Painting

UNIT 8 PAINTING
Structure
8.1 Introduction
Objectives
8.2 Paints
8.2.1 Painter’s Tools
8.2.2 Characteristics of a Good Paint
8.2.3 Main Constituents of Paint
8.2.4 Preparation of Paint
8.2.5 Types of Paint
8.2.6 Process of Painting on Different Surfaces
8.2.7 Application of Paint
8.3 Varnishes
8.3.1 Composition of Varnish
8.3.2 Characteristics of Good Varnish
8.3.3 Types of Varnish
8.3.4 Application of Varnish
8.3.5 French Polish or Spirit Varnish
8.4 Summary
8.5 Answers to SAQs

8.1 INTRODUCTION
Paint is applied on the timber, metal, bricks or other materials in the form of a
liquid which on drying forms a thin film on the surface. Varnish and polish is a
solution of resinous substances dissolved in either oil or alcohol. The solution on
drying forms a hard transparent glossy film on the surface. Varnish and polish
play an important role in finishing structural wooden surfaces.
Most of the metals get corroded if not painted time to time. Varnish and polish
may also be applied on unpainted wooden structural work without hiding the
beautiful grains of wood. Painted surfaces are varnished to enhance the
appearance of the paint and to increase the durability of the paint film.
The main function of paint, varnish and polish is to decorate the surfaces and also
to protect the surface against the adverse influence of the atmosphere.
Objectives
After studying this unit, you should be able to
know the characteristic of paint, varnish and polish,
describe the ingredients of paint, varnish and polish,
know the classification of paints and varnishes,
describe the process of painting, varnishing and polishing,
study about painter’s tools, and
explain methods of painting.
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8.2 PAINTS
These are used to protect metals, timber and plastered surfaces from the corrosive
effects of weather, heat, moisture and gases etc. and also to improve their
appearance.
8.2.1 Painter’s Tools
Generally, the following tools are used by a painter :
(a) Wire brush
(b) Painting brushes
(c) Scraper
(d) Stopping knife
(e) Burning stove
Wire Brush
It is used to remove the mild scale, dirt and rust from the surface before
painting.
Painting Brushes
Painting brushes are used to apply the paint coat on the surfaces. Mostly flat
round or oval shapes of brushes are used. A good brush should have
springiness in the bristles. Any new brush may have loose bristles. Prior to
painting, the loose bristles should be removed by twirling it rapidly between
the palms of hand and finally putting the loose bristles out. The brush
should not be dipped too deep in the paint, and the excess paint should be
removed by gently rubbing the brush against the inside surface of paint
container. After use, the brushes should be cleaned very thoroughly with the
kerosene oil.
Scraper
It is simply a flat steel piece consists of sharp cutting edge at one side. To
perform scraping operation, it is used as a tool. By scraping operation we
can remove the mild scale, rust and paint layer from any old surface.
Stopping Knife
Stopping knife is used as a tool in filling up all nail holes, cracks, open
joints and cavities with putty before painting on any surface.
Burning Stove
When the old painted surface is in bad condition and the paint has badly
blistered and flaked, it may be completely removed by using of heat
through the flame of burning stove.
8.2.2 Characteristics of a Good Paint
A good paint should have the following characteristics :
(a) The dried paint film should be able to withstand the adverse weather
effect.
(b) Its colour should not fade with the passage of time.
(c) It should dry out at the earliest.
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 (d) Its consistency should provide easy workability. Painting

(e) It should be cheap.

(f) The thickness of paint film should be adequate for good protection
and appearance of the surface.
(g) It should possess good fire and moisture resistance.
(h) It should show resistance to failure by cracking and flaking.
(i) It should not be very thick.
(j) It should be easily spreadable on the surface.
8.2.3 Main Constituents of Paints
An oil paint consists of the following main constituents :
(a) Base
(b) Vehicle
(c) Solvent or thinner
(d) Colouring Pigment
(e) Drier
(f) Inert filler or extender
Base
It is the main constituent of the paint which forms the body. It is used in the
form of fine ground powdered. It makes the film of coating resistant to
abrasion and prevents shrinkage cracks formed in the film during drying.
The commonly used bases are white lead, zinc oxide, red lead and iron
oxide.
Vehicle
It is a liquid which acts as a binder for the various pigments viz, extender,
base and colouring pigment. It makes the paint in the fluid state and thus
helps to spread its constituents uniformly over the surface which is to be
painted. As a vehicle, generally, refined linseed oil is used in oil paints.
Stand oil, poppy oil and nut oil may also be used as a vehicle.
Solvent or Thinner
It is a liquid which reduces the viscosity and increases the fluidity of paint.
It imparts to the paint film good properties such as smoothness, easy flow
and brushability. Turpentine oil, petroleum spirit and highly solvent
naphtha are widely used as a solvent or thinner. Thinner should not be
added in excess because excess quantity of thinner may damage the shining
quality of the paint.
Colouring Pigments
As its name indicates, it is a white or coloured pigment, mixed with paint to
get the desired colour of the paint. The best pigment is one which does not
change its colour even on being exposed to heat and sun. The commonly
used pigments and the corresponding colours they impart are given below :
Colour Pigments
Red Red lead, Venetian red, Indian red. 153
Workshop Technology Brown Burnt umber, raw sienna, burnt sienna and raw umber.
Green Chrome green and verdigris.
Black Lamp black, vegetable black and graphite
Blue Cobalt blue, Indigo, purssian blue.
Yellow Chrome yellow, zinc chromates and lrium chromate.
Drier
These are materials containing metallic compounds and are mixed in small
quantity for accelerating the drying of paint layer. It acts as catalyst for the
oxidation of the vehicle used in the paint. Lead oxide, red lead, lead acetate,
zinc sulphate and manganese sulphate etc. are the driers which are
commonly used. They are used either in liquid or pasted form. In liquid
form, they are dissolved in a volatile liquid and in paste form mixed with an
excess amount of an inert material like whiting or baryte. Not more than
10% (by volume) of the drier should be used in an oil paint. If used in
excess, it tends to destroy the elasticity of the paint which finally leads to
the flaking of the paint.
Inert Filler or Extender
It modifies the volume of the paint and makes it more durable. It is a cheap
kind of pigment added in paint to reduce its cost. The commonly used inert
fillers are whiting, silica, sodium sulphate, gypsum and charcoal etc.
8.2.4 Preparation of Paint
The base and pigments are mixed in a little quantity of linseed oil separately and
then mixed with the turpentine oil. The drier is separately ground and mixed with
linseed oil. It is then diluted by mixing some quantity of turpentine oil. These two
separately prepared masses are then mixed together thoroughly and finally stained
through suitable means. Now the paint is ready for applications. For a good paint,
it should have enough fluidity so that it can be easily spread by a brush over the
surface.
8.2.5 Types of Paint
The paints which are commonly used are listed and described below :
(a) Enamel Paint
(b) Aluminium Paint
(c) Cellulose Paint
(d) Rubber based Paint
(e) Bituminous Paint
(f) Cement based Paint
(g) Asbestos Paint
(h) Casein Paint
(i) Bronze Paint
(j) Anti-corrosive Paint
Enamel Paint

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 Enamel paint is prepared by adding base like zinc white or white lead to a Painting
vehicle which is a varnish. Colouring pigments is also mixed to obtain the
desired colour. On drying slowly, it forms a smooth, hard, glossy and
permanent solid thin film. These types of paint are used both for interior as
well as exterior painting work like stairs, decks, porches and concrete
surfaces etc. Enamel painted surfaces are washable and are not affected by
acids, alkalies, gases or steam.
Aluminium Paint
Finely ground aluminium powder forms the base in this paint which is held
in suspension and bound by either quick drying spirit varnish or slow
drying oil varnish to suit the requirements of the surface to be painted.
Aluminium paint is well established for its good weather resisting and water
proofing qualities. This paint is used for painting wooden or metallic
surfaces both. It is commonly used for painting metal roofs, electric and
telegraphic poles, towers, hot water pipes or tanks, machinery and gas or oil
storage tanks.
Cellulose Paint
It is prepared by mixing cellulose sheets and amyl acetate substitutes. For a
superior quality of cellulose paint, Nitro-cotton is also mixed. It dries
rapidly and possesses the additional advantage of flexibility, smoothness
and hardness. It remains unaffected by hot water, acidic or smoky
atmosphere and can be washed or cleaned easily. Being much superior in
quality and on account of its high cost, it is preferred for painting
aeroplanes, mortar cars and other costly things.
Rubber Based Paint
It is made by treating rubber with chlorine gas (chlorinated rubber) which is
dissolved in suitable solvent. This paint has excellent alkali, acid and
moisture resistance properties. It can be used for application on new lime
and concrete plastered surfaces.
Bituminous Paint
It consists of asphalt, bitumen or pitches, generally dissolved in mineral
spirit. This type of paint is available in black colour but this black colour
may be modified by adding certain pigments like red oxide etc. It
deteriorates when exposed to the direct rays of the sun. Being alkali
resistant, it is widely used for painting, exterior brick work, plastered
surfaces and steel work under water.
Cement Based Paint
It is available in powder form. As a base white or coloured portland cement
is used. The base is thinned with water which acts as a vehicle. No oil or
other organic matter is used in its preparation. In market, it is available in
variety of shades. It forms a strong, durable and water resisting layer on
drying. It shows its great importance on the surfaces which remain in
contact with damp weather.
Asbestos Paint
For patch work or stopping leakages in metal roofs, this type of paint is
most suitable. It may also be used for painting flashings, spouts and gutters
etc. to prevent these from rusting. Its coating forms a damp-proof cover for
the outer face of the basement walls.
Casein Paint 155
Workshop Technology Casein is a substance which is extracted from the milk-curd. This casein is
mixed with a base like titanium or whiting etc. to form the casein paint.
Generally, it is available in powder or paste form. As casein paint has high
capacity, therefore it can be applied on new plastered surface without any
chance of scaling. Widely, it is used to develop the appearance of surface.
For painting on exterior surfaces of stone, brick and cement masonry,
varnish is also added to the paints to make more durable against
atmospheric reactions.
Bronze Paint
It consists of either powder of aluminium bronze or copper bronze as a base
whereas nitro cellulose lacquer as a vehicle. On account of its high
reflective property, it is preferred to apply on radiators. It can also be used
for painting both exterior and interior metallic surfaces.
Anti-corrosive Paint
Several types of anti-corrosive paint are used in practice. For the
preparation of anti-corrosive types of paint, zinc oxide, iron oxide, dry red
lead, zinc chromate or zinc dust are used as a base whereas linseed oil as a
vehicle. It is referred as a metal protection paint for preserving steel
structural work against the anti action of acids, fumes and the ravages of
weather. These types of paint are cheap and durable. Usually, they are
available in black colour.
8.2.6 Process of Painting on Different Surfaces
Process of Painting on New Wood Work
The proper preparation of surface plays an important role in preserving the
properties and the life of paint. For painting on new wood work, the
complete process may be divided in the following steps :
(a) Preparation of surface
(b) Knotting
(c) Priming
(d) Stopping
(e) Surface coat or under coat
(f) Finished coat
Preparation of Surface
Wooden surface to be painted should be well seasoned, clean, dry and
free from dust. It should be smoothened by rubbing it with a sand
paper.
Knotting
The process of sealing the knots is known as knotting. Before painting
sealing of knots is must, otherwise the resin of knots may destroy the
paint film by way of cracking, peeling or brown discoloration. For
sealing purpose, one or more coats of shellac are applied on the knots.
Priming
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 The function of primer is to fill up the pores of surface by penetrating Painting
inside the surface. Priming coat on the surface is used to serve as the
foundation for the subsequent coats. The composition of primer or
priming coat is similar to subsequent coat but proportion of
ingredients may vary.
Stopping
When the priming coat has dried up, nail holes, dents, open joints and
cracks etc. are filled up with putty and this process is known as
stopping. Putty is made by mixing whiting, raw linseed oil and
litharge. When the putty has become sufficiently hard, the whole
surface is rubbed with pumice stone or glass paper till it gives a
smooth surface.
Surface or Undercoat
Surface or undercoats are applied after stopping. This undercoat
serves as a building layer for the paint. It should be thin, free from
brush marks and of the same shade as that of the desired finish. The
final appearance of painted surface and its durability totally depends
upon the quality of undercoat. One or two coats are sufficient to
achieve the target. For good result, the undercoats must invariably be
allowed to dry properly before applying the final coat.
Finishing Coat
Two or more coats of paint having the desired colour are applied to
the surface already prepared. Each finishing coat should be applied
after the previous one, on having fully dried, has been slightly rubbed
with fine glass paper. This finishing coat should be applied carefully
in a skilled manner so that the finished surface may be free from
brush marks and thin patches.
Painting on Old Wooden Work
First of all, we have to remove the old paint by applying the caustic soda
solution on the surface and then scrapped it with sharp edges knife. After
removing the film of old paint, two or three coats of fresh paint are applied
on the cleaned surface to obtain the desired finish.
If the old painted surface has its paint film badly flaked and blistered, it
should be completely removed by use of paint remover or flame of blow
lamp. Heating of old paint surface, by means of flame, makes it soft and
then softened paint can be removed easily with a striping knife.
Painting on Iron and Steel Surfaces
In the preparation of surfaces for painting, rust and mild scale should be
removed by brushing or scraping with steel wire brush or scraper.
The presence of oil or grease on the surface is removed by washing the
effective surface with caustic soda solution. This process technically known
as “degreasing” while for derusting and descaling, hydrochloric acid (HCL)
or sulphuric acid (H2SO4) is used as per requirement and this process
technically denoted as “pickling”.

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Workshop Technology The cleaned surface is then coated by using priming coat of red lead. When
the priming coat has dried completely, two or more coats of the desired
paint are applied over the surface with a brush or by spraying.
Painting on Plastered Surfaces
The fresh plastered surface should not be painted until it has dried
thoroughly. The fresh plastered surface has the free alkalies which destroy
its oil and discolour the paint. For better result, leave such surfaces
unpainted for about 12 months to dry completely. After this duration, the
surface is washed with a diluted solution of zinc sulphate to neutralise the
free line on the surface. Plaster of paris is used to fill up the holes cavities.
Before application of prime coat, surface should be rubbed to form a
smooth level. For priming coat, primer is prepared by adding equal parts of
red lead, white lead in boiled linseed oil. Once the primed coat has dried,
the coats of desired paint can be applied in routine way.
Now-a-days, new plastered surfaces can be painted quite easily by using
emulsion paints. It can be directly applied on fresh plastered surfaces. It has
good alkali resistance and sealing properties.
Painting on Concrete Surfaces
Cement paint is commonly used for painting on concrete surfaces. It is
available in powder form. For the preparation of paint, powder is mixed
with water. As it takes less time for its setting, hence it should be consumed
within 1½ -2 hours of its preparation. At an interval of 24 hours, at least
two coats are sufficient for a better result. The cement painted surfaces are
preserved by sprinkling of water at intervals.
8.2.7 Application of Paint
For the application of paint on any surface, methods commonly used are given
below :
(a) Manual or Brush Painting Method
(b) Dip Painting Method
(c) Spray Painting Method
Manual or Brush Painting Method
In this method, the paint is applied on the surface with brush. According to
nature of work, these are available in different sizes. The brush should not
be dipped too deeply in the paint, the excess paint should be removed by
gently rubbing the brush against the inside edge of the container. It is a slow
speed method of painting and not suitable for fine and smooth finishing.
Dip Painting Method
Hollow and typical shapes of jobs are painted by this method. The portion
of job where the approach of brush cannot be possible, may be painted by
this method easily and rapidly. This is a simple and cheap type of painting
method but not suitable for high class finishing.
Spray Painting Method
Spray painting consists of main parts spray gun and air compressor. The
paint is put on a container which is arranged at the top of spray gun. The
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 gun is also provided with a spray nozzle and a hosepipe, conveying Painting
compressed air through air compressor.
When the trigger of the gun is pulled out, both the air and fluid values get in
open position. The compressed air strikes the paint and practically converts
the fluid into automised form which is sprayed on the surface in a uniform
coat. Beautiful appearance of perfection, achieved by spray painting, can
never be achieved in painting by brushes. All superior class painting work
is performed by spray painting method.

SAQ 1

(a) What are the characteristics of a good paint?

(b) What are the main constituents of an oil paint? Describe in brief.
(c) Explain in brief the painting process on following :
(i) new woodwork,
(ii) old wooden work, and
(iii) iron and steel surfaces.
(d) Give the names of any five types of paint. Describe any one in brief.

8.3 VARNISHES
It is a solution of some resinous substance (like copal, shellac, lac or amber)
which is dissolved either in turpentine oil or alcohol. It plays an important role in
finishing wooden surfaces only like windows, doors, floors and furniture etc. To
accelerate the drying process of varnish, litharge is also added as a drier. It shows
a hard, glossy and transparent film on the surface. Varnish can be applied on both
painted or unpainted surfaces. For painted surface, varnish is applied to increase
its brilliance and also to protect it from the atmospheric action and to the
unpainted fresh wooden surface with a view to brighten the ornamental
appearance of the grains of wood.
8.3.1 Composition of Varnish
The main ingredients or constituents of varnish are resins, solvent and driers
which are described below :
Resins
Generally used resins are mastic, amber, gum, lac and copal. Quality of
varnish totally depends upon the quality of resin used. Copal resin is
considered to be the best, toughest and hardest for external work.
Solvents
These depend upon the resin used as linseed oil is used to dissolve copal or
amber, methylated spirit for lac and turpentine oil for mastic.
Driers
Litharge or lead acetate are the commonly used driers in varnish which are
added to accelerate the drying process.
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Workshop Technology 8.3.2 Characteristics of a Good Varnish
(a) It should have good weathering properties.
(b) After drying it should leave a durable, tough and hard film.
(c) It should be able to retain its appearance and colour for a long time.
(d) It should be resistant to wear and abrasion.
8.3.3 Types of Varnish
On the basis of solvents used, varnishes may be classified in the following
categories :
Oil Varnish
It is prepared by dissolving copal or amber in linseed oil. It is slow to dry,
but is hardest and most durable amongst all varnishes. Oil varnish is used
both for exterior and interior surfaces.
Asphalt Varnish
It is prepared by dissolving melted hard asphalt in linseed oil and then
thinned with petroleum spirit or turpentine oil. This type of varnish mainly
used on fabricated iron and steel products to give a black shop coat.
Turpentine Varnish
Turpentine varnish is made from soft resin like mastic resin dissolved in
turpentine oil. It is cheaper, light in colour and dry more quickly than oil
varnish. However, it is less durable and not so tough.
Spirit Varnish
Varnish where spirit is used as a solvent known as “spirit varnish” or
“French-polish”. It is prepared by dissolving the shellac or lac in
methylated spirit. It gives a thin and transparent finish on wood work.
Being easily affected by atmospheric action, it is used to polish such
surfaces which are not exposed directly to weather.
Water Varnish
It is made by dissolving lac in hot water with some quantity of barax or
soda. Water varnish is used for painting paper, wall and delicate type of
work.
8.3.4 Application of Varnish
After knotting and stopping, the prepared clean and dry surface of wood work is
given a coat of thin and hot solution of glue. When dry, the surface should be
rubbed down smooth with sand paper. A second coat of thin solution of glue is
then applied on the surface. In second coat, solution of glue should be nearly
cold. The sized surface is again rubbed down and cleaned. Two or more coats of
varnish are then applied. Second and subsequent coats should be applied when
the first one has dried thoroughly.
8.3.5 French Polish or Spirit Varnish
French polish is prepared by dissolving pure shellac in methylated spirit. It can be
coloured by mixing some colouring pigments as desired. This solution is then
strained through a double thickness of coarse muslin as compared with turpentine
varnish, it dries quicker and becomes harder and more brilliant. It does not
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with-stand weathering and is used only for superior wood work not subjected to Painting
the vagaries of weather.

SAQ 2

(a) What is varnish? In what way do varnishes differ from paints?

(b) Describe “French-polish”. How does it differ from Turpentine
Varnish?
(c) What are the advantages of polishing the surface?

8.4 SUMMARY
Paints and varnishes are used in civil engineering field to protect the exterior of
work surfaces and also to beautify the interior work surfaces. The usual
constituents of paints are the vehicle and pigments. The former comprises the
drying oil, solvent and drier and binds the grains of pigment to one another while
the latter, i.e. pigment, provides the colouring and obscuring properties. The
consistency, spreading or covering capacity, drying and durability are the
desirable properties of paints and varnishes.
A number of paints and varnishes, specially designed for easier application and
higher durability are available now-a-days. Amongst these are oil based paints,
enamel paints, water paints, and distempers etc. The procedure and precautions
for application of paint or varnish, though practically the same, only would differ
with the nature of the painting job, with regard to the type of surface (either made
by wood masonry or steel) and nature of the surface (old or new).

8.5 ANSWERS TO SAQs

Refer the relevant preceding text in the unit or other useful books on the topic
listed in section “Further reading” to get the Answers to SAQs.

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FURTHER READING
S. K. Hajra Choudhury, Elements of Workshop Technology, Vol-I, Manufacturing
Process, Media Promoters and Publishers Pvt. Ltd.
B. S. Raghuwansi, A Course in Workshop Technology, Vol-I, Dhanpat Rai and
Co. (P) Ltd., Delhi.
K. C. Arora, Workshop Practice, S. K. Kataria and Sons, Publishers and
Distributors.
R. K. Singhal, Workshop Practice, S. K. Kataria and Sons, Publishers and
Distributors, Delhi.

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 Painting
WORKSHOP TECHNOLOGY
The knowledge of Workshop Technology is very useful and important in the field
of engineering and technology. This course will enhance your knowledge and
skills of techniques and processes pertaining to basic mechanical engineering.
This course on Workshop Technology comprises eight units.
Carpentry is the art and trade of cutting, working and joining timber. The term
includes both structural timber work in framing and items such as doors,
windows, and staircases. The scope of the carpenter’s work has enhanced with the
passage of time. Unit 1 discusses the details about carpentry work.
In the production of sand casting, the important functions to be performed include
making the patterns, making the sand moulds with the use of the pattern, melting
and alloying the metal, pouring the alloy into the mould and cleaning the casting.
A pattern of wood or metal is needed to form the cavity in the sand into which
molten metal will be poured. The most commonly used pattern material is wood,
the main reason being the easy availability and its low weight. Unit 2 deals with
the pattern making and foundry.
Fitting and benchwork play a vital role in giving the desired shape and accuracy
while plumbing is concerned to join or repair of pipes, carrying water, oil, steam
and gases etc. In Unit 3, you will be introduced to different facets of fitting and
plumbing.
In modern manufacturing processes, the knowledge of sheet metal work is very
important. Sheet metal, generally, considered to be a plate with thickness less
than 5 mm, is used for making the jobs such as pipes, funnels, automobiles,
boxes, mechanical toys etc. In Unit 4, we shall be discussing about different
aspects of sheet metal work.
Welding is a process by which two similar or dissimilar metals may be joined by
heating them to a suitable temperature with or without the application of pressure
and with or without the use of filler metal. Unit 5 deals with the different types of
welding process. The unit covers the description of gas and arc welding.
Forging is the operation where the metal is heated and then a force is applied to
manipulate the metal in such a way that the required final shape is obtained.
Smithying and forging are the oldest of the metal working processes known to
mankind since the copper age. You will be introduced to the smithying and
forging operation in Unit 6.
Machining is accomplished with the use of non-portable power driven machines
known as ‘machine tools’. A machine tool and its accessories securely hold the
workpiece and the cutting tool while power is applied so that the motion of the
cutting tool relative to the workpiece cause a cutting action. Different types and
sizes of the machine tools are discussed in Unit 7. In this unit, you will also learn
that the machine tools are classified as general-purpose machine tools, special
purpose machine tools, production machine tools and single-purpose machine
tools.

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