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Due to the continuous impact of destructive atmospheric influences and erosive environments, most metal structures and concrete gradually change in appearance over time and lose their functionality. Additionally, metal surfaces often suffer from wear and abrasion. Below are some notable applications of polyurea in surface protection – let’s explore them together.
Waterproofing and corrosion protection for pipes
Introduction
Vietnam has a hot and humid tropical climate, with a coastline extending over 3,200 km from north to south. This environmental condition leads to a very high rate of metal corrosion. According to survey data from the Vietnam Association of Corrosion and Metal Protection, corrosion damage in our country accounts for no less than 5% of GDP. Thus, it can be seen that the economic loss in Vietnam each year reaches up to 20-25 billion USD due to corrosion, which is indeed a significant figure. The damage caused by corrosion globally is also substantial; in the United States alone, this loss amounts to several hundred billion USD annually. Therefore, protecting metals from corrosion to extend the lifespan of structures and equipment plays a crucial role in the economy. Various measures can be applied to combat metal corrosion, including:
- Selecting suitable materials with high corrosion resistance for the working environment;
- Using methods to alter the corrosive aggressiveness of the environment, including the use of corrosion inhibitors;
- Choosing and using high-durability coatings with strong mechanical properties;
- Electrochemical protection.
In practice, the use of coating materials is a very common method that has been around for a long time and is a key strategy in preventing metal corrosion. In specific cases such as pipelines and underground storage tanks, a combination of coatings and electrochemical protection (cathodic) is often employed. For exposed pipelines and storage tanks, coatings are combined with corrosion inhibitors.
Metal pipes are painted with protective coating
Therefore, the choice of protective measures must be carefully considered right from the design stage of the project. In other words, the choice of anti-corrosion coating materials is especially important in determining the life of the project.
Conditions for metal corrosion
The primary agents causing metal corrosion are the presence of both water and oxygen. Steel (Fe-C) equipment and pipelines that come into contact with water (or water vapor) and oxygen typically undergo the following reactions:
- 3Fe+2O2→Fe3O4 (iron oxide)
Alternatively, oxidation-reduction reactions can occur in electrolytic environments (such as soils with low resistivity, acids, alkalis, and salts), leading to the formation of Fe3O4⋅nH2O (iron oxide). This process generates a corrosion current, accelerating the rate of corrosion. In some cases, steel corrosion can occur even in the absence of oxygen, particularly in the form of sulfate corrosion. The element sulfur is produced by microorganisms that decompose organic impurities.
Corroded steel pipe
Types of Corrosion in Buried Steel Pipelines
- Uniform corrosion: This occurs at a consistent rate across most surfaces along the length of the pipeline. This phenomenon is typically observed in older pipelines or those with protective coatings that have a short lifespan, as well as in relatively uniform corrosive environments.
- Localized corrosion (pitting): This refers to localized corrosion reactions, primarily caused by defects in the coating or low mechanical strength of the protective layer, which may be damaged during installation, leading to scratches in the coating.
- Erosive or mechanical wear corrosion: This type occurs on the inner surfaces of the pipes, caused by the flow of fluids that leads to the abrasion of impurities against the pipe surface.
- Stress corrosion: This is caused by the effects of compressive forces, soil loads, rocks, sand, etc., which deform the pipeline and interact with corrosive agents, resulting in corrosion.
Corrosion Protection for Buried Pipelines
Buried pipelines, when designed and installed, typically require a minimum lifespan of over 30 years. Maintenance and repair of underground pipelines can be very costly and sometimes impractical due to clearance conditions, deep burial in the ground, and the difficulties associated with dismantling and replacement. Therefore, any damage caused by corrosion is something users want to avoid, as it can lead to significant economic losses. One of the preventive measures from the outset is that users or designers must select the most suitable coating, with the highest mechanical and chemical durability, as well as the longest lifespan.
Underground steel pipe
The coatings for buried pipelines must possess the following characteristics:
- High resistance to water and oxygen penetration
- Good electrical insulation and electrochemical properties
- High adhesion to the pipe surface
- High mechanical and chemical durability
- Good impact resistance
- Scratch and abrasion resistance to protect against damage during handling, testing, transportation, installation, and other activities on-site
- Ability to withstand changes in soil conditions and thermal stress
- High crack resistance
Currently, various types of coatings are used worldwide to protect buried pipelines, including:
- Bituminous coal tar coating: This type of coating has been used for a long time. Its advantages include low cost, but it has the disadvantages of low durability, poor impact resistance, and being easily scratched during installation. Additionally, it contains harmful solvents. This type is now very limited and rarely used globally.
- Epoxy-based paint: This is a commonly used epoxy coating system that is easy to apply. However, its disadvantages include poor impact resistance, brittleness, susceptibility to cracking, and inability to withstand thermal shock. The lifespan of epoxy is not very long, typically ranging from 10 to 15 years.
- Polyethylene jacketing: This coating is applied by wrapping it around the pipeline, leaving multiple joints. The polyethylene jacket can be damaged during installation. It softens at 80°C (176°F) and melts at temperatures close to 100 to 110°C (212 to 230°F). It is not feasible to apply protective coatings on the inside of the pipeline. Therefore, the application of this type is quite limited.
- Polyurea coating: This has been widely used worldwide for about the last 30 years and has been employed in Vietnam for protecting pipelines for over 10 years. This type of coating can be considered the perfect solution for the 21st century, offering many superior advantages compared to other coatings.
- VOC-free polyurea coatings for buried pipelines are an example of newly developed coatings due to stringent regulatory requirements. These coatings are used for water and wastewater pipeline systems, oil and gas pipelines, and various industrial applications.
- Pure polyurea is used to line clean water pipelines because it is inert, water-resistant, and does not promote the growth of microorganisms and bacteria. The polyurea coating is highly suitable for wastewater pipelines as well as wastewater treatment systems due to its excellent chemical corrosion resistance and high mechanical abrasion resistance.
Polyurea coatings have several advantages over other types of coatings, including:
- Fast curing: Polyurea cures quickly (in 10-15 seconds), ensuring economic efficiency with high application rates and production effectiveness.
- High adhesion: It exhibits excellent adhesion to steel, concrete, and other surfaces.
- High impact resistance: Polyurea has a strong ability to withstand impacts.
- Excellent corrosion resistance: The corrosion resistance of polyurea is very high.
- High crack resistance: Polyurea is highly resistant to cracking.
- High tensile strength and elasticity: It has a high elongation and flexibility.
- Reduced hydraulic losses: The smoother internal surface of the pipe leads to lower hydraulic losses.
- Long-term economic efficiency: There is minimal degradation due to erosive wear.
In the case of industrial pipelines or wastewater pipelines, the pipes may be attacked by chemicals such as chlorides, alkalis, and acids. In such instances, polyurea exhibits high chemical resistance, ensuring a longer economic lifespan.
Corrosion inside oil and gas pipelines occurs when the pipe surface reacts with a combination of contaminants (e.g., moisture, oxygen, carbon dioxide, chlorides, and sulfur compounds) present in the gas. Operating parameters such as gas temperature, flow rate, and particle velocity are also crucial in preventing corrosion. Additionally, corrosion can be caused and sustained by microorganisms when nutrients are available on the inner pipe surface. This corrosion can be minimized by adhering to operational guidelines regarding temperature, velocity, and pollutant control. Polyurea coatings are used as an optimal solution to prevent corrosion in gas pipelines and oil pipelines.
Selecting a corrosion protection method, or in other words, choosing a protective coating for buried pipelines is particularly important. This choice ensures both economic and technical efficiency while also guaranteeing the longevity of the structure. Polyurea-based materials are currently the optimal choice for long-term corrosion protection of buried pipelines. With a lifespan of over 30 years in underground environments, polyurea provides significant economic benefits to society as a whole and minimizes the damages caused by corrosion.
Protection of foundations and walls
In rooms designed for operation or clean rooms with high humidity conditions, it is crucial to implement high-quality waterproofing and protection for floors and walls.
Polyurea coating on concrete floor
Depending on the specific technical requirements of the project, select appropriate waterproofing and protective materials. When making a choice, consider:
- The type of room and its operational characteristics (mechanical loads, temperature, chemicals)
- Aesthetic requirements
- Base condition
- Mandatory installation terms and conditions
- Project budget
We provide the installation of epoxy-based, polyurethane mastic, or polyurea waterproofing coatings. These modern materials have significant advantages that distinguish them from traditional roll and membrane materials. The Polyurea system is a wonderful and highest quality waterproofing and protective material for floors and walls. These are seamless, elastic, and durable membrane coatings that are commonly sprayed onto surfaces of any complexity.
The main advantages of Polyurea over traditional waterproofing and protective methods are:
- Solid, seamless, and crack-free structure
- Excellent material strength and durability
- Fast curing time (10-15 seconds)
- Fire safety and environmental friendliness
- High elasticity, vibration resistance, and load-bearing capacity
- Ability to withstand large temperature changes and high humidity
- High resistance to chemicals
- High abrasion resistance
Waterproofing and protection of car parking floors
The Polyurea system creates a seamless, high-durability product that performs well even when exposed to weather conditions and specific external impacts (such as oils, grease, and gasoline). The abrasion resistance and slip resistance are achieved by applying the Polyurea coating.
Actual construction of Polyurea coating for apartment parking floors
Advantages:
- Complete and absolute protection of the structure.
- Application after completion is flat and sustainable in submerged water environments.
- Direct application to existing substrates: reduces waste generation and contributes to improving the sustainability of the project.
- Faster installation: reduces labor time and optimizes costs.
- No additional weight on the existing structure (only ± 2.5-3 kg/m²).
- Cost reduction: eliminates the need for a protective plaster coating.
- Various finishes (colors and surface textures) ensure slip safety.
- High-temperature resistance: does not cause membrane collapse due to environmental factors.
- Working lifespan (over 15 years).
NewTec is a leading manufacturer and supplier of polyurea coating materials and solutions in Vietnam, under the brand name Polycoat. We continuously improve technology and enhance the quality management of our waterproofing and corrosion protection coatings to ensure long-lasting durability and the highest economic efficiency for every investor’s project.
If you are seeking a reliable B2B partner for high-quality polyurea products, look no further than NewTec Group! Contact us today to discover our competitive wholesale pricing on polyurea products and elevate your projects with our exceptional polyurea solutions. Don’t miss the chance to enhance the quality and durability of your constructions!
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