PAINT APPLICATION (Surface treatment procedure)

Basic composition of paint

Solvents (Liquids) Pigments

Additives

Resin (Binder)

Typical paint composition

Component Binder Organic solvent Water Pigments Extenders Additives Weight % 30 27 10 19 12 2

RESIN

Types: Latex, Alkyd, Epoxy, Polyurethane Binds or glues ingredients (pigments and additives) of paint together Resin provides adhesion to the substrate Resin provides durability & resistance properties: U-V resistance Moisture resistance Chemical resistance Stain resistance Fade resistance Chalk resistance Block resistance

Drying stages Alkyd paint

Physical drying solvent evaporates / film formed Chemical drying also called oxidative drying Four overlapping phases during drying process : Induction period Hydroperoxide formation Hydroperoxide decomposition into free radicals Polymerisation / crosslinking

1. 2. 3. 4.

The methods of pretreatment

Method Blast cleaning Mechanical wire-brushing Mechanical disc-sanding Needle chipping Mechanical scraping Hand brushing Hand scrapping Water jet cleaning

Result Ideal Acceptable Acceptable Fair Fair Poor Poor Acceptable

 While Alkyd thinner is MTO-145, the thinner used in PU paint is Xylene which is toxic (Isocyanate). Ford cup No. 4 80 to 120 seconds As per IS 8662

For Alkyd DFT ranges between 120 to 150 microns 2 coats of primer 50 micron 2 coats of surfacer (undercoat) 50 micron 15 + 15 micron finish 25 microns Total around 125 microns. For PU , DFT ranges between 200 to 250 microns (PU primer is expoxy based 60 microns)

Gloss / Sheen levels

Gloss or Sheen of paint refers to reflectivity of the dry paint film. There is lack of standards and confusion in the paint industry related to gloss or sheen levels. Gloss is measured at 60 for flat to gloss ranges. Sheen is measures at 85 between flat to eggshell Some paint manufacturers use different terms to define products between flat and semi-gloss: silk, suede, satin, velvet, eggshell, low sheen, low luster, pearl, etc.

Gloss / Sheen levels

Term
Flat Velvet/Low Luster Eggshell Low Sheen Semi-Gloss Gloss

Gloss @ 60
0-5 5-10 10-20 20-30 55-70 75+

Sheen @ 85
0-5 5-15 15-25

Alkyd Resin Technology

ALKYD (Oil-Based)
A synthetic resin made by reaction between alcohols and fatty acids Soya bean & linseed oil commonly used Benefits of alkyds: Superior brushing characteristics Abrasion resistance Excellent flow and leveling Good adhesion Used in rust preventative paint

Factors Affecting Coating Performance

Structural Design Coating Selection Surface Preparation

Protection

PAINT DEFECTS (Exterior):

Poor Gloss Retention: Deterioration of the paint film, resulting in excessive or rapid loss of luster of the top coat.

Possible Causes: Use of an interior paint outdoors. Use of a lower quality paint. Use of a gloss alkyd/oil-based paint in areas of direct sunlight.

Solution: Direct sunshine can degrade the binder and pigment of a paint, causing it to chalk and lose its gloss. While all types of paint will lose some degree of luster over time, lower quality paints will generally lose gloss much earlier that better grades. The binder in top quality acrylic latex paint is especially resistant to UV radiation, while oil & alkyd binders actually absorb the radiation, causing the binders to break down. Surface preparation for a coating showing poor gloss retention should be similar to that used in chalking surfaces.

Enamel , synthetic exterior

Alkyd polyester polymers used to form solvent-based coatings; coating formulations also contain drying oils derived from plant or vegetable oils Antifouling paints coatings designed to prevent the growth of barnacles and other marine organisms on ships bottoms. Anti-microbial a substance that kills or inhibits the growth of microorganisms. Curing agent chemical used to cause a reaction necessary for formation of the finished coating after the coating formulation has been applied to the surface Electrostatic deposition a technique for moving and charging a powder coating so that it is deposited on a grounded substrate or surface Enamel a smooth, hard, highly glossy coating; can be based on polyester or other types of polymers; initially referred only to solvent or oil-based paints, but now some waterborne coatings have adopted the term Epoxy polymers containing numerous carbon and oxygen linkages; the structure provides chemical and temperature resistance, weatherabilty and other high performance properties; initially only available in solvent formulations, but water-based versions are being developed High solids coatings dissolved in solvents where the content of the solids in the solvent is very high (usually 80% or higher) Inorganic zinc coatings made from zinc-rich silicate materials that contain no carbon; they are often used as a base coat over steel to protect the surface in high temperature applications

Electrocoating
THE MANUFACTURING PROCESS Auto bodies are coated with paint in a five step process. The steps are as follows: precleaning (to remove dirt and grease) phosphating (to provide a better surface for the paint and for additional corrosion protection) electrocoating (the actual application of the paint) rinsing (to remove the "cream coat" of paint that hasn't bonded to the metal surface) baking (to crosslink the polymeric coating)

Polyurethane polymers made from isocyanates, organic compounds that contain nitrogen; also contain carbon and oxygen groups; often used as protective coatings; initially developed as solventborne formulations, but water dispersions are now available Polymerization chemical reaction in which two or more small molecules (monomers) combine to form large molecules (polymers, macromolecules) that contain repeating structural units of the original molecules and reflect the percentage composition of the original molecules Post-cure the period after curing of a coating is complete but before the coating is completely finished Powder coating dry coating formulation that exists in a powder form; applied using electrostatic attractive forces created between the surface and the coating Pre-treatment a step required to prepare a metal surface before coating; involves surface cleaning and corrosion protection Resin polymer that forms the paint or coating film on a surface; also referred to as the binder

 Since polyurethanes are hard and glossy, they will show every surface imperfection, so starting with a very clean, smooth surface is essential, as is sanding between each coat. Follow label directions for application methods and drying time. Read more: What is Polyurethane Paint? | eHow.com http://www.ehow.com/about_461822 8_polyurethane-paint.html#ixzz1u0OpPV2P

Gloss
Gloss is the measure of reflection of light that is reflected into specu;lar direction.

 Gloss Range with 60 Gloss MeterMeasure With:If Semi Gloss - 10 to 70 GU60 If High Gloss > 70 GU20 If Low Gloss < 10 GU85

Gloss measurement

 Pot life Pot life is the length of time that a catalyzed resin system retains a viscosity low enough to be used in processing. Pot life is measured by determining the length of time required for the viscosity of a paint product, after mixing, to double via the chemical reaction. By thinning the paint, it is possible to influence the pot life. The temperature also plays an important role in determining pot life. As two-component coatings depend upon chemical reactions, an increase in temperature will reduce pot life, whereas a decrease in temperature will often extend it. For some years now, products have been available with good curing characteristics even at lower temperatures. As a result, the drying characteristics are still good even at temperatures as low as 0-5C, without this having any influence on pot life

 Some of the most common paint failures are: cracking blistering poor adhesion corrosion

The following application methods are dealt with: pneumatic spraying (conventional air spraying); airless spraying; airmix spraying; hot spraying; electrostatic spraying; two-component spraying; HVLP spraying; roller and brush.

Adhesion (determination)
The checkerboard incision test: adhesion is determined with the help of a ruler and a Stanley knife with a straight knife edge. A pattern of lines is cut into the surface whereby 6 parallel lines are first cut, followed by a second set of 6 parallel lines perpendicular to the first set. Tape with the required characteristics (adhesive strength 10N, 25 mm wide) is then lightly pressed onto the surface. Finally, the tape is pulled away from the surface in one smooth motion at an angle of 60. The extent to which the paint squares in between the lines are pulled off the surface is a measure of the adhesion. Sellotape type 1112 or 1401 or Scotch tape 828.

Method: ISO2409:1992(E)

Classification

Class

Loss of adhesion

Illustration
-

-very good
-good

Gt0
Gt1

0%
< 5%

-mediocre

Gt2

5 - 15%

-poor

Gt3

15 - 35%

-very poor

Gt4

35 - 65%

-total loss of adhesion

Gt5

65 - 100%

Depending upon the film thickness, the distance between the lines is as follows; 0-60 micron dry film thickness 1 mm interval 60-120 micron dry film thickness 2 mm interval 120-250 micron dry film thickness 3 mm interval >250 micro St Andrew's cross cut test or Elcometer test (ISO-4624) If the paint coating may be subjected to mechanical forces, the adhesion of the paint system should be class GT0/GT1 or better. If no mechanical loading factors are present, it should be GT2 or better

Gloss
Gloss is the visual impression created by the light-reflecting properties of a surface and depends upon the incidence of light and observation. Method: ISO2813-1978(E), measurement angle: 60 Classification: Classification: Mat Eggshell Silky gloss Semigloss Full gloss Gloss % 0-10% 10-20% 20-45% 45-75% 75-100%

Amount of paint consumed

A rough estimate of the paint loss percentages associated with various spraying methods is indicated below:

Application method

Application loss %

Viscosity DIN-cup 4

Pneumatic spraying
Airless spraying Air-assisted spraying Hot spraying Electrostatic spraying

30-40
20-40 20-40 20-40 10-20

18-35
30-60 30-60 30-60* 18-30

Two-component spraying HVLP spraying Roller and brush

20-40 5-10 4-6

30-60 20-35 80-120

Heat resistance
Heat resistance is specified in terms of the maximum temperature to which the coating can be continuously exposed without suffering damage. Yellowing and/or discolouration may occur. Some rough general guidelines are given below.

Type of binder used in the coating

Bitumen/chlorinated rubber/vinyl coatings Alkyd coatings Epoxy-tar coatings Polyurethane coatings Epoxy coating Alkyd aluminium Epoxy aluminium

Maximum temperature
70 C 120 C 120 C 120 C 150 C 175 C 200 C

 Airmix spraying Airmix spraying is, in principle, the same as airless spraying. The only difference is that airmix spraying also makes use of compressed air, which is why it is also referred to as air-supporting spraying. In this method, an airless pump applies a pressure of circa 50 bar to the paint. During the application stage, an additional 1 1.5 bar of compressed air is added to achieve an improved spray pattern. The application information for this spraying method is also included on the product data sheet. The layer thickness that can be realized in one paint run using this method is less than with airless spraying. This application method is more effective when it comes to obtaining optimum results with the application of polyurethane paints.

 Airless spraying Airless spraying was developed to make it possible to cover large areas with thicker paint coatings in a single run. In airless spraying, the paint is converted into a fine spray mist as it is forced through the spray opening under high pressure (150 - 250 bar). Many of the products supplied by Baril Coatings can be applied using this method. Every product data sheet specifies the viscosity to which the paint must be adjusted for airless spraying under the header "application information." Polyurethane paints can be applied via airless spraying, but extra attention must be paid to the layer thickness in that case. If a layer is applied in one run which is too thick, it will result in blistering (trapped air) and foam formation as well as a somewhat matt paint finish, thereby reducing the glossiness of the coating.

Alkyd paint This group of paints is often referred to synthetic paint or alkyd paint. They are one of the most popular types, and hardening of the paint film is the result of oxygen absorption. Alkyd paints are used practically everywhere, as they are extremely versatile. They are used in the house painting sector, construction sector and for ship coatings.

Generally speaking, alkyd paints have the following characteristics:

durable good flow characteristics fast drying good gloss retention good elasticity reasonably good corrosion control

Polyurethane paint

Polyurethane paints are mostly two-component products, whereby the primary component is mixed together with a curing agent shortly before use. There are two important types of polyurethane paints, the aliphatic and aromatic polyurethane paints. The most important difference between these two types is that the aromatic type is subject to yellowing over time whereas the aliphatic type is not. Besides the two-component versions, there are also single-component polyurethane paints, the so-called moisture-curing polyurethane paints which use moisture for the curing or hardening process. There are many possibilities for formulating polyurethane paints, which is why there are many types on the market, which can also differ markedly in characteristics.
Some important characteristics of these paints are:

hardness and wear-resistance resistance to water and chemicals excellent overall adhesion fast drying

Glossmeter
Medium or Semi Gloss - 60 - The Universal Measurement AngleOne must remember that all gloss levels can be measured using the standard measurement angle of 60. This 60 degree angle is used as the reference angle for all products. So why choose some other another angle? Because for extreme gloss, one obtains better measurements with the complimentary angles of 85 or 20 often used for low and high gloss levels respectively.

AIRLESS SPRAY PAINTING Fluid injection hazard: General Safety Airless spray equipment generates very high fluid pressure. Spray from the gun, leaks, or ruptured components can inject fluid through the skin and into your body and cause extremely serious bodily injury, including the need for amputation. Also, fluid or splashed into the eyes or onto the skin can cause serious damage. Never point the spray gun at anyone or at any part of the body. NEVER put hand or fingers over the spray tip. Always have the tip guard in place on the spray gun when spraying. Always follow the pressure relief procedure before cleaning or removing the spray tip or servicing any system equipment. Never try to stop or deflect leaks with your hand or body. Be sure equipment safety devices are operating properly before each us