technical overview of the protective coatings paint market

Technical Overview of the

Protective Coatings

Paint Market

DC 170206

Content:

1) Photo over-view2) DFT over-view3) Why Paint Steel? Corrosion/Millscale4) Surface Preparation5) Paint types6) Paint Specification parameters including

DFT calibration7) Guides for Specifiers8) EPA9) Typical systems10) Protega products in detail

DFT Overview

Primer/Finish75 - 125um

Immersed, GF, etc.400um

One coat spec200um

Finish40umBlast Primer

25um50um

Structural Steelwork:

Inner flange

Outer flange

Typical PC conditions:

- Airless spray- Graco King pump, 45:1 or 60:1- input pressures of ~80psi, so fluid pressures around 3500psi plus- 13’40o or 15’40o tip typical for most work- DFT’s of twice target usually achieved in webs- steelwork sprayed in unheated shop, often moved outside after 1 to 2 hours in any weather- multi-coat systems only done by certain applicators due to lay-out space

• The Corrosion ProcessAt the Anode (-) : Fe Fe++ + 2e

(Solid metal dissolves into solution)

At the Cathode (+) : 4Fe + 302 + 2H2O = 2Fe2O3H2O

(Dissolved metal reacts to form rust)

Why Paint Structural Steel?

• The Corrosion Process• Millscale

Intact, fresh millscale

Millscale beginning to crack

Advanced millscale detachment

Millscale• Chemically active layer

• WILL detach and form corrosion, in the presence of moisture and oxygen

• If painted over, detachment will be slowed but NOT stopped

• Removal by blast cleaning, followed by protective coating, advised

Hand Cleaning

• The use of hand or power tools such as:

– wire brush– scraper– power wire brush– chipping hammer– grinder/abrasive paper or sander

Hand Cleaning• Cannot remove tight millscale• Not recommended for new steelwork

• Swedish Standard SIS SS 05 59 00 (Edition 3 -1988) (EN ISO 8501-1: 1988) :

– St2 - ‘thorough hand and power tool cleaning’– St3 - ‘very thorough hand and power tool

cleaning’• (see also SSPC - SP2 and SP3)

Standard of Cleanliness

Different rust grades of steel:

A – intact millscale (rare, hard to blast)B – millscale partly weathered (usual)C – millscale all weathered off (sometimes)D – rusted and pitted (common in

maintenance)

Standard of Cleanliness• Usually called ‘Quality (or Standard) of

Blast’

– Swedish Standard SIS SS 05 59 00 (Edition 3 -1988) (EN ISO 8501-1: 1988) :

– Sa1 - ‘light blast cleaning’– Sa2 - ‘thorough blast cleaning’– Sa2½ - ‘very thorough blast cleaning’– Sa3 - ‘blast cleaning to visually cleaned steel’

• See also BS 7079 (Part A1:1989) and American SSPC (Steel Structures Painting Council):

– Sa2½ - ‘near white metal’– Sa3 - ‘white metal’– (Sa2 - ‘commercial blast)’

You will never get a grade D surface to the same Sa2½ as a grade A or B surface.

Surface Profile

• Also called ‘Surface Roughness’

• For any specified standard of blast cleaning, many different profiles are possible

• Depends on the type of abrasive used

Round Shot Angular Grit

Profile required for most paints:

• 50 - 75 microns, slightly angular

• Zinc Silicates: – 75 microns - angular (‘sharp’)

– High thickness, offshore splashzone: – 100 microns - very angular

Water/Hydro Blasting

• Usually for maintenance, not new construction

• Water Blasting (‘Wet blasting’): use of water, mixed with air and abrasive

– Keeps down dust– Reduces spark hazard– Washes steel of salts in corrosion profile– Standards: as dry blasting– Inhibitor may be used to prevent flash rusting– Abrasive gives profile

• Hydro Blasting: use of water alone, at ‘ultra high pressures’

– No abrasive used, no site clean-up required, no dust (also no profile)

– No spark hazard– Washes steel of salts in corrosion profile– Standards: as dry blasting, but informal

‘HB2½’ being used

Basic Components of Paint

• 3 principle components:

• Resin

• Pigment

• Solvent

Common ‘Convertible’ Resins

• Epoxy– epoxy resin+amine/polyamide (base+curing agent)

• Alkyd– alkyd resin+oxygen from air (single pack)

• Polyurethane– isocyanate resin+polyalcohol (base+curing agent)

• Moisture Cured Urethane– isocyanate resin+moisture from air(single pack)

Common ‘Non-convertible’Resins

• Chlorinated Rubber

• Acrylated Rubber

• Vinyl

Resin Properties - Epoxy• “Pro’s”:

– Hard– Chemical/solvent resistant– High film builds/more protection in fewer coats

• “Con’s”:– Two pack– Minimum curing temperature/hardening time– ‘Chalk’ on exterior exposure– Health and Safety - skin sensitisation

Resin Properties - Epoxy• Chalking:

Resin Properties - Epoxy

Keadby Power StationMain Turbine &

Steam Turbine Halls(Bourne Steel)

1 x 175µm ProtegaShield [EPY666] SPF seriesEpoxy Zinc Phosphate

Resin Properties - Alkyd• “Pro’s”:

– Single pack/ease of use– Very fast handling times– Excellent performance in non-aggressive areas– Cost

• “Con’s”:– Chemical/solvent resistance– Long-term cosmetics (10yrs+)

Resin Properties - Alkyd

Exeter Retail Park(Bourne Steel)

1 x ProtegaPrime MPH 800 Series (Alkyd Zinc Phosphate)- Blue

1 x ProtegaLac [ASV] OCF90 (Alkyd Zinc Phosphate)Primer/Finish - White

Resin Properties - Polyurethane

• “Pro’s”:– Excellent long term cosmetic finish– Chemical/solvent resistance

• “Con’s”:– Health and Safety - breathing– Cost

Resin Properties - Polyurethane

Millennium Dome Masts(Watson Steel Structures)

Finish Coat: 1 x ProtegaThane PLV Series - recoatable polyurethane finish

Resin Properties - Epoxy/Acrylic

• “Pro’s”:– Cosmetic finish - used in place of polyurethane– Avoids isocyanate hazard

• “Con’s”:– Lower performance than polyurethane– Slightly less chemical/solvent resistance than

‘pure’ epoxy or polyurethane

Resin Properties - Epoxy/Acrylic

Tom Finney StandPreston North End FC

(Wescol Glosford Structures)

Finish Coat: 1 x ProtegaSeal [EAV] EA80epoxy/acrylic finish

Basic Components of Paint

• 3 principle components:

• Resin

• Pigment

• Solvent

Paint Pigments• Colouring pigments:

– Titanium Dioxide (white)– Iron oxides (brick red and others)

• Fillers and extenders• Anti-corrosive pigments:

– Zinc metal (‘dust’)– Zinc Phosphate– MIO (micaceous iron oxide)

• Coatings often classified by pigment -– “a coat of zinc phosphate ...”

• The Corrosion ProcessAt the Anode (-) : Fe Fe++ + 2e

(Solid metal dissolves into solution)

At the Cathode (+) : 4Fe + 302 + 2H2O = 2Fe2O3H2O

(Dissolved metal reacts to form rust)

GALVANIC / ELECTROCHEMICALSERIES

+ ANODIC END (MORE PRONE TO CORROSION)

MagnesiumZinc

AluminiumStructural Steel

LeadCopper/Brass

TitaniumStainless Steel

- CATHODIC END (LESS PRONE TO CORROSION)

Metallic Zinc

• Provides galvanic protection to steel

• Alkaline metal - will saponify alkyd resins• Carrier resins used: epoxy, silicate, polystyrene

• Forms zinc salts on surface

• Natural colour - grey

“Zinc Rich”

Paint film

“Zinc Rich”

High Bay Warehouse,

Oldham(Wescol Glosford

Structures)

1 x 75µ Temazinc 99UK - zinc rich epoxy

Zinc PhosphatePaint film

Zinc Phosphate

• Totally different from metallic zinc

• Laminar pigment• Protects through barrier

effect/mild chemical interaction• Natural colour - inert (white)

• BS 5493: ‘40% by weight of pigment’

Key Anti-corrosive Pigments

• Metallic Zinc

• Zinc Phosphate

• MIO - micaceous iron oxide

Paint film

Micaceous Iron Oxide

• No chemical action• Protects through intense barrier

effect• Gives good overcoatability• Natural colour - black

• BS 5493: ‘80% by weight of pigment’

DTp item 111: ProtegaShield [EWP155] EMP700 - ZnP epoxy

DTp item 112: ProtegaShield [EWM112] EMM800 - epoxy mio

DTp item 168: ProtegaThane PLV series - PU finish

Hammersmith Bridge

Key Anti-corrosive Pigments

• Metallic Zinc

• Zinc Phosphate

• MIO - micaceous iron oxide

• Glass Flake

Glass Flake

Paint film

Glass Flake

• Very hard/abrasion resistant

• No chemical action

• Protects through intense barrier effect

• Natural colour - clear

Glass Flake

Conoco ‘Caister Murdoch II’

(‘CMS 2’)Barmac, Ardesier

1 x ProtegaBlast EV110 to 15µm (- weldable ZnP epoxy)1 x Temaglas EP 400 Series to 400 - 1000µm(- epoxy glass flake)1 x ProtegaSeal [EAV] EA80 Series - epoxy/acrylic finish

Paint Specification

• Essential parameters to understanding paint specifications:

– Volume Solids

– DFT (dry film thickness)

– ‘Life to first maintenance’

Volume Solids

75% Solvent

Resin+Pigment

55% by volume

45% by volume

Volume solids = 45%

Volume Solids

75% 40% by volumeSolvent

Resin+Pigment 60% by volume

Volume solids = 60%

Paint Specification

– Volume Solids

Wet Film Thickness

100µm

Wet Film Thickness = 100 microns@ 60% solids

Dry Film Thickness

100µm

Dry Film Thickness = 60 microns

Dry Film Thickness

– Specify DFT required

– No need to specify wet film thickness -this will be determined by required DFT and volume solids

Dry Film Thickness– Correct DFT is crucial– Too thin or too thick can both cause

problems - “minimum” DFT’s can be fatal!

– Success of system:– Surface Preparation - 60%– DFT - 25%– Choice of paint type - 15%

Dry Film Thickness -Measurement

– Gauge can be calibrated in two main ways:• ‘nominal’• ‘over-the-peaks’

Smooth steel plate - ‘nominal’ calibration

Nominal: set gauge on smooth steel reference plate (draft CEN standard)

Zerodft

Over-the-peaks: set gauge on blast-cleaned reference plate

Zerodft

– Over-the-peaks ‘loses’ around 20-30 microns on a typical blast profile

– Over-the-peaks DFT’s cause increase in costs and can be highly damaging to coating performance

– All paint manufacturer’s recommended DFT’s are ‘nominal’

– BS 5493, NBS, CIRIA and ISO 12944 recommend ‘nominal’

– New standard ISO/FDIS 2808 – “Paints and Varnishes – Detemination of film thickness” due out ~Feb 2007 says calibrate on smooth steel.

DFT - Advice to Specifiers

Always specify:

“nominal dft’s, measured in accordance with paint manufacturer’s

recommendations”

Paint Specification

– Volume Solids

‘Life to First Maintenance’

• ROUGH estimate of coating lifetime

• Does not mean coating has to be replaced after this period

• Most useful as a relative measure to compare different systems

• ‘Maintenance’ could be simply for decorative reasons

Guides for Specifiers

• BS 5493

• Corus Group (formerly British Steel)

• CIRIA

• ISO 12944

Guides for Specifiers - BS5493

• BS 5493 : 1977 -

• “Code of Practice for protective coating of iron and steel structures against corrosion”

• Defines environments:– Exterior/interior– Inland/coastal– Polluted/non-polluted– Dry/wet– Water immersion– Seawater splashzone/immersed

Specifies PRODUCTS & SYSTEMS:e.g. System SK3:

Epoxy primer KP1A - 70umEpoxy intermediate KP2B – 100umPU Finish FP1C – 100umTotal 270um

10-20 years in ‘Exterior Exposed Polluted Coastal’

• Defines “Typical time to first maintenance”:

– Very long (20 or more)– Long (10 to 20)– Medium (5 to10)– Short (less than 5)

Guides for Specifiers - Corus Group (formerly British Steel)

Guides for Specifiers CIRIA

• CIRIA =

• Construction Industry Research and Information Association

Guides for Specifiers

CIRIA Report 174(pub. March 1997)

Guides for Specifiers - CIRIA

• Excellent review of legislation relevant to paint and general issues

• Deals only with steelwork in ‘normal’environments (not chemical, offshore, immersed)

• Only 5 paint systems given (could be considered as 2 or 3 with variations), all epoxy

Guides for Specifiers ISO 12944 (1998)

• BS 5493 ‘declared obsolescent’

• Began circulating early 1999

• Environment categories (‘C1 - C5’) used in CIRIA and British Steel

ISO 12944 (1998)• C1 – Heated buildings with clean atmospheres, e.g.

offices, shops, schools, hotels (Exterior – n/a)

• C2 – Unheated buildings where condensation may occur, e.g. depots, sports halls (Exterior – low pollution, mainly rural).

• C3 – Production rooms with high humidity and some air pollution, e.g. food-processing plants, laundries, breweries, dairies (Exterior – urban and industrial, mod pollution, coastal low salinity)

• C4 – Chemical plants, swimming pools, coastal shipyards (Exterior –industrial, mod salinity)

• C5-I – Almost permanent condensation, high pollution (Exterior – high humidity, aggressive atmospheres)

• C5-M – as C5-I (Exterior – coastal and offshore, high salinity)

Guides for Specifiers - ISO 12944 (1998)

Defines ‘durability’ as:

Low - 2 to 5 years

Medium - 5 to 15 years

High - >15 years

Guides for Specifiers - ISO 12944 (1998)

Specifies SYSTEMS:

e.g. System S1.34

Epoxy primer(s)Epoxy build coat(s)Polyurethane finish(es)

240um total in 3-5 coatsDurability 5-15 years in C4

Guides for Specifiers - Protega

Protega Specifier Guide:

- paper- web- cd

Specifiers - HIGHWAYS AGENCY- One of the two main specifiers for BRIDGE painting in the UK- lengthy and costly approvals procedure, now through the BBA (British Agrémont Board)- approves PRODUCTS; e.g. Item 115, Item 168- major changes in progress in next few years

Specifiers - HIGHWAYS AGENCYFor new construction:

Metal sprayItem 159 (ES50)Item 111 (EMP700)Item 112 (EMM800)Item 168 (PLV)

Specifiers - HIGHWAYS AGENCYFor maintenance:

Item 115 (ST200)Item 116 (WG500)Item 168 (PLV)

Volume 2 Series NG 1900 Notes for Guidance on the Specifications for Highway Works Protection of Steelwork Against Corrosion

(05/01) APPENDIX 19/1 (SPECIFICATION FOR HIGHWAY WORKS) Sheet No. FORM HA/P1 (NEW WORKS) PAINT SYSTEM SHEET 1. CONTRACT TITLE: A4104 UPTON SEVERN VIADUCT STRUCTURE. NO: B541 UPTON VIADUCT GRID REF: TBA 2. DATE OF ISSUE OF DOCUMENTS TO TENDERERS:

3. ENVIRONMENT AND ACCESSIBILITY: INLAND / READY 26

4. REQUIRED DURABILITY OF SYSTEM MAJOR MAINTENANCE: AFTER 20 YEARS NO MAINTENANCE : UP T2 10YEARS MINOR MAINTENANCE FROM 12 YEARS

5. COLOUR OF FINISH: 18 B 29 (DARK GREEN)

6. PAINT SYSTEM TO BE APPLIED OVER: SHOT BLAST CLEANED TO SWEDISH STANDARD SA 2.5, ENSURE ALL SURFACES ARE DRY AND CLEAN AND FREE FROM CONTAMINATION AS PER DOCUMENTS. 7. DETAILS 1ST COAT 2ND COAT 3RD COAT 4TH COAT Registered Description Item No. and Colour Date Registered Brand Name and Manufacture's Ref. No. Data Sheet No. Where applied How applied Min dry film thickness (mdft) Max local dft (See CI.1914.7) Estimated total volume of paint likely to be used. (litres) 'A' type testing required? (YES/NO) (See C1 1912.3) 'B' type testing required? (YES/NO) (See CI 1912.9)

Zinc Phosphate 2K Epoxy H/B, Q/D Red Oxide 10/01/01 Temasheild EMP 700 111 Shop / Site AS 125µm 150µm

MIO H/B, Q/D Epoxy Undercoat Medium Grey 10/01/01 Temasheild EMM 801 112 Shop / Site AS 125µm 175µm

2 Pack poly Semi Gloss 18 B 29 01/08/98 Temathane PLS 169 Shop / Site AS / B 50µm 75µm

8. STRIPE COAT DESCRIPTION (Including Item No. and colour) Shop: Item 112 Natural Grey 75µm DFT Between 2nd and 3rd Coats Site:

9. PAINT MANUFACTURER'S OFFICIAL STAMP:

10. Mdft (350um) NOTE. The minimum total dry film thickness of the paint system, neglecting primers and sealers under 30 microns, shall be 15% greater (to the nearest 25 microns) than the sum of the mdfts of the individual paint coats.

11. APPROVED BY: DATE 24/05/04

Note to Compiler: (i) The above is Appendix 19/1 Form HA/P1 (New Works) paint System Sheet: a separate form should be provided for each

structure, including CCTV masts and lighting columns if appropriate, with items 1 to 5 completed. Sheets should be numbered for easy identification.

Ammendment - May 2001 A1 SC-(a)

Every contract needs a ‘happy’(HA/P1) form like this, different for new construction and maintenance

Specifiers - NETWORK RAIL

- the other main specifier for BRIDGE painting in the UK- two specification documents known as “RT98”:

- RT/CE/S/039- RT/CE/C/002

- lengthy and costly approvals procedure- approves SYSTEMS; e.g. N1, M24- talking about merging specs with HA?

For new construction (N1):

Metal sprayItem 7.1.1 (ES50)Item 7.1.4 (was EMP702)Item 7.3.1 (PLV or PLS(HS))

For maintenance (M24):

Item 7.1.5 (ST200)Item 7.1.7 (WG500)Item 7.3.1 (PLV or PLS(HS))

EPA - The Environmental Protection Act

• Environmental Protection Act 1990, Part 1

– Wide ranging legislation, not just paint– Details for different areas of activity given in

‘Process Guidance Notes’ (PG’s)– Changing situation - subject to review

• For PC-type paints: ‘PG6/23’

– “Secretary of State’s Guidance -Coating of Metal and Plastics”

– PG6/23(97) (revision at March 1997) gives VOC figures for paints effective 1st April 1998

• VOC = ‘Volatile Organic Compound’

i.e. SOLVENTS

• Restrictions apply to ‘manufacturing processes’ (fixed shop, regular use)

• They do not apply to exterior use (site coats, maintenance painting)

• Small users exempt (less than approximately 200lts/week of paint, or 30tns of steel/week)

• Users have a choice under EPA:– Reduce VOC emissions by vapour

recovery/filtration technology (£££)– Use ‘compliant’ coatings (no cost)

• ‘Compliant’ Coatings:

– contain prescribed levels of VOC’s

• Compliant Coating limits in force from 1st April 1998 (PG6/23-clause 20[d]) [now dead]:

– Blast/etch/wash primers - 780gm/lt– Primer/undercoats - 250gm/lt– Top coats - 420gm/lt– (Heat resisting and intumescent have separate limits)

• Effect of EPA on paints:

– increase of volume solids to technical limits

– many widely used coatings obsolete

EPA - EffectsSolvent

Resin+Pigment

45% solids 60% solids 70% solids

• EPA compliant (shop applied) paint systems:– Epoxy– ‘Corrosion Resistant Finish’– Water Based

• Others (zinc silicate) still available

Compliant Systems - Epoxy

• Readily available

• Meet 250 gm/lt (primer/intermediate) 420gm/lt (finish)

• Minimum 75 microns per coat– 100 microns preferred

• Slightly increased lay-out time in shop

Compliant Systems - Epoxy

ProtegaShield EMP 700 - zinc phosphate epoxy primer*(72% volume solids)

ProtegaShield EMM 800 - epoxy mio intermediate/finish*(72% volume solids)

ProtegaShield ERV(HS) - recoatable epoxy intermediate/finish(70% volume solids)

ProtegaThane PLV - full gloss polyurethane finish

Compliant Systems -‘Corrosion Resistant Finish’

• Readily available

• Meet 420 gm/lt

• ‘Industry standard’ alkyd zinc phosphate included

• Must be single coat to comply with EPA

Compliant Systems –Primer/Finishes

ProtegaShield EPY300 - zinc phosphate epoxy primer/finish(54% volume solids)

ProtegaPrime MPH700 – alkyd zinc phosphate primer/finish(58% volume solids)

ProtegaLac OCF90 – alkyd zinc phosphate GLOSS primer/finish(55% volume solids)

Compliant Systems -‘Corrosion Resistant Finish’

• Lower solids (faster drying) epoxy

• Zinc-rich epoxy

- can also be considered as:

‘Corrosion Resistant Finishes’‘Protective Finishes’‘Primer/Finishes’

VOC Regulations for ‘building’ coatings2004/42/EC

• Former ‘EPA’ solvent regs (‘compliant coatings’) replaced in Oct 2005 with ‘SED’

• Applied to ‘fixed’ installations using ~>200lts per week of paint

• EPA did NOT apply to site work, building maintenance, bridges, etc.

• New regs for ‘buildings’ and vehicle refinishing (Nov 2005)

• Effective 1st Jan 2007, second phase 1st Jan 2010 (vehicle refinish – 2007 only)

• Brings paints used for maintenance into VOC regs for the first time

• CEPE defines a ‘building’ as something with walls and a roof (a bridge would be a ‘structure’)

• ‘The Volatile Organic Compounds in Paints, Varnishes and Vehicle Refinishing Products Regulations 2005’

• One common name in use is: ‘VOC product directive’

• Other reference seen is 2004/42/EC, the European Directive which this product directive is implementing

• Defines 12 categories for building paints:

– a – interior walls (matt)

– b – interior walls (glossy)

– c – exterior wall coatings (masonry, brick, etc.)

• Cont’d:

– d – interior/exterior trim and cladding paints for wood, metal or plastic

– e – interior/exterior trim varnishes and woodstains –transparent or semi-transparent

– f – minimal build woodstains

– g – primers – with sealing or blocking properties

– h – binding primers – to stabilise loose substrates or protect wood

– i – one pack performance coatings – special applications such as:

• For plastics

• Primers for steel, zinc, aluminium

• Anticorrosion finishes

• FLOOR COATINGS

• Anti-graffiti, flame retardant, hygiene

– j – two pack performance coatings – as (i) but 2 pack

– k – multicoloured coatings – multicoloured finishes

– l – decorative effect coatings – treated with tools during drying period

– From Jan 2007 (then Jan 2010), all paints made for the ‘buildings’ market must have less than the defined VOC content

– Paint MADE before Jan 2007 can be sold until 31st

Dec 2007 irrespective

– Cans (made after Jan 07) must also be LABELLED, with:

• VOC limit value and date

• VOC content of product in ready to use form

• 2004/42/11A(j)(500g/l2010)419g/l

Compliant Systems -Water Based

• Available but rarely used for new construction

• Very temperature, humidity and ventilation sensitive (ideal: 15°C, 65%RH, good air movement)

• Ideally needs purpose-built plant

• Steel surface cleanliness crucial (weld flux, oil)

Content:

1) Photo over-view2) DFT over-view3) Why Paint Steel? Corrosion/Millscale4) Surface Preparation5) Paint types6) Paint Specification parameters including

DFT calibration7) Guides for Specifiers8) EPA9) Typical systems10) Protega products in detail

EPA - Typical Systems

Interior - Protective: 75 - 150µm Alkyd ZnP Primer/Finish(Low sheen)

ProtegaPrime MPH700 Series - (low sheen, colour range)

Notes:1) EPA compliant as ‘Corrosion Resistant Finish’ to 420gm/lt 2) Fast-track erection/sheeting programme required3) Slightly slower hardening than non-compliant alkyd ZnP primers4) ‘Industry standard’ for decades

Interior - Protective: 75 - 150µm Alkyd ZnP Primer/Finish(Low sheen)

ProtegaPrime MPH800 - (low sheen, colour range)ProtegaLac ACV90 – (gloss, colour range)

Notes:1) Fast-track erection/sheeting programme required2) ‘Industry standard’ for decades

EPA – Typical SystemsExterior - Cosmetic:‘10 - 20 yrs’

75 - 100µm Epoxy ZnP Primer100 - 150µm Epoxy int’/finish50 - 60µm Polyurethane Finish225-310 µm (Full Gloss - long term)

ProtegaShield EMP700 - (zinc phosphate, recoatable)

ProtegaShield ERV(HS) - (recoatable, colour range)

ProtegaThane PLV - (Full Gloss, recoatable)

Notes:1) Intermediate - mio available but may give topcoat opacity problems2) Similar to: BS 5493 - SG1, SK2, SK3; CIRIA - E1, E2, I5

EPA - Typical Systems Exterior - Protective:‘10 - 20 yrs’

100 - 150µm Epoxy ZnP Primer100 - 120µm Epoxy int’/finish200 - 270 µm (Mid-Sheen - will chalk)

ProtegaShield EMP700 - (ZnP, recoatable, colour range)

ProtegaShield ERV(HS) - (recoatable, colour range)

Notes:1) Topcoat - mio available but not in range of colours2) Similar to: BS 5493 - SD5; CIRIA - I2, I4

Interior - Protective/Cosmetic: 75 - 125µm Epoxy ZnP Primer(Semi-gloss)

ProtegaShield EPY300 - (semi-gloss, red or grey)OR

ProtegaShield SPF – (semi-gloss, colour range primer/finish)

Notes:1) EPA compliant as primer/finish to 420gm/lt 2) Slower drying and slightly more expensive than alkyd, but

overcomes long project time & coastal locations at 125um3) Similar to CIRIA - I2, I4; industry standard for decades

EPA – Typical SystemsEXTERIOR INTERIOR

‘Cos

‘Pr o

ive’

75 - 100µm Epoxy ZnP Primer100 - 150µm Epoxy int’/finish50 - 60µm Polyurethane Finish225-310 µm (Full Gloss - long term)

100 - 150µm Epoxy ZnP Primer100 - 120µm Epoxy int’/finish200 - 270 µm (Semi-gloss - chalking)

75 - 150µm Alkyd ZnP Primer/Finish(matt or gloss)

75 - 125µm Epoxy ZnP Primer/Finish(Semi-gloss)

As above, use higher end dft’s

AcknowledgementsWe are grateful to the following for their permission to use copyright material in this presentation:

• Elcometer Instruments (‘elcometer’ is a registered trademark)

• Hodge Clemco/Wolverhampton Abrasives• Corus Group (formerly British Steel)• Heubach• Glass Flake Ltd• Swedish Standards Institute• a variety of our fabricators, contractors and clients

Product Overview150um

780gm/lt

420gm/lt

250gm/lt

PRODUCT OVERVIEW –

PC-MARKET PRODUCTS

Product Overview

ProtegaPrime

ALKYD PRIMERS

780gm/lt

420gm/lt

250gm/lt

Product Overview

ProtegaPrime

MPH800alkyd zinc phosphate primer

VS %780

420gm/lt

250gm/lt

• non-compliant• fast dry• fast overcoating• typical metal primer• Red, Grey & tint bases• OPUS ZP is now cheaper• KEY PROPERTY: cheaper than compliant MPH700 – xylene basedDFT

Product Overview

ZPalkyd anticorrosive primer

VS %780

420gm/lt

250gm/lt

• good performance at low price• non-compliant• fast dry• fast overcoating• typical metal primer• Red & Grey only at present• KEY PROPERTY: cheaper than MPH800 – white spirit basedDFT

Product Overview

ProtegaPrime

MPH700alkyd zinc phosphate primer

VS %780

420gm/lt

250gm/lt

58%• compliant <420 gm/lt• compliant version of MPH800• typical metal primer• Red, Grey, White & tint bases• KEY PROPERTY: compliant <420

Product Overview

ProtegaPrime

VRPalkyd primer for TF95

VS %780

420gm/lt

250gm/lt

• part of high quality, high gloss system for CV and related markets• primer for TF95 (FD95)• Grey and tint bases• Excellent flow, wet edge and protection• KEY PROPERTY: designed for CV marketDFT

Product Overview

ProtegaLac

ALKYD INTERMEDIATES

& TOPCOATS

780gm/lt

420gm/lt

250gm/lt

Product Overview

ProtegaLac

OCF90mod. alkyd One Coat Finish

VS %780

420gm/lt

250gm/lt

55%• high gloss, 1 coat system• contains zinc phosphate• fast dry• high build• KEY PROPERTY: high gloss

Product Overview

ProtegaLac

C12mod. alkyd primer/finish

VS %780

420gm/lt

250gm/lt

• Eggshell finish, 1 coat system• designed for container market• non-compliant• fast dry• high build• KEY PROPERTY: cheaper than Containergard

Product Overview

ProtegaLac

Containergard®mod. alkyd primer/finish

VS %780

420gm/lt

250gm/lt

• Satin finish, 1 coat system• designed for container market• Compliant <420 gm/lt• fast dry• high build• KEY PROPERTY: compliant

Product Overview

ProtegaLac

OPUS VT90mod. alkyd finish

VS %780

420gm/lt

250gm/lt

• Gloss finish• cheap• designed as topcoat for OPUS ZP• fast dry• base form• KEY PROPERTY: cheap

Product Overview

ProtegaLac

ACV90mod. alkyd gloss finish

VS %780

420gm/lt

250gm/lt

• Gloss finish• very fast dry • base form• KEY PROPERTY: fast dry, full gloss

ProtegaLac

AFVmod. alkyd semi-gloss finish

780gm/lt

420gm/lt

250gm/lt

• Semi-gloss finish• fast dry • base form• KEY PROPERTY: semi-gloss, fast dry

ProtegaLac

ABV90mod. alkyd HB gloss finish

780gm/lt

420gm/lt

250gm/lt

• High build, brush or spray• Gloss finish• fast dry • base form• KEY PROPERTY: brushable, high build

ProtegaLac

PU90urethane alkyd gloss finish

780gm/lt

420gm/lt

250gm/lt

• Conventional alkyd gloss• brushable, white spirit based• Gloss finish• base form• KEY PROPERTY: white spirit based

ProtegaLac

FD95urethane alkyd gloss finish

780gm/lt

420gm/lt

250gm/lt

• High performance CV/ACE market finish• excellent durability, flow, gloss• Compliant <420• base form• to be replaced by TF95, 2nd

generation version• KEY PROPERTY: performanceDFT

ProtegaLac

AM112, 113, 114urethane alkyd MIO

780gm/lt

420gm/lt

250gm/lt

• alkyd MIO• undercoat or topcoat• Compliant <420• silver grey AM113 currently mto• KEY PROPERTY: alkyd MIO

Product Overview

ProtegaShield

EPOXY PRIMERS &

PRIMER/FINISHES

780gm/lt

420gm/lt

250gm/lt

ProtegaShield

EPY300-1EPY372-3

Epoxy zinc phosphate primer & MIO

780gm/lt

420gm/lt

250gm/lt

• EPY300 ‘standard’ epoxy primer (red & grey only)• EPY372 zinc phos/MIO version• Compliant <420 (primer/finish only)• 75um to 125um typical• fast dry• KEY PROPERTY: cheap ‘commodity’ epoxy primer

ProtegaShield

SPF epoxy zinc phosphate primer/finish

780gm/lt

420gm/lt

250gm/lt

• Coloured epoxy ZnP• fast dry, HB, good low temp cure• 75um – 200um range• semi-gloss, will chalk• ready-made and base form• KEY PROPERTY: performance, colours

ProtegaShield

EMP700 compliant epoxy zinc phosphate primer

780gm/lt

420gm/lt

250gm/lt

• compliant <250 as a primer• Highways Agency and RT98• Red & grey only• MIO version – see EMM800• KEY PROPERTY: <250, HA/RT98

ProtegaShield

EPY102 epoxy adhesion coat

780gm/lt

420gm/lt

250gm/lt

• good adhesion to difficult substrates• good adhesion coat for problem floors• white primer/undercoat for galv purlins• white only• KEY PROPERTY: adhesion

ProtegaShield

EV710 epoxy zinc phos blast primer

780gm/lt

420gm/lt

250gm/lt

•Highways Agency and RT98 spec• KEY PROPERTY: spec product

ProtegaShield

ES50 epoxy sealer for metal spray

780gm/lt

420gm/lt

250gm/lt

• Sealer for aluminium and zinc METAL SPRAY• Highways Agency and RT98 spec• KEY PROPERTY: metal spray sealer

ProtegaLine

TPL50epoxy pipe line coating

780gm/lt

420gm/lt

250gm/lt

• Internal liner for pipelines• Approved to Transco spec• MTO only• KEY PROPERTY: Transco spec

Tematar

TFAmodified epoxy

780gm/lt

420gm/lt

250gm/lt

• tar-free epoxy (vs. ECF036, ECT036) • high build for immersion, buried steelwork, abrasion• black only (for colours, use RM40)• mto• KEY PROPERTY: tar freeDFT

Temacoat

RM40modified epoxy

780gm/lt

420gm/lt

250gm/lt

• tar-free epoxy • high build for immersion, buried steelwork, abrasion• colours, use TFA for black only and better immersion• mto• KEY PROPERTY: immersion, abrasion and chemical resistance

Product Overview

ProtegaShield / Coat

EPOXY INTERMEDIATES

& FINISHES

780gm/lt

420gm/lt

250gm/lt

ProtegaCoat

GPLEpoxy finish & floor coating

780gm/lt

420gm/lt

250gm/lt

• chemical resistance• gloss/sheen finish• floor coating or chemically resistant finish • KEY PROPERTY: chemical resistance, floor coating

ProtegaShield

ERV(HS)Compliant epoxy int. or finish

780gm/lt

420gm/lt

250gm/lt

• compliant <250 gm/lt• intermediate build coat or finish• RT98 • KEY PROPERTY: high build, high solids

ProtegaShield

EMM800compliant epoxy MIO

780gm/lt

420gm/lt

250gm/lt

• compliant <250 as a primer• Highways Agency• primer – see EMP700• KEY PROPERTY: compliant

Product Overview

ProtegaBond

SURFACE TOLERANT

EPOXIES

780gm/lt

420gm/lt

250gm/lt

SURFACE TOLERANT EPOXIES:

• Developed in late 1970’s as “answer to all prayers”• first high performance coating for hand prepared steel• very high build by brush, also sprayable• tolerant of hand prepared surfaces and old conventional coatings• based on LIQUID EPOXY resins, stay TACKY until cured• can convert aged alkyd systems to high performance epoxy/PU system• heat resistant up to 150oC (used under pipe insulation)

ProtegaBond

ST200surface tolerant epoxy aluminium primer

780gm/lt

420gm/lt

250gm/lt

• dull silvery, will yellow• very high solids• HA & RT98• “when in doubt, use ST200”• KEY PROPERTY: surface tolerant

ProtegaBond

WG200surface tolerant epoxy aluminium primer

780gm/lt

420gm/lt

250gm/lt

• lower temp curing version of ST200 (“winter grade”) • NOT HA approved• dull silvery, will yellow• very high solids• KEY PROPERTY: lower temp curing

ProtegaBond

WG500surface tolerant epoxy int. or finish

780gm/lt

420gm/lt

250gm/lt

• coloured intermediate or finish • lower temp curing version (“winter grade”)• very high solids• HA and RT98• KEY PROPERTY: coloured

Product Overview

ProtegaSeal

TWO PACK NON-

ISOCYANATE

780gm/lt

420gm/lt

250gm/lt

ProtegaSeal

EA80isocyanate-free gloss finish

780gm/lt

420gm/lt

250gm/lt

• alternative to PU finish • RT98 (HA does not use epoxy acrylic)• (see also Temacryl EA50)• KEY PROPERTY: isocyanate free finish

Product Overview

ProtegaThane

TWO PACK POLYURETHANE

FINISHES

780gm/lt

420gm/lt

250gm/lt

ProtegaThane

PLVrecoatable PU gloss finish

780gm/lt

420gm/lt

250gm/lt

• HA and RT98• standard PU finish• clear – special mto PLV001• KEY PROPERTY: PU finish gloss

ProtegaThane

PLS(HS)recoatable PU semi-gloss finish

780gm/lt

420gm/lt

250gm/lt

• HA and RT98• standard semi-gloss PU finish• high build• KEY PROPERTY: semi-gloss

ProtegaThane

PDVPU gloss finish

780gm/lt

420gm/lt

250gm/lt

• anti-graffiti • RT98• not recoatable without abrading• KEY PROPERTY: resistant

Product Overview

ProtegaBlast

FAST DRY HOLDING & ETCH

PRIMERS

780gm/lt

420gm/lt

250gm/lt

WELDING APPROVALS:

1) HEALTH: NEIHA (North of England Industrial Health Authority) – looks at possible toxicity of fumes from welding through paint

2) WELD INTEGRITY: (Lloyds, DNV Det Norsk Veritas) – looks at whether paint affects structure/strength of the weld

ProtegaBlast

EV110zinc phosphate epoxy blast primer

780gm/lt

420gm/lt

250gm/lt

• standard epoxy zinc phosphate blast primer • Lloyds welding approval• low flash, very fast dry (5 mins)• KEY PROPERTY: very fast dry

ProtegaBlast

ET335pvb/phenolic blast primer

780gm/lt

420gm/lt

250gm/lt

• single pack• low flash, very fast dry (5 mins)• KEY PROPERTY: very fast dry, single pack

ProtegaBlast

ET352pvb/phenolic blast primer

780gm/lt

420gm/lt

250gm/lt

• high flash version of ET335• flash point >22oC• KEY PROPERTY: high flash >22oC

ProtegaPrime

MPH465mordant solution for galv

780gm/lt

420gm/lt

250gm/lt

• “T-wash”• etches fresh galv to a mottled grey• KEY PROPERTY: acid etch

ProtegaPrime

MPH4572p zinc chromate etch primer

780gm/lt

420gm/lt

250gm/lt

• pvb adhesion promoter• galv, aluminium, etc.• 5 – 10um dft• KEY PROPERTY: pvb etch

ProtegaBlast

ET330-Wwater borne blast primer

780gm/lt

420gm/lt

250gm/lt

• water borne option for ET335• single pack• very low VOC’s• red & grey• suitable for automatic spray• KEY PROPERTY: low VOC

Product Overview

ProtegaZinc

ZINC PRIMERS

780gm/lt

420gm/lt

250gm/lt

Note: “Zinc-rich”:

• previously meant >90% zinc by wt of dry film (BS4653 Type 3 and BS5493)

• last few years has meant >80% zinc by wt in dry film in line with ISO 12944

Temazinc

99UKzinc rich epoxy primer

780gm/lt

420gm/lt

250gm/lt

• conforms to ISO 12944 zinc levels• ‘standard’ zinc primer• KEY PROPERTY: zinc epoxy

Temasil

90zinc silicate primer

780gm/lt

420gm/lt

250gm/lt

• ethyl silicate zinc rich primer• mainly offshore related• high temp up to 480oC• KEY PROPERTY: zinc silicate

Temazinc

EEsingle pack zinc primer

780gm/lt

420gm/lt

250gm/lt

• single pack zinc primer• high solids• used for touch-up of zinc primers• KEY PROPERTY: one pack zinc

Product Overview

Protega

PHYSICALLY DRYING SINGLE PACK COATINGS

780gm/lt

420gm/lt

250gm/lt

ProtegaChlor

HBVchlor rubber high build

780gm/lt

420gm/lt

250gm/lt

• intermediate or finish• single pack• chem resistant (not solvent resistant)• KEY PROPERTY: chlor rubber

Product Overview

ProtegaTar

BITUMINOUS & TAR BASED COATINGS

780gm/lt

420gm/lt

250gm/lt

Note:‘pitch’, ‘coal tar’, ‘bitumen’, ‘tar’

all tend to be used interchangeably, and are often classed as simply “bituminous”.

ProtegaTar

BTB136single pack bituminous coating

780gm/lt

420gm/lt

250gm/lt

• high build: 100 – 300um per ct• single pack bituminous for site use• RT98 approved for bridge undersides• KEY PROPERTY: single pack bituminous

ProtegaTar

ECT036coal tar epoxy

780gm/lt

420gm/lt

250gm/lt

• traditionally used for immersed and buried structures, pipelines, jetty legs, etc.• high build (up to 400um, lower dft preferred)• tar increasingly avoided for H&S• KEY PROPERTY: coal tar epoxyDFT

ProtegaTar

ECF036isocyanate coal tar epoxy

780gm/lt

420gm/lt

250gm/lt

• faster drying version of CTE for tidal areas, lower temps, etc.• high build 1 coat system (up to 500um, 1 x 400um typical)• tar increasingly avoided for H&S• KEY PROPERTY: isocyanate coal tarDFT

Product Overview

ProtegaLac

HEAT RESISTING COATINGS

780gm/lt

420gm/lt

250gm/lt

ProtegaLac

HRA150bright aluminium finish

780gm/lt

420gm/lt

250gm/lt

• heat resistant to 150oC• used as general purpose bright aluminium finish• does not require heat to cure• KEY PROPERTY: aluminium finish

Product Overview

ProtegaClad

CLADDING MAINTENANCE

COATINGS

780gm/lt

420gm/lt

250gm/lt

ProtegaClene

‘C’biodegradable degreasing agent

780gm/lt

420gm/lt

250gm/lt

• use concentrated or diluted• general purpose degreaser/cleaner• specified as part of ProtegaClad systems• KEY PROPERTY: cleaner

ProtegaClad

GCS-Wepoxy sealer/barrier coat

780gm/lt

420gm/lt

250gm/lt

• water borne• part of ProtegaClad system• primer/sealer/barrier/adhesion coat for ‘difficult’ surfaces - bitumen, graffiti, porous surfaces (e.g. plaster), non-porous surfaces (e.g. ceramic tiles)• KEY PROPERTY: sealer/barrier for difficult surfaces

ProtegaClad

Bonding Coatepoxy primer/bonding coat

780gm/lt

420gm/lt

250gm/lt

• primer for ProtegaClad system (where required)• KEY PROPERTY: ProtegaClad primer• PHASING OUT IN 2007

ProtegaClad

50high performance cladding topcoat

780gm/lt

420gm/lt

250gm/lt

• 2 pack PU semi-gloss topcoat• specially formulated for cladding• may or may not need a primer• KEY PROPERTY: cladding topcoat

ProtegaClad

M50metallic cladding topcoat

780gm/lt

420gm/lt

250gm/lt

• metallic version of ProtegaClad 50• RAL9006 ex stock, others mto• KEY PROPERTY: metallic cladding topcoat• PHASING OUT IN 2007

ProtegaClad

LJFCladding Lap Joint Filler

780gm/lt

420gm/lt

250gm/lt

• gunnable filler for joints in cladding• overcoatable with CEP• KEY PROPERTY: cladding joint filler

ProtegaClad

CEPCladding Cut Edge Protection

780gm/lt

420gm/lt

250gm/lt

• elastomeric narrow gap filler and primer/finish for cladding (larger gaps – use LJF)• overcoatable with ProtegaClad 50 for colour blending/dirt shedding• KEY PROPERTY: cladding elastomeric sealer

ProtegaClad

PVone pack cladding topcoat

780gm/lt

420gm/lt

250gm/lt

• cheap cladding coating• low build, high solvent• far inferior to ProtegaClad 50• KEY PROPERTY: economic cladding topcoat• PHASING OUT IN 2007

Product Overview

ProtegaClad

INTUMESCENT COATINGS

780gm/lt

420gm/lt

250gm/lt

ProtegaFire

S168intumescent coating for steel

780gm/lt

420gm/lt

250gm/lt

• water borne fire resistance coating for steelwork• 30, 60, 90 mins for beams & columns• KEY PROPERTY: intumescent

ProtegaFire

S167intumescent coating for steel

780gm/lt

420gm/lt

250gm/lt

• water borne fire resistance coating for steelwork• 30, 60, 90 mins for hollow sections• covers areas S168 cannot• KEY PROPERTY: intumescent –hollow sections

Product Overview

ProtegaFloor

FLOOR COATINGS

780gm/lt

420gm/lt

250gm/lt

FC50single pack floor paint

780gm/lt

420gm/lt

250gm/lt

• economic floor coating• urethane alkyd• fast drying (3* to 16 h)• red & grey• KEY PROPERTY: cheap floor paint

ProtegaFloor

EEFsingle pack floor paint

780gm/lt

420gm/lt

250gm/lt

• conventional coating• epoxy ester• red & grey, tint bases• OPUS FC50 cheaper but not in base form (yet)• KEY PROPERTY: floor paint

ProtegaCoat

GPLEpoxy finish & floor coating

780gm/lt

420gm/lt

250gm/lt

• chemical resistance• gloss/sheen finish• floor coating or chemically resistant finish • KEY PROPERTY: chemical resistance, floor coating

ProtegaCoat

WBH-Wwater borne epoxy

780gm/lt

420gm/lt

250gm/lt

• epoxy floor coating• general purpose epoxy intermediate or topcoat• low odour, low VOC’s• red & grey• KEY PROPERTY: water borne epoxyDFT

Temafloor

210solvent free epoxy

780gm/lt

420gm/lt

250gm/lt

• floor primer/sealer• clear• used as standard in UK for years• can be used as clear screed topcoat• Temafloor 400 cheaper and may replace• KEY PROPERTY: solvent free epoxy sealer for floorsDFT

Temafloor

400solvent free epoxy

780gm/lt

420gm/lt

250gm/lt

• same as Temafloor 210 but ~20% cheaper• slightly less tough and less chem’resistant than 210, but in practice probably no difference• KEY PROPERTY: cheaper than 210

Temafloor

P300solvent free epoxy

780gm/lt

420gm/lt

250gm/lt

• high build ~300um dft• for heavy wear and chemical resistance• concrete needs blasting or similar and priming with 210/400• mix with filler to make self-leveller Temafloor 3000 (2-3mm)• KEY PROPERTY: hard wearingDFT

Temafloor

3000self levelling epoxy

780gm/lt

420gm/lt

250gm/lt

• made by mixing Temafloor P300 with ProtegaFloor 2000 filler (sand)• 2 to 3mm typical dft• very heavy wear and chemical spillage areas• KEY PROPERTY: very hard wearing

ProtegaFloor

AGGREGATES780

420gm/lt

250gm/lt

• No1 – fine/medium bauxite, anti-slip• No2 – coarse bauxite, anti-slip• 2000 – mix with 210/400 to make ‘filled primer’ or with P300 to make self-leveller• KEY PROPERTY: aggregates

technical overview of the protective coatings paint market

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