Industrial Coatings +

Corrosion Protection
INDUSTRIAL COATINGS

Content

1. Introduction // Monopol Colors

2. ISO 12944 // Modern Anticorrosive Protection
3. Environmental and Health Protection // Regulations and Trends
4. Economical Comparisons // Differences in Coatings
5. Coating System for Siemens // Bilacryl PU D81
6. Pre-Treatment // Giving a good grip to the Coating
7. Processing Sequences // Always reproducible results
8. Quality Standards // Maintaining and Improving Quality
9. Contact // Monopol Colors

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1. Introduction
2. ISO 12944
ISO 12944

Corrosion Protection
Introduction to ISO 12944:
<Corrosion protection of steel structures by protective paint systems>
 Part 1: General Introduction
 Part 2: Classification of Environments
 Part 3: Design Considerations
 Part 4: Types of Surfaces and Surface Preparation
 Part 5: Protective Paint Systems
 Part 6: Laboratory Performance Test Methods
 Part 7: Execution and Supervision of Paint Work
 Part 8: Development of Specifications for new Work/Maintenance

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ISO 12944

Corrosivity Categories
Corrosivity Examples of typical environments
Category and Risk in a temperate climate (examples)

Exterior Interior

C1 - Heated building with clean atmosphere, e.g.

shops, offices, schools, hotels.
Very low

C2 Atmospheres with low level of pollution. Unheated buildings where condensation may
Mostly rural areas. occur, e.g. depots, sports halls.
Low

C3 Urban and industrial atmospheres, Production rooms with high humidity and some
moderate sulphur dioxide pollution. Coastal air pollution, e.g. food processing plants,
Medium
areas with low salinity. laundries, breweries, dairies.

C4 Industrial areas and coastal areas with Chemical plants, swimming pools, coastal, ship
moderate salinity. and boatyards.
High

C5-I Industrial areas with high humidity and Buildings or areas with almost permanent
aggressive atmosphere. condensation and high pollution.
Very high industrial)

C5-M Coastal and offshore areas with high Buildings or areas with almost permanent
salinity. condensation and with high pollution
Very high (marine)

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ISO 12944

Durability

Protection Time of Coating Systems

 Low = 2 – 5 Years
 Medium = 5 – 15 Years
 High = above 15 Years

 The protection time is not a warranty period but the time after
which first bigger renovation should take place (based on a
corrosion degree Ri 3 [approx. 1 %])
 Example: Corrosivity Requirement C3 H

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ISO 12944

Performance Testing
Salt Spray Test Humidity Testing Chemical
Corrosivity Durability
ISO 7253 ISO 6270 Testing
low 48 h
C2 low medium 48 h
high 120 h
low 120 h 48 h
C3 medium medium 240 h 120 h
high 480 h 240 h
low 240 h 120 h
C4 high medium 480 h 240 h
high 720 h 480 h
low 480 h 240 h
C5-I very high medium 720 h 480 h 168 h
high 1440 h 720 h
low 480 h 240 h
C5-M very high medium 720 h 480 h
high 1440 h 720 h

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ISO 12944

Certified Corrosive Protection

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ISO 12944

Minimum DFT for Certified Protection

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3. Environmental + Health Protection
ENVIRONMENT + HEALTH

Global Regulations are increasing

Compliance Examples for Paints

 RoHS (Restriction of Hazardous Substances Directive)

 REACH (Registration, Evaluation, Authorization
and Restriction of Chemicals)
 Conflict Mineral Law
 Lead and Chromefree Regulations by countries/
companies (e.g. Siemens)
 VOC Regulations

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4. Economical Comparisons
ECONOMY

Composition of a Paint

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ECONOMY

Is 1 kg = 1 kg?

1 lit

D = Density

1 kg

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ECONOMY

Is 1 lit = 1 lit?
1 lit

Volatile Parts Volatile Parts

(VOC, Water) (VOC, Water)

D = Coverage

Solid Parts Solid Parts

(Solid Content) (Solid Content)

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ECONOMY

Calculation Paint Coverage

DFT
• Dry Film Theoretical
Thickness µm
• (Density Paint Coverage
kg/l) m2/l (m2/kg)

Solid Content
Volume-%
• Solid Content by Weight
in %
• Density of Solvent kg/l
• Density of Paint kg/l

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ECONOMY

Coverage Formula

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ECONOMY

Coverage Calculation - Example

Paint A Paint B

Paint Price per lit 120 IRS 240 IRS

Solid Content Weight-% 60 % 66 %

Density kg/l 1.5 kg/l 1.2 kg/l

Density Solvent 0.85 kg/l 1.0 kg/l

Solid Content Volume-% 29.4 % 59.2 %

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ECONOMY

Coverage Calculation - Example

Paint A Paint B

Solid Content Volume-% 29.4 % 59.2 %

DFT 30 µm 30 µm

Theoretical Coverage m2/l 9.8 m2/l 19.7 m2/l

Theoretical Consumption kg/m2 153 g/m2 61 g/m2

Costing per m2 18.3 IRS 14.6 IRS

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5. Coating System for Siemens
BILACRYL PU D81

Bilacryl PU D81
Modern High Solid 2-pack PU Coating
 Cost effective 2-pack PU single coat (2 in 1) or top coat
 High Solid coating
 Easy and safe to apply, very quick drying
 Application of 100 µm in single coat
 Excellent adhesion and hardness
 Good water, oil and chemical resistance
 Good anticorrosive properties, chalking and weathering
resistance
 Excellent color retention

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BILACRYL PU D81

Siemens Environmental Policy

No compromise on compliance - also for the future
 Environmental friendly coating with low VOC
 Chrome and lead free pigmentation
 Compliant with current VOC-regulations and environmental
regulations (REACH, RoHS)
 Compliant with safety and occupational health regulations
 Compliant with Siemens Global Environmental Policy

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BILACRYL PU D81

Technical Values
BILACRYL PU D81
2-pack PU High Solid Top Coat/Unicoat with fast drying
RAL 1003 RAL 2004 RAL 7046
Signal Yellow Pure Orange Tele Grey 2

Article No. D081.27015 D081.27016 D081.27017

Density 1.33 1.29 1.40
Solid Content Weight % 69.90 % 67.50 % 75.80 %
Solid Content Volume % 58.20 % 54.80 % 62.80 %
Coverage m2/kg @ 60 µm 7.3 7.1 7.5
Coverage m2/lit @ 60 µm 9.7 9.2 10.5

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BILACRYL PU D81

Coating Systems – Current Situation

# DFT Function Coating Remark
(practical values)

1 70 – 80 µm Anticorrosive EP-Zn - Good anticorrosive protection

Primer Silicate - To high DFT
2 40 – 60 µm Top Coat Alkyd - Easy to apply, good gloss, good
levelling
- No weathering resistance, no
chemical resistance
- Thermoplastic system – softening
with temperature, long drying
time
3 40 – 60 µm Top Coat Alkyd - do.

Σ 150 – 200 µm

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LIFETIME OF A BUILDING

Coating Systems – Future Proposal

DFT Function Coating Remark

A 100 – 120 µm Single Coat Bilacryl PU D81 - C2 H

B 50 – 60 µm 1st Coating Bilacryl PU D81 - As system A but

due to operational
50 – 60 µm 2nd Coating Bilacryl PU D81 reasons in 2 coats

C 50 – 60 µm Anticorrosive Monopoxi Steelguard - C3 H

Primer C80
50 – 60 µm Top Coat Bilacryl PU D81

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6. Pre-Treatment
PRE-TREATMENT

Steel Pre-Treatment

 Blasting Sa 2 ½ according ISO

8501-1 is recommended
 The surface must be dry and free of
grease and rust
 Abrasive residues and dust have to Reference Photo for Sa 2 1/2

be removed from the surface.

 Coating after blast cleaning as soon
as possible to prevent rusting

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PRE-TREATMENT

Cleaning by Solvent

A manual cleaning by solvents is not recommended

 it can affect the adhesion of the coatings especially when epoxy
coatings are used.
 Often the grease particles will be spread or concentrated into the
edges.
 Solvents can penetrate into porous substrates and will take long
time for a complete evaporation/drying. A quick overcoating will
seal the surface, entrapping the solvents and weakening or even
causing complete loss of adhesion.

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PRE-TREATMENT

Rust Degrees

ISO 8501-1 Bild 1

Bild 2

Definition and photo Bild 3

documentation of 4 rust
degrees (A, B, C, D)
which do lead to
different surfaces after
blasting

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PRE-TREATMENT

Surface Roughness

 The blasting is evaluated by the roughness

 Recommended roughness values:
- Epoxyester/2-pack
Epoxy-Zincprimer 35 – 45 µm
- Zincsilicates 40 – max. 60 µm
 The measurement can be made either by
using electronic measuring gauge or stripes
(e.g. Testex Press-O-Film)

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PRE-TREATMENT

Roughness // WFT // DFT

40 µm WFT 30 µm DFT

200
175
150
125
100
75
50 Surface Roughness min. 25 µm Surface Roughness max. 50
25
Steel blasted
0

Total DFT with min./max. surface roughness profile

 Maximum = 50 µm surface roughness + 30 µm DFT = 80 µm Total DFT
 Minimum = 25 µm surface roughness + 30 µm DFT = 55 µm Total DFT

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7. QC – Processing Sequences
PROCESS

Quality Control – Processing Sequence

Check the actual Technical Cleaning and rinsing
Stir the paint accurately
Data Sheet equipment/hoses

Checking pot life and Apply 100 µm WFT for a Measure viscosity, dilute if
respect ing time limits DFT of 60 µm required and stir again

Cleaning/rinsing
Forced drying possible (e.g. Checking DFT possible after
equipment/hoses
after 15 min @ 80 °C/30’) approx. 12 hours
immediately after application

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 PROCESS

Measuring of Wet Film Thickness

 WFT can be measured with a wet-

film-thickness gauge
 WFT lies between wetted and non
wetted tooth and can easily be
metered with the scale printed on
the gauge.
 Reliable average requires approx.
10 measurements on different
spots.

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PROCESS

Measuring of Dry Film Thickness

 The DFT can be measured after drying

of the paint.
 On rough surfaces it is recommended to
make an “average value-zero point
calibration” on several uncoated spots.
This will allow while measuring the DFT
to consider the surface roughness of the
substrate.

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PROCESS

Appropriate Spraying Equipment

Air Spray
Pressure: 3.5 - 6 bar
Nozzle e.g. 1.4 - 1.8 mm

Very good results by using Airmix or

Airless with HVLP-devices (with closed
pressure-tank (including integrated
stirring device)
HVLP Devices
(High Volume Low Pressure)

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PROCESS

Maturing Time of Coatings

 Maturing Time = Dry through time till a complete load of the

system will not damage the coating
 Rule of thumb for 2-pack systems: Loading capacity only after
7 days (drying @ ambient temperature of 20 °C)
 Following parameters do influence the maturing time:
- Temperature
- Air circulation
- DFT of the coating
- Humidity

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PROCESS

Dew Point and Monsoon

 Dew point is the temperature at which the air is saturated with
vapor. Undercutting this temperature will condense the water
vapor into liquid water, which – when it forms on a solid surface –
is called dew.
 Dew point is associated with relative humidity.
High relative humidity = dew point close to current air
temperature.
 With 100 % rel. humidity the dew point is equal to ambient
temperature. When moisture content remains constant and
temperature increases, relative humidity decreases.

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PROCESS

Dew Point – Good to know

 Water condensation can not be detected visually or by touching!
It is very common that humidity occurs only in micro range.
 Coating on “wet” surfaces will cause blisters or paint delamination!
 If the temperatures falls under dew point after coating the curing process
can slow down.
 Measuring either with combined instruments (air temp, substrate temp
and rel. humidity) or with hygrometer, temperature measuring device and
comparative tables.
 Surface temperature should always be 3 – 4 °C above dew point.

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PROCESS

Dew Point – Table Example

Relative Humidity
40% 50% 60% 70% 80% 90%
Air Temperature Dew Point in ° C
25° C 10.5 13.9 16.7 19.1 21.3 23.2
24° C 9.6 12.9 15.8 18.2 20.3 22.3
23° C 8.7 12.0 14.8 17.2 19.4 21.3
22° C 7.8 11.1 13.9 16.3 18.4 20.3
21° C 6.9 10.2 12.9 15.3 17.4 19.3
20° C 6.0 9.3 12.0 14.4 16.4 18.3
19° C 5.1 8.3 11.1 13.4 15.5 17.3
18° C 4.2 7.4 10.1 12.5 14.5 16.3
17° C 3.3 6.5 9.2 11.5 13.5 15.3
16° C 2.4 5.6 8.2 10.5 12.6 14.4
15° C 1.5 4.7 7.3 9.6 11.6 13.4
14° C 0.6 3.7 6.4 8.6 10.6 12.4
13° C -0.1 2.8 5.5 7.7 9.6 11.4
12° C -1.0 1.9 4.5 6.7 8.7 10.4

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8. Quality Standards
QUALITY STANDARDS

Color Conformity

 Definition of color standards by selecting master sample

 Colormetric definition of master samples according
CIE L*a*b-System
 Definition of ∆E for every color, e.g.
- RAL 1003 and 2004: ∆E ≤ 2
- RAL 7046: ∆E ≤ 1
 Colormetric Report for every paint batch
 Master samples for every Siemens subcontractor in order to
check color conformity

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QUALITY STANDARDS

CIE L*a*b Color Definition

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MONOPOL COLORS

Contact

Monopol Colors India Pvt. Ltd.

R-21, TTC Industrial Area
Rabale, Thane Belapur Road
Navi Mumbai, Maharashtra – 400701

Tel +91 (22) 2769 - 8242

www.monopol-colors.com

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We live colors.