Introduction to Protective Coating

Introduction

Prepared by : Tri Wahono

Version : July 2023
 contents
1. Introduction

2. Corrosion as related to coatings

Day 1
3. Essential coating characteristics

4. Coating fundamentals

5. Surface preparation

Day 2
6. Application of coatings

7. Inspection and testing

8. Coating selection

9. Coating repair and maintenance

10. Pipeline coatings

Day 3
11. Safety and Environmental

12. Specifications

Session I 08:00 – 12:00

Session II 13:30 – 16:00
Break time 10:00 – 10:15
14:45 – 15:00
Objectives of the Course
▪ An overview of the protective coating technology,
▪ Provide a technical basis of protective for
preparation, application, inspection and
specifications,
▪ Exchange knowledge between course
participants
Historical Development of Paint
30,000 Years Ago
Paint – the group of emulsions generally consisting of
pigments suspended in a liquid medium for use as
decorative or protective coatings – made its earliest
appearance about 30,000 years ago. Cave dwellers
used crude paints to leave behind the graphic
representations of their lives that even today decorate
the walls of their ancient rock dwellings.
Today
Many of today’s paints and coatings may go
unnoticed by the consumer, but play immeasurably
valuable roles in delivering high-quality foodstuffs,
durable goods, housing, furniture and thousands of
other products to market. Total value of product
shipments for the industry were approximately
$26.1 billion in 2020.
Introduction (internal use only)
1700 – 1867
The paint and coatings industry, however, had to
wait for the Industrial Revolution before it became
a recognized element of the American national
economy. The first recorded paint mill in America
was reportedly established in Boston in 1700 by
Thomas Child. A century and a half later, in 1867,
D.R. Averill of Ohio patented the first prepared or
“ready mixed” paints in the United States.
1950s – 1970s
Industry consensus standards limiting the use of
lead pigments date back to the 1950s, when
manufacturers led a voluntary effort to remove lead
from house paints. Common house paints have
contained little, if any, lead since then. In 1978, the
Consumer Product Safety Commission banned the
use of lead in consumer paint
Mid-Late 1800s
In the mid-1880’s, paint factories began springing up in population
and industrial centers across the nation. Mechanization was
making the manufacturing process accessible to a larger and less
specialized group of entrepreneurs. The weight of prepared paint
made it expensive to transport, so a decentralized structure of
small manufacturers in discrete markets dominated the industry
until the mid-1900s
Early 1900s
Besides mechanizing and
professionalizing the paint industry, the
Industrial Revolution also created vast
new markets for paints and coatings.
Virtually every product created on an
assembly line — from the Model T Ford
to the latest-model television — makes
extensive use of paints and coatings to
beautify, protect and extend the life of
the manufactured goods.
Before WWII (1939)
As soon as the impact and potential risks of various paint
components have been quantified, paint manufacturers
act. Historically, the industry readily responded to
environmental and health concerns by altering the
chemistry of its products to control risks. Paint
manufacturers started replacing lead pigments in some
paints, for example, before World War II, when safer
alternatives became available.
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Definitions

wrapping
coating
painting

lining

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Introduction (internal use only)
Definitions
Paint may be defined as any liquid material containing drying oils alone or in combination with natural
resins and pigments which, when applied to a suitable substrate, will combine with oxygen from the air to
form a solid, continuous film over the substrate, thus providing a weather-resistant decorative surface.

A protective coating is chemically a substantially different material. It outperforms paint in adhesion,

toughness, and resistance to chemicals, weather, humidity, and water

In order to provide corrosion protection, the protective coating must also:

(1) Resist the transfer or penetration through the coating of ions from salts that may contact the coating;
(2) Resist the action of osmosis;
(3) Expand and contract with the underlying surface;
(4) Have and maintain a good appearance, even under extreme weather conditions.

Reff: Corrosion Prevention by protective Coatings by Charles G. Munger

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 Purposes
Protection
o The major consideration in painting is preservation of the structure or equipment from the environment.
Appearance
o The most important reason for painting (in mild environments) and second most important reason outdoors is the
decorative value of paint in producing pleasant and attractive surroundings.
Sanitation and cleanliness
o Painted surfaces are generally relatively smooth and nonporous so that they are easily kept clean
Illumination
o White and pastel-colored paints, when applied to ceilings, are highly efficient in natural and artificial light.
Efficiency
o Improved illumination and reduction of glare both aid markedly in improving efficiency of personnel in the area.
Visibility and Safety
o Increased illumination improves general visibility in the area, thus also preventing potential accidents

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Introduction (internal use only)
Codes, Standard & Regulations
Code:
A group of general rules or systematic standards
for design, materials, fabrication, installation and
inspection prepared in such a manner that it can
be adopted by legal jurisdiction and made into
law

Standard:
Documents prepared by a professional group
having requirements believed to be good and
proper engineering practice and which area
written with mandatory requirements (i.e. the verb
shall is used)

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Codes, Standard & Regulations
Recommended practice:
A documents prepared by a professional group
indicating good engineering practice but which
are optional (i.e. the verb should is used)

Guides and Guidelines:

Documents by agencies, organization , and
committees enumerating various engineering
methods which are considered good practice,
without any specific recommendation or
requirement. These guides may be used at
engineer’s discretion

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Major Organization Standards
USA ANSI American National Standard Institute

Canada SCC Standards Council of Canada

France AFNOR Association Française de Normalisation

United Kingdom BSI British Standards Institute

Europe CEN Committee of European Normalization

Germany DIN Deutsches Institut fur Normung

Japan JISC Japanese Industrial Standards Committee

India BIS Bureau of Indian Standards

Worldwide ISO International Organization for Standardization

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Personnel Certification

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Personnel Certification

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