Data are based on results of a continuing research program, initiated by the Corrosion Engineering Products Department of the Pennsylvania Salt Manufacturing Company some eighteen months ago to determine factors and materials which promote maximum protective life in chem-industrial painting. This research includes 429 individual studies of the protective value of 62 maintenance painting compositions of 10 different basic types.
Determinations have all been conducted within the operating process areas of three major chemical manufacturing plants, widely divergent geographically, in fourteen different environments. Wire brushed, corroded and blasted surfaces have been examined. No artificial or simulated exposures were used in any phase of the program.
Where performance comparisons were required and in order to determine performances over surface irregularities normally encountered in maintenance painting, a new type test panel was used. The reliability of results from these panels was confirmed by 101 individual paint applications to actual operating plant equipment and structures. During the course of this program, actual and projected protective life expectancies of various painting systems and procedures were determined and converted to direct dollar cost and savings.
Some results from this program included in this article are:
Over 60 percent of the industrial maintenance paint compositions which by long experience have proved their adequacy in straight industrial use will fail rapidly when used for maintenance painting in a chem-industrial exposure.
Surface preparation by blasting will increase by two to four times the protective life of the maintenance paint system over wire brushed, corroded surfaces.
Maintenance paint system thicknesses below 5 mils are undependable in aggressive chem-industrial environments.
Regular schedules of paint inspection and repair can reduce cost of plant protection to the magnitude of 5 cents per square foot per year even in aggressive chem-industrial exposure.
