Professional Documents
Culture Documents
The Revolutionary in
Protective and Marine Coating Technology
Introduction
MCU is a coatings manufacturer specializing in rust inhibitive and
corrosion control coatings. It began operations in Reno, Nevada,
USA in 2001, conducting intensive research, testing and
certifications culminating in the Products reaching the consumer
markets in 2003
Born in The U.S.A.
Corrosion !!
What is Corrosion
•Corrosion is the deterioration of materials by chemical
interaction with their environment.
RUST
IRON OXIDE
CHEMICALLY STABLE
Danger of Corrosion
STEEL CORRODES
RUST IS WEAK
RUST IS POROUS
RUST DETACHES FROM STEEL
Corrosion & Scale Stages
Corrosion & Scale Stages
Stage 1
• no scale is present but the
metal may have loose,
powdery, or small granular
deposits on the surface,
base metal is sound
Stage 2
• Metal surface may be
etched or pitted
Stage 0
• the surface
shows no rust
stain or trace
of rust
Stage 3
Stage 4 • Surface conditions and
corrosion deposits present are
• Corrosion has advanced to the similar to Stage 2 except that
point where the metal has been metal in corroded area is
penetrated throughout unsound and small pin holes
may be present.
Type of Corrossion
Consequences of
Corrosion
•Reduction of metal thickness leading to loss of mechanical
strength and structural failure or breakdown.
• Barrier Protection - It forms a barrier that blocks moisture, oxygen and chemicals from
penetrating. While all coatings are permeable to some degree, It provides a superior barrier
coating.
• Inhibition - It contains special pigments that inhibit or interfere with corrosion reactions.
These pigments slowly dissolve with the moisture that does pass through the barrier coating,
in aid in stopping future corrosion.
• Sacrificial Action - It is rich in aluminum. This aluminum will slowly "sacrifice" surface
integrity to preserve the iron or steel substrate.
Property:
1. SINGLE COMPONENT
• MCU product is A Moisture Cured
Urethane Coating means using the
natural elements of the atmosphere for
curing, no artificial heat source is
required, no additional activator or
hardener / curing agent required.
• No Need Thinner
• Due to the cross-lingking density of a
Polyurethane Coating (short chains and
branching) it shows a high degree of
chemical (pH 3-10) and moisture
resistance, as well as excellent adhesive
properties
2. ALUMINUM FLAKES
• The layers of interlocking Al flakes form a new
surface that protects the metal against corrosion
attack,
•Overlapping alumunium flakes add strengh and
durability as opposed to alumunium powders
• UV Resistant - No Topcoat
Necessary
•Xylene is recommended for the preparation and cleanup of all spray equipment. When the
spray gun is not in use, such as between coats, it should be completely submerged in a
container of Xylene. Application equipment must be thoroughly cleaned immediately after
use to avoid damage; any remaining MCU coating will cure and likely destroy the equipment.
AIRLESS SPRAY TIPS
•The MCU coating is supplied ready to stir and apply with an airless sprayer.
•Straining through a nylon bag strainer is recommended.
•Follow Stirring Instructions thoroughly before application.
•Recommended tip size is 011-015 (517-519 tip).
•Inspect all spray equipment and ensure it is clean and in good working order prior to
application.
•Flush Xylene or Toluene through pump, line, and gun to remove any existing moisture or
alcohol from previous coatings or solvents. Do not re-circulate the solvent through the
pump, as the solvent will be contaminated with moisture and debris; draw solvent from one
container and flush into another. Never allow old solvent in the coating lines to enter MCU
coating.
•Ensure that minimum cure times are followed before the application of a subsequent coat.
Published cure times (under normal weather conditions) are specified in the product's
Engineering Data Sheet. When excessive wet film is applied, additional cure time will be
necessary.
EQUIPMENT CLEAN-UP
Use Xylene, Toluene, or MEK for cleanup; do not substitute any other solvent.
Even a very small contamination of this paint with alcohol or other hydroxyl-containing solvents can
destroy the moisture-cure reaction, partly or entirely, without any indication or jelling.
Always flush equipment clean.
Do not leave the MCU paint residue as it will harden and become insoluble in solvent.
Clean equipment as you would with any typical two component catalyzed coating.
Always clean brushes and rollers thoroughly.
Dunking dirty equipment in solvent will not prevent the coating from curing overnight.
SAFETY TIPS
A certain degree of risk is involved in the use, or more properly, the misuse, of most industrial
materials; MCU coating is no exception to this rule. Ensure adequate ventilation and fresh air when
working with MCU coatings. Use a NIOSH Approved Respirator with an 8051 Organic Vapor chemical
cartridge and an R95 filter attached with a filter cover. Filters must be changed if and when they
become saturated. Wear protective clothing, gloves, and eye protection during set up, application, and
clean up. Due to the superior adhesive properties of MCU coating, we strongly recommend that
protective clothing be worn including long sleeves and a spray sock. It is critical to avoid any conditions
that may cause a fire. Avoid open flames, pilot lights, sparks, heating elements, cigarettes, or any and
all possible sources of ignition.
STIRRING and MIXING
Do not open and stir MCU coating when the temperature is below the dew point.
It is a single-component material. It is not necessary to mix "part A with part B"; however,
Itshould be stirred thoroughly for at least 2 minutes or until completely uniform (avoid
whipping air into product). Shaking the container of this paint prior to application may cause
the formation of bubbles in the finish of the coating.
It products that have been sitting for six months or longer may develop settling. Follow the
same stirring instructions, but increase the stir time and be sure to break up any clumps on
the bottom of the container, if any.
The exact balance of viscosity, solvent, and active ingredients must be maintained; therefore,
this paint must not be thinned.If thinning is somehow to take place, please consult our Tech
Department for advice. Thinning or adding any other product to this MCU coating will affect
the performance and quality of the finished product.
PRODUCT STORAGE and HANDLING
Care should be taken to ensure that new unopened containers or left-over partial containers
are kept sealed. A plastic polyethylene film may be laid on top of remaining material to
displace as much air as possible.
This MCU coating is moisture sensitive; limit the time the container is opened. During
application, pour out the portion you will use in approximately one hour and reseal the lid as
soon as possible. Immediately wipe clean any It from the rim of the container and reseal.
This should be done every time you use it and in between coats. Never pour back into the
original container any MCU coating that has been exposed to the outside air for any length
of time because it will destroy the remaining this MCU coating.
The shelf life of MCU coating is approximately two years for unopened containers and
approximately three to four months for containers that have been opened. Product storage
temperature range is 33°F to 120°F. It is a specialized moisture sensitive product; containers
that have been opened should be used within in a few months for proper coating
performance.
CLEAN UP TIPS
Use Xylene, Toluene, or MEK. Do not substitute any other solvent. Do not make assumptions
about other cleanup solvents without consulting the Customer Support. Even a very small
contamination of MCU coating with alcohol or other hydroxyl-containing solvents can
destroy the moisture-cure reaction partly or entirely without any indication or jelling.
Spills must be cleaned up immediately or the product will harden and become next to
impossible to remove. Avoid getting on body, clothes, or any surface not intended to be
coated. It is permanent; after curing, It can only be removed with rigorous abrasive action.
Clean up fresh, uncured Rust Bullet immediately by using Xylene, Toluene, or MEK, following
the solvent manufacturer's directions. Washing with soap and water may work, if done
immediately.
Application equipment must be cleaned immediately after use to avoid damage. Thoroughly
flush equipment clean. Do not leave residue as it will harden and become insoluble in
solvent. Clean equipment as you would with any typical two component catalyzed coating.
Always clean brush or roller thoroughly. Dunking dirty equipment in solvent will not prevent
the coating from curing overnight.
IMPORTANT POINTS TO REMEMBER WHEN USING MCU COATING PRODUCTS
Never allow sweat, rain, or mist to fall into this MCU coating.
Never over stir, entrap, or whip air into this MCU coating.
Never allow lacquer thinner, vinyl thinner, epoxy solvent, or any alcohol or unapproved solvent to enter
It.
For clean-up use only clean Xylene, Toluene, or MEK.
Never neglect to purge all paints, moisture, or debris from equipment before spraying MCU coating.
Never apply this MCU coating while raining or under threat of rain.
Applying a topcoat over this MCU coating is not necessary. If one is desired, wait 24 to 48 hours after
the application of the final coat of this MCU coating.
Only pour out what you intend to use in one hour and replace the lid immediately.
Never pour back into the original container any MCU coating that has been exposed to outside air for
any length of time as this will destroy the remaining MCU coating.
Care should be taken to ensure that new unopened containers or left-over partial containers are kept
sealed. Heavy Duty Plastic Wrap can be placed over the top of the remaining coating with the excess
plastic exceeding beyond the rim of the container. This will displace as much air as possible from the
remaining coating and will help prevent the lid from permanently sealing closed.
Historical Train Trestle Bridge
Obetz, Ohio – with PU finish coat
9. ENVIRONMENTAL FRIENDLY
• INORGANIC ZINC
• ACRYLIC
• ALKYD
Alumunium
Epoxy Primer Pigmented Moisture
Epoxy Finish Cured Polyurethane
Epoxy Zinc
Epoxy Abrasion Rest.
• EPOXY Epoxy Glass Flake
Epoxy Lining
Epoxy Food Grade
Epoxy Mastic
Epoxy Coat Tar
• POLYURETHANE
MCU coatings vs Zinc
• Zinc Paint is based on Zinc or Zinc-varied chemical forms to act as a scarifying anode protection. This technology
is decades old and is effective but is not without its drawbacks. Like all Zinc based coatings, they are not strong
enough to withstand abrasive or harsh atmospheres for any length of time.
• A Zinc based coating will be compromised during normal exposure more rapidly than new technology products.
Free Zinc ions are very toxic and harmful to plant and water life, as well as infants and young children when
released into the water table. Overexposure to Zinc will cause health problems and there are many and varied
ways these unwanted Zinc ions are absorbed. Many Coatings Engineers believe Zinc-based coatings should not
be used as a single barrier coating. If a customer is insistent in their demand to use such coatings, the Engineer
will generally recommend additional coating products, such as two-part epoxy or a polyurethane coating.
• MCU coating Formulas are new technology and unlike the Zinc based coatings described above, may be used
alone as a barrier or protective coating.
• MCU coating Formulas are designed to be applied as a stand-alone product without the necessity of additional
expensive products and applications. As its Formulas do not contain oxides they will not experience the
problematic issues of an Aluminum oxide based coating. The MCU coatings Formula has tested with results far
superior to Aluminum oxides in both chemical resistance and abrasion resistance.
• When considering overall cost of a project, the use of one rather than multiple products reduces labor in
preparation, application, and clean-up. The use of one rather than multiple products reduces cost in product,
equipment, and tools as well. The use of one product will eliminate any unwanted chemical reactions between
coatings that may occur when using multiple brand coatings.
• MCU coating can stand alone with multiple coats creating a strong, resistant surface while Zinc rich coatings are
unable to perform to this standard.
MCU coatings vs Epoxy Primer
• Urethane coatings provide a high degree of chemical and moisture resistance as well as excellent
adhesive properties.
• Additionally MCU Products have demonstrated a high competition with epoxy coatings due to the
ease of application, one-component product and ease of repair, when necessary. A properly applied
and cured MCU Coating will not break like the epoxy and powder coatings.
•
If an epoxy finish is desired, and the existing surface is an epoxy finish, scrape off any loose rust and
epoxy coating, rough-up the remaining tight epoxy with 100 grit sandpaper prior to applying MCU
coating then re-apply the epoxy coating over the final coat of MCU coating.
• Please note: For best results, the surface should be prepared down to bare metal, removing as much
of the existing failing coating as possible.
• MCU coating works best when it is in direct contact with rusted or clean metal.
• Conventional coating method
is filming the surface of
substrate
•Rust will occur under coating
layer (Under Corrosion)
CONVENTIONAL COATING
MCU Coating
MCU coating: the simple way…..
SYSTEM 1 Type DFT
Primer Alkyd 50
Intermediate Alkyd 50
Top Alkyd 50
SYSTEM 2 Type DFT
Primer Inorganic Zinc 25
Intermediate Epoxy 125
MCU Coating System: (DFT)
Top Polyurethane 75
Primer --- 100 micron
SYSTEM 3 Type DFT Intermediate ---100 micron
Primer Epoxy Mastic 100 Top Coat --- 75 micron
Intermediate Epoxy Mastic 150
Top Epoxy Finish 100
SYSTEM 4 Type DFT
Primer Inorganic Zinc 25
Epoxy Glass
Intermediate 250
Flake
Epoxy Glass
Top 250
Flake
MCU COATING SYSTEM AND APPLICATION
PROCEDURES
General Coating System
•Total Dry Film Thickness (DFT) : min. 300 micron for Marine and Heavy Industries or
thicker for extreme environment or depend on potential corrosion rate each area. Each
layer is about 75 micron DFT
•It requires no Top Coat since it already UV Resistant, however for decorative or
identification purposes , the common PU paint can be applied as Top Coat. The DFT is
about 75 micron.
•For Ship or Marine application, Anti Fouling (AF) also can be applied as finish coat after
this MCU layers
Simple Surface Preparation
LOOSE SCALE
Application Procedure
BRUSH ROLLER
SPRAYER
MCU COATINGS APPLICATIONS AND
FIELD PROVEN EXAMPLES
PERTAMINA RU IV-Balongan
CHEVRON – Tj,.Santan
Platforms - Star Energy (Natuna)
NEWMONT –NUSA TENGGARA
KAPUK NAGA BRIDGE PILE –
PANTAI INDAH KAPUK
PT. DAHANA- Subang
Sea Water Intake,
WILMAR Dumai
CONDITIONS
- Sea water intake located 800 M
from shore
- 5-10 Ph level
- Application as internal lining
BEFORE
AFTER
Coal Barge
Tug Boat
Cargo Oil Tanks
PT. Timah – Suction Vessel
Galvanized Roof PT SCI
INDUSTRIAL PIPES (PT KNI)
INDUSTRIAL PIPES (PT KNI)
CONCRETE COATING
Project
Logistics/specification
Application/Inspection
Contract Management
Installation/Erection
Fabrication
Paint
Asset Maintenance
Lifetime costs - The true cost of
paint
• What are the factors affecting the cost of the “painting process” at new
construction?
Surface Preparation
Application
Coatings
Paint is only a relatively minor part of the overall painting costs , and in turn Painting
costs are only a small portion of the overall project
Surface Preparation & Application Cost are major parts.
Lifetime costs - the true cost of
paint
120
100 Coatings
80
Application
60 Coatings
40 Application
Surface
Preparation Surface
20
Preparation
0
System 1 System 2
System 2 will provide a LONGER lasting system – the time to first maintenance will
be extended
MAINTENANCE : Lifetime costs –
the true cost of paint
• Most maintenance engineers will recognise in very simple terms that for ANY
maintenance scenario
• The COST element is effectively fixed – the big affect is the INCIDENCE.
• If the engineer can cut down the number of times maintenance has to be
performed (the incidence) then he can dramatically cut the overall costs over
the lifetime of a project.
Maintenance cost = INCIDENCE x COST
Year 6 - 10 = $500000
Year 0 - 10 = $500000
Year 0 - 5
= $500000