Paints, varnishes and metallic coating

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 Paint

• Paint is defined as a unique homogeneous mixture of

three major ingredients namely Binder, Pigment, VOC &
additives, which when applied on the surface as a thin
layer that forms a solid dry adherent film after
oxidation/evaporation/ polymerisation”.

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 Functions of Paints

➢To protect the surface from weathering

effects of the atmosphere and actions by
other liquids, fumes and gases
➢To provide pleasing, colorful and
decorative appearance to the surfaces
➢To prevent decay of wooden members
➢To prevent corrosion of metallic surfaces
➢To provide a smooth surface for easy
cleaning
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CONSTITUENTS OF PAINT
Paints are variable combinations of :-
–Binder
–Pigment
–Filler/ Extender
–Volatile organic compound (Thinner)
–Driers
–Additives (Anti skinning agents, Anti
settling agent, Plasticizers, fire
retardants etc
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BINDER
➢“Binders are usually resins or oils but can be inorganic
compounds”
➢Binds pigment, fillers & additives together
➢Imparts adhesion & strongly influences: Gloss ,Durability,
Flexibility and Toughness
➢The actual film forming component & absolutely required
ingredient of any paint”
➢Consists of a resin and a solvent thinner
➢It is the part which solidifies to form the dry paint film when
the solvent evaporates
➢Non-volatile & mainly polymers of various types. They are
alkyd, epoxy, polyester, polyurethane resins etc

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 PIGMENTS
“Pigments are finely ground inorganic or organic powders of
higher RI (> 1.5)
–Higher the RI, more the light is bent & greater the opacity
–Good opacity has good lighting absorbing & /or scattering
properties
–Average diameter ranges from 0.01 to 5μ

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 PROPERTIES OF PIGMENT
•Should be opaque so that it may have good covering power.
–When a coating is opaque the pigment particles scatter &/or
absorb light sufficiently to prevent it from reaching the
substrate
–Opacity depends on two characteristic properties:
•Refractive Index (RI)
–If the particles do not have a high RI, less the bending of light
travelling & thus insufficient hiding of the substrate.
•Particle size:
–Particle size has also an effect on the effectiveness of the
pigment. As the particle size decreases , opacifying ability
increases.
•Should be non-toxic so that they have no bad effect on health
of painter & inhabitants
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 PURPOSE OF PIGMENT
Purpose:
Pigment plays a major role to attain the following essential
properties of paint system
–provides colour, opacity, film cohesion and sometimes corrosion
inhibition
–provides aesthetic look to the paint
–obliterates the substrate and previous colour on the substrate, if
any
–protects the film by reflecting the destructive UV light

White Lead, Zinc Oxide, Titanium Dioxide, Red Oxide, Carbon

Black, Prussian Blue, Chrome Yellow, Aluminium powder etc.
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 Widely used pigments:

• Coloring pigments: finely divided solid coloring

matter to provide shade, color to paint
– Blacks: lamp black, vegetable black, ivory black
– Blues: indigo, Prussian blue
– Yellows: chrome yellow (lead(II) chromate), raw Siena
(iron oxide and manganese oxide), yellow ochre
(ferric oxide and varying amounts of clay and sand)
– Greens: copper sulphate
– Browns: raw umber (iron oxide and manganese
oxide), burnt umber
– Red: red lead, vermillion (HgS), carmine (aluminium
salt of carminic acid) 10
 Titanium dioxide.
Titanium dioxide is the most important white pigment
produced commercially.

Titanium dioxide exists in three crystal forms: rutile, anatase,

and brookite. Only anatase and rutile are important as rutile
pigments. Anatase and rutile differ in their chemical
structures.

The rutile crystal has a more compact structure than anatase

and hence a higher density, higher RI, greater pacifying
power, and greater exteriorbdurability.

Rutile is used in larger volumes primarily because it gives anatase

about 20 percent greater hiding power than anatase.
However, rutile is not perfectly white and absorbs a certain
amount of radiation in the 400- to 500-nm region, giving a
yellowish undertone, whereas anatase absorbs almost no
light. The color of rutile coatings can be adjusted by tinting
with a violet pigment. 11
brookite
 EXTENDER/FILLER
Non-expensive commonly natural
inorganic materials added to the paint in
order to increase its volume.(RI <1.5)

Extenders are mainly inorganic

substances & do not provide colour to
the paint but added to improve
adhesion, ease of sanding and film
strength

As they are cheap in comparison to

prime pigments, they reduce overall
cost of the paints
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Average dia: up to 50μ
 EXTENDER/FILLER
Properties:
✓Do not provide colour
✓Poor optical properties (reflectance, opacity, etc)
✓It improves adhesion
✓If extender pigment added are of needle shaped or flaked shape,
the settling may be very little
Purpose:
–thickens the film
–Increases volume, paint film thickness
–reduces cost of the paint
–imparts toughness, abrasion resistance & texture
–Control consistency
Widely used fillers:-
–Calcium carbonate, Gypsum, Ground silica, Barytes, Slate powder
,French chalk, china clay, asbestos, silica, mica, whiting etc. 13
 VOC/THINNER
“Liquid used for viscosity adjustment for correct application”
Used to dissolve the binder and to facilitate application of
paint. Solvents are usually organic liquids or water.
not a part of the paint film.
Excessive thinner dulls the colour & gloss
Most hazardous due to its toxicity & flammability
Once the solvent gets evaporated, the remaining paint is
fixed on to the surface

Purpose:-
•Control flow and application properties
•Act as carrier for binders & pigments
•Help penetration into porous surfaces
•Used to clean brushes & other painting tools
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VOC/THINNER
Widely used thinner:
•Turpentine oil (distilled pine tree sap): the most commonly
used thinner
•Benzene & Naphtha: as substitute.
•Mineral spirit, acetone, carbon tetra chloride, ethyl alcohol

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 DRIERS
•Depending upon the nature of the solvent and film thickness,
the drying process may take as long as several hours.
–Thicker the film, longer the drying time. If the drying process is
artificially accelerated, there may be problems with adhesion
between the protective film and the metal surface.
•Metallic salts of Lead, Manganese, Cobalt, etc. of organic acids
–Easily soluble at ordinary temp
–Added in small quantity
–One drier should be used at a time
–Added to the paint just before use.
Purpose:-
–to accelerate the drying process.
Examples:-
•Lead acetate, Cobalt octate, Manganese octate, Litharge, Red
lead, Lead octate, Manganese dioxide, Zinc sulphate, etc. 16
 ADDITIVES
“Additives are small amounts of different chemical
substances improving or modifying the paint properties.

Added to a paint in amounts 0.001% & ≤ 5% & have a

profound influence on physical & chemical properties of
the paint

Prevent clustering of pigments

Surfactants such as polyoxyethylene ethers of dodecyl

alcohol, e.g. C12H25O (CH2. CH2.O)6H is added to attain
compatibility of different material in the paint system

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 ADDITIVES
•Driers accelerate the paints drying (hardening) by
catalyzing the oxidation of the binder.
•Plasticisers (liquids of MW higher than that of solids to
limit volatility)increase the paints flexibility, durability,
compatibility & minimise film cracking
•Fungicides, Biocides and Insecticides prevent growth and
attack of fungi, bacteria and insects. (protect the paint in
storage from spoilage due to bacterial growth)
•Flow control agents improve flow properties.
•Defoamers prevent formation of air bubbles entrapped in
the coatings.
•Emulsifiers are wetting agents increasing the colloidal
stability of the paints in liquid state.
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 ADDITIVES
•UV stabilizers provide stability of the paints under ultra-
violet light.
•Anti-skinning agents prevent formation of a skin in the
can.
•Adhesion promoters improve the adhesion of the coating
to the substrate.
•Corrosion inhibitors reduce the corrosion rate of the
substrate.
•Texturizers impart textures to the coatings.
•Antifreezers helps to withstand exposure
•Pigment stabilizers improve pigment stability
•Fire retardant properties
•Anti settling
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 Characteristics of Good Paints

• Should have a good body or spreading power

• Should work smoothly and freely to be laid in thin coat
• Should form durable, tough and wear resistant film upon
drying
• Color should not fade or change
• Painted surface should dry in about 9 hours
• Should become hard enough in 24 hours to take up
another coat
• Should not crack upon drying
• Should give a smooth and pleasing finish
• Should dry quickly
• Should not damage the painted surface

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 Defects in Painting

• Cracking: cracks extending throughout the entire

thickness of paint, due to
– Improper seasoning of wood
– Excessive use of drier
– Application of too many coats
• Crazing and crocodiling: Hairline cracks in top
coat, due to
– Use of excessive oil
– Use of impure oil
– Insufficient drying of under coat
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 Defects in Painting

• Blistering and peeling:

– Exposure of paint to strong sunshine
– Leaving oil or grease on the surface to be painted
– Painting a surface with moisture on surface or in
pores of wood
• Runs and sage:
– Application of too thick or slow drying paint
– Painting over a glossy surface
– Use of excessive drier
– Excessive humidity or rapid thermal changes during
drying period
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 Defects in Painting

• Chalking: rub off with hands or clothes

– Use of insufficient oil in priming coat

• Washing off: deposition of water soluble dissolved matter

at lower edges forming streaks

• Dull appearance: caused by use of excessive drier or on

aging

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 Defects in Painting

• Slow drying:
– use of inferior or old oils
– Painting over damp surfaces
– Painting during unfavorable weather
• Yellowing of white paint:
– Use white enamel where glossy finish is
desired
– For indoors use linseed oil with yellow tint that
does not bleach unless exposed to sunshine
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 The manufacturing process
The manufacture of paint is basically a physical process involving
weighing, mixing, grinding, tinting, thinning, filtering, and packaging
(filling).
No chemical reactions are involved. These processes take place in large
mixing tanks at approximately room temperature.

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 The manufacturing process

1. Raw material: Resin, pigment and additive agents are generally

major components of paint.

2. Mixing: Resin, pigment and solvent are mixed to produce an

even mill base.

3. Milling: Mill base produced at the pre-mixing process is sent to

the disperser to finely disperse the pigment particles.

4. Blending: Resin, additive agents and so on are added to the

mill base, the dispersion of which is completed. Also, the color
phase is adjusted with color materials.

5. Filtering: Blended and toned paint is filtrated.

6. Packing: Filtrated paint is packed into a container.

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Pigment dispersion

The solid pigments and extenders are usually supplied as a fine

powder by the pigment manufacturers. These fine powder particles
must be dispersed and evenly distributed throughout in the vehicle
or the liquid phase. For this suspension to have a maximum stability
in the liquid phase, the surface of each particle should be completely
wetted with the liquid vehicle and there should not be any
intervening layers of air or adsorbed water. To achieve the fine
dispersion, there are a number of types of different dispersion
equipment (ball mill, sand mill, roller mill, or other high-energy milling
equipment) in common use in the paint industry.

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 TYPES OF PAINTS

PAINTS ARE CATEGORISED IN DIFFERENT

GROUPS:

1. OIL PAINTS
2. SYNTHETIC PAINTS
3. EMULSION PAINTS
4. CELLULOSE PAINTS
5. VARNISHES
6. WATER PAINTS (DISTEMPER)
7. SPECIAL PAINTS

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 TYPES OF PAINTS
OIL PAINTS
• These are the traditional type having a linseed oil medium.
• They are respectively termed as primes, undercoats and finishing coats.
• This paint is cheap and easy to apply and it possess good opacity and
low Glow.
IT CONSISTS OF VARIOUS COATS:
1. PRIMING COAT: Primers are pigmented coatings that are applied to
new surfaces or to old cleaned surfaces, prior to the application of
undercoats or top coats. Its main functions are to achieve adequate
adhesion to the substrate and to provide good intercoat adhesion for
subsequent coats.
2. UNDER COAT: The undercoats are pigmented paints that are applied
to primed surfaces prior to the application of finished coats. The
undercoats are high pigment paints with a matte finish and a color to
complement that of the ultimate finishing coats.oil.
2. FINISHING COAT: The finish coat or the top coat are the final coats for
use both over primers or undercoats, and directly on a substrate. They are
formulated to provide good adherence to the undercoat, high durability, the
desired appearance, and other properties. These properties are invariably 29
controlled by the class of resin used as the principal binder in the top coat.
 SYNTHETIC PAINTS

• The medium for these is a

chemical compound, one type
being an oil modified alkyd resin.

• They have the advantages over

oil paints in setting more quickly
and offering greater durability
where corrosion is a danger.

• They also have a better flow and

are easier to apply.

• Drying is by evaporation of the

solvent, by oxidation and chemical
change.
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 EMULSION PAINTS
• An emulsion paint has the pigments and the
medium dispersed as small globules in water.
• Oil , synthetic resin and bitumen are common
medium.
• The different emulsion paints are alkyd, bitumen,
olyvinyl acetate and styrene emulsions.
• They are used mainly on walls surfaces.
• Alkyd emulsion paints contain pigments, oil, and
synthetic resins, they give a flat finish.
• Bitumen emulsions are those of bitumen in water
plus pigments and extenders.
• They are for use on asphalt and bituminous
surfaces.
• Polyvinyl acetate(p.v.a.)emulsion paints have a
p.v.a. medium and give a finish from flat to egg
shell gloss.
• Styrene emulsions incorporate the synthetic resin
styrene in several forms and have a medium 31
gloss. Its cost is RS-130/litre.
CELLULOSE PAINTS
• These are synthetically reproduced
from cellulose compounds and most of
them have to be applied as a spray for
they dry very quickly by evaporation of
the solvent.
• Apart from some kinds metal
powders(aluminium and bronze) they
are not satisfactory for general building
work but can be used for furniture and
fittings in houses.
• They are widely used in the motor car
industry.

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 Varnish
• Varnish is a transparent or nearly transparent solution of resinous
material and oil, alcohol or turpentine to form a clear, tough, glossy
film on woodwork

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 OIL VARNISH:
• They contain linseed oil or other
drying oils, dryers, synthetic or
natural resins and solvents such as
white spirit or turpentine.
• They dry by evaporation of the
solvent and oxidation of the oil.
• The relative proportions of the oil
and the resins control the usage, if
the oil is predominant a more elastic
varnish reserved for external work.
• If the solvent is the major ingredient
a high gloss, which dries out rapidly,
is obtained for internal work.
• Copal varnish is a good quality
type.

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 SPIRIT VARNISH
• Spirit varnish is a solutions of
shellac and spirit resins dissolved in
commercial alcohol(methylated
spirits).
• The are only suitable for internals
surfaces like furniture(e.g. in French
polishing).
• Polyurethane varnish is a type of
resin varnish producing a very
durable finish.
• Its cost is RS- 230/kg

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Characteristics of an ideal Varnish:-
1. When applied to the surface, it should form a thin film
of uniform nature.
2. The colour of the stainer should withstand for a long
time.
3. It should be easily Cleaned later on.
4. It should have an attractive and pleasuring appearance.
5. The surface of the Varnish should not show cracks or
blurry whiteness after drying.
6. Must be able to withstand change in temperature.
7. It should possess good spreading or covering power, as
it determines the cost.
8. No marks Should be Visible
9. It should not have any joints visible in between.
10. Grains should be visible to give it a natural look f done
on wooden surface.
11. It should have a smooth surface after drying up
12. No dust particles should be there and no drop off of
final coat should ne visible. 36
WATER PAINTS (DISTEMPER)
• Water paint also known as DISTEMPERS.
• They are used mainly on internal walls and
ceilings and most of them give a flat finish.
• There are several kinds are prepared on the site
by adding water to make a paste.
• They have a drying oil or varnish medium
emulsified in water containing glue or other
fixatives.
• Bartyes is a common pigment along with tinting
pigment.
• The cheapest type known as soft or ceiling
distemper, contains only a glue size vehicle and
tinted powdered chalk.
• It can be removed by washing or brushing and so
is only used for ceilings.
• Oil bound distemper is a better quality having a
mixture of linseed oil, pigment and extenders.
• It will withstand limited careful washing. 37
 SPECIAL PAINTS
THERE ARE MANY TYPES OF SPECIAL PAINTS:
ALUMINIUM PAINTS:
1. These are often used as a primer on resinous woods like Columbian
and oregon pine because they have a good sealing effect.
2. They contain aluminium powder in a quick drying medium.
ANTI-CONDENSATION PAINTS:
1. These containing cork filler and whilst.
2. They are not a substitute for adequate ventilation( the best safeguard
against condensation).
3. They afford some relief by reducing the transfer of heat.
BITUMINOUS PAINTS:
1. The vehicle for these is mostly bitumen.
2. They provide a cheap method of protecting steel where appearance is
secondary.
CHLORINATED RUBBER PAINTS:
1. This contains chlorinated rubber combined with pigments and special
thinner.
2. The paints offer good resistance to acids and alkalis and can be used
where fumes from these chemicals arise.
3. They are suitable for internal use on brickwork, concrete and steelwork.
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FIRE-RESISTANT PAINTS:
• These are used to increase the resistance to fire of wood and
certain building boards.
• There are several proprietary types incorporating ammonium
phosphate.
FUNGICIDAL PAINTS:
• These include special ingredients which render them resistance
to mildew and other fungoid attack, useful in humid
surroundings.
HEAT-RESISTING PAINTS:
• They incorporate special varnishes and pigment which do not
discolour on heating.
IMITATION STONE PAINT:
• This imitates natural stone, it contains stone granules in an oil or
emulsion medium.
TEXTURE PAINTS:
• These contain different powders and pigments with glue.
• They used in a stiff consistency to make textured surface on
which patterns can be formed by brush or special implements.
WOOD STAINS:
• It consists of various shades in oil, spirit or water medium
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 PAINTING TECHNIQUES BY BRUSH:
• Correctly prepared the surface and
using a good quality brush, the top of
the brush is dipped in the paint and the
excess removed by drawing it against
the edge of the tin.
• Working from right to left a narrow strip
of the work is covered with vertical
brush strokes, the area is then
“crossed”.
• The surface is then finally “laid off”.
• A strip must be joined to its neighbour
as soon as possible and the work so
arranged that the surface is finished
without interruption.

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 SPRAY PAINTING:

• It is an alternative technique essential for

cellulose paint.
• Simple spray equipment comprises a motor
and fan giving a current of air delivered by
tube to a container and spray gun.
• The gun has a nozzle from which the paint is
forced in a fine spray when a trigger is
depressed.
• An air compressor is used in large equipment.
• Painting by spray is quicker for large areas
then brushing.
• It also uses less paint for this has to be thinner.

Electrochemical painting/coating
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