines when combined with the latest following benefits :
material technology. We will also look at future
a. higher service operating temperature to
trends associated with the economics of this coating
85°C
by employing the Canadian Standard Z 245.21
specification. Several projects will be examined, b. improved penetration / abrasion / impact
both off-shore and land pipelines. resistance in field handling and
transportation which saves on considerable
Key coating design criteria and material principles
repair costs and time for the contractor
will also be discussed and comparisons with other
coating systems will be made as a reference. Aspects c. improved hardness , physical properties to
of improved materials through the adhesive tie-layer withstand higher compressive forces and
and epoxy primer will be offered to show the mechanical stresses in hot field
benefits of these in combination with tailored high environments saving on repairs (less
density pipecoating grades and how it can advance damage)
the protection of pipelines while giving the best
d. improved moisture permeation which
lifetime cost performance. Girth weld coatings using
offers better disbondment resistance
new shrink sleeve adhesive technology for
polyethylene based systems will also be included to e. ability to use less top coat thickness which
show the benefits of this combination with the saves on raw material costs = less costly
multi-coat. coating product thus opening the market
Key Words: Multi-Coat, anti-corrosion, exterior up for further use in areas such as
coating system, girth weld shrink sleeves, new off—shore with concrete weight coating
adhesive technology, epoxy, high density systems
polyethylene’s, purpose designed coatings f. higher adhesion forces in the overall
system relative to the material strengths
which enables the coating to withstand
more demanding shear stresses on
installation under a wide variety of service
temperatures ( from - 40°C to 85°C ).
COST EFFECTIVENESS: TRENDS

With more emphasis on value added costing, low
maintenance and on installed cost of the pipeline,
214
clients are demanding higher performance as the be 3 X the raw material costs for large projects and
design life gets longer and the pay-out period gets is a small portion ( perhaps 15 % ) of the coated
shorter. This has led to use of powder materials for steel pipeline cost.
adhesive systems and high density polyethylene top
The major thinking and concern of the end-use
coat systems coupled with improved epoxy powders.
client should be on long term performance/low
Material technology-coating emphasis is on better
maintenance/environmental safety/no-leak worries
adhesion, better cathodic disbondment , better hot
and where cost is evaluated: on the final field
water immersion values and higher service
-installed project cost by the contractor.
temperatures, with similar or less cost. Table 1 shows
some of the raw material cost relationships for By using the CSA Z 245.21 standard one can design
different types of coatings which—-can vary widely a high performance coating system to suit the needs
by region, applicator and project. of the project where flexibility in material
component thickness is allowed. Most clients are
TABLE 1 Typical System Costs for Raw Materials for moving towards thicker epoxy primer ( greater than
Pipeline Exterior Coatings 150 microns ) for better cathodic disbondment
resistance, thinner adhesives through use of powders
Coating System Thickness Price *Performance
( mm ) ($u.s./sq.m.) and higher performance grafted adhesives and
Coat Tar Enamel 4.000 3.530 #1 thinner top coats by use of higher density
FBE 0.400 2.600 #4
polyethylenes tailored for this end use.
FBE 0.600 3.900 #5
FIELD INSTALLATION CONSIDERATIONS
3 layer LDPE 3.000 4.400 #4
3 layer HDPE * 1.500 2.600 #5 Contractors are well aware of the need to add rock
3 layer HDPE * 1.250 2.300 #4
shielding such as plastic netting and sand padding
P.E. Powder Composite 0.925 2.720 #5
when installing thin film epoxy coatings in rough
rocky terrain to protect the coating from damages.
2 layer HDPE 1.500 1.655 #3
This is additional cost for them and can add up to
3 layer P.P. 1.625 3.525 #6
100 % more to the coating cost: this is often NOT
reflected in coating system comparisons. An
* where Performance of # 1 is poorest rating; performance additional expense is the massive repairs done to
based on Cathodic Disbondment resistance, Adhesion values
thin film epoxy coatings from holidays in
and Hot Water Soak at higher temperatures
transportation, field handling and steel laminations :
this cost is usually buried in the contractors bid and
Use of the Canadian standard specification CSA Z can be excessive if his people are not fully
245.21 to design the corrosion coating to fit the experienced with how to handle this coating. Each
needs of the project has resulted in a less costly repair has the potential to weaken the coating
coating mainly through material thickness reduction integrity.
but with no sacrifice in performance, see Ref. # 1
Repair costs with people and material resources to
and 2. This standard has been in use for over 14
do a good job is at a critical level with coatings that
years and gaining popularity in emerging countries.
are not high performance multi-layer types ; we have
Typical multi-layer final coating reference costs may
215
seen a great deal of new coatings such as two layer TABLE 2 Typical anode needs for off-shore pipelines
epoxy and epoxy plus urethanes or polymer concrete
over epoxy, to combat this growing field applications Coating Anodes Typical Installed Cost
need. (including anode)
C.T.E. 1 per joint $ U.S. 695,000
The resistance of the Multi-layer coating to impact F.B.E. 1 per 4 joints $ U.S. 171,000
by stones and dropping of crushed rock is explained 3 LP.E. 1 per 15 joints $ U.S. 45,300
well as part of a paper presented in 1977 ( Ref. # 4)
and tells of the minimum thickness needed : 900 to **where the typical bare steel design factor for FBE is 5 to 7 %
1600 microns for stones of 1.1 to 2.2 pounds weight initially and 11 to 15 % after 20 years and for the 3 L Multi-coat; it
and 1800 microns for crushed rock of 1.4 to 2.2 is 2 to 3 % initially and 5 to 6 % after 20 years. These are often
conservative ratings especially for the multi-layer coating system.
inches size and 110 pound weight. Coal tar enamel has a much higher bare steel design factor.
This is nearly independent of steel pipe diameter for
equal diameter/wall thickness. Today one sees more demand for high temperature
However, these tests were done on local low density off-shore flow lines coupled with insulated hot lines
polyethylene coatings which is much “ softer” than which lead to specialty coatings of multi-layer +
high density polyethylenes; for example, hardness of foam and girth weld coatings that must perform
Low density is about 40 and hardness of High similar to the plant applied coating and yet, be
density is about 62. Thus, less thickness may equate applied in the field quickly and economically. This
to the same property characteristics. has become an area of specialists and custom
application coatings that center around the
OFF-SHORE REQUIREMENTS lay-barge time and requirements since this is the
Off-shore coatings have different criteria such as cost driver that all installation and handling aspects
negative buoyancy using concrete weight coatings work towards.
over the corrosion coating ; sacrificial anodes Land pipe lines may have different C.P. design needs
installed on the joint to last over a 20 or 25 year and MUST have this active cathodic protection
period and usually much thicker epoxy primer layer system as regulated by the local authorities. The
applied over heavy wall pipe. However; the coated Multi-layer coating will use very little current and
pipe system must be lay-barge friendly for virtually not change over time; with polyethylene’s
installation and handling ( bending ) where zero very high electrical resistance properties, one sees
repairs are required. A major cost is in the anodes + little change over time compared to other coatings
anode installation . Table 2 compares the number of as illustrated by the charts 1 and 2 ( ref. # 3).
anodes needed for different coatings in order to
Typical C.P. requirements ‘IF’ Coal Tar Enamel
adequately protect the pipeline with the correct C.P.
would be used; at one oil and gas company, would be
over its design life.
average of 1.0 milliAmps per square foot and for
either FBE or 3 Layer PE they would use 0.10
milliAmps per square foot one tenth the
requirement.
216
CHART 1 COATING DESIGN
1 Besides many Standard specifications used today,

several leading experts in the field of corrosion
Electric Resistance log Rs (Ω-m2)
10
coatings have offered principles and methods to
2 help in choosing the best coating for the pipeline
environment and life. An excellent example of this is
4 the paper on “Designing the Ideal Pipeline Coating”
( Ref. # 5 ). Most standards call for the “minimum”
5 3 requirements and end use clients or engineering
Buried in soil companies must then assess the pipeline needs
relative to what is known in corrosion theory or used
in the past; however, it appears that each project has
1 10 100 its own circumstances to consider.
Time (Months)
1. High Density Polyethylene
If we understand the importance of key parameters
2. Glass Cloth Reinforced Coal Tar Enamel such as steel surface preparation & pretreatment;
3. Vinyl Cloth Reinforced Asphalt epoxy primer-thickness function; adhesive
4. Polyethylene Tape performance and polymer top coat purpose; then
one can relate these to the pipeline field conditions
FIGURE 10 Electric Resistance in Soil
(3 inches O.D.) and ‘Purpose Design the coating. Rocky terrain ;
Wet soils; Service temperature; Field handling
CHART 2
conditions; Installation requirements; Service life;
1 Soil type; Environmental —- Risk assessment and
project Economics are all factors to address. Past
Electric Resistance log Rs (Ω-m2)
10
history / coating use is also a good benchmark
2 relative to similar parameters. Steel sourcing and
coating applicator proximity often are factored into
4
3
the decision along with local politics.
5 Three Layer High Density Polyethylene design

Immersed in water considerations:
Given that the surface preparation should always be
done “properly” regardless of coating system ( FBE
1 10 100
Time (Months)
or 3 Layer Multi-coat ) and with the same
techniques for anchor pattern and white metal
1. High Density Polyethylene
2. Glass Cloth Reinforced Coal Tar Enamel cleanliness, the next prime consideration is the
3. Vinyl Cloth Reinforced Asphalt grade of epoxy primer and the thickness. Ideally, an
4. Polyethylene Tape FBE grade should be used as a “primer” in the
multi-coat and for best corrosion resistance, the
FIGURE 11 Electric Resistance in Water thickness should be at least from 150 to 250 microns.
(3 inches O.D.)
217
Added epoxy thickness from minimum standard Note: These figures are from a 36 inch diameter - multi-layer
recommendations will add cost. Adhesive tie layer High density coated pipeline project . Similar estimates are from
same circumstances done on the FBE and Extruded p.e. 2 layer
should be such to offer high adhesion values; coating.
through chemical bonding , over the entire service
range ( - 40 to + 85 deg. C ), and typically to give at TABLE 4
least 200 N / cm at room temperature. The adhesive Estimated Construction Repair Costs for Several
thickness is not important as long as the Coated Lines on a 36 inch diameter x 465 kms Steel
performance value is achieved. The specific line pipe using 18 meter joints
pipecoating grade of compounded high density
polyethylene ( greater than 0.95 ) should have some Coating System Number of Repairs ***Cost of
critical thickness values subject to the chemical and Repairs ($ US)
mechanical requirements of the coated line and Multi-Coat 25,833 x 1.45=37,458 $189,165
installation factors. Typically, 1000 microns is a @ 1750 microns
minimum on any pipe size with additional thickness FBE 25,833 x 12.03 =310,771 $51,553,855
depending on the engineering requirements and @400 microns
field conditions listed above. Table 3 offers a look at Extruded pe 25,833 x 3.08=79,566 $395,283
coating defects in a recent project. Table 4 shows @ 1500 microns
construction costs related to repairs of holidays in
* * *where each repair is costed at $ 5 US
coatings.
This assessment assumes that all coating defects are
TABLE 3 detected and repaired by the contractor prior to the
Comparison of Number of Coating Defects and line being backfilled and after lowering into the
Estimated Defects per 12 meter Joint for Various ditch. These are the “ hidden costs “ by the
Coating Systems contractor and has led more of them to recommend
using the Multi-Coat system in order to save time
Activity J D N Multi-Coat FBE Extruded 2 layer and money during the construction process. This
P.E.**
improved mechanical resistance to field damages is
Load 0 defects 0.1 0.05 defects
a another benefit which ultimately results in a
Truck to site 0.20 1.00 0.50
superior pipeline over its design life.
Off-load 0.20 2.00 0.33
Storage 0 0.10 0.10 IMPROVED MATERIAL TECHNOLOGY
Re-load 0.20 2.00 0.33
In recent months we are working with improved
Truck to field. 0.10 1.00 0.12
epoxy powder grades for better cathodic
Off-load 0.20 2.00 0.33
disbondment resistance and also for higher
String 0.20 2.00 0.50
temperature service. These will be used with
Weld 1 coat 0.10 0.33 0.12
improved adhesive tie-layer resins that offer better
Ditch / lower-in 0.20 1.00 0.50
hot water adhesion and the next step will be to offer
Padding/ backfill 0.05 0.50 0.20
higher temperature polyethylene top coats to 100 °C
Total per 12 m. it. 1.45 12.03 3.08 service.
Bending /joint done 0.20 2.00 1.00
218
Coating ‘Trials’ are being done now to gain some References
experience with these new tailored resins with the
# 1. Nace paper # 575 ; 1991 ; High
benefit of better anti-corrosion integrity and more
Temperature Performance of Three-layer/
protection for the pipeline asset over time, see Table
Epoxy P.E. Coatings
# 5.
Mike Alexander, Pipe Coating Systems
TABLE 5
# 2. Nace paper # 415 ; 1989 ; Development
of Three Layer High Density P.E. Pipe
Cathodic Disbondment Sample 1 Sample 2 Sample 3 Sample 4 Coating,
test conditions (new) (new)
S. McConkey and M.A.Triecieski
1.5V @ 65°C 28 days 8 mm 5 mm 2.5 mm NIA
1.5V @ 140°C 28 days – – – 3 mm # 3. NKK Technical Bulletin # 243-127
where # 1 current 3 layer p.c. with 100 microns of epoxy primer # 4. Nace paper # 142; 1977;
where # 2 current 3 layer p.c. with 200 microns of epoxy primer Polyethylene-Extrusion-Coating of Buried
where # 3 new epoxy generation with 200 microns of primer Steel Pipe
where # 4 new epoxy generation with high Tg and 300 microns primer Properties, Experiences, Valuation,
Ruhrgas and Mannesmann.
Girth weld coating systems and products are now # 5. Designing the Ideal Pipeline Coating,
being offered showing improved adhesion up to 60
deg. C operating temperature through combining Toni Pfaff; Pfaff International, Toronto,
epoxy primers as the anti-corrosive layer and Ontario, Canada; 1996
bonding with special “anti-corrosive ‘Adhesives in a
multi-coat shrink sleeves product. This girth weld
system is patterned after the plant applied coating
and follows a similar procedure.
CONCLUSION
For long term service greater than 50 years with low
maintenance; low installed cost; our multi-coat
exterior coating system offers tremendous value to
the end client in protection of his pipeline asset.
219
MATERIALS SELECTION & DESIGN
NEW TEST METHODS

FOR EVALUATING PIPELINE
COATINGS
Peter J. Singh and John J. Baron

Shell Canada Limited,
3653 – 36th Street N.W.,
P.O. Box 2506, Calgary, Alberta T2P 3S6 Canada
220
Peel and shear strength tests of several external pipe soil in the longitudinal direction. Soil anchoring
coatings are detailed that characterize the adhesion causes high stress levels as a result of laying and
properties of the coatings at elevated temperatures. backfilling at one temperature and operating the
An apparatus to conduct both types of tests at pipeline at another temperature. Stresses are also
different temperatures is also described. The results produced in the circumferential direction by the
show significant differences between the adhesion weight of backfill, pipe and the contents, and soil or
properties of individual products. The coatings pipe movement. Excessive stresses on the pipeline
could be differentiated into two groups; those leads to coating-pipe bond failure, which results in
containing lower-performance mastic/rubber-type coating displacement, wrinkling, and even tearing.
adhesives and those containing high-perfmmance The importance of coating/soil stress, assessment in
hot-melt adhesives. The rate of testing affected the preventing coating failures and for development of
values obtained. better coatings have been addressed in the
literature.1.2 To maintain protection, the coating
Research was conducted to characterize and qualify
must have adequate adhesion strength to the pipe at
various externally coated pipe products. The aim of
conditions of exposure. Thus, coating pipe adhesion
the program was to obtain data on engineering
at operating conditions is of major importance in
properties that would be needed for designing
preventing coating failure. Room temperature
buried pipeline systems, espescially for
testing of adhesion is not adequate for determining
high-temperature applications. The requirements
the effectiveness of the coating system.
for high-temperature pipelines in new gas and oil
production developments are becoming increasingly In Canada, external pipe coatings are commonly
common. Deeper wells are being sunk with manufactured as two or three-layered systems. The
higher-temperature produced fluids. Capital costs two-layered systems use a thermoplastic outer layer
can be reduced by designing with high-temperature (primarily poly-ethylene) with a mastic/rubber-type
operating pipelines. The use of adhesive layer. Three-layered systems use a
low-temperature-rated pipeline coatings may fusion-bonded or liquid-applied epoxy layer,
require higher capital and operating costs associated together with a hot-melt adhesive layer and the
with both in-line heat exchangers and line heaters. external thermoplastic layer of either polyethylene
The heat exchangers are required to cool the or, in some cases, polypropylene. In recent years, the
products downstream from the compressor stations high-temperature performance of these
so that they can be handled by the pipeline, and the three-layered coatings have been supported.3.4 In the
line heaters are used to maintain the product two-and three-layered systems, the polyethylene
temperature above a set level to prevent hydrate layer acts as a barrier coating. It isolates the
formation. underground environment from the steel pipe, as
well as protecting it from mechanical damage. The
A pipe coating system should protect the steel pipe
polyethylene layer is bonded to the steel pipe by the
against corrosion, mechanical damage from
adhesive layer(s). This layer transfers the stresses
manufacturing to installation, and against stresses
from the outer surface to the steel. It also acts as an
incurred during normal operation. The most severe
additional barrier to the outside environment.
stresses are often due to differential thermal
expansion or contraction of the pipe relative to the
221
Product Samples used to hold the pipe sample while the test was being
Two and three-layer-coated pipe samples were conducted. The test apparatus consisted of a frame
obtained from several manufacturers. The products that supports a ball bearing mounted rotating shaft
were varied in construction from polyethylene tape and is mounted to the base of the tensile testing
wraps to extruded polyethylene jacket, and with machine. The entire assembly was sized so that it
various types of adhesive undercoat. The samples can be installed inside an environmental chamber,
were classified as outlined in Canadian Standards allowing tests to be conducted at either subambient
Association document CAN/CSA-Z.245.215 (Table and above-ambient temperatures. The frame was
1). The two-layer coatings were divided into systems designed with multiple sets of mounting holes so
A1 and A2, with system A2 having higher peel that the alignment of the device could be altered for
strengths than Al. The three layer coatings were several diameters of pipes. This allowed alignment
classified as system B. Tape systems were segregated of the specimen with the top grip of the tensile
on their layers as the document only addressed machine. A sample of coated pipe was centered on
continuous polyethylene jacket coatings.
TABLE 1 Tensile Load

CLASSIFICATION OF SELECTED
EXTERNALLY-COATED PIPE PRODUCTS Coated Pipe Sample
Rotating
Two-layer systems Spindle on
Ball Bearings
A, D, J, L Extruded polyethylene jacket, adhesive
Spindle
Wrapped polyethylene jacket, adhesive
Lock
Three-layer systems Baseplate with
Adjustable
B, K Extruded polyethylene jacket, adhesive epoxy Holes
TEST METHODS AND APPARATUS

Mounting
Pedastal
Peel/Shear Apparatus
The apparatus for measuring peel and shear
strength was designed and built at Shell Canada’s
Calgary Research Center. A schematic is shown In Base Tensile Tester
Figure 1. The basic procedure for peel testing was to
cut along a 2.54-cm wide strip of the polyethylene
jacket, lift one end off the pipe. and then pull it off at
90 degrees to the pipe surface at a constant speed.
An Instron Model 4204 Universal Testing Machine
was used to pull the polyethylene strip at a constant
FIGURE 1
speed while measuring the force. The apparatus was Schematic diagram of peel/shear apparatus
222
the shaft using conical end plates clamped to the
shaft. A double-blade knife was temporarily
mounted on the frame and was used to cut a 2.5cm
wide strip through the Jacket to the steel pipe. Once PE COATING 2.5cm WIDE STRIP
the strip was cut completely around the
circumference of the pipe, it was cut at one end,
pried up, and peeled off far enough to be fastened in
the upper machine grip.
Peel Tests
In the peel tests, the shaft was free to rotate as the
(a)
strip was being pulled. Thus, a peel angle of 90
degrees from the jacket strip to the pipe surface was
maintained. The force measurement was averaged
over a length of the peeled jacket not including the
beginning or end of the test. Peel tests were PE COATING
conducted according to speeds specified in the DIN
306706 and ASTMD10007 standards. ASTM requires
a speed of 254mm/min while DIN’s requirement is NO PIPE
2.5cn x 2.5cm ROTATION
10mm/min. Peel tests were also conducted at AREA
elevated temperature levels by enclosing the
apparatus in a circulating-air oven. (b)
Shear Tests
FIGURE 2
Shear tests (Figure 2a) were performed by clamping Schematic diagram of (a) peel
the pipe firmly, thus preventing it from rotating and (b) shear testing
(Figure 2b). A 25.4mm wide strip was cut in the
same manner as the peel procedure. The jacket strip Tests Comparison
was peeled back, and a transverse cut was made so The use of lap shear tests of the adhesive on steel
as to leave a 2.5 by 2.5cm area still bonded to the backing, as specified in ASTM D 1002, were
pipe. The fixture was positioned so that the jacket eliminated because of the difficulties in obtaining
strip could be held in the upper grip and pulled adhesive samples as well as the lack of adhesive
tangentially to the pipe circumference. The Instron application knowledge. Another alternative was to
was then used to pull on the strip at a tangent to the use the Alyeska shear test, which is conducted on
pipe. The shear tests were performed at several the pipe sample itself. The Alyeska shear test
different temperatures for selected pipe products. measures the shear rate (movement of a coating)
The shear tests were performed at a speed of when subjected to a fixed shear stress of 0.1 kg/cm2
1 mm/min. and a normal stress of 0.2 kg/cm2 for24 hours. This
apparatus can be put into an oven and the test
223
conducted at the pipe operating temperature. TABLE 2
However, the shear rate cannot be compared to
Peel Strength Measured
imposed shear stresses on a pipeline.
by ASTM D 1000
and DIN 30-670 Standards
RESULTS AND DISCUSSION
Peel Strength (N/cm)
Peel ASTM D-1000 DIN 30-670
The two-layer systems exhibited partly cohesive and Standards Standards
partly adhesive failure at the faster peel rate. Peel Rate Peel Rate
Approximately half the peel area showed bare steel Label 254mm/min 10 mm/min
pipe. At the slower peel rate of 10mm/min, the A 28.3 11.7
failure mode was fully cohesive, leaving a thin, even D 16.7 6.89
layer of mastic covering the steel pipe. At 60°C, H 40.7 10.2
failure occurred cohesively in the mastic. The mastic The effect of temperature on the peel strength of
appeared to be near melting, showing some flow. the coatings are presented in Figures 3a to 5a. A
The steel was fully covered by the mastic. The best fit curve is used to illustrate the relationship in
polyethylene jackets of the three-layer systems were each case. The peel strength showed an
extremely difficult to remove from the pipe samples. exponential drop with temperature for all the
The polyethylene strip would peel only briefly different coating samples. The peel strength for the
before it necked and broke. The slower peel rate three-layer (System B) coatings were much higher
resulted in slightly easier peeling but still involved than those of the two-layer coating (Systems Al,
the necking and breaking of the polyethylene strip. A2, and Tape). Both samples of System B fulfilled
The adhesive peeled cleanly away with the the CAN/CSAZ.245-21 and DIN 306706 require-
polyethylene jacket, leaving the epoxy layer on the ment of minimum peel strength at room
steel. At higher temperatures, the failure mode was temperature. A comparison of the peel strengths of
similar with no damage to the epoxy. types A1, A2, and tape coatings in Figure4a shows
Selected results of the peel tests at 254 and 10 similar trends of exponential decrease with
mm/min as per DIN and ASTM standards, temperature. Sample D (System A1) has a lower
respectively, are presented in Table 2. The results room temperature peel strength but equivalent to
show that the peel strengths of the coatings varied slightly higher values above 40°C when compared
significantly with the peel rate. The values were to samples A and H (System A2 and Tape,
lower at the slow peel rate, and the failure modes respectively). In Figure 5a, the peel strength data
were different at the two rates. A simple correlation from three samples of System A2 coatings illustrate
relating the peel strength values obtained for the the differences in behavior within the group.
various coatings to the peel rate could not be found. Samples J and L have higher room temperature
From this consideration, it is essential that the peel peel strengths when compared to sample A.
rate be specified when reporting peel strength values However, they also show a greater decrease with
obtained from coated pipe samples. temperature. This shows that room temperature
measurements alone may not provide reliable indi-
cation of higher temperature performance.
224
and the resistance of the dashpot are lowered, thus
150 the peeling force is reduced.
B – system B
K – system B
120 Shear
PEEL STRENGTH (N/cm)
The three-layer coatings (samples B and K) did not

90
fail in shear even at high temperatures. The
polyethylene strip elongated and broke without
60
shear failure of the adhesion between the coating
and steel pipe. Thus, the shear strength coating was
30
documented as being greater than the stress
required to break the polyethylene strip. The results
0
0 20 40 60 80 100 120 are plotted for sample K in Figure 3b. Sample B had
(a) TEMPERATURE (C) a shear strength of more than 125 N/cm2 at 60°C.
Shear testing of the two-layer systems was easier to
150
K – system B
complete. The coating-pipe bond underwent shear
failure without excessive stretching or breaking of
120
the polyethylene strip. The effect of temperature on
the shear strength is similar to the effect on peel
SHEAR STRENGTH (N/cmˆ2)
90
strength. There are also significant differences
between the samples. It is interesting to note the
60
differences between the peel and shear behavior with
temperature. In Figure 4, sample H (System Tape) has
30
similar peel strength as sample A, however, the shear
strength at high temperature is significantly better. In
0
0 20 40 60 80 100 120
Figure 5, the shear strength of sample J is
(b) TEMPERATURE (C) approximately three to four times that of A and L, but
the peel strength is only about twice. This indicates that
FIGURE 3
(a) Peel strength and (b) shear strength vs temperature
comparison of peel strength measurements are not
for System B coatings reliable in place of shear strength.
The peel adhesion behavior of the coating can be The importance of shear strength of the
explained largely by the visco-elastic nature of the coating-pipe interface in preventing coating damage
adhesive layer. The adhesive can be viewed as a has been strongly emphasized in the literature. At
Maxwell† element visco-elastic model8 consisting of the operating temperature, the shear strength of the
a spring and dashpot in series. The stress required to coating to pipe must be higher than the stress
deform the elements is highly rate and temperature imposed by thermal expansion. High-temperature
dependent. With increasing peel rates, the dashpot operations have the double effect of increasing
element offers greater resistance, thus increasing the pipeline shear stress as well as reducing the shear
force required for separation. At higher strength of the applied coating.
temperatures, the modulus of the spring element In an example in Reference 1, a 304.8-mm diameter
225
20 50
A – system A2 A – system A2
H – system Tape J – system Tape
16 D – system A1 40 L – system A1

12 30
8 20
4 10
0 0
0 10 20 30 40 50 60 0 10 20 30 40 50 60
(a) (a) TEMPERATURE (C)
TEMPERATURE (C)
20 150
A – system A2 A – system A2
H – system Tape J – system Tape
16 120 L – system A1

12 90
8 60
4 30
0 0
0 10 20 30 40 50 60 0 10 20 30 40 50 60
(b) TEMPERATURE (C) (b) TEMPERATURE (C)
FIGURE 4 FIGURE 5
(a) Peel strength and (b) shear strength vs temperature (a) Peel strength and (b) shear strength vs temperature
for System A1, A2 and tape coatings for System A2 coatings
pipe that is buried 3 m deep and operating at 120°C selecting coatings in a Shell Canada project. The
will have a longitudinal shear stress of 8.3 N/cm2 upper limit for longitudinal soil-coating stress in a
imposed on the coating. A bend in the same pipe has high-temperature pipeline was calculated using
an average stress of 13.6 N/cm2. The coating selected finite element analysis. The calculation showed that
for this pipeline must have a shear strength more a force of 17.5 kN/m would be exerted on the
13.6 N/cm2 for successful operation. A coating with a l68.3mm diameter pipe buried at 2 m and operating
shear strength lower than both values will under go at 90°C. This translates to a 3.3 N/cm2 shear loading
failures throughout the line, whereas a value in on the pipe-coating interface. The coating was
between would most likely result in failures only at required to have a shear strength more than 3.3
the bends. A similar analysis has been used in N/cm2 at 90°C.
226
The ideal approach for selecting coating for a given
application is to qualify the coating systems 1000
B B
according to their stress-temperature profile. At any K
given use temperature, the shear strength can be 100 A

specified. With this type of data, coated pipe systems
can be selected to meet the design specifications as
well as realize economical benefits. 10
The effect of temperature on the peel and shear

strength of the coatings can be modeled using 1
Arrhenius type plots. Figure 6 illustrates the peel 90C 60C 23C
and shear relationships, respectively, of selected
.1
samples. The Arrhenius relationship can be written 2.5 2.6 2.7 2.8 2.9 3 3.1 3.2 3.3 3.4 3.5
as: (a) 1/T (1/K)
Peel strength (N/m) or 1000

A K
shear strength (N/m2) = k0e(E/RT) J H
where k0 = constant, R = gas constant =8.31434J/ 100

mol K, and T= temperature (K).
The advantage of using this model is that few data 10
points need to be generated to obtain a correlation
of the property vs temperature, and properties can
1
be estimated for any given temperature with
reasonable accuracy. 90C 60C 23C
.1
2.5 2.6 2.7 2.8 2.9 3 3.1 3.2 3.3 3.4 3.5
SUMMARY (a) 1/T (1/K)
The successful selection and application of external
pipe coatings for high temperature requires an FIGURE 6
appreciation of shear stresses that are induced in the Arrhenius plots of (a) Peel strength and (b) shear strength
vs temperature for Selected Samples
pipeline, as well as the shear strength capability of
the coating at that temperature. Shear testing of this to higher temperatures. The three-layer coating
coatings should be a requirement because it can be systems tested were vastly superior in peel and shear
extremely useful when designing and selecting adhesion properties compared to the two-layer
coatings for buried high temperature pipeline. systems. There were also differences within each
Coating-pipe adhesion properties, measured at category. The peel strength does not appear to
room temperature only, should not be used to correlate with the shear strength. Thus, peel
predict high-temperature performance as the rate of strength measurements should not be used in place
decline of properties varies with different products. of shear strength values. The testing of adhesion
Often properties of coatings are reported at room properties’ retention at elevated temperatures
temperature only, however, there is a need to extend should be integrated with other commonly used
227
testing methods, for example, cathodic
disbondment, to provide a more complete
evaluation of pipe coatings.
REFERENCES
1. B.C. Yen,G.D. Tofani, Oil & Gas Journal,
Aug. 26,1985: pp. 63–70.
2. J.A. Davis, F.H. Hammond, J.D. Kellner,
H.L. Simmons, J.M. Serra, H. Schonhorn,
E.T. Selig, NACE Canadian Region
Western Conference, Calgary,
Feb. 25–27, 1986.
3. M. Alexander, CORROSION/91
paper no. 575, (Houston, TX. NACE,
1991).
4. G. Connelly, G. Gaillard, Y. Provou,
B. Cavalie R. Locatelli, Internal &
External Protection of Pipes–Proceedings
of the 8th International Conference,
1990,pp. 179–188.
5. Canadian Standards Association
Document Draft CAN/CSA–Z245.21,
External Polyethylene Coating, Feb. 8th,
1991.
6. DIN 30 670, Polyethylene Sheathing of
Steel Tubes and of Steel Shapes and
Fittings, Deutsches Institut fur Normung,
Berlin, July 1980.
7. “Peel Strength of Polyethylene Coated
Pipes,” Annual Book of Standards,
Volume 10.01 (Philadelphia, PA: ASTM).
8. S.L Rosen, Fundamental Principles of
Polymeric Materials, (Toronto: Barnes
& Noble Inc. 1971).
228
HIGH TEMPERATURE PERFORMANCE
OF THREE-LAYER EPOXY/POLYETHYLENE COATINGS
Mike Alexander, P.Eng.

Pipe Coating Systems Ltd.
P.O. Box 137
Nisku, Alberta TOC 2GO
229
ABSTRACT diameter of pipe. Various types of polyethylene
coatings are produced following DIN 30670 and the
Recent development of new oil and gas producing
new Canadian CSA Z.245.21 standard, at present in
areas in Canada created a demand for pipelines
the draft form.
operating at elevated temperatures.
In North America and the U.K. the preferred
A new three-layer epoxy/polyethylene coating was coating of choice on large-diameter pipe over the
developed to answer a growing need of the last decade has been fusion bonded epoxy; however,
Canadian pipeline industry for high temperature tape coatings and coal tar enamel are still
resistant coatings. An industrial research program occasionally being used, especially in the U.S. (2).
was undertaken to select the most suitable materials Fusion bonded epoxy coatings are usually applied
and to determine the highest operating temperature and tested according to the Canadian CSA
of this type of coating, as well as to define properties Z.245.20-M86 standard (3).
of this type of coating at elevated temperatures.
There are many reasons for these geographical
This paper describes the work performed at Pipe differences in the pipeline coatings of choice. Some
Coating Systems to better understand the physical, of them are technical and have to do with
chemical and mechanical properties of this type of construction methods, cathodic protection or lack
coating. thereof, safety expectations, and economics, but are
Keywords: also caused by the history of some nations and their
adhesion, adhesive, cathodic disbondment, culture. Discussion of this interesting topic,
chromate, epoxy, fusion bond, high temperature, hot however, goes beyond the scope of this presentation.
water soak, pipeline coatings, peel test,
Neither one of the types of coating described above
polyethylene, three-layer coating.
fully meets a definition of a “perfect” pipeline
coating. Each of the above mentioned coatings has
INTRODUCTION some disadvantages and shortcomings. So, for
Historically, pipeline coatings have developed example, polyethylene coating extruded over a soft
following certain geographical preferences. Three adhesive has a relatively poor adhesion and a
major types of pipeline coatings used in the world relatively low temperature limit’. Coating systems
today can be generically called polyethylene based on polyethylene extruded over hard adhesive
coatings, epoxy coatings and enamel coatings. have excellent mechanical protection and adhesion
but relatively poor cathodic disbondment
In Europe, plant applied extruded polyethylene has
characteristics (4). Fusion bonded epoxy coatings
been the coating of choice (1). Polyethylene can be
adhere extremely well to steel, but exhibit a
extruded over soft asphalt-based adhesive, hard
relatively poor resistance to mechanical damage,
polymeric adhesive or it can be sintered onto the
resulting in numerous holidays during construction.
pipe. For small and medium diameter pipe,
polyethylene can be applied using a cross-head Recently developed three-layer epoxy/polyethylene
extrusion technique. While side-extruded coatings seem to be an answer to the concerns of the
polyethylene can be applied to almost any pipe pipeline industry (5). They offer a combination of all
diameter, it is usually preferred to use it on larger the best properties of fusion bonded epoxy,
230
including excellent adhesion and cathodic This section describes the preparation of steel pipe
disbondment, and at the same time offer excellent and the various coating layers applied to the pipe.
mechanical protection, typical for the rigidity of
Various types of processes and raw materials are
polyethylene. This type of coating was first
relatively well known and there is no need to repeat
developed in Europe a few years ago and has
them at this stage.
immediately met an enthusiastic reception. At
present, three-layer epoxy/polyethylene coating Steel Pipe
seems to have found also wide acceptance on many
large international pipeline projects. All tests were performed using a 4” steel pipe. The
steel surface was blasted to a near-white condition,
A lot of interest over last few years has been in reference to the Swedish Standard SIS 05 59 00
generated among the pipeline community in the (11) by using a mixture of steel and grit. The anchor
area of high temperature gas and oil exploration. pattern depth did not exceed 60 micrometers.
There are many areas where the well temperature
can reach in excess of 100°C in different parts of the Chromate
world (6). In Canada, temperatures do not generally
The advantages of using chromate surface treatment
exceed 85°C. Wells which produce oil or gas at such
systems are well known in the industry. Their
elevated temperatures offer specific challenges to
beneficial effect becomes especially evident during
the technical personnel involved, due to some
high temperature wet tests, such as the hot water
specific corrosion and mechanical problems
soak and elevated temperature cathodic
associated with exploration. The challenges are
disbondment tests (7).
compounded by the fact that a large part of pipeline
construction takes place during the winter months, For the test pipe, a commercial chromate solution
and therefore the coating has to be able to resist was applied at a 10:1 dilution ratio at an average wet
both temperature extremes, low temperatures for film thickness of 50 micrometers. The pipe
construction and high temperatures for operation. temperture for chomate application was in the range
of 70 to 85°C.
This paper summarizes some of the research
conducted into the performance of three-layer Fusion Bonded Epoxy Primer
epoxy/polyethylene coatings in conditions of low and
high temperature. Epoxy powders, however widely used as one-layer
FBE coatings, differ substantially when employed as
COATING SYSTEM DESCRIPTION primers. Chemical and physical properties, as well as
the powder ingredients themselves, are suited to
The coating system tested in this program consisted provide a desired combination of application
of the following layers, each applied separately: temperature, gel time and cure time. Powder
1. chromate surface treatment, application temperature and distance to next unit
operation, combined with line speed, become the
2. fusion bond epoxy primer, most critical factors in producing a high quality
3. polymeric adhesive, three layer epoxy polyethylene coating.
4. high density polyethylene. In the case of the test pipe, the fusion bonded epoxy
231
primer was applied to a nominal thickness of 100 micrometers, in order to maximize the adhesion.
microns, using four electrostatic powder spray guns
Application of the adhesive followed fusion bonded
equally spaced around the pipe. In reality, the
primer application very closely, to optimize the
powder primer thickness differs quite significantly
chemical bond between the primer and the adhesive.
from the nominal value, following the contour of the
The time lapse between these two steps never
anchor pattern. The pipe was pre-heated to the
exceeded 15 seconds and was monitored very
temperature of 200°C to 210°C immediately prior to
closely.
powder primer application, as suggested by the
fusion bond primer supplier. Polyethylene Outer Coat
The distance between the powder spray application There are several different kinds of polyolefins
and the next unit operation was kept very short in which can be used as an outer coat for the
order to minimize the curing effect of the powder three-layer epoxy/polyethylene coating. Historically
prior to adhesive extrusion. the oldest and still commonly used, is low density
polyethylene, followed by medium linear low and
Adhesive Intermediate Layer
high density polyethylene. Polypropylene can be
The purpose of the adhesive is to provide an used for applications in excess of 100°C.
intermediate layer between the epoxy primer and
In this set of tests, high density polyethylene (0.945
polyethylene outer coating. The adhesive has a
g/ml) was used, as it was felt that this material offers
number of polar groups which bond chemically to
the optimum degree of mechanical protection.
the epoxy, providing that the epoxy primer is not
fully cured yet (8). Polyethylene was extruded onto the pipe in a
co-extrusion die, together with the polymeric
At the same time, the adhesive layer provides a
adhesive. Co-extrusion offers the largest degree of
strong bond to the polyethylene outer coating, due
adhesion between the intermediate and outer layers,
to the chemical affinity of adhesive and
as it virtually squeezes both layers together in a
polyethylene. One has to realize that the number of
molten state, causing them to adhere under high
polar groups providing chemical bond to the primer
pressure and high temperature. At the same time, it
in the adhesive is relatively small (1-2%), with the
does not allow air to penetrate between the adhesive
bulk of the adhesive being made up of polyethylene.
and polyethylene layers, which sometimes occurs in
In the case of the test pipe, a polyethylene modified non-coextrusion processes.
(grafted) with maleic anhydride was used. This type
of polymeric adhesive is the newest development in EXPERIMENTAL PROCEDURE
this area. It offers a much stronger bond than any of Most of the tests were conducted following major
the previously used adhesives, based on national specifications, such as German DIN 30670
ethylene-vinyl acetate (EVA), ethylene-ethyl (9), Canadian CSA Z.245.20 (3), CSA Z.245.21
acrylate (EEA) and ethylene-acrylic acid (EAA), (draft,) and French NF A 49–710 (10). In lieu of a
and has a very low water absorption, resulting in standard for high temperature evaluation of
superior properties in cathodic disbondment and coatings, some of the existing standard test methods
hot water testing. In the case of the test pipe, the required modifications or amendments.
adhesive thickness was approximately 100
232
Materials Evaluation prepared on the lathe by cutting 25 mm wide strips of
coating, separated by 6 mm gaps, pre-cut to the bare
Each of the materials used in the three-layer
steel, to allow hot water ingression from the sides.
epoxy/polyethylene coating was evaluated separately
at first, in order to establish its high temperature Several parallel sets of test runs were conducted at
limit. The fusion bond epoxy primer was tested on various water temperatures. The samples were
the D.S.C. for its Glass Transition Temperature. immersed in the hot water bath for a period of time
Glass Transition is a point at the temperature scale, ranging from 1 day up to 14 days.
at which the material starts to display elastomeric
The samples conditioned in the above manner were
properties. Glass Transition Temperature for the
allowed to cool for 1 hour and tested for peel
fusion bond epoxy primer was found to be at 104C.
strength at room temperature.
Two other components, the adhesive tie-layer and
polyethylene were evaluated, too. Vicat softening Cathodic Disbondment
point is a measure of upper temperature limit for
plastic materials. Vicat softening point for the Cathodic disbondment followed essentially the CSA
adhesive was found to be at 95C and the Vicat Z.245.20 fusion bond specification with some
softening point for polyethylene was at 121C. modification of voltage and test duration. Typically,
the test was conducted at room temperature at 5
Peel Adhesion Test volts DC for 1 month, at 65°C and 1.5V for 2, 14, and
30 days, and at 95°C and 1.5V for 2, 14, and 30 days.
Peel adhesion is presently considered as one of the
The resistance to cathodic disbondment was found
most important tests for any type of coating. The test
to be excellent at all of the above temperatures,
conducted for the purpose of this paper followed
including 95°C.
mostly DIN 30670 and NF A 49–710 standards, but
was conducted over a very wide temperature range, Direct Impact Test
from -40C and up to 95C.
The impact test and evaluation criteria were
The values generated vastly exceed 35N/cm, as per conducted according to CSA Z.245.20 fusion bond
DIN 30670, and 400N/50mm, as per French NF A specification, at several different temperatures,
49-710 specification. starting from -40°C up to 80°C. The impact values
Alternatively, the hanging weight test was also exceeded the values specified for the fusion bond
conducted as per DIN 30670 specification. This test was epoxy by at least one hundred percent.
performed only at room temperature on a variety of
Shear Test
samples, and all numbers generated corresponded well
to values generated by using Instron. The shear test was originally developed to measure
the resistance of tape coatings to forces of soil stress
Hot Water Soak Resistance at elevated temperatures. In evaluating the
Hot water soak resistance is considered one of the performance of three-layer epoxy/polyethylene, this
most crucial properties of any coating. This type of kind of test was used to measure lateral movement
test is generally conducted on fusion bond epoxy of coating at several temperatures, up to and
coating. In the case of the three layer including 95°C. In this test a 150mm x 30 mm sample
epoxy/polyethylene coating, circular ring samples were of the coated pipe is glued to a test fixture base and
233
a normal load of 20 kg is applied onto a sample. A TABLE 1
penetrometer gauge is attached to the test fixture. PEEL ADHESIVE VALUES
The whole fixture is placed in the oven at a test
temperature, usually 90-100°C for conditioning, Temp (°C) Peel value DIN 30670 NF A 49
after which time the shear load of 7.0 kg is applied. (kg/cm) -710
After the test period, usually 72 hours, the -40 25
movement of the coating is measured using the -20 21
penetrometer gauge. The obtained test results were 0 18
fully satisfactory and met the most demanding 20 15 3.5 8
criteria. 40 12
60 8
Pull-off Adhesion 80 5 5
95 3
The pull-off adhesion test was used as another
measure of the adhesion of coating to the pipe. An
aluminum dolly measuring one square inch was RESULTS
glued to the coating, following coating preparation Peel adhesion values were found to exceed the
to improve adhesion, and the glue allowed to cure applicable German DIN and French NF
for 24 hours at 50°C. specifications by a very substantial margin. At low
temperatures the adhesion values increase rapidly;
The dolly was then pulled off, using a calibrated at elevated tempratures they drop off. Even at 95°C
wrench. The failure occurred usually between the the adhesion values meet 35N/cm. For experimental
dolly and the coating. The values generated usually results, please see Table 1.
exceeded 10 MPa (1500 psi).
TABLE 2
Bend Test at -30C HOT WATER SOAK RESISTANCE
Flexibility of the coating is one of the most Water Temp (°C) Duration (days) Peel value
important properties, especially for winter at 20C (kg/cm)
construction. 100 0 15
The test procedure followed CSA Z.245.20 fusion 1 10
bond specification. Evaluation was done differently, 7 8
14 7
since use of a high-voltage holiday detector is 80 0 15
generally considered impractical on samples coated 1 12
with this type of epoxy/polyethylene coating. 7 11
Following the bending, samples were allowed to 14 10
warm up for a few hours to 20C. A peel test was
conducted at room temperature on bent samples. Three-layer epoxy/polyethylene coating is not
Some peel strength reduction was observed, but all significantly affected by hot water. Even hot water
samples remained well within acceptable peel penetrating from the side does not create any
adhesion criteria. undercutting of epoxy primer film. Peel values,
following hot water soak conditioning, decrease
234
slightly but still remain well within the accepted The direct impact test result of three-layer
criteria. Please refer to Table 2 for results. epoxy/polyethylene is several times higher than
similar values for fusion bond epoxy coating. At the
TABLE 3
same time, it is about 50% higher than similar values
CATHODIC DISBONDMENT
for polyethylene extruded over asphalt mastic. For
results, please see Table 4.
Test conditions Disbonded radius:
(mm)
20C, 5V, 30D 3
TABLE 5:
65C, 1.5V, 2D 2
SHEAR VALUES, 72-HOUR TEST
14D 5
Temperature (°C) Movement (mm)
30D 8
80 0
95C, 1.5V, 2D 2
14D 8 90 0.1
30D 17 95 0.2
100 0.5
Cathodic disbondment at all three temperatures
tested—-20°C, 65°C and 95°C—-is not severe. All
samples tested passed the required disbondment The shear test indicates that the coating is resistant
radius by a significant margin. In fact, there is very to lateral shear forces up to 95°C. At temperatures
little difference between the disbondment at 65°C equal to or higher than 95°C, the coating begins to
and 95°C conducted over the same period of time. slide slightly, but it still meets accepted industry
The room temperature cathodic disbondment is so standards. Results are contained in Table 5.
small that it is almost negligible. Please see Table 3
for results. TABLE 6:
PULL-OFF ADHESION OF 3-LAYER
TABLE 4 EPOXY/POLYETHYLENE COATING.
DIRECT IMPACT TEST
Temperature (°C) Adhesion (MPa)
Typical Fusion
Temperature (°C) Impact value (J): Bond Impact (J) 20 10.3
-40 15
-20 12 The pull-off adhesion values indicate that all three
0 10 layers of the coating adhere very well together and
20 8 2-3 pulling them off exceeds the physical strength of the
40 7 two-component, chemically set, specially formulated
60 6 adhesive. Please look at Table 6 for experimental
80 5 test data.
100 3
235
TABLE 7: TABLE 8:
BEND TEST AT -30C, FOLLOWED BY PEEL AT 20C GLASS TRANSITION AND VICAT SOFTENING POINTS
Bend Peel value Component TG (°C) Vicat soft. pt.

(degree/pipe dia) at 20°C (kg/cm) (°C)
Fusion bond 104 N/A
1.5 8
epoxy primer
3.5 6
Adhesive tie layer N/A 95
Bending tests at -30°C indicate that the coating is Polyethylene N/A 121
fully bendable down to and including -30°C. Table 7
contains experimental numbers. CONCLUSIONS
The glass transition temperature of the fusion bond Based on the properties of the raw materials and
epoxy primer is approximately 104°C. It is the based on the test results, as described above, this
experience of the author of this paper that the coating system can be recommended to be used at
coating should not be operated at the glass temperatures of up to 84C.
transition temperature or near it. It is a matter of
many technical arguments what constitutes a ACKNOWLEDGEMENT
reasonable safety margin for the highest operating The author wishes to express gratitude to the
temperature of the coating and how much lower that management of Pipe Coating Systems Ltd. of Nisku,
temperature should be than the glass transition Alberta, for giving permission to present this paper.
point of the material. It is the view of the author of
this paper that the highest operating temperature of REFERENCES
the coating should be approximately 20°C lower
1. P. Blome, G. Friberg, “Multilayer Coating
than its glass transition temperature. Using this
Systems for Corrosion Protection of
logic, the three-layer epoxy/polyethylene coating
Buried Pipelines”, CORROSION/90,
should be operated at up to 84°C. Both other
paper no. 248 (Houston, TX: NACE,
components, the adhesive and polyethylene with
1990).
their Vicat softening points of 95°C and 120°C
respectively, will also easily meet the 84°C 2. K.E.W. Coulson, S. Nunez, L.C. Choate,
benchmark. Table 8 contains glass transition J.L. Banach, “A Review of Gas Industry
temperature and Vicat Softening Point of all Pipeline Coating Practices”,
components, respectively. CORROSION/90, paper no. 242
(Houston, TX: NACE, 1990).
3. CAN/CSA-Z.245.20-M86, “Fusion Bond
Epoxy Coated Steel Pipe”, Canadian
Standards Association, Rexdale, Ontario,
1986.
236
4. G. Gaillard, G. Connelly, “Pipe Line
Industry”, March 1989.
5. G. Connelly, G. Gaillard, “3-layer
Polyolefin Pipe Coatings”, U.K.
CORROSION 187.
6. P. Barrien, S.E. McConkey, M.A.
Trzecieski, “Coating Evaluation Program
for 116C Service Temperature”,
CORROSION/84, paper no. 358
7. G.L. Higgins, J.P. Cable, “Aspects of
Cathodic Disbondment Testing at Elevated
Temperature”, Industrial Corrosion, 5,
1(1987).
8. J.W. Cox, K. Fogh, “Dual Coating System
for Pipelines in High Temperature
Service”, CORROSION/90, paper 247
9. Polyethylene Sheathing of Steel Tubes and
of Steel Shapes and Fittings, DIN 30670,
Beuth Verlag GmbH, Germany.
10. Revetement externe triple couche a base
de polyethylene, NF A 49-710, March
1988, Ass. Franc. de Normalisation, Paris.
11. Pictorial Surface Preparation Standards
for Painting Steel Surface, Swedish
Standards Institution, SIS 05 59 00,
Stockholm, Sweden.
237
CORROSION 89
April 17–21, 1989

New Orleans Convention Centre,
New Orleans, Louisiana
DEVELOPMENT OF THREE LAYER HIGH DENSITY

POLYETHYLENE PIPE COATING
S. E. McConkey and M. A. Trzecieski

Shaw Pipe Protection Limited
25 Bethridge Road
Rexdale, Ontario,
Canada M9W 1M7
238
ABSTRACT The extruded polyethylene systems have been used
generally along geographical lines. In North
Development of a three layer pipe coating system America, the Type A system has been the
consisting of an epoxy primer, a copolymer predominant system but has been mainly restricted
adhesive and cross head extruded high density to small and medium diameter pipe. Large diameter
polyethylene is described. pipelines are generally coated with fusion bonded
The system combines the good cathodic epoxy (FBE) although over the ditch coal tar is also
disbondment properties of epoxy with the superior used. The Type A systems have occasionally been
mechanical properties of high density polyethylene. used up to 36 inch (914 mm) diameter but only on a
Use of high density polyethylene permits reduced limited basis due to problems related to mechanical
coating thickness compared with traditional three handling damage.
layer systems resulting in a more cost effective The Type C and D and 3 layer systems have found
coating system. widespread use in Europe and have dominated the
large diameter market with fusion bonded epoxy
INTRODUCTION also in use. These versions of extruded polyethylene
Extruded polyethylene is one of the most widely are more costly than fusion bonded epoxy and this
used pipe coating systems in the world. Until very has essentially kept them out of the North American
recently, the three extruded polyethylene systems market.
described in NACE RP0185-85 were the only The three layer high density polyethylene (HDPE)
standardized systems available. pipe coating described in this paper utilizes the
superior mechanical properties of HDPE to reduce
The Type A system which is cross head extruded
the coating system cost compared to the
high density polyethylene over a hot applied asphalt
conventional 3 layer system while maintaining
mastic adhesive and the Type C and D systems which
superior performance.
are low or medium density polyethylene, cross head
(C) or spirally (D) extruded over an ethylene
copolymer adhesive are the most widely used COATING DEVELOPMENT
systems. The Type A system was developed in North The objective of the HDPE 3 layer system
America where it finds widespread use on small and development was to match or exceed the
medium diameter pipe. Types C and D were performance properties of existing polyethylene and
developed in Europe where they are produced to fusion bonded epoxy coating systems (within the
the DIN 30670 standard. temperature limits of HDPE). To this end
qualification tests were chosen from existing
Recently the European product has been modified standards where possible. The basic assumption is
by using an epoxy primer to produce a fourth type of that HDPE is a suitable material for extruded
extruded polyethylene system. This 3 layer system is coating systems for underground or submerged pipe
described by G. Gaillard and G. Connelly and based on the 30 year history of this material as used
J. Llorens and has found ready acceptance in on the Type A systems, especially in the Canadian
Europe although, to date, no national standard environment.
exists which covers this system.
239
The following tests were utilized to qualify the 3
layer high density polyethylene pipe coating High Density Polyethylene
system:
Copolymer Adhesive
Test Method
Cathodic Disbonding CSA Z245.20-M865 Clause 12.9

(except some voltage and
duration variations).
Peel Resistance DIN 30670
Shear Resistance Alyeska Shear Test
Impact Resistance CSA Z245.20-M86 Clause 12.13

Epoxy Primer
Indentation Resistance DIN 30670
Cold Bend CSA Z245.20-M86 Clause 12.12 Steel Pipe

followed by peel test
Hot Water Soak CSA Z245.20-M86 Clause 12.15,

@ 100° C (duration 1D, 7D, 14D, 28D)
Fig 1 Multilayer H.D.P.E.
followed by peel test.
Epoxy Primer
Meeting or exceeding the requirements of these A 100% solids epoxy liquid primer was developed
tests produces a technically superior coating which which is compatible with the cross head extrusion
overcomes the high temperature limitations of the process. The epoxy is applied at a thickness of 25-75
Type A coatings and eliminates the sensitivity to microns (0.001 - 0.003 inches) over the anchor pattern
steel surface conditions inherent in thin film fusion (as measured with a wet mil gauge). This solventless
bonded epoxy coatings. The HDPE coating is also epoxy remains in a liquid state until the copolymer
more cost effective than the traditional 3 layer adhesive is applied but gels prior to subsequent
systems due to reduced material costs and more pressure application. The epoxy primer contributes
efficient production due to reduced extruder output good resistance to both cathodic disbonding and to hot
requirements. water soak adhesion performance.
Copolymer Adhesive
MATERIALS
A schematic diagram of the HDPE 3 layer coating The copolymer adhesive is a grafted polyethylene
system is shown in Figure 1. The epoxy primer and system which provides excellent adhesion to both
copolymer adhesive are proprietary materials the epoxy primer and the high density polyethylene
developed specifically for this application. sheath. Adhesive application of about 150-300
microns (0.003 - 0.006 inches) is achieved by cross
head extrusion to form a seamless layer which bonds
the HDPE outer sheath to the epoxy primer.
240
HDPE
Extrusion
Blast Epoxy Initial Final
Cleaning Application Quench Quench
Induction
Heating
Pre heat Copolymer

Chromate
Pretreatment Adhesive Pressure
Extrusion Applicator
Fig 2 Schematic Multilayer H.D.P.E. Application
High Density Polyethylene Top Coat coating system. Figure 2 is a schematic diagram of
the application process for the 3 layer HDPE
High density polyethylene has superior impact and
coating. The cross-head extrusion process is capable
abrasion resistance compared to low or medium
of coating up to and including 36 inch (914 mm)
density polyethylene. High density polyethylene is
diameter pipe.
not used in traditional 3 layer or Type D extruded
systems because it does not weld together at the Pre Heat
overlaps in side extruded systems. The use of HDPE Prior to blast cleaning, the bare pipe is preheated to
allows lower coating thickness without sacrificing remove residual moisture and ensure that the clean
impact resistance. For example 1.5 mm (0.060 pipe is always at least 3°C above the dew point and
inches) of HDPE will provide the same impact the pipe is at the proper temperature for the
resistance (15 J) as 3.0 mm ( 0.12 0 inches ) of the chromate pretreatment.
traditional 3 layer or Type D coatings as specified in
Blast Cleaning
DIN 30670. The material savings resulting from use
Grit/shot blasting to Sa 21⁄2 finish with a minimum
of HDPE provide a cost effective alternative to
anchor pattern of 25 microns (0.001 inches) is
traditional 3 layer systems using low or medium
required to achieve final product performance.
density polyethylene.
APPLICATION PROCESS Chromate Pretreatment
Chromate pretreatment is applied to the preheated
General pipe (maximum 90°C) via a wiper method in an
Blast cleaning to a near white metal finish Sa 21⁄2 in enclosed, ventilated booth designed to meet local
accordance with SSPC-SP10 is necessary to achieve health, safety and environmental regulations. The
the required product performance. In addition, pretreatment enhances the hot water resistance of
during development of the product, it was the 3 layer HDPE coating system.
discovered that a chromate surface pretreatment
enhanced the performance of the 3 layer HDPE
241
Epoxy Application approximately 10 psi (70 kPa) at this stage provides
The two component, solventless, liquid epoxy is optimum adhesion.
pumped through an in-line static mixer to a self
Final Quench
centering application head. A controlled thickness
The final quench reduces the pipe temperature
of epoxy is applied to the bare pipe by the annular
below 100°C or (212°F) to enable the pipe to be
wiper. The epoxy remains liquid through the heating
handled without damaging the coating.
and adhesive application stages but gels prior to the
pressure application. COATING PERFORMANCE
Heating Cathodic Disbonding
The pipe is heated to approximately 150°C (300°F) in The test method followed was essentially that of
order to accelerate the gel and cure rates of the epoxy CSA Z245.20-M86 Clause 12.9 which uses the
primer and to ensure optimum adhesion between individual cell technique similar to British Gas
epoxy and copolymer adhesive layers. Induction coils PS/CW 6. Test duration and some voltages were
provide uniform heating in the straight through (endo) varied to suit the coating system. The test results are
process used for cross-head extrusion. summarized in Table 1 with a comparison to typical
values for FBE coating systems which are generally
Adhesive Application acknowledged to have superior cathodic disbonding
Copolymer adhesive is applied using cross-head resistance. The 3 layer HDPE coating system is seen
extrusion to provide a seamless uniform coating. to be at least as good as FBE.
The adhesive reacts with the uncured epoxy primer
to achieve maximum adhesion. TABLE 1
HDPE Extrusion TYPICAL CATHODIC DISBONDMENT VALUES
High density polyethylene is applied via cross-head Temp. Duration Volts Disbonded Radius (mm)
extrusion in a manner developed over 30 years of (°C) (Days) 3 Layer HDPE FBE
applying the Type A systems. Pipe up to 36 inch (914 20 28 3 <8 <10
mm) diameter can be coated in this process. The 65 2 1.5 <3 <5
cross-head extrusion process produces a tough 65, 28 1.5 <15 <20
seamless outer sheath which provides mechanical
protection and minimizes moisture permeation. Peel Resistance
Method II of DIN 30670 was used to measure the
Initial Quench
peel strength of the coating system. Peel resistance
The initial quench stage is designed to freeze the
was measured from 20°C (68°F) to 95°C (203°F).
outer surface of the HDPE sheath while the
The results are presented in Table 2. Test results
adhesive layer remains molten. This enables the
greatly exceeded the DIN 30670 requirements of 3.5
application of pressure to the outer sheath which
kg/cm at 20°C and 2.5 kg/cm at 50°C in the recent
improves interlayer adhesion, without distorting the
revision (draft) of DIN 30670. In fact, peel
outer sheath.
resistance at 90°C meets the DIN 30670
Pressure Applicator requirement at 20°C indicating the excellent high
Pressure is applied to the coating to improve temperature properties of the 3 layer HDPE
adhesion and peel strength values. Application of coating.
242
TABLE 2
Normal load: 18.6kg
TYPICAL PEEL STRENGTH VALUES FOR 3 LAYER HDPE
Temperature Peel Strength
(°C) (kg/cm) Sandpaper bonded
to upper plate
20 12-15
50 10-12 Upper, movable
plate
80 5-7
95 3-4
Shear Resistance
The “Alyeska” shear test originally developed to Fixed Lower fixed
evaluate heat shrink sleeves for the Alyeska Pipeline backplate plate
was used to evaluate the shear resistance of the 3
Adhesive bond
layer system. Figure 3 illustrates the Alyeska shear
test apparatus. Test results are shown in Table 3. The Sleeve backing
3 layer HDPE coating meets the requirement of
<0.63 mm up to and including 100°C (212°F). Shear load: 6.8kg
TABLE 3
ALYESKA SHEAR TEST RESULTS AT VARIOUS Fig 3 “Alyeska” Shear Test
TEMPERATURES FOR 3 LAYER HDPE COATING
Temperature Movement
TABLE 4
(°C) (mm after 50 hours)
IMPACT RESISTANCE OF 3 LAYER HDPE
80 NIL
90 <0.1 Coating Thickness Typical Impact Resistance
(mm) (joules)
95 <0.1
0.75 4-5
100 0.5
1.0 5-7
Impact Resistance 1.5 15-18
Coated pipe samples were tested in accordance with
CSA Z245.20M86 Clause 12.13. Typical impact Indentation Resistance
values are summarized in Table 4. The impact values Samples were tested in accordance with DIN 30670.
for 1.5 mm of 3 layer HDPE polyethylene meet the Indentation was measured at <0.1 mm which easily
requirements of DIN 30670 for 3 mm thick coating exceeds the DIN 30670 requirement of 0.3 mm
on large diameter pipe, illustrating the superior maximum indentation.
mechanical properties of high density polyethylene.
243
Cold Bend CONCLUSIONS
Coating flexibility at low temperature was evaluated 1. The performance of the 3 layer HDPE
by bending coated pipe samples 4.75°/pipe diameter coating meets the requirements of existing
at -30°C according to CSA Z245.20-M86 Clause standards and matches or exceeds the
12.12 followed by a peel test at 20°C. No significant performance of FBE and other extruded
reduction in peel strength or cracking of the epoxy polyethylene systems.
primer was noted.
2. The use of HDPE in the 3 layer extruded
Hot Water Soak polyethylene construction significantly
One of the major advantages of polyethylene as a improves the cost effectiveness of the
pipe coating is its inherent ability to resist moisture system while maintaining performance
permeation. In order to evaluate the ability of the 3 requirements at reduced coating thickness.
layer HDPE coating system to perform in a hot, wet
environment the coating was subjected to immersion 3. The use of HDPE in the 3 layer extruded
at 100 °C for up to 30 days followed by a peel test at polyethylene system extends the upper
20°C. Prior to immersion the coating was scored to service temperature to 90°C (195°F).
the substrate to allow for water undercutting. No
significant reduction in peel strength was noted. REFERENCES
1. NACE RP0185-85. Extruded Polyolefin
DISCUSSION Resin Coating Systems for Underground
The 3 layer HDPE coating system is able to match or Submerged Pipe.
or exceed the toughest requirements of FBE and 2. DIN30670. Polyethylene coatings of buried
DIN 30670 coating systems. Cathodic disbonding steel tubes, fittings and matching pieces.
resistance, impact resistance and hot water soak
resistance are superior to FBE. Indentation and 3. G. Gaillard, G. Connelly, Paper C2, 7th
impact resistance indicate that 1.5 mm (0.060 International Conference on the Internal
inches) of HDPE will meet the DIN 30670 and External Protection of Pipes (1987).
requirements for 3 mm (0.120 inches) of LDPE or 4. G. Gaillard, G. Connelly, J. Llorens, “3
MDPE. For small diameter pipe, a coating thickness Layer EpoxyPolyolefin Pipe Coatings,”
of 0.75 mm (0.030 inches) will exceed the impact CORROSION/88, Paper No. 309,
performance of the NACE Type A extruded National Association of Corrosion
polyethylene system. The results of peel, shear and Engineers, Houston, Texas, 1988).
hot water soak tests indicate the 3 layer HDPE
coating system is suitable for operating at 5. CAN/CSA Z245.20-M861, External
temperatures up to 90°C (195°F). Fusion Bond Epoxy Coated Steel Pipe.
244
CORROSION 77
The International Corrosion Forum

Devoted Exclusively to the Protection
and Performance of Materials
March 14-18, 1977, San Francisco Hilton Hotel,

San Francisco, California
POLYETHYLENE – EXTRUSION – COATING OF BURIED STEEL PIPE

PROPERTIES, EXPERIENCES, VALUATION
N. Schmitz-Pranghe,
MANNESMANNROEHREN-WERKE AG
DUESSELDORF
W. von Baeckmann
RUHRGAS AG
ESSEN
Fed. Rep. of Germany
245
INTRODUCTION Ageing resistance
Application
One of the important tasks of pipe manufacturers
and pipeline users is to apply the technically best Field coating.
and most economic corrosion protection in order to
Each of these properties and combinations with
assure a longtime usage of the pipelines.
others have to be considered. The requirements
have to be seen from two points of view, firstly under
Fig 1. Data to evaluate pipe coatings aspects of mechanical resistance during transport,
storage and pipe laying and secondly concerning
Mechanical properties Corrosion protection longtime corrosion protection which postulates
tensile strength no porosity knowledge about the constance of the related
elongation electric resistance properties during operation time of the pipelines.
adhesion permeation of H20 and O2
coating thickness cathodic disbonding
POLYETHYLENE COATING
penetration resistance tightness and strength of Polyethylene as coating material has an excellent
counterbalance of properties concerning these
impact resistance coating after loss of adhesion
requirements. They are summarized in Fig. 2 for the
abrasion resisstance cathodic protection
low density polyethylene used by our company.
Especially high values of elongation, impact
Resistance against Field coating resistance, electric resistance, low permeation
ageing due to UV and O2 girth welds coefficients for oxygen and water vapour and the
great temperature application range should be
aggresive soils damaged areas
emphasized.
micro organism
MECHANICAL PROPERTIES
Application process Thermal loads Mechanical resistance is important concerning loads
quality low temperature during storage, transport and laying as well as soil
economics high temperature loads after burying during operation.
temperature cycles The shown properties of low density polyethylene
assure high load-bearing capacity against tension
and deformation during the above mentioned
Fig. 1 summarizes the requirements for corrosion operations.
protection as existing in nowadays or which have to
be regarded as minimum to assure a long operation Additionally very good adhesion and peeling off
time. The different characterizing properties have strength are important. Fig. 3 compares data of
been condensed into the following classes: peeling off strength of polyethylene coatings with
different adhesive types . By this it appears that the
Mechanical properties peeling off resistance depends on the peeling off
Corrosion protection velocity. The special hard type adhesive used with
246
MECHANICAL DATA peeling off resistance in N/cm in lb/inch
Property Unit Value Testing Method
1000
tensile at yield N/mm2 (psi) 11 (1.5 x 103) DIN 53455
11.4 (1.6 x 103) ASTM D 638
ultimate tensile strength N/mm2 (psi) 15 (2.1 x 103) DIN 53455 100
17 (2.4 x 103) ASTM D 638 molten PE - Copolymer
100
ultimate elongation % 500 DIN 53455
600 ASTM D 638
E-modulus N/mm2 (psi) 300 (4.2 x 104) DIN 53455 molten polyolefines 10
280 (4.0 x 104) ASTM D 638 10
shear-modulus N/mm2 (psi) 210 (3.0 x 104) DIN 534455
hardness shore C – 85 DIN 53505
1
1.0
bitumen or butyl - rubber based

CORROSION PROTECTION
Property Unit Value Testing Method 0.1
DIN 53472 0.1
water absorbtion weight % max 0,1
ASTM D 570 0.1 1 10 102 103
gm DIN 53122 test time in minutes
transmission 0,9
water m2 x 24hrs ASTM E 96
vapour gm DIN 53429 Fig 3 Peeling off resistance of various adhesives
permeation x 10-9 2,1
cm x hrs x Torr
cm3 DIN 53380
transmission 1700
oxygen
m2 x 24hrs x ATM ASTM D 4094 our coating process shows the highest adhesion
permeation
cm2
x 10-9 25,9
DIN 53536 values and lowest dependence. Essential reasons to
sec x Torr
develop such a special adhesive were
specif.
cm 1017 DIN 53482
non-displacibility on the pipe surface during
electrical resistance ASTM D 257
temperature cycling, practicability of proof field
coating of girth welds, bending capability with field
THERMAL DATA equipment and suitability to press coated pipe under
Property Unit Value Testing Method highways and railroads.
melting point °C (°F) 111 (232) polar. microscope
Further important properties concerning
low temp. brittleness °C (°F) to -72°C (-98) ASTM D 746
(no cracks) mechanical loads are penetration, impact and
abrasion resistance. They essentially determine the
1,5 to 2,2 x 10-4 data of coefficient
linear expansion
coefficient
1
°C ()1
°F (0.85 to 1,2 x 10-4) material producer required thickness of pipe coatings. Therefore many
cal Btu laboratory and practical tests were conducted with
heat conductivity
cm x s x°C ( )
ft x hrs x°F
8 x 10-4 (0.2) DIN 52612
pipe samples of different polyethylene coating
thickness including:
Fig 2 Properties of low density Polyethylene
(Density 0.933–0.939 g/cm3) Penetration as function of load,
(Melting index MFI/2.16 0.35–0.55 g/10min) temperature and time
Simulation of penetration of sharp edged
stones during pipe laying
247
Falling weight tests with variations of thickness is generally sufficient as will be shown in
falling height, weight and temperature the following. The resistance of the coating against
impact by rounded single stones and by dropping
Drop tests with crushed rock under crushed rock is nearly independent of steel pipe
practical conditions of falling height and diameter for equal diameter / wall thickness ratios.
temperature The required PE coating thickness is 0,9 to 1,6 mm
Mechanical load tests with big inch coated (35 to 63 mils) for single stones of weights between
pipe of O.D. 812 mm (32 in) and 1420 500 and 1.000 g (1,1 to 2,2 lb) and 1,8 mm (71 mils)
mm (56 in) by axial dragging, rolling and for crushed rock of 35 to 55 mm (1,4 to 2,2 in) size
falling on sharp edged crushed rock and and, 50 kg (110 lb) weight.
sandy soil with stones. The practical mechanical transport and laying loads
require under normal conditions 3 mm (120 mils)
minimum polyethylene coating thickness for steel
minimum coating
thickness in mm in mils
pipe of 812 mm (32 in) O.D. and 3,5mm (140 mils)
4,0 160
for 1420 mm (56 in) O.D. With special care during
allowable height of handling and in stonefree soils 2 mm (80 mils)
sharp edged and
3.5 flattened stones 140 respectively 2,5 mm (100 mils) can be regarded as
7/12mm 56” o.D. 7/12mm
3.0 0.27/0.47in 0.27/0.47in
120 sufficient.
6/9mm practical mechanical DIN 30 670
0.24/0.35in
2.5
load tests (normal)
100 Concerning penetration loads by stones in the
32” o.D.
3/7mm
0.12/0.27in
impact resistance
crushed rock 50kg (110lb)
burying material surrounding the pipe surface the
2,0 80
height of fall 2m (6.6ft)
minimum coating thicknesses according the German
1,5 60 standard DIN 30670 (normal range) require
impact resistance rounded stones, 500–1000g (1.1–2.2lb)
height of fall 2m (6.6ft) maximum tolerable stone sizes which can be covered
1,0 40
by the practical burying procedures.
corrosion protection
0 0 In conclusion the performed tests and additionally
0 200 400 600 800 1000 1200 1400 1600 in mm the long time practical experiences show that under
0 0 16 24 32 40 48 56 64 in inch normal conditions pipe size dependable thickness
normal Pipe Size
ranges of the above mentioned German DIN 30670
standard are sufficient and also necessary.
Fig 4 Recommended minimum PE-coating thickness
for various loads effects2
RESISTANCE AGAINST AGEING & MEDIA
The natural ageing of polyethylene especially is
Detailed results of these tests have been published influenced by UV-radiation, i.e. from sunlight,
2)3). Fig. 4 summarizes all discussed loads and oxygen in the air and heat. By additions of stabilizers
resistance properties and shows the resulting and carbon black this ageing can be counteracted.
requirements of minimum polyethylene coating The protective effect will depend on type and
thickness as function of steel pipe diameter. quantity of the additions.
Referring to corrosion protection 1 mm coating In order to test this behaviour, measurements of
248
elongation prior to rupture and melting index of the Moreover, polyethylene possesses excellent
coating after accelerated ageing in the Xenotest resistance to aggressive soils, fresh and salt water,
-equipment at elevated temperatures and with fouling organisms of the sea and soil vegetation as
increased ultraviolet radiation or only in hot air, well as to chemical agents, for which details are
have proved suitable, noticeable changes in these available in publications of the raw material
data being regarded as initial stage of material producers. Special prominence should be given to
deteriorations. the substantial resistance to mineral oils.
full stabilisation
THERMAL APPLICATION RANGE
part stabilisation Recently long-distance pipelines in Arctic regions,
elongation in %
800
e.g. Canada and the Soviet Union, have come into
prominence. The low temperatures prevailing there
600
make exceptional demands on the protection of the
400 steel pipe.
200
0
60°C Xenotest 100°C air-aging impact resistance in N/cm in lb/inch
melting index 140°F 212°F
3 80
2 50
1 60
40
0
1 10 102 103 104 1 10 102 103 104
time in hours time in hours 30
40
20
Fig 5 Elongation and melting index as function of time
20
10
Fig. 5 illustrates such test results. In the case of fully
stabilized polyethylene no appreciable change will
0 0.1
occur during both tests up to duratious of 6,000 -60 -40 -20 0 20 °C
hours, whereas non-stabilized or only partially temperature in
°F
-76 -40 -4 32 68
stabilized types reveal the first deteriorating effects
already after 100 to 1,000 hours, which under Fig 6 Impact resistance as function of low temperatures
conditions of storage in the open air, may already (PE - coating thickness 2.2mm (87 mils), pipe 65/8” O.D.)
cause cracks. Since these short-time tests especially
concerning heat influence will only allow relative Still these requirements can well be met with the
conclusion to he drawn as to the long time behaviour help of PE insulation, as may be seen from Fig. 6
over decades, for safety reasons, fully stabilized concerning the impact resistance, which decisively
polyethylene should be used in pipeline coatings. determines the lower temperature limit.
249
Accordingly the impact resistance will reach a The qualification for application of the proper
maximum value at approx -30°C (-20°F), in order coating is decisively influenced by an investigation
then to drop at -60°C (-75°F) to values as at +10°C into the question as to whether the protective effect
(50°F). can be affected over longer periods of time by
permeability and cathodic disbonding.
Additionally temperature cycling tests were
conducted with PE coated big inch pipe between
-50°C (-58°F) and room temperature respective GENERAL CORROSION BY OXYGEN AND
+65°C (+150°F). Also under these conditions the WATER PERMEATION
coating performed well. In general corrosion of steel necessitates the
From all investigations concerning temperature presence of oxygen. On the basis of permeation data
dependance it may be inferred that for PE-coating of the polyethylene which are shown in Fig. 7, it is
an overall temperature range can be indicated as theoretically possible, to calculate a maximal surface
65°C (150°F) to lower than -40°C (-40°F). oxidation rate of 6µm (0.24 mils) per year, given a
polyethylene coating thickness of 1 mm (40 mils). In
reality this oxidation rate is not reached on account
PROTECTION AGAINST CORROSION of inhibiting influences. Observations made during
The corrosion protection supplied by the coating practical use show, according to Fig. 8, an amount
must be fully efficient and trouble-free over longer which is only about 10% of the theoretical value. For
periods of time. Therefore it is intended to keep mere reasons of corrosion protection a polyethylene
away from the pipe surface any environmental coating thickness of 1 mm (40 mils) will therefore be
substances that may cause corrosion attack such as sufficient even though working from the above
oxygen, water and salt solutions. Additionally the maximum estimate, for safety aspects.
coating must be compatible with any specified
additional precautions as for instance the drainage
of stray currents and cathodic protection. coating type permeation of
It is, however, a well established fact that all organic H20 in 10-9 02 in 10-12
substances reveal permeation rates for oxygen and g - cm-1 - h-1 - Torr-1 cm2 - s-1 - Torr-1
water vapour. Moreover, we know that, as a result of

mechanical injuries going as far as the steel surface high density 0,6 – 1 10 – 15
PE
and which are, as a matter of fact, unavoidable low density 2–3 24 – 27
during pipelaying operations, in particular of large- PP 2 12
size pipe and in rocky soil, adhesion can be lost by
PVC, plastified 20 – 50 3
what we call alkaline or cathodic disbonding.
Investigations we have carried out have shown that powder 3 – 10 0,5 – 0,8
EP
this behaviour is likewise a general property of all liquid 2–6 –
organic coating substances, the salt content of the coal tar / PU 14 6
soil or the cathodic protection potential chosen
being of greater influence than the type of adhesion
Fig 7 Impact resistance as function of low temperatures
agent. (PE - coating thickness 2.2mm (87 mils), pipe 65/8” O.D.)
250
oxidation rate in µm in mils coating type disbonding *)
5 0.2
in mm in inch
4 PE-extruded 8 – 21 0.3 – 0.8
Asphalt 27 – 45 1.1 – 1.8
3 EP - powder 9 – 25 0.4 – 1
Coal Tar / PU 6 – 12 0.2 – 0.5

1
2 *) Diameter of disbonded coating minus diameter

of artificial damage 5mm (0,2in) after 30 days in
1% NaCl + 1% Na2SO4 + 1% Na2CO3 solution
1 Polarisation with magnesium anode

Potential U – 1.45 to – 1.55V
Cu/CuSO4
0 0 Fig 9 Cathodic disbonding test (ASTM G8) of different coatings

0 2 4 6 8 10
operation time in years
behaviour the ASTM-disbonding test G8 frequently
Fig 8 Oxidation rate of buried PE-coated steel pipe is used. In this test an artificial damage of 5 mm (0,2
(1mm (39 mils) coating thickness) in) is used and the samples are polarized in a
chloride-sulfate-carbonate solution for 30 days.
Fig. 9 gives results of such an investigation with
DISBONDING AT COATING DAMAGES different coating types.
If the coating is holiday free, no additional
Beside direction and level of polarisation also the
protection by cathodic polarisation is needed.
medium is important. Tests conducted in our
However, during transport, laying operations and
laboratories showed that the disbonding is caused by
soil movement after burying coating damages may
cathodic areas with high pH-values caused by
occur and practical experience has shown that this is
differential aeration cells. The center of the damage
unavoidable. In these cases the corrosion protection
reacts as local anode and the rim as local cathode.
is obtained by cathodic polarisation.
The enlargement of the disbonded area is also
On the other hand the question could raise whether
influenced by hydroxyl ions caused by reduction of
any coating is necessary because the cathodic
oxygen which permeates through the coating.
protection generally should be sufficient alone.
However it can be shown that the equipment and Additionally the tests showed that alkaline ions are
high protection current in such a case would be necessary together with hydroxyl ions to create
uneconomic and could effect interference to other disbonding.
pipelines located nearby.
All tests revealed that between the non adhesive
Technical publications mention that caused by coating and the steel surface,a non corrosive water
cathodic protection the coating adhesion is lost in film exists. In no case rust formation could be
the surrounding of damages 5–7). For testing this established. Beside this kind of disbonding at
251
influencing disbonding transport through material
coaltar-epoxy or -polyurethane are susceptible to
factor at coating damages electroosmosis/permeation permeation or electroosmosis but more resistant
concerning disbonding.
enforced
alkaline but corrosion protection
pH Value no specific effect
acid
lowered CATHODIC PROTECTION AT COATING
but corrosive
cathodic
enforced enforced, possible
DAMAGES WITH DISBONDING
but corrosion protection
polarisation lowered
blistering of thin-film Concerning disbonding it is essential whether the
anodic coatings
but corrosion accelerating cathodic protection is effective in crevices under
aerated alkali-salt lowered by
solution
enforced
high concentration
such disbonded coatings. The protective current is
non polar coating mat- restrained by the geometric situation. Corrosion
susceptible lower susceptibility
erials i.e. PE, bitumen danger, however, is only existing if the potentials are
polar coating materials
i.e. EP, coal tar PU, lower susceptibility susceptible
coal tar EP
potentiostat U1 measured oxygen diffusion stream
jO = -4f D grad c
Fig 10 Different parameters and effects concerning = -0.9 V 2
disbonding of plastic coatings corrosion protection stream
j = -x grad U
U2 measured k
coating damages also exists adhesion loss by jO
2 4f D c
Fe R2
permeation of water and oxygen. (cathode) R1 anode
jk x U
f = Faraday constant
These phenomena both have been intensively, = 1,1 A . d (d=1 day)
tested concerning the influence factors and coating crevice of D =
=
diffusion constant
1 cm2 . d-1
disbonded
performance. The results are summarized in PE-coating x =
=
el. conductivity of electrolyte
10-4Ω -1 . cm-1
Fig. 10. Cathodic protection enforces the disbonding c = O2 concentration difference
= 10mg . I-1 ( I = 1 litre)
whereas it is lowered by anodic polarisation. electrolyte U = potential difference in crevice
(soil water) = 50mV
However in this case there will be corrosion.
Concerning transport processes. cathodic as well as bonded ⇒ j ≈ 3jO
2
PE-coating k
anodic polarisation enforce adhesion loss because of
electroosmotic behaviour. pH values have similar testing device
effects as polarisation. Alkaline media enforce
disbonding whereas acid media lower it but are
corrosive. Concerning transport processes pH values Fig 11 Relation between cathodic protection current and
oxygen diffusion at coating damages with disbonding
don’t have a significant influence. Aerated alkali (according W. Schwenk5)7))
salt-solutions in high concentration enforce the
disbonding but lower the transport processes. very positive and if enough oxygen is present.
Because for oxygen diffusion the same differential
The coating materials can be defined roughly in two equations are valid as for the protective current 5),
classes, polar and nonpolar materials. Nonpolar the derivation in Fig. 11 results in the equation
materials like polyethylene and bitumen are
somewhat susceptible to disbonding but have low jk ≈ 3j
O2
transport coefficients. Polar materials like epoxy This relation shows, that the cathodic protection
252
current in any case should be greater than the potential (Cu/CuSO4)in mV
oxygen diffusion current. The assumed electric
cathodically protected area
conductivity is very low if one has in mind that the -900
observed films under disbonded coatings are very
alkaline and have a considerable greater 1m (3ft) distance from
cathodically protected
conductivity. The assumed potential difference of 50 -800 area beneath disbonded
coating [1,5mm duration of
mV results from the consideration, that under an (60 mils) crevice] polarisation
external potential U Cu/CuSO4 = -0,9V a security of 7d

-700
50 mV exists to the limit of the protection potential. 13 d
5h
The validity of the equation between protection <1 h
-600
current density and oxygen current density has been 0 5 10 in cm
0 10 20 30 70 80 90 100
veryfied by a special test. Fig. 11 schematically shows 0 2 4 in inch
test duration in days
the experimental method. Between steel and distance from cathodically
protected area
polyethylene of a coating thickness of 2 mm (80 steel surface: without mill scale with mill scale
mils) a 1,5 mm (60 mils) wide crevice exists which is m NaHCO + m Na CO : 25°C
3 2 3
200 200
filled up by an electrolyte. The protective current is
introduced by a platinum anode at the plastic
coating. The potential is controlled by a reference Fig 12 Efficiency of cathodic protection under disbonded
electrode R1 at this position to a value of PE-coating
U Cu/CuSO4 = -0,9V.
of a steel surface covered with mill scale, however, a
The steel potential in the crevice is determined by a
sufficient polarisation is not possible because the
second reference electrode R2. Because the
cathodic protection current is not sufficient for the
reference electrode R1 is fixed at the surface, the
reduction of the mill scale. From these test results
potential of the steel in the depth of the crevice is
the conclusion can be drawn, that under the
uncontrolled.
condition of a blasted steel surface free of mill scale
Fig. 12 shows the test results. A diluted solution of and a holidayfree polyethylene coating a cathodic
sodium bicarbonate and sodium carbonate of protection in the crevice between steel and coating is
concentration m/200 was chosen as test medium. possible.
This solution has a conductivity, which is lower by a
Basing on these results a valuation of such thickfilm
factor of 50 than in the case of a concentration of
PE-coatings according the cathodic disbonding test
m/2.
ASTM G8 has minor importance.
Therefore it can be assumed, that the relatively
This test procedure 5)6)7) theoretically is applicable
great crevice of 1,5 mm (60 mils) compared to the
to all coating types and gives the most important
practical crevice dimensions is compensated by the
result, whether cathodic protection is effective is
diluted solution. The results in Fig.12 show, that in
areas of disbonded coatings surrounding damages,
the case of an oxygen free steel surface complete
which cannot be wholly excluded.
polarisation of the crevice down to a depth of 1 m
(40 in) will be reached after short time. In the case Resulting from the fact, that no coating can be
253
buried without any damages or imperfection in the
UCu/CuSO in V
field coating it follows that also in the case of 4
-0.6 SCC
polyethylene coating the combination with active in ammonium
carbonate
cathodic protection is optimal. Polyethylene coating, SCC
in SCC
because of its holidayfreeness and low susceptibility -0.7 carbonate- in
bicarbonate nitrate
to mechanical damages has high electric coating
resistivity. This facilitates protection. The current -0.8
consumption is very low. Usual values of the specific
surface resistance of polyethylene coating, which
define the current consumption, are about 1010 Ω m2 -0.9 criteria of cathodic protection against SCC
in alcaline-
(1011 Ω ft2) after coating application in the mill and general carbonate
105 to 106 Ω m2 (107 Ω ft2) in buried condition -1.0 SCC

corrosion attack
according practical experience of German pipeline in
NaOH
companies. The low protection current requirement
-1.1
remains constant over long time.
PROTECTION POSSIBILITIES AGAINST SCC -1.2
It has been published 8)9) that intercrystalline stress

Fig 13 Critical potential ranges for SCC
corrosion cracking (SCC) of high pressure gas pipe
lines behind compressor stations may have been
caused by disbonding of corrosion coatings. be present in special soils seems to be not possible
under practical conditions. Constant strain rate
According to available informations, however. in all laboratory tests 9) have shown however that the
cases high operation temperature, cathodic SCC susceptibility for sodium hydroxide and
protection and high mechanical load with additional alkaline carbonates depends on temperature. As
slow pressure variations can be expected as result, limiting the maximum temperature to about
additional influences. 40°C (105°F) protection could be achieved.
Fig. 13 summarizes possible corrosions types.
Stress corrosion cracking can be induced by:
REQUIREMENTS FOR HIGH QUALITY
POLYETHYLENE PIPE COATINGS
Fertilizers, like nitrates and amonium salts
As a result of research and long time practical
Alcaline bicarbonate - solutions experiences in Germany we have recognized the

requirements to be met by a pipe coating of high
Sodium hydroxide alcaline carbonates
quality which are shown in Fig.14. The first
under special conditions
condition is a clean abrasive blasted pipe surface
The shown potential ranges for SCC are typical for free of mill scale. The polyethylene extrusion
the nominated classes of media. Complete coating shall have a minimum coating thickness of 2
electrochemical protection both against general or mm (80 mils). It has to be holidayfree and to fit
pitting corrosion and SCC in these media which may mechanically strong and tight around the steel pipe.
254
Abrasive blasted pipe surface Property Requirements
surface preparation removal of oil, grease, loose scale and humidity
PE – extrusion coating ≤2 mm (80 mils) thickness, mechanically blast cleaning Grade 2 according to DIN 18 364
resistant, stable, no porosity SA 21/2 according to SIS 05 5900
near white according to BS 4232/67
Low susceptibility to mechanical damage during transport, storage
and laying operation minimum coating nominal pipesize normal reinforced
thickness ≤100mm (4 in) 1,8mm (70 mils) 2,5mm (100 mils)
Controlled cathodic protection < -0.9V off-potential ≤250mm (10 in) 2,0mm (80 mils) 2,5mm (100 mils)
≤500mm (20 in) 2,2mm (90 mils) 3,0mm (120 mils)
Upper temperature limit during pipeline operation ≤750mm (30 in) 2,5mm (100 mils) 3,5mm (140 mils)
≤750mm (30 in) 3,0mm (120 mils) 3,5mm (140 mils)
ultimate elongation ≤200% PE-extruded
≤100% PE-fusion bonded
impact resistance falling weight, sphere shape ø 25mm (1 in)
falling height 1m (3 ft)
≤5 N m/mm (9 ftlb/100 mils) PE-coating thickness
Property Requirements
Fig 14 Requirements of high quality pipe coating
penetration penetration, metal stud 1,8mm (70 mils) ø
The polyethylene material shall be ageing resistant. resistance load 10 N/mm2 (1422 lb/in2) after 24 hrs
≤0,3mm (12 mils) PE-extruded
The coating thickness has to be adjusted to the ≤0,15mm (6 mils) PE-fusion bonded
practical loads during transport, storage and laying peeling off quality grade A: ≥20 N/50mm (4 lb/2 in) strip width
operations to secure mechanical resistance and low grade B: ≥175 N/50mm (39 lb/2 in) strip width
susceptibility for damages. High adhesion of the holiday test no holidays with 25 KV high voltage testing
coating is necessary. As further requirements 13) the setting a.c. or d.c.
pipe line shall be cathodically protected (checked electrical resistance ≥108 Ωm2 (109 Ωft2) after 100 days
in 0,1m NaCl-solution
off-potential ≤ -0,9V). Finally an upper temperature
resistance against the melting index measured after 800 h
limit of 40°C (105°F) during pipe line operation light-heat ageing Xenon-test exposure shall not be changed
should not be exceeded. more than±25%
GERMAN STANDARD DIN 30670 FOR Fig 15 Requirements for Polyethylene coated steel pipe
according to German standard DIN 30670
POLYETHYLENE COATING 4)
Because polyethylene coated steel pipe is broadly continous flow process, simultaneously a coating of
used in Germany a special coating standard DIN a special hard type adhesive serving as bonding
30670 has been established by the German Institute agent – in the present case a PE-copolymer – and a
of Standardization (DIN). The requirements stated layer of low density (HD) polyethylene are extruded
are summarized in Fig.15. A similar European onto the peened steel tube surface which has
standard is being worked out. previously been heated to approximately 200°C
(390°F). This operation is followed by water cooling,
MANUFACTURE OF PE-MILL COATING quality controls in order to verify coating thickness,
The manufacture at the Mannesmann pipe works in absence of holidays and tube end finish prior to
principle is effected in such a way that, in a shipping the pipe to the storage yard.
255
extrusion press extrusion press extrusion press extrusion press
for adhesive for polyethylene for adhesive for polyethylene
film-extrusion slits
(for adhesive and PE)
peened and PE - coating
heated pipe
PE film
adhesive film
adhesive
peened and press roll

heated pipe PE - coating
Fig 16 Oblique-head extrusion process Fig 17 Extrusion and wrapping process
We currently use two different processes, which FIELD COATING OF GIRTH WELDS
distinguish themselves by the peculiar method by For purposes of field joint coating well-tried
which the coating is applied. processes suggest themselves for polyethylene
The oblique-head extrusion process is illustrated in coated steel pipe such as insulation with bitumen or
Fig. 16. In this case adhesive and PE-coating, in the plastic wraps, which in the cold process are mostly
shape of seamless sleeves, are being continuously applied on a butyl rubber based adhesive, or in the
and simultanously extruded onto the tube which hot process by melting on the insulating material.
passes through the special ring (circular) slot dies of Irradiated PE shrink-sleeves and two component
the extruders. Fig. 17 shows the second process by duromeric resins have also proved effective.
extrusion wrapping. Here adhesive and polyethylene,
as continuous strip material from two slot dies of the EXPERIENCE MADE WITH POLYETHYLENE
extruders, are helically wound onto the tube which COATED PIPELINES
slowly revolves and advances in longitudinal direction. Advantages in pipeline construction and
The adhesive layer covers the entire steel surface. The operation
polyethylene jacket fuses together from several
In the Federal Republic of Germany, the pipe
individual layers to result in a uniform coating which
manufacturers normally deliver coated pipes to the
firmly adheres to the steel tube.
site. Until late 1960, when plastic coating materials
According to these application processes we are able were developed, glass fibre reinforced bituminous
to coat pipe from 12 to 1620 mm (0,5 to 64”) O.D. coatings were mostly used. Because the pipelines
256
normally were bedded in sand, this type of coating impregnated with butyl rubber adhesive are
and the application of cathodic protection in most particularly suitable, because they do not only
cases were sufficient to protect the pipelines from provide a good bond to the pipe surface, but because
corrosion. the different layers fuse and are, therefore,
practically a continuation of the polyethylene pipe
After development to the stage of economical and
coating 12).
proof production mill applied polyethylene coatings
have now been in use in the Federal Republic of According to the new pipe laying regulations
Germany for about 15 years and steadily increased contained in work sheet G 463 of Deutscher Verein
in used quantity. Resulting from practical von Gas - und Wasserfachmännern (DVGW), the
experience, main reasons for the broad application coating used when the trench may contain rocks,
of this coating type are the good mechanical must have good penetration and impact resistance
properties, expectally penetration and impact properties, (like e.g. polyethylene), if the pipeline is
resistance which proved as advantages during not bedded in sand 13). When pipelines are laid in
transportation, handling, storage and pipe laying rocky areas, the bottom of the trench must be as
10). Field bends of 1.5°/pipe diameter can be smooth as possible and no rocks shall protude into
manufactured without damage to the coating or the trench; if required, soil which does not contain
disbonding. The progress of pipeline construction rocks, must be filled into the trench to provide for
could be accelerated, because the amount of repairs the smoothness required. Damage to the pipeline
in the field is very low. Additionally high quality coating may, however, also be prevented by sand
production and inspection together with the bags, styrene material or used car tyres filled with
material properties well meet the application sand which are placed at the bottom of the trench, if
requirements. Ruhrgas as main German Gas it is too expensive to obtain soil without rocks.
Pipeline Company has built polyethylene coated big
An additional advantage of polyethylene coating is
inch pipelines (greater 750 mm (30”) O.D.) of about
the fact that it can be used over a wider range of
1.000 km (600 miles) in length since 1970.
temperatures; in particular, this material is used
Girth welds of pipelines burried in sand or clay soils downstream of compressor stations where the gas
are normally coated by Ruhrgas by the application temperature is often increased by the operation of
of special bituminous tapes modified by plastic the compressors. Ruhrgas always installs air coolers.
material 11). So the temperature cannot exceed a certain limit.
This type of field coating is sufficient in soils where Nevertheless, the field coating tape must have the
the coating material is not subject to mechanical same temperature resistance to prevent softening or
stress. In addition to the special bituminous tapes, peeling off at elevated temperatures behind
rock-shielding tissue made from porous plastics is compressor stations greater 30°C (86°F)
used in rocky areas. Sometimes, self-adhesive
Due to the good bonding properties and the smooth
polyethylene tapes additionally are wrapped round
surface of polyethylene coatings with hard type
the special bituminous tapes. If polyethylene tapes
adhesives the pipes coated with this material can be
are used, the minimum layer thickness of the
installed more easily under roads and railway lines
multi-wrap coating is 1 mm. Polyethylene tapes
without the use of casings. At casings, faults in the
257
cathodic protection system occur quite frequently
even if the carrier pipe is insulated from the casing.
For this reason, it is usually better to push the carrier
pipe under roads or railway lines without the use of
casing, if the soil does not contain rocks. The
polyethylene coating will not even be damaged in
the area of the cutter; on the other hand, holidays
may occur at the field joints. Therefore special field
coating with smooth surface is necessary.
Before the carrier pipe is welded to the rest of the
pipeline, it is essential to show that the pipe coating
was not damaged in order to avoid problems of
cathodic protection. For this reason, a feed-in test is
made prior to the welding operations; the
polarization data, average current densities and
-200
coating resistivities are measured. The coating v
resistivity usually is higher than the average coating -1,50
ON POTENTIAL
resistivity of transmission lines.
UR - Cu
-1,00
-0,85 OFF POTENTIAL
POLYETHYLENE COATINGS AND CATHODIC 1,0A 0,8A
LINE CURRENT
1,0A 1,1A
0,60
PROTECTION 0 50 100 150 200 250 km
For polyethylene-coated pipelines the electrical
coating resistance is considerably high and therefore
Fig 24 Potential graph of Polyethylene-coated pipeline
the corresponding current requirements for
cathodic protection are low. The reasons are lower
density and size of coating holidays because of protection stations have been switched off are both
mechanical resistance of PE. Fig. 23 as example indicated in the table. The coating resistivity is
shows data of some transmission lines in the Federal determined by dividing the difference between the
Republic of Germany; the table contains the current on-potential and the off-potential by the current
requirements and the coating resistivities after start density.
up of the cathodic protection and operation time up
In the Federal Republic of Germany, cathodic
to 10 years. The coating resistivity of
protection is required for crude and product
polyethylene-coated pipelines is higher than 100 km
pipelines by the authorities in the Technical Rules
even after the above mentioned service life.
for inflammable liquids No. 301 14) and for gas
Fig. 24 shows the cathodic protection potentials of a transmission pipelines operating at a pressure above
polyethylene coated pipeline; the on-potential 4 bar (43 psi) by DVGW in the Technical Rules No.
measured when the cathodic protection stations G 462 11 15) and G 463 13. The cathodic protection
supply current to the system and the offpotential is, therefore, not only required for economic reasons
measured approx. 1 sec. after the cathodic but also for safety reasons.
258
The pipe coating must not contain any major frequently used for about 15 years. Fig. 26 shows
holidays to make sure that the entire pipeline will be that the spread of the cathodic protection system of
protected. For example at major holidays in a polyethylene-coated Pipelines is considerably large.
bituminous coating in rocky area, the cathodic For this reason, the spacing of cathodic protection
protection potential required was not reached stations may be wide and the current required for
although the potential measured at the test points at the protection of pipelines in lakes, moors and
a distance of approx. 1km was in accordance with off-shore may also be generated by impressed
the specifications. Actually, corrosion (i.e. 3 mm current stations (cf. Fig. 26).
pitting after 6 years) caused by such unsufficient
polarisation was found in chemically aggressive soils.
Studies showed that the potential distribution at
coating holidays may vary considerably; the SUBMARINE WATER PIPELINE MISCHAN ISLAND
KUWAIT – FAILAKA ISLAND
insufficient potential is not necessarily measured at
distant test points. This was one of the reasons for SALMIYAH TRANSFORMER/RECTIFIER
20V/40A
the decision to use coating materials of greater
mechanical strength. If the pipeline is coated by 103/4”/0.63” WATER PIPELINE FAILAKA
polyethylene material, the on-potential is, in ISLAND
Range of cathodic protection with one sited current feeding

general, adjusted to a voltage of less than -1.2 V ARABIAN GULF
(measured by reference to a copper/copper sulphate 5
electrode located on the ground). Due to km 103/4”/0.63”
2
the-voltage drop in the soil, the on-potential may,
however, not provide sufficient information on the 102
potential at the coating holidays which is more 5 l = f(is)/∆U Drainpoint =1V
positive 16). This has been verified by potential
2
measurements at unburied coating damages. For
this reason the regulatory authorities require a 101
PE-coated
minimum off-potential of -0,85 V. Experience has 5
Bituminous-coated
shown that the off-potential of polyethylene coated
2
pipelines is in general -0,85 V to -0,95 V (Cu/CuSO4
reference electrode), if the on-potential is less than 100
5 103 2 µA/m 5
2
2 5101 2 5 102 2
-1,2 V. No corrosion pitting has so far occured in Protective current density
polyethylene-coated pipelines as a result of Range of cathodic protection of bituminous and PE-coated pipelines
insufficient cathodic protection.

Fig 26 Spread of cathodic protection system
In the Federal Republic of Germany, the current
required for the cathodic protection of pipelines is
usually supplied by impressed current stations. In
the event of stray current interference due to the
existance of direct current railway or tramway
systems, potential-controlled rectifiers have been
259
U 30 holiday in the coating
∆U in mV
10m 20
10
0 50 100 150
Fig 28 Voltage field of polyethylene-coated pipeline and

unburied detected holiday
holiday in the coating

Coating holidays are usually the reason for high
A20 current requirements, if the pipeline is isolated by
insulating joints. At the holiday, a considerable
B2
voltage drop exists in the soil; this voltage drop can
be located exactly by two electrodes (usually spaced
A10
at a distance of 10m over the pipeline); d.c. and a.c.
10m
methods are used (Fig. 27). If the d.c. method is
used, the cathodic protection station should be
B1 switched on and off at regular intervals to eliminate
the difference in voltage between the reference
A0 electrodes and the direct currents in the soil. If the
6V=
30-100V
pipeline is coated by polyethylene, even very small.
holidays of some mm2 may be located easily
(Fig. 28). In this case a detected damage of the
coating in rocky soil has been unburied. As can be
20m seen the sensitivity of the method was proofed. Even
the size of holidays can be determined by measuring
the on-potential and the off-potential at the located
Fig 27 Method of locating coating holidays holiday.
The cathodic protection systems of pipelines are
maintained in accordance with DVGW work sheet
In general, silicone-iron anodes installed near the
GW 1018). Impressed current cathodic protection
surface in coke backfill are employed in groundbed
stations are inspected at monthly intervals. The
stations. Deepwell anodes are sometime installed in
pipe-to-soil potentials are measured each year at the
very high resistivity soil or in hotspot applications
test points spaced at 1 to 2 km distances. Due to the
(compressor station piping or casings), if the
large number of surveys made, Ruhrgas evaluates
resistivity of the soil is lower in greater depths. A
the results of the survey by computer; plotters are
followup survey of the cathodic protection system
used to produce the graphs required.
(on-potential and off-potential) is made some
months after the start-up of the impressed current Summarizing in actual practice the following
cathodic protection stations. essential advantages of polyethylene coatings have
260
proved their worth: type of coating
PE PE Coal Asphalt Tar/EP Tar/PU EP
High mechanical resistance and adhesion extrudes sintered Tar sintered
coating thickness 1,8-3,5 1,8-3,5 4-6,5 4-6,5 0,5-1 1-2 ≤0,4
as required in modern pipeline in mm (mils) (70-140) (70-140) (160-260) (160-260) (20-40) (40-80) (≤16)
construction during transportation, cost of raw + + + + + + – – + –
storage and laying operations. material
application + + + + + + + ++
High resistance to electric currents. The process
cathodic protection current requirements mechanical

properties
+ + + + – – – – – – + –
are very low. The protective current corrosion + + + + – – + + + –

requirements measured over longer protection
periods on buried pipelines remain at an temperature + + – – – – – – + –

range
almost constantly low level. field + + + + + + + – + – +
coating
High mechanical and ageing resistance in
pipe + + + + + – + – + +
case of fully stabilized PE. laying
longtime + + + + – –
Low permeation rates for oxygen and experience
water vapour. Broad temperature summarized + + – – + –
valuation
application range.
Fig 29 Valuations of various pipe coatings
VALUATION OF VARIOUS PIPE COATINGS
As known, various types of material and application
techniques have been used traditionally or
developed and tested as steel pipe coatings for
corrosion protection. Based on our tests and References
experiences in Germany as well as published results 1) V. Hauk, W. Meyer and W. Schwenk.
we have tried to give a semiquantitative valuation, Testing of coated steel pipe,
shown in Fig. 29. Materialprüfung 16, p. 6-10 (1974).
In many cases the valuation of a parameter gives a 2) E. Günther, W. Meyer, W. Quitmann and
mean value over several criteria. As a result of these N. Schmitz-Pranghe. Required thickness
considerations we extract advantages for of polyethylene coated steel line pipe, 3 R
polyethylene coating taking into account all international 13, p. 128-131 (1974).
parameters which in our opinion are relevant for
V. Hauk, W. Meyer and W. Schwenk.
pipeline coating.
Required coating thickness for external
In conclusion, thanks to intensive research and protection of buried line pipe with
technical development and positive long time polyethylene, Proceedings of the First
practical experience mill coating of steel pipe with International Conference on the “internal
polyethylene in combination with cathodic and external protection of pipes”,
protection represents a safe and economic corrosion University of Durham, Paper B2-11/20
protection of buried steel pipelines. (1975).
261
3) N. Schmitz-Pranghe, W. Meyer and 9) R. Pöpperling and W. Schwenk.
W. Schwenk. Mannesmann approach to Discussion of possible causes for stress
extruded PE mill coating, International corrosion cracking of buried pipelines
Pipeline Industry, p. 40-43 (March 1976). with elevated temperatures, Werkstoffe
und Korrosion 27, p. 81-85 (1976).
4) German tentative standard DIN 30670
(1974). Polyethylene Coating of steel pipe 10) R. Beysel. Pipeline coating considerations
for gas and water, BeuthVertrieb, Berlin. by pipeline constructors, paper presented
at the “ Moderne Korrosionsschutzumhü
5) W. Schwenk, Influence of adhesion for
llung für erdverlegte Rohrleitungen”
thick film coatings concerning corrosion
conference on 16 October 1975, Haus der
Protection of buried steel pipe, Rohre,
Technik Essen, ZFGW-Verlag GmbH,
Rohrleitungsbau, Rohrleitungstransport
6000 Frankfurt/M. 90.
12, p. 15-20 (1973).
11) Kebulin-Gesellschaft. Information 10 and
6) W. Schwenk. Possible effects of cathodic
Dipl.-Ing. E.Vogelsang GmbH, company
protection on corrosion protection
journal (October 1976).
coatings, 3R international 15, p. 389-394
(1976). 12) G. Heim. Paper presented at the
“Moderne Kunststoffumhüllung für
7) W. Schwenk. Influence of coating
erdverlegte Rohrleitung” conference on
disbonding on corrosion protection of
16 October 1975, Haus der Technik
pipelines and technical importance,
Essen, ZFGW-Verlaq GmbH, 6000
gwfgas/ erdgas, will be published.
FrankfurtIM. 90.
8) Proceedings Fifth Congress, American
13) G 463, Technical rules for the
Gas Association Houston, Texas
construction of gas steel pipelines
(Nov.1974).
Operating at pressure of more than 16 bar
R. Fessler. Studies reveal causes of (1975), ZFGW-Verlag GmbH, 6000
stress-corrosion cracking, Pipeline Frankfurt/M. 90.
Industry, p. 37-39 (March 1976).
Technical rules for flammable liquids no
Combination of conditions causes 301, “Rules for pipelines for the
stress-corrosion cracking, The Oil and transmission of hazardous liquids” (1971),
Gas Journal p. 81-83, February 16 (1976). Karl Heymanns-Verlag KG, 500 Köln 1.
262
15) G 462 11. Technical rules for the
construction of gas steel pipelines
operating at a pressure of 4 to 16 bar
(draft 1975), ZFGW-Verlag GmbH,
6000 Frankfurt/M. 90.
16) W. V. Baeckmann. How Ruhrgas
cathodically protects pipe lines,
International Pipe Line Industry
(January 1976).
17) W. Schwenk and H.Ternes. Test procedure
for detecting coating holidays of buried
pipelines, gwf-gas/erdgas 108 (1965).
18) GW 10. Rules for the maintenance of
cathodic protection systems of buried
steel pipelin.es (1971), ZFGW-Verlag
GmbH, 6000 Frankfurt/M. 90.
263
POLYETHYLENE COATINGS IN EUROPE
A LOOK BACK ON 30 YEARS OF EXPERIENCE
By Dipl-Ing Johannes G Haimbl1 and Dr Johanns Geiser2

1
Eupec Pipe Coatings GmbH, Essen, Germany
2
Ruhrgas AG, Essen, Germany
PREVENTION OF PIPELINE CORROSION CONFERENCE
Marriott Westside Hotel

Houston, Texas
October 31 – November 2, 1995
Organized by
Pipe Line & Gas Industry
&
Pipes & Pipelines International
264
POLYETHYLENE COATINGS IN lower In comparison with bitumen coating. Most
coating defects are located on field-joint coatings.
EUROPE For pipelines with high-quality coatings, the
measures against ac interference caused by nearby
A LOOK BACK ON 30 YEARS OF high voltage lines are generally more complicated
EXPERIENCE AND RECENT DEVELOPMENTS and expensive. In a few cases, disbonded coating has
IN POLYOLEFIN COATINGS been found. Corrosion or stress corrosion cracking
of steel under disbonded coating was not observed.
Two-layer and three-layer polyethylene (pe) coating
systems have been successfully applied in
Continental Europe for more than 30 years, while in PART 1
the USA and in the UK fusion-bonded epoxy (FBE)
coatings prevail. The three-layer pe coating INTRODUCTION
philosophy is explained with its specific features and
advantages that lead to the so called “purpose Extruded pe coating has been used for the
designed” coatings for the specific laying and protection of steel line pipe in Germany and other
operational conditions of a pipeline project. Continental European countries since the beginning
of the 1960s. Whereas in the US its use was limited
Taking into consideration the properties required of to the smaller pipe diameter range for many years,
a high-quality coating, comparative testing has in Continental Europe plants were built which
shown that multi-layer pe or pp coatings represent enabled the polyethylene-based passive corrosion
an optimum solution to the related problems. In the protection to be employed even for the largest line
Continental European coating philosophy, pipe sizes. This was partly due to the fact that the
mechanical impact resistance is the most important soft adhesive used in the US was not suitable for
single service property of a coating system. In this application to larger and heavier pipe.
respect, multi-layer polyolefin coatings afford a wide
safety margin and stand up even to unforeseeable Where as in Continental Europe, the
mechanical loads. previously-used bitumen was predominantly
replaced by polyethylene (pe) in thicknesses from
Decades of constant, extremely low protective 1.5 to 3.5mm, the coal-tar enamel coating which was
current requirements for correctly laid used in the US and the UK has been partly replaced
large-diameter pipelines give proof of the excellent by the typical 14-mil (0.35-mm) thick pipe coating of
service properties of multi-layer polyolefin coatings. epoxy resin.
The current required for cathodic protection of However, for line pipe, coal-tar enamel coating is
pe-coated pipes is low in comparison with still being used, especially in North and South
bitumen-coated pipelines. The long-term behaviour America. In Continental Europe, the processing of
of the insulation resistance is constant. coal tar in pipe coating was abandoned many years
A summary of investigations done on Ruhrgas’ ago, due to the carcinogenic properties of these
pipelines shows that the quantity and size of coating materials and the resulting health hazards for
defects on pe-coated pipelines are considerably persons working with them.
265
Fig 1. Corrosion protection for steel line pipes – Fig 2. Impact resistance as a function of coating
requirements profile thickness – PE vs FBE
100
PE, δ = 0.95
Inde tance to
n
Resis
ersio
imm f ter
90
ntati
a
PE, δ = 0.93
hot wdhesion
on re abrasion
ater
80
Im ce
sista
pa
tan
A
ct
res sis rier
ist
an nce c a l re bar 70
i n
ce ctr sio
Ele Diffu
60
Service temperature
Ambient temperature RT (50 years design life)
30°C 50°c [Nm] 50
-0/+
60
65°c
60°C
0m
/cm
-25/+ 80°c
m
5N
80°C Ca 100°c
40
-40/+
>3
tho
20
th
ng
0m
dic
tre th)
m
dis
n s reng bo
10
o
/cm
i
s t nd
0m
30
he d s
Agein
0N
me
m
Ad (Bon
ility
Defo dability
>5
nt
10
rmab
g sta
mm
20
/cm
Ben
bility
0N
0m
>7
FBE
m
10
0
2 3 4 5 6 7 8
Transport & Laying Operation mm PE
0.2 0.3 0.4 0.5 0.6 0.7 0.8
mm FBE
Although a great variety of requirements must be It is a basic fact that certain desirable properties
met by efficient corrosion protection measures, the exist to an optimum degree sometimes in polar, at
effectiveness of passive protection under service other times in non-polar materials. A typical
conditions depends mainly on the resistance to example in this respect is the strong adhesion of the
mechanical damage of a specific protective coating. coating to the steel surface which, on the one hand,
The requirements placed on passive corrosion is effected via polar groups in epoxy, while on the
protection for underground pipelines have other hand non-polar thermoplastic materials do
increased over the past years (Fig.1). This also have a very high electrical resistance and the
concerns the temperatures not only during handling, disinclination to integrate the polar water molecule
but also under service conditions. Excellent into the coating material (swelling) as well as high
behaviour of the coating is required in the mechanical resistance (Fig.2).
temperature range -75°F – +175°F (-60°C – +80°c).
Therefore, in Continental Europe the conclusion
was that coating can be optimized by multi-layer
MULTI-LAYER DESIGN PHILOSOPHY design which combines the favourable properties of
Considering the chemical properties of the two most various coating materials.
important materials used for the production of
modern high-quality coatings – polyethylene and Another starting point leading to the multi-layer
epoxy – it becomes evident that these materials principle is the functional separation of corrosion
possess rather strongly opposed characteristics. protection and protection against mechanical
266
damage. It was on the basis of this idea that extruded been verified in the case of several pipeline sections
pe pipe coating was first produced in Germany. between 30 and 600km long by Ruhrgas AG over a
More generally speaking for Continental Europe, period of about 15 years.
the main target was to replace the bitumen coating
For the sake of comparison, it should be mentioned
by a new system that offers excellent mechanical
that in contrast to this, in the case of fusion bonded
resistance against the dynamic forces to which a
epoxy (fbe) coatings, the polar structure of the
buried pipeline is subjected while undergoing
coating material reveals itself by the strong
ground movements due to vibrations and
dependence of the electrical resistance on the
temperature variations, as well as in the case of
temperature, and by the more or less marked
impact stresses acting on small areas – such as
negative effect of the surrounding water. Fig.7 shows
sharp-edged stones.
an example of the variation in the coating resistance
An additional requirement was that there should be as a result of increasing and decreasing
an excellent adhesion to the steel surface to avoid temperatures (6°C per hour), measured with and
the formation of water pockets that subsequently without the influence of water.
would make the cathodic protection system
ineffective in the respective area (the “shielding Fig 7. Coating resistance as a function of
effect”). Furthermore, the coating should have high temperature
electrical resistance and be tight against diffusion of [Ω m2]
water and oxygen as well as any other oxidizing
12
agents. The cathodic protection system was 10
considered to be an additional ‘safety belt’ for the 10

11
‘worst case’, but basically the system should be

effective even without cathodic protection. 10
10
Contrary to this approach in Continental Europe, 10

9
the cathodic protection system in North America

Coating resistance
DRY
8
10
always has been an integral part of the epoxy
corrosion protection System due to the inherent 10
7
porosity and relatively-low mechanical resistance IN WATER

that unavoidably leads to defects on the pipe 10
6
surface. The electrical resistance of pe three-laver 5

10
coatings lies at values above 1010ohm.m2, irrespective
of the service temperature or the influence of water. 10
4
The actual resistance of the buried pipeline depends

on possible defects. insufficient field joint coating, or 10
3
inefficiently insulated pipeline installations. 0 20 40 60 80 100

Temperature [°C]
Thanks to the excellent mechanical strength of pe Coating resistance as a function of temperature
coatings, outstanding electrical resistance values can (6°C/hr, dry and in water, FBE 0.35 mm)
be obtained under service conditions, which has
267
The two-layer pe system that was used until the late extreme conditions, e.g. when pipe is thrust through
1970s, and which still performs adequate passive the soil (as in directional drilling), no failure has
corrosion protection to thousands of kilometers of been observed to the three-layer coating at the
pipelines in Continental Europe, basically offers the pipe/coating interface.
same mechanical properties. However, it
In the case of directional drilling to cross under
theoretically involves a higher risk of cathodic
rivers, roads, and railway lines, the application of a
disbondment leading to water pockets and to the so
poly-propylene (pp) top layer has given outstanding
called “shielding effect” described above. For that
results – unmatched. by any other coating system.
reason, three-layer systems have been gaining
ground steadily in the course of the years. Thus, a coating system is achieved that can no longer
Nevertheless, pipelines coated with a two-layer pe be separated mechanically from the pipe surface –
system still are in excellent condition after 20 or only scratches and grooves can occur during
more years of service with Ruhrgas in Germany, as handling and laying of pipe – but no damage occurs
practical experience demonstrates. over large pipe surfaces. These (very few) scratches
and grooves can normally be protected by a cathodic
We in Continental Europe are fully aware of the fact
protection system.
that some US experts have a reluctant attitude
towards polyethylene that may even go as far as Two clearly-identifiable lines of development
being negative towards pe, because of the “shielding regarding pe coatings should be mentioned:
effect” and disbondment problems that have
The transition from adhesives with low melting
occured in the US. We have found out that these
points, first to hot-melt types, and then to
negative experiences were due to the use of soft
ethylene-based copolymers, which brought about a
adhesives which were not suitable for the
definite improvement in the high temperature
application to large and heavy pipe. In the course of
bonding strength.
further development, the pe types, the thicknesses of
pe coatings, and the adhesives used, have undergone A second line of development concerns the pe type
some modifications. As of today there is a wide selection. Here. a growing tendency towards
range of adhesives available that lead to adhesive utilizing higher-density types of pe with a low melt
strength levels that could not have been thought of index plus appropriate stabilizing techniques has
some 20 years ago. become characteristic over the years. This enables
the production of coatings suitable for elevated
The adhesive strength (bond strength) level
service temperatures (Fig.8).
required by the very stringent German standard
DIN 30670 test, of 35N/cm at 20°C in modern This design is coupled with a thermosetting epoxy
coating production, is easily shifted up to 180N/cm primer, thus purposefully utilizing the optimum
and above when applying the right combination of properties of thermoplastic and thermosetting
fbe, adhesive, and polyolefin top layer. materials, combined. The result is the ‘marriage’ of
the benefits of both the US and the Continental
The specified minimum value of 35N/cm usually
European approaches.
ensures sufficiently strong adhesion between the
steel pipe and the plastic coating, so that even under At this point, a side look should be taken at the
environmental stress-cracking phenomenon. This is
268
Fig 8. Ageing of differently stabilized PE grades
6
10 100 Years
50 Years
MAX. STABILIZED PE
5
10 10 Years
Service life in hrs
4
10
1 Years
STABILIZED PE
3
10
2
NON STABILIZED PE
10
1
10
5 1
230 250 270 290 310 - 10 T
150 130 110 90 80 70 50°C
no longer a point of concern, as test results have Ambient temperature during

shown the high reliability of the polyolefin material transport, stacking, bending and
at present available on the coating material market. laying of the line pipes pipe
Only high-density polyolefin material (hdpe) is,
under certain conditions, subject to the risk of cracks Handling, stacking and transport
due to internal stresses, whereas ldpe and mdpe, conditions.
copolymerized with a small proportion of System design for three-layer polyolefin coatings can
vinyl-acetate, are particularly suitable for giving a be exactly tailored to the project requirements. All
coating with characteristics that will withstand pipeline installation and operating conditions are
extremely severe environmental conditions. evaluated and incorporated into the coating system
best suited for any specific project. The thickness of
PURPOSE-DESIGNED COATING the The primer layer, as well as the thicknesses of
the adhesive and the pe/pp top layer, can be
The pipeline coating must be selected bearing in specifically adapted to the project requirements.
mind the following factors: Standard nominal thickness of fbe of 4mils (100
Pipeline characteristics microns) assures excellent adhesion to the steel
surface which is conveyed to the pe/pp top layer via
Construction/installation site the chemical reaction of the adhesive. The thickness
Pipelaying environment of the primer layer can be kept as thin as this,
because the top layer has a high mechanical
Presence of other structures resistance.
Operating temperature Under normal conditions, a minimum pe/pp top
269
layer thickness of 1mm would be sufficient. The top layers extruded from high-performance
basic functions of the pe/pp top layer, i.e. as a water polyolefin material, there is no difference in
barrier and electrical resistance, are fully performed production capacity when compared to the fbe case.
by a 1mm pe top layer. Any additional thickness of
the top layer, i.e. above 1mm, adds to the safety FIELD-JOINT COATING
margin of the mechanical protection. In field-joint coating, the modern three-layer
Of course, the thickness of the fbe primer layer can concept is gaining ground as well. Blast cleaning of
also be increased up to a nominal thickness of 12mils the cut-back area on site has become more common
(300microns) in order to obtain an even higher and, for larger projects, the preheating of the
safety margin against cathodic disbondment. This is cut-back area is done by induction coil instead of
what ‘purpose-designed coating’ is all about. Taking propane flame.
into account this interdependence, we can actually The first layer of the field-joint coating system is a
engineer the set-up of the three-layer coating. special liquid two-pack epoxy that is applied to a
In terms of cost effectiveness, we can state that thickness of approx. 3 mils (80 microns). Following
excellent mechanical resistance and the presence of the liquid epoxy coating. a special two-layer
an effective water barrier – as is the pe/pp top layer polyethylene sleeve is wrapped around the pipe, and
of a multi-layer system – are real advantages, since subsequently shrunk around the pipe by being
additional costs which occur after the pipe has left treated with a mild propane flame. This would
the coating plant are considerably reduced: provide an adequate field-joint coating system for a
pipeline that has been coated with a three-layer
Lower cost during handling as, for
polyolefin, system. The quality of a well applied
instance, protective bands to prevent
three-layer shrink-sleeve system comes very close to
damage to mechanically vulnerable
the original mill coating quality.
coatings are not necessary.
We actually do observe a slow but steady tendency
Less defects in the coating due to
away from cold-applied tapes towards new systems
anticipated damage despite extra care
as quality specifications for field-joint coating
during transportation. In addition to lower
become more stringent. In many projects however
repair costs, locally-reduced quality
laminate tapes, (self-amalgamating butyl-rubber
properties after repair are avoided.
tapes) are still successfully applied without
Lower cost for the installation of the preliminary blast cleaning and preheating of the
cathodic-protection system and its cut-back area. The final result depends, of course,
operation throughout the life of a pipeline, on how well field-joint coating and pipelaying
depending on the electrical resistance of activities are organized.
the coating and the extent of damage to
In recent years, completely new developments have
the coating which occurs in the course of
entered the scene such as the ‘injection moulding’
pipelaying and backfilling work.
process. This process offers the advantage that the
Another aspect is production speed of polyolefin linepipe coating and the field-joint coating actually
coatings - due to the relatively low thicknesses of the weld together, and not just adhere to each other.
270
The coating quality achieved when using the Fig 9. Field joint insulation coating – injection
injection moulding process is actually the same as moulding
mill-applied three-layer polyolefin line pipe coating
(Fig.9).
The application procedure comprises the following

steps:
Closed-cycle abrasive blasting to prepare
the steel surface to an SA 21⁄2 finish;
induction heating of steel surface to
240-250°C.
Fluid air systems apply ‘fluidized’ epoxy
powder and subsequently pe-resp.
pp-adhesive powder is applied.
Injection mould equipment is positioned
and the mould is closed centrally.
The molten pe resp. pp-based infill is
injected.
Cooling down the infill.
Injection moulding is a proven technology applied
by Eupec to pipe diameters up to 350mm OD, and
good results have been achieved over a period of
four years in more than 4000 completed field joints.
271
A LOOK AHEAD cp problems, the coating material must have a high
Looking into the future, we believe that we will have mechanical strength and field-joint coatings have to
to deal with several major development directions: be applied carefully.
Purpose-designed coatings will be In the following, our experiences of the ‘teamwork’

introduced and custom-tailored technical of cp and pe/pp coating are described.
solutions will be required by pipeline
operators. Fig 10. Radius of action for CP stations
There will be a tendency for line-pipe

CP Stations
coating and field-joint coating to be
awarded as one package to the coating Pipeline
contractor. L L
1000
As already observed with recent projects, Diameter/wall
thickness of
we expect pipelaying contractors to take 100 the pipeline
in mm
pipe coating into their range of L
in 800/9
responsibilities. So there will be new km 10
partners that the pipecoating companies 400/7
will have to deal with. 1 100/4

0,001 0,01 0,1 1
work in the pipe-coating field will remain CP current density in mA/m2
as challenging and exciting as ever.
CP CURRENT REQUIREMENT
PART 2 The current tequired for cathodic protection
depends on the quality of the coating. The current
INTRODUCTION demand is not primarily determined by the coating
For the efficient corrosion protection of buried resistance as a constant of material, but by the
structures such as pipelines, a combination of average frequency and size of the coating defects.
coating and cathodic protection (cp) is required. Because of the voltage drop along the pipeline, the
quantity of cp rectifiers depends on the amount of
For economical cp, the pipeline coating has to meet the cp current density. Fig. 10 shows the radius of
the following demands: action for a cp rectifier depending on the cp current
density for some different pipe diameters and wall
High electrical insulation thicknesses. Older, bitumen-coated, pipelines need
As few coating defects as possible a cp current density of the order of 0.1 – 1mA/m2.
For that purpose, the installation of cp rectifiers in
Good long-term behaviour.
intervals of about 10km along a bitumen-coated
Most of the damage to pipe coatings result from pipeline is necessary. The cp current density of
transportation and pipelaying, and from poor modern, pe-coated, pipelines is of an order of a few
application of field-joint coatings. In order to avoid microamperes per m2 and below. Under these
272
Fig 11. CP current of a PE coated pipeline Fig 12. Intensive measurements – principle
Potential
Pipeline: Forchheim-Bierwang Pipe to soil drop
potential
Length: 110 km V
Diameter: 800mm CP test V
point reference
1
Year of construction: 1981 electrode
[A]
0.8 reference
electrode
CP current
0.6
0.4
0.2
0
pipeline
1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994
conditions, up to some hundreds of km of pipeline locate large coating defects where the cp does not
can be protected by only one cp rectifier. This entails work sufficiently, or where the cp current may cause
lower costs for installition and maintenance. interference with nearby installations such as other
cathodically protected pipelines. At these coating
As an example, Fig. 11 shows the long-term
defects, the pipeline has to be excavated in order to
behaviour of the cp current of a 15 year old pe
repair the coating. Subsequently. the cathodic
coated pipeline in the South of Germany. The field
protection is effective on the total length of the
joints of this pipeline are coated with cold applied pe
pipeline.
tapes. From the geometrical data and the cp current
demand, a value of cp current density of about During the 1980s, intensive measurements were
3mA/m2 can be calculated. During the last ten years, taken on all Ruhrgas’ pipelines and pipelines
this value did not vary substantially. From our operated and maintained by Ruhrgas (approx.
experience, the coating quality does not in general 10,000km). A summary of the results of these
decrease with increasing life time of pe-coated measurements is shown in Fig.13. On average,
pipelines, with the exception of pipelines laid in approximately 7 points per 100km pipeline length
mining areas or after nearby underground working. had no sufficient cathodic protection. The amount
of points without cp on pipelines with bitumen
INTENSIVE MEASUREMENTS coating was nearly three times higher than that on
For complete verification of the effectiveness of pe-coated pipelines.
pipeline cp, in Germany we do intensive We found similar proportions concerning large
measurements after pipelaying (see Fig.12). For that coating defects as shown in Fig. 13. Excavations of
purpose, the pipe-to-soil potentials and potential these points showed that most of the coating defects
drops are measured in intervals of 5m along the occured on field-joint coatings. Nearly all of the
pipeline. The aim of intensive measurements is to coating defects were obviously caused by poor
273
application of field-joint coating. Bitumen field-joint drilling. By these methods the use of casings, such as
coatings were particularly subject to defects, because for road crossings, which may cause problems to cp,
bitumen tape has less mechanical resistance than pe can be avoided in many cases.
tape.
Less damage on pe-coated pipelines (compared with Fig 14. High-voltage interference
bitumen-coated pipelines) results in lower repair
costs.
B = B(IL1) + B(IL2)
Fig 13. Results of intensive measurement + B(IL3) + B(ILE) E
L1
Quantity of coating defects Quantity of coating defects
without sufficient CP without sufficient CP B = B(IF) + B(IS)
L2 L3 IF
per 100 km pipeline-length per 100 km pipeline-length
12 150 U IBI U
IBI
S
8 100
Bitumen coating
Bitumen coating
Pipeline Pipeline
Average
Average
4 50
PE coating
coating
PE
0 0
HIGH-VOLTAGE INTERFERENCE
> Most of defects are located High-voltage interference is caused by short
on bitumen field joint coating distances between pipelines and high-voltage power
lines or electric railway lines (Fig.14). The magnetic
The damage rates for pe-coated pipelines in Fig.13 field of the electrical current in the cables induces a
are average values for all pe-coated pipelines, which voltage into nearby pipelines, which can have a value
were laid up to 25 years ago. On new pipes with varying from a few volts up to over 100V, depending
modern field-joint coating systems, there are on the conditions.
virtually no substantial coating defects. An example
In general, the interference voltage on pipelines has
of this is a pipeline which was laid in 1992. The
two consequences (Fig. 15). It may cause a risk of
pipeline has a length of 264km and a diameter of
electric shock for persons touching the pipeline, and
1200mm. The coating defects on this pipeline
it may cause ac-induced corrosion on coating
produce an electric potential drop up to
defects. even if the cathodic protection works
approximately 50mV. Altogether, there were eight
sufficiently. The personal hazard has to be avoided
coating defects with an electric potential drop of
in any case. AC-induced corrosion may occur, if the
30–50mV, and 26 with values between 10 and 30 mV.
ac density at the coating defects reaches a value of
Modern coatings have a high impact and peel 30A/m2 or more. Depending on the soil parameters,
resistance. PE coated pipes can be used for the critical value of 30A/m2 can be reached if the
pipelaying without ditch, as pressing or horizontal interference voltage is as low as 2 or 3V.
274
Fig 15. High-voltage interference – consequences DISBONDING
Under disbonded coatings in general, corrosion and
> risk of electric shock in case of touching (because of the special electric potential conditions)
the pipeline stress-corrosion cracking of the pipeline steel can
theoretically occur.
> AC corrosion on coating defects may occur
Coating areas with poor or no adhesion cannot be
located by the measuring methods used for cathodic
> Measures against high-voltage interference
are more extensive on PE coated pipelines protection, because the unattached coating shields
the cp current flow. On Ruhrgas’ pipelines, with pe
– altitude of AC voltage is higher on coatings, in few cases disbonded coating has been
well coated pipelines
Fig 16. Disbonding
– probability of AC corrosion increases
with decreasing costing defect size > on pipelines in operation
– disbonding observed in a few cases
In order to reduce the interference voltage, the – no corrosion caused by disbonded PE or
pipeline can be grounded. On cathodically protected
PP coating
pipelines, earth electrodes are usually connected to
the pipeline using decoupling devices, which give ac – no stress corrosion cracking of the steel
connection on the one hand but dc separation on the
other.
> similar experiences from laboratory tests
One reason for the growing problems caused by ac – Mannesmann
interference is the continually-improved quality of
pipeline coating in recent years. Because of higher – Ruhrgas
coating resistance (caused by less and smaller
coating defects), the earthing effect of the pipeline
itself ceases, and the value of interference voltage found accidentally during pipeline excavation (Fig.
increases. Moreover, small coating defects (which 16). The pipe steel surface under these disbonded
predominate on pe-coated pipelines) are more likely coating areas showed a thin layer of rust. In no case
to have ac corrosion because of higher ac density. was corrosion or stress-corrosion cracking was
observed. Moreover the only pipeline on which
The requirements for the pipeline coating are intelligent pigging has been done showed no
contrary concerning cathodic protection and ac indication of corrosion or stress-corrosion cracking
interference. This means that for pipelines with an after being in operation since 1971.
optimized coating for cathodic protection purposes,
the measures against ac interference are generally We have similar results from laboratory tests. In the
more complicated and expensive. Mannesmann Research Institute, long-term
experiments have been done [1] wherein pipes were
put into soil or water for a period up to 27 years. The
275
pipes were coated with different materials. Some REFERENCES
pipes had a pe tape coating without adhesive layer I. G. Helm, T. Schäfer, W. Schwenk, B.
and thus without bonding. The pipes analysed after Wedekind:Untersuchungen der
excavation showed merely a thin layer of rust. The Korrosionsschutzwirkung von
corrosion rate was in the order of one micron Umhüllungen auf Stahlleitungsrohren
(0.04mils) per year. nach langzeitiger Auslagerung in Wasser
Experiments concerning stress-corrosion cracking und im Erdboden, Forschungsbcricht für
were made in Ruhrgas’ laboratories in the 1980s [2]. den DVGW, 1993.
PE-coated pipes with coating defects were exposed 2. W. Delbeck, A. Engel, D. Müller, R. Spörl,
to controlled corrosion and stress conditions. The W. Schwenk: Protection of high-pressure
corrosive conditions were represented by a sand steel pipelines for the transmission of gas
environment containing NaHCO3 at constant against stress corrosion cracking at high
temperature of 70°C (158°F) and pipe-to-soil temperature, Werkstoffe und Korrosion
potentials of -680 to -430mV. Pipe steel with 37, 1986.
different surface treatment was used. All pipes were
tested by internal pressure cycling. 3. DIN30670 Polyethylene-coating of
steel-tubes, fittings and matching pieces,
At the end of the tests, the surrounding of the Beuth VerIag, Berlin, 1991.
coating defects was more or less disbonded, but no
corrosion within the disbonded area had occured.
Pipes without millscale on the steel surface showed
no stress-corrosion cracking. Millscale removal is
perfectly achieved by blast cleaning. Only the tested
pipes with millscale on the steel surface showed
cracks with a maximum depth of 0.2mm (8mils),
which were partly considered to be due to stress
corrosion. According to these investigations, stress
corrosion for pipelines built and operated in
accordance with German standards (which includes
blast cleaning under mill-applied coatings[3]) seems
to be impossible.
276
INTERNATIONAL LINEPIPE COATING FORUM
JUNE 4 & 5, 1996
HOTEL NIKKO, SYDNEY, AUSTRALIA
LINEPIPE COATINGS SESSION
TRILAMINATE as a PIPE COATING
JAMIE W. COX, DUPONT CANADA INC

18 Shawnee Cres. S.W.
Calagary, Alberta, Canada
T2Y 1W3
277
TRILAMINATE as a PIPE COATING RECOGNIZED STANDARDS
SYSTEM Major international trilaminate or multi-layer
coating specifications used today are:
To clarify “trilaminate”, we can state that it is usually
a coating system for the exterior of steel pipelines European:
made up of 3 specific materials all applied in-line
German —- DIN 30670 ( p.e. ) spec latest ==1991
together in a stationary coating plant under
controlled conditions. French —- NF A.49-710 ( p.e.) spec latest ==1988
Each material has a distinct role to play and all North American:
complement each other so as to gain the benefits of CAN. CSA Z. 245.21 -M92 ( p.e.) spec latest
each, resulting in an improved coating system. ==1 992 + revisions 1995
Currently, they can be described as follows:
1. epoxy powder primer layer next to the steel
Japan:
substrate that offers excellent adhesion, Japanese Industrial Standard JIS G 3469 ( p.e.) spec
oxygen barrier, chemical resistance and latest == 1986
functions as the cathodic disbondment
Korean:
resistant member of the trilaminate.
K S D 3589 which follows the JIS standard
2. adhesive co-polymer tie-layer between the
epoxy and polyolefin top coat, which forms China:
a chemical bond to the epoxy and a Q/BT 005—-95Standard; “Specification of
homogeneous melt blend with the top Application and Acceptance of Buried Steel
coat; it is the “glue” to keep the 3 materials Pipeline with 3 Layer Fusion Bonded
together under all forms of stress and Epoxy/Extruding Polyethylene Coating”
shear forces.
** Used for projects as Beijing Nat. Gas
3. polyolefin top coat ( polyethylene is major Transmission Company.
offering, polypropylene is being
The Ku-Shan Oil Pipeline Anti-Corrosion Project
introduced for high temperature
Tender Document/April 1995 specifications have
applications over 80 deg. C ) whose
also been used by the Northwest Oil pipeline
function is to act as a barrier for moisture
Bureau.
as well as mechanical, thermal and
electrical property characteristics There is a task force in Europe to standardize on a
contributing to the coating needs. European specification as a combined document
from all parties :
** currently numbered as “ ECISS/TC 29/SC 4/WG
1 N 29 E” —— 1993 latest revision -This group has
bogged down in trying to settle many issues.
278
There are many Engineering and Company specific Numerous material supplier “ Technical Bulletins”
standard specifications for the purchase of external such as : NKK : Polyethylene Coating for Line Pipe
multi-layer coatings. ; are valuable reference documents listing many tests
done.
A very few examples are
The N.A.C.E. and N.A.P.C.A. have issued standard
1. STATOIL R-SP-632; 1990 practices and bulletins associated with plant coating
2. SNAMPROGETTI – project specific for guides on the 2 layer P.E. coating system, as have
the client such as a bid document – ie. other countries.
SPC GA-E-96000 A.D.C.O., ABU Many key applicators also have there own internal
DHABI, JARN YAPHOUR FIELD, 1991 specifications they work too. Most are versions of
3. Transcontinental Gas Pipe Line recognized standards that have been adopted for use
Corporation – 1990 construction in scenarios of the local market needs.
specifications article 70.14 three layer All reflect some requirement of the project ; local
coating system country or market where the standard to follow has
4. Conoco Inc: Pipe Coating Guidelines, referenced others used before it and personal
1995 for DuPont and Conoco Inc philosophy of the corrosion engineer employed.
Economic issues also drive the coating system
5. Shell International Petroleum product.
Maatschappi B.V.: Design and
Engineering Practice DEP 31.40.30.31 – Some of these standards or tender documents are a
Gen. ; issued latest 1993 guideline for manufacturing a quality coating, as a
common reference for tenders around materials and
6. National Petroleum Construction finished coating and also to satisfy good engineering
Company, Abu Dhabi – U.A.E. practices of the company such as to outline the
== project bid document specification service temperature limits ( -30 deg. C up to + 84
7. CMPS Engineers – Technical deg. C ).
Specification for Trilaminate External Since coating systems are continuously improving
Line Pipe Coating through material technology and application
8. EuRoPol GAZ S.A.; Poland. practices, so do we see revised standards that
Specification for External Coating of incorporate the benefits of this new learning.
Steel Pipe Using Plant Applied 3 Layer
Epoxy/Polyethylene Pipeline Coating COMMENTS ON MAJOR STANDARDS
System for 1420 mm Diam. The DIN 30670 standard is one of the oldest in use
9. Brown & Root Associated Companies: today and encompasses extruded and sinter coating
Cusiana 1 Cupiagua Full Field P.E. for steel pipelines in soil or water environments.
Development Project; Specification for It’s scope lists the document for use as a “quality
Coating Line Pipe using a Three Coat assurance” purpose. It is based around the
Polyethylene Systern” 1994 philosophy of using polyethylene as a “barrier” and
279
“mechanical, thermal, chemical” resistant coating wider body of people on the committee, including
for the steel in service up to 70 degrees C. The key international input. This standard is continually
factors expressed by the spec revolves around being upgraded and has been operating as a task
thickness and coating quality as expressed by several group for over 10 years.
tests such as impact, elongation, aging by light and
Thus new coating technology is easier to
heat, indentation and coating resistivity.
incorporate.
The method of doing these tests is spelled out in
detail. OPTIMUM THICKNESS for each layer
DIN does not stress cathodic disbondment The exact thickness of each component layer can be
resistance ; high adhesion values or the benefits of varied to suit the pipeline environment and the
material property differences associated with epoxy, corrosion engineer’s need based on his thinking.
adhesive copolymers or polyethylenes.
A basic structure may look like the following:
General industry feelings are that DIN does not go
1. white metal grit blasted steel with an
far enough in its thinking and is quite generic, and
anchor pattern of 50 to 100 microns
easy to meet by any applicator.
2. about 3 to 10 mils ( 80 to 250 microns) of
The French based specification ( NF A 49-710 )
epoxy primer powder or more
reflects more liberal thinking with higher adhesion
values, limits the coating to extrusion not sintering, 3. about 3 to 12 mils ( 75 to 300 microns) of
has more description of application procedures, adhesive co-polymer
inspection, repair, marking and handling. It also has
4. about 40 to 120 mils ( 1000 to 3000
provisions for 3 different thickness classes and
microns) of compounded polyethylene
tolerances for the steel weld bead when applicable (
10 % reduction in thickness without qualification ). General thinking is that more epoxy thickness
contributes to better cathodic disbondment
The Canadian Standard Z 245.20 and Z 245.21 - M
resistance. It adds an incremental cost for the extra
92 incorporates both the Fusion Bonded Epoxy thin
material usage, but gives one a step change in added
film spec and several 2/3 layer coatings of
security.
polyethylene. Its scope is quite broad and is based
on “minimum” requirements allowing for more Industry recognizes a minimum of 1000 µm or 1 mm
design flexibility as the need arises. thickness of polyethylene is needed for “corrosion”
protection and then further thickness contributes to
Cross references are made back to the epoxy
addition mechanical and barrier protection
standard for the 3 layer polyethylene portion of the
properties. Since the adhesive co-polymer has the
standard. It also requires pre-qualification of the
sole purpose to tie the other 2 components together
coating systems, application, inspection testing and
its functional aspects are in chemical linkage to the
handling. It allows for the differences in density of
epoxy and melt blending to the p.e. top coat. Its
polyethylene used. relative to thickness needs and
thickness is based more on what is needed to achieve
does stress cathodic disbondment resistance. It also
the desired adhesion level per specification and test
more closely represents industry practice and has a
temperature used. Using a “grafted” adhesive with
280
maleic anhydride has shown us that a fairly thin experiences. Any time the steel has been exposed to
layer 3 to 6 mils ( 80 to 160 microns )can be an environment ( ie. ocean transport or stockpiling
adequate. One of its key properties is the ability to near salt water or SO2 atmosphere) where ferrous
“wet-out” the substrate so as to generate good salts can form on the steel surface, one needs to
chemical bonding with the epoxy and at the same employ a test and method to confirm cleanliness.
time become homogeneous with the polyethylene
Typical test used for salt detection is that of using
top coat used.
Potassium Ferricyanide or Phenanthroline tests.
Optimum thickness suggestion, based on our Typical method to ensure a very clean surface is by
materials and cost -value conscious may be: using a weak Phosphoric Acid solution (10 % of 75
% conc. acid) or Oakite 31 solution ; followed by
Epoxy = 150 – 175 microns nominal thorough water washing immediately by clean water
Adhesive = 100 – 200 microns nominal so no detrimental contaminants are left. The steel
surface can be tested to confirm its state and that its
High Density P.E. = 1000 microns minimum ready for coating.
Total range being : 1250 microns to 1375 microns Chromate pretreatment after this step is often
minimum and then if one feels the need for added employed when one is looking for enhancement of
mechanical protection due to heavy rock or a the coating under conditions of high temperature
concrete coating overtop; add an extra 1000 service so as to get better cathodic disbondment
microns. We must stress that the field handling of resistance and hot water soak results. Safe handling
the coated pipe is done in a responsible manner such and disposal of any chromates may present a
as to prevent damages. challenge, since they are classified as “carcinogenic”.
Should the polyethylene COMPOUNDED density Local environment laws must be strictly followed.
be lower than 0.95 then additional thickness will be Typical thickness is up to 5 microns and it is applied
required to compensate for the pipeline as a wash coat over the steel prior to heating and
construction environment. coating with epoxy.
Traditional thinking in using chromate pretreatment
STEEL PRETREATMENTS is to establish a surface condition that is stable and
Much work has been done in the last 5 years in uniform for any epoxy product used and to obtain an
evaluating steel pretreatments relative to improved inert conversion coating of a mixed oxide film that
coatings through hot water soak and cathodic enhances long term adhesion.
disbondment resistance tests. Since adhesion to Conversion coating technology has been in the
metal and to each other in the designed coating metal finishing industry for over 60 years and the
system is of utmost important, these 2 tests are a current “dry-in-place” product and process has a
good indicator of performance . They are often used history of about 10 years.
to rate coatings against each other.
Steel surface contamination ( grease, oils, dirt, salts)
is often the cause of poor adhesion as seen in
coating disbondment in short and long term
281
DEVELOPMENTS OF TRILAMINATE as and the use of shrink sleeves were most effective and
associated with AUSTRALIA fast.
The system has been introduced in 1994-5 with the Some coating damages from handling or grit-dusting
Pilbara project. The pipe was coated in Malaysia and has been seen. This caused scratches on the pipe.
transported to the job site by ocean vessel. It had a Three layer coatings using a polymeric P.E. adhesive
system thickness of about 1600 microns in total. This have much higher shear stress resistance than 2 layer
coating consisted of about 75 microns of epoxy coatings with a soft adhesive.
primer, 225 microns of adhesive co-polymer and This is a benefit of having a grafted adhesive and
1300 microns of a high density black polyethylene high chemical bonding in that the coating is much
(Sclair 35 BP). more homogeneous and resists normal forces
It basically followed the CSA standard, taking associated with the coating in-ground. Essentially
advantage of the higher density effect to use a being a polyethylene, it acts the same.
reduced thickness of top coat. The coating also used The dust on black coloured pipe also gave the
a grafted adhesive co-polymer (Fusabond E MB 158 appearance of surface imperfections often when
D) that offered increased peel strength and higher there was no real problem. Major scratch and gouge
service temperatures to 80 deg. C. The epoxy primer damages have been repaired by employing three
(D 2003 PR) was of “fusion bonded quality”. The main procedures:
system was designed to take full advantage of
current materials technology in obtaining a cost 1. strip and re-coat the entire joint
effective coating. 2. over-coating of the coated pipe joint by
North America has used this type of coating very running it through the plant again
successfully in a 2 layer situation with a soft adhesive 3. repair by using a suitable shrink sleeve
of about 250 microns and a high density top coat of
1250 microns so the top coat polyethylene and The coated/repaired pipe then had further
thickness experience is well known. With the added inspection by jeeping @ 15-20 Kv.
advantage of a hard P.E. adhesive chemically The decision on which method of repair to use was
bonded to an epoxy primer, the three layer system based on the severity of the gouge in the coating, as
offered a much superior coating by way of adhesion NO specification exists to cover this question.
and cathodic disbondment resistance. This 3 layer Essentially one is looking to make sure the final
coating design using High Density Polyethylene was coating integrity is intact and the top layer of
introduced in North America in 1988 and has been polyethylene is offering the mechanical support
gaining momentum ever since. required.
TRILAMINATE EXPERIENCES in AUSTRALIA NOTE: Water and Gas P.E. “Pressure Pipe” testing
is often done on scratches that are 20 to 25 % of the
We experienced some exterior damages to the P.E. wall, so this would be a starting criteria for
coating from nails spilt into the ocean vessel hold repair discussion in a p.e. coating, ie: the
during shipment from Malaysia to Pilbara. These imperfection must go beyond this in order to be
had to be repaired in the field prior to installation cause for real concern. As this is an area not defined
282
today, a great deal of basic research to answer effect Immediate references that come to mind would be
on service, needs to be undertaken. relative to rock impingement on the coating and the
ability of the polymer to resist this type of
Since a black colour picks up and magnifies any
penetration ; polyethylene’s of this type and density
imperfection, the coating surface is often questioned
behave most favourable under these conditions and
over minor superficial conditions such as water
would have a tendency to “cold flow” under pressure
marks, etc. These have absolutely no effect on long
of the ground protrusion rather than split and crack.
term performance. Sound and practical judgment is
See the attached chart on penetration resistance
the key. When dealing with large diameter & heavy
relative to temperature.
pipe; several countries even use a white acrylic water
based paint on the black polymer (to lessen the Another situation often related to fusion bonded epoxy
black body effect which leads us to the next item. powder is foaming. Foaming is mainly entrapment of
air during the curing process or volatiles from moisture
One area often questioned is the effect of the heat
or reactants in the mix. Generally, higher steel preheat
on the black coloured high density polyethylene.
temperature, the worse foaming can be, since higher
Two effects come to mind; the (U. V. degradation of
temperature results in faster gel time of the epoxy and
the polymer itself and the effect of the high
more air to be entrapped as the epoxy cross-links and
temperature on the mechanical properties of the
also more reactant volatiles to be produced. There can
system.
also be some degradation of the surface layer of the
Our stabilization package well dispersed with a FBE used.
special carbon black, can withstand the sunlight-
Normal production may see slight variations in this
effects for up to 10 years without excessive loss in
phenomena from lot to lot and from one product to
key properties.
another, due to the differences in formulations used.
See the attached chart on outdoor weathering of Some of these differences are in the viscosity of the
Sclair polyethylenes. base resin and moisture levels of the finished batch.
It is a minor situation easily dealt with. Suggested
As polyethylene is a thermoplastic, it will soften with
ideas to reduce or eliminate this may be :
heat; this is one reason for using a high density type
polymer in hot environments. Higher density has 1. use of longer gel epoxy formulas so as to
higher softening points than low density allow more time for the volatiles to
polyethylene’s ( 124 deg.C versus about 90 deg.C ). escape prior to the adhesive film being
Shore D hardness is one property characteristic applied
associated with density. Hardness is directly related
2. lower preheat temperatures of the steel
to the polyethylene crystallinity which is governed by
cooling rate. Both of these are a function of plant 3. reduced epoxy build up rate on the steel
processing conditions. Thus, published data sheets to allow the volatiles to escape
may not accurately reflect finished coating hardness.
4. ensure no contamination (moisture/oils)
The test value to measure is really the indentation or of the plant compressed air used to
penetration resistance of the top coat. The is defined fluidize the epoxy powder
by ASTM G-17 or the DIN 30670 reference
5. change in epoxy supply and/or
procedure. 283
formulation
SLOW CRACK GROWTH PHENOMENA: at stress levels exceeding 40 % of the yield stress. At
P.E. COATINGS stress levels less than about 40 % of the yield stress,
the failure mechanism is that of slow growth of a
NOTE: This is more applicable to 2 layer coatings
crack that initiates from a defect or stress
with a soft adhesive.
concentrator. This mode of failure appears “ brittle-
RESIDUAL STRESSES IN POLYETHYLENE COATINGS like” and can follow these steps:
In the crosshead extrusion coating of steel pipe with 1. Immediately after loading the specimen, a
polyethylene, the molten polymer is drawn down craze forms at the root of the defect.
onto the pipe and is immediately quenched with 2. The craze grows slowly creating fibrils
cooling water. After entering the cooling station, the which resist growth,
polyethylene quickly recrystallizes. Once solidified,
the polyethylene coating continues to cool, shrinking 3. Fracture is initiated by rupture of the
further in accordance with its thermal coefficient of fibrils near the base of the craze,
expansion. This coefficient is approx. 30 times that 4. The crack grows at an accelerated rate as
of the steel pipe. The potential for residual strain, is the “effective stress” increases due to the
largely offset by inter and intra-molecular strain decrease in cross-sectional area.
relaxation. The rate of strain relaxation is very fast at
5. When the remaining ligament reaches a
temperatures exceeding the crystalline melting
critical size, failure occurs by yielding of
temperature. The polyethylene coating has a
the ligament.
residual circumferential strain of approx. 1 % at this
point. Note: Steps 4 and 5 will repeat if the necessary stress
is available to continue the growth of the crack.
The resultant residual stress can be determined by
multiplying residual strain by the Young’s modulus,
which is approximately 696 MPA. Thus, immediately POLYETHYLENE PIPECOATINGS-FACTORS
after cooling, the residual stress is in the range of 3.5 TO MINIMIZE SLOW CRACK GROWTH
to 8.4 MPA. Slow crack growth generally in polyethylene’s (such
Polyethylene, being a viscoelastic material, will as pipe ) has been the subject of extensive research
stress relax when strained. The polymer molecules and has been found to be dependent on these
will slowly re-organize themselves so as to reduce factors:
the stress. Under normal storage conditions the 1. The average molecular weight of the
residual stress may decrease to 2.1 to 3.5 MPA. This polyethylene
behaviour of polyethylene stress relaxation is
2. The molecular weight distribution of the
important in understanding the in-field service use
polyethylene
of the pipecoating.
3. The branch density of distribution in
FRACTURE MECHANISM — SLOW CRACK GROWTH copolymers
Polyethylene will exhibit two distinct failure modes 4. Morphological structure ( eg. degree and
depending on stress levels. Ductile failure will occur orientation of crystallites)
284
5. Residual stress or strain TYPICAL APPLIED COATED PIPELINE COSTS
6. Temperature EUROPE — 1984
7. Environmental conditions
COATING TYPE THICKNESS (mm) COST (per sq.m.)
All these factors are considered when “tailoring” a $U.S.
polyethylene for pipecoating application such as the 3 Layer L.D.P.E. 3.0 11.00 to 13.50
Sclair 35 BP and Novapol resins. Previous work has Epoxy Powder 0.4 10.00 to 12.00
established Novapol HE-Y449-A as an excellent Asphaltic Bitumen 4.0 6. 70 to 8. 40
H.D.P.E. pipecoating, particularly resistant to slow Coal Tar Enamel 4.0 7. 6 to 9. 30
crack growth (1). Building on its use in Australia Adhesive Tape 2.2 10.1 to 12. 7
(TPA Ethane pipeline project With a 2 layer coating 3 Layer H.D.P.E. ***** 1.5 9.00 to 10.50
product in 1995), a compounded black version
Note: These budget prices are still quite valid today.
Novapol HD-2079 BK was introduced. The purpose *** 1995 costing estimates
of the carbon black is to provide long term They are relative to large proiects of several hundred kilometers of pipe.
resistance to U.V. radiation, which the coating is
likely to experience during periods of storage. Its The “trilaminate” is the fastest growth
physical and mechanical properties are largely anti-corrosion coating system today. It combines the
determined by the base resin properties of HE-Y obvious benefits of 2 well known material
449-A. For example, resistance to penetration technologies with the ability to design a coating
(Table supplied) is superior to other polyethylene’s product to suit the pipeline environment and
of lower density. In effect, the base density construction needs. Its window of application will
parameters of molecular weight, molecular weight continue to grow into new markets from marine
distribution, and density impart excellent resistance pilings to water pipes to sub-sea coiled tubing.
to slow crack growth, in Novapol HD-2079-BK.
Now beyond the European and Eastern Europe
markets, “trilaminate” is being used as the coating
REFERENCES of choice in the Far East Markets such as Malaysia
1. Mechanisms of initiation, Propagation and Arrest for PGU 3 project and India, Pakistan, China and
of Cracks in Mastic-based Polyethylene Pipe soon ( 1996 ) Indonesia pipelines. South America
Coatings, Dr. D. Wong, Shaw Industries Ltd. and has used this coating system for the past several
Mr. C. D’Agostino, Nova Chemicals; Australian years in some very large projects demanding top
Pipeline Industry Association, 1995, Wollangong. integrity and corrosion/mechanical protection
(Gasandes project in Argentina and the Ocensa
SUMMARY project in Colombia).
As in any new product first introduced, some
growing pains will be seen while an understanding of
the system and its practicalities are experienced. We
trust this will set the stage for a more informal
discussion on the queries of this coating technology.
285
AKNOWLEDGEMENTS:
1. JOTUN POWDER COATINGS, U.K.: MR. DENIS GRIMSHAW
2. NOVA CHEMICALS, CANADA: MR. CARMINE D’AGOSTINO
3. BREDERO SHAW COMPANY, CANADA:
MR. STEVE Mc CONKEY /DR. DENNIS WONG
NOVAPOL HD-2079 BK
INDENTATION/PENETRATION RESISTANCE
PROPERTIES
TEMPERATURE DIN 30670 (1) ASTM G 17 (2)
23°C < 0.001 in. < 0.001 in.
50°C < 0.001 In. < 0.001 in.
70°C < 0.001 In. < 0.001 in.
90°C 0.005 in. < 0.001 in.
(1) 2.5Kg weight, 1.8mm probe diameter

(10 N/mm2)
(2) 4.453Kg weight, 6.35mm probe diameter
(1.41 N/mm2)
286
UPDATE ON HOW TO SELECT MILL Application to pipe with a minimum of defects.
APPLIED PIPE COATINGS Defects during application are unavoidable on some

coating systems. Defects are repaired. No coating is
perfect, and that is why cathodic protection is
By Bredero Price (A Dresser Shaw W Company) required.
Pipe coating on underground or underwater
structures isolates metal from contact with the Good adhesion to pipe surface.
surrounding environment. Pipe coatings from the Coating adhesion is important to eliminate water
first line of defense against corrosion. A properly migration between the metal substrate and the pipe
selected, applied and installed coating should coating. Coating adhesion assures permanence and
provide 99%+ of the protection required, has the ability to withstand handling during
supplemented with cathodic protection.. installation without losing its effectiveness.
Today, with the many available coating systems, the Ability to resist development of holidays with time.
job of selecting the proper coating necessitates
careful analysis of many desired properties for an Once the coating is buried, two areas that may
effective pipe coating. The NACE International destroy or degrade coatings are soil stress and
Standard RP01-69-92 clearly defines the desirable environmental contaminants. Soil stress, brought
characteristics of coatings in Section 5: COATINGS. about in certain soils that are alternately wet and
dry, creates tremendous forces that may split, bog or
The desirable characteristics of a pipe coating cause thin areas. Adhesion, cohesion and tensile
include the following: strength are important properties to evaluate in
Effective electrical insulator. order to minimize this problem. The coating’s
resistance to chemicals, hydrocarbons, acidic or
As soil corrosion is an electrochemical process in alkaline conditions must be known in order to
which an electrical current flows from the structure evaluate performance in known contaminated soils.
to the soil carrying metallic ions with the flow of
current, a pipe coating has to stop this current by Ability to withstand normal handling, storage and
effectively isolating the structure from the installation.
environment. Ability of a coating to withstand damage is a
Effective moisture barrier. function of its impact, abrasion and ductile
properties. Pipe coatings are subjected to a great
High resistance to water penetration maintains deal of handling between the time of application and
higher electrical resistance and results in most the time of backfill. While precautionary measures
efficient, longer life protection. of proper handling, shipping and stockpiling are
recommended, the coatings vary in their ability to
Application to pipe by a method that will not resist damage. Outside storage requires resistance to
adversely affect the properties of the pipe. ultraviolet rays and temperature changes. These
properties must be known and evaluated to assure
proper performance.
287
Ability to maintain substantially constant electrical followed. Field condition variables will influence
resistively with time. your selection of materials.
Corrosion is an electrochemical reaction; a coating Retention of physical characteristics.
with a high electrical resistance over the life of the
system is important. The percentage of initial Non-toxic to the environment.
resistance drop is not as indicative of the pipe
coating quality as is the overall level of electrical All thirteen of the above properties are necessary. It
resistivity. is impossible to cite one as being the most
important. All contribute to a successful pipe
Resistance to disbonding when under cathodic coating.
protection. The following factors should also be considered
Most pipelines will eventually be cathodically when selecting a pipe coating:
protected so it is necessary for the coating to be able 1. Type of soil or backfill.
to withstand cathodic disbondment. The amount of
cathodic protection required is directly proportional 2. Accessibility of pipeline.
to the quality and integrity of the coating. 3. Operating temperature of piping.
Considering interference and stray current
problems, this becomes a most important 4. Ambient temperatures during
requirement. construction and installation.
Cathodic protection does two things to a coating: 5. Geographical and physical location.
First, it has the ability to drive water through a 6. Handling required and storage
coating which would ordinarily resist such conditions.
penetration. Second, cathodic protection may
produce hydrogen at the metal surface wherever 7. Costs.
current reaches it. In turn, the hydrogen will break Evaluation of pipe coating properties coordinated
the bond between the coating and the metal surface. with the above considerations will assist in the
While no coating is completely resistant to damage selection process. Of the above factors, the one most
by cathodic protection, it is very important to choose misunderstood is “costs”. In pipe coating economics
a coating that will minimize these effects. as in all cost analysis, the end has to justify the
means. In other words, the added cost of coatings
Resistance to chemical degradation.
and cathodic protection has to earn its way by paying
for itself through reduced operating costs and longer
Ease of repair.
life. “True” protection costs should not only include
Recognizing that some damage may occur, as well as initial costs of coating and cathodic protection, but
the necessity of field coating the weld area, also installation, joint coatings and repairs. Field
compatible field materials are required to make engineering and facilities to correct possible damage
repairs and complete the coating after welding. to other underground facilities that may be damaged
Manufacturers’ recommendations should be by increases in current requirements may add
288
additional costs, possibly even outweighing the Reputation.
initial costs of the pipe coating.
This is an asset that has to be earned through
Selecting a coating. performance as promised
How can you select the best pipe coating to meet Reliability.
your requirements? Past experience has proven a
Consistent quality performance that can be
reliable method. Be aware however of any changes
depended upon.
in the various generic coating systems and what
result they may have on their properties. If your Conformance to coating manufacturers’
company uses accelerated tests such as those specifications. Manufactures have established
established by ASTM to make a quantitative minimum specifications for application of their
evaluation of these properties, be sure you use materials which should be met, if not exceeded.
random, production samples. The user must weigh
Modern automated equipment. Capital expenditure
the importance of these properties as they apply to
on automated application equipment has been an
their conditions.
important part of the overall success of plastic
The foreword to the NACE recommended practice coatings. The elimination of human errors through
“Application of Organic Coatings to the External automation and controls will continue to be an
Surface of Steel Pipe for Underground Service”, important factor in obtaining improved pipe
notes that “Experience shows that a major cause of coatings.
pipeline coating failure is due to improper
application”. Quality control.
Therefore, the selection of an applicator might Conformance to specifications must be checked

prove to be the most important consideration. A regularly. Knowledge of applicator’ quality control
quality material poorly applied is of little value and procedures on materials, application and finished
the quality of pipe coating is only as good as the product are essential in the selection of an
quality of application. In evaluating an applicator, applicator.
the following points should be considered.
Summary
Experience. It is not an easy task to select the “best” coating
Much research and trial and error has gone into the system. This selection requires knowledge of your
development of every coating that is now on the operating and installation conditions to be able to
market. This has required close cooperation evaluate the properties of the pipe coatings in filling
between applicator, coating manufacturer, these needs. Selection of a quality applicator is the
equipment manufacturer and customer. The most important consideration and frequently is the
transition from laboratory to production line is most neglected. After the coating and applicator
usually a costly experience but the value of having have been selected, inspection at the coating mill
accomplished this cannot be underestimated. and especially during construction phases will go far
in assuring maximum benefits from your pipe
coating system.
289
Designing the Ideal Pipeline Coating
by: T.A. Pfaff, Toronto – CANADA
ABSTRACT
Pipelines must be kept from leaking during their Engineered Design Life (EDL). The
most effective way to achieve this is by using a corrosion protection system consisting of
protective coatings and cathodic protection (CP). The ‘ideal’ pipeline coating will achieve
this objective, with due considerations being given to operating conditions and life
expectancy. A sound understanding of the fundamentals of substrate surface chemistry,
corrosion theory, coating technology and cathodic protection principles are essential for
designing such a coating and its integration with an optimum corrosion control system.
This paper will examine some of the important fundamentals and conclusions will be
drawn, which should help with the selection of an ‘ideal’ coating system for different
operating and environment conditions.
290
INTRODUCTION corrosion protection of the pipeline. We must look
at a Total Pipeline Protection System which also
The purpose of a pipeline is to transport materials includes: Steel quality, coating application, surface
from a source to a point of use. This must be conditioning and treatments, design of the coating
accomplished in a manner that is: effective, safe, and CP systems.
economical and un-interrupted during its entire
engineered design life (EDL). It is always helpful when facing any complex
problem to ask WHY something works. The
The most suitable construction material for following is intended to briefly examine and
pipelines is carbon steel. Steel is strong, has well understand all of the crucial elements making up an
defined performance specifications, is easy to ‘Ideal Pipeline Protection Systern’; i.e. Corrosion
fabricate and lends itself well to field construction. Theory, Surface Chemistry, Coating Technology and
Steel is also economical. The shortcoming of steel is Cathodic Protection.
that it CORRODES in certain exposure
environments.
CORROSION THEORY
The challenge for the pipeline corrosion engineer is There are several processes which can cause
to prevent LEAKS from happening. According to a pipeline corrosion problems:
study published in the September 1993 issue of the
Oil & Gas Journal, it is reported that 28% of all ELECTROCHEMICAL
Reportable Incidents (major leaks) during a 10 year CHEMICAL (such as SRB, Sulfate
period in the USA were attributable to Reducing Bacteria)
CORROSION. The best way to prevent external
pipeline corrosion is by a combination of coatings STRESS CORROSION CRACKING
and cathodic protection (CP). (SCC)
The ideal pipeline coating may well be perceived We will look in detail at the electrochemical
quite differently depending on ones particular corrosion process and touch on the others lightly. It
interest or point of view. The PipeCoating World is widely accepted that it takes four elements for
looks different when viewed through the eyes of a electrochemical corrosion to occur and proceed:
Scientist, a Pipeline Engineer, an Applicator, a Anode, Cathode, Electrolyte, Electron Path [Fig. 1].
Laying Contractor or a Purchasing Agent. My Elimination of any one of the four will stop
definition of an Ideal Pipeline Coating is: ‘A coating corrosion. An understanding of the principles
material or system, which economically involved will allow us to control
accomplishes the pipeline designer’s expectations’. ELECTROCHEMICAL CORROSION.
Once these expectations have been clearly
Anode
identified, it is a relatively easy task to design the
Metal goes into solution (oxidation) at the anode as
most appropriate protection system, including the
cations. (In the case of steel it will be Fe++).
ideal coating.
Electrons are released and will be transferred to the
It is most important to recognize that the coating cathode through a metallic path. The rate of metal
material by itself will not result in optimum dissolution will be strongly influenced by the metal’s
291
electromotive force (EMF), the electrolyte salts, such as sodium chloride (NaCl) or calcium
composition and the potential difference existing chloride (CaCl) dissolved in water. It may also be an
between the anodes and cathodes. acid, often sulfuric. It is also important to know that
the electrolyte type will influence the unique
Cathode potential each metal assumes when immersed in it
The electrolyte is not necessarily ‘visible’ water. It
At the cathode electrons are consumed (reduction).
may be a molecular layer of moisture on the metal
Receptors for these electrons are usually oxygen
surface, or soil, or in some instances even apparently
(dissolved in water) or hydrogen ions. H reduction is
solid matter. Resistivity measurements are useful
predominant in acidic conditions. It is an important
means to establish the strength of the electrolyte.
fact that a large accumulation of electrons, which
results if no receptors are present, will stifle any Electronpath
associated anodic reactions because of an
electrochernical imbalance. The terms Polarization A metallic connection between an anode and a
and Depolarization are often used to describe these cathode is necessary to allow movement of
conditions. It is obvious that it is highly desirable to electrons. This requires that a potential difference
maintain a polarized condition. Oxygen is the most exists and that the metal surface permits electron
frequent ‘depolarizer’ and, therefore, very transfer. The composition of the metal surface is,
detrimental. The cathodic reduction reaction therefore, very critical for the effectiveness of
involving ‘O’ is producing hydroxyl (OH-) anions. In electron conductance.
the presence of alkali metal cations, such as sodium These are the most important principles involved in
(Na+) or potassium (K+), a highly alkaline the electrochemical corrosion process. We will refer
condition can be created having a pH as high as 14. back to these in some of the following
This can have a very detrimental effect on coatings considerations.
performance, particularly when the coating has poor
Chemical and SCC Corrosion
alkali resistance. Another cathode reaction is
In recent years bacteria incited corrosion has
formation of some very tight oxide layers (often
become a serious problem with some pipeline
Ferric Oxide) which, while being protective, can also
installations both in Canada and Venezuela. In
form a new interface between the steel and the
Canada the problem appears to be associated mostly
coating. Evidence of this is the oxide layer
with SRB (Sulfate-Reducing Bacteria). It is strongly
(characteristically concentric) under the coating at
suspected that bacteria from the soil consume
holidays, resulting from reactions associated with
coating components as nutrients (Koch, 1994). In
excessive Cathodic Protection potentials (above the
the process, Hydrogen Sulfide (H2S) is formed
H-Overvoltage potential). The resultant loss of
which can attack the steel directly (chemical
adhesion is commonly called Cathodic
corrosion) and forms Ferrous Sulfide (FeS), while
Disbondment.
also ‘depolarizing’ the cathode. It is also strongly
Electrolyte suspected that both SCC (Stress Corrosion
Cracking) and HIC (Hydrogen Induced Cracking)
Electrolyte is the medium which accommodes ionic are associated with bacterial corrosion in
conductance. This is usually provided by alkali metal conjunction with disbonded coatings. A senior
292
corrosion engineer of a major Canadian pipeline cleaned pipe. This may cause significant decrease of
company said: ‘The whole key to preventing SCC the steel surface-free energy which will seriously
and HIC is establishing a very high integrity of interfere with proper wetting of the surface by the
coating on your pipeline’. coating polymer. It is a well established fact that in
order to achieve good wetting, the surface tension of
SURFACE CHEMISTRY the liquid (coating) must be lower than the wetting
Steel surfaces are by no means uniform in tension of the substrate.
composition. Steelplate used for pipe-making is A non-contaminated steel surface has a surface
made by a hot rolling process. This creates a surface energy (wetting tension) higher than 73 dyne/cm2
of varying oxide composition (mill scale). In (which is the surface tension of water at 23°C). On a
addition, during the pipe making process different ‘clean’ surface, water will spontaneously spread
contaminants, such as forming and lubricating oils, without breaking. The surface tension of FBE in its
are deposited on the surface. During storage and application state is approximately 45 dyne/cm2.
transportation, the pipe may be further exposed to Therefore, if the wetting tension of the steel is near
sulfate and chloride environments. The end result or below 45, proper wetting is not possible. The
may be an assortment of potentially very harmful RULE is: ‘Lower energy liquids will wet higher
surface conditions. energy surfaces’. The wetting tension can be easily
We used to believe that abrasive cleaning to a White tested with appropriate wetting solutions such as
or Near White Blast quality would produce a described in ASTM D-2578.
‘paintable’ surface. We were wrong! The ill effects of Another characteristic of a steel surface is that it has
chloride contamination were widely publicized by mixed surface potentials (micro anodes and
the British Paint Research Association in the late cathodes), mostly because of the steel chemistry and
1970’s (McKelvie, 1986), but very few coatings sometimes because of incomplete removal of
people paid much attention. Many coating failures millscale components.
in the ship building and pipeline industries remained
unexplained. Most harm was done by the presence Surface Conditioning
of invisible ferrous salts embedded in the steel grains In order to overcome the possible problems
and especially at the bottom of corrosion pits. described in the SURFACE CHEMISTRY section,
Abrasive cleaning does NOT remove these ferrous it is necessary to appropriately treat the blast
salts, nor does High Pressure Water Blasting. A very cleaned surface.
simple test to determine the presence of ferrous
salts is to use Potassium Ferricyanide or Surface conditioning has several components. In
Phenanthroline reagents. [These reagents actually addition to the traditional requirements of removing
test for presence of ferrous ions (Fe++), which are millscale, corrosion products, and to establish an
symptoms of active corrosion]. anchor pattern, we must also look for a ‘chemically
clean’ surface. This means that (a) there must be no
It is most important to recognize that a ‘visually deleterious contaminants on the surface and (b) that
clean’ surface may be very deceptive. In addition to optimum conditions exist for wetting by the coating
the invisible ferrous salts, there may also be invisible polymer. One can most effectively achieve this with
organic contaminants present on the abrasive
293
a phosphoric acid based treatment. Several excellent this electrical ‘shielding’. Figure 2 illustrates that
proprietary cleaning materials are available. type of a problem. This will be looked at a little more
closely when we discuss CP and how it relates to the
If additional performance enhancements are to be
corrosion theory principles.
gained, then a further treatment with conversion
coatings such as chromates or silicates, or using Let us examine adhesion more closely. The most
adhesion promoters, such as silanes or titanates, are widely held views are that adhesion is based on three
strongly recommended provided that appropriate mechanisms: Mechanical, Polar and Chemical
health and safety issues are met. Some of these adhesion. [Mills, 1992]. Mechanical adhesion is not
treatments have the additional benefit of interfering very useful since it is strictly relying on a very deep
with the corrosion process by: (a) making the surface profile to achieve physical anchoring. Polar
surface potential more uniform, which reduces the adhesion is the most widely occurring mechanism
driving force between anodes and cathodes, (b) with coatings. The bond strength depends very much
increasing resistance to electron flow, and (c) on availability of polar sites on both the substrate
passivating the surface. and the coating. The best adhesion is achieved when
an abundance of polar groups are in very close
Proper surface conditioning should be considered a
(molecular) proximity. This is why surface
normal part of any protective coating system for
conditions and the wetting ability of coatings
pipelines. It must not be considered a luxury, nor an
become so important. Chemical adhesion gives by
optional process, if we are serious about ‘good’
far the strongest bonds, but is rarely used in
corrosion protective systems.
protective coatings for pipelines. Chemical bonding
Adhesion is achieved by functional groups on the substrate
and the coating interacting chemically.
Adhesion functions most effectively when intimate
contact is achieved between the coating polymer and Adhesion is extremely important for favorably
favorable bonding sites on the substrate. affecting many performance properties, the most
critical one being resistance to cathodic
When the question of importance of adhesion disbondment. Under CP influences, the effects of
comes up, my feelings are very strong that it is the the electrolyte (particularly if metal cations such as
perhaps THE most important property of a pipeline Na+ or K+ are present) can be very destructive to
coating. Many argue that it is not important as long the interfacial bond. This can lead to ineffective CP
as the pipe is enveloped in a mechanically and and corrosion, including SCC and HIC.
di-electrically strong envelope, such as a very thick
polyethylene membrane. I accept this as long as Poor adhesion may well be the fault of an unsuitable
there is not a defect in the coating (such as a cut or coating. But, even a ‘good’ coating may bond poorly,
break), which is not a realistic proposition. MY mostly for three reasons: (a) Poor wetting of the
concern is that in aggressive operating environments surface, (b) presence of ‘soluble’ ferrous salts at the
such coatings, if damaged, will be extremely prone to interface, or (c) physically weak boundary layers
localized corrosion because CP (Cathodic such as dirt, porous oxides, or organic residues.
Protection) currents may not be able to reach active
corrosion cells. Corrosion engineers commonly call
294
On a poorly wetted surface it is easy for water coating system designer to make some basic
molecules to displace some of the polar bonds, judgment about the suitability of a particular coating
particularly those relying on Hydrogen bonding. The for a particular operating environment. A
second problem is more serious since the ferrous generalized categorization can be made to
salts may enter into an autocatalytic pitting distinguish polymers by the manner in which film
corrosion process, with potentially serious formation is achieved, as shown in Figure 4..
consequences. The third reason is simply a physical
separation which is most easily avoided by proper Following are the most important characteristics of
surface preparation techniques. major polymers used for protective coatings:
Two widely respected authorities on Corrosion Thermoplasts Achieved by heating and

(Haagen & Funke, JOCCA 1975) have stated: re-solidification after cooling, or by solvent
‘Preceding any corrosion reaction, adhesion must be release of a solvated coating.
lost, at least locally, due to the action of corrosive Examples: Polyethylene(PE),
agents. Water has been shown to be primarily
responsible for this’. Polypropylene (PP),
Polyvinylchloride (PVC),
COATINGS
NYLON,
Coatings can be classified as Organic or Inorganic. I
will only discuss Organic Coatings, although Coal Tar.
Inorganic Coatings do have some specialized Common characteristics of these polymers are:
potential use for pipelines, i.e. mechanical Good mechanical properties and resistance to
protection. moisture, but sensitive to exposures to heat and
certain chemicals. Their greatest weakness is poor
Coatings generally provide corrosion protection by
adhesion to steel because of their non-polar
the following means:
molecular structure.
Passivation (using inhibitive pigments such
Thermosets Films form by
as: chromates, molybdates, phosphates)
cross-linking induced by heat, radiation, or
Barrier (limiting the permeation or chemicals. The set films cannot be
absorption of water, gases, cations) reversed by heating nor by the action of
most solvents.
Sacrificial (using zinc rich primers, for
example, which perform similarly to CP) Examples: Epoxies,
Most coatings for pipelines are based on the barrier Polyesters,
concept for achieving corrosion protection. While
Phenolics.
sacrificial type coatings are not well suited as pipe
coatings, considerable opportunities exist for Have generally good chemical resistance and heat
making use of the ‘passivation’ approach. Coating resistance. Many have excellent adhesion,
performance characteristics are decided mostly by particularly Epoxies. Shortcomings are often related
the resin (polymer) systems used. This allows the to mechanical properties.
295
Elastomers. A hybrid of the above sharing ‘constrained’ by the concrete and as long as the
many of both the advantages and operating temperature does not exceed the coal tar
disadvantages. limitations, and there are no concerns about toxicity
aspects, there is nothing wrong in considering this
Examples: Rubber, coating.
some Urethanes. Polyethylenes have their place where operating
TABLE 1 shows what I believe to be the most conditions are favorable (non-aggressive), and
important performance requirements for an ideal where the primary reason for the coating is to
pipecoating. achieve ‘long pipeline resistance’, which is important
to control CP costs.
The most popular pipecoatings during the last three
decades have been based on Polyethylene, Coal Tar, FBEs are perhaps the best ‘general purpose’
and Fusion Bonded Epoxy (Coulson, 1990). Here is pipeline coating. They have excellent compatibility
a brief summary of their strength and weaknesses, with CP and stand up well to high operating
considering only the most important performance temperatures, when used at a thicker film thickness
requirements: and over chemically conditioned surfaces. The
weaknesses of FBE are: Proneness to impact
POLYETHYLENE COAL TAR FBE
damage and sensitivity to moisture absorption.
Adhesion – 0 ++ During the past five years Combination Coating
CP Compatibility – – ++ systems, consisting of FBE and Polyolefins, have
Water Absorption ++ ++ – been introduced with excellent results. [Nunn &
Mechanical Strength ++ 0 – Norsworthy, 19931, [J.W. Cox, 1993 ASME paper
Soil Stress Resistance 0 – ++ G0068 11. Such coating systems take full advantage
Temperature Stability 0 – ++
of each coating’s strength, while minimizing their.
weaknesses.
Legend: – = DEFICIENT
0 = ACCEPTABLE
++ = SUPERIOR
All three coating types have had successes and

failures. It is extremely important to recognize the
strength and weaknesses of each coating. I have seen
Coal Tar Enamel coated pipe in service for 30 years
and the pipe is in perfect condition. Does this make
Coal Tar Enamel the ideal coating for every
operating condition? Definitely not. However, it
does show that under certain conditions it is a
perfectly acceptable coating. Coal Tar Mastics have
found a particular niche for offshore use under
Concrete Weight Coatings. Here, the coating is
296
CATHODIC PROTECTION into this area, a serious corrosion condition can
Cathodic protection (CP) is an integral part of any result because the protective CP current may be
pipeline corrosion protection system. Unfortunately, shielded from reaching any active corrosion cells. I
the corrosion engineers often look at CP and strongly believe that this is a serious problem, which
coatings as separate responsibilities. It is imperative can be avoided by proper coating system design.
that the two disciplines are done in concert. I believe
that a well designed CP system, in conjunction with SUMMARY
the appropriate coating system, will ensure a The Ideal Pipeline Protection System consists of
leak-free pipeline operation in the most economical several important elements. There is NO single
fashion. coating that can be called ‘ideal’. However, by
carefully considering the particular pipeline
CP works by impeding electrons from leaving the
requirements, and by studying the characteristics
iron atom. The problem is to know how much CP to
and history of the available coatings, a sound
use. Too little CP will not stop the electrons from
decision can be made.
being freed and too much CP may cause coating
disbondment, which will be counterproductive and I believe that the BEST pipeline coating we know
eventually there will not be enough power to today is not a SINGLE coating, but a
maintain an effective cathodic protection system. COMBINATION COATING System. By combining
well established existing coatings having
The CP process works by providing an excess of
COMPLEMENTARY performance qualities (such
electrons to the cathode so that there is simply no
as FBE and PolyOlefins), one can achieve excellent
place to go for electrons that want to leave the iron
pipeline protection, for even the most aggressive
atoms at the anode. At the same time the surface
operating conditions.
potential of the pipeline shifts in a more negative
direction and the potential differences are It is still true what Prof. Fontana said 20 years ago:
practically eliminated. Experience tells us that once ‘Virtually all premature corrosion failures occur for
the pipe surface potential (pipe to soil) has a reasons which were already well known and these
minimum negative value of 0.85V (NACE RP failures can be prevented!’
0169-83), corrosion will no longer occur, or at least
It is most important that the pipeline designer also
will be greatly mitigated. One of the corrosion
considers the following points:
engineer’s challenges is to achieve this condition
uniformly over the entire pipeline. This task 1. Know and understand the pipeline
becomes easier if the pipe surface can be ‘polarized’ requirements [see TABLE 2]
readily to a protective potential. A well bonded 2. Make surface conditioning part of every
coating along with a ‘uniformized’ pipe surface coating specification.
potentials will greatly help in achieving this.
3. Choose coating systems which best meets
One of the most controversial topics in the use of the owner’s expectations.
coatings and CP is the concept of shielding, as
shown in Figure 2. If dielectrically strong coatings 4. Do not shy away from new technology
disbond from the pipe and if electrolyte can enter which is based on sound scientific
principles.
297
5. If in doubt, over-engineer the Coating 5. A COMBINATION Coating System such
System. (Even a tiny bit of as:
underengineering can have disastrous
Full-fledged FBE Coating and
consequences).
Appropriate outer Layer of polymeric
6. Find time to tell people WHY and HOW
material which is chemically bonded to
to do things.
the FBE. This layer may be chemically
modified POLYOLEFIN or other
CONCLUSIONS suitable polymers.
The ideal pipeline coating is one that contributes
6. Same coating system is also used for
effectively to the overall pipeline protection system
appurtenances, field joints and coating
and meets the owner’s expectations. It must have
repairs.
excellent compatibility with CP systems and stand up
to the rigors of transportation, handling and field 7. A CP system which is capable of yielding a
installation without excessive damage, when using uniform, ‘polarized’ potential of -0.9V
sound construction practices. (Cu/CuS04). (In widely varying soil
resistivities this should be accomplished
SURFACE CONDITIONING is a most significant,
with a combination of impressed current
and neglected, component of pipe coating
and galvanic anode systems).
application practices. It deserves attention and
should be a mandatory component of every pipe 8. Regular monitoring of the entire pipeline
coating system, and Specification. operation.
The ultimate pipeline protection system consists References:

of: Coulson K.E.W. et al., 1990, A Review of Gas
1. Pipe of high quality, uniform steel Industry Pipeline Coating Practices, ‘NACE
composition. Corrosion 90’, Paper 292, April 1990.
2. Pipe surface prepared to have no mill scale Koch, George, 1994, A Test of Stress, ‘Oil Week’,
present, and with an angular anchor Oct. 17, 1994, pp 12-16.
pattern. McKelvie, AX, 1980, Can Coatings Successfully
3. A chemically treated pipe surface having Protect Steel, ‘NACE Corrosion 80’, Plenary
high surface-free energy, and free of Lecture.
harmful contaminants. Mills, Dr. George, 1992, Mechanisms of Coating
4. Pipe surface treated with additional Adhesion, ‘NACE Corrosion 92’, Paper No. 4.
performance enhancing chemicals, such LW. Cox, 1993, Dual Coating System..., ASME Book
as: chromates, silanes, silicates or titanates. No. G00681-1993
Nunn, LA. and Norsworthy, R., 1993, Two-layer
coating effective with high temperature lines,
‘Pipeline Industry’, March 1993, pp 61-63.
298
Table I.
COATING PERFORMANCE CRITERIA

PERFORMANCE REQUIREIVIENT: COATING PROPERTY REOUIRED:
High Electrical Resistance – Low Absorption of Moisture and Gases

Resisting CP Exposure – Adhesion
– Chemical Resistance
– Moisture Resistance
– Impermeability to “O” and metal Cations
Resisting Soil Stresses – Adhesion
– Mechanical Strength
Resisting Temperature Shock – Heat Resistance
– Adhesion
– Coeff. of Expansion and Contraction
Resisting Exposure to Water – Water Resistance
– Adhesion
Resisting Micro Organisms – Inertness
– Adhesion
Resistance to Handling – Mechanical Strength
and Installation Rigors Adhesion
299
TABLE II
CHECKLIST FOR PIPELINE DESIGN

REQUIREMENTS
1. What is Life Expectancy?
2. Operating Conditions:
Temperature
Soil Conditions: Chemical
Resistivities
Microbial Presence
Water Pressure
Resistivities
Temperature
3. Environmental Aspects
Impact of Leaks
Construction Restrictions
4. Safety
People
Property
Ecology
5. Construction Limitations
Offshore
Arctic
Climatic Factors
Logistics
6. CP Design and Costs

7. Pipeline Operation
Maintenance and Costs
8. Leak Consequences
Economic Cost of Shut downs
Public Image
300
ENVIRONMENTAL AND ECONOMICAL ASPECTS
OF MULTILAYER COATINGS
Gunnar Friberg
Norwegian Pipeline A/S Norway
Co-author
Peter A. Blome
Blome GmbH & Co. KG Germany
International Conference for

Corrosion Prevention of the
European Gas Grid System
1992
301
Economical The choice should be based on a long term
environmental policy and planning. Only the
The total cost of corrosion protection of a pipeline traditional “End of Pipe Solution” where filters,
may be split into several cost factors. burners, scrubbers have been the acceptable method
for “good environment policy” is no longer valid.
Material, application, repair, installation, cathodic
protection, maintenance, inspection, design life Life Cycle Analysis
logistics, are all small and large cost centres which
combine to influence the total cost. Products, Application and Waste.
Short sighted decisions will result in higher total cost Although no consistent (direct) method for
at the end of a project when compared to carefully measuring or comparing materials in a Life Cycle
considered selections of a total coating concept. Analysis is available. it should be a part of the
Substantial savings are possible by correct design. evaluation of the individual coating systems. Total
energy input.(Fig 1) design life and possible re-use
Corrosion Protection of pipelines is normally a
of the materials (waste or by re-coating) are part of
combination of a barrier coating and cathodic
the main criteria for a life cycle analysis. Also cost
protection.
during the life time of the pipeline is an important
Modern high performance coatings however will factor for such an analysis.
keep the cathodic protection as a supplementary
system only. Environment and Safety
The application process of High Performance
Pretrentment Corrosion Top Layer
Coating Coatings in modern plants has low level of
environmental impact or safety risk for the
System 1 FBE Polyethylene
Blastcleaning Sa 2.5 30–70 microns 2–3 mm operators. The safety risk is mainly on the
mechanical equipment including the movement of
System 2 pipes, which is the same for all types of coatings. The
Blastcleaning Sa 2.5 FBE Polypropylene materials used are controlled within the application
Phosphoric wash 250–400 microns 2–4mm
equipment itself and not exposed to the operators.
Chromate
Exception is of course abrasive blast cleaning is by
(Fig 2) cleaning and FBE powder application operation,
where particular protection gear should be used.
Pipe Coating and the Environment This area of operation is well defined and
equipment and protective clothing now fully proven.
External Coatings
Waste deposit of coating material is not only
Preventive Environmental Protection expensive but also an environmental hazard.
The selection of a coating system should include an Products which can be re-eycled should be specified.
evaluation of the environmental risks and possible and non-recycling products avoided. Products with
effect on man and his surroundings. deposit hazards should be banned.
302
Multilayer coatings with Polyethylene or adequate distribution and maintenance of the
Polypropylene can be recycled in the event of cathodic protection system arise.
stripping or from the cut back area waste.
Re-coating the line, rather than increasing the size
Pipelines in Operation of the existing cathodic protection system may be
necessary in order to maintain the integrity of the
Coating material with an environmental problem in line. (l.)
application will also later in the event of repair to
the pipeline, or by a re-furbishing process present The corrosion protection cost for off-shore lines
an environmental and safety problem. may be reduced in the order of 20% with the correct
balance between Coating and Anodes.
The design life of the coating should be sufficient for (Fig. 5)
the total life of the pipeline. including any
considerations for extended operations.
DM COST SAVING/IMPROVED COATING
Cost of Corrosion Protection of Pipelines 9 000 000
500km – 36” Pipe
Only Factory applied coatings are discussed in this 8 000 000 1% Bare Area
paper. Coatings applied over the ditch are Multilayer 2
7 000 000
considered to be temporary protection only, with 3% Bare Area PP
short design life. The coating systems tested and 6 000 000 Multilayer 1
evaluated have a minimum design life of 50 years. PE
5 000 000
4 000 000
Transport/Handling/Installation
3 000 000
Transport, handling and risk for coating damage 2 000 000
should be closely evaluated in the design phase. Risk
1 000 000 Asphalt/Coal Tar
of coating damage during installation should be
7% Bare Area
included in the design of the coating system. Any 0
damage to the coating will involve additional money. 1 2 3
and reduce the barrier function of the coating. It will

also increase the need for inspection and Fig. 5
maintenance.
Cathodic Protection Experience obtained by Elf Aquitaine (2) even on

hot pipelines protected by FBE, shows very low
Correct design of the coating system will reduce the
current values. For instance only 1A is enough to
cost of the cathodic protection system and
protect 100km of a 10” pipe protected by impressed
considerably extend the life in the case of sacrificial
current buried in Oman. This should correspond
anodes.
roughly to 0.1 to 0.2% of coating damage. Similar
In the event cathodic protection ends as the primary values were estimated through cathodic protection
corrosion protection system. as it will with badly measurement on a 20km long 12” gas line laid in
deteriorated coating problems with monitoring, Dutch waters.
303
COST SAVING WITH IMPROVED COATING
Pipeline km 500 500 500

Pipe size inch 36 36 36
Total Cost Cathodic Protection DM 25 443 688 10 904 438 3 634 813
Cost Coating Application DM 31 583 376 38 761 416 44 503 848
Total Cost Corrosion Protection DM 57 027 064 49 665 854 48 138 661
Savings with improved coating DM 0 7 361 211 8 888 404
% of Total Cost 0 15 18
304
POWDER COATINGS
PLAYING ITS PART IN
THE PROTECTION OF PIPELINES
Denis Grimshaw
Technical Director
Functional Powder Coatings,
Jotun Powder Coatings
Powder coatings has played a part in the protection of pipelines for almost 40 years and is
still developing to ensure that it will continue to have an important role in pipeline
protection long into the future
In the 1960s the USA pioneered the technology of to improve mechanical resistance through the use of
fusion bond epoxy (FBE) which gave raise to a additional layers of modified FBE, liquid
generation of pipeline protection, focusing on the Polyurethane or thermoplastic outercoats.
excellent anticorrosion properties of Fusion Bond
Epoxy and tolerance to active cathodic protection The European technology
systems. The application of a thin film (350–600 Also in the 1960s the Europeans adopted
micron) provided an excellent anticorrosion coating technology based on isolating the pipe from its
for the alkali conditions obtained from cathodically environment through the use of a polyethylene
protected pipelines. The limitations of the system coating. Over the years this has developed from the
include relatively low mechanical resistance which initial sinter coat systems, which showed poor
can cause an increase in handling and laying costs adhesion, through soft adhesive and hard adhesive
for the pipeline during installation. two-layer systems. Eventually liquid epoxy primed
Some areas of Europe adopted this type of coating three-layer systems were developed which lead to
as the primary anticorrosion coating – notably the real breakthrough with the introduction of
British Gas in the UK who developed world class powder epoxy primers in the 1980s. These gave
specifications for fusion bond epoxy, Over the years economic, environmental and performance
the expertise in formulating fusion bond epoxy, advantages and converted most of the market to
greater understanding of the application methods what is known as three layer PE coatings consisting
and better controls have resulted in much better of thin (60–120 micron) fusion bond epoxy, adhesive
performance from FBE systems. More recently and polyethylene topcoat. More recently the
FBE-based coatings have undergone developments thickness of the epoxy has increased in appreciation
305
that better performance can be obtained with 200+ Where pipelines are being asked to operate in new
microns of epoxy. This increase in epoxy thickness environments such as high temperature, under
and the American trend for additional protection on insulation or in deep water then the failure modes to
the FBE shows a coming together of the North be expected may not be understood or even known.
American and European view to enhance Traditional methods such as evaluating loss of
mechanical and anticorrosion properties of the adhesion under cathodic protection or the
protection system through multi-layered complex formation of blisters may not be relevant to a
coatings involving a variety of materials and coating held at 130°C when water may not be
application methods. present and cathodic protection is unlikely to be
effective. New methods of predicting the life
Unique coating application expectancy of the pipeline protection system need to
Pipeline protection is perhaps a unique coating be adopted. Electrochemical Impedance
application in which competing technologies, from Spectroscopy is one such tool which is gaining
plastic through powder to liquids applied by popularity. The traditional anticorrosion aspects of
methods from extrusion through to spray and even coating are also being supplemented and even
flame spray methods actually work together to replaced by the additional demands of a coating
achieve the best end results. system for insulation/mechanical protection etc.
Pipeline protection, particularly in the oil and gas The new challenges are creating an atmosphere for
sectors has a high safety requirement as the failure innovation that has not existed in pipeline coating
of a highly flammable gas pipeline in an urban area for 40 years, producing potential solutions at an
could have catastrophic consequences. But as the ever-increasing rate.
search for oil and gas takes the industry to more
remote areas, deeper water, deeper wells and Optimised design
contaminated oils, the demands for protection of the The array of innovative solutions gives opportunities
transport system are increasing all the time. These for the pipeline engineer to optimise his design both
give rise to the problems of today that require functionally and economically. In order to do this he
solutions from tomorrow, with a history to is required to understand the local requirements for
guarantee success! protection/performance along the entire length of
the pipeline. Projects will depend less on utilising
An ever-more competitive world drives the
the same coating system throughout the line but use
technologies for new solutions to reduce total
different coating solutions and active protection
lifetime costs but without loss of confidence. A
systems in different areas to satisfy a local
potential example of this is the use of
requirement in the most economical manner. For
powder/powder or powder/liquid systems. They
example high temperature coatings after the
improve the mechanical properties of FBE which
compressor stations, instilated lines to maintain
may yield a lower material cost than three layer
minimum temperatures in critical zones, mechanical
polyethylene and/or reduce the lay costs compared
protection in rough terrain, high electrical insulation
to standard FBE but has the proven track record of
coating in area of stray current etc.
FBE as an anticorrosion coating.
306
This changing emphasis in design will lead to a need
for standardisation not only of the coating systems
but for categorising the end use environment criteria
which establishes the evaluation methods for the
environment/operating condition independent of
the coating system solution.
Internal coating of pipelines for improved efficiency
of the product flow or for anticorrosion purposes is
a mostly untouched market for powder coatings but
with improvements in application methods and the
need for faster coating operations, powder solutions
for this area will increase.
New powder products for use in the pipeline
industry over the last few years include High Tg
epoxy (150–160°C) with flexibility to facilitate reel
lay operations. High abrasion resistant coatings for
thrust bore protection. Energy absorbing coatings
for impact and backfill protection. Improved surface
tolerance.
Rapid changes
In conclusion the pipeline industry, which brings
together a wide range of coating technologies
ranging from plastics extrusion to conventional
paint, is undergoing rapid changes through the
demands of new situations, which is and will,
continue to challenge all the support industries for
solutions. Powder coatings will be amongst the most
innovative in offering solutions.
307

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CONTENTS

1. PRODUCT OUTLINE 4. PROCESSING

Standard product to cover most application

Two pack epoxy repair compound.

Product Gel Time

Corro-Coat EP-F 1010 15 seconds ±20%

Corro-Coat EP-F 1003 LD 15 seconds ±20%

Corro-Coat EP-F 1003 HW 21 seconds ±20%

Corro-Coat EP-F 3001

Antislip epoxy overcoat to enhance the adhesion

Corro-Coat EP-F 3002

Mechanical protection epoxy for use over FBE to

PRODUCT CORRO COAT CORRO COAT CORRO COAT CORRO COAT

@ 220°C 6 sec 10 sec 20 sec 7 sec

@ 240°C 3 sec 5 sec 15 sec 3 sec

Special application grade Corro-Coat EP-F 2004.

Strained Polarization CSA-Z245.20-M98 (12.13)

Typical Powder Properties

Typical Film Properties

Typical application temperature range is 225°C –

Typical Powder Properties

Typical Powder Properties

Typical Film Properties

Typical Powder Properties

Typical Film Properties

Typical Powder Properties

Typical Powder Properties

Property Test method Result

Moisture content CSA-Z245.20-M98 (12.3) Below 0.50 % (at time

Theoretical coverage N/A 1.72 m_ / Kg / 400m

Particle Size CSA-Z245.20-M98 (12.5) 99.5 % below 250m

Shelf life 25 °C or cooler 12 months (see text

Cure Time 230 °C @ 80 s

Differential Scanning Calorimeter Tg1 58 °C +/- 10 %

Typical Film Properties

Property Test method Result

Flexibility CSA-Z245.20-M98 (12.11)

Strained polarization CSA-Z245.20-M98 (12.13)

Chemical resistance CSA-Z245.20-M98 (12.9) No change

Hardness Shore D ASTM 2583 90

Impact resistance CSA-Z245.20-M98 (12.12) Pass (1.50 J)

Dielectric strength ASTM D149-95 >550v per 25µm

10 March 2000 Revision 1 English

Typical Powder Properties

HPL 100 – 75F650

PRODUCT DESCRIPTION : A 100% solids, two component modified urethane.

Film thickness per coat Theoretical spreading rate

HPL 100 – 75F650

HPL 100 BRUSH GRADE – 75F650R

Film thickness per coat Theoretical spreading rate

HPL 100 BRUSH GRADE – 75F650R

35°F (1.6°C) 6 Hours 96 Hours 24 Hours

88°F (31°C) 3 Hours 24 Hours 24 Hours

104°F (40°C) 1 Hour 8 Hours 24 Hours

HPL 100 BRUSH GRADE – 75F650R

HANDLING: Handle with care. Stir well before use.

1. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION

III. COMPOSITION/INFORMATION ON INGREDIENTS

IV. HAZARDS IDENTIFICATION

IV. FIRST AID

V. FIRE FIGHTING MEASURES

VI. ACCIDENTAL RELEASE MEASURES

VIII. ENGINEERING CONTROLS AND PERSONAL PROTECTIVE EQUIPMENT

IX. PHYSICAL AND CHEMICAL PROPERTIES