Applying Plural Component Spray

Presented By: Art Webb, Naval

Research Laboratory
Scope
This webinar provides an introduction and
overview of plural component spray
methods of applying industrial/marine
protective coatings.
Learning Outcomes
 At the end of this webinar the student will be
able to:
 Recognize the use of plural component application
 Define a high solids coating
 Identify plural component application systems
available
 Recognize the methods for properly mixing material
or coating components (e.g., Part A, Part B)
Why the Interest in Plural
Component Application
Economics
Environmental Compliance
Application Readiness
Safety
Application Quality
High-Solids Coatings
 For our purposes, high-solids coatings are
considered to be at least 90% solids
Various Names for A and B Components

A Component B Component

Base Catalyst

Resin Amines

Prepolymer Isocyanate

Polyol Accelerator or
Promoter
Activator
Plural Component Coatings
Types
 e.g., Epoxies / Polyurethanes / Polyureas

Components of a Typical Epoxy

 Component (A): Resin or Base
 Component (B): Co-reactant or Curing Agent

Curing Mechanism
 Reaction of Components A and B to form a
chemically crosslinked protective film
Characteristics of Two
Component Epoxies
 Ratio
 Volume by ratio of Components A to B (i.e.. 1:1, 4:1)
 Induction Time (Sweat-in-Time)
 Time mixed components must stand to allow for
initial chemical reaction prior to application
 Pot Life
 Time mixed components remain usable without
affecting applied coating performance
Characteristics of High Solids
Epoxies
Solids by Volume

Primer Characteristics

Topcoat Characteristics
Characteristics of High-Solids
Epoxies
 Viscosity (resistance to flow)
 Generally twice that of solvent based epoxies
 Higher pressure required to pump and atomize
 Heating coating reduces viscosity
 Pot Life
 Measured in minutes vs. hours (ex. 45 minutes @
77°F)
 Exothermic reaction (heat generated by mixed
components in container)
Characteristics of Polyurethane
Coatings
Polyurethane Coatings
 Advantages
 Limitations
Characteristics of Moisture-
Cured Urethane Coatings
Moisture-Cured Urethane (MCU)
Coatings
 Advantages
 Limitations
Polyurethane Advantages

Turn Around Time

100% Solid
Ability to Apply During Winter Months
Unique “Self-Inspecting” Property
Plural Component Application
Process - Summary
 Components A and B are power mixed/agitated
separately
 Components are heated to reduce their viscosities and
re-circulated uncombined from the reservoir to the mixer
and back until the desired temperatures and viscosities
have been reached and maintained
 Both components are pumped separately in their
desired proportions (flow rates) toward the spray gun
 Components are combined in a manifold/mixer
immediately before reaching the gun
Examples of Plural Component Spray
Units

A B C
 Plural Component Equipment Schematic
Heater B

Gun 1

“B”

Heated Hose to Manifold

55 gal. “B” Supply Mix
Proportioner
Agitator and Elevator
“A”
To Catalyst (B) Inlet
Gun 2

Heater A

“A” Inlet “B” Inlet

30:1 Solvent Flush to
Mix Manifold

55 gal. “A” Supply

Agitator and Elevator To Resin (A) Inlet
System Components
Feed system
Pump/proportioning system
Hoses
Heating system
Mixing manifold system
Spray gun
Feed System
Feed Pumps
Characteristics of Pump
Systems
Available Spray Pressure
Normal atomization/spray pressure
Flow rate
Compatibility of wetted parts with
materials pumped
Power source
Characteristics of Pump
Systems - Impact on System
Feed pumps must be of a sufficient size
Need sufficient spray pressure
Power Sources for Pumps
Air-powered supply pumps
Hydraulic supply pumps
Photo of Proportioning
(Metering) Pumps

Courtesy of Courtesy of Graco,

WIWA Inc.
Critical Nature of Mixing Ratio
Proper Ratio
Check Ratio
Off-Ratio
Monitoring System
Unit Control Panel
Remote Mountable Controls - Up to 30.5 m

Digital Heat Controls Digital Pressure Control

Park “A” pump

Target and Actual Temp PSI or Bar

F° or C°
Cycle Counter
Stop

Error Codes
Heated/ Insulated Hoses
Portable Unit with Spray Hose
Heating System
(In-line)
Coating Material
Temperature Requirements
Too low a temperature will restrict flow
Too low a temperature may also cause
amine blush or amine bloom as it is
sometimes called
Amine Blush on Steel
Taking Material Temperature
Using Infrared Gun
Critical Material Temperature
Check Points
Storage Temperature
 Reservoir/supply container
 Pump
 Manifold
 Gun
Mixing Manifold System

The mix manifold is where the material

components A & B are brought together to
be mixed at proper ratio.
Manifold Mixer
Mix Manifold System
Mix Manifold
Mix Manifold Assembly and Connections
Mixing Manifold Maintenance & Care
Mixing Block (isolated)
Solvent Purge System
Used to flush mixed components from
manifold, spray hose, and gun
Purging of Mixed Components
After Interruption of Work
Mixed components must be solvent
purged or flushed from the gun whenever
application is interrupted for several
minutes
Equipment Clean-up
Plural-component application equipment
must be thoroughly cleaned after use,
especially interiors of pumps, manifold,
hoses, guns and tips
Cut-away of plural component impingement
gun with component hoses joined at the tip
Airless Spray Gun
Proper Atomization
Atomization occurs in airless spraying
when coating is forced under high
pressure through tip orifice
Factors Affecting Spray
Pattern Size
Size of tip orifice (typically 0.017 to 0.021)
Wear of tip
Fan angle
Distance of gun from substrate being
painted
Tip Wear
High solids coatings wear tips more
rapidly than traditional solvent borne
coatings
Diagram of Changes in Airless
Spray Pattern with Tip Wear
Application Thickness
Theoretically, wet film thickness of high-
solids coatings is the same as the dry film
thickness
Area with restricted working space can
easily become coated with excessive film
builds
Matching of System
Components
 All system components should be properly
matched for size and capacity
 The heating system should also match the
components
 Clean, lubricate and otherwise maintain
equipment parts for best service
 Never modify equipment without consulting with
manufacturer
Plan the Work
Application team should be briefed about
planned work before beginning it.
Summary
In this Unit, we covered:
 Why industrial/marine customers are
considering use of plural component spray
technology to apply 100% solids coatings
 Brief introduction to high solids material
 Plural component application systems
 Mixing methods
Questions?