Lecture 4. HGH Performance Coatings For Corrosion Protection MR R Venu Akzo Nobel PDF

High Performance Coatings for Corrosion
Protection
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale Protective Coatings
01 High Performance Coatings
High Performance Coatings -
Definition
Coatings which give superior performance and add value

/ enhance the life of the structure to which it is painted
High Performance Coatings - Types
Based on Chemistry: zinc rich epoxies, zinc silicates, epoxies,

polyurethanes, polysiloxanes.
Based on Durability / Design Life: with reference to ISO12944

Global Corrosion Standard
Based on Functionality: serving dual purpose of corrosion

protection as well as an additional functionality like fire
protection or having a specific performance criterion based on
surface tolerance, zinc level, U.V. resistance etc.
High Performance Coatings – Generic Types
based on Chemistry
Coatings have evolved from traditional alkyd based systems to epoxy and zinc based over the years; the latest
developments being PU & polysiloxanes in the finishes segment
In terms of corrosion resistance it is generally found that: Alkyd < Epoxy < Polyurethane < Polysiloxane
UV resistance Corrosion Resistance Indicative Temp (Dry) °C
Alkyd Fair Poor-Fair 90-120
Inorganic Zinc N.A. Excellent 400
Zinc Rich Epoxy N.A. Excellent 200
Epoxy Poor-Fair Excellent 90-120
Polyurethane Excellent Good 90-120
Polysiloxane Excellent Good 90-120
High Performance Coatings
ISO 12944 – Who uses it?
• Many engineers prefer dealing with ISO - it is an independent, internationally

recognized organization
• ISO 12944 was released in 1998 and it has rapidly replaced local standards in
Europe e.g. BS5493 and DIN55 928
• It has also been adopted where no strong local standards are in place
• Within the Americas and Australasia where NACE/SSPC and AS/NZ
standards are well established respectively, the switch to ISO 12944 is less
advanced, however it is growing in popularity in these areas
ISO 12944 Part 1 - Design Life Guide
• ISO12944 contains three Corrosion Durability Ranges - these are

better described a projected design life of the building These design
lives relate primarily to corrosion performance - it is also useful to
consider the color and gloss durability of the topcoat used.
• ISO 12944 Durability Ranges
• The Design Life should be used to select the most cost effective
system for the anticipated project lifetime.
• It should be noted however that durability does not equate to a

guarantee time - it is more appropriate to equate durability to the
"Design Life" of the coating system - regular minor maintenance
should always be anticipated
High Performance Coatings-
Types
• ZINC BASED COATINGS
• SURFACE TOLERANT COATINGS
• POLYSILOXANE FINISHES
• GLASS FLAKE EPOXIES.
• VINYL ESTER COATINGS
• COLD SPRAY ALUMINIUM
• INTUMESCENT/FIRE PROTECTION
Zinc based Primers
• Zinc-Rich Primers
• Contain particles of metallic zinc dust suspended in
the binder
• Must be in intimate contact with the steel substrate
• Require high level of surface cleanliness
• Provides galvanic protection by zinc sacrifice
• Provides barrier protection by the zinc particles
• Required by AS/NZS 2312-2002 and ISO 12944 to
achieve long-term corrosion protection
• Equivalent to hot dip galvanizing (inorganic zinc)
• Poor chemical resistance
• Two generic types:

• Zinc-Rich Epoxy Primers
• Inorganic Zinc Primers
Zinc Based Coatings – SSPC PAINT20
Zinc silicates v/s. Zinc Rich
• Zinc-Rich Epoxy Primers

• Good cohesive strength
• Positive cure mechanism
• Can be formulated for low temperature cure
• Good for multi-coat systems
• Inorganic Zinc Primers

• Poor cohesive strength
• Requires atmospheric moisture to cure
• Not applicator friendly – requires experienced
applicators
• Excellent single coat protection in mild exposure
High Performance Coatings –
Surface Tolerant epoxies
• What are ‘Surface Tolerant Epoxies’?
• Surface Tolerant Epoxies are also referred as epoxy mastics or

simply mastic paints. These are the products that can accept
(adhere to) less than perfectly prepared surfaces. In other words
surface tolerant epoxies are paints that can be applied over manual
or power tool cleaned surfaces, in addition to the surfaces blast
cleaned.
• A category of surface tolerant epoxies can also provide satisfactory

adhesion over damp substrate.
High Performance Coatings –
Surface Tolerant epoxies
• How do surface tolerant epoxy materials work?
• Surface tolerant epoxies have better wetting properties to the

steel, hence able to provide relatively better adhesion over manually
cleaned or power tooled cleaned surface. This property is achieved
by ensuring that the film remains open/ wet condition for a longer
period in relation to pure epoxies, which helps in aiding the wetting
properties. Also these materials are flexible in nature, hence can
accommodate volume expansion due to formation of corrosion
products.
• Surface Tolerant products protect the surface by barrier protection

and slow down the corrosion process.
• Internally flexibilized Surface tolerant epoxies can take higher

fluctuations in temperatures and do not suffer loss of flexibilizer
resins as encountered in some of the hydrocarbon flexibilized
resins.
04 Finishes – that stand the test of time
A word about UV Resistance
• The ultra-violet (UV) component of natural sunlight contains a certain

amount of energy
• This energy is damaging to certain coating types such as those
containing epoxy binder
• The energy causes a breakdown of the binder ‘chemistry’
• This causes a release of the pigmentation and discolouration of
the binder itself
• Resulting in Chalking, Colour loss and gloss loss
• The polysiloxane binder has very good resistance to the energy from
natural sunlight and is able to slow down the onset of chalking, gloss
loss and colour change
Polysiloxane Technology - Inorganic Backbone
The Carbon-Carbon (C-C) bonds

within traditional “organic”
coatings are less resilient than
those found in acrylic
polysiloxanes
The energy required to break a

C-C bond is
350 kJ/mol
Polysiloxane coatings are

significantly more resilient to UV
(sunlight) degradation
The energy required to break the

Silicon –Oxygen (Si-O) bond is
452 kJ/mol - 29% higher than
the C-C bond found in traditional
coatings
Durability
• Typically measured as UV resistance on top coats

• Alkyd < Epoxy < Polyurethane < Epoxy Polysiloxane < Acrylic
Polysiloxane
• The graph below dramatically illustrates the differing UV durability
on accelerated testing
Gloss Retention Over Time - UV A
100
etention(%
POLYSILOXANE
)
80
60
loaaR
POLYURET HANE
40
G
20 ALKYD
EPOXY
EPOXY - ACRYLIC
0
0 500 1000 1500 2000 2500 3000
T im e (hrs)
Summary
• Acrylic polysiloxane technology delivers a number of

distinct advantages for architectural buildings and facilities:
• Making your colors last

• When used as part of a high performance system, the color and
gloss retention of polysioloxanes can last up to four times that
of traditional polyurethane finishes. The UV degradation of
Interfine is lower, ensuring the color and gloss you see today
will last longer over the years.
• Staying cleaner for longer

• The technology used in polysiloxane helps to reduce dirt
retention, which is important when you consider most buildings
are not cleaned Whilst comparative products attract dirt and
deposits, polysiloaxne stays cleaner for longer.
• A safer option
• No free isocyanate formulation contributes to a healthier
workplace and adds to the social aspect of your project
01 High Performance Coatings – Fire Protection
Why do we require Fire Protection?
• The primary objective of providing fire protection is – preserve

Life safety and the secondary objective is to protect property &
safeguard the environment.
• Fire Protection protects steel frame constructions from

structural collapse. Steel - does not burn, BUT, it starts to lose
its structural strength at temperatures above 400 °C.
• High Performance coatings known as Intumescent coatings

give the additional benefit of fire protection along with
corrosion protection to the steel structures
What is an Intumescent Coating?
• Intumescence = “to swell up”
• Coating which rapidly swells when subjected to heat to form a stable
carbonaceous char
• Char or foam thermally insulates the substrate from the heat source
Char Expansion (16x expansion)
How does an Intumescent Coating work?
An Uncoated steel takes approximately 5- 20 minutes to reach the

critical temperature.
1000
900
800
Temperature ° C
700
600 Critical Temperature
500
400
300
200
In this example Interchar provides 70 minutes of protection
100
0
0 10 20 30 40 50 60 70
Time (minutes)
Furnace Uncoated Steel Interchar Coated Steel
How do we correlate Hp/A values to the
Intumescent coating film thickness?
• Loading tables published by third party testing agencies take into

account all the factors involved (like shape of structure, Fire rating in
minutes, etc.) and provide information on the required thickness, for
the correct Hp/A and critical temperatures
For
presentation
purposes only –
check with
international
Paint for project
specific
loadings
Fire Protection - Standards
• Common standards for fire protection include .
Standard Prime Location Notes

UL263 USA Global acceptance
BS476 (pt 20-22) UK Global acceptance
GOST Russia Russia only
AS1530:4 Australia Most of the Asia Pacific
ENV 13881-4 Europe Relatively new standard
GB14907 China Mainland China only
01 High Performance Coatings - Sustainability
Sustainable Coatings
There is an endeavor reduce (and where possible eliminate) the

use of hazardous materials in coatings.
There is a need to provide suitable alternatives to coatings that use

potentially hazardous substances, e.g.
• Isocyanates
• Coal tar
• Red lead
• Zinc chromates
• Lead chromate
VOC
VOC stands for Volatile Organic Compounds. At International Protective

Coatings we want to help our customers select products that reduce
organic solvent (VOC) emissions, thereby reducing the potential for
photo-chemical pollution.
IGBC LEED requirement:
What is Ecotech®?
• The world’s Responsible leading suppliers of protective coatings,

have seriously taken responsibility to help end users to use
coatings in a safer, more environmentally conscious manner.
• This is an active programme in place to review the raw materials

used in coatings and, where appropriate, reformulate to less
hazardous and more environmentally acceptable
constituents.
• Ecotech® is the banner which promotes and support the use of

protective coatings in a manner that is both safe and
environmentally responsible.
01 High Performance Coatings – Q & A

Lecture 4. HGH Performance Coatings For Corrosion Protection MR R Venu Akzo Nobel PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Lecture 4. HGH Performance Coatings For Corrosion Protection MR R Venu Akzo Nobel PDF

Uploaded by

Copyright:

Available Formats

High Performance Coatings for Corrosion

Coatings which give superior performance and add value

Based on Chemistry: zinc rich epoxies, zinc silicates, epoxies,

Based on Durability / Design Life: with reference to ISO12944

Based on Functionality: serving dual purpose of corrosion

UV resistance Corrosion Resistance Indicative Temp (Dry) °C

Alkyd Fair Poor-Fair 90-120

Inorganic Zinc N.A. Excellent 400

Zinc Rich Epoxy N.A. Excellent 200

Epoxy Poor-Fair Excellent 90-120

Polyurethane Excellent Good 90-120

Polysiloxane Excellent Good 90-120

• Many engineers prefer dealing with ISO - it is an independent, internationally

• ISO12944 contains three Corrosion Durability Ranges - these are

• ISO 12944 Durability Ranges

• It should be noted however that durability does not equate to a

• Two generic types:

• Zinc-Rich Epoxy Primers

• Inorganic Zinc Primers

• Surface Tolerant Epoxies are also referred as epoxy mastics or

• A category of surface tolerant epoxies can also provide satisfactory

• Surface tolerant epoxies have better wetting properties to the

• Surface Tolerant products protect the surface by barrier protection

• Internally flexibilized Surface tolerant epoxies can take higher

• The ultra-violet (UV) component of natural sunlight contains a certain

The Carbon-Carbon (C-C) bonds

The energy required to break a

Polysiloxane coatings are

The energy required to break the

• Typically measured as UV resistance on top coats

Gloss Retention Over Time - UV A

• Acrylic polysiloxane technology delivers a number of

• Making your colors last

• Staying cleaner for longer

• The primary objective of providing fire protection is – preserve

• Fire Protection protects steel frame constructions from

• High Performance coatings known as Intumescent coatings

• Intumescence = “to swell up”

• Coating which rapidly swells when subjected to heat to form a stable

An Uncoated steel takes approximately 5- 20 minutes to reach the

• Loading tables published by third party testing agencies take into

• Common standards for fire protection include .

Standard Prime Location Notes

There is an endeavor reduce (and where possible eliminate) the

There is a need to provide suitable alternatives to coatings that use

VOC stands for Volatile Organic Compounds. At International Protective

IGBC LEED requirement:

• The world’s Responsible leading suppliers of protective coatings,

• This is an active programme in place to review the raw materials

• Ecotech® is the banner which promotes and support the use of

You might also like