Paint technology
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Manufacturing a paint
Paint production is a complex production process Here, we have simplified the process by showing some of the most important steps.
Paint technology / What is paint1
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Paint consist of:
Binder Colour pigments Extenders Solvents Additives
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Composition of paints
Paints
Binder
Natural Resin Drying oil Coal Tar Nitrocellulose Synthetic Resin Alkyd CR Epoxy Polyester Polyurethane Silicate Vinyl Paint School
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Pigments
Colouring
Solvents
Hydro carbons
Additives
Wetting agent
Extender
Inhibitive pigm. Cathodically protective Biocides
Ketones
Esters Ethers Alcohols Water
Anti-settling
Drier Anti-skinner Plasticiser
Generic types of paint
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The properties of a paint will be decided by the binder
Three generic type of binders are applied to test panels: Alkyd, epoxy and polyurethane Exposed to sunlight, water chemicals Different properties are demonstrated. Important to select the correct type of paint for the purpose
Paint technology / What is paint2
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Alkyd paints
Properties
Advantages
Good application
properties 1-component Good weather durability Good wetting properties Good recoatability Good levelling properties Good gloss retention Dry heat resistant up to 120 C.
Limitations
Poor chemical resistance
(especially against alkaline) Limited water resistance (submerged) Limited solvent resistance Limited film thickness per coat Poor adhesion to CR Never to be used on Zinc
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Alkyd paint
Where to use
Segments
Ships Industry
Objects
Newbuildings / Maintenance All exterior and interior objects Only above water
St 2 to Sa 2 or shop primed steel
Surface preparation
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Flaking of Alkyd on Zinc
1. Coat: Zinc rich coatings 2. Coat: Alkyd
Never use Alkyd on top of Zinc Alkyd on Zinc will give saponification
Gjerde flaker 1-8
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Modified Alkyd paints
Styrene alkyds - Quicker drying Silicone alkyds - better gloss retention
Urethane alkyds - Quicker drying, better water and chemical resistance. Can be applied in thicker coats (60-100 microns DFT)
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Vinyl paints
Properties
Advantages
Physically drying Good chemical resistance Good water resistance Quick drying Not temperature dependent One-component
Used for:
Exterior objects above water Offshore on top of Zinc-ethyl silicate
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Limitations
Low solid content Poor resistance against
strong solvents Dry heat resistant up to approximately 80 C
Vinyl Tar - Modified type
Properties
Advantages Disadvantages
Higher content of
solids Higher water resistance Better wetting properties Cost advantages
Bleeding Dark colours Tar on cancer list
Used for: Under water areas
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Pure Epoxy paints
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Epoxy paints
Epoxy resin Solvents Pigments Extenders Additives Curing agent Solvent
Part A:
+
Part B:
Chemical reaction Evaporation of solvent
Result Insoluble 3-dimensional network
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Curing agents for Epoxy paints
Polyamides:
Normal epoxy paints
Amine and amine adduct:
Solvent free coatings Tank coating
Isocyanates:
Low temperature curing Reaction with -OH
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Pure Epoxy paints
Properties
Advantages Limitations
Chemical curing Very good chemical resistance High alkali resistance Moderate resistance to acids Good adhesion Very low permeability High mechanical strength Dry heat resistant up to 120 C
Chalking Temperature dependent 2 - component Requires blast cleaning Overcoating time
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Pure Epoxy paints
Where to use
Segments Ships Offshore Industry New buildings / Maintenance Chemical cargo tanks Blast-cleaned to Sa 2 or shop primed steel
Objects
Surface preparation
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Modified Epoxy paints
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Modification of paints
We can modify a paint by replacing some of the original binder with another, suitable binder. Examples of modified Epoxies are: Epoxy mastic Coal tar epoxy Epoxy phenolic We can thereby achieve new properties, such as Improved penetration Better water resistance Better chemical resistance We will most probably also loose some of the original properties
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Epoxy Coal Tar
Properties
Advantages:
Chemically curing More flexible Excellent water resistance Better wetting properties Dry heat resistant up to 90 C
Limitations:
Dark colour Temp. dependent 2-component Recoating interval Bleeding when overcoated Coal Tar is carcinogenic
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Epoxy Coal Tar versus Pure Epoxy
Reduced chemical and solvent resistance Reduced dry heat resistance Increased water resistance Better wetting properties
Used for: Submerged areas, cargo holds and ballast tanks
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Epoxy - acrylic
Properties
Positive
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Limitations
2-pack Overcoating time
Very good weather resistance Very good gloss retention Very good chemical resistance Very good solvent resistance Cures down to 0 C Potlife (24 timer)
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Epoxy - acrylic paints
Where to use
Segments Ships Offshore Industry New buildings / Maintenance Above water Indoor and outdoor Top coat on Epoxy, Epoxy
Objects
Surface preparation
Mastic, Polyester glass flake
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Epoxy Mastic paints
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Epoxy Mastic paints
Properties
Advantages
Chemically curing Surface tolerant Light colours Very good water resistance Very good wetting properties Good chemical resistance High solid content High build (Thick coats) Winter curing agent Dry heat resistant up to 90 C
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Limitations
Chalking Temperature dependent Not to be applied on
thick coats of physically drying paints Minimum DFT 150 m by airless spray
Epoxy Mastic paints
Where to use
Segments
Ships Offshore Industry Newbuildings / Maintenance Ballast tanks and Cargo tanks All exterior and interior surfaces,
above and below water
Objects
Surface preparation
St 2 to Sa 2 or Water jetted, Magnesium descaled or shop primed steel
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Polyurethane paints
Properties
Advantages Limitations
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Very good weather resistance Excellent gloss durability Very good chemical resistance Very good solvent resistance Cures down to 0 C
2-pack May cause skin irritation Overcoating time
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Polyurethane paints
Where to use
Segments
Ships Offshore Industry
Objects
Newbuildings / Maintenance All exterior substrates above
water (Also internal at times)
Surface preparation
On top of Epoxy, Epoxy Mastic and Polyester coatings
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UV - Light
Gloss Retention for various paints
Gloss
100 90 80 70 60 50 40 30 20 10 0
Acrylic Polyurethane Epoxy Alkyd
400
800
1200
1600
2200
Hours accelerated testing
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Zinc rich paints
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Zinc Epoxy
Properties
Advantages
Chemically curing Good corrosion protection Good adhesion Require min. Sa 2 Good mechanical strength May be recoated with all types of paint, except Alkyd Dry heat resistant up to 120 C
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Limitations
Temperature dependent 2-component Film thickness: 25 - 50 m Not acid- and alkaline resistant (Resistant between pH 5-9)
Zinc Epoxy paints
Where to use
Segments
Ships Offshore Industry Newbuildings / Maintenance All exterior and interior objects
above and below water (as holding primer for underwater use 20-30 microns).
Objects
Surface preparation
Blast-cleaning to minimum Sa 2
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Zinc Ethyl silicate paints
Properties
Advantages
Very good solvent resistance Very high heath resistance
(max 400 Very high mechanical strength Very good adhesion to blast cleaned steel Relatively good recoatability
oC)
Limitations
Requires humidity for
curing 2-pack Max. DFT: 100 m At higher DFT tendency of mud-cracking or checking
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Zinc Ethylsilicate paints
Where to use
Segments
Ships Offshore Industry Newbuildings / Maintenance All exterior objects above the
waterline. Tank coating and Water ballast tank (No paint on top)
Objects
Surface preparation
Blast-cleaning to minimum Sa 2
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