4. What is paint?

Table of content

Section Title Page

4.1 Definition of paint 4.2

4.2 What does paint consist of? 4.2

4.3 Composition of paint 4.2

4.3.1 General overview 4.2
4.3.2 Binder 4.3
4.3.3 Pigments 4.4
4.3.4 Solvents 4.6
4.3.5 Additives 4.7

4.4 How does paint protect a structure? 4.7

4.4.1 Barrier effect 4.7
4.4.2 Inhibition 4.8
4.4.3 Cathodically protective pigments 4.9

4.5. What does a paint system consist of? 4.10

4.5.1 Primers 4.10
4.5.2 Intermediate coats 4.11
4.5.3 Topcoats 4.11
4.5.4 Variations 4.11

Section 4 : “What is paint” Page 4.1

Copyright© 2010 Jotun Paints South Africa (Pty.) Ltd. All rights reserved.
4. What is paint?

4.1 Definition of paint

The following definitions are based on:
ISO Standard 4618/1 (Paints and Varnishes - Vocabulary - Part 1: General terms).

Paint is a product, liquid or in powder form, containing pigment(s), which, when applied to
a substrate, forms an opaque film having protective, decorative or specific technical
properties.

Varnish is a product which, when applied to a substrate, forms a solid, transparent film
having protective decorative or specific technical properties. In fact, varnish (clear coating)
is substantially the same as a paint, the difference being that varnishes contain no
pigments.

4.2 What does paint consist of?

The main ingredients of a paint can be grouped as follows:

• Binder
• Pigment / Extender
• Solvent
• Additives

The ingredients used and the relative amounts in the paint are of paramount importance
for the final properties of the paint. To formulate a modern paint to satisfy both technical,
health, safety, environmental and economical requirements is very complicated. Small
variations in the relative amount of the paint ingredients constitutes may lead to great
variations in the final properties of the paint. If other compounds not recommended by the
paint manufacturer are added, the balance between these materials will be altered. There
are always poor results when meddling with the composition. As a rule: Check instructions
for use on the label and the technical data sheets.

4.3 Composition of paint

4.3.1 General overview

A summary table of the most important ingredients of a paint is given below. The
ingredients mentioned under each group are the most important constituents, but by no
means all that may be included to make a particular paint. Some of these components are
described more thoroughly in the following sections.

Section 4 : “What is paint” Page 4.2

Copyright© 2010 Jotun Paints South Africa (Pty.) Ltd. All rights reserved.
 Table 4.1
Composition of paints

Paint
Binder Pigment Solvent Additives

Colouring pigment
•Titanium oxide Water Wetting agent
•Zinc oxide Hydrocarbon Anti-settling agent
•Carbon black Alcohol Drier
•phtalocyamine Ester Anti-skinner agent
Natural resin
Kethone Plasticiser
•Drying oil
•Coal-tar Extender pigment
•Nitrocellulose •Clay
•Talc
•Calsium carbonate
•Barium sulphate

Synthetic resin
Anti - corrosive
•Alkyd resin
•Red lead
•Chlorinated rubber
•Zinc powder
•Epoxy resin
•Zinc phosphate
•Phenolic resin
•Zinc chromate
•Polyester
•Aluminium powder
•Polyurethane
•Silicate
•Vinyl resin Antifouling agents
•Cuprous oxide
•Tin compounds

* Carl-tar binders are considered as a health risk

4.3.2 Binder
The binder is the non-volatile portion of the vehicle of the paint. Vehicle is defined as the
liquid portion of the paint and consist of the binder, the solvent and any other dissolved
matter.

Resin is the binder that holds the pigment particles together and provides adhesion of the
paint to the surface. Most paints or coatings are named by the generic type of resin (i.e.
vinyl, epoxy, acrylic etc.). The resin, or binder, is responsible for most of a coating’s physical
and chemical properties, chemical resistance, weather resistance, adhesion properties and
also influence the hardness and abrasion resistance.

Table 4.2
Curing Mechanisms of binders

Oxidising Physically drying Chemically curing

Alkyd Chlorinated rubber Epoxy
Vinyl Polyurethane
Acrylic Polyester
Asphalt Silicate
Tar

Section 4 : “What is paint” Page 4.3

Copyright© 2010 Jotun Paints South Africa (Pty.) Ltd. All rights reserved.
The resin or binder can be classified as thermoplastic or thermoset. Thermoplastic resins
can be repeatedly softened by heating and hardened by cooling. They can also be dissolved
by the original solvent used in the coating; they are resoluble (i.e. vinyl, chlorinated rubber,
acrylic etc.) They are usually one-packed products.

Thermosetting resins undergo a chemical reaction by the action of heat, catalysts, UV-light
etc. They do not melt by heating or re-dissolve in solvent. Epoxy, polyurethane and silicates
are such resins. They are usually two-packed products, but can also be one-packed coatings,
cured by oxygen in the atmosphere, like alkyds. A more detailed discussion on curing agents
will be given in connection with description of the different generic types of coatings.

The choice of the binder is determined by the purpose for which the paint is intended. For
example epoxy for good chemical resistance and polyurethane for weather and gloss
resistance.

The binders can be modified to give certain properties. For example pure epoxy have very
good chemical resistance but must be applied on a blast cleaned surface. Paints based on
coal tar have very good water resistance and penetrating properties (surface tolerant), but
are not very resistant to chemicals such as solvents. A combination of the binders give the
paint fairly good chemical resistance as well as good resistance to water and good
penetrating properties.

Figure 4.1
Curing mechanism of two-pack paints

Solvents evaporating

= Polymer = Curing agent (hardener)

Polymer & hardener molecules reacted

to form a new chemical substance:

4.3.3 Pigments
Pigments can be separated into various classes such as either colouring pigments, extenders
(also called fillers or reinforcing pigments), inhibiting pigments or metallic pigments.

Section 4 : “What is paint” Page 4.4

Copyright© 2010 Jotun Paints South Africa (Pty.) Ltd. All rights reserved.
Colour Pigments.
Colour pigments, of course, provide the pleasing colour and decorative characteristics of a
coating. The colour pigments in the use of corrosion-resistant coatings should have

• High hiding power.

• Colour fastness.
• Non bleeding (insoluble in solvents).
• Chemical resistance.
• High ultra violet light absorption.

Some pigments used in coatings should not be used in corrosion resistant coatings. When
selecting a colouring pigment care should be taken not to influence the corrosion
protection characteristics of the paint. The effect of colouring pigments on the corrosion
protection properties is debatable, but generally the inorganic pigments, like iron oxide in
different colours, have better performance than the organic ones. On the other hand the
organic colour pigments are brighter. Titanium dioxide is a commonly used pigment for
white and light tints and have high hiding power. All the colour pigments have hiding power
which can differ to a greater or lesser extent.

Extender pigments
Extender pigments (also called fillers or reinforcing pigments) have their own function in
the paint. An extender is in powder form with different particle size and shapes (needles,
fibres, balls or plates), which is practically insoluble in media. The colour of the dry powder
is usually white or slightly coloured, but dispersed in the vehicle they become more or less
transparent. Extenders can be described as a special type of pigment without, or with very
little, hiding power. The shape can also show great variations, from round to a more
irregular shape and form. The type of extenders, relative amounts and the different particle
shapes, sizes, etc. must be carefully chosen, to give the best possible quality to the paint.

Figure 4.2
The gloss of a paint depends on the PVC (Pigment-Volume-Concentration)

B in d er G lossy
C o lou r P V C 15 -25
p igm en ts
E x ten d ers
S em iglo ss
P V C 30 - 40

F la t
P V C 3 5 - 50

Section 4 : “What is paint” Page 4.5

Copyright© 2010 Jotun Paints South Africa (Pty.) Ltd. All rights reserved.
Extenders are sometimes used to partially replace expensive colouring and covering
pigments in order to obtain an optimal price-setting. Nowadays, however, they are mostly
used to improve the quality and to impart certain desirable properties to the paint.
Extenders are added to reinforce the paint film and to give the paint the correct gloss and
consistency to make it suitable for spraying, rolling, brushing, etc. The addition of extenders
enables the paint to be applied in high film thicknesses without sagging. They also prevent
sedimentation of pigments, improve the mechanical properties and increase the resistance
of the paint to water and chemicals. Also they form a barrier to ultraviolet radiation.

Anti-corrosive pigments
Pigments in anticorrosive paints may be divided into three groups:

1. Inhibiting pigments.
Inhibitive pigments are principally used in primers or first coat. These are pigments which
react with the moisture absorbed by the coating to form sufficient ions which react with the
underlying metal surface to passivate it and make it more corrosion resistant. These
pigments are used primarily in atmospheric coatings and are not recommended for
immersion or constantly wet area as they may promote osmotic blistering. Examples of
inhibiting pigments are Zinc Chromate, Zinc Phosphate, Red Lead etc.

2. Metallic pigments.
Some pigments have a very special function. Paints pigmented with aluminium flakes have
a very low water and water vapours permeability, which gives the paint higher water
resistance. These flakes will lie parallel to the substrate and have in fact the same effect as
tiles or fish scales. These flakes are very impermeable and water, oxygen etc. must
therefore work its way through long and intricate paths before it reaches the steel surface.

Zinc, however, acts in a different way to Aluminium. Zinc coatings are protective in two
different ways: They serve as a barrier and also as a galvanic protection of steel surfaces. In
the case of an organic or inorganic zinc primer the zinc acts as a sacrificial anode. (See
section regarding Cathodic protection). This action tends to protect the base material from
corrosion while the pigment itself is corroding.

3. Flake formed pigments

The protective mechanism of the flake formed pigments, i.e. glass flakes and micaceous
iron oxide (MIO), are more or less the same as for the aluminium flakes. In addition, they
give a better reinforcement of the paint and better resistance against shrinkage.

Anti fouling agents

Some paints contain biocides to prevent marine fouling. These compounds are in most
cases based on copper, zinc or tin. For further discussion reference is made to the section
dealing with anti-foulings.

Section 4 : “What is paint” Page 4.6

Copyright© 2010 Jotun Paints South Africa (Pty.) Ltd. All rights reserved.
4.3.4 Solvents
Solvents, diluents and thinners are liquids used to dissolve the binder and to adjust the
viscosity of the paint. It also influences the flow properties, drying speed, spraying or
brushing characteristics and gloss. Certain binders, such as drying oils, themselves have a
low viscosity and therefore do not need to be dissolved. Most binders, however, are either
solid materials or highly viscous liquids, and must therefore be dissolved in organic solvents.
A few types of binders, such as certain silicates are dissolved in water, while emulsions and
water based epoxies are water dilutable.

Some painters do not realise the importance of solvents or thinners in the formation of a
paint film. Too much thinning of a paint may cause sagging and formation of pinholes
during, or shortly after, application. By using a wrong solvent this can create porosity,
discolouration, poor gloss, floating of pigment, fisheying, poor coating strength and lack of
adhesion. All those things can happen if the proper solvent or solvent combination is not
used in a protective coating.

Whether a given liquid e.g. xylene, is a solvent or a diluent is determined by the nature of
the binder. Xylene is a solvent for alkyd and chlorinated rubber paints, whereas for vinyl
paints it is a diluent.

The solvent is a liquid, single or blended, which is volatile under normal conditions and is
capable of solving the binder completely. The only reason for having a solvent in the paint is
to make the paint applicable. As soon as the paint is applied on to a structure the solvent
evaporates from the paint layer.

A diluent is a volatile liquid, single or blended, which will not dissolve the binder. It may be
used in conjunction with the solvent without causing any deleterious effects. Normally, a
diluent is mixed with the binder solution (vehicle) to obtain certain effects, e.g. regulation
of the evaporation pattern, adjustment of the paint viscosity or cost reduction of the
volatile part of the paint.

A thinner is a volatile liquid, single or blended, added to a product to lower the viscosity.
Normally, thinners are either solvents or diluents or mixtures of both.

4.3.5 Additives
In addition to binder, pigments and solvents, most coating formulations contain additives.
They are usually in small quantities, with the level of use seldom exceeding 1 - 2% of the
entire formulation. They are a must for having homogeneous paints and contribute to ease
in manufacture, improve package stability and application, and also to improve appearance
and quality of resistance.

An Alkyd, for example, contains dryers to promote curing. Hard, brittle resins, such as vinyl,
contain plasticizers to produce a more flexible film. Other additives may be incorporated
into a coating formulation to control pigment settling, give a certain gloss or improve sag
resistance.

Section 4 : “What is paint” Page 4.7

4.4 How does paint protect a structure ?
In corrosion prevention with paints, three main principles are employed:

• The BARRIER effect

• The INHIBITOR effect.
• The GALVANIC effect.

4.4.1 Barrier effect

The barrier effect is a concept basic to most available anticorrosive coatings. No coating is
totally impermeable. Barrier coatings are designed to be unaffected by accumulated
moisture or vapor within the coating up to the point of normal moisture absorption
content.

A barrier coating is most often used as an immersion coating and must therefore be inert to
surrounding chemicals. It must be as impervious to air, oxygen, carbon dioxide, and the
passage of ions and electrons as possible. The adhesion to the underlying surface must be
very good, and also it must wet the surface well enough to prevent any voids at the coating
substrate interface. All in all, a barrier coating forms an inert barrier over the surfaces. Flake
pigments (aluminium or glass) are used in many coatings to optimize the barrier effect.

Figure 4.3
Principle of protective mechanism of flake pigments.

Water

Steel

Flakeformed pigments make it more difficult for moisture

to reach the steel as the distance becomes longer.

4.4.2 Inhibition
Inhibitors are usually added to the primer only and consists of pigments that react with the
absorbed moisture within the coating. Thus, instead of having an inert paint film, as with
barrier coatings, the inhibitor coatings contain chemicals that react in the absorbed water
in the film to passivate the substrate. The inhibitors react with the steel surface in order to
passivate it and decrease its corrosive characteristics.

Section 4 : “What is paint” Page 4.8

Inhibitive pigments are sometimes characterised as anodically active, which means that the
pigments ionise by water and subsequently react with the steel or metal substrate at
anodic sites. This maintains that area in a passive or inactive condition.

In contrast to the coatings developed on the basis of the barrier effect, the inhibitive
coatings are mostly used for atmospheric exposures; that is, as coatings for steel or other
metals which are subject to weathering but not to immersion. Several pigments are so
water-sensitive (draws so much water into the coating) that an immersed exposure will
create osmotic blistering.

4.4.3. Cathodically protective pigments

The concept of cathodically protective pigments is, in many ways, an extension of the
inhibitive primer principle. However, the reactions taking place, are entirely different. In
the case of an inorganic Zinc primer or an organic zinc-rich primer, the Zinc acts as a
sacrificial anode (See section regarding Cathodic protection). This action tends to protect
the base material from corrosion while the pigment itself is corroding. Many times, where
scratches or narrow damage to inorganic Zinc coating have occurred, the zinc products from
the corrosion process fill in the scratch or damaged area and seal it against further
deterioration by the atmosphere.

Figure 4.4
Cathodically protective pigments
D a m a g e in c o a tin g to s te e l s u rfa c e

M o istu re a llo w s Z in c to
io n iz e , c a th o d ic a lly p ro te c tin g th e s te e l.

S u p e rio r a d h e s io n p re v e n ts c o a tin g u n d e rc u t
2 n d O r g a n ic T o p c o a t

2+ I n o r g a n ic Z in c P r im e r
Zn
S te e l

A n in o r g a n ic Z in c p r im e r r e a c ts to p r o te c t th e
s te e l s u b s tr a te w h e n th e to p c o a t is d a m a g e d .

The inorganic Zinc coatings may be used alone or as a primer over which topcoats may be
applied. Zinc silicate primers are highly adherent, reacting with the substrate to form a
chemical bond in addition to the physical bond with the steel surface. The high adhesion of
the zinc primer prevents undercutting of the organic topcoats. This is an important property
in case of a coating break or if a defect in the paint film should occur. Good adhesion will
reduce the risk of expanding the damaged area, as is the case with many organic inhibitive
primer systems. Although organic zinc-rich primers protect in a similar manner, provided
the zinc is in particle-to-particle contact within the primer, the organic binder does not
chemically react with the substrate. Thus, the coating may be undercut if corrosion occurs.

Section 4 : “What is paint” Page 4.9

4.5 What does a paint system consist of?

Coating systems, may consist of any number of coats and combinations of materials. In
most cases, coating systems will consist of 2 to 4 coats. We usually split a coating system
into three main parts:

• Primers (may include shop primer)

• Intermediate coats (midcoats)
• Topcoats

Each part of the paint system has a definite function, although some paints can play a dual
role in a paint system. (See also “Variations” later in this section).

4.5.1 Primers
The primer is the first coat of a paint system. The primer is the base on which the rest of
the coating system is applied. As a base, it must have strong adhesion to the substrate
surface and must form a good basis for the next layer of the coating system.

Primers normally provide corrosion protection during the application period and the whole
service life of the paint system. The primer is considered to be one of the most important
components of the coating system.

Most primers for steel contain anti-corrosive pigments such as red lead, zinc powder (zinc
dust), zinc chromate, zinc phosphate, calcium phosphate etc. Due to their toxicity, red lead
and zinc chromate are used less frequently nowadays and certainly not in prefabrication
(shop-priming) as they will release noxious or toxic fumes during welding and flame-cutting.

If the coating system is an inhibitive one, it must contain the inhibitive pigments and be
capable of using these pigments in a way which will passivate the metal surface and reduce
its tendency to corrode. In cathodically protective primers, zinc silicates to a certain extent
reacts with the steel surface in order to obtain an even greater and stronger adhesion.

The primer must also provide a proper and compatible base for the intermediate coat. It
must provide a surface that can be thoroughly wetted by the subsequent coat. The
generally flat, non-glossy surface must also provide some physical adhesion to the next
coat. Primers, then have dual requirements; adhesion to the substrate and provision of a
surface which will allow proper adhesion of the following coats.

Where primers are used for immersed conditions or tank linings they must have a chemical
resistance equivalent to the remainder of the coating system in order to satisfactorily
protect against the chemical cargo / substance in which it is immersed.

Section 4 : “What is paint” Page 4.10

4.5.2. Intermediate coats
In some paint systems intermediate coats are applied between primers and topcoat(s).
Intermediate coats, often also called undercoats or body coats, must adhere well to the
primer; they are essential for obtaining a sufficient “build” to the paint system.
Furthermore, they should have high mechanical strength, good covering power and their
colour should preferably be nearly the same as that of the top coat, but sufficiently
different to allow the contrast to be obvious when applying the final coat. The colour
should be lighter than the topcoat to allow good hiding by the topcoat. Often a white, or
nearly white, intermediate coat is beneficial for the hiding power of the topcoat.

The formulation of the intermediate coats is important. Coatings that build up high
thickness of the paint per coat are often termed “High Build coatings”. The body coat (or
intermediate coat) must also provide strong adhesion to the primer, as well as a good base
for the topcoats. The intermediate coat must have a surface ideal for good adhesion of the
topcoat. Without the ability of this material to properly adhere to the primer and to
provide proper adherence to the topcoats, the problem of inter-coat adhesion would cause
early coating breakdown.

Tie coat
A Tie coat is designed to improve inter-coat adhesion and/or avoid certain defects like
pinholes and popping during application. The main purpose of applying a tie coat is
therefore to displace air from narrow gaps and “valleys” on the steel substrate. In order to
let the air out from the substrate it is important to apply a thin coat, usually in the range of
20 - 30 microns. Tie coats are mainly applied on inorganic zinc primers.

4.5.3. Topcoats
The top coat is the last coat(s) of a paint system, designed to protect the coats beneath
from the environment, to contribute to the overall corrosion protection offered by the
system and to give the required colour and gloss.

The finishing paint or top coat has many functions. Beside being decorative, it should be
weather-resistant. The topcoat is the first line of defence against different environments
such as: Wind and weather, highly polluted atmospheres, water and aggressive chemicals.
It is the initial barrier of the coating system. This means that the finishing paint also must
have several properties: Good colour- and gloss retention, non chalking in bright sunlight
and good adhesion under humid conditions.

Moreover, the finishing paint may also be required to have good mechanical properties, i.e.
resistance against scratching, physical impact and abrasion and resistance to growth. Glossy
topcoats are formulated with a low pigment to vehicle ratio. In order to satisfactorily apply
a topcoat over a reactive base coat containing zinc, the topcoats must be highly alkali-
resistant. Such topcoats would include vinyls, chlorinated rubbers, epoxies and coal tar
epoxies.

Section 4 : “What is paint” Page 4.11

4.5.4 Variations
A coating system however, need not to be composed of the three different parts; even a
single coat can provide a coating system, depending upon the requirements of the coating.
Inorganic zinc coatings, for example, provide an excellent one-coat system for the storage
of refined oil products and many solvents. A single coating formulation applied in two or
more coats may provide the best answer to a specific problem. In most barrier coating
systems special intermediate coats are omitted. The surface tolerant mastics can be applied
directly on to steel and therefore serves both as a primer and an intermediate coat.

As for all paint systems the properties of these products must satisfy a number of
requirements, like:

• Expected lifetime (design life)

• Future maintenance
• Classification society requirements
• International standard requirements
• Health, safety and environmental requirements
• Cost for the total design life.

Section 4 : “What is paint” Page 4.12