Paint technology overview

Paint technology
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JPS-E / Paint technology / 1
Paint consist of:
• Binder
• Colour pigment
• Extenders
• Solvents
• Additives
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Composition of paints
Paints
Binder Pigments Solvents Additives

Natural Resin Colouring Hydro carbons Wetting agent
•Drying oil
•Coal Tar Extender Ketones Anti-settling
•Nitrocellulose
Synthetic Resin Inhibitive pigm. Esters Drier
•Alkyd
•CR
Cathodically Ethers Anti-skinner
•Epoxy
protective
•Polyester
•Polyurethane Alcohols Plasticiser
•Silicate Biocides
•Vinyl Water
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What Is A Binder ?
A binder is a fluid or a solution that forms a film

during drying or curing (is responsible of cohesion
& adhesion).
Drying/curing takes place by:
A. Solvent/water evaporate
(physically drying).
B. Solvent evaporation and a chemical reaction
takes place during the drying process.
(chemically drying/curing).
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The Properties of a Paint Will Be
Decided By The Binder
• Describes what type of
paint/coating we have
• Bind pigments and
extenders to a solid film
• Provides the adhesion to
the substrate
• Provides the water, chemical,
solvent and UV resistance
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The Dry Binder
Consists of Large Molecules
Large molecules gives:
a) Good mechanical strength
b) Good chemical resistance
Physically drying binders:

Molecules are large before drying starts
Chemically curing binders:

Large molecules are formed during curing
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Main Groups Of Binders
The binders are grouped according to:

• Drying process
• Curing mechanism
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Different Drying Processes
• Oxidatively drying
• Physically drying
• Chemically curing
• IR/UV - cured
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Curing Mechanism of Binders
Oxidising Chemically curing

• Alkyd • Epoxy
Physically drying • Polyurethane
• Chlorinated rubber • Polyester
• Vinyl • Silicate
• Acrylic
• Asphalt
• Tar
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DRYING THROUGH OXIDATION
Solvents evaporating
Oxygen enter.
Reaction starts:
Polymer molecules
linked together through
chemical bonds
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PHYSICAL DRYING.
Solvent Born Paints
Polymer molecules are packing:
Polymer molecules stick together (no chemical bonds):
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PHYSICAL DRYING
Water Born Paints
Water evaporating
= Dispersed droplets
Droplets are packing
Droplets melt together, co-solvents evaporate
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Curing Mechanism of
Two -Pack Paints
= Polymer = Curing agent (hardener)
Polymer & hardener molecules reacted

to form a new chemical substance:
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The Surface Tolerance Depends on the
Penetrating Properties of the Binder
Vinyl
Chlorinated rubber
Epoxy
Polyurethane
Urethane alkyd
Surface tolerant paint: Alkyd

Epoxy Mastic Boiled linseed oil
Raw linseed oil
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Epoxy Mastics are
“Surface Tolerant” and “High build”
Traditional paints
• Low coverage
Steel • Poor flow
Epoxy Mastic
• Good penetration
Steel • High Build
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Pigments, Examples
Rust preventing pigments: Coloured pigments

• Red Lead (hiding / opaque):
• Zinc • Inorganic; red, yellow,, brown, black
• Zinc Chromate • Organic, all colours
• Zinc phosphate • Titan dioxide (white)
Extender pigments
(non/limited hiding/opacity properties):
• Talcum
• Barium sulphate
• Microdol (dolomite)
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PVC: Pigment - Volume - Concentration
Definition
Ratio of the volume of pigment to the

volume of total non-volatile material in a coating
 Non-volatile matter: E.g. pigment and binder

 The figure is usually expressed as a percentage.
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The Gloss of a Paint Depends on the PVC
(Pigment - Volume - Concentration)
Binder Glossy
Colour PVC 15 -25
pigments
Extenders
Semigloss
PVC 30 - 40
Flat
PVC 35 - 50
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Solvents / Diluents
• Dissolve the binder

• Give lower viscosity
• Give application properties for brush,
roller, spray
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Solvents / Diluents , Examples
• Water
• White Spirit
• Xylen
• Toluen
• Ketones
• Glycoles
• Alcohols
• Reactive solvents
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Addition of Thinner
Evaporation rate and solubility of a thinner will
influence a paint’s:
• Drying time
• Film-forming properties
• Quality of the film
 Most paints are ready to be applied as
supplied by the manufacturer.
 Never add an unspecified thinner to a paint,
it may lead to disastrous results
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Additives
• Wetting agent
• Anti-foam
• Anti-settling
• Anti-skin
• Anti sagging
• Catalysts
• UV-absorbers
etc.
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Protection
For corrosion prevention with paints, three main

principles are employed:
• Barrier effect
• Inhibitor effect
• Galvanic effect
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An Impervious Coating Serves as an
Inert Barrier to Protect the Surface
Impervious to ions,
oxygen, carbon dioxide
Low moisture transmission
2nd coat
1st coat
Primer
Steel
Strong adhering No voids at interface
coating thoroughly to accumulate water
wets steel surface Clean surface - no salts
Physical as well as
to create osmotic blistering
chemical adhesion
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Barrier effect
Why are some paints pigmented with
aluminium, MIO or glass flakes ?
Water
Paint with glass or

aluminium flakes
Steel
Flake-formed pigments make it more difficult for moisture

to reach the steel as the distance becomes longer than the D.F.T.
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Inhibition
Moisture Absorption
Ionisation of Inhibitor
Reaction with Steel Surface
Passive layer forms
2nd Coat
1st Coat
Inhibitive Primer
Steel
In inhibitive coatings, moisture may penetrate to reach the inhibitive

primer where the reactive pigments are activated, which in turn
passivate the metal substrate at the coating/metal interface.
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Cathodically Protective Pigments
Damage in coating to steel surface
Moisture allows Zinc to

ionize, cathodically protecting the steel.
Superior adhesion prevents coating undercut

2nd Organic Topcoat
2+ Inorganic Zinc Primer

Zn
Steel
An inorganic Zinc primer reacts to protect the

steel substrate when the topcoat is damaged.
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Primers
Primers are universal for all anticorrosive coating systems
and are considered the most important component of the
system. The most important properties of primers are
listed as follows:
1. Adhesion (strong bonding to substrate).

2. Cohesion (high internal strength in the film).
3. Inertness (strong resistance to corrosion and chemicals).
4. Intercoat bond (high bonding to intermediate coat).
5. Appropriate flexibility.
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Intermediate or Body Coats
The principal purposes of an intermediate coat is to
provide:
1. Thickness for total coating.

2. Strong chemical resistance.
3. Resistance to moisture vapour transfer.
4. Increase electrical resistance for the coating system.
5. Strong cohesion.
6. Strong bonding to primer and topcoat.
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Topcoats
Topcoats also perform several important

functions as they:
1. Provide a resistant seal for the coating system.

2. Form the initial barrier towards the environment.
3. Provide resistance towards chemicals, water, and
weather.
4. Provide a tough and wear-resistant surface.
5. Provide a pleasing appearance.
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What film-thickness should corrosion
protecting paint systems have ?
• Deciding factor is the environment:
In a dry inland atmosphere and indoor 120 microns
will be sufficient. In an aggressive industrial
environment and along the coast and at sea, 250 - 300
microns will be necessary.
Number of coats is also of importance and not only
the film thickness
100 microns in 2 coats (50 + 50 microns) are giving
better protection than 100 microns in 1 coat. Special
coatings may be applied in thick coats.
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Penetration of moisture
Moisture transfer through a coating with excellent adhesion
Moisture vapour Moisture vapour 3 Coat system

evaporating penetrating Strong adhesion
Steel
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Penetration of Moisture in Areas
with Poor Adhesion.
A three coat system
2. Moisture 3. Vapour pressure
lifts coats in areas
1. Moisture vapour penetrating into void with poor adhesion
(Poor adhesion)
Steel
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Water absorption.
Different types of paint
Coating type Test Grams/m²/24 hours

thickness
Epoxy Polyamide 125 µm 1.71

Amine Catalysed Epoxy 125 µm 3.10
Vinyl Chloride-Acetate 125 µm 11.94
Vinyl Acrylic 125 µm 12.87
Alkyd (Short Oil) 125 µm 57.36
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What influence the drying process ?
• Relative humidity, % R.H.

• Ventilation
• Temperature
• Film thickness
• Number of coats
• Evaporation rate of the solvents
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Atmospheric Conditions.
Requirement During Blasting and Painting
Surface temperature of the

structure must be minimum
3 °C above the dew point
of the surrounding air
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Solvent Retention in % By Weight
for Various Dry Film Thicknesses
Solvent retention
in % by weight
100
80
60
500 micr.
40
20 250 micr.
100 micr.
50 micr
0
0 100 200 300 400
Time in days
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Water uptake
Water uptake of a coal tar epoxy paint

(dry film thickness approx. 250 mm.)
Uptake in % weight
20
Cured under very poor ventilation conditions
15
10
Cured under poor ventilation conditions
5
Cured under good ventilation conditions
0
0 100 200 300 400 500 600 700 800 900 1000
Time in hours
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Oxidative Drying Binder
The binder absorbs oxygen from the air, causing
the binder molecules to link together to form larger macro
molecules.
The original binder molecules are “free to move”

while the macro molecules in the dry film are fixed.
Air drying alkyds and boiled linseed oil dries in this way.
Alkyds, however, have comparatively larger molecules

from the beginning and therefore dry faster than linseed-oil.
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Alkyd Drying Process
Oxygen O2 Solvent
Wet film
Substrate
Dry film
Substrate
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Sophisticated Paints
• Vinyl • Acrylic
• Vinyl tar • Zinc Ethyl Silicate
• Epoxy • Polyurethane
• Epoxy tar • Polyester
• Epoxy mastic
Paints with large binder molecules generally require a

good quality surface preparation.
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Epoxy paints
Epoxy resin
Solvents
Part A: Pigments
Extenders
Additives
+
Curing agent
Part B: Solvent
Chemical reaction
Evaporation of solvent
Insoluble
Result 3-dimensional
network
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Curing agents
Polyamides:
Standard epoxy paints
Amine and amine adduct:
Solvent free coatings
Coatings with increased chemical resistance
Isocyanates:
Low temperature curing
Reaction with -OH
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What is the Difference Between
a Paint, a Varnish and a Stain ?
Only matt or
Binder
satin finish
Pigments Paint
Extenders
Solvents
Varnish
Additives
Stain
Vehicle: Binder + solvents

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What is Chemical Resistance ?
“A coatings ability to remain

unaffected, physically and chemically,
when exposed to a chemical environment”
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Why are Chemicals
Aggressive to Coatings ?
The most important factors are:

• Molecular size: Penetration
(Methanol, water)
• Solvents for organic binders
(epoxy, vinylester, polyester)
• Take pleasure in decomposing the binder
molecule (NaOH, Sodium hypochlorite)
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Molecular Size and Chemical Resistance
• Small molecules - C3 and lower
– migrates easily in and out of the coating
– examples: Methanol, Ethanol, Ethyl acetate, Acetic acid
• Medium size molecules - C3 to C6
– migrates easily into the coating
– remains in the coating
– examples: Butanol, Butyl acetate
• Large molecules - C6 and higher
– do not migrate into the coating
– can still be aggressive
– examples: Benzyl chloride, Butyl octadecanoate
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Ambient Temperature and
Steel Temperature
Is the temperatures important ? YES !
• Ambient temperature will influence:
– shelf life
– viscosity/sprayability
– steel temperature
• Steel temperature will affect:
– speed of cure
– degree of cure
– recoating interval
– service life of the coating
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The Characteristics of an
Aggressive Chemical
An aggressive chemical can be:

• Corrosive
• Cause swelling
• Have high temperature
• Chemical attack (acids, alkaline)
• Etching
• Erosion in combination with
effects above
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Chemical Family and
Resistance
• Acids Chemflake Classic/Special/CV
• Alcohols Tankguard S, Chemflake C/S/CV, Resist GTI,
Jotacote 5
• Alkalies Tankguard HB, Tankguard Special,
• Crude oil Chemflake C/S/CV
• Fatty acids Chemflake C/S/CV
• Gasolines Tankguard HB, Tankguard Special,
Chemflake C/S/CV, Resist GTI, Jotacote 5
• Solvents Tankguard Special, Resist GTI, Jotacote 5,
Chemflake C/S/CV
• Methanol Resist GTI, Jotacote 5
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• Thank You !
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Paint technology

Binder Pigments Solvents Additives

A binder is a fluid or a solution that forms a film

Physically drying binders:

Chemically curing binders:

The binders are grouped according to:

Oxidising Chemically curing

Polymer molecules are packing:

Polymer molecules stick together (no chemical bonds):

Droplets melt together, co-solvents evaporate

= Polymer = Curing agent (hardener)

Polymer & hardener molecules reacted

Surface tolerant paint: Alkyd

Rust preventing pigments: Coloured pigments

Ratio of the volume of pigment to the

 Non-volatile matter: E.g. pigment and binder

• Dissolve the binder

For corrosion prevention with paints, three main

Low moisture transmission

Paint with glass or

Flake-formed pigments make it more difficult for moisture

In inhibitive coatings, moisture may penetrate to reach the inhibitive

Moisture allows Zinc to

Superior adhesion prevents coating undercut

2+ Inorganic Zinc Primer

An inorganic Zinc primer reacts to protect the

1. Adhesion (strong bonding to substrate).

1. Thickness for total coating.

Topcoats also perform several important

1. Provide a resistant seal for the coating system.

Moisture vapour Moisture vapour 3 Coat system

Coating type Test Grams/m²/24 hours

Epoxy Polyamide 125 µm 1.71

• Relative humidity, % R.H.

Surface temperature of the

Water uptake of a coal tar epoxy paint

The original binder molecules are “free to move”

Alkyds, however, have comparatively larger molecules

Paints with large binder molecules generally require a

Vehicle: Binder + solvents

“A coatings ability to remain

The most important factors are:

An aggressive chemical can be:

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