Introduction to Pre Primed Plate

•

Agenda

• Types and brands of primers from Blastech• Key properties of REDI -PLATE• Key advantage s of pre primed plate• Blastech’s REDI-PLATE process.

Typical Concerns

• Cannot weld through paint• Zinc will be a problem for the welders• Cannot know it was blasted to specification• It will be destroyed while fabricating• The recoat window will be missed• My specification will require it blasted off

Pre-Construction Primers - History

• First Developed in the 50’s

• One of the most important innovations in marine coatings technology

• Designed to increase through put and protect steel during the building process

What are Pre-Construction Primers?

• Typically thin film coatings, automatically sprayed to abrasive blast cleaned steel prior to fabrication. These are commonly called:– Pre-construction primers (PCP)– Pre-fabrication primers– Weldable primers– Shop Primers– Nippe

Traditional Inorganic Zinc

Weldable Inorganic Zinc

Pre-Construction Primers are different from typical paint

Primers available at Blastech

• Redi-Plate (solvent based inorganic zinc) PCP

• Water based inorganic zinc PCP

• Epoxy PCP (special applications)

• REDI-PLATE ED (Extended Durability)

• CPP (Clear plate preservative)• Any other paint by special inquiry (We are in the painting

business!!)

REDI-PLATE Features• Super resistance to high temperatures

• Excellent anti-corrosive protection even after heating to 1,475 degrees Fahrenheit

• Minimal secondary surface preparation

• Wide over coating capability

• Compatible with high speed automated welding

• Compatible with high speed plasma and laser cutting

• Low production of zinc fume during welding and cutting

Benefits of REDI-PLATE™ • Increase throughput in fabrication process.

• Proven to save time and money through reductions in secondary surface preparation.

• Better work environment

• Elimination of open abrasive blasting

• Improved health, productivity, safety and quality

Additional Benefits

• Removes painting bottlenecks

• Weld spatter removal savings

• Defective plate reduction

• Transportation savings ( in supply chain)

Excellent Welding Performance

Fully compatible with most advanced welding processes and consumables:

– semi automatic

– fully automatic

– robotic

• Improved welding speeds

• Reduced porosity levels and repairs

• Reduced burn damage

• Low weld spatter adhesion

• Reduced distortion

• Lloyd’s/DNV/ABS certified

• CWB/API certified

Spatter on mill scale

Spatter on CPP Spatter on Blast only

Reduced Sandblast Costs

• Typical production rate to blast mill scale plate is 200 square foot per hour

• Typical rate to completely remove PCP is 600 square foot per hour

• Typical rate to sweep blast PCP is 1000 square feet per hour.

*** Enter own rates when applicable ***** Tank Diameter feet

Tank Height feet

Square feet exterior sides and top 20,427

Square feet bottom 7,863

Square feet interior 28,289

Average plate thickness 0.35

Tons of plate 202

Plate width in feet 8

Steel cost per lb 0.45$

Steel total cost w/10% drop 200,151.83$ Total Estimated cost

66,139$ 124,998$ 128,605$

PCP Option Shop Option Field Option

Pre Prime plate with PCP 0.44$ SQ FT

Total 24,894.32$ 24,894$

Blast In shop rate inside and out 0.75$ SQ FT

Total Blast cost 36,536.63$ 36,537$

Labor rate to paint 1st coat inside and out 0.15$ SQ FT

Total Labor to Paint 7,307.33$ 7,307$

Material cost to paint 1st coat inside and out 0.20$ SQ FT

Total Material 9,743.10$ 9,743$

Prepare welds to job specification on non primed surface all 1.25$ Lin FT

7,067.25$ 7,067$ 7,067$

Prepare welds to job specification on PCP exterior 0.25$ Lin FT

1,413.45$ 1,413$

Containment for blasting based on exterior square foot only 1.00$ SQ FT

Total 20,426.50$ 20,427$

Abrasive Blast damaged areas in paint/PCP exterior

Blast Labor 0.25$ SQ FT

Abrasive cost / compressor / clean up 0.25$ SQ FT

Total 10,213.25$ 10,213$ 10,213$

Abrasive Blast to job specification interior from mill scale 2.50$ SQ FT

51,066.25$ 51,066$ 51,066$

Abrasive Blast or HP water wash to job specification Interior containing PCP 1.00$ SQ FT

20,426.50$ 20,427$

Abrasive blast all exterior surfaces to job specification ( side shell and roof ) 2.00$ SQ FT

Total blast cost (no containment) 40,853.00$ 40,853$

Labor to Touch up 1st coat applied in shop exterior 0.1 SQ FT

2,042.65$ 2,043$

Material to touch up 1st coat applied in shop exterior 0.05$ SQ FT

1,021.33$ 1,021$

Apply 1st coat at job site over pcp or fresh blast on exterior

Labor 0.25$ SQ FT

Total Labor to Paint 5,106.63$ 5,107$ 5,107$

Material 0.20$ SQ FT

Total Material 4,085.30$ 4,085$ 4,085$

Grand Total 66,139$ 124,998$ 128,605$

10040

ENTER TANK DIMENSIONS FOR ESTIMATED COST

*Model is for comparision when interior and exterior requires painting

*Other cost savings not reflecting in this model

include: Cycle time savings, Overhead due to cycle time, Environmental impacts,

Blastech Plate Line -Automated Blasting and Coating Process

Plate Entering Process

• Programmable Cranes

• Continual process

• Constantly monitored

Surface Preparation

• SSPC SP10, SA 2.5 Near White Metal Specification• Automatic centrifugal wheel blasting with shot and

grit mixture• Sharp, dense, angular profile of 1.5 - 2.5 mils depth

Application of PCP

• Automatic computer controlled system to

• Two reciprocators

• Enclosed spray booth to capture and burn VOCs

Coating Inspection

• Reference Samples• Testex tape attached to

panel• Inspect dry film thickness

in-process• Retained as permanent

record

Quality Documentation

The details of every plate processed are permanently recorded

Tank roof after 12 months exposure

How can Blastech Help?

• Technical experts in painting and pre primed plates

• Jobsite assistance to realize all cost savings

• Work with steel distributors to ensure availability

• Working with engineers and paint manufacturers