6 Paint coating materials Objective ‘When you have gone through this chapter, you should be able to explain how the different paint coatings prevent corrosion be able to explain the composition of paints be able to explain the most important types of anticorrosion paints and coat- ings and their properties know how paint coating systems are built up be able to select a paint type on the basis of information regarding environ- mental class, degree of cleanliness and the conditions during paint application know how paints cure and how they can be thinned down : know of other possibilities than paint for protecting steel Introduction Paint is the coating material most widely used for protection against corrosion, but it is not the only type. Also large quantities of aluminium and zinc are used, as described in chapter 8 about thermal spraying. In addition, a number of other coat- ing materials are available. Some of them are very similar to paints and often they can only be distinguished from paints by their thickness. In this chapter paints will be discussed first. We will learn how paint can have a corrosion-preventing effect. In order to understand how paint functions as a mate- rial — both in its liquid and dry forms — we must know how it is composed. The properties of the many paints available on the market are largely deter- mined by their binder material. The binder determines which type of paint we have in front of us. This is often referred to as generic type. Paints of the same generic type contain the same binder. Other components may also be the same, for example the zinc powder pigment. Primers with epoxy binder and zinc powder as pigment constitute a generic type of paint. Other epoxy primers without zinc powder constitute another generic type. Important properties can be assumed to be the same for paints within the same generic type. However, variations of individual properties may occur. There may be differences in the formulations, and the raw materials may have been purchased from different suppliers. In the section about paint types we will first look into typical primer paints. After that, the physically drying paints, the oxidatively curing and the chemically curing paints will be discussed. For each paint type we must know the area of use, the types of influences that 172 Corrosion PROTECTIONthe paint may be able to tolerate, which surface preparation is required, and how the paint is to be applied. How does the paint coating system work? Anticorrosion paints may have different ways of working: they passivate the metal surface they keep out water and air and impede ion movement by a barrier effect they “sacrifice” themselves and thereby provide cathodic protection of the steel The different coats in a paint coating system serve different purposes. Usually, the paint system is built from a primer coat, an intermediate coat and a finishing coat. The function of the primer is to ensure good adhesion to the substrate. It must be compatible with the subsequent system build-up. Ina passivating paint system the primer coat must contain pigments to provide assivating effect. The designation of such primers is often based on the pig- ment used, for example zinc phosphate or red lead. Passivating and cathodically protective primers must be in direct contact with the steel in order to have their intended effect. The function of the intermediate coat is generally to build up the thickness of the paint system. This coat must also ensure that the finishing coat obtains good adhe- sion and is free from pores, craters and blisters. The finishing coat must provide the surface with the required colour and gloss. This is the coat primarily exposed to external influences from sun, rain and chemi- cals. . The paint type of the intermediate coat is usually named after the binder, for example vinyl paint or epoxy paint. Normally, the paint coating system is built up from similar based paint types in the intermediate and finishing coats. The primer may often be of a different type provided it is compatible with the other coats. Paint composition The main components of paints are binder, pigment and extenders and often also solvents and various additives. Binder The primary functions of the binder are to ensure that the pigment particles are bound together and to ensure that the paint has proper adhesion to the substrate. To a very large extent the binder determines the properties of the paint. In most paint types the binder is an organic material related to plastic materials. In some cases the binder is inorganic, such as silicates and cement. The binder determines the film-forming process of the paint. A distinction is 6 PAINT COATING maTERIALS 173made between physically drying paints, drying by evaporation of solvents chemically curing paints, curing by two components reacting with one another In achemically curing paint the two components, A and B, react with one another, while the solvents evaporate. A special variety of chemically curing paints is seen in the case of paints where the binder reacts with substances in the ambient environment, for example with the oxygen in the air or with water. Oxidatively curing is the term used for the reaction with oxygen during the drying of an alkyd or oil paint. white spirit | evaporates solvents evaporate i 4 ‘and react with one another | Figure 6.1 Most chemically curing paints first undergo a phase of physical drying by evapora- tion of the solvetis. It is important to note that paint which has only dried physically may be dis- solved by the same solvents that were used in the paint. Consequently, such paints normally have very good intercoat adhesion. The solvents in the subsequent coat dissolve the previous coat in such a way that the coats “melt” well together. The resistance to solvents, petrol and oil is poor. Chemically curing paints, on the other hand, are resistant to such chemicals. ARTI TO 1 Homopotymer water evaporates, Bom Homopolymer acrylic Copolymer PVACacrylic Figure 6.2 a) Drying of dispersion paint. b) The binder in the small globules may be of different types 174 Corrosion protectionPaints based on plastic dispersions, also called latex, are physically drying. In such paints the binder is finely dispersed as small globules in water. When the water evaporates, the globules “melt” together to form a film. After this, the paint film is no longer soluble in water, but it may be quite sensitive during the initial period. Many of the binders are what is termed high-polymeric substances. This applies to latex binders as well as acrylic and vinyl binders dissolved in solvents. The high- polymeric substances are composed of long chains of similar molecule units. If only one type of molecule is repeated in this chain, this is called a homopolymer. If two different molecule types are incorporated, it is called a copolymer. For exam- ple, a vinyl-acrylic copolymer consists of chains with alternating vinyl chloride and acrylate units. ‘Atom Individual Molecule Family te PM Highpolymeric chains Human chains Figure 6.3 Atoms can be likened to individual persons. The binder molecules are then like long chains of people The high-polymeric substances consisting of long molecule chains are thermoplas- tic. This means that they soften at increasing temperatures. High-polymeric sub- stances may also be built from large molecules in a three-dimensional network. Such networks are found in two-component binders like epoxy and polyurethane. These are called chemically curing resins, They do not soften like the thermoplas- tic materials at increasing temperatures. 6 Paint coatinc materiacs 175sere ee — — _~—~ _ Thermoplastic resin Te J NY Figure 6.4 Pigments Usually the function of pigments is to impart colour and opacity to the paint. Apart from that, they protect the binder from being broken down by the ultraviolet rays of the sun. Some pigments provide active corrosion prevention. They are primarily used in primer coats. Examples of such pigments are: zinc chromate, which has now been replaced by zinc phosphate due to the health hazard, red lead is not used any longer for the same reason, and zinc molybdate and barium metaborate are other examples of passivating pigments. Zinc powder is used in paints providing cathodic prevention. There must be metallic contact between the individual particles of zinc and between them and the steel surface in order for the paint to have its desired effect. Other metals; like aluminium, are used in the shape of pigment flakes. They strengthen the barrier effect of the paint by impeding the transport of air and mois- ture through the film. At the same time they have a reinforcing effect. Micaceous iron oxide is also used to obtain a barrier effect. The penetration of water, both in its liquid form and as water vapours, is impor- tant for the barrier effect. The vapour penetration is called the water vapour per- meability. The amount of water vapour permeating through a paint sample during a certain period of time is measured at a specific difference in the vapour pressure on either side of the paint film. Figure 6.5 Flake pigments provide a barrier effect 176 Corrosion PROTECTIONOrdinary pigments are available as fine-grained powders. The particles are ap- proximately I um in diameter, in some cases even considerably smaller. During paint production it is important that the pigments are finely dispersed in the binder phase. To the greatest possible extent the pigment particles should be fully enclosed by binder and not form agglomerates together with other pigment particles. The process of having the pigments finely distributed in the binder is called dispersion or grinding. ‘The pigments determine the colour, hiding power and gloss of the paint. The most important white pigment is titanium dioxide. The refractive index of titanium dioxide is higher than for other white pigments. This results in high opac- ity. The opacity is determined by the difference in refractive index between the pigment and the medium around the pigment particles, i.e. the binder. B® __ ee, Bae 2 0% 8 Figure 6.6 Dispersion of pigment particles Figure 6.7 Hiding power. Paint with good opacity hides colour differences of the substrate Colour pigments can roughly be divided into inorganic and organic pigments. Within the group of inorganic pigments some are made of coloured minerals, also known as earthy colours, like italian red, terra di siena, umbra, etc. Other inorganic pig- ments may be produced synthetically, like red iron oxide and yellow iron oxide. The organic pigments provide the widest range of colours. These pigments are produced through a long series of chemical synthesis processes. The basis may be raw materials from mineral oil or coal. In simplified terms, the organic pigments can be said to have inferior resistance to for example light and heat than the inor- ganic types. 6 PAINT COATING MATERIALS 177Extenders Extenders, also called fillers, are mineral materials used in finely powderized form in the paint. The extenders should provide body to the paint without impairing its properties. The extenders are usually white or light grey, but in general they do not contribute to the opacity nor colour of the paint. The refractive index is low. Indi- vidual extenders may contribute to improved properties of the paint by strengthen- ing the paint film or protecting it against deterioration by ultraviolet light. ‘A number of paint properties are determined by the ratio between the pigments or extenders and the binder in the paint film. An important issue in this respect is the pigment volume concentration (PVC). PVC indicates the proportion of pig- ments and extenders contained in the dry paint film. With a high PVC the paint film has low gloss (matt surface), little tendency to blistering, and is more open to water and chemicals. Pigment volume x 100% jgment + binder volume 20% = 0% Wm CPYC 50% 60% Glossy film Matt film Figure 6.9 When the PVC is changed, important properties of the paint film are changed 178 Corrosion protectionItis primarily the engineer in the paint factory who calculates the PVC of the paint. In that case he or she calculates the volume of pigments and extenders contained in a litre of paint. This is divided by the volume of the binder plus pigments and extenders. This latter figure is the solids volume of the paint, the parts remaining after the solvent has evaporated. _ Volume of pigments and extenders a Solids volume (total) Solvents Solvents in a paint should rather be avoided, but binders often have properties which make the use of solvents necessary. The solvents dissolve the binder in such a way that the paint obtains a suitable viscosity. Some binders are solid and others highly viscous so that they are not suitable for use in a paint without a solvent. Only some chemically curing binders have such a low viscosity that no solvent is re- quired. The solvent must be compatible with the binder. Not all solvents dissolve all binders. The paint factory chemists must know which solvents can be used. The painter must be careful to use the correct thinner if the paint is to be thinned down. ‘The thinner is a mixture of solvents suitable for the paint. For epoxy paint a differ- ent type of thinner is used than for vinyl paint. When paint producers are to select solvents, they must not only take technical properties like dissolving power and evaporation rate into consideration, but also factors such as health hazards and price. The health hazards associated with solvents will be discussed later in the book on page 411. Solvents are volatile substances. This means that they evaporate from the paint film more or less quickly. The boiling point provides an indication of the evapora- tion rate of the solvent. A high boiling point means slow evaporation. Often the evaporation rate is measured in relation to the solvent butyl acetate, which is given the evaporation rate 1. Ethyl alcohol (spirit) has an evaporation rate of 1.9. Conse- quently, ethyl alcohol evaporates almost twice as quickly as butyl acetate. The solvent mixture used in a paint must have the correct rate of evaporation. If the solvent evaporates too quickly, the paint will “set” to soon and be difficult to apply. If it evaporates too slowly, solvent entrapment in the film may easily occur, resulting in defects in the paint. A much-used term in recent years is VOC. This is an abbreviation of Volatile Organic Compound. This corresponds to the solvent contents and any other sub- stances which may evaporate from the paint film. Several countries have imposed guidelines or restrictions in order to lower the VOC contents in paints. The objec- tive is to reduce the environmental impact. Table 6.1 lists some of the most important solvents and their areas of use. F is the symbol used for the fire hazard class “highly flammable”. Many paints and solvents belong to the fire hazard class “flammable”, which does not have its own warning symbol. In this table the symbol Fo is therefore used to indicate that the solvent is flammable. 6 Paint CoatinG MATERIALS §179Table 6.1 Solvent summary T T e i | | | $i : id le a] ea] i gl oe e «El sz i igi og | 2 UBER EE g | | i8 . B8) ge ef gee a2 Solvents and properties i i BE) 252 | area of use (examples) Alpha hyrocarbons White spirit (ordinary) F,, 40 160200 | 0.2 | 275 | Alkyd varnish | | White spirit, high flash F,| 53. | 180-210 |0.05 | 275 | Allyd paint | | mite spit dearometzes |) 40. | 160200 0.1 | 278. | pd paint "aromatic hydrocarbons i | Toluene F 7 | 410. | 2.6 | 94 | Chiorinated rubber paint Xylene F,, 27 [130240 0.8 | 108 | viny! paint Tiimethylbenzene Fl 48 | 0.2 | 100 | Epoxy and polyurethane | i \ paint | i Hydroaromatic hydrocarbons || | | (cycloaliphatic) | Turpentine F,| 3540 | 150180 | 1.7 | 140 | artists’ colours | | bipertene |Fe, 43° | a7sa9s 140. | Alkyd paint \ | Chlorinated hydrocarbons | | \ | Trichloroethylene [- | Non: 86.7 50 | Industrial degreasing | 7 | Inemmabie| Methylene chloride | se | 40 | 9° | 225 | Paint removers led | | Alcohols ee 1 | | Ethyl alcohol (spirit) |F} 13.9 78.3 i 1.9 | 950 | Zinc ethy! silicate paint | Isopropyl alcoho! F) 447 | 823 | 4.7 | 245 | etch primer | Butyl alcohol (butanol) fF, 34.5 | 117.7 | 0.5 | 75 | Epoxy paint Ketones | | Acetone F| pelowo |} sea | 7.7 | 295 Methyl ethyl ketone F| belowo } 78.6 | 4.6 | 220 | Epory paint Esters | Ethyl acetate Fl 4 774 | 4.1 | $50. | Epoxy paint | | Bury! acetate F,| 25 | 1265 | 1 | 355 | Polyurethane paint | Giyeot esters | | | Methyl glyco! acetate |r| 44 | 144s | 0.3 | 22 | Ethyl glyco! acetate F,| 82.2 | 186.4 |0.2 | 27 | (previously vinyl paint) Giycol methy! ether F,| 36 | 1245 |os | 16 | | Glycol ethy! ether F,| 42.8 | 135.1 | 0.2 | 18 | (previously epoxy paint) | t I i i 180 Corrosion protectionAdditives Additives may be of many different types and serve many different purposes. Siccatives or drying agents are used in oxidatively drying paints such as alkyd and oil paints to improve drying times. They consist of compounds of cobalt, man- ganese, calcium, zirconium and fatty acids, etc. They affect the oxygen uptake in the paint film. Other catalysts having an influence on the curing rate are used in other paints and coatings, for example hydrogen peroxide in polyester. Antifoaming agents and bactericides are used in water-borne paints. Dispersing agents are normally used in paint to assist in getting the pigments finely dispersed during paint production. Other additives are to prevent pigments from settling in the can. Paint types The different paint types will now be discussed, beginning with the most common primer coatings. After that the physically drying paints, the oxidatively curing and the chemically curing paints will be described. Antifoulings, preventing marine growth, are given a separate section, before we look at the selection of paints. In order to illustrate how the individual paint systems tolerate various external influences, the symbols shown in Figure 6.10 are used. A cross-out or a line across the figure means that the paint cannot withstand the influence. A representation like this will in some cases mean simplification. The degree and types of influence have not been definitely established. Consequently, we must use this representation as an initial guideline only. In the following figures these symbols have been used: Chemicals like alkalis and acids Je) fa ei i o/g ¢/4/ Outdoor exposure to water Sea water Sunlight yy. , Figure 6.10 6 Paint coarine MaTeriais = 181Primers Paints containing corrosion-preventive pigments are normally used for the primer coat. They may work by passivating the steel or they provide cathodic protection. If the paint does not contain such pigments, it must be able to provide a good barrier effect. Epoxy mastic paints are examples of the latter type. Previously the range of inhibiting pigments available was more comprehensive. Several of the old pigments have already gone out of use and are on their way out because they are toxic. This is the case of red lead and zinc chromate. Zinc phos- phate is an inhibiting pigment which has become more widely used as a result of this development. Zinc-rich paints are extensively used. There are two main types: with organic binder and with inorganic binder. The zinc contents must be at least 80% by weight of the solids content in both The paints are primarily used as primers, but in some environments they are also used without any further protection. Organic zinc-rich paints The most durable types have epoxy or polyurethane binders. Other binders used are vinyl and chlorinated rubber. In order to avoid the formation of zinc soaps it is important that the binder is alkali-resistant. This also applies to the binder of the paint to be used on top of the zinc primer. The organic zinc-rich paints provide less cathodic protection than zinc ethyl silicate paint. This is due to the fact that the metallic contact between the individual zinc particles is not as good and that the binder is not electrically conductive. Areas of use During the 1960's and 1970's organic zinc-rich epoxy primers were used in the marine industry and in the onshore and offshore oil industries. These paints were usually overcoated with chlorinated rubber and modified chlorinated rubber paints. Later zinc ethyl silicate took over this role, but now it looks as if zinc epoxy is going to make a major comeback. It has, for example, been included in systems indicated in the Norwegian standard NORSOK M3501 for the offshore industry. Today, mainly zinc-rich epoxy paints are used for primer coats, both for new constructions and maintenance and for repair of minor damage. Usually both inter- mediate and finishing coats are applied on top of them. In the case of touch-up work it is not of critical importance if the paint is applied with overlap on organic paints, This paint type is also used for repair of damage on hot dip galvanized steel. Surface preparation All zinc-rich paints require thorough surface preparation to Sa 2%. This surface preparation results in a well-cleaned and rough surface which ensures that the paint adheres firmly to the steel. Hot dip galvanized steel requires light sweeping. Application Organic zine-rich paints, for example zinc epoxy, are applied by brush and by 182 Corrosion PROTECTIONairless spray. Rollers should not be used for application of the first primer coat. Inorganic zinc-rich paints, zinc ethyl silicate Zinc ethyl silicate paints are normally two-component products where the zinc powder and the binder are supplied in separate containers. Before use the compo- nents are mixed in the correct proportions Zinc ethyl silicate paints are based on an inorganic binder, ethyl silicate, which is electrically conductive. In order to obtain cathodic protection it is therefore not of critical importance in this case that the zinc pigments are in direct contact with each other. Areas of use Zinc ethyl silicate provides excellent corrosion protection of the steel. Zinc ethyl silicate is generally used as a primer coat to be overcoated with barrier paints. In the offshore industry epoxy systems are widely used on top of zinc ethyl silicate as far as structural parts above the water line are concerned. In the case of damage down to the steel the zinc has a protective effect on the steel and sacrifices itself. However, an alkaline environment is formed around the damaged area. It is therefore important that the paint system chosen is able to tolerate this environment. In the case of chlorinated rubber or epoxy paints this is not a problem, but blistering may occur in oil and alkyd paints. | ae os Corrosivity category C3 4 . 2 7 A (ISO 12944-2) Zinc ethyl silicate Sa 2%3 Figure 6.11 In certain environments, for example in oil cargo tanks and exposed pipelines under southern skies, such paints are also used without being overcoated, with excellent results. Zinc ethy] silicate paints also have a high resistance to heat, up to approxi- mately 400°C. Provided that proper curing has taken place, the resistance to wear and tear is high. Surface preparation The paint requires good electrical contact to the substrate. In order to obtain the desired cathodic effect, the surface preparation is of particular importance. The cathodic effect is not obtained if the paint is applied on top of organic paints, The paint requires direct contact with the steel in order to work properly. ‘The surface preparation required is blast cleaning to a degree of cleanliness of Sa 2¥4-Sa 3 and a maximum roughness, R,, within the range of 50-75 um. 6 PAINT CoaTING MATERIALS §=183Application Generally, airless spray application provides the best result. It is not easy to apply zinc ethyl silicate paints by brush. The paint requires humidity to cure. Too low humidity during the curing process results in too low strength in the paint. This is also the case if the paint is applied in too thick layers. The supply of humidity can take place in various ways. Some major works have large halls where temperature as well as relative humidity can be controlled. Steam can also be used. Otherwise, it has been standard practice to sprinkle water on the constructions and if necessary cover them up in plastic to retain the humidity. Before overcoating with organic paints takes place, the zinc primer must be completely cured. This is best controlled by the use of the solvent methyl ethyl ketone (MEK). The test method is available as a standard ASTM D 4752-87. In some cases, sprinkling with cold water has resulted in imperfect through-curing, not revealed by the MEK-test. If the zinc silicate is applied too thickly. the paint will crack. This type of crack- ing is called “mud-cracking” because the surface looks like dry clay, Normally zinc ethy| silicate is specified in a dry film thickness of approximately 75 pm. Zinc alkali silicate Zinc alkali silicate contains a water-glass type of water-borne silicate binder. Sili- cates are substances which form part of glass and a number of minerals. The alkali silicates have been made water-soluble by a special process. During the curing process zinc silicate is formed due to the reaction between zinc and binder. Zinc silicate functions as cement between the pigment particles. Over time the paint becomes more water-resistant. Alkali is formed during the curing process and is deposited on the,surface. Before any overcoating is carried out, it is necessary to remove this by washing with fresh water. The disadvantages of zinc alkali silicate paints are that they dry slowly at low temperatures and high humidity. In addition, alkali is formed, and the paint is quite water-sensitive and brittle during curing. During application, large quantities of water evaporate from the paint applied. This may create problems when painting tanks. If the ventilation is not sufficient, flash rust appears on the steel. Areas of use Alkali silicate is very durable in most corrosive environments. Outdoors they are little affected by sunlight, wind and weather. As these types of zinc paints are inor- ganic, they are not affected by organic solvents. Even in contact with strong sol- vents such as ketones, chlorinated hydrocarbons and the like, nothing happens. The paint is not resistant to alkalis and acids. The paint is also extensively used for the inside of storage tanks for oil, petrol, etc. . Zine silicate paints do not shrink. They withstand extreme temperatures, i.e. temperatures around 400°C, without disintegrating. 184 Corrosion protectionSurface preparation The surface preparation required is blast cleaning to a degree of cleanliness of Sa M-Sa 3. Application For the application of alkali zinc silicate paints conventional pressure-fed air-spray equipment with agitator is recommended. For small areas brush can be used. Shopprimers Steel profiles, plates and pipes are cleaned by centrifugal blasting and applied with shopprimer (prefabrication primer) in large closed-in plants at the fabricators and steel suppliers. After degreasing the steel is transported into a centrifugal blast cleaning ma- chine where metallic abrasives are propelled against the steel surface. The speed through the plant can be adjusted and thereby the desired cleanliness can be achieved After centrifugal blast cleaning the steel is applied with a thin anticorrosion primer. The film thickness is low, approximately 15-20 pm. Several types of shopprimers are available with different binders and rust-pre- ventive pigments. Generally, the main distinction is between iron oxide shopprimers and zinc-rich shopprimers. Itis a requirement for the shopprimer that it must be possible to weld and cut the steel without any negative influence from the shopprimer. If it is not to be removed by blast cleaning before the paint system is built up, it must provide a suitable substrate for the subsequent paint coatings. In such a case it is of extra great impor- tance that the centrifugal blast cleaning has produced a surface with a cleanliness of Sa 2%. In recent years the term “prefabrication primer” has become widely used. This is a paint coat applied in the workshop to provide protection during erection. lron oxide shopprimer The most common iron oxide shopprimers use polyvinyl butyral (PVB) or epoxy: binders. Stee! shopprimed with iron oxide usually has a red or yellow colour. Areas of use Iron oxide shopprimers are intended for protection of steel exposed outdoors for up to approximately 6 months. ‘When shopprimed steel is used in onshore industry it is general practice to apply the subsequent paint system on top of this. Within the offshore industry it is a general requirement that the shopprimer is removed and zinc ethyl silicate applied. Within shipbuilding, on the other hand, it has been standard practice to leave the shopprimer on. This may be perilous if the steel has not been cleaned sufficiently during the centrifugal blast cleaning. 6 Paint coarine materis 185,Surface preparation Centrifugal blast cleaning to Sa 22. Application ‘Application takes place in automatic plants with airless spray. The shopprimer is usually applied in a film thickness of 15-20 um. After application the steel can be handled after a few minutes. Zinc-rich shopprimers Zinc-rich shopprimers are produced with epoxy or ethyl silicate binders. Plates applied with zinc-rich shopprimers are usually greyish. Areas of use Also zinc-rich shopprimers are applied in low film thicknesses, 10-15 um. The advantages of using these types of shopprimers over the iron oxide types are that the steel is protected for a longer period of time and that the paints withstand higher mechanical impact. In order to avoid welding problems the shopprimers must be approyed as weld- ing primers. When welding plates or pipes applied with zinc-rich shopprimer the welder may get what is called zinc fever. This creates nausea and is a bit similar to the flu. Zinc fever is caused by inhalation of zinc fumes. Surface preparation Centrifugal blast cleaning of the steel to Sa 24. Application In automatic plant with airless spray. Wash primers Wash primers are based on polyvinyl butyral (PVB) binder. They are used as a first coat on degreased zinc and aluminium surfaces in order to provide improved adhe- sion for subsequent coats. ‘Wash primers are two-component products mixed before use. The base contains the binder polyvinyl butyral and the curing agent is an alcohol solution with phos- phoric acid. ‘Some people have experienced problems with the adhesion in spite of the use of wash primer. This is often due to the wash primer having been applied too thickly. Film thicknesses above approximately 10-15 um are not recommended. If the film is thicker, not all of the phosphoric acid is consumed and the residue forms a thin layer between the wash primer and subsequently applied primers. Areas of use Wash primers are used on aluminium and electroplated zinc or hot dip galvanized steel, 186 Corrosion PROTECTIONIn some cases they are also used on blast cleaned steel surfaces. In case two- component epoxy paint is to be applied, wash primers must not be used. Surface preparation It is a general requirement that the surface is sufficiently clean. For aluminium and hot dip galvanized steel this means thorough degreasing. In many cases the choice is made to blast clean such surfaces with a fine abra- sive in order to obtain good adhesion in preference to the use of wash primer. Application In order to obtain a sufficiently thin film conventional air-spray should be em- ployed. If airless spray is used, small-sized nozzles must be used, for example 0.3 mm or less. Rust converters Rust converters contain substances which are to “bind” the rust or convert it to a more dense and stable compound, i.e. magnetite (from Fe,O,xH,O to Fe,0,). A study indicates that the conversion to magnetite takes place over several months. After eight months at 20°C the oxide layer consisted of 65% magnetite and 35% hematite (Fe,O,) [1]. Several rust converters contain tannic acid or similar substances which immedi- ately bind the rust in a black compound. The paints may have binders based on acrylic dispersions or the like. Such binders form a kind of barrier which is to provide some protection against further corrosion. The best result is obtained when the rust layer is as thin as possible and it is overcoated with a barrier-forming paint. Thick rust has resulted in breakdown of the rust layer in pull-off tests. In several studies the rust-converting paints have shown poor results, but it cannot be ruled out that usable products may be available. Surface preparation In accordance with instructions, the paints are to be used on a substrate with some rust. Wirebrushing (St 2-3) or light blast cleaning (Sa 1) are recommended pretreatments. Application The paints should be applied by brush or airless spray. Physically drying paints These paints dry by evaporation of the solvents. The binder originally existed in a solid state and it reverts to the solid state during drying. No chemical reaction takes place during the drying process. The evaporation of solvents is slower at low tem- peratures, but it does not stop. Provided that other conditions are acceptable (no ice 6 Paint COATING maTERIALS 187on the surfaces) the paint can also be applied at sub-zero degrees. The paints are reversible. When the same type of paint is used for overcoating, the underlying coat will dissolve a litle. The coats “melt” together, so to speak. The result is good adhesion between the old and the new paint. If thorough degreasing has been carried out, maintenance painting on top of a physically dried paint will rarely present any problems. Chlorinated rubber paints Chlorinated rubber is produced either synthetically or by a reaction between natu- ral rubber and chlorine. Chlorinated rubber is soluble in solvents such as aromatic hydrocarbons (xylene), ketones and chlorinated hydrocarbons. The paint also con- tains plasticizers that help to provide the binder with good mechanical properties. Corrosivity category C3 (iso 2944.2) Example: System $3.13, 1S0 12944-5 Annex A 60 um DFT CR top coat 60 um DFT CR'mid coat 80 pm DFT CR primer Sa 2% or silicate primer Figure 6.12 Areasofuse -* Chlorinated rubber paints are extensively used for chemical, marine and other envi- ronments. As the paint is reversible, it has little resistance to solvents. However, it is quite resistant to splashes and sprinkles of acid and alkali solutions. Chlorinated rubber paints have low permeability to water vapours. Consequently, the paints are suitable for protection in damp environments. On submerged areas aluminium flakes are often added to the chlorinated rubber paint. The aluminium flakes make the paint more dense. Depending on the area of use and surface prepa- ration requirements, chlorinated rubber paints are also modified. Alkyd, acrylic and tar are binders which they can be combined with. Chlorinated rubber paints are so-called thermoplastic paints. They become soft at elevated temperatures and hard at low temperatures. As a consequence, the paints become very soft on for example ships operating in hot climates. On deck areas this may create problems. The paint will then be tacky. Under colder conditions the paint becomes hard again. If the paints are exposed to temperatures above approximately 60°C, there is a risk of hydrogen chloride being released. Care should be taken, especially when welding, because of the release of hydrogen chloride and the consequent formation of hydrochloric acid in combination with water. Poor sunlight resistance results in the paint becoming matt and dull after a few 188 Corrosion PROTECTIONyears. Cracking has also been seen as a problem if the paint has been applied in too thick layers. Both chlorinated rubber and polyvinyl] chloride are binders which will be used less in paints in the future. This is because they contain chlorine compounds, which are considered harmful to the environment. In addition, these paints have a high content of solvents. This also harms the environment. To some extent acrylic paints have already taken over from these paints. Surface preparation Like most paints also these types require good surface preparation when they are to be exposed in aggressive environments. Normally, a pretreatment to cleanliness degree Sa 2% is required. The protection obtained is based on the formation of a barrier between the steel and the surrounding environment. Application Application should be carried out by airless spray. Rollers are not suitable. Prob- lems may easily arise as “cobwebbing” is formed during rolling. Nor is brush ap- plication suitable. Even if the paint becomes dust-dry rather quickly, it takes quite some time be- fore all solvents have evaporated. This is especially the case when thick coats are applied. As a result of this, the paint film remains soft and it can be difficult to handle painted objects. Vinyl paints Vinyl paints are closely related to chlorinated rubber paints. They dry as the sol- vents evaporate, and they are reversible. The vinyl binder is produced synthetically and may consist of different copolymers with polyvinyl chloride (PVC). It is solu- ble in aromatic hydrocarbons, ketones, esters and the like. The solids content in vinyl paints is low and rarely above 30-35% by volume. Consequently, more coats must be applied in order to obtain the film thickness required. The low solids volume is the reason why also this type of paint is going to be phased out like chlorinated rubber paints. Areas of use Vinyl paints are widely used in most industrial environments and withstand expo- sure in quite severely corrosive areas. They have good resistance to inorganic acids and alkalis. In addition, vinyl paints are relatively resistant to water, oil, alcohols and the like. Vinyl paints have been widely used in the offshore industry. The paint system is generally built up from a zinc ethyl silicate primer on the steel and then several coats of vinyl paints. When zinc ethyl silicate paints are overcoated with vinyl, it is important to apply the first coat in a very thin layer, approximately 30 ym. This thin layer is usually called a tie coat. Zinc-rich paints are porous, and this thin paint layer is to displace air from the porous primer and at the same time provide improved adhe- sion for the subsequent coats. If a vinyl coat is applied in full film thickness directly 6 Paint coarinc MATERIALS §189‘on top of the zinc primer, blistering and popping may occur. In connection with offshore structures epoxy tie coats on zinc ethyl silicate are now being used, irrespective of the subsequent system. One of the reasons is the wider choice of intermediate and finishing coats available. Vinyl systems should not be used at temperatures above approx. 60°C either, due to the risk of hydrogen chloride release. A vinyl system is usually finished with a top coat of acrylic or vinyl-acrylic that has improved UV-resistance. Vinyl systems are also used under water. In order to improve the resistance to some extent they are modified by the addition of tar. This product is called vinyl tar. Previously vinyl tar was widely used in the power plant sector and on ships. Cortosivity categories 3.04 Jad fy (“(is0 129442) Wie p Example: System $4.27, 1S0 129445 Annex A, for C4 70 ym DFT PVC top coat 70 ym DFT PVC mid coat TED 20 3m DFT PVC tie coat 80 um DFT ethy! silicate primer Figure 6.13 Surface preparation Vinyl paints require good surface preparation prior to application. Blast cleaning to Sa 2% is recommended. Application Vinyl paints are normally applied by airless spray. The paint sets quickly. It is difficult to use brush or roller as the paints are reversible. When overcoated, previ- ously applied coats will dissolve, and the use of brush or roller may easily result in air entrapment. Acrylic paints These paints have several properties in common with chlorinated rubber and vinyl paints. They can be distinguished in particular by better sunlight resistance. As a result, painted areas will retain their gloss and colour better. The resistance to solvent exposure is slightly lower than chlorinated rubber and vinyl paints. Resistance in case of immersed use is also slightly lower. Areas of use Acrylic paints have essentially the same areas of use as chlorinated rubber and vinyl, but are preferred where colour and gloss stability is of major importance. Acrylic paints can be used as finishing coats on top of vinyl paints. 190 Corrosion protectionApplication Airless spray is the most suitable method. Brush and roller are less suitable. Water-borne paints Water-bome anticorrosion paints based on different binders are available. The largest group is dispersion paints based on acrylic or a combination of acrylic and other substances. Such combinations are the result of reacting the substances with each other during the production of the dispersion. Copolymer compounds are produced. Thereby certain properties can be im- proved compared to those of the substances individually. The binder is a disper- sion, i.e, small droplets or globules finely distributed in water. The size of these globules is usually less than 1 pm. Water Latex particle Pigment Water Latex particle Figure 6.14 “Binder globules” in water The reason why we want to use water-borne paints is of course the health hazard associated with solvents. This does not mean that the water-borne paints are with- out any problems. It must be taken into consideration that the water-borne anticorrosion paints do contain some solvents which are to assist in the film forma- tion. Additionally, they contain biocides, which are additives to prevent attacks from bacteria and fungi. Apart from that, pigments, inhibitors and other substances in the paints may have an effect that is harmful to the health. The risk of being exposed to these substances depends on the method of applica- tion and the protective equipment used. During spraying, spray dust is formed. The particle sizes of this spray dust lie mainly within the range of 100-400 pm. The part of the spray dust which can be inhaled and end up in the lung alveoli (respirable dust) is likely to be much lower than 1% of the total spray dust. In addition to the dust, a continuous evaporation from the painted surfaces takes place. For health and safety reasons, the water-borne anticorrosion paints based on acrylic or other binders must be considered to be beneficial due to less exposure to solvents. When spray-applying them, it is still necessary for us to protect ourselves against the inhalation of spray dust and against skin contact. But the exposure is lower for other people working nearby and who normally do not wear any protec- tion. 6 Paint coarinc MATERIALS §=194Paint application causes a risk of allergy from skin contact or damage due to solvents in the air. Consequently, the different requirements for protective precau- tions must be evaluated. The use of a mask is always recommeded for spray appli- cation of paint, including water-borne acrylics. The binders of the most common water-borne paints are copolymers of styrene acrylate or vinyl chloride-vinylidene chloride-acrylate. Paints with emulgated alkyd or alkyd in aqueous solutions are not yet used to any great extent. The same applies to water-borne epoxy paints. Some water-borne two-component epoxy paints have been proposed for use in anticorrosive systems. Their mode of action may be galvanic (zinc-rich water-borne epoxy), inhibitive (when pigmented with rust-inhibiting pigments like zinc phos- phate), and/or purely a barrier effect. The water-borne acrylic and vinyl paints are physically drying paints. After the binder globules have fused together the binder will not dissolve nor disperse in water again. The water was never a solvent for the binder. This is how water-borne dispersion paints are distinguished from other physically drying paints. For alkyd and epoxy paints an oxidative or chemical curing takes place after the water has evaporated. The water in the paints produces flash rust if effective inhibitors are not used. They must be effective as long as the paint is liquid. Such inhibitors are water- soluble. An example of inhibitor is sodium benzoate, possibly mixed with sodium nitrite. In particular, there is a risk of flash rust when the paint dries at a relative humidity of the air of more than 65%. The permanent corrosion-preventive effect is primarily based on special pig- ments in the primer coat. The paint must have a water uptake in order for the relatively water-soluble anticorrosive pigments to work. The anticorrosive pigments used include zinc phosphate, zinc borate, zinc molybdenum phosphate and alu- minium triphosphate. Paints based-dn dispersions are usually not as diffusion tight as solvent-based paints. If the anticorrosive effect is based on the barrier effect, the development of suitable paint formulations presents a number of problems. The pigment dispersion is particularly important. Consequently, factors such as the pigment contents (pigment volume concentration — PVC) and the dispersion agent for the pigments are of major importance. The water-borne vinyl and acrylic paints can be produced in many colours. They are not easily disintegrated by sunlight. They can therefore be expected to retain their colour and gloss quite well. On the other hand, the paints are not strong on areas with much condensation or areas immersed in water. The resistance to acidic industrial gases, salt-containing air and a number of chemicals is average. The temperature of the substrate should preferably be below 60°C. Areas of use The areas of use for water-borne paints are primarily less aggressive environments, but products have been seen to perform well in corrosivity category C4, provided that the paint system has been built up properly. The paints can be applied on zinc-rich primers and on galvanized areas. 192 Corrosion proTECTIONCorrosivity categories C1.C4 JA Us. y (ISO 12944-2) Iffd/ Example: System $3.13, |SO 12944-5 Annex A, for C3 60 um DFT AY/PVC top coat 60 um DFT AY/PVC mid coat 80 jum DFT AY/PVC primer Sa 2% Figure 6.15 Surface preparation Common practice is to blast clean to Sa 24. Application The paint can be applied by brush, roller, and airless spray. During application the temperature of the substrate or of the air should not be below 5°C. Usually recoating can take place after a couple of hours, but high relative hu- midity may result in a longer wait. It is important to note that the’ drying time depends on both the relative humidity (RH), the air velocity across the surface and the temperature. Since the paint is sensitive to humidity during the period before it is sufficiently dry, it is important to try to protect the construction and ensure optimum drying conditions for the first 24 hours after the paint has been applied. If the temperature is low and the humidity high in the ambient surroundings, good ventilation must be provided. Otherwise, it may be expedient to dehumidify the air around the struc- ture. ” Bituminous paints Bituminous paints are relatively inexpensive one-component paints. The paint dries in the usual way as the solvents evaporate. The paints are normally not pigmented and are black and brown. This results in a rather limited area of use. Bituminous products which are solvent-free and applied after heating are also available. As the paints do not withstand direct sunlight, they are in principle not suitable for outdoor use. If aluminium flakes are added, both appearance and durability in outdoor exposure are improved. Areas of use The products are eminently suited for areas immersed in water. Bituminous paints are widely used in humid areas without any major mechanical impact, for example in ballast tanks. Under warm atmospheric conditions the coating has a tendency to crack and sag. Itis difficult to overcoat bituminous paints. The paint is relatively soft. When it is overcoated with a harder paint, the top coat usually cracks. The cracking may also extend slightly into the bituminous coat, but rarely all the way to the bottom. 6 Paint coarinG mareriats 9193When a bituminous paint is overcoated with a light-coloured paint, the result is often discoloration. The discoloration arises because the bituminous paint “bleeds”, i.e. it migrates into the subsequently applied coat. A white vinyl or acrylic paint applied on top of a bituminous paint tends to turn yellowish after drying. ; t CY if #22 Sa 2/St3 ¥ We Figure 6.16 Surface preparation Bituminous paints often have less requirements to surface preparation than a number of other paints. It is often sufficient to wirebrush to St 3 or blast clean to Sa 2. Application These paints can be applied by brush, roller and by airless spray. The paint is generally applied in a thick film. This involves many coats if brush or roller are used. Tar paints When coal is distilled, coal tar remains as a distilling residue after the volatile components of the tar have evaporated. Coal tar is not soluble in white spirit, but is soluble in aromatic hydrocarbons like toluene and xylene. Areas of use Coal tar paints do not contain any inhibiting pigments and therefore only protect by a barrier effect. They offer good protection under particularly damp and difficult conditions and have been widely used in industries like water power. Besides excel- lent water-resistance they are also resistant to diluted alkali and acid solutions. The light-fastness is poor and the.coatings have a tendency to crack. This may result in the formation of a pattern resembling crocodile skin. Coal tar coatings can be applied as a thick film in each coat. Tar is considered to be carcinogenic. Consequently, such products will eventu- ally be removed from the market. This also applies to paints where the tar is com- bined with other binders, for example epoxy. Surface preparation Blast cleaning to minimum Sa 2'4 is required. 194 Corrosion PROTECTIONApplication Application isuusually done by means of airless spray. Brush or roller can also be used, but this involves more coats to be applied. Oxidatively curing paints Some binders may react with the oxygen in the air and thereby cure to a solid film. This can be described as a special type of chemical curing. The binder must be based on a content of drying oils. Linseed oil is an example of a drying oil. It contains unsaturated fatty acids. They have a tendency to grab hold of oxygen molecules in the air, react with them and thereby build a network of several fatty acid chains. In alkyds unsaturated fatty acids have been incorporated. Consequently, alkyds also cure by reacting with oxygen. During the initial period after application of the paint a certain drying takes place as the solvent (white spirit) evaporates. After this, the actual curing stai Several factors have an influence on the curing process. Low temperature slows down the curing. This is also the case of limited air supply, limited light and extra- high or extra-low relative humidity of the air. In order to increase the curing rate metal compounds called siccatives.or drying agents are added. Alkyd paints Alkyds are produced by a reaction between acid (for example phthalic acid), alco hol (for example glycerol) and oil (for example soybean oil or tall oil). The reaction takes place in large boilers when heated. Alkyds are usually grouped according to their oil lengths. The oil length indicates the volume of oil relative to the other raw materials used for the production. Terms used are short, medium and long oil lengths, or short, medium and long oil alkyds. Their areas of use vary to some extent. For corrosion protection medium oil alkyds are generally used. Alkyd paints are often modified. This means that other binders have been added to or combined with the alkyd in order to bring out special properties. Among the binders with which alkyds can be modified can be mentioned chlorinated rubber, vinyl, silicone and urethane. Alkyd is often used in combination with zinc phos- phate or other inhibiting pigments in the primer. Figure 6.17 The raw materials for alkyd production 6 Pant cosine marERIALs 195In connection with painting and maintenance of steel structures linseed oil or alkyd oil binders with red lead were previously widely used. Red lead paints were ex- tremely durable and red lead primer can probably still be found on many construc- tions painted 40-50 years ago. There are great problems involved in the removal of old paint on such constructions. Red lead dust may cause poisoning of the opera- tors and result in the spreading of an environmentally harmful substance. Spent abrasives must be collected and deposited as hazardous waste. One solution can be to remove paint applied on top by means of ultra high pressure water jetting and leave the red lead where itis. y |, Corrosivity categories 2.4 Joffe “(180 12944-2) Vija/ Leff — Example: System $2.06, ISO ? [|S 12944-5 Annex A, for C2 80 pm DFT alkyd top coat SS. WV, sss 22 27 FF te primer Y Cede Ve Sa2% Figure 6.18 Areas of use Alkyd paints have been and are still widely used as anticorrosion paints. They are generally used in corrosion environments which are not too aggressive and where the influerice from water on the surface is not too extensive. The international paint standard ISO 12944 also includes alkyd paints in corrosivity category C3 (medium) and in category C4 (high). In the latter category only low durability is expected (below 5 years). Surface preparation Generally, alkyd paints have better penetration properties than many of the other paints mentioned here, and are often provided with corrosion-preventing pigments. They often require less surface preparation before overcoating: wirebrushing to St 2-3 or blast cleaning to Sa 2. Application Application can be carried out by brush, roller or by airless spray. Urethane alkyd paints During the production of urethane alkyd one of the raw materials has been replaced by another. Thereby a film which is harder and stronger than an ordinary alkyd is obtained. It is used both for primers and finishing coats. Some paint manufacturers have called this type one-component polyurethane, which is a rather misleading name. 196 Corrosion PROTECTIONEpoxy ester paints Epoxy esters should not be confused with two-component epoxy paints. The word epoxy does form part of the name, but this is a one-component type of paint. Epoxy esters are like alkyd paints and dry when they react with oxygen in the air. They are produced by a reaction between an epoxy compound and alkyd at high temperatures. Areas of use Epoxy esters are relatively quick-drying, and they are harder and have somewhat better chemical resistance than alkyds. They are often used as primer on steel. They have a usable resistance outdoors, but tend to chalk. Chalking takes place when the binder disintegrates in the outermost layer of the paint. Thereby pigments and fill- ers are exposed, When the paint surface is gently rubbed, the pigments can be seen to come off. Chalking also makes the surface more matt. Surface preparation Normally wirebrushing to St 2-3 or blast cleaning to Sa 2 is recommended. Application Epoxy ester paints are applied by brush, roller or by airless spray. Silicone paints Silicone paints can be considered as a combination of glass and organic binders. The binder is expensive and is often modified with other binders such as alkyd or acrylic. Silicone alkyd has considerably better weatherability than both pure alkyds and other modified types. Such paints are often used for maintenance. The heat resistance of silicone paints is remarkable. Some types withstand 500°C over extended periods of time, while others may tolerate temperatures of 600°C and higher for short periods. Silicone paints are very resistant to outdoor exposure and have less tendency to loss of gloss, discoloration and chalking than many other paints. Silicone acrylic is also used for the formulation of heat resistant paints. Such paints tolerate temperatures of approx. 250°C. Aluminium silicone is used for sealing off thermally sprayed aluminium coat- ings. In this connection aluminium silicone is often called a sealer. This type of paint is extensively used on exhaust pipes, flare booms, gas turbines, etc. Areas of use Silicone paints are used on areas with elevated temperatures. They are used in combination with zinc ethyl silicate and then tolerate up to 400°C. Surface preparation High-quality surface preparation with blast cleaning to Sa 244 is required. 6 Paint coarine MATERIALS 197BY Gf) a Sars 9 Silicone paint TEE Thermally sprayed ese. aluminium Figure 6.19 Application Usually application is done by airless spray. Small areas can be applied by brush. Thorough cleaning of the spray equipment is necessary before another paint is used. Chemically curing paints Corrosion protection by means of two-component paints, such as epoxy and poly- urethane paints, is obtained by barrier effect. Two-component paints are delivered in two separate containers. The compo- nents are usually called base and curing agent. The containers are often marked A (base) and B (curing agent). Before use the components must be mixed in the proper proportions. The components should always be mixed by using power tools like mechanical stirrers. The mixing ratio is usually written on the tins or cans. If it is not found there, it will be stated in the technical data sheet for the paint. The correct mixing ratio is extremely important. Otherwise problems may arise if too little or too much curing agent is added to the base. ‘After mixing, a chemical reaction takes place between the components. The chemical reaction is temperature dependent and is faster at high temperatures. Con- sequently, the pot life of the paint after mixing decreases with increased tempera- tures. Some types need to be left for a while after mixing before they are used. As the paint cures, a film with a three-dimensional and insoluble network is formed. The paint film is extremely strong and resistant to chemicals, acids and alkalis. Epoxy paints Epoxy paints form a very strong and hard paint film, and they are resistant to most environments. Pure epoxy paints are usually divided into solvent-free (coatings), solvent-less, solvent-borne or water-emulsion paints. The base of epoxy paints consists of epoxy molecules of varying length. Sol- vent-free and high solids (>60% solids volume) epoxy paints usually have low- molecular epoxies with short molecule lengths. Especially these types may cause 198 Corrosion PROTECTIONeczema problems. Solvent-based epoxy paints with a solids volume of less than 60% usually con- tain high-molecular epoxies and have longer molecule lengths. Generally these types require strong solvents. ‘A number of different curing agents can be used in epoxy paints. The most common curing agents are polyamines, polyamides, amine adducts or isocyanates, depending on the area of use. The curing agents mentioned are compounds that are able to react with other compounds, for example epoxy. The substances can be liquid or solid. In order for the curing agent to be suitable, the curing agent molecules must have two or more reactive groups in the molecule which work as “hands” catching hold of the epoxy compound and forming a network or chain. When this network has been formed, the paint has cured. When an amine curing agent is mixed into an epoxy paint, a characteristic ammonia-like smell can be noticed. The curing agents provide the epoxy paints with somewhat different properti In the solvent-borne epoxy paints the curing agent polyamide is normally used. This results in longer pot life and makes the mixing ratio less critical to the paint than the use of polyamine. Polyamide cured epoxies are more flexible and resistant, but often have longer curing time than polyamine cured types. In the most aggres- sive environments polyamine cured types are often preferred. . Areas of use Epoxy paints are extensively used in the offshore industry and in aggressive and chemically polluted environments. They are also used in less polluted environments for long-term protection, Epoxy paints are resistant to most solvents, and to alkalis and acids. In outdoor exposure they have a tendency to chalk, and for this reason they are very often topcoated by a more weather-resistant type, for example polyurethane paint. Sys- tems used offshére above the water line are usually based on a zinc-rich primer, then an epoxy tie coat and intermediate coat, and a polyurethane top coat in a total film thickness of approximately 250-350 um. Coating of tanks generally requires surface preparation to Sa 2% and build-up of 3 x 100 um of amine adduct cured epoxy. ? | Corrosivity categories C2-C5 M/I S / ad iy /d sasssece ay Ce (ISO 12944-2) Wifal FE ~~ example: system $7.09, |S 180129445 annex A, for CSM ESSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSS 100 um DFT epoxy mid coat 100 um DFT epoxy mid coat 40 im DFT zinrich epoxy primer Figure 6.20 6 PAINT COATING MATERIALS 199 slSurface preparation Epoxy paints require blast cleaning to a degree of cleanliness of Sa 2%. Application The paint can be applied by brush, roller and airless spray. It is important to ob- serve the pot life of the paint. If the system is built up from several coats, it is also important to observe the maximum recoating interval. ‘There are differences as far as recoating intervals of amine and amide cured epoxies are concerned. Epoxy paints have a lower temperature limit of approx. 10°C for application. At lower temperatures, low-temperature curing types must be employed. In this case the curing agent can be isocyanate or special polyamide adducts. In addition, it is important to observe minimum and maximum drying times. Due to the curing process which is started after mixing of the components, two- component epoxy paints should not be left overnight in the airless spray equipment. It is not as simple to maintain an epoxy paint as a one-component paint. Epoxy paints have a tendency to continue curing as they age. This results in adhesion problems for maintenance paints. Before overcoating, the surface of the epoxy paint should therefore be roughened by light abrasive sweeping. A special phenomenon which may create poor adhesion between the layers in an epoxy system is what is often termed amine sweating. Sometimes the curing agent or other substances sweat out and form a thin, greasy or sticky layer on the surface. Combined with low temperature, high relative humidity of the air and high contents of carbon dioxide from combustion gases may contribute to such exudation. The exudation must be washed off in water with emulsifying agent added or possibly by thinner. Coal tar epoxy paints Coal tar epoxy, or tar epoxy, is a two-component epoxy paint modified with coal tar. The modification provides a less expensive paint. In addition, the coal tar con- tents provide the paint with flexibility and excellent water resistance. The epoxy imparts high resistance against chemicals and solvents. Coal tar epoxy contains no corrosion-preventive pigments and protects the steel by means of a pure barrier effect. Areas of use Coal tar paints possess high water resistance and are widely used for immersed structural details in the offshore industry and in ballast tanks on ships. They are also used in connection with cathodic protection of steel structures in sea water, They tolerate the alkaline environment associated with cathodic protec- tion, These paints have high resistance against alkalis and acids. Various curing agents are used for these paints. Polyamides are to provide the paints with better tolerance towards humidity, and an isocyanate curing agent has the effect that the paint can be applied at lower temperatures. Otherwise, the same minimum temperature limits apply as for ordinary epoxy. 200 Corrosion protectionOne of the weaknesses of tar epoxy paints is that they are sensitive to sunlight. They become brittle and chalk. As a result of this, and the fact that they are prima- rily produced in black or brown, coal tar epoxy paints are basically only used on non-exposed areas. In recent years a lighter type, bleached coal tar epoxy, has become available. A special problem in connection with overcoating coal tar epoxy with a light- coloured, solvent-containing paint is that bleeding will occur in the subsequent coat. The tar part migrates into the top coat and causes discoloration. Tar is considered to be carcinogenic. As a result, restrictions are in already in force in many countries today and it must be anticipated that this binder will be- come less widely used in the future Surface preparation Blast cleaning to Sa 24% is required. Application Coal tar epoxy paints are normally applied by airless spray. As is the case for other epoxy products, a maximum recoating interval applies. Often seven days are re- garded as absolute maximum. If the recoating interval is exceeded, a light abrasive sweeping of the surface may improve the adhesion of the following coats. However, it is important that the paint film is not damaged too much by the abrasive. Consequently, a fine abrasive must be chosen and the abrasive sweeping must be carried out with reduced pres- sure. Polyurethane paints Two-component polyurethane paints have several properties in common with epoxy paints. When the components are mixed, a chemical reaction takes place and a three-dimensional, insoluble network is formed. Polyurethane paints can generally be used at lower temperatures than epoxy paints. Products are also now available that can be applied at sub-zero degrees. The polyurethane paints have better weatherability and sunlight resistance than epoxy paints. For finishing coats, an aliphatic polyisocyanate-type curing agent is used. It also tends to yellow less. For primers and intermediate coats aromatic isocyanate-type curing agents can be used. Polyurethane paints are sensitive to high relative humidity of the air during application. The isocyanates often react faster with the water in the air than with the base. However, also one-component isocyanates are produced which require humidity to cure. Areas of use Polyurethane paints are very resistant towards solvents, have high chemical resist- ance and low water vapour permeability. They have better weatherability and sunlight resistance and are therefore often used as finishing coat on top of epoxy systems. The film thickness is in the range of 30-75 um. High-build polyurethanes applied in more than 50 ym dry film thick- ness generally have a lower gloss than dedicated finishing polyurethanes. 6 Paint coatinc mareriacs §=201