Photocured Hydropower Repair Coatings

Hydropower facilities are under constant exposure to extreme moisture conditions. When metal components such as gates and penstocks are exposed to water they experience rusting, corrosion and ultimately parts failure. Coatings are the primary method to prevent corrosion of metal systems, they act as a barrier preventing moisture from contacting metal surface. New coating systems are required to decrease repair time, increase corrosion resistance, and reduce environmental impact of coating applications. We will design a new photocuring coating system for improved corrosion protection and reduced overall repair times. Photocuring is a process of using light to turn liquid resins into solid materials; standard commercial coatings for hydropower systems use thermally cured epoxy and urethane coatings that require days or weeks to full cure. Our system will offer a 100% solid, single coat, highly corrosion resistant coating, with a long pot life and instant “snap” cure on exposure to the correct light source. During Phase I of this project, we will identify the optimal formulation to provide the highest level of corrosion protection compared to standard commercial coatings. We will develop the curing method and systems and collect the necessary physical data to assess the performance of the coatings. We will test the coatings against corrosion through electrochemical impedance spectroscopy and salt spray. We anticipate that our coating system will result in fast repair times and longer service life. This will reduce downtime at hydropower facilities resulting in higher electricity outputs. For penstock repair companies, our resin can result in faster turnaround time at client repair sites, increasing the annual output. We expect that our resin system can expand to other areas of hydropower including turbine repair and spillway repair and into other applications such as marine, industrial, and civil engineering coatings.