Chemlok® Adhesives for the Rubber Lining Industry

Doug Mowrey, LORD Corporation

September 2013
Presented at the SLTC
Buenos Aires, Argentina
 Outline
• What is rubber lining
• Applications
• Drivers
• Types of Elastomers and Substrates
• Focus of Presentation
• Rubber Lining Process
• Typical Results
• Summary and Conclusion
• Acknowledgement
• Questions
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 What is Rubber Lining?

• Applications where rubber is bonded to metal for protection against

harsh chemicals, abrasion, and corrosion

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 Where is it used?

• Applications include the lining of pipes, barges, rail cars, storage

tanks, scrubbers, coal handling equipment, tank trucks, processing
tanks, plating tanks, extraction tanks, and pumps

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 Industries that Drive the Need for Rubber Lining:
Mining / Oil & Gas

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 Types of Elastomers
• Natural (NR)
– High percentage of rubber linings are natural rubber (~90%)
– Natural rubber backed calendered stocks
− HCl resistance
– Inorganic salts
– Sliding abrasion (rock slurries)
• Chlorobutyl (CIIR)
– Chemical and heat resistance
• Ethylene Propylene (EPDM)
– Brine & bleach
• Polychloroprene - Neoprene® (CR)
− Oil resistance
• Nitrile (NBR)
− Oil resistance
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 Substrates

• Steel (Majority of substrates are mild steel)

• Stainless steel
• Aluminum
• Glass
• Titanium
• Phosphor bronze
• Concrete (Prime with epoxy primer)
• Wood

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 Focus of Presentation

• Bonding steel and natural rubber during vulcanization of

the rubber lining

• Current Chemlok ® adhesive systems (System below or

Chemlok 205 primer/ Chemlok 220 adhesive):

Substrate
Chemlok 289 Primer

Chemlok 290 Adhesive

Chemlok 286 Tacky Tie Adhesive Rubber

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 Chemlok Systems:

- Proven 30 years +
- Products easily mixed
- Color coded:
Chemlok 289/ Chemlok 290/ Chemlok 286 system and
Chemlok 205 / Chemlok 220
- Typically applied by roller or brush
- Fast drying
- Tack cement allows for repositioning ( Chemlok 286)
- Works with steam, autoclave, hot water, or chemical cure
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 Physical Properties
Chemlok 289 Chemlok 290 Chemlok 286 Tacky
Primer Adhesive Tie Adhesive
Solids (wt%) 23-26% 5.5-7.5% 12-16%
Solvents Xylene/MEK/IPA Toluene Toluene
Color Green Red Black
Flashpoint 6°C (42°F) 7°C (44°F) 5°C (40°F)

Chemlok 205 Chemlok 220

Primer Adhesive
Solids (wt%) 22-26% 23-27%
Solvents MIBK/Xylene/MEK Xylene/Perc
Color Gray Black
Flashpoint 19°C (66°F) 28°C (83°F)

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 Safety Considerations and Precautions
• Mixing, handling, and application of
the adhesive
– Eliminate all spark hazards
• Ground all equipment
• No electric power tools / switches
nearby
• No smoking, cutting, welding,
grinding in area
• Tools or implements should not be
capable of producing a spark
• Use adequate ventilation at all
times
• Consult the MSDS
• Follow industry recommendations
• Train all employees in safety

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 The Rubber Lining Process Overview

1. Remove the old lining (hydroblast)

2. Blast to a white metal finish
3. Vacuum or sweep
4. Apply primer and allow to dry
5. Apply adhesive and allow to dry
6. Apply tack cement and allow to dry
7. Stitch
8. Spark test
9. Vulcanize
10.Spark test

Every step is very important!

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 Proper Preparation of the Substrate
A properly prepared surface is the foundation to a good bond

• Remove rust, loosely adhered metal, and other contaminants by sandblasting

• The profile should be 38-76 micron (1.5 – 3.0 mil) in depth
• Surface should be a white metal finish per NACE No. 1 (or SSPC-SP5)

“A white metal blast cleaned surface, when viewed without magnification, shall
be free of all visible oil, grease, dust, dirt, mill scale, rust, coating, oxides,
corrosion products, and other foreign matter. No light shadows, slight streaks, or
minor discolorations caused by stains of rust shall be visible.”

• All dust and foreign materials from blast process needs removed
• Primer application should take place within 8 hours

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 Application & Handling of Chemlok Primers

• Stir before use

Apply at full strength
Brush or roll applied
• 10 micron (0.4 mil) dry film thickness
Dry to touch (30 – 60 minutes)
Recoat if longer than 7 day layover
• Container sizes (3.8 – 208 liters)
12 month shelf life

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 Application & Handling of Chemlok Adhesives

Chemlok 290 Chemlok 220

• Stir before use • Stir before use
Use at full strength Use at full strength
Brush or roll applied Brush or roll applied
• Chemlok 290 is low in solids • Chemlok 220 has increased solids
2.5 micron (0.1 mil) dry film thickness 12.5 micron (0.5 mil) dry film thickness
Dry to touch (dry time 30 – 60 Dry to touch (dry time 30 – 60
minutes) minutes)
• Chemlok 290 adhesive is UV Chemlok 220 adhesive is UV
sensitive sensitive
Limited layover (7 days, much less in Limited layover (7 days, much less in
sunlight, i.e. 4 hours) sunlight, i.e. 4 hours)
• Container sizes (3.8 – 208 liters) • Container sizes (3.8 – 208 liters)
12 month shelf life 12 month shelf life

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 Application & Handling of Chemlok 286 Tacky
Tie Adhesive

• Stir well before use

Use at full strength
Brush or roll applied
• One coat on the rubber, one on the adhesive coated metal
2.7 micron (0.5 mils) dry film thickness
Dry but very tacky to touch (dry time ~ 30 – 60 minutes)
• Repositioning is possible
3 day layover maximum layover
• Available in multiple container sizes (3.8 – 208 liters)
6 month shelf life
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 Rubber Stitching

• Rubber stitching is a very important step in the rubber lining process since
it removes trapped air and improves adhesion by providing improved
wetting/contact between rubber and substrate and the various adhesive
layer.
• Poor stitching or lack of stitching can lead to blisters or raised areas during
the cure. Blistered areas will need repaired since they often lead to early
failure of the lining.
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 Spark Test, Before & After Cure

• Spark testing is a very important step in the rubber lining process since it
locates areas where there is incomplete rubber coverage

• Once spark testing identifies a problem area the necessary patch work
or repair can be completed before bonded component goes into service

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 Key Challenges Facing an Applicator
• Metal Preparation
– Ensuring that the steel is properly grit blasted and free of corrosion.
– Removing all dust and contaminants from blasting process
• Application
– Temperature at which one will be using the adhesives. Do not want to be
below 12 °C or much above 40 °C.
– Proper mixing of adhesive at application site
– Minimizing layover time for each layer of adhesive
– Allowing for adequate drying times to ensure all solvent is gone
– Coating thickness
– No open sources for sparks or flame
• Performance
– Proper stitching and spark testing to eliminate blisters and voids
– Proper cure time and temperature
– Choice of elastomer / adhesive system - will it last for the 10-15 years?
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 Vulcanization & Bonding Methods
• Chemical cure 7 days at Room Temperature
– Repair

• Hot Water Cure 24-72 hours @ 82 -95°C (180-203°F)

• Open steam 24hrs @ 82°C (180°F)

– Rail cars
– Large tanks

• Pressurized steam 4 hrs @ 0.3 Mpa (40 psi), 143°C (290°F)

– Pipes
– Flanges
– Metal boxes, fittings
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 LORD Laboratory Capability

• Hot water cure

• Open steam cure
• Autoclave cure
• Testing (ASTM D 429-E,
modified)
• Customer or in-house test
compounds

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 Autoclave (Pressurized Steam) Bonding Data

90 Degree angle / RT / 5.08 cm per minute (2 inches)

8.93 Kg/cm 100R

Natural Rubber 32 Shore A Cure 60’ @ 132°C
(50 pli 100R)
11.61 Kg/cm 100R
Natural Rubber 50 Shore A Cure 120’@ 110°C
(65 pli 100R)
14.29 Kg/cm 100R
Natural Rubber 60 Shore A Cure 4 hrs @ 110°C
(80 pli 100R)

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 Open Steam (Atmospheric) Bonding Data

90 Degree angle / RT / 5.08 cm per minute (2 inches)

10.00 Kg/cm 100R

Natural Rubber 32 Shore A Cure 24 hrs @ 88°C
(56 pli 100R)
9.11 Kg/cm 100R
Natural Rubber 60 Shore A Cure 23 hrs @ 88°C
(51 pli 100R)
10.18 Kg/cm 100R
Natural Rubber 60 Shore A Cure 46 hrs@ 82°C
(57 pli 100R)

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 Summary and Conclusions
• The need for rubber lining of steel is growing in all regions of the world

• Rubber Lining market is growing as the need to store and transport corrosive
fluids increases

• For more than 30 years LORD has provided the Chemlok adhesives for
bonding rubber to metal for use in rubber lining applications

• Tank Lining is a key market for LORD and as the industry evolves, LORD will
continue to develop systems that meet industry requirements and help the
applicator.

• Safety is our priority and we strongly urge all applicators to follow safe
practices

• Shortcuts are seldom worth the effort, and all steps in proper metal
preparation through the bonding process is important - Failures are
expensive

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 Acknowledgement

Norman Spence
President
Spence Corrosion Services LTD.
1401 - 8th street,
Nisku, Alberta, Canada
T9E 7M5

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 Questions?

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