PROTECTIVE COATING

Understanding Important Definition in

painting

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 PROTECTIVE COATING

Difference between Thermoplastic and Thermosetting

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Curing of paint
 CURING OF PAINT
Drying and curing are two different processes. Drying generally refers to
evaporation of vehicle, whereas curing refers to polymerization of the binder.
Depending on chemistry and composition, any particular paint may undergo
either, or both processes. Thus, there are paints that dry only, those that dry then
cure, and those that do not depend on drying for curing.

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Curing of paint

CURING OF PAINT
 Paints that dry by simple solvent evaporation contain a solid binder dissolved in
a solvent; this forms a solid film when the solvent evaporates, and the film can
re-dissolve in the solvent again.
 Paints that cure by oxidative cross linking are generally single package coatings
that when applied, the exposure to oxygen in the air starts a process that cross
links and polymerize the binder component. Classic alkyd enamels would fall
into this category.
 Paints that cure by catalyzed polymerization are generally two package coatings
that polymerize by way of a chemical reaction initiated by mixing resin and
hardener, and which cure by forming a hard plastic structure. Depending on
composition they may need to dry first, by evaporation of solvent. Classic two
package epoxies or polyurethanes would fall into this category.
  
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Curing of paint

 Latex paints cure by a process called coalescence where first the water, and then
the trace, or coalescing, solvent, evaporate and draw together and soften the latex
binder particles together and fuse them together into irreversibly bound
networked structures, so that the paint will not redissolve in the solvent/water
that originally carried it.
 Recent environmental requirements restrict the use of Volatile Organic
Compounds (VOCs), and alternative means of curing have been developed,
particularly for industrial purposes. In UV curing paints, the solvent is
evaporated first, and hardening is then initiated by ultraviolet light.

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Gloss Levels

 In paint technology, the sheen is the glossiness of a paint finish. Glossy and flat
(or matte) are typical extreme levels of glossiness of a finish. Glossy paints are
shiny and reflect most light in the specular (mirrorlike) direction, while on flat
paints most of the light diffuses in a range of angles.
 The gloss level of paint can also affect its apparent colour.
 Between those extremes, there are a number of intermediate gloss levels. Their
common names, from the most dull to the most shiny, include: matte, eggshell,
satin, silk, semigloss and high gloss.

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Gloss Levels
 Gloss Levels
 Typical gloss values have been determined in accordance with ISO 2813:1994
using a 60º gloss head.
 The categories used in the product data sheets are:
 Finish (Sheen) Gloss (60º Head)
 Matt 0-15
 Eggshell 16-30
 Semi Gloss 31-60
 Gloss 61-85
 High Gloss >85
 In practice, the level of sheen and surface finish will be dependent upon a
number of factors, including application and the condition of the surface to be
overcoated. 7
 PROTECTIVE COATING

Gloss Levels

 Manufacturer measures gloss as percentages (at an unspecified angle) and gives:

 Flat (1–9% gloss)

 Low Sheen (10–25% gloss)

 Eggshell (26–40% gloss)

 Semi Gloss (41–69% gloss)

 Gloss (70–89% gloss)

 The sheen or gloss level of a paint is principally determined by the ratio of

resinous, adhesive binder which solidifies after drying, and solid, powdery
pigment. The more binder the coating contains, the more regular reflection will
be made from its smooth surface; conversely, with less binder, grains of pigment
become exposed to the surface, scattering the light and providing matte effect.
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To a lesser extent, gloss is also affected by other factors: refraction index of the
pigment particles, viscosity and refraction index of the binder.
 PAINTING
Paint system
 The Gloss of a paint depends on the PVC (Pigment - Volume - Concentration)

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 PROTECTIVE COATING

Gloss Levels

 An important indicator is pigmentvolume concentration (PVC), defined as the

ratio of pigment volume and total paint Volume:

 PVC affects both physical and optical properties of a paint. Matte paints have
less binder, which makes them more susceptible to mechanical damages
(however, they are less visible than on glossy surfaces). More binder provides
a smoother and more solid surface. However, at a certain PVC, called critical
PVC (CPVC), the paint is already saturated with binder and the surface
becomes solid and glossy, without protruding particles; adding more binder
(lowering PVC) will not affect the sheen. CPVC generally depends on the
binderpigment system used, and generally falls in the 35–65% range.
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Gloss Levels

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Gloss Levels

 As a gloss finish will reveal surface imperfections such as sanding marks,

surfaces must generally be prepared more thoroughly for gloss finishes. Gloss
finish paints are generally more resistant to damage than flat paint, more
resistant to staining, and easier to clean. Flat paint may become glossier
through burnishing or staining with grease; glossy paint may lose its gloss and
look scratched if abraded. Unlike gloss paint, flat paint can generally be
touched up locally without repainting the entire surface.

 Gloss level can be characterized by the angular distribution of light scattered

from a surface, measured with a glossmeter, but there are various ways of
measuring this, and different industries have different standards

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Gloss Levels

 Applications
 In traditional household interiors, walls are usually painted in
flat or eggshell gloss, wooden trim (including doors and
window sash) in high gloss, and ceilings almost invariably in
flat.
 Similarly, exterior trim is usually painted with a gloss paint,
while the body of the house is painted in a lower gloss.

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 PROTECTIVE COATING

DFT & WFT

 DFT - The thickness of the final dried film applied to the

substrate. The DFT is typically measured using a magnetic gauge,
which will give a value measured from the surface of the coating
to the magnetic plane within the surface profile. The magnetic
plane is the theoretical point within the surface profile that the
 DFT gauge sees as being the average position of the substrate.
Some variations exist in methods of DFT measurement; DFT
gauges can be calibrated on smooth or blasted steel panels and a
correction factor for surface profile may or may not be
considered. ISO 2808:2007, ISO 19840:2004 and SSPC-PA2 are
accepted standards for measuring DFT.
 WFT - The initial thickness of the wet coating applied to the
substrate. 14
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Volume Solids

 The volume solids figure given on the product data sheet is the percentage
of the wet film that remains as
 the dry film and is obtained from a given wet film thickness under specified
method and conditions.
 Unless otherwise stated, these figures have been determined under
laboratory conditions using the test
 method described in the standard ISO 3233:1998 – Determination of
percentage volume of non-volatile
 matter by measuring the density of a dried coating. The volume solids of a
coating is determined using
 the recommended dry film thickness quoted on the product data sheet and a
specified drying schedule
 at ambient temperature, i.e. 7 days at 23ºC ± 1ºC.
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Coverage

 Theoretical coverage is calculated from a product’s volume solids and a

specific DFT:

 It is possible to calculate practical coverage using theoretical values and

loss factors but these calculations
 are complex and subject to great variability in external factors such as
environment, substrate, access
 limitations, application methods and the complexity of the structure being
coated. It is advised that such
 calculations are left to professional estimators with experience and
knowledge of the application of
 protective coatings under various site conditions.. 16
 PROTECTIVE COATING

Drying Time
 The drying times quoted in the product data sheets have been determined in the
laboratory using a typical dry film thickness, the ambient temperature quoted in the
relevant product data sheet, and the appropriate test method, i.e.
 Touch Dry (ISO 9117-3:2010)
 The surface dry state of a coating when ballotini (small glass spheres) can be lightly
brushed away without damage to the surface of the coating. In this state the bulk of
the coating is still mobile.
 Hard Dry (ISO 9117-1:2009)
 The condition of the film in which it is dry throughout its thickness.
 This through drying state is determined by the use of a “mechanical thumb” device
which, when applied using a specified gauge, under specified pressure, torsion and
time, does not mark or damage the film.
 The drying times achieved in practice may show some slight fluctuation, particularly
in climatic conditions where the substrate temperature differs significantly from the
ambient air temperature. Other environmental factors such as air flow and relative
humidity may also affect drying times. 17
 PROTECTIVE COATING

Overcoating interval
 The product data sheets give both minimum and maximum overcoating intervals and the figures
quoted at the various temperatures are intended as guidelines, consistent with good painting practices.
Certain terms require elaboration as follows:
 Minimum over coating period
 The minimum over coating time quoted is an indication of the time required for the coating to attain
the necessary state of dryness and hardness to allow the application of a further coat of paint. It
assumes:
 The coating has been applied at the normal recommended thickness
 Environmental conditions both during and after application were as recommended for that particular coating, especially in
respect of temperature, relative humidity and ventilation
 The paint used for over coating is suitable for that purpose
 An understanding of the method of application. For example, if a coating can be applied by both brush and spray it is
expected that over coating may be carried out more rapidly if sprayed; it is the lower figure that is quoted.
 If the above conditions are not met, the quoted minimum overcoating times are liable to variation and
will invariably have to be extended.
 Maximum over coating period
 The maximum over coating time indicates the allowable time period within which over coating should
take place in order to ensure acceptable inter coat adhesion is achieved.

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Overcoating interval
 Extended over coating period
 Where an extended overcoating time is stated, the product can be overcoated after an
indefinite time period but the anticipated level of intercoat adhesion can only be achieved
if:
 The existing coating has been applied in accordance with good painting practices and
at the specified film thickness
 The existing coating has the intended surface characteristics required for long term
overcoatability.
 For example, an over-applied epoxy MIO may not have its usual textured surface and will
no longer be overcoatable after ageing unless it is abraded
 The existing coating is intact, tightly adherent, clean, dry and free from all
contaminants. For example, the rough textured surface of an MIO may require
extensive cleaning, especially in an industrial and/or coastal environment
 Glossy surfaces can negatively affect the adhesion of subsequent coats and should be
lightly abraded, sweep blasted, or treated with other suitable processes to remove the
sheen. Surface treatments should not cut through or detract from the performance of 19
the
underlying coating.
 PROTECTIVE COATING

Flash Point

Flash Point:
 Measured as the minimum temperature to which a product confined in a
Setaflash closed cup must be heated for the vapours emitted to ignite
momentarily in the presence of a flame. (ISO 3679:2004).

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Product weight

 Product weight:
 The weight of coating per unit of volume; for example, if a coating has a product
weight of 1.5 kg/l this simply means that one litre of the coating will weigh 1.5 kg. It
follows that products containing large pigment loads or dense metallic pigments will
have a greater product weight.
 Product weight can be calculated from the mixed formulation or measured
experimentally. The most widely used experimental method is ISO 2811-4:1997.

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Volatile Organic Content (VOC)

 Volatile Organic Content (VOC) is the weight of organic solvent

per litre or kilogram of paint.
 Legislative requirements differ from country to country and from
region to region and are constantly being reviewed. It is
recommended that users check with local agencies for details of
current VOC regulations to ensure compliance with any local
legislative requirements when proposing the use of any coating.

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Mix Ratio

Mix Ratio:
The proportions in which multi-pack products are mixed. These
can be given by volume or by weight. For example, a two-pack
product with a mix ratio of 2:1 by volume would imply 2 litres
of Part A should be mixed with 1 litre of Part B.

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Working Pot Life

Working Pot Life

 The maximum time during which a product supplied as separate
components should be used after being mixed together at the
specified temperature (ISO 9514:2005).
 The values quoted have been obtained from a combination of
laboratory tests and application trials and refer to the time periods
under which satisfactory coating performance will be achieved.
 Application of any product after the working pot life has been
exceeded will lead to inferior product performance and potential
loss of application equipment. For these reasons it must not be
attempted, even if the material in question appears liquid in the
can. 24
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Shelf Life

Shelf Life
 The shelf life quoted on the data sheets is generally a conservative value,
and it is probable that the coating can be applied without any deterioration in
performance after this period has elapsed. However, storage conditions can
affect shelf life and this must be taken into consideration. For example,
prolonged storage at extreme temperatures (outside the range 4 – 40°C (39 –
104°F)) can result in deterioration of application and performance
properties. Water borne products must always be protected from freezing
and should be stored at 4 – 30°C (39 – 86°F).
 It is recommended that the condition of the material is checked before any
large scale application is undertaken using materials beyond the quoted shelf
life. It is also advisable after long periods of storage to ensure that the
containers are still sound.
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Induction Time:
 Induction time is the time interval needed to start a reaction or further action. For
example, an induction period is necessary for a pre-catalyst to undergo a transformation
to form the active catalyst, before the catalyst can take effect in a catalytic reaction. In an
auto-catalytic reaction, the rate of reaction remains slow until sufficient products have
formed to catalyze the reaction.
 Insufficient induction times in coatings or paints cause coating failures. For example,
many epoxy coatings require a fixed time interval in order to make the epoxy resin and
hardener fully compatible. When this pre-reaction time is not met, it will produce poor a
film appearance and poor coating performance. Induction time will usually increase with
low temperatures and/or high humidity.
1. In coating industries, improperly inducted epoxies will lead to:
2. A reduced gloss (than expected)
3. Polyamide/amine blushing
4. Poor color appearance
5. Lower corrosion and chemical resistance
6. Poorer film
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(Induction time also called "sweat-in time.“)
 PROTECTIVE COATING
What Are Epoxies?
What Are Epoxies?
 Epoxies are polymer materials, which begin life as liquid and are converted to the solid
polymer by a chemical reaction.
 Epoxy systems physically comprise two essential components, a resin and a hardener.
The resin component is the ‘epoxy’ part and the hardener is the part it reacts with
chemically and is usually a type of ‘amine’.
 The resin component is usually light, sometimes almost clear coloured and near odour-
free, hardeners are usually dark and have a characteristic ‘ammonia-like’ odour.
 When these two components are brought together and mixed intimately in a prescribed
way, they will react chemically and link together irreversibly, and when the full reaction
has been completed they will form a rigid plastic polymer material. This polymer is
called a ‘thermoset’ plastic because, when cured, it is irreversibly rigid and relatively
unaffected by heat.
 Epoxy polymers have many uses: as industrial adhesives, or as coatings, or as matrices in
which to embed reinforcement fibres to form advanced reinforced plastics, and also as
encapsulation media.
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Curing stages of Epoxies.
Epoxy Cure Stages
(i) Mixing in pot - bringing together resin and hardener as a uniform liquid, to initiate the chemical
reaction, followed by transfer to a large surface area tray to produce a thin film. The chemical
reaction begins, producing heat, much of which escapes to the environment, because of the large
surface area.
(ii) Gelation - point of which a significant proportion of the reaction has occurred. Usually between 1 - 4
hours.
(iii) ‘Almost tack free’ - the last stage at which the surface is ‘active’ and can accept further layers/coats
of epoxy and still form good bond. This stage is indicated when a finger on the surface does not
indent the layer deeply, but does leave a fingerprint. Usually between 1 hour to 6 hours.
(iv) Hardening - occurs after almost tack free - touching the surface with a finger leaves no fingerprint.
However, the epoxy film is still less than 30% cured and can be indented with a thumbnail. Usually
not before 3-6 hours.
(v) Earliest sanding time - epoxy film is firm enough to withstand abrasion. At this stage sanding will
produce a fine dust rather than crumbling lumps. Usually 8-24 hours.
(vi) Full cure - at room temperature ‘full cure’ for most epoxies means 80-90% of their theoretical
maximum crosslinking, which can only be obtained by heating to higher temperatures (40-100°C
typically). ‘Room temperature cure’ epoxies are designed to give good performance even though not
cured to their theoretical maximum. ‘Full cure’ is usually after a minimum of one week. 28
 PROTECTIVE COATING

Relative humidity and Dew point

 As a general rule, not to paint when the Relative Humidity is above 85% or when the Dew Point is
closer than 3 degrees to the ambient air temperature.

What is Relative Humidity?

 Relative Humidity is a ratio of how much water vapour is in the air compared to the maximum it
could hold at any specific temperature.
 RH is a measure of water vapour and does not take into account any discreet form of water present
such as rain. On a rainy day RH measures the level of water vapour in the air between the raindrops
so when it is raining the RH is not 100% as some people may think.

What is Dew Point?

 Dew Point is the temperature surface temperature at which the air can no longer hold it’s water
vapour and a percentage of it starts to form discreet water droplets i.e. condensation. This occurs
because the lowering of the air temperature reduces the amount of energy available to keep the water
in vapour form.
 To be able to paint a surface and avoid condensation forming, it is a rule of thumb that the surface
temperature of the object you are painting must be around 3 degrees above the Dew Point.
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Why not to paint when Relative humidity is above 85%

What is relationship between Relative Humidity and Dew Point?

 Whenever the Relative Humidity is 100% the ambient temperature and the Dew Point are the same.
At this level of humidity the air is holding the maximum amount of water vapour it can possibly hold
and any slight decrease in temperature would lead to an immediate deposition of moisture onto the
surface.
 It is clear from above table that a Dew Point around 3 degrees below the ambient temperature and
they all have a Relative Humidity around the 81 to 84% level.
 Now it is clear that why we should as a general rule not paint when the RH is greater than 85%. If
30 has
the RH is greater than 85% then surface temperature (to be 3 degrees higher than the Dew point)
to be equal or higher than the ambient air temperature.
 PROTECTIVE COATING

Surface Tolerant paint:

Surface-tolerant epoxy is epoxy that is rust and moisture-tolerant as well as wet-tolerant. The surface-
tolerant epoxy primer can be used on little or no prepared surfaces with any humidity and wet
surfaces. These epoxies are anti-corrosive, surface-tolerant and water-dilatable. This is very useful
where metal has the potential to corrode. This epoxy coating produces excellent adhesion with iron
and non-ferrous substrates. This epoxy can be applied on a range of substrates, for example:
 Hand-prepared rusty steel
 Hydro-blasted steel and abrasive blast cleaned
 Range of intact & aged coatings
 It is also suitable for protection in both open air and immersion conditions. The
following can be protected from using this epoxy:
 Storage tanks
 Piping, roof decks, water towers
 Structural steel and plant equipment
 Marine vessels, offshore structures
 Other variant surfaces exposed to humidity, chemicals and corrosive environments

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What is the meaning of one coat

The operation for each coat consist of a stroke of the brush given from the
top downwards, another from the bottom upwards over the first stroke, and
similarly one stroke horizontally from the right and another from the left
before it dries.

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 PAINTING

Varnish

What is Varnish ??
Varnish is a product which, when applied to a substrate, gives a solid
transparent film and has protective, decorative or special properties.

Varnish does not contain covering pigments and is therefore regarded as "clear
paint".

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