High Performance Organic Coatings: Selection, Application and Evaluation

✍ Scribed by A.S. Khanna

• Publisher: Woodhead Publishing Ltd
• Year: 2008
• Tongue: English
• Leaves: 429
• Category: Library

✦ Synopsis

Paint coatings remain the most widely used way of protecting steel structures from corrosion. This important book reviews the range of organic paint coatings and how their performance can be enhanced to provide effective and lasting protection. The book begins by reviewing key factors affecting the success of a coating, including surface preparation, methods of application, selecting an appropriate paint and testing its effectiveness. It also discusses why coatings fail, including how they degrade, and what can be done to prevent these problems. Part two describes the main types of coating and how their performance can be enhanced, including epoxies, polyester, glass flake, fluoropolymer, polysiloxane and waterborne coatings. The final part of the book looks at applications of high-performance organic coatings in such areas as reinforced concrete, pipelines, marine and automotive engineering. With its distinguished editor and international team of contributors, High-performance organic coatings will be a valuable reference for all those concerned with preventing corrosion in steel and other metal structures.

✦ Table of Contents

wp7969_c000.pdf......Page 1
High-performance organic coatings......Page 3
Contents......Page 5
Contributor contact details......Page 13
Introduction......Page 16
Part I: General issues......Page 18
Table of Contents......Page 0
1.2 Primers......Page 19
1.3 Intermediate and top coats......Page 22
1.5 Pigments......Page 23
1.5.1 Color and opacity......Page 24
1.5.4 Enhancing corrosion resistance......Page 25
1.5.5 Functional properties such as heat resistance and fire protection......Page 27
1.7 Alkyds......Page 28
1.8 Epoxies......Page 31
1.9 Coal-tar epoxies......Page 35
1.10 Polyurethane coatings......Page 36
1.12 High-performance coatings......Page 38
1.13 References......Page 42
2.1 Introduction......Page 43
2.2.1 Blast cleaning techniques......Page 44
Pressure blasting......Page 45
Ambient conditions......Page 47
Wet blasting......Page 48
2.2.3 Important characteristics of abrasives......Page 49
2.4 Measuring the impurities on the blasted surface......Page 50
2.6 Hydrojetting (water blasting)......Page 51
2.6.2 Slurry blasting......Page 53
2.7 Summary......Page 54
2.8 References......Page 56
3.2 Application by brush and roller......Page 57
3.3.1 Air spray......Page 58
3.3.3 Airless spray......Page 61
3.3.5 Electrostatic spray......Page 64
3.4 Transfer efficiency......Page 65
3.5 Mixing components......Page 66
Manual mixing......Page 67
Electronic mixing......Page 68
3.7 References......Page 69
4.1 Introduction......Page 70
4.2 Tests carried out prior to application......Page 71
4.2.1 Volume solid......Page 72
4.4.1 Density cup method......Page 73
4.5 Practical coverage calculations......Page 74
4.5.2 Actual losses......Page 75
4.6.1 Ford cup......Page 77
4.6.4 Cone and plate viscometer......Page 78
4.7 Volatile organic components......Page 79
4.8 Pigment volume concentration......Page 80
4.9 Critical PVC (CPVC)......Page 81
4.11.1 Thickness measurements......Page 82
4.11.2 Drying time......Page 83
4.12.5 Dry through......Page 84
4.13.1 Salt spray test......Page 85
4.13.2 Humidity test......Page 87
4.14 Evaluation of physical properties......Page 88
Pull-off adhesion test......Page 89
Falling abrasive method (ASTM D 968)......Page 90
Indentation hardness......Page 91
Pencil hardness tester......Page 92
4.14.6 Gloss......Page 94
4.14.7 Holiday test......Page 95
4.15 Summary......Page 98
4.16 References......Page 99
5.1 Introduction......Page 101
5.3 Key steps in the decision-making process......Page 104
5.4 Coating selection criteria for offshore structures......Page 106
5.8 Application alternatives......Page 107
5.9 Cost of painting......Page 108
5.10 Summary......Page 109
7.1 Introduction: paint damage produced by mechanical action......Page 113
7.2 Mar degradation......Page 115
7.3 Reduction of protection properties due to mechanical damage......Page 117
7.3.2 Abrasive wear......Page 118
7.3.3 Abrasive wear in presence of solution......Page 122
7.3.4 Limitations of test methodology and measurement of the damage......Page 123
7.4 Understanding damage morphology......Page 126
7.5 Conclusions......Page 129
7.6 References......Page 130
Part II: Types of organic coating......Page 133
8.2.1 Structure of epoxy resin......Page 134
8.2.2 Characteristics of epoxy resin......Page 136
8.3 Curing agents......Page 137
Amino resin......Page 138
Polyamine......Page 139
8.4 Epoxy reactive diluents......Page 140
8.5 Corrosion......Page 141
8.6.2 High solids/high build epoxy coating......Page 142
8.6.3 Marine coatings......Page 144
8.6.4 Baking-type epoxy coatings......Page 145
8.7 Solventless epoxy systems......Page 146
8.7.1 Self-leveling epoxy flooring......Page 147
8.7.3 Anti-static epoxy flooring......Page 148
8.7.4 Radiation cure coatings......Page 149
8.9 Summary......Page 151
8.10 Bibliography......Page 153
9.2 Polyester resin......Page 154
9.3 Raw materials and reactions......Page 155
9.3.1 Reaction setup......Page 157
9.4.2 Transesterification......Page 158
9.5 Determination of hydroxyl value and acid value......Page 159
9.6 Backbone modification of polyester resin for high solid coatings......Page 160
9.6.1 Functional branched polyesters for coating application......Page 161
9.7 Polyester-melamine coatings......Page 163
9.7.2 Reaction of polyester with melamine resin......Page 164
9.7.4 Properties of the cured coatings......Page 166
9.8 Polyester-urethane coatings......Page 168
9.8.2 Reaction of polyester polyol with isocyanate......Page 169
9.8.4 Waterborne polyester-urethane coatings......Page 172
9.8.5 Photo- and thermal cure polyester-urethane-acrylate coatings......Page 173
9.8.7 Polyester-urethane-imide coatings......Page 176
9.8.8 Polyurea coatings......Page 177
9.9.2 Polyester-epoxy coatings......Page 178
9.9.3 Polyester-β-hydroxyalkylamide coatings......Page 179
9.9.4 Polyester-amide and polyester-imide coatings......Page 180
9.9.5 Polyester-alkoxysilane hybrid coatings......Page 181
9.11 References......Page 182
10.2 The development of glassflake coatings......Page 190
10.3 Factors affecting the effectiveness of glassflake coatings......Page 192
10.4 Testing the performance of glassflake coatings......Page 197
10.5 Applications of glassflake coatings......Page 199
11.1 Introduction......Page 201
11.2 Corrosion protection of aluminium metal matrix composites......Page 202
11.3 Application of fluoropolymer as corrosion resistant coatings......Page 203
11.4.1 Clear fluoropolymer top coat......Page 204
11.4.2 Pigmented fluoropolymer top coat......Page 209
11.5 Salt spray chamber and adhesion performance tests......Page 210
11.5.1 Adhesion performance tests......Page 211
11.7 References......Page 212
12.1 Introduction: what is a polysiloxane?......Page 214
12.2 Direct method for producing polysiloxanes......Page 215
12.5 Polymerization......Page 216
12.5.2 Interjections......Page 218
12.6 Siloxanes for protective coatings......Page 219
Co-condensation of siloxane–organic resins......Page 220
12.6.2 Coil coatings......Page 223
12.6.3 High heat resistant coatings......Page 225
12.7 Concrete protection......Page 227
12.8 Siloxanes as paint additives......Page 232
12.9.3 Concentration of the products on top of the coating......Page 234
13.2 Alternatives to solventborne coatings......Page 236
13.4 Classification of waterborne coatings......Page 237
13.5.1 Polarity......Page 238
13.5.3 Freezing......Page 239
13.5.5 Surface tension......Page 240
13.6.2 Development of sol-gel derived waterborne coatings......Page 241
13.7.2 Polyester......Page 244
13.7.3 Alkyd......Page 245
13.7.4 Epoxy......Page 247
Cationic polyurethane dispersion......Page 250
Anionic polyurethane dispersion......Page 251
13.7.7 Silicone......Page 252
13.8 Additives in waterborne coatings......Page 254
13.8.2 Surfactants......Page 255
13.8.3 Rheology modifier......Page 257
13.9.1 Film formation by water-soluble polymer......Page 258
13.9.2 Film formation by latex paint......Page 259
13.10 Application methods......Page 260
13.11.1 Corrosion resistance......Page 261
13.11.3 Hydrophobicity......Page 264
13.11.4 UV resistance......Page 265
13.11.5 Solvent resistance......Page 266
13.12.1 Coatings on wood......Page 267
13.12.2 Coatings on glass......Page 269
13.12.4 Coatings on metals......Page 271
13.12.6 Coatings on automobiles......Page 272
13.14 References......Page 274
Part III: Applications for high-performance organic coatings......Page 276
14.2 Deterioration of reinforced concrete......Page 277
14.3 Corrosion of steel reinforcement in concrete......Page 278
14.4 The corrosion process......Page 279
14.5.1 Carbonation/ingress of carbon dioxide......Page 280
14.5.2 Chloride ion effect/ingress of chloride ions......Page 281
14.7 Modification of steel composition......Page 282
14.9 Corrosion inhibitors in concrete......Page 283
14.11 Protective coatings......Page 285
14.12 Concrete coatings......Page 286
14.13 Galvanic coatings......Page 287
14.14.1 Liquid epoxy coatings......Page 289
14.14.2 Fusion bonded epoxy coatings......Page 290
14.15 Modified FBE coatings......Page 291
14.16 Cement polymer composite coatings (CPCC)......Page 292
14.17 References......Page 293
15.2 History and importance of pipelines......Page 295
15.3 Pipelines and corrosion......Page 296
15.4 The need for pipeline coatings......Page 297
15.5 Types of coatings for pipelines......Page 298
15.6 Characteristics of good coatings......Page 299
15.7 Selection of coatings......Page 300
15.8 Coal-tar coatings......Page 302
15.8.1 Advantages of coal-tar coatings......Page 304
15.8.3 Coal-tar coating application......Page 305
15.9 Single-layer fusion bonded epoxy coatings......Page 306
15.9.2 Limitations of fusion bonded epoxy coatings......Page 308
15.9.3 Method of application......Page 309
15.10 Dual-layer FBE coatings......Page 310
15.10.2 Limitations of dual FBE coatings......Page 311
15.11 Three-layer polyethylene/polypropylene coatings......Page 312
15.11.1 Benefits of three-layer PE/PP coatings......Page 314
15.11.3 Application of three-layer PE/PP coatings......Page 315
15.12 Surface preparation and its importance in coating......Page 316
15.12.3 Final cleaning and inspection......Page 317
15.12.6 FBE coating application and cooling for standalone FBE......Page 318
15.12.9 Final inspection......Page 319
15.13 Comparison of various coatings......Page 320
15.14 Coatings and cathodic protection......Page 322
15.16 Future trends......Page 323
15.18 Bibliography......Page 324
16.1 Introduction......Page 325
16.2.1 Introduction......Page 326
16.2.2 Cargo tanks......Page 328
16.2.3 Ballast tanks......Page 329
16.2.5 Decks......Page 330
16.2.6 Superstructure......Page 331
16.2.8 Steam pipes and pipelines......Page 332
16.2.9 Surface preparation......Page 333
Formation of conductive pathways......Page 334
Transport of corrosive species to the metal surface......Page 335
16.3.2 Mechanisms and techniques of corrosion protection......Page 338
16.4.1 Introduction......Page 339
16.4.2 Current and future developments in antifouling......Page 341
Introduction......Page 345
Design for lifetime......Page 346
Assessment of performance......Page 347
Maintenance and repair......Page 352
Assessment of performance......Page 353
16.6 Conclusions and future trends......Page 355
16.7 References......Page 356
17.1 Introduction......Page 360
17.2 Understanding the coil coating process......Page 361
17.2.2 Coating application......Page 362
17.2.3 Curing......Page 363
17.2.4 Quality control......Page 364
17.3 Substrates and paints......Page 365
17.4 Coil coating uses......Page 370
17.5 Future of coil coating......Page 372
17.6 References and further reading......Page 373
18.1 Introduction......Page 376
18.2.1 Industrial wastewater treatment plants......Page 377
18.2.3 Municipal waste treatment plants......Page 378
18.3.1 Corrosion prevention......Page 380
18.4 Protection by coatings......Page 382
18.5 Glassflake-filled coating systems......Page 383
18.6.3 Vinyl esters......Page 387
18.8 Formulation issues......Page 388
18.8.2 Glassflake levels......Page 389
18.9.1 Chemical resistance......Page 390
18.9.3 Bond strength and abrasion resistance......Page 391
18.11 Application of glassflake coating to wastewater treatment plants......Page 392
18.12 Conclusions......Page 393
18.13 References......Page 394
19.1 Introduction: automotive coatings......Page 395
19.2.1 Natural......Page 397
19.2.4 Melamine formaldehyde (MF)......Page 398
19.3.1 Pretreatments of metallic substrate......Page 399
19.3.2 Electrodeposition......Page 400
19.3.5 Clearcoats......Page 401
Formulation of anticorrosion primers......Page 402
19.4.2 Basecoat technology......Page 403
19.4.4 Clearcoat technology......Page 404
19.5 Anti-scratch and anti-mar coatings......Page 405
19.7.1 High solids basecoats......Page 408
19.7.3 Powder based clearcoats......Page 409
19.8.1 Three-coat one-bake system (3-WET)......Page 410
19.9.3 Nanoparticles of cerium oxide......Page 411
19.9.4 Nanosilica......Page 412
19.10 Nanocomposites in surface coatings......Page 413
19.14 Non-chromate corrosion inhibitors......Page 414
19.16 References......Page 415
20.1 Introduction......Page 417
20.2 Conventional systems......Page 418
20.3 Developments in conventional coatings......Page 420
20.4 ‘High-performance’ coatings......Page 421
20.6 Complete surface tolerance......Page 422
20.7 Urethane surface tolerance......Page 424
20.8 Epoxy ‘mastics’......Page 425
20.10 Moisture-cured urethanes (MCUs)......Page 426
20.11 Rust converters......Page 427
20.12 Conclusions......Page 428