Coating Types. Coating Systems. Coating Basics. Why coatings are used Component of coatings Methods of protection Service environment

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1 Coating Basics Why coatings are used Component of coatings Methods of protection Service environment Coating types Curing mechanism Design characteristics Limitations Suitable Use Coating Systems Coating systems organization for atmospheric service Immersion linings 1

2 Coating Basics What are the components of paint? Vehicle Pigments Finely dispersed particles Binders Adhesive to bind pigment particles Solvents Liquids to dissolve the binder Additives Special purpose ingredients Vehicle Binder and solvent Coating Basics 2

3 ISO C2: Low: C3: Medium: C5-I:Very High, Industry: C5-M: Very High, Marine: FACILITY CONDITIONS Normally wet / Normally Dry Splash / Spill High Corrosive / Low Corrosive High Temperature Light Foot / Heavy Truck Traffic Secondary Containment Coating Basics Barrier Serve as a protective barrier, isolating substrate from the environment Inhibitive Pigments control corrosion by forming inhibitive compounds that are slightly soluble in water Sacrificial A zinc coating is applied to steel and is sacrificed to protect the steel from corrosion Coating Basics 3

4 Zinc-Rich Acrylic Epoxy Polyurethane Inorganic Coalescing Polysiloxane MCU Organic High Density FBE Acrylic Linings Polyester Linings Protection Curing Types Sacrificial Carbolic Acid Inorganic Barrier Solvent Evaporation/ Chemical Polymerization Organic Designed specifically for priming ferrous metal. Zinc rich coatings contain high percentage of Zinc dust in the dried Film. Provide direct contact between zinc particles and steel 4

5 Zinc on Steel Takes Advantage of Corrosion Reaction Inorganic: Vehicle does not contain carbon Usually Silicates Advantages: Performance Similar to Galvanizing Heat Resistance to 750 F Low Temperature Application Class B Slip Certification 5

6 Limitations: Requires angular surface profile Minimum SSPC-SP 6 Cleaning Spray Application Only Dry spray Mud Cracking at high DFT Minimum 24 hour cure to recoat Organic: Resin contains carbon Epoxy MCU Advantages Limitations: Tolerates Less Stringent Surface Preparation, SP- 11, SP-15, Touch-up Inorganic Zinc (IOZ) Minimum 2 hour cure to recoat Not used for high temperature applications Resin Chemistry not as conductive as inorganic zinc 6

7 Shop Primed Field Repaired Coating types Protection Curing Types Barrier Coalescence Waterborne Inhibitive Self Crosslinking Acrylic coatings are designed as primers and finish coats for various substrates. With the exception of block fillers the typical thickness per coat is 2 4 mils. The volume solids are between 38 50%. Acrylic finish coats perform best in C2 C4 environments. 7

8 Wet Film Cured Film Co-Solvents: Coalescing Solvents act as plasticizers for acrylic coatings. Co-solvents must remain in the film until evaporation. Ambient Cure Acrylics O 2 Polymer after film formation before ambient cure. Polymer chains after crosslinking at ambient temperature in the presence of atmospheric oxygen. 8

9 CONCRETE / CMU Acrylic Block Filler Acrylic Primer Epoxy Block Filler Epoxy Multipurpose FERROUS METAL Acrylic Primer Alkyd Primer Epoxy Multipurpose Zinc Rich NONFERROUS METAL Acrylic Primer Epoxy Multipurpose PVC / CPVC Acrylic Primer Epoxy Multipurpose Design Characteristics: Fast Drying & Low Odor Excellent Gloss and Color Retention (Weathering) Ease of Application Flexible Films (formulation dependent) Excellent Adhesion after Full Cure Unlimited recoatablility Limitations: Poor resistance to aromatic hydrocarbon solvents Sensitive to temperature and humidity during application AND curing (up to 30 days for cure) 9

10 Protection Curing Types Barrier Solvent Evaporation Solventborne Inhibitive Chemical Crosslinking Waterborne Epoxy coatings are designed as primers and finish coats for various substrates. With the exception of block fillers the typical thickness per coat is 4 10 mils. The volume solids are between 50-80% for thin film epoxies. Epoxy finish coats perform best in corrosive environments, immersion conditions, secondary containment applications. Catalyzed Epoxy Vehicle may be Water or Solvent Potentially reinforced CA VOC requirement forces exempt solvent use. (HAPS Free) Required Conditions for Cure RH below 85% Temperature 5 F above Dew Point. Minimum temperature varies. 2 Component Epoxy Resin Component (Pert A) is mixed with a Hardener Component (Part B) Finite application time Pot Life Curing Process Solvent releases from wet film. Crosslink polymerization of the two components. Crosslinking is defined at the chemical joining of two polymer chains. 10

11 Crystals of MIO are fractured into thin flakes. Flakes align in parallel fashion in the dried film.. Naturally occurring lamellar (scale like) form of ferrous oxide. The horizontal layering of the particles, overlapping like fish scales, gives strength to the coating and acts as an inert barrier to the penetration of corrosive elements and ultraviolet light. In use for more than 100 years in Europe (e.g. the Eiffel Tower) BPA BPF Chemical Resistance Flexibility Resin Type (Part A) Flexibility Chemical Resistance Bisphenol A (BPA) Moderate Low Bisphenol F (BPF) Low Moderate Moderate Phenolic Low - Moderate Moderate - High Novolac Low - Moderate High Vinyl Ester Low High 11

12 Hardener Type (Part B) Characteristic Resin Amido Amine BPA, BPF Aliphatic Amine BPF Adduct Aliphatic Amine Solvent Resistance Phenolic / Novoloc Aromatic Amine Acid Resistance Phenolic / Novolac Cycloaliphatic Amine Viscosity BPA Phenalkamine Low Temperature BPA Polyamide Flexibility, Adhesion, Blush Resistance, Color Stability BPA Steel Primer for New Previously Painted Marginally Prepared Concrete CMU Block Filler Concrete Sealer /Primer Interior Corrosive Finish Thin Film Sytstem, mils Structural Piping Concrete Walls Light Duty Floors Exterior Intermediate Coat Corrosive Compatible with zinc rich primers Compatible with Polyurethane and Acrylic Finishes Immersion Lining Thin Film, mils Medium, mils High, Potable Water Storage Wastewater Petrochem 12

13 Design Characteristics: Water replaces hydrocarbon solvent Low Odor / No Fire Hazard Ease of Application and Clean Up Apply Over Existing Coatings Excellent Acid and Stain Resistance Good Alkali Resistance Good Flexibility More Resistant to Yellowing Limitations Temperature and Humidity Restrictions Poor Solvent Resistance Chalks and Fades on Exterior Exposure Lower Dry Film Build than Solvent Based Design Characteristics: Excellent alkali, solvent and water resistance Good abrasion resistance Good acid resistance Good exterior durability but... High film build possible Low temperature application available Dry heat resistance to 250 F Limitations Two-Component, Limited Pot Life* Induction Time (Sweat-In)* Recoat Window Restrictions Chalks and Fades on Exterior Exposure Solvent Odor Special Application Equipment May be Required Curing is time and temperature dependent 13

14 Siloxane component Reacts with atmospheric moisture Imparts exterior durability and chemical resistance in wet environments Designed as exterior finish Compatible with epoxy and zinc primers. Epoxy component Reacts with amine Imparts toughness and corrosion resistance Design Characteristics: High solids epoxy siloxane combines properties of high performance epoxy and polyurethane in one coating Isocyanate-free High-gloss, self-priming coating High solids, low VOC Long term color and gloss performance Corrosion and chemical resistant Outstanding application properties Limitations Temperature and Humidity Restrictions Poor Solvent Resistance Chalks and Fades on Exterior Exposure Higher Cost per Square Foot 14

15 Protection Curing Types Barrier Solvent Evaporation Solventborrne UV Chemical Polymerization Waterborne Chemical MCU Polyurethane coatings are designed as finish coats for various substrates. Conventional Urethane Polyol + Isocyanate = Polyurethane Moisture Cure Urethane Isocyanate terminated urethane polymer + Humidity = Urethane Polymer + CO 2 Polyurea / Polyurethane Technology Amine + Isocyanate = Polyurea (Urea Linkage) Polyaspartic Polyaspartic Ester + Isocyanate = Polyurea 15

16 Design Characteristics: Can Be Applied During High Humidity Versatility of Application Fast Cure / Fast Recoat Low Temperature Application to 20 F. Single Component Aliphatic Tint Bases Possible Limitations Potential Limited Recoat Window Needs Relative Humidity to Cure Special Reducers Required Unused Portion Has Limited Shelf Life Sensitive to Moisture During Manufacture, Storage, and Thinning Steel UV Resistant Finish MCU Primer DTM Finish New Previously Painted Marginally Prepared Concrete UV Resistant Finish CMU Concrete anti-graffitti Interior Corrosive Finish Thin Film Stain Resistant Finish Structural Piping Concrete Walls Floors Exterior Finish Coat Corrosive Compatible with zinc rich primers Compatible with Polyurethane and Acrylic Finishes Immersion Lining Steel / Concrete Urethane elastomers Polyurea High, Potable Water Storage Wastewater Petrochem 16

17 Design Characteristics: Long term color and gloss performance Corrosion and chemical resistance Hard, Yet Flexible Films Excellent Color and Gloss Retention Low-Temp. Application, Formula Dependent No Sweat-In Time, Formula Dependent Outstanding application properties Limitations Two Components Limited Pot Life Sensitive to Moisture During Application and Cure Expensive Limited Recoat Window HS Epoxy UHS Epoxy Polyurethane Bis F / A Phenolic Novolac FBE Bis F Bis A Novolac Vinyl Ester Aromatic Polyurea Hybrid Immersion grade linings are comprised of various types of epoxy and urethane. Lining products are formulated to meet specific immersion conditions established prior to specification. : Immersion Buried 17

18 Conventional Urethane Polyol + Isocyanate = Polyurethane + CO 2 Moisture Cure Urethane Isocyanate + Humidity = Amine + CO 2 Polyurea / Polyurethane Technology Amine + Isocyanate = Polyurethane (Urea Linkage) Polyaspartic Polyaspartic Ester + Isocyanate = Polyurea Design Characteristics Fast setting: 30 seconds High film build: mils No VOC s, no odor Seamless, flexible Impact, tear and abrasion resistant Can be applied to -20 F Bridges cracks Low permeability Limitations Surface preparation: profile critical Critical application Terminations 18

19 Design Characteristics Fast setting: 30 seconds 45 minutes High film build: mils No VOC s, no odor Seamless, flexible Impact, tear and abrasion resistant Can be applied to -20 F Bridges cracks Low permeability Limitations Surface preparation: profile critical Critical application Terminations Design Characteristics 24 hour cure mils Low VOC s, no odor Variety of formulations Impact, tear and abrasion resistant Low permeability Limitations Surface preparation: profile critical Critical application Terminations : Linings 19

20 Design Characteristics 24 hour cure mils No VOC s, no odor Impact, tear and abrasion resistant Can be applied to damp surfaces Low permeability Limitations Surface preparation: profile critical Critical application Terminations : Linings NACE Paper 08729: 2008: EXPECTED SERVICE LIFE AND COST CONSIDERATIONS FOR MAINTENANCE AND NEW CONSTRUCTION PROTECTIVE COATING WORK Coating System Surface Preparation # of Coats Min DFT Service Life C5 E, E SP E, Epoxy Siloxane SP E, E, Epoxy SP E, E, Polyurethane SP OZ, E, Polyurethane SP IOZ, E, Polyurethane SP IOZ, Acrylic SP Coating Systems 20

21 Lining System Surface Preparation # of Coats Min DFT E, E, Epoxy SP-10, 2 or 3 15 E, E, Epoxy SP-10 2 or 3 20 UHS Epoxy SP Polyurethane SP Polyurea SP Coating Systems: Linings 21

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