Epoxy rebuilding and lining systems for corrosive, erosive, and chemical service

ARCOR manufactures 100% solids, solvent-free, amine-cured epoxy systems for rebuilding and protecting metal and concrete. Formulations are based on Bisphenol F and novolac resins rather than standard Bisphenol A, for higher crosslink density, chemical resistance, and adhesion. The most aggressive-service products use 3.6-functionality novolac. Filled products use ceramic beads, mineral fillers, or Kevlar for abrasion and impact resistance. ARCOR has manufactured in the US since 1982.

Chemical resistance depends on concentration, temperature, and cure schedule. Recommendations are checked against ARCOR's chemical resistance data for the specific service conditions.

Systems

• Rebuilding compounds (2211, 8505–8509, 8526, TS-RB): paste and putty compounds for restoring worn or pitted metal to dimension. Up to 500 mils on vertical surfaces without slump (2211, 8526, TS-RB). Machinable with carbide tooling. Compressive strength up to 19,900 psi (8508). 8509 reaches immersion cure in 4 hours.
• Immersion coatings (S-30 Prime, S-30, S-16): novolac and multifunctional coatings for salt, brackish, and fresh water service, 20–60 mils per coat. S-30 is rated to 250°F immersion. S-30 Prime contains zinc phosphate to resist undercutting and fluoresces under UV light for inspection. S-16 is NSF/ANSI 61 certified for potable water.
• Chemical linings (EE-10, EE-11, EE-101, EE-121, S-20, 8518): EE-10 is rated for 98% sulfuric acid immersion. EE-101 and EE-121 are 3.6 novolacs rated to 350°F immersion. EE-11 is ceramic-filled and flexibilized for large tank walls and floors without fiberglass mat.
• Cavitation coatings (Spraythane, SLR-50, 8510): Spraythane and SLR-50 are epoxy-urethane hybrids with 300% elongation. 8510 is a ceramic compound applied up to 60 mils in one coat for hydro turbines and high-velocity pumps.
• Concrete systems (Arcrete, with EE-11 or S-20 topcoats): epoxy mortar for rebuilding chemically attacked concrete. Full cure in 72 hours, compared with 28 days for conventional concrete.
• Emergency repair (EE-99, 25551): moisture-insensitive compounds that set in 5 minutes and can return to service within an hour.

Product supply

ARCOR products are available both to end users and for resale. Plant maintenance teams and contractors can buy the same material ARCOR crews use, for in-house repairs, stocked spares, and outage kits. Distributors can stock and resell the line. Products ship as pre-measured two-component kits, and most compounds have a shelf life of up to 5 years.

• Hand application: brush, roller, squeegee, or trowel, for repairs and detail work.
• Cartridge spray: brushable products can be sprayed from cartridge systems on shop air, for medium-size areas such as tubesheets and pump casings.
• Plural-component spray: for large tank, duct, and containment linings, applied by trained operators.

Product selection is based on the substrate, operating temperature, chemicals and concentrations, and the cause of the damage. Application support, written procedures, and on-site training or supervision are available for crews applying ARCOR for the first time.

Key figures

• 13%condenser efficiency gain after sealing leaking tube-to-tubesheet joints with S-30 Prime and S-30 at 40 mils (nuclear plant)
• 95%of condenser tube leaks eliminated after tubesheet rebuild with TS-RB and S-30 (nuclear plant)
• 30 yearsin service on an FGD duct lining (EE-11, 75–100 mils), with only annual touchup (coal plant)
• ~85%of coating intact after 12 years on salt water circulating pumps (nuclear plant)
• 0% VOC100% solids, solvent-free systems suited to confined-space application

Case: condenser and evaporator tubesheets

Two condensers and two evaporators in treated city water service, retubed with tube ends flush to the tubesheet face. Blasted to SSPC-SP10 with a 3–4.5 mil profile, pits filled and weld seams striped with ceramic rebuilding compound, then two coats of immersion epoxy to 40 mils DFT and holiday tested. Full case study.

Applications

Power generation: condenser tubesheets and waterboxes, including galvanic isolation at copper-alloy tube to carbon steel tubesheet joints. Also circulating water pumps, FGD absorbers and ducts, sulfuric acid and caustic tanks for water treatment, and secondary containment.

Mining and mineral processing: slurry pumps, cyclones, chutes, flotation cells, leach tanks, and thickeners.

Pulp and paper: bleach plant equipment exposed to ClO2, NaOH, and peroxide, plus stock pumps and chip and lime mud handling.

HVAC and chillers: condenser and evaporator tubesheets and waterboxes.

Surface preparation and inspection

• Steel prepared to SSPC-SP5 white metal where possible, with an angular anchor profile of 3 mils minimum.
• Soluble chlorides tested by swab before coating. The limit for immersion service is below 3 µg/cm²; surfaces are pressure washed until they pass.
• Application only when the surface temperature is at least 5°F above the dew point. Conditions are logged through the job.
• Wet film thickness checked during application and dry film thickness after cure.
• Holiday testing to ASTM D5162: low-voltage wet sponge up to 20 mils, high-voltage spark above 20 mils.
• Material batch numbers recorded for traceability.

For larger scopes, ARCOR crews handle surface preparation, application, and inspection on site, or supervise and train the plant's own crews.