19/12/2018 Paint coatings - Steelconstruction.

info

Home
Print PDF

SteelConstruction.info
The free encyclopedia for UK steel construction information

Steel For Life BCSA SCI Steel Knowledge

Log in / create account

Views

Paint coatings
From Steelconstruction.info

Paint is the most commonly used material to protect steel. Paint systems for steel structures have developed over the years to
comply with industrial environmental legislation and in response to demands from bridge and building owners for improved
durability performance. Previous five and six coat systems have been replaced by typically three coat alternatives, and the
latest formulations have focussed on application in even fewer numbers of coats, but with increasing individual film
thickness. Examples of this are epoxy and polyester glass flake coatings that are designed for high build thickness in one or
two coat applications, and single coat high build elastomeric urethane coatings, up to 1000μm thick.

Modern specifications usually comprise a sequential coating application of paints or alternatively paints applied over metal
coatings to form a ‘duplex’ coating system. The protective paint systems usually consist of primer, undercoat(s) and finish
coats. Each coating ‘layer’ in any protective system has a specific function, and the different types are applied in a particular
sequence of primer followed by intermediate / build coats in the shop, and finally the finish or top coat either in the shop or
on site.

Contents
1 Composition of paints and film formation
2 Classification of paints
3 Paint coatings
3.1 Primers
3.2 Intermediate coats
3.3 Finish coat
3.4 Stripe coats
3.5 The paint system
4 Main generic types of paint and their properties
5 Prefabrication primers
5.1 Etch primers
5.2 Epoxy primers
5.3 Zinc epoxy primers
5.4 Zinc silicate primers
6 Application of paint coatings
6.1 Methods
6.1.1 Brushing
https://www.steelconstruction.info/Paint_coatings 1/9
19/12/2018 Paint coatings - Steelconstruction.info

6.1.2 Roller
6.1.3 Air spray
6.1.4 Airless spray
6.2 Conditions of application
6.3 Coating applicator training and
certification (ICATS)
6.4 Additional education
7 References
8 Resources
9 Further reading
10 See also
11 External links
12 CPD

[top]Composition of paints and film

formation
Paints are made by mixing and blending three main components:

(a) The pigments

Pigments are finely ground inorganic or organic powders which provide colour, opacity, film cohesion and sometimes
corrosion inhibition.
(b) The binder
Binders are usually resins or oils but can be inorganic compounds such as soluble silicates. The binder is the film forming
component in the paint.
(c) The solvent
Solvents are used to dissolve the binder and to facilitate application at the paint. Solvents are usually organic liquids or
water.

Paints are applied to steel surfaces by many methods but in all cases this produces a 'wet film'. The thickness of the 'wet
film' can be measured, before the solvent evaporates, using a comb-gauge. As the solvent evaporates, film formation occurs,
leaving the binder and pigments on the surface as a 'dry film'. The thickness of the 'dry film' can be measured, usually with
an electro-magnetic induction gauge. The relationship between the applied 'wet film' thickness and the final 'dry film'
thicknesses (dft) is determined by the percentage volume solids of the paint, i.e. dft = 'wet film' thickness multiplied by
the % vol. solids.

In general the corrosion protection afforded by a paint film is directly proportional to its dry film thickness.

Paint constituents and their function Schematic diagram of a paint system

[top]Classification of paints
https://www.steelconstruction.info/Paint_coatings 2/9
19/12/2018 Paint coatings - Steelconstruction.info

Since, in the broadest terms, a paint consists of a

particular pigment, dispersed in a particular binder,
dissolved in a particular solvent then the number of
generic types of paint is limited. The most common
methods of classifying paints are either by their
pigmentation or by their binder type.

Primers for steel are usually classified according to the

main corrosion inhibitive pigments used in their
formulation, e.g. zinc phosphate primers and metallic
zinc primers, etc. Each of these inhibitive pigments can
be incorporated into a range of binder resins giving for
example, zinc phosphate alkyd primers, zinc phosphate
epoxy primers, etc. Multi-coat paint system

Intermediate and finish coats are usually classified

according to their binders, e.g. epoxies, vinyls, urethanes, etc.

[top]Paint coatings
Paints are usually applied one coat on top of another and each coat has a specific function / purpose. These are described as
follows.

[top]Primers

The primer is applied directly onto the cleaned steel surface or, in the case of duplex systems, the sealed metal coating. Its
purpose is to wet the surface and to provide good adhesion for subsequently applied coats. For primers applied directly to
steel surfaces, these are also usually required to provide corrosion inhibition. There are two basic types of primer.

(a) Primers pigmented with metallic elements anodic to steel

These primers are formulated so that, when a break in the coating (due to damage or local corrosion) exposes the steel
substrate, the anodic metal corrodes sacrificially in preference to the steel. This effectively stifles steel corrosion and under-
rusting of the primer until the anodic metal is exhausted. Zinc-rich primers are the most commonly used of this type.

(b) Primers relying on the high adhesion and chemical-resistance properties of the binder
With these primers, good adhesion is obtained (provided that the surface is very thoroughly cleaned) and it is sufficient to
prevent under-rusting at any break in the coating (due to damage). Two-pack epoxy primers are typical of this type. These
primers may contain inhibitive pigments to interfere with the corrosion process. Zinc phosphate, for example, is a mildly
inhibitive pigment and is widely used in modern primer formulations.

[top]Intermediate coats

Intermediate coats are applied to ‘build’ the total film thickness of the system. Generally, the thicker the coating the longer
the life. Intermediate coats are specially designed to enhance the overall protection and, when highly pigmented, decrease
permeability to oxygen and water. The incorporation of laminar pigments, such as micaceous iron oxide (MIO), reduces or
delays moisture penetration in humid atmospheres and improves tensile strength. Modern specifications now include inert
pigments such as glass flakes to act as laminar pigments. Undercoats must remain compatible with finishing coats when
there are unavoidable delays in applying them.

[top]Finish coat

The finish coat provides the required appearance and surface resistance of the system. Depending on the conditions of
exposure, it must also provide the first line of defence against weather and sunlight, open exposure, and condensation.

[top]Stripe coats

Stripe coats are additional coats of paint that are applied locally to welds, fasteners and external corners. Their function is to
build a satisfactory coating thickness at edges and corners where paint has a tendency to contract and thin upon drying.
Specifications should indicate the type and number of stripe coats required and state when they are to be applied.

https://www.steelconstruction.info/Paint_coatings 3/9
19/12/2018 Paint coatings - Steelconstruction.info

[top]The paint system

The various superimposed coats within a painting system have, of course, to be compatible with one another. They may be
all of the same generic type or may be different, e.g. chemical resistant types, such as a recoatable polyurethane finish coat,
may be applied onto epoxy primer and intermediate coats. However, as a first precaution, all paints within a system should
normally be obtained from the same manufacturer and used in accordance with the manufacturer’s recommendations.

An important factor in the coating system is the definition and measurement of the dry film thickness (dft). Dry film
thicknesses are generally checked on the complete paint system, although individual films may be checked separately.
Usually, nominal dry film thicknesses are specified but sometimes minimum values are quoted.

For nominal dry film thicknesses, individual values less than 80% of the nominal thickness are not acceptable. Values
between 80% and 100% are acceptable provided that the overall average (mean value) is equal to or greater than the
nominal.

Specifications for minimum dry film thicknesses require careful paint application to avoid excessive film thickness. The
‘over application’ of paints can result in the formation of high stresses and may cause premature failure of the system. Wet
film thickness (wft) checks may also be required during the application of the coating to check that a subsequent satisfactory
dry film thickness will be achieved.

[top]Main generic types of paint and their properties

(a) Air drying paints
For example alkyds
These materials dry and form a film by an oxidative process, which involves absorption of oxygen from the atmosphere.
They are therefore limited to relatively thin films. Once the film has formed it has limited solvent resistance and usually
poor chemical resistance.

(b) One pack chemical resistant paints

For example acrylated rubbers, vinyls
For these materials, film formation requires only solvent evaporation and no oxidative process is involved. They can be
applied as moderately thick films though retention of solvent in the film can be a problem at the upper end of this range. The
formed film remains relatively soft and has poor solvent resistance but good chemical resistance. Bituminous paints also dry
by solvent evaporation. They are essentially solutions of either asphaltic bitumen or coal-tar pitch in organic solvents.

(c) Two pack chemical resistant paints

For example epoxy, urethane
These materials are supplied as two separate components, usually referred to as the base and the curing agent. When these
two components are mixed, immediately before use, a chemical reaction occurs. These materials therefore have a limited
'pot life' before which the mixed coating must be applied. The polymerisation reaction continues after the paint has been
applied and after the solvent has evaporated to produce a densely cross linked film which can be very hard and has good
solvent and chemical resistance. Liquid resins of low viscosity can be used in the formulation thereby avoiding the need for
a solvent. Such coatings are referred to as 'solvent less' or 'solvent free' and can be applied as very thick films.

https://www.steelconstruction.info/Paint_coatings 4/9
19/12/2018 Paint coatings - Steelconstruction.info

Summary of the main generic types of paint and their properties

Tolerance
System Chemical Solvent Water Overcoating
Binder of poor Comments
cost resistance resistance resistance after aging
surface
Black Coatings Very good with Limited to black or dark
(based on Tar Low Good Moderate Poor Good coatings of colours. May soften in hot
products) same type conditions.
Low – Poor – Good decorative properties.
Alkyds Moderate Poor Moderate Good
Medium Moderate High solvent levels.
High build films that
Medium
Acrylated Rubbers Poor Good Poor Good Good remain soft and are
– High
susceptible to sticking.
Epoxy Medium Can be applied to a range
Good Good Good Good Good
(Surface Tolerant) – High of surfaces and coatings.
Epoxy
Medium Very Very Susceptible to ‘chalking’ in
(High Very Poor Good Poor
– High Good Good U.V. light.
performance)
Urethane and Very Very Can be more decorative
High Very Poor Good Poor
Polyurethane Good Good than epoxies.
Organic Silicate
May require special surface
and Inorganic High Very Poor Moderate Good Good Moderate
preparation
Silicate

[top]Prefabrication primers
Also referred to as blast primers, shop primers, temporary primers, holding primers, etc., these primers are sometimes used
on structural steelwork, immediately after blast cleaning, to maintain the reactive blast cleaned surface in a rust free
condition until final painting can be undertaken. They are mainly applied to steel plates and sections before fabrication. The
main requirements of a prefabrication primer are as follows:

The primer should be capable of airless spray application to produce a very thin even coating. Dry film thickness is
usually limited between 15-25μm. Below 15μm, the peaks of the blast profile are not protected and 'rust rashing'
occurs on weathering. Above 25μm, the primer affects the quality of the weld and produces excessive weld fume.

The primer must dry very quickly. Priming is often done in-line with automatic blast cleaning plant which may be
handling plates and/or sections at a pass rate of between 1-3 metres/minute. The interval between priming and
handling is usually of the order of 1-10 minutes and hence the primer film must dry within this time.

Normal fabrication procedures (e.g. welding, gas cutting) must not be significantly impeded by the coating, and the
primer should not cause excessive weld porosity. A welding certificate should be available from the paint
manufacturer.

Weld fume omitted by the primer must not exceed the appropriate Occupational Exposure Limits. Proprietary primers
are tested and certified by the Newcastle Occupational Health Agency. A health and safety certificate should be
available from the paint manufacturer.

The primer coating should provide adequate protection until either overcoated or placed within a non corrosive
environment e.g. indoor storage or within a building construction. In practice, such periods are rarely met except in
the least arduous conditions, e.g. indoor storage. In aggressive conditions, durability can often be measured in weeks
rather than months. Zinc rich and zinc silicate primers provide the highest order of protection of all prefabrication
primers.

The primed surface, after weathering, should require the minimum of re-preparation for subsequent painting and must
be compatible with the intended paint system. Many proprietary prefabrication primers are available but they can be
classified under the following main generic types:

[top]Etch primers

https://www.steelconstruction.info/Paint_coatings 5/9
19/12/2018 Paint coatings - Steelconstruction.info

These are based on polyvinyl butyral resin reinforced with a phenolic resin to increase water resistance. These primers can
be supplied in a single pack or two pack form, the latter providing better durability.

[top]Epoxy primers

These are two pack materials utilising epoxy resins and usually have either polyamide or polyamine curing agents. They are
pigmented with a variety of inhibitive and non-inhibitive pigments. Zinc phosphate epoxy primers are the most frequently
encountered and give the best durability within the group.

[top]Zinc epoxy primers

These primers can be either zinc rich or reduced zinc types. Zinc rich primers produce films which contain about 85% by
weight of metallic zinc powder and the reduced zinc type as low as 55% by weight. When exposed in either marine or
highly industrial environments, zinc epoxy primers are prone to the formation of insoluble white zinc corrosion products
which must be removed from the surface before subsequent overcoating.

[top]Zinc silicate primers

Zinc silicate primers produce a level of protection which is comparable with the zinc rich epoxy types and they suffer from
the same drawbacks, e.g. formation of zinc salts and production of zinc oxide fume during welding. There are currently
different categories of zinc silicate primers based upon the binder (organic or inorganic) and the zinc content. Low zinc
primers in this group have been developed to improve their weldability and to minimise weld porosity, however their
durability is also reduced. The organic silicate primers are the most suitable as prefabrication primers.

[top]Application of paint coatings

[top]Methods

The method of application and the conditions under which paints are applied have a significant effect on the quality and
durability of the coating. Standard methods used to apply paints to structural steelwork include application by brush, roller,
conventional air spray and airless spray.

Airless spraying has become the most commonly used method of applying paint coatings to structural steelwork under
controlled shop conditions. Brush and roller application are more commonly used for site application, though spraying
methods are also used.

[top]Brushing

This is the simplest method and also the slowest and therefore most
expensive. Nevertheless it has certain advantages over the other
methods, e.g. better wetting of the surface and can be used in restricted
spaces, be useful for small areas, with less wastage and contamination of
surroundings.

Brush application of paint

Brush application of paint

(Video courtesy of Corrodere/MPI)

[top]Roller

https://www.steelconstruction.info/Paint_coatings 6/9
19/12/2018 Paint coatings - Steelconstruction.info

This process is much quicker than brushing and is used for large flat
areas, but demands suitable rheological properties of the paint.

Roller application of paint

Roller application of paint

(Video courtesy of Corrodere/MPI)

[top]Air spray

Paint coatings for structural steelwork are usually spray applied. The paint is atomised into fine droplets and projected onto
the surface to be protected where the droplets join together to form a continuous film. The atomisation can be accomplished
in a number of ways.

In air spraying, the paint is atomised by mixing it with a stream of compressed air in a conventional spray gun. The paint can
be either sucked into the air stream (as in the simple suction-cup gun used for application to small areas) or fed to the spray
gun under pressure from a pressure pot. For ideal application, careful adjustments of the spray nozzle and air pressures must
be made by a skilled operator, according to the consistency and composition of the paint product and the film thickness
required. The application rates for air spray are quicker than for brushing, or rolling, however paint wastage by overspray is
high.

[top]Airless spray

For airless spraying, the paint is hydraulically compressed and, on

release through a small orifice in an airless spray gun, it is atomised and
projected onto the surface. By changing the orifice size and shape and by
varying the hydraulic pressure, atomisation can be accomplished for a
wide range of paint consistencies from thin to thick, to give a wide range
of rates of deposition. The equipment required is much more expensive
than for conventional air spraying, because it must withstand the much
higher pressures involved. However, the application rates are higher than
for air spray with overspray wastage greatly reduced. For conventional
air spraying, the maximum air pressure will normally not exceed 100 psi
(6.9 bar); for airless spraying, hydraulic pressures up to 4,000 psi (280
bar) may be required.

A variant of the above involves heating to reduce the consistency of the

paint rather than adding diluents. In this way greater film thickness per Airless spray application of paint
application is achieved. This method can be used for the application of (Image courtesy of Mabey Bridge Ltd.)
solvent-free materials such as two-pack products, which can be mixed at
the spray gun nozzle at the moment of application. The use of expensive
equipment and highly skilled labour is necessary for the achievement of optimum results but may be justified for the
protection of large and important structures.

https://www.steelconstruction.info/Paint_coatings 7/9
19/12/2018 Paint coatings - Steelconstruction.info

Airless spray application of paint

(Video courtesy of Corrodere/MPI)

[top]Conditions of application

The principal conditions that affect the application of paint coatings are temperature and humidity. These can be more easily
controlled under shop conditions than on site.

(a) Temperature
Air temperature and steel temperature affect solvent evaporation, brushing and spraying properties, drying and curing times
and the pot life of two-pack materials, etc. Where heating is required, this should only be by indirect methods.

(b) Humidity
Paints should not be applied when there is condensation present on the steel surface or the relative humidity of the
atmosphere is such that it will affect the application or drying of the coating. Normal practice is to measure the steel
temperature with a contact thermometer and to ensure that it is maintained at least 3°C above the dew point.

However, moisture cured paints are available. These paints are specifically formulated for application in damp and humid
conditions; reference should be made to the manufacturer’s data sheets for details of limiting conditions of application.

[top]Coating applicator training and certification (ICATS)

With modern high performance coatings, correct

application has become increasingly important to achieve
the intended performance. Industry has recognised this
and established a training and certification scheme for
paint applicators (ICATS – Industrial Coating Applicator
Training Scheme). ICATS registration (or to an
equivalent scheme) has subsequently become a
mandatory requirement for work on Highways England
and Network Rail bridges.

ICATS is owned by the Institute of Corrosion and

operated through Correx Ltd., a wholly owned subsidiary
of the Institute. The scheme has a mandatory Basic Unit
'Industrial Coating Applicator' that comprises 6 modules:

Health & Safety

Site Access
Plant & Equipment
Surface preparation
Paint Types & Application ICATS Training Programme
Quality Control

There are also 2 optional specialist modules:

Abrasive Blast Cleaning

Spray Painting

ICATS is a registered training scheme that meets the requirements of NHSS 19A[1] and enables contractors to provide 'best
value' service to maximise coating performance over structure life and to reduce whole life costs.

[top]Additional education

For engineers and inspectors wishing to further their knowledge of corrosion control in the context of structural steelwork,
there are web based training programmes available from a specialist training provider, Corrodere:

Trainthepainter
Traintheinspector
Trainthecoatingspecialist

https://www.steelconstruction.info/Paint_coatings 8/9
19/12/2018 Paint coatings - Steelconstruction.info

Trainthepainter is an internationally recognised and certified training programme that provides trainee coating applicators
with a comprehensive package of training modules that ensure professionalism and give an insight into methods of surface
treatment and application of protective coatings. As with ICATS, this is a registered training scheme that meets the
requirements of NHSS 19A[1].

[top]References
1. NHSS 19A: National Highways Sector Schemes for Quality Management in Highway Works, 19A. For corrosion
protection of ferrous materials by industrial coatings. UKAS, Issue 4 (9001:2015), August 2018

[top]Resources
Hendy, C.R.; Iles, D.C. (2015) Steel Bridge Group: Guidance Notes on best practice in steel bridge construction (6th
Issue). (P185). SCI
Guidance Note 8.05 High performance paint coatings
Steel Buildings, 2003, The British Constructional Steelwork Association Ltd.
Chapter 12 – Corrosion Protection

[top]Further reading
D.Deacon & R.Hudson (2012), Steel Designer’s Manual (7th Edition), Chapter 36 - Corrosion and corrosion
prevention, The Steel Construction Institute.
D.A. Bayliss & D.H.Deacon (2002), Steelwork Corrosion Control (2nd edition), Spon Press.

[top]See also
Corrosion of structural steel
Influence of design on corrosion
Surface preparation
Standard corrosion protection systems for buildings
Metallic coatings
Appropriate specifications
Inspection and quality control

[top]External links
British Coatings Federation
Paint Research Association
ICATS
Corrodere

[top]CPD
Corrosion protection

Retrieved from "https://www.steelconstruction.info/index.php?title=Paint_coatings&oldid=281267"

Category: Corrosion protection

Sitemap
Contact
Cookies

https://www.steelconstruction.info/Paint_coatings 9/9