ARC® 

Efficiency & Protective Coatings
Product Overview
‐ Pranav  Purani

Coatings for Metal Substrates

 Metal Coating  Systems 
MCS

Erosion
Erosion Chemical
Chemical
Specialty
Specialty Abrasion
Abrasion
Corrosion
Corrosion Corrosion
Corrosion

5ES 855 BX2 S1PW

5 858 BX1 S2

10 HT-T HT-S I BX1/ I BX1 RC SD4i

MX1
S4+

MX2 MX5
S7
T7AR

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ARC® Efficiency & Protective Coatings
for Metal
Specialty Products
Emergency Repair and Resurfacing
 ARC 5 
 Rapid setting, (5 to 10 minutes) emergency repair composite
 Wear resistant; trowelable
 Cures under water

 ARC 5ES 
 User Friendly “2‐in‐1” stick packaging
 Rapid setting (5 to 10 minutes)
 Cures under water
 Use only what you need
 NSF Std 61 Potable water certified

 ARC 10 
 Machinable to tight tolerances
 Non‐slumping paste grade

 ARC MX5 
 Rapid‐cure wear resistant composite
 Cures in 10 minutes; ready for service in <1 hour
 3 mm (.125”) minimum film thickness

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 5ES Emergency repair of cracked valve body
 Cracked valve for fire 65 foot high 
fire water suppression tank 
needed immediate repair until 
new valve could be brought in.

 Valve was pressurized while leak 
was sealed.

 Temporary plugging was used with 
wood shims then ARC 5ES was 
pressed into crack to seal leak 
under active pressure

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ARC 5 Emergency repair of cracked valve body
 After 5ES sealed low pressure 
leak crack repair was 
structurally addressed to 
provide added strength.  One 
coat of ARC 5 was applied and 
fibrerglass scrim cloth was 
applied over crack.
 Second coat was applied to 
scrim cloth and area 
 Entire repair occurred while 
valve was under 65 feet of head 
pressure equivalent to 30 psi

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 Emergency Repair and Resurfacing
Applications
Shaft Repair Leak Repair
Flange Repair Small Pump repair
Chute repair Valve Repair
Elbows Pump bases

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 ARC 10

 Repairing scored shaft as 
opposed to sleeving.  May 
also be used to rebuild 
worn keyway or rebuild 
splines of gears.

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ARC® Efficiency & Protective Coatings
for Metal 
Corrosion/Erosion
 Erosion Corrosion

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 ARC Efficiency and Protective Coatings
Rebuilding And Protection

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ARC Coatings and Corrosion/Erosion
To protect rotating equipment against corrosion, we 
must first understand the Corrosion/Erosion Cycle, 
which greatly affects metal loss. 

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How Advanced Reinforced ARC Coatings 
Stop the Erosion/Corrosion Process
 Every metal
corrodes

 Flow removes
corrosion layer

 Flow remains
laminar
 Surface does
not corrode!!!
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 Laminar Flow vs. Turbulent Flow

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Where to Find Erosion Corrosion Applications 
for ARC 
 Fluid handling systems
 Vertical turbine pumps
 Single and multi stage 
 End suction centrifugal
 End suction split case
 Hydro electric systems
 Pipes
 Valve bodies
 Elbows
 Reducers

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 ARC METALS ‐ PRODUCT SELECTION
Erosion / Corrosion
Fine Ceramic Series

General HT Aqueous
Erosion Erosion Rebuilding and Faring
Corrosion Corrosion Erosion
Corrosion

855   HT‐T
858
HT‐S
HT‐T

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 Erosion / Corrosion Fine Ceramic  Series
 ARC 855 ‐ Abrasion Control Liquid
 Erosion/corrosion coatings
 Potable water certified – WRAS UK
 855 & S2
 Brush or roll applied

 ARC 858 ‐ Abrasion Control Compound
 Rebuilding and fairing grade material
 Anti‐slump for vertical sag resistance
 Trowel applied

 ARC HT‐T  ‐ High Temperature, 
Abrasion control Compound
 Rebuilding and fairing grade material
 Anti‐slump for vertical sag resistance
 Trowel applied
 Spark‐Testable for pinhole free verification

 ARC HT‐S  ‐ High Temperature, 
Sprayable Abrasion control liquid 
 Applied By brush Roller or Spray
 Spark‐Testable for pinhole free verification

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 Erosion/Corrosion Systems
855
 Standard colors are BK/GY
 0.75, 1.5, 5 and 15 liter package 
availability
 Brush/roll viscosity for high film 
build
 Bis A/F/amine cured chemistry 
with 31% ceramic particles 
reinforcement for erosion 
resistance
 Low coefficient of friction
 Cured RMS finish of 20
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 Erosion/Corrosion Systems
HT‐S
 Standard colors are GR/BL
 5 and 16 liter package availability
 Sprayable viscosity for high 
coverage and ease of application
 Novolac amine cured chemistry 
with 31% particles reinforcement 
for erosion resistance
 “In‐situ” cure capability
 Immersion service ≤302°F / 
150°C

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 Erosion/Corrosion Systems
HT‐T
 Standard colors are BK/GN
 5 and 16 liter package availability
 Trowel viscosity for high film 
build
 Bis F/cycloaliphatic amine cured 
chemistry with 40% ceramic 
particles reinforcement for 
erosion resistance
 “In‐situ” cure capability
 Immersion service ≤230°F / 
110°C
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 Erosion/Corrosion Systems

858
 Standard colors is GY
 250 gr QP, 400 cc “cartridge, 1, 
4.5 kg and 15 liter (24.8 kg) 
package availability
 Paste viscosity for high film build.  
Color change on mix.
 BisA/F/amine cured chemistry 
with 31% ceramic particles 
reinforcement for erosion 
resistance

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How do Coatings Optimize Rotary Equipment?

 Reliability Improvement

 Corrosion Reduction

 Wear Reduction

 Energy Efficiency

 Friction Reduction

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ARC Applications and Sales Potential in 
the Corrosion/Erosion Segment

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 1 ‐ Waste Water Pump with ARC 855 – Wet Well

Potential ARC sale = $ 900 + Labor = $ 1,500

Annualized (10 Pumps) ARC = $ 9,000 + Labor = $ 15,000

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 2 ‐ Cooling Water Pump with ARC 858 & 855

Potential ARC sale = $ 1,200 + Labor = $ 2,500

Annualized (3 Pumps) ARC = $3,600 + Labor = $ 7,500
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 3 ‐ Vacuum Pump Protected with ARC 858 & S2

Potential ARC sale = $ 1,500 + Labor = $ 3,200

Annualized (10 Pumps) ARC = $ 15,000 + Labor = $ 32,000
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 ARC for Pump Rebuilding and Efficiency 
ARC EPC
 For Fluid Flow Efficiency
Low Coefficient of Friction-Maximizes Output,
Decreases Energy

Ceramic Reinforcements Eliminate

Wear and Erosion
Tolerances Remain Virtually Unchanged
Thus Maintaining Efficiency Throughout the
Life of the Pump

 For New and Old Pumps

Result:
Pumps Maintain Maximum Capacity
Lowest Pump Maintenance Cost
Maintain Maximum Efficiency

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Engineered Protective Coatings
Impact on Performance
New Pumps
 1% to 3% Efficiency Increase
 Lower Specific Speed pumps show the greatest 
improvement.
 Longer Wear/Corrosion Life
 Increased Reliability
 Increased Performance ‐ Head & Flow
 Lower Surface Energy = Less Friction 

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 Typical Pump Efficiency Loss in a Clean 
Cold Water Pump Over Time

Pump coated
with
Advanced
Reinforced
ARC Coatings
maintains
Tolerances

European Union’s Save

Report 2001

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Engineered Protective Coatings
Impact on Performance
In‐Service Pumps
 Restoration of Performance to design point.
 Typically a 10% to 20% increase.
 Plus potential increase of 1% to 3%.
 Life Cycle Cost Impact
 Restoration of existing asset vs. purchase of new.
 Life extension of wet‐end components
 Decrease in net energy consumption
 Immediate Energy Cost savings
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ARC® Efficiency & Protective 
Coatings for Metal 
Abrasion
 What is Abrasion?
The wearing of a hard material on a softer material causing removal of 
the softer material. 

Sliding wear (Two Body Wear) - caused by

particles impinging on a surface in a laminar or
turbulent flow pattern scratching away a surface
– Main application area for ARC BX2/BX1/MX
Series
High Stress - Three Body Wear
 Surface to surface contact with gouging and
plastic deformation – Normally not a
suitable area for ARC

Impact
 Rapid impact weakens and fatigues surface
– Main Application area for ARC I BX1,
I BX1 RC and MX1
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Where do Abrasion based applications exist?

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 Failures 
Abrasion Resistant Technologies

Rubber/Urethane Ceramic Metal

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 Competing Abrasion Resistant Technologies
Material Benefits Restrictions
Manganese Self hardening/healing Requires work hardening to perform

High Chrome Heavy sliding wear resistance More brittle

Ni-Hard /Cr-Mo Best of both manganese and high chrome Difficult to weld
Preferred over High Chrome in grinding if brittle failure is
possible
Rubber Low velocity impact Resistance to oils/aromatics
Tolerance to particle size and shape variations in sliding Impact angle needs to be considered
wear and impact Temperature
Chemicals
Polyurethane Tough sliding wear Large size
Wet applications High velocity
Better chemical resistance than rubber Temperature
Chemicals
Ceramics Sliding wear Impact
Temperature
Chemical
ARC Coatings Low velocity impact Temperature
Tolerance to particle size and shape variations Chemicals
Tough sliding wear
Wet applications
Better chemical resistance than rubber or polyurethanes

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 Abrasion Systems
BX2
 Standard color GY
 BX2 – 1.5L, 5L and BX1 – nesting 
20Kg (2.5 gal)
 Convenient 4:1 W/V mix ratio
 Color change on mix
 Trowel viscosity for high film build
 Bis A/F/amine cured chemistry with 
65% ceramic bead and flake 
reinforcement for mild to moderate 
abrasion resistance
 Minimum 3mm Thickness
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 Abrasion Systems
BX1
 Standard color GY
 BX1 – 1.5L, 5L and BX2 – nesting 
20Kg (2.5 gal)
 Color change on mix
 Trowel viscosity for high film build
 Bis A/F/amine cured chemistry with 
75% ceramic bead and particle 
reinforcement for moderate to 
aggressive abrasion resistance
 Minimum 6mm Thickness

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 Abrasion Systems
ARC I BX1
 Standard color GY
 Nesting 20Kg (2.5 gal)
 Color change on mix
 Trowel viscosity for high film build
 Bis A/F/Urethane/amine cured 
chemistry with 75% ceramic bead 
and particle reinforcement for 
moderate to aggressive abrasion 
resistance with improved impact 
resistance
 Minimum 6mm Thickness

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 Abrasion Systems
MX1
 Standard color blue
 6 kg and 20 kg  kits
 MX1 ‐ MXP‐Primer A/B, MX1 A/B 
Resin, MXC Ceramic Bead
 Color change on mix
 MX1 ‐Trowel viscosity for vertical 
film build and
 Bis A/F/amine cured chemistry 
with 90% ceramic bead and 
particle reinforcement for severe 
to extreme abrasion resistance
 Minimum 6mm Thickness

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 Abrasion Systems
MX2
 Standard color White
 2.5L and 16 liter kits
 2 Component
 Trowel viscosity for high film 
build
 Bis A/F/amine cured chemistry 
with 70% high purity Al2O3
ceramic bead and particle 
reinforcement for moderate to 
severe abrasion resistance

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 Bark Screw, Wood Yard, P&P Mill, with ARC MX1

Potential ARC sale = $ 3,500 + Labor = $ 12,000

Annualized (3 screws) ARC = $10.500 + Labor = $ 36,000

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 Gypsum Extraction, FGD, ARC BX2/BX2 & S2
Cost of Repair 30-
50% That of a
New Pump

Potential ARC sale = $ 1,500 + Labor = $ 4,000

Annualized (10 Pumps) ARC = $ 15,000 + Labor = $ 40,000

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 CaCO2 Agitator Blades, Coal Power, ARC BX2

Potential ARC sale = $ 800 + Labor = $1,600

Annualized (4 blades) ARC = $ 3,200 + Labor $ 6,400

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 Quick Abrasion Product Selection Guide
Extreme
 Abrasion of metal parts  MX1, MX2, 
between 0 and 4 months T7AR
Abrasion

Severe
 Abrasion of metal parts  BX1, I BX1,  
between 5 and 8 months
Abrasion I BX1 RC

Moderate
 Abrasion of metal parts  BX2, MX5
between 9 and 12 months Abrasion
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 Key Selling Points to Remember
 Hardened alloys are difficult and costly to repair
 Rubber and other elastomers are limited by temperatures 
and the presence of hydrocarbons.  In addition lap seams 
are leak paths and points of premature failure.
 Ceramic tile is prone to impact failure and relies on silicone 
or epoxy adhesive bonds
 ARC Efficiency and Protective Coatings are highly 
reinforced with abrasion resistant ceramic particles at
exceptional high loading levels and they use chemical 
coupling agents to promote retention of ceramics in film 
to provide reliable wear resistance in abrasion service.
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Where to Find Applications for ARC 
Composites
 Sliding dry particle abrasion
 Chutes, hoppers, cyclones, fans and housings,
 Sliding wet particle abrasion ‐ Slurries
 Pumps, pipes, elbows, tank baffles, agitators
 Impact abrasion
 Hoods, chutes, elbows
 Abrasion with chemical attack
 Tanks with agitators, pumps

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