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Friday, August 28, 2020

Repairing Powercrete Coatings

 How to Repair Powercrete Coatings

    This document is designed to offer a procedure how how to make repairs to Powercrete field joint coatings.  If you are instead looking for information detailing how to make a repair to Powercrete-DD, I would advise you to contact the pipe coater who applied the DD.  That will be your best source.

    When evaluating coating repair options for Powercrete field joint coatings (which may be Powercrete J, Powercrete R65/F1 or Powercrete R95), the starting point is always:  "how much damage is there?"

     In this specific article we are recommending that Powercrete R65/F1 50ml cartridges, Powercrete R95 50ml cartridges or hand applied kits of Powercrete J 2#, Powercrete R65/F1 1# or Powercrete R95 2# kits be used.  Powercrete products are the best choice for repairing Powercrete coatings.  

Detail Conditions of Coating Damage

#1:  Defects 2.5" in diameter and less (including a pin hole)

#2:  Defects larger than 2.5" in diameter


To Repair Damage Less than 2.5" OD (#1)

     For repairing Powercrete Coatings (Powercrete J, Powercrete R65/F1 or Powercrete R95) that are minor, use the following procedure:  Clean any bare metal showing with a wire brush to obtain a clean metal surface.  DO NOT REMOVE THE SURFACE PROFILE.  For adjacent (undamaged) Powercrete, use light sandpaper (60-80 grit) to clean the epoxy surface.  Then wipe the surface clean with solvent to remove dust, dirt, grit, sandpaper residue, etc.  Apply the Powercrete J, Powercrete R65/F1 or Powercrete R95 repair material (talk with JSI customer service to determine most efficient size for your needs) to coat the damage area and adjacent not-damaged area by at least 1" in every direction.  Use a trowel or brush to spread the applied Powercrete repair material over the previously prepared surface.  Insure the Powercrete coating is smooth and the coating thickness is equal to the applied coating thickness outside of this impacted area.  Allow sufficient time for the repair area to cure and then evaluate that coating just as you evaluate the field joint coating area.  Allow sufficient cure time and then follow the procedure set forth by the end user in their specification (in terms of potential hardness testing, holiday testing, etc).  If holiday testing, 125 volts per mil is appropriate.  If necessary, record the defect and repair procedure in the construction journal. 

To Repair Damage Greater than 2.5" OD (#2)

     First thing to do in cases of larger damaged areas:  contractor must determine from the end user coating and construction specification if defects in the FJC of this size are allowed to be repaired, or if the coating must be removed and re applied.  If the end user specification allows the Powercrete product to be repaired, use a one or two pound kit to perform the repair using the same installation steps as listed above under the #1 category.  



Monday, March 30, 2020

Powercrete Installation Procedure

General Powercrete Installation Procedure

     Here is a very general guideline of the things we cover when training crews; or training trainers with regard to field applying Powercrete J, Powercrete R65/F1 or Powercrete R95 as a hand applied ARO or field joint coating. 


  1. Preheat the pipe to 120 to 125 F prior to blasting
  2. Blast the pipe with suggested grit size
  3. Verify that proper anchor pattern has been achieved
  4. Re-preheat if necessary to bring pipe surface up above the dew point (or higher if you are wanting to cure faster)
  5. Make sure steel and adjacent coating are free of oil, dirt, dust, etc
  6. Mix the Powercrete - normally pouring the B into the A
  7. Using either a drill or doing it manually, mix the epoxy thoroughly without introducing air into the mixture
  8. Mix epoxy until it begins to have a glossy look (typically 3-5 minutes by hand).
  9. Pour a bit of the mixed epoxy back into the B container and coat the inside in order to use up all hazardous material in the B container.
  10. Pot life will vary significantly based on ambient weather conditions.  The hotter it is, the quicker things cure.  Generally speaking you might have:
    1. ~18 minutes for Powercrete J
    2. ~8 minutes for Powercrete R65/F1
    3. ~15 minutes for Powercrete R95
  11. Apply 1st thin coat and let that coat sit until it is tacky
  12. Apply next coat, beginning to build coating thickness as needed
  13. Monitor the pipe for potential drips until the epoxy has begun to gel and get tacky.

Friday, March 27, 2020

Powercrete Outer Wrap Applications

Powercrete Powershield-XT Outer Wrap Applications

     A few examples of applications which may be perfect for Powercrete Powershield-XT:


  • Soil to air transition of pipelines:  rigid mechanical protection of corrosion preventing coating systems on risers against soil shear, mechanical impact and indentations.
  • Field Applied Coatings:  Rigid mechanical protection of corrosion preventing coating systems on pipeline girth welds against soil shear, abrasion, mechanical impact and indentations such as an aggressive backfill and directional drilling operations.
  • Pipe Saddles:  Mechanical protection of your corrosion prevention system on pipe saddles is improved dramatically when wrapped with Powershield
  • Pipe and Fittings:  Add extra physical protection to abnormally shaped objects like bends, tees, valves and flanges for added protection against soil shear, abrasion and impacts.