4 - Coating Fundamentals

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Introduction to Protective Coating

Coating Fundamentals

Prepared by : Tri Wahono


Version : March 2023
Content of Presentation
▪ Principles of coating formation
▪ Generic type
▪ Curing mechanism
▪ Basic coating concepts
▪ Structure of a coating system
▪ Coating components
▪ Type of coatings
▪ Coating properties and characteristics

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Introduction
Technology for paint application is well developed

❑ The cost of application is reasonable


❑ Organic coating are available in a wide range of pigments and vehicle
❑ Many paints can resist to more than one corrosive condition
❑ Paint have good dielectric strength properties (to inhibit galvanic action)

Paint systems like epoxy paints allow adequate protection during 5 to 10 years
depending on the ambient conditions provided that it is properly applied

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Principles of Coating Formation
Coating Film Formation by Solvent Evaporation
Resins that dry by solvent evaporation are all thermoplastic film formers, such as vinyl resins. The quality and
quantity of solvents is critical to homogenous coating films. If the solvent evaporates too fast, the resin tends to dry
before it applies to the structure. If the solvent evaporates too slowly, a slow film formation is caused and the coating
film can remain tacky, making it less resistant to chemical and corrosion attack

Film Formation by Oxidation


A coating film formed by oxidation applies primarily to dry oils, which are placed on the surface of substrates in a thin
film for a certain time period until that they have reacted with oxygen in the air to become dry and hard.

Film Formation by Polymerization


Polymerization usually occurs between a monomer and one or more polymers of different types to produce a resin
film that is cross-linked with a rigid, three-dimensional molecular structure. The coating formed is thermoset. Coatings
formed by this principle are much more resistant to corrosion

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Generic Type
Film-Forming Mechanism (Drying and/or curing)

Solvent Evaporation Chemical Reaction Fusion Coalescence

Non-Convertible Convertible

Vinyl Thermal-Spray Metals Water-based Emulsions


Chlorinated Rubber Zinc, Aluminum, Etc. Latex
Bitumen/Asphalt/Coaltar Thermoplastic Powder (some) water based
(solution or cutbacks) Polyethylene Epoxy
Nitrocellulose

Water Oxygen Carbon Dioxide Co-Reaction Heat

(Multicomponent Coating)

Moisture-Cured Alkyd Epoxy


Water based Silicone
Urethane Epoxy ester Polyurethane
Inorganic Zinc Baked Phenolic
Solvent-bourne Drying Oils Vinyl Ester
Inorganic Zinc Zinc-rich Epoxy
Coal-Tar Epoxy

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Curing Mechanism
❑ Non-convertible Coatings; Evaporation Cure, Coalescence
❑ Convertible Coatings; Oxidation,Co-reaction (polymerization),Hydration, Fusion

Non-convertible drying process Convertible curing, solvent based

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Basic Coating Concepts
Impermeability/barrier
Impermeability is a concept basic to most available anticorrosive coatings. While no coating is totally
impermeable to moisture vapor, an impermeable coating contains no materials that will react with moisture
vapor.
Barrier Coating

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Basic Coating Concepts
Inhibition
The second concept involves an inhibitor, which usually is only in the primer and consists of pigments that
react with the absorbed moisture vapor within the coating. These then react with the steel surface in order
to passivate it and decrease its corrosive characteristics.

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Basic Coating Concepts
Cathodically Protective Pigments/Sacrificial Coating
The concept of cathodic pigments is, in many ways, an extension of the inhibitive primer principle. The
reactions that take place, however, are entirely different. In the case of inorganic zinc (IOZ) primer or an
organic zinc-rich primer, the zinc acts as an anode to the steel, and whenever there is a break in the film,
the sacrificial action of the anode (zinc film) tends to protect the basic steel substrate from corrosion. Many
times, where scratches or damage to an IOZ coating have occurred, the zinc reaction products have
proceeded to fill in the scratch or damaged area and seal it against further atmospheric action.

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Structure of a Coating System
In general, a coating system consists of multiple layers: primarily a coat of primer, an intermediate coat (or body
coat), and a top coat. Each layer is functional for certain purposes to ensure that the whole system maximizes
its protection from corrosion attack to the substrate structure

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Structure of a Coating System
Primer
The primary purposes of a primer are listed as follows:
1. Adhesion (strong bond to substrate)
2. Cohesion (high order of internal strength)
3. Inertness (strong resistance to corrosion and chemicals)
4. Intercoat bond (high bond to intermediate coat)
5. Distension (appropriate flexibility)

Epoxy Zinc and zinc silicate are generally used as a primer


If humidity/water penetrates the paint film:
• Zinc corrode and protect the steel
• The water solubility of the corrosion product, zinc oxide, is very low and the porosity is filled by this product. An
impermeable film is formed.

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Structure of a Coating System
Intermediate Coat (or Body Coat)
The primary purposes of an intermediate coat are to provide:
1. Thickness for total coating;
2. Strong chemical resistance;
3. Resistance to moisture vapor transfer;
4. Increased coating electrical resistance;
5. Strong cohesion; and
6. Strong bond to primer and topcoat.

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Structure of a Coating System
Top Coat
Topcoats also perform several important functions in that they:
1. Provide a resistant seal for the coating system;
2. Form the initial barrier to the environment;
3. Provide resistance to chemicals, water, and weather;
4. Provide a tough and wear-resistant surface; and
5. Provide a pleasing appearance.

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Coating Components

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Coating Components

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Coating Components

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Coating Components
Resin/Binder
The resin gives most of the properties of our paint:
❑ Strength
❑ Adhesion
❑ UV Resistance
❑ Water Resistance
❑ Solvent & Chemical Resistance

…so the paint is named after the resin (e.g. Alkyd, Epoxy)

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Coating Components
A Pigment is a finely ground, natural or synthetic, inorganic or organic, insoluble dispersed particle (powder)
that when disperse in the liquid portion of the paint (vehicle) may provide in additional to color and many of the
essential properties of paint/ coating

These are mixed into the paint to provide :


Colour
❑ Opacity
❑ Anticorrosive Properties
❑ Reduced Permeability
❑ Modified properties e.g. spray & gloss
❑ Reduced costs

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Coating Components
Pigment
❑ Pigments are dispersed as tiny solid particles throughout the paint.
❑ Under microscope they look like this.

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Coating Components
Pigment
Low & High Opacity paints look identical as wet paint in the can.

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Coating Components
Barrier Effect
Paint films looks like this in X section, with pigments dispersed in the film.

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Coating Components
Typical Pigments

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Coating Components
Barrier Pigment

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Coating Components
Extenders
❑ Eg: Talc, Chalk, Barytes
❑ Used to modify properties:
• Viscosity
• Paint flow
• Gloss
❑ Reduce Costs

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Coating Components
Solvents

❑ They serve no purpose once the paint has dried.


❑ Solvent are expensive waste products
❑ They are used only because they reduce viscosity
• To make manufacturing easier
• To make application easier
❑ They also damage the environment

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Coating Components
Additives

Used in small quantities to modify properties such as :


❑ Drying Time
❑ Hold-Up
❑ Settling
❑ Improved pigment dispersion
❑ Improved flow after application

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Type of Coatings
Organic Coating (Painting) : In-organic Coating :
❑ Vinyl Esther Lining ❑ Anodizing
❑ Epoxy Paints ❑ Enamel
❑ Polyurethane paint ❑ Phosphating
❑ Alkyd paint ❑ Nitriding
❑ Chromate filming
❑ Binder/resin
❑ Pigment
Metallic Coating :
❑ Solvent
❑ Additive ❑ Electroplating
❑ Hot dip galvanizing
❑ Thermal spraying

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Coating Properties and Characteristics
❑ Effective electrical insulation
❑ Effective moisture barrier
❑ Good adhesion to pipe steel
❑ Applicable by a method that will not adversely affect pipe properties
❑ Applicable with a minimum of defects
❑ Ability to resist generation and development of holidays over time
❑ Ability to resist damage and deterioration during handling, storage, and installation
❑ Ability to maintain substantially constant resistivity over time
❑ Resistance to disbonding
❑ Resistance to chemical degradation
❑ Ease of repair
❑ Retention of physical characteristics
❑ Nontoxic to environment
❑ Be compatible with CP

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Coating Properties and Characteristics
Corrosion resistance in various environments

Outdoors exposure Alkyds, Amino resin-modif. Alkyds, Acrylics


Marine atmosphere Alkyds, urethanes, Vinyls, Vinyl-Alkyds, Phenolics
Chemical fumes Epoxy, Vinyls, Urethanes
Sunlight Vinyls, Acrylics, Silicone alkyds
High humidity Amino resin-modif.Alkyds, Epoxy, Phenolic
High temperature Epoxies (120C dry), Modified selicones (200C). Silicones (290C), Al-
pigmented paints (650C)
Water immersion Phenolics Vinyls, Urethanes

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Coating Properties and Characteristics
Paint compatibility

Epoxy-amine epoxy amine, coal tar epoxy, epoxy amide, zinc organic, zinc inorganic

Apoxy-amide epoxy amine, coal tar epoxy, epoxy amide, zinc organic, zinc inorganic, urethane aliphatic

Epoxy ester epoxy amine, coal tar epoxy, epoxy amide, zinc organic, zinc inorganic, chlorinated rubber, acrylic,
epoxy ester, vinylic

Acrylic Acrylic, epoxy amine, coal tar epoxy, epoxy amide, zinc organic, zinc inorganic, silicone, chlorinated
rubber, vinylic

Epoxy coal tar epoxy amine, urethane aliphatic, zinc organic, zinc inorganic

Urethane epoxy amine, epoxy coal tar, epoxy amide, zinc organic, zinc inorganic

Silicone Acrylic, epoxy amine, coal tar epoxy, epoxy amide, zinc organic, zinc inorganic, silicone, chlorinated
rubber, vinylic, epoxy ester

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Coating Properties and Characteristics
Cost

Cost against performance


❑ Low cost coating with reduced performance
❑ High labour cost with low cost coating
❑ High labour cost and high cost coating
To be considered
❑ Paint cost
❑ Spreading rate
❑ Paint coverage (m2 of surface / m3 of paint)
❑ Application time
❑ Labour cost
❑ Equipment required for application
❑ Expected service life

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