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Objective
The objective of this training unit is 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.
Always check the product data sheets and consult the supplier for
recommendations and guidance.
Always check the data sheets and container label to ensure the
product is a brushing grade.
A paintbrush is also good for getting coatings into pitted and rough
surfaces.
Convertible Coatings
Coatings which when applied and cured cannot be re-dissolved in
their own solvents.
Coating Types:
Alkyd Types.
Epoxy Ester.
Polyurethane.
Epoxy.
Non-Convertible Coatings
Coating Types:
Chlorinated Rubber.
Acrylated Rubber.
Vinyl.
Bitumen.
Convertible Coating
This animation illustrates the application of a convertible coating.
The second coat will not dissolve the first coat, which in some
circumstances can lead to adhesion problems.
Non-Convertible Coating
This animation illustrates the use of a non-convertible coating.
The second coat dissolves the first coat giving good adhesion in
general.
Alkyd.
Epoxy Ester.
Chlorinated Rubber.
Acrylated Rubber.
Vinyl.
Bitumen.
Siloxanes.
Polyurethane.
Epoxy.
Siloxanes.
Polyester.
Zinc Silicates.
Coating Specification
Coatings are specified depending upon a number of factors which
include:
Environment.
Cost.
Durability.
Performance.
Preparation requirements.(level of surface preparation)
Availability.
Application conditions i.e. temperature.
Lifetime requirements.
Maintainability.
Examples include:
Cost
The cost of coatings can vary tremendously depending upon the
generic type, thickness and availability of the coating.
Always use reputable coating suppliers who can offer the technical
support if needed.
Durability
Coating systems differ in terms of durability.
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.
Availability of Products
It is important to ensure the coating system is available when
specifying a specific type of product.
Some countries will not allow the import of chemicals and paints.
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.
Lifetime Requirements
When specifying a coating system, the lifetime of the structure
should always be considered.
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.
Paint Manufacturer
Paint Mixing
Correct paint mixing is essential, even with single part coatings.
The older the paint the more mixing that will be required,
especially with heavily bodied coatings.
Mix the product until you get a consistent colour and consistent
blend with no lumps or resin variations.
Do not part mix two-part products unless you know the exact ratio
etc and only if agreed with the specification.
Application.
Adhesion.
Durability.
Economics.
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.
The primer must give good adhesion with no voids on the interface.
The topcoats protect the intermediate coats and supply colour and
aesthetics.
Supply build.
Supply thickness.
Provide hiding power (cover primer)
Aluminium Flake
Zinc Phosphate
Paint Mills
In paint manufacturing, pigments, extenders, resin, solvents and
additives are mixed together to form a paste.
Mills
The apparatus to perform the milling includes:
Paint Dispersion
The stages involved in paint dispersion are:
The unit also reviewed the basic chemistry and the "ingredients" of
a coating including the use of different pigments etc.