PAINT & COATINGS. Construction Materials

PAINT & COATINGS

INTRODUCTION

The primary purpose of paint is to protect the surface to which it is applied

 First known paintings that depict humans, animals and diagrams, made between 20,000 and 30,000 years ago, survive in caves in France and Spain.

 Early artists relied on easily available natural substances to make paint, such as natural earth pigments, charcoal, berry juice, lard, blood, and milkweed sap.

 The ancient Chinese, Egyption, Greeks and Romans used varnishes, and pigments such as yellow and red ochres, chalk, arsenic sulfide yellow, and malachite green were mixed with binders such as gum arabic, lime,

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INTRODUCTION

• Thomas Child built the earliest

American paint mill, a granite trough

within which a 0.5 meter granite ball

rolled, grinding the pigment in Boston

(around 1700).

• In 1865, D.P. Flinn obtained the first

paint patent was issued for a product

that improved whitewash, a

slaked lime (a patent for a

water-based paint that also contained zinc

oxide, potassium hydroxide, resin,

milk, and linseed oil).

• In 1867, D.R. Averill of Ohio patented

the first prepared or “ready mixed”

paints in the United States.

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INTRODUCTION

• In the mid-1880’s, paint factories began springing up in population and industrial centers across the nation.

• Mechanization was making the

manufacturing process accessible to a larger and less specialized group of entrepreneurs.

• The weight of prepared paint made it

expensive to transport, so a decentralized structure of small manufacturers in

discrete markets dominated the industry until the mid-1900s.

• In 1930, the first commercial paint mills replaced Child's granite ball with a

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INTRODUCTION

• Sand mills and high-speed dispersion

mixers are used to grind easily dispersible pigments.

• Synthetic pigments and stabilizers are commonly used to mass produce uniform batches of paint.

• New synthetic material (eg alkyd resins) were developed from polymers such as polyurethane and styrene-butadene

emerged during the 1940s and they have dominated production of paint.

• In 1978, the Consumer Product Safety Commission banned the use of lead in consumer paint.

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PAINT CLASSIFICATION

Paints

•

https://www.moglix.com/blog/different-types-of-industrial-paint-coatings/

• Commercial coatings: Paint; Primer;

Sealer; Lacquer; Powder Coating;

Stain; and Varnishes.

• Powder coating: are applied as a dry

powder using spray-applicators. The

particles of powder coatings are

exposed to heat during or after the

coating process in order for the

powder to bind to the surface.

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Lacquer vs Stain vs Varnish

Lacquer are typically clear and are created using sap of the lacquer tree,

which grows in Asian countries such as China and Japan. Lacquer coatings are used to protect wood, metal and other surfaces. Lacquer is

extremely durable and can be used as a base for pigmented coatings, which are called shellac (spirit-drying

and generally removable).

Stains are semitransparent coatings used to add protection and/or color to

wood surfaces. These coatings are semisolid, allowing wood grain to

remain visible and forming a protective film to preserve the

surface.

Varnishes are liquid coatings composed of oil, resin, and thinners or solvents. These coatings provide a

durable, waterproof, chemical & abrasion resistant covering to many

surfaces. Varnish can be impregnated with pigments to add

both color and protection to a substrate. Varnish can be applied in

multiple layers for added durability.

https://www.linkedin.com/pulse/7-types-commercial-coatings-uses-molly-keesling

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POWDER COATING

• Powder coating is a dry finishing process that has become extremely popular since its introduction in North America over in the 1960s.

• Powder coatings are based on polymer resin systems, combined with curatives, pigments, leveling agents, flow modifiers, and other additives.

• These ingredients are melt mixed, cooled, and ground into a uniform powder similar to baking flour. A process called electrostatic spray

deposition (ESD) is typically used to achieve the application of the powder coating to a metal

substrate. This application method uses a spray gun, which applies an electrostatic charge to the powder particles, which are then attracted to the grounded part. After application of the powder coating, the parts enter a curing oven.

https://youtu.be/IFeMX1O6Epk

“Powder coatings are commonly applied to metal surface, and can also be applied to

non-metallic substrates such as plastics and medium density fiberboard (MDF)” https://www.powdercoating.org/page/WhatIsPC

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CLASSIFICATION FOR ARCHITECTURAL

COATINGS

(by American Coatings Association, ACA)

• Concrete curing, sealing, & protective coatings: A clear or opaque coating that is formulated primarily for application to concrete and masonry surfaces.

• Floor coatings: An opaque coating that is formulated for application to flooring, including, but not limited to, decks, porches, steps, garage floors, and other horizontal surfaces which may be subject to foot traffic.

• Primers, sealers, and undercoaters: A coating formulated for one or more of the following

purposes: to provide a firm bond between the substrate and the subsequent coatings; to prevent subsequent coatings from being absorbed by the substrate; or to prevent harm to subsequent

coatings by materials in the substrate; or to provide a smooth surface for the subsequent application of coatings; or to provide a clear finish coat to seal the substrate; or to prevent materials from

penetrating into or leaching out of a substrate.

• Wood coatings: The wood coatings category includes the following coatings: lacquers; varnishes; sanding sealers; penetrating oils; shellacs; stains; wood conditioners; and wood sealers.

• General exterior coatings & interior coatings: A coating that is not defined under any other definition in this rule and that is a decorative or protective paint or coating that is formulated for

interior or exterior architectural substrates including, but not limited to: drywall, stucco, wood, metal, concrete, and masonry.

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EXAMPLE: NIPPON

CLASSIFICATION

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Product Name Paint Type Substrate Composition

Pigment Binder Thinner Vinnilex 5500 Wall

Sealer

Water based Masonry, brick, plastering substrate, fibre board

Titanium Dioxide, Mineral Extender Styrene Acrylic Emulsion Water Flexiseal Elastomeric Membrane

Water based Wall, brickwork, wallboard, asbestos, concrete slab roof, window sill

Titanium Dioxide, Mineral Extender

Styrene Acrylic Emulsion

Water

Red Oxide Primer Two-pack amine-adduct cured epoxy

Aluminium, galvanising, steelwork, concrete (lining systems for portable water, chemical and fuel storage tank)

Red oxide SA-65

Momento Primer Water based Wall, ceiling, cement based plaster, gypsum based plaster, brickwork, hard and soft boards, asbestos

Titanium Dioxide, Silica Sand and Mineral Extender

Styrene Acrylic Emulsion

Vinilex 510

Undercoat Solvent based Wood, metal Titanium Dioxide, Mineral Extender

Soya Bean Oil Modified Long Oil

Alkyd

White Spirit

Weatherbond Solareflect (topcoat)

Water based Masonry, brick, plastering substrate, fibre board

Titanium Dioxide, Iron Oxide, Carbon Black and Organic Pigments, Mineral Extender

Pure Acrylic Emulsion

Water

Timbershade (topcoat)

Water based Wood, fiber cement, galvanised iron surfaces

Titanium Dioxide, Iron Oxide, Carbon Black and Organic Pigments, Mineral Extender

Pure Acrylic Emulsion

Water

Odourlite Gloss Solvent based Wood, metal Titanium Dioxide, Iron Oxide, Carbon Black and Organic Pigments, Mineral Extender

Modified long oil alkyd

Low aromatic hydrocarbon

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https://nipponpaint.co.in/difference-between-water-based-vs-solvent-based-paints/

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TYPES OF PAINT

Solvent-based Paint

• Solvent-based paints contain pigment and a resin in an organic compounds as solvents. When the solvent evaporates, the resin

forms a hard coating, make an ideal choice for exterior coating

• Solvent-based coatings are too thick and you need mineral spirits or turpentine to clean and thin the paint.

• Painters should use solvent-based paint for any surface where they want the finish to last for a long time, and they are not

planning to change the color often. The latter can be obtained in a wide range of colours and finishes such as matt, semi-matt, eggshell, satin, gloss and enamel. Water-based Paint

• The paint are also called latex paints, consist of a pigment and binder with water as the solvent.

• They make up about 80 percent of household paints and environmentally

responsible paint option. They provide great color retention over time, dry faster than

alternatives, and produce fewer odors. • The various finishes available being

obtained by adding to the water medium additives such as alkyd resin and polyvinyl acetate (PVA). Finishes include matt,

eggshell, semi-gloss and gloss. Emulsion paints are easily applied, quick drying and can be obtained with a washable finish and are suitable for most applications.

PAINT RAW

MATERIALS

A paint is composed of: pigments give the paint color; solvents make it easier to apply; resins help it dry; and additives serve as everything from fillers to antifungicidal agents.

 Hundreds of different pigments, both natural and synthetic, exist.

 The basic white pigment is titanium dioxide, selected for its excellent concealing properties, and black pigment is commonly made from carbon black.

 Other pigments used to make paint include iron oxide and cadmium sulfide for reds,

metallic salts for yellows and oranges, and iron blue and chrome yellows for blues and greens.

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https://www.mixerdirect.com/blogs/mixer-direct-blog/how-paint-is-made

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RAW MATERIALS

• Solvents are materials which added to a paint to alter its viscosity. This increases

workability and penetration. They include petroleum mineral spirits and aromatic solvents such as benzol, alcohols, esters, ketones, and acetone. Many solvents evaporate into what are known as volatile organic compounds (VOCs). Water-based coatings have either no, or considerably less solvents, thus lower a VOC output. For solvent-based paint, the VOC in these paints are also powerful enough to cause strong headaches, troubles breathing and just an overall feeling of being unwell

• Binder (resin) is the liquid vehicle which dries to form the surface film. The natural resins most commonly used are linseed, coconut, and soybean oil, while alkyds, acrylics,

epoxies, and polyurethanes number among the most popular synthetic resins.

• Additives serve many purposes. For example, calcium carbonate and aluminum silicate, are simply fillers that give the paint body and substance without changing its properties. Other additives produce certain desired characteristics in paint, such as the thixotropic agents that give paint its smooth texture, driers, anti-settling agents, anti-skinning agents, defoamers, and a host of others that enable paint to cover well and last long.

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PAINT vs

PRIMER

Paints are suitable for most

applications if used in conjunction with the correct primer and undercoat. Primer/Undercoat help adhesion of paint to the surface, increase the durability of the paint itself, and protects the surface that is being painted (such as blocks lime from coming on to the surface, alkaline resistant formula, anti-corrosive properties)

Top coat is used to protect, preserve, decorate or add functionality to an object or surface by covering it with a pigmented coating.

https://nipponpaint.co.in/products/primers-undercoats/

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http://www.differencebetween.net/science/differenc e-between-primer-and-paint/

https://mccormickpaintingservices.com/blog/priming-separately-vs-paint-and-primer-in-1

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MANUFACTURING PROCESS OF

PAINT

There are five critical parts in the paint manufacturing process. They are a measurement of ingredients, preparation and pigment dispersion, let-down, laboratory testing, and canning.

1. Using calibrated vats, the ingredients are measured and weighed on scales. Pigments are added next. These powders are small and stick together forming clumps.

2. They are broken down by the resin and additives that keep them from sticking together, which is called dispersion. Industrial paint mixer machines are used to combine and disperse the

pigments.

3. In the let-down stage, the resin, solvent, and additives are combined in a large vat. The mill-base is stirred in during this phase. Any final additions are added during this stage, if necessary.

4. The finished product is tested in a laboratory. Before manufacturing is approved, critical ingredients are tested. They will ensure it is sufficiently mixed and no further processing is needed. They check the viscosity, tint strength, color, gloss, dry time, and overall appearance. 5. When the batch is complete, it can be canned. Two samples are taken during this phase. A

retained sample is kept and stored for future references, and then there is the final inspection sample. The final sample is inspected to guarantee conformance to standards. Once the final sample has been completed, it can be dispatched.

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PAINT COATS

1. Priming Coats - these are used on unpainted surfaces to obtain

the necessary adhesion and to inhibit corrosion of ferrous metals.

New timber should have the knots treated with a solution of shellac

or other alcohol-based resin called knotting prior to the application

of the primer.

2. Undercoats - these are used on top of the primer after any defects

have been made good with a suitable stopper or filler. The primary

function of an undercoat is to give the opacity and buildup

necessary for the application of the finishing coat(s).

3. Finish - applied directly over the undercoating in one or more coats

to impart the required colour and finish.

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TIMBER SURFACE PREPARATION

NEW TIMBER

• The timber surface should be prepared using an abrasive paper to produce a smooth surface brushed and wiped free of dust and any grease removed with a suitable spirit.

• Careful treatment of knots is essential either by sealing with two coats of knotting or in extreme cases cutting out the knot and replacing with sound timber.

• The stopping and filling of cracks and fixing holes with putty or an appropriate filler should be

carried out after the application of the priming coat.

• Each coat of paint must be allowed to dry hard and be rubbed down with a fine abrasive paper before applying the next coat.

EXISTING PAINTS

• On previously painted surfaces if the paint is in a reasonable condition the surface will only require cleaning and rubbing down before repainting.

• When the paint is in a poor condition it will be necessary to remove completely the layers of paint and then prepare the surface as described above for new timber.

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OTHER SURFACES

BOARD

• Most of these boards require no special preparation except for the application of a sealer as specified by the manufacturer.

METAL/STEEL

• Good preparation is the key to painting iron and steel successfully and this will include removing all rust, mill scale, oil, grease and wax.

• This can be achieved by wire brushing, using mechanical means such as shot blasting, flame cleaning and chemical

processes and any of these processes are often carried out in the steel fabrication works prior to shop-applied priming. PLASTER

• The plaster surface should be perfectly dry, smooth and free of defects before applying any coats of paint, especially when using gloss paints.

• Plaster which contains lime can be alkaline and such surfaces should be treated with an alkali-resistant primer when the surface is dry before applying the final coats of paint.

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APPLICATIONS

• Brush : the correct type, size and quality of brush such as those

recommended in BS 2992 (painters' and decorators' brushes) needs

to be selected and used. To achieve a first class finish by means of

brush application requires a high degree of skill.

• Spray : as with brush application a high degree of skill is required to

achieve a good finish. Generally compressed air sprays or airless

sprays are used for building works.

• Roller : simple and inexpensive method of quickly and cleanly

applying a wide range of paints to flat and textured surfaces. Roller

heads vary in size from 50 to 450 mm wide with various covers such

as sheepskin, synthetic pile fibres, mohair and foamed polystyrene.

All paint applicators must be thoroughly cleaned after use.

THANK

YOU