Surface Protective Systems

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Aderan Dej Co. in one hand by using the benefit the years of experience of local team, and on the other hand by close cooperation with the most experienced engineers from Steuler-KCH as one of the leader companies in the world and JL Goslar, has been providing the wild range of services (Engineering, material procurement and construction) to its client in Iran in the field of Surface Protective and Anti-Corrosion Systems.

Generally, these systems can be divided in four major group:

Synthetic Resin Coatings
Ceramic Linings
Rubber Lining
Thermoplastic Lining / Bekaplast Systems
Lead Lining

Selecting the best system as an anti-acid or anti-alkaline coating or lining will be based on different parameters such as type of chemical media, process conditions, temperature, concentration, mechanical situation and any effective stresses, service and operational conditions and the status of maintenance.

Synthetic Resin Coatings

In this coating systems, the resin is applied as an integrated layer of coating normally with the thickness of 3 to 6 mm on the concrete or metal surfaces.
Resin coatings are based on synthetic types that during application by adding the hardener part will be cured and reach to the maximum chemical and mechanical resistance.
There are many different types of coating with difference base of Resins for wide range of applications and operational situation in Rigid type or Flexible properties.

Synthetic Resins coatings are based on below types:

Epoxy Base Resins:
very good mechanical strength and good chemical resistance to alkalis
Very good adhesion to concrete and metal surfaces
shrinkage characteristics (Shrinkage Free) and no cracking after application
Self-Level application on the floors or applying with Glass fibers as Laminate systems, also with different fillers to increase mechanical properties

Polyurethane Base Resins
Flexible coating with good mechanical and chemical resistance
high elasticity and no conveying the substrate cracks out to upper surface (Crack-Bridging)
Very good adhesion to concrete and metal surfaces
Self-Level application on the floors or wall surfaces or applying with different fillers to increase mechanical properties
Available in different colors based on RAL standard

Furane Base Resins
highly desirable of Mechanical and Thermal resistance
Very good chemical resistance against a variety of non-oxidizing chemicals and solvents
Very good adhesion to concrete and metal surfaces, with the use of layers (primer)
Very good application on the floor and wall surfaces with using glass fibers as Laminate

Vinyl Ester Resin Base
Very good Mechanical and Thermal resistance
Very good chemical resistance against a variety of acids and solvents
Very good adhesion to concrete and metal surfaces
Very good application on the floor and wall surfaces with using glass fibers as Laminate

Unsaturated Polyester Base
Very good Mechanical and Thermal resistance
Very good chemical resistance against a variety of acids and solvents
Very good adhesion to concrete and metal surfaces
Very good application on the floor and wall surfaces with using glass fibers as Laminate

These Resin coatings also can be applied with some additional properties like:
● Anti-slip or completely smooth surfaces (Skid or non-skid coatings)
● Anti-Static property
● Different colors based on RAL standard

There are different methods of applications:
● Self-leveling
● Troweling
● Rolling & Brushing
● Laminating
● Air-less spraying

Also, to achieve higher mechanical and chemical properties of Resin coatings normally some different types of fillers use such as
● Mineral fillers
● Organic fillers like Carbon fillers
● Glass fibers and synthetic fibers 

Ceramic Linings (Anti-acid Tile / Brick lining)

The anti-acid tiles and bricks normally are being used to protect surfaces against mechanical stress and increase the thermal and chemical resistance of coatings and linings.
The Tiles and Brick lining systems of Steuler-KCH due to enjoying the highest level of relating standards such as DIN, ASTM, etc. has the most suitable and required mechanical strength, thermal and chemical resistance in linings in process surfaces of areas, tanks, sumps, towers, ….

In the operating units in petrochemical plants, refineries, power plants and chemical industries, normally anti-acid Tile & Brick Lining is being used in neutralization, process and reservation tanks and sumps, inside towers, quenches, columns as well as areas and trenches.
Specially in the surfaces of trenches and neutralization sumps which higher thermal resistance is required, tiles and brick lining could be the best lining option.

Standard dimensions of Steuler-KCH Tiles & Brick (240 x 115 mm) with different standard thicknesses ranges of 14 to 100 mm, advanced and high-tech extrusion production methods to create very homogeneous texture and exact quantitized amount of minerals specially SiO2 and Al2O3, the standard rate of porosity and unglazed, backside slots and grooves (split tiles) for enhanced adhesion totally are some of factors that making the highest mechanical strength, abrasion and chemical for acid resistance tiles and bricks of Steuler-KCH.

Variety of standard dimension with different thickness of Ceramic, Carbon and Graphite tiles and Bricks, and besides special and customized shape and dimensions, could set Steuler-KCH brand as one of the leading suppliers in the market.

Special Brick lining of internal surfaces of towers and tanks, is one the main and professional activities of Aderan Dej and Steuler-KCH companies. In such projects, at the first step, based on the design and dimensions of the tower or tank, as well as the shape of interior arcs, the position and size of nozzles and other relating details, the drawing of brick lining will be created which consists of bricks arrangement in the body and nozzles, brick cutting details, number of brick lining layers in bottom and walls. Thermal conditions, calculating the thermal coefficients of layers, process

conditions such as type of material, design and actual pressure and temperature, are among the factors that are effective to design the brick lining drawings.

Steuler has developed a very special brick lining design named Self-Supporting Dome Bricks for absorption and packing towers in specially in sulfuric acid plants, which is a very specific replacement for Grid Beam system. Today almost all packing towers brick linings are using Self-Supporting Dome system.

Design and production of ceramic Dome bricks are being completely done by Steuler-KCH team in Germany as a customized case for each project.

Application of acid resistance (anti-acid) Tile and Brick Lining
In tile and brick lining systems, using special anti-corrosion mortars for bedding and jointing the tiles and bricks.

Acid and Alkaline Resistance Mortars are based on different synthetic resins as below:

● Mortars based on Epoxy Resin
● Mortars based on Furan Resin
● Mortars based on Vinylester Resin
● Mortars based on Unsaturated Polyesters Resin
● Mortars based on Potassium and Sodium Silicate modified types.

Selecting the suitable mortar for bedding and jointing will be based on process and chemical conditions, material type, concentration, temperature, and operating conditions of the lining.
In Tiles and Brick lining system of Steuler-KCH, applying a middle coating as a membrane layer is necessary and a must.
Because of porosity of the tiles, bricks and mortars, in fact the main chemical resistance layer is the membrane coating. If there are no membrane layer, even if they look totally a problem free lining of tile, bricks, and mortars, due to reaching the corrosive media to the bottom substrate layer, the lining will be failed and collapsed after a short time of application and operation. 

Rubber Lining
Soft & Hard rubbers – on site and workshop rubber

Rubber lining is normally used for internal surface protection of metallic and non-metallic tanks, vessels, columns, towers, reactors to increase chemical, erosion, corrosion, and thermal resistances, subject to selecting the right and correct type of Rubber based on the process and operation conditions.

Rubber lining is one of the most quick and fast application methods of surface protective systems.
Also Rubber lining can be used as a membrane layer in Brick lining systems. This is very useful combination of layers in the best linings for the tanks of Pickling Plants.

Steuler-KCH is one of the high-tech and leading manufacturers of a very wide range of Rubbers in Germany that enjoys Extruding production method. Compare to old production method of Calendar, method of extrusion enjoys many advantages to increase the quality of Rubbers.
Modern laboratory and testing equipment for controlling the product quality based on relating standards, always help to keep the products quality very high, that the number of sales references confirm this matter.

Generally, Rubbers are in two types of Hard and Soft Rubbers.
Normally Soft Rubbers has high flexibility, good abrasion resistance and excellent adhesion to metal and concrete surfaces.
Hard Rubbers also, after application and complete vulcanization become very rigid layer, has higher thermal resistance and excellent adhesion to metal and concrete surfaces.

Vulcanization process is in two methods:
● in Autoclaves (Workshop Rubbers)
● after application by hot water, steam or in only by ambient temperature (on-site Rubbers).
Pre-Vulcanized Rubber doesn’t need any vulcanization process after installation.
Self-Vulcanized Rubbers also will pass vulcanization process by the ambient temperature in atmospheric pressure after application on the surfaces. 

Thermoplastic Lining / Bekaplast Systems

Thermoplastic Lining system with registered commercial brand name Bekaplast in 70’s was announced for the first time by Steuler as a very special and different method of surface protective system in the world.

In this method anchor Bekaplast anchor sheets (with special conic shape anchors) are installed by the small space from the surface of concrete walls. Then by casting the concrete into the space between backside of Bekaplast and walls, and after curing the concrete because of special conic shapes of anchors, anchors will get fixed in the concrete.
Bekaplast material are based on:
● High Density Poly Ethylene (HDPE)
● Poly Propylene (PP)
● Poly Vinyl Chloride (PVC)
● Poly Vinylidene-Fluoride (PVDF)
In thickness range 3 to 15 mm and in types of sheet up to 2x4 meter and roll as well.
Thermoplastic lining system (Bekaplast) are divided in different types suitable for different operation conditions:

Standard Bekaplast (Bekaplast S)
Normal single layer Bekaplast system, suitable for concrete sumps, tanks, trenches, …

Double Wall Bekaplast

Double layer special Bekaplast system, suitable for very sensitive and high risk leakage material.

Bolted Lining

This lining system use special stainless steel expansion bolts with very special design of sealing system, to install thermoplastic sheets to the surfaces of walls and bottom of concrete sumps and tanks.

Lining 400 and Aqua Lining
This lining enjoys more number of extruded anchors behind sheets and usually are suitable for Water and Sewage systems for sump, tanks and concrete pipe. This sheets produced in 1.5 mm of thickness and more.

One the most highlighted advantages of Bekaplast system is the possibility of installing the sheets on the concrete frame at the time of concrete casting of the main structure. In fact, by constructing the concrete structure, the protective system will be installed at the same time.
Also, there is the possibility of Pre-Fabrication specially for trenches and basins.

Some of Bekaplast advantages:

● Very good chemical resistance
● Very good mechanical bonding with concrete
● Crack-Bridging property
● Spark Test
● UV Resistance
● Very good resistance to thermal shock and mechanical impact, abrasion, and corrosions
● Special design of Anchor shapes to make the highest mechanical bonding
● Uniformly distribution of anchor on backside of thermoplastic sheets to make equal distribution of mechanical pressure of Expansionary and contractionary
● German DIN standard compliant, ISO 9001 and accredited environmental standard SCC
● Meets the approval DIBt German Institute of Building
● The first Patent Holders of Bekaplast 

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