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Coating Types and Characteristics

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Chapter 4 4-2. Film-Forming Mechanisms

Coating Types and Characteristics
Coating binders can be subcategorized according to the
mechanism described above. However, with both oxidation
4-1. Introduction and most polymerization film-forming mechanisms, solvent
evaporation occurs initially, followed by a subsequent
a. All coatings—whether used for corrosion protection, chemical reaction consisting of either a reaction with oxygen
to provide good aesthetics or a pleasing appearance, or for or chemical crosslinking. Solvent evaporative coatings also
any other purpose—will contain a film-forming material. are called thermoplastics because, when heated, they become
This material may be organic or inorganic and, after plastic and can soften and deform. Oxidation and
application, may form a hard, impervious film, a soft porous chemically crosslinked coatings “set” and harden when
film, or combinations in between. Furthermore, the film- cured; they do not soften or deform on heating and,
forming material may be clear (unpigmented) or filled with therefore, are called thermosets. After application, most
a variety of different pigments, depending on its function. coatings “dry” by solvent evaporation to form a film that
When the film-forming material (resin) contains pigments, feels dry to the touch. However, the dried coating may not
it is called a binder. The binder will hold the pigment be cured, and additional chemical reactions may be required.
particles together and to the substrate over which it has been Oxidation coatings require crosslinking with oxygen from
applied. When the binder (resin plus pigment) is dissolved the air, and polymerization coatings require a crosslinking
in a solvent to make it liquid, the combination (solvent, chemical reaction between two or more coreactants to attain
binder, and pigment) is considered to be a vehicle. The their final physical and chemical properties.
term vehicle comes from the ability to transport and apply
the liquid to the surface being coated. Once on the surface, a. Oxidation (thermoset). Thermoset coating types dry
the solvent evaporates and the vehicle becomes a pigment- and ultimately crosslink by reaction with oxygen from the
binder system. Application properties of the paint usually atmosphere. All such coatings in this class contain drying
are characterized by the vehicle in a liquid condition. The oils that consist mainly of polyunsaturated fatty acids. The
viscosity, rate of solvent evaporation, and consistency of the drying oil frequently is combined with a resin, usually by
wet coating are most important during application. After cooking or heating to enhance water and chemical
application, the pigments determine the corrosion-inhibitive resistance. The curing reaction is accelerated by the
properties and, generally, the color and some flow control presence of metallic salts as driers. After application, the
properties of the applied coating. The binder determines the coating dries by solvent evaporation. However, to attain
weatherability of the coating, its environmental resistance, maximum chemical and moisture-resistance properties, the
and the coating's ability to function in a given environment. oil must react with oxygen from the air to crosslink, cure,
The required surface preparation, and often the application and further harden. The auto-oxidation reaction occurs at a
equipment and techniques, are determined by the binder. relatively fast rate shortly after application of the wet paint;
and it continues throughout the life of the coating, although
b. The principal mechanisms by which binders form at a much slower rate. For most oil-based coatings, suitable
films are reaction with oxygen from the air (oxidation), moisture and chemical resistance occur within a few days
evaporation of the solvent from the vehicle (solvent after application, although maximum resistances may not be
evaporation), or chemical crosslinking (polymerization). obtained until months or years after application. In time
The coating film attained by these mechanisms can be either (often 20 or 30 years later), the oxidation reaction and
thermoplastic or thermosetting. Thermoplastic materials continued drying of the oleoresinous binder system leads to
deform and soften on exposure to heat. Thermoset materials cracking, embrittlement, and deterioration of the coating
do not deform and remain hard upon heat exposure. Each film.
type of coating resin or binder categorized by its film-
forming mechanism, different types of pigments, and the b. Solvent evaporation (thermoplastic). A second film-
various solvent families will be discussed. Drying oils are forming mechanism is solvent evaporation. The solvent
an integral part of some coating formulations, and they as within which the resin is dissolved or emulsified may be
well as driers that aid in the drying reaction will be covered. water or an organic solvent. The liquid resin returns to a
Miscellaneous additives that are formulated into many solid material when the solvent evaporates. The coating is
coatings for specific purposes are itemized and discussed. formed as a result of solvent evaporation and drying, with
Sections are presented on powder coatings, thermal spray no attendant crosslinking or polymerization. Solvent-based
organic and inorganic coatings, and galvanizing tapes and coating systems that dry solely by solvent evaporation
wraps. Problems with VOCs also will be discussed. (vinyls and chlorinated rubbers) have their usage severely

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restricted because of VOC regulations. These resins must reactions are becoming increasingly important in the
be dissolved in relatively high amounts of noncompliant formulation of modern VOC-compliant coating systems.
solvents to be formulated into a corrosion-resistance Small molecule units, that by virtue of their low molecular
protective coating. Latex emulsion coatings consist of weight are liquid, can be reacted with other low molecular
pigmented synthetic resin particles emulsified in water. weight liquid molecules to form a higher molecular weight
Because latex emulsion coatings dry by water evaporation molecule that will harden to form a solid (nonliquid)
(and perhaps one percent or less of a coalescing organic protective film. The most successful adaptations to
solvent), coatings formulated in this fashion comply with manufacturing low VOC coatings have been two-pack,
VOC legislation; and they have rapidly advanced in recent chemically cured coating systems such as the epoxy,
years to become environmentally safe, long-lasting, polyurethane, polyester, and vinyl ester systems.
protective coating systems. Thermoplastic coatings in the
context used here are coatings that dry principally, or solely, 4-3. Binders (Resins)
by water or solvent evaporation; they do not undergo
chemical crosslinking. Principal coatings in this class are The binder, sometimes called a resin, and a suitable solvent
acrylic lattices, solvent cutbacks, and hot melt bituminous (to make it liquid) are combined to form the vehicle.
coatings and vinyl coatings (zinc chromate vinyl butyral Pigment particles then are dispersed and mixed into the
wash primers, vinyl chloride-vinyl acetate copolymers, and liquid resin, and the paint is packaged, usually in a can or
waterborne vinyls). pail, for sale. Upon use, the liquid paint is
applied—perhaps by brush, roller, or spray—after which the
c. Chemically crosslinked (thermoset). Thermoset solvent volatilizes, the liquid resin dries or cures, and the
coatings, by definition, are coatings that are “set,” and are pigment particles “bind” together and to the surface being
nondeformable when exposed to elevated temperatures. painted. Binders may be natural or synthetic resins and may
Thermoset coatings achieve their characteristic “set” and the be organic or inorganic. The binder used in a particular
ability to resist heat deformation by virtue of a three- coating system is primarily responsible for the coating's
dimensional crosslinking. This crosslinking is achieved by chemical, water, and UV light-resistant properties.
coreacting two or more monomers, with at least one However, to optimize protective capabilities, most coatings
monomer having a functionality of three or greater, and the must be pigmented to provide color and opacity, to reduce
other a functionality of at least two. (The functionality is shrinkage, and to obtain enhanced moisture and chemical
the number of reaction sites where crosslinking can occur.) resistance. When properly applied and dried and/or cured,
This film-forming mechanism involves a chemical reaction the pigmented binder provides the decorative, protective
combining smaller molecules (mers) to create a larger layer referred to as a paint or coating. The characteristic of
molecule (polymers). The reactions can consist of the same the binder and its method of drying and/or curing
kind of mer units reacting to form larger molecules determines the mechanism of film formation. Many of the
(homopolymers) or different mer units reacting to form natural resins used as binders are derived from exudations
copolymers, tripolymers, or, generically, polymers. After from trees or insect secretions. Synthetic binders are
crosslinking, and depending on the type and extent of generally by-products of chemical refining or manufacturing
crosslinking, the resin system is solvent resistant, ranges processes. These resins are man-made and, when refined
from tough and flexible to hard and brittle, and does not and modified for coatings use, can be used as film formers
significantly deform on the application of heat. In coating for protective and decorative coatings. Because of their
formulations, most coreactive coating systems are supplied improved moisture, chemical, and UV resistant properties
in multipack systems consisting of two or more containers compared with the natural resins, synthetic resins have
that must be mixed prior to application. However, some obtained widespread use in a variety of different service
thermoset materials react with moisture from the air environments as corrosion-protective coatings.
(moisture and ketimine curing isocyanates) and can be
supplied as a one-package system. After application in all a. Natural resins (oxidative). Natural resins are derived
instances, the coating system, when properly applied and from tree exudations, fossilized vegetable remains, or insect
cured, forms a single, extremely large molecule by virtue of secretions. Natural resins derived from tree exudation may
its polyfunctional crosslinking. When suitably dissolved in be named after the region from which they originated; this
a solvent and pigmented, many coreactive materials can be accounts for some exotic names such as Kauri, Batu,
formulated into a protective coating. Some of the more Sandric, and others. Natural resins generally are cooked
commonly used protective coating systems are based on with drying oils to make varnishes with faster drying rates,
catalyzed epoxy resins, polyurethane reactions, acrylic/vinyl higher gloss, and harder films than can be attained from the
ester resins, and modifications thereof. Each of these oil alone. Some were used as a sole binder in so-called
coating systems will be discussed later. Polymerization spirit varnishes, i.e., the resin was simply dissolved in

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volatile solvents. When applied to a surface, the solvent depend on the drying oil, its type, and the degree of
evaporated from the spirit varnish leaving a film of the resin unsaturation (available crosslinking sites). Soybean oil has
on the substrate. This type of drying mechanism involves been shown to give good drying rates and good color
no substantial chemical change and is typical of what today retention. However, linseed oils generally dry faster but
is called lacquer. In general, clear films of natural resin, oil darken on exposure to light. Castor and coconut oils have
varnishes, and spar varnishes have poor exterior durability. good color-retentive properties and are used as plasticizing
Accordingly, these resins are no longer used extensively resins because of their nonoxidizing characteristics.
except for interior use such as for wood furniture finishing.
(2) The amount of oil combined with the resin influences
(1) Rosins. The natural resin, rosin, is obtained from the protective capability of the applied alkyd coating. Long
oleoresin, a sap exudation of pine trees. Lighter fractions oil modifications (greater than 94.6 liters [25 gallons] of oil
(i.e., the fastest evaporating, when heated, also usually the per 45.36 kilograms [100 pounds] of resin) result in less
lowest molecular weight) of the sap include turpentine, moisture and chemical resistance and longer drying times.
dipentene, and pine oil. Rosins generally have a high acid However, long oil alkyds have a greater ability to penetrate
value and poor resistance to water and alkalies. They also and seal a poorly cleaned surface. Short oil alkyds (less
are sensitive to oxygen in the air and are tacky to the touch. than 37.85 liters [10 gallons] of oil per 45.36 kilograms
Rosins are most commonly used to produce rosin maleic [100 pounds] of resin) are fast-drying coatings that usually
esters, and they are adducted (partially reacted) with maleic require baking to attain full cure (approximately 95 °C
anhydride and then esterified with glycerol. These esters (200 °F)) for a few minutes. Short oil coatings have good
sometimes are combined with castor and/or soya oils to moisture and chemical resistance but are relatively hard and
reduce yellowing and to increase the hardness and gloss of brittle. Medium oil alkyds (37.85 to 94.6 liters [10 to 25
paints. Coatings manufactured from rosin maleic ester gallons] of oil per 45.36 kilograms [100 pounds] of resin)
binders are clear and unpigmented and are intended for are a practical compromise between the long and short oil
interior wood surfaces and furniture finishes. modifications. They usually dry hard within 24 hours and
are the oil length of choice for most new and maintenance
(2) Shellac. Lac is a resinous secretion of a coccid alkyd coating systems.
insect from India and Thailand used to make shellac. The
dry secretion is collected, crushed, and washed. Afterward, (3) All alkyd coating systems initially dry by solvent
it is melted and dried in sheets that are broken up and evaporation and cure by auto-oxidative crosslinking of the
exported for use as an alcohol-soluble coating resin. The oil constituent. Because of the presence of the drying oil,
shellac film is both hard and fairly elastic, and it has a alkyd coating systems have limited chemical and moisture
variety of uses including knot sealers and sealers for wood resistance, cannot be used in highly chemical environments
and plaster. (acid or alkali), and are not resistant to immersion or near
immersion condensing conditions. However, their relatively
(3) Copals. Natural resins called copals are derived low cost, ease of mixing and application, and excellent
from fossilized or semifossilized vegetable remains. These ability to penetrate and adhere to relatively poorly prepared,
resins have high carboxyl-functional hydrocarbons of high rough, dirty, or chalked surfaces make them the coating
acid number and, therefore, are reactive. The fossil resins system of choice on steel exposed to nonchemical
frequently are cooked with vegetable oils to result in a resin atmospheric service. Alkyd coatings are widely used for
with an improved drying time, hardness, gloss, and water or structural steel such as the exterior of buildings, handrails,
alkali resistance. Because of their flexibility, these resins cranes, gantries, etc. Alkyd coating systems should not be
most commonly are used for coating paper (paper labels). used in immersion or in environments in which the coating
will be subjected to prolonged wetting, dampness, or
b. Oil-based alkyds (oxidative). condensing humidity. Because drying oils are saponified by
alkalies, they should not be applied to alkaline surfaces,
(1) Alkyd resins are derived as a reaction product of including applications over galvanizing (as a result of the
polyhydric alcohols and polybasic acids. Alkyds use a alkaline nature of zinc hydroxide, a corrosion product of
polybasic acid derived from a semidrying or drying oil so zinc), concrete, mortar, and most cementitious surfaces (as
the resin formed can undergo auto-oxidation at any a result of inherent alkalinity because of the use of lime as
temperature. This definition also includes polyester resins, a component of cement).
of which alkyds are a specific type. The properties of alkyd
coatings predominantly are the result of the properties of the c. Alkyd modification (oxidative). Alkyds are perhaps
drying oil used in the manufacture of the alkyd resin. the most widely used industrial protective coating by virtue
Drying time, hardness, color, and moisture sensitivity all of their ease of application, relatively low cost, color

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stability, and good weather ability in most atmospheric urethane oil coating. The isocyanate reaction decreases the
environments; therefore, it is reasonable to assume that drying time of the coating and provides enhanced resistance
coating formulators would seek to improve properties of the to chemicals, moisture, weathering, and abrasion. Uralkyd
drying oil alkyd by modification with other resin types. coatings are used as marine coatings of wood boat hulls,
Although these modifications will somewhat increase the machinery enamels, and an upgrade to an alkyd coating.
cost of the coating system, improved properties usually
result and make the modification cost effective. d. Waterborne acrylic emulsion coating. An emulsion
is essentially a dispersion of droplets of one liquid in
(1) Phenolic modification. Modification with a phenolic another liquid, in which the first is not normally soluble.
resin improves gloss retention, water, and alkali resistance. Examples of emulsions are milk and mayonnaise; in both of
Phenolic alkyd resins have performed satisfactorily in water these, fat globules are disbursed in water. For paints,
immersion, a service in which nonphenolic modified alkyd emulsion technology is promising for VOC compliance
resins are not suitable. because water is not a restricted solvent, and only small
amounts of solvents—called coalescing solvents—are
(2) Vinyl modifications. Alkyd resins with vinyl required in the formulation. The resin is polymerized to a
modification are commonly formulated as universal primers. relatively high molecular weight (10,000 or higher) in
These primers generally can be topcoated with most generic- emulsion paints. The pigment is incorporated in the resin,
type intermediate and topcoats. The alkyd constituent and the semisolid resin-pigment polymer is emulsified in
improves adhesion, film build, and solvent and thermal water. Acrylic polymers are especially popular as an
resistance; the vinyl modification enhances recoatability and emulsion resin because they provide coatings with
chemical and moisture resistance. These coatings frequently unexcelled color retention and have excellent exterior
are used as shop primers or as tie coats between different weathering and durability properties. The hardness and
generic coatings (e.g., over inorganic, zinc-rich primers or flexibility of emulsion polymers vary considerably because
between alkyd primers and epoxy topcoats). of the types and amounts of monomers used in their
molecular weights. Methyl methacrylate monomer gives the
(3) Silicone modifications. Silicone modification of hardest thermoplastic polymer, and acrylate monomers yield
alkyd resins is perhaps the most widely promoted the softest product. Copolymers of acrylic and methacrylic
modification for corrosion-protective coatings. A silicone esters are used extensively for exterior acrylic emulsion
intermediate is added to the alkyd resin in quantities up to paints. Vinyl acetate-acrylic copolymers also are popular,
30 percent to provide polymers with greatly improved particularly for interior use. The acrylic constituent
durability, gloss retention, and heat resistance. Moisture upgrades water and alkali resistance, film flexibility, and
resistance is greatly improved by the silicone modification, durability; and it acts as a permanent plasticizer for the
and this type of paint is used extensively as marine and vinyl acetate.
maintenance paint.
(1) Styrene-acrylic. Styrene-acrylic waterborne systems
(4) Epoxy modifications. Alkyd resins can be combined in which the styrene is copolymerized with lower
with epoxy resins to produce coatings with improved alkylacrylates have gained in importance. They are
chemical and moisture-resistant properties. Epoxy ester characterized by high gloss and good gloss retention. When
coatings are similar to alkyds, and they are used when properly formulated, they dry quickly and develop good film
improved performance is required. Epoxy esters result from hardness. Styrene-acrylic systems are used primarily as
the direct esterification of an epoxy resin and a fatty acid interior house paints or as coatings for relatively mild
such as a vegetable oil or rosin. The resulting epoxy ester interior industrial service conditions. These coatings may
resin is prepared by reacting it with drying oil by heating in yellow on exterior exposure and do not have good moisture
the presence of an esterification catalyst. The same drying resistance. They also are used as concrete block fillers.
oils used to prepare alkyds also are used to prepare epoxy
esters. Oil length is categorized as long, medium, and short (2) Latex emulsions. Latex emulsion coating systems
with properties similar to those for alkyds. Epoxy resin oil- have gained in popularity because of their ease of
based coatings have better adhesion, moisture, and chemical application and cleanup and their good color retention and
resistance than alkyds, although they are slightly more durability on exterior surfaces. One hundred percent acrylic
expensive. These coatings are used as baking and air dry copolymer formulations have been developed that provide
original equipment manufacturers’ coatings applied to good protection as complete water-based systems (primer,
appliances, machinery, pumps, valves, etc. intermediate, and topcoat) on blast-cleaned structural steel.
Acrylic latex coating systems also are used extensively for
(5) Urethane modifications. Alkyd resins are commonly protecting aluminum and other nonferrous metals and for
reacted with isocyanates to form a so-called uralkyd or

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painting wood in exterior weathering environments. moisture and chemical resistance. Because of UV light-
Because they are also VOC compliant, acrylic latex coating induced cracking, unmodified coal tar coatings most
systems have gained popularity as shop-applied systems. commonly are used below grade or in water-immersion
Even more popular are latex emulsion intermediate and/or service. Thermoplastic bituminous coatings are applied as
finish coats used in conjunction with a water-based, hot melts, solvent cutbacks, or water emulsions.
inorganic, zinc-rich primer. Water-based, zinc-rich primers,
coated with acrylic emulsion intermediate and top coats, are (1) Hot melt. Hot melt application involves heating the
rapidly becoming popular because of their VOC compliance, bitumen to a temperature of approximately 178 °C (350 °F)
good corrosion protection, and aesthetic properties. to 246 °C (475 °F); its viscosity at that temperature is low,
Although many of the acrylic emulsion coating formulations almost waterlike. The hot melt then is applied by mop or
have dramatically improved moisture resistance, these swab to the surface being coated, although other techniques
coatings are not recommended for use in areas of high such as brush, rolling, or spraying may be used. Flow
condensing humidity, ponding water, splash zones, or for coating of the interiors of pipes and small vessels also is
immersion service. The ionic surfactants used in the possible. In this method, the hot melt is flowed onto the
emulsion to provide in-can stability will result in water pipe or vessel while the item is rotated or turned. In
sensitivity after application. Water vapor transmission may general, hot melt applications provide the best moisture and
be a problem for wood or masonry surfaces, and latex paints chemical resistance, followed in order by solvent cutback
may be suitable for these surfaces because they are said to and water emulsions. Pipelines coated with hot melt coal
breath. Breathing occurs as a result of irregularities during tar have 100-year successful exposure experience
the coalescence part of film formation. A series of pores or underground and in water immersions. In the pipe coating
defects in the coalesced film allow passage of water vapor shop, the pipe is blast-cleaned to SSPC-SP 10 metal by a
but retain the larger liquid water molecule. Water-based rotary blast machine. The bitumen is flow-coated onto the
paints develop poor film properties when applied in cold, pipe with alternate reinforcement of asphalt- or coal tar-
damp weather. Both cold weather and high humidity or impregnated felt paper. The finish wrap is of kraft paper
dampness retard water evaporation and the drying and for UV protection. Field application of a hot bitumen is
coalescence of the paint film. The result can be a soft, best done by swabbing with a mop. However, swabbing is
poorly adherent film that, when drying finally occurs, may rarely done at present because of safety considerations and
be cracked or brittle with poor adhesion. Too fast a water the development of suitable, safer, alternate coatings that are
evaporation rate on a hot surface can lead to a powdery, more easily field applied.
poorly adherent paint or a film with many voids, pinholes,
or cross-sectional porosities. Storing emulsion paints at (2) Solvent cutback. Asphaltic or coal tar bitumens are
excessively high temperatures for prolonged periods or dissolved in a suitable solvent (aliphatic and aromatic
freezing the emulsion may destabilize it and cause settling, hydrocarbon solvents). Dissolving the bitumen in a solvent
de-emulsification, and/or severe viscosity changes. lowers its viscosity enough that the cutback can be applied
by brush, roller, or spray as appropriate. After application,
e. Bituminous (solvent evaporation). Bitumens used in the solvent volatilizes and the bitumen resolidifies into a
the coatings industry are coal tar and asphalt. These film. The coating thickness and moisture resistance of a
materials are distinctly different physically and chemically; solvent cutback is considerably less than that achieved by
but in appearance they are essentially identical black, hot melt application, but the convenience of not having to
thermoplastic, tar materials. Coal tar enamels, or pitches, heat the bitumen at the jobsite immediately prior to
are derived from the coking of coal. When coal is heated application is a major advantage. Cutbacks are used on
in the absence of air to a temperature of approximately pipelines, pump stations, below grade, and immersion
1093 °C (2000 °F), it decomposes partially into a gas and applications when hot melt bitumens cannot be applied.
a coke. Coal tar is formed when the gas is subsequently
condensed. Lighter oil fractions are removed from the tar (3) Water emulsion. Water emulsions are prepared by
by subsequent heating and gas extraction until the desired suspending minute particles of the bitumen in water using
coal tar composition for use in coatings is obtained. Asphalt emulsifying agents. Pigmentation with inert fillers such as
may be mined or obtained as a residue from the distillation coal dust, powdered silica, mica, and limestone dust may be
of crude petroleum. Lighter fractions are removed during incorporated with the bitumen. After application, the water
distillation until the desired asphalt tar suitable for coating evaporates and coalescence occurs to form a protective film.
use is obtained. Asphaltic coatings have much greater UV Latex emulsions (both asphaltic and coal tars) are widely
resistance than the coal tars, and they are suitable for use in used as driveway or parking lot sealers and as waterproofing
above-grade atmospheric weathering applications. However, agents. Bitumen latex emulsions are VOC compliant. Some
coal tar coatings are vastly superior to asphaltic coatings in solvent cutback applications may not be VOC compliant

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because of the use of solvents; and hot applied, hot melt modified vinyl resin coatings in common use in USACE
bitumens may release VOCs into the atmosphere during will not adhere to the wash primer. Many other coatings
heating and application. Furthermore, volatile phenol- adhere well to the wash primer, including oil-based alkyds,
containing compounds produced during the heating of the epoxies, and urethanes. When mixing, the acid diluent must
bitumen are considered carcinogenic and skin irritants. be added slowly to the base with agitation to prevent local
Accordingly, suitable worker protection must be provided in gelation. These wash primers should be used within 8 hours
the form of protective clothing and appropriate respirators. after mixing; any primer remaining after 8 hours should be
discarded because there will be a gradual decline in
f. Vinyl (solvent evaporating copolymer). Most vinyl adhesion of the mixed wash primer. There may be no
coatings consist of a resin comprised of a copolymer of physical change in appearance after 8 hours but adhesion
PVC and polyvinyl acetate (PVA) in the ratio of will be diminished substantially. The mixed wash primers
approximately 86 percent PVC to 13 or 14 percent PVA. must be applied thin (as a “wash”) to a thickness not
Approximately 1 percent or less maleic acid is used as a exceeding approximately 1.9 cm (3/4 mil). Coating failures
modifier to provide adhesion to metallic surfaces, and the may result if mixing and application instructions are not
same amount of hydroxyl modification (using a vinyl followed. Vinyl wash primers range in VOC content from
alcohol) provides adhesion to vinyl butyral wash primers or 680 to 765 grams/liter (g/L) (5.7 to 6.4 lb/gal). (To convert
other organic coatings. Increasing hydroxyl modification of grams per liter to pounds per gallon, divide by 119.8, for
vinyl chloride or vinyl acetate resins enables the example, 250 g/L ÷ 119.8 = 2.1 lb/gal).
incorporation of the vinyl into alkyds, epoxies, and other
resin systems. This incorporation improves air dry, moisture (3) Vinyl chloride-vinyl acetate copolymers. These vinyl
resistance, and compatibility. Maleic acid modification to solution coatings are noted for outstanding toughness and
the vinyl chloride-vinyl acetate copolymer improves water resistance. USACE has used a five-coat vinyl system
adhesion to blast-cleaned steel, zinc-rich coatings, or other for years on steel exposed in both freshwater immersion and
metal surfaces. Additionally, the carboxyl groups atmospheric service on locks and dam gates. Although the
introduced into the vinyl copolymer resins provide points of five-coat system is somewhat expensive to apply, it is
reactivity for crosslinking reactions. extremely durable when properly applied. Repainting
intervals of more than 20 years are commonplace, although
(1) Vinyl chloride. Vinyl acetate copolymer coatings maintenance repainting and touchup of deteriorated or
have been used extensively by USACE for protection of damaged paint may be necessary at more frequent intervals.
submerged steel or as a coating systems specified for the The common USACE vinyl system uses a vinyl resin
protection of steel used in locks and dams. Because of the containing 86 percent polyvinyl chloride, approximately
high amounts of solvents that must be used to dissolve vinyl 13 percent polyvinyl acetate, and maleic acid modification.
resins, most vinyl coatings, except water-based vinyl The coating system has excellent toughness, moisture
formulations, are not VOC compliant. resistance, and light resistance; and it can be topcoated
easily after extended periods of time. Generally, PVC-PVA
(2) Vinyl butyral wash primer. Basic zinc chromate copolymer coatings range in VOC content from 540 to
vinyl butyral wash primers have been used extensively as 650 g/L (4.5 to 5.4 lb /gal).
primers to provide excellent adhesion to a variety of
surfaces, including carbon steel, stainless steel, zinc, (4) Waterborne vinyl. Vinyl resins and modified vinyls
cadmium, tin, aluminum, galvanized steel, magnesium, and frequently are emulsified vinyls modified with acrylic resins
even glass. These wash primers are preferred when to provide enhanced flexibility, toughness, and recoatability.
exposure to salt water or salt spray occurs because they Vinyl acrylics are most commonly used for exterior
inhibit underfilm corrosion. Basic zinc chromate and vinyl surfaces. Waterborne vinyl coatings consisting of pigmented
butyral wash primers formulated in accordance with polyvinyl acetate are formulated for interior use. The
DOD-P-15328 D incorporating a vinyl butyral resin, basic polyvinyl acetate can be used alone as a homopolymer, or
zinc chromate pigments, and a phosphoric acid alcohol it can be coreacted with other monomers such as the lower
solvent system have been used extensively in the past. For molecular weight esters of acrylic, fumaric, or maleic acid.
best performance, wash primers should be topcoated with a Latices based on polyvinyl acetate generally have relatively
coating based on a hydroxyl modified vinyl solution resin. poor moisture resistance, light fastness, and exterior
This is an especially effective system in seawater and durability. They are not the preferred choice for exterior
freshwater immersion and in corrosive environments. Wash surfaces, although they are eminently suitable for interior
primers have many application particularities. If an all-vinyl use. Polyvinyl acetate based homopolymer and copolymers
system is desired, the wash primer must be coated with a are relatively inexpensive, and they are easy to apply and
hydroxyl modified vinyl solution coating. The maleic acid clean up. These emulsion coatings are suitable for

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interior use and exterior nonaggressive environments. (a) Polyamine crosslinked epoxy coatings generally have
However, an acrylic modification is required when greater excellent alkali resistance and the greatest chemical
moisture and exterior weathering resistance is needed. resistance of the epoxies. They also have good moisture
and water resistance. These epoxies are the most brittle and
g. Catalyzed epoxies (crosslinking copolymers). The the least flexible; and they have a strong tendency to
epoxy resin most commonly used for industrial protective degrade on UV light exposure, resulting in chalking.
coatings is of the glycidal-ether type, specifically, that Amine-cured epoxies, with suitable nonreactive pigments,
derived from bisphenol-A and epichlorhydrin. This are used widely as tank lining systems for the protection of
combination of raw materials yields a series of related steel and concrete in water and aqueous chemical immersion
compounds that, prior to crosslinking, have an epoxide service. Because of their high crosslink density (achieved
group at each end of the molecule, and a alcoholic hydroxyl as a result of the small molecular size of most of the amines
group as a midchain pendant. Crosslinking takes place used as coreactants), amine-cured epoxies are the epoxies of
preferentially through the terminal epoxy groups then choice in atmospheric or immersion environments of high
through the midchain hydroxyl groups. Other epoxy resins and low (pH 3-12+) hydrolyzing chemicals.
have been developed, including cycloaliphatic epoxies, that
offer improvements in light stability and UV light (b) Phenolic modification to the epoxy resin further
degradation; but these epoxy resins do not exhibit the enhances water resistance; and phenolic modified epoxies,
adhesion, chemical resistance, and flexibility of resins with amine coreactants, are perhaps the most popular
derived from epichlorhydrin and bisphenol-A. Epoxy cresol coating system for freshwater and saltwater immersion and
novolacs also have been developed and provide high many aqueous chemical solutions, even at elevated
temperature resistance and great chemical resistance at the temperatures. Phenolic modification enhances moisture and
expense of brittleness and a lack of toughness and heat resistance properties of the epoxy, but it imparts
flexibility. The epoxy molecules, particularly those of the slightly more brittleness and diminishes alkali resistance.
bisphenol-A type, are relatively small and must be coreacted
with copolymer curing agents to attain crosslinking (c) Polyamine crosslinked epoxy coatings are readily
properties sufficient to provide a protective coating. The formulated as VOC-compliant coating systems as a result of
copolymer crosslinker frequently is called a catalyst or the low molecular weights of both the amine and epoxy
curing agent, and it usually is a polyamine- or polyamide- coreactants. If a relatively low molecular weight bisphenol-
containing material. A epoxy is used, both the epoxy and amine coreactants are
in liquid form. Little if any solvent is needed to dissolve or
(1) Polyamine curing agents for epoxies. The dilute the resins, and 100 percent solids coatings are
polyamines (i.e., diethylenetriamine, hydroxyethyldiethylene- feasible.
triamine, bishydroxydiethylenetriamine) are relatively small
molecules with a low molecular weight compared to the (d) Amine adduct epoxies were developed to reduce the
epoxy resin. When reacted, they lead to tight crosslinking tendency toward amine blushing; to eliminate an induction
and high chemical and moisture resistance. However, time; and to make the low molecular weight amine less
during the crosslinking reaction, any unreacted amine may volatile, safer, and easier to mix. An amine adduct is
be squeezed out of the crosslinked film to the surface and prepared by reacting an excess of a polyfunctional (three or
develop the so-called amine blush, a hazy white coloration more reactive sites) amine with some of the epoxy resin to
on the coating surface. The blush, a reaction between the increase its molecular size. The prereacted amine adduct
amine and carbon dioxide from the air, is not detrimental then is packaged in a separate container, sometimes with
and can be allowed to remain on the surface unless additional pigment and solvent. As with all other coreactant
topcoating is necessary. However, the blush must be curing agents, the components in the separate containers are
removed by wiping or washing it from the surface (it is mixed prior to application. Because of the greater
water soluble) before a subsequent epoxy coat is applied. molecular size of the amine adduct relative to the
To minimize formation of the amine blush, many unprereacted amine, amine blush is eliminated and most of
formulators require a 15- to 30-minute induction time after the other problems associated with small molecular weight
mixing prior to application. This allows the reaction to amines are minimized. Chemical crosslinking in the applied
begin and initial crosslinking to occur before the paint is film is not considered to be as extensive as that provided by
applied. Some of the small amine molecules will partially the nonprereacted amine, and the chemical resistance is
crosslink with the epoxy resin molecules and increase their somewhat less. However, application is much easier and
size and reduce the tendency for migration. not nearly as dependent on thorough mixing and adequate
induction time.

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(2) Polyamide curing agents for epoxies. Polyamide (b) The 100 percent solids epoxies generally have short
curing agents are the condensation products of a dimerized pot lives because the coreactants are not diluted. Some
fatty acid with the polyamine. Terminal amine functionality formulations require the use of special twin-feed airless
allows crosslinking to occur as with a straight amine, spray equipment for external mixing (refer to paragraph 8-
although the polyamide molecule is much larger. The 2g). When aromatic polyamines are used for curing,
crosslinked film has improved flexibility, improved gloss hardening times of 4 to 12 hours can be attained even at
and flow, excellent water resistance, and good chemical temperatures as low as freezing. Although these coating
resistance. However, polyamide-cured coatings have systems are relatively expensive, they are used primarily as
somewhat less solvent and alkali resistance than amine- and corrosion-resistant linings for storage tanks (e.g., oil
amine-adduct-cured epoxies. Because fatty acids have a tankers), both on land and in marine vessels. Because of
water repellent tendency, polyamide-cured epoxies are said their low molecular weight liquid formulation, these
to be tough, flexible, water-repellent coatings. Compared to materials also can be used as self-leveling epoxy flooring
the amine and amine-adduct types, polyamide-cured epoxies systems. These coating systems generally are clear or high
have significantly better UV light resistance, resulting in gloss and, when applied, have a waterlike consistency that
substantially less chalking on exterior exposure. Polyamide- hardens to a smooth, glossy flooring.
cured epoxies are perhaps the most widely used of the three
types of curative systems, and they have wide application in (4) Coal tar epoxies.
the protection of steel and concrete in freshwater and
saltwater immersion. Polyamide-cured epoxies have the (a) Coal tar epoxy is a combination of a coal tar and an
best exterior weathering resistance and the best ability of the epoxy resin. The epoxy resin usually is packaged separately
epoxies to recoat after extended periods. Polyamide epoxies from the curing agent, which frequently is combined with
are used to protect substrates exposed to condensation and the coal tar resin. The curing agent may be an amine,
high humidity. Specially formulated polyamide-cured amine addict, or polyamide. The crosslinking reaction is the
epoxies have the ability to displace water from a surface. same as those previously described, with active hydrogens
These coating materials can be applied and cured under from the amine nitrogen providing a crosslinking site to the
water to form corrosion-resistant coatings. epoxide groups and, in some situations, the hydroxyl groups
of the epoxy resin. The coal tar acts as a filler within the
(3) 100 percent solids epoxies. crosslinked epoxy matrix, and the resulting film has the
toughness, adhesion, UV resistance, and thermal stability of
(a) The 100 percent solids epoxies can be formulated the epoxies combined with the extremely high moisture
from low molecular weight polyfunctional liquid epoxy resistance afforded by the coal tar. The amine-cured coal
resins. The viscosity of these resins can be lowered even tar epoxies generally have great chemical and moisture
further by the use of compatible reactive diluents with an resistance but are more brittle and harder to apply and
epoxy functionality of one; they do not contribute to topcoat than the amine adduct and polyamide-cured coal tar
crosslinking but are chemically bound into the final epoxies. The polyamide-cured coal tar epoxies are more
crosslinked film. The liquid epoxy resin system is water resistant, flexible, easier to topcoat, and more tolerant
crosslinked by a liquid polyamine or polyamide without the of application variables than the other epoxies.
addition of any solvent. A tertiary amino phenolic catalyst,
such as tri-(dimethylaminomethyl) phenol may be added to (b) One problem with coal tar epoxies is recoating. The
produce polymerization of the epoxy resin with itself. This recoat window for application of a coal tar epoxy topcoat to
and other phenols act as accelerators in the curing reaction. a coal tar epoxy undercoat can be as little as 18 hours with
Silicone resins may be added as flow agents, and dibutyl some formulations, and with most formulations it usually is
phthalate can be added as a plasticizer. Thus, the entire within 48 hours. Extensive intracoat disbonding may occur
liquid paint can be converted to a crosslinked coating that after this time. The disbonding is believed to result from
becomes a 100 percent solids epoxy. These materials have low molecular weight hydrocarbon oils from the coal tar
little, if any, volatile organic material so they are VOC exuding to the surface after application and from UV light-
compliant. Coatings formulated in this fashion show typical induced oxidation. Amine-cured coal tar epoxies are more
epoxy finish properties; but they are less flexible than other susceptible to this phenomenon than the amine adduct and
epoxies because the films are thicker and the close spacing polyamide types. However, even with the latter types, the
of the reacting groups leads to a high crosslinked density. first coat may cure so hard and glossy after only a few
The film is tough and relatively nonbrittle. Solventless hours that adhesion of subsequent coats may be a problem.
epoxy systems have low internal stress and are less brittle To attain adhesion between an undercoat and subsequent
because there is negligible volume contraction on curing to coats of a coal tar epoxy, it may be necessary to roughen
a solid. the surface by sweep blast cleaning or other scarifying

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techniques and to remove the oxidation and exudate high gloss finish coats. The appearance of polyurethane
products. Alternately, slow evaporating strong solvents such coatings formulated with aliphatic isocyanates are
as methylene chloride and diacetone alcohol can be applied unsurpassed in this regard by any of the epoxies, acrylics,
to the coal tar surface being overcoated. These solvents will or other coating materials. One of the most important
penetrate, attack, and partially dissolve or swell the coal tar aliphatic isocyanates is HDI. In its monomeric form, HDI
epoxy surface so molecular entanglement and adhesion may is an irritant as is true with TDI and MDI. However, HDI
occur. However, because these solvents are slow can be reacted (commonly with water) to obtain a higher
evaporating, they may be retained within the coal tar epoxy molecular-weight modification that is less volatile and safer.
film. If the coal tar epoxy is immersed in water, these When HDI or its higher molecular-weight modifications are
relatively polar solvents may attract water and blistering reacted with a suitable polyol in the presence of certain
may occur. Therefore, care should be taken when using metal catalysts (tin, bismith, zinc, iron, cobalt), a urethane
solvents to increase intracoat adhesion for coal tar epoxies coating with excellent resistance to discoloration, hydrolysis,
in immersion service. The problem is of much lesser and heat degradation is produced.
consequence if the coal tar epoxy is used on an atmospheric
or nonwater immersion surface. (c) Because of the potential presence of unreacted
monomeric forms of TDI, MDI, and HDI—all of which are
h. Urethanes (crosslinking copolymer). Crosslinking respiratory irritants—an air-fed respirator should be used
reactions in urethane coatings consist of a reaction between when mixing and applying these materials. Workers and
an isocyanate containing (-N=C=O) material and a material painters may never develop an isocyanate sensitivity, or the
with a polyhydroxylated (-OH) containing coreactant. sensitivity may occur only after prolonged exposure.
Crosslinking occurs because of the high reactivity and However, some individuals may become sensitized quickly,
affinity of the isocyanate group for the active hydrogen of on initial contact or on only a short exposure. When
the polyolhydroxyl or any other active hydrogen atom isocyanate respiratory sensitization occurs, it occurs
attached to a nitrogen or oxygen atom. The rate of this suddenly and drastically, and the affected individual should
crosslinking reaction depends on a number factors, such as be removed from the work site. The sensitization is
the type and configuration of both the isocyanate and polyol permanent, and increased exposure leads to increased
materials and temperature. However, the reaction is such irritation to affected tissues and membranes (refer to Chapter
that, with most formulations, crosslinking can occur at 10).
temperatures as low as 18 °C (0 °F) or less.
(2) Polyols. Polyols coreact with isocyanates to form a
(1) Isocyanates. The isocyanate reactant can be either polyurethane film. A polyol consists of large molecules
aromatic (containing the benzene ring) or aliphatic (straight (commonly acrylics, polyesters, polyethers, epoxies, vinyls,
chain or cyclical) hydrocarbons. Aromatic polyurethanes and alkyds) that have been reacted with di- or
are prone to darkening and yellowing on exposure to polyfunctional alcohols such as propylene glycol,
sunlight because of the chromophoric nature of the benzene trimethylolpropane, pentaerythritol, and others. The
ring. Because aliphatic polyurethanes, by definition, do not hydroxyl-terminated polyol materials are packaged
contain the benzene ring, they do not yellow or darken and separately from the isocyanate, and the packaging usually
are preferred for exterior use. includes appropriate solvents and pigments. On application,
the isocyanate and polyol constituents are mixed and
(a) The most important monomeric diisocyanates used crosslinking proceeds via the isocyanate-hydroxyl functions
for coatings are toluene diisocyanate (TDI), 4,4, and liberates a carbon dioxide gas. To prevent bubbles and
diphenylmethane diisocyanate (MDI), and 1,6, voids in the coating cross-section as a result of the carbon
hexamethylene diisocyanate (HDI). Because of their irritant dioxide gas inclusion, all polyurethane coatings must be
characteristics, these materials rarely are used in unreacted applied relatively thin (0.038 to 0.05 mm [1.5 to 2.0 mils]
form for the compounding of urethane coatings. They per coat). This allows the gas to pass easily from the
normally are converted into isocyanate terminated polymers coating before the coating cures and hardens. In general,
or adducts of polyols such as hydroxyl terminated polyesters the characteristics and properties of the urethane coating
and polyethers. The molecular weight of these isocyanates depend predominantly on the properties of the
can be increased by self-reaction in the presence of catalysts polyhydroxylated coreactant. The VOC content of most
to form dimers and/or trimers. polyurethane coatings ranges from 250 to 550 g/L (2.1 to
4.6 lb/gal).
(b) Aliphatic isocyanates react more slowly and are
considerably more expensive than the aromatic isocyanates, (3) Acrylic urethanes. Acrylic urethanes are perhaps the
but they allow the formulation of nonyellowing, light stable, most widely used urethanes for corrosion protection and

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atmospheric service. When properly formulated, these resistant urethanes for interior use; or as primers in exterior
materials have excellent weatherability, gloss, and color exposures.
retention and good chemical and moisture resistance. They
can be tinted easily and pigmented to provide a variety of (7) Vinyl polyurethanes. Urethane coatings using vinyl
deep and pastel colors at a lower cost per gallon than the polyols combine abrasion resistance of the urethane with the
next most popular class, the polyester urethanes. Acrylic toughness, flexibility, and chemical resistance of the vinyl.
urethanes are not used for water immersion service and, for These urethane coatings are promoted for use when
the most part, they do not have the chemical resistance of flexibility and abrasion resistance are important. However,
the polyester urethanes. However, they have excellent vinyl urethane coatings are subject to some chalking or
weathering and color retentive properties when an aliphatic fading on exterior exposure and do not have the color, gloss,
isocyanate coreactant is used. These are the most popular weatherability, or solvent resistance of the acrylic and
aliphatic polyurethanes; they are widely used as topcoats polyester urethanes. Because the vinyl is thermoplastic and
over epoxy primers and intermediate coats in most is attacked and softened by solvents, recoating after
nonchemical atmospheric environments. Many water tanks, extended periods is not a major problem and is a primary
bridges, railroad cars, aircraft, and other highly visible advantage of vinyl urethane systems. Coatings based on
structures are coated with these light-fast, glossy, these resins are used on structural steel, ships, tanks, and
aesthetically appealing coatings. other steel structures for which corrosion resistance
flexibility and abrasion resistance are important.
(4) Polyester urethanes. As a result of their high
isocyanate demand when coreacted, polyester urethanes (8) Moisture-cured polyurethanes. Isocyanates can react
form relatively hard, chemical-resistant poly films. Because with the hydroxyl group in water (H-OH) to form a unique
they are tightly crosslinked, they have great chemical and class of coatings known as moisture-cured urethanes. Single
moisture resistance; but they are not as flexible and tough package moisture-cured urethanes use an isocyanate
as the acrylic urethanes. This high isocyanate demand also prepolymer that, when applied, reacts with the humidity in
substantially increases the cost of polyester urethane over the air to form a tough, hard resinous film. Because of their
acrylic urethanes. Polyester polyurethanes are used in rapid rate of reaction, aromatic isocyanates are used almost
exterior chemical environments in which acid fumes or exclusively in moisture-cured urethanes. The pigments must
highly corrosive conditions are encountered. They have be essentially nonreactive with the isocyanate. Although it
high gloss, are light fast, and have a good appearance. is possible to use a number of pigments, aluminum leaf is
common. Properly formulated and applied, urethanes have
(5) Polyether urethanes. The polyether prepolymer is excellent adhesion to blast-cleaned structural steel surfaces.
considerably less expensive than either acrylic or polyester When spray applied, urethanes form a tough, glossy, highly
polyols. However, polyethers are sensitive to UV-induced protective chemical and solvent-resistance film. Because of
oxidative degradation. Ether linkages within the polyether their high crosslink density, the recoat window of some
are somewhat water sensitive; and, in polyethers, they are formulations is less than 24 hours, or it may be more than
repeated throughout the polymer chain without separation by a month in exterior environments. Sufficient solvent
long water-insensitive hydrocarbon chains or aromatic hardness and permeability does not occur in 24 hours, and
groups. Polyester polyurethanes are used as elastomeric topcoating is considered safe. Topcoating is also safe after
urethane coatings, for coal tar urethanes, and for other a month or more of exterior chalking and weathering to
urethane coatings that are sheltered or protected from light. remove the slick, glossy surface that often occurs shortly
They frequently are used as pipeline coatings or for below after curing. However, within the range of 24 hours to a
grade corrosion protection, and coatings for minimum month or more, subsequently applied polyurethane topcoats
service. may exhibit disbonding or poor adhesion. Moisture-cured
urethanes are used as primers under some epoxies, used as
(6) Epoxy polyurethane. Epoxy urethanes are full system coating on steel and nonferrous metals, and as
considerably more expensive than conventionally cured primers on marginally cleaned steel. Frequently, the
amine or polyamide crosslinked epoxies. The epoxy moisture-cured polyurethane primer and/or intermediate
addition induces a tendency for an epoxy urethane to chalk, coats are topcoated with a nonmoisture-cured aliphatic
and the lower moisture resistance resulting from the polyurethane to minimize yellowing and darkening.
urethane crosslink produces a less chemical- and moisture-
resistant polymer than a conventionally cured epoxy coating. i. Vinyl ester (crosslinking copolymer).
Most epoxy urethanes are formulated with a less expensive
aromatic isocyanate. They are promoted primarily as low- (1) Strictly speaking, vinyl esters can be called vinyls
temperature-curing epoxies; as fast curing, chemically because of the vinyl unsaturation (-C=CH2) on the epoxy

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backbone chain; actually, they are manufactured from and various chemical compounds that make up the oil.
are closely related to acrylics. Methacrylic esters of Specifically, the oil must have polyunsaturated fatty acids,
bisphenol-A or other epoxies, such as novalacs, are prepared commonly ethylenic carbon double bonds (-C=C-). When
by reacting methacrylic acid with terminal oxirane groups of combined with oxygen and accelerated by metallic driers,
the epoxy. The resins have high viscosity at room auto-oxidative polymerization occurs and transforms the oil
temperature and are mixed with monomeric styrene, which from a liquid to a solid. Some vegetable oils (e.g.,
acts as a reactive diluent to reduce viscosity. Crosslink cottonseed, rapeseed, peanut, and coconut oils) are not
curing is by free radical initiation generated from peroxide drying oils. Fatty vegetable oils that exhibit proper drying
degeneration using benzyl peroxide, methyl ethyl ketone oil characteristics and can be formulated into paints or
peroxide, or peroxide blends. protective coatings include linseed, tung, soybean,
dehydrated castor, oiticica, and fish oils. Linseed oil, one
(2) Compared to normal unsaturated polyester resins, of the most widely used drying oils, is obtained from
vinyl ester resins have better chemical resistance because of pressing the flax seed. Raw linseed oils dry too slowly for
the stability of the epoxy backbone and the presence of most purposes; therefore, they require processing and the
stable methyl groups on the methacrylate terminations. addition of driers to hasten the hardening rate.
Compared to a polyester resin, there are fewer points of
unsaturation on the backbone, and even these are effectively b. Processing usually consists of heating the raw oil and
shielded by methacrylate terminations. Vinyl esters have dissolving mixtures of manganese and cobalt driers—which
excellent resistance to acids and alkalies, bleaches, and other are soluble in the oil at ordinary room temperatures—in the
oxidizing agents. Vinyl esters are used as thick film (1.02 raw oil. The oil can be further treated by bodying, which
to 1.52 mm [40 to 60 mils]) tank and chimney linings when consists of blowing gasses (oxygen and/or hydrogen)
great strength and high chemical resistance are required. through the oils to increase viscosity and reduce drying
They most commonly are applied by spray, have a short time. All of these treatments (heating, blowing, and adding
potlife, and build readily to thicknesses approaching 0.50 driers) result in an increased oil viscosity that occurs as a
mm (20 mils) per coat. Because of their short potlife and result of auto-oxidative crosslinking polymerization and
high chemical and solvent resistance, topcoating after even oxygen absorption into the oil film. In general, bodied oils
a short period of time (as little as 3 or 4 days) may be a (those that have been thickened by heat treating and blowing
problem with some formulations. Because the coatings are air through them) dry more quickly, are tougher, and have
applied so thick and because of high inherent shrinkage better water, chemical, and after-yellowing resistance than
stresses on curing, a deep anchor pattern (0.10 to 0.13 mm untreated, unbodied oil. However, bodied oils do not wet
[4 to 5 mils]) is required for most applications. Care must and penetrate as well. Even if blown or bodied, drying oils
be taken to ensure that the coating is not applied excessively may have their properties enhanced considerably by the
thick, or cracking may occur. addition of a synthetic resin. When added to the processed
and treated drying oil, synthetic resins (e.g., alkyds,
(3) Vinyl ester coatings can be applied as highly phenolics, epoxy esters, or urethanes) enhance the chemical
pigmented, sprayable coatings or with a fiberglass veil and moisture-resistant properties of the drying oil.
reinforcement as fiberglass reinforced plastic laminants.
Vinyl ester coatings have excellent abrasion and wear c. Animal oils, principally menhaden fish oil, have
resistance, and these attributes combined with their chemical properties similar to drying vegetable oils, except they are
resistance lead to application as high build monolithic somewhat slow drying, become tacky in humid weather, and
concrete floor systems and tank linings. Because of their give off an unpleasant odor in confined spaces. Animal oils
high volume solids content and because styrene is used as are not recommended for interior use, and they frequently
a reactive diluent (combined thinner and coreactant), little are combined with other drying oils.
thinner is required in a formulation. Thus, vinyl ester
coatings are VOC compliant. d. In a strict sense, oil paints consist of a pigment, a
drying oil, and an aliphatic solvent used to thin the
4-4. Drying Oils pigmented oil. The oil is not modified with any synthetic
resins. The coating initially dries by solvent evaporation;
a. If a drying oil is reduced or dissolved in a solvent this is followed by auto-oxidative crosslinking of the drying
and pigmented, a drying oil coating results. Not all oils are oil. The addition of driers to the oil aid in the formation of
drying oils. An oil is classified as drying if, when spread the solid film. The characteristics of these oleoresinous
out in the air as a thin layer, it changes from a liquid to a paints are determined primarily by the characteristics of the
solid film with a great strength, toughness, and hardness. drying oil, and to a lesser degree by the pigments
This drying ability depends on the molecular structure of the incorporated into that oil. Because these paints have a high

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oil content, drying times are slow with 2- to 3-day recoat contribute significantly to the viscosity and application
periods over the soft film. However, long oil paints were characteristics of the wet coating and, ultimately, properties
formulated for use over poorly prepared, rusted, and/or mill of the dried, protective coating.
scale surfaces; so for these situations, long oil paints may be
the best paints. a. Inhibitive pigments. A select few pigments provide
active corrosion inhibition to metal substrates when
4-5. Driers formulated into a coating composition. These pigments are
slightly water soluble; and, when the paint film is exposed
Driers are materials that promote or accelerate the curing or to and permeated by moisture, the water in the film cross-
hardening of drying oil paints. Drying of oil-based paints section partially dissolves constituents of the pigment and
by auto-oxidation is affected considerably by temperature carries it to the underlying metal surface. The dissolved ion
and the presence of certain catalysts. Driers act as a species react with the metal (commonly steel or aluminum)
catalyst to aid in both surface and through drying of drying to form a reaction product that passivates the substrate and
oil paints. Driers are considered metallo-organic materials reduces the rate of underfilm corrosion.
that can be classified as surface driers and through driers.
The metal constituent is lead, cobalt, zinc, or manganese; (1) Chromate. Chromate-containing pigments (e.g., zinc
the organic radical of the metallo-organic dryer is usually a and lead chromates) partially solubilize, liberating the
naphthenate derived from naphthenic acid. Surface driers chromate anion that, when carried by moisture to the
are compounds of cobalt and manganese. The use of these underlying steel or aluminum substrate, reacts to form a
materials will cause a surface of the drying oil paint to chromate film on the metal surface. This chromate film
rapidly set to a near solid, but the underlying paint does not strongly passivates the metal surface and prevents
reach this advanced state of oxidation. In thick films an establishment of electrochemical corrosion cells by reducing
uneven hardening will cause wrinkling; therefore, through electron transfer. Additionally, this passivating film is
driers should be used in conjunction with surface driers. slightly alkaline, which further inhibits underfilm corrosion.
Through driers are metallo-organic compounds of lead, To a lesser degree, molybdate and borate pigments also
cadmium, zinc, or zirconium. When used in conjunction provide active underfilm passivation, but not nearly as well
with surface driers, through driers help cause auto-oxidative as the chromate-containing pigments.
crosslinking through the cross-section of the film. Driers
may lose their effectiveness with prolonged storage. This (2) Lead and zinc. Lead and zinc also may disassociate
storage problem affects the primary surface driers (cobalt partially on moisture permeation into a paint; these elements
and manganese) and, to a lesser degree, secondary driers also provide inhibitive protection, but in a different fashion.
(calcium and zinc). The loss of dryer effectiveness is When pigmented into oil-based coatings, lead and zinc react
believed to result from the absorption and deactivation by with acidic degradation products that occur as a result of
certain pigments, notably carbon black. If an oil-based paint oxidation and UV light exposure. If these complex organic
is aged, it may be best to test its ability to dry by applying acids reach the underlying steel, under-film corrosion may
some of it to a nonabsorptive surface to see if it dries be hastened. However, the lead and zinc cations react with
properly. the acids complexing, insolubilizing, and/or neutralizing
them. Lead and chromate pigments are considered
4-6. Pigments hazardous paint ingredients, and many coating formulators
are restricting or eliminating these materials from their
Virtually, all protective coatings used for corrosion formulations. Although substitute pigments may be safer,
protection contain pigments. Although the obvious purpose they may not offer the inhibitive properties of the pigments
of pigmentation in a coating is to provide color and opacity, they replace.
proper formulation of pigments into a protective coating
does far more than that. For corrosion-protective coatings, b. Barrier pigments. Barrier protection is offered to a
pigments function by providing inhibition or passivation of greater or lesser degree by all inorganic pigments formulated
a metal surface, preventing corrosion; reinforce the paint into a coating. Any permeating moisture must migrate
film; act as a barrier to provide water impermeability to the around the pigment particle and, by so doing, increase its
dried paint film; and with zinc-rich coatings, sacrifice permeation path length to the substrate. However, some
galvanically to protect the underlying steel substrate (refer pigment types are specifically formulated as barrier
to Chapter 2). Certain pigment types enhance heat, pigments, or alternately impart barrier properties to the paint
abrasion, acid, or alkali resistance to coatings. Pigment film. Most notable of the barrier pigments is flaked
particle size and shape, ease of wettability by the binder, aluminum.
and bulking or properties relating to specific density

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(1) Aluminum flake. Aluminum flake, in the form of a inorganic, frequently are used in combination with titanium
leafing aluminum (coated with a stearic or other fatty acid dioxide to add color. Natural iron oxides range in color
to cause it to be displaced to the surface by the coating from a yellow to a bright brown red, to a greenish brown,
binder) or nonleafing flake (noncoated), is specifically added and a deep rich brown. Synthetic iron oxides range in color
to many types of coatings, particularly oil-based coatings from yellow and red to brown and black. Red chromate
and epoxy mastic coatings to enhance UV light resistance pigments with sulfate, and sometimes molybdate additions,
and reduce moisture permeation. No other pigments can range in color from a light yellow to a bright orange or
provide the leafing properties that aluminum flake does. scarlet red. Because of their bright, clean color, lead
Leafing aluminum pigments are widely used in alkyd finish chromate pigments frequently are used in highway striping
coats to provide a bright, shiny appearance and for paints and in safety color paints. Even though lead
resistance to atmospheric weathering (UV) and moisture. chromate is considered hazardous, the pigments in these
paints will be difficult to replace because no other pigments
(2) Micaceous iron oxide. Micaceous iron oxide, have a similar light fastness and brightness. The purpose of
commonly used in Europe and to a lesser degree in the organic pigments is primarily to provide paint color.
United States, has lamellar (platelike) particles. Any Originally, organic coloring pigments were extracted as
relatively large sized pigment particle, even if it is not plate colorants from insects and vegetables. Synthetic organic
shaped, will increase the permeating path of moisture and pigments now have been developed, but few of these have
result in a barrier-type protection. Some recently technical or commercial importance in corrosion-
manufactured pigments consist of hollow glass spheres that preventative coatings. Compared with inorganic pigments,
have been developed to aid in VOC compliance and to fill organic pigments generally are brighter colored, have less
a coating and make it more moisture impermeable. hiding, are more prone to bleed, have much poorer heat and
light fast resistance, and are substantially higher in price.
c. Sacrificial pigments. High purity zinc dust, with The most important class of organic color pigments are
little zinc oxide or carbonate contamination, is the only called azo pigments and are manufactured from aromatic
sacrificial pigment used in paint manufacture. These zinc hydrocarbons, which are available from coal tar or
dust pigments consist of particles that are of a relatively petroleum distillates. These pigments are characterized by
large (1 to 3 µ) diameter and are essentially pure zinc. If the presence of a chromophore consisting of one or two azo
the zinc pigment particles are in contact with both each groups (-N = N-).
other and the underlying steel surface when incorporated
with a binder into a dry paint film, galvanic protection e. Hiding pigments. Pigments with a high light
results. On the galvanic series zinc is anodic to steel and refractive index provide the best hiding. Rutile titanium
becomes the anode in a zinc-steel galvanic couple. The zinc dioxide, followed by anatase titanium oxide, zinc sulfide,
anode corrodes and dissipates, and the underlying steel and zinc oxide have relatively high refractive indices.
cathode remains galvanically protected. This phenomenon Conversely, silica, whiting, and barytes all have relatively
occurs for all zinc coatings, including those deposited by hot low refractive indices and do not provide good hiding when
dip galvanizing and thermal spraying. Thermally sprayed formulated into paints.
aluminum coatings (both aluminum powder and wire) also
are believed to have sacrificial capability when applied to f. Extender pigments. Certain types of pigments do not
blast-cleaned steel. However, this sacrificial capability may provide inhibition or have good barrier or sacrificial
last for only a short time—within a few days after characteristics. They do not have a high refractive index
application until the aluminum oxidizes sufficiently to and do not impart good color or hiding to a paint film.
insulate the aluminum from the steel. Galvanic protection However, as reinforcing pigments and flow control
ceases after a sufficient thickness of intact aluminum oxide pigments, they are important in coating formulation. As a
forms on the sprayed aluminum coating. class, these pigments can be called extender pigments
because they are relatively inexpensive compared to most
d. Color pigments. A number of inorganic pigments other pigments; they are used in conjunction with more
provide color to paint. Titanium dioxide in both the rutile expensive pigments to reduce costs. The use of extender
and anatase forms is the most popular white pigment pigments reduces shrinkage stresses within the paint film,
because of its high refractive index and excellent hiding giving it strength, and “extending” the pigment volume
power (the ability to render a paint opaque). Rutile titanium content at relatively low cost. Extender pigments include
has the highest refractive index and the best tinting strength those based on carbonates, silicates, sulfates, barytes, and
of all other pigment types. (Tinting strength is the ease by mica. Each of these types of pigments is somewhat
which color pigments can be mixed with another pigment to different, but they all are relatively low cost materials that
color the paint.) Other pigments, both organic and can be added in finely divided form to a paint to aid in its

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rheological properties (viscosity and flow control) and to based house paints and varnishes. Gum-spirits turpentine is
reinforce the dry film strength. distilled from crude gum rosin obtained by tapping southern
pine trees. Wood turpentine has a somewhat different
4-7. Solvents composition from gum turpentine and is obtained by
distillation of the crude rosin extracted from the ground
a. In a true sense, a solvent is defined as a substance, wood from southern pine stumps. Sulfate turpentine is
usually a liquid, that will dissolve and change a solid to a obtained as a by-product of the Kraft paper industry.
liquid state. In the coating industry, solvents are considered Turpentine has good solvent power for most oil and
any volatile liquid formulated into a paint, even though it oleoresinous binders, but its use is limited in modern paint
may not have solvency power. Some liquids are diluents technology because of its relatively high price and slow
and, even though the diluent may not have solvency power, evaporation rate. Other turpentine-like solvents, such as
it may enhance the solvency of other solvents in the paint. dipentene and pine oil, also are obtained from southern pine
Water is the universal solvent, except for its use as a trees and have specialized uses.
dispersant in emulsion coatings, but it is not used as a paint
solvent in durable coatings. Water-soluble resins are d. Hydrocarbon solvents. Hydrocarbon solvents are
susceptible to softening and swelling by water; therefore, obtained from both petroleum and coal tar sources.
coatings made from them will not be addressed in this Petroleum hydrocarbon solvents are the lighter (more
manual. However, water-soluble resins should not be volatile) fractions from the distillation of crude oil. Coal tar
confused with water-emulsified resins, which were discussed hydrocarbons are distillation products from coke oven by-
earlier in this chapter. Organic solvents impart low water products. Hydrocarbon solvents may be classified as
sensitivity and are the solvents of choice when dissolving aliphatic or aromatic.
solid resins.
(1) Aliphatic hydrocarbons. Aliphatic hydrocarbons are
b. The purpose of any solvent is to dissolve solid paint straight or cyclical carbon-hydrogen containing liquids that
constituents, reduce viscosity, and render the paint fluid are nonpolar in character and exemplified by mineral spirits,
enough that it can be satisfactorily applied. The solvent is “varnish makers and painters” (VMP) naphtha, and other
undesirable after application and must evaporate from the materials such as hexane and heptane. For the most part,
drying coating film. In addition to enabling application of these solvents have poor to moderate solvency for all but
the coating material, solvents must be able to wet the oil-modified coatings. Their solvency can be increased by
substrate being coated and penetrate into and help the blending them with various amounts of other, more
coating seal any crevices, voids, or depressed irregularities. powerful solvents such as aromatic hydrocarbons or ketones.
Also, the solvent must volatilize fast enough to prevent runs Aliphatic hydrocarbons are generally the least expensive of
and sags in the drying coating film. However, a solvent that all solvents and can be obtained in a wide range of
is too volatile can cause solvent pops, loss of gloss, dry evaporating rates. Aliphatic solvents are considered the
spray, poor surface wetting and penetration, and poor film least toxic of any of the solvent classes, although—as with
flow and inhibit cure. Virtually all coating formulations use any other solvent—gloves, respirators, and protective
a blend of solvents to achieve optimum properties. Some clothing should be used by individuals applying paints
solvents within the blend will evaporate fast, enabling the containing these solvents. Naphthenic hydrocarbons are
drying paint to set quickly. Other solvents may dry slower aliphatic hydrocarbon solvents, but with a cyclical ring
and provide wettability and penetrability. Ultimately, all molecular structure. The naphthenic solvents are midway
solvents should evaporate to allow the coating to achieve between the aliphatic and aromatic solvents in solvency
hardness, cure, and final properties. Solvents can be power. Naphthenic solvents are used in alkyd and epoxy
categorized according to their chemical composition. The ester coatings and asphaltic and coal tar-containing coatings.
most commonly used categorization subdivides solvents into
classes called turpentines, hydrocarbons, ketones, esters, (2) Aromatic hydrocarbons. Aromatic hydrocarbon
alcohols, and glycol ethers. solvents contain a benzene ring structure. The most
common solvents of this type are toluene (toluol), xylene
c. Turpentines. Turpentine solvents are actually (xylol), and high-flash naphtha. Aromatic hydrocarbon
hydrocarbon solvents; they are categorized separately solvents have a greater solvent power than aliphatic
because they are derived from southern pine trees as hydrocarbon solvents. They generally are good solvents for
opposed to solvents fractionated from petroleum and coal tar oils, oleoresinous binders, alkyds, bitumens (asphalts and
refining. Turpentine is used infrequently today in coal tars), and some synthetic resins. Aromatic solvents can
manufacturing corrosion-protective coatings, although it is be blended with more powerful solvents to enhance their
widely sold in retail paint stores for field thinning of oil- power of solvency.

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e. Ketone solvents. Ketones such as acetone, methyl phenolics, vinyl butyral wash primers, most epoxies, and
ethyl ketone, methyl isobutyl ketone, and diacetone alcohol inorganic zinc-rich coatings based on ethyl silicate vehicles.
have varying evaporation rates and relatively strong Because of reactivity of the alcohol hydroxyl group, alcohol
solubility parameters. These solvents exhibit strong solvents cannot be used as solvents in polyurethane coatings.
hydrogen bonding and high polarity. When retained in a Alcohol is a solvent common to many epoxies. Chlorinated
paint film, they may attract and draw moisture into the solvents such as 1,1,1, trichloroethane, chloroforms,
coating. As with all other solvent classes, each of the dichloroethane and dichloroethylene, and methylene
ketone solvents has a different evaporation rate; care should chloride, although used infrequently in paints, are good paint
be taken when using ketone solvents with slow evaporative strippers, especially for epoxies and polyurethanes.
rates to minimize solvent entrapment within the coating. As Chlorinated solvents are nonflammable and VOC compliant
a class, ketones are polar materials characterized by because they generally are nonphotochemically reactive.
exceptionally strong solvency for many resins used in However, they are toxic to humans and are environmental
protective coatings. They are used extensively as solvents contaminants. These solvents should not be stored in, or
for vinyls, urethanes, epoxies, and acrylics. Ketones usually used with, aluminum containers or equipment.
are more expensive than ester-type solvents, but they are
cost effective because the use of ketones allows for greater h. Glycol ether solvents. Glycol ether solvents, such as
use of inexpensive aromatic diluents. As with all solvent ethylene glycol monoethyl ether and ethylene glycol
families, solvency decreases as molecular weight and monobutyl ether, are a specific subcategory of the ester
branching increase. solvents. The most important solvent of this type has been
ethylene glycol monoethyl ether (Cellosolve®1) acetate.
f. Ester solvents. Ester solvents contain the acetate However, because of toxologic considerations, this solvent
functionality (-C-O-R). Ethyl acetate, isobutyl acetate, largely has been replaced by propylene glycol monomethyl
ethylene glycol, and monoethyl ether acetate are examples ether acetate, which appears to be less toxic. Glycol ethers
of ester solvents. They have solvency power between the are tail solvents for epoxies, vinyls, and urethanes. Glycol
aromatic hydrocarbons and ketones, but they have a high ether solvents are water-miscible and will attract moisture in
hydrogen bonding index and a relatively high polarity. Care buried or immersion conditions; therefore, care must be
should be taken to avoid solvent entrapment when using taken to ensure they completely volatilize from coatings to
ester solvents. Ester solvents are strongly polar and are be used in immersion or below grade service. Anhydrous
used as solvents for similarly polar resin film formers. The solvent grades are necessary if glycol ethers are used in
esters are characterized by a sweet, pleasant, strongly fruity urethane formulations. Glycol ethers are particularly good
odor. Ester solvents are used in cellulosic lacquers, solvents for epoxy resins.
urethanes, vinyl, epoxy, and acrylic coatings. Slow-
volatilizing ester solvents are used as tail solvents in i. Solvent safety. Safety should be a consideration at
waterborne acrylic emulsions to aid coalescence and as tails all times when using solvents because all solvents are
in solvent-borne coatings to maintain solvency and reduce combustible and some are highly flammable. Solvents with
resin precipitation. Tail solvents are designed to be the last lower molecular weight or faster evaporating rates usually
solvents to evaporate from a coating. are more flammable. Fast volatilizing, flammable solvents
can lead to explosions, especially within confined spaces.
g. Alcohols. Alcohols are water miscible, and care All solvents are heavier than air and tend to flow
should be taken when using them so water is not introduced downward; so, unless adequate ventilation and air movement
into the coating. Alcohols are highly polar with a strong are used, solvent vapors will collect and concentrate in low-
affinity for the water molecule. They are used to dissolve lying spaces. Safety considerations are discussed in detail
polar materials; and, when formulated into a coating, care in Chapter 10.
should be taken to ensure that all alcohol will volatilize.
Water miscibility and hydroscopisity are reduced as the 4-8. Miscellaneous Additives
alkyl group increases, and few alcohols above butanol
(CyHgOH) have high miscibility with water. An exception A number of miscellaneous compounds are added by the
is tertiary butanol, which—because of the compactness of paint formulator to paints for specialized purposes. These
the alkyl structure—retains complete water miscibility. The include antiskinning agents, fungicides, thixotropes, UV
three most important alcohols are ethanol (denatured), light absorbers, plasticizers, flow agents, and emulsion aids.
isopropanol, and n-butanol. Methanol is toxic and is used
only as a polar additive in paint removers because its low
molecular weight serves it well as a penetrant. Alcohols are
1
used as solvents for resins such as polyvinyl acetate, some Union Carbide, Indianapolis, Indiana.

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a. Antiskinning agents. Skinning sometimes occurs on thickener based on ethoxylated polyether-based urethane
storage of coatings containing drying oils. The surface of block copolymers. The nonionic thickeners give the most
a paint dries and forms a skin on the paint surface in the improved flow and leveling characteristics to water emulsion
can. When used excessively, driers have a tendency to coatings, providing better gloss and semigloss paints. In
aggravate skinning. To avoid skinning, antioxidants such as roller applications, the nonionic thickeners result in a
certain phenols and oximes can be added. The oximes, significantly reduced roller spatter. Thixotropes prevent
characterized by the reactive group (-C=N-OH) are by far hard settling of many heavy pigments, such as zinc. Most
the most commonly used antiskinning agents. Skinning is thixotropes deteriorate on aging, which causes variations in
the result of the drier functioning properly, and it usually is viscosity of the paint in the can. Some paints have
not a problem in unopened or full cans. Antiskinning agents increased viscosity; others may suffer a viscosity decrease.
are volatile and accordingly, when using some of the paint
in a can, close it tightly after use. d. Flow agents. The addition of flow agents enhances
the freshly applied paint film's ability to flow out after
b. Fungicides. Fungicides or mildew inhibitors are application, eliminating brush marks, roller patterns, orange
added to paints to prevent mold growth. Mildew feeds on peel from spraying, and other film irregularities and defects.
some components of a paint film, particularly oleoresinous The flow rate of paint is affected by the rate of solvent
vehicles, most latex paints, and some polyamide epoxies that release and solvent system evaporation. Surface tension and
offer a source of food. Mildew spores are omnipresent in the coating’s viscosity, which vary as a function of
air, will deposit on the paint, and, under the right conditions, temperature, also affect the rate of flow or leveling of the
will begin to grow. In the past, compounds based on phenyl applied paint film. Depending on the type of flow problem
mercuric and tributyl tin compounds were used as encountered, the generic type of coating, and the coating
fungicides; but, because of their high toxicity, they have formulation, different flow and leveling agents are added in
been replaced by complex organics such as carbamates, small amounts (usually less than one percent) to eliminate
benzothiazoles, alkylisothiazolinone, chlorinated or minimize problems. Most flow agents function by
isophthalonitriles, and chlorinated adamantane complexes. increasing the viscous force in the coating, overcoming the
However, the new materials have not attained the paint's tendency to flow. Surfactants also help to overcome
effectiveness of the older materials. Fungicides function in leveling problems by reducing surface tension.
the can to kill organisms that might upset paint stability,
which is particularly important in latex emulsion paints that e. Emulsion aids. Emulsion aids are used in waterborne
can become rancid if microbiological growth is not stopped. paints and often are called surfactants. Proper use of
surfactants enable a waterborne emulsion to remain in
c. Thixotropes. Rheological coating properties such as suspension and keep it from settling and packing at the
film build, sag control, flow and leveling, and pigment bottom of a can during prolonged storage. All surfactants
settling properties can be adjusted through the use of have a hydrophilic (water-loving) group and a hydrophobic
thixotropic additives. Thixotropes can enable a rapid (water-hating) group, which is water repelling. The
increase in the viscosity of a liquid coating material and hydrophobic group is usually in the form of a long
allow it to build thicknesses over edges and plane surfaces hydrocarbon tail terminating in a simple long polar alkyl
and to resist sag. However, when mixing and applying the group. The hydrophilic group is usually a charged species
coating, shear stresses can break down the coating such as an ammonia ion, a polar organic group (carboxylic
thixotropy rapidly, enabling it to be applied as if it were low acid), hydroxyl, sulfate, etc. The surfactant molecules
in viscosity. Thixotropy recovers after application, and film containing both the hydrophobic and hydrophilic ends orient
build and antisag resistance again occur. There are a themselves around the emulsion particles to effectively
number of thixotropes that can be added to solvent-borne separate them and keep them apart. However, prolonged
coating systems, including castor oil derivatives, high storage at elevated temperatures, or freezing the emulsion,
molecular weight polyolefins, montmorillonite and other may destabilize it and cause separation and possible de-
clays, fumed silicas, fibrated minerals, calcium sulphonate emulsification. A number of different types of surfactants
derivatives, and others. Each of these classes has specific can be used, depending on cost, solution, pH, and specific
advantages and disadvantages with each of the binder emulsion requirements. Emulsion chemistry is complex and,
systems in which they are incorporated. Similarly, unlike formulating solvent-based paints, often requires
thixotropes are important for waterborne systems to provide considerable trial and error.
the same properties. The more common waterborne system
thixotropes are nonionic cellulosic thickeners, polyacrylic f. UV absorbers. UV light, particularly in the actinic
acids and salts, anionic polycarboxylic acid-based region of 280 to 315 nm, can degrade exterior paint films.
thixotropes, and, more recently, a nonionic associative Incident UV light is absorbed by the paint, raising the paint

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to a higher energy state. This causes bond cleavage and butyl, or urethane. After the coating is applied to a
release of free radicals, which leads to depolymerization, thoroughly cleaned steel substrate, the binder holds the
chain scission, or, in some instances, crosslinking and metallic zinc particles together and in contact with the steel.
embrittlement. This surface effect ultimately results in Thus, metal-to-metal contact of the two dissimilar metals is
degradation of the coating at either the surface (as is made and results in a galvanic cell. Zinc becomes the
generally true with epoxies that readily chalk) or the coating anode in this cell and sacrifices itself to protect the
interior, if the coating is partially transparent to UV light underlying steel cathode. Properly applied zinc-rich
energy. To prevent this, UV absorbers are added to the coatings, zinc galvanized coatings, and thermally sprayed
formulation at the rate of approximately 1 to 3 percent, by zinc eliminate pitting and under-film corrosion even at
weight, depending on the type of coating, the degree of voids, pinholes, scratches, and abrasions in the coating
pigmentation, and the type of surface. Zinc oxide is an system. This cannot be said of any other type of coating,
effective UV absorber, but it sometimes leads to and this protective capability makes zinc-rich coatings
embrittlement of oil-based coatings and may not be unique and widely used (refer to Chapter 2).
appropriate for other generic types of coatings. Most UV
light absorbers are complex substituted aromatic compounds a. Inorganic zinc-rich binders. All inorganic zinc-rich
that absorb UV radiation strongly without being degraded. coatings require an extremely clean surface (SSPC-SP 10 or
Hydroxy substituted benzophenones and benzotriazoles are SP 5), or application over a clean, pickled surface. Because
used most commonly. of their inorganic nature, inorganic zinc-rich coatings are
highly resistant to scuffing, scraping, and mechanical
g. Plasticizers. Plasticization is a process of increasing damage. They have good dry heat resistance to
the flexibility and adhesion of an organic coating film and temperatures as high as 399 °C (750 °F) and good resistance
decreasing its brittleness, cohesiveness, and glass transition to immersion in oil, petroleum distillate products, solvents,
temperature (the temperature at which a polymer changes fresh water, and many other neutral pH aqueous solutions.
from a flexible, rubber-like material to one that is hard and Some formulations are suitable for immersion in salt water;
brittle). Plasticization can be achieved by chemically others are not. The high conductivity of salt water enhances
modifying the resin polymer or by adding compounds to the corrosion of both the zinc and zinc pigment particles within
coating formulation. Chemical modification of the the coating and the underlying steel. Therefore, the
compound can be done by reducing crosslinking or by protective life of zinc-rich coating in saltwater immersion
formulating resin molecules with bulky side chains to may not be as long as that in freshwater immersion. In
prevent parallel orientation and crystallinity. Alternately, atmospheric environments, inorganic zinc-rich coatings
external plasticizers (such as monomeric phthalates, provide long-term corrosion protection in damp, humid
phosphates, adipates, and septacates), chlorinated paraffin, environments and where chemical attack does not occur.
or biphenyls can be added to a resin system to soften it and Inorganic zinc-rich coatings can be applied to steel at
lower the glass transition temperature. The plasticizing thicknesses of from 0.05 to 0.09 mm (2 to 3.5 mils) to
materials generally are relatively low molecular weight, provide atmospheric and immersion corrosion protection and
slow-evaporating materials that, when mixed with a resin, left without a topcoat for long periods of time. Salt
soften it by preventing crystalline orientation and contamination may be a problem in marine environments;
terminating crosslinking sites. The type of plasticizing agent and research and panel testing done by NASA have
used depends principally on the generic type and molecular established that zinc-rich primers, particularly inorganic
weight of the resin system used in the coatings formulation. zinc-rich primers, protect longer without topcoats than the
In time in some applications or service conditions (such as same primers with an organic topcoat. However, other
high temperature/humidity), low molecular weight studies for chemical and weathering environments have
plasticizers may migrate to the surface of the coating; and established that topcoating with an organic topcoat may
the surface may become sticky and attract and hold dirt. increase coating system longevity. Both inorganic and
More importantly, the coating often embrittles, becomes less organic zinc-rich coatings can be specially formulated as
flexible, or shows surface or through-cracking. preconstruction primers. This type of primer is applied to
ships, subassemblies, and other prefabricated steel. When
4-9. Zinc-Rich Coatings the steel is fabricated, welding can be done without removal
of the preconstruction zinc-rich primer. Topcoating
Zinc-rich coatings, or zinc-rich primers, are unique in that inorganic zinc-rich coatings may be more difficult than with
they provide galvanic protection to a steel substrate. As any other coating because of the inherent porosity of the
“rich” in the name implies, the binder contains a large zinc primer. The binder partially wets and adheres the zinc-
amount of metallic zinc dust pigment. The binder can be an dust particles together and to the underlying substrate, but
inorganic zinc silicate or an organic resin such as an epoxy, it does not fully encapsulate or seal the surface. Therefore,

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topcoats applied over the porous surface may displace the most prevalent. After application and initial solvent
entrapped air causing pinholes, bubbles, or voids within the drying, the coating system hardens; but to cure, hydrolysis
topcoat cross-section. This problem is not nearly as with moisture from humidity in the air is required. The
prevalent when using organic zinc-rich coatings because the hydrolysis of the silicate binder liberates ethyl alcohol (or an
organic binder more thoroughly wets, encapsulates, and alkyl alcohol if other alkyl silicates are used). The alcohol
seals the porosity of the highly zinc-dust-loaded dry film. volatilizes, makes the hydrolysis reaction irreversible, and
Inorganic zinc-rich coatings may be one of three major hardens and cures the binder. If the silicate binder is
groups: post-cured water-based alkali metal silicates, self- applied indoors or in an arid exterior environment, water
cured water-based alkali metal silicates, and self-cured may be sprayed onto the surface with a spray gun or a
solvent-based alkyl silicates. garden hose with a fine atomization. Two or three
applications may be required over a 2- or 3-day period to
(1) Post-cured, water-based alkali metal silicates. Post- obtain optimum curing of the binder. All inorganic zinc-
cured, water-based inorganic silicates come as a three- rich coatings can attain VOC compliance because of their
package system: zinc dust, silicate binder, and curing high solids content, but the water-based post- and self-curing
solution all packaged separately. The binder is an inorganic alkali silicates have virtually no VOC release.
alkali metal silicate, usually of the sodium, potassium, or
lithium family. Zinc powder is slowly mixed into the alkali b. Organic zinc-rich binders. Organic zinc-rich
metal silicate binder, and the resulting solution is spray coatings most commonly are formulated from epoxy
applied with an agitated spray pot to keep the zinc-dust polyamide, urethane, vinyl, and chlorinated rubber binders.
pigment in proper suspension. After water evaporation and Alkyds have been used for some air-dry formulations, but
hardening of the zinc silicate coating, a phosphoric-acid- they most commonly are used with baking formulations,
based curing solution is sprayed or brushed over the surface notably in the automotive industry. Drying, hardening, and
to neutralize the alkali metal binder. The neutralization ultimate curing of the organic zinc-rich coating is
reaction and subsequent interactions with zinc and iron ions determined by the type of binder used. The hardening and
further neutralize the silicate alkalinity and insolubilize the curing mechanisms of the various organic binders have been
film. The coating becomes insoluble to water and resistant described previously (paragraphs 4-2 and 4-3) and are the
to weathering exposure. Post-cured, inorganic zinc-rich- same for organic zinc-rich coatings. The major difference
coatings are believed to be the best performing of the is that, with organic zinc-rich coatings, the pigment is zinc
inorganic zinc-rich coating materials because of their dust in high concentrations to attain a dry film pigment
relatively complete, insolubilized, hard cure attained after volume of 75 percent or greater. This high zinc loading
application of the curing solution. enables the organic zinc-rich coatings to provide galvanic
sacrificial protection. The zinc-dust particles within the
(2) Self-cured, water-based alkali silicates. The most coating system must be in electrical contact with the
common of these silicate binders is based on potassium and thoroughly cleaned, underlying steel surface, and the zinc-
lithium silicates, or combinations. Lithium hydroxide- dust pigment particles must touch each other for galvanic
colloidal silica and quaternary ammonium silicate binders protection. Usually when formulated into organic vehicles,
also can be used. The alkali silicate binder is partially the binder more thoroughly encapsulates the zinc and
dehydrolized so its high alkalinity is considerably reduced reduces the sacrificial capability of the applied film.
in comparison with post-cured, inorganic silicate vehicles. However, this encapsulation does not prevent galvanic
Therefore, after application, initial water evaporation, and protection by organic zinc-rich primers. In fact, the
insolubilization, sufficient neutralization and cure are encapsulation of the organic binder makes organic zinc-rich
attained by further reaction with atmospheric moisture and coatings more tolerant of deficient surface preparation
carbon dioxide. Carbon dioxide in the presence of because the binder more readily wets and seals the prepared
atmospheric moisture forms a weak carbonic acid, which in surfaces where residues of rust or old paint may remain.
time is sufficient to neutralize the alkalinity of the silicate Also, topcoating with the same generic type of topcoat (e.g.,
binder. If a more rapid insolubilization or cure is desired, a polyamide epoxy zinc-rich topcoated with a polyamide
heat or an acidic curing solution can be applied. When final epoxy topcoat) is more easily accomplished because organic
curing is attained, most water-based, zinc-rich coatings— zinc-rich coatings have a less porous surface and are more
whether post- or self-cured—experience a color change, similar to conventional organic coatings than the inorganic,
usually from a reddish or light gray to a darker blue-gray. zinc-rich coatings.

(3) Self-cured, solvent-based alkyl silicates. The binders (1) Organic zinc-rich coatings frequently are used to
for these silicate coatings consist essentially of partially touch up and repair inorganic zinc-rich coatings because the
hydrolyzed alkyl silicates of the series methyl through hexyl wettability of the organic binder provides better adhesion to
or glycol ether silicates. Of these, the ethyl silicate type is

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the inorganic surface than another coat of inorganic zinc- been of considerable concern to many coating manufacturers
rich coating. Organic zinc-rich primers generally are whose products are sold nationally. A particular coating
considered to be easier to apply by spray than inorganic material may comply with the laws of one state but not with
zinc-rich coatings, and they are somewhat more tolerant of those of another state. Even within a given state, the
poor surface preparation because of the wettability and coating may be legal in most areas but illegal in certain
penetrability of the organic binder. Organic zinc-rich cities or regions. For years the coatings industry has pushed
coatings have less of a tendency for mud cracking at for national VOC legislation that will supersede and pre-
excessive thicknesses (over 0.13 mm [5 mils]) and are easier empt local legislation regarding VOC emissions. However,
to topcoat than inorganic zinc-rich coatings; however, they national VOC legislation has not been enacted, and
do not have the heat and abrasion resistance of the inorganic permissible VOC emissions vary widely, depending on the
zinc-rich coatings. Organic zinc-rich coatings do not provide generic type of coating and the location where it is applied.
the same long-term corrosion protection to steel as most VOC compliant coatings are formulated principally by
inorganic zinc-rich coatings. increasing the percent volume of solids, chiefly by
minimizing solvent content, use of relatively high volume
(2) The VOC characteristics of organic zinc-rich coatings low density pigments, and the use of lesser amounts of
are similar to those of the nonzinc-dust-pigmented binders. stronger solvents. Additionally, the alkyd resin is combined
Organic zinc-rich coatings are highly pigmented, but this with other synthetic resins (such as epoxies, phenols, and
does not substantially reduce VOC because the pigment has urethanes) and results in a more reactive higher solids
a high specific gravity and is dense relative to its volume. coating system. Straight alkyd systems currently are
Generally there is less organic binder per gallon of organic formulated with VOCs of 350 g/L (2.9 lb/gal) or higher.
zinc-rich paint, and VOC emissions are slightly less than for Future formulations probably will require a VOC as low as
nonzinc-rich-pigmented coating systems using the same 250 g/L (2.1 lb/gal). Chapter 11 discusses VOC regulations
binder. in detail.

(3) Properly applied zinc-rich coatings, zinc galvanized 4-11. Powder Coating
coatings, and thermally sprayed zinc eliminate pitting and
under-film corrosion even at voids, pinholes, scratches, and Powder coatings are made by mixing resins, pigments, and
abrasions in the coating system. This cannot be said of any additives together and heating them to form a melt. The
other type of coating, and this protective capability makes melt is extruded, cooled, and broken up by milling to
zinc coatings unique and widely used. The binders of zinc- produce a powder with a particle size distribution of
rich coatings can be organic or inorganic. approximately 10 to 100 µm. The article to be coated
usually is preheated to 204 to 260 °C (400 to 500 °F),
4-10. Volatile Organic Compounds depending on the powder to be applied. The pigmented
powder is applied, either by immersing the article in a
VOCs are in most protective coatings. Common paint fluidized bed of the powder (which is kept mobile by the
solvents such as aromatic hydrocarbons, aliphatic passage of air through it) or by electrostatic spray guns.
hydrocarbons, ketones, acetates, and alcohols are After application, the article being coated is heated to the
photochemically reactive. On evaporation into the melting point of the powder so the powder flows together.
atmosphere, these paint solvents react with nitrous oxides The powder can be thermoplastic or thermosetting. With
(combustion compounds from automotive emissions and thermoset powders, crosslinking agents also are made into
burning of fuels) and sunlight to form ozone and air a powder, and this powder is applied at the same time as the
pollutants. In the 1960s, air pollution problems usually base powder. After application, crosslinking occurs on
were handled by state and local agencies. There was no melting. Epoxy powder coatings are by far the most
national goal to address air pollution. In the 1970s, popular, although polyester, polyurethane, acrylic, and other
Congress passed the Clean Air Act and established the U.S. resin types can be used.
Environmental Protection Agency (USEPA). The Clean Air
Act gave USEPA the responsibility of identifying the most a. Powder coatings do not readily give satisfactory films
serious air pollutants and setting national air qualities at thicknesses below approximately 0.05 mm (2 mils); they
standards for each. Ozone was at the top of the list. The require special application and heating equipment. Powder
air quality legislation was an attempt to reduce levels of coatings form good-looking, thick, tough coatings that
ozone and other air pollutants. Rules limiting the amount of contain no solvent. Because they are VOC compliant, they
VOCs in paint have been established since then, but they comprise a technology that is of considerable interest in the
vary from state to state and even regionally within a given protective coatings area. Currently, powders are used
state. Such variability in laws regarding VOC emissions has mostly in the coating of relatively small items that can be

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easily heated to the melting point of the powder being aluminum also is suitable. Aluminum is preferable for
applied. Fusion-bonded powder coatings are applied to aqueous solutions above 60 °C (140 °F).
preheated pipe surfaces with or without primers. The
coating usually is applied 0.30 to 0.63 mm (12 to 25 mils) c. Organic sealers or topcoats commonly are used over
thick for aboveground pipe installations to eliminate the thermally sprayed metal to extend the life of the system
chalking and to maximize surface life; topcoating frequently and provide color for decorative purposes. Common sealers
is done with a urethane coating system. include many of the synthetic resin coating systems,
especially vinyls, epoxies, polyurethanes, and phenolics.
b. Thermally sprayed organic powders have been Sealers are essential for most immersion or severe chemical
applied to structural steel and other large metal objects. The corrosion applications. Most sealers are applied in at least
process is expensive and adhesion sometimes is a problem two coats, the first thinned for penetration into the porosity
because the large item being coated does not attain a of the thermally deposited metal coating. The second and
uniformly high substrate temperature when heated; and the sometimes third coat of a sealer are applied unthinned as
applied powder, even though in a liquid “melt,” does not build coats.
have good surface wetting properties. Current furnaces or
heating ovens are large enough to handle concrete d. Because there are no solvents or volatile material in
reinforcing rods, small- to medium-diameter pipe, small any metallic thermal spray system, VOC compliance is not
structural steel pieces, and sheet piling. a problem. However, VOC compliance may depend on the
organic sealer coating used.
c. Although of considerable interest to the protective
coating industry, powder coating has not been used e. An advantage of the thermal spray system is that
commercially to protect large steel surfaces or heavy, essentially no startup or cleanup procedures are involved.
massive structural steel shapes. The wire or powder feed stock is fed to the spray gun, the
heat source is ignited, and spraying of the molten feed stock
4-12. Thermal Spray begins. On conclusion of thermal spraying, the device is
shut off, and the process stops, with virtually no equipment
a. Thermal spray coatings consist of a process by which cleanup required.
an organic powder or metal wire is melted and spray-
deposited onto a surface. In the past, metallizing was the f. Blast cleaning surface preparation to a clean white
term used to describe wire flame spraying. However, metal, preferably with an anchor profile exceeding 0.08 mm
because of dramatic improvements in equipment used to (3 mils) is required for any thermal spray coating. Thermal
heat and spray the molten metal and nonmetallic polymers spray metal (and plastic) coatings have little wetting ability
onto a surface, the term thermal spraying is more at the time of application so cannot penetrate, seal, or
descriptive. Thermal spraying is a process by which a encapsulate any contaminates on the surface to be coated.
finely divided molten metallic or nonmetallic material is On cooling after application, the metal particles undergo a
sprayed onto a prepared substrate to form a coating. The thermal contraction that applies a shrinkage stress to the
sprayed material is originally in the form of a wire or metallic film. A minimum anchor pattern of 0.08 mm
powder. The thermal spray-gun heats the wire or powder to (3 mils), and preferably 0.10 to 0.13 mm (4 to 5 mils), is
a molten or plastic state, and compressed air or gases propel required to withstand the shrinkage stresses and to dissipate
it to the surface being coated and deposit it into a film. these stresses over a greater interfacial area between the
Refer to CWGS 05036. applied metallic film and the underlying steel substrate.

b. Zinc, aluminum, and their alloys are the most widely g. The common methods of thermospray are:
used metals for thermal spray, corrosion-resistant coatings.
These metals provide excellent protection in a variety of (1) Wire flame spraying. Acetylene or other common
marine and industrial environments. After spray application, fuel gases are combined with oxygen and ignited in the
zinc is anodic to an underlying steel surface. Because of its spray gun. A wire—usually zinc, aluminum, or zinc-
aluminum oxide coating, aluminum exhibits galvanic aluminum alloys but sometimes nickel, stainless steel, or
protection for only a short period of time. Afterward, the another metal—is fed through the flame, is melted, and is
oxidized aluminum coating functions principally as a barrier deposited on the surface. Wire flame sprayed coatings
coat. In general, aluminum corrodes less rapidly than zinc generally exhibit lower bond strengths, higher porosity, a
in highly acidic conditions, but zinc performs better in narrow working temperature range, and a higher heat
alkaline environments. Zinc frequently is the preferred transmittance to the substrate than plasma or electric arc
metal for protection of steel in fresh cold waters, although spray coatings.

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(2) Powder flame spraying. A common fuel gas is used rust. This is usually done by sulfuric acid or phosphoric acid
with a metal or plastic powder. The powder is stored in a pickling. The steel to be galvanized is immersed in a hot
hopper mounted on top of a spray gun, and a small amount acid bath. The hot acid aggressively attacks the steel
of oxygen is diverted from the gas supply to carry the surface, cleaning, etching, and roughening it. After
powder by aspiration into the oxygen-fuel gas flame. The continuous strip or batch pickling, the steel is water-rinsed
melted powder is carried by the flame to the object being or dipped to remove acid residues prior to immersion in the
coated. An air/propane mixture is used for polymer molten zinc galvanizing bath. The immersion in molten
powders. The object to be coated must be preheated to at zinc may be done by one of two methods: continuous or
least 79 °C (175 °F) prior to the spray application of the batch processing. Sheet steel may be hot dipped by
polymer powder. Because of the lower particle velocities continuously passing the metal through a molten zinc bath.
obtained, the coatings generally have a lower bond strength, Continuous processing is highly automated and often is
a higher porosity, and a lower overall cohesive strength than associated with steel mill operations. Batch processing
the coatings produced by any of the other thermal spray generally is performed on fabricated items that range in size
methods. The bond strength and other film properties can from large structural steel objects to small items such as
be improved considerably by preheating the substrate to nuts, bolts, and fasteners. With batch galvanizing, the
49 °C (120 °F) or more prior to application of the powder. objects are submerged into the molten zinc bath, held there
for a suitable time, then removed.
(3) Electric arc spraying. The spray gun used in electric
arc spraying uses two feed stock wires as electrodes. An b. A major advantage of galvanizing is that the zinc
electric current is applied across the wires so that an electric coating alloys itself with the steel. The extent of the alloy
arc is formed at the intersection. Heat from the electric arc is a function of the heat of the zinc bath (the bath is
melts the wires, a stream of compressed air flows across the generally maintained at a range of 443 to 460 °C [830 to
arc zone, and the melted metal is removed from the wires 860 °F]) and the amount of time the steel is submerged in
and propelled to the surface. Because of the high the bath. The greater the submersion time, the greater the
temperatures in the arc zone, the coatings have excellent extent of the iron-zinc alloying. The item being galvanized
adhesion and high cohesive strength. Super heating of the must be at the bath temperature for optimum galvanizing
particles after impact may lead to a metallurgical “weld” adhesion. This, however, has two disadvantages. The
bond with some metals, substantially increasing adhesion object being coated must not undergo any undesirable
and cohesive strength. property changes at the temperature required for
galvanizing. Also enclosed or sealed cavities in the object
(4) Plasma spraying. Plasma is a hot gas issuing from being galvanized (particularly with hot dip batch
the spray gun; it resembles a bright flame and is created by galvanizing) must be avoided by design or be opened by
passing inert gas through an electric arc within the gun. drilling to provide a vent hole to allow release of entrapped
The arc heats the gas to temperatures well above the melting air that will expand when heated in a galvanizing bath.
point of any known substance. Powder feed stock is
introduced into and melted by the plasma stream that also c. Corrosion protection afforded steel by galvanizing is
carries the molten metal to the work piece. The plasma greater than that provided by thermal spraying zinc-rich or
system produces excellent quality coatings, but the organic coatings of similar thicknesses. This is a result of
equipment is complex, expensive, and difficult to operate. the smooth, continuous nature of the zinc coating deposited
Plasma spraying is used when coatings are needed to during the hot dip process and the iron-zinc alloying that
provide the utmost in corrosion protection against chemical occurs at the interface between the zinc coating and the steel
or high temperature corrosion, and when the work can be surface. For small steel objects, grating, small-diameter
done in a shop environment. piping, conduit, and other configurations with a high surface
area-to-weight ratio, galvanizing is preferable to painting
4-13. Galvanizing and thermal spraying because immersion in a molten zinc
bath readily coats all surface areas quickly and
a. Hot dip galvanizing is the process by which a zinc economically. Conversely, when coating thick, heavy steel
protective coating is applied to steel by immersing an object objects with a relatively low surface area-to-weight ratio,
in a molten zinc bath. Prior to immersion in the zinc bath, thermal spraying and/or painting may be more economical.
contaminants on the steel must be removed. Oil, grease,
and other surface deposits are removed by immersing in a d. Although almost any steel can be galvanized, steel
hot water detergent solution prior to pickling, steam chemistry can dramatically affect the thickness, structure,
cleaning, or steam-detergent cleaning the steel. The steel and appearance of the galvanized coating. Silicon,
surface also must be thoroughly cleaned of mill scale and phosphorus, carbon, and manganese may be present in steel

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and affect the galvanizing properties. The most influential has not been added. The freshly galvanized surface should
steel constituent affecting galvanizing is silicon, which is be roughened slightly by light brush blast cleaning or
added to steel as ferro-silicon to remove oxygen from the mechanical means. Alternatively, vinyl butyral wash
molten steel before casting. In high silicon steels, an primers or other pretreatment primers can be applied that
undesirable increase in coating thickness occurs because of will etch and adhere to the underlying galvanized surface.
the accelerated growth of the zinc-iron alloyed layers. This
growth is caused by the formation of loosely packed small h. If coating after weathering, the galvanized surface
grains or crystals in the outermost alloy layer of the coating will be eroded by zinc corrosion and the formation of
that allows zinc from the bath to penetrate to the steel insoluble zinc-corrosion products. The zinc corrosion
surface. In general, steels with the following maximum roughens the galvanized surface and frequently no further
impurity levels are best suited to galvanizing: 0.05 percent mechanical roughening or brush blast cleaning is required.
silicon, 0.05 percent phosphorus, 0.25 percent carbon, and However, care should be taken to ensure that all loose zinc-
1.3 percent manganese. corrosion products are removed by scrubbing or power
washing the surface prior to painting. Wash primers, or
e. Hot dip galvanizing has a number of advantages, primers specially formulated for application over galvanized
including the ability to coat recessed or difficult-to-coat surfaces, frequently are preferred.
areas (such as corners and edges) with a sufficient coating
thickness. Also because the coating is metallic and i. Galvanized steel can be topcoated with any
metallurgically combined with the steel, it has good abrasion nonsaponifiable alkali-resistant paint. Zinc dust, zinc oxide-
and corrosion resistance. When coating steel with a large containing paints are particularly recommended, as are zinc-
surface area-to-weight ratio, galvanizing is much more rich coatings. Water-based acrylic latex emulsions, epoxies,
economical than painting because galvanizers charge by the vinyl copolymer paints, and chlorinated rubber and coal tar
weight of the object being galvanized and painters charge by epoxy coatings all have been applied with good success over
the square foot of surface area of the object being painted. properly prepared galvanized steel surfaces.
A major disadvantage is that the hot dip process is not
portable, and the object being coated must be taken to the 4-14. Tapes and Wraps
zinc-coating facility for galvanizing.
a. Protective tapes and wraps are used almost
f. Hot dip galvanizing causes no significant alteration exclusively for protecting pipelines and tubular structural
in the bend, tensile, and impact properties of galvanized shapes from below-grade or (underground) corrosion.
steel, so steel strength and ductility are unaffected. Welded Cathodic protection is used in many situations to supplement
structures have higher strength when galvanized than when corrosion protection. The tape or wrap must provide a
uncoated because hot dip galvanizing reduces weld stresses barrier resistance to the below-grade environment, have
by 50 to 60 percent. For most steels, little reduction in good adhesion, and be able to act as an effective electrical
fatigue strength occurs as a result of galvanizing. Steel does insulator to aid in effective cathodic protection.
not embrittle as a result of hot dip galvanizing. Hydrogen
embrittlement does not occur when ordinary carbon or low b. A tape is a composite material consisting of at least
alloy steels are galvanized. Hardened steels may become two layers. The first or innermost layer is usually a soft,
embrittled if the hydrogen picked up during the pickling elastomeric material formulated to adhere to an underlying
cleaning operation is not expelled during immersion in the substrate. The substrate can be either primed bare metal or
molten zinc bath. Steels of medium to high strengths that another tape layer. The tape backing or outer layer is a
have been severely cold worked may have local areas monolithic polymeric material designed for tensile strength,
susceptible to hydrogen embrittlement. As a rule, however, mechanical strength, temperature, and electrical resistance.
hydrogen embrittlement as a result of cold working is not a Typical tape backings include polyvinylchloride,
problem for steel subject to hot dip galvanizing. polyethylene, polyolefin, butyl, ethylene propylene diamine
monomer (EPDM), and, occasionally, nylon or glass fibers.
g. Coatings can be successfully painted immediately Adhesives are usually butyl rubbers or butyl chlorinated
after galvanizing or after extended weathering. A white rubbers but can be petrolatum and petrolatum wax
rust-preventative oil or wax may be applied to the compounds.
galvanized surface to prevent the formation of zinc-
corrosion products such as zinc hydroxides, oxides, and c. The tapes can be cold applied, hot applied, and cold
carbonates that result in a white discoloration on the applied with subsequent heat application as a heat-shrink
galvanized surface. If painting is to be done immediately material. Multilayered tapes frequently are used on a
after galvanizing, check to ensure that a rust preventative pipeline by applying a one-tape system then overcoating it

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with a different tape system. When this is done, the inner prior to filling the ditch. Another tape system, extruded
layer is designed primarily for corrosion protection, and the polyethylene, is relatively new and is gaining acceptance in
outer layer is designed to resist moisture, soil stresses, UV the United States. This coating system generally consists of
light, or other environmental influences. blast cleaning to SSPC-SP 6 followed by the application of
an epoxy primer to approximately 0.05 mm (2 mils) dry
d. Most tape systems are applied over a blast-cleaned film thickness. The pipe then is heated to approximately
surface, usually SSPC-SP 6 or better. This standard 135 °C (275 °F) and approximately 0.20 mm (8 mils) of a
generally is a requirement for all adhesives except those polyethylene copolymer adhesive is extruded around the
based on petrolatum wax, which can be applied over a pipe, followed by 3 mm (118 mils) of a polyethylene outer
lesser prepared surface because of its wettability and wrap extruded spirally over the adhesive. The preheating
softness. Most tapes perform better when applied over a melts the adhesive and provides wetting capability.
primer, which commonly is an epoxy. The primer provides Additionally, the polyethylene extrusion to the hot pipe
a bonding surface for best adhesion of the subsequently shrinks to form a tightly adhered, thick, seamless coating
applied tape coatings. with high resistance to mechanical damage, moisture
permeation, and UV light.
e. Tape systems are applied by hand or, preferably, by
a hand-assisted tape wrapster that is pushed and pulled h. During pipe-laying operations in the field, the joints
around a pipe by as many as four or five workers per must be protected by application of paints or protective
machine. Powered wrapsters provide the best application coatings or, more commonly, a tape wrapping system.
and allow for a more constant tension, uniform overlaps,
fewer wrinkles, and a lesser clearance underneath the pipe (1) Polyvinyl chloride tapes. Tapes with a PVC backing
(as little as 304.8 mm [12 in.]). Tape wrapping machines can be used with a variety of adhesive materials, including
are available that will simultaneously apply two tape layers butyl rubber and petrolatum wax. The greatest advantage of
to a pipe. These tape wrapping machines are most useful PVC-backed tapes is that they have an ability to conform to
for over-the-ditch applications. regular substrates and provide a good barrier to penetrating
moisture. However, because of plasticides and migration,
f. For tape applications in the pipe mill or fabricating sometimes the backing material separates from the adhesion.
shop, surface preparation by blast cleaning is the most PVC backings are suitable for temperatures up to 60 °C
common, usually to an SSPC-SP 10 quality. Application of (140 °F).
a primer and two or more tape layers applied by automatic
pipe-coating equipment under constant tension of 10 to (2) Polyethylene tapes. Polyethylene-backed tapes most
14 psi results in a tight, wrinkle-free coating. The coating commonly are used with butyl or chlorinated rubber
is inspected by automated high voltage holiday inspection adhesives. These tapes are used as outer tapes to provide
(minimum 6,000 V). After mill application of a tape increased mechanical strength and UV light resistance.
system, careful handling is required to avoid damaging or They can be used over primed steel as an inner tape wrap
stripping the applied tape system. because of their excellent adhesive quality. Polyethylene
tapes are considered suitable for use in cold climates
g. In the pipe mill, hot-applied plastic tapes also have because they retain their flexibility at temperatures as low
been used. The pipe surface is cleaned to an SSPC-SP 10 as -40 °C (-40 °F). The polyethylene backing generally
and heated to approximately 121 °C (250 °F) to melt the ranges from 0.25 to 1.27 mm (10 to 50 mils) thick; adhesive
tape adhesive to provide a good bond. Mill-applied tape ranges from 0.08 to 0.30 mm (3 to 12 mils) thick.
coating systems require careful handling and installation,
and over-the-ditch application eliminates the need to repair (3) Petrolatum tapes.
shipping and handling damage. However, over-the-ditch
application generally is more labor intensive and is subject (a) Petrolatum wax, obtained from the refining of
to weather variables and adverse application conditions. petroleum, is purified and used as a corrosion-protective
During installation of any pipeline system—whether coated material. The petrolatum is a soft, viscous to semisolid
by a tape wrapping system, fusion bonded system, or waxy-like material with excellent wetting properties.
extruded high density polyethylene wraps—care is necessary Petrolatum tapes are fabricated by impregnating the
during backfilling operations to prevent rock and stone petrolatum into a woven or nonwoven, cellulose-free
damage and impact into the coating. Insulating mats and/or synthetic fiber fabric, usually nylon or glass fiber. Inert
blankets are sometimes wrapped around a pipe to prevent fillers are added to improve thixotropy. The resulting
backfilling damage or, alternatively, specially conductive coating possesses a low water vapor transmission rate, is
backfilling earths are initially placed around the pipe layer relatively moisture impermeable, and is nondrying,

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nonhardening, nonhazardous, and nontoxic. The adhesive of these tapes is usually a butyl or chlorinated
rubber, and this type of tape is noted for good adhesion and
(b) Petrolatum tapes have some moisture-displacing resistance to mechanical damage.
capability and often are applied over hand- or power tool-
cleaned surfaces (instead of blast-cleaned surfaces as (6) Heat shrink polyolefin tapes. A crosslinked
required by most other tapes). Because of the high polyolefin backing is combined with a high shear strength
conformability of petrolatum tapes, they are suitable for use crystalline adhesive to form a heat shrinkable pipeline tape.
over irregular surfaces, on pipelines, and to protect valves, Prior to tape wrapping, the steel is usually hand- or power
flanges, and other irregular shapes. Petrolatum tapes are tool-cleaned and preheated to approximately 60 °C (140 °F).
soft and they are susceptible to mechanical damage. A The tape is wrapped around a pipe with a 50 percent
polyvinyl chloride outer wrap or membrane is applied over overlap and heated with a propane torch after wrapping.
the petrolatum tape to improve mechanical properties, Heat from the torch causes the crystalline adhesive to melt
particularly during handling and backfilling. This exterior and flow, filling surface irregularities. Additionally, the
wrap also keeps the petrolatum from oxidizing and drying backing shrinks tightly to the steel substrate to provide good
out. adhesion and conformability. There are calorimetric heating
indicators in the backing to indicate when the proper
(c) Petrolatum formulations have been developed to temperature has been reached.
allow use at temperatures as high as 82 °C (180 °F). These
tapes are well suited for protecting metal couplings and 4-15. Other Coatings
valves and other pipeline irregularities and for coating
repairs on existing pipes when the existing coating has Any listing of coating systems cannot be all-inclusive.
deteriorated or failed in service. There always will be specialized coating systems that are
not widely used or are of little interest to USACE. Some of
(4) Coal-tar and asphalt tapes. Coal-tar and asphalt these systems may include fluoropolymer coating systems,
mastic tapes are used as hot-applied systems. The backing used principally for high heat, corrosion-resistant surfaces;
is usually a synthetic fiber of nylon or woven glass fiber. silicone resin coating systems, used as thin film, high heat
These tapes have good resistance to water penetration and, systems or in combination with metal or ceramic frits for
when properly applied, have excellent adhesion. They high heat, abrasion-resistant corrosion service; chlorinated
usually are used for over-the-ditch application and for the rubber, neoprene, and other coating systems that are not
protection of welded joints. widely manufactured and have been replaced by other
generic-type coating systems; and variations or combinations
(5) Butyl or EPDM vulcanized rubber tapes. Butyl or of systems that are not different enough to warrant a
EPDM vulcanized rubber-backed tapes have excellent separate category.
flexibility, mechanical resistance, and moisture resistance.

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