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The new international magazine about corrosion control and prevention

Protective Coatings

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2012 1st YEAR Quarterly N4-December

PROTECTIVE COATINGS

INNOVATIONS

NANOTECHNOLOGIES INCREASES LONG-LIFE PERFORMANCE OF PROTECTIVE COATINGS UP TO 40% Le nanotecnologie aumentano le prestazioni di lunga durata dei rivestimenti protettivi no al 40%

n 2012 the total cost of corrosion in the US exceeded $1 trillion annually for the rst time; this has been a signicant step in the eect of corrosion on the U.S. Instead, in 2011, as mentioned in a widely-cited study by the National Association of Corrosion Engineers, NACE, the direct cost of corrosion was 3.1% of the 15.1 Trillion U.S. GDP, which in 2011 was equal to $ 468.1 Billion and estimated more than 200 billion in Europe. These data show the increasing need for more eective and less costly protective coatings. At the same time EU and government regulations are driving demand for lower content of chemicals in coatings. Nanotechnology oers great potential for creating materials and systems with properties and functions not currently available. Polymer nanocomposites possess superior physical characteristics and mechanical performance. They have found extensive applications in aerospace, defence, aviation, transportation, marine and sports and recreation industries. Novel additives, nano-sized resins and coating formulations incorporating one or both of these technologies are now commercially available. Nanotechnology is already being applied in specic cases such as nanomaterials that enable the controlled release of corrosion inhibitors. However, very few paint and coatings containing nanoparticles have reached the market and found wide application. The result of this need for innovation and for cost eciency in the corrosion protection eld is a nanostructured protective coating which combines the traditional know-how of coating formulation with nanotechnology. The extensive research & development brought to the formulation of nanocoatings after 3 years and was held by Nanto team under the direction of Roberto Cafagna and prof. Samuel Kenig in cooperation with the Shenkar College of Engineering and Design in Tel Aviv and the University of Trento for products testing. Nanto Protective Coating Srl is the company - founded in 2010 - which is proprietary of the patented nanoclay formulations designed to improve viscosity and barrier properties of coatings and polymer by increasing the barrier eect to oxygen, humidity and chemical agents. This technology has also a positive impact in terms of delamination resistance, impact resistance, colour and gloss retention (UV resistance). In 2008, after more than six years of scientic research, NPCs Technical Director for nanoclay functionalization and new production plant Prof. Samuel Kenig, (Shenkar University of

el 2012 il costo totale della corrosione negli USA ha superato per la prima volta il triliardo di dollari lanno; si tratta di un passo signicativo negli eetti della corrosione sugli Stati Uniti. Al contrario, nel 2011, come accennato in uno studio ampiamente citato della NACE (National Association of Corrosion Engineers) il costo diretto della corrosione era stato del 3,1% del PIL totale USA di 15,1 trilioni di dollari, che nel 2011 corrispondeva a $ 468,1 miliardi. In Europa stimato essere di 200 miliardi di euro. Questi dati mostrano la crescente necessit di rivestimenti protettivi pi ecaci e meno costosi. Allo stesso tempo, le norme dellUnione Europea stanno stimolando la domanda di rivestimenti con basso contenuto di sostanze chimiche. Le nanotecnoIogie orono grande potenzialit per la creazione di materiali e sistemi con propriet e funzioni attualmente non disponibili. I nano-compositi polimerici possiedono caratteristiche siche e resistenze meccaniche superiori. Hanno trovato ampia applicazione nei settori aerospaziale, della difesa, dellaviazione, dei trasporti, della nautica e nellindustria dello sport e ricreativa. Nuovi nano-additivi, resine nanometriche e formulazioni di vernici che incorporano una o entrambe le tecnologie sono oggi disponibili in commercio. Le nanotecnologie sono gi applicate in alcuni casi specici come nano-materiali che consentono il rilascio controllato di inibitori della corrosione. Tuttavia, pochissime vernici contenenti nano particelle hanno raggiunto il mercato o trovato vasta applicazione. ll risultato di questo bisogno dinnovazione un rivestimento protettivo nano-strutturato, che unisce il tradizionale know-how formulativo con la nanotecnologia. Lestesa attivit di ricerca e sviluppo ha portato alla formulazione delle nano-coating dopo tre anni ed stata condotta dal team Nanto sotto la direzione di Roberto Cafagna e del prof. Samuel Kenig in collaborazione con lo Shenkar College of Engineering and Design di Tel Aviv e dellUniversit di Trento per i testing dei prodotti. Nanto Protective Coating Srl lazienda, fondata nel 2010, che detiene il brevetto della formulazione dei nanoclay progettati per migliorare la viscosit e le propriet di barriera di vernici e polimeri, in grado di aumentare leetto protettivo nei confronti di ossigeno, umidit e agenti chimici. Questa tecnologia ha anche una ricaduta positiva in termini di resistenza alla delaminazione, allimpatto, ritenzione del colore e della brillantezza (resistenza agli UV). Nel 2008, dopo oltre sei anni di ricerca scientica, Il direttore tecnico di NPC per la funzionalizzazione delle nanoclay e del nuovo impianto produttivo Prof. Samuel Kenig (Shenkar University di Tel Aviv) condusse i test iniziali insieme al team italiano di Nanto. Nelle fasi

54 DECEMBER 2012

Roberto Cafagna, Nanto Protective Coating Srl, Trieste, Italy np@nantopaint.com

Tel Aviv) - run the initial tests together with the Italian Nanto team. During the following stages, the team was totally focused on the technological optimization and chemical characterization of the epoxy matrix formulation. The new product portfolio has been chemically characterized by Prof. Pierluigi Bonora Full Professor at Material Science & Engineering Department at University of Trento, and International expert in corrosion. Today, thanks to a manufacturing and product development agreement with the Italian paint producer Franchi & Kim Spa, Nanto Protective Coating Srl provides innovative nanocoatings which are cost eective, green and have unique anticorrosion properties which ensure a 40% improvement of the long life performance.

successive, il team si focalizzato totalmente sullottimizzazione tecnologica e sulla caratterizzazione chimica della formulazione della matrice epossidica. Il nuovo portafoglio prodotti stato caratterizzato chimicamente dal Prof. Pierluigi Bonora professore ordinario di Scienza e Ingegneria dei Materiali presso lUniversit di Trento ed esperto internazionale di corrosione. Oggi, grazie alla sottoscrizione di un accordo di produzione e sviluppo prodotto con il produttore italiano di vernici Franchi & Kim Spa, Nanto Protective Coating Srl fornisce nanorivestimenti innovativi verdi, ecienti dal punto di vista dei costi, e con propriet anticorrosive uniche che assicurano un miglioramento del 40% delle performance di durata.

The Technology: Introduction to Nanoclays


Nanoclays (montmorillonite) are composed of layered aluminosilicates bound together by Na+ ions (Fig. 1). In nature they form a closed structure that, to be useful, has to be delaminated (exfoliated). When eectively exfoliated the single layer is 1 nm thick and has a surface area of (0.5-1m) x (0.5-1m). The surface area of exfoliated Nanoclays is 700 m2/gr.

La tecnologia: introduzione ai nanoclay


I nanoclay (montmorillonite) sono composti alluminio-silicati straticati legati insieme da ioni Na+ (g. 1). In natura essi formano una struttura chiusa che, per essere utile, deve essere delaminata (esfoliata). Quando viene esfoliata in modo ecace, il singolo strato ha uno spessore di 1 nm e ha una supercie di (0,5-1 m) x (0,5-1 m). La supercie dei nanoclay esfoliati di 700 m2/gr.

1 1

Structure and composition of nanoclays. Struttura e composizione dei nanoclay.

The Technology: The principle


Proper exfoliation and orientation of the nanoclay (Fig. 2) platelets reduce permeability in the paint system. Reduction of permeability is attributed to the tortuous path available for diusion of gases (oxygen) and liquids (water). The reduction of permeability results in corrosion inhibition of metal structures (Fig. 3).

La tecnologia: il principio
Lesfoliazione e lorientamento corretto delle piastrine dei nanoclay (g. 2) riducono la permeabilit del sistema di pitturazione. Questa riduzione attribuibile al percorso tortuoso disponibile per la diusione dei gas (ossigeno) e dei liquidi (acqua). La riduzione della permeabilit ha come risultato linibizione della corrosione nelle strutture metalliche (g. 3).

The Technology: Advantages

Comparison between a NPC treated nanoclay (left) and an untreated nanoclay (right). Comparazione tra una nanoclay trattata da NPC (sinistra) e una

La tecnologia: vantaggi

The patented NPC technology nanoclay non trattata (destra). develops the eectiveness of nanoclays as barrier elements to corrosion, in order to obtain anticorrosion coatings, and as re retardant elements in polymers. Nanto Protective Coating products are unique in that they combine the features of high end anticorrosion coatings with the additional benets of innovative nanoparticles as barrier elements.

La tecnologia brevettata di NPC sviluppa lecacia dei nanoclay come elementi di barriera contro la corrosione, al ne di ottenere rivestimenti anti-corrosivi ed elementi ignifughi nei polimeri. I prodotti NPC sono unici in quanto combinano le caratteristiche dei rivestimenti anticorrosivi di alto livello e i beneci aggiuntivi delle nano particelle come elementi barriera.

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PROTECTIVE COATINGS

INNOVATIONS

Questi prodotti anticorrosivi nanoThese nanostructured anti-corrosion strutturati sono stati sviluppati per products are developed to create creare sistemi durevoli e ecienti dal durable and cost eective systems punto di vista dei costi per sconggeto defeat corrosion even in the most re la corrosione anche negli ambienchallenging environments. Thanks to ti pi severi. Grazie alla presenza delthe presence of treated nanoparticles, le nano-particelle trattate, i prodotti products display a high barrier eect mostrano un eetto barriera tale da which improve the coating resistance migliorare la resistenza delle vernici e and reduce the permeability to water. ridurre la permeabilit dellacqua. The advantages of NPC 3 I vantaggi dei rivestimenti NPC nanonanostructured coatings are: strutturati sono: - increased barrier eect; 3 - aumento delleetto barriera; - reduced permeability; The anticorrosion eect is enhanced by nanoparticles orientation. - permeabilit ridotta; - improved crack bridging Leetto anticorrosivo potenziato dallorientamento delle nanoparticelle. - propriet di crack bridging miglioproperties; rate; - enhancement of both modulus - potenziamento del modulo e della forza; and strength; - miglior bagnabilit superciale; - better surface wettability; - riduzione dello spessore della vernice rispetto a una vernice equi- reduction of coating thickness in comparison of equivalent valente; coating; - ecienza dal punto di vista dei costi; - cost eciency; - assenza di inuenze negative su altre propriet delle vernici (ad es. - absence of negative inuence on other coating properties propriet siche, condizioni applicative, requisiti di preparazione such as physical properties, application conditions, surface superciale, e tempi di essiccazione); preparation requirements or drying time; - customizzazione del prodotto; - product customization; - miglioramento delle prestazioni a fronte della riduzione di sostan- improvement of the level of performance reducing the use ze chimiche nocive (tecnologia ecosostenibile). of chemicals (greener technology). NPC anticorrosive paint intellectual property, is protected by three patents: US2002/0173559: High Barrier Paints IT2009/000550: Vernici e Rivestimenti anticorrrosivi, contenenti nanoparticelle WO2010/064274: Anticorrosive paintings & coatings containing nanoparticles. La propriet intellettuale delle vernici anticorrosive NPC coperta da tre brevetti: US2002/0173559: High Barrier Paints IT2009/000550: Vernici e rivestimenti anticorrosivi contenenti nanoparticelle WO2010/064274: Anticorrosive paintings & coatings containing nanoparticles.

Health and Safety


In recent years, a lot of concerns has been expressed relatively to nanomaterials and nanotoxicity. The nanoparticles incorporated in Nanto Protective Coatings products are absolutely safe compounds. They are treated with non-toxic biocompatible chemicals currently used in manufacturing of biodegradable polymer-based nanocomposite and in food packaging. Nanoclays are based on silicates which are materials widely spread in the environment. Nanotoxicity: Bentonite and montmorillonite are not classied as dangerous substances according to Directive 67/548/EEC; Solvent content: NPC products are certied UNI EN ISO 90012000 and UNI EN ISO 14001 in accordance to the quality and

Salute e Sicurezza
Negli ultimi anni stata espressa molta preoccupazione relativamente ai nano-materiali e alla loro tossicit. Le nano-particelle incorporate nei prodotti NPC sono composti assolutamente sicuri. Sono trattati con prodotti chimici non tossici e biocompatibili utilizzati correntemente nella produzione di nano-compositi polimerici biodegradabili e nel packaging alimentare. Le nanoclay si basano su silicati, ossia materiali ampiamente presenti in natura. Nanotossicit: bentonite e montmorillonite non sono classicate come sostanze pericolose ai sensi della Direttiva 67/548/CEE. Contenuto del solvente: i prodotti di NPC sono certificati UNI EN ISO 9001-2000 e UNI EN ISO 14001, in conformit alle di-

56 DECEMBER 2012

Roberto Cafagna, Nanto Protective Coating Srl, Trieste, Italy np@nantopaint.com

environmental provisions of the EU directives; NPC products are VOC (Volatile Organic Compound) compliant. Testing and manufacturing of NPC products have been certied by Franchi & Kim Spa, NPCs partner, at its Brescia facilities

sposizioni di qualit e ambientali delle direttive UE; i prodotti NPC sono conformi alle norme che regolano i COV (Composti Volatili Organici). Produzione e collaudo dei prodotti NPC sono stati certificati da Franchi & Kim Spa, partner NPC, presso i propri stabilimenti di Brescia.

The rst set of NPC products ready to market


The N.P.C.-100 Series is a cluster of high eciency anticorrosion coatings for the heavy, marine and construction industry. High-performance anticorrosion coatings are applied to steel and concrete structures to provide protection within corrosive environments, following the ISO 12944-2 Environment Classication.

La prima serie di prodotti NPC pronta per il mercato


La serie NPC-100 un gruppo di rivestimenti anticorrosione ad alta ecienza per lindustria pesante, edile e navale. I rivestimenti anticorrosione ad alte prestazioni sono applicati a strutture in acciaio e calcestruzzo per fornire protezione negli ambienti corrosivi, secondo la classicazione fornita dalla ISO 12944-2.

Table 1: Technical characteristics and related benets of NPC100 Series painting products
Product NPC 101 Description

Tabella 1: Caratteristiche tecniche e beneci relativi alla serie di prodotti vernicianti NPC-100
Benets Blister resistant Excellent adhesion High elasticity Improved wettability High barrier properties Extreme crack bridging High gloss nish UV protection Excellent durability Blister resistant Excellent adhesion High elasticity High barrier properties Improved wettability Extreme crack bridging Easy to apply Dries quickly

High solid epoxy-polyamide primer with high anticorrosive properties due to the active pigments content. Suitable for new painting systems and maintenance works according to its excellent adhesion both to manually prepared supports, old paints, hot galvanized steel plates and light alloys. Primer in paint systems for C4 High atmospheric-corrosivity. High solid epoxy intermediate. Applicable up to 200 pm in one single coat. Due to its high barrier properties, it is excellent for new painting systems and maintenance works, according to its very good adhesion both to epoxy primer, old well preserved paints, hot galvanized steel plates and light alloys. Overcoatable with several top-coats (N.PC. 103). Intermediate in paint systems for C4 High atmospheric-corrosivity. Polyurethane nishing paint with aliphatic isocyanate hardener, medium high thickness. Wide compatibility range with pure or modied epoxy primers and intermediates coats, as well as with other specic products. Very good lasting gloss and colour retention, good resistance properties outdoor, in marine and industrial environment, good lasting exibility. Not yellowing, re-coatable for long time. Two pack epoxy-polyamide primer. Suitable for new painting systems and maintenance works according to its excellent adhesion both to steel and hot galvanized steel plates. Primer in paint systems for C3 medium atmospheric-corrosivity. High solid epoxy intermediate. Provides a high barrier protection due to micaceous iron oxide content. Suitable for new painting systems and maintenance works, for shop and on-site applications. It can be overcoated even after a long period of time. Intermediate in paint systems for C4 High atmospheric-corrosivity. Two component epoxy air-dried coating. Low solid content. Zinc powder as active pigment. Characterized by fast drying and possible application in thin layers in thickness of 10-15 m. Used as basic anticorrosive coating for protection of sanded steel tanks, technological equipment, containers and other metal surfaces. Low solid content intermediate. Characterized by fast drying and possible application in thin layers in thickness of 10.15 m. Used as basic anticorrosive coating for protection of sanded steel tanks, technological equipment, containers and other metal surfaces. Intermediate in pant systems for C3 Medium atmospheric-corrosivity Epoxy top-coat. Fast drying, good stability of shades, as well as resistance to water chemicals, different oils and oil products. Used as nal coating in systems with adequate epoxy primer for protection of technological equipment and steel constructions in chemical petrochemical industry for protection of steel and concrete tanks for industrial water, solvents of aggressive chemicals.

NPC 102

NPC 103

NPC 104

NPC 105

NPC 106

NPC 107

Resists to abrasion Easy to apply

NPC 108

Durable nish Wear-resistant Excellent durability

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PROTECTIVE COATINGS

INNOVATIONS
Tabella 2: Panoramica dei sistemi di verniciatura basati sui prodotti della Serie NPC-100 e relative applicazioni e durata secondo la norma ISO 12944.
Industrial Applications Steel infrastructures Lifting and industrial equipment Marine sector Energy and Oil&Gas sector Transport systems Energy and Oil&Gas sector Transport systems Lifting and industrial equipment Marine sector Steel infrastructures Transport systems Industrial equipment Environments classication by ISO 12944-2 C5-I High durability. Aggressive corrosive environments C3 High durability. Low to medium corrosive environments C3 High durability. Low to medium corrosive environments C4 High durability. Medium corrosive environments C4 Medium durability. Medium corrosive environments

Table 2: Overview of the painting systems based on NPC100 Series products and related applications and durability according to ISO 12944 standard
SYSTEM ID SYSTEM 1 Product Name NPC-101 NPC-102 NPC-103 NPC-102 NPC-103 SYSTEM 3 SYSTEM 4 NPC-104 NPC-105 NPC-104 NPC-102 NPC-103 NPC-106 NPC-107 NPC-108 Suggested Film thickness (m) 80 180 60 150 60 80 120 60 120 60 30 80 60

SYSTEM 2

SYSTEM 5

The Technology: Laboratory Testing Certication


NPC patented nanoclay formulation has been extensively tested at the following research facilities: - Shenkar College of Engineering and Design (Tel Aviv, Israel) Faculty of Engineering and Plastic Engineering (prof. Samuel Kenig) - Trento University (Italy), Materials Science and Technology dept. (prof. Pierluigi Bonora, prof. Flavio Deorian) - Franchi & Kim Spa industrial manufacturing facilities, Brescia, (Italy). The products formulated with the nanoclays has been tested rst according to the following standards: - ISO 2812 1: Chemical resistance - ISO 6270: Resistance to humidity - ISO 7253: Salt spray - ASTM 02794: Impact resistance - ASTM 4060-90: Abrasion resistance - ASTM 4541 Pull-O Strength - Electrochemical Impedance Spectroscopy (EIS) (Fig. 4)
Standard NanoInter09 EP HS

La tecnologia: prove di laboratorio certicate


La formulazione brevettata NPC stata testata in modo estensivo presso i seguenti istituti di ricerca: - Shenkar College of Engineering and Design (Tel Aviv, Israele), facolt di Ingegneria dei Materiali Plastici (prof. Samuel Kenig) - Universit di Trento, dip. Scienza e Tecnologia dei Materiali (prof. Pierluigi Bonora, prof. Flavio Deorian) - Impianti di fabbricazione Franchi & Kim Spa (Brescia). I prodotti formulati con le nanoclay sono stati testati dapprima secondo le seguenti normative: - ISO 2812-1: resistenza chimica - ISO 6270: resistenza allumidit - ISO 7253: nebbia salina - ASTM 02794: resistenza agli urti - ASTM 4060-90: resistenza allabrasione - ASTM 4541: pull-o - Spettroscopia dimpedenza elettrochimica (EIS) (g. 4).
Standard NanoInter09 EP HS

1X10-9

1014

Coating Capacitance [F2/cm]

Coating Resistance [F2/cm]


0 100 200 300 400 500 600 700 800

1013 1012 1011 1010 109 108 107 106 -100 0 100 200 300 400 500 600 700 800

1X10-10

10-11

10-12

4 4

-100

Time [Hours]

Time [Hours]

NPC - SERIES 100: EIS analysis

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Roberto Cafagna, Nanto Protective Coating Srl, Trieste, Italy np@nantopaint.com

For example, industrial tests for product certication run by Franchi & Kim in 2011-2012 reveal on NPC products reveal that the product identied for instance as Primer Epox NPC-01 is suited to be classied accordingly to UNI EN ISO 12944-6 with corrosiveness class C4 H. Comparative industrial tests have been run on the same product with and without Nanto nanotechnology additive (NPC NP-02 ) with the solid content constant in weight and volume, as well as the pvc, the ratio binder/powders and the catalysis report. Tests highlighted an equivalent trend up to around 600 hours of exposure in salt spray according to ISO 9227, while later, as reported in the table below, the product with the nanotechnology additive showed a performance increase up to 40%, beyond 1,000 hours. Table 3: Results of Salt Spray testing of NPC epoxy primer with and without the nano-additive.

Ad esempio, test industriali di certificazione prodotto condotti da Franchi & Kim nel 2011-2012 sui prodotti NPC rivelano che il prodotto identificato ad esempio Primer Epox NPC-01, adatto a essere classificato secondo la UNI EN ISO 12944-6 con la classe di corrosivit C4 H. Test industriali comparativi sono stati condotti sullo stesso prodotto NPC con e senza laggiunta delladditivo nanotecnologico di Nanto (NPC NP-02) con contenuto di solido costante in peso e in volume, cos come il pvc, il rapporto legante/ polvere e il rapporto di catalisi. Come riporta la tabella sottostante, i test industriali hanno evidenziato una tendenza equivalente fra i due prodotti a resistere intorno alle 700 ore in nebbia salina secondo ISO 9227, mentre il prodotto con ladditivo nanotecnologico ha mostrato un incremento delle prestazioni no al 40%, oltre le 1.000 ore. Tabella 3: Risultati delle prove di nebbia salina del primer epossidico NPC con e senza ladditivo nano tecnologico.
Test of salt spray According to ISO 9227

700 hours Primer Epox NPC-01 with additive NPC NP-02 Primer Epox NPC-01 without additive NPC NP-02 no blistering no blistering

1,000 hours no blistering Generalized blistering and presence of rust around the cutting point. Test not passed

Performance enhancement +42%

Applications of NPC Nanostructured Protective Coatings. Applicazioni dei rivestimenti protettivi nanostrutturati NPC.

59 DECEMBER 2012

Protective Coatings

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The new international magazine about corrosion control and prevention

Protective Coatings

ipcm PC digital on www.ipcm.it


2012 1st YEAR Quarterly N4-December

Ing. Ilario Maconi: Materials Engineer, Nace inspector lev.2 quality inspections of coatings

EDITORIAL BOARD
Prof. Massimiliano Bestetti: Department of Chemistry, Material and Chemical Engineering, Politecnico of Milan Section of Applied Chemistry and Physics Prof. Paolo Gronchi: Department of Chemistry, Material and Chemical Engineering, Politecnico of Milan Chemical Engineering Section
The new international magazine about corrosion control and prevention La nuova rivista internazionale sul controllo e la prevenzione della corrosione

Ing. Luca Valentinelli: Materials Engineer, PhD, Nace inspector lev.3 M.d.L. Paolo Rami: Rail and Tram Dr. Antonio Tolotto: Marine and industrial anticorrosive coating cycles

Ivano Pastorelli: Measurement and quality control Prof. Fabrizio Pirri: Department of Material Sciences and Chemical Engineering, Politecnico of Turin, Micro and Nanosystems, Nanomaterials and Surfaces

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