SPRAY PAINTING

UNIT 1.4
COATING TYPES AND SYSTEMS

Objective:
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.

Coating Types and Systems

Coatings should:

• be capable of 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

The video used on the website demonstrates the use of airless spray to apply a primer coating to a
blast cleaned surface.

The coating is specifically developed for spray application.

Copyright 2010 Fitz-Coatings Ltd Page 1

SPRAY PAINTING
UNIT 1.4
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

The video used on the website 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.

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. Levels of addition
have to be carefully controlled as a positive effect on one property may adversely effect another.

Copyright 2010 Fitz-Coatings Ltd Page 2

SPRAY PAINTING
UNIT 1.4
Typical plasticizers are dibutyl phathalate and dioctyl phthalate.

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 can be re-dissolved in their own solvents.

Coating Types:

Chlorinated Rubber.

Acrylated Rubber.

Vinyl.

Bitumen.

Copyright 2010 Fitz-Coatings Ltd Page 3

SPRAY PAINTING
UNIT 1.4
Convertible Coating

The animation used on the website illustrates the application of a convertible coating.

Convertible coatings can not be re-dissolved in their own solvents.

The second coat will not dissolve the fist 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

The animation used on the website illustrates the use of a non convertible coating.

The coating can be re-dissolved in it's 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.

Coating Types and Systems

Single Part Type Coatings:

Alkyd.

Epoxy Ester.

Chlorinated Rubber.

Copyright 2010 Fitz-Coatings Ltd Page 4

SPRAY PAINTING
UNIT 1.4
Acrylated Rubber.

Vinyl.

Bitumen.

Siloxanes.

Two Part Type Coatings:

Polyurethane.

Epoxy.

Siloxanes.

Polyester.

Zinc Silicates.

Specification Coatings are specified depending upon a number of factors which

include:

• Environment.
• Cost.
• Durability.
• Performance.
• Preparation requirements.
• Availability.

Copyright 2010 Fitz-Coatings Ltd Page 5

SPRAY PAINTING
UNIT 1.4
• 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 a certain criteria on performance.

Copyright 2010 Fitz-Coatings Ltd Page 6

SPRAY PAINTING
UNIT 1.4
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 other remain less durable.

There are many types of durable coating depending on the type of resin, pigment, thickness etc.

Copyright 2010 Fitz-Coatings Ltd Page 7

SPRAY PAINTING
UNIT 1.4
This is a illustration of a hard wearing floor coating system used in a factory environment which is
subject to high wear.

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 which have been developed by organisations and paint
bodies to establish the desired coating life in different environments.

Preparation Requirements:

The method of surface preparation and 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.

Copyright 2010 Fitz-Coatings Ltd Page 8

SPRAY PAINTING
UNIT 1.4
Always seek advice from the coating supplier on the standard of surface preparation.

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

Availability:

It is important to ensure the coating system is available when specifying a specific type of product.

Some construction projects are spread world-wide 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.

Copyright 2010 Fitz-Coatings Ltd Page 9

SPRAY PAINTING
UNIT 1.4
It would be no good recommending a high performance paint system which requires 20oC during
application if a heat source is not available.

Always read the application criteria on the product data sheets.

This is an illustration of a site containment where heat is vented into the paint area on a large
structure.

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.

Copyright 2010 Fitz-Coatings Ltd Page 10

SPRAY PAINTING
UNIT 1.4
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 former.

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 require, 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.

Copyright 2010 Fitz-Coatings Ltd Page 11

SPRAY PAINTING
UNIT 1.4
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 suppliers recommendations with regards to mixing.

Do not part mix two part products unless you know the exact ratio etc.

Paint Mixing - Two Part

The animation used on the website demonstrates the mixing of a two part coating with the use of a
air 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 maybe difficult or even impossible.

Ideal Performance -Coatings

The animation used on the website sets out the basis for the coating having the ideal performance.

The main groups consist of:

• Application.
• Adhesion.
• Durability.
• Economics.

Further sub groups are then formed below each main group.

Copyright 2010 Fitz-Coatings Ltd Page 12

SPRAY PAINTING
UNIT 1.4
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, thixotropic agent and anti-skinning agent.

Some of the ingredients names relates 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.

Copyright 2010 Fitz-Coatings Ltd Page 13

SPRAY PAINTING
UNIT 1.4
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.

• Anti-corrosive properties.

Copyright 2010 Fitz-Coatings Ltd Page 14

SPRAY PAINTING
UNIT 1.4
• Good wetting Properties.

Intermediate coat should:

• Supply build.
• Supply thickness.
• Supply Hiding power.

Finish or top coat should:

• Supply the right colour.

• Offer the coating aesthetics.
• Offer ease of cleaning.

One coat systems are available for specialist areas such as tanks, pipes, splash zones etc. The
single coat is usually high solids.

Function of Corrosion Preventative Pigments

Zinc Dust

The Zinc particles can function as sacrificial anodes to cathodically protect the steel. A high pigment
percentages 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 efficient moisture barrier.

Copyright 2010 Fitz-Coatings Ltd Page 15

SPRAY PAINTING
UNIT 1.4
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 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.

Copyright 2010 Fitz-Coatings Ltd Page 16

SPRAY PAINTING
UNIT 1.4
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 manufacturer 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

Copyright 2010 Fitz-Coatings Ltd Page 17

SPRAY PAINTING
UNIT 1.4
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

Copyright 2010 Fitz-Coatings Ltd Page 18