SURFACE TREATMENT

Paint systems
Version: 1.1

Last updated: 27/04/18

Introduction
Can we find a paint for all environments and surfaces?
Different paints can be used to protect a variety of construction materials. No paint can be used in all
environments!

Factors influencing the selection of a paint system

Customer’s expectation (durability)
Service environment
Availability of paint and/or other protective materials
Substrate
Structure design
Surface preparation available
Paint application methods available
Ease of maintenance
Cost
Health, safety and environmental factors

Customer Expectations
Customers are usually concerned with corrosion and the durability of the asset with aesthetics normally
not as important
To meet their durability requirements coating system durability should be discussed
According to ISO 12944-1 durability is defined as the expected life of a protective paint system to the first
major maintenance painting
Durability is not the same as a “guarantee” period

Corrosivity of the Environment

It is important to identify the corrosivity category of an environment since it will relate to:
Corrosion rate of the building material
Material selection of building products
Selection of proper corrosion protection methods for the building materials
ISO 12944-2 defines the classification of environments by corrosivity category

Corrosivity Categories of Environment

Corrosivity Categories of Environment – ISO 12944-2

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 Atmospheric condition Immersion

C1 Very low
Im 1 Fresh water
C2 Low

C3 Medium
Im 2 Sea or brackish water
C4 High

C5 Very high Im 3 Soil

CX Extreme Im 4 Sea or brackish water

Description of corrosivity categories

C1 Very low
Interior: Heated buildings with clean atmospheres, e.g. offices, shops, schools, hotels

C2 Low
Exterior: Atmospheres with low level of pollution. Mostly rural areas
Interior: Unheated buildings where condensation may occur, e.g. depots, sports halls

C3 Medium
Exterior: Urban and industrial atmospheres, moderate sulfur dioxide pollution. Coastal areas with low
salinity
Interior: Production rooms with high humidity and some air pollution, e.g. food-processing plants,
laundries, breweries, dairies

C4 High
Exterior: Industrial areas and coastal areas with moderate salinity
Interior: Chemical plants, swimming pools, coastal ship- and boatyards

C5- Very high

Exterior: Industrial areas with high humidity and aggressive atmosphere and coastal areas with high
salinity
Interior: Buildings or areas with almost permanent condensation and with high pollution

CX- Extreme
Exterior: Offshore areas with high salinity and industrial areas with extreme humidity and aggressive
atmosphere and subtropical and tropical atmospheres
Interior: Industrial areas with extreme humidity and aggressive atmosphere

Im1 Fresh water

River installations, hydro-electric power plants

Im2 Sea or brackish water

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 Immersed structures without cathodic protection (e.g. harbor areas with structures like sluice gates,
locks, jetties)

Im3 Soil
Buried tanks, steel piles, steel pipes

Im4 Sea and brackish water

Immersed structures with cathodic protection (e.g. offshore structures)

Selecting a paint system according to ISO 12944-5

ISO 12944-5 is an industrial standard which can be referenced to find a suitable system for new
construction. There are lists of typical systems categorized by:
Substrate (low-alloyed carbon steel, hot-dip galvanized steel and thermally sprayed steel)
Corrosivity category (C1, C2, C3, C4, C5, CX, Im1, Im2, Im3, Im4)
Expected durability (low, medium and high)

Build-up of a Paint System

There are no “magic” paints that can do everything, hence, multi-layer systems are normal in most cases:
Primer / Intermediate coat / Topcoat

However, one coat system may also be specified:

Paint is specially designed for a single coat
Constant, mild environment
Minor job such as maintenance
Low expected durability

Primers
Primers are universal for most anticorrosive coating systems and are considered the most important component
of the system. The most important properties of primers are listed as follows:
Adhesion (strong bonding to substrate)
Cohesion (high internal strength in the film)
Intercoat adhesion (high bonding to intermediate coat)
Appropriate flexibility

Intermediate coats
The principal purposes of an intermediate coat is to provide:
Thickness for total coating system
Strong chemical resistance
Resistance to moisture vapor transfer
Increase electrical resistance for the coating system
Strong cohesion
Strong bonding to primer and topcoat

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Topcoats
Topcoats also perform several important functions as they:
Provide a resistant seal for the coating system
Form the initial barrier towards the environment
Provide resistance towards chemicals, water, and weather
Provide a tough and wear-resistant surface
Provide a pleasant appearance

General rules – thickness of coating system

Deciding factor is the environment:
An example:
In a dry inland atmosphere, and indoors 120 µm will be sufficient, while in a coastal environment, 250 -
300 µm may be necessary to achieve the same number of years durability

Number of coats is also of importance

100 µm in 2 coats (50 + 50 µm) will give better protection than 100 µm in 1 coat

Where can we find the properties of a paint?

It is impossible to know all different paint products
Technical data sheet (TDS) from supplier is a suitable source
Information that may be found in a TDS or Application Guide:
Product description
Recommended use and typical paint system
Film thickness and spreading rate
Approvals
Physical properties
Surface preparation (methods and requirements)
Application (ambient condition, methods, technical parameters)
Drying time
Brief HSE requirements (Refer SDS)
Packing size

Inspectors need to understand and be familiar with the technical data in TDS

Environmental factors not covered in ISO 12944-2

The Corrosivity categories in ISO 12944 do not cover all situations
Some factors causing increased corrosion:
Heat (high)
Chemicals
Stray current
Mechanical stress
To find proper paint systems for these environments is not easy
We can always consult paint supplier and also confirm with pre-qualification testing

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