Paint Constituents and Basic Technology Paint is a material which will change the texture colour or appearance of a surface and give some form of protection to the underlying surface. Paint has been classified in many ways eg by principle involved. .1-—” Barrier: The material forms a thick impermeable layer of a high electrical resistance eg urethane. jon: Causing a chemical reaction between the paint constituents and rate eg rust inhibitive primers. 3. Cathodic protection: Employs the bi-metallic principles by using a less noble ‘metal as pigmentation eg zinc in zinc rich primers. By function eg Arti fouling: Inhibits marine growth on ship hulls marking: Gives white or yellow lines on roads. Fire’proofing: Provides resistance to fire. Heat resistant For surfaces working at high temperatures. (nti-corrosive, and many more. Paints can be classified by binder type (the main constituent) or by colour, and in some cases even by the pigment type. No matter which identification system is used, all the paints contain the same basic ingredients. “Binder 2 Pigments and other additives Solvent (where applicable) It is the chemical structure and composition of these constituents, which gives the paints their own individual properties. Paints are supplied as either liquids or solids in powder form and can be subdivided into groups a)__ Liquid paints containing solvent This group is still the largest in terms of sales. It is important to realise that solvent does not relate solely to Hydrocarbon solvents, but also includes water. Due to the modem Environmental Protection Act (EPA) requirements, manufacturers are researching into new paint technology involving vastly reduced amounts of volatile organic compounds. Some are using water based technology, some are concentrating on the solvent free materials. b) Solvent free As the name implies these materials contain no (or in some cases a minute amount of) solvent. These are generally chemical curing materials which require the mixing Rev 2 January 2010 - "WORLD CENTRE. Paint Constituents DWE wonscours Copyright © TWI Ltd 2010 JOMING TECHNOLOGYof two or more components and usually go under the name of MCLs (multi component liquids). Some MCLs are made using solvent borne materials. c) Powders Virtually solvent free MCLs, which are solid at room temperatures. The base resin and the chemical activator, along with the other constituents required to complete the formulation are heated up to the resins melting point, mixed into an homogeneous liquid, cooled and ground into powder form. In theory every particle contains all necessary ingredients to effect a cure into a protective film. The powder can be applied onto a preheated substrate (in the case of substantial steel thicknesses) at about 240°C, or onto thin plate electro statically and post heated. In either case the powder melts, undergoes a chemical reaction and in approximately three minutes the reaction is complete. The three subdivisions are all made up from the basic ingredients mentioned earlier, binder, solvent, pigment and other additives. The binder is the main constituent of a paint and is often referred to as a film former. Other terms are yebicle and gon volatile. A paint binder is selected according to the function the paint has to perform within vastly different environments. Some major considerations of a binder are “46; Ease of application (flow properties or viscosity). ws a Adhesion to the substrate for the expected life of coating. .3- Resistance to abrasion 4~ Resistance to chemical attack according to environment. ©, Cohesive strength, its ability to hold together as a film. &~ Dialectric strength. 7 Ability to resist the passage of water. ‘6 Ability to change from a liquid as applied, into a solid to provide the above properties, and others, for the expected life of the coating, Several materials satisfy the criteria above for different environmental conditions, among them are: % 04) Acrylic: Synthetic resins, can be used in HC.solvents or water. Good colour ‘fetention, good film properties can be hybridised with other binders eg urethane ‘modified acrylic as used by BG (Jb) Alkyd: A term derived_from alcohol - acid reaction, usually associated more with the domestic market, they have a low resistance to alkalis. In common with most resins they are brittle and need modification with oils. c) _Ashphaltic_bitumens: Petroleum based materials, thermoplastic, relatively inexpensive, known for water proof properties, poor resistance to sunlight, very low resistance to HC solvents. ~ ~~ Rev 2 January 2010 TWI won cemne Paint Constituents FOR MATERIALS Copyright © TWI Ltd 2010 JOMING TECHNOLOGYqd) Bg) d -Solvent borne. Cellulose resins: Synthetic material, not extensively used for i but a good example of reversible materials. Chlorinated rubber: Organic resins derived from reaction of rubber with chlorine. Widely used years ago until strict VOC regulations came into force. Especially resistant to alkalis and acids and were used on chemical plants, water treatment plants etc. Very poor resistance to hydrocarbon solvents, but can still be found in many locations and structures. algo revercszble rateriall Emulsions: Obviously not used for anti corrosive systems but are included for other factors eg drying mechanisms. Epoxies: Synthetic organic resins, generally provide good chemical, solvent and water resistance. Good exterior durability but are_prone to chalking (discussed later). Epoxies come as two pack, single pack, solvent free and Ethyl and methyl silicates: _Inorganic_mat Solvent and heat resistance. When cured the binder a high percentage of zinc dust, thus protecting by galvanic action. Natural oils: Many natural oils can be used in the paints industry but because Of their slow drying properties, cannot be used on their own as binders. They are mixed with resins to modify the film properties, Some natural oils used in the paint industry are linseed oil, tung oil (also known as China wood oil), soya oil, tall oil and safflower oil Natural resins: Natural resins are brittle by nature and fast drying. As mentioned above they need to be mixed with oils to modify some properties. A mixture of oil and resin is known as oleoresinous. Examples of natural resins are copals, dammars and coumarones. Natural resins are not soluble in water. Phenolic resins: Made ftom_phenol_and formaldehyde, coal derivatives, characterised by excellent adhesion _properties and resistance ta heat and chemicals. Were used in temperature ranges where Chlorinated rubber couldn't be used eg greater than 65°C. Commonly called hot drying oils. Polyurethanes: Can come in several forms, moisture curing, two pack polyurethanes, chemically curing and single pack. industrial Coatings are mainly the first two. They produce an excellent synthetic coating, with outstanding abrasion resistance, chemical resistance, and good exterior gloss and colour retention with a minimum of chalking. 0 faiton dary’ Cukdface Silicones: Designed as high temperature service materials for temperatures leally above _150°C service temperature. Usually carbon or aluminium pigmented, they are used to seal inorganic zinc silicates or metal sprayed surfaces. Rev 2 January 2010 Re Pani Consents EWE ronscours Copyright © TWI Ltd 2010 JOINING TECHNOLOGYn) Styrene: Sometimes referred to as a binder and is used to modify other properties.-Styrene is referred to as a vinyl type monomer and is used to cross- link the film. ©) Vinyl: The actual composition of the vinyl depends upon the designed end use, but in general has slightly better properties than a similar material, chlorinated rubber. However vinyls use a different solvent group, and water. CR is limited to one solvent group. Both are doneftrc Sefe, Binder — solvent groups and compatibility A solvent free binder, or a binder using a very weak solvent, will cause very few problems when over coating another product. Usually in this situation the problem would be limited to different expansion and contraction ratios. Providing a key by abrading can mostly rectify or at least minimise this. However, a very strong chemically curing binder like epoxy, needs a strong solvent and can cause problems over coating other materials, even when they are fully cured Guide to binder solvent combinations. Emboldened name is the main one. used. SS ‘Strength in descending order__| Common names Binders 1) | Water Emulsions PVC/PVA y week dobvent Vinyls ; Acrylics ~ other materials eg epoxy Bitumins, polyurethanes, + Alkyds, acrylated rubbers") ) Aliphatic White spirit Natural oils d hydrocarbons Turpentine Natural resins Turpentine substitute | Alkyds st] Solvent naphthas Phenolics Hexanes upwards ”) \ ‘Aromatic Xylene [Chlorinated rubber hydrocarbons | Toluene & Benzene 4 Ketones ‘Acetone Epoxy 4 very SI Y Methyl ethyl ketone + ~ J Spee Methyl ISO butyl ketone “We am pauk own Can’ To uP Paw rethanes use ketones and esters with aromatic diluents. In descending order down the table the solvent groups increase in strength. It is not advisable to use a binder with a strong solvent over an existing coating, which uses a weak solvent. For example chlorinated sr coated over an alkyd would result in Jifting, and wrinkling, but alkyd_over chlorinated rubber would have no ill effect. Because an epoxy is chemically cured, there is no problem over coating with polyurethane two pack, chemically cured, but a hydrocarbon solvent borne epoxy coating applied over chlorinated rubber would not be advisable. Rev? Janvary 2010 TWI vonocenme Paint Constituents: FOR MATERIALS Copyright © TWILtd 2010 OMG TECHNOLOGYEthyl and methyl silicates do not appear on the list because they are high (or low) temperature performance coatings, the criteria for compatibility with these materials for over coating is working temperatures. ie will the over coating material withstand the operating temperature? Usually the only material suitable is silicone. Ethyl and methy| silicates will not adhere over any substrate other than bare, clean steel. Any binder which can be converted into a polymeric salt can be modified to be water based and many of the binders mentioned above fall into that category. Chlorinated rubber doesn't, neither can it be made using reduced amounts of solvents, and “Werefore to comply with modern EPA requirements its usage now is limited, although many structures, both on and off shore are still coated in this material. It used to be the main material for ambient temperature usage for BG. The advantages of using this material were: ~— dd: pet ssdesuse ofthe chlorine content, high resistance to mould growth. 2 Again because of the chiorine, non-flammable after solvent release. 3- Very resistant to chemical attack eg acids and alkalis. A~ Very high resistance to water vapour transmission. &__ Material is non-toxic and provides a very durable film. &~ Very easily maintained, no abrasion required, clean surface only. 4 Disadvantages were: 4—“ts position on solvent compatibility list shows low resistance to solvents ie only resistant to aliphatics and water Low temperature tolerance, 65°C maximum. 3 Spray application often results in ‘cobwebs’. Polymers One of the properties expected of a binder is to change from a liquid into a solid to form a film. To perform this function all binders form polymers or use polymers already partially formed. The word polymer means literally many parts, poly = many, mer = single unit or part. Mer (meras Gk) can be a single atom, or a molecule, (a ~ group of atoms) and polymerisation can be described as being a string or structure of repeated units, and polymerisation is the joining together of a string or structure of repeated units”. In the case of most paints the main constituents of the polymers are: ves “UH hydrogen -@~ carbon N= nitrogen 9 oxygen C&A chlorine Although there are variations, the main three polymer types are linear, branched and cross-linked Rev 2 January 2010 comme Pant Conatuente TOWE vonscooe Copyright © TWI Ltd 2010 SOMING TECHNOLOGY