Paints for

Corrosion Protection

By

Dr. S. SYED AZIM

Chief Scientist
Protective Coatings Group
Corrosion & Materials Protection Division
CSIR-CENTRAL ELECTROCHEMICAL RESEARCH INSTITUTE
KARAIKUDI-6300 006

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 Outline
 Definition
 Surface Preparation
 Application Methods
 Coatings
 Steel Structures

 Nano Technology in Coatings

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 Corrosion is defined as the deterioration of a
material, usually a metal, because of a reaction with
its environment.
 Natural phenomenon that occurs over time.
 An electrochemical reaction (on metals)
 Happens at different rates with different metals and
in different environments
 One of the most successful methods for controlling
corrosion is by the application of paint coatings.

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 A protective coating is a material composed of synthetic resins
or inorganic silicate polymers which, when applied to a suitable
substrate will provide a continuous coating, that will resist
industrial or marine environments.
 In order to provide corrosion protection, the protective coating
must also.
 Resist the transfer or penetration through the coating of ions
from salts, which may contact the coating.
 Resist the action of osmosis.
 Expand and contract with underlying surface, and
 Maintain a good appearance, even under extreme weather
conditions.

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Protection by coating mainly depends upon three factors

1. The material
2. The surface preparation
3. The application

If any one of the three is weak, protection value is

affected to that extent

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 The key to a successful coating project is surface
preparation.

 Surface should be clean and suitably roughened.

 Adhesion is the most important attribute of a coating. A clean

surface with the proper profile provides a surface to which a
coating can adhere.

 A clean steel surface should be free of all:

 Oil Oxides
 Grease Corrosion Products
 Dust Other foreign matter
 Dirt
 Mill scale
 Rust
 Coating
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National Association of Corrosion
Engineers (NACE)

 NACE 1 White metal Blast Cleaning

 NACE 2 Near - White Blast Cleaning
 NACE 3 Commercial Blast Cleaning

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Steel Structures Painting Council (SSPC)
SP-1 Solvent Cleaning
SP-2 Hand Tool Cleaning
SP-3 Power Tool Cleaning
SP-4 Flame Cleaning
SP-5 White Metal Blast Cleaning
SP-6 Commercial Blast Cleaning
SP-7 Brush-Off Blast Cleaning
SP-8 Pickling
SP-9 Weathering Followed By Blast Cleaning
SP-10 Near-White Blast Cleaning
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 Swedish Standard (St, Sa)

St 2 Hand Tool Cleaning

St 3 Power Tool Cleaning
Sa 1 Brush-Off Blast Cleaning
Sa 2 Commercial Blast Cleaning
Sa 2 1/2 Near-White Blast Cleaning
Sa 3 White Metal Blast Cleaning

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 Surface Preparation in Descending Order of
Effectiveness

Each lower grade in the list allows greater amount of contamination to

be left on the surface prior to the coating
1. White Sandblast NACE # 1, SSPC SP 5-63, SA-3
2. Near-White Sandblast NACE # 2, SSPC SP10-63. SA 2.5
3. Commercial Blast NACE # 3, SSPC SP 6-63, SA 2
4. Brush Blast NACE # 4, SSPC SP 7-63, SA 1
5. Acid pickling SSPC SP 8-63
6. Flame Cleaning SSPC SP 4-63
7. Power Tool Cleaning SSPC SP 3-63
8. Chip &Hand Wire Brush SSPC SP 2-63
9. Solvent Wipe SSPC SP 1-63

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Shot blasted steel surface

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 Anchor Pattern
• The anchor pattern or profile is extremely important to
protective coatings in that it provides for excellent
coating adhesion.
• Anchor pattern can be thought of as tiny peaks and
valleys in the substrate being blasted.
• The depth of these “valley’s” is determined by the size,
type and hardiness of the abrasive being used; by the
air pressure; and by the distance and angle of the
nozzle to the surface.
• Too much anchor pattern wastes coating and allows
substrate to show through; too little anchor pattern
reduces the bonding surface between the material and
the substrate.

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General guidelines to achieve specific anchor
patterns. Assumption is 90PSI nozzle
pressure, 2 feet from surface
ANCHOR PATTERN BLAST MEDIA
0.5 Mil 120/150 Jetmag, 100 garnet,
120 aluminum oxide
1 Mil 35-70 Jetmag, 80 garnet, 100
aluminum oxide, 80 steel grit
1.5 Mil 35-70 Jetmag, 36 garnet, 36
aluminum oxide, 50 steel grit
2.0Mil 32-B4 Jetmag, 36 garnet, 36
aluminum oxide, 40 steel grit
2.5 Mil 30-60 Jetmag,36 garnet, 24
aluminum oxide, 25 steel grit
3.0 Mil 30-60 Jetmag, 16 garnet, 16
aluminum oxide, 16 steel grit
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Abrasive sizes vary and a tolerance of 10% should be maintained to expect these results

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Minimum Surface Preparation Requirements

Coating Type Min. Sur. Pre.

Alkyd NACE #3
CoalTar Enamel NACE #3
Vinyl NACE #2
Chlo. Rub NACE #2
Epoxy NACE #2
CoalTar Epoxy NACE #2
Urethane NACE #2
Organic Zinc NACE #2
Inorganic Zinc NACE #2
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1. The purpose of coating application is to develop
a continuous highly adherent film with an even
thickness over the substrate.
2. To achieve this, various factors have to be
considered such as type of coatings and weather
conditions, application methods etc.
3. It is advisable to avoid painting below 100C and
above 400C,
4. If the relative humidity is above 80%, during the
rainy weather and wind velocity is above 24km/hr
or else freezing will occur before the paint dries.

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Application Methods
 Brush
 Air Spray
 Airless Spray
 Hot Spray
 Hot Airless Spray
 Roller

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 Area Coverage / day

Method of Application SQ.M

Brush 65
Roller 120-260
Air spray 200-600
Airless spray 300-800

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 Main Ingredients for Paint Formulation

Polymer(Binder)
Pigment
Solvent
Additives

Properties of the coatings can be changed

by changing ingredients.

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Most coatings are named after the binder
(resin).

Examples:
Alkyds
Epoxies
Urethanes
Acrylics

Other coatings may be named after the

pigment such as zinc rich primer or red lead
primer. CPC 2014 IIT Chennai 20
 Pigments
 Pigments are finely divided insoluble solid particles
that are dispersed in the binder and remain
suspended in the binder after film formation.

 To provide color and reinforcement

 To hide the surface
 To decrease the permeability of the film
 To provide rust inhibiting characteristics and
 To protect the film from the effect of ultraviolet light
and weathering.

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PROTECTIVE COATING SYSTEM

 Primer
 Undercoat
 Topcoat
 Finish coat

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 Primer
 The primary function of a primer over steel is to provide
corrosion protection.
 The primer is in direct contact with the metal surface
and must therefore provide a firm bond between the
metal and the subsequent coats of paint.
 The primers may well be classified as follows on the
basis of the working principal.
a. Inert primer (primer containing only inert pigments)
b. Inhibitive primer (primer containing inhibitive
pigments)
c. Galvanic primer (primers containing zinc or
aluminum pigment)
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 Undercoat

 Undercoats are highly pigmented high build paints possessing

high impermeability, which follow the primer and provide
necessary ground for the finishing coat.

 In addition an undercoat should posses the following properties.

a. Fairly rapid set to avoid sagging and pulling away from

sharp edges
b. Very high impermeability to ions, moisture and air
c. Good adhesion to primer and topcoat.

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 Top Coat

 The topcoat completes a paint scheme and serves as the first

line of defense against the corrosive environment whilst providing
decoration.

 A good finish coat should offer adequate protection and be

capable of retaining its decorative effect (measured in terms of
color and gloss) for a long period.

 The topcoat also protects the entire paint scheme from UV

degradation.

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 Coatings Classifications
 Some general classifications of
coatings are

 Organic
 Inorganic Silicones, Silicates
 Non-Convertible
 Convertible
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 Non-convertible coatings are those
coatings that dry and cure by solvent
evaporation.

 When they are dry they are cured.

Examples are:
 Vinyl
 Chlorinated Rubber
 Asphalt
 Bitumen

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 Convertible coatings are those that cure
principally by some type of polymerization.
 The solvent must evaporate before the
polymerization takes place.
 After polymerization it is a different chemical
compound.

Examples are:
 Epoxies
 2-Pack Urethanes
 Polyesters
 Vinyl Esters
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 ROLE OF BINDERS

Alkyds - Can be used in mild atmosphere

Phenolics - Has got high electrical resistance
Acrylics - Has got good resistance against acids
and alkalies
Epoxies - good in very aggressive atmospheres
except strong acids and UV light
Aliphatic
Polyurethane - Very stable against ultra violet radiations.

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Schematic representation of Tortuous
path formed by glass flakes
SEM OF TiO2 PIGMENT
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SEM of glass flakes
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 Typical Protective Coating Specifications

a) Conventional Epoxy specification

Thickness
Coat Material
(mm)
Epoxy Zinc
Primer 75
Phosphate
Barrier Epoxy MIO 125

Finish Polyurethane 50
Aliphatic
Finish 50
Polyurethane
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b) Zinc rich epoxy specification
Thickness
Coat Material
(mm)
Epoxy Zinc
Primer 40
Rich

Barrier Epoxy MIO 150

Barrier Epoxy MIO 150

Aliphatic
Finish 50
Polyurethane
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 COATINGS FOR MARINE STRUCTURES
Atmospheric zone

1. Vinyl system (3 to 4 coats) - 200 - 250 µm

2. Epoxy-zinc phosphate primer

Epoxy -polyamide undercoat - 300 µm
Epoxy-polyamide topcoat

3. Inorganic zinc silicate primer

Epoxy polyamide undercoat - 325 µm
Epoxy polyamide topcoat

4. Chlorinated rubber primer - 250 - 300 µm

Chlorinated rubber topcoat
(Contd.,)
 COATINGS FOR MARINE STRUCTURES
Atmospheric zone

1. Vinyl system (3 to 4 coats) - 200 - 250 µm

2. Epoxy-zinc phosphate primer

Epoxy -polyamide undercoat - 300 µm
Epoxy-polyamide topcoat

3. Inorganic zinc silicate primer

Epoxy polyamide undercoat - 325 µm
Epoxy polyamide topcoat

4. Chlorinated rubber primer - 250 - 300 µm

Chlorinated rubber topcoat
(Contd.,)
Splash zone:

1. Coaltar epoxy - 300 µm

2. Epoxy polyamide primer - 300 µm

Epoxy polyamide topcoat

Underwater:

1. Epoxy polyamide -200 - 300µm

2. Epoxy coal tar - 400µm + Cathodic protection
3. Bitumen - 1 mm
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Nanotechnology in Coatings

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 Conclusions
 Application of nanotechnology in the field of coating can
facelift the coating industry.
 Properties like corrosion resistance , flame resistant, UV
stability, gloss retention, chemical and mechanical
properties are improved significantly using nano particles.
 Hybrid coating has many properties in single coating
system and hence can give corrosion protection without
affecting its gloss and appearance.
 However, nano-coating also have some limitations, like
agglomeration of Nano particles, hardening of ultra fine
particles etc. However, benefits of nano-coating outweigh
its drawbacks.

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 CSIR-CECRI's EXPERTISE IN
PROTECTIVE COATINGS
 Protective coatings for steel structures.
 Integrated coatings system for concrete structures.
 Coating for underwater and wet surface application.
 Cement polymer coatings for rebars.
 Epoxy-coaltar coating formulation for splash zone areas.
 Paint systems for structures in chloroalkali industries.
 Rust converter.
 Zinc silicate primer for marine environment.
 Coating schemes for offshore structures.
 Paint specification for oil storage tanks, pipelines and other
structures in different corrosive environments.
 Neutral paint removingCPC
jelly.
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Protective Coating Schemes for Concrete Surfaces

 M/s. FOSROC Chemical (India) Limited

 M/s. Krishnaconchem Products Limited, Mumbai
 M/s. Berger Paints Limited, Calcutta
 M/s. Devika Chemicals, Mumbai
 M/s. Asian Paints, Mumbai
 M/s. Morsun Paintss Pvt.Ltd., Mumbai
 M/s. Cipy polyurethane Pvt. Ltd., Pune
 M/s. Saibaba Corrosion Technologies Pvt. Ltd.,
Srivilliputtur
 M/s. Coating & Forming Inc Pvt. Ltd., Mumbai
 M/s. Grand Polycoats Company Pvt. Ltd., Vadodara
 M/s. Konkan Polycons, Goa
 M/s. Crystal Chemical Corporation, Thane

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