07/2010

EPOXY ENCYCLOPAEDIA
Strong protection at all points

Untitled-1 1

09-07-2010 14:41:51

3rd edition

Easy application ...

10

... at all points

Exceptional strength ...

Right from prehistoric times, mankind has had to protect

itself and its structures against the four elements air,
fire, water and earth. These four forces help to sustain
life. Under adverse circumstances, however, they threaten
both our environment and our lives.
In modern times, we are still familiar with the effects of
the harsh conditions in the world around us. Even today,
we and the structures we build need protection against
the same elements.

Long-term protection ...

Hempel contributes to mitigating the destructive effects of

the forces of nature by providing the optimum protective
coating systems for both steel and concrete. Today, the
most durable and cost-effective coating products are
based on epoxy technology, which can be varied infinitely
to provide coating products with exactly those specific
performance properties required by structures exposed to
widely different environments.
As for all types of coatings though, surface preparation
is also for epoxy coatings the most crucial consideration,
because it sets the limits on the exposure, and the service
life to be expected.

Many different terms are used in the coatings industry to

differentiate between the varied types of epoxy coatings
and their uses. The pages that follow give Hempels
explanation of the terms most commonly used. A fast and
easy guide to the various most commonly referred epoxy
types is found in the fold-out guide to the left.
Hempel has also developed a special tool named
the Radargram, which is used to illustrate the main
characteristics of each epoxy type in a unique form. The
Hempel Radargram highlights the special features of each
of the different types of epoxy products.
Hempel produces, and can supply, the entire range of
epoxy products. Each product is uniquely engineered and
has specific characteristics in order to meet the many
different customer requirements.
If you wish to know more about Hempel epoxy products,
than this guide provides, then please visit our website
www.hempel.com, where we have developed a site
specifically dedicated to epoxy products.
As we say at Hempel: We cannot predict the future but
we can protect it.

Value for money ...

Contents

foreword

the history of epoxy

What characterises epoxy?

The Hempel Radargram

11

radargram SCORING TABLES

13

Universal epoxy

15

Pure epoxy

17

Modified epoxy

19

Phenolic epoxy

21

mastic Epoxy

23

Surface-tolerant EPOXY

25

Zinc epoxy

27

Aluminium epoxy

29

Glass flake epoxy

31

Fibre epoxy

33

MIO (micaceous iron oxide) and zinc phosphate epoxy

35

Epoxy tie coat/sealer

37

IMPACT AND Abrasion resistant epoxy

39

High, very high and ultra-high solids epoxy, and solvent-free epoxy

41

Water borne epoxy

43

Coal tar epoxy

45

www.hempel.com

49

Hempel worldwide

50

The history of epoxy

The word epoxy is derived from two Greek prefixes epi,
which means upon and oxy, which means sharp/
acidic.
The history of epoxy chemistry began in the early 1900s,
when the Russian chemist Prileschajew discovered that
olefins react with peroxybenzoic acid to form epoxides. In
the mid-1930s, the German P. Schlack applied for a patent
on the preparation of high molecular weight polyamines
by making amines react with epoxide compounds that
contain more than one epoxide group. He described the
preparation of epoxide compounds by the reaction of
epichlorohydrin with bisphenol A.
The epoxy chemistry that we know today within the fields
of maritime and industrial protection was recognised
simultaneously by P. Castan from Switzerland and S.
Greenlee from the USA. These two chemists applied for
various patents in the late 1930s. The first type of epoxy
resin was commercialised by Ciba in 1947.

Hempel launched its first epoxy

products in the mid-1950s, under
the names Tanker Protect Primer
and Tanker Protect Topcoat. Epoxy
has since grown to become the most
important product used as surface
protection in maritime and industrial
applications.

What is epoxy
Epoxy is an organic compound that incorporates an
oxygen atom linked to two adjacent carbon atoms. An
epoxy resin contains a minimum of two epoxy groups, and
this enables each molecule to react at both ends to form
the cured epoxy.
This group, commonly called epoxy,
characterises the epoxy resins.

Time line

1909

1928

1940

1947

1953

Today

Prileschajew (Russian
chemist) discovered
that olefins react with
peroxybenzoic acid to
form epoxides.

First patents
registered.

Initial attempts
to market epoxy
products, with
limited success.

Successful debut
for commercial
epoxy resins.

Hempel launched
its first epoxy
tank coating.

The Hempel epoxy

success continues.

What characterises
epoxy?
No other resins fulfil the role of the ideal binder for highperformance coating systems as well as the epoxies. The
most important single property of epoxy resin is its ability
to transform readily from a liquid to a hard, resilient solid
coating.

Because epoxy has such versatile qualities, epoxy resins

are now used in numerous fields, including protective
coatings, marine coatings, floorings, adhesives, glues,
moulding compounds, insulating materials, reinforced
plastics, textiles and many more.

Additives
Adding plasticisers, flexibilisers, defoamers, reactive
diluents, UV-absorbers, etc., to the epoxy binder
improves physical properties such as mechanical
strength and resistance to thermal shock. Additives
can also increase flexibility, lower viscosity and improve
sag resistance of the epoxy coating.

The two main epoxy resins used in conjunction with maritime

and industrial protective coatings are based on either a
low-molecular liquid epoxy resin or a solid epoxy resin.

The epoxy formulation

Epoxy binder
The epoxy binder forms a barrier to give anti-corrosive
properties and provides adhesion to the substrate,
resistance to chemicals and heat, as well as excellent
mechanical and physical properties. Epoxies do,
however, chalk when exposed to ultraviolet light.

Curing agent
The curing agent is also part of the binder, but seldom
described in relation to the type definitions for epoxy

products. Without the curing process, however, the

epoxy coating would not be able to perform as required.
Accelerators can be added to improve the curing
properties at low temperature.

Pigments
Pigments are normally added to give colour to the
coating. Some pigments, including zinc, MIO and
aluminium, also add to the anti-corrosive properties.

Extenders
Extenders are non-hiding pigments in powder form.
Extenders are used for their film-forming properties and
to avoid settlement during storage. Special extenders,
such as fibres and glass flakes, can be added to the
epoxy binder to improve mechanical properties of the
coating such as crack resistance, flexibility, fatigue
properties, strength and abrasion resistance.

Solvents
Organic solvents or water are used in the manufacture
and use of epoxy coatings to act as a carrier for and/
or to dissolve or thin the film-forming constituents
and other paint ingredients. Water/solvents evaporate
during the drying/curing process and therefore do not
become a part of the cured coating film.

Application
Airless spray equipment is the most common technique
used today for applying epoxy coatings in both the maritime
and industrial sectors. It is fast, efficient and above all
economical.
Two-component airless spray equipment is the latest
development within coating application. This eliminates
mixing the base and curing agent manually and makes pot
life considerations insignificant.

Features and benefits

Epoxy-based products have numerous advantages during
and after application. The most important of these
include:

Low viscosity
Curing can take place at temperatures down to
-10C/14F

Excellent adhesion to many substrates

Very high mechanical strength
Very good chemical resistance
Superior corrosion protection

Health, safety and environment

Working with epoxy involves a number of potential
physical/chemical and biological hazards. It is therefore
important to keep work places clean and tidy, and to
provide adequate protection for users. They should avoid
direct contact with resins and curing agents, and should
take care not to inhale any vapours. It is also extremely
important to take adequate precautions relating to both
the environment and potential fire risks. Always follow
the instructions provided in the Safety Data Sheets and
Product Data Sheets when handling and working with
coating products.

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The Hempel Radargram

The Hempel Radargram mapping tool provides customers with a considerable amount of crucial information about epoxy
coatings in a straightforward, easy-to-understand form. The Radargram displays a range of important quantitative and
qualitative product performance criteria.

How to read the Hempel Radargram

The Radargram uses a scale from 0 to 10, with 10

as the highest score. An average score of around 4
should be the minimum for an epoxy coating, unless
the product has specially designed features. Such
products are difficult to describe in a Radargram, which
makes general comparisons between all types of epoxy
coatings.

The Radargram is intended as an overall indication of

the characteristics and performance features of the
product. The left side of the Radargram provides an
indication of the general performance properties the
main focus for the end-user/owner. The right side gives
an indication of the application properties, which are of
prime interest for the applicator.

A blue Radargram indicates that the product is intended

for both submerged and dry areas.

A red Radargram indicates that the product is intended

for dry areas.

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The Radargrams for the different epoxy types in this

epoxy Encyclopaedia show the typical performance
range for common products within each epoxy type in
the market place.

Try out the live Radargrams on www.hempel.com. The

online Radargrams provides access to pictorial data
sheets of the entire Hempel assortment of high performance epoxies. It is an important tool that, with just
a few clicks, enables owners and applicators to compare different epoxy products and find the perfect epoxy
coating for their vessels or steel structures depending
on the intended/desired exposure, service and performance parameters.

Check out live Radargram on the epoxy

pages under the Marine and Protective
sections on www.hempel.com

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Strong protection
Volume solids %

Score

Minimum/maximum recoating intervals

100%

Solvent-free epoxy

10

Fast drying, no maximum on wet/dry areas

10

9990%

Ultra-high solid epoxy

8980%

Very high solid epoxy

Fast drying, very long maximum on wet areas, no maximum on dry

areas

7970%

High solid epoxy

Fast drying, long maximum on wet areas, no maximum on dry areas

6960%

Average solid epoxy

5950%

Medium solid epoxy

4940%

Low solid epoxy

3920%

Very low solid epoxy

Few hours drying, reasonable maximum on wet areas, long maximum

on dry areas
Few hours drying, relatively short maximum on wet areas, reasonable
maximum on dry areas

Manual cleaning - St3

Abrasive sweeping - Sa1
Water jetting - dry surface

Abrasive sweeping - Sa2

Sweeping of shop primer

Abrasive blasting to Sa2 with a normal profile

Abrasive blasting to Sa2 with a high, sharp profile

Abrasive blasting to Sa3 - chemical tank grade

Not relevant for this product

Passed all Hempels internal performance tests according to

intended use in severe environments

Passed all Hempels internal performance tests according to

intended usage in medium environments

7
6
5

Not relevant for this product

Not relevant for this product

Standard equipment, long hoses, paint temperature as surroundings

Standard equipment, long hoses, paint temperature warmer
than surroundings in cold climates

10

Special requirements

Flexibility in relation to equipment, length of hoses,

temperature, pot life, etc.

Score

Passed external tests as high quality epoxy product for general use
or local/customer performance standards (e.g. DNV/Marintek B-1;
low flame spread)

Product used in a combined coating system, therefore not relevant

to list separate certification/approvals

Application
10

Passed all relevant external tests and certified according to global

standards and/or intended specialized usage (e. g. NORSOK; PSPC;
drinking water; FDA; chemical resistance; grain carriage)

Mill scale, dirt, salts and other contaminants removed

prior to minimum listed below

Score

Certification/approvals/tests

Few hours, short maximum on wet areas, relatively short maximum

on dry areas

Surface preparation grades

Water jetting moist surface

10

General steel with no abrasion, topcoats, void space, etc.

Special purpose epoxy

Not relevant for this product

9
8

Product tanks

Oil tanks

Saltwater tanks (ballast tanks)

Spillage (chemicals)

Not relevant for this product

The best

Score
10

Excellent

Short pot life, special equipment and skills required

(i.e. dual feed spray equipment)

General steel with little abrasion/handling, ballast tanks, etc.

Sewage tanks

Standard equipment, normal length hoses, paint min. +10C/50F

Freshwater tanks

Heavy-duty equipment or standard equipment with paint

min. +15C/59F

Medium, light traffic decks, flat bottom, vertical bottom, topsides, etc.

10

Superior

10

Medium to heavy abrasion, fender areas, boottop, vertical bottom

w/light ice condition, helidecks, cargo holds (grain), etc.

and/or
Anticorrosive performance

Heavy-duty equipment

Suited for areas with heavy abrasion, icebreaker, splash zone,

heavy traffic, drill decks, cargo holds (abrasive cargoes), etc.

Chemical tanks

(indicated by a red Radargram)

9

Score

Chemical resistance

(indicated by a blue Radargram)

Score

Abrasion resistance

Submerged performance

Standard equipment, normal length hoses, paint min. +5C/41F

Can only be applied by hand tools (putty knife or similar)

13

Score

at the right score

Very good

Good

Average

Acceptable

Not relevant for this product

Score

14

Volume solids (%)

10

Universal epoxy

HEMPEL Product examples

HEMPADUR QUATTRO 17634

HEMPADUR Quattro alu 45604
HEMPADUR quattro FIBRE 47604

universal epoxy
The commonly used classification of epoxies as pure or
modified is not really relevant from a coating performance
point of view. To put performance first, Hempel has
defined a new term universal epoxy to designate a class
of overall high-performance coatings, which essentially
combines the highest quality raw materials used in both
pure and modified epoxies and exploits the best features
and properties of both.
The universal high-performance epoxy binder is based
on the same raw materials as used in the so-called pure
epoxy, but the formulation is improved to also cater for
very versatile application properties. As a result, the

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universal high-performance epoxies combine all the

best properties to yield coatings that feature optimum
application properties as well as excellent anticorrosive
properties.
As such, this new class of universal epoxies is an
obvious choice for both ship yards and shipowners when
focusing on productivity, performance and/or regulatory
requirements.
With the fast drying and flexible recoating intervals,
the universal high-performance epoxy is in the marine
segment excellently suited at the newbuilding stage as

a universal primer system for an entire vessel. The only

exceptions are areas that require ultimate fresh water,
chemical and abrasion resistance, such as fresh water,
grey water and chemical product tanks, as well as severely
exposed cargo holds. For maintenance the universal highperformance epoxy is used on a large variety of areas
such as ballast tanks, cargo holds, decks, the hull, both
below and above water, etc.

refineries, chemical plants and other steel constructions

in general. Basically there is no limit to the use, except
when it comes to applications which require the very best
chemical and abrasion resistance.

The universal high-performance epoxy is also perfectly

suitable in the protective segment as primer for protection
of structural steel and the exterior of tanks, pipes, etc.
in applications that include oil and gas installations,

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10

Pure epoxy

HEMPEL Product examples

HEMPADUR 15400
HEMPADUR 15500
HEMPADUR MULTI-STRENGTH 35530

HEMPADUR 35560
HEMPADUR MULTI-STRENGTH GF 35870
HEMPADUR MULTI-STRENGTH 45751/3
HEMPADUR ULTRA-STRENGTH 47500
HEMPADUR UNIQ 47741/3
HEMPADUR 85671

Pure epoxy
The phrase pure epoxy is a broad coating industry term
and not technically well defined. At Hempel we use the
term pure epoxy to denote an epoxy binder that has no
other unreacted additional binder types added.
Pure epoxies are numerous and used for all kinds of
applications for protection against corrosion in steel
structures such as ships, offshore platforms, industrial
complexes, infrastructure, etc.
On new constructions and major refurbishing jobs, pure
epoxies are commonly used as high-performance universal
primers and for exceptional abrasion resistance.

a very high chemical resistance, using phenolic epoxy

technology (see page 21 for specific description).
As a general rule, most pure epoxies require slightly more
care during preparation and application compared with
universal or modified epoxies. This is indicated by the
Radargram shifting towards the left.
Several pigments and additives can be added to a pure
epoxy coating formulation to increase performance.
Additives are also used to improve the application
properties, but these are normally not mentioned in the
product description.

Pure epoxies are also used for more special applications

such as internal tank linings. Here, pure epoxies provide

17

18

10

Modified epoxy

HEMPEL Product examples

HEMPADUR 15570

HEMPADUR XO 35790

HEMPADUR 45141/3
HEMPADUR 45182
HEMPADUR HI-BUILD 45200
HEMPADUR MASTIC 45880/1
HEMPADUR 47080
HEMPADUR 47140

Modified epoxy
The term modified epoxy is also a term invented by the
coating industry. In fact, the term should cover all epoxy
products that are not universal or pure epoxies (according
to Hempels definition, page 15-17). However, several other
epoxy-types have been invented in order to differentiate
one coating from another. In most cases, modifications
are carried out on the binder part by adding accelerators, plasticisers, extenders, reactive solvents, etc.
Modification can also be taken to extremes in order to
achieve special properties. In these cases, substances
such as acrylic or vinyl are added to extend recoating
intervals and secure intercoat adhesion.

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Formerly another important modified epoxy was formulated

by adding tar. This resulted in one of the most successful
modifications ever made, coal tar epoxy. This is, however,
by now being phased out from most uses due to
environmental as well as workability issues. (see page 45)
Modified epoxy coatings are very well suited for the
protection of structural steel and the exterior of tanks,
pipes, etc. in applications that include oil and gas
installations, refineries, chemical plants and steel
constructions in general.

On board ships, modified epoxies are typically used during

the newbuilding stage as a universal primer system for
an entire vessel. For maintenance, modified epoxies are
used on specific areas such as ballast tanks, cargo holds,
decks, the hull, both below and above water, etc. There
is no limit to the use of a modified epoxy, except when it
comes to very high chemical and abrasion resistance.

Correct identification of the coating requirements allows

selection of the most appropriate formulation, which
results in a system with optimum all-round properties.
Modified and universal epoxies have shown that they
outperform many pure epoxy-based products in terms of
versatility, flexibility and inner strength.

The term modified epoxy should not be interpreted to

suggest any negative assessment of the performance to
be expected from such a coating. On the contrary, it is
important to know that the modification is done to improve
specific properties and characteristics of the coating.

20

Volume solids (%)

10

Phenolic epoxy

HEMPEL Product examples

HEMPADUR 15500
HEMPADUR 35760
HEMPADUR 85671

phenolic epoxy
Phenolic epoxy, also referred to as epoxy novolac, is
probably one of the purest epoxies currently on the
market. Phenolic epoxy is very different in its fundamental
chemical structures from other types of epoxy. Because
there is a minimum of three epoxy groups in the resin
molecule, the product has a greater degree of crosslinking. A cured phenolic epoxy therefore results in a much
tighter network of molecular chains.
If additional post-curing takes place (normally within the
first six months after application), the cross-linking will

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become even denser, resulting in even greater chemical

resistance.
Phenolic epoxy (novolac) generally has a better elevated
temperature performance and chemical resistance than
its other epoxy counterparts.
The usage area of phenolic epoxies is often as specialised
coatings for chemical and product tanks, storage tanks
as well as inside of pipelines where a high resistance to
elevated temperatures and/or chemicals is required.

22

Volume solids (%)

10

mastic Epoxy

HEMPEL Product examples

HEMPADUR MASTIC 45880/1

HEMPADUR 47140
HEMPADUR 47200

mastic epoxy
The term mastic epoxy originates from the time when
epoxy coatings were introduced into maintenance
specifications. These generally required a lower degree of
surface preparation, compared with new structures.
In addition to their inherent resilience, mastic epoxy
coatings possess low water permeability as well as
exceptional adhesive properties for marginally prepared
surfaces. Mastic epoxy coatings also feature good
resistance to spillage of a wide range of chemicals which
the coating typically can be exposed to when being used
as a deck coating or similar.

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Mastic epoxy coatings normally feature 60 85% volume

solids, with the higher solids versions obviously containing
less solvent. This means that it is possible to make mastic
epoxy coatings that are both reasonably environmentally
friendly and economical in use, even in high solids
versions. This increases the coverage per square metre
and reduces the number of coats necessary to obtain the
recommended dry film thickness. Mastic epoxy coatings
can be applied by brush, roller and airless spray.

24

Volume solids (%)

10

Surface-tolerant epoxy

HEMPEL Product examples

HEMPADUR 15570
HEMPADUR ER 35740
HEMPADUR 45141/3
HEMPADUR OBM 47150

Surface-tolerant epoxy
Surface-tolerant epoxy is a product description often used
for a modified or mastic epoxy. The different types of
modification possibilities currently available make certain
modified epoxy coatings suited for surfaces that are well
prepared prior to application. Other types are suitable
for areas where it has been difficult to achieve a high
standard of surface preparation. Some modified or mastic
epoxy coatings designated surface-tolerant epoxies can
even be applied on damp or otherwise marginally prepared

25

surfaces. This is particularly relevant when using ultrahigh-pressure water for cleaning.
Universal epoxies are normally also surface tolerant
epoxies, but they are not included and depicted in
this description as they generally feature much higher
performance characteristics than traditional surface
tolerant epoxies.

26

Volume solids (%)

10

Zinc epoxy

HEMPEL Product examples

HEMPADUR ZINC 15360

2

HEMPADUR ZINC 17310

HEMPADUR ZINC 17340
HEMPADUR ZINC 17360
HEMPADUR ZINC 17380

zinc epoxy
The superior performance of the zinc-rich epoxy coatings
available today is attributed to the metallic nature of zinc.
It is the galvanic protection associated with conductivity,
where zinc is sacrificed instead of the steel, that makes
zinc epoxy coatings superior (see illustration below).

Zn++

Zn++
OH
OH- OH-OH
OH--OH
OH
OH- -

Zn primer
Steel substrate

e-

27

Electrolyte

The earliest lead-free inhibitive pigments were chromates,

in particular zinc potassium chromate, which are anodic
inhibitors.
Zinc epoxy coatings are currently widely used as the first
primer coat in very corrosive above-water environment
and are overcoated with other types of epoxies to suit
individual protection requirements.
If zinc epoxies are left unprotected, they corrode, resulting
in a material known as zinc salts. Due to the nature of
the metallic zinc, they are only corrosion-resistant in
environments within a pH range of 6 9. Normal usage areas
of zinc epoxies are containers and installations in protective
segments such as offshore, cranes and bridges.

28

Volume solids (%)

10

Aluminium epoxy

HEMPEL Product examples

HEMPADUR Quattro alu 45604

HEMPADUR MULTI-STRENGTH ALU 45701/3

HEMPADUR Quattro FIBRE 47604
HEMPADUR UNIQ 47741/3

aluminium epoxy
For many years, aluminium pigments have been widely used in
maritime and industrial coatings for several reasons. One reason
is the colour, which in most cases results in a light, shiny surface.
A very important performance feature of aluminium pigmentation
in epoxy coatings for wet/submerged areas is its ability to reduce
disbondment. Although aluminium does not have the same
anticorrosive effect as metallic zinc, it can significantly improve
the anticorrosive protection of steel immersed in seawater.
Aluminium pigments are commercially available as leafing or nonleafing grades. The leafing pigments float to the surface of the
applied film, while the non-leafing pigments are evenly distributed
in the film after application.
The aluminium pigments are normally shaped as flakes of different sizes. Their geometry, along with their metallic nature,
is responsible for most of their properties in conjunction with

29

protective coatings. Because aluminium pigments are impermeable to water and oxygen, the diffusion is forced to go around
the particles. This can increase the diffusion path significantly,
thus reducing permeability through the coating (see illustration
on next page). The aluminium pigment will also be chemically
reactive at the cathodic site that is created on the steel in case
of damage to the coating.
Therefore, in order to take full advantage of the anticorrosive
properties of aluminium pigmentation, it is important that the
aluminium pigmented epoxy is used as the first coat in contact
with the steel.
If the colour effect is more important, it should naturally be used
as the top coat.
The cost of the coating is increased when aluminium pigments
are used.

STEEL

Coating containing non-leafing aluminium

pigments. The aluminium pigments are
distributed throughout the entire coating
thickness.
Aluminium flakes reduce permeability. Water,
oxygen and ions have to find a path around
the pigments to reach the substrate.

STEEL
30

Volume solids (%)

10

Glass flake epoxy

HEMPEL Product examples

HEMPADUR MULTI-STRENGTH GF 35870

glass flake epoxy

Glass flake epoxy provides excellent corrosion protection
due to a superior barrier effect that stems from the
coating being reinforced with a high content of lamellar
glass flakes. It is normal for glass flake epoxies to have a
very high solids content, which makes it possible to apply
a high dry film thickness per coat as well as allows the
structure to be re-immersed very soon after application.
Glass flake epoxy coatings are often specified for areas
characterised by high abrasion and impact, such as
offshore legs, drill decks, exterior hull of ice breaker
vessels and similar areas.

31

Scanning electron microscopical photo of a HEMPADUR

MULTI-STRENGTH GF 35870 paint flake, that shows the
distribution of lamellar glass flakes inside the coating.
These glass flakes not only increase the barrier properties
of the coating, they also improve the impact and abrasion
resistance properties of the product.

32

Volume solids (%)

10

Fibre epoxy

HEMPEL Product examples

HEMPADUR Quattro FIBRE 47604

HEMPADUR FIBRE 47601/3

fibre epoxy
The fibre epoxy is an epoxy coating where micro fibres
are incorporated into the paint formulation, in order
to significantly improve the mechanical properties.
The specific fibres are chosen to achieve maximum
performance as well as to ensure ease of application
of the paint. The fibre epoxy can be applied by standard
spray application equipment.
The coatings reinforced with fibres have significantly
increased fatigue properties, higher strength, better
flexibility and improved crack resistance. This is especially
important at excess film thickness which is often a result
of painting the narrow and complex internal structures of
a ship; e.g. the inside of ballast tank spaces.

33

Fibre epoxy is often specified for high stress areas

characterised by harsh in-service conditions such as
mechanical flexing/impacts, cycling of wet/dry conditions
and high/low service temperatures. In such areas the
fibre epoxy will provide extended protection time and
longer service life.
Vibration in the hull and the ships
movement in the water can
cause cracks in conventional
ballast tank coatings.

Scanning electron microscopical

photo of a paint flake fracture,
showing the (green) fibres dispersed
in the paint matrix in a network
creating a mechanically reinforced
paint film.

34

Volume solids (%)

10

MIO (micaceous iron oxide) and

zinc phosphate epoxy

HEMPEL Product examples

HEMPADUR FAST-DRY 15560
HEMPADUR 15570
HEMPADUR 17410
HEMPADUR QUATTRO 17634
HEMPADUR MASTIC 45880/1

MIO (micaceous iron oxide)

and zinc phosphate epoxy
A typical epoxy primer coat relies on the high adhesive
property of the binding medium, and on a very thoroughly
cleaned surface. This is sufficient to prevent underrusting at mechanical breaks. However, epoxy primers can
also contain inhibitive pigments designed to retard the
corrosion process. Micaceous iron oxide (MIO) and zinc
phosphate, for example, are mildly inhibitive pigments and
are therefore used in some modern primer formulations.
Micaceous iron oxide can also be added to increase
the flexibility of the coating and to extend recoating
intervals.

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Generally speaking all types of epoxies can be pigmented

with inhibitive pigments. In this description only specialised
inhibitor containing primers are considered. Typical
examples of such epoxy product use are for containers,
wind mill towers and other installations in protective
segments, where the paint is applied by automated
application equipment and/or in shop application.

36

Volume solids (%)

10

Epoxy tie coat/sealer

HEMPEL Product examples

HEMPASIL NEXUS 27302
HEMPADUR NEXUS X-Seal 27600
HEMPADUR 45182 (below water)
HEMPADUR 47080 (above water)
HEMPADUR 47200 (above water)

Epoxy tie coat/sealer

Epoxy tie coats and sealers are actually very similar coatings.
Both are epoxies that have been heavily modified to suit the
particular application requirements. A tie coat is a coating
which facilitates or improves the adhesion between
different generic coating types, especially to bridge
between e.g. epoxies and antifouling, fouling release
or other top coat technologies. In vessel newbuilding
situations a tie coat is applied on areas above water to
prolong the maximum recoating interval between an epoxy
system and the following e.g. polyurethane or polysiloxane
topcoat.

37

A sealer coat is a layer of paint that is used to seal off or

fill the pores of a porous surface such as a zinc silicate
surface, an empty leached layer or an insoluble matrix of
certain antifouling types.
Previously such sealer coat has also been used to seal
off tin-based antifouling paint in order to comply with the
IMO convention (International Convention on the Control
of Harmful Anti-Fouling Systems on Ships, 2001) without
removing the TBT-based antifouling paint.

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Volume solids (%)

10

IMPACT AND Abrasion-resistant epoxy

HEMPEL Product examples

HEMPADUR SPRAY-GUARD 35490/3

HEMPADUR MULTI-STRENGTH 35530

HEMPADUR MULTI-STRENGTH GF 35870

HEMPADUR MULTI-STRENGTH 45540
HEMPADUR MULTI-STRENGTH 45751/3
HEMPaDUR ULTRA-STRENGTH 47500
HEMPADUR UNIQ 47741/3

IMPACT AND Abrasion-resistant epoxy

To define an abrasion-resistant epoxy is a matter of simple
comparison between properties of the various epoxy coatings.
Epoxy coatings are all normally more abrasion-resistant than
previous technologies (such as acrylic, chlorinated rubber,
alkyd, etc.) used to coat similar areas. Additives such as
extremely hard calcinated material, glass flakes, glass fibre,
synthetic mineral fibres etc. are most often used in epoxies

to give particularly high abrasion-resistant properties.

Pigments like aluminium, on the other hand, do not increase
the anti-abrasion properties of the coating, although they
can have an influence on its adhesion to a well-prepared
surface. Typical use of abrasion resistant coating is for cargo
holds of bulk carriers transporting e.g. coal or iron ore, drill
decks and other areas within the oil and gas industry.

Low impact resistant coating

High impact resistant coating

Impact

Impact

Paint

Paint with
hard inert
pigments

Steel

The energy of the impact is spread laterally throughout the coating.

The coating takes the impact, which can lead to cracking.

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The energy of the impact goes through the coating into the steel.
The steel takes the impact.

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Volume solids (%)

10

High, very high and ultra-high solids

epoxy, and solvent-free epoxy

HEMPEL Product examples

HEMPADUR MULTI-STRENGTH 35530

HEMPADUR 35560
HEMPADUR 35600
HEMPADUR ER 35740
HEMPADUR XO 35790
HEMPADUR MASTIC 45880/1

High, very high and ultra-high solids epoxy, and solvent-free epoxy
The definition of a high-build or high-solids epoxy comes
from the time when single-component products with a
solids volume content of approx. 40% were the only such
products available. A high-build/high-solids epoxy was
a product with a solids content higher than 40%. The
definitions high, very high and ultra-high solids are today
often used in relation to national regulations or specific
concerns relating to the environment.
It is impossible to draw up one single Radargram covering
very high and ultra-high solids epoxy, and solvent-free
epoxy. Except for the solids content each parameter can
vary within a 4 10 scale depending on the design and
intended use of the particular product.

41

The only feature products in this group have in common is

the fact that the solids component is epoxy.
Products within this category are very versatile, with uses
that range from ships to offshore structures and from
infrastructure to industrial objects in general, resulting in
good film formation at the intended dry film thickness
of the paint. The epoxy binder can be any type, with or
without pigments added to provide a special feature.

Today, products are normally named more accurately,

featuring either the intended use or pigmentation in the
product name, rather than the solids content.
Solvents are added to formulations in order to achieve
the best possible spray ability, flow control and levelling,
resulting in good film formation at the intended dry film
thickness of the paint. The use of volatile organic compounds
(VOCs) ranges from high levels in shop primers to very low
levels in heavy-duty solvent-free coatings. Irrespective of the
VOC level, special care must always be taken, both towards
the applicator and the surrounding environment.

The latter product group has a number of different

names, which are used at random, but zero VOC,
100% solids and solvent-free essentially have the
same meaning. The general use of these products are
often where it is of particular interest and/or requirement
to avoid solvent smell and exposure in the application
scenario, or where it is of utmost importance that no
contaminants can leach out of the dried/cured paint such
as in potable water tanks.

Especially due to emerging environmental legislation and

worker health care in different areas, the use of higher
solids or solvent-free epoxy coatings is rapidly increasing
for different uses.

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10

Water borne epoxy

HEMPEL Product examples

HEMUDUR 18500

HEMUDUR ZINC 18560

HEMUDUR SHOPPRIMER 18580
HEMUDUR 48500

WATER BORNE EPOXY

43

The description of the preceding epoxy types could just

as well have included water borne epoxies also. Water
is simply the medium in which the other raw materials
are dispersed in the liquid coating, in the same way that
organic solvents are used in solvent borne epoxies.

on level with their solvent borne countertypes. They are

quick drying and can be overcoated with both water borne
and solvent borne topcoats according to specification.
The resistance to abrasion and impact is equivalent to
that of solvent borne epoxies.

Most water borne epoxies are used as primers and

intermediate coatings for corrosion protection of steel.
The primers often have a content of metallic zinc or zinc
compounds, and they can show anticorrosive properties

When water borne epoxies were first introduced to the

marine, protective and container markets, they were
primarily used for internal dry areas, such as engine rooms
on ships and living areas on offshore platforms, but later

their use was extended to exterior areas of containers,

superstructures on ships, storage tanks, etc.
There are still some obstacles to overcome in broadening
the use of the more environmentally friendly water borne
epoxies for heavy duty coating purposes. Technically,
application at very low temperatures, close to the freezing
point of water, is the toughest challenge. Another limitation
is that they have traditionally been more expensive than
their solvent borne counterparts. However, with the

increasing environmental awareness and concern for the

general working conditions of applicators, reduction of
VOC emissions is on everyones mind. Water borne epoxy
presents a very good solution to this problem as it is
non-flammable and has an ultra low VOC content. Wet
application equipment can be cleaned with fresh water
and the normally strong smell from organic solvents is
avoided.

44

Volume solids (%)

10

Coal tar epoxy

HEMPEL Product examples

HEMPADUR LTC 15030

HEMPADUR 15100
HEMPADUR 15130

Coal tar epoxy

Coal tar epoxy is an old and well-proven solution within the
field of epoxy technology. It is probably the first modified
epoxy developed, with an extensive track record. Coal tar
epoxy was ideally suited for use as a protective barrier
coating. It developed a tough, chemically resistant surface
and provided excellent protection against the deteriorating
effects of water, petroleum oil and fuel.
There are, however, a few disadvantages, including the
colour. To quote Mr. Henry Ford, founder of the Ford Motor
Company: You can have any colour you want as long as
it is black.
However, black is often not the preferred colour, and for
many applications, a light-coloured epoxy provides far
better visibility, both in the application and in-service
inspection situation. And for coating ballast tanks light

45

coloured epoxy is now a formal requirement according to

IMO-PSPC, resolution MSC.215(82). Due to this as well
as environmental concerns, coal tar epoxy is now being
phased out in many parts of the world and coal tar epoxy
products are likely to disappear from the market in the
near future.
Depending on the ratio between coal tar and epoxy, coal
tar epoxy products have always had a significant cost
advantage in relation to competing products.

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47

48

Find the right product on

www.hempel.com

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49

10

Hempel A/S makes no representations or warranties whether express or implied whatsoever with respect to the information or graphics
contained in this brochure, which has been compiled in good faith and to the best of Hempel A/S knowledge for informational purposes only.
NB: Some of the products mentioned in this brochure are not available worldwide.

Hempels worldwide presence is perfectly

suited to the multinational construction
business, regardless of whether this involves
ships, petrochemical plants, tank farms,
bridges, power plants or offshore platforms.

This is why the rapid, efficient and correct

supply of paint is an important key to our
customers success.

Most major marine and protective construction

projects today involve companies from more
than one country, with different sections being
constructed in different countries before final
assembly on site. Delays in the construction of
any of these sections mean costly delays for
the entire construction project.

Hempel worldwide

The Hempel Group of companies currently

comprises 20 manufacturing plants, 2 main
and 6 regional R&D centres, 49 sales and
service offices and more than 150 stock
points around the world.
We operate with a worldwide product
assortment, which means our products
are readily available wherever and
whenever required. For operators
within the maritime industry, Hempel
paints are readily available from all
major ports of call.
Contact your local Hempel office for
further information and answers to any
questions.

50
500

07/2010

The Hempel Group Head Office

Hempel A/S
Lundtoftevej 150
DK-2800 Kgs. Lyngby
Denmark
Phone: +45 45 93 38 00
Fax:
+45 45 88 55 18
E-mail: protective@hempel.com
E-mail: marine@hempel.com
www.hempel.com

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