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HIGH SOLIDS COATINGS

High solids coatings were first introduced to comply with the amplifying VOC regulations and Clean Air Act. Traditional coatings systems have a composition that is about 25 solids and !"

solvents. The high solids coatings introduce a different concept by adding little to no solvent to the composition. #n comparison to traditional systems these coatings have a much higher percentage of solids$ around !5 to %" . Very high solids coatings have as much as &"" solid

content. 'ue to this increased solids content and lac( of solvent$ these coatings have much higher viscosities$ ) to * times thic(er$ ranging around 2$""" to &"$""" centipoises.The removal of solvents$ which are used in traditional paints to compensate for viscosity$ flow and curing$ re+uire the new coatings to have very different characteristics and re+uire new methods of handling. These coatings not only provide reduced VOC emissions$ they also provide increased corrosion resistance$ coating thic(ness and edge retention.They provide a higher level of performance$ re+uiring less surface preparation and the ability to self,prime. The thic(ened coating provides the advantage of fewer re+uired coats$ reducing cost per application. The coatings are produced as both single and dual component systems. -or dual component systems$ the two parts are mi.ed at application to minimi/e some of the problems encountered with the reduced solvent and high solids. After the dual component system is mi.ed the chemical reaction begins and heat within the mi.ture rises. This new composition causes three main challenges$ reduced pot life due to +uic( reaction time$ temperature sensitivity during application and high viscosities$ re+uiring new application methods. The use of typical application e+uipment does not provide the ade+uate pressure levels to deliver a smooth layer of paint.Higher,pressure pumps were then introduced as a solution to the viscous mi.ture. 0roblems encountered range from pump clogging$ pump seal lea(age$ e.cessive pump down time and finally$ e.tensive flushing and clean up re+uirements after each use.Additional issues included high,pressure spray gun$ accessories and tip problems.0aint mi.ing problems became an issue due to viscosity and the short pot life of the materials.Temperature sensitivity and personnel e.posure problems were also reported. 1e.t$ the plural component spray e+uipment was introduced. This e+uipment not only produces the increase in pressure needed to properly atomi/e the coating but also provides the added

advantage of increased production rates due to the product delivery rate increase. #n addition$ with reduced solvent content coatings$ thic(ness per coat can be increased2 therefore fewer coats are needed to obtain the specified dry film thic(ness.3electing the appropriate e+uipment for the 4ob is essential to the successful application of these coatings. Single Component Spray Equipment (High Pressure) Advantages 5sing higher,pressure single component paint spray e+uipment to apply two component high solids coatings has its advantages.0rimarily the initial e+uipment set up cost is much less.Training for e+uipment operators is minimi/ed6mainly safety related for operating higher pressure e+uipment7$ ma4or process modifications are not re+uired$ and it gets the 4ob done. Disadvantages The two primary disadvantages are the short pot life management and the advantages of bul( product supply cannot be reali/ed.The short pot life$ in some cases )",*5 minutes$ will always be a process issue and product mi.ing and product tending will remain labor intensive.0ersonnel are e.posed to the products during the mi.ing process. 8ul( purchase and delivery is not possible.0aint waste and delivery container 65 gallon cans7 waste stream is costly.9i.ing ratios and homogeneity can be an issue2 small +uantities of the coating cannot be easily produced.#n some cases 5 gallons must be mi.ed to deliver the final few pints of product re+uired.:+uipment must be flushed and cleaned after each operation 6large +uantities of solvent are used$ along with higher solvent emissions to the environment$ and many man,hours e.pended7.An e+uipment or process hold up can result in e+uipment damage due to product solidifying while still in the pump.;apid cure technology is not feasible.#n the final analysis larger paint teams are re+uired$ more product is wasted$ ris( of production delays is real and it is the more e.pensive application method. Plural Component Equipment (High Pressure) Advantages <ith the introduction of 0lural Component 3ystems into the application process$ numerous process improvements can be instituted and production and economic advantages reali/ed.These improvements not only provide a manpower savings but also can dramatically reduce application costs. The advantages can be divided into four main categories. &.;eduction

in 9aterial Costs.2.;eduction in =abor Costs ).:nvironmental Concerns. *.0roduction :fficiencies. Reduction in Material Costs Coating materials can be drawn from large$ recyclable$ space,saving containers 6drums$ tan(s$ etc.7.There is no loss of material due to spillage or residual left in emptied paint cans.The e.pensive disposal of paint cans with residue 6ha/ardous materials7 is eliminated.1o material is lost due to e.cess pre,mi.ed paint and short pot life losses. 3mall +uantities of paint needed for finishing a 4ob or touch up can be dispensed. 3olvent cost savings are reali/ed when cleaning the system$ since only those parts that come in contact with mi.ed material must be flushed.9aterial is also saved$ especially when using long hoses$ by use of an attached high,pressure flush pump that enables mi.ed material still located in the spraying hoses to first be applied before flushing the system at the end of the application. Reduction in a!or Costs 1o e.tra personnel are re+uired for manually mi.ing the materials to be sprayed$ scraping material from the sides and bottoms of containers$ and managing the hot potting evolution.1o logistics trail of supplying paint cans to the site$ and then removing and storing these cans for disposal.=abor costs are also reduced$ since each component in the system is transferred separately.=ess wor( is necessary for cleaning$ since only those parts that come in contact with mi.ed material must be flushed. :+uipment does not have to be cleaned after each application because the 2 components are not mi.ed until the mi.ing manifold$ which can be positioned near the final spray point.0aint teams could possibly be reduced by & or 2 personnel. Environmental Concerns Ha/ardous waste is reduced through the use of large recyclable containers 6no more paint cans with residual material needing disposal7.1o solvents are necessary to apply coatings.3olvents used for clean up are drastically reduced since only those parts that come in contact with mi.ed material must be cleaned. Production E""iciencies 'elays due to poor management of product pre,mi.ing are eliminated.0roduction delays due to wor( slow down$ and e+uipment clogging due to material curing in the single component pump$ are gone.#naccurate proportioning due to personnel error is eliminated.:liminating manual

agitation ensures an accurate homogenous mi.ture. 0re,heating the components with in,line heaters is possible$ thereby contributing to efficient atomi/ation of the mi.ed coating at lower pressures.Coatings go on easier with less over,spray. The lower pressures also provide a safer wor( environment for applicators and less e+uipment wear and tear.#n some cases colder weather applications are possible.0ump clean up after every painting evolution is not re+uired$ and e+uipment down time is reduced.Containeri/ed$ climate controlled units can be positioned on or near the 4ob site. ;apid cure coatings can be utili/ed. Disadvantages The initial e+uipment start up cost is the biggest detractor for shifting to plural component e+uipment.The units are larger and heavier.0lural systems are slightly more complicated to operate and operator training 6generally provided by the e+uipment manufacturer7 is re+uired. PR#CESS Single Component Equipment Process #vervie$ (Application o" high solids coatings) Application of two component high solids coatings utili/ing higher,pressure single component e+uipment presents several challenges to the application process.The viscosity of the paint ma(es it not only a challenge to spray but manual mi.ing can be a problem. The base must first be stirred and then the hardener manually mi.ed in at the specified mi.ing ratio to ma(e a homogeneous mi.ture prior to the pump.The short pot life prevents pre mi.ing and staging$ as well as re+uiring constant attention and coordination with applicators to prevent production delays or material wastage. The mi.ed product then enters the pump and e.its through the hose to the paint gun.All parts of the pump from the suction on are e.posed to the mi.ed material and must be thoroughly cleaned after each application. Plural Component Equipment Process #vervie$ <hen applying two component high solids coatings by high,pressure plural component e+uipment$ the base and hardener are stored separately in bul( supply containers that can be refilled without interrupting production.These containers can be supplied with level indicators$ agitators and pre,heaters if desired.:ach product is supplied separately to its individual pump fluid end.The products do not come in contact with each other until the mi.ing manifold$ or in some cases$ at the spray gun itself.1o mi.ed product goes through the pump$ thereby eliminating clogging or solidification of product in the pump.Coating specified mi.ing ratios could be set by

mechanically changing out the lower end of a fi.ed ratio unit or by ad4usting the stro(e on a variable ratio pump.

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