The Problem
How to Renovate Rusty Steel Without Abrasive Blast Cleaning.
All steel structures will corrode over time when located in an exterior environment and exposed to harsh weather conditions. This will vary dependant on the original paint system selected and on the location.
ISO 12944 classifies environments with C4 Heavy Industrial and C5-M Coastal being the most aggressive.
Ideally corroded metal surfaces should be abrasive blast cleaned to remove rust and loosely adhering paint prior to application of an anticorrosion maintenance paint system.
However abrasive blast cleaning is not always practical or economic. Restrictions may apply on the use of abrasive grits for safety, access or clean up reasons.
Elastometal is a cost-effective solution, easy to apply, an Anticorrosion Waterproof Elastomeric coating which will protect steel structures in C4 Heavy Industrial and C5-M Marine environments without the need for abrasive blast cleaning.
For a matt smooth architectural finish it can be overcoated with a topcoat of Monoguard, both products are available in a range of RAL Classic and NCS colours.
The Solution
Elastometal & Monoguard
Elastometal is a high performance ecological and sustainable coating with excellent corrosion resistance, adhesion and flexibility. With 200% elasticity it has the flexibility to withstand expansion and contraction of steel structures without cracking or detachment.
Applied direct to metal without the need for abrasive blast cleaning, it is a single product solution for renovating steel fabrications in aggressive Industrial C4 and C5-M Marine environments. It can be applied direct to steel and weathered galvanized steel.
A Low Odour, Low Emission, Ecological and Sustainable coating available in an extensive range of RAL Classic and NCS colours in a semigloss finish.
Elastometal has a rubber like touch and appearance. Should a smooth matt architectural finish be required, it can be overcoated with Monoguard, a fast drying anticorrosion topcoat, providing a smooth durable weather resistant finish.
This Elastometal-Monoguard system is specified for the Oresund Bridge, connecting Denmark to Sweden and one of the longest island bridges in Europe.
Elastometal can be applied by airless spray in two coats to achieve the recommended dry film thickness of 350 microns per coat. It has a theoretical coverage rate of 0.8 Kg per square metre when two coats are applied.
Elastometal is a unique primer finish, it is easy to apply onto rusty steel which has been high pressure water jetted or mechanically cleaned to St2. A fast drying, reliable economic solution that does not compromise on quality, health or safety.
Available in an extensive range of NCS and RAL Classic colours, made in the West Midlands for free delivery throughout the UK in 5kg and 25kg containers.
Benefits & Performance
The Elastometal Monoguard system has a global track record Weatherproofing and providing Anticorrosion properties to steel bridges, metal structures, roofs and cladding. It delivers great benefits to the owner of the building in terms of a cost-effective maintenance solution for steelwork in harsh environments where abrasive blast cleaning is not practical or economic. It has excellent adhesion to steel, weathered galvanised steel and other metal structures. For the applicator it is a simple safe, easy to apply two coat system without the need for abrasive blast cleaning.
For the project manager:
- Economical solution. No abrasive blast cleaning required.
- Ideal in Heavy Industrial & Coastal areas.
- High performance and durable system.
- Ecological and sustainable paint.
- Low VOCs and Emissions. No fire risks.
- Low Odour, minimal disruption.
- Made in the West Midlands.
- Wide choice of RAL & NCS colours.
- Free Delivery no hidden costs.
For the applicator:
- No abrasive blast cleaning required.
- Suitable for rusty steel and weathered galvanised steel.
- Quick drying and overcoating.
- Two coat system, easy and safe to apply.
- No isocyanates or pot life issues.
- Low Odour, Low Emissions. No fire risks.
- Proven track record on Oresund Bridge.
- Made in the West Midlands.
- Wide choice of colours.
- Free Delivery to site.
Preparation
Weather
As with any outdoor project, try to avoid starting a job in wet conditions. A minimum of 10°c (50 °f) and no rain forecast during and immediately after application are required to be able to apply the product successfully. Above 15°c (59 °f), working conditions are perfect and enable higher productivity. If the project is located in a very hot area with very intense sunshine avoid applying the system when the sun is the most intense and work early in the morning or in the late afternoon.
If you are working in humid climates, and especially if it is cold after sunset such as in the autumn, be sure to complete the job a few hours before dark, to avoid the risk of condensation covering the fresh paint and slowing the drying process. If you are working at dawn, be mindful of condensation on the surface.
Surface preparation
Eco Powerclean a powerful biodegradable alkaline concentrate composed of anti flash rust additives is recommended for cleaning and preparing surfaces before painting. When high pressure water blasting up to 4% Eco Powerclean can be added to clean water to improve degreasing and temporarily protect the surface from flash rusting. After application the surface should be left for 2 to 3 minutes for it to react with the metal. It will significantly improve the corrosion protection on exposed metal surfaces and reduce cleaning times. At 5% dilution usage is 100m2 per litre. Allow to dry before applying Elastometal.
High pressure water blasting is recommended at a minimum of 300-350 bar or 4-5000 psi equipped with a rotating zero-degree angle oscillating tip. This method will remove surface contaminants, loosely adhering paint and rust.
Cleaning by mechanical or power tools to St2 may also be used when more detailed surface preparation needs to be done on objects such as access ladders, and bolts that could be heavily rusted.
Moss and mould can be removed with Eco Powerclean biodegradable solution.
Inspect and treat bolts
It is important to inspect the condition of the bolts and fastenings, defective fasteners and bolts must be repaired or replaced. Brush on a coat of Elastometal on each fastener after inspection. This will help visualize the progress of the inspection and add a protective first layer on vulnerable areas.
Edges
Check edges, especially when sharp. They are vulnerable and will corrode quickly if not treated correctly. Apply a spot coat of Elastometal by brush for additional protection.
Preparing the products
Products are supplied ready for use. Mechanically stir the products for a few minutes before the application.
If you are working in hot weather conditions, you may dilute the coatings with tap water to slow its drying. But do not add more than 3% of water in order not to diminish its anti-corrosion properties.
Elastometal and Monoguard are best to be applied by brush on localised areas such as ladders and piping, airless spray should be used for large areas. If spraying is not possible, you can apply by roller although more coats will be required to achieve the recommended dry film thickness.
Equipment
Elastometal when applied by airless spray use a pressure of at least 180 bar or 2600 psi and a spray tip between 0.015 and 0.023 inches.
Monoguard when applied by airless spray use a pressure of at least 180 bar or 2600 psi and a spray tip between 0.013 and 0.019 inches.
For application by roller, it is recommended to use 14 mm / ½ inch polyamide rollers or /8 inch nap rollers.
System Application
Ensure the surface to be painted is free from oil, grease and other contaminants. If interrupted during the application we recommend that the areas to be coated be re-pressure washed or rinsed, usually if the surface has sat for more than 3 days without rain fall or located in a polluted environment.
When spraying Elastometal, overspray is minimal. The coating is also Dry Fall, overspray paint dust can easily be removed once it is dry.
Elastometal is a high build coating, using airless spray, the recommended thickness can be achieved in a single pass.
Application by brush or roller, will require additional coats to achieve the recommended dry film thickness. Allow 6 hours for Elastometal to dry.
Elastometal produces a rubber like semigloss finish on the steel which will provide excellent adhesion and anticorrosion properties.
Should a hard to touch architectural type finish be required apply a topcoat of Monoguard over the entire surface by airless spray.
Monoguard is a fast drying topcoat and is available in a range of RAL Classic and NCS colours in a matt finish, delivered free throughout the UK in 5lt and 20lt containers.
Elastometal is also available in the same colours in 5kg and 25kg containers for free delivery.
For information on specialist roofing contractors and guides to best practice in the selection of roofing materials you may find interesting information from the federation of traditional metal roofing contractors association https://ftmrc.co.uk/ read more about how to renovate metal roofs following this link