Quik-Coating System

Best Practices – 12th in the series

Quik-Coating

This section will explore best practices to use for coating pipe with the Quik-Coating process. We are at the stage of selecting coating as the best option for this pipe and all the pipe has been properly cleaning and preparing for the lining. Before beginning the coating process a final look and last-minute cleaning may be in order to proceed.

  1. Preparation of Coating Machine For Installation Process
    1. Inspect all hoses and components to make sure they are clear of any debris
      • The A-side tends to form crystals in the A resin when moisture and cold temperatures are present. Heat dissipates the crystals and returns them to liquid.
      • If crystals present in the A-side that doesn’t return to liquid, the hardened crystals can be dissolved in our brush cleaning paint stripper. Soaking components in the brush cleaner will clear the components
      • The B-side resin contains a hardener that begins to settle within 4 hours after discontinued use. This hardener must be mixed back into the B-side prior to use and can be remixed used these steps
        • Loosen and stir with a paint stick stirrer
        • After loosening and mixing back into the rest of the resin, shake the container by hand to complete the mixing process
        • After the use of the resin, disconnect and store upright so the settling forms opposite the container opening
      • Store resins between 40F and 120F. These temperatures are best to extend the life of the resin
    2. Plugin the remote-control device then plug in the unit to 120V AC
      •  Test the motor and pump in both modes, control panel, and remote control
        • Test the local position by setting the flow rate to 0.
        • Energizing the on/off switch, then slowly advance the potentiometer to see if the pumps speed up.
        • Switch to the remote control, again energizing the remote potentiometer that is set to 0. Advance the flow control to see if the pumps speed up.
        • If pumps do not turn, dis-assemble the pumps and check them for resin plugging the pumps
      • Turn the power off after testing proves the pumps turning
    3. Before connecting the resin containers to the machine:
      • Inspect the A side for any crystallization.
        • Strain out or heat resin crystals until returning to liquid. Discard any remaining crystals
        • Connect the Quick Connect to the A-side resin container spout
      • Inspect the B-side and remix any settled hardener off the bottom of the container back into a homogenized mix
        • Remove the lid of the B-side
        • With a stir stick, stir up the hardener off the bottom of the resin mix
        • Shake or continue stirring until fully mixed back in.
        • Connect the Quick Connect to the B-side resin container spout
    4. Fill Hoses (if empty) by starting the pump
      1. When hoses full, stop the flow
Quik-Coating Standard System
  1. Proving Flow & Weighing Containers
    • After completing the processes above, the next step in the process is to prove flow
      • Into a disposable cup begin the pump and pump about ½” to 1” of resin observing the flow quantity being discharged
        • If one side or the other doesn’t appear to flow in the same amount as the other side, stop and check your pumps and hoses for any obstructions in the line & clean if plugged
        • After establishing an equal flow to the eye, pump the ½” to 1” resin quantity into the disposable cup
          • Mix the two components together with a stir stick
          • Resin should set in 10 to 30 seconds & if it sets in this range your mix should be close to specification
          • You may wait the 5 minutes to full cure to test the “stickiness” of the mixture. If sticky, check for air pockets in hoses and recheck again by repeating the process and upon proving the 5-minute cure you are ready to proceed.
      • You may dispose of the cup and move to the next step
    • Disconnect the quick connects holding the resin containers & weight both containers together
      • This weighing will tell you how much resin you are starting with
        • Do not weigh containers individually as the weight of each varies vs. the volume so individual weights and adding together is meaningless
        • Record the combined weight you are starting with
        • Calculate the total weight of the resin you will need for this segment of the project
          • Use the guide on the Pipe Lining Supply website for calculating resin demand
          • Record the amount of resin you will need per segment
            • Calculate each run separately
            • Record each run separately
        • You should now have a starting point for calculating whether you’ve applied enough resin for your individual segments.
      • Prepare a sheet recording how much resin you will use for each line segment
      • Plug any open hose ends
  2. Preparation of your coating assembly for coating
    • Prepare the coating assembly for the entire length of the line segment you are coating
      • Secure the brushes to the cable using the set screw to tighten the brushes to the cable. One brush should be the diameter of the pipe while the second brush should be one pipe diameter larger than the actual pipe diameter (installer preferences based on the level of expertise in application)
      • Apply a stop collar to the very end of the cable to catch any brushes that may have come loose as you apply materials. Under tightened screws are the main cause of this issue
    • Tape the red and blue hose no more than 2” behind the brushes to the sheathing on the high-speed cable machine
      • Use the medical tape provided by Pipe Lining Supply as it will stay adhered to the assembly even when dipped into the brush cleaner between coats
      • Tape every 12” to 18” to keep the assembly together
    • Tape the camera head to the assembly not more than 4” behind the red and blue hose ends
      • Check camera to see that you can see a segment of the brushes in your view
      • Tape the entire assembly every 12” to 18” as you insert the assembly down the line to be coated. (You are using the pipe as a convenient storage area to hold your assembly as you continue taping)
    • Once the taping is complete remove the assembly from the pipe to be coated watching your CCTV camera to make sure your pipe has been cleaned to a level you’re comfortable with for the coating process. (no obvious scale or debris left behind)
  3. Application
    • Remove the hose plugs from your assembly
    • Insert the assembly into the pipe and push down the line to the far end of the coating process. Spin the cable to negotiate turns if the assembly won’t push by a point in the pipe.
    • Press the foot pedal on the high-speed cable and start the brush spinning
    • Turn on the potentiometer to begin the flow
      • Select a slow speed to start
      • As soon as you see flow begin pulling the assembly back toward you
    • Maintain a bead of resin in front of the brushes
      • If you retrieve faster than the flow push back and pick up the resin bead before retrieving the assembly
      • Match your pulling speed to the flow of the resin to maintain the bead
        • The experience will allow you to increase flow and pull faster as you gain knowledge and the “touch” of the assembly you are retrieving
        • If you’ve applied too much resin that has balled up in front of your camera and you’ve gone blind, continue at a little faster pace and retrieve your assembly
          • If the ball of resin doesn’t come out with the assembly, you will need to find and remove it
          • You may need to insert a chain knocker to remove any balled up resin or resin that has run before subsequent coats
        • Turns – You will be “blind” for part of a turn and will need to come through the turn
          • Slow the flow and push back to pick up any excess on the inside of the turn and spread it to the outside
          • After you are satisfied you’ve covered the corner increase the flow and continue to pull back
        • Connections or “Tie-Ins”
          • Your camera will view the tie in before the resin and brush assembly
          • Slow the flow of resin through the tie in to prevent or minimize resin running up the connection
          • Push back the assembly and increase the flow slightly before getting to the tie-in where you will slow the flow again moving through the connection point before establishing regular flow rates and pull speed
    • Stop flow about 3” before the retrieval end of the pipe and finish brushing to the end of the pipe
  4. Completion of a coat of material
    • Remove the assembly and plug the hoses to prevent resin flowing into your cleaning solutions
    • Dip the brush into the Brush cleaner paint remover first and spin the brush
      • BEWARE THIS SOLUTION AND READ THE SDS SHEET. IT WILL EAT THROUGH CLOTHING, LEATHER, AND SKIN.
      • Spin for 5 to 7 seconds
      • Pull brush(s) a couple of inches out of the solution but in the pail and spin the brush to remove excess liquid back into the solution
      • Immediately dip the brush(s) into the Acetone and spin for 5 to 7 seconds
      • Pull brush(s) above the liquid and spin the brushes inside the pail to remove excess liquid
      • If the CCTV lens is fouled, clean it with Acetone
    • Dry the brushes with a rag
    • Wire brush off any excess resin still clinging to the brush(s). Any resin left on the brush(s) will fling off on your next pass and leave beads on the subsequent pipe coatings
  5. Wait 5 minutes & test surface of the pipe
    • After 5 minutes your coat should be dry to the touch and ready for subsequent coats
    • Repeat the coating and waiting process until you have enough resin applied. You will apply about 0.5mm of thickness per pass depending on your rate of flow and rate of pullback.
      • Too fast – less than 0.5mm
      • Too slow – run evident from CCTV camera
  6. Finishing & resin delivery verification
    • Disconnect the resin containers from the quick connects and weight the material.
      • If over the amount but less than double the amount you were scheduled to use you are complete
      • If under the amount, reconnect and apply more resin until you’ve met or exceeded your planned resin delivery
      • If over 2 times the resin quantity planned, and the material to achieve the thickness you scheduled
    • Record the amount of resin you applied under that pipe segment on your application log
    • Close the opening from your application access point and return the pipe to regular service

This will complete your line segment and can repeat this process for subsequent line segments. If, upon completion, you are not satisfied with the finish you have some options. Within the first 24 hours, you can remove the material with a chain knocker or sander. You can polish the surface with a cylinder hone of the size that fits the pipe. The pipe can be used 5 minutes after the last coat you applied without regard that the material will slough or wash away.

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