Day 3 ATC88

ATC 88
BGAS Painting Grade 2/3
Copyright © TWI Ltd
Paint Systems
(Single or Multilayer)
Primer: anti corrosive to protect the steel.
Mio: protects primer,

primer provides impermeability.
impermeability
Mid coat or build coat: protects underlying coating,

builds thickness, and provides good adhesion for
subsequent layer.
Finish coat: aesthetic , correct colour, provide a

smooth surface to allow cleaning and shedding
of water.
1
Primers
Rust inhibitive pigments passivate the substrate.
Mordant or wash primers (t-wash), acid reaction

with the substrate produces inhibitive salts. No
measurable thickness.
Etchant primers, (polyvinyl butyral) similar

Reaction but leaves a measurable thickness of 15
15-
25 um.
Midcoat or Build Coat
Extender particles increase surface area to

provide adhesion for any subsequent layer.
2
Finish Coat
Mainly aesthetic, but have other properties.
Gloss finish,
finish to assist in shedding water.
water
Solar reflective (white), heat absorbent (black).
Moisture tolerant:- moisture has no appreciable ill

effect.
g p
Moisture curing y
polyurethane:- p
uses water vapour
from the atmosphere to cure, damp or moist, but not
wet.
Low RH is a problem (min 35%).
Damp: no signs of water, but temperature is below
dew point.
Moist: no standing
g water,, but a noticeable film of
water.
Wet: droplets or standing water are present
Moisture sensitive: moisture reacts with the
isocyanates to produce carbon dioxide.
3
Paint Systems
Powder Coatings
p
 Thermoplastic g
or thermosetting.
 Most commonly thermosetting, needs heat.
 Convertible coatings chemically cured.
 Usually electrostatically applied.
 Thin plate ,heat applied after powder.
 Thicker plate, heat applied before powder.
Paint Systems
Sacrificial systems
Zinc
Steel
Particles in close contact The zinc acts as a barrier,

allow electron circuit and corrodes in its own
when an electrolyte right until there is coating
enters the film. damage and both metals
are exposed to
electrolyte. Zinc oxides
are formed, and repairs
the damage. Copyright © TWI Ltd
4
Waterborne Coatings (Section 8)
Use water instead of hydrocarbon solvents.

Most binders now available water borne.
Environmentally friendly, cheap, and
compatible with any binder.
Many coats can be applied in a day.
Disadvantages include smaller application window,
storage conditions and weather.
Coatings used on BGAS contracts must be compliant.
A compliant coating is one which complies with the
requirements of the environmental protection act
1991.
Paint Manufacture (Section 9)
1. Ball Mill
Steel
St l balls
b ll rotate
t t iin cylinder,
li d
grind mill base to required
particle size (5000 - 40000 lts).
5
2. Attritor Mill
Upright static cylinder,

the steel balls are
moved by motorised
paddles.
g speed
3. High p p
disperser
A 2500 rpm blender, produces mill base.
(see Figure 9.2 in course notes for picture of a high

speed disperser).
6
4. Kady Mill (another type is silverson mill) .
For
F the
th manufacture
f t off emulsions
l i and
d waterborne
t b
paints.

13
5. Sand Mill (pearl mill or bead mill).

Mill base injected at bottom, forced through sand,
refined, removed at top. Water cooled.
7
Sand Mills
6. Colloid Mill
(High speed stone
mill)
Vertical or horizontal
2 stone discs (approx 10” dia) bottom disc rotates at

3600 rpm. Base is gravity fed to centre of discs.
Ground by centrifugal force and friction.
8
7. Triple Roll Mill
Used to produce
mastics, fillers and
putties. 3 rolls travel at
different speeds, paste
sticks to faster of rolls.
8. Single Roll Mill
Used to produce small batches of expensive materials

(gilts, silvers etc.)
9
Testing of Paints for Properties and
Performance (Section 10)
BS 3900 Methods of test for paint.
BGC PS PA9 Table 2 : RESULTS REQUIRED BY
BGAS.
BGAS
Tests subdivided into:

 Tests on wet materials.
 Tests on dry materials.
Paint Testing
Determination of volatile/non-volatile
Procedure:
1. Clean glass plate and rod is weighed.
2. Add 2g of paint, and weigh again.
3. Place into hot air oven (or hot plate).
4. Stir paint to evaporate solvent (volatile).
Note: No naked flame!
When dry, weigh glass plate to determine ratio of

volatile/non-volatile.
10
Paint Testing
Flash Point
Test carried out in accordance with BS 3900 part A8

using abel cup.
Defined as: the temperature at which vapour from a

solvent will ignite in the presence of an external
source of ignition.
High flashpoint is safer than a low flashpoint.
Flash Point of Solvents
Abel closed cup
11
Paint Testing
The density (SG) Cup
Pyknometer, SG cup, weight per litre, weight per gallon.
The density cup is used to check for addition of

thinners, or the correct mix ratio of 2 pack paints.
Caused by
PART A PART B Mixing
g Site test Data sheet
too much
(Base) (Catalyst) Ratio result says
of PART
1.35 0.95 6:1 1.29 1.35 A
1.28 0.80 6:1 1.21 1.40 A
1.40 0.79 4:1 1.27 1.20 B
1.19 0.75 5:1 1.11 1.39 A
1.22 0.80 7:1 1.16 1.08 B
1.50 0.82 4:1 1.36 1.16 B
12
Paint Testing
Hegman grind gauge

For fineness of grind, degree of dispersion.
Hegman Grind Gauge
Particles submerged by scraper bar.
Particles protrude through the film if they are too

large to be submerged. The surface changes from
gloss to matt, and where between 5 and 10
protrusions is noted, this is the degree of dispersion
or fineness of grind.
13
Paint Testing
Viscosity
Defined
D fi d as:
A fluid’s resistance to flow.
Rotational viscometer with

rotothinner measures dynamic
viscosity.
Units = poises.
1 poise = The force required to

maintain unit velocity between 2
surfaces separated by 1cm of
fluid.
Paint Testing
Viscosity
Krebs Stormer Viscometer
Kinematic Viscosity.
Driven by a falling weight,

the heavier the weight the
faster it rotates
rotates. Criteria
200 rpm units stoke or poise.
14
Paint Testing
Flow Viscosity
Ford flow cup showing the
4mm hole.
hole
Ford flow cup in its retort Lid containing spirit level.

stand.
15
Ford flow cup in use.
Paint Film Thicknesses (Section 11)
WFT measurement: Eccentric Wheel.

Must be used circumferentially on curved surfaces.
16
WFT Measurement: Comb Gauges
Must be used longitudinally on curved surfaces.
Last wet tooth First dry tooth
25 35 45 60
Steel
Comb gauge shows WFT reading of 35/45 um
17
Destructive Test Gauges: The PIG
Turn PIG 90deg. Light comes on - view graticule

scale through eyepiece. Tables in instruction book
give conversion factors for each blade, from
graticule units into microns.
18
View through eyepiece

with graticule scale.
Tables in instruction
book give conversion
factors for each blade,
from graticule units to
microns.
Destructive test gauges. The Saberg test drill.
19
DFT Measurements, Magnetic
The banana gauge 211 Calibration shims
Purple
p 25um
l
Blue 50um
Brown 125um
Scale moves to the curser White 250um
Yellow 500um
Dry Film Thickness

Measurement, Magnetic
The tinsley pencil (foremans gauge)
20
DFT Measurements: Electronic
Gauges
Electrophysic
Mini test The exacto Elcometer 456
Dry film thickness measurement, magnetic, horseshoe

gauge (used on TSA).
21
Tests For Mechanical Properties
On Paint
Abrasion resistance
Sample plates are weighed, and placed beneath

abrasive discs for a number of cycles, then
weighed again to determine abrasion
resistance.
Tests for Mechanical Properties

on Paint
Impact
I t resistance:
i t
Tubular impact tester.
1kg weight dropped 1 metre onto the paint
surface of a test panel. Assessed for damage,
direct or indirect.
22
Flexibility test: conical mandrel
Test plate bent over 3mm to 37mm diameter
mandrel
Check location where

cracking begins
Accelerated Testing,
Weatherometers
0
Humidity cabinets: 95% humidity and 55 C.
Salt spray cabinets: Salt laden environment.
Water soak test: Panel submerged, weighed.
Temperature cycling: hotter and colder than normal

operating temperatures.
Prohesion testing: (Protective adhesion) 3% salt

0
water spray @ 35 c, (60 min on : 60 min off) no
undercut, blisters etc. Beyond 3mm boundary, after
test duration of 1000 hours.
23
Drying and Curing Tests: Ballotini
Test
Steel block
Hopper
H graduated in hours
containing of travel
small glass
beads
Drying and Curing Tests
BK (Beck-koller) drying time recorders
Glass plate
inserted into
front slot and the
stylus drawn
across.
Solvent evaporation
time, sol/gel
transition, surface
dry and final dry
times recorded.
24
Mechanical Thumb Test, Through
Drying
Wolff-Wilborn Pencil Scratch Test
Uses the pencil

hardness rating.
25
Opacity: The Pfund Cryptometer
Use Of The Pfund Cryptometer
1. View through the glass

prism.
prism
2. Record the point where
the background can no
longer be seen.
3. This is the opacity
thickness.
26
Hiding Power Charts and
Adjustable Applicator
Gloss
Measured with a glossmeter (reflectometer)

Gloss can be affected by:
 Pigment volume concentration.

 Fineness of grind (particle size).
 Resin type.
 Refractive index.
 Solvent type.
27
Degree of
Gloss
High Low
Ai
Air
Water
RI, stick appears to bend
Digital Gloss Meter (Reflectometer)
Measures % of light
Received,
Received from amount
of light transmitted
> 80% = Gloss finish

< 80% = Matt finish
28
Adhesion Testing: V Cut Test
Cut v using craft

knife
Apply leverage
Insert blade tip

30 0
Testing for: primer to substrate failure, intercoat

adhesion failure and cohesive failure.
Adhesion Tests: Cross Cut

(Cross Hatch) Test
Cut 6 lines vertical and 6 lines horizontal,

squares
creating 25 x 2mm squares.
Apply an agreed tape.
Pull off and compare % area of detachment
as per BS 3900 PT E6.
29
Adhesion Tests The Dolly Test
Failure force
measured in
Expendable psi on this
aluminium scale
dolly
Circular
cutter
Paint adhesion tester

dolly test
30
Hand Operated Type
(with scale of failure force
on view)
i )
Hydraulic Adhesion Test Equipment
Re-usable dolly
Units are: Mega- pascales
31

Day 3 ATC88

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ATC 88

BGAS Painting Grade 2/3

Copyright © TWI Ltd

Primer: anti corrosive to protect the steel.

Mio: protects primer,

Mid coat or build coat: protects underlying coating,

Finish coat: aesthetic , correct colour, provide a

Copyright © TWI Ltd

Rust inhibitive pigments passivate the substrate.

Mordant or wash primers (t-wash), acid reaction

Etchant primers, (polyvinyl butyral) similar

Copyright © TWI Ltd

Midcoat or Build Coat

Extender particles increase surface area to

Copyright © TWI Ltd

Mainly aesthetic, but have other properties.

Solar reflective (white), heat absorbent (black).

Copyright © TWI Ltd

Moisture tolerant:- moisture has no appreciable ill

Copyright © TWI Ltd

Copyright © TWI Ltd

Particles in close contact The zinc acts as a barrier,

Use water instead of hydrocarbon solvents.

Paint Manufacture (Section 9)

Copyright © TWI Ltd

Upright static cylinder,

Copyright © TWI Ltd

Paint Manufacture (Section 9)

A 2500 rpm blender, produces mill base.

(see Figure 9.2 in course notes for picture of a high

Copyright © TWI Ltd

4. Kady Mill (another type is silverson mill) .

Copyright © TWI Ltd

Paint Manufacture (Section 9)

5. Sand Mill (pearl mill or bead mill).

Copyright © TWI Ltd

Copyright © TWI Ltd

Paint Manufacture (Section 9)

2 stone discs (approx 10” dia) bottom disc rotates at

Copyright © TWI Ltd

7. Triple Roll Mill

Copyright © TWI Ltd

Paint Manufacture (Section 9)

8. Single Roll Mill

Used to produce small batches of expensive materials

Copyright © TWI Ltd

Tests subdivided into:

Copyright © TWI Ltd

Note: No naked flame!

When dry, weigh glass plate to determine ratio of

Copyright © TWI Ltd

Test carried out in accordance with BS 3900 part A8

Defined as: the temperature at which vapour from a

High flashpoint is safer than a low flashpoint.

Copyright © TWI Ltd

Flash Point of Solvents

Abel closed cup

Copyright © TWI Ltd

The density (SG) Cup

Pyknometer, SG cup, weight per litre, weight per gallon.

Copyright © TWI Ltd

The density cup is used to check for addition of

Copyright © TWI Ltd

Hegman grind gauge