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NACE

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Title: NACE


1
Polymer Modified Cements in Rustproofing
NACE International
Northern Area Eastern Conference 2008
The Westin Harbour Castle Toronto, Ontario,
October 26-28, 2008
2
Content
  • Introduction
  • Polymer Modified Cements
  • Polymer modified cement based rust-proofing
    materials
  • Testing
  • Typical Properties
  • Applications
  • Conclusions

3
PORTLAND CEMENT
binding material in the form of a finely ground
powder, usually gray, that is manufactured by
burning and grinding a mixture of limestone and
clay or limestone and shale. When mixed with
water, the anhydrous calcium silicates and other
constituents in the Portland cement react
chemically with the water, combining with it
(hydration) and decomposing in it (hydrolysis)
and hardening and developing strength.
4
POLYMER
Any of class of natural or synthetic substances
composed of very large molecules, called
macromolecules, that are multiples of chemical
units called monomers
5

PORTLAND CEMENT
POLYMER
  • Organic
  • Inorganic
  • Low modulus of elasticity
  • High modulus of elasticity
  • Tough
  • Brittle
  • High tensile strength
  • Low tensile strength
  • Relatively high elongation
  • Very low elongation
  • Sensitive to temperature
  • Insensitive to temperature
  • Expensive
  • Inexpensive

6

Modern synthetic polymer modifiers
  • 1960s polymer latexes
  • Styrene butadiene rubber
  • Poly-acrylics
  • Poly-vinylidene chloride and many others
  • 1980s introduction of re-dispersable polymer
    powders
  • Ethylene-Vinyl Acetate (EVA)
  • Polyvinyl acetate-Vinyl Carboxylate (VA/VeoVa)
  • Acrylics
  • Styrene-acrylics and others

7

POLYMER CLASSIFICATION
Elastomeric
Thermoplastic
Polymer latexes
Thermosetting
Blends
Re-dispersable Powders
Polymer, monomer cement modifiers
Water-soluble polymers
Liquid resins
Monomers
8

SIMPLIFIED PROCESS OF POLYMER FILM FORMATION IN
CEMENT HYDRATES
Polymer latex flocculation of polymer particles
Formation of close packed structure
Formation of uniform polymer film
9

Polymer films connecting hydrated cement phase,
SBR latex polymer modifier
10
Performance Properties vs. Level of Polymer
Modification

3.00
2.50
Compressive Strength
2.00
Impact Strength (N/mm.10-3)
28 Day Air Cure Strength (MPa)
Impact Strength
1.50
Flexural Strength
1.00
Tensile Strength
5.00
Shear Bond Adhesion
0
Modification Level (Ratio of Polymer Solids on
Cement)
11

Polymer Modified Cement Rust-Proofing
Typical properties
Compressive strength (ASTM 109/C109M-05) 31.8-33.7 MPa
Tensile strength (ASTM D 2370 02) 4.5-5.3 MPa
Pull-Off Strength (ASTM D 4541-02) steel 2.76-3.45 MPa
Cathodic Disbondement (CSA-Z245) No disbondement
Freeze/Thaw Resistance (ASTM C666/C666M-03(2008) Procedure A 0 loss
12

Polymer modified cements as rust-proofing
material
Natural passivation/protection of steel surface
due to high pH of cement paste pH 13-14
To improve the effectiveness of polymer modified
cements as rust-proofing they can be further
modified with a variety of corrosion inhibitors
13

Polymer modified cement one cost approx 0.5
mm 300 hrs salt chamber
Solvent borne acrylic, one coat, approx 0.2 mm
300 hrs salt chamber
14

Polymer modified cement one cost approx. 1.0
mm 300 hrs salt chamber
Solvent borne acrylic, one coat, approx. 0.5 mm
300 hrs salt chamber
15

Cathodic disbondment testing
16

Polymer modified-cement rust-proofing after
cathodic disbondment testing upper three
specimens a thin coating , lower three
specimens a thick coating.
17
Chicago, Illinois, parking garage repair,
1988-1993
Saint John parking garage, 1996
18
Corrosion protection of steel pipes, Mariupol,
Metalurgstroj Company Ukraine, 2002
19

Kerkosand Company, Slovakia, steel tank holding
water for washing the processed sand, 2004
20

Kerkosand Company, Slovakia, rusted interior of
the steel tank, loose rust removed by scraping
21

Kerkosand Company, Slovakia after the loose rust
was removed by scraping, the surface was cleaned
by mechanical steel brushes
22

Application of Polymer Cement Rust-Proofing,
approx thickness 1 mm, 2004
23

Steel tanks for holding oil water, Nafta Gajary,
Slovakia, 2004
24

After wet sandblast
25

Coated with Polymer Modified Cement Rust-Proofing
26
Chemical and water cleaning of the rust from the
surface of the tank, Nafta Gajary, Slovakia, 2005
27
Steel tank after surface cleaning
28
Application of Polymer Modidified Cement
Rust-Proofing to a steel tank, Nafta Gajary,
Slovakia
29
Application of asphalt emulsion to a tank, coated
with polymer modified cement rust-proofing to
increase electrical strength of the protective
coating system, Nafta Gajary, Slovakia
30
Steel tank coated with Polymer Modified Cement
Rust-Proofing
31
Tank coated with 100 solids epoxy over polymer
modified cement rust-proofing for acid protection
32

Liptovsky Mikulas, Slovakia, winter 2007
interior structural reinforcement was treated
with polymer modified cement for corrosion
protection
33

Initial testing of bonding to wet steel - wetting
of the steel surface
34

Application of Polymer Modified Cement
Rust-Proofing to a wet steel surface
35
Polymer Modified Cement Rust-Proofing
Advantages
  • Water borne insensitive to surface moisture
  • Does not require white metal sandblast surface
  • Very good rust-proofing characteristics shown by
    testing and field performance
  • Less sensitive to pin-holes when compared with
    polymer based rust-proofing coatings
  • Very easy to repair if necessary

36
CONCLUSION
Coatings based on polymer modified cements
present another type of rust-proofing coating
systems for steel. The testing and field
evaluation of material originally used only for
rust-proofing of reinforcing steel in concrete
shows, that it can also be used as a protective
coating for other steel surfaces
Thank you
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