Powercrete J: The Ultimate Choice for Pipeline Coating

When it comes to protecting pipelines against corrosion and ensuring their long-term integrity, the selection of the right pipeline coating is crucial. Among the various options available, Powercrete J has emerged as a frontrunner in the industry. With its exceptional performance and proven track record, Powercrete J has become the most recommended pipeline coating solution for a multitude of applications. In this article, we will explore the key reasons why Powercrete J stands out as the ultimate choice for pipeline coating.

1.     Unmatched Corrosion Resistance: Powercrete J is specifically formulated to provide exceptional resistance against corrosion. It creates a robust barrier between the pipeline and its surroundings, effectively protecting the metal from the damaging effects of moisture, chemicals, and soil conditions. This coating is engineered to withstand harsh environments, including offshore installations, underground pipelines, and subsea applications. Its ability to resist cathodic disbondment and provide long-term protection makes it a preferred choice for pipeline operators globally.

2.     High Flexibility and Adhesion: Flexibility is a crucial aspect of any pipeline coating, especially in applications where the pipeline may experience movement or undergo bending. Powercrete J offers remarkable flexibility, allowing it to adapt to the movements of the pipeline without cracking or delaminating. Its exceptional adhesion properties ensure a strong bond with the pipe surface, preventing the ingress of water and corrosive agents. The coating's superior adhesion contributes to its long-term durability and enhances the overall performance of the pipeline system.

3.     Rapid and Easy Application: One of the significant advantages of Powercrete J is its ease of application. It can be applied by hand or spray, making it suitable for both field and factory applications. The coating cures quickly, minimizing downtime and accelerating the installation process. Unlike some other coatings that require extensive surface preparation, Powercrete J can be applied to a wide range of substrates, including steel, concrete, and various alloys. This versatility makes it a cost-effective choice for coating new pipelines or rehabilitating existing ones.

4.     Environmental Friendliness: Powercrete J is designed with environmental sustainability in mind. It is a 100% solids, solvent-free coating that eliminates volatile organic compound (VOC) emissions, reducing the potential harm to the environment. Furthermore, this coating does not contain heavy metals or hazardous substances, ensuring it complies with the most stringent environmental regulations. Its low carbon footprint combined with its exceptional performance makes Powercrete J an environmentally friendly choice for pipeline coating projects.

5.     Proven Performance and Industry Recognition: Powercrete J has a proven track record in the pipeline industry, with countless successful applications around the world. It has been extensively tested and certified to meet industry standards, including NACE International and ISO 21809. The coating's reliable performance and durability have earned it the trust of major pipeline operators, who consistently recommend Powercrete J for critical infrastructure projects.

When it comes to pipeline coating, Powercrete J stands tall as the most recommended choice. Its unrivaled corrosion resistance, high flexibility, easy application, environmental friendliness, and industry recognition make it a preferred solution for pipeline operators worldwide. By choosing Powercrete J, pipeline owners can ensure the long-term integrity of their assets and protect them against corrosion-related issues, enhancing safety and reliability.

 

Protol Epoxy for Pipelines

Protol 7200 Pipeline Epoxy

Protol Epoxy being hand applied to a 36" pipeline.

          For the last decade or more, two part epoxies like Protol 7200 have seen an increased market share as more and more end users (oil and gas companies) have selected two part epoxies as their coating of choice on pipeline field joints.  Protol offers excellent adhesion to properly prepared bare steel and the adjacent factory applied line coating (fusion bond epoxy).  It offers excellent Shore D hardness ratings, good flexibility and is highly resistant to soil stresses.  The truth is, there are many different technologies out on the market, and each has its own niche.  Each of these technologies is strong in some areas and sometimes weaker in another.  It really is like a universal game of rock-paper-scissors where we pit different pipe coatings against different pipeline and soil conditions!

   

     Epoxies like Protol do depend on an installer to properly prepare the surface, properly apply the epoxy (with no voids or air bubbles) and apply the epoxy in the proper coating thickness as required by the pipeline owner company's specification (please make sure your crews have a wet film gauge!!).  As more and more epoxies have been used in recent years, of course it is a natural trend that there are more and more pipeline crews out there who have experience properly applying it.  Protol is no longer considered to be a pioneer in the pipeline coatings world; Protol is now simply a proven product that has been used often and pipeline companies are collecting data on its performance for more than ten years now.  

     One big factor when coating your pipeline with an epoxy is going to be the cure time of the epoxy.  Protol has a very fast cure time which is good for a whole bunch of reasons that I won't list here (other than to say that coating a field joint and then having to wait 36 hours before burial can present some unique problems).  That fast cure time (and high build status) does mean that no matter how effective and efficient your pipeline field joint coating crew is, you will almost always end up with some epoxy cured in the bucket...wasted.  To attempt to keep that to a minimum, Protol is available in several different kit sizes:  1 Liter, 1.5 Liter, 2 Liter and even 75 Liter and 800 Liter (which would only be used in spray equipment). 

Protal 7200 - Successful Project

Protal 7200 In Stock

Protal 7200 Hand Applied on a 42" Line

      The year was 2010 and one of the largest pipeline jobs in the country was just wrapping up:  500 miles of 36" and 42" pipe.  Kinder Morgan's Mid-Continent Express used Protal 7200 on all of the field joints; hand applied (as opposed to brush applied).  500 miles of 36" and 42" pipe uses a LOT of liters of Protal 7200!

     A situation like this; a large project requiring many, many pallets of material is where Joint Specialists can really add some value to your project.  Why would you want to purchase and store dozens of pallets worth of Protal 7200 somewhere? In addition, why pay the prices that you have to pay to purchase all of those liters one pallet at a time?  You shouldn't have to do either of those things - and now with Joint Specialists as your partner - you don't.

     We have plenty of warehouse space.  We understand the value of on hand inventory.  We excel at customer service.  Simply place your blanket order with us and we'll store all of the Protal 7200 you are going to need right here on hand.  We'll ship it out as you need it (even if it is a pallet at a time or less) and we will invoice you as we ship; for what we ship. 

     In addition, stop getting nickel and dimed!  We will offer the same, great project prices to you even if you really only need a few liters.  We think the most fair thing to do is to consider your purchases over the course of a year; rather than taking of advantage of you on those small jobs...and being fair is important to us. 

     So give us a shot on your next project that requires Protal 7200.  We'll treat you well and we'll treat you right.  No games.  No bickering back and forth.  We try to make things easy on you...we know you've got bigger things to deal with than buying field joint coatings!

Protal 7200 - How Do I Reduce Waste?

5 Ways to Get More From a Liter of Protal 7200 Paint On Epoxy Pipeline Coating

     Every epoxy manufacturer our there will tell you to anticipate as much as a 35% waste factor when calculating how much two part epoxy you will need for your pipeline coating job (see a usage chart here).  This can be a hard pill to swallow!  If you're paying $40 or more per liter, 35% can quickly add up to an astounding number! (On a quick side note, if you're paying $40 per liter, please give us a call the next time you need a liquid epoxy pipeline coating because you are not buying through the proper channels!).  

     So in this article, I'm going to be discussing some of the ways you can maximize that liter of Protal 7200 and maybe even get your wastage number down to a less painful level.  There will always be SOME waste, that is just the nature of liquid epoxies given that they do have a limited pot life due to their curing nature.

1. BE ORGANIZED

     The biggest danger to waste (ie - Protal 7200 epoxy curing in the can; unused) is down time.  Anyone who has ever been on a pipeline spread knows that there is going to be down time.  But we've got to minimize it as much as we can.  As an example, if you're going to be coating field joints on a 12" pipe (in this case: not a road bore), then in a perfect world you are hoping to get 3 field joints coated with each Liter of Protal 7200.  So, before you even open the lid on that 1 Liter kit of Protal 7200; you'd better be absolutely CERTAIN that you've got 3 field joints welded; preheated and cleaned.  Otherwise, you're just giving your money away.  I'll repeat:  THREE FIELD JOINTS READY TO GO before you even pop the lid on that Protal kit.  

 2. Control The Pipe Temperature 

      After the pipe has been welded, preheated and blasted clean (proper surface preparation is vitally important prior to applying any pipeline coating), there is probably going to be SOME temperature to that steel that is higher than the ambient weather conditions.  Here is the interesting thing about epoxies:  Their 'thickness' is going to vary depending on temperature; very much like honey.  Picture a cold morning: you're eating your breakfast outside at deer camp.  You reach over to where the honey sat on a table all night and it is COLD (say 40 degrees F).  You turn up the honey and....nothing.  It isn't flowing at all.  You squeeze the tube and find that it is hard to squeeze!  You've practically got a block of cement in there!.

     Now picture the same thing, but the weather is different.  It is a HOT, HOT Houston summer afternoon and that honey has been sitting in the sun all day.  You tip up the honey and it pours out faster than you can blink; spilling all over your plate.  Now you've got a mess on your hands!  

     In any case, you can control (to some degree) what the temperature of your pipe is when you begin brushing on the Protal 7200.  If you start applying it when the pipe is 190F, the epoxy is going to get very thin.  The epoxy is going to run off the pipe faster than you can work it and you're going to end up with a patch of ground that is the color of Protal 7200. Pipe too hot = high waste factor as epoxy ends up running down on the ground.

     If, on the other hand, you've got a pipe that is COLD to the touch (say 75F - quick disclaimer - installing on a hunk of 75F steel would not be recommended) then the Protal 7200 is going to go on VERY thick.  It won't hardly move at all, which means it is difficult to work, which means the pot stays full longer and means that your coating thickness is probably going to significantly exceed the thickness required in the specification.  Longer install time (due to cold pipe) = waste factor as Protal cures in the pot.  A single coat that is drastically thicker than what is required in the specification = waste as you're putting 60 mils on a field joint instead of the required 25 mils (50% waste!). 

3.  Use a Wet Film Gauge

Having one of these on site can ultimately save you a LOT of money!

      This builds just a little bit on the last point.  If you want to minimize your waste with the Protal 7200, you absolutely MUST know two things:  1.  What is the specification thickness required and 2. How thick am I putting it on?  If you don't know two things; you've got a lot of problems - and waste is only one of them.

     So, every crew needs to have a wet film gauge.  If the spec calls for 25 mils; there is no reason to be putting on 60 mils.  I know it sounds simple, but there are a lot crews out there wasting large amounts of epoxy because they don't have a way to measure their work!  Insanity!  Say you can buy a wet film gauge for $15.  That wet film gauge will last FOREVER as long as you don't lose it (and as long as you wipe it off after every use).  That wet film gauge might pay for itself over the course of 2 Liters of Protal 7200!!!  Imagine the savings it could offer on a project where 15,000 Liters are used!  Such a simple thing.  Such a fantastic investment.  Why aren't you buying a box of wet film gauges for every project?

4.  Mix Carefully, Thoroughly, Evenly and Quickly

      Anytime you're working with Protal (or any epoxy) you need to be sure you're mixing properly.  If you don't mix evenly; you are probably going to get a different (sometimes significantly) pot life than projected.  This can cause all kind of problems.  In addition you want to make sure you are not mixing in a way that fills your epoxy with air bubbles - boy will that slow down a job - resulting in epoxy curing in cans - wasting your money.  At the same time though, you need to mix that Protal quickly!  Mixing for 15 minutes instead of 10 has just wasted 5 minutes of your pot life.  Now you're going to have to work quick.

5.  Get Your Crews Trained!!

     All of these points that I've listed would be covered in a training session.  Yes, sometimes a training session costs money (it all depends on job size, location, notice, length, etc).  But those training costs (if you even had to pay them) truly pay for themselves over the course of a pipeline job.  Better trained crews absolutely lead to less Protal waste.  Better trained crews lead to fewer repairs (and fewer repair costs).  Better trained crews lead to faster field joint coating time (which means less labor cost).  Better trained crews leads to fewer problems with inspectors (which means less labor and less repair costs). 

     Getting your crews properly trained is beneficial on every single level.  So put in that phone call today.  Ask if your next project can kick off with some product training.  It will more than pay for itself in the long run. 

Protal 7200 Coverage Calculator

Protal 7200 Coverage Chart

     A couple of disclaimers first:  There are many factors that will determine how many field joints can be coated with a liter of Protal 7200 epoxy.  Like all epoxies, the ambient temperatures will play a role (the hotter it is outside, the hotter the pipe is etc, the faster the epoxy will cure).  In addition, humidity, properly mixing both components of epoxy and the temperature of the epoxy itself will play a role in determining cure time.  Cure time can be directly translated into pot life (for the most part) and pot life is likely going to determine how many field joints can be coated with Protal 7200 more than actual epoxy volume will (at least where smaller pipe diameters are concerned). 

     For that reason, most all epoxies manufacturers out there (if they are being honest) will advise that people using liquid epoxy coatings for pipelines figure in 25-35% 'wastage'.  This is found mostly in the epoxy that is left partially cured in the bucket.  Part of that 25-35% is ultimately found on the ground beneath the field joint.  So for all of those reasons - this chart is to be taken with a large grain of salt. 

     In tomorrow's article, I will discuss further how to maximize your efficiency with Protal 7200 epoxy usage.  Again:  for smaller pipe diameters, I think this chart is just a little bit too 'optimistic'.

Protal 7200 in a 1 Liter Kit (the most commonly used size)

Protal 7200 Weld Joint Coverage

with Standard FBE Cutbacks (2-3" per side)

4.5" OD ----- 1 Liter of Protal 7200 can coat as many as 9 field joints in a 25-30 mil thickness

6.625" OD ----- 1 Liter of Protal 7200 can coat as many as 6 field joints in a 25-30 mil thickness

8.625" OD ----- 1 Liter of Protal 7200 can coatas many as 4.5 field joints in a 25-30 mil thickness

10.750" OD ----- 1 Liter of Protal 7200 can coat as many as 3.6 field joints in a 25-30 mil thickness

12.750" OD ----- 1 Liter of Protal 7200 can coat as many as 3 field joints in a 25-30 mil thickness

16.0" OD ----- 1 Liter of Protal 7200 can coat as many as 2.25 field joints in a 25-30 mil thickness

20.0" OD ----- 1 Liter of Protal 7200 can coat as many as 1.8 field joints in a 25-30 mil thickness

24.0" OD ----- 1 Liter of Protal 7200 can coat as many as 1.5 field joints in a 25-30 mil thickness

30.0" OD ----- 1 Liter of Protal 7200 can coat as many as 1.2 field joints in a 25-30 mil thickness

36.0" OD ----- 1 Liter of Protal 7200 can coat as many as 1 field joints in a 25-30 mil thickness

42.0" OD ----- 1 Liter of Protal 7200 an coat as many as .86 field joints in a 25-30 mil thickness

48.0" OD ----- 1 Liter of Protal 7200 an coat as many as .75 field joints in a 25-30 mil thickness

4.5" OD ----- 1 Liter of Protal 7200 can coat as many as 4.5 field joints in a 45-60 mil thickness

6.625" OD ----- 1 Liter of Protal 7200 can coat as many as 3  field joints in a 45-60 mil thickness

8.625" OD ----- 1 Liter of Protal 7200 can coat as many as 2.25 field joints in a 45-60 mil thickness

10.750" OD ----- 1 Liter of Protal 7200 can coat as many as 1.8 field joints in a 45-60 mil thickness

12.750" OD ----- 1 Liter of Protal 7200 can coat as many as 1.5 field joints in a 45-60 mil thickness

16.0" OD ----- 1 Liter of Protal 7200 can coat as many as 1.125 field joints in a 45-60 mil thickness

20.0" OD ----- 1 Liter of Protal 7200 can coat as many as .9 field joints in a 45-60 mil thickness

24.0" OD ----- 1 Liter of Protal 7200 can coat as many as .75 field joints in a 45-60 mil thickness

30.0" OD ----- 1 Liter of Protal 7200 can coat as many as .6 field joints in a 45-60 mil thickness

36.0" OD ----- 1 Liter of Protal 7200 can coat as many as .5 field joints in a 45-60 mil thickness

42.0" OD ----- 1 Liter of Protal 7200 can coat as many as .43 field joints in a 45-60 mil thickness

48.0" OD ----- 1 Liter of Protal 7200 can coat as many as .375 field joints in a 45-60 mil thickness