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    Guide toFabricating FRP

    Compositeswith Corrosion-Resistant VipelResins

    www.corrosionresins.com

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    Acknowledgments & Credits

    Cover photos,clockwise from upper left: PITSA Heil Process Equipment Belco Manufacturing Co. Inc.Tri-Clor, Inc

    End-use application photos: Beetle Plastics

    Belco Manufacturing Containment Solutions, Inc. HEE Environmental Engineering Heil Process Equipment JTI Companies PITSA Ram Fiberglass RL Industries, Inc. Tri-Clor, Inc. U.S. Composite Pipe, Inc.Materials & compositemanufacturing photos: Heil Process Equipment

    JTI Companies Justin Tanks, LLC Plasteel International, Inc. RL Industries, Inc.

    To the best of our knowledge, the information contained in this publication is accurate. However, we assume no liability for the accu-

    racy or completeness of such information. The data in this publication were gathered using generally accepted industry practices and

    equipment. Because equipment, material and environmental conditions may not be precisely the same, we cannot guarantee that oth-

    ers will achieve exactly the same results. The user of this publication is solely responsible for determining the suitability of the guides

    information to the users particular operation or end-use application.

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    Table of Contents

    1. Introduction ..............................................................Page 3

    2. Selecting a Corrosion Resin System .............................Page 4

    3. Selecting Reinforcements ............................................ Page 12

    4. Initiator, Promoters and Other Additives .......................Page 16

    5. Resin Quality Assurance and Record Keeping ...............Page 20

    Table 1. Common Quality Control Tests .....................Page 22

    Table 2. Getting Started with

    Quality Assurance Equipment .................................. Page 23

    6. Resin Handling, Safety and Regulatory Issues...............Page 24

    7. Composite Processing Guidelines ................................Page 26

    8. Appendix

    Typical Formulations and Gel Times

    of Select VipelResins ............................................ Page 32

    Trademark Notices ................................................. Page 36

    Vipel Corrosion Resin Cross Reference ......................Page 37

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    1Introduction

    2

    Portion of a blower fanVipelK022-CCHeil Process Equipment

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    Depending on the experience and expertise of the reader, this guide can serve asa reference source, a shop handbook or an educational tool. It has been prepared

    primarily for fabricators who may benefit from AOC resin technology to makefiber-reinforced polymer (FRP) composites that will be used in corrosive environ-ments. This publication may also prove helpful to engineers, consultants, facilitymanagers and other decision-makers who recommend, design or use compositesfor their corrosion-resistant properties.

    In thousands of locations around the world, FRP composites made with AOC res-ins have been fighting the high cost of corrosion for decades. Vipelchemistrieshave set the global standard for large diameter water and sewer pipes, under-ground fuel storage tanks and sewer line rehabilitation. Applications using Vipelcorrosion-resistant resin technology are also found in chemical processing plants,mineral solvent extraction operations, power generation sites and food processingfacilities.

    AOC continues its leadership in corrosion-resistant composites with a wide rangeof Vipel thermoset resins designed to resist corrosive attack from chemicals, mois-ture, thermal cycles and fatigue-stress. Certain Vipel products are also designedfor food contact, potable water, pharmaceutical and other applications requiringregulatory compliance from such authorities as the U.S. Food and Drug Admin-istration (FDA) and the U.S. Department of Agriculture (USDA). For specific re-quirements, there are Vipel resin grades for flame retardance, low smoke, highertemperature resistance and higher mechanical properties.

    You can use this manual to determine which Vipel corrosion resin from AOC meetsspecific performance requirements without over designing or overpricing theapplication. Because Vipel resin technology is part of an engineered materialsystem, this guide also covers: reinforcement selection, catalysts and related chem-istries, performance additives, quality checks and record keeping. In addition, theguide covers important issues related to fabri-cation, the environment, health and safety.

    ScrubberVipel K022-CC

    HEE Environmental Engineering

    1

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    2Selecting a

    CorrosionResin System

    4

    Stack liner rib sectionVipelK022-ACTri-Clor

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    Fabricator responsibilityMost fabricators warrant materials, workman-ship and compliance with referenced standards.Material warranties generally exclude corrosionresistance or performance. The chemical make-up and process are controlled by the user, not thefabricator. While most users accept these condi-tions, the fabricator has the ultimate responsi-

    bility for proper resin selection. Resin manufac-turers provide critical resin physical property,regulatory, laminate corrosion resistance andlaminating process and cure system data.

    AOC is committed to providing the fabricatorand his customer the best information possibleto guide the selection of resin systems withultimate confidence in equipment performance.

    What the fabricator needs to knowReliable resin selection demands accurate andcomplete information about the application anduse of the proposed equipment. When the cus-tomer is depending on the fabricator to makethe resin selection, detailed service informationis needed. The fabricator should demand thedata even when the customer clearly specifiesa particular resin and inquires about the accept-ability of alternate resins.

    Frequently the user will identify a resin system byname and provide detailed laminate construc-tions for particular applications. These require-ments may be based on past experience, resin

    manufacturer recommendations, the supplier ofthe chemicals being handled, or the manufac-turer of an equipment package.

    The fabricator should always verify the sourceof the selection and the acceptability of alter-nate systems. In the absence of clear informa-tion from the user, the fabricator should confirmthe users stipulation in writing and absolvehis/her company of any selection responsibil-ity. The conscientious fabricator wants to dothe best possible job for the customer. It canonly be done with thorough and accurate

    information about the chemical service and theprocess conditions.

    The chemical environment and service temperature

    typically govern the selection of resins for corrosionresistant equipment. Other factors which may influ-ence the selection include:

    Knowledgeable users specify particular resins orgeneric resin types based on past experience withFRP equipment in their plants.

    Engineering rms tend to specify several resinsbased on guidance from resin suppliers and fabri-cators when generating specifications for particularindustries and processes.

    Mechanical and structural performance require-ments may be more significant than the chemical ex-posure.

    If historical chemical performance or publishedexposure data is not available, laboratory testing ofcandidate resins is dictated.

    Economic considerations are more important tothe decision-maker than long-term performance orlife cycle cost.

    The fabricator controls the selection based on theusers inexperience, or satisfaction from prior pur-chases.

    The fabricators compliance with U.S. Environ-mental Protection Agency (EPA) Maximum Achiev-able Control Technology (MACT) standards for thereinforced plastic industry dictate accountability ofresin consumption by Hazardous Air Pollutant (HAP)content. For corrosion resins, the regulated HAPs arestyrene and methyl methacrylate monomers.

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    Rinse tank designPITSA

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    Fabricator recommendation

    When the user, specifer or owner depends on thefabricator to make a recommendation for selectionof the resin system, be certain the user states allaspects of the application and service. Some infor-mation in the following checklist of application and

    service factors does not directly impact resin selec-tion but clearly influences the acceptable design. Toselect the proper resin system, determine:

    The common name and, when possible, thechemical nameof the substance to which the com-posite will be exposed. For example, muriatic is acommon name for hydrochloric acid. This type ofinformation is generally contained in the MaterialSafety Data Sheet for the medium.

    The concentrationof each of the chemical com-ponents. In waste streams or other mixtures, it is

    imperative that every component be identified bychemical name and concentration.

    Specific gravity of each chemical solutionor mixture.

    pH, if it is an aqueous system.

    Normal operating temperature range.Include any anticipated temperature excursions dueto process upset or other abnormal condition.

    Maximum use temperature not maximum de-

    sign temperature. Refer to AOC Resin Data Sheetsfor specific information about resin heat deflectiontemperature.

    Pressure and/or vacuum conditions.For tanksit is also important to know if filling will be by pres-sure such as from a tank truck. Closed vent systemsmust be clearly identified with a statement of pres-sure drop to be applied to the equipment.

    Length of exposure to the medium if less thatcontinuous. In unusual cases, only a short periodof exposure is to be expected. For example, thelaminate may need to only withstand occasionalsplashes.

    Process description where a reaction such asneutralization takes place in the tank. Exothermic re-actions must be described with detailed temperaturerange from the start to the maximum with controlmethodologies to insure operating temperature lim-its are not exceeded. Time range may also be impor-tant to avoid thermal shock.

    Flow rates range of inlet and outlet flows.

    Fire retardancy, where applicable. This mustbe clearly stated, including flame spread ratingand smoke requirements.

    Installation location (indoors or outdoors). Ifoutdoors, annual ambient temperature ranges,local wind, snow load and seismic requirementsare needed.

    Insulation and heating requirements.This is particularly important when freeze protec-tion or other temperature maintenance is dictated.When heating coils are used, adequate clearanceat coil entry and exit nozzles must be provided toprevent localized overheating.

    Agitation and/or re-circulation re-quirements. Tank supported agitationequipment can significantly impact designconsiderations. All loads must be providedincluding dead weight, horsepower, and imposedtorque and bending moments. Side entry mixersshould be independently supported. Re-circula-tion should not interfere with normal fill, outlet oroverflow openings.

    Other mechanical loads such as platforms orwalkways that may need to be supported on theequipment.

    Food and drug requirements. Use in foodand drug applications must be identified whereapplicable.Cleaning and sterilization techniquescan be more severe than the chemical exposure.Composite applications in food and pharmaceu-tical processing must meet requirements for foodcontact and resistance to specific cleaning andsterilization materials and techniques. AOC offersresins that comply criteria of the U.S. Food andDrug Administration (FDA). Refer to AOC resindata sheets for specific information.

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    AOC Corrosion Resistant Resin GuideAOC has a Corrosion Resistant Resin Guide both inprint form and on its dedicated corrosion resins Website www.corrosionresins.com. Normally a suitableresin can be selected from the Corrosion ResistantResin Guide based on the information covered in theprevious section.

    The temperature data presented in the guide repre-sent the highest temperature at which the individualresin has demonstrated acceptable service in either alaboratory environment, other similar service or actualfield use. Refer to AOC Resin Data Sheets for specificinformation about resin heat deflection temperature.Environments not tested may be done at customer re-quest. Serviceability should not be interpreted to meanthe full retention of all visual and mechanical proper-

    ties, but rather an expectation of how a properly de-signed and fabricated structure will perform.

    The resistance of Vipel resins to the chemical envi-ronments listed in the guide has been established ac-cording to ASTM C581 or in actual use. The ASTMC581 immersion test is generally more stringent thanactual service conditions. The list does not apply tomixtures of different media unless explicitly stated. Itcontains chemically declared media and some brandname chemicals, which were not precisely identifiedwith respect to chemical composition.

    Short exposure periods at higher temperaturesusually do not affect product integrity if the heatdistortion temperature of the cured resin is notexceeded. However, the highest temperaturereached and exposure duration at this tempera-ture should be indicated when making inquiries.

    In those instances where the specific applica-tion is not listed, the fabricator is encouraged tocontact AOC. The checklist information aboveshould be included and should be directed to:

    Corrosion Product LeaderAOC950 Highway 57 EastCollierville, TN 38017Phone: (901) 854-2800Fax: (901) 854-2895

    The Corrosion Advisor button on the AOC cor-rosion website (www.corrosionresins.com) pro-vides a direct link to send an e-mail message withthis information to the Corrosion Product Leader.

    Resin Selection OptionsThe fabricator has a number of options that caninfluence the resin selection process. Less aggres-sive chemical environments result in a broaderrange of possible resins. More aggressive ser-vices typically leave fewer choices. Furthermore,the selected resin system must have reasonableprocessing characteristics in the various moldingand fabrication operations to be used.

    AOC Vipel resins listed in this guide are suit-able for typical hand lay-up, spray-up and fila-ment winding processes, principally used in themanufacture of tanks, pipe, duct and other cor-rosion resistant equipment. Brief descriptions ofavailable resin technologies follow. To assist thefabricator with more detailed resin information,typical formulations and gel times of select Vipel

    resins are listed in the Appendix of this guide.AOC technical support can also help fabricatorsdevelop formulations for closed mold processessuch as resin transfer molding, resin transfermolding light and resin infusion.

    CAUTION: Many applications and chemicalservices listed in the guide make reference toNOTES in the column adjacent to the chemical.These notes are an integral part of the listing rec-ommendation and must be strictly followed. Thenotes indicate application-specific requirements

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    for veil materials, cure systems, liner construction,thickness and post cure.

    Resin Technologies

    AOC manufactures a wide range of corrosion resis-tant products comprised of vinyl esters and polyesters.Vinyl ester resins include bisphenol A epoxy and ep-

    oxy novolac products. Polyesters include isophthalic,terephthalic and chlorendic products. Vinyl esters aresold to the chemical, pulp and paper, pharmaceutical,mining, power, food and high purity markets. Vinylesters and polyesters are used for municipal water andwaste treatment and a wide range of general chemicaland food processing applications. High tensile elon-gation properties of bisphenol A vinyl esters providesuperior toughness for improved impact resistance.

    Vinyl Esters

    Most vinyl ester resins are provided unpromoted togive the fabricator maximum flexibility in formulaingto meet in-shop process and cure requirements. Lessexperienced fabricators are urged to carefully study

    the formulations providedand consult the AOCProduct Leader for guid-ance in developing pro-moted cure systems.

    Bisphenol A epoxy vi-

    nyl esters are well suitedto all processes and arecompatible with most veiland reinforcement ma-terials. These resins alsohave the greatest rangeof promoter and initiatorsystem flexibility. Special-ized systems like BPO/DMA cures for sodium

    hypochlorite service work reliably with these resins.Other systems are available for thick parts and thinparts where gel time and exotherm temperature flex-ibility is important.VipelF010series resins are the most commonly usedresins for corrosion service. The styrene content of Vi-pel F010 is relatively low which helps fabricators meetMACT requirements.

    Vipel F007has an even lower styrene content and is apossible alternative. Vipel F010 will have better corro-sion resistance in most harsh chemical environments.

    Vipel F017 is an elastomeric epoxy vinyl ester usedfor bonding primer applications and where inherenttoughness is required.

    Vipel K022 fire-retardant bisphenol A epoxy vinylesters are for fire and corrosion resistant service.

    Vipel K022 series includes several technologies: Vipel K026-AA series meets Class I ame spreadand smoke development code requirements as testedper ASTME 84 without the use of synergists. This ver-sion is the highest in specific gravity. Vipel K022-AC series meets Class I ame spreadcode requirements as tested per ASTM E84 withoutthe use of synergists. It is suggested for chimney linerapplications. Vipel K022-CC series meets Class I ame spreadcode requirements as tested per ASTM E84 with the

    addition of 1.5% antimony trioxide. It is suitable for awide range of applications. Vipel K022-CN series meets Class I ame spreadcode requirements as tested per ASTM E84. It doescontain synergistic antimony products. The primaryuse is for structural parts. Vipel K022-E series meets Class I ame spreadcode requirements as tested per ASTM E84 withoutthe addition of synergists. The product is designed forinfusion processes.

    High-strength HVAC ductingVipel K022-AARam Fiberglass

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    Dual laminate tankVipel F010RL Industries

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    High cross-linked bisphenol A epoxy vinyl estersareunique variations of the basic vinyl ester chemistry.

    Vipel F080 series are high performance epoxyvinyl esters that provide superior corrosion resistanceto both acidic and alkaline environments and havegood thermal mechanical values.

    Vipel F083is a low styrene (

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    ric chloride, coagulant aids, potable water, municipalwaste water and water-based polymer emulsions. Re-fer to the AOC Corrosion Resistant Resin Guide forspecific recommendations.

    Isophthalic resins are considerably less expensive thanvinyl esters and are easier to work with in some fabri-

    cating operations. Because of the lower cost, for lessdemanding environments, these resins are often usedin the structural layers behind inner corrosion barriersconstructed with premium corrosion-resistant resins.Isophthalics are usually pre-promoted and providedwith reasonable gel times for most hand lay-up andspray-up using conventional room temperature MEKperoxide cure systems. The absence of fabricatormeasuring and promoting requirements enhances thesavings.

    Vipel F701 isophthalic polyester is a classic 1:1isophthalic acid/maleic anhydride resin with excellenthandling and processing characteristics. Vipel F701has been used extensively in a variety of mildly corro-sive environments for storage vessel, piping, potablewater, food grade, pollution abatement, ductwork andother applications.

    Vipel F701-S series products contain less styrene inorder to address MACT compliance issues.

    Vipel F737 and Vipel F739 are resilient isophthalicpolyester resins. These resins also have excellent han-dling and processing characteristics; are ideally suitedfor aqueous environments and are proven products formany large diameter pipe applications such as intakeand outlet pipes for power stations.

    Vipel F707 is a NPG (neopentyl glycol) version thatwill adhere to certain grades of PVC. Bonding testsare needed to confirm that adequate adhesion is ob-tained.

    Vipel F764is a high cross linked isopolyester resin andmeets Underwriters Laboratories1316 and 1746 re-quirements for underground storage applications. UL1316 applies to all-composite underground storagetanks for petroleum products, alcohols and alcohol-gasoline mixtures. UL 1746, Parts II and III, applies tosteel tanks that are protected with an external polymercomposite laminate.

    Vipel K733series are fire retardant isophthalic resins.Vipel K733-A series meet Class I code flame spreadrequirements when tested per ASTM E84 without theuse of synergists. Vipel K733-B series require additionof 1.5% antimony trioxide to meet Class I code flamespread requirements when tested per ASTM E84.

    Tank section oblated for shipmentVipel F737PITSA

    Cooling water pipe headerVipel F737Beetle Plastics

    0

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    Terephthalic polyester resinsare chemically similarto isophthalic resins and provide corrosion-resistantservice that competes very favorably with isophthal-ics. Since terephthalics generally have a higher heatdistortion temperature and higher elongation thanisophthalics, terephthalics are generally recommend-ed over isophthalics except where UV resistance is

    required. The primary chemical difference betweenterephthalics and isophthalics is the type of acid terephthalic or isophthalic used to create the basepolyester resin.

    Vipel F713 is a standard 1:1 terephthalic/maleicresin that also has excellent handling and processingcharacteristics.

    Vipel F774 is a high crosslinked version engi-neered primarily for composite underground fuelstorage tanks but may be used for any applica-tion needing resistance to a wide range of sol-vents and chemicals, including many acidic solu-tions. These resin technologies meet UnderwritersLaboratories1316 and 1746 requirements for

    underground storage applications.

    Product Selection GuideThe AOC Product Selection Guide is designed tohelp fabricators select the optimum Vipel resin thatmeets the needs for value and performance. TheProduct Selection Guide lists and describes Vipelresins by resin type and product series designa-tion. The Product Selection Guide also has a CrossReference to AOC Corrosion Resins that lists simi-lar resins from other major corrosion resistant res-

    in manufacturers. This table can help fabricatorsselect the appropriate AOC resin or resins wherespecifications allow or equal or equivalentsubstitution. This Cross Reference is also includedin the Appendix of this publication. If youwould like a copy of the most currentProduct Selection Guide, contact your AOCCorrosion Specialist or download a copy fromwww.corrosionresins.com.

    2

    Underground storage tanksVipel F774Containment Solutions

    Section of sewer interceptorVipel F701U.S. Composite Pipe

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    3Selecting

    Reinforcements

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    Fiberglass woven roving

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    Selection of reinforcements is not as complex as se-lection of resins. Chemical service can influence theselection of veil material for exposed surfaces and thetype of glass for gun rovings and mats used in inte-rior layers adjacent to the surface. Industry standards,project specifications, fabrication processes and ap-plication techniques usually include stipulations for the

    other forms of reinforcement to be used.

    Surface Veils

    Surface veils are intended to provide limited reinforce-ment to thin [0.01 to 0.03 inches, (0.25 mm to 0.76mm) thick] resin rich layers on the exposed surfacesof corrosion resistant equipment to reduce cracking

    and crazing of the resin. The most commonly usedveil material is monofilament fiber made from Type Cor ECR glass. Synthetic veils, such as Nexus, madefrom polyester or other man made fibers are used inchemical environments that would attack glass fibers.Specialty veils are frequently preferred in some severeenvironments.

    The weight and thickness of the veil plies dictate thethickness of a veil-reinforced layer. The resulting sur-face layer is usually 90 to 95% resin by weight. Typi-

    cal veils produce [0.010 to 0.015 inches (0.25 0.38 mm)] thickness per ply or layer. As notedin the Corrosion Resistant Resin Selection Guide,some aggressive service conditions require two(2) plies or layers of the required veil material.

    Chopped Strand Mats

    The strands in chopped strand mats are typically1.5-inch (3.8 cm) long Type E or ECR glass fi-ber. Mats are typically available as roll goods inweights from 0.75 to 3.0 oz/ft2(225 to 600 g/m2) and widths from 3 to 120 inches (7.6 cm to304 cm). The most commonly used for corrosionresistant laminates are 0.75 and 1.5 oz/ft2(225to 450 g/m2). Binders applied to the chopped fi-bers to hold the mat together must be compatiblewith the resin systems used.

    Some chopped strand mats, while compatiblewith most corrosion resins, can exhibit a visualphenomenon in some vinyl ester resins referredto as glint and jack straw. While this appear-ance does not impact the laminate structurally,it may affect long term chemical performancein aggressive environments. Presence of glintand jack straw may be a cause for rejection bysome users.

    C-glass veil

    Synthetic veil

    Chopped strand mat

    Hand lay-up of fiberglass mat

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    Woven Roving, Specialty FabricsWoven roving[24 oz/yd2(814 g/m2)] is the mostcommonly used supplemental reinforcement for handlay-up and spray-up structural layers in corrosion resis-tant laminates. These materials are usually precededand followed by a layer of chopped strand mat orspray-up equivalent to avoid adjacent woven plies.

    Accepted industry practice is to alternate mat or chopplies with these fabric reinforcements.

    Bi-directional fabricsare similar to woven roving ex-cept that the rovings are held together with a non-glassknitted stitch yarn. This keeps the rovings straight inthe finished laminate and tends to increase the physi-

    cal properties in comparison to woven roving.

    Uni-directional fabricsare used to impart strength inone direction. Uni-directional fabrics generally havethe glass fibers in the fill direction (across the width ofthe roll) and the knitting yarns in the weft direction (thelength of the roll). These fabrics are frequently addedto filament wound structures to add longitudinal oraxial strength, particularly where the winding angleis shallow (nearly circumferential). These materials are

    available in a variety of widths from 4 inches to 120inches (10.2 to 305 cm) depending on the type ofproduct and the weaving or knitting process and ma-chinery used.

    Combination FabricsThese fabrics are a combination of chopped strand

    mat with woven roving or bi-directional fabric on asingle roll. Numerous weight combinations and widthsare available. The most common combination is a 1.5oz/ft2 (450 g/m2) mat attached to a [(24 oz/yd2(814 g/m2)] woven roving or [(18 oz/yd2 (610 g/m2)] bidirectional fabric. These specialty materials areconvenient for exterior joints in pipe, tanks and duct.Some specifications restrict or prohibit the use of thistype of reinforcement without prior written approval.

    Gun Roving

    Gun roving is a continuous fiber suitable for choppingor cutting with a conventional spray-up chopper gun.The roving is delivered in a coreless package called adoff or ball. The density of the material is typicallygiven as the yield expressed in yd/pound. Typicalgun roving yields are in the 210 to 230 yd/pound(423 to 463 m/kg) range. Gun rovings are usuallyType E glass. Type ECR rovings are also availableand provide better chemical performance in aggres-sive environments.

    As with chopped strand mat, the binder on the rovingmust be compatible with the resin system being used.The binder or sizing on the roving also impacts theprocessing attributes such as choppability, fiber fall-out from the resin glass stream, degree of static build-up and catenary.

    Woven roving

    Unidirectional fabric

    Gun roving

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    Probably most important are the wet out and roll outcharacteristics after the roving has been chopped andsprayed onto the part with the resin. The ultimate qual-ity of the laminate is a function of the degree to whichentrapped air is removed. Ease of air removal dur-ing rollout will directly impact the workers ability toachieve acceptable quality.

    Filament Winding Rovings

    Filament winding rovings, like gun rovings, are con-tinuous fibers provided in doffs or balls. Roving weightis measured as yield and expressed in yd/pound.Typical yields are from 113 to 675 yd/pound (227 to1,359 m/kg). Winding rovings are usually Type E

    glass. Type ECR rovings are also available andprovide better chemical performance in aggres-sive environments. Binders or finishes on windingrovings must be compatible with the resin systembeing used. The binder impacts the wet-out, pro-cessing and handling characteristics.

    Winding rovings need to be resistant to fiberbreakage as they are pulled from the package ina creel through various guide eyes to the wet-outbath or applicator head. Some systems pre-wetthe roving in a resin bath while others apply resinto the mandrel. In either case the handling char-acteristics from the roving package to the partare very important. Once the roving is on thepart, the wet-out, ribbon tension and uniformity of

    the multi-roving band influence the thickness, den-sity and glass-to-resin ratio in the cured laminate.

    Filament winding roving on creel

    Filament winding process

    Automated spray-up process

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    4Initiator,Promotersand OtherAdditives

    Adding promoter to unpromoted resin

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    Open molding processes typically utilize room tem-perature cure systems. Catalyst is added to resin thatis pre-promoted as purchased or blended by the fab-ricator using promoters, accelerators and other addi-tives to provide specific process curing characteristics.Gel time, gel to peak exotherm time and temperaturecan be selectively tailored by careful knowledgeable

    use of these additives.

    Typical Vipelresin gel times in the Appendix of thisguide gives detailed formulations for various resins toprovide the fabricator maximum flexibility in dictatingcure behavior. Each formulation listed identifies thecatalyst, promoter, accelerator and any other additivepreferred to achieve the indicated gel and cure times.

    InitiatorsInitiators,frequently referred to as catalysts, start thegelling process. Initiator is mixed into promoted resinsimmediately prior to use or are injected by spray gun.When practical it is best to pour additives into thevortex so that they do not cling to the side wall of thecontainer. Initiator is injected into the promoted resinstream in spray-up equipment systems. CAUTION:

    Initiator is NEVER mixed with promoters or accelera-tors. The best procedure is to add initiators to resinthat already contains promoters or accelerators. Di-rect contact of an initiator with a promoter or accel-erator can create an explosive condition or cause afire. Consult the MSDS for each of these materials forsafe handling and storage.

    MEKP (methyl ethyl ketone peroxide)is the mostcommonly used organic peroxide initiator. In NorthAmerica, active oxygen content of MEKP provided by

    suppliers is typically in the area of 9%. The activeoxygen content of organic initiator peroxide var-ies by geographical region. Fabricators shouldcheck with their local organic peroxide initia-tor supplier for specific active oxygen contentguidelines. MEKP is typically used with cobaltnapthanate (CoNAP) promoter and DMA/DEA

    accelerators for room temperature curing of mostpolyester and vinyl ester resins. Concentration ofisomers/active oxygen variations of MEKP canprovide additional cure flexibility with some resinand promoter systems. There are several versionsof MEKP. For example, some have low dimer con-tents and others have high dimer contents. Forvinyl ester resins, MEKP initiator with a high di-mer content is the preferred initiator. Examplesof MEKP products that are high in dimer contentare Hi Point90, LupersoxDHD 9 and Norox

    MEKP 925 H. Examples of MEKP that are lowin dimer content are Luperox DDM-9 and NoroxMEKP 9.

    CHP (cumene hydroperoxide) is principallyused with high reactivity vinyl ester resins such asVipel F085 to provide lower exotherm tempera-tures and reduced shrinkage. CHP performs wellwith CoNAP/DMA formulations. CHP is also suit-able for some other resins where slower curesare required or thicker laminates are made in a

    single pass without intermediate cure and exo-therm stopping points.

    BPO (benzoyl peroxide) is available in powderform, as a paste or in a liquid emulsion. Powdersand pastes are difficult to use and control. WhenBPO is required, emulsions with 40% active BPOcontent are preferred for use with Vipel vinyl es-ter resins. When determining BPO additive con-centration take into account the dilution factor.(Gel time tables are based on 98% active BPO.)

    BPO initiator with DMA accelerator is preferredfor laminates in sodium hypochlorite service inplace of conventional MEKP/CoNAP/DMA curesystems. The ratio of BPO to DMA is critical toavoid gel and cure inconsistencies. Post curingis required to achieve complete cure with BPO/DMA.

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    MEKP catalyst with dispenser

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    Blended initiatorsTrigonox239A is an example of a proprietary blendof initiator that may reduce foaming in some vinyl es-ter resins.

    Promoters and AcceleratorsCoNAP (cobalt naphthanate) promoteris typically

    a 6% solution in an organic solvent. Other versionssuch as 12% are available. The formulations provid-ed in the Appendix of this guide are based on 6%CoNAP solutions.

    DMA (N,N di-methylaniline)is used as an accelera-tor in conjunction with CoNap promoter when usingMEKP or CHP initiators or by itself with BPO. DMA isnormally provided as a 100% active liquid however10% active versions are available.

    DEA (N,N di-ethylaniline) can be substituted forDMA in some systems to extend gel times and reduceexotherm temperatures in highly reactive systems.With respect to health safety, DEA is marginally saferthan DMA. Consult the MSDS for current status

    Inhibitors and Gel Time ExtendersTBC (tert butyl catechol) is an inhibitor frequentlyadded to styrene monomer to provide longer shelf lifewhen the monomer is purchased in drum quantities.When any styrene containing TBC is added to promot-ed resin mixes, the resin gel time and cure characteris-

    tics may be altered. TBC as purchased is usually 85%active inhibitor and should be used very carefully. Avery small amount of TBC can have a significant andinconsistent impact on gel and cure. Addition of smallquantities is best controlled using a 5 or 10% solu-tion in styrene and adjusting formulations accordingly.CAUTION:Care must be taken to prevent TBC solu-

    tions from contacting the skin. Refer to the MSDS.

    2,4-pentanedione (2,4-P) is a gel time extender orretarder for vinyl ester resins; however, it is also a pro-moter for polyester resins. 2,4-P is recommended forlong gel times because it has minimal effect on theultimate cure. It is effective for MEKP and CHP initiatorsystems but is not effective with BPO initiator systems.Caution is needed using 2,4-P. Refer to the MSDS forhandling instructions. Several of the tables in the Ap-pendix of this publication demonstrate formulations

    where gel times have been adjusted through the useof 2,4-P.

    Other Resin AdditivesOther chemicals and materials may be added to theresin formulation to achieve specific end-use require-ments. Fabricators should review the appropriate lit-erature and check with an AOC technical representa-tive and the additive supplier to see how a particularadditives use may affect resin processing or perfor-mance. Here are the more widely-used resin additives

    that unlike catalysts, promoters and inhibitors, are notdirectly related to resin cure:

    Ultraviolet absorbersare typically added for appli-cations that must resist the degrading effects of long-term exposure to sunlight. UV absorbers are usedon the exterior portion of the laminate and wherespecified by the buyer. Most specifications define theamount and type of UV absorber. Alternatively, therecommendation of UV absorber manufacturers canbe followed. UV absorbers are most commonly added

    to the top coat but may be added at a lower loadingto the structural layer.

    Synergistsmay be added to added to fire retardantresins to meet specifications calling for code flamespread requirements. The most commonly used fireretardant synergist fillers are antimony oxides. Theseproducts are used with halogenated resins to enhance

    8

    Resin bath for filament winding

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    the fire retardant properties. Addition of these prod-ucts to non halogenated resins does not improve theflame resistance significantly. Antimony trioxide hasbeen the most common product, and it should be in-corporated with a high shear mixer in order to ensurethat the particles are suitably dispersed into the resin.Frequent mixing is recommended to prevent settling in

    the resin.

    Liquid dispersions of antimony products are alsoavailable and preferred by many fabricators. Sincethe liquid dispersions such as NyacolAPE3040 areonly 40% active, this dilution factor must be taken intoaccount. Nyacol is a dispersion of the synergist in anon corrosion-resistant resin. This should be taken intoconsideration for some severe corrosion applications.Generally, antimony oxides are not incorporated intothe corrosion barrier, so this is not normally a concern.

    Some grades of antimony trioxide fillers and disper-sions have been known to cause gel drift. Thus anyantimony oxide product should be added to the resinjust prior to use and the gel time checked daily.

    One significant advantage of using a liquid disper-sion such as NyacolAPE3040 is that the laminate isless opaque. Thus the removal of air bubbles from aresin containing Nyacol APE3040 is easier.

    Pigmentsadd inherent color to the finished part. Pig-ments are not widely used in the fabrication of corro-sion resistant equipment and are prohibited in the cor-rosion barrier by many specifications except by userfabricator agreement. AOCs Chroma-Tek pigmentdispersions are recommended if color is desired.

    Thixotropessuch as Cab-O-SilTS-720 or Aero-silR 202 can be added for viscosity control ormaking putties and pastes. However, it is recom-mended that they not be used in corrosion linerresins as they will reduce chemical resistance.

    Abrasion resistant additivessuch as aluminum

    oxide, silica and silicon carbide can be addedto resin to improve the abrasion resistance of thecomposite. Otherfillers are generally prohibitedin many corrosion-resistant equipment specifica-tions. Occasionally, inert conductive fillers suchas graphite or carbon black will be added toa resin to meet electrical conductivity require-ments. Abrasion resistance of the composite canbe improved through the use of hard, inert fillerssuch as silicon carbide.

    Defoaming agentsare occasionally needed toenhance release of air bubbles that form in theresin when cobalt and MEKP initiators are used.Foaming is less common when high dimer initia-tors are used than when low dimer imitators areused. Examples are BYK-A 555 and Foam Kill.

    Vapor suppressants can be added to resinsto reduce styrene and other monomer emissionsand are becoming a more important part in emis-sion compliant issues. Resins containing these ad-

    ditives must be tested per the MACT specifiedtest method to determine the particular emissionreduction index for each additive in each resin.Fabricators also need to be aware that theseadditives can affect secondary bonding and inmany cases this will need to be tested also. Ifsecondary bonding is not an issue, paraffin waxcan be used. For some applications where sec-ondary bonding is necessary, BYK-S 740/750have been used. However, acceptable second-ary bonding can never be assured when prod-

    ucts such as these are used. It is always best togrind before applying secondary laminates.

    4

    Three specimens of VipelK022-C series resin show the effect of

    synergist addition on translucency. The clear one has no syner-gists. The middle one contains 2.5% NyacolAPE3040. Themost opaque one contains 1.5% antimony trioxide.

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    5Resin QualityAssurance &RecordKeeping

    Gel time test

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    Good recordkeeping is the essential first step to ensur-ing the quality and consistency of corrosion resistantparts. From incoming raw materials to finished partsshipment, the fabricator should keep a record of anyvariables that may affect the parts ability to meet me-chanical and physical property targets. The fabricatorshould keep the quality control information provided

    by material suppliers.

    The quality assurance measurements in Table 1. Com-mon Quality Control Tests are conducted, using prop-erly maintained and calibrated equipment. A step-by-step protocol for each of the AOC test procedures isavailable on request and can also be obtained from theAOC Corrosion Specialist for your region. In additionto those pre-shipment tests performed by AOC, severaltests that should be routinely checked by the fabricatorare also listed. Table 2. Getting Started with Quality

    Assurance Equipment is intended for composite manu-facturing operations that may need help in selectingequipment for these measurements.

    Quality AssuranceQuality control testing guidelines on incoming raw ma-terials are listed in detail in ASME RTP-1. This is anexcellent reference document for all corrosion fabrica-tors. An AOC certificate of analysis should accompanyevery batch of resin. If the certificate is lost in transit,fabricators are encouraged to obtain replacement cer-

    tificates from the producing AOC plant or the distribu-tor as needed. Fabricators who have quality controltesting capability can compare their test results with theAOC results. If there is a significant variation betweenthe two values, fabricators should contact the technicalservice lab at the AOC producing plant.

    Record KeepingASME RTP-1 is also an excellent reference documentfor record keeping guidelines. Basic resin informationthat is useful for record keeping follows:

    1) Identification of the resin used in the corrosionliner, structural layer and the topcoat. Include thebatch number.

    2) The amount and type of promoter, thixotrope,monomer, inhibitor, UV additive, styrene sup-pressant and other additives included in theresin formulation.

    3) Type and quantity of catalyst usedin the resin to manufacture the corrosionliner, structural layer and the topcoat.

    4) Ambient temperature and the temperatureof the resin used for all fabrication steps.

    5) Viscosity and gel time of the resin.Gel times should be checked periodicallyfor each application process.

    6) Quantity of resin used in the manufac-ture of the corrosion liner, structural layerand the top coat.

    7) The quantity of reinforcement should berecorded. If glass reinforcement is used, aclose approximation the glass contentwould be an ash content.

    8) AOC certificate of analysis and thefabricators comparative data.

    9) Post cure temperature and time.

    10) Mechanical testing on finished com-posites. Examples are flexural strength,flexural modulus, tensile strength, ten-sile modulus, glass resin ratio (by burn-out)and Barcol hardness.

    11) Other records should be kept such

    as the thickness of the corrosion barri-er and the structural portion, hardnessmeasurements, cut outs, acetone sensitiv-ity, visual effects, etc.

    5

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    Barcol hardness test

    22

    Viscosity test

    * A step-by-step protocol of AOC test procedures is available upon request.

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    1 2

    Barcol impresser No. GYZJ 934-1 (hard) Gardco (800-762-2478)

    Beakers - 100, 250, 400 & 800 ml,tri-cornered polypropylene 02-593-50B, -C, -D & -E Fisher Scientific (800-766-7000)

    Blender (commercial mixer) HA908 Hamilton Beach (800-572-3331)

    Desiccant bags 08-594-17B Fisher Scientific (800-766-7000)

    Desiccator 08-595D Fisher Scientific (800-766-7000)

    Disposable transfer pipettes 13-711-5A Fisher Scientific (800-766-7000)

    Gel timer 22A Sunshine (800-343-1199)

    Glass rods 11-380A Fisher Scientific (800-766-7000)

    Lubricant 14-635-5D Fisher Scientific (800-766-7000)

    Muffle furnace 10-750-14A Fisher Scientific (800-766-7000)

    Oven 13-247-826F Fisher Scientific (800-766-7000)

    Pipette 2 ml 13-671-108B Fisher Scientific (800-766-7000)

    Pipette bulb 13-681-102A Fisher Scientific (800-766-7000)

    Scale (gram triple beam) Ohaus 710-00 Fisher Scientific (800-766-7000)

    Scale digital Model# PR2003DR Fisher Scientific (800-766-7000) Cat# 01-918-29

    Spatula - 4 inch blade 14-365B Fisher Scientific (800-766-7000)

    Specific gravity cup CB-1130 BYK-Gardner (800-343-7721)

    Stopwatch 14-648-1 Fisher Scientific (800-766-7000)

    Test tubes 19x150 cat 14-925K Fisher Scientific (800-766-7000)

    Thermometer digital (pyrometer) MP20700 Fisher Scientific (800-766-7000)

    Thermometer Infrared U-35629-10 Cole-Parmer (800-323-4340)

    Thermometers (standard glass:-10 to 260C range) 15-041-4F Fisher Scientific (800-766-7000)

    Tongue depressors 01-346 Fisher Scientific (800-766-7000)

    Viscometer Brookfield RVF Brookfield (800-628-8139)Water bath 15-460-6 Fisher Scientific (800-766-7000)

    1 Manufacturers may change product designation or replace models with new versions.

    2 Specific manufacturer names are provided as a starting point and do not constitute an endorsement by AOC.

    5

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    6Resin Handling,Safety andRegulatory Issues

    Resin storage area

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    StorageIdeally, vinyl ester and polyester resins should bestored out of direct sunlight at below 77F (25C).Temperatures above 77F (25C) will shorten the us-able working life of a resin. Generally, non-formu-lated resins (ones without thixotrope or promoters)are much more stable than formulated resins. Bulkstorage tanks should either be stainless steel or car-bon steel. Drums should have bungs closed to keepmoisture out. Inventory of resins should be rotated sothat the first in is the first used.

    SafetySafe procedures must be followed in using vinyl esterand polyester resins, promoters, iniators and otheradditives. For example, promoters or accelerators(such as cobalt naphthanate) must never come in di-rect contact with any catalyst such as MEKP. A violentexplosion and fire can occur. Thus promoters or ac-

    celerators must be completely mixed into the resinbefore any catalyst is added. A complete review ofMSDS information on all raw materials used to makecomposites is necessary.

    Regulatory Issues

    MACTComposite fabricators must comply with MaximumAchievable Control Technology (MACT) regulationsestablished by the U.S. Environmental Protection. For

    composites fabrication, styrene (the principal mono-mer in polyester and vinyl ester resins) and methylmethacrylate (frequently used monomer in gel coatsand some resins) are listed as Hazardous Air Pollut-ants (HAPs).

    Affected composites manufacturers must demon-strate compliance in accordance with options pro-vided in the final EPA National Emissions Standardsfor Hazardous Air Pollutants (NESHAP), codified in40 CFR Part 63 Subpart WWWW. The AmericanComposites Manufacturers Association (ACMA) is

    an excellent source of information and guidanceabout the rule. ACMA also provides MACT com-pliance calculators for member companies andlinks to EPA documents. Generally, detailed MACTinformation is not available for non-members. Formore information about AMCA, go to www.acmanet.org. Copies of the MACT rule, revisions and other re-lated documents are is available on the EPA web siteat http://www.epa.gov/ttn/atw/rpc/rpcpg.html

    Resin selection is usually a significant variable indeveloping and implementing a MACT compli-ance strategy. For years, AOC has maintaineda leadership position in the development of lowstyrene resin systems that offer processabilitythat is as good as, and in some cases betterthan, that offered by higher styrene-content res-ins. AOC is committed to providing resins en-

    gineered to offer the optimum combination ofprocessability, end-use performance and regu-latory compliance. In addition, AOC offers theindustrys best technical support for helpingfabricators achieve the highest levels of quality,consistency and regulatory compliance.

    OSHAExposure to styrene in the workplace is regulat-ed by the U.S. Occupational Safety and HealthAdminstration (OHSA). Industries producing

    and using styrene agreed to establish a volun-tary program with the OSHA to limit workplaceinhalation exposures to styrene to 50 ppm on an8-hour Time Weighted Average (TWA), and a100 ppm 15-minute Short Term Limit (STL). Oneof the best sources for more details on this issueis AMCA whose website iswww.acmanet.org.

    State and LocalFabricators should check with their state and lo-cal government agencies to determine if they aresubject to emission standards that are in addi-tion to those established by the EPA and OSHA.A listing of significant state and local regulationsis maintained by ACMA.

    6

    Storing resin behind a dam prevents spreadof accidental spills.

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    7CompositeProcessingGuidelines

    Fiberglass roving conveyed through guides

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    The following rules, principles and recommendationsare based on shop experiences and in many casesreflect practices outlined in industry standards. Formore details on the manufacture and fabrication offiber-reinforced polymer composites for corrosion-resistant service, contact the AOC Corrosion Team.To find the team member for your geographical re-gion, go to Corrosion Team on the homepage menu

    ofwww.corrosionresins.com.

    Post CuringTo ensure that the final composite will meet fire retar-dant and corrosion resistant expectations, post curingis recommended. In addition, post curing is requiredon any composite that will be used for food/drug ap-plications and aggressive chemicals such as sodiumhypochlorite. Post curing vinyl ester options are:

    1) Two hours at 200F (93C) 2) Four hours at 180F (82C)

    Depending on the chemical environment, novolacresin composites may need to be post cured for fourhours at 212F (100C). Depending on the heat dis-tortion temperature of the isophthalics or terephthal-ics, post cure is generally accomplished by heatingfor four hours at 160F (71C) to 180F (82C). Ide-ally, laminates cured with BPO should be post curedwithin one week of lamination. This is not neces-sary with composites cured with MEKP. Temperatureshould be closely monitored during ramp-up, at peaktemperature and during cool down. Direct any ques-tions on this procedure to AOCs Product Leader forCorrosion Resins.

    Secondary BondingSecondary bonds can easily be applied to most com-posites manufactured with Vipel products. Laminatesare typically ground prior to secondary bondingoperations. The structural layer is usually applied to

    the corrosion liner within 24 hours. In this casegrinding is normally not required. Other casesinvolving grinding are:

    1) Resins Containing Wax. Very fewVipel resins contain wax or wax typeproducts but sometimes the fabrica-tor may add wax to minimize styrene evapo-

    ration and or facilitate the fast cure of theresin. When wax is used, the surfaceshould be ground with a coarse (16 or 24grit) grinding disc.

    2) Novolac Resins. Novolac resins arehighly reactive and present more of achallenge with respect to secondarybonding. Before applying a secondarybond, the surface should be ground with agrinding disc, as mentioned above. Re-

    move all dust and debris after grindingprior to the application of the secondarylaminate.The secondary bonding shouldbe started within 2 hours from the time thesurface preparation was completed. Oth-erwise, foreign material may get on thesurface that could interfere with the bond.

    Test PatchesTest patches may be used when making repairsto interior surfaces that have been exposed tochemicals that reduce adhesion. Primer coats

    with Vipel F017 are recommended to improvethe adhesion with or without the test patch result.If you need assistance in the proper preparationof a test patch, contact an AOC Corrosion Spe-cialist.

    Top CoatsA top coat of 0.002 - 0.004 inches (0.05-0.1mm) is used to protect the glass fiber contentbelow. Paraffin wax is often added to improvecure on the air-exposed surface. Achieving the

    optimal coating thickness is important. A thin-ner coat usually cures poorly; a thicker coat ismore prone to cracking.

    Small batches and short gel times are preferredtechniques for preventing the top coat from run-ning off the surface.

    7

    Bonding composite to composite

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    It is important that a top coat gels and cures quickly.The potential for entrapment of foreign materials onthe surface increases as the gel time is extended.Polyester and vinyl ester laminates that are exposedto air during cure in an open molding process re-main tacky due to air inhibition of the resin on thesurface. Degree of inhibition varies depending onthe generic resin type. Air-exposed surfaces will not

    reach complete cure over time or with post curing.

    Paraffin wax is added to resins to reduce air inhibi-tion and improve the cure of these surfaces. Sec-ondary bonding is impaired when paraffin has beenadded to laminating resins.

    Paraffin Wax Styrene SolutionA ten percent (10%) solution by weight of paraffinwax dissolved in styrene is added to laminating res-ins in the formulation of topcoat resins systems. Thesolution may be purchased from a fiberglass materi-als distributor or can be prepared by the fabricator.When the fabricator chooses to make the solution,several precautions are important:

    The parafn wax used must have a melting pointof 118 -122F (48-50C).

    Warming of the solution is required to dissolve theparaffin.

    Equipment used for warming must be explosion

    proof. Solution should be re-heated immediately prior touse to insure that the paraffin is not crystallized orsolidified when added to the resin.

    Formulating Topcoat ResinsFormulation and gel time of topcoat resins are criti-cal for optimum cure and performance of coatedsurfaces. The required paraffin content is generally0.05-0.20 % by weight depending on the genericresin type. Since the paraffin is insoluble in the resin,a solution of paraffin wax in styrene is added to theresin.

    Resin and parafn solution temperatures should beat least 70F (21C) when preparing the topcoat mix-ture.

    Parafn solution should be slowly added to theresin after mixing has been started.

    Addition of thixotropic agents should be avoided.

    Topcoat resins should be thoroughly re-mixed im-mediately prior to use. Mixing action should be mildto avoid generation of air bubbles.

    Batch size should be dictated by estimated needsfor use within one day of preparation.

    Initiator level should be such that the exotherm tem-perature is reached in a relatively short time aftergelation to insure complete cure of the thin topcoatlayer.

    Gel time of the topcoat resin should be 5 to 10

    minutes at the application temperature.For recommended promoter, paraffin solution andinitiator formulations, contact a member of the AOCCorrosion Team or your AOC technical representa-tive.

    28

    Left: improperly applied wax topcoatRight: properly applied wax topcoat

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    Application of TopcoatsSurface preparation: Surfaces should be clean,dry and free of dust and other foreign matter. Whenapplying the topcoat to the air inhibited side of pri-mary laminates the surface to be coated should belightly sanded or scuffed to remove loose fiber andany other blemishes. For fresh (recently laminated,exothermed and cooled) secondary surfaces sand-

    ing should only be necessary to remove loose fiberand any other blemishes. Solvent wiping should beavoided to prevent contamination of the preparedsurface.

    Catalyzing topcoat resin for brush or roller appli-cation:The quantity of topcoat resin to be catalyzedshould be approximately the amount of resin thatcan be applied before it gels in the container. Sincethe mix has been formulated for a relatively shortgel time, the amount may be small. After thoroughstirring to ensure complete mixing of the initiator, al-low the mixture to rest for a moment to allow frothor foaming to dissipate before applying the topcoat.

    Brush or roller application:Where practicalthe topcoat should be poured on the preparedsurface and then spread with a brush or roller.Strokes with the brush or roller should be mini-mized. Excessive brushing or rolling can pre-vent the paraffin from surfacing and leave theexposed surface shiny and tacky. Avoid disturb-ing adjacent surfaces that have already beencoated. Use care to insure coverage of all pre-pared areas with as little overlap as possibleonto unprepared surfaces.

    Spray application: Spray-applied topcoatsshould also have relatively short gel times. Lightbrushing or rolling shortly after spraying will as-sist in spreading the topcoat uniformly and pro-

    mote the release of any froth or foaming fromthe initiator. As with brush or roller application,it is important not to disturb the paraffin on ad-jacent wet surfaces.

    Appearance:Properly topcoated surfaces willhave a dull hazy surface that is not tacky aftercomplete cure. Shiny or streaky areas will likelybe tacky and are indications that the paraffindid not come to the surface or was disturbed.

    7

    Surface grinding

    Applying a topcoat

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    Bonding to ConcreteThe following guidelines are for applying an FRPlaminate to concrete. For specific questions, contactyour AOC Corrosion Team member.

    For best results the concrete should be at least onemonth old.

    Grind or sandblast the surface to remove looseconcrete and oil spots.

    Pits or cracks should be repaired with a putty andsanded.

    Wash the surface of the concrete with 10:1 muri -atic acid.

    Rinse the surface with tap water starting 20 min-utes to 45 minutes after the muriatic acid is applied.

    Allow the concrete surface to thoroughly dry.

    Apply 0.002-0.003 inches (0.05-0.08 mm) VipelF017 primer. Vipel F017 is supplied unpromoted andthus a promoter and initiator must be added for theprimer to gel and cure properly. The recommendedinitiator for Vipel F017 primer is Methyl Ethyl KetonePeroxide (MEKP).

    The temperature of the concrete surface must beover 65F (18C).

    Inspect to make sure no foreign material such asdirt or water landed on the primer. If so, clean upand spot repair primer, as needed.

    Apply the composite after the primer has curedand plan to lay up on the primer within 3 days of theprimer being tack free.

    Apply a top coat onto the nal cured composite asdescribed above.

    30

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    7

    Bonding to SteelThe following guidelines are for applying an FRPlaminate to steel. For specific questions, contact amember of the AOC Corrosion Team. Sandblast or grind the surface to white metal con-forming to NACE No 1 or SSPC-SP-5.

    Fill holes, pits or defects with a putty.

    Fill in sharp radius surfaces with a putty. This ap -plies to all bolts, overlapping plates holes, etc. Allow

    the putty to cure and sand to a smooth surface.

    Vacuum the surface to remove any dust.

    Apply 0.002-0.003 inches (0.05-0.076 mm) Vi-pelF017 primer. Vipel F017 is supplied unpromot-ed and thus a promoter and initiator must be addedfor the primer to gel and cure properly. The recom-mended initiator for Vipel F017 primer is MethylEthyl Ketone Peroxide (MEKP).

    Apply composite as soon as possible after the prim-

    er has cured and plan to lay up on the primer within3 days of the primer being tack free. The choice ofspecific resin will depend on the chemical environ-ment that the composite is exposed to, temperature,specific mechanical stresses, etc. Avoid contamina-tion of the primer surface prior to the application ofthe composite.

    Grind off stray bers with an 80 grit abrasive.

    Apply a top coat onto the nal cured composite asdescribed above.

    Applying composite to steel.

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    8Appendix

    32

    Interior of a scrubber in the shopVipelK022-CCHeil Process Equipment

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    8

    Typical Formulations and Gel Timesof Select VipelResins

    The information contained in the following tables isa guide for promoting and inhibiting non-promotedVipelresins. The recommended method of makingadditions is:

    1) After the mixer is turned on, drop theadditive onto the surface of the resin in sucha way as to minimize the possibility of theproduct clinging to the top edge of thecontainer.

    2) Mix until uniform.

    3) Repeat for each additive and beware thatpromoters or accelerators must nevercome in direct contact with initiators.

    It is usually a good plan to prepare a small sampleand check the gel time before proceeding to make alarger production quantity.

    Cobalt solutions, tertiary butyl catechol (TBC) andbenzoyl peroxide (BPO) are available in several con-centrations. The concentrations of these products inthis guide are 6, 85 and 98% respectively. In manycases, adjustments will be needed to account for theconcentration of the product in hand.

    There are advantages and disadvantages to some ofthese additives as described below:

    1) N,N-Diethylaniline (DEA) is a slightlysafer product to handle than N,N-Dimethyl-aniline (DMA). Gel times with DEA arelonger (about twice as long) than whenDMA is used at the same concentration.

    2) 2,4-Pentanedione (2,4-P) is the preferredinhibitor because there is minimal effect onthe gel to peak and the peak temperature of

    vinyl esters. 2,4-P is not effective whenbenzoyl peroxide is used as an initiator.2,4-P acts as a promoter for polyester resins,thus it can only be used as an inhibitor invinyl ester resins.

    3) Extra care must be taken tohandle tertiary butyl cath-ecol (TBC) because it can burnthe skin upon contact. The higher the con-centration, the more likely TBC will burn.TBC will inhibit any initiator system butits use should not exceed 0.05% ofthe 85% version. TBC is best

    used as a 10% solution in sty-rene. The solution can be preparedfrom solid TBC or an 85% concentrated so-lution depending on availability.

    4) Methyl Ethyl Ketone Peroxide (MEKP) isavailable in many different raw materialcomponents. By varying the concentrationof the components, many different versionof MEKP are available. High dimer versionsare suggested preferred for vinyl esters.

    Care must be used in handling these chemicalsfrom a health and safety perspective. Reviewinformation available in the MSDS documentbefore using the product.

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    Legend for abbreviations2,4-P: PentanedioneCoNAP: Cobalt Naphthanate 6% solutionBPO: Benzoyl Peroxide 98% active (Adjust addition level for other concentrations)DEA: N,N DiethylanilineDMA: N,N DimethylanilineTBC: Tertiary Butyl Catechol 85%THQ: Toluhydroquinone 10% solution in styrene (Available from AOC as Inhibitor A)

    Gel Times for Vipel F010CNL, CNM and CNT seriesBenzoyl Peroxide Catalyst (BPO) with DMA and alternative DEA[For laminates less than 3/16 inches (4.8 mm) thick]

    Resin Temperature (F) 60s 70s 90s

    10 20 min. 17 16 17 18 13 13

    BPO,% 1.0 1.0 1.0 1.0 1.0 1.0

    DMA,% 0.3 0.2 0.1DEA,% 0.6 0.45 0.3

    20 40 min. 36 35 27 30 38 25

    BPO,% 1.0 1.0 1.0 1.0 1.0 1.0

    DMA,% 0.1 0.1 0.05

    DEA,% 0.3 0.25 0.15

    40 60 min. 54 44 57 52 48 52

    BPO,% 1.0 1.0 1.0 1.0 1.0 1.0

    DMA,% 0.07 0.05 0.04

    DEA,% 0.2 0.15 0.1

    Gel Times for Vipel F010CNL, CNM and CNT seriesCobalt Naphthenate (6%) & DMA and alternate DEA with 1.25% Hipoint 90 MEKP Catalyst

    DMA DEA

    ResinTe perature

    (F)60s 70s 90s 60s 70s 90s

    10 20 min. 19 16 13 18 17 15 12 15

    MEKP,% 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25

    CoNAP,% 0.3 0.3 0.1 0.1 0.3 0.3 0.1 0.1

    DMA,% 0.05 0.05 0.05 0.05

    DEA,% 0.2 0.1 0.1 0.12,4-P,% 0.01 0.01

    TBC,% 0.01 0.005

    20 40 min

    .

    26 32 29 25 38 32 29 36 34 27 29 30

    MEKP,% 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25

    CoNAP,% 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.1 0.1

    DMA,% 0.05 0.05 0.05 0.05 0.05 0.05

    DEA,% 0.1 0.1 0.1 0.1 0.1 0.1

    2,4-P,% 0.02 0.05 0.05 0.02 0.05 0.04

    TBC,% 0.01 0.015 0.025 0.01 0.015 0.02

    40 60 min. 43 43 50 52 51 46 47 49 44 51 48 51

    MEKP,% 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25

    CoNAP,% 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.1 0.1

    DMA,% 0.05 0.05 0.05 0.05 0.05 0.05

    DEA,% 0.1 0.1 0.1 0.1 0.1 0.1

    2,4-P,% 0.05 0.08 0.1 0.05 0.07 0.06

    TBC,% 0.017 0.03 0.04 0.016 0.03 0.035

    m

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    8

    Gel Times for Vipel K022-AC, CCC , CCL, CNC seriesCobalt Naphthenate (6%) & DMA and DEA alternative with 1.25% Hipoint 90 MEKP Catalyst

    DMA DEA

    ResinTemperature

    (F)60s 70s 90s 60s 70s 90s

    10 20 min. 20 13 17 16 17 13

    MEKP,% 1.25 1.25 1.25 1.25 1.25 1.25

    CoNAP,% 0.2 0.3 0.3 0.3 0.3 0.3

    DMA,% 0.2 0.15 0.05

    DEA,% 0.5 0.3 0.2

    20 40 min. 24 32 36 27 31 30 28 35 36 33

    MEKP,% 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1 .25 1 .25

    CoNAP,% 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2

    DMA,% 0.1 0.05 0.05 0.05 0.05

    DEA,% 0.1 0.1 0.1 0.1 0.1

    2,4-P,% 0.05 0.08 0.05 0.08

    TBC,% 0.0075 0.01 0.004 0 .017

    40 60 min. 44 52 48 50 46 55 44 45 48 56 52 43

    MEKP,% 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25

    CoNAP,% 0.2 0.1 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2

    DMA,% 0.05 0.05 0.05 0.05 0.05 0.05

    DEA,% 0.1 0.1 0.1 0.1 0.1 0.1

    2,4-P,% 0.04 0.075 0.1 0.04 0.06 0.1

    TBC,% 0.007 0.015 0.02 0.005 0.01 0.025

    Gel Times for Vipel K022-AC, CCC , CCL, CNC seriesBenzoyl Peroxide Catalyst (BPO) with DMA and alternativ e DEA[For laminates less than 3/16 inches (4.8 mm) thick]

    Resin Temperature (F) 60s 70s 90s

    10 20 min. 17 18 18 18 10 15

    BPO,% 1.0 1.0 1.0 1.0 1.0 1.0

    DMA,% 0.35 0.23 0.2

    DEA,% 0.8 0.5 0.3

    20 40 min. 23 27 26 28 26 27

    BPO,% 1.0 1.0 1.0 1.0 1.0 1.0

    DMA,% 0.25 0.12 0.09

    DEA,% 0.5 0.3 0.2

    40 60 min. 49 56 44 55 42 54

    BPO,% 1.0 1.0 1.0 1.0 1.0 1.0

    DMA,% 0.1 0.1 0.05

    DEA,% 0.25 0.15 0.1

    Gel Times for Vipel F085-AAA, AAB. ABB seriesCobalt Naphthenate (6%) & DMA w ith CHP (90% active)

    Resin Temperature (F) 60s 70s 90s

    10 20 min. 17 16

    CHP,%

    1.5 1.25

    CoNAP,% 0.4 0.2

    DMA,%

    No Data

    0.2 0.02

    20 40 min. 23 29 30

    CHP,% 2 1.5 1

    CoNAP,% 0.4 0.3 0.3

    DMA,% 0.2 0.05 0.05

    40 60 min. 46 50 43

    Alternative #1 CHP,% 1 1 1

    CoNAP,% 0.3 0.2 0.15

    DMA,% 0.05 0 0

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    Gel Times for Vipel F701-BBB seriesCobalt Naphthenate (6%) & DMA w ith Hipoint 90 MEKP Catalyst

    Resin Temperature (F) 60s 70s 90s

    10 20 min. 15 16

    MEKP,% 1.0 1.0

    CoNAP,%

    No Data

    0.6 0.2

    20 40 min. 23 24 21

    MEKP,% 1.0 1.5 0.75

    CoNAP,% 0.6 0.2 0.2

    40 70 min. 70 43

    MEKP,% 1.0 1.0

    CoNAP,% 0.2 0.2

    No Data

    Gel Times fo r Vipel K095-AAA-00Cobalt Naphthenate (6%) & DMA w ith CHP (90% active)

    Resin Temperature (F) 60s 70s 90s

    10 20 min. 20 16

    CHP,% 1.5 1.5

    CoNAP,% 0.4 0.3

    DMA,%

    No Data

    0.1 0.05

    20 40 min. 35 30 30

    CHP,% 2.0 1.5 1.0

    CoNAP,% 0.4 0.3 0.2

    DMA,% 0.2 0.05 0

    2,4-P,% 0 0 0.05

    40 60 min. 49 45 49

    CHP,% 1.5 1.0 1.0

    CoNAP,% 0.3 0.2 0.2

    DMA,% 0.05 0 0.1

    36

    Legend for abbreviations2,4-P: PentanedioneCoNAP: Cobalt Naphthanate 6% solutionBPO: Benzoyl Peroxide 98% active (Adjust addition level for other concentrations)DEA: N,N DiethylanilineDMA: N,N DimethylanilineTBC: Tertiary Butyl Catechol 85%THQ: Toluhydroquinone 10% solution in styrene (Available from AOC as Inhibitor A)

    Trademark NoticesAerosil is a registered trademark of Degussa Corp. Aropol is a registered trademark of Ashland Inc.BYK is a registered trademark of BYK. Cab-O-Sil is a registered trademark of Cabot Corp.Chroma-Tek is a registered trademark of AOC, LLC. CoREZYN is a registered trademark of Interplastic Corp.Derakane is a registered trademark of Ashland Inc. DION is a registered trademark of Reichhold Inc.Hetron is a registered trademark of Ashland Inc. Lupersox is a registered trademark of Arkema Inc.Mylar is a registered trademark of DuPont Teijin Films. Norox is a registered trademark of Norac, Inc.Nyacol is a registered trademark of Nyacol Nano Technologies, Inc. Trigonox is a registered trademark of Akzo Nobel nv.Underwriters Laboratories is a registered trademark of Underwriters Laboratories Inc. Vipel is a registered trademark of AOC, LLC.

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    8

    If you are considering or using resins made by another manufacturer, use this reference to find Vipel technologies that most nearlymatch competitors resins. This list is only a guide. Confirm your selection with an AOC Corrosion Specialist before making a finaldecision because some environments may require an a lternative.

    AOC ASHLAND INTERPLASTIC REICHHOLD

    Vipel Derakane Hetron Aropol CoREZYN DION

    Bisphenol-A Epoxy Vinyl Ester F010 411 922 830091009102

    Bis-A Epoxy VE (higher HDT) F007 441 942 8360Elastomeric, Bis-A VE F017 8084 8550 9085Bis-A Epoxy VE(higher cross linked)

    F080 441 98087108770

    Bis-A Epoxy VE(higher cross linked, low VOC)

    F083 441 980/35 8360

    Fire Retardant Brominated Bis-AEpoxy VE Class I flame spreadand smoke developed without theuse of synergists *

    K022-AA 510A 8440

    Fire Retardant Brominated Bis-AEpoxy VE Class I flame spreadwithout the use of synergists *

    K022-AC

    Fire Retardant Brominated

    Bis-A Epoxy Vinyl Ester Class Iflame spread with the use ofsynergists

    K022-CC 510C FR992 VE8450 FR9300

    Fire Retardant BrominatedBis-A Epoxy VE containingantimony products Class I flamespread *

    K022-CN FR992SB 8440M-AT

    Fire Retardant Brominated Bis-AEpoxy VE (higher cross linked)Class I flame spread without theuse of synergists *

    K023 FR998/35

    Epoxy Novolac Vinyl Ester F085 470 970 8730 9400Epoxy Novolac VE (higher HDT) F086 470HTFire Retardant Brominated EpoxyNovolac Vinyl Ester Class I flamespread and smoke developedwithout the use of synergists *

    K095

    Fire Retardant Brominated EpoxyNovolac Vinyl Ester Class II flamespread without the use ofsynergists *

    510N

    Isophthalic Polyester(rigid high cross-linked)

    F764

    Isophthalic Polyester(rigid)

    F70172417242

    75-AQ-001, S & W75-AQ-010, S & W

    75-AQ-0116631

    Isophthalic Polyester (resilient) F737 7334 75-AQ-610 6334Fire Retardant HalogenatedIsophthalic Polyester Class I flamespread without the use ofsynergists *

    K733-A FR7767

    Fire Retardant HalogenatedIsophthalic Polyester Class I flame

    spread with the use antimonytrioxide *

    K733-B

    604T-20

    99P

    Terephthalic (rigid) F713Terephthalic Polyester(rigid high cross-linked)

    F774 490

    Chlorendic Acid Polyester Class Iflame spread with the use ofantimony trioxide *

    K190 197 16-DA-097 797

    Bisphenol-A Fumarate Polyester F282 700 6694* Tested according to ASTM E84

    VipelCorrosion Resin Cross Reference

    K026-AA

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    AOC is a leading producer of unsaturated polyester and vinyl

    ester resins and is the world leader in innovative resin technology.

    AOC manufactures its products in facilities strategically located

    throughout North America and Europe. AOC owned facilities are

    ISO 9001:2008 certied and use AOCs proprietary process

    control technology to guarantee batch to batch consistency.

    From isophthalic polyesters, and terephthalics, to epoxy novolac

    and bisphenol A vinyl esters, AOC offers local availability,

    worldwide, of a broad range of proven Vipel resins through its

    network of distributors and plants. Please contact the AOC

    Corrosion Specialists for Vipel resins that meet your corrosion

    resistant specications, and put the technology and service of

    the AOC Corrosion Team to work for you.

    CORROSIONRESINS.com

    Sales Contacts

    North America +1 866 319 8827 Fax: +01 901 854 7277 [email protected]

    Latin America +01 863 815 5016 Fax: +01 863 815 4733 [email protected]

    Middle East +44 1473 288997 Fax: +44 1473 216080 [email protected]

    Europe +44 1473 288997 Fax: +44 1473 216080 [email protected]

    India +91 20 2547 2011 [email protected]

    Asia/Australia

    +44 1473 288997 Fax: +44 1473 216080 [email protected]

    THE WORLD OF

    AOC World Headquarters955 Highway 57 EastCollierville, TN 38017

    +01 901 854 2800 +01 901 854 1183 ([email protected]

    The internets best resource on corrosion-resistant composites.


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