How to renovate and sustainably protect a metal platform in an industrial environment?

The products you need

RD-Elastometal

High performance elastomeric coating combining superior anti-corrosion and waterproofing...

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RD-Eco Powerclean

Powerful biodegradable alkaline concentrate composed of anti-flash rust additives for cleaning...

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The problem

Rust accumulates and begins to create deformations in the metal. Over time, the action of the rust will weaken the structure to the point where it may have to be replaced.  

This process will be faster if the platform is located outdoors or subject to an aggressive industrial environment, such as fumes or vapors.

Platforms also tend to deform to the point where rainwater or other substances can accumulate and stagnate for some time, further accelerating deterioration.

It is therefore necessary to use a solution that combines several performance criteria, including:

  • resistance to corrosion
  • resistance to chemical splashes
  • resistance to sometimes aggressive fumes
  • resistance to traffic
  • resistance to stagnant water

The solution

RD-Elastometal + RD-Hydrograff HP

RD-Elastometal: very high performance elastomeric coating combining superior anti-corrosion and sealing properties.

RD-Hydrograff HP: highly resistant coating with a glossy, satin or matt appearance, formulated for the long-term protection of surfaces against UV, wear, abrasion, chemical aggression and erosion.

Recommended quantities and thicknesses

RD-Elastometal: 
350 µ / 14 mils dry in minimum 2 coats. That is a consumption of 0.8 kg/m² / 67 ft²/gallon.

RD-Hydrograff HP:
50 µ / 2 mils dry. That is a consumption of 0.10 l/m² / 400 ft²/gallon.
A second coat is recommended if the substrate is subject to very high traffic.

Choose a low dirt or safety colour from our colour chart!

Benefits of the system

This system offers multiple benefits for the contractor and the applicator:

  • low VOC (volatile organic compounds) and CO₂ levels
  • easy to use solution
  • quick and easy surface preparation
  • fast drying times
  • reduced downtimes
  • wide range of colours

Our water-based products prevent:

  • bringing hazardous products to the worksite while eliminating the risk of fire or explosion
  • nuisances around the site with annoying odours during and after the application
  • emissions of noxious substances

Getting ready

Temperature and humidity

If the project is outdoors, avoid starting work in rainy or cold weather.

A minimum of 10°C / 50°F and no rain expected during and immediately after application is required to apply the products. From 15°C / 59°F, working conditions are comfortable and enable higher productivity.

If the project is located in a hot climate with a lot of sunshine during application, avoid if possible applying the system when the sun is strongest and prefer to work early in the morning or late in the afternoon while paying attention to dew or condensation.

If the project is being carried out during a season or in a location where there may be significant temperature differences between day and night (e.g. in autumn, a space heated during the day and not at night), be sure to complete the work a few hours before nightfall or when the heating is turned off to avoid condensation forming on the fresh paint and preventing it from drying. If working at dawn, let condensation dry on the surface and never paint over dew.

Surface preparation

The most popular and fastest way to achieve good surface preparation is to clean the object with a pressure washer equipped with a rotating nozzle at an angle of zero degrees and with a minimum pressure of 200 bar / 2900 psi.
In an industrial environment and depending on the soiling, the recommended pressure may be between 300 and 350 bar / 4000 and 5000 psi. This procedure will remove contaminants, paint and loose rust from the surface.

Any paint or rust residues that have resisted cleaning should not be removed as they still have sufficient adhesion.

Mechanical cleaning with manual (abrasive paper or wire brush) or power tools is also an option. It is even recommended when more detailed surface preparation is required.

Ensure that the surface is free of moss, mould, oils, grease and chlorides (salts). Rinse with an alkaline solution (this can sometimes be added to the pressure washer). Do not hesitate to use RD-Eco Power Clean to clean the surface! A powerful biodegradable cleaner.

Check that the existing coating is still adhering properly and that there is no hidden rust underneath. Never paint on a coating that does not adhere properly!

Inspect and treat bolts

Inspect bolts and screws, repair or replace defective ones if necessary. Apply a coat of RD-Elastometal with a brush after the inspection. This will assist in the inspection process and at the same time provide additional sealing and corrosion protection to these sensitive components.

Edges

Check the edges, especially where they are sharp. These are the most vulnerable areas and quickly prone to corrosion if not treated properly. Apply a coat of RD-Elastometal with a brush. Its texture will cover these edges perfectly and protect them further.

Equipement

RD-Elastometal and RD-Hydrograff HP are normally applied by brush to specific areas and by airless or roller to the main areas.

Specifications for an airless application

RD-Elastometal: minimum outlet pressure of 180 bar / 2600 psi. Nozzle opening size between 0.015 and 0.023 inches.

RD-Hydrograff HP: minimum outlet pressure of 70 bar / 1015 psi. Nozzle opening size between 0.007 and 0.009 inches.

Both products can also be applied using Graco's Ultra Max portable airless device. This is a simple and effective method for small jobs or for touch-ups on larger projects.

Simply rinse the airless device with clean water when changing the product.

Tool cleaning

At the end of the work, clean the equipment with clean water or according to the equipment manufacturer's manual.

Application of the system

Preparation of RD-Elastometal

RD-Elastometal is ready to use, stir it mechanically for several minutes before application.

When working in very hot weather (> 30°C / 86°F), add a maximum of 3% water to slow down the drying somewhat. But never add more than 3% water to avoid reducing the anti-corrosion and waterproofing properties.

Tip!

Choose two different shades for the first and second coat. This is a good way to distinguish them and to be sure that the right amount has been applied everywhere.

Application of RD-Elastometal

If applying with a roller, load it well with product. RD-Elastometal has a viscous appearance and is applied in a relatively thick layer compared to more traditional products. Once dry, it has a rubbery, soft and elastic feel. 

If the application is done with an airless, the final result will be smoother. Because RD-Elastometal is dry fall, it is easy to remove unwanted splashes or droplets. It is also easier to control the thickness and achieve a more uniform finish by spraying.

Drying time (typical at 20°C / 68°F)

Touch dry: +/- 3 hours depending on thickness
Recoatable: +/- 6 hours depending on film thickness

Preparation of RD-Hydrograff HP 

RD-Hydrograff HP is a two-component product, which means that the base and hardener must be mixed before application.

Just before application, add component B to component A slowly, while mixing mechanically.
After mixing, let stand for about 5-10 minutes until air bubbles disappear.

Mixing ratio by weight:
270 g of component B for 995 g of component A.
For ease of use, we always supply the exact quantities for mixing, simply pour the entire component B into the component A pot. This avoids any risk of incorrect dosing.

Pot life of the mix:
2 hours at 20°C / 68°F

Tip!

Set an alarm so that the mixing time is not exceeded. RD-Hydrograff HP is available in small packs, order a pack size according to the estimated application time.

Application of RD-Hydrograff HP

Whether applying with an airless or a roller, avoid overthickness as bubbles may appear in the film.

After a few hours, when the paint film is dry, a chemical reaction still continues for several days. This is typical of two-component products. It is therefore important to put the freshly painted surface into service gradually, if optimum performance is to be achieved. This reaction time is influenced by the temperature; the hotter, the faster the reaction.

Drying time (typical at 20°C / 68°F)

Touch dry: 6 hours
Recoatable: min. 8 hours, max. 72 hours, without sanding
Low to moderate handling resistance: 3 days
Intensive handling resistance: 7 days