Investigating Failure
A Hairy Situation: Coating Failure in a 10,000-Gallon Shampoo Tank

From JPCL, May 2016

By Warren Brand Chicago Corrosion Group, LLC


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Tagged categories: Coating failure; Failure analysis; Quality Control; Tank interiors; Warren Brand

Comment from Ronald Lewis, (11/30/2016, 8:34 PM)

What exactly is ambient temperature? Would surmise this temp figure would depend on the place or season one describes as being ambient. (Very dubious isn't it). Coating used was selected too close to the parameters between possible success and possible failure. Why not step it up a few notches and pay a few more dollars per liter just to insure getting well past that range. I would say the fault for the failure is the coating manufacture for allowing a lining so close to an acceptable margin for error is at fault > 85%. And 15% fault to the contractor for applying a lining so close to that margin of error at the so called ambient temperature.

Comment from Warren Brand, (11/30/2016, 11:48 PM)

Hi Ronald. Ambient temperatures are generally considered to be around 74F to 78F. Highly sophisticated, high-performance coating systems are just that. They are designed to perform exceedingly well within their design parameters. If you buy an air conditioner that is rated for 10,000 BTU, you will get an air conditioner that provides 10,000 BTU's. This is true for any product one purchases. As a professional corrosion mitigation consultant, we take great care in determining exactly what the operating parameters of a tank are. And I would agree that to be conservative within 10 or 20 degrees is reasonable. As indicated in my article, however, every 10 degrees C increase in temp doubles the chemical reaction. As I recall, the tank tops were operating at around 125F, well above whatever a reasonable margin of error would be.

Comment from Ronald Lewis, (12/1/2016, 2:51 AM)

Warren; Thanks for the elaboration for ideal temperatures for lining tanks: (20 to 25C). Our firm supplied the internal linings for many of the Refined Palm Oil Storage Tanks in Malaysia and Indonesia for the international “Cosmetics Export Market”. You can imagine what the temperature and humidity range is in that tropical environment is. A small metal sample like that shown in your article would have been a reject for the entire tanks contents. So, we couldn’t afford to be incorrect in our selection of a system & inspection. We supplied a 100% volume solids, 100% Novolac chemistry with zero (VOC) to provide chemical & heat resistance including: non-staining. Those Tanks linings/Contents; were guaranteed by international underwriters Indemnifying the quality required.

Comment from Warren Brand, (12/1/2016, 8:36 AM)

Hi Ronald, Sounds really fascinating. I've never heard of that type of guarantee. If you don't mind, shoot me an email. I'd love to chat.

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