ALKA-9940

Economical Maintenance Protective Coating System

Cost-effective epoxy protective coating system designed for routine maintenance and refurbishment of industrial steelwork requiring practical, reliable corrosion protection without the complexity of a premium multi-coat system.

PROTECTION STRATEGY

ALKA-9940 uses a straightforward:

Prepared Steel → Epoxy Zinc-Phosphate Primer → Maintenance / High-Build Epoxy

strategy.

The system avoids unnecessary complexity while retaining two essential protective functions:

Epoxy Zinc-Phosphate Primer

ALKA-416 provides the corrosion-inhibiting foundation directly over properly prepared steel.

Maintenance Epoxy Barrier

ALKA-412 or ALKA-413 provides the main protective barrier and final functional epoxy surface.

The choice between ALKA-412 and ALKA-413 allows the system to be adapted to different maintenance conditions.

ALKA-412 OPTION

ALKA-412 is particularly appropriate where:

• Existing steel is being refurbished
• Surface preparation is maintenance-oriented
• Surface tolerance is useful
• Existing compatible coating may remain
• Complex or difficult-access steel is involved
• Local repair and maintenance coating are required

ALKA-413 OPTION

ALKA-413 is particularly appropriate where:

• Higher epoxy film build is desired
• The steel can be prepared to a suitable standard
• A robust high-build epoxy barrier is preferred
• The project is closer to new-build or major refurbishment conditions
• Barrier performance is more important than surface tolerance

This makes ALKA-9940 a flexible economical system rather than a single rigid coating build.

KEY PERFORMANCE BENEFITS

• Cost-effective industrial corrosion-protection system
• Designed for routine maintenance and refurbishment
• Epoxy zinc-phosphate corrosion-inhibiting primer
• Choice of ALKA-412 surface-tolerant epoxy
• Choice of ALKA-413 high-build epoxy
• Practical two-stage coating construction
• Suitable for general industrial atmospheric exposure
• Suitable for existing industrial steelwork
• Suitable for new fabricated steel where economically appropriate
• Lower system complexity than premium three-coat specifications
• Reduced number of coating stages
• Good general-purpose barrier protection
• Suitable for factory and warehouse maintenance
• Suitable for plant utility structures
• Suitable for equipment supports and steel frames
• Flexible product selection according to substrate condition
• Suitable for planned maintenance programmes
• Practical balance between cost, durability and ease of application
• Straightforward system for contractors and maintenance teams
• Appropriate where decorative polyurethane finishing is not a primary requirement

COAT 1 — ALKA-416 Epoxy Zinc-Phosphate Primer

Function: Corrosion-Inhibiting Foundation Primer

ALKA-416 is applied directly to properly prepared carbon steel.

It provides the initial corrosion-inhibiting protective layer and establishes a suitable foundation for the subsequent epoxy maintenance coat.

The zinc-phosphate pigmentation provides a practical corrosion-control approach for general industrial steel where a premium zinc-rich primer is not required.

Product: ALKA-416 Epoxy Zinc-Phosphate Primer
Position: Directly over prepared carbon steel
Primary Function: Corrosion inhibition and adhesion
Nominal DFT: To project specification and current ALKA TDS

COAT 2 OPTION A — ALKA-412 Surface-Tolerant Epoxy

Function: Maintenance-Oriented Protective Barrier

ALKA-412 is selected where the project involves existing steel, maintenance preparation or conditions where a more surface-tolerant epoxy is beneficial.

It provides a high-build protective epoxy layer over the ALKA-416 primer and helps create a durable functional barrier against general industrial atmospheric exposure.

Product: ALKA-412 Surface-Tolerant Epoxy
Position: Maintenance / barrier coat
Primary Function: Surface-tolerant epoxy barrier protection
Nominal DFT: To project specification and current ALKA TDS

COAT 2 OPTION B — ALKA-413 High-Build Epoxy

Function: High-Build Industrial Barrier

ALKA-413 may be selected where a more conventional high-build epoxy barrier is preferred.

This option is particularly relevant where steel preparation is suitable and the project requires increased barrier film thickness rather than the additional maintenance flexibility of ALKA-412.

Product: ALKA-413 High-Build Epoxy
Position: Protective barrier / finish coat
Primary Function: High-build atmospheric barrier protection
Nominal DFT: To project specification and current ALKA TDS

OPTIONAL ADDITIONAL EPOXY COAT

Where additional protective film thickness is required, a further compatible epoxy coat may be incorporated according to the project specification.

This may be appropriate where:

• Exposure is moderately more demanding
• Existing steel is irregular
• Greater total DFT is required
• Additional maintenance life is desired

Nominal Total System DFT: Project-Specific

The final system DFT should be selected according to:

• Exposure severity
• Steel condition
• Surface-preparation method
• ALKA-412 or ALKA-413 selection
• Number of coats
• Required maintenance life
• Project economics

Final individual coat thicknesses and total DFT must be confirmed against the current ALKA technical data sheets.

SUITABLE SUBSTRATES

ALKA-9940 is primarily intended for:

Prepared Carbon Steel

Typical assets include:

• Structural beams
• Columns
• Steel frames
• Equipment supports
• Pipe supports
• Platforms
• Utility structures
• Machinery frames
• Equipment skids
• Warehouse steelwork
• Factory steelwork
• Plant-room structures
• General industrial fabricated steel

EXISTING COATED STEEL

Where the system is used for maintenance over existing coating, the retained coating must be:

• Sound
• Well adhered
• Clean
• Compatible with the new system

Poorly adhered or incompatible coatings must be removed before recoating.

SERVICE & EXPOSURE ENVIRONMENT

ALKA-9940 is designed primarily for general and moderate industrial atmospheric exposure.

Typical environments include:

• Factories
• Warehouses
• Workshops
• Plant rooms
• Utility areas
• Manufacturing facilities
• Internal industrial steelwork
• Moderate external atmospheric exposure
• Equipment-support structures
• General maintenance environments

The system is intended for applications where a specialist severe-service coating is unnecessary.

TYPICAL APPLICATIONS

Factory Structural Steel

Columns, beams, frames and support steel within manufacturing facilities requiring routine corrosion-protection maintenance.

Warehouse Steelwork

Existing warehouse frames, loading-area steelwork, internal structural members and general support structures.

Plant Utility Structures

Steel supports associated with:

• Water services
• Air systems
• Mechanical equipment
• Electrical services
• Utility pipework

where normal industrial atmospheric corrosion protection is required.

Equipment Frames & Skids

Fabricated equipment supports, machinery skids and structural frames requiring economical maintenance protection.

Workshop Steelwork

Columns, brackets, support structures, equipment frames and general steelwork within mechanical and industrial workshops.

Pipe Supports

General pipe-support frames, brackets and associated steelwork in moderate industrial environments.

Industrial Platforms & Stairs

Platforms, access frames, stair structures and service steelwork requiring practical routine maintenance.

Machinery Support Structures

Steel frames supporting pumps, compressors, motors and other industrial machinery.

General Plant Steelwork

Non-critical steel assets throughout manufacturing and processing plants where a standard industrial epoxy maintenance system is appropriate.

Storage & Utility Buildings

Structural steel within storage buildings, utility sheds and service facilities.

Routine Asset-Maintenance Programmes

Large industrial facilities where steel structures are recoated progressively as part of scheduled maintenance rather than through complete premium refurbishment.

New Fabricated General Industrial Steel

Selected new steelwork where project conditions do not require a zinc-rich primer, polyurethane finish or more specialised protective coating system.

SURFACE PREPARATION

Even though ALKA-9940 is an economical system, surface preparation must not be reduced below the level necessary for reliable coating performance.

The required preparation depends partly on whether ALKA-412 or ALKA-413 is selected.

Before coating, the steel should be assessed for:

• Rust
• Mill scale
• Loose existing coating
• Oil
• Grease
• Dust
• Industrial contamination
• Weld spatter
• Sharp edges
• Moisture
• Condensation
• Surface defects

NEW STEEL

For new steel, preparation should comply with the requirements of ALKA-416 and the project specification.

EXISTING STEEL

For maintenance work, loose corrosion and failed coating must be removed.

Existing retained coating should be assessed for:

• Adhesion
• Compatibility
• Condition
• Contamination

SURFACE-TOLERANT DOES NOT MEAN PREPARATION-FREE

If ALKA-412 is selected, the surface-tolerant nature of the coating should not be interpreted as permission to coat over:

• Loose rust
• Oil
• Grease
• Failed coating
• Heavy contamination
• Moisture

Correct preparation remains essential.

EDGE, WELD & DETAIL PREPARATION

Special attention should be given to:

• Welds
• Edges
• Corners
• Bolts
• Nuts
• Brackets
• Steel connections
• Complex fabricated details

These locations can receive lower coating thickness than flat steel surfaces.

STRIPE COATING

Where required by the project specification, stripe coating may be applied to vulnerable details before the full coat.

This is particularly relevant to:

• Welds
• Sharp edges
• Bolts
• Brackets
• Corners

APPLICATION CONSIDERATIONS

Application should comply with the current ALKA product technical data.

Important controls include:

• Ambient temperature
• Steel temperature
• Relative humidity
• Dew point
• Surface dryness
• Surface cleanliness
• Mixing ratio
• Mechanical mixing
• Pot life
• Application method
• Wet-film thickness
• Dry-film thickness
• Recoat intervals
• Cure conditions
• Ventilation
• Protection from contamination

COATING SELECTION — ALKA-412 OR ALKA-413

Selection of the final epoxy coat should be intentional rather than arbitrary.

Use ALKA-412 where:

• Existing steel is being maintained
• Preparation is restricted
• Surface tolerance is beneficial
• Existing compatible coating remains
• Repair work is localised or complex

Use ALKA-413 where:

• Steel preparation is suitable for a conventional high-build epoxy
• Higher barrier film build is desired
• Surface tolerance is not the main requirement
• The project involves new construction or major refurbishment

INSPECTION & QUALITY CONTROL

The economical positioning of ALKA-9940 should not remove the need for basic coating quality control.

Inspection may include:

• Substrate condition assessment
• Surface-preparation verification
• Environmental-condition monitoring
• Primer coverage inspection
• Wet-film thickness measurement
• Dry-film thickness measurement
• Recoat-window verification
• Inspection of edges and welds
• Final total DFT measurement
• Visual inspection for missed areas
• Final coating appearance
• Batch-number recording

WHY SPECIFY ALKA-9940?

ALKA-9940 should be selected when the project requires reliable general industrial corrosion protection at a practical system cost.

Not every steel asset requires:

• Zinc-rich primer
• Glass-flake reinforcement
• Chemical-resistant lining
• Marine splash-zone protection
• Polyurethane architectural finish

For routine general industrial maintenance, adding unnecessary system complexity can increase application time and project cost without delivering meaningful additional value.

The ALKA-9940 strategy is therefore:

Use the corrosion-inhibiting primer required → Select the appropriate maintenance epoxy → Achieve the specified DFT → Inspect the completed system

WHEN TO CHOOSE ALKA-9940

ALKA-9940 is particularly appropriate when:

• Exposure is general industrial atmosphere
• The project is maintenance-focused
• Cost control is important
• A straightforward epoxy system is desired
• Premium zinc-rich protection is unnecessary
• UV-retentive polyurethane appearance is not critical
• Direct chemical exposure is absent
• Marine splash/tidal exposure is absent
• The asset is routinely accessible for future maintenance
• General corrosion protection is the main objective

ALKA-9940 VS ALKA-9931

ALKA-9931 uses:

ALKA-416 → ALKA-413 → ALKA-421

and provides a complete three-coat system with a polyurethane exterior finish.

ALKA-9940 generally uses:

ALKA-416 → ALKA-412 or ALKA-413

and is designed as a more economical maintenance solution.

Therefore:

Complete industrial system + UV-stable appearance → ALKA-9931

Economical functional maintenance protection → ALKA-9940

ALKA-9940 VS ALKA-9932

ALKA-9932 is specifically a surface-tolerant refurbishment system, typically using two ALKA-412 coats with optional polyurethane finish.

ALKA-9940 uses ALKA-416 primer + ALKA-412 or ALKA-413 and is aimed at economical general maintenance.

Therefore:

More dedicated refurbishment / difficult preparation → ALKA-9932

General economical maintenance → ALKA-9940

ALKA-9940 VS ALKA-9937

ALKA-9937 is designed for severe-duty industrial maintenance and uses MIO glass-flake reinforced ALKA-418.

ALKA-9940 is a lighter and more economical maintenance option.

Therefore:

Routine industrial maintenance → ALKA-9940

Severe-duty reinforced maintenance → ALKA-9937

WHEN NOT TO USE ALKA-9940

A more specialised system should be selected where the asset is exposed to:

• Severe marine atmosphere
• Splash zones
• Tidal zones
• Continuous seawater immersion
• Aggressive chemical immersion
• Chemical tank internals
• High-barrier lining requirements
• Severe coastal exposure requiring premium protection
• Critical high-value structures where extended premium durability is required
• Areas where long-term UV colour and gloss retention are important

LIMITATIONS

Key limitations include:

• Not intended as a universal severe-service system
• Surface preparation remains essential
• Existing coating compatibility must be confirmed
• ALKA-412 surface tolerance does not eliminate preparation requirements
• Direct chemical resistance must not be assumed
• Not intended as a specialist immersion lining
• Not the preferred marine splash/tidal system
• Epoxy-only finishes may change appearance under prolonged UV exposure
• Structural corrosion damage requires repair before coating
• System life depends on achieved DFT and quality of application

SPECIFICATION GUIDANCE

A complete ALKA-9940 project specification should define:

Asset Condition → Exposure Environment → Surface Preparation → Existing Coating Assessment Where Relevant → ALKA-416 Primer → Primer DFT → ALKA-412 or ALKA-413 Selection → Epoxy Coat DFT → Number of Coats → Total System DFT → Stripe Coating → Environmental Conditions → Recoat Windows → Inspection → Acceptance Criteria

The specification should clearly identify whether the system is being applied to:

New Steel

Bare Existing Steel

Partially Coated Existing Steel

Local Repair Areas

This allows the correct preparation method and maintenance epoxy option to be selected.

SYSTEM POSITIONING

ALKA-9940 should be presented to maintenance contractors, facility managers, engineers and asset owners as:

A cost-effective general industrial epoxy maintenance system for steel assets that require dependable corrosion protection without the cost or complexity of premium severe-service coating systems.

Its core value proposition is:

Economical zinc-phosphate primer + flexible ALKA-412 / ALKA-413 epoxy selection + straightforward application + reliable routine industrial protection.

Application Examples

Representative applications; final system selection depends on substrate, preparation and service conditions.

Industrial Platforms & Stairs

Photographic visuals on this page are AI-generated application illustrations, not completed ALKA projects. Colours are illustrative. The system schematic is conceptual and not to scale; refer to current ALKA technical data and project specifications.