Auto Body Surface Coating Guide PDF

Auto Body
Surface Coating:
A Practical Guide
to Reducing Air
Emissions
Small Business
Pollution Prevention Center
University of Northern Iowa

Auto Body Surface Coating:
A Practical Guide to Reducing Air Emissions
Copyright 1998
Iowa Waste Reduction Center
Creation of this manual was funded by the U.S. Environmental Protection Agency
under Cooperative Agreement CR 821492-01-4.
Auto Body Surface Coating:
A Practical Guide to Reducing Air Emissions
Copyright 1998
Iowa Waste Reduction Center
Creation of this manual was funded by the U.S. Environmental Protection Agency
under Cooperative Agreement CR 821492-01-4.
Table of Contents
1. Introduction.........................................................................................................1
2. Auto Refinishing Process Overview...................................................................3
A. Recommended Steps for Practical Reduction of Air Emissions.................4
3. Spray Equipment ...............................................................................................7
A. Conventional Air Atomization Spray Equipment.......................................7
Siphon Tube Feed Conventional Spray Guns .............................................8
Gravity Fed Conventional Spray Guns .......................................................9
B. High-Volume / Low-Pressure (HVLP) Turbine ...........................................9
C. High-Volume / Low-Pressure (HVLP) (non-turbine) ................................10
HVLP Spray Guns with Pressure Assist Cup...........................................10
HVLP Gravity Fed Spray Guns .................................................................11
HVLP Siphon Fed Spray Guns ..................................................................11
D. Low-Pressure / Low Volume (LPLV)..........................................................12
E. Recommended Practices for Spray Equipment.........................................12
4. Spray Application Techniques..........................................................................13
A. Recommended Practices for Spray Techniques.........................................17
5. Spray Equipment Cleaning..............................................................................19
A. Manual Cleaning Processes .......................................................................19
B. Pneumatically Powered Mechanical Cleaning Systems...........................20
C. Recommended Practices for Spray Equipment Cleaning.........................21
6. Determining Product VOC Content ................................................................23
7. Surface Prep......................................................................................................25
A. Soap and Water...........................................................................................25
B. Synthetic Reducers....................................................... ..............................25
C. Solvent-Based Cleaners..............................................................................25
The following individuals have volunteered to review the manual, Auto Body Surface D. Waterborne Cleaners .................................................................................26
Coating: A Practical Guide to Reducing Air Emissions. E. Recommended Practices for Surface Prep.................................................26
Steve Wiedner 8. Undercoats........................................................................................................27
Northeast Iowa Community College, Calmar A. Prep Coats...................................................................................................27
Metal Conditioners / Conversion Coatings ...............................................27
Jim Phillips Wash-Primers / Vinyl Wash-Primers.........................................................28
Hawkeye Community College
Zinc Phosphate Primers .............................................................................28
John Arnold Self-Etching Primers ..................................................................................29
Arnolds Body Shop Epoxy Primers.............................................................................................29
Carl Sutton
Adhesion Promoters....................................................................................30
McIntyre Oldsmobile-Cadillac, Inc. Recommended Practices for Prep Coats....................................................30
B. Primer-Surfacers ........................................................................................30
Mark Clark Acrylic Lacquer Primer-Surfacer...............................................................31
Clark Supply Corporation Alkyd Synthetic Enamel Primer-Surfacer.................................................31
Ron Toyne Self-Etching Primers (as a Primer-Surfacer)............................................31
Kirkwood Community College One-Component Waterborne Primer-Surfacer..........................................32
Table of Contents
1. Introduction.........................................................................................................1
2. Auto Refinishing Process Overview...................................................................3
A. Recommended Steps for Practical Reduction of Air Emissions.................4
3. Spray Equipment ...............................................................................................7
A. Conventional Air Atomization Spray Equipment.......................................7
Siphon Tube Feed Conventional Spray Guns .............................................8
Gravity Fed Conventional Spray Guns .......................................................9
B. High-Volume / Low-Pressure (HVLP) Turbine ...........................................9
C. High-Volume / Low-Pressure (HVLP) (non-turbine) ................................10
HVLP Spray Guns with Pressure Assist Cup...........................................10
HVLP Gravity Fed Spray Guns .................................................................11
HVLP Siphon Fed Spray Guns ..................................................................11
D. Low-Pressure / Low Volume (LPLV)..........................................................12
E. Recommended Practices for Spray Equipment.........................................12
4. Spray Application Techniques..........................................................................13
A. Recommended Practices for Spray Techniques.........................................17
5. Spray Equipment Cleaning..............................................................................19
A. Manual Cleaning Processes .......................................................................19
B. Pneumatically Powered Mechanical Cleaning Systems...........................20
C. Recommended Practices for Spray Equipment Cleaning.........................21
6. Determining Product VOC Content ................................................................23
7. Surface Prep......................................................................................................25
A. Soap and Water...........................................................................................25
B. Synthetic Reducers....................................................... ..............................25
C. Solvent-Based Cleaners..............................................................................25
The following individuals have volunteered to review the manual, Auto Body Surface D. Waterborne Cleaners .................................................................................26
Coating: A Practical Guide to Reducing Air Emissions. E. Recommended Practices for Surface Prep.................................................26
Steve Wiedner 8. Undercoats........................................................................................................27
Northeast Iowa Community College, Calmar A. Prep Coats...................................................................................................27
Metal Conditioners / Conversion Coatings ...............................................27
Jim Phillips Wash-Primers / Vinyl Wash-Primers.........................................................28
Hawkeye Community College
Zinc Phosphate Primers .............................................................................28
John Arnold Self-Etching Primers ..................................................................................29
Arnolds Body Shop Epoxy Primers.............................................................................................29
Carl Sutton
Adhesion Promoters....................................................................................30
McIntyre Oldsmobile-Cadillac, Inc. Recommended Practices for Prep Coats....................................................30
B. Primer-Surfacers ........................................................................................30
Mark Clark Acrylic Lacquer Primer-Surfacer...............................................................31
Clark Supply Corporation Alkyd Synthetic Enamel Primer-Surfacer.................................................31
Ron Toyne Self-Etching Primers (as a Primer-Surfacer)............................................31
Kirkwood Community College One-Component Waterborne Primer-Surfacer..........................................32
1. Introduction
Epoxy Primer (as a Primer-Surfacer)........................................................32
Agency (EPA), many of which are
Polyester Primer-Surfacer..........................................................................32
solvents used in surface coating
Acrylic Urethane Enamel Primer-Surfacer...............................................32 operations. HAPs include toluene,
Recommended Practices for Primer-Surfacers .........................................33
C. Primer-Sealers ............................................................................................33
Lacquer Primer-Sealers..............................................................................33
T he federal Clean Air Act
Amendments (CAAA) of 1990 are
having a significant impact on small
xylene, and methyl ethyl ketone.
Eventually, all HAP emissions will
be subject to rigid standards and
Enamel Type Primer-Sealers......................................................................33 businesses. New regulations are strict controls. The Clean Air Act
Single Component Waterborne Primer-Surfacer (as a Primer-Sealer)....34 being proposed and implemented
The EPA has estimated that the
Amendments of
Epoxy Primer (as a Primer-Sealer)............................................................34 that require air emission permits,
automobile refinishing industry 1990 are signifi-
Acrylic Urethane Primer-Sealers...............................................................34
Recommended Practices for Primer-Sealers .............................................34
and in many cases, expensive air
emission control devices. alone is responsible for over 287,000 cantly impacting
D. Sealers .........................................................................................................35 tons of VOCs released in the U.S. small businesses
These new requirements have had every year. As much as 20 lbs
Tie Coat Sealers..........................................................................................35 a tremendous effect on how of organic solvents may be emitted
Barrier Coat Sealers...................................................................................35 automobile surface coating processes during the surface coating of just one
Recommended Practices for Sealers..........................................................35 are performed. Specific chemicals medium-sized automobile.
9. Top Coats ..........................................................................................................37 and materials used by the auto body
A. Single Stage Topcoats.................................................................................38 Control systems have been
industry are targeted for regulation
Acrylic Lacquer............................................................................................38 developed to help combat VOC
and control. The lists include
Alkyd Enamel..............................................................................................38 emissions from surface coating
chemicals known as Volatile Organic
Acrylic Enamel.............................................................................................39 operations. Many manufacturing
Compounds (VOCs) and Hazardous
Polyurethane Enamel..................................................................................39 firms are currently using these
Air Pollutants (HAPs). Both Volatile
Acrylic Urethane Enamel............................................................................39 systems in their paint booths to
Organic Compounds and Hazardous
B. Two Stage Basecoat / Clearcoat Topcoats .................................................40 reduce VOC emissions by as much as
Air Pollutants are not only harmful
Waterborne Basecoat Systems...................................................................40 95 percent. These add-on controls
to the environment, but can also
Advantages of Waterborne Basecoat Systems ..........................................41 include: Carbon Adsorption, Thermal
cause severe health problems for
Incineration, Catalytic Incineration,
Disadvantages of Waterborne Basecoat Systems .....................................42 technicians exposed to these
and Condensers.
C. Paint Additives ...........................................................................................42 materials.
D. Recommended Practices for Topcoats .......................................................43 Although proven effective in the
10. Recommended Approach to Practical Air Emissions Reduction...................45 Volatile Organic Compounds manufacturing industry, emission
11. What to Expect in the Future.........................................................................49 (VOCs) are considered air control systems are extremely
pollutants because they create expensive, ranging from $20,000 to
unwanted ozone smog in the lower $70,000. For this reason, they are
VOCs and
atmosphere. Many VOCs are also considered impractical for use in HAPs
toxic to humans. Most organic controlling VOCs from small- to
solvents used in the automotive medium-sized auto body repair
painting industry are VOCs and shops. Currently the only practical
emissions of these materials have means of reducing the VOCs emitted
fallen under new federal air from automobile refinishing
regulations. operations is to reduce the volume of
VOCs and HAPs being used. This
Hazardous Air Pollutants requires changes in products,
(HAPs) are 189 materials listed by equipment and application
the Environmental Protection techniques for auto refinishers.
1
Emission Reduction for Auto Body Shops
1. Introduction
Epoxy Primer (as a Primer-Surfacer)........................................................32
Agency (EPA), many of which are
Polyester Primer-Surfacer..........................................................................32
solvents used in surface coating
Acrylic Urethane Enamel Primer-Surfacer...............................................32 operations. HAPs include toluene,
Recommended Practices for Primer-Surfacers .........................................33
C. Primer-Sealers ............................................................................................33
Lacquer Primer-Sealers..............................................................................33
T he federal Clean Air Act
Amendments (CAAA) of 1990 are
having a significant impact on small
xylene, and methyl ethyl ketone.
Eventually, all HAP emissions will
be subject to rigid standards and
Enamel Type Primer-Sealers......................................................................33 businesses. New regulations are strict controls. The Clean Air Act
Single Component Waterborne Primer-Surfacer (as a Primer-Sealer)....34 being proposed and implemented
The EPA has estimated that the
Amendments of
Epoxy Primer (as a Primer-Sealer)............................................................34 that require air emission permits,
automobile refinishing industry 1990 are signifi-
Acrylic Urethane Primer-Sealers...............................................................34
Recommended Practices for Primer-Sealers .............................................34
and in many cases, expensive air
emission control devices. alone is responsible for over 287,000 cantly impacting
D. Sealers .........................................................................................................35 tons of VOCs released in the U.S. small businesses
These new requirements have had every year. As much as 20 lbs
Tie Coat Sealers..........................................................................................35 a tremendous effect on how of organic solvents may be emitted
Barrier Coat Sealers...................................................................................35 automobile surface coating processes during the surface coating of just one
Recommended Practices for Sealers..........................................................35 are performed. Specific chemicals medium-sized automobile.
9. Top Coats ..........................................................................................................37 and materials used by the auto body
A. Single Stage Topcoats.................................................................................38 Control systems have been
industry are targeted for regulation
Acrylic Lacquer............................................................................................38 developed to help combat VOC
and control. The lists include
Alkyd Enamel..............................................................................................38 emissions from surface coating
chemicals known as Volatile Organic
Acrylic Enamel.............................................................................................39 operations. Many manufacturing
Compounds (VOCs) and Hazardous
Polyurethane Enamel..................................................................................39 firms are currently using these
Air Pollutants (HAPs). Both Volatile
Acrylic Urethane Enamel............................................................................39 systems in their paint booths to
Organic Compounds and Hazardous
B. Two Stage Basecoat / Clearcoat Topcoats .................................................40 reduce VOC emissions by as much as
Air Pollutants are not only harmful
Waterborne Basecoat Systems...................................................................40 95 percent. These add-on controls
to the environment, but can also
Advantages of Waterborne Basecoat Systems ..........................................41 include: Carbon Adsorption, Thermal
cause severe health problems for
Incineration, Catalytic Incineration,
Disadvantages of Waterborne Basecoat Systems .....................................42 technicians exposed to these
and Condensers.
C. Paint Additives ...........................................................................................42 materials.
D. Recommended Practices for Topcoats .......................................................43 Although proven effective in the
10. Recommended Approach to Practical Air Emissions Reduction...................45 Volatile Organic Compounds manufacturing industry, emission
11. What to Expect in the Future.........................................................................49 (VOCs) are considered air control systems are extremely
pollutants because they create expensive, ranging from $20,000 to
unwanted ozone smog in the lower $70,000. For this reason, they are
VOCs and
atmosphere. Many VOCs are also considered impractical for use in HAPs
toxic to humans. Most organic controlling VOCs from small- to
solvents used in the automotive medium-sized auto body repair
painting industry are VOCs and shops. Currently the only practical
emissions of these materials have means of reducing the VOCs emitted
fallen under new federal air from automobile refinishing
regulations. operations is to reduce the volume of
VOCs and HAPs being used. This
Hazardous Air Pollutants requires changes in products,
(HAPs) are 189 materials listed by equipment and application
the Environmental Protection techniques for auto refinishers.
1
1: Introduction
2. Auto Refinishing
This practical pollution prevention guide was developed to help
automotive refinishers:
Process Overview
Surface Prep (8%)
Reduce the amount of VOCs and HAPs emitted during painting Undercoats (17%)
operations
Avoid the need for expensive ($20,000 - $70,000) emission control
devices
Decrease the amount of paint-related wastes generated
T he basic steps in automotive
refinishing include:
1. Prepaint surface cleaning:
Maintain a high quality finish
Solvents are used for the removal of
Equipment
In essence, "how to do more with less" in surface coating processes. contaminants such as grease, tar, wax, Cleaning (20%) Topcoats (55%)
and silicone, all of which can have an
This Guide provides: adverse effect on the bond between the
An overview of the auto refinishing process (Section 2)

coating and the substrate. Poorly Figure 2: EPA Estimates of VOC Emissions
cleaned surfaces result in finish
A review of the spray equipment currently used for auto imperfections or even the peeling of
refinishing operations (Section 3) the topcoat from the substrate.
Although these solvents are not 3. Application of the topcoat:
An outline of proper spray application processes (Section 4)
typically atomized for application More than half of the VOCs
A look at spray equipment cleaning (purging) processes (Section 5) purposes, VOCs are released through released during the refinishing
Information on determining products VOC content (Section 6) the simple evaporation of the liquid process occur during the top coat
solvents. Many of the solvents used for application, with metallics and
A review of surface prep cleaners (Section 7)
prepaint surface cleaning contain lacquer finishes releasing the highest
An overview of undercoats (Section 8) toluene and xylene. Each is listed as a volume. As with undercoats, the
A look at automotive topcoat systems (Section 9) VOC and HAP. In fact, most of these primary reason for the high release of
cleaners contain 75 to 100 percent VOCs in topcoat application is the Over half the VOCs
Recommended approach to practical air emission reduction (Section 10) VOCs. EPA studies indicate the poor transfer efficiency of traditional released during the
A projection of what to expect in the future (Section 11) evaporation of these solvents accounts spray equipment. Less than one-half refinishing process
for approximately 8 percent of the total
VOC emissions released during the
of the topcoat material will be applied are from top coat
to the desired surface using conven-
refinishing process (see Figure 2). tional spray equipment. The rest is
application
expelled as overspray.
2. Undercoat application:
The application of undercoats (prep 4. Spray equipment cleaning
coats, primer-surfacers, primer-sealers, operations:
and sealers) contributes significantly Approximately 20 percent of VOCs
to the volume of VOCs released released from auto refinishing occurs
during surface coating operations. during equipment cleaning
Undercoats generally contain less operations. This figure reflects the
than 50 percent solvents by volume. volume of organic solvents emitted to
However, because of the poor transfer the atmosphere during conventional
efficiency of the equipment and the equipment cleaning (purging)
number of coats typically applied, procedures. The majority of
solvent based undercoats are commercial spray equipment cleaners
responsible for about 17 percent of all found on the market today are made
VOCs released during surface entirely of organic solvents.
2 coating applications.
3
Emission Reduction for Auto Body Shops Emission Reduction for Auto Body Shops
1: Introduction
2. Auto Refinishing
This practical pollution prevention guide was developed to help
automotive refinishers:
Process Overview
Surface Prep (8%)
Reduce the amount of VOCs and HAPs emitted during painting Undercoats (17%)
operations
Avoid the need for expensive ($20,000 - $70,000) emission control
devices
Decrease the amount of paint-related wastes generated
T he basic steps in automotive
refinishing include:
1. Prepaint surface cleaning:
Maintain a high quality finish
Solvents are used for the removal of
Equipment
In essence, "how to do more with less" in surface coating processes. contaminants such as grease, tar, wax, Cleaning (20%) Topcoats (55%)
and silicone, all of which can have an
This Guide provides: adverse effect on the bond between the
An overview of the auto refinishing process (Section 2)

coating and the substrate. Poorly Figure 2: EPA Estimates of VOC Emissions
cleaned surfaces result in finish
A review of the spray equipment currently used for auto imperfections or even the peeling of
refinishing operations (Section 3) the topcoat from the substrate.
Although these solvents are not 3. Application of the topcoat:
An outline of proper spray application processes (Section 4)
typically atomized for application More than half of the VOCs
A look at spray equipment cleaning (purging) processes (Section 5) purposes, VOCs are released through released during the refinishing
Information on determining products VOC content (Section 6) the simple evaporation of the liquid process occur during the top coat
solvents. Many of the solvents used for application, with metallics and
A review of surface prep cleaners (Section 7)
prepaint surface cleaning contain lacquer finishes releasing the highest
An overview of undercoats (Section 8) toluene and xylene. Each is listed as a volume. As with undercoats, the
A look at automotive topcoat systems (Section 9) VOC and HAP. In fact, most of these primary reason for the high release of
cleaners contain 75 to 100 percent VOCs in topcoat application is the Over half the VOCs
Recommended approach to practical air emission reduction (Section 10) VOCs. EPA studies indicate the poor transfer efficiency of traditional released during the
A projection of what to expect in the future (Section 11) evaporation of these solvents accounts spray equipment. Less than one-half refinishing process
for approximately 8 percent of the total
VOC emissions released during the
of the topcoat material will be applied are from top coat
to the desired surface using conven-
refinishing process (see Figure 2). tional spray equipment. The rest is
application
expelled as overspray.
2. Undercoat application:
The application of undercoats (prep 4. Spray equipment cleaning
coats, primer-surfacers, primer-sealers, operations:
and sealers) contributes significantly Approximately 20 percent of VOCs
to the volume of VOCs released released from auto refinishing occurs
during surface coating operations. during equipment cleaning
Undercoats generally contain less operations. This figure reflects the
than 50 percent solvents by volume. volume of organic solvents emitted to
However, because of the poor transfer the atmosphere during conventional
efficiency of the equipment and the equipment cleaning (purging)
number of coats typically applied, procedures. The majority of
solvent based undercoats are commercial spray equipment cleaners
responsible for about 17 percent of all found on the market today are made
VOCs released during surface entirely of organic solvents.
2 coating applications.
3
2: Auto Refinishing Process Overview 2: Auto Refinishing Process Overview
A. Recommended Steps for Practical Recommended Steps, cont

Reduction of Air Emissions: EQUIPMENT CLEANING
To reduce VOCs released during refinishing operations, facilities should Use an air powered mechanical gun cleaning system.
See Section 5 for
use the following recommended steps for practical air emission reduction: Use low VOC cleaning solvents.
Equipment Cleaning
If the guns are to be cleaned manually, spray into an enclosed backdrop to capture
SPRAY EQUIPMENT atomized solvents.
Determine the price range you are willing to spend for spray equipment. Use a broom straw, cleaning broach, or a soft wood toothpick to clear
Determine the types of coatings that will be sprayed through the equipment, and passageways.
the atomization properties required for proper application of these coatings.
SURFACE PREP
See Section 3 Prior to purchasing any paint gun, consult your paint representative to determine
Always wash dirt and grime from the vehicle using water or a soap and water
for Spray what type of gun works best for the application of the product you will be using.
mixture.
Equipment Contact your paint representative and/or spray gun representative to determine See Section 7 for
Use waterborne cleaners when possible.
the fluid tip/air cap combination and gun settings recommended for the materials Surface Prep
being sprayed. If, due to heavy contamination, waterborne cleaners prove unsatisfactory, use
solvent based cleaners for the initial cleaning. For secondary cleaning operations,
Choose spray equipment that will achieve the highest transfer efficiency while use the waterborne products.
providing the required atomization properties within your price range.
If waterborne cleaners prove unsatisfactory due to substrate make-up, use
solvent based cleaners sparingly.
SPRA Y APPLICATION PRACTICES
Keep solvent laden dirty rags in a closed container.
Select the suggested air pressure and tip sizes for the specific product and
Keep solvent containers closed when not in use.
equipment being used.
Avoid operations that require multiple prepaint surface cleanings.
Always hold the gun perpendicular to the surface being sprayed, using parallel
strokes. Never arc the gun.
PREP COATS
Feather the trigger at the beginning and end of each pass. Use versatile products such as epoxy primers or self-etching primers. The use of
Use a 50 percent overlap for each pass. (Note: This technique may need to be these products may alleviate the need for additional surface coating operations
altered slightly when applying high metallic, high solids basecoats, and some such as primer-surfacing or primer-sealing.
See Section 8.A for
See Section 4 three stage systems.) If a self-etching primer or epoxy primer is not desirable, use a wash-primer, or
Prep Coat
for Spray When painting small and medium sized panels, make each pass the full length of metal conditioner, conversion coating system.
Application the panel. Avoid zinc-phosphate primers with high VOC content.
Practices With larger panels, use a comfortable stroke, with a 4 - 5 " overlap of the strokes.
PRIMER-SURFACERS
If blending is necessary, keep the blend area as small as possible without
Use a properly operating primer gun with the correct fluid tip/air cap combination
jeopardizing the appearance of the blend.
for your particular type of primer-surfacer.
Spray the border edges of the substrate first (banding). This will assure all edges
are covered without extending the spray pattern well beyond the borders of the
Use low VOC waterborne primer-surfacer products. See Section 8.B for
object. If the curing time of waterborne products proves unsatisfactory, consider the use Primer-Surfacers
of versatile urethane primers.
Use color hiding power labels to determine the thickness of the applied paint film.
These markers will also indicate when adequate coverage has been achieved. To reduce VOC emissions, limit material costs, and achieve a better quality
product, perform body work using a minimal amount of primer-surfacer.
If a colored sealer is not used, make sure the primer-surfacer is a color that can
easily be covered with the desired topcoat.
4 5
2: Auto Refinishing Process Overview 2: Auto Refinishing Process Overview
A. Recommended Steps for Practical Recommended Steps, cont

Reduction of Air Emissions: EQUIPMENT CLEANING
To reduce VOCs released during refinishing operations, facilities should Use an air powered mechanical gun cleaning system.
See Section 5 for
use the following recommended steps for practical air emission reduction: Use low VOC cleaning solvents.
Equipment Cleaning
If the guns are to be cleaned manually, spray into an enclosed backdrop to capture
SPRAY EQUIPMENT atomized solvents.
Determine the price range you are willing to spend for spray equipment. Use a broom straw, cleaning broach, or a soft wood toothpick to clear
Determine the types of coatings that will be sprayed through the equipment, and passageways.
the atomization properties required for proper application of these coatings.
SURFACE PREP
See Section 3 Prior to purchasing any paint gun, consult your paint representative to determine
Always wash dirt and grime from the vehicle using water or a soap and water
for Spray what type of gun works best for the application of the product you will be using.
mixture.
Equipment Contact your paint representative and/or spray gun representative to determine See Section 7 for
Use waterborne cleaners when possible.
the fluid tip/air cap combination and gun settings recommended for the materials Surface Prep
being sprayed. If, due to heavy contamination, waterborne cleaners prove unsatisfactory, use
solvent based cleaners for the initial cleaning. For secondary cleaning operations,
Choose spray equipment that will achieve the highest transfer efficiency while use the waterborne products.
providing the required atomization properties within your price range.
If waterborne cleaners prove unsatisfactory due to substrate make-up, use
solvent based cleaners sparingly.
SPRA Y APPLICATION PRACTICES
Keep solvent laden dirty rags in a closed container.
Select the suggested air pressure and tip sizes for the specific product and
Keep solvent containers closed when not in use.
Avoid operations that require multiple prepaint surface cleanings.
PREP COATS
Feather the trigger at the beginning and end of each pass. Use versatile products such as epoxy primers or self-etching primers. The use of
Use a 50 percent overlap for each pass. (Note: This technique may need to be these products may alleviate the need for additional surface coating operations
altered slightly when applying high metallic, high solids basecoats, and some such as primer-surfacing or primer-sealing.
See Section 8.A for
See Section 4 three stage systems.) If a self-etching primer or epoxy primer is not desirable, use a wash-primer, or
Prep Coat
for Spray When painting small and medium sized panels, make each pass the full length of metal conditioner, conversion coating system.
Application the panel. Avoid zinc-phosphate primers with high VOC content.
Practices With larger panels, use a comfortable stroke, with a 4 - 5 " overlap of the strokes.
PRIMER-SURFACERS
Use a properly operating primer gun with the correct fluid tip/air cap combination
for your particular type of primer-surfacer.
Spray the border edges of the substrate first (banding). This will assure all edges
are covered without extending the spray pattern well beyond the borders of the
Use low VOC waterborne primer-surfacer products. See Section 8.B for
object. If the curing time of waterborne products proves unsatisfactory, consider the use Primer-Surfacers
of versatile urethane primers.
Use color hiding power labels to determine the thickness of the applied paint film.
These markers will also indicate when adequate coverage has been achieved. To reduce VOC emissions, limit material costs, and achieve a better quality
product, perform body work using a minimal amount of primer-surfacer.
easily be covered with the desired topcoat.
4 5
2: Auto Refinishing Process Overview
Recommended Steps, cont

3. Spray Equipment these new technologies were found to
be unacceptable for use in the
application of automobile topcoats.
PRIMER-SEALERS Excess orange peel, pinholing,
See Section
Use low VOC primer-sealers such as single component waterborne primers or
waterborne epoxy primers. P rior to the Clean Air Act, most
technicians chose spray
solvent popping, and mottling were
common with many of these systems.
8.C for Use low VOC urethane primer-sealers as an alternative when possible. equipment based solely on its ability Fortunately, a few of these new Transfer efficiency is
Primer-Sealers Always choose a color of primer-sealer that can be easily covered with the topcoat
to apply a quality finish. As the technologies proved capable of a major factor in
focus on VOC emissions within the producing a high quality finish and
to be sprayed, or choose a tintable primer-sealer and tint it to an easily covered
refinishing industry continues to thus are able to compete with
spray equipment
shade.
grow, transfer efficiency has become conventional spray equipment in the selection
a major factor in spray equipment refinishing industry. These new
SEALERS selection. systems include gravity fed conven-
Choose the proper sealer for each specific job. tional, high-volume/low-pressure
See Section 8.D If filling capabilities are required, use a primer-sealer in place of a sealer.
Simply put, transfer efficiency is
turbine, high-volume/low-pressure
for Sealers Always choose a primer-sealer of a color that can be easily covered with the
the percentage of material atomized
through the gun that actually ends
non-turbine, and low-pressure/low-
coating to be sprayed, or choose a tintable primer-sealer. volume spray guns.
up as a coating on the desired
surface. However, the transfer
A. Conventional Air
TOPCOATS efficiency of any type of spray
Atomization Spray Equipment
Mix color coats in-house, making certain the formula for the proper shade of the equipment is subject to change under
a variety of conditions. Variables For decades, the conventional
specific color code is used. This will help avoid the need for blending the
suction feed spray gun has been the
See Section 9 for finish to achieve a satisfactory color match. affecting transfer efficiency include:
overwhelming favorite of automotive
Topcoats Keep good records of paint match information, including spray-out cards and Technician's spraying technique refinishers worldwide. These The conventional
detailed notes. Size and configuration of the systems provide excellent suction feed spray
Avoid the use of lacquer-based topcoats. object to be sprayed atomization of the coating while gun has been the
Distance of the gun from the object
Choose low VOC topcoats that require fewer than three coats to achieve adequate
coverage (polyurethane or urethane). to be sprayed
giving the operator the control
needed to achieve an even, high gloss
overwhelming favorite
Size of air cap and nozzle used finish. Conventional air guns rely on
of auto refinishers
Apply only the number of coats needed to achieve a quality finish.
Air pressure at the tip high pressure air (35 - 80 psi) to
Use high solids / low VOC clears to topcoat color coats.
Volume of material exiting the gun atomize the coating for application.
Keep the use of paint additives to a minimum. at the tip This atomization of coatings takes
When available, use waterborne basecoats. Volume of air leaving the gun at place in three separate stages.
the tip
1. The paint is surrounded by a
Viscosity of the material being
highly pressurized column of air.
sprayed
This air column causes turbulence
Atmospheric conditions
to occur in the paint, which begins
(temperature, humidity and
to separate the paint into small
barometric pressure)
droplets.
Spray gun manufacturers have 2. The paint is then forced through
developed several new spray the fluid nozzle of the gun. Air is
technologies in an attempt to achieve released through containment
optimum efficiency. While achieving holes in the air cap, enhancing the
excellent transfer efficiency, many of atomization of the fluid.
6 7
2: Auto Refinishing Process Overview
Recommended Steps, cont

3. Spray Equipment these new technologies were found to
be unacceptable for use in the
application of automobile topcoats.
PRIMER-SEALERS Excess orange peel, pinholing,
See Section
Use low VOC primer-sealers such as single component waterborne primers or
waterborne epoxy primers. P rior to the Clean Air Act, most
technicians chose spray
solvent popping, and mottling were
common with many of these systems.
8.C for Use low VOC urethane primer-sealers as an alternative when possible. equipment based solely on its ability Fortunately, a few of these new Transfer efficiency is
Primer-Sealers Always choose a color of primer-sealer that can be easily covered with the topcoat
to apply a quality finish. As the technologies proved capable of a major factor in
focus on VOC emissions within the producing a high quality finish and
to be sprayed, or choose a tintable primer-sealer and tint it to an easily covered
refinishing industry continues to thus are able to compete with
spray equipment
shade.
grow, transfer efficiency has become conventional spray equipment in the selection
a major factor in spray equipment refinishing industry. These new
SEALERS selection. systems include gravity fed conven-
Choose the proper sealer for each specific job. tional, high-volume/low-pressure
See Section 8.D If filling capabilities are required, use a primer-sealer in place of a sealer.
Simply put, transfer efficiency is
turbine, high-volume/low-pressure
for Sealers Always choose a primer-sealer of a color that can be easily covered with the
the percentage of material atomized
through the gun that actually ends
non-turbine, and low-pressure/low-
coating to be sprayed, or choose a tintable primer-sealer. volume spray guns.
up as a coating on the desired
surface. However, the transfer
A. Conventional Air
TOPCOATS efficiency of any type of spray
Atomization Spray Equipment
Mix color coats in-house, making certain the formula for the proper shade of the equipment is subject to change under
a variety of conditions. Variables For decades, the conventional
specific color code is used. This will help avoid the need for blending the
suction feed spray gun has been the
See Section 9 for finish to achieve a satisfactory color match. affecting transfer efficiency include:
overwhelming favorite of automotive
Topcoats Keep good records of paint match information, including spray-out cards and Technician's spraying technique refinishers worldwide. These The conventional
detailed notes. Size and configuration of the systems provide excellent suction feed spray
Avoid the use of lacquer-based topcoats. object to be sprayed atomization of the coating while gun has been the
Distance of the gun from the object
Choose low VOC topcoats that require fewer than three coats to achieve adequate
coverage (polyurethane or urethane). to be sprayed
giving the operator the control
needed to achieve an even, high gloss
overwhelming favorite
Size of air cap and nozzle used finish. Conventional air guns rely on
of auto refinishers
Apply only the number of coats needed to achieve a quality finish.
Air pressure at the tip high pressure air (35 - 80 psi) to
Use high solids / low VOC clears to topcoat color coats.
Volume of material exiting the gun atomize the coating for application.
Keep the use of paint additives to a minimum. at the tip This atomization of coatings takes
When available, use waterborne basecoats. Volume of air leaving the gun at place in three separate stages.
the tip
1. The paint is surrounded by a
Viscosity of the material being
highly pressurized column of air.
sprayed
This air column causes turbulence
Atmospheric conditions
to occur in the paint, which begins
(temperature, humidity and
to separate the paint into small
barometric pressure)
droplets.
Spray gun manufacturers have 2. The paint is then forced through
developed several new spray the fluid nozzle of the gun. Air is
technologies in an attempt to achieve released through containment
optimum efficiency. While achieving holes in the air cap, enhancing the
excellent transfer efficiency, many of atomization of the fluid.
6 7
3: Spray Equipment 3: Spray Equipment
3. Finally, air is released from the Siphon Tube Feed Conventional Gravity Fed Conventional Spray Many painters adjust well to the
horns of the air cap and comes in Spray Guns Guns gravity fed technology and can apply
contact with the atomized paint. quality finishes with the first or
The siphon tube spray gun has Gravity fed technology first
This not only helps in the second use. Others find adapting to
been by far the favorite of auto body became popular with European auto
atomization process, but also this type of equipment difficult.
refinishing technicians for both refinishers for its ability to apply
shapes the paint pattern. There are four specific obstacles that
undercoat and topcoat applications. higher viscosity coatings such as
must be overcome to use gravity fed
This equipment produces a epoxy primers and high solids paints
spray guns effectively. First, because
fully atomized paint and clears. As the use of these
of the gravity fed design of these
pattern for even surface coatings has increased in the U.S., so guns, as the paint level decreases, so
coverage and gives the has the acceptance of gravity fed does the rate of material feed.
control needed for the guns within the automobile repair
HVLP Turb Although minor, the operator must
application of metallic industry. still adjust technique throughout the
finishes. The spray
HVLP The major design difference coating process to compensate for the
LPLV pattern allows even distri-
between the gravity and siphon fed change in fluid flow. Second, some
bution of metallic flakes
designs is the location of the paint painters find that the high
throughout the substrate
cup. The cup is located on top of the positioning of the cup interferes with
resulting in a finish free of
Gravity gravity fed guns, as opposed to the the visibility of the surface during
metallic mottling flaws.
Siphon siphon tube spray guns, which have coating applications. Modifications
The simple design of these
the cup located below the body of the to a painter's spray technique may
guns makes them very
gun. This cup location gives the be required to compensate for this
economical to purchase
gravity fed guns a distinct advantage obstruction. Third, difficulties occur
and maintain. A good
when spraying the underside of body
quality siphon tube spray in clearance over siphon fed
panels. If the gun is pointed
gun costs from $120 - equipment. This advantage becomes
upwards, the material will not flow
$300. evident when spraying the lower
to the gun from the cup. Finally, the
panels of today's smaller
Depending on the physical design of the equipment
automobiles. Gravity fed spray guns
material sprayed and the does not allow the operator to set the
Figure 3: Transfer Efficiency of Spray Equipment pressure used, the transfer efficiency
rely on gravity, not air pressure, to
gun down without the aid of a stand
feed the fluid to the gun. Higher
of a siphon tube spray gun may be as or spray gun hanger.
viscosity solutions can be sprayed
low as 35 percent. Sprayable
and atomized more effectively than
material is lost through the exhaust B. High-Volume/Low -
in siphon fed equipment.
The sudden release of this high system or as overspray on the booth Pressure (HVLP) Turbine
pressure air through the small floor. Because air pressure is used to Because of cup placement, The HVLP turbine spray guns
openings of the nozzle breaks up the pull the fluid from the cup to gun, virtually all the paint in the cup can have reportedly achieved transfer
paint and propels the spray away only low viscosity coatings may be be used with little or no waste. The efficiencies of 80 to 90 percent,
from the gun. The atomized
material is transferred to the
used effectively in these systems.
The higher the materials viscosity,
majority of these cups are made of a
semi-clear solvent-resistant plastic
exceeding all other automotive HVLP
substrate at a high velocity causing the greater the air pressure required which gives the painter the added
refinishing spray equipment on the
market today (see Figure 3, pg 8).
Turbine Guns
violent air turbulence to occur at the to draw the material up the siphon advantage of being able to see the These systems use columns of low
surface of the substrate. This tube. The higher the pressure, the amount of material left in the pressure air to cause turbulence
turbulence forces much of the greater the amount of material reservoir while spraying. The within the paint as the first stage of
atomized material away from the wasted as overspray. The siphon transfer efficiency of the gravity fed atomization. The air used for the
surface to be coated, resulting in design makes it impossible to guns is slightly better due to the final step of atomization originates
more than half of the atomized paint retrieve all the paint from the cup, so higher viscosity material used, from high-volume turbine driven
particulates and solvents being lost there will always be some unused averaging approximately 40 percent. blowers. This air is heated to assist
as waste overspray. material.
8 9
3. Finally, air is released from the Siphon Tube Feed Conventional Gravity Fed Conventional Spray Many painters adjust well to the
horns of the air cap and comes in Spray Guns Guns gravity fed technology and can apply
contact with the atomized paint. quality finishes with the first or
The siphon tube spray gun has Gravity fed technology first
This not only helps in the second use. Others find adapting to
been by far the favorite of auto body became popular with European auto
atomization process, but also this type of equipment difficult.
refinishing technicians for both refinishers for its ability to apply
shapes the paint pattern. There are four specific obstacles that
undercoat and topcoat applications. higher viscosity coatings such as
must be overcome to use gravity fed
This equipment produces a epoxy primers and high solids paints
spray guns effectively. First, because
fully atomized paint and clears. As the use of these
of the gravity fed design of these
pattern for even surface coatings has increased in the U.S., so guns, as the paint level decreases, so
coverage and gives the has the acceptance of gravity fed does the rate of material feed.
control needed for the guns within the automobile repair
HVLP Turb Although minor, the operator must
application of metallic industry. still adjust technique throughout the
finishes. The spray
HVLP The major design difference coating process to compensate for the
LPLV pattern allows even distri-
between the gravity and siphon fed change in fluid flow. Second, some
bution of metallic flakes
designs is the location of the paint painters find that the high
throughout the substrate
cup. The cup is located on top of the positioning of the cup interferes with
resulting in a finish free of
Gravity gravity fed guns, as opposed to the the visibility of the surface during
metallic mottling flaws.
Siphon siphon tube spray guns, which have coating applications. Modifications
The simple design of these
the cup located below the body of the to a painter's spray technique may
guns makes them very
gun. This cup location gives the be required to compensate for this
economical to purchase
gravity fed guns a distinct advantage obstruction. Third, difficulties occur
and maintain. A good
when spraying the underside of body
quality siphon tube spray in clearance over siphon fed
panels. If the gun is pointed
gun costs from $120 - equipment. This advantage becomes
upwards, the material will not flow
$300. evident when spraying the lower
to the gun from the cup. Finally, the
panels of today's smaller
Depending on the physical design of the equipment
automobiles. Gravity fed spray guns
material sprayed and the does not allow the operator to set the
Figure 3: Transfer Efficiency of Spray Equipment pressure used, the transfer efficiency
rely on gravity, not air pressure, to
gun down without the aid of a stand
feed the fluid to the gun. Higher
of a siphon tube spray gun may be as or spray gun hanger.
viscosity solutions can be sprayed
low as 35 percent. Sprayable
and atomized more effectively than
material is lost through the exhaust B. High-Volume/Low -
in siphon fed equipment.
The sudden release of this high system or as overspray on the booth Pressure (HVLP) Turbine
pressure air through the small floor. Because air pressure is used to Because of cup placement, The HVLP turbine spray guns
openings of the nozzle breaks up the pull the fluid from the cup to gun, virtually all the paint in the cup can have reportedly achieved transfer
paint and propels the spray away only low viscosity coatings may be be used with little or no waste. The efficiencies of 80 to 90 percent,
from the gun. The atomized
material is transferred to the
used effectively in these systems.
The higher the materials viscosity,
majority of these cups are made of a
semi-clear solvent-resistant plastic
exceeding all other automotive HVLP
substrate at a high velocity causing the greater the air pressure required which gives the painter the added
refinishing spray equipment on the
market today (see Figure 3, pg 8).
Turbine Guns
violent air turbulence to occur at the to draw the material up the siphon advantage of being able to see the These systems use columns of low
surface of the substrate. This tube. The higher the pressure, the amount of material left in the pressure air to cause turbulence
turbulence forces much of the greater the amount of material reservoir while spraying. The within the paint as the first stage of
atomized material away from the wasted as overspray. The siphon transfer efficiency of the gravity fed atomization. The air used for the
surface to be coated, resulting in design makes it impossible to guns is slightly better due to the final step of atomization originates
more than half of the atomized paint retrieve all the paint from the cup, so higher viscosity material used, from high-volume turbine driven
particulates and solvents being lost there will always be some unused averaging approximately 40 percent. blowers. This air is heated to assist
as waste overspray. material.
8 9
in the atomization process and is auxiliary air supply sources or separate regulated air line, to feed siphon fed spray guns come as close
transferred to the gun using large turbines are needed. These spray the paint to the gun. The as any of the HVLP equipment to
diameter air lines. The air is used to guns do require high volumes of air pressurized cup improves the looking and feeling like a conven-
atomize the paint in basically the (13 - 30 cfm at 10 psi), so at least a transfer efficiency of the gun. tional siphon spray gun. Some
same manner as a conventional gun, five horsepower compressor, with companies are even producing
As with any pressurized paint gun,
but is much more efficient. The adequate piping (i.e. 3/4") is usually conversion kits to make a conven-
care must be taken not to over-
turbine supplies all the air needed required to supply the needed volume tional siphon fed into an HVLP
pressurize the paint cup or remove a
for the system to operate. No outside of air. As with all non-turbine low pressurized cup.
air source is required. pressure spray equipment, incoming Equipment damage or
air must be dry to prevent water operator injury may
HVLP turbine spray guns have some condensation within the gun. result. Some atomization
distinct disadvantages.
The non-turbine HVLP technology problems may also be
The cost of these systems is high, has proved to be a vast improvement experienced when spraying
with price tags commonly over the turbine models, but it still epoxy primers and high
exceeding $3,000. has obstacles that must be overcome. solids coatings due to their
The application rates of the HVLP high viscosity.
The large air lines are often systems are much slower than that
cumbersome for the operator. of conventional spray equipment. HVLP Gravity Fed Spray
Blending metallic finishes is very Also, non-turbine HVLP spray guns Guns
difficult using the HVLP system do not offer the metallic control of
conventional style guns, making the The gravity fed HVLP
due to the heavy application coats.
spraying of metallic topcoats difficult guns (see Figure 4)
The atomization of the turbine to master. As with all HVLP spray combine the finest
HVLP spray guns may not give equipment, non-turbine models clog qualities of the HVLP and
the quality finish required to easily. For this reason, coating conventional gravity fed
material filtration and proper gun spray guns into one design.
match automotive factory finishes.
cleaning practices are essential. Like its conventional counterpart,
Figure 4: HVLP Gravity Fed Spray Gun
Finally, blending topcoats using the these guns work especially well on
C. High-Volume/Low- HVLP technology has been a high solids and water-based paints,
Pressure (HVLP) (non-turbine) challenge for painters. The thick clears, and primers due to their top siphon feed gun. This makes the
The problems of the HVLP turbine coats applied using the HVLP guns mounting, gravity fed material cup. price of this HVLP technology
in automotive refinishing were do not produce the gradual tapering extremely affordable. These guns
quickly realized by the spray gun effect needed for blending of high This design also shares the produce basically the same soft spray
manufacturers. To help alleviate solid and metallic topcoats. disadvantages of its conventional pattern as all HVLP guns with
counterpart; as the paint level
HVLP Non- some of these downfalls, manufac-
HVLP Spray Guns With Pressure decreases, so does the feed rate.
atomizing pressures as low as 5 psi.
Turbine Guns turers developed more versatile, less

expensive HVLP spray equipment. Assist Cup Therefore, the operator must adjust
The siphon design has a lower
transfer efficiency than other HVLP
Depending on the make of gun, these technique to compensate for the technologies.
One attempt to improve the HVLP
systems have a transfer efficiency change in fluid flow.
technology to better suit the auto
ranging from 55 - 75 percent, and repair industry was the addition of a D. Low-Pressure/Low- Volume
report a savings in material of 20 - pressure cup to the system. These HVLP Siphon Fed Spray Guns (LPLV)
30 percent over conventional spray systems use a paint cup mounted To gain acceptance in the auto Another spray technology
guns. The non-turbine HVLP guns under the gun, similar to a conven-
refinishing industry, some spray gun developed to improve transfer
use only conventional shop air for tional spray gun design. With this
manufacturers are producing siphon efficiency is the Low-Pressure/Low-
their operations. No expensive style, the cup is pressurized, using a
fed HVLP spray equipment. The Volume (LPLV) spray equipment.
10 11
in the atomization process and is auxiliary air supply sources or separate regulated air line, to feed siphon fed spray guns come as close
transferred to the gun using large turbines are needed. These spray the paint to the gun. The as any of the HVLP equipment to
diameter air lines. The air is used to guns do require high volumes of air pressurized cup improves the looking and feeling like a conven-
atomize the paint in basically the (13 - 30 cfm at 10 psi), so at least a transfer efficiency of the gun. tional siphon spray gun. Some
same manner as a conventional gun, five horsepower compressor, with companies are even producing
As with any pressurized paint gun,
but is much more efficient. The adequate piping (i.e. 3/4") is usually conversion kits to make a conven-
care must be taken not to over-
turbine supplies all the air needed required to supply the needed volume tional siphon fed into an HVLP
pressurize the paint cup or remove a
for the system to operate. No outside of air. As with all non-turbine low pressurized cup.
air source is required. pressure spray equipment, incoming Equipment damage or
air must be dry to prevent water operator injury may
HVLP turbine spray guns have some condensation within the gun. result. Some atomization
distinct disadvantages.
The non-turbine HVLP technology problems may also be
The cost of these systems is high, has proved to be a vast improvement experienced when spraying
with price tags commonly over the turbine models, but it still epoxy primers and high
exceeding $3,000. has obstacles that must be overcome. solids coatings due to their
The application rates of the HVLP high viscosity.
The large air lines are often systems are much slower than that
cumbersome for the operator. of conventional spray equipment. HVLP Gravity Fed Spray
Blending metallic finishes is very Also, non-turbine HVLP spray guns Guns
difficult using the HVLP system do not offer the metallic control of
conventional style guns, making the The gravity fed HVLP
due to the heavy application coats.
spraying of metallic topcoats difficult guns (see Figure 4)
The atomization of the turbine to master. As with all HVLP spray combine the finest
HVLP spray guns may not give equipment, non-turbine models clog qualities of the HVLP and
the quality finish required to easily. For this reason, coating conventional gravity fed
material filtration and proper gun spray guns into one design.
match automotive factory finishes.
cleaning practices are essential. Like its conventional counterpart,
Figure 4: HVLP Gravity Fed Spray Gun
Finally, blending topcoats using the these guns work especially well on
C. High-Volume/Low- HVLP technology has been a high solids and water-based paints,
Pressure (HVLP) (non-turbine) challenge for painters. The thick clears, and primers due to their top siphon feed gun. This makes the
The problems of the HVLP turbine coats applied using the HVLP guns mounting, gravity fed material cup. price of this HVLP technology
in automotive refinishing were do not produce the gradual tapering extremely affordable. These guns
quickly realized by the spray gun effect needed for blending of high This design also shares the produce basically the same soft spray
manufacturers. To help alleviate solid and metallic topcoats. disadvantages of its conventional pattern as all HVLP guns with
counterpart; as the paint level
HVLP Non- some of these downfalls, manufac-
HVLP Spray Guns With Pressure decreases, so does the feed rate.
atomizing pressures as low as 5 psi.
Turbine Guns turers developed more versatile, less

expensive HVLP spray equipment. Assist Cup Therefore, the operator must adjust
The siphon design has a lower
transfer efficiency than other HVLP
Depending on the make of gun, these technique to compensate for the technologies.
One attempt to improve the HVLP
systems have a transfer efficiency change in fluid flow.
technology to better suit the auto
ranging from 55 - 75 percent, and repair industry was the addition of a D. Low-Pressure/Low- Volume
report a savings in material of 20 - pressure cup to the system. These HVLP Siphon Fed Spray Guns (LPLV)
30 percent over conventional spray systems use a paint cup mounted To gain acceptance in the auto Another spray technology
guns. The non-turbine HVLP guns under the gun, similar to a conven-
refinishing industry, some spray gun developed to improve transfer
use only conventional shop air for tional spray gun design. With this
manufacturers are producing siphon efficiency is the Low-Pressure/Low-
their operations. No expensive style, the cup is pressurized, using a
fed HVLP spray equipment. The Volume (LPLV) spray equipment.
10 11
3: Spray Equipment
Like the HVLP equipment, LPLV

guns use conventional shop air and
pressurized cup, used in some LPLV
systems, which is only pressurized 4. Spray Application According to a study done by the
Pacific Northwest Pollution
do not require expensive turbine
units. The LPLV spray guns require
only 7 - 8 cfm of compressed air at
when the gun trigger is pulled.
Some changes in spray technique
may be required to accommodate
Techniques Prevention Research Center,
"Transfer Efficiency and VOC
Emissions of Spray Gun Coating
10 psi (as opposed to the 13 - 30 cfm this delay in material delivery. Technologies in Wood Finishing", the
LPLV Guns required for HVLP equipment).

Unlike HVLP equipment, the first
LPLV spray equipment has gained
only minimal acceptance in the
B oth the quality of the finish and
transfer efficiency greatly depend
on the technicians skill and spraying
VOC emissions released during a
surface coating process are directly
The quality of the
finish and transfer
stage of atomization occurs within automobile refinishing industry. related to the skill of the spray gun
the LPLV spray gun. Air and paint
techniques. Cost and sophistication
operator. The study concluded that efficiency depend on ht
are mixed inside an internal chamber
Prior to purchasing any paint of paint application equipment do not
ensure a quality finish. In order to "the difference in transfer efficiency skill and technique of
gun, consult your paint represen-
of the air cap to further assist in the
tative to determine which type of achieve a quality finish, the painter due to painter skill level with a the technician
paint atomization. The LPLV single gun type were often larger
gun will work best for the must focus on the proper combination
systems boast a transfer efficiency than the differences between gun
application of the product you will of the following variables:
ranging from 55 - 75 percent. types." In other words, proper
use. Your paint and/or spray gun Type of material to be sprayed painting technique is often more
As with all the new spray representative can also help you Viscosity of material important than high transfer
technologies, the LPLV systems have determine the proper fluid tip/air Thinner/reducer speed used efficient spray equipment when it
obstacles that the painter must cap combination and proper gun Type of hardener or reactor used comes to reducing emissions. A Painting technique is
overcome. Among these is a settings. Addition of additives skilled technician will adjust often more important
E. Recommended Practices for Spray Equipment Booth air temperature spraying style with each specific job than transfer efficient
Booth air flow to compensate for the type of coating
Determine the price range you are willing to spend for spray equipment. Paint gun orifice size being sprayed, the atmospheric
spray equipment in
Determine the types of coatings that will be sprayed through the Paint gun air cap style conditions, the size and shape of the reducing emissions
equipment and the atomization properties required for their proper Paint gun adjustments (air, fluid, object being coated and the spray
application. fan size) equipment used. Due to all the
Distance of the spray gun from variables involved, it is impossible to
Choose spray equipment that will achieve the highest transfer efficiency surface specify the one best spray technique
while providing the required atomization properties within your price Operator's spray gun speed for all situations.
range.
Prior to purchasing any paint gun, consult your paint representative to In general, technicians should follow these basic rules.
determine what type of gun will work best for the application of the
product you will be using. A. Always have the correct gun setup for the coating to be sprayed and the size of
the area to be covered. These variables include the size of fluid tip and air cap
Contact your paint representative and/or spray gun representative to used. Fluid tip size is determined by the viscosity of the coating as well as the
determine the fluid tip/air cap combination and gun settings that should flow rate setting of the gun. The viscosity is determined using a Zahn cup
be used with the material being sprayed. measuring system (see figure 5, pg 14).
The flow rate can be determined through the following process:
For pressure fed spray equipment:
1. Turn off the atomizing air.

2. Aim spray gun tip towards a container (preferably a graduated container).
3. Pull the trigger of the gun, spraying the unatomized coating into the container
for 60 seconds.
4. Measure the amount of material expelled from the gun into the container to
determine the flow rate in ounces/minute.
12 13
3: Spray Equipment
Like the HVLP equipment, LPLV

guns use conventional shop air and
pressurized cup, used in some LPLV
systems, which is only pressurized 4. Spray Application According to a study done by the
Pacific Northwest Pollution
do not require expensive turbine
units. The LPLV spray guns require
only 7 - 8 cfm of compressed air at
when the gun trigger is pulled.
Some changes in spray technique
may be required to accommodate
Techniques Prevention Research Center,
"Transfer Efficiency and VOC
Emissions of Spray Gun Coating
10 psi (as opposed to the 13 - 30 cfm this delay in material delivery. Technologies in Wood Finishing", the
LPLV Guns required for HVLP equipment).

Unlike HVLP equipment, the first
LPLV spray equipment has gained
only minimal acceptance in the
B oth the quality of the finish and
transfer efficiency greatly depend
on the technicians skill and spraying
VOC emissions released during a
surface coating process are directly
The quality of the
finish and transfer
stage of atomization occurs within automobile refinishing industry. related to the skill of the spray gun
the LPLV spray gun. Air and paint
techniques. Cost and sophistication
operator. The study concluded that efficiency depend on ht
are mixed inside an internal chamber
Prior to purchasing any paint of paint application equipment do not
ensure a quality finish. In order to "the difference in transfer efficiency skill and technique of
gun, consult your paint represen-
of the air cap to further assist in the
tative to determine which type of achieve a quality finish, the painter due to painter skill level with a the technician
paint atomization. The LPLV single gun type were often larger
gun will work best for the must focus on the proper combination
systems boast a transfer efficiency than the differences between gun
application of the product you will of the following variables:
ranging from 55 - 75 percent. types." In other words, proper
use. Your paint and/or spray gun Type of material to be sprayed painting technique is often more
As with all the new spray representative can also help you Viscosity of material important than high transfer
technologies, the LPLV systems have determine the proper fluid tip/air Thinner/reducer speed used efficient spray equipment when it
obstacles that the painter must cap combination and proper gun Type of hardener or reactor used comes to reducing emissions. A Painting technique is
overcome. Among these is a settings. Addition of additives skilled technician will adjust often more important
E. Recommended Practices for Spray Equipment Booth air temperature spraying style with each specific job than transfer efficient
Booth air flow to compensate for the type of coating
Determine the price range you are willing to spend for spray equipment. Paint gun orifice size being sprayed, the atmospheric
spray equipment in
Determine the types of coatings that will be sprayed through the Paint gun air cap style conditions, the size and shape of the reducing emissions
equipment and the atomization properties required for their proper Paint gun adjustments (air, fluid, object being coated and the spray
application. fan size) equipment used. Due to all the
Distance of the spray gun from variables involved, it is impossible to
Choose spray equipment that will achieve the highest transfer efficiency surface specify the one best spray technique
while providing the required atomization properties within your price Operator's spray gun speed for all situations.
range.
Prior to purchasing any paint gun, consult your paint representative to In general, technicians should follow these basic rules.
determine what type of gun will work best for the application of the
product you will be using. A. Always have the correct gun setup for the coating to be sprayed and the size of
the area to be covered. These variables include the size of fluid tip and air cap
Contact your paint representative and/or spray gun representative to used. Fluid tip size is determined by the viscosity of the coating as well as the
determine the fluid tip/air cap combination and gun settings that should flow rate setting of the gun. The viscosity is determined using a Zahn cup
be used with the material being sprayed. measuring system (see figure 5, pg 14).
The flow rate can be determined through the following process:
For pressure fed spray equipment:
1. Turn off the atomizing air.

2. Aim spray gun tip towards a container (preferably a graduated container).
3. Pull the trigger of the gun, spraying the unatomized coating into the container
for 60 seconds.
4. Measure the amount of material expelled from the gun into the container to
determine the flow rate in ounces/minute.
12 13
4: Spray Application Techniques 4: Spray Application Techniques
F. The spray gun should be held at a distance of 6 - 8" from the substrate, and
For siphon fed spray equipment:
this distance should be maintained with each stroke (Figure 7). In general, the
1. Measure the amount of material in the spray painter should use a 50 percent overlap for each pass, feathering the trigger at
cup the beginning and end of each stroke (Figure 8). This technique may need to be The spray gun
2. Pull the trigger of the gun, spraying the gun altered slightly when applying high-metallic, high-solids basecoats and for some should be held 6-8
at normal operating settings for 60 seconds. three stage systems to avoid striping. The speed of each pass should be a from the substrate
3. Measure the amount of material left in the comfortable pace for the technician while maintaining a full wet coat, free of sags
spray cup to determine the volume of material or runs.
sprayed per minute.
B. Once the proper fluid tip size has been
determined, an air cap can be chosen. The 6 - 8
choice of an air cap depends on fluid tip size
and the desired air consumption of the gun.
Many paint gun manufacturers have fluid
tip/air cap combinations preset to help
determine the proper pairing. Because fluid
tips and air nozzles are precision machined to
very stringent tolerances, it is important that
their orifices remain free from obstructions to
Figure 5: Zahn Cup assure proper atomization and spray pattern
uniformity. Figure 7: Proper Spray Distance and Technique
C. Set the air pressure at the lowest possible setting that will provide the
required degree of atomization. Too low of a setting may result in a heavy
centered spray pattern. Too high of a pressure setting will cause a dry spray
pattern, resulting in a dry rough finish. Never exceed the coating manufacturers
recommended air pressure settings.
Always hold the D. The size of the fan pattern will vary with the size and configuration of the The painter should
gun perpendicular to surface to be coated. For small spot repair operations, a small pattern is usually use a 50% overlap
the substrate preferable. For large panels, a full pattern is generally the most desirable setting.
for each pass
E. When spraying, always hold the gun perpendicular to the surface being
sprayed, using parallel strokes. Never arc the spray gun (Figure 6), with two
notable exceptions:
spraying
extremely large panels
that exceed the length
of the painters reach.
In these cases, the
painter will arc the gun
at the end of the pass to
help blend the overlap
areas, and
performing panel
spotting or blending
Figure 8: 50% Overlap Technique
operations. Figure 6: Improper Spray Technique
14 15
F. The spray gun should be held at a distance of 6 - 8" from the substrate, and
For siphon fed spray equipment:
this distance should be maintained with each stroke (Figure 7). In general, the
1. Measure the amount of material in the spray painter should use a 50 percent overlap for each pass, feathering the trigger at
cup the beginning and end of each stroke (Figure 8). This technique may need to be The spray gun
2. Pull the trigger of the gun, spraying the gun altered slightly when applying high-metallic, high-solids basecoats and for some should be held 6-8
at normal operating settings for 60 seconds. three stage systems to avoid striping. The speed of each pass should be a from the substrate
3. Measure the amount of material left in the comfortable pace for the technician while maintaining a full wet coat, free of sags
spray cup to determine the volume of material or runs.
sprayed per minute.
B. Once the proper fluid tip size has been
determined, an air cap can be chosen. The 6 - 8
choice of an air cap depends on fluid tip size
and the desired air consumption of the gun.
Many paint gun manufacturers have fluid
tip/air cap combinations preset to help
determine the proper pairing. Because fluid
tips and air nozzles are precision machined to
very stringent tolerances, it is important that
their orifices remain free from obstructions to
Figure 5: Zahn Cup assure proper atomization and spray pattern
uniformity. Figure 7: Proper Spray Distance and Technique
C. Set the air pressure at the lowest possible setting that will provide the
required degree of atomization. Too low of a setting may result in a heavy
centered spray pattern. Too high of a pressure setting will cause a dry spray
pattern, resulting in a dry rough finish. Never exceed the coating manufacturers
recommended air pressure settings.
Always hold the D. The size of the fan pattern will vary with the size and configuration of the The painter should
gun perpendicular to surface to be coated. For small spot repair operations, a small pattern is usually use a 50% overlap
the substrate preferable. For large panels, a full pattern is generally the most desirable setting.
for each pass
E. When spraying, always hold the gun perpendicular to the surface being
sprayed, using parallel strokes. Never arc the spray gun (Figure 6), with two
notable exceptions:
spraying
extremely large panels
that exceed the length
of the painters reach.
In these cases, the
painter will arc the gun
at the end of the pass to
help blend the overlap
areas, and
performing panel
spotting or blending
Figure 8: 50% Overlap Technique
operations. Figure 6: Improper Spray Technique
14 15
G. Always paint small and medium size panels without breaking the stroke. With A. Recommended Practices for Spray Application Techniques
larger panels, use a 4 - 5" overlap of the strokes, arcing the gun at the end of each Use the suggested air pressure and tip sizes for the specific product and
pass. When spotting or blending a panel, keep the blend as small as possible equipment being used.
without jeopardizing the appearance of the blend. To help insure proper coverage
of edges while reducing overspray, spray the outer boundaries of the panel first. Always hold gun perpendicular to the surface being sprayed, using
This technique, called banding, allows the painter to maintain adequate coverage parallel strokes. Never arc the gun.
at the edges of the panel without extending the spray stroke well beyond the end
Feather the trigger at the beginning and end of each pass.
of the panel surface (Figure 9).
Use a 50 percent overlap for each pass. This technique may need to
When applying a topcoat, use hiding power labels to determine when the be altered slightly when applying high-metallic, high-solids basecoats and
surface has been adequately covered. Through the use of these labels, the some three stage systems.
technician can be assured of achieving proper coverage without the application of
excess material (Figure 10). When painting small- and medium-sized panels, make each pass the full
length of the panel.
With larger panels, use a comfortable stroke, with a 4 - 5 " overlap of the
strokes.
If blending is necessary, keep the blend area as small as possible
Always paint without jeopardizing the appearance of the blend.
small and medium Spray the border edges of the substrate first (banding). This will assure
size panels without all edges are covered without extending the spray pattern well beyond the
breaking the stroke borders of the object.
Use color hiding power labels to determine the thickness of the applied
paint film. These markers will also indicate when adequate coverage
has been achieved.
Figure 9: Banding
Figure 10: Self-Adhering Power Label

16 17
G. Always paint small and medium size panels without breaking the stroke. With A. Recommended Practices for Spray Application Techniques
larger panels, use a 4 - 5" overlap of the strokes, arcing the gun at the end of each Use the suggested air pressure and tip sizes for the specific product and
pass. When spotting or blending a panel, keep the blend as small as possible equipment being used.
without jeopardizing the appearance of the blend. To help insure proper coverage
of edges while reducing overspray, spray the outer boundaries of the panel first. Always hold gun perpendicular to the surface being sprayed, using
This technique, called banding, allows the painter to maintain adequate coverage parallel strokes. Never arc the gun.
at the edges of the panel without extending the spray stroke well beyond the end
of the panel surface (Figure 9).
Use a 50 percent overlap for each pass. This technique may need to
When applying a topcoat, use hiding power labels to determine when the be altered slightly when applying high-metallic, high-solids basecoats and
surface has been adequately covered. Through the use of these labels, the some three stage systems.
technician can be assured of achieving proper coverage without the application of
excess material (Figure 10). When painting small- and medium-sized panels, make each pass the full
length of the panel.
strokes.
If blending is necessary, keep the blend area as small as possible
Always paint without jeopardizing the appearance of the blend.
small and medium Spray the border edges of the substrate first (banding). This will assure
size panels without all edges are covered without extending the spray pattern well beyond the
breaking the stroke borders of the object.
Use color hiding power labels to determine the thickness of the applied
paint film. These markers will also indicate when adequate coverage
has been achieved.
Figure 9: Banding
Figure 10: Self-Adhering Power Label

16 17
5. Spray Equipment
With the air hose and cup
removed, pull the gun trigger to
Cleaning remove all remaining paint

from the siphon tube.
Rinse the cup with a small amount
of thinner.
T he proper cleaning and
maintenance of spray equipment
has always been an essential part of
Pour clean thinner into the cup
and reattach it to the gun.
achieving a quality finish. This is
especially true with newer high With the air supply reattached,
transfer efficiency spray spray the thinner through the gun
technologies. These new spray guns to remove any paint remaining in
are machined to very close tolerances the interior orifices.
and are highly susceptible to dried Remove the cup and pour thinner
paint or other obstructions that can out of the cup.
affect the performance of the gun.
The EPA has estimated that 20 Wipe off the outside of the gun,
percent of all VOC emissions and inside and outside of the cup
released by automobile refinishers using a rag or paper towel.
occur during cleanup operations Remove the air cap and clean with
(Figure 11). a cleaning brush. A cleaning
brush is also used to clean other
external moving parts and behind
the trigger.
Surface Prep (8%)
Undercoats (17%) Reassemble the
gun and return it
to its storage area.
20% of VOC
Many painters emissions are released
remove the air cap during gun cleaning
from the gun and operations
place it in the cup.
Equipment A small amount of
Topcoats thinner is left in
Cleaning (20%)
the cup so the cap
can soak during
storage.
Figure 11: EPA Estimates of VOC
Using metal objects to clean the
small passageways can result in
A. Manual Cleaning Processes severe damage which greatly reduces
the efficiency of the spray gun. If
Prior to the introduction of paint
needed, use a soft wooden toothpick to
gun cleaning systems, all spray
remove obstructions from the orifices.
equipment was cleaned by hand
using the following basic steps: These manual cleaning techniques,
still commonly used in many small
Remove all remaining paint from shops, release an excessive amount
the cup. of VOCs to the atmosphere. They
19
5. Spray Equipment
With the air hose and cup
removed, pull the gun trigger to
Cleaning remove all remaining paint

from the siphon tube.
of thinner.
T he proper cleaning and
maintenance of spray equipment
has always been an essential part of
Pour clean thinner into the cup
and reattach it to the gun.
achieving a quality finish. This is
especially true with newer high With the air supply reattached,
transfer efficiency spray spray the thinner through the gun
technologies. These new spray guns to remove any paint remaining in
are machined to very close tolerances the interior orifices.
and are highly susceptible to dried Remove the cup and pour thinner
paint or other obstructions that can out of the cup.
affect the performance of the gun.
The EPA has estimated that 20 Wipe off the outside of the gun,
percent of all VOC emissions and inside and outside of the cup
released by automobile refinishers using a rag or paper towel.
occur during cleanup operations Remove the air cap and clean with
(Figure 11). a cleaning brush. A cleaning
brush is also used to clean other
external moving parts and behind
the trigger.
Surface Prep (8%)
Undercoats (17%) Reassemble the
gun and return it
to its storage area.
20% of VOC
Many painters emissions are released
remove the air cap during gun cleaning
from the gun and operations
place it in the cup.
Equipment A small amount of
Topcoats thinner is left in
Cleaning (20%)
the cup so the cap
can soak during
storage.
Figure 11: EPA Estimates of VOC
Using metal objects to clean the
small passageways can result in
A. Manual Cleaning Processes severe damage which greatly reduces
the efficiency of the spray gun. If
Prior to the introduction of paint
needed, use a soft wooden toothpick to
gun cleaning systems, all spray
remove obstructions from the orifices.
equipment was cleaned by hand
using the following basic steps: These manual cleaning techniques,
still commonly used in many small
Remove all remaining paint from shops, release an excessive amount
the cup. of VOCs to the atmosphere. They
19
5: Spray Equipment Cleaning 5: Spray Equipment Cleaning
also expose the operator to solvents placed in the gun washer. The gun's
for an extended amount of time. siphon tube is placed in the siphon
tube holder, and the gun trigger is
B. Pneumatically Powered locked open using a locking plate.
Mechanical Cleaning Systems The cup is simply inverted and
placed over a cleaning jet. The lid of
Within the last few years the the washer is then closed and the
mechanical gun wash system has washer turned on. The operator can
gained popularity in the refinishing leave the cleaning station and
industry. Mechanical gun washers remain away from paint, thinner,
Mechanical cleaning (Figure 12) provide a safe, quick way
to effectively clean paint equipment,
and isocyanate fumes. After 1 - 3
systems reduce the including HVLP and LPLV spray
minutes, the painter can remove the
cleaned spray gun from the washer.
amount of thinner guns. The initial cleaning steps used The washer lid must then be closed
used during the with mechanical gun cleaners are to prevent the thinner from
cleaning process by the same as cleaning a gun using evaporating and to keep the VOC
manual techniques.
more than one half emissions to a minimum.
Remove all the remaining paint With proper use and maintenance,
from the cup. these units reduce the amount of Figure 13: A Two Gun Capacity Gun Wash System
With the air hose removed, pull thinner used during the cleaning
the trigger of the gun to remove process by more than one-half (some
all remaining paint from the manufacturers boast a 75 - 90 C. Recommended Practices for Spray Equipment Cleaning
siphon tube. percent reduction). Mechanical Use an air powered mechanical gun cleaning system.
systems also reduce the labor time Use low VOC cleaning solvents.
needed for equipment cleaning by
of thinner. If cleaning guns manually, spray into an enclosed backdrop to capture
over 60 percent.
Following these initial cleaning atomized solvents.
Although VOC emissions from gun
steps, the disassembled gun is then Never use metal objects to remove dried paint or other obstructions from
washing systems (Figure 13) have
the small orifices of spray equipment. If necessary, use a soft wooden
yet to be accurately measured, the
toothpick.
reduction should be substantial. In
addition, some solvent manufac-
turers offer a low VOC gun wash
solvent to further reduce emissions
from cleaning operations.
Figure 12: Enclosed Air Powered Mechanical Cleaning System

20 21
5: Spray Equipment Cleaning 5: Spray Equipment Cleaning
also expose the operator to solvents placed in the gun washer. The gun's
for an extended amount of time. siphon tube is placed in the siphon
tube holder, and the gun trigger is
B. Pneumatically Powered locked open using a locking plate.
Mechanical Cleaning Systems The cup is simply inverted and
placed over a cleaning jet. The lid of
Within the last few years the the washer is then closed and the
mechanical gun wash system has washer turned on. The operator can
gained popularity in the refinishing leave the cleaning station and
industry. Mechanical gun washers remain away from paint, thinner,
Mechanical cleaning (Figure 12) provide a safe, quick way
to effectively clean paint equipment,
and isocyanate fumes. After 1 - 3
systems reduce the including HVLP and LPLV spray
minutes, the painter can remove the
cleaned spray gun from the washer.
amount of thinner guns. The initial cleaning steps used The washer lid must then be closed
used during the with mechanical gun cleaners are to prevent the thinner from
cleaning process by the same as cleaning a gun using evaporating and to keep the VOC
manual techniques.
more than one half emissions to a minimum.
Remove all the remaining paint With proper use and maintenance,
from the cup. these units reduce the amount of Figure 13: A Two Gun Capacity Gun Wash System
With the air hose removed, pull thinner used during the cleaning
the trigger of the gun to remove process by more than one-half (some
all remaining paint from the manufacturers boast a 75 - 90 C. Recommended Practices for Spray Equipment Cleaning
siphon tube. percent reduction). Mechanical Use an air powered mechanical gun cleaning system.
systems also reduce the labor time Use low VOC cleaning solvents.
needed for equipment cleaning by
of thinner. If cleaning guns manually, spray into an enclosed backdrop to capture
over 60 percent.
Following these initial cleaning atomized solvents.
Although VOC emissions from gun
steps, the disassembled gun is then Never use metal objects to remove dried paint or other obstructions from
washing systems (Figure 13) have
the small orifices of spray equipment. If necessary, use a soft wooden
yet to be accurately measured, the
toothpick.
reduction should be substantial. In
addition, some solvent manufac-
turers offer a low VOC gun wash
solvent to further reduce emissions
from cleaning operations.
Figure 12: Enclosed Air Powered Mechanical Cleaning System

20 21
6. Determining Product respectively, then the VOC content
should be calculated as follows.
VOC Content Paint VOC content - 4.50 lbs/gal x 50% = 2.25

Hardener VOC content - 6.44 lbs/gal x 25% = 1.61
Reducer VOC content - 7.55 lbs/gal x 25% = 1.89
T he VOC content of paints or

related products may be found on
the Material Safety Data Sheet
100% = 5.75 lbs/gal
(MSDS) provided by the This sprayable product has a VOC

manufacturer. The MSDS lists the content of 5.75 lbs/gal, not 4.50
VOC content of the product as lbs/gal as listed on its MSDS.
shipped in pounds per gallon, minus
water and non-VOC solvents When comparing product VOC
(Figure 14). content, the amount of the product
needed should also be considered. If
The listed VOC content gives the a product has a low VOC content but MSDS sheets list
user a means of comparing different requires 3 - 4 applications, it may the VOC content as
products. Use caution when
comparing these values because the
actually release a greater volume of packaged
VOCs during the operation than a
listed VOC content is of the product high VOC product that will perform
as packaged, not necessarily its equally well using two light coats.
sprayable form. Most products
require the addition of reducers,
thinners,
hardeners or
reactors
prior to
application.
These
additives
contain up to
100 percent
VOCs by
volume and
will change
the VOC
content of
the coating.
For example,
if a topcoat is
to be mixed
with a
hardener and
reducer at a Figure 14: Determining VOC Content from the Material Safety Data Sheet
ratio of 2:1:1
23


100% = 5.75 lbs/gal

thinners,
hardeners or
reactors
prior to
application.
These
additives
contain up to
100 percent
VOCs by
volume and
will change
the VOC
content of
the coating.
For example,
if a topcoat is
to be mixed
with a
hardener and
ratio of 2:1:1
23


100% = 5.75 lbs/gal

thinners,
hardeners or
reactors
prior to
application.
These
additives
contain up to
100 percent
VOCs by
volume and
will change
the VOC
content of
the coating.
For example,
if a topcoat is
to be mixed
with a
hardener and
ratio of 2:1:1
23
7. Surface Prep Surface Prep (8%)
T o achieve maximum adhesion

between the surface to be
refinished (the substrate) and the
Under Coats (17%)
undercoat, the surface must first be

cleansed of all contamination.
Cleaners are used to remove dirt,
grease, wax, silicon, mold release
agents (used in plastic and rubber Equipment
production) and any other contam- Cleaning (20%) Topcoats (55%)
inants that could compromise the
undercoat's adhesion to the substrate.
Many of these cleaners contain Figure 15: EPA Estimates of VOC Emissions
toluene, which is listed as both a
because they eliminated the need for
VOC and a HAP. The EPA has
the purchase of a second, less
estimated that 8 percent of all VOCs
versatile product. But reducers have
released during the refinishing
process result from surface prep
proved to be unsatisfactory pre-paint To limit the amount
operations (Figure 15).
cleaners for several reasons. Reducers
do not remove silicone from surfaces
of solvents used, a
as efficiently as commercially mild detergent should
A. Soap and Water
produced cleaners and they have a be used to remove road
Prior to working on an automobile, tendency to soften existing paints grime and dirt.
all dirt should be removed from the and primers, causing them to swell
surface. To limit the amount of and blister. In addition, synthetic
solvent used for surface prep, use a reducers are 100 percent VOCs.
mild detergent or car wash soap to
clean off road grime and dirt. Then C. Solvent-Based Cleaners
rinse the surface with water to
remove any remaining soap. This is After all the road dirt and grime
one of the simplest and least have been removed, a solvent-based
expensive means of reducing both cleaner can be used to effectively
VOC emissions and material costs. remove all grease, wax and silicone
This process also flushes the dirt and from the surface. Solvent-based
dust from body seams, reducing the cleaners typically have a VOC
risk of dirt blowback during content of 6.0 lbs/gal and may
refinishing. Biodegradable contain up to 100 percent solvent.
detergents do not generate any VOC
Most prep cleaners come in two
emissions.
formulas and strengths. One type is
used for the initial surface cleaning
B. Synthetic Reducers prior to sanding. They are designed
In the past, some painters have to remove heavy silicone, wax and
used reducers as a pre-paint cleaner. grease contamination. Many of these
Reducers were popular mainly cleaners contain harsh solvents such
25
7: Surface Prep
as xylene and mineral spirits. These

highly concentrated solvents, if used
as a final wash, can cause poor
generally come in two concen-
trations. One for the general
cleaning of surfaces, and another for
8. Undercoats representative with any questions
prior to application. It is also
advisable to use one brand of product
adhesion and/or "solvent popping" of
the topcoat.
the final preparation of surfaces
prior to painting. U ndercoats are defined as all
material applied over the
substrate prior to the application of
throughout the surface coating
operation while following all factory
The second formula is designed for Waterborne cleaners remove wax, recommendations. This will help
the removal of light contamination grease and silicone like their solvent-
a topcoat. These primers fall into
four separate categories:
take the guess-work out of Use one brand of
and is used primarily for final based counterparts, but with less determining which products are
compatible. It will also cut down
product, following
cleaning prior to painting. These
final cleaners will not soften the
than one-sixth the VOC content.
However, waterborne cleaners do
Prep Coats
Primer-surfacers product inventory and product waste all factory
painted or primed surface like some have three distinct disadvantages. Primer-sealers within the shop. recommendations
Waterborne cleaners of the harsher solvents, nor do they First, they may not remove heavy Sealers
have been developed leave harmful residues on the silicon and grease contamination as
The EPA has estimated that
The prep coat has two major
to replace high VOC substrate. well as traditional solvent-based
undercoating processes account for
functions:
cleaners cleaners. Second, they do not

17 percent of all VOCs released during 1. Provide a corrosion resistant
D. Waterborne Cleaners evaporate as quickly as solvent-
refinishing operations (Figure 16). coating.
based cleaners, thus increasing the
Recently, waterborne cleaners 2. Provide maximum adhesion
time needed for surface prep.
have been developed to replace the between the substrate
Finally, many of these cleaners are
high VOC solvent-based cleaners. and the next coating
not recommended for specific Surface Prep (8%)
Like their solvent-based Undercoats (17%) to be applied.
substrates, such as water-based or
counterparts, waterborne cleaners
acrylic lacquer finishes.
Metal Conditioners/
E. Recommended Practices for Surface Prep Conversion Coatings
To reduce the VOCs emitted during surface prep operations, the following Metal conditioners
practices should be implemented: are acidic solutions
that clean the surface
Always wash dirt and grime from the vehicle using water or a soap and of the substrate,
water mixture. Equipment
removing contam-
Cleaning (20%) Topcoats (55%)
Use waterborne cleaners when possible. inants that would
otherwise compromise
If, due to heavy contamination, waterborne cleaners prove unsatisfactory, the bond between the
use solvent-based cleaners for the initial cleaning of the surface. For Figure 16: EPA Estimates of VOC substrate and the undercoat. The
secondary cleaning operations, use the waterborne products. metal conditioner is generally wiped
If waterborne cleaners prove unsatisfactory due to substrate make-up, on with a rag, and after 2-4 minutes
A. Prep Coats
use solvent-based cleaners sparingly. neutralized with water. Metal
The prep coat is applied directly conditioners work well only if the
Keep solvent-laden dirty rags in a closed container.
over bare metal or metal alloy, surface has been wiped completely
Keep solvent containers closed when not in use. galvanized or plated metal, plastic or dry after the neutralization process
If possible, avoid operations that would necessitate multiple prepaint rubber substrates. The type of prep has been completed. If moisture
cleaning operations (e.g., post surface prep repair operations which could coat used will vary depending on the remains on the metal surface and is
contaminate the substrate with grease or oil). substrate and the type of coating to allowed to air dry, the integrity of
be applied over the prep coat. It is the bond between the substrate and
important to read and follow all the primer-surfacer will be
directions for these products very compromised. The remaining
carefully and contact your factory moisture may also cause oxidation to
form on the bare metal surface.
26 27
7: Surface Prep
as xylene and mineral spirits. These

highly concentrated solvents, if used
as a final wash, can cause poor
generally come in two concen-
trations. One for the general
cleaning of surfaces, and another for
8. Undercoats representative with any questions
prior to application. It is also
advisable to use one brand of product
adhesion and/or "solvent popping" of
the topcoat.
the final preparation of surfaces
prior to painting. U ndercoats are defined as all
material applied over the
substrate prior to the application of
throughout the surface coating
operation while following all factory
The second formula is designed for Waterborne cleaners remove wax, recommendations. This will help
the removal of light contamination grease and silicone like their solvent-
a topcoat. These primers fall into
four separate categories:
take the guess-work out of Use one brand of
and is used primarily for final based counterparts, but with less determining which products are
compatible. It will also cut down
product, following
cleaning prior to painting. These
final cleaners will not soften the
than one-sixth the VOC content.
However, waterborne cleaners do
Prep Coats
Primer-surfacers product inventory and product waste all factory
painted or primed surface like some have three distinct disadvantages. Primer-sealers within the shop. recommendations
Waterborne cleaners of the harsher solvents, nor do they First, they may not remove heavy Sealers
have been developed leave harmful residues on the silicon and grease contamination as
The EPA has estimated that
The prep coat has two major
to replace high VOC substrate. well as traditional solvent-based
undercoating processes account for
functions:
cleaners cleaners. Second, they do not

17 percent of all VOCs released during 1. Provide a corrosion resistant
D. Waterborne Cleaners evaporate as quickly as solvent-
refinishing operations (Figure 16). coating.
based cleaners, thus increasing the
Recently, waterborne cleaners 2. Provide maximum adhesion
time needed for surface prep.
have been developed to replace the between the substrate
Finally, many of these cleaners are
high VOC solvent-based cleaners. and the next coating
not recommended for specific Surface Prep (8%)
Like their solvent-based Undercoats (17%) to be applied.
substrates, such as water-based or
counterparts, waterborne cleaners
acrylic lacquer finishes.
Metal Conditioners/
E. Recommended Practices for Surface Prep Conversion Coatings
To reduce the VOCs emitted during surface prep operations, the following Metal conditioners
practices should be implemented: are acidic solutions
that clean the surface
Always wash dirt and grime from the vehicle using water or a soap and of the substrate,
water mixture. Equipment
removing contam-
Cleaning (20%) Topcoats (55%)
Use waterborne cleaners when possible. inants that would
otherwise compromise
If, due to heavy contamination, waterborne cleaners prove unsatisfactory, the bond between the
use solvent-based cleaners for the initial cleaning of the surface. For Figure 16: EPA Estimates of VOC substrate and the undercoat. The
secondary cleaning operations, use the waterborne products. metal conditioner is generally wiped
If waterborne cleaners prove unsatisfactory due to substrate make-up, on with a rag, and after 2-4 minutes
A. Prep Coats
use solvent-based cleaners sparingly. neutralized with water. Metal
The prep coat is applied directly conditioners work well only if the
Keep solvent-laden dirty rags in a closed container.
over bare metal or metal alloy, surface has been wiped completely
Keep solvent containers closed when not in use. galvanized or plated metal, plastic or dry after the neutralization process
If possible, avoid operations that would necessitate multiple prepaint rubber substrates. The type of prep has been completed. If moisture
cleaning operations (e.g., post surface prep repair operations which could coat used will vary depending on the remains on the metal surface and is
contaminate the substrate with grease or oil). substrate and the type of coating to allowed to air dry, the integrity of
be applied over the prep coat. It is the bond between the substrate and
important to read and follow all the primer-surfacer will be
directions for these products very compromised. The remaining
carefully and contact your factory moisture may also cause oxidation to
form on the bare metal surface.
26 27
8: Undercoats 8: Undercoats
Following the metal conditioner, a water and dried prior to surface simple, one step, process. A light adhesion to bare metal substrates.
conversion coating is applied to the coating. Most of these conditioners coat of zinc phosphate is sprayed on These primers also have some filling
substrate. This conversion coating, are low in VOCs, with average the metal surface and allowed to dry properties to hide minor surface
usually phosphoric acid, etches the contents of approximately 1.0 lb/gal. for 30 to 60 minutes. The zinc imperfections. The primed surface
metal to improve bonding with the Some of the newer water based phosphate etches the substrate and may be sanded and recoated usually
primer-surfacer. The conversion wash-primers do not contain VOCs. deposits a phosphate coating on the after 45 - 60 minutes.
coating also leaves a phosphate surface to provide protection from
Conversion coating coating on the surface of the
Application of these products
moisture. The result is a non-
The VOC content of self etching
primers ranges from 5.0 - 6.5 lbs/gal
requires caution. Some are designed
leaves a phosphate substrate, forming a more corrosion-
for use on steel surfaces only, and
reactive roughened surface that is
as packaged. With the addition of
coating on the resistant surface.
should not be used on aluminum
perfect for the application of a
the activator and reducer, the total
substrate Although this system contains low substrates. Application to any
primer coat and needs no sanding
prior to surface coating. These
VOC content of the sprayable
amounts of VOCs (approximately 1.0 surface other then a bare metal product may be as high as 6.0 - 7.0
primers can be used on both steel
lbs/gal) it has some distinct surface must also be avoided, as lbs/gal. In addition to the high VOC
and aluminum surfaces. Zinc
disadvantages. First, the primer- lifting of the surface coat may result. content, these coatings also have the
phosphate does not have a pot-life,
surfacer must be sprayed on shortly disadvantage of a pot-life ranging
Some wash-primers are designed but must be stirred before each use
after the metal conditioning process from several hours to several days
for use on most metal surfaces as due to excessive settling.
has been completed to avoid depending on the product.
well as plastic and rubber
corrosion of the metal. Second, the substrates. These wash-primers Zinc phosphate has a VOC concen-
employee performing the metal form a good bond between the tration of 4.5 - 5.0 lbs/gal as Epoxy Primers
conditioning operation is exposed to topcoat and the hard-to-adhere-to, packaged. The VOC content of the
Epoxy primers are one of the most
an acidic solution which may cause plastic and rubber surfaces. sprayable solution, reduced 1:1 with versatile automotive paint products
skin irritation. Finally, the metal enamel reducer, is as high as 6.0 on the market today. These two
conditioner-conversion coating Since wash-primers react with lbs/gal. component primers can be used as a
Epoxy primers are
system is time consuming, especially
metal surfaces, the use of a paint
gun for application should be In addition to the high VOC level, primer, primer-surfacer, primer- one of the most
when large areas require treatment.
avoided. Wash-primers can react zinc phosphate has four other sealer, and adhesion promoter. versatile products on
Wash-Primers/Vinyl Wash- with the metal spray gun, resulting distinct disadvantages. Epoxy primers provide excellent the market
in an adhesive coating formed inside corrosion resistance and adhesion to
Primers 1. It is not recommended for use as a
Some water based the cup and on the interior primer under many waterborne
bare metal and coated surfaces. The
epoxy resins in the primer produce a
wash-primers Wash-primers were developed to
eliminate one of the steps associated
components of the gun. For this primer-surfacers.
strong chip resistant surface over the
reason, the solution should be
contain no VOCs with metal conditioner and applied by hand or with a non- 2. Zinc phosphate does not adhere as substrate.
conversion coating systems. Wash- metallic spray bottle. Check with well as the wash-primers or self-
Solvent-based self-etching epoxy
primers contain either phosphoric your paint supplier for specific etching primers.
primers have a VOC content of
acid or nickel dihydrogen phosphate, recommendations. 3. The primer has no filling approximately 3.5 - 4.0 lbs/gal. With
which forms an adherent phosphate capabilities. the addition of the activator and
coating when applied to steel and Zinc Phosphate Primers
4. The 30 - 60 minute curing time of reducer, the sprayable primers have
aluminum. The acid also removes
Many automobile manufacturers the zinc phosphate may be VOC contents of approximately 5.0
rust, welding scale, and oil from the
use zinc phosphate coatings as a unsatisfactory for production lbs/gal.
bare metal while etching the surface
primer during surface coating surface coating operations. These products also have a pot-life,
to insure the good adhesion of the
operations. In the factory, the
primer-surfacer. some as little as 6-8 hours, which
application of the zinc phosphate Self-Etching Primers may increase the amount of waste
Wash-primers are usually sprayed coating is a multi-step, time
Self-etching primers are usually material generated. The curing time
on the metal surface using a hand consuming process. But zinc
two component primers that provide for these primers ranges from 1 to 2
held plastic sprayer. Many wash phosphate systems used as a primer
good corrosion resistance and good hours for the solvent-based, to as
primers must be neutralized with in the refinishing industry are a
much as 10 hours for the waterborne
28 29
Following the metal conditioner, a water and dried prior to surface simple, one step, process. A light adhesion to bare metal substrates.
conversion coating is applied to the coating. Most of these conditioners coat of zinc phosphate is sprayed on These primers also have some filling
substrate. This conversion coating, are low in VOCs, with average the metal surface and allowed to dry properties to hide minor surface
usually phosphoric acid, etches the contents of approximately 1.0 lb/gal. for 30 to 60 minutes. The zinc imperfections. The primed surface
metal to improve bonding with the Some of the newer water based phosphate etches the substrate and may be sanded and recoated usually
primer-surfacer. The conversion wash-primers do not contain VOCs. deposits a phosphate coating on the after 45 - 60 minutes.
coating also leaves a phosphate surface to provide protection from
Conversion coating coating on the surface of the
Application of these products
moisture. The result is a non-
The VOC content of self etching
primers ranges from 5.0 - 6.5 lbs/gal
requires caution. Some are designed
leaves a phosphate substrate, forming a more corrosion-
for use on steel surfaces only, and
reactive roughened surface that is
as packaged. With the addition of
coating on the resistant surface.
should not be used on aluminum
perfect for the application of a
the activator and reducer, the total
substrate Although this system contains low substrates. Application to any
primer coat and needs no sanding
prior to surface coating. These
VOC content of the sprayable
amounts of VOCs (approximately 1.0 surface other then a bare metal product may be as high as 6.0 - 7.0
primers can be used on both steel
lbs/gal) it has some distinct surface must also be avoided, as lbs/gal. In addition to the high VOC
and aluminum surfaces. Zinc
disadvantages. First, the primer- lifting of the surface coat may result. content, these coatings also have the
phosphate does not have a pot-life,
surfacer must be sprayed on shortly disadvantage of a pot-life ranging
Some wash-primers are designed but must be stirred before each use
after the metal conditioning process from several hours to several days
for use on most metal surfaces as due to excessive settling.
has been completed to avoid depending on the product.
well as plastic and rubber
corrosion of the metal. Second, the substrates. These wash-primers Zinc phosphate has a VOC concen-
employee performing the metal form a good bond between the tration of 4.5 - 5.0 lbs/gal as Epoxy Primers
conditioning operation is exposed to topcoat and the hard-to-adhere-to, packaged. The VOC content of the
Epoxy primers are one of the most
an acidic solution which may cause plastic and rubber surfaces. sprayable solution, reduced 1:1 with versatile automotive paint products
skin irritation. Finally, the metal enamel reducer, is as high as 6.0 on the market today. These two
conditioner-conversion coating Since wash-primers react with lbs/gal. component primers can be used as a
Epoxy primers are
system is time consuming, especially
metal surfaces, the use of a paint
gun for application should be In addition to the high VOC level, primer, primer-surfacer, primer- one of the most
when large areas require treatment.
avoided. Wash-primers can react zinc phosphate has four other sealer, and adhesion promoter. versatile products on
Wash-Primers/Vinyl Wash- with the metal spray gun, resulting distinct disadvantages. Epoxy primers provide excellent the market
in an adhesive coating formed inside corrosion resistance and adhesion to
Primers 1. It is not recommended for use as a
Some water based the cup and on the interior primer under many waterborne
bare metal and coated surfaces. The
epoxy resins in the primer produce a
wash-primers Wash-primers were developed to
eliminate one of the steps associated
components of the gun. For this primer-surfacers.
strong chip resistant surface over the
reason, the solution should be
contain no VOCs with metal conditioner and applied by hand or with a non- 2. Zinc phosphate does not adhere as substrate.
conversion coating systems. Wash- metallic spray bottle. Check with well as the wash-primers or self-
Solvent-based self-etching epoxy
primers contain either phosphoric your paint supplier for specific etching primers.
primers have a VOC content of
acid or nickel dihydrogen phosphate, recommendations. 3. The primer has no filling approximately 3.5 - 4.0 lbs/gal. With
which forms an adherent phosphate capabilities. the addition of the activator and
coating when applied to steel and Zinc Phosphate Primers
4. The 30 - 60 minute curing time of reducer, the sprayable primers have
aluminum. The acid also removes
Many automobile manufacturers the zinc phosphate may be VOC contents of approximately 5.0
rust, welding scale, and oil from the
use zinc phosphate coatings as a unsatisfactory for production lbs/gal.
bare metal while etching the surface
primer during surface coating surface coating operations. These products also have a pot-life,
to insure the good adhesion of the
operations. In the factory, the
primer-surfacer. some as little as 6-8 hours, which
application of the zinc phosphate Self-Etching Primers may increase the amount of waste
Wash-primers are usually sprayed coating is a multi-step, time
Self-etching primers are usually material generated. The curing time
on the metal surface using a hand consuming process. But zinc
two component primers that provide for these primers ranges from 1 to 2
held plastic sprayer. Many wash phosphate systems used as a primer
good corrosion resistance and good hours for the solvent-based, to as
primers must be neutralized with in the refinishing industry are a
much as 10 hours for the waterborne
28 29
epoxy primers. It should also be B. Primer-Surfacers When applying primer-surfacers, properties as well as excellent
noted that some of these primers as with all coatings, it is important corrosion resistant qualities. They
The best way to limit VOC
contain lead and chrome, and their to use a gun specially designed for produce a flexible, tough, chip-
emissions during the primer-surfacer
activators may contain isocyanates. stage of the refinishing process is to use with that type of product. Using resistant base that is excellent for
minimize the number of coats a properly operating primer gun the application of a topcoat. Because
Adhesion Promoters
Minimizing the applied. By ensuring that all major with the correct fluid tip/air cap
combination will help reduce
of their enamel base, these primer-
surfacers are less likely than their
body imperfections are removed prior
number of coats Adhesion promoters do not provide
to priming operations, the technician overspray and reduce the waste of lacquer-based counterparts to A properly operating
the corrosion protection supplied by
applied limits the other prep coats and should not be not only reduces the amount of time and material due to a dry or adversely affect sensitive substrates. primer gun with
amount of VOCs used over bare metal substrates.
expensive material used during the uneven coating.
Alkyd enamel primer-surfacers correct fluid tip/air
repair process, but also reduces the
emitted during the However, these products do provide
amount of VOCs released. Primer- contain 4.0 - 4.5 lbs/gal VOCs as cap combination will
Acrylic Lacquer Primer-Surfacer
primer-surfacer improved adhesion to plastic and surfacers should only be used to packaged. When thinned to a help reduce overspray
stage rubber components, as well as
painted surfaces.
remove small imperfections such as Acrylic lacquer primer-surfacers sprayable concentration, the amount
sanding scratches; they are not have been very popular in auto body of VOCs increases to 4.5 - 5.0 lbs
The application of adhesion meant to fill dents. shops over the years. These primer- gal. The one distinct drawback of
promoters has become an important Primer-surfacers are sprayed over surfacers provide an easy sanding alkyd enamel primer-surfacers is
step in the refinishing process with primers and have the following surface that drys quickly (usually their slow curing time. These
the growing popularity of the harder, functions: within 30 minutes) and has good primer-surfacers must dry for at
more durable high tech surface filling capabilities. Acrylic lacquer least four hours before sanding
1. Provide adhesion between the
coatings. When sprayed over OEM primer-surfacers also provide good operations can be performed. For
primer and the material to be
urethane, water-based, or high solids corrosion resistance and excellent this reason, alkyd enamel primer-
applied over the primer-surfacer.
paints and clears, adhesion This includes the primer-sealers, holdout characteristics. Lacquer surfacers are not typically used for
promoters provide improved sealers, and topcoats. based primer-surfacers are good for spot repair operations, but rather
adhesion between the substrate and spot repair and small panel jobs. large panel surfaces and complete
2. Provide corrosion protection to the However, using lacquer-based paint jobs.
the topcoat. Adhesion promoters metallic substrate.
Primer-surfacers come ready to spray with a VOC primers over deteriorating or
3. Act as a filling material to cover Self-Etching Primers (as a
should be used to fill content of 6.5 - 7.0 lbs/gal. They
minor surface flaws.
sensitive surfaces may result in
lifting or accelerated deterioration of Primer-Surfacer)
small imperfections generally require a curing time of
approximately 15 - 30 minutes prior 4. Provide a coating that can be ` the old painted substrate. These
only to topcoating. easily sanded to a smooth surface. primers are not generally
Self-etching primers are usually
two-component primers that provide
recommended for large jobs due to
good corrosion resistance with fair
Recommended Practices for Prep If a primer-sealer or sealer will not their poor durability and lack of
filling qualities. The primed surface
Coats be used over the primer-surfacer, or compatibility with the majority of
may be sanded and recoated after 45
if the sealer to be used is today's topcoat systems.
Use versatile products such as - 60 minutes of drying time.
epoxy primers or self-etching transparent, the color of the primer-
Acrylic lacquer primers usually
primers. These products may surfacer must be considered. To The VOC content of self etching
have a VOC content ranging from
alleviate the need for additional reduce VOC emissions and the primers ranges from 5.0 - 6.5 lbs/gal
4.5 - 5.0 lbs/gal. When thinned
surface coating operations such amount of paint required, choose a as packaged. With the addition of
(usually 100 - 125 percent) and
as primer-surfacing or primer primer which is a color that can the activator and reducer, the total
ready to spray, VOC content is
sealing. easily be covered by the topcoat. VOC content of the sprayable
approximately 5.5 - 6.0 lbs/gal.
Some primers on the market today product may be as high as 6.0 - 7.0
If a self-etching primer or epoxy
primer is not desirable, use a are tintable, allowing for easy lbs/gal. In addition to high VOC
Alkyd Synthetic Enamel Primer-
wash-primer, or metal conditioner, coverage of the surface-primer by the content, this product also has the
Surfacer
conversion coating system. topcoat. Many primer-surfacers still disadvantage of a pot-life ranging
contain lead and chromium. Most Alkyd enamel primer-surfacers from several hours to several days
Avoid high VOC content zinc two component primer-surfacers have good filling and holdout depending on the product.
phosphate primers.
contain isocyanates.
30 31
epoxy primers. It should also be B. Primer-Surfacers When applying primer-surfacers, properties as well as excellent
noted that some of these primers as with all coatings, it is important corrosion resistant qualities. They
The best way to limit VOC
contain lead and chrome, and their to use a gun specially designed for produce a flexible, tough, chip-
emissions during the primer-surfacer
activators may contain isocyanates. stage of the refinishing process is to use with that type of product. Using resistant base that is excellent for
minimize the number of coats a properly operating primer gun the application of a topcoat. Because
Adhesion Promoters
Minimizing the applied. By ensuring that all major with the correct fluid tip/air cap
combination will help reduce
of their enamel base, these primer-
surfacers are less likely than their
body imperfections are removed prior
number of coats Adhesion promoters do not provide
to priming operations, the technician overspray and reduce the waste of lacquer-based counterparts to A properly operating
the corrosion protection supplied by
applied limits the other prep coats and should not be not only reduces the amount of time and material due to a dry or adversely affect sensitive substrates. primer gun with
amount of VOCs used over bare metal substrates.
expensive material used during the uneven coating.
Alkyd enamel primer-surfacers correct fluid tip/air
repair process, but also reduces the
emitted during the However, these products do provide
amount of VOCs released. Primer- contain 4.0 - 4.5 lbs/gal VOCs as cap combination will
Acrylic Lacquer Primer-Surfacer
primer-surfacer improved adhesion to plastic and surfacers should only be used to packaged. When thinned to a help reduce overspray
stage rubber components, as well as
painted surfaces.
remove small imperfections such as Acrylic lacquer primer-surfacers sprayable concentration, the amount
sanding scratches; they are not have been very popular in auto body of VOCs increases to 4.5 - 5.0 lbs
The application of adhesion meant to fill dents. shops over the years. These primer- gal. The one distinct drawback of
promoters has become an important Primer-surfacers are sprayed over surfacers provide an easy sanding alkyd enamel primer-surfacers is
step in the refinishing process with primers and have the following surface that drys quickly (usually their slow curing time. These
the growing popularity of the harder, functions: within 30 minutes) and has good primer-surfacers must dry for at
more durable high tech surface filling capabilities. Acrylic lacquer least four hours before sanding
1. Provide adhesion between the
coatings. When sprayed over OEM primer-surfacers also provide good operations can be performed. For
primer and the material to be
urethane, water-based, or high solids corrosion resistance and excellent this reason, alkyd enamel primer-
applied over the primer-surfacer.
paints and clears, adhesion This includes the primer-sealers, holdout characteristics. Lacquer surfacers are not typically used for
promoters provide improved sealers, and topcoats. based primer-surfacers are good for spot repair operations, but rather
adhesion between the substrate and spot repair and small panel jobs. large panel surfaces and complete
2. Provide corrosion protection to the However, using lacquer-based paint jobs.
the topcoat. Adhesion promoters metallic substrate.
Primer-surfacers come ready to spray with a VOC primers over deteriorating or
3. Act as a filling material to cover Self-Etching Primers (as a
should be used to fill content of 6.5 - 7.0 lbs/gal. They
minor surface flaws.
sensitive surfaces may result in
lifting or accelerated deterioration of Primer-Surfacer)
small imperfections generally require a curing time of
approximately 15 - 30 minutes prior 4. Provide a coating that can be ` the old painted substrate. These
only to topcoating. easily sanded to a smooth surface. primers are not generally
Self-etching primers are usually
two-component primers that provide
recommended for large jobs due to
good corrosion resistance with fair
Recommended Practices for Prep If a primer-sealer or sealer will not their poor durability and lack of
filling qualities. The primed surface
Coats be used over the primer-surfacer, or compatibility with the majority of
may be sanded and recoated after 45
if the sealer to be used is today's topcoat systems.
Use versatile products such as - 60 minutes of drying time.
epoxy primers or self-etching transparent, the color of the primer-
Acrylic lacquer primers usually
primers. These products may surfacer must be considered. To The VOC content of self etching
have a VOC content ranging from
alleviate the need for additional reduce VOC emissions and the primers ranges from 5.0 - 6.5 lbs/gal
4.5 - 5.0 lbs/gal. When thinned
surface coating operations such amount of paint required, choose a as packaged. With the addition of
(usually 100 - 125 percent) and
as primer-surfacing or primer primer which is a color that can the activator and reducer, the total
ready to spray, VOC content is
sealing. easily be covered by the topcoat. VOC content of the sprayable
approximately 5.5 - 6.0 lbs/gal.
Some primers on the market today product may be as high as 6.0 - 7.0
If a self-etching primer or epoxy
primer is not desirable, use a are tintable, allowing for easy lbs/gal. In addition to high VOC
Alkyd Synthetic Enamel Primer-
wash-primer, or metal conditioner, coverage of the surface-primer by the content, this product also has the
Surfacer
conversion coating system. topcoat. Many primer-surfacers still disadvantage of a pot-life ranging
contain lead and chromium. Most Alkyd enamel primer-surfacers from several hours to several days
Avoid high VOC content zinc two component primer-surfacers have good filling and holdout depending on the product.
phosphate primers.
contain isocyanates.
30 31
One-Component Waterborne the addition of the activator and Recommended Practices for shade of the finish, especially when
Primer-Surfacer reducer, the sprayable primer- Primer-Surfacers using topcoats containing
surfacer formula has a VOC content transparent pigments. The primer-
When waterborne primers were
of up to 4.5 lbs/gal. Waterborne
Use low VOC waterborne primer-
sealer should be as close to the color
The choice of sealer
surfacer products.
introduced to the collision repair
epoxy primers, which are also of the factory sealer as possible. color affects not only
market in the mid-to-late 1980's,
they were met with controversy and
available, have a VOC content of less
If the curing time of waterborne
products is unsatisfactory,
the coverage of the
resistance. Waterborne primers have
then 2.1 lbs/gal for the sprayable
consider the use of versatile
Lacquer Primer-Sealers topcoats but may
been reported to cause rusting of
product. urethane or epoxy primers. Lacquer primer-sealers produce also affect the final
untreated metallic substrates and
Polyester Primer-Surfacer To reduce VOC emissions, limit fair filling qualities with good color shade of the
non-coated ferrous spray equipment
Polyester primer-surfacers contain
material costs, and achieve a adhesion properties. These primers
are designed to be topcoated with
finish
components. Some painters feel better quality product, make sure
these products have a curing time polyester resins which, when cured, body work is done in such a lacquer topcoats. One coat is
too slow for production work, form a durable surface with excellent manner as to require only a
especially in regions with high high building qualities and minimal minimal amount of primer-
shrinkage. Because of their high surfacer.
humidity. While many of these
reported problems are due to viscosity, polyester primer-surfacers If a colored sealer will not be used,
improper use of the product, long are best sprayed using gravity feed make sure the primer-surfacer
curing times remain the primers spray equipment. used is a color that can easily be
greatest adversary. covered with the desired topcoat.
Polyester primer-surfacers have a
relatively long curing time, ranging Use a properly operating primer
These primers do have some very
from 2 - 3 hours. These primer- gun with the correct fluid tip/air
beneficial qualities. They possess
cap combination for your particular
Single component excellent high building properties surfacers generally do not sand as
easily as other primer-surfacers, and type of primer-surfacer.
waterborne primers with tremendous hold-out
capabilities. Many can be used on some loss in productivity may result.
come ready to spray flexible parts as a primer without The topcoats that can be applied to
C. Primer-Sealers
with a 4.5 - 5.0 the need for the addition of a flex these primer-surfacers are usually
Primer-sealers differ from primer-
lbs/gal VOC content agent. Single component waterborne limited to the newer polyurethanes.
The VOC content of polyester surfacers in two basic areas. First,
primers come ready to spray with a
primer sealers fill only very minor
4.5 - 5.0 lbs/gal VOC content,
primer-surfacers ranges from 4.6 to Figure 17: Application of the Primer-Sealer
5.0 lbs/gal thinned and ready to imperfections. Second, they should
resulting in a 20 percent reduction in
spray. not be sanded prior to the
VOC emissions as compared to generally recommended prior to
application of a topcoat.
conventional solvent- based primers. painting with a 30 minute drying
Acrylic Urethane Enamel Primer- Primer-sealers must meet the time.
Surfacer following performance criteria:
Epoxy Primer (as a Primer-
Lacquer primer-sealers are
Surfacer) Acrylic urethane was developed for 1. Provide corrosion resistance. commonly used for spot repair and
the newer high tech topcoats. These 2. Provide adhesion to bare metal
As a primer-surfacer, epoxy small paint jobs, but not generally
primer-surfacers provide high build substrate.
primers provide excellent filling for large surface coating operations.
characteristics with little or no 3. Fill minor surface imperfections.
qualities and possess excellent hold- VOC content is approximately 6.0
shrinkage. Urethane primer- 4. Seal sanded surfaces to prevent
out capabilities. The tough surface lbs/gal as packaged in sprayable form.
surfacers have a VOC content solvent penetration and bleed-
produced by the epoxies makes a
ranging from 4.3 - 5.0 lbs/gal after through.
good durable base for the application Enamel Type Primer-Sealers
the addition of the activator and 5. Provide a single, neutral-colored
of any topcoat.
reducer. Urethane primer-surfacers base for easy topcoat coverage. Enamel type primer-sealers also
Solvent-based self-etching epoxy have a relatively slow curing time, have fair filling qualities with good
some requiring up to two hours to The choice of sealer color affects
primers have a VOC content of adhesion and holdout properties.
cure under ideal conditions. not only the coverage of the topcoats,
approximately 3.5 - 4.0 lbs/gal. With Usually used for large panel or
but may also affect the final color
32 33
One-Component Waterborne the addition of the activator and Recommended Practices for shade of the finish, especially when
Primer-Surfacer reducer, the sprayable primer- Primer-Surfacers using topcoats containing
surfacer formula has a VOC content transparent pigments. The primer-
When waterborne primers were
of up to 4.5 lbs/gal. Waterborne
Use low VOC waterborne primer-
sealer should be as close to the color
The choice of sealer
surfacer products.
introduced to the collision repair
epoxy primers, which are also of the factory sealer as possible. color affects not only
market in the mid-to-late 1980's,
they were met with controversy and
available, have a VOC content of less
If the curing time of waterborne
products is unsatisfactory,
the coverage of the
resistance. Waterborne primers have
then 2.1 lbs/gal for the sprayable
consider the use of versatile
Lacquer Primer-Sealers topcoats but may
been reported to cause rusting of
product. urethane or epoxy primers. Lacquer primer-sealers produce also affect the final
untreated metallic substrates and
Polyester Primer-Surfacer To reduce VOC emissions, limit fair filling qualities with good color shade of the
non-coated ferrous spray equipment
Polyester primer-surfacers contain
material costs, and achieve a adhesion properties. These primers
are designed to be topcoated with
finish
components. Some painters feel better quality product, make sure
these products have a curing time polyester resins which, when cured, body work is done in such a lacquer topcoats. One coat is
too slow for production work, form a durable surface with excellent manner as to require only a
especially in regions with high high building qualities and minimal minimal amount of primer-
shrinkage. Because of their high surfacer.
humidity. While many of these
reported problems are due to viscosity, polyester primer-surfacers If a colored sealer will not be used,
improper use of the product, long are best sprayed using gravity feed make sure the primer-surfacer
curing times remain the primers spray equipment. used is a color that can easily be
greatest adversary. covered with the desired topcoat.
Polyester primer-surfacers have a
relatively long curing time, ranging Use a properly operating primer
These primers do have some very
from 2 - 3 hours. These primer- gun with the correct fluid tip/air
beneficial qualities. They possess
cap combination for your particular
Single component excellent high building properties surfacers generally do not sand as
easily as other primer-surfacers, and type of primer-surfacer.
waterborne primers with tremendous hold-out
capabilities. Many can be used on some loss in productivity may result.
come ready to spray flexible parts as a primer without The topcoats that can be applied to
C. Primer-Sealers
with a 4.5 - 5.0 the need for the addition of a flex these primer-surfacers are usually
Primer-sealers differ from primer-
lbs/gal VOC content agent. Single component waterborne limited to the newer polyurethanes.
The VOC content of polyester surfacers in two basic areas. First,
primers come ready to spray with a
primer sealers fill only very minor
4.5 - 5.0 lbs/gal VOC content,
primer-surfacers ranges from 4.6 to Figure 17: Application of the Primer-Sealer
5.0 lbs/gal thinned and ready to imperfections. Second, they should
resulting in a 20 percent reduction in
spray. not be sanded prior to the
VOC emissions as compared to generally recommended prior to
application of a topcoat.
conventional solvent- based primers. painting with a 30 minute drying
Acrylic Urethane Enamel Primer- Primer-sealers must meet the time.
Surfacer following performance criteria:
Epoxy Primer (as a Primer-
Lacquer primer-sealers are
Surfacer) Acrylic urethane was developed for 1. Provide corrosion resistance. commonly used for spot repair and
the newer high tech topcoats. These 2. Provide adhesion to bare metal
As a primer-surfacer, epoxy small paint jobs, but not generally
primer-surfacers provide high build substrate.
primers provide excellent filling for large surface coating operations.
characteristics with little or no 3. Fill minor surface imperfections.
qualities and possess excellent hold- VOC content is approximately 6.0
shrinkage. Urethane primer- 4. Seal sanded surfaces to prevent
out capabilities. The tough surface lbs/gal as packaged in sprayable form.
surfacers have a VOC content solvent penetration and bleed-
produced by the epoxies makes a
ranging from 4.3 - 5.0 lbs/gal after through.
good durable base for the application Enamel Type Primer-Sealers
the addition of the activator and 5. Provide a single, neutral-colored
of any topcoat.
reducer. Urethane primer-surfacers base for easy topcoat coverage. Enamel type primer-sealers also
Solvent-based self-etching epoxy have a relatively slow curing time, have fair filling qualities with good
some requiring up to two hours to The choice of sealer color affects
primers have a VOC content of adhesion and holdout properties.
cure under ideal conditions. not only the coverage of the topcoats,
approximately 3.5 - 4.0 lbs/gal. With Usually used for large panel or
but may also affect the final color
32 33
complete paint jobs, only one coat of Urethane primer-sealers provide In general, sealer types include Recommended Practices for
primer-sealer is generally needed high build characteristics with little lacquer sealers, enamel sealers, and Sealers
urethane sealers. These sealers are
prior to topcoating. VOC content or no shrinkage. They also have Chose the proper sealer for each
developed to be coated by lacquer,
averages 4.5 - 5.0 lbs/gal. superior holdout properties which specific job.
enamel and urethane topcoats
make them an excellent primer- If filling capabilities are required,
respectively, and generally require
Single Component Waterborne sealer. use primer-sealer in place of a
only one coat prior to painting.
Primer-Surfacer (as a Primer-Sealer) sealer.
Urethane primer-sealers have a These sealers come ready to spray
Single component water-based VOC content ranging from 4.3 - 5.0 with VOC contents of approximately Always choose a primer-sealer
primers possess excellent high lbs/gal after the addition of the 6.5, 6.0, 6.0 lbs/gal respectively. color that can be easily covered
building qualities and work well as activator and reducers. Urethanes with the next coating, or choose a
As with primer-sealers, the choice tintable primer-sealer.
barrier coats with tremendous hold- must usually be topcoated within 24 of sealer color affects coverage and
out properties. Many can be used on hours to avoid the need for sanding the final shade of your topcoat,
flexible parts as a primer without the and recoating. especially topcoats containing
addition of a flex agent. transparent pigments. Therefore,
D. Sealers when choosing a sealer, always take
These primers come ready-to-spray
into account the sealer color as well
with a 4.5 - 5.0 lbs/gal VOC content. Recommended Practices for
as the topcoating.
Because water is used as the primary Primer-Sealers
solvent, the flash and cure times of Along with these basic sealers,
these products are relatively long,
Use low VOC primer-sealers such
as single component waterborne, there are also specialty sealers When choosing a
especially in regions of high or waterborne epoxy primers. available for use on specific problem sealer, take into
humidity. The water may also cause surfaces. account the color of
the corrosion of non-coated ferrous The use of low VOC urethane
primer-sealers would also be an Tie Coat Sealers the sealer as well as
application equipment if not cleaned
properly.
acceptable choice. the topcoating to be
Tie coat sealers are used to
achieve extra adhesion between
applied
Always choose primer-sealer color
Epoxy Primer (as a Primer-Sealer) that can be easily covered by the lacquer topcoats and factory enamel
topcoat to be sprayed, or choose a finishes.
As a primer-sealer, epoxy primers
tintable primer-sealer and tint it to
provide excellent hold out
an easily covered shade. Barrier Coat Sealers
capabilities. The tough surface
produced by the epoxies makes a Barrier coat sealers are applied
good durable base for the application Sealers are applied prior to the over very sensitive and or checked
of all topcoats. topcoat if needed. They should have surfaces. These sealers supply
the following qualities: superb holdout, preventing the
Solvent-based self-etching epoxy lifting or checking of the new
primers have a VOC content of 1. Provide adhesion between the
topcoat.
topcoat and the surface.
approximately 3.5 - 4.0 lbs/gal. With
2. Provide a single, neutral-colored
the addition of the activator and
base for easy coverage.
reducer, the sprayable primer-surfacer
3. Seal sanded surfaces to prevent
formula has a VOC content of 4.5
solvent penetration.
lbs/gal. Waterborne epoxy primers
4. Fill minor imperfections.
have a VOC content of less then 2.1
lbs/gal for the sprayable product.
Acrylic Urethane Primer-Sealers
34 35
complete paint jobs, only one coat of Urethane primer-sealers provide In general, sealer types include Recommended Practices for
primer-sealer is generally needed high build characteristics with little lacquer sealers, enamel sealers, and Sealers
urethane sealers. These sealers are
prior to topcoating. VOC content or no shrinkage. They also have Chose the proper sealer for each
developed to be coated by lacquer,
averages 4.5 - 5.0 lbs/gal. superior holdout properties which specific job.
enamel and urethane topcoats
make them an excellent primer- If filling capabilities are required,
respectively, and generally require
Single Component Waterborne sealer. use primer-sealer in place of a
only one coat prior to painting.
Primer-Surfacer (as a Primer-Sealer) sealer.
Urethane primer-sealers have a These sealers come ready to spray
Single component water-based VOC content ranging from 4.3 - 5.0 with VOC contents of approximately Always choose a primer-sealer
primers possess excellent high lbs/gal after the addition of the 6.5, 6.0, 6.0 lbs/gal respectively. color that can be easily covered
building qualities and work well as activator and reducers. Urethanes with the next coating, or choose a
As with primer-sealers, the choice tintable primer-sealer.
barrier coats with tremendous hold- must usually be topcoated within 24 of sealer color affects coverage and
out properties. Many can be used on hours to avoid the need for sanding the final shade of your topcoat,
flexible parts as a primer without the and recoating. especially topcoats containing
addition of a flex agent. transparent pigments. Therefore,
D. Sealers when choosing a sealer, always take
These primers come ready-to-spray
into account the sealer color as well
with a 4.5 - 5.0 lbs/gal VOC content. Recommended Practices for
as the topcoating.
Because water is used as the primary Primer-Sealers
solvent, the flash and cure times of Along with these basic sealers,
these products are relatively long,
Use low VOC primer-sealers such
as single component waterborne, there are also specialty sealers When choosing a
especially in regions of high or waterborne epoxy primers. available for use on specific problem sealer, take into
humidity. The water may also cause surfaces. account the color of
the corrosion of non-coated ferrous The use of low VOC urethane
primer-sealers would also be an Tie Coat Sealers the sealer as well as
application equipment if not cleaned
properly.
acceptable choice. the topcoating to be
Tie coat sealers are used to
achieve extra adhesion between
applied
Always choose primer-sealer color
Epoxy Primer (as a Primer-Sealer) that can be easily covered by the lacquer topcoats and factory enamel
topcoat to be sprayed, or choose a finishes.
As a primer-sealer, epoxy primers
tintable primer-sealer and tint it to
provide excellent hold out
an easily covered shade. Barrier Coat Sealers
capabilities. The tough surface
produced by the epoxies makes a Barrier coat sealers are applied
good durable base for the application Sealers are applied prior to the over very sensitive and or checked
of all topcoats. topcoat if needed. They should have surfaces. These sealers supply
the following qualities: superb holdout, preventing the
Solvent-based self-etching epoxy lifting or checking of the new
primers have a VOC content of 1. Provide adhesion between the
topcoat.
topcoat and the surface.
approximately 3.5 - 4.0 lbs/gal. With
2. Provide a single, neutral-colored
the addition of the activator and
base for easy coverage.
reducer, the sprayable primer-surfacer
3. Seal sanded surfaces to prevent
formula has a VOC content of 4.5
solvent penetration.
lbs/gal. Waterborne epoxy primers
4. Fill minor imperfections.
have a VOC content of less then 2.1
lbs/gal for the sprayable product.
Acrylic Urethane Primer-Sealers
34 35
9. Topcoats flakes, as well as their location
within the finish layer, affect the
perceived color and richness of the
painted surface. The positioning of
A pplication of the topcoat is the
next phase of the surface coating
operation. Topcoats are applied
these flakes within the finish is
dictated by the type of paint, the
directly over the undercoats, which
may be a prep coat, primer-surfacer,
speed of the thinner and hardener,
the type and settings of the spray
Topcoats are
primer-sealer or sealer. Topcoats equipment, along with the spraying responsible for 55%
include paints and clears that give the techniques used. of the VOCs released
surface the color, gloss and durability Topcoats are categorized as either during surface
demanded by today's consumers. single stage or two stage systems. coating operations
The EPA estimates indicate that Three stage systems are used by
topcoats are responsible for 55 percent some automobile manufacturers, but
of all VOCs released during surface will not be addressed in this manual.
coating operations (Figure 18).
Many paint
companies offer
Surface Prep (8%) the option of
Undercoats (17%) high-solids paints
or clears which
contain 60
percent or more
solids by volume.
Solvents such as
glycol esters,
Equipment esters and
Cleaning (20%)
Topcoats (55%) ketones, which
keep more of the
solids in
Figure 18: EPA Estimates of VOC Emissions suspension with
less solvent, are
generally used in
Paints are considered to be either
high-solid paints, primers and clears.
solid or metallic-type topcoat. The
These systems reduce the amount of
solid color paints are made up of
VOCs released by up to 75 percent,
solvents, binders and opaque
while reducing the amount of paint
pigments that produce the color of
material needed by almost one-half
the finish. Metallic colors are made
as compared to conventional systems.
up of solvents, binders and opaque
Generally, only one to three coats are
pigments like the solid colors, but
needed to achieve adequate coverage
also include small light-refracting
using high solids paints.
flakes. These small metallic,
polychrome or mica flakes refract High solids paints have a high
some of the light that enters the viscosity in their sprayable form.
finish, resulting in a surface that High viscosity materials are more
appears richer and deeper in color. difficult to atomize into the fine
The orientation of the refracting droplets needed to achieve a quality
37
9. Topcoats flakes, as well as their location
within the finish layer, affect the
perceived color and richness of the
painted surface. The positioning of
A pplication of the topcoat is the
next phase of the surface coating
operation. Topcoats are applied
these flakes within the finish is
dictated by the type of paint, the
directly over the undercoats, which
may be a prep coat, primer-surfacer,
speed of the thinner and hardener,
the type and settings of the spray
Topcoats are
primer-sealer or sealer. Topcoats equipment, along with the spraying responsible for 55%
include paints and clears that give the techniques used. of the VOCs released
surface the color, gloss and durability Topcoats are categorized as either during surface
demanded by today's consumers. single stage or two stage systems. coating operations
The EPA estimates indicate that Three stage systems are used by
topcoats are responsible for 55 percent some automobile manufacturers, but
of all VOCs released during surface will not be addressed in this manual.
coating operations (Figure 18).
Many paint
companies offer
Surface Prep (8%) the option of
Undercoats (17%) high-solids paints
or clears which
contain 60
percent or more
solids by volume.
Solvents such as
glycol esters,
Equipment esters and
Cleaning (20%)
Topcoats (55%) ketones, which
keep more of the
solids in
Figure 18: EPA Estimates of VOC Emissions suspension with
less solvent, are
generally used in
Paints are considered to be either
high-solid paints, primers and clears.
solid or metallic-type topcoat. The
These systems reduce the amount of
solid color paints are made up of
VOCs released by up to 75 percent,
solvents, binders and opaque
while reducing the amount of paint
pigments that produce the color of
material needed by almost one-half
the finish. Metallic colors are made
as compared to conventional systems.
up of solvents, binders and opaque
Generally, only one to three coats are
pigments like the solid colors, but
needed to achieve adequate coverage
also include small light-refracting
using high solids paints.
flakes. These small metallic,
polychrome or mica flakes refract High solids paints have a high
some of the light that enters the viscosity in their sprayable form.
finish, resulting in a surface that High viscosity materials are more
appears richer and deeper in color. difficult to atomize into the fine
The orientation of the refracting droplets needed to achieve a quality
37
9: Topcoats 9: Topcoats
automotive finish. The high solids A. Single Stage Topcoats dries by solvent evaporation similar Enamel products usually do not
coatings, due to their high viscosity, to lacquer type coatings. This stage need the addition of a flex agent on
also have poor metallic flake Acrylic Lacquer takes from seven to nine hours, fairly rigid parts. If used on very
orientation capabilities compared to depending on drying conditions. In flexible parts, the addition of a flex
low solids coatings. Lacquer finishes are most the following six hours to 30 days, agent may be required, increasing
To help reduce the Whichever paint system is used, it
commonly used for small spot repair the enamel cures due to the oxidation the VOC content.
operations due to their fast cure time of the binder as it reacts with air.
mount of paint waste is important to mix material as and minimal overspray concerns. Polyurethane Enamel Single
and VOCs released, specified by the manufacturer. Lacquer coatings cure solely due to
The drying time, the gloss and the
durability of the finish can all be Stage Topcoats
color coats should be Today's high-tech finishes, especially
when used in the newer HVLP spray
solvent evaporation, producing a
improved with the addition of a Polyurethane topcoats are a two-
mixed in-house equipment, must be mixed accurately
hard, brittle finish. chemical hardener. However, these part painting system requiring the
to produce a high quality finish. Because quick evaporating hardeners not only reduce the pot- addition of a hardener or reactor (the
Consequently, painters must have solvents are used to thin lacquer life of the paint, they also release second component) to assure proper
coatings, the finish does not have a isocyanates during spraying and curing of the finish. Polyurethane
the means to accurately measure the
chance to flow adequately prior to curing operations.
volumes of paint, reducers, and top coats have great spraying charac -
additives during mixing. To achieve drying, resulting in a dull, relatively Alkyd enamels are thinned 15 - 33 teristics along with good metallic
the proper viscosity of a paint mixture rough finish. The fully cured lacquer percent depending on the brand. flow properties. They produce a high
for specific conditions, a viscosity cup finish must be polished to achieve a Only two to three coats usually are gloss, chemically resistant finish that
(Figure 5, pg 14) should be used when smooth, high-gloss finish. Usually required to provide adequate will withstand the effects of
mixing all paints and clears. This four to five coats of lacquer are coverage. Alkyd enamels contain ultraviolet radiation for many years.
will help to ensure viscosity of the applied to insure proper paint approximately 5.0 - 5.5 lbs/gal VOCs
thickness is maintained after in sprayable form, approximately 55 Polyurethane enamels have a VOC
material is adequate to achieve a
polishing. - 75 percent VOCs by volume. concentration of 5.0 - 5.5 lbs/gal in
good quality finish while keeping
their sprayable form. The high VOC
overspray and VOCs to a minimum. The hard, brittle coating of the Acrylic Enamel content of these coatings is offset by
To help reduce the amount of lacquer products is not designed to their excellent coverage. Normally,
withstand the flexing of nonrigid Acrylic enamels are used for both
paint waste and VOCs released, color only two to three coats are needed to
surfaces. For this reason, a flex spot repairs as well as overall
coats should be mixed in-house. provide a good quality finish. Poly-
additive is used when coating rubber painting operations. These enamels
Mixing paints in-house allows the urethane finishes have good flexibility
and flexible plastic components with offer more durable finishes and
facility to make any tint changes and can be used over flexible parts
faster drying times than the alkyd
needed to achieve a color match. It lacquer paints. without the addition of flex additives.
enamels. Acrylic enamels dry in five
also gives the technician the freedom To achieve the correct viscosity for to seven hours, with the second
to mix only the amount of paint conventional spray gun application, curing period taking an additional
Acrylic Urethane Enamel
required for that specific job. Paint lacquer paints are thinned 125 - 150 six to 72 hours at 72F. Acrylic urethanes produce one of
jobbers will generally only mix paint percent. This high solvent concen- the most durable automotive finishes
in quantities of one pint or greater. tration results in a VOC content of
Drying time, gloss and durability
available today. They have twice the With acrylic enamels
of acrylic enamels can all be improved
This amount is often more than 6.0 - 6.5 lbs/gal, 70 - 90 percent by with the addition of a chemical durability of polyurethanes, with less requiring only two-
needed, resulting in waste paint. volume. The EPA estimates that the hardener. These hardeners increased curing time needed to achieve a tack three coats to provide
Spray-out cards with appropriate use of lacquer paints increases the
amount of VOC emissions by 45
the durability of the surface by free finish.
adequate coverage,
information on the product used and
color match should be made and percent compared to enamel topcoats.
almost 50 percent compared to
acrylic enamels without hardeners.
Acrylic urethanes have a relatively the VOCs are reduced
high VOC content (ranging from 5.0 -
catalogued. This will decrease the Acrylic enamels, on average, 5.5 lbs/gal) in their sprayable form.
by 45% over lacquers
time and money wasted matching a Alkyd Enamel Generally, only two coats of these
contain 5.0 - 5.5 lbs/gal VOCs in
color, especially considering the Alkyd enamels are the least
their sprayable form. With acrylic topcoats are required to produce a
number of colors and variations of durable of all the automotive paints.
enamels requiring only two to three quality finish, reducing the amount
paint formulas for each type of Alkyd enamels dry in a two stage
coats to provide adequate coverage, of material needed for the top
vehicle on the road today. curing process. First, the finish the VOCs are reduced by 45 percent coating process.
over lacquer type paints.
38 39
automotive finish. The high solids A. Single Stage Topcoats dries by solvent evaporation similar Enamel products usually do not
coatings, due to their high viscosity, to lacquer type coatings. This stage need the addition of a flex agent on
also have poor metallic flake Acrylic Lacquer takes from seven to nine hours, fairly rigid parts. If used on very
orientation capabilities compared to depending on drying conditions. In flexible parts, the addition of a flex
low solids coatings. Lacquer finishes are most the following six hours to 30 days, agent may be required, increasing
To help reduce the Whichever paint system is used, it
commonly used for small spot repair the enamel cures due to the oxidation the VOC content.
operations due to their fast cure time of the binder as it reacts with air.
mount of paint waste is important to mix material as and minimal overspray concerns. Polyurethane Enamel Single
and VOCs released, specified by the manufacturer. Lacquer coatings cure solely due to
The drying time, the gloss and the
durability of the finish can all be Stage Topcoats
color coats should be Today's high-tech finishes, especially
when used in the newer HVLP spray
solvent evaporation, producing a
improved with the addition of a Polyurethane topcoats are a two-
mixed in-house equipment, must be mixed accurately
hard, brittle finish. chemical hardener. However, these part painting system requiring the
to produce a high quality finish. Because quick evaporating hardeners not only reduce the pot- addition of a hardener or reactor (the
Consequently, painters must have solvents are used to thin lacquer life of the paint, they also release second component) to assure proper
coatings, the finish does not have a isocyanates during spraying and curing of the finish. Polyurethane
the means to accurately measure the
chance to flow adequately prior to curing operations.
volumes of paint, reducers, and top coats have great spraying charac -
additives during mixing. To achieve drying, resulting in a dull, relatively Alkyd enamels are thinned 15 - 33 teristics along with good metallic
the proper viscosity of a paint mixture rough finish. The fully cured lacquer percent depending on the brand. flow properties. They produce a high
for specific conditions, a viscosity cup finish must be polished to achieve a Only two to three coats usually are gloss, chemically resistant finish that
(Figure 5, pg 14) should be used when smooth, high-gloss finish. Usually required to provide adequate will withstand the effects of
mixing all paints and clears. This four to five coats of lacquer are coverage. Alkyd enamels contain ultraviolet radiation for many years.
will help to ensure viscosity of the applied to insure proper paint approximately 5.0 - 5.5 lbs/gal VOCs
thickness is maintained after in sprayable form, approximately 55 Polyurethane enamels have a VOC
material is adequate to achieve a
polishing. - 75 percent VOCs by volume. concentration of 5.0 - 5.5 lbs/gal in
good quality finish while keeping
their sprayable form. The high VOC
overspray and VOCs to a minimum. The hard, brittle coating of the Acrylic Enamel content of these coatings is offset by
To help reduce the amount of lacquer products is not designed to their excellent coverage. Normally,
withstand the flexing of nonrigid Acrylic enamels are used for both
paint waste and VOCs released, color only two to three coats are needed to
surfaces. For this reason, a flex spot repairs as well as overall
coats should be mixed in-house. provide a good quality finish. Poly-
additive is used when coating rubber painting operations. These enamels
Mixing paints in-house allows the urethane finishes have good flexibility
and flexible plastic components with offer more durable finishes and
facility to make any tint changes and can be used over flexible parts
faster drying times than the alkyd
needed to achieve a color match. It lacquer paints. without the addition of flex additives.
enamels. Acrylic enamels dry in five
also gives the technician the freedom To achieve the correct viscosity for to seven hours, with the second
to mix only the amount of paint conventional spray gun application, curing period taking an additional
Acrylic Urethane Enamel
required for that specific job. Paint lacquer paints are thinned 125 - 150 six to 72 hours at 72F. Acrylic urethanes produce one of
jobbers will generally only mix paint percent. This high solvent concen- the most durable automotive finishes
in quantities of one pint or greater. tration results in a VOC content of
Drying time, gloss and durability
available today. They have twice the With acrylic enamels
of acrylic enamels can all be improved
This amount is often more than 6.0 - 6.5 lbs/gal, 70 - 90 percent by with the addition of a chemical durability of polyurethanes, with less requiring only two-
needed, resulting in waste paint. volume. The EPA estimates that the hardener. These hardeners increased curing time needed to achieve a tack three coats to provide
Spray-out cards with appropriate use of lacquer paints increases the
amount of VOC emissions by 45
the durability of the surface by free finish.
adequate coverage,
information on the product used and
color match should be made and percent compared to enamel topcoats.
almost 50 percent compared to
acrylic enamels without hardeners.
Acrylic urethanes have a relatively the VOCs are reduced
high VOC content (ranging from 5.0 -
catalogued. This will decrease the Acrylic enamels, on average, 5.5 lbs/gal) in their sprayable form.
by 45% over lacquers
time and money wasted matching a Alkyd Enamel Generally, only two coats of these
contain 5.0 - 5.5 lbs/gal VOCs in
color, especially considering the Alkyd enamels are the least
their sprayable form. With acrylic topcoats are required to produce a
number of colors and variations of durable of all the automotive paints.
enamels requiring only two to three quality finish, reducing the amount
paint formulas for each type of Alkyd enamels dry in a two stage
coats to provide adequate coverage, of material needed for the top
vehicle on the road today. curing process. First, the finish the VOCs are reduced by 45 percent coating process.
over lacquer type paints.
38 39
B. Two Stage Basecoat/ although acrylic enamel and lacquer

achieve low solids and low VOC remains relatively unchecked.
Clearcoat Topcoats clears are also available. These
clears are designed to flow upon content is through the use
It has been estimated that nearly To help combat the difficulties
application resulting in a smooth, waterborne technology.
half of the automobiles on the road associated with the early waterborne
glass-like finish in as few as two Early versions of waterborne systems, new waterborne
today have a basecoat / clearcoat
coats. basecoats were very sensitive to technologies were developed.
finish. The first stage of the finish,
the basecoat, contains the pigments VOC content of the clears ranges atmospheric conditions in the booth. Currently, there are two types of Currently, the only
that give the finish the desired color. from 5.0 - 5.5 lbs/gal in their Waterborne paints generally contain waterborne basecoats being way to achieve the
In the case of metallic finishes, the sprayable form. Many of the major less than 10 percent solvents produced, acrylic latex and urethane low solids and VOC
basecoat also contains the "metallic" paint companies are producing low (excluding water and exempt polymer. Both use melamine content is through
VOC clears (3.5 lbs/gal or less) for
flakes.
use with basecoat / clearcoat
solvents) by weight. To achieve
proper crosslinking of the coating,
formaldehyde polymers as the basic
film former. The addition of these
the use of
When basecoat / clearcoat systems
systems. These low VOC, high-solid both the water and the other polymers and glycol ethers has been waterborne
first came out, the basecoats were
primarily lacquer based. Today, paint
clears create a high-gloss finish solvents must evaporate at the same instrumental in controlling the flow technology
with half the materials of a low time and rate. This will not occur if of waterborne basecoat finishes
companies are producing acrylic
solids clear. the humidity is above the acceptable during topcoating operations. Since
enamel, polyester, and urethane
basecoats; all of which have better range of that coating (generally 65 - the initial stage of curing is no
Waterborne Basecoat Systems 80 percent). High humidity and/or longer dependent on the rate of
metallic control then their lacquer
counterparts. The basecoat is Waterborne basecoats are low temperatures also increase the water evaporation, the need for
designed to be easy spraying and currently being used by a small curing time of the finish, and increase expensive humidity control devices
quick drying with excellent metal number of automobile manufacturing the possibility of runs and sags. are no longer necessary. Adequate
VOC content of control. The quick-drying effect is plants in North America. But with In order to achieve a good quality air movement within the spray booth
is necessary to assist in the curing of
designed to keep the base free of dirt
waterborne base and other contaminants. It also
the implementation of stricter VOC
regulations, these coatings are
finish, humidity and temperature of
the waterborne coating. This has
coats is relatively locks the metallic flakes in position expected to gain popularity within
the booth must be closely regulated.
In an industrial setting, painting made waterborne basecoat
low, ranging from to achieve a mottle-free finish. the industry. VOC content of these conditions can be closely monitored technology accessible to the auto
2.5 - 3.5 lbs/gal The sole purpose of the basecoat is waterborne basecoats is relatively to provide an ideal painting repair industry. These systems are
to achieve the desired color tint and low, ranging from 2.5 - 3.5 lbs/gal in now being utilized in the regulated
environment. In the repair industry,
metallic appearance. Only two coats their sprayable form. areas of the west coast with some
such control can not be adequately
of the base are normally needed to success. However, waterborne
The waterborne technology uses achieved without expensive control
achieve adequate surface coverage. coatings are still susceptible to cold
water as the main solvent, giving devices. Modern paint booths can
Basecoats do not contain the weather and must be protected
these basecoats low VOC emissions effectively control application
additives needed to withstand from freezing during transportation
while retaining low solids content. temperature as well as curing
chemical and ultraviolet deterio- and storage.
The low solids level means greater conditions, but booth humidity
ration or the chemicals needed to
achieve a high gloss surface. metallic control, resulting in a Advantages of Waterborne Basecoat Systems
uniform finish free of mottling.
To protect the basecoat, a durable Some experts note that to achieve Low VOC content of the sprayable product (2.5 - 3.5).
clear finish is applied. This clear the optimal metallic flake Good metallic flake orientation properties.
coating can often be applied over the orientation, the volume of solids in a
base after only 15 to 30 minutes of Good atomization properties.
coating must be less than 20 percent
cure time. Commonly the VOC by weight. Yet to achieve compliance No catalyst is needed for the latex basecoat, only the clear will require
content of the basecoats range from within the regulated areas of the U.S., the addition of a catalyst.
6.0 - 7.0 lbs/gal.
the solids volume in solvent based No flash time is required between color coats.
Clearcoats are typically acrylic basecoats must be in excess of 45
urethane or polyurethane coatings, percent. Currently, the only way to
40 41
B. Two Stage Basecoat/ although acrylic enamel and lacquer

achieve low solids and low VOC remains relatively unchecked.
Clearcoat Topcoats clears are also available. These
clears are designed to flow upon content is through the use
It has been estimated that nearly To help combat the difficulties
application resulting in a smooth, waterborne technology.
half of the automobiles on the road associated with the early waterborne
glass-like finish in as few as two Early versions of waterborne systems, new waterborne
today have a basecoat / clearcoat
coats. basecoats were very sensitive to technologies were developed.
finish. The first stage of the finish,
the basecoat, contains the pigments VOC content of the clears ranges atmospheric conditions in the booth. Currently, there are two types of Currently, the only
that give the finish the desired color. from 5.0 - 5.5 lbs/gal in their Waterborne paints generally contain waterborne basecoats being way to achieve the
In the case of metallic finishes, the sprayable form. Many of the major less than 10 percent solvents produced, acrylic latex and urethane low solids and VOC
basecoat also contains the "metallic" paint companies are producing low (excluding water and exempt polymer. Both use melamine content is through
VOC clears (3.5 lbs/gal or less) for
flakes.
use with basecoat / clearcoat
solvents) by weight. To achieve
proper crosslinking of the coating,
formaldehyde polymers as the basic
film former. The addition of these
the use of
When basecoat / clearcoat systems
systems. These low VOC, high-solid both the water and the other polymers and glycol ethers has been waterborne
first came out, the basecoats were
primarily lacquer based. Today, paint
clears create a high-gloss finish solvents must evaporate at the same instrumental in controlling the flow technology
with half the materials of a low time and rate. This will not occur if of waterborne basecoat finishes
companies are producing acrylic
solids clear. the humidity is above the acceptable during topcoating operations. Since
enamel, polyester, and urethane
basecoats; all of which have better range of that coating (generally 65 - the initial stage of curing is no
Waterborne Basecoat Systems 80 percent). High humidity and/or longer dependent on the rate of
metallic control then their lacquer
counterparts. The basecoat is Waterborne basecoats are low temperatures also increase the water evaporation, the need for
designed to be easy spraying and currently being used by a small curing time of the finish, and increase expensive humidity control devices
quick drying with excellent metal number of automobile manufacturing the possibility of runs and sags. are no longer necessary. Adequate
VOC content of control. The quick-drying effect is plants in North America. But with In order to achieve a good quality air movement within the spray booth
is necessary to assist in the curing of
designed to keep the base free of dirt
waterborne base and other contaminants. It also
the implementation of stricter VOC
regulations, these coatings are
finish, humidity and temperature of
the waterborne coating. This has
coats is relatively locks the metallic flakes in position expected to gain popularity within
the booth must be closely regulated.
In an industrial setting, painting made waterborne basecoat
low, ranging from to achieve a mottle-free finish. the industry. VOC content of these conditions can be closely monitored technology accessible to the auto
2.5 - 3.5 lbs/gal The sole purpose of the basecoat is waterborne basecoats is relatively to provide an ideal painting repair industry. These systems are
to achieve the desired color tint and low, ranging from 2.5 - 3.5 lbs/gal in now being utilized in the regulated
environment. In the repair industry,
metallic appearance. Only two coats their sprayable form. areas of the west coast with some
such control can not be adequately
of the base are normally needed to success. However, waterborne
The waterborne technology uses achieved without expensive control
achieve adequate surface coverage. coatings are still susceptible to cold
water as the main solvent, giving devices. Modern paint booths can
Basecoats do not contain the weather and must be protected
these basecoats low VOC emissions effectively control application
additives needed to withstand from freezing during transportation
while retaining low solids content. temperature as well as curing
chemical and ultraviolet deterio- and storage.
The low solids level means greater conditions, but booth humidity
ration or the chemicals needed to
achieve a high gloss surface. metallic control, resulting in a Advantages of Waterborne Basecoat Systems
uniform finish free of mottling.
To protect the basecoat, a durable Some experts note that to achieve Low VOC content of the sprayable product (2.5 - 3.5).
clear finish is applied. This clear the optimal metallic flake Good metallic flake orientation properties.
coating can often be applied over the orientation, the volume of solids in a
base after only 15 to 30 minutes of Good atomization properties.
coating must be less than 20 percent
cure time. Commonly the VOC by weight. Yet to achieve compliance No catalyst is needed for the latex basecoat, only the clear will require
content of the basecoats range from within the regulated areas of the U.S., the addition of a catalyst.
6.0 - 7.0 lbs/gal.
the solids volume in solvent based No flash time is required between color coats.
Clearcoats are typically acrylic basecoats must be in excess of 45
urethane or polyurethane coatings, percent. Currently, the only way to
40 41
Advantages, cont D. Recommended Practices for Topcoats

Waterborne basecoats have superb hiding properties and generally Mix color coats in-house, making certain the formula for the proper shade
require only two coats for complete coverage. of the specific color code is used. This will help avoid the need for
blending of the finish to achieve a satisfactory color match.
Equipment can be cleaned with water instead of solvents.
Keep good records of paint match information, including spray-out cards
At least one waterborne paint manufacturer offers a coagulating agent and detailed notes.
that will separate the solids from the cleanup water, allowing the water Avoid the use of lacquer-based topcoats.
to be reused while reducing the volume of waste generated.
Choose low VOC topcoats that require fewer than three coats to achieve
adequate coverage (polyurethane or urethane).
Only apply the number of coats needed to achieve an adequate finish.
Disadvantages of Waterborne Basecoat Systems Use high solids, low VOC clears to topcoat color coats.
The addition of paint additives should be kept to a minimum.
Current mixing systems need to be modified or replaced to accommodate When available, use waterborne basecoats.
waterborne basecoats.
All waterborne products must be transported and stored in such a
manner as to protect them from freezing.
All spray equipment used to apply waterborne coatings will need to be of
a material such as stainless steel to protect against corrosion.
Booth temperature and adequate air movement is essential for achieving
a finish free of runs and sags.
To hasten curing, infrared drying systems or forced air curing systems
may be needed.
Waterborne products are more susceptible to substrate contamination
than are solvent-borne products.
The waste water/paint mixture resulting from equipment cleanup
operations may require more expensive disposal fees than solvent/paint
wastes.
C. Paint Additives
The use of any Along with the chemical hardeners additives not only affects the spraya-
additives can and flex additives previously bility of the product and the quality
of the finish, it also increases the
mentioned, there are many other
increase VOC paint additives available. These VOC content of that system. To keep
content include flatting compounds, VOC emissions low and material
accelerators, retarders, color blenders costs down, the use of additives
and fisheye eliminators. The should be kept to a minimum.
addition of any one of these
42 43
Advantages, cont D. Recommended Practices for Topcoats

Waterborne basecoats have superb hiding properties and generally Mix color coats in-house, making certain the formula for the proper shade
require only two coats for complete coverage. of the specific color code is used. This will help avoid the need for
blending of the finish to achieve a satisfactory color match.
Equipment can be cleaned with water instead of solvents.
Keep good records of paint match information, including spray-out cards
At least one waterborne paint manufacturer offers a coagulating agent and detailed notes.
that will separate the solids from the cleanup water, allowing the water Avoid the use of lacquer-based topcoats.
to be reused while reducing the volume of waste generated.
Choose low VOC topcoats that require fewer than three coats to achieve
adequate coverage (polyurethane or urethane).
Only apply the number of coats needed to achieve an adequate finish.
Disadvantages of Waterborne Basecoat Systems Use high solids, low VOC clears to topcoat color coats.
The addition of paint additives should be kept to a minimum.
Current mixing systems need to be modified or replaced to accommodate When available, use waterborne basecoats.
waterborne basecoats.
All waterborne products must be transported and stored in such a
manner as to protect them from freezing.
All spray equipment used to apply waterborne coatings will need to be of
a material such as stainless steel to protect against corrosion.
Booth temperature and adequate air movement is essential for achieving
a finish free of runs and sags.
To hasten curing, infrared drying systems or forced air curing systems
may be needed.
Waterborne products are more susceptible to substrate contamination
than are solvent-borne products.
The waste water/paint mixture resulting from equipment cleanup
operations may require more expensive disposal fees than solvent/paint
wastes.
C. Paint Additives
The use of any Along with the chemical hardeners additives not only affects the spraya-
additives can and flex additives previously bility of the product and the quality
of the finish, it also increases the
mentioned, there are many other
increase VOC paint additives available. These VOC content of that system. To keep
content include flatting compounds, VOC emissions low and material
accelerators, retarders, color blenders costs down, the use of additives
and fisheye eliminators. The should be kept to a minimum.
addition of any one of these
42 43
10. Recommended Approach to Practical
Air Emission Reduction
Spray Equipment
Determine how much you are willing to spend for spray equipment.
Determine the types of coatings that will be sprayed through the equipment
and the atomization properties required for their proper application.
Prior to purchasing any paint gun, consult your paint representative to

determine what type of gun will work best for the products you will be using.
Contact your paint representative and/or paint gun representative to determine

the fluid tip/air cap combination and gun settings that should be used with the
material being sprayed.
Choose spray equipment that has the highest transfer efficiency while providing
the required atomization properties within your price range.
Spray Application Techniques

Use the recommended air pressure and tip sizes for the specific product and
Use a 50 percent overlap for each pass. This technique may need to be altered
slightly when applying high-metallic, high-solids basecoats, and for some three
stage systems.
When painting small and medium sized panels, make each pass the full length
of the panel.
strokes.

Spray the border edges of the substrate first (banding). This will assure all
edges are covered without extending the spray pattern well beyond the borders
of the object.
Use color hiding power labels to determine the thickness of the applied paint
film. These markers will also indicate when adequate coverage has been
achieved.
45
10. Recommended Approach to Practical
Air Emission Reduction
Spray Equipment
Determine how much you are willing to spend for spray equipment.
Determine the types of coatings that will be sprayed through the equipment
and the atomization properties required for their proper application.
Prior to purchasing any paint gun, consult your paint representative to

determine what type of gun will work best for the products you will be using.
Contact your paint representative and/or paint gun representative to determine

the fluid tip/air cap combination and gun settings that should be used with the
material being sprayed.
Choose spray equipment that has the highest transfer efficiency while providing
the required atomization properties within your price range.
Spray Application Techniques

Use the recommended air pressure and tip sizes for the specific product and
Use a 50 percent overlap for each pass. This technique may need to be altered
slightly when applying high-metallic, high-solids basecoats, and for some three
stage systems.
When painting small and medium sized panels, make each pass the full length
of the panel.
strokes.

Spray the border edges of the substrate first (banding). This will assure all
edges are covered without extending the spray pattern well beyond the borders
of the object.
Use color hiding power labels to determine the thickness of the applied paint
film. These markers will also indicate when adequate coverage has been
achieved.
45
10: Recommended Approach to Practical Air 10: Recommended Approach to Practical Air
Emission Reduction Emission Reduction
Equipment Cleaning Primer-surfacers cont

Use an air powered mechanical gun cleaning system.
Use low VOC cleaning solvents. easily be covered with the desired topcoat.
If cleaning guns manually, spray into an enclosed backdrop to retain atomized
solvents. Primer Sealers
Use low VOC primer-sealers such as single component waterborne or
If necessary, use a broom straw, cleaning broach or a soft wood toothpick to clear
waterborne epoxy primers.
passageways. Never use metal objects.
The use of low VOC urethane primer-sealers would also be an acceptable
Surface Prep choice.
Always wash dirt and grime from the vehicle using water or a soap and water Always choose a color of primer-sealer that can be easily covered by the
mixture. topcoat to be sprayed or choose a tintable primer-sealer and tint it to an easily
Use waterborne cleaners when possible. covered shade.
If, due to heavy contamination, waterborne cleaners prove unsatisfactory, use Sealers
solvent-based cleaners for the initial cleaning. For secondary cleaning
operations, use the waterborne products. Chose the proper sealer for each specific job.
If waterborne cleaners prove unsatisfactory due to substrate make-up, use If filling capabilities are required, use a primer-sealer in place of a sealer.
solvent-based cleaners sparingly. Always choose a primer-sealer of a color that can be easily covered with the
Keep solvent laden dirty rags in a closed container. coating to be sprayed, or choose a tintable primer-sealer.
Keep solvent containers closed when not in use. Topcoats

If possible, avoid operations that would necessitate multiple prepaint cleaning Mix color coats in-house, making certain the formula for the proper shade of
operations. the specific color code is used. This will help avoid the need for the blending of
the finish to achieve a satisfactory color match.
Prep Coats
Keep good records of paint match information, including spray-out cards and
Use versatile products such as epoxy primers or self-etching primers. The use
detailed notes.
of these products may alleviate the need for additional surface coating
operations such as primer-surfacing or primer-sealing. Avoid the use of lacquer-based topcoats.
If a self-etching primer or epoxy primer is not desirable, use a wash-primer or Choose low VOC topcoats that require fewer than three coats to achieve
metal conditioner, conversion coating system. adequate coverage (polyurethane or urethane).
Avoid high VOC content zinc phosphate primers. Apply only the number of coats needed to achieve an adequate finish.
Use high solids, low VOC clears to topcoat color coats.
Primer-Surfacers
Keep addition of paint additives to a minimum.
Use a properly operating primer gun with the correct fluid tip/air cap
combination for your particular type of primer-surfacer. When available, use waterborne basecoats.
Use low VOC, waterborne primer-surfacer products.

If the curing time of waterborne products proves unsatisfactory, consider the
use of versatile urethane primers.
To reduce VOC emissions, limit material costs, and achieve a better quality
product, make sure body work is done in such a manner as to require only a
minimal amount of primer-surfacer.
46 47
10: Recommended Approach to Practical Air 10: Recommended Approach to Practical Air
Emission Reduction Emission Reduction
Equipment Cleaning Primer-surfacers cont

Use an air powered mechanical gun cleaning system.
Use low VOC cleaning solvents. easily be covered with the desired topcoat.
If cleaning guns manually, spray into an enclosed backdrop to retain atomized
solvents. Primer Sealers
Use low VOC primer-sealers such as single component waterborne or
If necessary, use a broom straw, cleaning broach or a soft wood toothpick to clear
waterborne epoxy primers.
passageways. Never use metal objects.
The use of low VOC urethane primer-sealers would also be an acceptable
Surface Prep choice.
Always wash dirt and grime from the vehicle using water or a soap and water Always choose a color of primer-sealer that can be easily covered by the
mixture. topcoat to be sprayed or choose a tintable primer-sealer and tint it to an easily
Use waterborne cleaners when possible. covered shade.
If, due to heavy contamination, waterborne cleaners prove unsatisfactory, use Sealers
solvent-based cleaners for the initial cleaning. For secondary cleaning
operations, use the waterborne products. Chose the proper sealer for each specific job.
If waterborne cleaners prove unsatisfactory due to substrate make-up, use If filling capabilities are required, use a primer-sealer in place of a sealer.
solvent-based cleaners sparingly. Always choose a primer-sealer of a color that can be easily covered with the
Keep solvent laden dirty rags in a closed container. coating to be sprayed, or choose a tintable primer-sealer.
Keep solvent containers closed when not in use. Topcoats

If possible, avoid operations that would necessitate multiple prepaint cleaning Mix color coats in-house, making certain the formula for the proper shade of
operations. the specific color code is used. This will help avoid the need for the blending of
the finish to achieve a satisfactory color match.
Prep Coats
Keep good records of paint match information, including spray-out cards and
Use versatile products such as epoxy primers or self-etching primers. The use
detailed notes.
of these products may alleviate the need for additional surface coating
operations such as primer-surfacing or primer-sealing. Avoid the use of lacquer-based topcoats.
If a self-etching primer or epoxy primer is not desirable, use a wash-primer or Choose low VOC topcoats that require fewer than three coats to achieve
metal conditioner, conversion coating system. adequate coverage (polyurethane or urethane).
Avoid high VOC content zinc phosphate primers. Apply only the number of coats needed to achieve an adequate finish.
Use high solids, low VOC clears to topcoat color coats.
Primer-Surfacers
Keep addition of paint additives to a minimum.
Use a properly operating primer gun with the correct fluid tip/air cap
combination for your particular type of primer-surfacer. When available, use waterborne basecoats.
Use low VOC, waterborne primer-surfacer products.

If the curing time of waterborne products proves unsatisfactory, consider the
use of versatile urethane primers.
To reduce VOC emissions, limit material costs, and achieve a better quality
product, make sure body work is done in such a manner as to require only a
minimal amount of primer-surfacer.
46 47
11. What to Expect in and primers may require modifi-
the Future
cation of current paint practices
within the refinishing industry.
Paint-heaters may be essential in
every paint shop to lower the
T he automotive refinishing
industry has undergone many
significant changes in the last ten
viscosity of the high-solids solvent-
based paints and primers prior to
spraying. Heaters are not effective
years, with even greater changes with waterborne paints due to their
anticipated within the next decade. lack of effect on these products'
The Clean Air Act Amendments viscosity.
require implementation of new
stringent emission control and The spray equipment used by the
typical paint shop will be of the
permitting requirements within the
next ten years. Although it is not yet HVLP variety. High transfer- The spray
clear what specific regulations are in efficient spray equipment will equipment used by the
store for the automotive refinishing continue to improve, providing the typical paint shop
industry, it is clear that some form of technician with better atomization
and metallic control.
will be of the HVLP
emission regulations will be imposed. variety.
Impending regulations are already Recently, a new paint system has
causing many changes within the been developed using super-critical
paint manufacturing and application carbon dioxide (CO 2) in place of
equipment industries. solvents to lower the viscosity of the
Paint manufacturers are focusing coating. These systems reduce VOC
their efforts on the development of emissions from 25 percent to as
paints and primers that will meet much as 80 percent, depending on
the rigid standards of the future. the coating used. Currently, the use
VOC contents of topcoats will of these systems is limited to
probably be limited to 5.0 lbs/gal or industrial painting; the finish quality
less, while undercoats may be limited needed for the application of
to as low as 3.5 lbs/gal. Paint manu- automotive finishes has yet to be
facturers will continue emphasizing achieved. As the technology improves
development of waterborne and high- and investment costs lower, CO2
solids paints and primers. systems may be used on a limited
scale for auto refinishing operations.
Waterborne paints will probably
be limited to basecoats which will Automobile refinishers will be
require the application of a urethane unable to rely solely on low VOC
clearcoat. The use of glycol ethers, products and high transfer efficient
esters, ester alcohols and water as spray equipment to reduce VOC
solvents for paint products will emissions. Employers will also need
continue to increase. Other high to train their painters and prep
solvency products such as propylene technicians in the proper use of all
glycol and methyl butyl ethers will existing and new equipment and
also gain popularity with paint products entering the market place.
manufacturers. Spray paint techniques must also be
High viscosity, high solids paints
49
11. What to Expect in and primers may require modifi-
the Future
cation of current paint practices
within the refinishing industry.
Paint-heaters may be essential in
every paint shop to lower the
T he automotive refinishing
industry has undergone many
significant changes in the last ten
viscosity of the high-solids solvent-
based paints and primers prior to
spraying. Heaters are not effective
years, with even greater changes with waterborne paints due to their
anticipated within the next decade. lack of effect on these products'
The Clean Air Act Amendments viscosity.
require implementation of new
stringent emission control and The spray equipment used by the
typical paint shop will be of the
permitting requirements within the
next ten years. Although it is not yet HVLP variety. High transfer- The spray
clear what specific regulations are in efficient spray equipment will equipment used by the
store for the automotive refinishing continue to improve, providing the typical paint shop
industry, it is clear that some form of technician with better atomization
and metallic control.
will be of the HVLP
emission regulations will be imposed. variety.
Impending regulations are already Recently, a new paint system has
causing many changes within the been developed using super-critical
paint manufacturing and application carbon dioxide (CO 2) in place of
equipment industries. solvents to lower the viscosity of the
Paint manufacturers are focusing coating. These systems reduce VOC
their efforts on the development of emissions from 25 percent to as
paints and primers that will meet much as 80 percent, depending on
the rigid standards of the future. the coating used. Currently, the use
VOC contents of topcoats will of these systems is limited to
probably be limited to 5.0 lbs/gal or industrial painting; the finish quality
less, while undercoats may be limited needed for the application of
to as low as 3.5 lbs/gal. Paint manu- automotive finishes has yet to be
facturers will continue emphasizing achieved. As the technology improves
development of waterborne and high- and investment costs lower, CO2
solids paints and primers. systems may be used on a limited
scale for auto refinishing operations.
Waterborne paints will probably
be limited to basecoats which will Automobile refinishers will be
require the application of a urethane unable to rely solely on low VOC
clearcoat. The use of glycol ethers, products and high transfer efficient
esters, ester alcohols and water as spray equipment to reduce VOC
solvents for paint products will emissions. Employers will also need
continue to increase. Other high to train their painters and prep
solvency products such as propylene technicians in the proper use of all
glycol and methyl butyl ethers will existing and new equipment and
also gain popularity with paint products entering the market place.
manufacturers. Spray paint techniques must also be
High viscosity, high solids paints
49
11: What to Expect in the Future
improved to reduce overspray to HAPs. Changes in coating products,

reduce material waste and VOC spray equipment and application
emissions. This will require painters techniques will all be met with some
to have additional training in proper resistance. But with continued
spraying techniques using the new cooperation and education, harmful
high transfer spray equipment. VOC and HAP emissions from
refinishing operations will be drama-
It will take the efforts of all paint
tically reduced, creating a cleaner
related industries to provide
and healthier environment for all.
adequate reduction of VOCs and
Laser TM The Iowa Waste Reduction Center has developed and

TM
patented the Laser Touch targeting system to help
Touch improve transfer efficiency, and reduce overspray and
TM
material consumption. The Laser Touch is designed
to provide spray technicians with a real-time means of
assessing their spray technique and improving their spray performance. It
uses a split laser beam image to provide the spray gun operator with a
visual indication of gun-to-part distance, gun angle and targeting.
TM
The Laser Touch has proved to be the most well received and productive
training tool used in the Spray Technique Analysis and Research program.
TM
STAR trainees using the Laser Touch have shown dramatic
improvements in maintaining a consistent
spray distance, proper gun angle, uniform
coating thickness and improved transfer
efficiency. The following comments are
representative of statements made by
TM
Laser Touch users:
I cannot believe my spray distance

varied that much, this device helps me
immediately in keeping me consistent.
Quite frankly, its perhaps one of the

biggest money saving devices that we
have ever seen come about it this
industry.
This is great for both experienced

painters as well as the beginners.
For more information on the Laser

TM
Touch call the IWRC at 319-273-8905.
50
11: What to Expect in the Future
improved to reduce overspray to HAPs. Changes in coating products,

reduce material waste and VOC spray equipment and application
emissions. This will require painters techniques will all be met with some
to have additional training in proper resistance. But with continued
spraying techniques using the new cooperation and education, harmful
high transfer spray equipment. VOC and HAP emissions from
refinishing operations will be drama-
It will take the efforts of all paint
tically reduced, creating a cleaner
related industries to provide
and healthier environment for all.
adequate reduction of VOCs and
Laser TM The Iowa Waste Reduction Center has developed and

TM
patented the Laser Touch targeting system to help
Touch improve transfer efficiency, and reduce overspray and
TM
material consumption. The Laser Touch is designed
to provide spray technicians with a real-time means of
assessing their spray technique and improving their spray performance. It
uses a split laser beam image to provide the spray gun operator with a
visual indication of gun-to-part distance, gun angle and targeting.
TM
The Laser Touch has proved to be the most well received and productive
training tool used in the Spray Technique Analysis and Research program.
TM
STAR trainees using the Laser Touch have shown dramatic
improvements in maintaining a consistent
spray distance, proper gun angle, uniform
coating thickness and improved transfer
efficiency. The following comments are
representative of statements made by
TM
Laser Touch users:
I cannot believe my spray distance

varied that much, this device helps me
immediately in keeping me consistent.
Quite frankly, its perhaps one of the

biggest money saving devices that we
have ever seen come about it this
industry.
This is great for both experienced

painters as well as the beginners.
For more information on the Laser

TM
Touch call the IWRC at 319-273-8905.
50

Auto Body Surface Coating Guide PDF

Diunggah oleh

Informasi Dokumen

Judul Asli

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

Auto Body Surface Coating Guide PDF

Diunggah oleh

Hak Cipta:

Format Tersedia

Auto Body

University of Northern Iowa

An overview of the auto refinishing process (Section 2)

An overview of the auto refinishing process (Section 2)

A. Recommended Steps for Practical Recommended Steps, cont

A. Recommended Steps for Practical Recommended Steps, cont

Recommended Steps, cont

Recommended Steps, cont

Turbine Guns turers developed more versatile, less

Turbine Guns turers developed more versatile, less

Like the HVLP equipment, LPLV

LPLV Guns required for HVLP equipment).

1. Turn off the atomizing air.

Like the HVLP equipment, LPLV

LPLV Guns required for HVLP equipment).

1. Turn off the atomizing air.

Figure 10: Self-Adhering Power Label

Figure 10: Self-Adhering Power Label

Cleaning remove all remaining paint

Cleaning remove all remaining paint

Figure 12: Enclosed Air Powered Mechanical Cleaning System

Figure 12: Enclosed Air Powered Mechanical Cleaning System

VOC Content Paint VOC content - 4.50 lbs/gal x 50% = 2.25

T he VOC content of paints or

(MSDS) provided by the This sprayable product has a VOC

VOC Content Paint VOC content - 4.50 lbs/gal x 50% = 2.25

T he VOC content of paints or

(MSDS) provided by the This sprayable product has a VOC

VOC Content Paint VOC content - 4.50 lbs/gal x 50% = 2.25

T he VOC content of paints or

(MSDS) provided by the This sprayable product has a VOC

T o achieve maximum adhesion

undercoat, the surface must first be

as xylene and mineral spirits. These

cleaners cleaners. Second, they do not

as xylene and mineral spirits. These

cleaners cleaners. Second, they do not

B. Two Stage Basecoat/ although acrylic enamel and lacquer

B. Two Stage Basecoat/ although acrylic enamel and lacquer

Advantages, cont D. Recommended Practices for Topcoats

Advantages, cont D. Recommended Practices for Topcoats

Prior to purchasing any paint gun, consult your paint representative to

Contact your paint representative and/or paint gun representative to determine

Spray Application Techniques

Feather the trigger at the beginning and end of each pass.

If blending is necessary, keep the blend area as small as possible without

Prior to purchasing any paint gun, consult your paint representative to

Contact your paint representative and/or paint gun representative to determine

Spray Application Techniques

Feather the trigger at the beginning and end of each pass.

If blending is necessary, keep the blend area as small as possible without

Equipment Cleaning Primer-surfacers cont

Keep solvent containers closed when not in use. Topcoats

Use low VOC, waterborne primer-surfacer products.

Equipment Cleaning Primer-surfacers cont

Keep solvent containers closed when not in use. Topcoats

Use low VOC, waterborne primer-surfacer products.

improved to reduce overspray to HAPs. Changes in coating products,

Laser TM The Iowa Waste Reduction Center has developed and

I cannot believe my spray distance

Quite frankly, its perhaps one of the

This is great for both experienced

For more information on the Laser