REZCOAT

Philippines , Brgy. Hugo Perez, Trece Martirez, Cavite

January 21,2014

I.

INTRODUCTION

Mission
Rezcoat aims to maintain its leading position as a provider of the highest quality
protective coating services by building and maintaining long-term relations of mutual confidence
and trust with our clients and suppliers.
Our objective is to exceed customer expectation by providing close technical support throughout
all stages of a project.

Company Profile:
Rezcoat started in Saudi Arabia until it branched in the Philippines.
Rezayat Protection Coatings Company Ltd. (Rezcoat) a member of the Rezayat Group
is a manufacturer of highest quality two-part polyurethane and polyurea as well as epoxy-based
products with quality certification ISO 9001:2008. It has been supplying protective coatings to
the Saudi Arabian market and Gulf Cooperation Council countries in the Middle East since 1998.
Along with its operations, Rezcoat has agency agreements with Metz and Stirling Lloyd and a
joint-venture and manufacturing agreement international coating manufacturer Winn & Coales
(Denso) Ltd.
The Rezayat Group is a major international business group inspired by family traditions
and led by family principles. Its trading roots reach back several generations and its horizons
have always been international.

The Group is actively involved in developing regions of the world with a focus on
trading, construction, support services, manufacturing, investment and financial services.
Integrity in relationships with major international companies, often as joint venture
partners, has made the Group an important trading and business partner everywhere it operates.
The Group's philosophy is founded on a commitment to sustainable growth and
development in an ever-changing global market. Its objective is to provide quality of the highest
order in its worldwide businesses. Loyalty, trust, professionalism and international expertise,
reinforced by the ability and determination to foster long-term relationships, are the hallmarks of
the Group.
Technical and Specification Project Support

We are committed to provide our clients full support in every stage of a project, from
design to completion. Our aim is to ensure customers and end-users fully understand our
products and systems. Rezcoats technical sales team has over 30 years of experience and is
ready to provide the necessary presentations and seminars to identify any potential design flaw
and suggest appropriate solutions.
Authorized Contractor Selection
Most of our products and systems are designed to be applied by experienced and
authorized contractors. We can assist you in selecting a suitable contractor or even provide you
with an application quote directly.
Site Application Service
Our team of experienced technical supervisors can provide on-site support to our
authorized contractors, ensuring the successful application of our systems. We also offer
advisory services related to site preparation, priming and application support, including site
training.

All monitoring (inspection and training) is provided by Rezcoat on-site to ensure quality
application. Qualified personnel are also available to follow up each application and maintain a
close relationship with the site staff.
Special application teams for specific supply and apply conditions are also available.
Maintenance and Rectification Service
We believe your assets should be properly protected. To this end, we have a high quality
range of products and reliable personnel on call. Touch-ups and minor remedial works are easily
managed by our technical team or contractors. We also provide site guidance and advice to
ensure that all applications are correctly maintained.
Engineering Consultancy
Our group of engineering consultants are available to assess your needs and requirements
and assist you in the product selection process to ensure the best results for your project.
Sales and After Sales Service
Apart from supplying products, our customer sales support team is committed to provide
the highest levels of service to go beyond your expectations with the utmost dedication. Whether
online or through the phone, we will provide you with general as well as technical assistance and
address rising issues and concerns relating to products and services.
Company Life
Rezcoat believes in the continuous professional development of personnel and provides
opportunities for employees to grow. The focus is on organizational excellence and a flexible
workforce. Care is taken to ensure that the work is clearly defined and evenly distributed. Great
importance is given to building a healthy work environment and delivering residential
accommodations for relaxation and recreational use. We keep our employees motivated and
empowered by means of various benefits such as:
Involvement in challenging work assignments and career development opportunities
Rewards for superior performance and results, respect for accountability, and gradual
realization of their fullest potential

Better and healthier relationships with family, friends, co-workers and others
The companys compensation and benefits programs are designed to attract and retain
qualified professionals by providing them with:

Competitive compensation

Yearly performance and salary reviews

Paid vacations

Health insurance and wellness programs

Emergency travel assistance

Training facilities

End of service benefits

Rezcoat is one of the leading manufacturers of polyurethane and polyurea coatings,

providing protective coatings to the most demanding market sectors in the Saudi Arabia and
globally. Our products have been used in many petrochemical projects as well as in the
residential and commercial sectors over the past decade.
Established in 1998, Rezcoat is an expert in developing polyurethane and polyurea
formulations used for substrate protection against aggressive environments in Sewage Treatment
Plants (STP), waterproofing coatings in wet areas in commercial buildings, underground
basement tanking, slip resistance flooring in multistory car parks, and roof waterproofing.
In order to stay abreast in the latest polymer technology and quality manufacturing,
Rezcoat has signed manufacturing license agreements with several global manufacturers such as
Winn and Coales (Denso) Ltd. We are also the exclusive agent for Metz and a distributor for
Stirling Lloyd.
Quality is of utmost importance to us. Our manufacturing plant, Quality Assurance and
Quality Control Department and Research & Development Lab are all equipped with the latest
technology to ensure every batch is tested according to quality standards and meets exact
specifications prior to dispatch. We strive to achieve excellent results and maintain the highest
quality through effective training. We have been accredited with ISO: 9001:2008 Quality
Management System.

II.

HISTORY
Rezcoat Inc. started its polymer emulsion, solution polymer and alkyd resin production in

1993. The original plant sites are located in the town of Trece Martirez, Cavite 35km south
of Makati, Metro Manila Philippines. The company progressed from strength to strength and
has become a multi-million dollar operation servicing various industries from architectural
and industrial coatings.
III.

PRODUCTS

There are two products of the company which are the Alkyd Resins and the Epoxy Resins

Epoxy Resin

Alkyd Resin

Product Range Overview

RezCoat offers long-term solutions to protect your assets at a great value through our wide range
of specialized products and systems:

Polyurethane and polyurea protective coatings

Acid proofing, acid bricks, acid tiles & grouts

High chemical, abrasion & erosion resistant coatings

Industrial resinous, & heavy duty tile flooring

Specialty ceramic tiles

Internal & external corrosion protection on gas & oil pipelines

Tape wrapping lining systems

Off-shore oil & gas exploration and production platform coatings

On-shore oil & gas and petrochemical coatings

Special marine coatings

Coatings for corrosion protection of lightweight steel structures

Chemical tank lining systems, lining for vessel protection

Protection coatings for potable and waste water tanks

Bridge deck and structural waterproofing systems

Multistory car park structure protective coatings

Internal and external protection of chimney stacks

Water and Waste Water Treatment Chemical Supply and Applications

IV.

MANUFACTURING PROCESS

Alkyd Resins
Alkyd coatings are produced in two processes; fatty acid process and the alcoholysis or
mono-glyceride process. Higher quality higher performance alkyds are produced in the fatty acid
process where the composition of the resulting resin can be more precisely controlled. In this
process an acid anhydride, a polyol and an unsaturated fatty acid are combined and cooked
together until the product has achieved a predetermined level of viscosity. Penta alkyds are made
this way. More economical alkyd resins are produced from the alcoholysis or glyceride process
where end product quality control is not as paramount. In this process raw vegetable oil, high in
unsaturated component, is combined with additional polyol and heated to cause
transesterification of the triglycerides into a mixture of mono- and diglyceride oils. To this
resulting mixture acid, anhydride is added to build the molecular weight of the resin into roughly
the same product as in the fatty acid process. However, the alcoholysis process, also known as
the glyceride process, produces a more randomly oriented structure. To remove the water
produced as a by-product and to increase the reaction rate, surplus phthalic anhydride was added.
Water was thus removed with the unreacted acid by heating the bulk to a temperature needed to
do this. It meant that the reaction was not as controllable as would be desired. A new process was
introduced, in which Xylene was added to produce an azeotrope with the water. This gave
greater control at a lower temperature, this also produced resins at a lower viscosity, useful in
making high solids paints; this process was known as the AZO process. In both cases the
resulting product is a polyester resin to which pendant drying oil groups are attached. At the
conclusion of both processes the resin is purified, diluted in solvent and sold to paint and varnish
makers.

Epoxy Resins
Most common epoxy resins are produced from a reaction between epichlorohydrin
(ECH) and bisphenol-A (BPA), though the latter may be replaced by other raw materials (such as
aliphatic

glycols,

phenol

and

o-cresol

novolacs)

to

produce

specialty

resins.

The epoxy resins can be obtained in either liquid or solid states. The two processes are similar.

Firstly ECH and BPA are charged into a reactor. A solution of 20-40% caustic soda is added to
the reaction vessel as the solution is brought to the boiling point. After the evaporation of
unreacted ECH, the two phases are separated by adding an inert solvent such as
methylisobutylketone (MIBK). The resin is then washed with water and the solvent is removed
by vacuum distillation.The producers will add the specific additivesto create a formula that lend
special properties such as flexibility, viscosity, color, adhesiveness, and fastercuring, depending
on a particular application.
In order to convert epoxy resins into a hard, infusible, and rigid material, it is necessary
to cure the resin with hardener. Epoxy resins can cure at practically any temperature from 5150oC depending on the choice of curing agent. Primary and secondary amines are widely used
to cure epoxy resins.

V.

ROLES OF A CHEMICAL ENGINEER

Process Engineer

Evaluates raw materials in laboratory scale before it proceed to large scale use

Receives and counterchecks raw materials before its consumption in the plant

Responsible for the production of alkyd resin products, performs in-process

testing procedures, and monitor its quality in every step of its processing

Supervises the production subordinate personnel on-duty on every activity

Operates processing equipment and controls all processing activities

Performs all alkyd finished product quality assurance test including the Nonvolatile Material, Acid Value, Viscosity, Color, Density in lbs/gal and Drying
Time before delivery

Investigates whenever there are abnormalities encountered during processing

Prepares incident report on the non-conforming batch, supervises the packaging,

performs lab testing for the rework procedure and supervises the product
reworking

Ensures the safety and security of manpower, equipment and batch during
emergency situations

Audits alkyd samples after 6 months and 1 year of delivery to customers if

scheduled as spare engineer

Forward the vehicle key to the gate guard for the incoming/outgoing delivery at
night

Checks and receives delivery receipt when suppliers delivery vehicle arrives at
night

Inspects worksite and accomplish safety work permit with necessary data and
monitors the activity every 30 min or 1 hour during preventive maintenance

Controls lock out and tag out device during preventive maintenance