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Acid Resistant Flooring for Battery Industry

01/05/2010 12:54 AM

I am working for a lead acid battery industry. In my factory floor due to electrolyte (diluted sulfuric acid) spillage and 2500 kg loaded hand pallet-truck movement floor eroding is inevitable. I have already tried floor epoxy, tiles and asphalt but failed due to loaded pallet-truck and feet of the MS skids containing plates. Can anyone help me to suggest a suitable solution to overcome this?

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#1

Re: Acid proof hard floor

01/05/2010 3:48 AM

Would it be easier to solve the spillage problem rather than fix the floor failures?

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#2

Re: Acid proof hard floor

01/05/2010 9:09 AM

My experience with battery manufacturing facilities, areas where battery powered equipment is re-charged and processing plants where acidic contaminates degrade a concrete floor all indicate the need to provide concrete with acid protection. In your situation you have the added problem of weight abrading away coverings you have tried.

In the case of an epoxy or other protective coatings that have failed; it could be that the bond to the host concrete was compromised from the start? It is very important to stabilize a concrete prior to application of a covering. StableCrete is a product that forms a solid inside the gel-pore/capillary system, thus preventing moisture migration up from a floor to collect at the coating interface that will destroy the bond. Combine that with heavy traffic and it is easy to understand why a coating has failed. Acid resistance is obtained with an application of StableCrete and you also prevent moisture and contaminate transmission in or out of the matrix. Sewage plants have a similar problem with sulphuric acids from Thiobacillus Bacteria Reactions!

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#13
In reply to #2

Re: Acid proof hard floor

03/08/2011 3:11 AM

Dear Sirs,

We Manufacture & Export complete range of: Acid Proof Bricks / Tiles & Mortars, Butyl Rubber Sheet and other Rubber Sheets, Epoxy Floor Coating since 1986.

We serve all kind of Industrial Plants with our Expertise in the field of Corrosion Technology & Manufacturing of complete range of Acid & Alkali Proof - Tiles, Bricks, Mortars, Resins base Mortars, Carbon / Graphite Tiles and its allied Products.

1. Acid Proof Ceramic Bricks & Tiles

2. Acid Proof Carbon / Graphite Bricks & Tiles

3. Acid Proof Granite Bricks & Tiles

4. Acid Proof Bedding & Joint Filling Mortars

4-1. Furan Resin Based Mortar

4-2. Phenolic Resin Based Mortar

4-3. K-Silicate Mortar (Water Glass Based Mortar)

4-4. Epoxy Based Mortar

4-5. Polyester Based Mortar

4-6. Carbon Based Mortar

5. Butyl Rubber Sheets, Natural Rubber Sheets and other Rubber Sheets & Concerned Glues.

We Export our Acid Proof products through out the World and undertake turnkey Jobs or offer technical guide for Acid Proof: Lining, Flooring & Coating jobs anywhere in the world.

If you have any further questions or requirements, please don't hesitate to contact us for more details.

Best regards,

Yuchun Tan / Sales Manager
Tiger Industrial Ceramics Co., Ltd.
Tel: + 86 - 799 - 3293558
Fax: + 86 - 799 - 3293559
Mobile: + 86 - 13907994349
E-mail: tanyuchun@gmail.com or tiger@tigerceramics.com
Website: www.tigerceramics.com
MSN ID: tanyuchun84@hotmail.com

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Guru

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#3

Re: Acid Resistant Flooring for Battery Industry

01/06/2010 11:24 AM

I remember the use of CARBON pipes for handling acid [98% oleum] in the acid dilution plant to dilute 98% H2SO4 to 72% H2SO4. In spite of the exothermic reaction the pipe was stable. Carbon is the element beyond which no further conversions under normal temperature conditions could be possible.

IN similar lines we can even think of SILICA as a possible protection surface.

You need to try plate/ sheet form formation to suit your need including bonding of joints.

Take up trials and conclude for yourself and post feed back if possible.

Best wishes.

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Guru

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#5
In reply to #3

Re: Acid Resistant Flooring for Battery Industry

01/07/2010 12:02 AM

I would like to add more optins on 1]PVC sheet forms for flooring 2] Rubber sheetings on the acid prone floor PVC gives a rigid breakable surface, whereas rubber mat gives a flexible surface You can fabricate as per your choice and fix up on floor. have periodic washings. the entire drain line connected upto Treatment point.

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#4

Re: Acid Resistant Flooring for Battery Industry

01/06/2010 4:49 PM

About 20 years ago I worked in a plant that included acid washing large quantities of sand for specialty glass production among its processes.

The floor in the acid treatment areas had to stand up to fork lift and pallet truck traffic like that you describe.

Basically, any "thin" floor coating or concrete topping will fail due to high point loads you get with fully loaded pallet trucks. If you are limited to this family of products, dedicated acid resistant toppings like "Ceilcrete" may be best.

Our plant, used a depressed concrete slab with tightly laid carbon bricks forming the floor surface. Between the bricks and slab there was a topping that may have been Ceilcrete (Sorry, I don't remember) to form a seal against acid seeping between the bricks themeslves.

The bricks formed the weaing surface, protected the concrete and took the brunt of abuse, pallet/fork lift traffic, dropped pallets, acid spills etc. for (as I understood it) 20 years before the process was moved to a new building. It worked well but was very expensive to install (the same system was replicated in the new building).

I'm sure better systems are around now, but for durability a comparable system of this type might be what you are looking for.

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#12
In reply to #4

Re: Acid Resistant Flooring for Battery Industry

02/20/2011 10:13 PM

Hello friend,

Could you please tell me the name of your factory? do you still work in it? if yes. can i contact you directly? or could you pls give me the relevant person's Email? Thanks very much. my email: tanyuchun@gmail.com. my website: wwwtigerceramics.com .

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#6

Re: Acid Resistant Flooring for Battery Industry

01/07/2010 5:57 AM

I agree with an earlier post that the bond surface of an epoxy coating may have been compromised, hence it breaks up and comes off easily.

No coating is any better than it's bond to the surface on which it is laid, unless it is thick enough to be a self supporting floor in it's own right, in which case the foundation is only a general support.

Glazed tiles are acid resistant, but the grout between them must also be acid resistant and impervious (as must the tiles). Their brittleness makes them subject to damage if subject to impact loads (things dropped).

Clean and thoroughly water blast the existing surface making sure all acid is neutralized and any soft/friable concrete is removed. A wash of lime should neutralize the acid, but wash the surplus lime off afterwards. Apply a good topping of epoxy cement (at least 1"), then follow up with a thick application of polyurethane rubber - about 1/4" min, preferably double that. The one I am thinking of can be trowelled or sprayed on and has a durometer of about 90. Good wear and chemical resistance.

This treatment will be expensive, but should get rid of both the acid corrosion of the floor and the wear problems.

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#7

Re: Acid Resistant Flooring for Battery Industry

01/11/2010 11:30 PM

Friend,

A number of years ago I read about a product called sulfur-crete. It was a sulfur-based product that was extremely acid resistant and could handle point loads. Probably it is still around.

--JMM

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#8
In reply to #7

Re: Acid Resistant Flooring for Battery Industry

01/13/2010 1:29 PM

try Starcrete.com

I believe this company still makes "sufurcrete" along with a similar "starcrete" product that was developed from sulfurcrete.

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#9

Re: Acid Resistant Flooring for Battery Industry

10/21/2010 8:57 AM

Why not try Ceramics acid proof tile. if you want ,I can send you detailed information. my Email: tanyuchun@gmail.com

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#10

Re: Acid Resistant Flooring for Battery Industry

10/21/2010 9:22 AM

Ceramic Acid-proof Brick & Tiles has two types: Typical Bricks and Atypical Brick. They have very
excellent acid/alkali resistance, high temperature resistance, and they can withstand violent heat and
cold. We also have heat & acids resistant grade.
They are used as chemical flooring, lining in many kinds of chemical reactors, towers (including drying
towers, absorption towers, etc.), and tanks of acids & other chemicals in chemical factories, fertilizer
factories, sulphuric acid factories, iron & steel factories, etc. They are used as lining of antiseptic pools
and ditches.

Tan

tanyuchun@gmail.com

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#11

Re: Acid Resistant Flooring for Battery Industry

10/21/2010 10:30 AM

Hello friend,

We can help you solve your problems. And we have some good successful projects of the lead battery industry.

Regarding to your working conditions and requirements, we have a good product - Acid Resistant Sandstone Bricks & Furan or Phenolic Resin Mortar to solve your problems. The Acid Resistant Sandstone has very good crushing strength - we have the right size and thickness Acid Resistant Sandstone Bricks for easily withstand your hand pallet-truck laod. And the Acid Resistant Sandstone Brikcs has very good dilute sulfuric acid resistance.

Yours

Tan

tanyuchun@gmail.com

www.tigerceramics.com

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#14

Re: Acid Resistant Flooring for Battery Industry

05/15/2015 10:48 PM

I have found the same problem in similar industries . I recommend Sika Cor VEL as floor covering

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#15
In reply to #14

Re: Acid Resistant Flooring for Battery Industry

05/16/2015 4:17 AM

I got some useful solution. Most suitable one is a cement based materials made by BASF/UK. Name of the products are UCRETE MF & MASTERSEAL SP 120.

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#16

Re: Acid Resistant Flooring for Battery Industry

05/17/2015 8:16 AM

Formation room in battery manufacturing uses more than 45% sulfuric acid . Ucrete MF is not resistant to such concentration for a longer time . Sika Cor VEL has required chemical resistance

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#17
In reply to #16

Re: Acid Resistant Flooring for Battery Industry

05/17/2015 11:44 PM

Thanks for your suggestion. We are using Ucrete MF in similar application. We are ensuring necessary house keeping to get the desired result. Even if we use very dilute acid and allow to stay for considerable time, it will get concentrated. So main thing is the proper washing in time.

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#18
In reply to #17

Re: Acid Resistant Flooring for Battery Industry

05/18/2015 12:10 AM

For how long this Ucrete MF is in operation . What is cleaning schedule adopted at site . What is the strength ( concentration of sulfuric acid ) ?

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#19
In reply to #18

Re: Acid Resistant Flooring for Battery Industry

05/19/2015 7:19 PM

Due to the high boiling point of sulfuric acid (about 180C if I remember correctly) evaporation of water will always mean acid spills will become more concentrated.

This means that in some areas you will be dealing with concentrated H2SO4 which will oxidize most organic materials.

Dilution of spills is no help unless the dilute acid is drained away.

1. Make sure your floor drains well and there are no pockets left undrained

2. Use an acid resistant cement or tiles with acid resistant grout to ensure the floor is draining.

3. Cover with 6mm+ thick polyurethane rubber to provide both wear and acid resistance

4. Have a schedule for hosing the floor sufficiently often that the acid doesn't get time to concentrate enough to become strongly oxidizing.

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