Training Guide Chapter 2 Paint

2.
Paint
▼ ▼ ▼▼ ▼ ▼ ▼ ▼ ▼▼ ▼ ▼ ▼
Contents Paint is …………………………………………………………………..
▼
2-1
Resins …………………………………………………………………… 2-2
Waterborne Polymer Vehicles ………………………………………. 2-3
Paint
Powder ………………………………………………………………….. 2-4
Radiation Cure ………………………………………………………… 2-4
What is Paint Pigments ……………………………………………………………….. 2-5
Solvents ………………………………………………………………… 2-7
Additives ……………………………………………………………….. 2-8
Curing of Coatings …………………………………………………… 2-8
Color, Gloss, DOI ……………………………………………………... 2-9
Properties of Dry Paint ………………………………………………. 2-9
Paint Manufacturing Process ………………………………………. 2-10
Reference Tables ……………………………………………………… 2-12
Solvent properties, particle size (filter bags), coversion
mathematics for paint operations
▼▼
Calculations for Painters …………………………….……………… 2-17

Colorant Usage & Tinting Procedures …………….……………… 2-23
Two main uses for paint

Uses of Paint • To protect surfaces
• To decorate
Paint Compo- Resin polymer

Also called a film-former OTHER ADDITIVES (0-5%)
sition or binder: binds pigment
ONE GALLON
particles together; the SOLVENT (30-80%)

backbone of paint.
Pigment
Decorative and protective VEHICLE (RESIN) (20-60%)
Solvent
Provides fluidity PIGMENT (2-40%)
Additives
Small quantities of substances added to carry out special jobs.
100%
Liquid 90%
Coatings 80%
70% Solids
Water
60%
Solvent
50%
40%
30%
20%
10%
0%
Lacquer Conventional High Solids Waterborne
2-1
Paint
Forms the film, suspends Properties Affected by Resins

RESINS pigments, dictates performance, • Controls properties like hardness, flexibility,
hardness, and durability. gloss, chemical resistance, adhesion.
Paint
• Acrylics • Controls basic drying and curing performance

• Alkyds • Influences exterior durability
• Urethanes • Governs application parameters
• Epoxies • Compromises with cost
• Polyesters
Alkyds Two Categories: Advantages:

• Cost
• High molecular weight air dry alkyds
Resins • Low molecular weight melamine-modified • Ease of application
force-cured alkyds • Sandability
• Work over marginal pretreatment
End Uses:
• Agriculture equipment Limitations:
• Railroad cars • Limited clarity
• House paint • Chemical resistance
• Misc. substrates • Recoat window
• Slow drying process
Excellent chemical and corrosion resistance Advantages:

Epoxy and adhesion. Available in air dry or forced cure.
Available in one-component or two-component.
• Air dry or forced cure
• Adhesion
Resins • Chemical and solvent resistance
End Uses: • Corrosion resistance
• Maintenance coatings
• Chemically resistant tank linings Limitations:
• Can coatings • More expensive than alkyds
• Corrosion resistant primers • Processing . . . Pot life
• Clean up
• Exterior durability
Acrylic Acrylic resins are polymers

containing acrylic-type monomers
Advantages: Limitations:
• Easy application • Adhesion
Resins (acrylates). Wide range of resins • Outdoor durability • Cost
available which vary in hardness, • Aesthetics • Rigid
functionality, and durability. • Compatibility • Narrow DFT window
• Solvents • Corrosion resistance
End Uses: • Other resins
• Automotive • Hard
• Industrial
2-2
Paint
Available in:
Urethane • Two-component air dry
Advantages:
• Chemical Resistance
Resins • One component force cure • Provide flexibility
Paint
• Modifying Resin • Durability
• Wide Range of Performance • Air dry
Properties Available
Limitations:
• Cost
End Uses: • Pot life
• Automotive • Hot Hardness
• Industrial
• Maintenance Coatings
• Flexible Advantages:
Polyester • Typically low molecular weight • Cost
• Modifying Resins • Compatibility
Resins • Many types Available • Flexibility
Limitations:
End Uses: • Chemical Resistance
• Industrial • Corrosion Resistance
• Automotive
Waterborne Emulsions or latexes are colloidal dispersions of high molecular weight polymer parti-
cles in water. When the water evaporates, the latex particles coalesce (with heat and/or
Polymer co-solvent) and form a film similar in properties to a solvent base cured film.
Vehicles • These resins use water as the primary solvent.
• Available in all resin chemistries.
• Can be air dry or force cure.
Types
• Low molecular weight dispersions
• High molecular weight emulsions or latexes
Issues with Waterbase

• VOC
• Application
• Disposal
• Co-solvent selection
• Electrostatic isolation / voltage block.
2-3
Paint
Powder Thermoset
1. Melt flow and chemically crosslinks
Thermoplastic
1. Melts and flows
Coatings 2. Different chemical structure after cure 2. Same chemically before and after cure
Paint
3. Small particle size 3. Will resoften on reheating

Examples: Examples:
Epoxy Nylon
Acrylic Polyethylene
Polyester Polypropylene
Hybrids (combination of Polyvinyl Chloride (PVC)
different resin chemistries.)
Advantages Disadvantages
1) Very high transfer efficiency 1) Specialized equipment necessary
2) Low operating costs 2) High capital cost
3) Most polymer types available 3) High bake temperature required
4) High film build capability 4) Color changes time consuming
5) No solvent used 5) Uniform thin film builds difficult to
achieve (i.e., 1.0 mil [25 microns])
UV/EB UV/EB is an advanced method of curing coatings by one of two forms that
mechanically duplicates the radiant energy and power of sunlight.
Cure
One form uses photons generated by high intensity ultraviolet (UV) light sources,
concentrated by reflectors and directed onto the coated substrate. The mechanism of
UV curing involves the interaction of UV light with catalyst molecules to trigger a
polymer crosslinking reaction.
The second form utilizes accelerated electrons from a device that processes
electron beams (EB) into a high-speed form of energy. The mechanism of EB curing
involves the interaction of accelerated electrons directly with the polymer itself to trigger
the crosslinking reaction. Sheets of wood, plastic, or flat metal substrate can be
processed at up to speeds of 1,000 feet per minute!
EB vs UV
EB Cure UV Cure
Inert Atmosphere Required Yes No
Opaque Coatings Yes Limited
Laminating Adhesives Yes Limited
Capital Costs
Most
High Line Speeds
Cost-Effective
Most
Low Line Speeds
Cost Effective
Heat Input Negligible Can Be
Significant
2-4
Paint
Markets • Furniture
• Flooring
Served By • Containers
Paint
Radiation • Mirrors
• Automotive
Curing
High speed curing is a crosslinked polymer structure that displays:
Advantages • Minimal shrinkage
of Radiation • High tensil strength
Curing • Strong adhesion
• Improved abrasion-resistance
• Handled immediately for further processing or shipping
• Low-energy consumption
• Low-VOC composition
The oven equipment necessary takes up merely one-tenth the space of a conventional
cure oven.
• Initial capital cost (i.e., electron beam)

Limitations • Hard, brittle films, cannot use on flexible substrates
PIGMENTS A pigment is any fine solid particle that does not dissolve in the binder, and is dispersed
within the binder.
Pigment Dispersion: Incorporates a powder into a liquid medium such that the final
product consists of fine particles evenly dispersed throughout the medium.
Pigment • Organic (natural, contains carbon)

• Inorganic (mineral or synthetic)
Types
Pigment • Provide color

• Improve strength of paint film
Functions • Improve adhesion
• Improve weathering and durability
• Hiding
• Filling Properties
• Increase protection against corrosion
• Reduce gloss
• Modify flow and application properties
2-5
Paint
Hiding Provide color, durability

Examples:
Pigments
Paint
• Titanium Dioxide
• Yellow Oxide
• Red Oxide
Functional Corrosion inhibitors, corrosion control

Examples:
Pigments • Zinc Phosphate
• Zinc Oxides
Toxicity concerns with certain types.
Provide filling, gloss, sandability, solids

Inert or Examples:
Extender • Talcs
Pigments • Silicas
• Carbonates
• Barium Sulfate
2-6
Paint
Keeps the coating liquid, imparts flow, viscosity control, liquid conductivity, set-up time,
SOLVENTS and application properties.
Paint
Main factors to consider about solvents:
• Solvency/Conductivity
• Volatility / Evaporation rate
• Odor
• Toxicity
Types of Solvents Three important factors:

• Aliphatics Evaporation rate: rate at which a solvent evaporates from the film.
• Aromatics • Fast: Acetone, Toluene, MEK
• Acetates • Medium: Xylene, Solvesso 100, MIBK
• Alcohols • Slow: Solvesso 150, BCA, MAK
• Ketones Conductivity: imparts electrical resistance and transfer efficiency.
• Water Hot: Alcohols, ketones, oxygenated solvents
• Glycol Ethers Dead: Aromatics, naphthas
Solvency power: the ability of the solvent to dissolve a binder.
Volatility
• Next to solvency in importance when selecting a solvent.
• Volatility governs the evaporation rate.
• Evaporation rate influences leveling, flowing, sagging, wet edge time, and gloss.
• Evaporation rate also influences method of application – spraying, dipping,
roll coat, etc.
Odor
• Odor refers to the odor of the vapor during or shortly after application
• Personal preferences.
Toxicity
• Toxicity refers to their potential danger to health from breathing solvent vapors.
• Prolonged breathing of concentrated vapors of any solvent should be avoided
• Impacts the atmosphere
2-7
Paint
ADDITIVES Those materials which aid in the stability, flow, mar resistance, manufacturability, gloss,
durability, and drying of the final coating.
Paint
• Catalyst Properties affected by additives

• Plasticizers Dry time Settling
• UV absorbers Wetting Skinning
• Amines Foaming Coalescing Vis-
• Wetting agents cosity Sagging
• Flow control agents Antifreeze Mar resistance
• Waxes Wet edge Fungicidal properties
• Silicones
• Defoamers
Curing • Evaporation: Coatings cured by evaporation of the solvents.

• Oxidation: Reacts with oxygen in the air.
of Coatings • Cross-Linking: Reaction within the coating that cures the paint (i.e. heat, catalyst,
moisture, radiation).
• Fusion: Coating going from solid to liquid back to a solid film. Heat required for fusion
(i.e. powders).
Thermoplastic
Coatings that cure by air drying or by force curing in a low temperature oven are known
as Lacquers or thermoplastic paint.
• Coatings that form by solvent evaporation only
• Long-chain polar molecule resins dissolved in a solvent
• As solvent evaporates, polymers come together and form a film
• No chemical reaction occurs
Thermoset
Coatings that cure by a cross linking mechanism are known as Enamels or
thermoset paints.
Examples:
• Oxidizing: After coating is applied, solvent evaporates, and crosslinking with
atmospheric oxygen begins.
• Moisture-Cure Coatings: Similar to oxidation but uses moisture in the air to react
with the resins.
• Heat Cross-Linking Coatings: A minimum temperature is required for cross linking
and curing.
• Radiation: Exposure to ultraviolet light causes cross-linking reactions to occur.
2-8
Paint
Color is the eye’s perception of the wave lengths of colored light relecting from the
Color surface of a material.
Factors affecting color:
Paint
• Light source
• Hiding
• Film thickness
• Gloss
• Application (metallics)
• Cure schedule
• Uniformity of the standard
Gloss Gloss: The paint’s ability to uniformly reflect light.

DOI: Distinction of image
and DOI • Clarity of film
• Through-film clarity
For dry paint to be useful, it must:

Properties • Have adhesion to the surface
of Dry Paint • Be easy to apply
• Maintain most of its decorative and protective properties
• Meet the customer requirements for durability, aesthetics, etc.
• Add value for our customers
• Be cost effective
Examples of testing done on dry paint:
• Adhesion
• Salt Spray
• Humidity
• Hardness
• Gravelometer
• Impact (Direct/Indirect)
• Cure
• Durability
• Solvent/Chemical Resistance
2-9
Paint
I. Raw Material Storage
Paint Manu-
facturing
Paint
Process
II. Preassembly
III. Pre-Mixing Operation
2-10
Paint
IV. Media Dispersion
Paint Manu-
facturing
Paint
Process Cont.
Media Mill
V. Filtering & Filling
VI. Shipping
2-11
Paint
Evap. Resist-
Solvent Name
kg/
Density
lbs./
Rate
( )
Flash Pt.
°F °C
ivity
(mega
Other Names
*
Properties liter gal. ohms)
Paint
Chart N-butanol
2 ethylhexanol
.811
.833
6.760
6.940
46
1
84
.64
29
18
.06
8.00
Methano .792l 6.600 200 52 11 .05
N-propanol .805 6.710 30 121 49 Propasol Solvent (BEP)
Isobutanol .803 6.688 90 86 30 .05
Isopropanol .787 6.560 240 53 12 .05
Sec-butanol .808 6.731 102 73 23 .05
Ethanol .814 6.780 330 57 14 .05
Ether Alcohols Primary amyl alcohol .816 6.804 23 90 32 .65
Tripropylene glycol methyl ethe .965 8.038 0.60 240 116 4.10 Dowanol TMP
Dipropylene glycol monobutyl ether .916 7.630 1 230 110 4.10 Butyl Dipropylsol
Butyl Cellosolve .902 7.520 6 70 21 .30 butoxyethanol
Propylene glycol monomethyl ether .919 7.660 70 100 38 .0 Dowanol PM
Dipropylene glylcol meyhyl ether .949 7.910 2 175 79 .30 Dowanol DPM
Propylene gylcol methyl ether .878 7.320 8 138 59 3.40 (Propasol P)
Butyl Carbitol .954 7.950 0.24 240 116 .40 Diethylene glycol monobutyl ether
Ektasolve EEH .890 7.420 216 0.30 -18 1.50 Mixture of 2-ethyhexyl ethers
Cellosolve .930 7.750 32 108 42 .05 Ethylene glycol methyl ether
Hexyl Cellosolve .889 7.410 0.82 195 91 .10 Ethylene glycol hexyl ether
Ester Alcohols Propylene glycol monopropyl ether .897 .385 22 119 48 20.00 Propyl Proposal (Proposol P)
Di-isobutyl ketone (DIBK) .811 6.760 15 120 49 6.00

Methyl hexyl ketone .817 6.806 12 130 54
Methyl ethyl ketone (MEK) .805 6.710 570 21 -6 .05
Acetone .790 6.580 1448 4 -16 .01
Methyl isobutyl ketone (MIBK) .804 6.700 165 63 17 22
Pentoxone .838 6.979 22 130 54 .05
Methyl n-propyl ketone (MPK) .810 6.750 230 46 8 .30
Methyl amyl ketone (MAK) .816 6.800 40 102 39 70
Kodak C11 .844 7.030 2 57 14 1.50
Di-isobutyl ketone (DIBK) .806 6.720 20 120 49 3.00
Ketones Diacetone alcohol .938 7.820 14 142 61 .05
Cyclohexane .782 6.520 550 1 -17 20.00

Napthalite- Rule 66 .755 6.290 105 50 10 20.00
Hexane .674 5.620 910 1 -17 20.00
Exempt Mineral Spirits .780 6.500 12 104 40 20.00
Heptane .697 5.810 430 25 -4 20.00
Hydrocarbons Tolusol 25 .734 6.120 390 24 -4 20.00
Solvesso 100 .874 7.280 19 108 42 20.00

Xylene .866 7.220 63 81 27 20.00
Aromatic Solvesso 150 .893 7.440 4 145 63 20.00
Hydrocarbons Toluene .865 7.210 224 40 4 20.00
Oxo-tridecyl acetate .878 7.322 .10 261 127 20.00 Exxate 1300-Exxon
Dipropylene glycol methyl
Ether acetate .976 8.130 1 186 86 3.00 Dowanol DPMA
Oxo-nonyl acetate .892 7.270 1.2 191 88 20.00 Exxate 900 Exxon
Isobutyl isobutyrate (IBIB) .856 7.130 43 97 36 20.00
Oxo-heptyl acetate .871 7.260 8 150 66 20.00 Exxate 700 Exxon
Othyl acetate 99.5 % .901 7.510 615 24 -4 3.80
Isobutyl acetate .870 7.250 145 69 21 0.00
N-butyl acetate . .881 7.340 100 78 26 19.00
2-ethyl hexyl acetate .872 7.270 3 160 71 20.00
N-amyl propionate (NAP) .871 7.260 18 105 41 0.00
Oxo-hexyl acetate .871 7.260 17 135 57 20.00 Exxate 600-Exxon
Ethyl 3-ethoxypropionate (EEP) .949 7.910 11 136 58 19.00
Butyl Cellosolve acetate .941 7.840 3 160 71 20.00 2-butoxyethanol acetate
Dibasic ester (DBE) blend 1.09 9.080 .30 212 100 .75
Primary amyl acetate .876 7.300 40 101 38 20.00
Butyl carbitol acetate .979 8.160 .20 221 105 20.00 Butyl diethylene glycolether acetate
PM acetate .964 8.030 40 108 42 .40 Propylene glycol menthyl ether acetate
Acetate Esters Oxo-decyl acetate .872 7.270 .60 212 100 20.00 Exxate 1000
N-methyl 2 pyrolidone 1.03 8.550 1 199 93 .02 M-Pyrol

Misc. Deionized Water 1.0 8.330 36 999 537 0.00
( ) Low numbers represent slower evaporation, high numbers represent faster evaporation.
*
2-12
Paint
Particle Cart- Vorti-

Size/Mesh ridge Felt Nylon Seive
Paint
Grind Inches Mils Micron Mesh Filter Bags Bags Rating
/Micron/Mil
*** 0.0787 78.7 2000 10 *** *** *** ***
Comparisons
*** 0.0331 33.1 840 20 *** *** #800 ***
*** 0.0232 32.2 590 30 *** *** *** ***
*** 0.0165 16.5 420 40 *** *** #400 ***
*** 0.0117 11.7 297 50 *** *** *** ***
*** 0.0098 09.8 250 60 *** *** #200 #60
*** 0.0083 08.3 210 70 *** *** *** ***
*** 0.0070 07.0 177 80 *** *** *** ***
*** 0.0059 05.9 149 100 C-7 *** #150 #100
*** 0.0049 04.9 125 120 *** *** *** ***
*** 0.0041 04.1 105 140 *** *** *** ***
*** *** *** 100 160 *** #100 #100 #160
*** 0.0035 03.5 88 170 *** **** *** ***
2.0 0.0029 02.9 74 200 C-6 #75 *** #200
*** 0.0024 02.4 62 230 *** *** *** ***
*** 0.0021 02.1 53 270 *** *** *** ***
*** *** *** *** 275 C-5 *** *** #275
4.0 0.0017 01.7 44 325 *** #50 *** #325
*** 0.0015 01.5 37 400 *** *** *** ***
**** 0.0014 01.4 31 500 *** *** *** ***
6.0 *** *** 25 550 C-4 #25 *** ***
7.0 *** *** 10 1250 C-3 #10 *** ***
7.5 *** **** 5 *** #5 *** ***
2-13
Paint
Metric From To Multiply

Conversion To From Divide By
Paint
Tables Area:
Square Inches Square Centimeters 6.452
Square Centimeters Square Feet .001076
Square Feet Square meters .0929
Square Yards Square Meters .836
Square Feet Square Yards .111
Flow:
gallons/min liter/min 3.785
gallons/min cubic meters/sec .00006309
cubic feet/sec cubic meters/sec .028317
liters/hour cubic feet/min (cfm) 2.118
Weight:
Kilogram Pound (lb.) 2.205
Ton (2000 lb.) Kilogram 907.18
Ounce Gram 28.349
Pound Gram 453.59
Length:
Meter Inches 39.37
Feet Meter 3048
Inches Millimeters 25.4
Inches Centimeters 2.54
Mil (thickness) Millimeters .0254
Mil (thickness) Inches .001
Yards Meters .9144
Microns Meters 000001
Microns Mils .04
Mils Microns 25.4
Pressure:
Bar (atmosphere) psi 14.696
Inches HG psi .4912
Inches Water psi .03613
Lbs./Sq. In. Kg/Sq. cm .07
Temperature:
°F °C °C = (°F - 32) ÷ 1.8
°C °F °F = (1.8 x °C) + 32
Velocity:
feet/min meter/min .3048
feet/sec meter/sec 3048
feet/min inches/sec .200
feet/min mile/hr .011364
Volume:
Gallons (US) Cubic Centimeters (cc) 3785.00
Gallons (US) Liter 3.785
Gallons (US) Cubic Meters .003785
Gallons (US) Cubic Inches 231.00
Gallons (US) Gallon (Imp) .83268
Quarts (US) Liter .946
Fluid Ounces (US) Cubic Inches 1.8047
Fluid Ounces (US) Cubic Centimeters (cc) 29.574
Liter Cubic Meters .001
Liter Cubic Centimeters (cc) 1000.00
Liter Cubic Inches 61.024
Torque:
Ft. Lbs. In. Lbs. 12.00
Newton Meter In. Lbs. 8.85
Gram Centimeter In. Lbs. .00087
2-14
Paint
Volumetric Cross Length

I.D. cc/ft. Section
Content inches (cc/ sq. in. 5 ft. = 60" 10 ft. = 120" 15 ft. = 180" 25 ft. = 300" 50 ft. = 600"
Paint
of Hose (mm) meter) (sq. cm) (152.4 cm) (304.8 cm) (457.2 cm) (762 cm) (1524 cm)
or Tube 1/8 2.36 .012 0.003 gal. 0.0005 gal. 0.009 gal. .015 gal. .03 gal.
(3.2) (7.74) (.077) 0.4 fl. oz. 0.8 fl. oz. 1.2 fl. oz. 2.0 fl. oz. 4.0 fl. oz.
11.82 cc 23.65 cc 35.48 cc 59.14 cc 118.29 cc
3/16 5.32 .027 .007 gal. .014 gal. .021 gal. .035 gal. .07 gal.
26.61 cc 53.23 cc 79.84 cc 133.08 cc 266.16 cc
47.31 cc 94.63 cc 141.95 cc 236.59 cc 473.18 cc
68.02 cc 136.04 cc 204.06 cc 340.10 cc 680.20 cc
107.94 cc 215.89 cc 323.83 cc 539.72 cc 1079.45 cc
(12.7) (126.7) (1.265) 6.5 fl. oz. 13.0 fl. oz. 19.5 fl. oz. 32.5 fl. oz. 65.0 fl. oz.
192.23 cc 384.46 cc 576.69 cc 961.15 cc 1922.31 cc
Multiply Area (sq. in.) x Length (in.) x .554 = FLUID OZ. 128 fl. oz per U.S. gallon
Multiply Area (sq. cm) x Length (cm) = cc 3785 cc per U.S. gallon
1000 cc per liter
2-15
Paint
Moisture PERCENT RELATIVE HUMIDITY ABOVE WHICH MOISTURE WILL

CONDENSE ON SURFACES
Condensation
Paint
Ambient Air Temperature

Dew Point 5°C 7°C 10°C 13°C 15°C 18°C 21°C 24°C 27°C 30°C 33°C 35°C 38°C
Temperature 40°F 45°F 50°F 55°F 60°F 65°F 70°F 75°F 80°F 85°F 90°F 95°F 100°F
2°C 35°F 60 33 11
5°C 40°F 65 39 20 8
7°C 45°F 69 45 27 14
10°C 50°F 71 49 32 20 11
13°C 55°F 73 53 38 26 17 9
15°C 60°F 75 56 41 39 21 14 9
18°C 65°F 78 59 45 34 25 18 13
21°C 70°F IMPORTANT 79 61 48 37 29 22
24°C 75°F No painting should be done when 80 64 50 40 32
27°C 80°F relative humidity is apt to cause 61 66 53 43
30°C 85°F moisture condensation – such as late 81 68 55
33°C 90°F in the day when temperatures change. 82 69
35°C 95°F 83
Example: if the ambient air temperature is 75°F (24°C) with relative humidity higher than
41% during the day and the temperature drops to 60°F (15°C) in the evening –
condensation will form. Or, if the temperature of the surface being painted is 60°F (15°C)
and the ambient air temperature is 75°F (24°C) with relative humidity higher than 41% –
condensation will form.
1. Wet film thickness multiplied by percent volume solids of coating = dry

Useful Data film thickness.
2. Celsius multiplied by 9/5 plus 32 = Fahrenheit.
3. Fahrenheit minus 32 multiplied by 5/9 = Celsius.
4. 1000 mils = 1 inch
5. Area of a sphere = the square of the diameter multiplied by 3.1416 (Pi).
6. Area of a polygon = the base of one triangle multiplied by 1/2 the height,
then multiply by the number of sides.
7. Area of a triangle = the base multiplied by half the altitude.
8. Area of a parallelogram = the base multiplied by the altitude.
9. Area of a trapezoid = the altitude multiplied by half the sum of the
parallel sides.
10. Area of a circle = the square of the radius multiplied by 3.146 (Pi).
11. Area of a cylinder = the length multiplied by the total area of both circles.
12. Circumference = diameter multiplied by 3.1416 (Pi).
2-16
Paint
Calculations The volume solids of paints is the portion of each gallon of paint, expressed as a per-
centage, that does not evaporate and stays on the part. The volatiles are the solvents
for Painters and reducers that disperse or dissolve the coating and allow it to be handled and
Paint
applied in the liquid form. The volume solids of the coating as received can be found on
the Product Data Sheet or the Material Safety Data Sheet.
The volume solids of a coating that has been reduced for application can be calculated
Volume Solids using the following formula:
Vu x VS
VS reduced =
Vu + Vt
Vu = volume of unreduced paint

VS = unreduced volume solids % of paint as received (from data sheet)
Vt = volume of thinner or solvent added
Sometimes referred to as “mileage,” the coverage is the surface area coated per liter of
Theoretical paint. Theoretical coverage is the coverage calculated from specifications given for the
Coverage product, and does not take into account losses due to surface porosity and shape of the
part being coated, overspray, material left in containers, guns and lines, spillage and so
forth. Nevertheless, this calculation is useful for comparing different coatings.
1604 x VS
Theoretical Coverage =
DFT (in mils)
VS = Unreduced volume solids % (from Product Data Sheet)

DFT= Dry Film Thickness, expressed in microns
39.4 = The sq. meter coverage of 1 liter of paint at 100% volume solids and
applied at 2.5 microns.
If the transfer efficiency is known, the above formula may be modified to

take this into account. The resulting calculation would provide an
estimate of actual coverage.
1604 x VS x TE
Actual Coverage =
DFT (in mils)
TE = Transfer Efficiency
2-17
Paint
Determining Container Measurement

It is often useful to monitor usage during a parts run. Paint consumption can be
Paint monitored using simple measurements of the container dimensions. First, measure the
Paint
diameter of the paint container. Before any coating is used, measure the distance from
Consumption the top rim of the container to the surface of the paint within the container. Remeasuring
Rate this distance after some of the paint has been consumed and using the following
formula will yield the paint consumption in gallons that corresponds to the difference in
the two measurements.
Gallons of Coating Used = 0.0034 x D2 x (H1 - H2)
D2 = the inside diameter of the container (cm) multiplied by itself

H1 = the first measurement from the rim to the surface of the coating
H2 = the second measurement from the rim to the surface of the coating
0.0034 is a constant that is part of the equation for calculating the
volume of a cylinder.
This measurement, like coverage, is sometimes referred to as “mileage,” “part

Parts Per coverage,” or “part mileage.” The following formula calculates the parts per
unreduced gallon of coating.
Gallon
1604 x VS x TE
Parts per Gallon =
DFT x A

1604 = The sq. meter coverage of 1 lgallon of paint at 100% volume solids and
applied at 1.0 mils.
DFT = Dry Film Thickness, expressed in microns
A = Surface area of each part, in sq. ft.
Transfer efficiency is a factor of process control. Painting processes that are “in control”
will almost always waste less paint. Knowing this figure is essential in order to monitor
Transfer cost variations and the overall efficiency of painting operations.
Efficiency P/G x DFT x A

Transfer Efficiency =
1604 x VS
P/G = Number of parts painted per unreduced gallon of coating

DFT = Dry Film Thickness of coating applied, measured in mils
A = Surface area of each part, in sq. ft.
VS = Volume solids of the unreduced coating, expressed as a percent
2-18
Paint
This formula takes into consideration the direct material costs, which include the
Material Cost purchased cost of the coating, as well as any solvents used to further reduce the
Per Piece coating in the application process. The full cost per piece would also include labor and
Paint
overhead and should not be overlooked. A coating material that can be applied in less
time will almost always result in a lower total cost per piece, even if its material cost
is slightly higher.
(Vu x Cp) + (Vt x Ct)

Cost per Piece =
#P (Vu + Vt)
Vu = Volume of unreduced paint

Cp = Paint cost in $/gallon
Vt = Volume of solvent used to reduce paint for application
Ct = Thinner or solvent cost in $/gallon
#P = Number of parts painted per gallon of reduced coating. Note that this
calculation makes use of the number of pieces painted per gallon of coating as
reduced and used on the paint line. This figure is simply the number of parts
painted per gallon of coating used on the paint line.
Weight of This formula calculates the weight of solvent in a gallon of coating as received, without
further reduction. Depending upon the environmental regulations that affect your
Solvent In painting operations, you might be required to keep track of and report the amounts of
Unreduced volatiles that are in the paint that you buy, the solvents you buy that you add to the
paint to reduce it, and the solvents that you buy and use for clean-up and
Coating maintenance operations.
Vu x P#/gal. x (1-WS)
Solvent in Unreduced Coating =
Vu
Vu = Volume of unreduced paint (in gallons)

p#/gal = Weight/gallon of unreduced paint (from Product Data Sheet)
WS = Weight solids % of unreduced paint (from Product Data Sheet)
This formula calculates the weight of solvent in a gallon of coating after reduction,
Weight of with solvent.
Solvent In
Reduced Vt x S#/gal.
Coating Solvent in Reduced Coating =
Vu + Vt
Vt = Volume of solvent used to reduce paint

S#/gal = The #/gallon of the solvent used to reduce the paint
2-19
Paint
Metric Units
The volume solids of paints is the portion of each gallon of paint, expressed as a per-
Calculations centage, that does not evaporate and stays on the part. The volatiles are the solvents
for Painters and reducers that disperse or dissolve the coating and allow it to be handled and
Paint
applied in the liquid form. The volume solids of the coating as received can be found on
the Product Data Sheet or the Material Safety Data Sheet.
The volume solids of a coating that has been reduced for application can be calculated
Volume Solids using the following formula:
Vu x VS
VS reduced =
Vu + Vt
Vu = volume of unreduced paint

VS = unreduced volume solids % of paint as received (from data sheet)
Vt = volume of thinner or solvent added
Sometimes referred to as “mileage,” the coverage is the surface area coated per liter of
Theoretical paint. Theoretical coverage is the coverage calculated from specifications given for the
Coverage product, and does not take into account losses due to surface porosity and shape of the
part being coated, overspray, material left in containers, guns and lines, spillage and so
forth. Nevertheless, this calculation is useful for comparing different coatings.
39.4 x VS
Theoretical Coverage =
DFT

DFT= Dry Film Thickness, expressed in microns
applied at 25 microns.
If the transfer efficiency is known, the above formula may be modified to

take this into account. The resulting calculation would provide an
estimate of actual coverage.
39.4 x VS x TE
Actual Coverage =
DFT
2-20
Paint
Metric Units continued
Container Measurement
Determining It is often useful to monitor usage during a parts run. Paint consumption can be
Paint monitored using simple measurements of the container dimensions. First, measure the
Paint
diameter of the paint container. Before any coating is used, measure the distance from
Consumption the top rim of the container to the surface of the paint within the container. Remeasuring
Rate this distance after some of the paint has been consumed and using the following
formula will yield the paint consumption in liters that corresponds to the difference in the
two measurements.
Liters of Coating Used = 0.001 liters x D2 x (H1 - H2)
D2 = the inside diameter of the container (cm) multiplied by itself

H1 = the first measurement from the rim to the surface of the coating
H2 = the second measurement from the rim to the surface of the coating
0.001 is a constant that is part of the equation for calculating the
volume of a cylinder.
This measurement, like coverage, is sometimes referred to as “mileage,” “part

Parts Per coverage,” or “part mileage.” The following formula calculates the parts per
unreduced liter of coating.
Liter
39.4 x VS x TE
Parts per liter =
DFT x A

applied at 25 microns.
DFT = Dry Film Thickness, expressed in microns
A = Surface area of each part, in sq. meter
Transfer efficiency is a factor of process control. Painting processes that are “in control”
will almost always waste less paint. Knowing this figure is essential in order to monitor
Transfer cost variations and the overall efficiency of painting operations.
Efficiency P/G x DFT x A

Transfer Efficiency =
39.4 x VS
P/G = Number of parts painted per unreduced liter of coating

DFT = Dry Film Thickness of coating applied, measured in microns
A = Surface area of each part, in sq. meter.
VS = Volume solids of the unreduced coating, expressed as a percent
2-21
Paint
Metric Units continued
This formula takes into consideration the direct material costs, which include the
Material Cost purchased cost of the coating, as well as any solvents used to further reduce the
Per Piece coating in the application process. The full cost per piece would also include labor and
Paint
overhead and should not be overlooked. A coating material that can be applied in less
time will almost always result in a lower total cost per piece, even if its material cost
is slightly higher.
(Vu x Cp) + (Vt x Ct)

Cost per Piece =
#P (Vu + Vt)

Cp = Paint cost in $/liter
Vt = Volume of solvent used to reduce paint for application
Ct = Thinner or solvent cost in $/liter
#P = Number of parts painted per liter of reduced coating. Note that this
calculation makes use of the number of pieces painted per liter of coating as
reduced and used on the paint line. This figure is simply the number of parts
painted per liter of coating used on the paint line.
This formula calculates the weight of solvent in a liter of coating as received, without
Weight of further reduction. Depending upon the environmental regulations that affect your
Solvent In painting operations, you might be required to keep track of and report the amounts of
Unreduced volatiles that are in the paint that you buy, the solvents you buy that you add to the
paint to reduce it, and the solvents that you buy and use for clean-up and
Coating maintenance operations.
Vu x P kg/liter x (1-WS)
Solvent in Unreduced Coating =
Vu
Vu = Volume of unreduced paint (in liters)

p kg/liter = Weight/liter of unreduced paint (from Product Data Sheet)
WS = Weight solids % of unreduced paint (from Product Data Sheet)
This formula calculates the weight of solvent in a liter of coating after reduction,
Weight of with solvent.
Solvent In
Reduced Vt x S kg/liter
Coating Solvent in Reduced Coating =
Vu + Vt
Vt = Volume of solvent used to reduce paint

S kg/liter = The kg/liter of the solvent used to reduce the paint
2-22
Paint
Tinting Colorant Usage & Tinting Procedure

& Colors
Paint
NOTE: The purchase of a tinting machine is required in order to use the following procedure.
You must have a tint machine (ie, Accutinter, Harbil/equipment supplier-Fluid Management
(800) 462-2466) that is capable of 48 increments per ounce. Ensure that you are using the
correct colorants for each base.
Usage
A. Establish an area close to tint machine that will hold one week's
worth of colorants. Main colorant stock should be stored
in a different area.
B. All colorants stored in this area should be recorded on colorant

usage log, prior to usage.
C. All stock should be rotated, oldest being used first.
D. As colorant stock in tint area is depleted, replenish and record

colorant taken from main storage area.
Daily Activities
A. Check all tint machine canisters and fill with appropriate
colorant. All canisters should be marked with colorant number
and sample of color.
B. Turn on tint machine agitators for 15 minutes. This will ensure

proper mixing of colorants that have just been added.
C. Verify that all tinting canisters are in working order. Preventative

maintenance should be done regularly, i.e., cleaning of tint canisters, etc.
Tinting
A. Find and Verify color that needs to be tinted in the formula book.
B. Verify base that will be needed in the appropriate type of paint.
Example:
Color Base Colorant 1 Gal Formula

621 W ABU 3Y 13
W - White
D - Deeptone
N - Neutral
A white base, in the appropriate type of paint, would be used

for the above sample.
2-23
Paint
Tinting & Colorant Usage & Tinting Procedure Cont.

Colors Cont.
Paint
C. Use the correct colorants.
D. 1 Gal Formula
• “Y” equals one fluid ounce

• The number preceding “Y” indicates the number of
ounces to be dispensed from canister.
The number following “Y” indicates additional 48ths required.
Example:
3y 13
3 full ounces + 13/48th ounce.
E. Remove lid from the appropriate hose and dispense colorant

from tint machine per formula.
F. Reattach the lid to the base, confirm lid is firmly attached, then
place in paint shaker and agitate for appropriate time.
G. Remove agitated paint from shaker. Verify that the base has been
successfully agitated without air entrapment.
H. Remove lid from paint and smear a small amount of paint on

paper and dry sample with hair dryer gun. Verify that dried
paint swatch is correct color by comparing to color sample
(see note).
I. A color swatch sheet should be kept for large repeat customers

and/or custom colors. This color swatch sheet should contain
the following:
Date, customer name and job #, color name,

formula #, gallon formula and actual paint
sample from every container that was tinted
with this formula.
A file should be set up and kept for color swatches.
J. Having confirmed and recorded resulting paint color, reattach

lid to the container; confirm container is firmly closed.
Note:
Color matches are approximate and will vary with the type of paint used, the
amount (film thickness) of paint that is applied, batch of colorant used, and the
conditions of drying the paint. Care has been used in developing the book of color
formulas, but users should verify resulting color in each case and every base that is
tinted. PPG does not guarantee conformance to standard.
2-24
Notes
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Training Guide Chapter 2 Paint

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2.

Calculations for Painters …………………………….……………… 2-17

Two main uses for paint

Paint Compo- Resin polymer

particles together; the SOLVENT (30-80%)

Forms the film, suspends Properties Affected by Resins

• Acrylics • Controls basic drying and curing performance

Alkyds Two Categories: Advantages:

Excellent chemical and corrosion resistance Advantages:

Acrylic Acrylic resins are polymers

Issues with Waterbase

3. Small particle size 3. Will resoften on reheating

Opaque Coatings Yes Limited

Laminating Adhesives Yes Limited

• Initial capital cost (i.e., electron beam)

Pigment • Organic (natural, contains carbon)

Pigment • Provide color

Hiding Provide color, durability

Functional Corrosion inhibitors, corrosion control

Provide filling, gloss, sandability, solids

Types of Solvents Three important factors:

• Catalyst Properties affected by additives

Curing • Evaporation: Coatings cured by evaporation of the solvents.

Gloss Gloss: The paint’s ability to uniformly reflect light.

For dry paint to be useful, it must:

Examples of testing done on dry paint:

III. Pre-Mixing Operation

V. Filtering & Filling

Di-isobutyl ketone (DIBK) .811 6.760 15 120 49 6.00

Cyclohexane .782 6.520 550 1 -17 20.00

Solvesso 100 .874 7.280 19 108 42 20.00

N-methyl 2 pyrolidone 1.03 8.550 1 199 93 .02 M-Pyrol

Particle Cart- Vorti-

*** 0.0232 32.2 590 30 *** *** *** ***

*** 0.0165 16.5 420 40 *** *** #400 ***

*** 0.0117 11.7 297 50 *** *** *** ***

*** 0.0098 09.8 250 60 *** *** #200 #60

*** 0.0083 08.3 210 70 *** *** *** ***

*** 0.0070 07.0 177 80 *** *** *** ***

*** 0.0059 05.9 149 100 C-7 *** #150 #100

*** 0.0049 04.9 125 120 *** *** *** ***

*** 0.0041 04.1 105 140 *** *** *** ***

*** *** *** 100 160 *** #100 #100 #160

*** 0.0035 03.5 88 170 *** **** *** ***

2.0 0.0029 02.9 74 200 C-6 #75 *** #200

*** 0.0024 02.4 62 230 *** *** *** ***

*** 0.0021 02.1 53 270 *** *** *** ***

*** *** *** *** 275 C-5 *** *** #275

4.0 0.0017 01.7 44 325 *** #50 *** #325

*** 0.0015 01.5 37 400 *** *** *** ***

**** 0.0014 01.4 31 500 *** *** *** ***

6.0 *** *** 25 550 C-4 #25 *** ***

7.0 *** *** 10 1250 C-3 #10 *** ***

7.5 *** **** 5 *** #5 *** ***

Metric From To Multiply

Volumetric Cross Length

Moisture PERCENT RELATIVE HUMIDITY ABOVE WHICH MOISTURE WILL

* 0.0232 32.2 590 30 * * * ***

* 0.0165 16.5 420 40 * * #400 *

* 0.0117 11.7 297 50 * * * ***

* 0.0098 09.8 250 60 * *** #200 #60

* 0.0083 08.3 210 70 * * * ***

* 0.0070 07.0 177 80 * * * ***

* 0.0059 05.9 149 100 C-7 * #150 #100

* 0.0049 04.9 125 120 * * * ***

* 0.0041 04.1 105 140 * * * ***

* * * 100 160 * #100 #100 #160

* 0.0035 03.5 88 170 * ** * ***

* 0.0024 02.4 62 230 * * * ***

* 0.0021 02.1 53 270 * * * ***

* * * * 275 C-5 * * #275

4.0 0.0017 01.7 44 325 * #50 * #325

* 0.0015 01.5 37 400 * * * ***

** 0.0014 01.4 31 500 * * * ***

6.0 * * 25 550 C-4 #25 * *

7.0 * * 10 1250 C-3 #10 * *

7.5 * 5 * #5 * *