engineering gf paints and coatings - general...

EngineeringGFPaintsandCoatingsInstructors:RyanDenny

TableofContents1.  Briefhistoryofthepaintsandcoa8ngsindustry2.  Composi8onofmodernpaintsandcoa8ngs3.  RawMaterials4.  Manufacturingprocess5.  QualitycontrolandExperimentaltes8ngprocedures6.  Applica8ontechniques

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Introduction1.  Tryandimaginesomethingthatdoesnothavea

coa8ngonit2.  PerhapstheWorld’ssecondoldestprofession3.  Constantlyevolvingwithnosingleinventor

a.  Oil-based,solventborne,waterbornetechnologiesb.  Advancesinrawmaterialtechnologyc.  Greenini8a8ve(ZeroVOC)

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PaintsandCoatingsTimeline

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• 30,000yearsagocavedwellersusedcrudepaintstoleaverepresenta8onsoftheirlives• 1,000BCGumArabicfirstusedtodeveloppaintsandvarnishes

• 600BC-400ADVariousciviliza8onsbeginusingoilsasvarnishesandpigmentandbindercombos• 1500sAr8stsbeginaddingdryingoilstohastenevapora8on;linseedoilbecomesthemostcommon

• 1856HenryPerkindiscoversfirstrealsynthe8cdye• 1865D.P.Flinnobtainspatentforthefirstwater-basedpaint

• 1867D.R.Averillpatents"ready-mixed"paints• 1930sAlkydsforhousepaintsandindustrialuse

• Late1930sEpoxiesaredevelopedforindustrialuses• 1940sNewsynthe8cbindersaredeveloped(polyurethanesandacrylics)

• 1970sPowdercoa8ngsaredeveloped• TodayhybridandUVtechnologiesarebeingdeveloped• Currentlyenvironmentalregula8onsarepushingwater-basedlowVOC/zeroVOCpaintsandcoa8ngs

Composition1.  Vehicles

a.  Solids-Resinb.  Vola8les-Solvents

2.  Pigmentsa.  Color-hidingpigments(TiO2,Carbonblack,Redironoxide)b.  Inert-fillerpigments(calciumcarbonate)c.  Effectpigments(Metallic)

3.  Addi8vesa.  Dispersantsb.  Driersc.  FlowandRheologicalmodifiersd.  Substrateweing/surfacetensionmodifiers 5

Composition

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10

20

30

40

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MilkPaintComposi8on

ChalkPaintComposi8on

Pigments

Vola8les

ResinSolids

Addi8ves

•  Paintismanufacturedandrawmaterialsarepurchasedviaweightforaccuracy.

•  Paintisusedandsoldbyvolume6

CompositionalVocabularyWeight/Gallon=weightperunitvolumePigmenttoBinderra3o=pigmentweight/resinsolidsweightPigmentVolumeConcentra3on(PVC)=pigmentvolume/volumesolids(cri8calPVCisapproximately60%)VOC=weightoforganicsolvent/gallon-water

*Notethatwaterdoesnotcountinthecalcula3onofVOC,soagallonof100%organicsolventhasthesameVOCasagallonof50%waterand50%organicsolvent

*Notesomeorganicsolventsareexempt,meaningtheydonotcontributeVOCtothecalcula3on.Henceyoucanhaveapaintorcoa3ngthatsayszeroVOCthats3llhasorganicsolventwithinit 7

Solvents•  Alipha8c•  Aroma8c•  Alcohols•  Glycolethers•  Ketones•  Acetates•  Water•  Blendsofthesolventsabove

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Water1.  Considereda“universal

solvent”2.  Physicalcharacteris8cs

governtheapplica8onofwaterbornecoa8ngs

3.  Evapora8onrateistemperatureandhumiditydependent

a.  Controls/Effectsthedryrateandopen8meofthecoa8ng

b.  Op8mumcondi8onsare70Fand40%humidity

4.  Airmovementwillalterdry8me

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VOC’s1.  Organicsolventsareregulatedbyhowmuchozone/smog

forma8ontheycausecomparedtoethaneasastandard2.  Exemptsolventsdonotcontributetosmogforma8onorthe

forma8onisconsiderednegligiblea.  Acetone,Methylacetate,andT-butylacetatearesomeexempt

solventsb.  No8cethatanexemptsolventcans8llbetoxictohumanseven

thoughitisnotregulatedasaVOC

3.  Apaintorcoa8ngcanandwillhaveotherorganicsolventswithinthemeventhoughtheyareconsideredzero/lowVOC

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IndustryStandards&Regulations

VOC:vola8leorganiccompound;limitedtolessthan420g/Lorlowerdependingonloca8onLabeling:certainmaterialsrequirespecificwarningsSafetyDataSheet(SDS):mustmeetOSHAstandard,mayneedANSIcompliance

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ResinBinders1.   Alkyds2.  Polyesters3.   Acrylics4.  Latexes5.  Melamine6.   Urethanes7.  Epoxies8.  Hybrids

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AlkydsAlkydsaremodifiedwithoilandweusethemineachofouroil-basedproductsonthemarket.

OilTypes

Drying Semi-Drying Non-Drying

Linseed Soya Coconut

Tung Safflower Castor

DehydratedCastorOil

TallOilAcids

FishOil

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Alkyds•  Highlyversa8lechemistry•  Householdpaint•  Industrialapplica8ons

•  Dryviaoxida8on•  Canbemodifiedwithotherresinsandchemicals•  Styrene•  Phenolic•  BenzoicAcid•  VinylToluene•  Rosin•  Acrylic•  Silicone 14

Acrylics•  Dryviasolventevapora8on(lacquer)orcrosslinkingmechanism(urethaneormelamine)

•  HighestUVresistanceofallorganiccoa8ngs•  Contributevaryingdegreeofcoa8nghardnesstothesystem•  Canbeblendedwithotherresinsystemstoimpartdifferentproper8es•  Polyurethanesincreasechemicalresistancewhenblendedwithacrylics

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Polyurethanes•  AlsoreferredtoasurethanesorPUD’s•  Ambientcurecoa8ngs•  Impartexcellentchemicalresistanceanddurability•  Cancrosslinkwithacatalyst(2Ksystem)forincreasedperformance,butreducingpotlife

•  Canbeblendedwithacrylicstogetbothsurfacehardnessandchemicalresistance

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FilmFormationMinimumFilmFormingTemperature(MFFT)=theminimumtemperatureneededtoformacon8nuousfilm

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ColorPigments1.  TiO2(Titaniumdioxide)istheonlyhidingpigmentthat

scapers/reflectslight2.  Allothercoloredpigmentsabsorblightatspecific

wavelengths3.  Blackpigmentsabsorballwavelengthsoflight

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Opacity1.  Opacityisdefinedbyhowmuchthepaintabsorbs,reflects

orscaperslighttohidetheunderlyingsubstrate2.  Measuredasapercentonaspectrophotometerovera

sealedwhite,sealedblack,andunsealedwhitesurface

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ExtenderPigments1.  Calciumcarbonate/claysactasfillersatalowcosttospace

outTiO2moleculesforimprovedlightrefrac8on2.  Talc/Magnesiumsilicateactsasflapeningagents3.  Amorphoussilicaactsasahigh-efficiencyflapener4.  Crystallinesilicaimprovesadhesion,fills,andflapens5.  Fumedsilicaimpartsrheologicalcontrolandflapens

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Additives1.  Dispersants:surfactantsthathelpthesystemacceptdry

pigmentwithinthegrindphase2.  Flow&Leveling:surfacemodifierssuchasfluorosurfactants

andsilanesthatimprovethewepabilityoftheproductovertheapplica8onsurface

3.  Rheologymodifier:actstothickenthepaintorcoa8ng4.  Defoamers/Deaerators:knockdownfoamforma8onduring

themanufacturingandapplica8onprocess5.  Slipaids:surfacemodifiersthatalterhowslipperyasurface

feels6.  Biocides:killersofbacteria,mildew,andfungusbothincan

andinfilmforincreasedstability 21

ManufacturingProcessGrindPhaseHighspeeddisperseanydrypigmentorflapeningagentintoeitherwaterortheresinsystemwithadispersantmakingsureyouhaveagoodvortexPremixInaseparatevesselmixtogetherwaterandanysolventneededforcoalescenceofthecoa8ngsoyoudonotshocktheresinsystemwhenaddedLet-downReducethespeedofyourdispersionandaddyourpremixandanyslip-aids,rheologicalmodifiers,biocides,andsurfacemodifieraddi8vestoimproveyourcoa8ngsperformance 22

ManufacturingProcessTechnology:HighspeeddispersionusingaCowlesblade•  Agoodvortexpullsthecontentsofthevesseltothebladesedge

•  Overchargingorundercharginganyonematerialcanresultinapoordispersion

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PerformanceCharacteristics1.  ChemicalResistance2.  WaterResistance3.  Heat/HumidityResistance4.  YellowingResistance/TanninBleedResistance5.  Weathering6.  Adhesion7.  Incanstability

a.  OvenStabilityb.  Freeze/ThawStability

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ChemicalResistanceMethod1.  Spraybirchpanelswiththreecoatsofproduct(3drymils)2.  Dryeachpanelundera120Fheatlampbetweeneachcoat

andallowthepanelstocureforfivedays3.  Applythe21differenthouseholdproductstoeachpanel

beingtested4.  Placewatchglassesontopofeachchemicalandallowtosit

foronehourbeforescoring5.  Scorethecoa8ng’sresistancetoeachchemicalwithascore

from1-5(1-completedegrada8on,5-noeffect)6.  Addupthescoresandcomparetheexperimental

compe88veproductstothestandard(105max) 25

HouseholdProducts•  Water•  Ketchup•  Mustard•  Coffee•  Iodine•  HydrogenPeroxide•  Windex•  409Cleaner•  Ammonia•  IPA•  SuntanLo8on

•  DEET•  Ethanol•  RedWine•  DenaturedAlcohol•  Naptha•  Bleach(6%)•  AmmoniumHydroxide(37%)

•  OliveOil•  SulfuricAcid(10%)•  SulfuricAcid(37%) 26

TestingPanels

OldExterior450Sa3n NewExterior450Sa3n

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WaterResistance1.  Applyagenerousamountof

waterovertheblackpor8onofthechemicalresistancepanel

2.  Placealargewatchglassoverthewaterspotandallowtositforonehourbeforescoring

3.  Givethespottestascorefrom1-5similarlytothechemicaltes8ng

4.  Lookforblushingandpermanentwaterspots

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YellowingResistance1.  Applyeachtopcoatoveralenetachartwithsnowwhite

milkpaint2.  Allowthetopcoattodryatambientcondi8ons(70-75F,

40-50%humidity)3.  Takeanini8alcolorreadingusingaspectrophotometerto

showthechangeincolora8onfromthepainttothetopcoat4.  Heatstresseachlenetachartina125Fovenandtake

addi8onalcolorreadingsevery24hours5.  Analyzethedifferencesincolora8onfromboththesnow

whitemilkpaintstandardandtheini8altopcoatreading

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Adhesion1.  Applya1mm.and2mm.crosshatchtothechemical

resistancepanelsauer24hrsofambientcure2.  Placecoa8ngindustrystandardtapetothecenterofthe

crosshatch3.  Applypressureandremovethetapetoassessany

delamina8onofthecoa8ngfromthewoodsubstrate

5-PerfectScore 1-Completeadhesionloss

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QualityControl1.  Viscosity2.  Gloss3.  Color4.  Opacity

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Viscosity1.  Viscosityisavaryingstateofthicknessorconsistency

rela8vetotemperature2.  CommonlymeasuredinmPas,cPs,orKrebunits3.  Temperaturemustbecontrolledwhenmeasuringviscosity

(75Fistheindustrystandard)4.  Therearemanydifferentwaytomeasureviscosity,butwe

useaFordcup#4forallofourtopcoatsandaBrookfieldandKrebsviscometersforourpaintsandstains

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Gloss1.  Glossismeasuredonanangletothepaintsurface2.  Determinestheamountoflightreflectedbythesurfaceand

ismeasuredinglossunitsnotpercent3.  Gloss:85+Semi-gloss:50-60Sa8n:25-35Flat:lessthan154.  FlatoutFlat:lessthan5

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Color1.  Viewcolorchangesbasedonvisualobserva8onofthein

processproductdrawndownonalenetachartagainstastandard

2.  Useaspectrophotometertomeasurethedifferenceincolorfromtheinprocessproducttoastandard

3.  Colorvalueslessthanoneareundetectabletothehumaneye

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ApplicationTechniques•  Brush•  Roller•  AirAtomizedSpray•  AirlessSpray•  Electrosta8cSpray•  CentrifugalAtomiza8on•  AirAssistedAirlessSpray•  Dip•  DirectorReverseRollcoat(coilcoa8ngs)•  CurtainCoa8ng•  FlowCoa8ng•  FluidizedBed(Powder) 35

SubstrateandPreparation•  Wood:sandand/orprime•  Sheetrock:sandand/orprime•  Steel:ironorzincphospha8zing,prime•  Aluminum:passivateandseal•  Plas8cs:solventselec8on,productscreening,flametreatment•  Magnesium:passivateandseal•  Galvanizedsteel:problema8cforconsumer,zincphosphate•  Glass:acidetchoruseofadhesionpromoters•  Commontheme:Prepara3oniskeyforperformance

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Wood•  Tannins(TannicAcid):Solubleinwater;causeofmajoryellowinganddiscolora8onofwater-basedpaintsandcoa8ngs

•  MineralStreaks:Concentratedareasoftannin•  VeneerGlue:Somegluesaresolubleinwaterandmigratetothesurfacecausingyellowinganddiscolora8on

•  Solu3on:GFSTAINBLOCKINGPRIMER•  Oilinessofthewood:Bewaryofsubstratedifferences•  Off-labeluse:DONOTRECOMMEND,butsomepeoplehavehadsuccess

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StainBlockingPrimer

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Thankyou!

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