Environmental Protection

(i)

Binder It is the most important component of paint. The Binder gives the paint most of it properties such as adhesion to the substrate, resistance to weathering, water, chemicals, temperature etc. Binders can be divided into groups (generic types) depending on the drying or curing process which takes place after the paint has been applied to the substrate. The first groups are known as the paint absorbs oxygen from the air and- dries. Example: alkyd paints. 'The next group are called physically drying. When the paint is applied to the substrate, the solvent simply evaporates. Examples: chlorinated rubber and acrylic. The third and final group contains chemically curing paints. These paints are usually two-component, e.g. epoxy.
AN

Solvents Evaporating

Polymer

o = Curing Agent (Hardener)

Polymer and Hardener Molecules Reacted to Form a New Chemical Substance

Figure 6.3: Curing Mechanisms of Binders

Oxidising

Physically drying

Chemically curing

Alkyd

Chlorinated rubber Vinyl Acrylic Asphalt Tar

Epoxy Polyurethane Polyester Silicate

I Binder
Colour pigments
A

Glossy PVC 15-25

Extenders

Semi-Glossy PVC 30-40 Flat PVC 35-50

Figure 6.4: Types of Paints

(ii)

Pigments In a paint, colour pigments give the paint opaqueness, the desired shade etc. Colour pigments, both organic and inorganic, are available in many shades. Titanium dioxide is a strong colouring, white pigment with good opaqueness and is used in white and pale colours. Rust-inhibiting pigments include zinc (cathodic protection) and zinc phosphate (inhibiting protection). Such pigments are used only in primers (first coat).

Paint Technology

(iii)

Extenders or Fillers Such as dolomite, talcum, etc. have little or no opaqueness and are transparent in the binder. They have different forms e.g. balls, needles, fibres, etc. and are used to give a sealed film, the right gloss, etc. In antifouling paints, for example, copper oxide is used as a pigment to prevent fouling of ships' hulls.
Solvents

(iv)

These are added to the paint to adjust the viscosity so the paint can be applied by brush, roller or spray gun. Different binders require special solvents or solvent mixtures to be able to dry or cure in such a way that the paint properties are not damaged. (v) Additives These are a small, but important, parts of the paint. Such substances include antisettling agents (to prevent fouling), thickeners (to prevent sagging/running), antifoaming agents (to prevent air entrapment), etc.

Paint Systems What does a paint system consist of ? Coating systems. may consists of any number of coats and combinations of materials. In most cases, coating systems will consist of 2 to 4 coats. We usually split a coating system into three main parts: Primers (may include shop primer) Intermediate coats (midcoats) Topcoats

Each part of the paint systems has a definite function, although some paints can play a dual role in a paint system. A coating system however, need not to be composed of the three different parts; even a single coat can provide a coating system, depending upon the requirements of the coating. Inorganic zinc coatings, for example, provide an excellent one-coat system for the storage of refined oil products and many solvents. (i) Primers The primer is the first coat of a paint system. The primer is the base on which the rest of the coating system is applied. As a base, it must have strong adhesion to the substrate surface and must forma good basis for the next layer of the coating system. Primers normally provide corrosion protection during the application period and the whole service life of the paint system. The primer is considered to be one of the most important components of the coating system. Most primers for steel contain anti-corrosive pigments such as red lead, zinc powder (zinc dust), zinc chromate, zinc phosphate, calcium phosphate, etc. Due to their toxicity, red lead and zinc chromate are used less frequently nowadays and certainly not in prefabrication (shop-priming) as they will release noxious or toxic fumes during welding and flame-cutting. The primer must also provide a proper and compatible base for the intermediate coat. It must provide a surface that can be thoroughly wetted by the subsequent 9

Environmental Protection

coat. The generally flat, non-glossy surface must also provide some physical adhesion to the next coat. Primers, then have dual requirements; adhesion to the substrate and provision of a surface which will allow proper adhesion of the following coats.

(ii)

Intermediate Coats
In some paint systems intermediate coats are applied between primers and topcoat(s). Intermediate coats, often also called undercoats or body coats, must adhere well to the primer; they are essential for obtaining a sufficient "build" to the paint system. Furthermore, they should have high mechanical strength, good covering power and their colour should preferably be nearly the same as that of the top coat, but sufficiently different to allow the contrast to be obvious when applying the final coat. The colour should be lighter than the topcoat to allow good hiding by the topcoat. Often a white, or nearl y white, intermediate coat is beneficial for the hiding power of the topcoat. The formulation of the intermediate coats is important. Coatings that build up high thickness of the paint per coat are often termed "High Build coatings". The body coat (or intermediate coat) must also provide strong adhesion to the primer, as well as a good base for the topcoats. The intermediate coat must have a surface ideal for good adhesion of the topcoat. Without the ability of this material to properly adhere to the primer and to provide proper adherence to the topcoats, the problem of inter-coat adhesion would cause early coating breakdown.

(iii)

Top Coats
The top coat is the last coat(s) of a paint system, designed to protect the coats beneath from the environment, to contribute to the overall corrosion protection offered by the system and to give the required colour and gloss. The finishing paint or top coat has man y functions. Beside bein g decorative, it should be weather-resistant. The topcoat is the first line of defence against different environments such as: Wind and weather, highl y polluted atmospheres, water and aggressive chemicals. It is the initial barrier of the coating system. This means that the finishing paint also must have several properties: Good colour- and gloss retention, non chalking in bright sunlight and good adhesion under humid conditions. Moreover, the finishing paint may also be required to have good mechanical properties, i.e. resistance against scratching, physical impact and abrasion and resistance to growth. Glossy topcoats are formulated with a low pigment to vehicle ratio. In order to satisfactorily apply a topcoat over a reactive base coat containing Zinc, the topcoats must be highly alkali-resistant. Such topcoats would include vinyls, chlorinated rubbers, epoxies and coal tar epoxies.

6.4 GENERIC PAINT TYPES

It is not possible to develop a "universal" paint which fulfils all possible functions. Paints are therefore developed for different jobs. As a result, each paint has a different set of properties. Paints are often grouped according to the chemical composition of the binder, which we refer to as `generic paint types'. To ensure that you choose the right paint or paint system with the right properties, it is important to know the strengths and weaknesses of the various generic types.

(i)

Alkyd Paints

Alkyd paints are made from alcohol and acid with the addition of fatty acid or oil. The addition of fatty acid and/or oil can be varied to give alkyds with different properties.

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