The Application and Measurement of Protective Coatings for Concrete

THE CONCRETE REPAIR ASSOCIATION YOUR MOST POWERFUL ALLY IN THE BATTLE AGAINST DETERIORATING CONCRETE

Kingsley House, Ganders Business Park, Kingsley, Bordon, Hampshire, GU35 9LU t: 01420 471615 f: 01420 471611 www.cra.org.uk

Introduction
The advent of technically advanced protective coatings in the construction industry has raised problems for specifier and applicator alike. Until fairly recently, coatings have been used for decorative purposes only. The life expectancy of these coatings was assumed (in many cases quite wrongly) to be short. Re-coating schedules of four or five years were common. The modern protective coating, which is used as its name suggests, as a protection, has caused the manufacturer, specifier and applicator to change his ideas and methods. This has caused problems due to lack of understanding of material, lack of understanding of the correct preparation of substrate and lack of understanding of the application techniques appropriate. This guidance note is intended to help the specifiers, applicators and manufacturers avoid some of the pitfalls. It will cover preparation, application and testing with a special section on quantity estimation, an area of coating application often misunderstood. There are also notes on choice and limits for specifying.

Protective coatings
What are protective coatings? They are a form of material applied as a continuous thin film. The thin film has properties which allow it to protect the underlying substrate from attack of various forms. These are chemical, either liquid or gas, or physical attack in the form of erosion or impact. They should not be confused with impregnation systems. These work by modifying the microscopic pores in the concrete. Either by total or partial blockage, or by modifying the capillary characteristic. These two systems are often combined to give enhanced performance to a protective system.

Type of protective coating

Protection Areas of use Chemical industry Production industry Food and drink Manufacture Sewerage and water Food and drink Manufacture Production engineering Sea defence Buildings Civil engineering Structures Type epoxy polyurethane polyester as above plus: polymer modified cementitious chlorinated rubber bitumen, tar acrylics of various types epoxies, polyurethane polymer modified cementitious epoxies, polyurethanes acrylics, silanes siloxanes, bitumens tars, polymer modified cementitious epoxies polyurethanes epoxies, polyurethanes polyester, chlorinated rubber

Chemical

Waterproofing

Anti-carbonation

Anti-chloride

Buildings Civil Engineering Marine structures Buildings Civil Engineering Structures Marine structures Production plants Sewerage and water

Anti-graffiti

Abrasion

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Specifying protective coatings

The parameters for specifying a suitable protective coating are many and varied. They will alter from project to project. Limits should be modified to suit each individual project. Limits should be set at realistic levels and have a bearing on the application. Specifying a large maximum value when not required can be counter productive, both in technical and financial terms. Listed below are a number of most widely quoted specification clauses. Carbon dioxide diffusion. The ability of a coating to resist the ingress of carbon dioxide and hence stop the carbonation of the concrete. Diffusion rate specified by various methods. Expressed using -8 2 flicks Law to Diffusion as a diffusion coefficient, typically 7 x 10 cm /sec. The diffusion resistance coefficient indicates how many more times impermeable a coating is than air. A good anticarbonation coating would have a value of of about 1 million. A more useful parameter is the diffusion Equivalent Air layer thickness [R]. R = x s metres where s is the film thickness (in metres) of coating. R expresses the thickness of an air layer which will have the same resistance to CO2 diffusion as the given thickness of s of coating. A value in excess of 50m is normally adequate for all situations. Figures in the high 3 figure values have little advantage because of the exponential nature of certain calculations. Equivalent thickness of concrete, Sc is another method of expression: Sc = R concrete
2

where concrete is taken to be 400 as this is an average value for concrete of strength 30N/mm . Sc gives the equivalent concrete layer which has the same resistance of CO2 diffusion as the given thickness of S of coating. Typically a high quality solvent based anti-carbonation system at 150 microns will have an equivalent concrete thickness of 700mm (0.7m) the normally recommended minimum is 150mm (0.15m). Water Vapour Diffusion is a common requirement of an anti-carbonation/anti-chloride coating. It can be expressed in several ways, as an analogous way to the movement of carbon dioxide. The key parameter is Diffusion Equivalent Air Layer thickness Sd. A generally accepted view is that we allow the coating to breathe sufficiently, so should be less than 4 metres. It can be expressed as a vapour transmission rate i.e. in g/m /day or (CM /S) as a diffusion coefficient. Chloride Diffusion is expressed in various ways but none give a comprehensive or accurate picture. The test methods for chloride diffusion usually involve submersion of the product. This can have adverse effects, particularly for emulsions. The normal effect is for no diffusion for a period of time followed by a steady continuous diffusion. Comparison of the time/diffusion curve compared with an identical untreated concrete sample (test coatings usually being applied to concrete) can give useful information. It is however, difficult to compare these curves, with curves from other materials and the shape is probably going to be the best method. Comparison with treated and untreated samples can e expressed as percentages. Elastic properties are usually expressed as results from BRE or ASTM tests. Low temperature o flexibility is far more important than flexibility at say 20 C. Cracks in concrete are at their greatest at low temperatures when coatings are losing their flexibility. A test ability to bridge cracks 50%-100% greater than the maximum crack envisaged on site would be a reasonable figure to quote. Water absorption is quoted in various forms as a percentage, (ASTMC642) or as a coefficient, but again because total immersion is necessary for absorption, but again because total immersion is necessary for absorption testing spurious results can be obtained from certain emulsions. Long time weatherometer testing, particularly when used in conjunction with CO2 diffusion is a useful techniques. The minimum period which should be considered is 2000 hours. However, commercial
2 2

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restraints have limited many manufacturers to shorter testing programmes and figures are not always available. 500 hour test programmes have in some instances given misleading results. Chemical testing for the water sewage and chemical industry should always be for prolonged periods and in the medium to which the coating will exposed. Effects on colour may or may not be important but do not insist on colour stability for a material in a sludge tank for instance. Specialised potability and leach testing as well as items such as bacterial growth are necessary for the clean water and food industry. Standard testing by Dept of Environment, WRC and Water Authorities are available. Pull off testing (adhesion) should be adequate. The level required should never be more than the material to which the coating will be applied. (In the case of repaired concrete approximately 2 1N/mm ). Due to the mechanism required to allow crack bridging elastic coatings will have an adhesion lower than a normal coating to allow for peel at crack edges and subsequent bridging. It should be noted that it is very difficult to carry out adequate pull off tests on concrete unless a large number of sites are examined.

Preparation
Like all disciplines in construction, preparation is of paramount importance. Without correct and thorough preparation the protective coating will not give either the degree of protection required or meet its design life. The surface of concrete when viewed at a microscopic level is like the surface of the moon, mountains and craters. When applying a protective coating as a continuous film it is necessary for this to be applied at a minimum thickness to meet its design performance. To achieve this it is usually necessary to modify the surface characteristics of the whole concrete surface. Minimum preparation will involve the removal of all extraneous materials from the surface, algae, old paint, dirt, mould, oil, etc. (note on existing coatings, later). The surface of concrete after correct preparation is unlikely to e suitable for application of protective coating directly. It will have opened blow holes, areas of low strength, will have a marked roughness. Many anti-carbonation coating systems have a dry film thickness of 200 microns or less (0.2mm) and the amplitude of the surface defects after preparation will be well in excess of this. Application to such a surface will clearly lead to ponding in the low spots and thinning on the peaks and it is unlikely that the required film thickness can be achieved without excessive layers or quantity of material. The use of a suitable fairing coat is imperative if a suitable surface is to be prepared for coating application. Blow holes, which are present in almost all concrete, also present a problem. Coating over blow holes is rather like trying to coat a colander, you are left with a mass of small pinholes. A pinhole is all that is necessary for the ingress of unwanted chemicals. The form of a blow hole, and its position, i.e. a bubble, usually just under the surface leads to the breaking out of usually only a small portion of the bubble during normal cleaning. It is important when preparing concrete to break out at least 50% of the bubble. Otherwise it will be impossible to subsequently fill. This will lead to subsequent bubbling and possible breakdown of the film due to entrapped air. The preparation of areas of existing coating must be addressed on each and every occasion. It is very rare for a contractor to have complete knowledge of an existing coating on a structure or for a manufacturer to be able to guarantee the application of a material over a competitors old coating. The usual reason for over-coating is the partial breakdown of the former coating and it is recommended that all former coatings are removed it they have started to degrade over a reasonable area. Most modern anti-carbonation and anti-chloride systems will have an effective life of well in excess of ten years and if the preparation has been correct are likely to have failed due to erosion, physical or climatic effects and not through the breakdown of the film. Compatibility between differing coatings can only effectively be tested by a prolonged site trial.

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If the same coating is to be applied, thorough cleaning may be the only preparation required, apart from localised repairs. This will depend on the types of coating and the manufacture should be consulted in all cases. The fairing coat should be capable of being laid from a feather edge to the maximum depth of repair required. Under certain circumstances dependent on manufacture, this may entail more than one material or application. The fairing coat should be applied to give a continuous surface with finish appropriate for the application of the particular coating. In the case of chemical resistant epoxy coatings for tanks, etc., the use of a suitable epoxy based filler/fairing coat should be used. Other points to watch during preparation are, if water has been used for preparation (particularly on porous concrete) a considerable period of time may have to elapse before a protective coating can be applied. It is important to start preparation at the top of a structure and work downwards to eliminate contamination of previously cleaned surfaces.

Application
The application method will depend on a number of factors and methods may include brush, roller, airless spray and even trowel for some of the very thick chemical resistant epoxy coatings. The use of airless spray equipment for the application of protective coatings should not be seen just as an easy way of applying large volumes in a short period of time. It should only be undertaken after careful consideration and after full consultation with the materials supplier. In many cases it is an ideal way of applying material. It can also be disastrous if the proper investigation and considerations are not carried out. Concrete, by its nature, is friable, and all concrete surfaces should receive some form of stabilisation. The primer should be there to stabilise the surface, promote adhesion between the top coat and the concrete and surface seal the concrete to stop absorption of the top coat into the substrate. Primers are of various types and will be typically: an impregnation, surface sealing silane/siloxane; a two part epoxy impregnation surface sealing primer; or a diluted version of the relevant top coat. It is vital that the correct primer is always used. Application of low viscosity primers particularly of the penetrative type should commence at the bottom and work sidewards and downwards. This is to avoid run down giving a false picture of coverage. Penetrative primers are applied at the application rate and are not expressed by the number of coats required as a norm. Care should always to taken to mask all adjoining surfaces which may be affected by overspray, etc. These will include glass if silane, silicone type materials are used, joint sealants, paving, etc. If solvent based coatings are used. It should also be appreciated the some emulsions can be more difficult to remove than solvent based systems if allowed to dry. Modern protective coatings are designed to be resistant to removal once they are dry and because of this extreme care should be taken to avoid over-painting, overspray, etc.

Measurement of coating thickness

Protective coatings are designed to be applied at a minimum dry film thickness, free from holes, so as to achieve a recognised level of protection. There have been several instances where contractors have been placed in a position when expensive re-coating has been necessary due to misunderstanding about film thickness. When external coatings was only a matter of colour, application thickness related only to the power to obliterate. The need to achieve recognisable and measurable thickness appears to create a problem. This is not the fact and with correct technique a given thickness can be achieved. It is necessary to understand several basic concepts before we can start to achieve correct thickness of coating: 1. Minimum thickness. Coating thickness is required at a minimum and not at an average. On a rough substrate it is quite possible to have variation of x10 on thickness.

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2.

Dry film thickness. The majority of coatings contain some form of carrier, either way (emulsions) or solvents. The measurable film required is for dry film, i.e. after the carrier has left the coating. The dry film thickness may vary considerably from the wet film. It is not normally possible to measure the average dry film thickness on concrete without physically damaging the coating at some period of time after the coating has dried over a large number of sites. The only readily available practical method of assessing film thickness on a concrete structure is to measure wet film thickness (i.e. when applied) and then calculate to the dry film thickness. The theoretical quantity of material required for a structure bears no practical relationship with the actual quantity required to achieve a minimum film thickness and must be calculated for each application.

3.

4. 5.

To help us achieve the required thickness, we need to use a wet film guide (as illustrated below).

The guide is used by pushing the edge into the wet film, repeatedly taking measurements. The use of a guide will quickly enable the applicator to judge accurately the required build. The guide measures minimum thickness.

Calculation of Quantity
As previously stated, the quantity of material required to achieve a given minimum dry film thickness bears little relationship to theoretical coverage and using the tables included it will be possible to calculate actual material requirements. Before starting the calculation we need to know certain basic pieces of information: a) b) c) d) e) the total area to be coated the method of application the relative profile (smoothness) of the concrete the volume solids (this is the percentage of solids and carrier expressed as a percentage) required dry film thickness

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To calculate theoretical coverage rate, given volume solids and dry film thickness: 10 x % solids by volume dry film thickness in microns 10 x % solids content by volume dry film thickness in microns x specific gravity
2

M /Litre
2

M /Kg
2

Usually figures above a consumption rate of 10m /litre are rounded up to 1m whilst a consumption 2 2 rate of less than 10m /litre is rounded off to 0.1m . To calculate practical coverage rate, a number of factors play a role in determination of a rate. Factors include: porosity of substrate, surface profile, method of application, weather conditions and workmanship. In the case of very absorbent surfaces, low viscosity primers or diluted top coats may be totally absorbed into the substrate and will make no contribution to the final film thickness. In the case of irregular substrates (and all concrete should be classed as such) coverage will be decreased due to increased surface area. Depending on substrate the following indicative factors should be used when assessing material usage: cold rolled steel slightly rusted steel blast cleaned heavily rusted steel blast cleaned rough, compact concrete x 0.96 x 0.85 x 0.78 x 0.50 to 0.70

The increase in surface area does not take into account the fact that to achieve minimum film thickness it will be necessary to exceed this in certain areas. Coverage rate should be increased by between 10%-20% to allow for this excess (multiplication factor 0.9-0.8 respectively). The method of application will also affect the coverage rate: Application by brush or roller x 0.90 Application by spray inside, no wind x 0.80 Application by spray outside, no wind x 0.70 (Application outside in windy conditions should not be attempted.) To calculate a practical coverage let us look at an example: A coating is required to be applied at 200 microns dry film thickness, total area 1500m solid content of coating 40%. Theoretical coverage Theoretical quantity Practical coverage Practical quantity = = = 10 x 40% 200 microns 1500 2 2 x 0.70 (concrete surface) 1.40 x 0.85 (15% excessive film thickness) 1.19 x 0.90 (application by roller) 1500 1.07 = = = = = = 2m /litre 750 litres 1.40m /litre 2 1.19m /litre 2 1.07m /litre 1400 litres
2 2 2,

An increase in quantity over the theoretical quantity by 650 litres of 86%. It is possible to make even more accurate calculations by splitting the coating into application layers, as, for instance, % excess film thickness will reduce with each coat as the previous coats tend to smooth out the substrate.

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The relationship between the solids content by volume and the dry and set film thickness is shown in the following table. Table 1: Calculation Chart, dry and wet film thickness and theoretical coverage rates. d.f.t. m 20 30 40 50 60 70 80 90 100 125 150 200 250 300 350 400 450 500 100 20 50 30 33 40 25 50 20 60 17 70 14 80 13 90 11 100 10 125 8.0 150 6.7 200 5.0 250 4.0 300 3.3 350 2.9 400 2.5 450 2.2 500 2.0 90 22 45 33 30 44 23 56 18 67 15 78 13 89 11 100 10 111 9.0 139 7.2 167 6.0 222 4.5 278 3.6 333 3.0 389 2.6 444 2.3 500 2.0 556 1.8 80 25 40 38 27 50 20 63 16 75 13 88 11 100 10 113 8.9 125 8.0 156 6.4 188 5.3 250 4.0 313 3.2 375 2.7 438 2.3 500 2.0 563 1.8 625 1.6 % solids content by volume 70 60 29 33 35 30 43 50 23 20 57 67 18 15 71 83 14 12 86 100 12 10 100 117 10 8.6 114 133 8.8 7.5 129 150 7.8 6.7 143 167 7.0 6.0 179 208 5.6 4.8 214 250 4.7 4.0 286 333 3.5 3.0 357 417 2.8 2.4 429 500 2.3 2.0 500 583 2.0 1.7 571 667 1.8 1.5 643 750 1.6 1.3 714 833 1.4 1.2 50 40 25 60 17 80 13 100 10 120 8.3 140 7.1 160 6.3 180 5.6 200 5.0 250 4.0 300 3.3 400 2.5 500 2.0 600 1.7 700 1.4 800 1.3 900 1.1 1000 1.0 40 50 20 75 13 100 10 125 8.0 150 6.7 175 5.7 200 5.0 225 4.4 250 4.0 313 3.2 375 2.7 500 2.0 625 1.6 750 1.3 875 1.1 1000 1.0 1125 0.9 1250 0.8 30 67 15 100 10 133 7.5 167 6.0 200 5.0 233 4.3 267 3.8 300 3.3 333 3.0 417 2.4 500 2.0 667 1.5 833 1.2 1000 1.0 1167 0.9 1333 0.8 1500 0.7 1667 0.6

Example: Volume solids 90% - required d.f.t. 125m Therefore a 139m wet film thickness is required to achieve 125m d.f.t. at 90% volume solids 125 8.0 139 7.2 156 6.4
2

125

179 5.6

208 4.8

250 4.0

313 3.2

417 2.4

which gives a theoretical coverage rate of 7.2 m /litre at a wet film thickness of 139m

Conclusion
It can be seen from the brief notes that the application of a technology based protective coating is a long way from the application of a coloured coating system which is being applied purely for aesthetic reasons and much care and attention must be shown to achieve the performance for which the coating has been designed.

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