PAINT SYSTEMS

A paint system is one or more layers of paint, which will give corrosion protection by one of, or
a combination of corrosion protection methods. For example, a single layer of Fusion Bonded
Epoxy or Urethane would give excellent protection employing the Barrier Principle. A zinc
phosphate pigmented primer would be a Passivation system but would need further protection in
the form of a barrier system to protect it. An organic zinc rich epoxy would provide galvanic
protection through bimetallic principles but would last longer with a barrier system to protect the
zinc. Each layer within a system has a function to perform as follows.

Primer

A primer will not work as designed anywhere else other than in contact with the substrate. A
primer, normally low volume solid materials, wets out the substrate and provides excellent
adhesion and also provides a key for any subsequent layer. The binders usually have a relatively
low resistance to vapour transmission, and allow water into the film to carry tiny amounts of the
rust inhibitive pigmentation onto the substrate to form a passivating layer. Older versions ofBG
specifications required that all primers should be brush applied. This was to ensure that any dust
or detritus left on a substrate was 'worked' into the film, and not left lying where air could be
entrapped, forming pinholes.

Other primers exist for non-ferrous substrates such as Wash or Mordant primers, and PVB etch
pnmers.

Mordant means 'of a corrosive nature, or will bite into", and as suggested contains an acid,
Phosphoric acid. Their use is limited nowadays, mainly through the EPA requirements to
reduce VOC emissions. These materials contain approximately 96% VOCs in the form of
Ketones, and approximately 4% phosphoric acid, tinted with copper phosphate (blue). Their
primary use was for etching new galvanising. The reaction turns the slJrface black (zinc
phosphate salts). Some specifications allowed painting as soon as dry, but others required a
water wash. Etchants do not leave a measurable thickness. PVB Etch primers, Polyvinyl
Butyrol are principally used on Aluminium, but were used on virtually every non ferrous metal.
PVBs are 2 pack materials, low volume solids with a dry film thickness of 15 to 25 urn. This
material also contains phosphoric acid. The acid etches the Aluminium (Aluminium Phosphate)
provided a key for the vinyl binder. The general appearance when dry, is a matt yellow
translucent film, with an underlying black or darkened substrate. Some specifications require
coating before 16 hours.

Because of the acid content if is not wise to spray apply these materials without extraction
facilities.

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Mid-coats

Mid-coats are mainly barrier coats. They are applied over the primers to prevent further water
passing into the film and leaching out the inhibitive pigmentation, without which there would he
no passivation. Mid-coats also build up the film thickness and even out any irregularities. They
also provide a key for any subsequent layer to adhere to. This is done by aggregates and
extenders. Some extender materials have particle sizes of 40 urn, ifthere is a high concentration
of extenders in the coating then many of these large particles will protrude through the surface.
increasing the area available for adhesion.

Finishing coats

Finishing coats of a system are mainly aesthetic, but also need certain properties. Colour and
appearance are important e.g. gloss. To have a gloss finish the surface must be perfectly
smooth, and this also helps in the removal of dust and dirt, and natural drainage or shedding of
water. The storage facilities of volatile materials need to have solar reflective properties to ~
reduce boil off and materials needing distillation require heat input and are very often black, to
absorb heat.

Moisture tolerant systems

Pipelines transport many different products at different temperatures and pressures. Gas is
transported in non-insulated pipes, over huge distances subsea and subterranean. Therefore the
gas is cool. Where a pipeline comes above ground (an AGI, Above Ground Installation) the gas
in the pipes is much cooler than the ambient temperature and condensation forms on the pipes,
posing a problem for repainting and maintenance. Either the gas stream can be diverted along
another route, or special materials can be used, tolerant of the situation.

The BG Transco specifications include a clause permitting the latter alternative, the use of
moisture curing polyurethane or a high sold epoxy. (Section SPA4 in paragraph 10). Three
definitions apply when referring to quantity of water present. Damp, Moist, and Wet
(Paragraph 10).

Damp and moist conditions will allow the use of the materials specified, but wet conditions
require excess water to be removed.

Single pack moisture curing polyurethane's are materials which use moisture from the
atmosphere to cure, not standing water on the substrate. Surface preparation as per the
specification, then any excess water should be swabbed off, before brush application of the
material. Because the material cures by using air borne moisture, as soon as the lid is removed
from the can the cure reaction starts. The more moisture there is present in the atmosphere, the
faster the cure. The criteria with this type of material is not high RH, 100% is no problem, but
low humidity. Some manufacturers state 35% as minimum RH criteria.

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Powder coating materials

As mentioned earlier, powder coatings are solvent tree materials, which are solid at room
temperature.

Thermosetting

Thermosetting means the material will cure with the application of heat and therefore are
convertible or non-reversible materials like epoxy and urethane. With thick steel sections like
underground pipes the powders are electrostatically sprayed onto a preheated substrate,
approximately 245°C, as soon as the powder hits the heated steel, it melts, undergoes a chemical
cure and is fully cross linked in approximately three minutes.

This group of materials is used extensively on subsea and subterranean pipes, office furniture
and kitchen white goods. Thinner plate sections are post heated, after electrostatic application of
powder.

Thermoplastic

Thermoplastic materials soften with the application of heat, are linear polymer and therefore
reversible or non-convertible. Polyethylene and Polypropalene being examples of these
materials. Usually flame sprayed as repair systems on existing thermoplastic coatings.

Sacrificial coatings

As the name implies, this classification of materials sacrifices itself to protect the underlying
substrate. In order to work in this way the sacrificial component must be less noble (more
electronegative) than the substrate which it is protecting. Zinc and Aluminium are the most
common materials used to protect ferrous substrates. Zinc and Aluminium have relatively low
melting points and so are commonly used in the form of metal spray, applied by flame onto
structural steel e.g. bridges, as an added form of protection which purportedly can extend the
major maintenance free life of steel work by as much as 20 years.

Zinc is used in hot dip galvanising of steel, to totally encapsulate a section. In this situation the
zinc works as a barrier coat initially and undergoes atmospheric corrosion itself fonning
corrosion products such as Zinc Sulphates and Zinc Carbonates. To stop this natural process on
the zinc it is usual to paint over the galvanising. However, if the galvanising is damaged,
exposing the steel underneath so that both metals are in contact with electrolyte, the zinc then
starts working sacrificially, corroding in preference to the steel, producing Zinc Oxides on the
damages faces until the damage is filled to exclude electrolyte contact. The zinc then works as a
barrier again.

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If the galvanising suffered damage of more than a scratch or gouge repair might be a better
option. In this instance a zinc rich epoxy might be used. These materials contain a very high
percentage content of zinc pigment. Specifications vary but 90% by weight of the dry film is a
typical requirement. If moisture, an electrolyte, passes into a film of this nature, each particle of
zinc needs to be in contact with at least one other, in order to form the metallic circuit through to
the steel for the electrons. These electrons, in the form of Hydroxyl ions will then return
through the electrolyte to the zinc and the zinc will corrode, sacrificially. In order to hold the
high concentration of zinc particles together, a very strong binder is required. This is usually an
organic epoxy.

Inorganic binders such as Ethyl or Methyl Silicates are zinc pigmented but are primarily
designed for high temperature service and need sealers such as aluminium or carbon pigmented
silicones.

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