High-Performance Protection Coating Selection for Interior and

Exterior Architectural Applications

AIA Wyoming Fall Conference

Learning Objectives

After viewing this presentation, participants will be able to:

• Identify the coating environments applicable for architectural applications

• Understand what generic coating type should be used for a particular environment

• Identify what generic coating type should be used for interior and/or exterior applications

• Understand a complete coating system includes a primer, intermediate and topcoat

• Identify where floor coatings can fit into a particular project scope

• Understand what coatings may be used on environmentally focused projects

Our Core Markets

• Water Storage Tank Market

• Water and Wastewater Market

• Specialty Architectural Market

• Processing & Manufacturing Market

• Industrial Market

Water Tank

WWTP Civic Building Manufacturing Plant Fuel Storage Tank

PROTECTION Choosing the appropriate covering for your project

Substrate Covering Options

Paint Systems

(Aesthetic appeal) Coating Systems (Protection)

Interior office spaces Exterior uses (color and gloss retention)

Low-traffic areas Areas subject to abuse

Traditional painted items Corrosion prevention

Aesthetic purpose Aesthetic value with long-term substrate

protection

Frequent repaints due to

color trends Life cycle cost value

COATING ENVIRONMENTS Applicable for Architectural Applications

High Rise – CA

Natatorium - MA

Gateway - CA

Protection For…

• Steel

• Aluminum

• Cast Iron

• Galvanized

• Non-Ferrous Metal

• Wood

• Concrete

• Masonry

• Stucco

High Rise Buildings

High Rise Building - Chicago, IL

• Corrosion protection

• Color and gloss performance

• Overcoating of aged panels (refurbishment) or new construction

• Life Cycle Savings

Sports & Recreation Facilities

Stadium - Atlanta, GA

• Color and gloss retention for exterior substrates

• Brand or logo color performance

• Durable floor and wall systems

• Water repellents

War Memorial Stadium

Processing & Manufacturing

Printing Facility – Kansas City, MO

• Structural steel

• Tanks

• Interior floors and walls

• Equipment

Healthcare Facilities

Medical Center - Bailey, OK

• Operating rooms

• Clean rooms

• Ceilings

• Abrasion resistant, floor and wall systems

• Non-staining

• Frequent cleaning

Educational Facilities

School District - Marion County, FL

• Steel, masonry and concrete protection

• Interior floors and

walls

• Roof coatings

• Graffiti protection

Correctional Facilities

County Jail - Hamilton, OH

• High abuse wall and floor systems

• Interior and exterior steel & masonry

• Kitchen

• Shower areas

Transportation

Airport - Indianapolis, IN

• High performance protection from UV and freeze/thaw cycling

• Interior and exterior steel & masonry

• Chemical resistance

DIA Canopy 2001

No Corrosion, No color/gloss loss

Natatoriums

Fieldhouse - Columbia, MO

• Overhead deck and

truss/joint protection

• Walls and floors in chemical environments

• Pool coatings

Properly Prepared and Primed Vulcraft

Pool OH

Parking Garages

Parking Garage -

Milwaukee, WI

• Light reflectant ceiling coatings

• Structural steel and concrete protection

• Water Repellents for chloride protection

Auraria Parking Garage, Original 2006

- still looking great

Local Coating Failures

DU Parking Garage – Original 2005

Faded Color

Union Station Canopy

Galvanized metal failure

RTD Dry Creek Ped Bridge

Same application time – two different

Manufacturers

COATING SELECTION Specifying the right coatings for your project

Volatile Solvents

Resin (Binder)

Pigment

SOLIDS

VEHICLE

Costs of Paints & Coatings • Resins: The framework on

which the coating’s

performance is built – Most

expensive part - FLORINE

• Pigments: Color, hide & anti-

corrosion Next Most

Expensive – Quality

important

• Solvents: Workability and

wetting

PERFORMANCE = HIGH QUALITY RESINS & PIGMENTS + HIGH

QUALITY SOLIDS CONTENT.

$230,625

$140,625

$96,000

$77,625

$71,250

20-Year Life-Cycle Cost of 30,000 sq.ft. (Based on acceptable aesthetics of topcoat only)

Alkyd

Acrylic

Polyurethane

Polysiloxane

Fluoropolymer

20 years

3-4 yrs. 3-4 yrs. 3-4 yrs. 3-4 yrs. 3-4 yrs.

4-6 yrs. 4-6 yrs. 4-6 yrs.

7-10 yrs. 7-10 yrs.

10-15 yrs.

15-20 yrs.

Polymer Type Applications Finish App. Cost

How Primers Protect Steel

Protective coatings and primers provide economical

protection to steel in two basic ways:

• A PHYSICAL BARRIER –

• Several coats of Epoxy

• SACRIFICIAL METALS –

• Zinc Rich primers offer galvanic protection as

sacrificial metals

Types of Primers

• Alkyd

• Acrylic

• Epoxy

• Urethane

• Zinc-Rich

Zinc-rich primer being applied in shop

Levels of Corrosion Protection

Unprimed

32 hrs.

Alkyd

500 hrs.

Epoxy

4,000 hrs.

Zinc-Rich Urethane

10,000 hrs.

Testing Standard: Salt Fog (ASTM B 117)

GENERAL PRIMER CONSIDERATIONS

• PART OF COATING SYSTEM

• SAME MANUFACTURER AS TOPCOATS

• USUALLY MUST BE TOPCOATED FOR DURABILITY

• BINDING TOPCOATS TO SUBSTRATE

• Div 5 – 05120, 05500 Spec sections must call out prep

and primer type – depending upon exposure

• Example: Interior Exposed versus Exterior Exposed

FAILURES?

• POOR SUBSTRATE PREPARATION

• IMPROPER APPLICATION

• WRONG MATERIAL – OFTEN DUE TO DIV 5 PRIMER

WAS WRONG MATERIAL FOR EXPOSURE

Alkyd & Acrylic Primers

• Application ease

• One-component

• Designed for shop and field applications

• Provide basic corrosion protection

• Suitable for steel fabricators, OEM’s

and field applications.

Often for INTERIOR EXPOSURES

Epoxy Primers

• Two-component, chemical cross-

linking

• Provide barrier protection

• Steel protection in field and during

erection

• Allows for high-performance

topcoat application

• Chemical-resistant

• Often used as primer or mid-coat

in shop-applied systems for

EXTERIOR EXPOSURE

Westat, Inc. – Rockville, MD

Galvanic Protection

• Primers are used to provide protection for a substrate

• Zinc-Rich Primers offer galvanic protection. GREAT

substitute for HDG when cost or size prohibited.

– The coating will sacrifice itself before allowing the steel

to corrode

– Used as part of a complete protective coating system

Extended Protection with Zinc Testing Standard: Salt Fog (ASTM B 117)

Test Method Salt Fog (ASTM B 117)

System 3 mils Moisture Cured, Organic

Zinc-Rich Urethane

Test Duration 30,000 hours

Report Measuring of corrosion on the

plane and at the scribe

• Results after 8,000 hrs

• Same barrier protection

provided by epoxy

• Different protection

provided by primer

Testing Standard: Salt Fog (ASTM B 117)

Extended Protection with Zinc

Epoxy (3 cts) Zinc-Rich Primer (1 ct)

Epoxy (2 cts)

Intermediate/Topcoat Protection

Performance and life expectation can vary significantly

based on topcoat selection.

• Alkyds

• Acrylics

• Epoxies

• Polyurethanes/Polyurethane Hybrids

• Fluoropolymers

Alkyds

• One component

• Easy application

• Provide basic UV protection

• Basic color and gloss retention

• Aged technology that requires frequent touch-ups, done by maintenance personnel

University - Georgetown, MD

Acrylics

• One component

• Easy application

• Provides basic UV protection

• Basic color and gloss retention

• Advanced technologies can

provide dry-fall and hydrophobic

characteristics

Airport, Concourse B - Boise, ID

Acrylic Finish – Laramie Ped Bridge

Epoxies

• Two-component, chemical cross-linking

• Excellent adhesion to the substrate

• Chemical and abrasion resistant

• Barrier protection from corrosion

• Epoxies should be top coated when

subjected to UV exposure

Gateway - Los Angeles, CA

Polyurethane/Polyurethane Hybrids

• Two-component, chemical cross-linking

• Superior color and gloss retention

• Topcoat over epoxies

• Resistance to abrasion

• Provides long-tern protection from

exterior weathering

TABLE MESA BRIDGE

BOULDER CO

Fluoropolymers

• “Gold” standard in protection against UV and weathering

• Provide exceptional color & gloss performance

• Air-dried version can be shop or field applied

• Alternative to a clearcoat system

• Many colors contain energy saving infrared reflective pigments

• Extended life cycle similar to factory applied fluoropolymer coil coatings

Aquarium - Baltimore, MD

Water Tank Exteriors

• Swan Ranch EWT

• 2012 with Hydroflon

finish by TNEMEC

Extreme Weathering Tank - Kauai, HI

Color and Gloss after 13 years

• Painted in 2000

• Only 1.05 Delta E (FMC II) color difference after 13 years of moist tropical

salty air and hot tropical sun! AMAZING!!!!

ZCMI Façade

City Creek Skylights

Aesthetic Performance

Fluoropolymer

Polyurethane

10,000 hrs.

QUV-A Exposure

Test Method: QUV (ASTM D 4587)

INTERIOR COATING SYSTEMS Specifying the right coatings for your projects

Interior Coating Systems

• Carbon Steel

• Concrete and Masonry

• Galvanized Steel

Natatorium - Chattanooga, TN

Dept. Store - Omaha, NE

Galvanized Steel

• Overhead decking

• Conduit and ducting

• Interior/exterior UV

• Passivated/Non-Passivated Steel

Fitness Center - Walla Walla, WA

Coating System (generic)

Primer/Finish Self-Crosslinking Hydrophobic

Acrylic Dry-Fall

Typical System May Include:

CU Boulder Hockey Rink OH

EXTERIOR COATING SYSTEMS Specifying the right coatings for your projects

Exterior Coating Systems

• Ferrous metal

• Non-ferrous metal

• Concrete & masonry

Stadium - State College, PA

Manufacturing - St. Peters, MO

Bridges

Pedestrian Bridge – Contra Costa County, CA

JHR Tram Building 2008

Exposed Steel Structures

ADAMS STATE COLLEGE

Lincoln Park Stadium, Grand Junction

Colorado

Series 626 Dur A Pell

GS

RTV Silicone Rubber

Series 680 Mark A Way

Dual Purpose Water

Repellent and Graffiti System

Product/Technology

Types of Anti-Graffiti

– Sacrificial

• A portion of or all of the protective coating is

removed during the cleaning of unwanted

graffiti.

• Does not crosslink chemically with the

substrate

• Can degrade do to weathering

• Must be reapplied after clean down, leaving

substrate unprotected while substrate dries

– Remember, speed of removal

Product/Technology

Types of Anti-Graffiti (cont.)

– Non Sacrificial

• Protective Coating remains after graffiti has been

cleaned

– Coating may chemically bond to the substrate

– Coating may mechanically bond to the

substrate

– No exposure after clean down

– May minimize MVT

– May substantially alter the look of substrate

Product/Technology

Definitions:

– Anti-Graffiti

• Clear or opaque coating formulated to deter

adhesion of graffiti and resist repeated

scrubbing and exposure to solvents, cleaners

or scouring agents used to remove graffiti

– Water Repellent

• Retards & reduces water intrusion

• Used in areas of intermittent hydrostatic

pressure

Before Tagging

Tagged Block

Cleaning Process

After Cleaning

Floor and Wall Coatings

• Offer durability, cleanability and seamless protection

• Easy application

• Stand up to impact, abrasion, aggressive cleaning, thermal shock and chemical exposure

WALL COATINGS Intended Uses and Types

AREA WITHIN FACILITIES

• Kitchens/food preparation

• Locker rooms and showers

• Laboratories

• Hygienically controlled rooms

• Restroom/wash rooms

• Coolers/freezers

• Battery charging area

• Anywhere concrete is exposed to physical and/or

chemical attack.

Spec-Finish®

Coated Concrete Masonry Wall Systems

SPEC FINISH BLOCK

Uncoated Standard CMU Wall

Coated Spec-Finish CMU

Pinhole free surface

Level I – Standard Block Finish

Prime Coat

Waterborne Filler

Intermediate Coat

Modified Polyamide Epoxy

Finish Coat

Aliphatic Polyurethane

Application: Roller-Applied

Level II – Orange Peel Block Finish

Prime Coat

Waterborne Filler

Intermediate Coat

Modified Polyamide Epoxy

Finish Coat

Aliphatic Polyurethane

Note: Prime Coat must be back-rolled and squeegeed

Application: Roller-Applied

Leprino Foods 2012

Atlanta Humane Society

Level II – Orange Peel Block Finish

Level III – Smooth Block Finish

Prime Coats (2 coats)

Waterborne Filler

Intermediate Coat

Modified Polyamide Epoxy

Finish Coat

Aliphatic Polyurethane

Note: Prime Coats must be back-rolled and squeeged

Application: Spray-Applied

Level III Finish 1 coat of block filler

2 coats Latex Finish

Level IV – Joint-Filled,

Fiber Reinforced Finish

Skim Coat (troweled)

Epoxy Filler and Surfacer

Fiberglass Mat

Fiberglass Reinforcing Mat

Saturation Coat

Modified Polyamine Epoxy

Intermediate Coat

Modified Polyamine Epoxy

Finish Coat

Aliphatic Polyurethane

Application: Roller-Applied

Level II Finish Level IV Finish

Georgia State University

LEVEL IV VIVARIUM WITH

SEAMLESS FLOORING

Common Substrates

• Wallboard

• Concrete Masonry Units (CMU)

• Existing Tile

Don’t Forget The Floors

Remember

• Every project needs a qualified

applicator in order to be successful

• Qualified applicator responsibilities:

– Perform substrate testing

– Address surface preparation

– Address environmental conditions

(i.e. temp, humidity)

– Mixing and application of coatings

per manufactures instructions

Wall Coatings

• Physical contact

• Public areas frequently

cleaned and wet

• Provides impermeable

surface over entire wall

• Easily cleaned and

maintained

• System can be tied into floor

system with cove base

Detention Facility Showers - TN

FLOOR APPLICATIONS Common Generic Coating Types

Types of Flooring Systems

• Thin-film flooring

• Thick-film flooring

– Laminate

– Mortar

Bakery Floor – San Antonio, TX

Other Environments

• Areas where floor coatings are typically found:

– Automotive service

– Transit authority

– Aircraft hangers

– Bus terminals

Airplane Hanger

Dealership

Corporate Hanger

Thin-Film Epoxy Systems

Repair Facility

Knight Transportation Denver CO.

2012

Common Resin Types for

Seamless Floor Applications

• Epoxies

• Urethanes

• Acrylics (MMA)

• Vinyl Ester

• Urethane modified concrete

Why Install Resinous Floor Systems?

• To protect concrete from physical and chemical abuse

• To provide a cleanable, sanitizable surface

• To create a seamless monolithic surface

• To beautify and protect

• To create non-slip properties

• To improve lighting

Quartz Aggregate

• Example of quartz/fleck aggregate added for visual

appeal

Mortar Floor System

Before After

Rescue Mission Kitchen

Various air districts throughout the

U.S. and Canada have VOC content

regulations, which must be followed in

regards to paints and coatings.

Specifications VOC Considerations for Coatings

Where to specify High Performance

Coatings • Division 4

– Masonry - 4205

• Division 5

– Structural Steel – 5120

– Steel Decks – 5310

– Metal Fabrications: Shop Primers - 5500

• Division 8

– Steel Doors & Frames - 8111

• Division 9

– High Performance Coatings - 9960

This concludes the educational content of this presentation.

Developed by Tnemec Company, Inc.

1-800-TNEMEC1 or www.tnemec.com

QUESTIONS?