Liquid vessel liner and method of application

Abstract

A liner and method of application for use on a metal surface to protect metal structures such as cooling towers, evaporative condensers, and other liquid containing vessels such as tanks from corrosion, leaks, and wear. The liner is an inexpensive apparatus and process comprising a coated metal having a second sealing and bonding layer and a third protective sealing layer. The liner method comprises applying an organic bonding layer onto the galvanized substrate, and applying an elastomeric barrier coating to the bonding layer. The barrier coating material is applied to preseal the seams between adjoining panels assembled to form the basin. The barrier coating is applied to the entire inside of the basin to form a homogenous barrier coating extending out of the basin. The liner edge is isolated from the basin by extending the liner to a point between the basin and an upper section. The liner comprises galvanizing layer, a bonding layer on the galvanized metal, and an elastomeric third layer on the bonding layer. The liner further comprises preseals at the seams, corner molds and link holes in the substrate to attach and protect the liners integrity.

1 . A multi-layer liner for use on a basin, the basin comprising a plurality of interconnected steel panels, the panels connected together forming a bottom, a top and sidewalls of the basin, the sidewalls having an inside and an outside, the inside of the sidewalls and the bottom defining an interior of the basin, seams between the panels, the liner comprising:
 a first galvanizing layer of zinc on the steel panels;   a thermoset layer of an organic coating on the first galvanizing layer, the organic coating comprising a powder coating electrostatically applied to the surface of each of the plurality of plates;   a preseal on the seams, the preseal comprising an elastomer liner material applied in liquid form to the seams;   a barrier coating mechanically linked to the basin, the barrier coating on the interior of the basin, the barrier coating comprising an elastomer material, the elastomer material bonding to the organic coating along the interior portion of the basin, wherein zinc attaches to the steel panels, the organic coating bonds to the zinc and the barrier coating bonds to the organic coating and the preseal to form a three layer liner on the basin.   
     
     
         2 . The invention of  claim 1  further comprising a link between the barrier coating and the basin, the link comprising a tie, a link hole and a knob, the link hole formed in one of the plurality of panels, the link hole having a tie diameter, the tie on the barrier coating and extending through the link hole, the knob on the outside of the basin adjacent the link hole, the knob on the tie, the knob having a knob diameter larger than the link hole whereby the knob resists being pulled through the link hole linking the barrier layer to the basin. 
     
     
         3 . The invention of  claim 1  further comprising a pipe connection on the basin, the pipe connection comprising a pipe stub having an inside end, an outside end, an inside wall and an outside wall, the basin further comprising a pipe hole, the pipe stub concentrically mounted in the pipe hole having the inside end flush with the inside of the basin, the thermoset layer on the pipe connection, the barrier layer on the inside end and a portion of the inside wall. 
     
     
         4 . The invention of  claim 1  wherein the elastomer material is selected from a group consisting of polyurethane, polyurea and a polyurethane/polyurea mixture. 
     
     
         5 . The invention of  claim 1  further comprising an upper section, the basin further comprising a top flange on the top of the basin, the upper section comprising side walls having a bottom, a bottom flange on the bottom, the barrier coating on the top flange, the barrier coating having a liner edge, the liner edge between the top flange and the bottom flange. 
     
     
         6 . The invention of  claim 5  further comprising a powder coating on the upper section, an elastomeric liner on the powder coating on the upper section, the elastomer liner on the inner surface of the upper section and the bottom flange whereby the elastomeric liner and the barrier coating on the basin are clamped between the top flange and the bottom flange. 
     
     
         7 . The invention of  claim 1  further comprising a corner mold, the corner mold comprising a bottom wall, a side wall and a interior wall, the corner mold disposed in the basin adjacent adjoining panels having the bottom wall on the bottom of the basin, the corner mold sidewall adjacent the wall of the basin, the corner mold intermediate the basin and the barrier coating. 
     
     
         8 . The invention of  claim 5  further comprising a plurality of fastener holes on the top flange intermediate the liner edge and the side wall, the bottom flange further comprising a plurality of fastener holes mateingly aligned to the fasteners holes in the basing mounting flange, a fastener in one of the plurality of fastener holes in the top flange and extending through an aligned fastener hole in the bottom flange, the fastener penetrating through the barrier coating on the top flange. 
     
     
         9 . The invention of  claim 1  wherein the barrier coating is a two part elastomer having additives mixed therein to give the barrier coating a quality selected from the group consisting of abrasion, color, Ultra Violet light resistance, fire resistance, chemical resistance, slip resistance, cure time adjustment, and durability, 
     
     
         10 . The invention of  claim 2  further comprising a corner mold disposed between the sidewalls and the bottom of the basin intermediate the barrier coating and an adjacent panel. 
     
     
         11 . The invention of  claim 2  wherein each basin panel further comprises a top flange adjacent the top of the basin, the barrier coating forming a one piece liner layer on the inside of the basin and extending onto the top flange, the barrier coating having a liner edge on the top flange, an upper section having a bottom flange mounted on and attached to the top flange, the barrier coating liner edge between the top flange and the bottom flange, whereby the liner edge is clamped between the top flange on the basin and the bottom flange on the upper section to isolate the liner edge from an interior of the basin. 
     
     
         12 . The invention of  claim 11  further comprising a corner mold disposed between the sidewalls and the bottom of the basin intermediate the liner and the panels. 
     
     
         13 . The invention of  claim 3  further comprising a tie between the basin and the barrier layer, the tie hole formed in one of the plurality of panels, the third protective coating further comprising a link extending into the link hole whereby the third protective coating is mechanically and chemically bonded to the panel adjacent the link hole. 
     
     
         14 . The invention of  claim 2  wherein the link hole further comprises a link hole in one of the plurality of panels, the link hole extending through the sidewall of the basin, a tie on the barrier coating extending through the panel at the link hole. 
     
     
         15 . The invention of  claim 6  further comprising a mechanical link between the barrier coating and the basin, the link comprising a tie, a link hole, the link hole formed in the interior wall of the basin, the tie extending from the barrier coating into the link hole, the link hole having a tie diameter, the tie on the barrier coating and extending through the link hole whereby the link hole is sealed and the tie binds the barrier layer to the basin. 
     
     
         16 . A liner for use on a basin, the basin comprising a plurality of panels interconnected to form a bottom, an inside sidewall, and a top flange, a seam between adjoining panels, the liner comprising:
 a link hole in one of the plurality of panels, the link hole extending from the inside of the liner to the outside of the basin;   a galvanizing zinc layer on each of the panels;   a connection pipe on the basin, the connection pipe concentrically mounted in a pipe hole cut in the panel, the connection pipe having an inside end and an inside wall, inside end aligned with the inside sidewall of the basin;   a thermoset organic layer on the zinc coating each panel and covering each connection pipe, the organic coating comprising a powder coating electrostatically applied to the surface of each of the plurality of plates;   a preseal on the seams, the preseal comprising an elastomer liner material applied in liquid form to the seams, the elastomer material solidifying after a cure time;   a barrier coating on the interior of the basin, the barrier coating comprising an elastomer material, the barrier coating bonding onto the organic coating along the interior portion of the basin and the preseal liner material, a tie extending from the barrier coating through the link hole, a knob in the tie adjacent the link hole, the basin intermediate the barrier coating and the knob.   
     
     
         17 . The invention of  claim 16  the barrier coating further comprising a liner edge on the top flange, an upper section on the basin, the upper section having a bottom flange connected to the top flange, the liner edge captured between the top flange and the bottom flange. 
     
     
         18 . The invention of  claim 17  further comprising a corner mold, the corner mold having a bottom wall on the basin bottom, a side wall on the basin side, the corner mold intermediate the barrier coating and the basin whereby the transition between the sidewall and the bottom is smoothed by the corner mold. 
     
     
         19 . A method of applying a liner to a basin to protect the underlying galvanized panels from corrosion in a wet environment, the galvanized panels assembled to form a basin having an interior configured for holding liquid, the basin having a plurality of seams between adjoining panels, the basin having an interior, a bottom, a top, a sidewall and a top flange adjacent the top, a mounting surface on the mounting flange, the method comprising the following steps:
 Modifying the panels of galvanized steel for assembly into a basin;   Forming a link hole in one of the panels;   Cleaning the panels to remove oil, dirt and contamination;   Applying a powdered organic coating to the surface of each panel by electrostatic spray;   Curing the powdered organic coating;   Applying a preseal comprising a liquid elastomer to the seams;   Applying a barrier coating on the organic coating and the preseal the barier coating comprising an elastomer compound compatible with the preseal.   The barrier coating on the inside of the basin including the mounting surface forming a one-piece liner from the bottom of the basin to the mounting surface;   
     
     
         20 . The method of  claim 19  wherein the spraying steps further comprising double spraying the seams in the basin. 
     
     
         21 . The method of  claim 20  wherein the method includes the step between the curing and applying the liquid elastomer the step of:
 sanding the surface of the basin and wiping the surface of the basin to be coated with the third elastomer spray liner with a cleaning solution.   
     
     
         22 . The method of  claim 20  wherein the method includes the step between the curing and applying the liquid elastomer the step of:
 prepping the basin and the elastomer application equipment to apply and spray while the basin is still clean and warm from the cure step.