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INDUSTRIAL AND PROTECTIVE COATINGS

A SUSTAINABLE APPROACH TO

MODERN COATING TECHNOLOGY

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A Sustainable Approach to Modern Coating Technology

Patcham FZC is a well-established manufacturer of specialty additives headquartered in the United Arab Emirates. Since its inception, Patcham has steadily grown into a leading supplier of specialty additives for the Paint & Coatings, Ink, PVC and Composite industries.

The company’s Pat-Add range of coating additives includes wetting & dispersing agents, defoamers, slip & leveling agents, rheology modifiers. Whilst keeping focus on environmental sustainability, the company produces products using green raw materials that are APEO free and have low or no VOC.

These products are multi functional and multi compatible, which simplifies the production process, reduces the chance of errors and minimizes inventory thus improving cost effective-ness.

Patcham has built a strong manufacturing and R&D infrastructure that enables the rapid transition from concept to products. The company has strategically located technical service laboratories, offices and representatives around the world to provide the most efficient customer service. In addition, a well-developed robust supply chain network enables it to deliver its products and services to customers around the globe with minimal lead-time.

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Introduction

Pat-Add additives for high performance industrial coatings

Industrial high performance primers

2K PU and Epoxy primer

Industrial high performance topcoat

Topcoat based on Alkyd, PU and Epoxy systems

Topcoats for high end application

Alkyd topcoats

Additives for waterborne epoxy systems

Contents

1

2

3

7

12

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An industrial coating is a paint or coating defined by its protective, rather than its aesthetic properties. The most common use of industrial coatings is for corrosion control of steel structures such as offshore platforms, pipelines, OEM machineries, engineering civil structures and other various substrates. The occurrence of corrosion is a universal phenomenon and defined as the deterioration of a material, usually a metal, because of a reaction with its environment. The ingress of water through the coating on a metal surface, can lead to the start of corrosion which if not corrected can weaken the metal structures.

The coating (both liquid and final dried film) has to have over all high performance in terms of superior flow, sag resistance, high build, hiding, gloss and above all provide corrosion resistance.

Furthermore, various pigments such as zinc phosphate are included in coating formulations in order to further alleviate the chance of corrosion. Due to the high specific gravity of these kind of pigments, very efficient wetting and dispersing agents are required to provide optimal stabilisation and avoid the possibility of settling. It also requires multicompatible additives that can work through systems such as polyurethane, epoxy, alkyds, thermo plastic, thermo setting acrylics, etc.

Introduction

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Pat-Add additives for industrial coatings

Patcham offers a package of additives, that can help to improve the appearance and durability of industrial and protective coating by providing optimum mill base viscosity, efficient grinding, flow, leveling, improved gloss and DOI. Efficient dispersion of the pigmented coatings further enhances the barrier properties, particularly against corrosion. This further boosts the performance of the coating system.

Pat-Add additive package for industrial applications includes dispersing agents, anti settling agents, leveling agents and defoamers. These multifunctional and multicompatible additives can be incorporated in Epoxy, PU, alkyds and other solventborne formulations.

A selection of Pat-Add additives for Solventborne (SB) systems are illustrated below in Table 1.

Additive Features

Additive for solventborne primers and topcoats

Pat-Add DA 1666

Pat-Add DA 1808

Pat-Add DA 786

Pat-Add DA 932

Pat-Add LE 1020

Pat-Add AF 62

Table 1: Patcham additives for solventborne industrial applications.

Uniquely designed multifunctional polymer with multi compatibility with different types of resin systems. Acts as wetting and dispersing agent, anti settling agent, anti sagging agent and anti flocculating agent.

Amphoteric dispersing agent effective in alkyd paints. Strongly adsorbed onto inorganic and black pigments, contributing steric stabilization against re-flocculation.

Efficient dispersing agent for alkyd system and suitable for organic, inorganic and black pigments

Water incorporation additive offers excellent gloss retention, stable viscosity, anti-settling and anti-sagging properties

High Molar Volume technology polymeric dispersing agent for all kind of carbon blacks, organic pigments and inorganic pigments. Enables high pigment loading for pigment concentrates (PC) and supports stabilization of pigments

Polyether modified polysiloxane surface modifier improves flow, leveling, DOI and gloss

Silicone free defoamer for both clear and pigmented systems. Suitable for all kinds of SB resin systems

0.3 - 0.8Grinding / Letdown

0.3 – 1.0 Grinding stage

0.3 - 0.8Grinding stage

0.5 – 1.0 Grinding stage

1.0 - 4.0 10.0 - 15.0 (PC)

Grinding stage

0.05 - 1.0Letdown stage


Pat-Add DA 707

Dosage on total formulation (%)



2K PU and epoxy primer

Patcham offers a package of additives, that can help to improve the appearance and durability of industrial and protective coating by providing optimum mill base viscosity, efficient grinding, flow, leveling, improved gloss and DOI. Efficient dispersion of the pigmented coatings further enhances the barrier properties, particularly against corrosion. This further boosts the performance of the coating system.

Pat-Add additive package for industrial applications includes dispersing agents, anti settling agents, leveling agents and defoamers. These multifunctional and multicompatible additives can be incorporated in Epoxy, PU, alkyds and other solventborne formulations.

A selection of Pat-Add additives for Solventborne (SB) systems are illustrated below in Table 1.

The primers are formulated generally with high levels of Zinc dust, Zinc phosphate or other anti-corrosive extenders to enhance the corrosive barrier. One of the draw backs of using high levels of these types of pigments is that these pigments are more prone to settling issues and require an efficient dispersing and stabilizing agent to overcome this problem.

Pat-Add DA 1666 is a special additive compatible with all solventborne systems such as PU, Epoxy, Alkyd, TPA, etc. The key features are:

2K PU Red oxide zinc phosphate primer

Raw materials Weight (%) Part A Pat-Add DA 1666/ReferenceRed oxideZinc phosphateCaCO3

TalcAcrylic polyolXyleneButyl acetate Letdown Acrylic polyol1% Patcat 3001 (DBTDL )Butyl acetate Total Part BAromatic isocyanateMixing ratio part A:B (weight)

0.258.008.00

22.0010.0018.0010.004.50

12.000.207.05

100.00

10.0010:1

Table 2: Formulation of 2K PU red oxide primer

Reference Pat-Add DA 1666

Visc

osity

(cP

)

Mill base viscosity of 2K PU primer

820

810

800

790

780

770

814

822

Figure 1: Mill base viscosities of 2K PU red oxide zinc phosphate primer

Excellent wetting and dispersing agent for fillers, anti-corrosive pigments, inorganic and organic pigments

Reduced mill base viscosity and milling time

Prevention of flocculation and floatation in pigment blends

Acts as a compatibilizer

Good anti sagging property and eliminates settling thereby enhancing the stability



Table 3: Viscosity and grinding parameters

Properties Reference Pat-Add DA 1666

Mill base viscosity (cP)

Paint viscosity (cP)

Fineness of grind (µm)

Grinding time (hour)

814325

25

2

822342

30

2

Figure 2: Representation of de flocculation in 2K PU red oxide primer with Pat-Add DA 1666

Figure 3: Sag resistance test - 2K PU and alkyd red oxide zinc phosphate primer



Figure 4: Pictorial representation of stability of alkyd primer with Pat-Add DA 1666



The formulation of 2K PU primer surfacer and epoxy zinc rich primer are given in Tables 4 & 5.

Pat-Add DA 1666 provides excellent stabilization of pigments and extenders that increases the stability of the system. The reference sample showed hard settling whereas DA 1666 did not have any settling. It also enhances the anti sagging property of the primer, wherein the reference sample sags from 100 microns WFT, while there is no sagging observed up to 225 microns WFT. The anti settling and anti sagging properties are evident in Figure 5 and 6 below.

Raw materials Weight (%)

Table 4: Formulation of 2K PU surfacer white Table 5: Formulation of epoxy zinc rich primer

2K PU surfacer white Epoxy zinc rich primer

Part A Pat-Add DA 1666 Silica Titanium dioxide Barytes Talc Acrylic polyol Solvesso 100 MIBK Butyl acetate Pat-Add AF 70 1% Patcat 3001 (DBTDL) Total Part B Aromatic isocyanateMixing ratio

0.50 15.00 8.00

14.00 10.00 32.80 9.00 3.00 7.00 0.50 0.20

100.00

10.00 10:1

Heavy settling

Figure 5: Stability test for 2K PU surfacer white Figure 6: Sagging test for 2K PU surfacer white


Raw materials Weight (%) Part APat-Add DA 1666 Moisture scavenger Epoxy resin (75%) Organoclay thickenerFumed silica Zinc dust Butyl cellosolve Butanol Xylene Total Part BPolyamide 125 (50%) Xylene TotalMixing ratio (w/w)

0.501.00

12.000.500.30

77.004.002.702.00

100.00

6.004.00

10.0010:1


Sagging limit

WFT inmicrons

75 µm

100 µm

125 µm

150 µm

175 µm

200 µm

225 µm

250 µm

275 µm

300 µm



As can be seen from the results for sag resistance, adhesion and bend test (Figure 7) from a formulation based on an epoxy zinc phosphate primer (Table 6), the addition of Pat Add-DA 1666 helps to optimise the overall performance of the epoxy zinc phosphate primer.

Raw materials Weight (%) Part AEpoxy resin (75%)Pat-Add DA 1666Organoclay thickenerRed oxideTalc CaCO3 Zinc phosphate Xylene Butyl cellosolve Letdown Epoxy resin (75%)Butyl cellosolve Xylene Total Part BPolyamide 125 hardenerMixing ratio A:B (w/w)

Figure 7: Performance of epoxy red oxide primer

Table 6: Formulation of epoxy zinc phosphate red oxide primer

23.230.600.305.758.00

19.257.005.79

10.08

14.003.003.00

100.00

10.0010:1

Pat-Add DA 1666 in Epoxy zinc phosphate primer


The function of a topcoat in an industrial coating is not only to provide the final barrier to the substrate but also to give an appealing and aesthetic appearance to the substrate.

Top coat based on alkyd, PU and epoxy systems

Specially designed multicompatible and multifunctional Pat-Add DA 1666 can be used in a formulation for industrial topcoat to provide the required characteristics such as stabilization of the pigments, good flow and improved final appearance such as gloss in a high performance coating.

Figure 8: L* value, yellow index and gloss value in polyurethane white paint

Table 7: Formulation for 2K PU white topcoat

Raw materials Weight (%)2K PU white topcoat

Part AAcrylic polyolOrganoclay thickenerPat-Add DA 1666/ReferenceTitanium dioxidePU solvent Letdown Acrylic polyolPat-Add LE 10201% Patcat 3001 (DBTDL)PU solvent Total Part BAliphatic isocyanate Mixing ratio A:B (w/w)

30.000.500.50

22.004.00

30.000.300.20

12.50100.00

28.00100:28

0.16

0.81

Pat-Add DA 1666Reference

Yellow index

93.05

92.35


L*


Gloss value

90.990.4

20

81.583.4

0

600


Pat-Add DA 1666 shows better coloristic values with PU direct grinding systems due to their efficient wetting and dispersing properties and compatibility with the system. Figure 8 shows that white paint made using this additive gives better brightness, low yellow index and good gloss values.


The function of a topcoat in an industrial coating is not only to provide the final barrier to the substrate but also to give an appealing and aesthetic appearance to the substrate.

Top coat based on alkyd, PU and epoxy systems

Specially designed multicompatible and multifunctional Pat-Add DA 1666 can be used in a formulation for industrial topcoat to provide the required characteristics such as stabilization of the pigments, good flow and improved final appearance such as gloss in a high performance coating.

The same trend of higher brightness, low yellow index and good gloss values are possible with Pat-Add DA 1666 in Alkyd, PU, Epoxy and other solventborne systems. It has the ability to reduce the mill base viscosity and improve the grinding efficiency. Mill base viscosity of Alkyd, PU and Epoxy systems are shown in Table 10.

Raw materials Weight (%)Raw materials Weight (%)

Epoxy white topcoat

Part AEpoxy resin (75%) Organoclay thickenerPat-Add DA 1666Titanium dioxideEpoxy solvent (xylene, butanol) Letdown Epoxy resin (75%) Pat- Add LE 1040Epoxy solvent (xylene, butanol) Total Part BPolyamide 115 (60% solution)Mixing ratio Part A:B (w/w)

20.000.500.50

22.0010.00

25.000.20

21.80100.00

30.00100:30

Table 8: Formulation of epoxy white topcoat

Table 10: Mill base viscosity of alkyd, PU and epoxy white paint

Alkyd white PU white Epoxy white

Reference Reference ReferencePat-Add DA 1666

Pat-Add DA 1666

Pat-Add DA 1666

Properties

Mill base viscosity (cP) 359 402 860 865 536 549

Paint viscosity (cP) 160 232 481 550 225 370

2K PU co-grinding system

Part A - Mill base Acrylic polyol Pat-Add DA 1666 Titanium dioxide Yellow PY 42 PB 15:3 Black oxide Organoclay thickenerPU solvent Letdown Acrylic polyol Pat-Add LE 1020 Pat-Add AF 62 1% Patcat 3001 (DBTDL) PU solvent Total

30.00 1.40

18.00 0.90 0.60 0.10 0.50 8.00

30.00 0.30 0.20 0.20 9.80

100.00 Part B Aliphatic isocyanate 28.00Mixing ratio (w/w) 100:28

Gloss @ 60 - 96 units0

Figure 9: Flow behaviour of 2K PU co-grinding system


Table 9: Formulation of 2K PU co-grinding system

Fineness of grind vs grinding time25

20

15

10

5

0

Parti

cle

size

(µm

)

30 mins 1 hr 1 hr 30 2 hr 3 hr

Grinding time



Topcoats for high end application

Pat-Add DA 932 is a dispersing agent based on High Molar Volume technology. The higher volume occupied by the dispersant results in a thicker adsorbed layer around the pigments which increases resistance to attractive forces and therefore gives a more stable pigment dispersion. It has wide compatibility with PU, epoxy, TPA, NC and other solventborne systems. High performances can be achieved in co-grinding, direct grinding, resin free and resin minimal pigment concentrates. The key features are:

NB: For optimum performance of Pat-Add DA 932 in grinding of pigments, it is advised to grind pigments till the required particle size is achieved in terms of Hegman gauge and color strength. Over grinding may lead to change in coloristic properties

As shown in Figure 10, Pat-Add 932 helps in reducing the grinding time of pigments. It also helps in obtaining stable dispersions and enriching the coloristic values.


Dense network of anchoring groups stabilize black, organic and inorganic pigments

Contributes to optimum mill base viscosity and reduced milling time

High jetness and blue under tone for black pigments

Provides excellent long term stability of pigment dispersions

Superior gloss and transparency

2K PU black topcoat

Part A Mill BaseAcrylic polyolOrganoclay thickenerPat-Add DA 932Carbon black FW 200Butyl acetateXylene LetdownAcrylic polyolButyl acetatePat-Add LE 1020MPAXylene1% Patcat 3001 (DBTDL) Total Part B Aliphatic isocyanate Mixing ratio A:B (w/w)

17.140.202.002.003.003.00

52.863.000.204.00

12.400.20

100.00

33.00100:33

Table 11: Formulation of 2K PU black

Figure 10: Grinding time vs particle size of PU black topcoat


®


Alkyd topcoats

Pat-Add DA 1808 shows excellent compatibility with most alkyds including long, medium, short and other modified alkyd systems used on different types of substrates such as plastic, and steel structures. Key benefits that Pat-Add DA 1808 can bring to the formulation includes

Optimization of the milling process Provides excellent color development Prevention of floating and flocculation Excellent compatibility with Alkyd resin systems

Formulation of Alkyd paint based on Pat-Add DA 1808 is shown in Table 12. It can be seen to bring out and enhances the jetness of carbon black in Alkyd black topcoat (Figure 14).

Pat-Add DA 932 shows less L* values and higher Mc values for 2K PU black with FW 200 which indicates higher jetness and bluish under tone of black is obtained.

Figure 11: L* value of 2K PU black topcoat Figure 12: Mc values of 2K PU black topcoat

Figure 13: Jetness of 2K PU black topcoat

Industrial high performance topcoatL*

val

ues

1.81.61.41.21

0.80.60.40.20


1.4

1.7

30 mins 1hr 1hr 30 2hrs 3hrsmins


285.58

274.12

284.72

276.56

287.14

274.67

283.56

286.23

277.35

271.35

Reference Pat- Add DA 932

®


Raw materials Weight (%)Alkyd black topcoat

Long oil alkyd Pat-Add DA 1808Carbon black N 330 White spirit LetdownLong oil alkyd Patcom 24 (Combination drier)Patox 1 (MEKO) White spirit Total

20.001.002.00

10.00

40.001.400.20

25.40100.00

Table 12: Formulation of alkyd black topcoat

Figure 14: Jetness of alkyd black topcoat

Figure 15: Rubout test of alkyd black topcoat


Alkyd black paint made with Pat-Add DA 1808 shows better jetness as can be seen in Figure 14. A stable black dispersion is achieved and is shown in Figure 15 with lower ΔE values for rubbed and unrubbed areas.

Rub out test results

ΔE

valu

es

0.3

0.25

0.2

0.15

0.1

0.05

0Reference Pat-Add DA 1808

0.26

0.06

®


Figure 16: Competition cycle of conventional surfactants and defoamers


Waterborne industrial epoxy coatings offer exceptional performance as a barrier to corrosion along with other performance properties, whilst being environmentally friendly. Applicators however come across issues of dewetting of substrate and foam. It is well under-stood that wetting agents (surfactants) help to increase substrate wetting, flow and to some extent leveling.

The challenge has always been to find the right wetting agent that does not lead to foam generation and if at all it does, a right defoamer to destroy this foam generated due to the presence of the wetting agent. The selection of a suitable surfactant and defoamer combination becomes critical to formulators.

Patcham has developed a package of additives (Table 13), for waterborne epoxy system which can overcome the issues related to these systems. It consists of

Surfactant

Foam generation

Anti foamingagent

De wetting

Dispersing agent with anti settling properties

Leveling agent with excellent flow, leveling and substrate wetting

Defoamer with excellent balance between defoaming and compatibility with the system


ww

w.p

atch

amlt

d.c

om


Waterborne epoxy grey

Table 13: Additives for WB epoxy topcoat


Pat-Add DA 817

Pat-Add AF 31

Pat-Add LE 1030

Additive Features

Efficient dispersing optimizes the milling process and strong prevention of pigment flocculation, floating and settling issues. Compatible with all WB and SB systems.

Easily dispersible and very effective anti foaming agent with optimum compatibility

Polyether modified polysiloxane surface modifier provides excellent flow and leveling enhances substrate wetting, avoids pinholes and craters.

0.3 - 3.0Grinding stage


0.05 - 0.4Letdown stage

Part A Mill baseEpoxy amine adductPat-Add DA 817Pat-Add AF 31BarytesTalcTitanium dioxideIron oxide blackIron oxide yellowFumed silicaButyl carbitolButyl cellosolveMPAWater LetdownEpoxy amine adductWaterPat-Add LE 1030 Total Part BLiquid epoxy resinMixing ratio A:B (w/w)

20.000.850.10

16.0010.008.000.460.240.202.000.603.00

10.00

18.0010.350.20

100.00

25.004:1

Table 14: Formulation of waterborne epoxy grey

Pat-Add DA 817 optimizes the viscosity of waterborne epoxy paint whilst the leveling and anti foaming agents provide the synergistic effect to avoid issues of dewetting and foaming.

Waterborne epoxy system

Dosage on total formulation (%)



Pat-Add DA 817 is a unique dispersing agent that also acts as an anti-settling agent. The electrostatic repulsion created by charged polymeric dispersants adsorbed on the surface of the pigments helps to reduce particle aggregation. This in turn reduces the chances of flocculation while continuing to maintain the smaller particle size.

Figure 17: Stability of WB epoxy primer

Figure 18: Substrate wetting of waterborne epoxy primer with Pat-Add LE 1030

Physical properties

Dry film thicknessGloss value @600Flexibility by conical mandrel 7mmAdhesion test after 24 hrs (1.5 mm)Adhesion test after 7 days (1.5 mm)

55-60µm90 unitsPasses5B passes5B passes

Table 15: Performance of waterborne epoxy paint

Figure 19: Adhesion and bending test results of WB epoxy paint

The package of Pat-Add additives have an excellent balance of compatibility and do not show any side effects such as de wetting (Figure 18), craters, fish eyes and intercoat adhesion issues (Figure 19).

Performance properties such as flexibility and adhesion tests showed no intercoat adhesion failure. These findings are illustrated in Table 15 and Figure 19.

The stability of waterborne epoxy primer is represented in Figure 17. Epoxy primer has optimum viscosity with no settling whereas, the reference sample shows settling of pigmnets during the stability test.


Reference Pat-Add LE 1030

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Notes


www.patchamltd.com

PATCHAM (FZC)

P.O. Box: 7753,Saif Zone, Sharjah, UAETel: +971-6-5570035Fax: +971-6-5570038Email: [email protected]

PATCHAM EUROPE BV

Klavermaten 65-1 7472 DD GoorNetherlandsEmail: [email protected]

PATCHAM INDIA

B-52, Pravasi Industrial Estate Vishweshwar Nagar, Off Aarey Road Goregoan (E), Mumbai - 400 063 (India) Tel: +91-22-29272471Email: [email protected]

PATCHAM USA LLC

10 Commerce RoadFairfield, New Jersey – 07004Tel: (201) 293-4282Fax: (201) 820-0818Email: [email protected]

The information given in this booklet is intended for technical guidance without obligation. Ver. 1.0

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