PAINT BASICS

AND
CORROSION IN METAL
AIA103


Provider J476



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Basic Composition of Paint
Solvents (Liquids)
Pigments
Additives
Resins (Binder)
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Prime Pigments
Titanium Dioxide (TiO
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)
provides excellent hiding power and whiteness
available as a solid (powder) or liquid (slurry)
Zinc Oxide
controls mildew
resists ultra-violet light
resists yellowing
Titanium dioxide is the world's
primary pigment for providing
whiteness, brightness and
opacity.
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Resins
Types: Latex, Alkyd, Epoxy, Polyurethane
Binds or glues ingredients (pigments and
additives) of paint together
Resin provides adhesion to the substrate
Resin provides durability & resistance
properties:
U-V resistance
Moisture resistance
Chemical resistance
Stain resistance
Fade resistance
Chalk resistance
Block resistance
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Gloss/Sheen Levels
Gloss or Sheen of paint refers to reflectivity or how
shiny the dry paint film is.
There is lack of standards and confusion in the paint
industry related to gloss or sheen levels.
Gloss is measured at 60 for flat to gloss ranges.
Sheen is measures at 85 between flat to eggshell
Some paint manufacturers use different terms to
define products between flat and semi-gloss: silk,
suede, satin, velvet, eggshell, low sheen, low luster,
pearl, etc.
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Gloss/Sheen Levels
Term Gloss @ 60 Sheen @ 85
Flat 0-5 0-5
Velvet/Low Luster 5-10 5-15
Eggshell 10-20 15-25
Low Sheen 20-30
Semi-Gloss 55-70
Gloss 75+
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Alkyd Resin Technology
ALKYD (Oil-Based)
A synthetic resin made by reacting alcohols and fatty acids
Soya bean, linseed, tung-oil oil commonly used
Benefits of alkyds:
-Superior brushing characteristics
-Abrasion resistance
-Excellent flow and leveling
-Good adhesion
-Used in rust preventative paint
Alkyds have limited availability and use in California.
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Latex Resin Technology
LATEX (water-based)
Synthetic polymers
Main resins
- 100% Acrylic
- Styrene Acrylic
- Vinyl-Acrylic
- Acrylic Copolymer
- Vinyl Acetate Ethylene
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QUALITY Latex paint benefits include:

* Ease of application * Low odor
* Yellowing resistance * Color retention
* Chalk resistance * Gloss retention
* Washability * Durability
* Good flow & leveling * Flexibility
* Excellent adhesion * Scrub resistance
* Improved adhesion * Water clean-up
Latex Resin Technology
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Acrylic vs. Alkyd Paints
These paints have been exposed to the
elements for 46 years. Over that time,
the PVA (and the alkyd) paints have
disintegrated.

The 100% acrylic paint remains in
remarkably good shape. The paint
film is essentially intact, and, while it
has chalked and faded, it retains its
original green color.

Top left: Alkyd paint
Top right: Vinyl-Acrylic paint
Bottom left: Alkyd paint
Bottom right: 100% acrylic paint
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Acrylic vs. Alkyd Paints
The paint on the left half of each
board is acrylic, the paint on the
right half, an alkyd.

The colors of the paints were
identical when applied. After 15
years of weathering, the
appearance of the alkyds has
changed dramatically.

All have lost gloss, faded, and
chalked. The acrylic paints, in
contrast, have proven remarkably
durable with good color retention.
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Premature Coating Failure
DEFINITION:
The deterioration of the coating system, or corrosion of the
coated surface, more rapidly than would normally be expected
under the service conditions.

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These metals will not rust or corrode
unless a conductor between the two
metals or atoms is present.
Water or oxygen in contact with the
metal for a longer period of time is
normally the conductor that starts
the rusting or corrosion process.
Salts in the water will accelerate the
process.
Corrosion
Simply put, corrosion is created when two dissimilar metals at
atomic levels come into contact with each other and create a
chemical reaction. The new compound is called oxide. In iron it
is called Iron oxide. In aluminum, aluminum oxide and in
copper, copper oxide.

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Galvanized Metal
White Rust
Pure water (rain, dew,
condensation) contain no
dissolved salts or minerals.
Pure water will react with zinc
hydroxide quickly to create
white rust.
Acid or acid rain, will accelerate
the deterioration of the zinc
finish.
Passivators are a coating
applied at time of manufacture
to protect the zinc.
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Faulty Products 2 - 5%

Unforeseen Circumstance 10-15%

Improper Specification 25-30%

Improper Prep/Application 45-55%
Causes Of Paint Film Failures
(New )

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THERE ARE TWO (2) MAJOR CAUSES
FOR IMPROPER
COATING SPECIFICATIONS

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1. Inadequate or incomplete project
information

2. Lack of product knowledge
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PROJ ECT I NFORMATI ON

NEEDED .

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DETERMINE
COATING
SYSTEM
EVALUATE
EXISTING SURFACE
CONDITIONS
CUSTOMER
NEEDS





EVALUATE
THE
ENVIRONMENT
EVALUATE
SERVICE
REQUIREMENTS

DETERMINE
SURFACE
PREPARATION

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Removing contamination
Providing a surface profile
Removing or smoothing irregularities
(pits, projections, sharp edges)
Removing tightly bound mill scale & rust

To provide a surface suitable for painting by:
What are the Goals of Surface
Preparation?
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What Surfaces Require
Preparation?
Iron and Steel
Galvanized Metal
Aluminum
Copper
Miscellaneous metals
Pre-Coated Metal Siding
Previously Painted
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CORROSION !

HOW MUCH ?

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Results of Pin Hole Rusting of
the Primer

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What is the Environment?

Type P
Type M
Type C
or
Type A

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Type P: Protected Architectural
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Not subject to chemical
contaminants
Normal humidity range
Normal industrial interior
Corrosion of steel or galvanized
surfaces negligible
Type P: Protected Architectural
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Type M: Moderate
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Type M: Moderate

Exterior weathering
Normal industrial atmosphere
Moderate concentrations of chemical fumes
Corrosion of steel < 3 mils / year and
galvanized substrates negligible
Concentrations of chemical interior
light to moderate fumes without humidity



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Type C: Corrosive
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Type C: Corrosive

Moderately aggressive chemical fumes, mists or dust
Corrosion of steel 3 - 6 mils / year and galvanized
substrates < 1 mil per year

Adjacent to Type A: but at least
30 yards away

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Type A: Aggressively Corrosive
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Type A: Aggressively Corrosive
Immersion service
Excessive exposure to aggressive chemical
fumes, mists dusts or contaminates
Corrosion of steel > 6 mils / year and
galvanized substrates > 1 mil per year
Usually confined to an
area within 30 yards
from corrosion source
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Application
Apply the coating system using one manufacturer
Apply according to the manufacturers recommendations
Apply to the Dry Film Thickness (DFT) as stated by the
manufacturer
Recoat within the window specified by the manufacturer
The finish system shall be a solid uniform finish free of
voids and pinholes.




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Protection
Factors Affecting Coating
Performance
Structural Design
(We cant control)
Coating Selection
Surface Preparation

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A Poor Design
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Other Design Considerations
Surfaces should be smooth (e.g. welds)
Welding preferred to riveting
All surfaces should be well drained
Stiffening members should be on the outside surface of
tank or vessel

THANK YOU

PROVIDER J476