Coatings Basics E-Book

Adrie Winkelaar

• Herausgeber: Vincentz Network
• Kategorie: Wissenschaft und neue Technologien
• Serie: European Coatings TECH FILES
• Sprache: Englisch

Seitenzahl: 147

Veröffentlichungsjahr: 2014

Beschreibung

This eBook edition gives a summary of detailed information concerning ingredients, formulations, manufacturing, application as well as useful explanations and guidelines coming first handed from the author's experience and expert knowledge. Separated in ten chapters Adrie Winkelaar summarizes the phenomena of paint and coatings with few references so that newcomers are able to read this book through freely and easily. A solid grounding in coatings technology - richly illustrated with numerous photographs.

Leseprobe

Vincentz Network GmbH & Co KG

Adrie Winkelaar

Coatings Basics

Cover: Evonik Degussa Coatings & Colorants – Dieter Debo, Infracor, Marl/Germany

Bibliographische Information der Deutschen Bibliothek

Die Deutsche Bibliothek verzeichnet diese Publikation in der Deutschen Nationalbibliographie; detaillierte bibliographische Daten sind im Internet über

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Adrie Winkelaar

Coatings Basics

Hannover: Vincentz Network, 2009

(European Coatings Tech Files)

ISBN 3-86630-802-7

ISBN 978-3-86630-802-2

© 2009 Vincentz Network GmbH & Co. KG, Hannover

Vincentz Network, P.O. Box 6247, 30062 Hannover, Germany

This work is copyrighted, including the individual contributions and figures.

Any usage outside the strict limits of copyright law without the consent of the publisher is prohibited and punishable by law. This especially pertains to reproduction, translation, microfilming and the storage and processing in electronic systems.

The information on formulations is based on testing performed to the best of our

knowledge.

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Layout: Maxbauer & Maxbauer, Hannover, Germany

ISBN 3-86630-802-7

ISBN 978-3-86630-802-2

eBook-Herstellung und Auslieferung: readbox publishing, Dortmundwww.readbox.net

European Coatings Tech Files

Adrie Winkelaar

Coatings Basics

Preface

The purpose of this book is to provide an insight to the development, manufacture and application of paint products for those who have little or no education in coating technologies. Paint is considered to be a straightforward product and simple to apply, however, all paints contain a variety of risk-involved chemicals that are in accordance with physical and chemical laws. Increasingly more safety, health and environment legislations have been and are being passed in order to protect paint users, such as professional painters, do-it-yourselfers and industrial applicators.

The physical and chemical processes when applying paint products are extremely important, it is therefore necessary for the user to understand what the properties are and what to expect so that the best possible protection is provided and disappointments of substrate decoration results are avoided. This book, comprising ten chapters, offers important and useful explanations and guidelines to understanding what happens and what to expect when paints are developed, manufactured and applied.

The following chapters have been divided into various topics, starting in Chapter 1 with a short summary of the lengthy history of paint, worldwide differences and definitions. Because paint products contain chemicals that are in accordance to physical and chemical laws some basic chemistry information is necessary for understanding the background and basics of paint. The book continues with information on ingredients and properties of paint. It is important to know something about the various paint formulas and the differences between wall paint, wood paint, and metal paint etc. Paint manufacture and paint application are steps in the process of understanding how sensitive paint can react. The final two chapters of this book are concerned with test methods and regulations for health, safety and environment. Solvents in paints are harmful to health, safety and to the environment and are gradually being reduced and replaced with water. Increasingly new technologies are being introduced in the paint industry. Hopefully this book will provide an insight, not only to the present properties and use of paint but also to future new developments.

This book has been written with very few references so that newcomers are able to read it through freely and easily. Many illustrations and figures have been inserted to show the various manufacturing machinery and test methods equipment. The appendix contains a list of reference books that provide more specific, extensive knowledge about organic chemical science. It is always possible to provide more detailed information regarding ingredients, formulations, manufacturing, application and legislation, however, this book offers concise information and guidelines for understanding the paint and coatings phenomena.

Adrie Winkelaar

Heemskerk, Netherlands, May 2009

Contents

1What is paint or coating?

1.1History

1.2Worldwide differences

1.3Definitions and standardization

2Basic principles of chemistry

2.1Substances

2.2Organic (carbon) chemistry

2.3Chemical reactions

3Paint ingredients

3.1Binders

3.1.1Natural binders

3.1.2Modified natural binders

3.1.3Synthetic binders

3.2Solvents

3.2.1Aliphatic hydrocarbons

3.2.2Aromatic hydrocarbons

3.2.3Ketones and esters

3.3Pigments and extenders (fillers)

3.3.1Inorganic pigments

3.3.2Organic pigments

3.3.3Extenders

3.3.4Special pigments

3.4Additives

3.4.1Auxiliaries in wet paints

3.4.2Auxiliaries in dried coating

4Consistency and stability

4.1Solutions, emulsions and dispersions

4.1.1Binder solutions

4.1.2Dispersions

4.1.3Emulsions

4.2Viscosity and thickeners

4.3High solid paints and solid paints (powder coatings)

4.4Stability and other wet properties

5Coating properties

5.1Drying

5.2Colour

5.3Protection

5.4Durability and sustainability

6Paint products and paint formulas

6.1Paint formula principles

6.2Paint product principles

6.2.1Wood

6.2.2Metal

6.2.3Stone/concrete

6.2.4Other substrates

6.3Paint product formulas

6.3.1Products for wood

6.3.2Products for metal

6.3.3Products for concrete and stone

6.3.4Other products

7Paint production

7.1Production process

7.1.1Raw materials

7.1.2Processing

7.1.3Equipment

7.2Grinding and milling

7.2.1Agitator or dissolver

7.2.2Stator-rotor dispersers or attrition mills

7.2.3Triple roll mill

7.2.4Extruder or kneader

7.3Colour mixing

7.4Filtration and filling

8Application, drying and removal

8.1Application

8.1.1Decorative applications

8.1.2Protective coatings

8.1.3Industrial application

8.2Drying processes

8.3Coating systems

8.3.1Decorative market

8.3.2Protective coating

8.3.3Industrial Coatings

8.4Removal methods

8.4.1Chemical coating removal

8.4.2Mechanical coating removal

8.4.3Thermal coating removal

9Paint test methods

9.1Wet properties

9.2Dried properties

10Health, safety and environment

10.1Pollution control (air, water, soil and packages)

10.2Safe handling according to Material Safety Data Sheet

10.3Exposure and emissions

10.4Transport and storage

References

Appendices

Appendix 1: Periodic table of elements

Appendix 2: Old fashion ingredients and formulations

Appendix 3: Labbeling phrases

Author

Index

1What is paint or coating?

To explain the many varieties of paint applications that are worldwide available, it is important to understand the rich and extensive history of paint. Paint is a personal experience to which emotions and feelings are linked and which vary worldwide. Architectural paint provides a new fresh appearance to many used things and because the question of what is beautiful is different for each and every one of us, it is a personal issue. Looking back through the ages we have learned that throughout the world of paint has varied. It is now possible to see how paint differs from country to country and perhaps we are gradually moving towards a common worldwide feeling towards paint by using the same compositions.

The first history questions are: When was the first paint made? How was the first composition devised? What was the first application?

Through ages paint has been more and more developed with the use of new experience which resulted in making new applications possible. The increasing introduction of different pigments, different dyes and different binders has resulted in an increase of paint applications that have provided even more possibilities to communicate worldwide. It is very important to communicate durability and sustainability to all cultures and future generations throughout the world.

Differences between paint and coating

When the substance is wet – it is paint and when it is a dried layer – it is a coating. People sometimes call thick layers “coatings” and thin layers “paint”, such as paint on wood. Wet paint products for thick layers (for metal protection) are also called “coatings”. Generally speaking – wet paints are in a tin or layer and “coatings” are dried layers on substrates.

1.1History

Paint goes far back in history. According to neuropsychologists, human beings developed their language between 50,000 and 70,000 years ago and the first paintings were discovered after that period. A language had been developed to enable communication and paint is in that case the first visual expression of communication. It is estimated that the first paint was composed between 30,000 to 40,000 years ago. The oldest cultures used carbonized wood to illustrate expressions of what they saw, such as animals and landscapes. The Cro-Magnon men painted on the walls in caves in France (Lascaux) and Spain (Altamira) between 15,000 and 10,000 B.C. Ferrous earth was also used as pigment and blood and milk as binders.

Throughout Europe many cave paintings have been found – from Spain and right across to The Ural. The oldest painting which was found in the Lions Cave, South Africa dates back to 40,000 years ago.

Figure 1.1: Cave paintings in Lascaux

Paint was later used to identify and decorate objects, clothes and the body. The natural substances used are still being applied for re-usable binding substances in the modern paint industry, such as casein, grease, waxes and resins from milk, plants and trees.

The advanced civilisation of the Egyptians, Chinese, Greeks and Romans used painting techniques to identify and decorate vessels, statues, tools and buildings. Paint was also increasingly being used to provide protection against the influences of weather. Wooden ships were made watertight with mixtures of natural bitumen and asphalt. The old Greeks used the first anti-fouling application to protect their ships against under water fouling, which increased the speed of their vessels compared to enemy ships.

Figure 1.2: Vessels in original colours from the Ancient Greece period

Approximately 2000 years before Christ marks an important period in the development of paint which is illustrated by the decoration techniques of the Ancient Chinese who produced smooth and glossy objects. Varnishes offered a new dimension to paintwork and the new raw materials such as balsams and natural resins provided many possibilities. The most famous resin is shellac, produced by certain insects called ‘lac insects’ that produce sap in Indian fig trees.

In the 11th century, monks made a spectacular step forward in the history of paint when they boiled linseed oil with molten amber and acquired a more durable coating. From that period coatings were used to maintain paintings, the shields of knights and as durable protection of wood, in addition to the old fashion bitumen and asphalt. This resulted in a unity of decoration and protection and thus the manufacture of paint as a trade was born. The famous painters in the 15th, 16th and 17th centuries made their own paints. At that time each part of the world had its own local artist who made paint and applied the colours to the inside and outside of houses and public buildings.

In the 18th century the industrial revolution caused a huge demand for paint for all objects, houses and ships. The world population increased and many cities and villages evolved. At that time the first paint factories were opened in England, Holland and Germany. At these factories investigations were carried out using brewing kettles for the manufacturing of linseed oil binders and machines for milling the pigments.

The final mega development came in the 20th century, when the industry produced new such as

•nitrocellulose,

•alkyds,

•acrylics,

•polyurethanes and

•epoxies

as binders for use in the paint industry. New production lines were opened for the manufacture of numerous consumer goods such as cars, buses and trains, but also for furniture, beds and paint for the decorative market. For all these applications the paint industry used micro-technology with of 1 to 10 micron. One micron is a one thousand part of a millimetre. At the beginning of the 21st century new technology introduced nano-particles consisting of new properties. A nanometre is a one thousand part of a micron. It is possible to introduce nano-particles into micro-particles for ‘self healing’ paints. The nano-particles open when a scratch occurs. “Smart coatings” have also been developed as structured coating systems that provide an optimum response to certain external stimuli, and react to outside conditions, such as temperature, stress, strain or the environment, in selective ways.

The production and the use of paint has developed together with humans and dates back from prehistoric times when it was used as an experimental communication tool, through the Middle Ages when it became a trade that introduced durable properties and right up to Modern Times resulting in an ever growing multi-disciplinary high coating technology.

1.2Worldwide differences

Table 1.1: European paint production and consumption in 1996, source: CEPE, the European Paint Makers Association in Brussels, www.cepe.org

Table 1.2: European Decorative market in 2006

kt deco

kg/ inhabitant

Germany

800

9.7

Spain

700

17.3

France

500

7.8

Italy

400

6.9

United Kingdom

400

6.5

The Netherlands

150

9.1

Denmark

70

13.0

Belgium

50

4.8

In Europe the decorative market also varies for each country. This market offers an impression of habitation and public buildings in each country. The paint quantity per population head provides another impression. Spain and Denmark show the highest figures and provide an impression of building and maintenance activities at a specific moment, see Table 1.2.

Table 1.3: Decorative consumption in tonnes in 2004 in The Netherlands, source: Dutch Paint Makers Association in The Hague, The Netherlands, www.vvvf.nl

The different habits and cultures of each country are also illustrated by the figures of the various paint types sold on the decorative market. Wall paints are applied more in Germany and in southern countries than in other countries. In northern countries a lot of wood paint and wood stains are applied.

In The Netherlands many different products, such as wood stains, lacquers, varnishes, wall paints for ceilings, interior walls, kitchens and exterior walls, etc are applied. In this country there is a difference between the professional decorative market and the do-it-yourself decorative market, see Table 1.3. The decorative market is 80 % of the total volume in The Netherlands.

The European paint makers association, CEPE, represents 85% of the European paint volume. CEPE represents 900 members; however there are approximately 3,300 paint manufactures in Europe. In the European paint industry in 2006, 120,000 people worked together and produced more than 4,000 kt of products with a total value of 17 billion Euros. The European decorative paint market is approximately 60 % of the total volume and represents about 7 billion Euros divided under 2.5 million professional painters and about 100 million do-it-yourselves. The paint impact on daily life is enormous and a world without paint is unimaginable.

1.3Definitions and standardization

A coating is a dried paint on a substrate. Our environment is full of coatings – it is the most ‘looked-at’ product in the world. Paint definitions are described in EN/ISO 4618 and paints are applied as coatings on substrates for identification, decoration and protection purposes.

In addition, an important property of a coating is indicated with information using colours in the design and the printing trades.

There is an increasing global harmonization regarding definitions, test methods and regulations. The International Organization of Standardization (ISO) is the world’s largest developer of international standards. ISO is a network of the national standards institutes of 160 countries, one member per country, with a Central Office in Geneva, Switzerland, that coordinates the systems. ISO is a nongovernmental organization that forms a bridge between the public and private sectors. The ISO 9000 is a standard quality system and the ISO 14000 is a standard environment system.

In the middle of the 1990’s the paint industry introduced a worldwide responsible care system based on the ISO system, called Coatings Care®. The Coatings Care® program was conceived as a voluntary initiative aimed at assisting industry professionals in their efforts to protect the health and environment of the worker and the community, as well as promote product safety. Coatings Care® is designed to foster best management practices, and promote the development of new technologies that improve product performance. The framework and resources for the program deliver comprehensive guidance for manufacturing operations as well as critical support for customers and business partners throughout the supply and distribution chain. Coatings Care® is tailor-made to be the most effective and practical system for the coatings industry to sustain safe and environmentally friendly operations around the globe.

2Basic principles of chemistry

Chemistry originated in Ancient Egypt. The name chemistry derives from the Egyptian word “kēme” (chem), meaning “earth”. Chemistry is the science concerned, not only with the composition, structure and properties of substances, but also the changes that substances undergo during chemical reactions. Modern chemistry results from alchemy practiced during the chemical revolution in the 18th and 19th century.

2.1Substances