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SPL Preparation and Corrosion Protection
The SPL system will effectively remove the paint, grease, oil, underseal, filler, anti-flutter, adhesives and the majority of all rust from Panels, Parts and complete bodyshells. The process is carried out via chemical immersion and so avoids the problems encountered with all types of blasting. Media blasting is regularly associated with irreversible damage to the surface and structure of panels and parts and offers no solution to cleaning areas that cannot be reached with the blasting nozzle. One of the major drawbacks with any type of blasting is the problem of media and debris removal from the seams and box sections of the project leading to poor paint fi nish, moisture entrapment and ongoing issues with paint adhesion. Modern, more “gentle” blasting medias are generally considered to be unreliable for the removal of rust. With the SPL system the rust is dissolved out and an advanced corrosion protection coating is applied to prevent its return.
Click here to view a video of the Process
The Stripping System
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Stage 1.
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Heavy organic coatings including underseal, filler, mastic sealants, anti-vibration materials, adhesives, etc. are broken down and de-natured using an advanced dehydration process.
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Stage 2. |
The remaining organic compounds ie. paint, grease, oil and carbon, together with the remnants from Stage 1 are removed via immersion in an alkaline hydrocarbon solution for and then water rinsed.
This leaves the mild steel free of any organic contaminants.
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Stage 3. |
Corrosion is now removed via immersion in a dilute solution of inhibited hydrochloric acid. Inhibitors prevent the acid from attacking the mild steel and will only allow it to break down the corrosion. This is followed by immersion in an alkaline rinse before going immediately to the next stage.
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Stage 4. |
An advanced agitated alkaline neutralisation and passivation immersion process designed to give maximum penetration leaves the component or shell in a bright, preserved condition. This is then followed by a high pressure manual wash containing a neutralising preservative which is driven into the folds, seams and recesses of the component or shell and will cause the water to evaporate quickly leaving a dry, bright and stable mild steel finish which can then be lightly oil protected prior to repair or painting.
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The Electrophoretic Coating System - THE ULTIMATE CORROSION PROTECTION COATING
The Electrophoretic (e-coat) painting process is universally used on all modern vehicle shells, bracketry and panels. Designed to offer in excess of 1000 hours salt spray resistance* it is widely regarded as the best available anti-corrosion primer paint for mild steel. The shell and parts are immersed in all stages of cleaning, phosphating and painting and this provides excellent penetration into seams, box sections and other areas that would be impossible to coat with a spray gun. The shell and skid are attached to a conveyor which carries them through the complete painting process. At each stage the shell is tilted forwards and backwards to reduce the formation of air pockets and improve solution and paint penetration.
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Stage 1. Pre-Treatment |
An 8 stage process covering Cleaning, Conditioning and Phosphating. The cleaning process utilises varying strength alkaline silicate solutions at 50ºC to remove oil and grease followed by water rinses. Following a conditioner rinse the shell is immersed in a bath of phosphoric acid with a zinc, manganese and nickel (tri-cation) solution. Water rinses remove the excess phosphate solution and finally the shell is rinsed with demineralised water. |
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Stage 2. Electrophoretic Deposition |
The shell / part is fully immersed into the 130,000 litre PPG paint tank at 33ºC and an electrical current of approx 320 volts drawing around 1000 amps is passed through it. Whilst the shell is tilted forwards and backwards a highly uniform paint film of between 22 μm and 28 μm is fully bonded to all surfaces via a process known as electrophoresis. It is then removed from the paint and rinsed with a low molecular resin solution called Ultra Filtrate. The excess paint and ultra filtrate are then returned to the paint tank – minimizing waste. The shell is then tilted to drain before being cured.
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Stage 3. Curing |
The shell is then passed through a high temperature oven at 180ºC. This will cross-link the polymer resin allowing the coating to fl ow out and become smooth and continuous. Not only does it cure the paint the high temperature also drives out any moisture from within the seams and box sections. Once cured, the colour may vary from panel to panel due to differences in steel thickness - this does not affect the performance of the coating. The shell is then ready to be seam sealed and primer coated. The e-coat is compatible
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