Evolution of Coating Applications

Methods & Technology For

Eastern NACE Conference
By Doug Klingensmith
President of USI
NACE Member
268050
 Does This Look Familiar?
Innovation & Tech has the answers
 The First Paints
• Found in
prehistoric
caves
• Using simple
ingredients
such as soil
water &
animal fats
The 3 P’s of Coating Effectiveness

1.Preparation
2.Preparation
3.Preparation
 Substrate Preparation
• Key reminder – The product you are applying is only
as good as your preparation.
• Follow application directions from manufacturer.
• Follow structure owner specification if available.
• Both may include items such as:
– Atmospheric conditions
• Moisture
• Wind
• Humidity
• Temperature
Substrate Preparation Continued
– Cleanliness of pipe
• Standards by NACE, SSPC, ISO
• Structure owner specification
– Anchor pattern
• How aggressive?
– Elimination of spurs and sharp edges
– Transition issues
• Overlap
• Tapered edge
Humidity, Temperature – Weather
Conditions
Pipe Conditions – Record your
findings.
Substrate Preparation
How well did you prepare the steel?
How clean is your air supply?
Blasting set up.
 The 3 P’s of Coating are:
Preparation, Preparation & More Preparation.
Conventional Grit
Blasting

Newly Developed
Bristle Blasting

MBX
Bristle
Blaster

Pneumatic Electric
 APPLICATION EQUIPMENT

• Before we examine the various Application Equipment available, we must first

consider the following:

– SHAPE AND SIZE OF THE OBJECT TO BE COATED

• (SPEED OF APPLICATION / MASKING / CUTTING IN)

– VISCOSITY OF THE MATERIAL

(GRADE OF MATERIAL FROM HVLP SPRAY TO TROWL GRADE)

– APPLICATION PROPERTIES OF THE MATERIAL

(SINGLE OR 2 PACK MATERIAL / POT LIFE / MIXING / WFT REQUIED)

– WHAT CONDITIONS ARE LIKELY TO AFFECT THE APPLICATION AND FINISH

OF THE COATING? (REQUIDED DFT / FINISH REQUIRED / PERCENTAGE OF
THINNER ADDED, SURFACE CONDITION, NUMBER OF COATS)
 BRUSH & ROLLER

• Advantages:
– Techniques are relatively simple
to master.
– Equipment cost is low.
– 100% “Transfer Efficiency”.
– Negligible lost of product due to
equipment.
• Disadvantages:
– Application is relatively slow.
– Difficult to eliminate Brush
Marks or “Orange Peel” from
roller application.
 BRUSHES
• To achieve a quality finish, use a quality brush. Forked bristles
with a good “stock”.

• For very viscous materials, the brush may be cut down to aid
application.

• Achieving an acceptable and smooth finish when brushing can be a

difficult. A lot depends on the properties of the coating material,
the dimensions of the work, and the skill of the operator.

• The operator must try to maintain an “open” edge to be able to

work with the “Wet Edge Time” of the material. Also, when
painting vertical surfaces, “Laying Off” vertically on the final stroke
will aid flow.
 ROLLERS
• The choice of rollers is increasing all the time.
Both the “SLEEVE” material and its “PILE” can be
chosen to suit a particular application.
• APPLICATION ROLLERS:
– Such as, Mohair, Wool, High Density Foam, Nylon
etc.
• EFFECT ROLLERS:
– Such as, Sponge, Stipple,
– Rag, etc.
 Application Continued
• Hand Applied
– Bell hole application
– Girth weld application
– Risers
– Anywhere spray
application is not
needed or possible
 Coating Tips
• Don’t forget about the
pot life of the product.

•Man is my wrist sore.

Where is the power
mixer?
 MIXERS
• DRILL and
• EPI-MIXER
• For mixing at High
Speed.
• Good for mixing Larger
Units of “Liquid” Coating
or small quantities of
screeds.
• Particularly if the Pot Life
is Short, or the coating is
difficult to mix by hand.
Coating Technology Applications
 Two-Part Epoxy Application
• Cartridge Format
– Pinhole repair
– Small diameter field
joint
– Small scrapes and
abrasions
– Test lead repair kit
 Coating Tips
• Icicle formation at the 6:00
position due to improper
roller application.

• Difference between spray application

and roller application.
 SPRAY APPLICATIONS
• Many types of equipment are available. Choice depends mainly on
the viscosity of the product to be sprayed, and the working
environment.
• Advantages over Brush & Roller Application ?
– Spray Application is much quicker.
– Reduced labor costs.
– Quality of finish is higher.
• Disadvantages ?
– Use of equipment and techniques is more skilled.
– Equipment can be very expensive.
– Transfer Efficiency is lower than 100 %
– More loss of product due to equipment.
 Method of Atomization
• TABLE OF GENERAL PROPERTIES FOR SPRAY EQUIPMENT

Application Material Working Application Speed Atomization Quality Transfer

Equipment Viscosity Pressure Efficiency

Conventional Air Spray Low - Medium 40 - 100 psi Medium - Fast Excellent 35 - 45 %

HVLP Low 40 - 80 psi Slow - Medium Good - Excellent 45 - 70 %

Airless Spray Medium - High 1500 - 5000 psi Very Fast Fair 55 - 80 %

Air Assisted Airless Medium - High 500 - 1500 psi Fast Good 55 - 75 %

Wet Low 40 - 80 psi Medium Good - Excellent 60 - 80 %

Electrostatic (+ 5-20 %)
(Induction)
 Conventional Air Spray
• Used for “FINE FINISHES”.
• Eg: Trains / Automotive / Furniture Applications Disadvantages:
Very Poor Transfer Efficiency Due to High Bounce Back.
ATOMIZATION
 AIRLESS SPRAY GUN
• Coating is pumped under EXTREME
pressure through an ORIFICE.

• This action ATOMIZES the paint AND

produces the FAN, without the use of
air at the tip.

• The Airless Spray Motor may be

driven by compressed air or
electricity.
Typical Unit
Changing Fan Pattern
 Airless Spray Application
– Handles Medium to High
viscosity materials.
– Application Rates are
very high.
– Used for “INDUSTRIAL
FINISHES”. Eg: Bridge /
Ship / Structural Steel
Coating.
– Very Good Transfer
Efficiency Achieved.
– Can only be used for 2
Pack materials if the
“Usable Life” is long.
 PLURAL FEED HOT AIRLESS SPRAY

• These units are used to spray

– 2 Pack materials that have a short “Usable
Life” or
– 2 Pack materials that are too viscous to
spray at ambient temperatures.
For example:
– Many solvent free 2 component Epoxies
or Polyurethane's
Plural Hot AS Schematic
Epoxy Unit
Fast Set Polyurethane Unit
 PLURAL COMPONENT GUNS

• Various plural
component guns
are available
 SOLVENT FREE EPOXY APPLICATION

• Graco Xtreme Mix Plural-component spray

machine
Gracy Xtreme Mix
Plural Unit
 Epoxy Application Clip
• Spray Applied
– Large rehab projects
– Plural component
spray
– Economical
 Plural Feed Spraying
•Advantages ? •Disadvantages ?
– Materials may be easily – Units are very
heated. expensive (but may be
hired).
– Short Usable Life’s are
not a problem. – Operation of units is
more skilled.
– Negligible waste. (Requiring 2
– Higher material operatives).
temperature provides – Equipment is bulky.
faster working rates and
better atomization. – Larger compressors
required.
– Shorter and fewer down
times. – Longer start up times.
 High-solids, cartridge spray systems
save time. Ideal for jobs that are too
small for Plural Spray
A 450mL cartridge can cover
6 to 7 sqft at 25-40 mils.
 Intended Uses
• As a patch material
• As a girth weld coating
• As an internal lining
• As a stand alone coating for pipe
rehabilitation
• In a wide variety of other field applications
where corrosion protection of metal is
required
 Q&A
• Various Application Equipment
• Brush & Roll
• Conventional Spray
• Heated Plural Spray Units
• Portable High Solids Cartridge Spray
 Summary
• Correct selection of application equipment with
fully trained personnel can result in a fast, stress
free application which in turn will result in a
better quality finish.

• This in turn will lead to better protection and

reliability of your valued assets and minimize
potential issues with the DOT or the public

• Lowering your company’s Life-Cycle Cost and

increasing corporate long-term profits.
Thank You
Doug Klingensmith
NACE Member
268050