DATA SHEET  
 
                                                        A SINGLE-PACK CO-POLYMER ANTI-CORROSION CHEMICAL COATING COMPOUND-CORRKIL-E 
 
 
INTRODUCTION 
 
Our Research Wings has successfully developed a special Class of Co-polymer thermoplastic based Anti-Corrosion Coating Compounds -CORRKIL-E through exhaustive work conducted over several years. This is quite a new Class of products, not placed in the market ever before by any Manufacturer and hence we claim these as our Monopoly products. The product takes, an excellent bonding with Metal & Concrete surfaces and offers a very good protection against corrosion resulting from a wide range of industrial chemicals, gases and adverse weather conditions. The products are variously coloured and their coatings almost look like those of paints. 
 
THE TERM “ANTI-CORROSION PAINT: 
 
Since paints are devised for protecting metal surfaces, it is broadly believed that all paints are anti-corrosion paints. But it is not a correct version. All oil-based paints, for example, are not anti-corrosion paints. They are merely decorative paints which protect the metal surface partially against the climatic corrosion but fail to stand against the drastic corrosion caused by various industrial chemicals & gases. Today, there exist in the World over Fifteen Million known chemicals of Organic & Inorganic origin. Hence it is obvious that there cannot exist a single, all purpose, Anti-corrosion paint or Coating material that can effectively combat the corrosions resulting from such a wide range of chemicals. Thus, ‘Anti-corrosion Paint’ itself is a loosely defined term that gives no clear promise for an effective and verstile anticorrosion effect. 
 
PROPERTIES & FEATURES: 
 
1. CORRKIL-E is SINGLE-PACK, ready-to-use product which do not require the addition of Hardener/Catalyst at the time of use, as it is necessary in the case of Polyurethane and Epoxy classes of anticorrosion paints.

 

2. For application of CORRKIL-E, the laborious and expensive method of sandblasting for cleaning the rusted metal surface is not necessary. Just a thorough manual cleaning with metal shrapnel & steel-wire brushes is enough.

 

3. Though CORRKIL-E possesses a unique self-priming property, the use of our special primer CORRKIL-EP is recommended to produce a durable coating.  

 

4. The components of CORRKIL-E chemically react and set into a stiff Co-polymer plastic laminate through intermolecular cross-linkages and takes a strong bonding with the clean metal surface. The resultant coating is impermeable to air & gases. 
 

5. V. IMPORTANT  :   The most spectacular feature of  CORRKIL-E  is that owing to the excellent solvation property, the well-stuck part of the old coating re-softens and completely merges with the new coating to produce a single consolidated coating at the time of next application. This means, while cleaning, do not remove the well-stuck part of the old coating off the metal surface at the time of next application. Just apply a fresh coating over the well-stuck old coating to produce an even coating. Thus, the continued use of our product ultimately produces such a tough coating on the metal surface which takes very long and becomes extremely resistant to the drastic conditions of corrosion. The coating effectively protects metal structures against the corrosion of saline weather conditions in coastal areas.

 

6. Besides metals, CORRKIL-E gives an excellent bonding with concrete surfaces. The product components in solution penetrate into the porous concrete surface through absorption and form plastic tentacles within the substrate which firmly hold the coating to afford an extra strong bonding with the concrete surface. The coating prevents erosion of the concrete by weather, water, chemicals and gases.

 

7. CORRKIL-E prevents the growth of fungus, moss, algae and other vegetative as well as bacterial life.

 

8. The heat tolerance temperature of the coating is about 125-135 deg. C.

 

9. COVERAGE:  Two Litres of material give TWO coatings on about 65-70 Sq. Ft. area of the metal surface, previously coated with a Primer. 
 
Coverage of CORRKIL-EP(Primer): One Litre of the CORRKIL-EP Coat covers approximately 4-7 Sq. mt. area of the cleaned metal surface.       Dry Film Thickness:  Collective DFT of one coat of CORRKIL-EP & Two coats of CORRKIL-E product is approximately 120-140 Microns. 
 
10. Minimum Shelf-life of our products in well closed containers is about 12 Months. 
 
NOTE:  The Products are supplied in silver colour in 20L & 5L packing. However, products in any other colour-choice of the Customers can be made and supplied as a special Order (At least 2500 L) against their shade sample, ofcourse subject to the possibility of doing so without sacrificing the anti-corrosion property of the Compound. 
 
SPRAY GRADE COATINGS:  
 
We have now successfully converted our current brush-applicable Coating Compounds, to a perfectly spray able range of products without affecting their original anti-corrosion properties. This SPRAY GRADE can be easily sprayed over cleaned metal surfaces under a pressure of about 8-10 Kgs/Cm2, by adding NC Thinner, as required. 
 
 
METHOD OF APPLICATION 
 
Remove the thick scales of rust on the metal surface with mild hammer strokes and clean out the surface thoroughly by scratching with metal shrapnel and steel-wire brushes. Then remove the loose rust particles on the metal surface by rubbing with dry cloth. Remove the stains of grease or oils, if any, on the metal surface by cleaning with kerosene or petrol. Make sure that the cleaned metal surface is completely dry before application. On the clean and dry metal surface, first give a coating of CORRKIL-PA. After 24 hours apply One coat of CORRKIL-EP(Primer) and allow to dry for one day. Then give two even coat of CORRKIL-E the Top Coat, each coating at an interval of one day. Please note, our Products being Solvent- based, the first coating does not give a complete hiding of the lower surface. The final coating, however, produces a total hiding of the lower surface. While giving the coatings, do not unduly rub the brush for a long time over the same spot. This leads to the formation of plastic fibres on the brush which disturb the coating with the pulling effect. In fact, this is a peculiar property of CORRKIL-E. To avoid fibres, again take a little fresh material or thinner on the brush and make an even coating. The surface of the coating becomes tack-free within six hours and dries up completely within 24 hours. Total hard drying through complete cross-linkages of the Co-polymer takes about a week. Please also shake/mix well before applying.  

NOTES  : 
1) At the end of use, quickly wash out the used brushes wit out Thinner or Xylene. 2) If the CORRKIL-E/CORRKIL-EP becomes thick due to solvent-loss through improper capping of the containers, thin it as necessary by adding to it our Thinner or Xylene. Do not use Turpentine, kerosene or oils or any other thinner for thinning since they spoil the material. 3) Though commercial quality Xylene is available in chemical markets, our special Thinner will be supplied to the users as per their need. 
 

 

CAUTION!!! 
While making the Primer/Compound application in non-ventilated or poorly ventilated conditions, arrange a powerful Exhaust Fan to evacuate the solvent vapours and protect the workmen from suffocation. Avoid flames and smoking to save from fire or explosion while working under such closed condition. It is, however, advised to avoid the applications in closed conditions. 
USES:   CORRKIL-Eeffectively protect iron structures such as, beams,girders, Pillars, railings etc. of buildings & bridges, Chemical Plant equipment such as the external sides of vessels, Tanks, pumps, pipelines, etc. Gas & Oil pipelines of fertiliser & power  industries; T.V. & Microwave Transmission Towers; Docks and harbor installations including ships, mechanised crafts etc., Cranes & earth-moving equipment; Under-surface of railway coaches, 

 
wagons, trucks, motor cars & scooters; Sluicegates, valves and other irrigation structures; sewage and water-treatment plants; Metal and concrete tanks of gas plants; R.C.C. water storage tanks, electricity poles, R.C.C. pipes, concrete machinery foundations and various other domestic uses such as the protection windowfrills, gates, shutters etc.

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Specifications for CORRKIL-PA  
   
 
Sl no Characteristics  Requirements 1 Appearance and Colour Dirty Black 2 Consistency Homogeneous free flowing liquid  without any lumps 3  Specific gravity  1-1.20  4  Dry film thickness  less than 2.0 microns   5  Acid content   13-13.5 gm/lt as equivalent to NaOH  6  pH value   Below 0.05  7  Rust removing capacity  Should remove rust within 10 minutes  (as per IS:15315)  8  Rust Conversion into iron (% by mass)  (a) In 5 mins : 1.8% - 2.15 %  (b) In 10 mins : 5.9-6.2 % (as per IS:15315)  9  Corrosion resistance (3% NaCl  solution)  No sign of corrosion after 1000 hrs  
 
 
Specifications for CORRKIL-EP  
 
 
Sl no  Characteristics  Requirements  Test Method   1  Drying time   a) Surface dry, max  b) Hard dry, max  c) Tack free, max     hour 1 hour  90 minutes  IS: 101-86 (Part 3/Sec.1)  2  Consistency   Smooth and uniform, suitable  for brush /spray application  IS: 101-89 (Part 1 /  Sec. 5)  3  Finish  Smooth and matt to egg shell  flat  IS: 101-87 (Part 3/ Sec.  4)  4  Colour  Self standard grey  IS: 101-89 (part 4 / sec.  2)  5  Dry film thickness/ coat  25-50 microns  IS: 101-89 (Part 3/ Sec.2)  By Elcometer  6  Stripping test  Free from jagged edges and does not strip  IS: 101-88 (Part 5/Sec. 2)  7  Scratch hardness (1.0 kg Load)  No such scratch so as to show base metal  IS: 101-88 (Part 5/ Sec. 2)  

 
8  Flexibility & adhesion  (6.25 mm mandrel)  
No visible damage or  detachment of film  
IS: 101-88 (Part5/ Sec.  2)  9  Flash Point  Above 30oC  IS: 101-87 (Part 1/ Sec. 6)  10  Resistance to salt spray (4 %NaCl)  No sign of corrosion & no sign of deterioration viz. Blistering, detachment of film up to 3000  hrs  ASTM B-117/90  11  Protection against corrosion under condition of  condensation  -do-  IS: 101 (Part6? Sec. 1)  12  Keeping properties for  both the packs  Minimum 12 months  Refer Appendix-III  13  Mass in Kg/10 litres.  Min  9.5  IS: 10187 (Part 1/ Sec.  7)   14 Adhesion Cross hatch  test 5B As per ASTM   15 Theoretical Spreading  capacity, min 7.0 Sq.m/ li, at 40 microns DFT As per appendix-I   16 Heat Resistance test at 125oC for 24 hours No visible damage, cracking, peelingor detachment of film By exposing painted panel for 24 hours at  125oC   17 Viscosity (Efflux time  by ford cup no. 4) 225-250 sec IS: 101-89 (Part 1 /  Sec. 5) 
 
 
 
 
Specifications for CORRKIL-E 
 
 
Sl no  Characteristic  Requirements  Test Method  1  Finish  Smoothe, uniform, matt to  eggshell gloss  IS:101-87 (Part 3  /Sec.4)  2  Drying time Surface dry, max Hard dry, max,  Tack free     hour 1 hour  90 minutes  IS:101-86 (Part 3  /Sec.1)  3  Consistency   Smooth and uniform and  suitable for brush/spray application  IS:101-89 (Part 1  /Sec.5)  4  Dry film thickness, min  40-50 microns  IS:101-89 (Part 3  /Sec.2) By Elcometer  5  Total DFT (Full  system)  120 microns (min)  -do-  6  Colour   Grey  IS:101-89 (Part 4  /Sec.2)  7  Viscosity (Efflux time  by ford cup no. 4) at 27±2oC  225-240 Sec  IS:101-89 (Part 1  /Sec.5)  

 
8  Scratch Hardness (1.0  Kg Load)  
No such scratch so as to show  base metal  
IS:101-88 (Part 5  /Sec.2)  
9  Flexibility &Adhesion  (6.25 mm mandrel)  
No visible damage or  detachment of film  
IS:101-88 (Part  5/Sec.2)  10  Flash point  Above 30oC  IS:101-87 (Part 1  /Sec.6)  11  Heat Resistance test at 125oC for 24 hours  No visible damage, cracking, peeling or detachment of film  By exposing painted panel for 24 hours at  125oC in air oven  12  Adhesion and compatibility with full  system (Primer & finish)  Close match to 4B  As per ASTM D- 3359-97 & appendix- V  13  Stripping test  Free from jagged edges and  does not strip  IS:101-88 (Part 5  /Sec.2)  
 
Mass in Kg/10 litres,  min  9.5  IS:101-87 (Part 1  /Sec.7)  15  Keeping properties  Min. 12 months  Appendix-III  16  Theoretical spreading  rate., min  7.0 Sq.m/lt @ 40 microns DFT  Appendix-I  17  Accelarated weathering  test for 1000 hours (on  full system) Slight change in colour but no  checking, chalking. Flaking or  cracking ASTM G154  
18 Immersion test in sulphuric acid (1:200)  (on full system) 
Should not damage the surface in 3000 hours 
IS 159-1981 
19 Immersion test in Nitric acid (1:20) (on full system) Immersion test in  Alkali(5% solution) (on full system) 
Should not damage the surface Should not damage the  Surface In 3000 hours 
IS-159-1969      IS 159-1950 
20   Resistance to salt spray (on full system) 4 % NaCl 
No sign of corrosion & no sign of deterioration up to 3000 hours 
ASTM B-117 
21 Humidity Test (on full system) 
No sign of corrosion & no sign of deterioration up to 33000  hours 
IS : 101-87 (Part 7 / Sec.1)