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Anti-Corrosion Lining & Coating

WHAT IS RUBBER LINING?
Rubber Lining is the skilled application of unvalcanized and vulcanized rubber sheets to prepared metal surfaces.

Advantages
The principal benefits of rubber lining are its excellent resistance to corrosive and abrasive chemicals and materials, e.g. acids, alkalis, salt water, slurries, sand, shot blast media, crushed rock etc. In addition rubber linings provide other benefits including noise and vibration reduction, electrical and thermal insulation and product protection.

Steps involved in a Rubber Lining Process:

1. Selection of Right Polymer

2. Surface Preparation

3. Primer and Adhesive Application

4. Rubber Lining Application

5. Rubber Lining Curing

6. Inspection & Testing


SELECTION OF RIGHT POLYMER
Selection of right polymer is a very vital requirement in a rubber lining job. We need to understand the material to be used should with stand the corrosive and abrasive chemicals or materials.

SURFACE PREPARATION
All surfaces to be lined shall be grit blasted to blasting quality SA 2.5 Swedish Standard, to be checked using "Tested" system once this is achieved. The temperature of the substrate shall be a minimum of 30C above the dew point during surface preparation and lining application. The substrate temperature during lining application shall be between 100C and 420C. The relative humidity shall not exceed 85%. Steel surfaces which are to receive rubber linings shall be smooth and free of protrusions.

PRIMER AND ADHESIVE APPLICATION
After blast cleaning and immediately before priming, dust and abrasive residue shall be removed with clean compressed air, clean soft bristle brushes or vacuuming. Priming of all surfaces shallbe completed within four hours of blasting.

Any surface which exceeds this time shall be re-blasted. The mixing, applying, drying and curing of the primers and adhesives shall be in accordance with the manufacturer's latest published instructions and the requirements specified therein.

Primers and adhesives shall be thoroughly mixed until they are smooth and free of lumps. The minimum and maximum drying times between coats of the adhesive system and after the final coat of adhesive shall be in accordance with the manufacturer's latest published instruction and approved procedures.

RUBBER LINING APPLICATION
The lining shall be applied in a workmanlike manner to provide an uninterrupted seal over the entire surface to be covered. During application, the sheets shall be carefully rolled or stitched and all seams and corners carefully stitched to eliminate all trapped air between the lining and the adhesive-coated surfaces to that there is full contact with all adhesive-coated areas. sheet shall be skived at a 450C angle. Scissor cuts will not be permitted. Rubber sheet stock shall be at a minimum temperature of 130C when applied to the surface.

RUBBER LINING CURING
Vulcanization of the rubber shall be carried out using steam in anutoclave or atmospheric pressure which ever is applicable. The following process parameters to be followed for above process.




INSPECTION & TESTING
Our rubber linings are subject to numerous inspections and testing, both pre-cure and post cure. At a minimum, all rubber lining will be tested and inspected for the following:

Pre-Cure Inspection

  • All linings will be visually inspected for proper adhesion and loose joints.

  • All linings will be visually inspected for blisters (trapped air), pulls, or surface defects.

  • All linings will be 100% spark tested using a properly calibrated spark tester to locate any possible
    pin-holes leaks.

  • All linings will undergo durometer checks using a properly calibrated durometer gauge to ensure
    the rubber is cured per the specification.


TYPES OF RUBBER LININGS

Soft natural rubber:
This has a good resistance to most inorganic chemicals, leaving aside the strong oxidizing agents. Rubber linings exhibit outstanding abrasion resistance and they expand and contract with the thermal variations of the metal substrate.

Semi-hard and hard natural rubber:
Linings made of semi-hard and hard natural rubber have better chemical and heat resistance than soft natural rubber. These linings have wide application in organic and inorganic acids and chlorine gas. Specific grades have excellent permeation resistance and such rubber linings have heat resistance to 200°F.

Neoprene:
This is a synthetic base elastomer with physical properties which is similar to natural rubber. These linings made of neoprene is superior to natural rubber in resistance to heat, ozone, sunlight, weather, flame and oil.

Butyl:
Butyl linings have good resistance to acids and caustic solutions up to 200°F. They have exceptional resistance to gaseous diffusion.

Chlorobutyl:
Chlorobutyl linings made of chlorobutyl have properties similar to butyl but easier to apply. They have heat resistance upto 200°F. The linings are unaffected by cold weather or rapid temperature changes.

Nitrile:
Linings made of nitrile have good resistance to greases, oils, petroleum hydrocarbons and other non-polar solvents.

EPDM:
The EPDM linings have good resistance to steam and oxygenated solvents. They also have good resistance to sunlight, ozone and heat.


USES OF RUBBER LININGS
  • Linings extend equipment life. 
  • Linings provide solutions for the.  
  • Toughest abrasion and corrosion
     applications.  
  • Extreme chemical environments.  
  • Severe wear situations.

Applications
Rail Car Tanks, Elutriation tank by acid, Removal
tank of grease, Plating tank, Bottom tank.

Chemical industry: Storage tanks of hydrochloric acid and sodium hydroxide, Reaction vessel, Heat exchanger, Filtration equipment, Condenser, Tank lorry, Piping, Vibration mill machine, and others.

Unvulcanised linings for shop and field use. Pre-vulcanised linings primarily for large erected tanks.

Self-vulcanising or chemical curing rubber sheets for repair work.es of Rubber Linings.

 
 
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