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CORROSION CELL
CURRENT-CARRYING ELECTROLYTE
(SEAWATER, SOIL, ETC.)
ANODE CATHODE
-OTHER CELLS
TANK DRAINAGE
INSUFFICIENT THICKNESS
CRACKED
OR SPONGY
GRIND FLUSH
PROJECTIONS
FILL WITH WELD METAL
& GRIND FLUSH
PITS CREVICES
ENTRAPPED AIR
GALVANIC SYSTEM OF CATHODIC PROTECTION
CURRENT-CARRYING ELECTROLYTE
GALVANIC ANODES
IMPRESSED CURRENT SYSTEM OF CATHODIC PROTECTION
(-) (+)
RECTIFIER
CURRENT-CARRYING ELECTROLYTE
Sun
Oxygen
Salt
Water
PINPOINT RUSTING
STEEL STEEL
INHIBITION BY ZINC PRIMER INHIBITIVE COATING CONCEPT
Break in coating to steel surface Moisture absorbtion into film
(moisture previous coating)
SOLVENT
RESIN
PIGMENT
SOLVENT
SOLIDS
PIGMENT
FUNCTION OF PIGMENT
Provide opacity
Provide colour
Control gloss
WET PAINT
VEHICLE PIGMENT
PRIMARY SECONDARY
SOLVENT RESIN
PIGMENT PIGMENT
RELATIONSHIP OF PAINT RESIN/PIGMENT
RATIO TO GLOSS
HIGH-GLOSS SEMI-GLOSS FLAT
PIGMENT PIGMENT
PIGMENT
CROSS-
SECTION
OF CURED
PAINT
HIGH MODERATE LOW
RESIN/ RESIN/ RESIN/
PIGMENT PIGMENT PIGMENT
* Amount of solvent may vary greatly
A PAINT FILM MUST BE:
Easy to apply
SUBSTRATE
Tightly adhering
Impermeable
Weather resistant
THREE METHODS OF PAINT CURING
Air oxidation
SOLVENT FUMES
OR WATER VAPOR
Application properties
(wetting, build, pot life etc.)
THE TOTAL QUALITY OF A COATING SYSTEM
ITSELF.
75% OF PAINT FAILURES ARE CAUSED BY
Proper construction
Z1 Z2 Z3 Z4 Z5
COMMON METHODS OF CLEANING SURFACES
FOR PAINTING
Flame
Solvent
Steam
Water blast
Abrasive blast
FLAME CLEANING
Removal oil/grease
Dust problems
Chemical waste
CLEANING METHOD CONTAMINANT
Solvent cleaning Grease / Salt / Dirt
Steam Oil / Weldmarks
Aluminium/Tin/Copper/Brass/Galvanized steel
SURFACE
PREPARATION
PAINT
APPLICATION
PAINT
MATERIAL
Advantages Disadvantages
One-package coating Poor chemical and solvent
Good exterior durability resistance
Moderate cost Poor water resistance
Good flexibility Poor resistance to
Excellent adhesion to most alkalinity
surfaces, including poorly
prepared surfaces
Easy to apply
Good gloss retention
LATEX (Acrylic or Vinyl)
Advantages Disadvantages
Moderate cost Limited durability outside
Good flexibility Poor chemical and solvent
Easy to apply, topcoat, repair resistance
Environmental acceptability Poor immersion resistance
Curing temperatures must be
above 50º F
BITUMINOUS
Advantages Disadvantages
Low cost Poor weathering properties
Good moisture barrier Black color only
Good corrosion protection Poor solvent resistance
Good film build
VINYL (Acrylic)
Advantages Disadvantages
Rapid drying and recoating Poor solvent resistance
Excellent durability Low film build per coat
Excellent durability
Very good gloss retention
Applicable at low temperatures
CHLORINATED RUBBER
Advantages Disadvantages
Rapid drying and recoating Poor solvent resistance
Fair chemical resistance Poor heat resistance
Good water resistance (158º F)
Poor gloss retention
Good durability
Applicable at low temperatures
Easy to repair
EPOXY
Advantages Disadvantages
Excellent chemical and Two-package coating - limited
solvent resistance potlife
Good water resistance Curing temperatures must be
Very good exterior durability above 50º F
Hard, slick film Poor gloss retention
Excellent adhesion Film chalks on ageing
Excellent abrasion resistance Roughening up required for repair
Good caustic resistance
COAL TAR EPOXY
Advantages Disadvantages
Excellent resistance to Chalking
fresh and salt water Topcoating may present problems
Good film build (tar bleeding)
Excellent resistance to
aliphatic petroleum products
POLYURETHANE
Advantages Disadvantages
Excellent gloss retention Gloss drop with high humidity
Can be applied at low during drying
temperatures Two component - limited pot life
Excellent durability in High cost
exterior exposure Personal protection required
Recoatable
ORGANIC ZINC
Advantages Disadvantages
Excellent corrosion protection High cost
Provides "galvanic" protection Spray application only
Easier to topcoat than inorganic Constant stirring necessary
zinc (less porous) during application
One or two-package depending Not suitable for acidic or
upon organic resin caustic service
Zinc salts to be removed
INORGANIC ZINC
Advantages Disadvantages
Excellent corrosion protection High cost
Excellent exterior durability Spray application only; skilled
Excellent heat resistance applicators required
Provides "galvanic" protection Not suitable for acidic or
properties caustic service
Provides "permanent" primer Requires careful selection of
capability when used in conjunction tiecoats and topcoats
with proper topcoats and/or
Drying influenced by
maintenace practices
humidity - depending on type
Excellent solvent resistance
Constant stirring necessary
FACTORS AFFECTING SELECTION OF
METHOD OF COATING APPLICATION
Characteristic Brush Roller Spray
Speed fair good excellent
Ease of application fair good poor
Simplicity of equipment excellent excellent poor
Safety excellent excellent poor
Material conservation excellent good poor/good*
Portability excellent good poor
Versatility good fair excellent
Initial economics excellent excellent poor
Long range economics fair fair excellent
Hiding power good fair poor/good*
Uniformity poor fair good
Paint temperature
Paint mixing
TEMPERATURE VS. VISCOSITY
80
VISCOSITY (SECONDS)
50
30
20
0
50º 70º 95º 125º
TEMPERATURE ( º F)
MIXING AND THINNING PROCEDURE
Inspection of materials
NO YES
Flames Temperature control
Sparks Stock rotation
Direct sun On pallets
Ventilation
Oil or grease contamination STEEL
STEEL WALL
SURFACE PREPARATION SPECIFICATIONS
Rusted
POWER
TOOL
COMMERCIAL
BLAST
NEAR WHITE
BLAST
WHITE
BLAST
0 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10
HOSE SIZE, LINE CFM FREE AIR PASSING THROUGH 50 FT. LENGTHS
COUPLED PRESSURE 40 60 80 100 120 150
END PSI
LOSS OF PRESSURE PSI*
60 1.2 2.8 5.2 8.6
3/4" 80 0.8 1.9 3.6 5.8 8.8
100 0.6 1.4 2.7 4.4 6.6 11.1
110 0.5 1.3 2.4 3.9 5.9 9.9
efficiency.
Versatile
Easy to use
POWER SOURCE
Electric
Gas
Air
AIRLESS SPRAY FEATURES
Increased production
Material savings
Labor savings
Energy savings
Improved coverage
TYPICAL AIRLESS TIP SELECTION
CHARGED PROBE
ELECTROSTATIC SPRAY FEATURES
Fewer passes
Fewer rejects
Reduced labor
(greater productivity)
SAFETY HAZARDS IN PAINTING OPERATIONS
High places
High pressures
Flammable materials
Toxic materials
HAZARDOUS MATERIALS IN
SURFACE PREPARATION
Acids
Alkalis
Steam
Spray gun
Aliphatic Petrol )
Bitumen
White spirit )
Aromatic Xylene )
Toluene ) Bit and tar
Naphta's )
Alcohols Methyl-
Ethyl-
Propyl-
Butyl-
Ketones Acetone, MEK, MIBK
Esters Methyl-, Ethyl-
Propyl-, Butyl-
Ethers Glycolethers
TYPE OF PAINTS
Epoxies
Polyurethanes
Chlorrubbers
Vinyls
Alkyds
Adhesion
Gloss
Viscosity
Protection
weather
water
chemicals
Mechanical properties:
strength
flexibility
hardness
Filmforming
Small molecules Large molecules
low viscosity high viscosity
Small molecules, little binding
Poor film forming capacity
Thermosetting plastics