Coating Types and Systems

Spray Painting
Coating Types and Systems
© Copyright 2016 Fitz-Coatings Ltd

Objective
The objective of this training unit is to understand the basic constituents and properties of coatings used for
corrosion control and gain an insight into coating systems.
Coatings are the most widely used method of protecting steel structures from corrosion.

Coatings should:
be capable of an application under the prescribed conditions

i.e. brush, spray and roller
be able to 'wet-out' a variety of substrates e.g. steel, concrete,
wood etc.
form an adherent, cohesive film after drying/curing.
give protection.
be durable.
Coatings should be ready for use on delivery without any

complications to the applicator.
Airless Spray Painting

This video demonstrates the use of airless spray to apply a primer
coating to a blast cleaned surface.
The coating is specifically developed for spray application.
Always check the product data sheets and consult the supplier for
recommendations and guidance.
Airless spray is by far the most popular method for applying

Industrial Coatings.
Various film thicknesses can be applied by airless spray.
Paint Application by Brush
This video demonstrates the application of a coating by brush

method.
The coatings are generally formulated to suit the application

criteria or brush or spray method.
Always check the data sheets and container label to ensure the
product is a brushing grade.
A paintbrush is an ideal tool for stripe coating and getting into

awkward areas.
A paintbrush is also good for getting coatings into pitted and rough
surfaces.
© Copyright 2016 Fitz-Coatings Ltd Page 1

Paint coatings consist of four components:
Binder which is sometimes referred to as resin, vehicle or

polymer.
Pigment and extender.
Solvent (organic or water).
Additives.
Plasticisers are organic additives used to increase film flexibility

and function by lowering the glass transition temperature of the
paint*. Plasticisers affect many properties of a paint film including
tensile strength, toughness, extensibility, permeability and
adhesion to different degrees. The levels of addition have to be
carefully controlled as a positive effect on one property may
adversely effect another.
Typical plasticizers are dibutyl phathalate and dioctyl phthalate.
*The glass transition of a polymer or coating is the temperature at

which the material goes from being hard and glassy to soft and
flexible.
Convertible Coatings
Coatings which when applied and cured cannot be re-dissolved in
their own solvents.
Coating Types:
Alkyd Types.
Epoxy Ester.
Polyurethane.
Epoxy.
Siloxanes. ( certain types )
Non-Convertible Coatings
Coatings which when applied and cured c a n be re-dissolved in

their own solvents.
Coating Types:
Chlorinated Rubber.
Acrylated Rubber.
Vinyl.
Bitumen.
Convertible Coating
This animation illustrates the application of a convertible coating.
Convertible coatings cannot be re-dissolved in their own solvents.
The second coat will not dissolve the first coat, which in some
circumstances can lead to adhesion problems.
A solvent test can sometimes be used to determine if the coating

is a convertible coating. This test should be conducted by
competent trained personnel such as painting Inspectors or
supervisors.
Non-Convertible Coating
This animation illustrates the use of a non-convertible coating.
The coating can be re-dissolved in its own solvents.
The second coat dissolves the first coat giving good adhesion in
general.
The surface must, however, be clean and ready for additional

coats.

Single Part Type Coatings:
Alkyd.
Epoxy Ester.
Chlorinated Rubber.
Acrylated Rubber.
Vinyl.
Bitumen.
Siloxanes.
Two-Part Type Coatings:
Polyurethane.
Epoxy.
Siloxanes.
Polyester.
Zinc Silicates.
Coating Specification
Coatings are specified depending upon a number of factors which
include:
Environment.
Cost.
Durability.
Performance.
Preparation requirements.(level of surface preparation)
Availability.
Application conditions i.e. temperature.
Lifetime requirements.
Maintainability.

Environment
Some environments can be very hostile and a good coating
system would be required to protect the substrate.
Examples include:
Offshore Platforms and oil rigs.

Jetties and piles.
Ballast tanks.
General marine locations.
Coating systems are generally pre-tested to meet certain criteria

on performance.
Cost
The cost of coatings can vary tremendously depending upon the
generic type, thickness and availability of the coating.
It would be, however useless to specify an expensive coating

which is designed for an abrasive blast cleaned surface, onto a
poorly prepared surface.
Cost should be only one of a number of factors when specifying a

coating.
Always use reputable coating suppliers who can offer the technical
support if needed.
Durability
Coating systems differ in terms of durability.
Some coating systems are extremely hard wearing, while others

remain less durable.
There are many types of durable coating depending on the type of

resin, pigment, thickness etc.
This is an illustration of an anti-corrosive high build plural

component coating system being applied to the internal of a steel
tank.
Performance
The performance of a coating system is extremely important.
Some coating systems are designed for long life, (more than) 20
years, while others are designed for (less than) 10 years.
You can refer to the relevant Standards such as ISO EN 12944

which details various corrosive environments such as C1(rural and
low corrosivity) to C5 Corrosive Industrial and Marine.
There is also ISO 20340 which is for performance requirements for

offshore structures.

Preparation Requirements
The method of surface preparation and the type of substrate will
determine the coating system choice.
Some coating systems require a high standard of surface

preparation while others require a minimum level of surface
preparation.
Always seek advice from the coating supplier on the standard of

surface preparation.
The foundation of a predicted coating life begins with the level of

surface preparation.
Availability of Products
It is important to ensure the coating system is available when
specifying a specific type of product.
Some construction projects are spread worldwide and products

may not be available universally.
Some countries will not allow the import of chemicals and paints.
Remember site touch up also when considering product

availability.
Local suppliers may not have the materials available to meet the
specification.
Application Conditions
Application conditions are important to know when specifying a
coating system.
It would be no good recommending a high-performance paint

system which requires 20o C during application if a heat source is
not available.
Always read the application criteria on the product data sheets.
Consider the application conditions when reviewing a coating

system.
Lifetime Requirements
When specifying a coating system, the lifetime of the structure
should always be considered.
If a structure has a 5 year life, a coating system designed for 10

years may be an uneconomical decision.
In general, most large structures such as ships and offshore

platforms are designed for 20 years or more.
The coating should therefore also be designed for 20 years

minimum.

Maintainability
The maintainability of a structure should be considered when
reviewing the coating system.
If a new structure is being built that will have difficult access in the
future, a high performance long life coating system should be
considered.
Maintenance painting is not always considered when designing a

new plant!.
Paint Manufacturer
This is a simplistic illustration of paint manufacture which consists

of:
The binder - Which is the film forming component of the paint.
The Pigments - Provides colour and opacity.
Solvents. - Used for application purposes.
Additives - Numerous types of additives used to suit the particular

requirement of the coating.
Paint Mixing
Correct paint mixing is essential, even with single part coatings.
The older the paint the more mixing that will be required,
especially with heavily bodied coatings.
A mechanical mixer is always recommended and is more critical

with two-part coatings.
Mix the product until you get a consistent colour and consistent
blend with no lumps or resin variations.
Paint Mixing - Two Part Coatings

The correct mixing is more critical when using two-part coatings.
Products from both containers must be completely used in the

mix and the mix must achieve a consistent colour.
Always follow the supplier's recommendations with regards to

mixing.
Do not part mix two-part products unless you know the exact ratio
etc and only if agreed with the specification.
Paint Mixing - Two-Part

This animation demonstrates the mixing of a two-part coating with
the use of a powered mixer.
It is essential that a consistent colour and mix is achieved with the

mixing.

Do not mix too much paint at the same time or you may have
problems with the product, especially in hot climates as the curing
may commence and application may be difficult or even
impossible.
Ideal Performance - Coatings

This animation sets out the basis for the coating having the ideal
performance.
The main groups consist of:
Application.
Adhesion.
Durability.
Economics.
Further subgroups are then formed below each main group.
Basic Coating Formulation - Ingredients

This table represents paints and coatings listing, function and
percentage by weight of each ingredient.
The largest ingredient is the binder which is the film former and
contributes to adhesion, cohesion, flexibility and durability.
You will also see the function of the pigment and solvent etc.
Basic Coating Formulation - Ingredients ( cont )

This table continues to look at other ingredients such as the drier,
hardener or curing agent, accelerator, a thixotropic agent and anti-
skinning agent.
Some of the ingredients names relate to the function such as

accelerator for curing.
Understanding the basic principles of this table will help you to

understand paint formulation and the different ingredients required
in the products.
Schematic of a Coating System

This diagram is a schematic of a coating system showing the
properties of each coat to protect a steel substrate.
The primer must give good adhesion with no voids on the interface.
Intermediate coats must have low moisture transmission and

generally supply opacity through film thickness.
The topcoats protect the intermediate coats and supply colour and
aesthetics.

Coating Systems
Primer coat should:
Provide good adhesion to the substrate.

Provide anti-corrosive properties.
Have good wetting Properties.
An intermediate coat should:
Supply build.
Supply thickness.
Provide hiding power (cover primer)
Finish or top coat should:
Supply the right colour.

Offer the coating aesthetics.
Offer ease of cleaning.
Provide UV protection
One coat systems are available for specialist areas such as

tanks, pipes, splash zones etc. The single coat is usually high
solids.
The function of Corrosion Preventative Pigments

Zinc Dust
The Zinc particles can function as sacrificial anodes to

cathodically protect the steel. A high pigment percentage is
required to ensure particle to particle and particle to substrate
contact.
Aluminium Flake
Known as leafing aluminium where the flakes tend to orientate

parallel to the plane of the film and the resultant close-packed
layer of the aluminium platelets creates an effective moisture
barrier.
The function of Corrosion Preventative Pigments

MIO
Micaceous iron oxide (MIO) is a naturally occurring iron oxide with

a crystalline plate-like structure that when incorporated into the
coating in relatively high percentages produces a film of low
permeability.
Zinc Phosphate
A white synthetic pigment that is virtually insoluble and hence

does not leach from the paint film. The protective mechanism is
not fully understood but it appears that the polarisation of both the
anodic and cathodic sites takes place.

Coalescence
Water-based coatings, e.g. Latex, consist of resin particles
dispersed in water with a pigment and additives.
During drying the water evaporates allowing the particles of

pigment and binder to come closer together, i.e. coalesce, and
bind to the substrate to form a continuous film.
Paint Mills
In paint manufacturing, pigments, extenders, resin, solvents and
additives are mixed together to form a paste.
The paint mixture is milled to grind the particles together to make

them smaller and disperse them homogeneously throughout the
mixture.
The introduction of micronised pigments decreased the necessity

for grinding and so high-speed dispersers became the norm.
Mills
The apparatus to perform the milling includes:
Ball Mill - Can use a horizontally rotating cylinder containing steel

or ceramic balls, or a stationary horizontal cylinder with an internal
agitator and glass or ceramic beads.
Sand Mill - Vertical mill with agitator and quartz sand.
Roller Mill - 2 or 3 rollers often rotating at different speeds and in

close contact with each other.
High-Speed Disperser - Vertical cylindrical unit with a disk

impeller on the end of a high-speed rotating shaft.
Paint Dispersion
The stages involved in paint dispersion are:
wetting of the pigment surface by the binder.

breakdown of the pigment agglomerates into individual
particles.
keeping the separated particles in a stable condition in a
homogeneous mixture.
Pigment dispersing agents are often used to assist the process.
The dispersing action depends on the mill used as follows:
Ball, bead and sand mill-impact and shear

Roller Mills-Shear
High Speed Dispersers

Summary
This training unit reviewed coating systems including convertible
and non-convertible along with single and two-part coatings.
The unit also reviewed the basic chemistry and the "ingredients" of
a coating including the use of different pigments etc.
Paint manufacturer was also discussed and lifetime requirements

of a coating system.

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