GENERIC COATING TYPES

Introduction to
Generic Coating Types
by Lloyd M. Smith, Ph.D., General Editor
Corrosion Control Consultants and Labs

Editors Note: With the article that

follows, JPCL introduces a 16-part
monthly series, Generic Coating
Types, which is intended to provide
basic information about the standard, generic classification of protective coatings. Edited by Lloyd M.
Smith of Corrosion Control Consultants and Labs (Reston, VA) and
written by industry personnel with
expertise in the generic types addressed, the series will also be compiled as a single volume in the fall
of 1995.

housands of coatings products are sold for industrial

use, making it impossible to
memorize the names, attributes,
properties, and limitations of all of
them. Therefore, a method is needed to classify coatings based on
some similarity so that the selection
process is manageable. The most
common method of classification for
coatings is generic type, which
refers to the chemical attribute
most often the resin typethat is
unique to a group of coatings.
Generic type is the most useful
classification principle because coatings of the same generic type have
similar handling and performance
properties. The name for most
generic types of coatings is based on
the resin (binder) in the formulation.
A secondary generic classification of
coatings is by curing mechanism or
some other compositional element.
Vinyl and epoxy, for example, are
generic coating types with names
based on the resin. Urethanes as a

Copyright 1995, Technology Publishing Company

The series will describe up-to-date

formulations of each generic type in
terms of their chemical and performance properties. It is intended to
offer guidance about the specifica-

Coming Up in
This Series:

Acrylic Coatings (Water-Borne)

Alkyd Coatings
Cementitious Coatings
Chlorinated Rubber and
Vinyl Coatings
Coal Tar and Asphaltic Coatings
Epoxy ICoatings for Steel
Epoxy IICoatings, Floorings,
and Linings for Concrete
Hybrid Generic Coatings
Phenolic Coatings
Polyester and Vinyl Ester
Coatings
Silicone (High Temperature)
Coatings
Urethane IChemical Cure
Coatings
Urethane IIMoisture Cure
Coatings
Zinc-Rich, Inorganic Coatings
Zinc-Rich, Organic Coatings

generic resin type are subdivided

very distinctly by curing mechanism,
so there are moisture-cure urethanes
and chemical-cure urethanes. Latex
coatings are a generic type in which
the classification is made solely by
curing mechanism. In latex emulsions, the resin is suspended as microscopic particles in water. The

tion and purchase of industrial

maintenance coatings.
The series will be most useful to
specifiers in architectural and engineering firms and to coating consultants. It will be useful as well to facility owners who specify coatings and
to contractors who select coatings. As
an educational tool, the series will be
a good resource for coating manufacturer personnel and others interested in understanding the characteristics and differences among
generic types of coatings.

coating cures by coalescence, which

means that after the coating is applied and the water starts to evaporate, the resin particles come together and eventually fuse. Many
different resins can be used in latex
coatings. Other generic coating
types are classified using systems
designed to indicate even broader
classifications. Inorganic zinc-rich
and organic zinc-rich coatings are
examples. Zinc-rich indicates that
high loadings of zinc dust are part of
the formulation, while the resin
component is only broadly classified
by its general chemistryinorganic
or organic. (Organic resins are based
primarily on carbon in the polymer
backbone; inorganic resins do not
contain carbon.)
This series describes the major
generic types of coatings used to
protect industrial structures. The list
is in no way complete but was selected to represent the most commonly used generic types.
continued

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GENERIC COATING TYPES

Generic Coating Types
Classified by Resin
Oil-Based and Alkyd
Materials in this class are based either on natural fish and plant oils or
on a synthetic resin (alkyd). While
the various resins have a particular
chemical composition (i.e., they all
are organic), the defining common
feature is that these coatings cure by
air oxidation. They can be formulated for use as primers, intermediate
coats, and topcoats.
Oil-based coatings are among the
original materials developed for protection or decoration. Because of a
100-year history of protecting
steel, they are the standard against
which other coatings are compared.
Coating systems based on oils and
alkyds have moderate moisture
vapor transmission rates, which indicate how fast moisture vapor travels
through a coating. As a result,
they have only limited barrier
protection properties, so anti-corrosive pigments are needed in the
primer when these coatings are used
to protect steel. Topcoats should
have good sunlight resistance
and color retention. Oil-based and
alkyd coating systems offer good exterior durability in nonaggressive atmospheres. In addition, they are relatively inexpensive.
Chlorinated Rubber and Vinyl
Chlorinated rubber and vinyl, which
also are organic resins, are grouped
together because they cure by solvent evaporation. Film formation is
essentially by precipitation, which is
solidification of the binder with no
changes to the resin occurring due
to any type of chemical reaction.
True vinyls and chlorinated rubber
coatings, as opposed to modified
versions, must be applied by spray
because of their curing mechanism.
They dry quickly and are easy to
topcoat or repair.
Chlorinated rubber and vinyl coatings have very low moisture vapor

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GENERIC COATING TYPES

transmission rates. They form very
good barrier coats with good chemical resistance. They also perform
well when they are immersed in
water. They have poor solvent and
heat resistance, however. Because
they are solvent-borne, they usually
are high in volatile organic compounds (VOC). Many state and local
regulations limit the VOC content allowed in paint. As a result, it is difficult formulating coatings that are
based on vinyl or chlorinated rubber
resins and that comply with VOC
content limits.
Good gloss retention is possible
with these coatings, so they can be
used as topcoats. Chlorinated rubber
formulations are the material of
choice for coating swimming pools.
Unmodified chlorinated rubber and
vinyl resin do not adhere well to
steel; the resin must be modified to
use these materials as primers.

Epoxy coatings are similar to

epoxy adhesives. They offer excellent adhesion to most substrates and
yield tough, durable films. Epoxies
are known for good resistance to
solvents, water, and chemicals, as
well as resistance to abrasion. However, they are known to break down
on reaction with sunlight in a
process called chalking. This tendency limits their use outdoors to
primers and intermediate coats.
The tough, slick film of an epoxy
coating can be either an advantage
or a disadvantage. It is an advantage
if cleaning or decontaminating the
surface is important but a disadvantage if another coat of material must
be applied, because there may be a
maximum recoat time, a period of
time after which the coating becomes too hard to overcoat.
The most commonly used epoxies
are polyamide-cured and aminecured. Polyamide-cured epoxies

have better water resistance; aminecured epoxies have better chemical

resistance. Other, related curing
agents are used in formulations such
as epoxy mastics. The latest development in epoxy coatings has been
thin film formulations used as sealers for overcoating existing oil-based
and alkyd coating systems.
Some epoxy resins and hardeners
can be used to formulate coatings.
Epoxy resins also can be used to
modify other resin types. In this series, the many modifications of
epoxies have been subdivided into
epoxies for steel and epoxies for
concrete, flooring, and linings. The
common factor for all epoxies is that
they must cure by chemical reaction
through the epoxide group.
Silicone
Silicone resins contain silicon in the
polymer backbone rather than carcontinued

Bituminous
The organic resin in a bituminous
coating is derived totally or in part
from distillation of crude oil or coal.
Bituminous coatings, such as coal tar
and asphaltic materials, are relatively
inexpensive and are known for their
water resistance. They come in 1
colorblack. Bituminous coatings
have been used for waterproofing,
protecting buried structures and lining tanks and other industrial waterholding structures. They have poor
resistance to sunlight, which can
cause them to crack.
Epoxy
The organic resin of epoxy coatings
contains a specific chemical group
known as an epoxide. Epoxy coatings cure by chemical reaction when
a hardener is added to the resin,
usually a nitrogen-containing entity
such as an amine or polyamide.
Epoxy coatings are packaged in 2
containers, one each for the hardener and the resin. They are mixed just
prior to application.
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GENERIC COATING TYPES

bon, which is found in organic
resins. Silicone resins are known for
2 properties: gloss retention and
temperature resistance.
When silicone resins are added to
alkyds, the resulting formulations are
better in color and gloss retention.
This coating, known as a silicone
alkyd, is more properly classified as
an alkyd or a hybrid coating because it cures by air oxidation.
Coatings employing silicone resins
by themselves or in combination
with other organic resins can yield a
range of temperature resistancethe
other main performance property of
silicone. Silicone coatings are one of
few coating types that can be used
to protect high temperature surfaces.

resin is dispersed in water to form a

water emulsion. While latex coatings
can be made with a number of organic resins, acrylics are the major
resin type. They are used as both
protective and architectural coatings
in the form of primers, intermediate
coats, and topcoats.
Water-borne acrylic coatings have
high moisture vapor transmission

rates. In coatings that protect wood

or concrete, where moisture in the
structure must be allowed to pass
through the coating, this is an asset.
But in primers for steel, it is a liability that requires the use of anti-corrosive pigments as compensation.
Water-borne acrylic coatings are
one-component materials that cure
continued

Phenolic
Phenolic coatings are based on phenol-formaldehyde, an inorganic
resin. Pure phenolic resins are cured
by heat and are referred to as baking phenolics. They are known for
their resistance to chemicals, solvents, and water. Phenolic coatings
are high performance materials used
to line vessels, tanks, and containers
exposed to certain chemicals and elevated temperatures. They also resist
boiling water and steam. Phenolformaldehyde can also be reacted
with drying oils to give air-dried, oilbased coatings. In this case, they are
considered to be oil-based coatings.
Polyester and Vinyl Ester
These coatings are based on an organic, unsaturated polyester dissolved in an unsaturated monomer.
They cure by a free radical reaction
initiated by a peroxide catalyst.
These coatings, known for their acid
and chemical resistance, are used
mainly as linings.
Generic Coating Types Classified
by Curing Mechanism
Water-borne Acrylic
Water-borne acrylic, or acrylic latex,
coatings are materials where the
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GENERIC COATING TYPES

by solvent evaporation followed by
coalescence of the resin particles.
These coatings are used to protect
steel in mild or moderate environments. They also are used as
overcoats for oil-based or alkyd
coatings, because they have low
shrinkage when they cure and,
therefore, apply very little stress to
the existing system.

Urethane (Chemical Cure)

Coatings in this generic class use an
isocyanate
functional
group
(N=C=O) to cross link the resin.
Thus, the classification is by type of
chemical bond (related to curing)
and not by resin. In fact, many different resins, such as acrylics, epoxies, polyesters, and vinyls can be
used to formulate urethanes. Chemi-

cally cured urethanes are packaged

in 2 containers and, like other chemically curing materials, have a limited pot life after mixing.
A number of different performance properties can be achieved
with this type of coating, depending
on the resin and the type of
isocyanate-containing molecule
used. In general, chemically cured
urethanes have good water and
chemical resistance. Aliphatic urethanes are known for gloss and
color retention, while aromatic urethanes yellow in sunlight but are
less expensive. Chemically cured
urethanes form a smooth, slick film.
The surface can be easily cleaned or
decontaminated.
Urethane (Moisture Cure)
Coatings in this generic class also
have the isocyanate group
(N=C=O) attached to a polymer.
Upon application, some of the isocyanate reacts with moisture to form
an amine. The amine then reacts
with other isocyanate polymers to
form the film.
Moisture-cured urethanes are
packaged in 1 container. The moisture needed for the curing reaction
comes from the air. These materials
have a limited pot life because moisture in the air will react with the isocyanate in the can.
The reaction with moisture takes
place at a reasonable rate, even at
low temperatures, if there is water in
the air. Moisture-cured urethanes,
therefore, have been used for cold
weather application. They do not
have the color and gloss retention of
aliphatic, chemically cured urethanes. However, they do have
strong performance properties as
coatings for steel.
Cementitious
Coatings in this generic class are
based on inorganic materials, such
as portland cement, that harden on
continued

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GENERIC COATING TYPES

reaction with water. Cementitious
coatings usually consist of a mixture
of cement, aggregate, and water.
They are applied in thick films,
which are measured in inches or
millimeters rather than mils or microns. They have high compressive
strength and other properties similar
to concrete.
Cementitious coatings are known

for their chemical resistance. The

specific chemical resistance depends
on the type of cement and aggregate
used. They are also used for
fireproofing and high temperature
service.
Cementitious coatings are applied
differently than other types of coatings, requiring pneumatic equipment, forms, and sometimes trowels

rather than spray guns, rollers, and

brushes.
Generic Coating Types Classified
by General Description
Inorganic Zinc-Rich
Zinc-rich coatings contain high loadings of metallic zinc dust. Inorganic
zinc-rich coatings are characterized
by the use of a silicate resin. They
cure by heating, application of a
curing solution, evaporation, or reaction with moisture, depending on
the particular type of coating.
Inorganic zinc-rich coatings protect by a galvanic or sacrificial
mechanism, which means the zinc is
consumed to protect a more noble
metal. They are used, therefore, as a
primer or one-coat system to protect
steel from corrosion. They may be
supplied with the zinc dust packaged separately from the binder, or
in 1 container that incorporates the
silicate binder and the zinc dust. Inorganic zinc-rich coatings require
constant agitation during application
to keep the zinc particles suspended
in the liquid vehicle of the coating.
Inorganic zinc-rich primers are unaffected by most organic solvents
but require a topcoat to resist exposure to acids or alkalis. They can
withstand exposure up to approximately 1,000 F (538 C) when used
without a topcoat. Inorganic zincrich primers also are known for their
abrasion resistance. These coatings
are high performance materials that
offer long service life, especially in
marine environments.
Organic Zinc-Rich
Organic zinc-rich coatings have high
loadings of metallic zinc dust in organic binders, which include epoxy
polyamide, urethane, vinyl, chlorinated rubber, silicone, phenoxy, and
other suitable organic resins.
Organic zinc-rich coatings combine the properties of the vehicle
with the abrasion resistance and sacrificial action of the zinc. Compared

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Journal of Protective Coatings & Linings

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GENERIC COATING TYPES

to inorganic zinc-rich coatings, they
tend to have better compatibility
with topcoats, be less tough and
abrasion-resistant, but be more tolerant of variations in surface preparation. Organic zinc-rich coatings also
are high performance materials that
provide a long service life in marine
as well as other environments.

tions. The classifications are general

and broad. Within each generic type
are many variations. For instance,
the generic type epoxy includes different resins and hardeners with a
broad range of specific properties.
Oil-based and alkyd coatings likewise include many different resins of
varying quality. In addition, most
generic types can be subdivided into

narrower, more descriptive classes.

For example, chemically cured urethanes can incorporate many different resins with the resultant film
having different performance properties. Using the example above,
which requires a coating with resistance to sunlight and to chemical
spills, the specifier can choose becontinued

Hybrid
Hybrid coatings are those that combine technologies from other categories. For example, modifying an
oil-based resin with an epoxy resin
produces an epoxy ester. A hybrid
coating has characteristics intermediate between the technologies used.
Thus, an epoxy ester, which has an
epoxy-modified oil resin, has better
chemical resistance and corrosion
protection than an oil-based coating
but not as good as an epoxy coating
that cures by chemical reaction.
Strengths and Limits of
Generic Classification
Classifying by generic type establishes groups of coatings with similar
chemical and performance properties. The person who must select
coatings can, therefore, more readily
sort among the thousands of products available to find the most appropriate one. For instance, when a
coating is to be exposed to splash
and spill of harsh acids in an exterior environment, the specifier of the
coating can exclude alkyds because
of their limited resistance to acids;
additionally, the specifier can exclude epoxies as topcoat candidates
because of their weakness in sunlight. A chemically cured urethane,
on the other hand, with strong resistance to both acids and sunlight, is
an appropriate candidate. The
search is narrowed in this way to
consideration of only those products
classified as chemically cured urethanes.
Generic coating classifications,
while useful, also have their limitaCopyright 1995, Technology Publishing Company

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tween acrylic urethanes, which have
better resistance to sunlight, and
polyester urethanes, which have better acid resistance. The choice between them will depend on which
of the 2 performance properties is
more important.
Another weakness of the generic
type classification system, indeed, of
any coating classification system,
is that it does not give any indication about the quality of the product. There are many constituents,
both major and minor, that are incorporated into a coatings formulation. In fact, formulation has as
much of an influence on performance as does the generic type. Any
classification system indicates only
generalities about the coatings in
each class and assumes that the material is properly formulated. Choice
of a specific product from a manufacturer is best made on the basis of
performance testing.

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Journal of Protective Coatings & Linings

Classification by generic type is

one of the most useful methods of
categorizing coatings. Some generic
types have specific uses, such as resistance to certain exposure environments, or specific strengths, such as
color and gloss retention. Some
generic types have more general
uses, and the user must select the
types of coating based on factors
such as the severity of the exposure
environment, level of surface preparation, and expected life. Compatibility of primers and topcoats is
also often expressed in terms of
generic types.
Referencing coatings by their
generic type usually indicates a use,
special attribute, or level of performance. The articles in this series describe the history, chemistry, properties, and handling of the most
common generic types so a better
understanding can be obtained
about coating materials. JPCL

Copyright 1995, Technology Publishing Company