An introduction to how coatings protect concrete

From JPCL, April 2013

More items for Coating Application
Charles H. Holl
Scott A. OConnor*

In a previous bulletin, we described the general make-up of concrete, reasons we coat concrete,
and some of the main mechanisms of concrete deterioration. This month, we will briefly review the
composition of concrete and why we coat it. We will then describe some of the characteristics that
make concrete difficult to coat and protect. The rest of the Bulletin will be devoted to explaining how
properly applied coatings protect concrete.
Concrete: What It Is and Why We Coat It
As we noted before, concrete is a mixture of Portland cement, water, fine and coarse mineral
aggregates, and sometimes various admixtures. When all of these materials are mixed in the
correct proportions, a complex chemical reaction takes place. This reaction is known as cement
hydration, the process by which concrete hardens and cures.
Even though it can be a very strong, hard substrate, bare concrete is also subject to deterioration.
Concrete can be very porous, so chemicals can penetrate the pores and attack the paste. The
paste and aggregate can also be worn down by physical impact and abrasion. Water can
sometimes penetrate concrete, freeze and expand inside it when the temperature drops, and
ultimately weaken the concrete from within. In addition, if the concrete has reinforcing steel bar
(rebar) to impart additional strength and other properties, the rebar can corrode if moisture and
oxygen are present (carbonation) or if moisture, oxygen, and chloride ions penetrate the concrete.
Corrosion of rebar contributes to the deterioration of concrete.
Thus, as noted earlier, we coat concrete to protect it from chemical and physical attack. We also
coat it to protect products stored or processed in direct contact with the concrete from
contamination caused by dust from the substrate. And we coat concrete to improve its appearance,
ease of maintenance, and light reflectance. As long as coatings are properly applied to an
adequately prepared concrete surface, they can prolong the life of the structure.
What Makes Concrete Difficult to Protect
As you might expect, it is difficult or impossible for any coating to protect concrete if the coating is
incompatible with it, or if the concrete itself is in some way weakened, contaminated, or inherently
defective. Here are some characteristics of concrete that can make it difficult to protect.

Alkalinity: The cement paste that holds concrete together is made up of materials called
alkaline hydrates. These materials create a property called alkalinity. Alkaline materials are
highly reactive to all acids and incompatible with some coatings, like alkyds.

Porosity: Because it has many pores, concrete can be attacked by water, gas, and other
contaminants. In addition, the porosity of concrete can contribute to the formation of coating
defects called pinholes. Pinholes, which are caused by the movement of gas or moisture
vapor through an uncured material, give contaminants in the environment an easy way to
reach the concrete.

Moisture content: Water is a key ingredient in concrete. Water left from the reaction that
forms concrete (called waters of convenience) makes its way to the surface, leaving
behind capillaries and void spaces. When a finished concrete structure contains large
amounts of water in a liquid or vapor state and transmits the water to the environment, the
escaping water can prevent a coating from adhering to the surface, curing properly, or
performing as needed.

Tensile strength: Tensile strength relates to the ability of the material to with stand tension

without fracturing. If concrete is too weak in tensile strength, the top layer of it can
delaminate, taking the coating off with it.

Laitance: Laitance is a weak, thin layer of the concretes surface that forms when cement
paste and fine aggregate are carried to the surface during the cure of the concrete. If the
laitance is not removed before coating application, the coating will most likely disbond.

Surface defects: Concrete may contain many surface defects, including dusting, grooves,
depressions, cracks, holes (called bugholes), and fins (sharp protrusions from the
concrete).

Before concrete is prepared and coated, its condition should be assessed, either by a
representative of the facility owner who is paying for the work or the project manager from your
company. For our purposes in this Bulletin, it is important for you to know that like steel, concrete
requires careful surface preparation and strict adherence to the specification and the
manufacturers recommendations for coating application. Future Bulletins will describe procedures
for surface preparation of concrete and application of coatings, linings, and floor toppings.
How Coatings Protect Concrete
In the May 1997 Bulletin, we described the three ways that coatings protect steel.

Barrier protection: The coating prevents moisture and oxygen from reaching the surface.

Inhibition: The coating interferes with the electro-chemical process of corrosion.

Sacrificial action: The zinc pigments in a zinc-rich coating are attacked instead of the steel
when corrosion occurs.

Unlike coatings for steel substrates, protective coatings for concrete do not, in most cases, require
or include inhibitive or sacrificial pigments to provide protection. Coatings applied to concrete are
typically barrier coatings. They provide protection by becoming a physical barrier, or shield, isolating
the concrete from its immediate environment. A barrier coating must prevent aggressive liquids and
gasses from passing through it and reaching the concrete.
Barrier Coatings
You probably have heard of many of the coating types that we classify as barrier coatings.
Examples include epoxies, vinyls, polyesters, methyl methacrylates, and polyurethanes. These
coatings are named from the resin type used to make them. (Remember, coatings are made of
resins, pigments, and solvents.) As we discussed before, the resin provides many of the protective
properties of a coating.
One important property of a barrier coating is called permeability. The permeability of a barrier
coatings film depends on its moisture vapor transmission (MVT) rate. The MVT rate is determined
by how fast water molecules pass through and move around the spaces between the resin
molecules (Fig. 1). The effectiveness of a coating in preventing permeation depends on how closely
and tightly bound the molecules of the resin are to one another. The coatings effectiveness also
depends on the type of resin molecule and the amount and type of pigment. Cross-linking is a
measure of the degree of intense bonding of coating resins.

Fig. 1:
The
permea
bility of
a
barrier
coating
depend
s on
how
fast
water
molecul
es pass
through
and
move
around
the
spaces
betwee
n resin
molecul
es.
Figures
courtes
y of
Phoeni
x
Service
s

The lower the permeability of a barrier coating, the more protective the coating is. Basically, the
higher the degree of the coating resins cross-linkage, the lower the permeability, the better the
adhesive bond of the coating to the surface, and the better the overall protective barrier.
By the way, these intermolecular spaces between the resin molecules are much larger than the
water molecules and should not be confused with physical holes (pinholes) in the coating film.
Pinholes in the coating film are generally considered defects and should be repaired. Spaces
between resin molecules are not defects.
The barrier properties of coatings can be improved by adding reinforcement fillers to the resin.
Fillers come in a variety of forms, such as silicate aggregates (sand), glass or mica flakes, fibers,
and woven fiberglass (incorporated as a mat in the resin system as it cures). The addition of fillers
physically increases the length of the path that the intruding liquid or gas molecules must take to
penetrate the coating. Flake materials form layers of overlapping platelets, parallel to the concrete
surface, somewhat like shingles on a roof (Fig. 2). Fillers and fiberglass mat can also be added to
improve the barrier coatings physical properties, such as impact and abrasion resistance.

Fig. 2:
Instead
of
being
able to
travel
straight
through
the
topcoat
to the
primer,
the
water
molecul
es are
forced
to
travel
around
the
long,
flat
glass or
mica
flakes
in the

topcoat
. The
increas
ed
distanc
e the
water
molecul
es must
travel
reduces
their
ability
to
permea
te the
coating.
Coatings That Breathe
As discussed earlier, the curing of new concrete often results in the release of substantial quantities
of water. If this water is trapped between the coating and the concrete, it can cause the coating to
lose adhesion or form blisters. It is sometimes necessary, therefore, to use coatings that breathe.
These coatings allow water vapor (the gas form of liquid water) to pass through them. However,
care should be taken when selecting a more permeable coating to ensure that the service
conditions are not beyond the range of the coating. The higher the permeability, the lower the
resistance in preventing water or other chemicals from the outside environment from passing
through the coating. It is the coating manufacturers and the specifiers responsibility to select and
furnish the coating with the right degree of breathability and permeability rating for the intended
service (use) of the coated concrete.
What About Coating the Steel Rebar?
Coating steel rebar in concrete is a special case. New rebar can be coated directly, before it is
incorporated in a concrete structure being built. Conventional barrier and inhibitive coatings for
steel, as well as special barrier coatings called powder coatings, can be used to protect new rebar.
Conclusion
Coatings can be used to add chemical resistance to concrete structures, such as the secondary
containment you see surrounding fuel storage tanks. Coatings can also be used to make areas
such as floors more resistant to abrasion and wear from foot and equipment traffic.
You dont have to know all the details of how coatings protect concrete, but some knowledge will
help as you learn to prepare concrete surfaces and apply coatings to them.
*Editors Note: This bulletin originally appeared in the August 1997 issue of JPCL and was written
by Charles H. Holl, who was then with Texas Industrial Floors Inc.; and Scott A. OConnor, who was
then with Phoenix Services.
THE JOURNAL OF PROTECTIVE COATINGS & LININGS 2013 Technology Publishing Company