Section 7
Paint Systems
7 Paint Systems
A paint system is one or more layers of paint, which will give corrosion
protection by one of, or a combination of corrosion protection methods. For
example, a single layer of fusion bonded epoxy or urethane would give
excellent protection employing the barrier principle. A zinc phosphate
pigmented primer would be a passivation system but would need further
protection in the form of a barrier system to protect it. An organic zinc rich
epoxy would provide galvanic protection through bimetallic principles but would
last longer with a barrier system to protect the zinc. Each layer within a system
has a function to perform as follows.
7.1 Primer
A primer will not work as designed anywhere else other than in contact with the
substrate. A primer, normally low volume solid materials, wets out the
substrate and provides excellent adhesion and also provides a key for any
subsequent layer. The binders usually have a relatively low resistance to vapour
transmission and allow water into the film to carry tiny amounts of the rust
inhibitive pigmentation onto the substrate to form a passivating layer. Older
versions of BG specifications required that all primers should be brush applied.
This was to ensure that any dust or detritus left on a substrate was worked into
the film and not left lying where air could be entrapped, forming pinholes.
Other primers exist for non-ferrous substrates such as Wash or Mordant
primers and PVB etch primers.
Mordant means of a corrosive nature, or will bite into and as suggested contains
an acid, phosphoric acid. Their use is limited nowadays, mainly through the EPA
requirements to reduce VOC emissions. These materials contain approximately
96% VOCs in the form of ketones and approximately 4% phosphoric acid, tinted
with copper phosphate (blue). Their primary use was for etching new
galvanising. The reaction turns the surface black (zinc phosphate salts). Some
specifications allowed painting as soon as dry, but others required a water
wash. Etchants do not leave a measurable thickness. PVB etch primers,
Polyvinyl butyrol are principally used on Aluminium, but were used on virtually
every non-ferrous metal. PVBs are two pack materials, low volume solids with a
dry film thickness of 15 to 25μm. This material also contains phosphoric acid.
The acid etches the aluminium (aluminium phosphate) provided a key for the
vinyl binder. The general appearance when dry is a matt yellow translucent
film, with an underlying black or darkened substrate. Some specifications
require coating before 16 hours.
Because of the acid content if is not wise to spray apply these materials without
extraction facilities.
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Mid-coats
Mid-coats are mainly barrier coats. They are applied over the primers to
prevent further water passing into the film and leaching out the inhibitive
pigmentation, without which there would be no passivation. Mid-coats also build
up the film thickness and even out any irregularities. They also provide a key
for any subsequent layer to adhere to. This is done by aggregates and
extenders. Some extender materials have particle sizes of 40μm, if there is a
high concentration of extenders in the coating then many of these large
particles will protrude through the surface, increasing the area available for
adhesion.
Finishing coats
Finishing coats of a system are mainly aesthetic, but also need certain
properties. Colour and appearance are important eg gloss. To have a gloss
finish the surface must be perfectly smooth and this also helps in the removal
of dust and dirt and natural drainage or shedding of water. The storage facilities
of volatile materials need to have solar reflective properties to reduce boil off
and materials needing distillation require heat input and are very often black, to
absorb heat.
Moisture tolerant systems
Pipelines transport many different products at different temperatures and
pressures. Gas is transported in non-insulated pipes, over huge distances
subsea and subterranean. Therefore the gas is cool. Where a pipeline comes
above ground (an AGI, Above Ground Installation) the gas in the pipes is much
cooler than the ambient temperature and condensation forms on the pipes,
posing a problem for repainting and maintenance. Either the gas stream can be
diverted along another route, or special materials can be used, tolerant of the
situation.
The BG National Grid specifications include a clause permitting the latter
alternative, the use of moisture curing polyurethane or a high solid epoxy.
(Section SPA4 in paragraph 10). Three definitions apply when referring to
quantity of water present. Damp, moist and wet (paragraph 10).
Damp and moist conditions will allow the use of the materials specified, but wet
conditions require excess water to be removed.
Single pack moisture curing polyurethanes are materials which use moisture
from the atmosphere to cure, not standing water on the substrate. Surface
preparation as per the specification, then any excess water should be swabbed
off, before brush application of the material. Because the material cures by
using air borne moisture, as soon as the lid is removed from the can the cure
reaction starts. The more moisture there is present in the atmosphere, the
faster the cure. The criteria with this type of material is not high RH, 100% is
no problem, but low humidity. Some manufacturers state 35% as minimum RH
criteria.
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Powder coating materials
As mentioned earlier, powder coatings are solvent free materials, which are
solid at room temperature.
Thermosetting
Thermosetting means the material will cure with the application of heat and
therefore are convertible or non-reversible materials like epoxy and urethane.
With thick steel sections like underground pipes the powders are
electrostatically sprayed onto a preheated substrate, approximately 245°C, as
soon as the powder hits the heated steel, it melts, undergoes a chemical cure
and is fully cross linked in approximately three minutes.
This group of materials is used extensively on subsea and subterranean pipes,
office furniture and kitchen white goods. Thinner plate sections are post heated,
after electrostatic application of powder.
Thermoplastic
Thermoplastic materials soften with the application of heat, are linear polymer
and therefore reversible or non-convertible, polyethylene and polypropylene
being examples. Usually flame sprayed as repair systems on existing
thermoplastic coatings.
Sacrificial coatings
As the name implies, this classification of materials sacrifices itself to protect
the underlying substrate. In order to work the sacrificial component must be
less noble (more electronegative) than the substrate which it is protecting. Zinc
and Aluminium are the most common materials used to protect ferrous
substrates. Zinc and Aluminium have relatively low melting points and so are
commonly used in the form of metal spray, applied by flame onto structural
steel eg bridges, as an added form of protection which purportedly can extend
the major maintenance free life of steel work by as much as 20 years.
Zinc is used in hot dip galvanising of steel, to totally encapsulate a section. In
this situation the zinc works as a barrier coat initially and undergoes
atmospheric corrosion itself forming corrosion products such as zinc sulphates
and zinc carbonates. To stop this natural process on the zinc it is usual to paint
over the galvanising. However, if the galvanising is damaged, exposing the
steel underneath so that both metals are in contact with electrolyte, the zinc
then starts working sacrificially, corroding in preference to the steel, producing
zinc oxides on the damages faces until the damage is filled to exclude
electrolyte contact. The zinc then works as a barrier again.
If the galvanised coating suffers damage of more than a scratch or gouge, a
repair might be a better option. In this instance a zinc rich epoxy might be
used. These materials contain a very high percentage content of zinc pigment.
Specifications vary but 90% by weight of the dry film is a typical requirement.
If moisture, an electrolyte, passes into a film of this nature, each particle of zinc
needs to be in contact with at least one other, in order to form the metallic
circuit through to the steel for the electrons. These electrons, in the form of
hydroxyl ions will then return through the electrolyte to the zinc and the zinc
will corrode, sacrificially. In order to hold the high concentration of zinc particles
together, a very strong binder is required. This is usually an organic epoxy.
Inorganic binders such as ethyl or methyl silicates are zinc pigmented but are
primarily designed for high temperature service and need sealers such as
aluminium or carbon pigmented silicones.
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