Protective Coatings
'Protecting the Substrate & the Environment'
24-25 October 2007
Amsterdam, The Netherlands
Proceedings Contents & Abstracts
1. Novel High Solid Systems based on Silicone-Epoxy Hybrid
Resins
Dr Udo Schiemann*, Christopher Howard, Anke Bartek &
Markus Hallack
Degussa, Germany
Climate changes due to global warming and the greenhouse effect
are likely to produce even more corrosive conditions in the future,
because higher temperatures accelerate corrosion, and greater
concentrations of carbon dioxide will increase carbonation rates
and the acidity of rainfall. Corrosion is responsible for the
failure of many systems and structures. Unchecked it can result
in excessive maintenance and repair as well as system downtime
and product contamination. Although this is primarily associated
with metallic materials, in fact all material types are
susceptible to degradation. Like taxes, corrosion is something
we hope to avoid, but ultimately it is something we must learn
to deal with.
Silicone-Epoxy Hybrid Resins
Organic-inorganic hybrid coatings are of increasing interest to
industry due to their potential widespread applications. The organic
component in the matrix offers the advantages of mechanical
toughness and adhesion while the inorganic compnent provides the coating
with its hardness, thermal and UV- stability properties.
This presentation give a brief outline of the developments undetaken
within our research laboratory of the different environmentally-compliant,
cure, pre-treatment systems which offer alternatives to exisitng anti-
corrosion coatings.
2. Waterborne Epoxy Technology and Top Performance:
No Longer a Fairy Tale?
Dominique Vandenberghe*, F. Heine, P. Claeys-Bouuaert,
K.Van Poppel, M. Rans, & A. Frederix
Hexion Specialty Chemicals, Belgium
Solventborne epoxy-amine technology has a long track record of
excellent anti-corrosion performance in a wide range of protective,
transportation and marine end-uses.
Environmental legislation has been stimulating the development of
high solids, solventfree and waterborne technologies.
Initially the reluctance towards the use of waterborne technology
for high demanding end-uses was strong as application technology
and formulation knowledge needed to be developed and acquired.
Nowadays, waterborne epoxy technology has already proven that it can
replace solventborne technology without sacrificing final performance, even offering new end-use areas for epoxies. At the present time, main difficulty for formulators lies in selecting the 'fit for purpose' available waterborne technology.
This paper will cover the latest waterborne epoxy-amine product and
formulation developments in order to be able to meet extensive end-use requirements such as: application on difficult substrates (metal and non-metal), thin film application, extreme cure condition (low and high temperatures), fast cure, etc.
This paper will show that with waterborne technology we can meet
these requirements without loosing performance and that
Waterborne Technology and Top Performance are indeed no longer a
Fairy Tale.
3. Radiation Curable Protective Coatings: Innovative and Feasible
Solutions for the Steel and Aluminium Industry
Dr Marc Heylen
Cytec Surface Specialties, Belgium
Radiation curing technology for industrial coatings has
been established for decades in different applications (
wood and paper coatings, plastic coatings, CD-DVD, optical
fibers coating, electronics, etc) and the advantages in
terms of performance and processing are very well known.
In metal applications, the use of radiation curing technology
has been rather limited, and many technical obstacles discouraged
the launch of new projects.
In the last 3 years however, innovative and targeted developments at
Cytec Surface Specialties, have lead to new and greatly improved
radiation curable resins for metal coating applications. These
innovative products belong to the eco-friendly technology of the
future and address the specific needs of the metal coating
industry.
4. Novel Polyurethane Spray Elastomers with Enhanced
Chemical Resistance
Dr Christian Bruchertseifer* & Gerhard Mueller
Dow Deutschland, Germany
Over the last decade polyurethane and polyurea spray elastomers
and hybrids derived from them have found widespread acceptance in
the protective coatings industry. However in some industrial use
scenarios like power generation, mining, refining, chemical
processing etc. the applicability of spray elastomers is limited
to light to medium corrosion environments. In heavy corrosion
environments where the protective coatings is exposed to severe
chemical attack from strong acids or bases, hot oils or solvents,
sometimes in combination with elevated temperatures, polyurethane
and polyurea based protective coatings are performing only
marginally. Despite this lack in performance there is an interest
by coating applicators to use a fast-set and fast-cure system which
would enable them to finish a project in a much shorter timeframe
than what is currently possible with incumbent protective coating
technologies like epoxy, epoxy-novolac or vinylester. The
objective of this study was to develop an approach to increase the
chemical resistance of polyurethane hybrid spray elastomers without
compromising processability or performance profile. To this end,
hydrocarbon and natural oil polyol backbones were introduced to
both reactive components. The incorporation produced a significant
enhancement in chemical resistance. This was especially noteworthy
for attack by acid medias and some solvents. It was furthermore
found that varying backbones in A-(isocyanate) and/or B- (polyol
resin) reactant produced an enhancing effect which surpassed the
pure additive effect.
5. Developments in Waterborne Acrylic Resins for Low VOC
Industrial Maintenance Coatings
Dr Andrew Trapani*, Anne M. Bacho,
Gary R. Larson, Leo J. Procopio, William J. Rosano &
Laura M. Vielhauer
Rohm and Haas Co, France
As environmental regulations become increasingly strict,
manufacturers and end-users of both architectural and industrial
coatings find themselves under increasing pressure to make and
use paints with more advanced environmental profiles, such as
those with lower VOC levels. Resin suppliers are challenged to
design binders which not only allow lower VOC levels, but also
aintain the expected high performance of traditional systems.
This paper will discuss the development of several waterborne
acrylic polymers for use in high performance, VOC-compliant
coatings for industrial maintenance painting. These include a
resin designed for corrosion-resistant,direct-to-metal coatings
with VOC levels under 100 g/L, a self-crosslinking acrylic for
clear coats to improve durability of pigmented basecoats, and
an elastomeric acrylic designed for use in thick film (
250 - 500 m), surface tolerant coatings for steel and concrete
with VOC levels below 50 g/L. Formulations and coating properties
will be described, along with comparisons to traditional,
higher VOC waterborne and solventborne coatings.
6. Blistering of Reactive Resin Coatings on Concrete: Causes and
Prevention
Lars Wolff*, Prof M. Raupach, & Dr Kidist Hailu
Institute of Building Materials Research
Aachen University, Germany
Epoxy resins have already been used for impregnation and coating
of concrete parts since more than 40 years. The phenomenon of
blistering of these coatings has been reported for the first time
about 35 years ago: Some weeks or months after application usually
liquid filled blisters occur within or under the coating. In recent
research projects the mechanisms of blistering were mainly described
as osmotic transport processes in the contact zone between concrete
and base coat.
In an ongoing research project at the Institute of Building
Materials Research of Aachen University, ibac funded by the German
Research foundation DFG it could be shown that osmotic processes
seem to be not involved in the effect of blistering. In the paper
both the result of the latest research regarding mechanisms of
blistering as well as different possibilities how to prevent
blistering are represented.
7. Recent Progress in the Development of International
Standards for the Surface Preparation and Painting of Steelwork
Dr Nigel Whitehouse
PRA, UK
The performance of protective coating systems on steelwork is
affected significantly by the surface cleanliness and surface
roughness of the substrate immediately prior to painting. The
principal factors known to influence this performance are: the
presence of rust and mill scale, the presence of surface
contaminants and the surface profile. Four International
Standards (ISO 8501 - ISO 8504) have been developed to provide
methods of assessing these factors and to offer guidance on the
techniques of surface preparation now available.
To complement the surface preparation International Standards,
ISO 12944 provides extensive information on the corrosion protection
of steel structures by protective coatings.
Recent developments in some of the most important parts of these
five ISO Standards will be described.
8. Effect of Soluble Salt Contamination of Steel Substrates on the
Performance of Coatings
Paul McBain
International Paint Ltd, UK
Coatings performance can be seriously affected by the presence
of soluble salts on the steel substrate that they are applied to.
Coatings applied to steel surfaces that are contaminated with
soluble salts would be expected to show a lower level of performance
than the same coating applied to uncontaminated steel, with a high
likelihood of sub-film corrosion and osmotic blistering occurring.
This paper details a work program that has been carried out to
attempt to rank a number of products which are usually used in
immersion conditions with respect to how tolerant they are to
soluble salt contamination and a comparison of their level of
performance when they have been applied to soluble salt
contaminated steel.
9. Soluble Salt Contamination on Blast Cleaned Surfaces
and the Effect on the Durability of Subsequently
Applied Coatings
Peter J. Longdon* & M. Bohm
Corus Group, UK
It is well known that residual water-soluble contaminants on steel
surfaces, prior to protective coating application are detrimental to
subsequent coating performance. Chloride / sulphate contamination levels of
0.3-0.6 micrograms cm-2 have been suggested [1] as the maximum that should
be permitted and if levels this low are incorporated into standards
documents, then this could result in expensive and unnecessary cleaning
operations prior to the coating of steel surfaces. Corus R,D&T has
undertaken an RFCS project (in collaboration with ProfilArbed, Max Plank
Institute For Iron Research (MPIE) and CENIM) in order to assess the impact
of water-soluble salt contaminants at steel/coating interfaces and to
establish realistic working limits. Typical industrial coating systems
incorporating elements such as zinc silicate primers, fusion bonded
epoxies, glass flake epoxies, micaceous iron oxide (MIO) primers, glass
flake epoxy polyamides and zinc rich systems, were evaluated. Acceptable
contamination levels of 10 - 40 micrograms cm-2 were typically observed.
Results also show that different coating systems can tolerate different
levels of residual salt and the maximum tolerable salt value, for a
specific coating system, depends on the exposure conditions (immersion,
splash or atmospheric environments). In general the safe limits suggested
by this work [2] are 1 - 2 orders of magnitude higher than the more
conservative assessment [1].
These results are reinforced by the observation that the artificial doping
of surfaces generates a greater "aggressivity" compared to natural
contamination. Thus the limits highlighted by this study are probably
conservative. Basic mechanistic studies on model systems performed by MPIE
support the idea of a critical contamination level, below which little
effect on durability is seen. One point of concern, however, is the impact
on cathodic protection (CP), where the effect of sulphate, when either
present alone or in combination with chloride, could be seen. CP is widely
used (particular offshore) and this observation requires further
investigation to fully understand the corrosion mechanism.
10. A Multi-Metal Corrosion Inhibitor with Relevance to Commercial
Surface Preparation and Coatings Technologies
Dr Thomas C. Bedard
Lonza Inc, USA
A new water soluble quaternary ammonium compound, didecyldimethylammonium
bicarbonate/carbonate (DDABC), has been evaluated as a corrosion inhibitor via standard
electrochemical tests on steel and shown to be highly effective.
At the proper dilution, the inhibitor migrates to the metal/solution
interface and forms a mono-molecular film on the anodic sites.
Preliminary evaluations reported here indicate that DDABC and its phosphate and glycolate
anion derivates also exhibit a remarkable ability to improve the
corrosion performance of several commercailly relevant coatings
including latex, alkyd and urethane e-coat systems when used either as a
pretreatment, sealing rinse, or formulated coatings additive. In some
instances, DDABC provides corrosion performance enhancement in B117 salt spray
tests of over 300% and creep improvements of 60 - 75%. Additional observations as an adhesion
promoter, wetting agent and flash rust inhibitor are also reported.
12. Innovative Polyamide Technology Delivering Long
Overcoat Window
Rob Rasing*, Michael I. Cook &
Neil T. Hunt, Air Products & Chemicals,The Netherlands
Growth in the global coating's market and economies coupled
with ongoing VOC requirements continue to bring challenges in
high performance protective coatings. Conventional high solid
polyamide technology for two pack epoxies provides outstanding
performance and has become the industry standard for application
in this sector. However, a major limitation to date is their
limited re-coat window after applying the initial coating;
this window or the time within which a second coating can be
applied to result in good adhesion, has become of mounting
importance. Increased geographical separation of the coating
and fabrication processes has resulted in a requirement for
primers with 3 to 6 months re-coat window. Conventional high
solids epoxies have only limited re-coat window, leading to
higher cost for surface pre-treatment and extended down times.
Innovative polyamide technology presented here offers significantly
increased performance to negate this issue.
13. Available Worldwide, but Locally Milled, Talc for Heavy
Duty Anti-Corrosion Primers
Juergen Spehn
Omya International AG, Switzerland
Many multinational paint producers face the same problem viz.
they are forced to adapt formulations to use local raw materials
since transporting components too costly, especially large
quantities of low-priced products like extenders. To solve this
quandary, MONDO MINERALS is now able to provide high quality talc
which is milled to the same specification in different locations
all over the world. The production of very similar PLUSTALC grades
is possible due to the cost-efficient shipment of rocks from very
similar raw material sources to the place of use. To prove its
suitability in anti-corrosion paints, PLUSTALC C325 was compared to
three talc grades that are already known to be used successfully in
both water-borne and solvent-borne 2 pack epoxy primers.
14. Exopolysaccharides (EPS) as Anti-Corrosive Additives for
Coatings
Dr Jurgen Scheerder*, Rik Breur, Ted Slaghek, Ineke van Geel,
Wessel Holtman, Marco Vennik & Gabriele Ferrari
DSM NeoResins, The Netherlands
The use of heavy metals and heavy metal based anti-corrosive
compounds in organic coatings has been known for decades. However,
environmental reasons and health concerns have restricted and
even banned the use of these compounds. ExoPolySaccharides (EPS)
are large sugar molecules (up to 50,000 sugar units) produced by a
variety of microorganisms that exhibit anti-corrosive properties.
In this contribution we report the use of EPS as anti-corrosive
additives in combination with aqueous styrene-acrylic primers for
anti-corrosive applications. The effect of the type and amount of
EPS on the anti-corrosive properties will be discussed. The
distribution of EPS in the coating is studied by Confocal Laser
Scanning Microscopy (CLSM) and related to the anti-corrosive
properties. Finally, a working mechanism will be proposed.
The results indicate that EPS can improve the anti-corrosive
performance of waterborne primers.
15. Outstanding Metal Protection in a Nutshell
Dr Jean-Luc Dallons
Cardolite Corporation, Belgium
Synthesis of a unique type of epoxy curing agent known as a
phenalkamine. While providing outstanding protection, tolerance to
poorly prepared surfaces and low VOC content, phenalkamines
cure epoxy resins very fast and allow coatings to cure at very low
temperatures. Phenalkamine based epoxy coatings are used successfully
in the shipbuilding, metallic construction and commercial vehicle
manufacturing industries.
16. Siloxanes for Concrete Protection
Karl-Heinz Kaesler
Momentive Performance Materials, Germany
Concrete is a universal usable and used construction material.
Although well known for it s long term durability it requires
protection. Humidity and chloride ions not only attack the
concrete also may lead to corrosion of the rebar steel.
The paper will show and demonstrate how siloxanes repel water and
humidity and stop chloride ion penetration. The life time of
concrete is prolonged by treatment with siloxanes, corrosion of
rebar steel will be suppressed.
17. New Chemistry Improves Surface Performance
Steven R. Block*, Peter Hupfield, Eiji Kitaura, Masayuki Hayashi,
Yasuo Itami, Tetsuya Masutani &
Katsuhiko Imoto
Dow Corning Corp., USA
Recent developments in the chemistry of silicone and fluorine materials for
exterior coating applicatons present exciting opportunities
resulting from their synergistic effects The introduction of
silicone cure fluorine resin technology for coating applications can
significantly increase corrosion resistance of the undrlying substrate.
Flexibility, anti stain, low dirt pick up, chemical resistance
and anti-graffiti properties are other key improvements achieved with this new technology.
These silicone cure fluoro polymer resins can be cured quickly
at room temperature, providing significant cost savings and process application
flexibility to the coating applicator. These functions must be
achieved while also meeting the demands of environmentally friendly
delivery systems, such as high solids content and solvent systems which comply
with strict environmental regulations.
18. New Driving Forces for Intumescent Coatings
Dr Claudio Pagella1*, R. Epifani2 & G. Baldi3
1ProCoat, Italy, 2IRIS Vernici &
3Politecnico di Torino
The protection of steel structures from fire by means of intumescent coatings is a well
established technology, yet still a growing business. Driven worldwide by
the increasing need for safely in building and in Europe strongly
influenced by the demanding new standards for fire testing and product
classification (ENV 13381, EN 13501) the intumescent coating business is set for changes.
While environmental issues and the VOC regulation push for
waterborne systems the largest market share is still controlled by solventbornes. The
need to prove durability according to meaningful predictive
methods is crucial in the competition with alternative technologies (boards, plasters).
Applications are widening, ranging from concrete structures to wood
(transparent intumescent systems are now available), to the use of intumescent systems to reduce flammability
of various materials.
19. Achieving a Utopian Green Coating Technology
Philip Hamlin
ProCoat Global Coatings Ltd, UK
Rubber has been well documented for its multiple protective
properties used to combat corrosion, wear, impact, vibration,
cavitation, electrical and thermal insulation and sound attenuation;
characteristics that are well known to industry. This presentation
sets out the development path and technical data and test results
from engineering an environmental VOC free sprayable rubber coating;
the initial goal at first appeared to border on organic transmodification
or alchemy, yet successfully culminated in a 100% binded system
utilising 50% cryogenically processed rubber crump of <200 microns
from recycled tyres delivering an adhesion factor to metal of
6.0 MPa after 4 years atmospheric corrosion testing. Achieving
this successful green coating technology and to comply with both
current and future legislative and environmentally acceptable
trends required an alternative development methodology focusing on
Life Cycle Analysis ‘LCA’ of materials, process and finished product.
This approach required a balance against the compromise of
delivering a credible cost effective and operationally acceptable
system for contractors, buyers, specifiers, designers and engineers.
20. Galvanic Corrosion Protection of Concrete Rebar by
Metallization and Paint Coating
Solveig Hölzinger* & Marc Arav
EMTS Quorum, France
Maintenance of civil and construction works in concrete is
becoming a need all over Europe. Till now, it was mainly solved
by heavy techniques. Today, it can be done by a single application
of metallization thickness 250µ of 8515 covered by tie coat and a
top coat. This technique well known in North America is rarely
used elsewhere. To evaluate it, EMTS QUORUM did first, as state
of the art in the USA and Canada, completed by an experimental
program done at ISITV laboratory
21. The Use of Optically Active Additives (OAAs) in the Protection
and Preservation of Structures
Howard Jess
Luminous Technologies, UK
The purpose of an OAA is to make a coating react to ultra
violet light. This effect enables quick, non-invasive
inspection of very large coated areas during the application
process allowing the inspector to identify and concentrate on
defective areas, thus reducing inspection time while assuring
the probability of good application and coverage. It works by
highlighting holidays and pin-holes, areas of over and under
application as well as giving the opportunity for defect
detection and identification of early coating deterioration
through life. Improved first time coating quality improves
coating performance
22.
No paper available.
23. New Applications for Coatings
Containing Glass Flakes
David Mason
NGF Europe Ltd, UK
The paper will present two recent developments illustrating how
coatings containing glass flake are used in new applications based
on improved protection of both the substrate and the environment.
Traditionally Glass Flake coatings have been used in high performance
for aggressive environments e.g. C5 and C5M
The protection of road and rail bridges in these environments has
traditionally been achieved with low solids multi-coat micaceous
iron oxide systems offering services lives of only 7-15 years.
The paper uses independent laboratory (CAPCIS, Manchester UK)
results to compare the performance of Glass Flake and micaceous
iron oxide pigmented systems in terms of:
Cathodic Disbondment
Electrical impedance spectroscopy
Abrasion resistance
Reverse bend impact tests.
Actual coating systems will then be compared to highlight costs
savings of up to 30% in applied cost that can be achieved using
appropriate glass flake systems.
Once applied high solids low VOC glass flake coatings offer
significantly longer services lives to first maintenance, systems
are available offering service lives to major maintenance of 25 years
These offer significant savings in the overall coat of corrosion
protection over the life of the structure.
In a separate development glass flake coating has been successfully
marketed as a biocide-free antifouling coating offering
significant environmental benefit over traditional TBT systems,
whilst improving the long-term protection of the substrate.
24. Phosphorous Rich Polymers and Mixed Intumescent Polymeric Salts
David Charles Aslin
Prometheus Developments Ltd
The paper will discuss Phosphorus Rich Polymers (PRP) and the
derivative technology, Mixed Intumescent Polymeric Salts (MIPS).
These provide a system of fire porotection and enhancing the reaction
to fire behaviour of flammable substrates and materials.
The products involve a novel chemistry that integrates the
functional components of conventional intumescents at the
molecular scale to produce non-flammable and intumescent
polymeric materials that activate at low temperatures
and produce negligible smoke.
PRP liquid oligomeric materials are used to produce fire protective
paints, varnishes, elastomers, foams and composites.
MIPS is a powder, which is used as a halogen free flame
retardant additive for a wide range of polymers. The progress of the
commercialisation and IPR protection of the system will be discussed.
25. Disputes in On-shore Coatings
Projects - Where They Arise and How to Avoid Them
Miles Robinson* & Andrew Briggs*
Mayer, Brown, Rowe & Maw LLP, UK
Disputes cost businesses both money and time. They often cannot
be avoided but by taking some practical steps before, during and
after a coating project, their scope and potential damage to
your business can be reduced. This paper considers the various
relationships and issues that arise in at typical on-shore coatings
project and which can lead to disputes arising. It also provides
some practical advice on how best to manage these areas to avoid
disputes arising - or at least to reduce their impact on your
business.
26. Coatings and Risk Assessment: Health
& Product Safety Issues
Philippe Legros*, Valérie Winne & Greet Cocquyt
Arcelor/OCAS, Belgium
Safety on the workplace and the health of employees are top
priorities for any employer Product and processes have to meet strict
requirements to ensure that they are not dangerous. Concerning
coatings OCAS has developed methods in order to lower the environmental
impact and to assess hazards and risks at the earliest stage of each development of new
product with an associated process. As example air samplings are performed
directly on line during application and curing of new coatings: recently a lot of attention was given to formaldehyde and isocyanates. OCAS has also vast experience in welding fumes analyses using the pyrolysis technique and the characterisation of residual volaties from coated steels.
27. Liquid Applied Coatings for High
Temperature Corrosive Environments
Michael MeLampy* & Peter Bock
Hi-Temp Coatings Technology, USA
This presentation will present the use of liquid applied coatings in providing solutions to difficult
temperature related corrosion prevention issues. A historical review
of technologies through new developments in modern technology products
will be discussed. Issues related to corrosion under insulation will also
be discussed. The presenter will also provide a prediction in future
technologies that may expand functional properties of spray applied
products beyond traditional corrosion prevention and aesthetic
properties.
28. A New Generation High
Temperature Corrosion Resistant Coating
Dr Adrian Andrews
International Paint, UK
Corrosion under Insulation is a major
problem in the petro-chemical and chemical industries
where the corrosion rates carbon steel can be significant
if operating at high temperature and subject to temperature
cycling, particularly when thermally insulated.
The protection of these assets thus provides some of the
most demanding environments faced by coatings. This paper
provides an outline of the development of "cold spray
aluminium" (CSA) coatings technology in comparison to
traditional high temperature coatings systems.
The performance (laboratory and field) of the new generation
high temperature corrosion resistant coating together with
test method development is discussed.
END OF CONFERENCE
