let’s talk about the benefits
Technical
from a technical perspective
Let’s talk about the benefits
ZCD has 2 fundamental systems, with products supporting the application and protection of those systems. Z-FP is the Zerosion Flange Protection system and is designed to protect flanges, valve assemblies and any complex structure with bolted joints. It is elastomeric in composition and is designed to flex with the substrate.
Z-FP is a single pot, cold and clean applied system designed to be removeable, simply by peeling it from the substrate. The system is applied by hand and does not require abrasive blasting and can be applied by any trained technician. Z-FP works by complete encapsulation of the substrate, when applied, as it cures, it will shrink around the structure, leaving a completely inert, safe membrane around the substrate that prevents electrolytic ingress and removes concerns of galvanic corrosion.
To support the application life extension of assets, we have created our Z-VP system.
Z-VP protects the flange void and crevices that cleaning might not get to. Z-VP is the Zerosion Void Protection system and is a simple mineral spray solution that provides passive care to the flange void, without harming any gaskets or seals.
The other primary system is Z-SP, Z-SP is Zerosion Surface Protection and is designed to be applied to larger areas, like:
- Pipelines
- Tanks
- Vessels
- Roofing structures
Z-SP is also cold applied and is applied via a roller and pole.
The system can be applied as a removable system, but is primarily designed to be a permanent fix for roofing, bunds and anywhere. The Z-SP system is similar in performance as GRP, but is a fraction on the cost, comes in any colour and is easy to apply. Both Z-FP and Z-SP contain out own Active Corrosion Inhibitor system that neutralises surface corrosion on application, thus the ZCD system REMOVES the requirement for abrasive blasting.
How it protects and how it works
The ZCD suite removes and protects against future corrosion, on two fronts:
1
Firstly, the inbuilt PCI active ingredient in Z-FP & Z-SP neutralised the oxidation process and arrests the entropy progression of galvanic corrosion, thus creating a stable substrate of your assets. The PCI is a weak acidic compound that will not damage the substrate, gaskets or seals.
If you look at the coated part of this spool piece, you can see the inpurities under the coating have turned blue-ish-black, that is where the PCI reacted with surface corrosion.
2
Secondly, the elastomeric compound of Z-FP / Z-SP then shrinks around the complex shapes of the flange, providing an unyielding barrier to elemental attack, actively removing the electrolytic pathway that completes the corrosion circuit. As the coating shrinks, it tacks onto the substrate, with a firm adhesion, that means the coating need to be pulled off, rather than it falling off.
3
The whole principle behind the Z-FP coating system is that it removable so, when access is required, you simply cut it and pull it off.
How we use it
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Preperation
ZCD is designed to be applied in dangerous areas and on complex shapes. Preparation for applicati is hand prep, meaning wire brush and scraper. ZCD does not require an ISO prepared surface to work. ZCD does not require an abrasively blasted surface to protect.
Application
The ZCD systems are designed to be hand applied or spray applied, using a roller or a brush, and is designed simply for ease of use. All you need is material, a wire brush, a roller / paint brush, and a little know-how.
Removable
Z-FP is designed to be removable; it is designed to be pulled off when access is needed. Z-FP will protect for 10 years, then when the day comes that you need to separate a joint, simply score it, rip it off, conduct your maintenance, then recoat and protect for another 10+ years.
Protection
Z-FP and Z-SP are designed to protect, full stop. We have put the systems through rigorous testing to ensure that the system is suitable for the task. The system meets the majority of industry standards, to afford long term protection to you assets, to the environment and to your bank account. The system works and the system carries a warranty
Training
ZCD is designed to be applied by anyone, there are obviously quirks with the system, but as easy to follow application training package is available upon request. We can supply a training video and literature to suit your requirements.
To ensure responsibility for extending the life of your assets, Zerosion contains different elements to build a complete system:
- Z-FP Zerosion Flange Protection: Flange protection coating system, this is our flagship product, used worldwide for joint and flange protection.
- Z-AP Zerosion Adhesive Primer: The Zerosion adhesive primer that makes Z-FP adhere to surfaces that require permanent coating.
- Z-OE Zerosion Oxide Elimination: Our own Oxide elimination system, designed to remove rust from your assets.
- Z-VP Zerosion Void Protection: Flange void protection, sprayable protection for flange voids.
- Z-EP: Zerosion all weather permanent coating system.
- PRK Pipe Repair Kit: Our own high density Pipe Repair Kit system.
- UK
- Holland
- Philippines
- USA
- Canada
- Russia
- British Steel
- BP
- Perenco
- Shell
- Spirit Energy
- EMTS
- Siemens
- RWE
- SSE
- National Grid
- TOTAL
- Interterminal
- UKPR
- Sembcorp
- TAQA
- TATA
- Denholm MacNamee
- Stork
- RATS
- DRAX
When it came to the build of Zerosion, we We understand that using bolted systems as sacrificial anodes makes sense from an engineering and operational point of view, but why, when we can have options?
- To create something that treats and inhibits corrosion
- Is WRAS / BS6920 accredited
- Can be applied in an ATEX 1 / Ex environment, is non-flammable and will not melt or burn or accelerate a flame
- Create something clean and easy to use
- Does not require an expensive training course
- That removes the requirement for a blasted or ISO / SA2 ½ prepared surface
- Cost effective (sub less than $100 for a 12” flange, for 10+ years of protection)
- That is hand applied (brush, roller, spray)
We wanted to revolutionize the protection of bolted joints, and had a list of basic criteria:
To create a protective coat (paint) that can be removed when access is required, putting the field engineer first
when it comes to ensuring the suitability of Zerosion
We have strong beliefs in putting the product through strict, recognised testing procedures
- WRAS (BS 6920) Pass, cold water
- Durometer: shore A (ASTM D -2240) 70
- Tensile: (ASTM D-638) 367psi
- Salt spray:(ASTM B-117) passed 2,000 hours
- Elongation: (ASTM D-638) >400%
- Dielectric: (ASTM D-149) 1,100 v/200μm
- U.V. Stability: 10 years
- Stone abrasion: (ASTM D-3170) excellent
- Temperature use range: -34°C to 112oC.
- Weatherability:(ASTM G -53) 10 years
- Cut resistance: (ASTM D-1044) very good
- Permeability: (ASTM E-96) .084 kgs/mm2.
- Colour availability: any, including clear.
- Recommended Application Temp: 5-35oC
- Coating thickness (3 coats): ~300-400μm
- Curing time: 30 mins @ 50-100μm, 4 hours @200μm
- Application: Brush (hand) or Airless spray
- Coverage: 3 coats@100μm, 1m2
- Shelf life: 2 year at 25°C
- Chemical resistance: Acids, alkaline, pollutants is Excellent.
- Viscosity range: 80 – 100 K.U. @ 25°C (+/- 2°C)
- Solids: (wt.) 58%
- Dry Mass: .56g/kg
- Appearance: Thick coating that follows that contours of the substrate
- Carbon factor manufacture: 5ltrs = 2.41 kgCO2/m2
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