Mexico’s Pemex Offshore Crude Piping in 2014 with HPC® Coating’s fresh application with Rust Grip® corrosion prevention and Enamo Grip® protective industrial coating. An average temperature reduction of 55% to a surface below 50°C.

Mexico’s Pemex Offshore Crude Piping in 2024 showcasing HPC® Coating‘s ability to withstand harsh oceanic conditions while providing energy efficiency, reducing maintenance and preventing corrosion and still keeping the average temperature reduction. No deterioration and no drop in performance. Photos: CS&A – SPI Coatings Distributor

Innovative thermal insulation and corrosion protection solutions offered by SPI Coatings

With over 35 years of proven performance in both field and laboratory settings, these coatings are designed to deliver significant energy savings, decarbonization, and long-lasting durability. The range of products, including HPC® Coating and Rust Grip®, provides comprehensive protection against corrosion under insulation (CUI) while maintaining surface temperatures and reducing maintenance costs. This highlights SPI’s commitment to enhancing energy efficiency, asset longevity, and personnel safety in demanding industrial environments.

Key benefits include:

• Energy Savings: SPI’s coatings offer up to 49% energy savings, contributing to lower operational costs and environmental benefits.
• Temperature Control: The coatings can handle a wide range of temperatures, from ambient up to 650°C, with specific products like HPC®, HPC®-INT, and HPC®-HT designed for different thermal applications.
• Corrosion Protection: The combination of Rust Grip® for corrosion prevention and Enamo Grip® for industrial protection ensures durability, even in harsh conditions like offshore environments. The products demonstrated no deterioration or performance drop over a 10-year offshore service in the Gulf of Mexico.
• Safety and Durability: These coatings not only reduce energy costs but also improve personnel safety by lowering surface temperatures, preventing corrosion under insulation (CUI), and extending the lifespan of assets in sectors like oil and gas.

This highlights the proven field and laboratory success of SPI Coatings in the most extreme environments, positioning HPC® Coating as a reliable solution for industries aiming to enhance energy efficiency and asset protection.
 

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Report extract in English
By Hideki Yonekura
AST Inc. (Advanced Storage & Transportation) Department Manager
ENVIRONMENT SAFETY DEPARTMENT

For Daiko Shokai Co. Ltd (Japanese SPI Distributor), 2010

A whole surface of a tank (1,000KL) in Hokko Terminal (Japan) had coated with Cool Therm (Super Therm® in Japan) in 1996, and we had recognized the beneficial effects. Therefore all of the 39 tanks in Hokko terminal (30,000KL) were coated with insulation coating.

The maximum effect is that VOC emission in the atmosphere has been reduced strongly. This is because a temperature in the tanks are kept at a low temperature constantly by full coating with Cool Therm (Super Therm®), and breathing of tanks are depressed.

Moreover, relating to cooling tanks and refrigerated storage is coated with Cool Therm (Super Therm®), the effect of freezing have risen by 20 percent.

The temperature in the tanks were controlled by using electricity and water before, but it is not needed any more after coating. Cool Therm (Super Therm®) is the superior eco product which lessens the burden on the environment.

The tank coated in 1996, which were recoated with top coat only in 2009, the heat insulating effect is still continuing, and the durability is demonstrated. We are promoting insulation coating of tanks and storages as part of environmental protection > Read PDF

Energy & Mining | Environmental Benefits

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The Super Therm® tank allowed the interior temperature to drop low enough to stop the blow-off or reduce the pressure to stop the flaring.  This was very significant in employee protection but loss of gas.

Project Description

Coating Solution

Results

NOTE: These readings may vary in different locations, weather conditions or climates.

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Rust Grip® – Unequaled Corrosion Protection
Over 3,500,000 feet of Completion Tubulars (Offshore Drill Pipe) with Zero Corrosion Downgrades

Read the article – PDF

A long-term lab and field study by Chevron and Workstrings International published by the Society of Petroleum Engineers, tested 18 leading coatings on drill pipes for eight years. Drill pipes are the toughest environment anyone can ever imagine and Rust Grip^® was the top performer. In that paper they highlight the cascading benefits that came from solving the corrosion problem. You solve the corrosion problem, that’s already millions of dollars in savings and then because you’re not having to swap out these drill pipes so often, you’re saving millions in logistics.

“Beyond the goal of eliminating corrosion and pitting-related damages, the introduction of externally coated completion tubulars has facilitated a paradigm shift in the way operators manage rental completion tubulars.”

“This coating system provides a trouble free solution and significant cost savings to the operator and pipe rental company through reduction in pipe repairs and damages; loss of capital assets; and rig time due to pipe issues, fluid issues and corrosion issues.”

“The savings realized in connection repairs alone is estimated to exceed $250,000 per well.”

Project Description

Coating Solution

Results

Read the article – PDF

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Surface was pressure-washed using Simple Green as a cleaner, and rinsed. It was allowed to totally dry before RUST GRIP® was applied. RUST GRIP® was applied at 190sqft/gallon. (8.5 mils wet – 4.25 mils dry). ENAMO GRIP Polyurethane was applied at 190sqft/gallon as well (8.5 mils wet – 4.25 mils dry), once the RUST GRIP® surface was “tack free”.

Existing tanks at Suncore Energy in Grand Junction, Colorado, USA had been previously coated with national competitor’s products. After failing, Superior Products’ RUST GRIP® and ENAMO GRIP coatings were chosen for improved durability and longevity. It was also required that the coating have a high reflectivity to repel visual light from the surface, and reduce heat gain. While at the same time, be a color that would be compatible with the surrounding colors of the landscape.

The RUST GRIP® / ENAMO GRIP polyurethane system proved to meet all requirements and was chosen for the application on the tanks and applied.

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Santiago-Chile, at Mall Plaza Vespucio Shopping Center

Located in Santiago-Chile, at Mall Plaza Vespucio Shopping Center, which is one of the oldest in Latin America. This place holds a house-care shop known as HOMY (www.homy.cl) located at the top level of the building. The problem started when HOMY noticed that they were not achieving their sales expectative, and they recognized that main reason was that the store has a high temperature during summer time, which leaded the customer to buy quickly and leave the place as soon as possible. There was not a “comfort temperature” which the retail business sets at 24°C. They realised that the roof had no insulation whatsoever, which leaded to surfaces temperatures up to 50°C inside the store. Another particularity is that the roof of the store is also a parking lot in the outside face. This store has 7,000 square meters of roof and was using 5 big A/C generators, full capacity all day.

Solution

Betapaint Ltda. proposed to generate thermal isolation (radiation) using Super Therm®, which was a perfect solution, given we won’t bother the normal development of the store –we didn´t intervened the inside of the shop. The works terms and the costs were also lower than they had as other solutions. We were the only company who could offer thermal isolation without asking them to close or interfere with the inside of the store. Super Therm® was the only solution that provided LEED points (In Chile the LEED program is very important). As said before, the coating was applied outside; facing the sun and it was a big success. The surface temperature dropped from 63°-65°C to 28°-30°C. (Data was taken during environmental temperatures of 32°C). Given the surface where Super Therm® was applied is also a parking lot, we had to protect the insulation from car and pedestrian transit. For that we applied Enamo Grip 5000 clear. It is also important to indicate that our proposal went through the architectural and engineering departments of Mall Plaza (owner of the building) and Sodimac-HOMY (owner of the store).

Results

Both Mall Plaza and SODIMAC – HOMY were both extremely satisfied with the performance of Super Therm® and the solution that we proposed and applied at the store. The inside temperature went down to comfort levels, and the usage of the A/C systems was substantially reduced.

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Products Rust Grip® and Enamo Grip®

Rust Grip® Encapsulates Lead-Based Paint, Asbestos and Rust

The United States Army Construction and Engineering Research Laboratory (CERL) contracted with Manta Industrial, Hammond, IN to conduct field demonstration and implementation of a cost-effective lead-base paint encapsulation procedure for the protection of steel structures, such as hangars, tanks, and bridges that contain lead-base paint usingRust Grip®. The maintenance and lead base paint encapsulation procedures include surface preparation, environmental protection requirements and paint application.

Rust Grip® is patented (Patent #5,695,812) as an effective abatement method of bio-hazardous material including lead-based paints, asbestos and rust.Rust Grip® is a moisture-cure urethane coating with special additives and resins. It is these additives and resins that separateRust Grip® from the other moisture-cure urethanes and allows it to be applied directly over existing, firmly bonded paint or rust without any loss of performance. Since the greatest expense in the coating of lead-base painted steel structures comes from the surface prep (abrasive blasting, etc.) and the containment of that residue, Rust Grip® will greatly reduce the overall costs of the project.Rust Grip® was developed to withstand the harshest environments and has a history of excellent performance.

The Problem

Lead-based paints (LBP) and primers have been used in the past by the Department of Defense (DoD) to protect steel structures from corrosion. LBP abatement and disposal is problematic because the removal of this paint creates hazardous dust and waste.

The DoD owns about 2 billion sq ft of buildings coated with some lead-based paint and about 200 million sq ft of steel structures coated with lead-based paint, such as aircraft hangars, tanks, and bridges. The Army owns 95,400 target facilities in the United States and 26,200 in foreign countries. The average age of these structures is 36 years; 90,000 were built before 1978 and probably contain lead-based paint. Furthermore, about 2600 of these facilities are on or eligible for the National Register of Historic Places, and require special procedures for preservation.

The removal of LBP is generally performed by abrasive blasting and abrasive blasting creates its own environmental hazard. Containment and disposal of surface preparation debris, worker protection, and other regulatory compliance costs combine to make removal of LBP very expensive. The residual waste from LBP removal often contains enough lead to be considered a hazardous waste, thereby requiring special handling and disposal.

The Simmons Army Airfield at Fort Bragg contained numerous steel structures such as water tanks, bridges, aircraft hangars, antennas, ladders, poles, railings, catwalks, fire hydrants, fuel storage tanks, and metal buildings were constructed or installed with lead-based coatings. The removal of lead-based paint from steel structures is currently accomplished through a variety of methods, the most common being abrasive blasting which brings many issues such as containment and public safety along with noise and additional cost.

Prior to recoating steel structures, abrasive blasting is required in order to remove the old lead-based paint and to provide adequate surface profile for bonding the new paint to the substrate. During abrasive blasting, a tight containment structure is required to prevent lead dust from contaminating air, soil or water. Inside such containment structures, increased worker protection is required due to high lead dust concentrations. The large, concentrated volume of waste generated by abrasive blasting is hazardous and requires additional stabilization treatment prior to disposal.

Rust Grip® was introduced as a vital strategy to eliminates sandblasting and safely container the lead paint along with the dramatic reduction in cost for the projects on the site. See the full Department of Defence Report.

More Military Applications

Contact SPI Coatings regarding RUST GRIP®

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114,240 m2 of roofing coated with the SUPER BASE (HS) / SUPER THERM® System

ENERGY AUDIT AND REPORT

Attached are comparisons of our terminal electric bills for August and September 2008/2009. I was trying to get a feel for the potential gains made by the application of the Super Therm® roof coating product that was completed in early August 2009. I calculated the Cooling Degree Days (CCD) for each month and compared the kWh used per CDD for each month. There was a 22% savings in August 2009, and a 8% savings in September 2009.

The temperature change was +3.3°F over 2008 in August and +1.4°F over 2008 in September. According to ConEdison Energy, a 6°F change can relate to a 40% change in A/C cost. With the ambient temperature in 2009 being 3.3°F hotter, this could push the A/C cost up another 20% before SUPER THERM® was applied. Therefore, the savings reported could be 20% to the benefit more than reported.

Chris Wilt Airport Facilities Manager Chris Wilt [cwilt@tucsonairport.org]

Note: Results are only for this location, environment, set of weather conditions and cannot be guaranteed to produce the same results in other areas.

Additional notes below placed by J.E. Pritchett (SPI) concerning the resulting:

• A very important point is that the 22% savings for the airport was on the TOTAL energy bill (lighting, elevators, food facilities, etc).
• This simply means that the SUPER THERM® made a 40% reduction in the A/C costs. From the ENERGY UTILITIES companies, the A/C portion of a total energy bill is 55% which when calculated on the 22% savings of the total relates to the 40% savings in pure A/C costs.
• This is very substantial savings in the A/C cost savings.
• It also means that the A/C tonnage can be reduced to save more money. Equipment savings.
• Run time on the units is reduced which extends their life cycle and saves a tremendous amount of money on replacement or repair of equipment. Maintenance and repair savings.
• Therefore, the cost savings is much more than just the 40% savings for A/C.

SAVINGS:

With the total utility savings of $22,144 (22%) in August for the total facility and the A/C portion of the total utility being 55%, this relates to a 40% savings in A/C operational cost. The savings are beyond the A/C running cost, the units cycle more giving long life, less maintenance work and less tonnage to take care of the main terminal and wings.

ROI: The total roof area of the terminal is 374,804 sq.ft. applied at $2.10+/ sq.ft. is $787,088. With a cost reduction of $22,144 / month, this results in a 35.54 months return. This average can be a little less and could be much more when taking in the summer months. Point is that after 35 months, this savings amount is now available to offset budget needs without the need to find new funding.

RENTAL CAR WASH BAYS:

The car wash bays were done first, and we had to remove the existing elastomeric coating which was not adhering, was not water proofing and was not insulating.

MAIN TERMINAL ROOF COMPLEX: 114,240 m2

We coated the entire Tucson Airport complex of roofing in Tucson, Arizona.

The attached pictures show the beginning with the centre roof coated and the remaining roofing sections.

There are also additional buildings off site that are scheduled to be coating also.

The roofing is “cap sheet” which is tar paper and this requires SUPER BASE (HS) at 9m² (100 sq.ft.) per gallon and then overcoated with SUPER THERM® at 9m² (100 sq.ft.) per gallon.

Other parts of the roofing is PVC or a plastic type material which is weathered but is in good condition and provides good adhesion to acceptSUPER THERM® easily at the 9m² (100 sq.ft.) per gallon.

Preparation was the use of “Simple Green” concentrate cleaner and power wash.

The roof was power washed to wet down, the simple green cleaner was sprayed over the roof and large hard bristled push brooms were used to clean the surface and then the power washer was used to rinse this all off before it dried. The power washer was working behind the push brooms to assure nothing dried before it could be washed off. When the roof surface dried, the SUPER BASE (HS) adhered very strong and tight to the surface.

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In order to stop further damage by severe corrosion to the metal underground structure of the Metro in Baku, a first test project was set up by Superior Products Caspian during first week of April 2014.

The purpose of this pilot test application was to verify the durability and corrosion encapsulation ability of Rust Grip® on non-sandblasted heavy corroded dry metal parts in the underground tunnel complex.
Therefore one section, nr.PK 27+33+34, was selected by the Metro.

Rust Grip® was applied in 2 layers at average of 250μ DFT on the test patch. Evaluation was made after full curing adhesion and scratch tests. The Metro responsible engineers were pleased with the highly satisfactory results. Full description of this demo application is available upon request.

End of June 2014, decision was made by Mr. Zaur Mir Tofiq oglu Hüseynovun, the Chairman from the Baku Metro, after meeting and discussions with J.E. Pritchett, President of Superior Products International II, to continue further applications in the Metro. Contract was concluded between Baku Metropolitan and Superior Products International II to start this encapsulation project with purchase of three 20 foot containers Rust Grip® (2660 gallon each). Superior Products Caspian, in coordination with Superior Products Europe, started organizing the purchase of all the necessary materials and equipment in order to carry out this work properly and in safe conditions. In September 2014 the first 20 foot container with 2660 gallon Rust Grip® arrived in Baku.

First application training was held between 12 December 2014 till 19 December 2014 under supervision of Superior Products Europe. Purpose was to give training and understanding how Rust Grip® must be applied; and to assure that the coating system fully encapsulate all corrosion on dry and sound parts.

Upon arrival in July 2015 of the 2nd container Rust Grip®, an area of +/- 20,000 m² was treated. At the time of my 2nd visit, from Sunday 8th till Friday 13th November 2015, 41,000 m² have been treated with a total consumption of 687 pails (or 3435 gallon) of Rust Grip®.

Before the end of 2015, the 3rd container is supposed to arrive for having continuity in the applications.

Results

In 5 nights, over 604 m2 of heavily rusted cast iron steel was encapsulated with Rust Grip®. Download the full report.

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