Coatings that Work - Pacific Southwest Coatings

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Nye Miller
Copyright Materials

Learn about corrosion resistant coatings, coating selection
for extending lifecycles thus reducing costs and infrared
reflective pigments.

Obtain broad knowledge of performance coating systems

Learn about coatings performance in terms of lifecycle of
generic types of coating systems

Learn about infrared reflective pigments and how they can
reduce energy costs, stress on structures and increase the
lifecycle of commercial coating systems.
Learning Objectives
Coatings that Work
Performance Coatings



Protecting against
corrosion
Coatings lifecycle
vs. cost
IR reflective
coatings…more than
just cool savings
Discussion

NACE definition
“The deterioration
of a substance,
usually a metal,
or its properties,
because of a
reaction with its
environment.”
What is Corrosion?

Steel to iron oxide, what stops this from
happening?
◦ Sacrificial zinc
 Galvanized steel
 Inorganic zinc coating systems
 Organic zinc rich coating systems
◦ Zinc phosphate containing primer systems
◦ Barrier coating systems
Ferrous Metal Corrosion
Inorganic Zinc Coating System
Organic Zinc Coating System
Zinc Phosphate Coating System
Barrier Coating System

Purpose
◦ Establish a 10, 15
and 20 year lifecycle
cost estimate per
square foot for
installed popular
performance coating
systems based on
aesthetics and
corrosion for the
commercial
architectural market.
Coatings lifecycle versus cost

Referenced documents and major contributors
NACE Paper 98509 Cost consideration of different coatings
Michael P. Reina, Kirk R. Shields, Michael F. McLampe, KTA-TATOR, Inc.
ISO12944 Corrosion protection of steel structures by protective coatings
AAMA 2605-05 Performance requirements and test procedures for high performance organic
coatings on aluminum extrusions and panels
Linda Marquez, Vice President, Global Infrastructure Systems
The CHEMARK Consulting Group, Inc.
Doug Hampton, Wilson and Hampton Painting Contractors,
Painting and Decorating Contractors Association
Paul Whitehead, Technical Service Manager North America
PPG Protective and Marine Coatings
Jeff Pearl, Technical Director and General Manager
Precision Coatings, Inc.
Coatings lifecycle versus cost

Parameters
◦ $84.00 per hour labor rate
for northern California
◦ 60 square feet per hour
production rate per coat =
$1.40 labor cost per
square foot per coat.
◦ Establish commercial
average cost per square
foot of coating.
◦ Establish average lifecycle
for each coating system.
Coatings lifecycle versus cost

Definitions
Epoxy: surface tolerant epoxy primer
 Organic zinc: zinc powder in epoxy or urethane resin primer

◦ Minimum 19 lbs. of zinc per gallon

Inorganic zinc: zinc powder in silicate matrix
◦ Minimum 14 lbs. of zinc per gallon
Industrial urethane: acrylic aliphatic polyurethane with crosslink
density of 600-800, industrial pigments, finish coat
 Automotive urethane: acrylic aliphatic polyurethane with crosslink
density of 370-500, automotive pigments, finish coat
 Fluorinated acrylic: fluoro-polymer acrylic finish coat for field
application
 Polysiloxane epoxy: oxidized silicone combined with an epoxy
creating a weatherable epoxy finish coat

Generic coatings
Coating
Surface Preparation
Years before
recoat commercial
Alkyd
SSPC-SP2 and SP3
4
Alkyd
SSPC-SP10
5
Acrylic Emulsion
SSPC-SP2 and SP3
6
Surface tolerant epoxy
SSPC-SP2 and SP3
12
Surface tolerant epoxy
SSPC-SP10
14
Organic zinc
SSPC-SP3
16
Organic zinc
SSPC-SP10
25
Inorganic zinc
SSPC-SP10
35 to structural life
Primers
Finish Coat
Stable Primer
Years before
recoat commercial
Alkyd
Alkyd
4
Acrylic emulsion
Acrylic emulsion
6
Industrial urethane
Epoxy
8
Industrial urethane
Organic zinc/epoxy
8
Automotive urethane
Epoxy
14
Automotive urethane
Organic zinc/epoxy
14
Fluorinated acrylic (field)
Epoxy
12
Polysiloxane epoxy
Epoxy
16
Polysiloxane epoxy
Organic Zinc
20
Polysiloxane epoxy
Inorganic zinc
20
Finish Coats
Minimal corrosive requirement
Renovation of previously coated surfaces (intact)
Barrier primers and finish coat
Moderate corrosive requirement
Exposed substrates and coastal environment
SSPC-SP3 Mechanical surface preparation minimum, organic zinc
primers, possible intermediate and finish coat
Corrosive requirement
Coastal location with exposure to salt laden air
SSPC-SP10 near white abrasive blast, barrier and organic zinc primers
with finish coats
Very corrosive requirement
Exposure to airborne chemical contamination as well as salt laden air
SSPC-SP10 surface preparation with inorganic zinc, possible intermediate
and finish coat
Coatings lifecycle versus cost
$12.00
$10.00
$8.00
$6.00
$4.00
Applied Cost
$2.00
10 year cost
$0.00
15 year cost
20 year cost
Metropolitan minimal corrosive
requirement
$9.00
$8.00
$7.00
$6.00
$5.00
$4.00
$3.00
$2.00
$1.00
$0.00
Applied Cost
10 year cost
15 year cost
20 year cost
Metropolitan moderate corrosive
environment
$16.00
$14.00
$12.00
$10.00
$8.00
$6.00
$4.00
$2.00
$0.00
Metropolitan corrosive requirement
SSPC-SP 10 near white abrasive blast
SSPC-SP10
Applied Cost
10 year cost
15 year cost
20 year cost
$18.00
$16.00
$14.00
$12.00
$10.00
$8.00
$6.00
$4.00
$2.00
$0.00
Metropolitan very corrosive requirement
SSPC-SP 10 near white abrasive blast
SSPC-SP10
Applied Cost
10 year cost
15 year cost
20 year cost

Surface preparation
◦
◦
◦
◦

SSPC-SP2 & SP3
SSPC-SP3 power tool
SSPC-SP6 shop blast
SSPC-SP10 near white
Primer
◦ Barrier
◦ Organic zinc
◦ Inorganic zinc

Finish
◦ Resin system resistance
◦ Pigment resistance
Coatings lifecycle versus cost

Conclusion
◦ The specification establishes the coating
lifecycle, coating costs and the future
maintenance cycle and costs.
 Surface preparation selection
 Primer selection
 Finish coat selection
Coatings lifecycle versus cost
IR reflective pigments
 Benefits
◦ Reduce cooling costs
◦ Reduce structure stress
◦ Longer pigment life


How they work
How they are made
Infra Red Reflective Coatings
Study – UNLV
Engineering
◦ Thermal Performance
Analysis of Highly
Reflective Coating on
Residences in Hot and
Arid Climates.
◦ By Samir F. Moujaes
P. E., PH.D. and
Richard Brickman
PH.D.

Study confirms a
decreased load on air
conditioning equipment
…“On a typical day in the
summertime, a 41%
reduction is shown to
exist where the roof and
walls are coated…”

“Roof plus wall
combination reduces
energy consumption by
about 33.3%.”
IR Reflective Coatings
In the visible spectrum the
color (light) reflected is black
In the near infrared spectrum
the color (heat) reflected is a
white
Visible vs. IR Spectrum

Synthetic mineral
inorganic pigments
•
Possess high infrared
spectrum reflectivity
•
Reactions to create IR
reflective pigment take
up to 24 hours at 1800
to 2200 degrees
Fahrenheit
•
Extremely stable
against environmental
degradation
IR Reflective Pigments
30
Atlanta Heat Growth
•
Buildings using IR reflective technology on
exterior walls and roofs use less energy, are
cooler and more pleasant for the occupants.
•
Products utilizing reflective technology are likely
to have a longer service life. Lower surface
temperatures will lessen chemical and
atmospheric degradation and also lessen
expansion and contraction.

For every 5% more reflectivity, a roof is
approximately 4 degrees Fahrenheit cooler in
direct overhead summertime sunlight.
Advantages of IR Reflective
Pigments
This presentation and back-up data including the
workable coatings lifecycle spreadsheet calculator is
available on-line at:
www.pacificsouthwest.net
Paul Bethke of TAVCO Chemicals,
representatives for Ferro IR reflective pigments is
here to answer any questions you might have
regarding IR reflective pigments.
Nye Miller, Pacific Southwest Coatings
714.337.1953 [email protected]
This concludes The American Institute of
Architects Continuing Education Systems and
Construction Specifications Institute
Construction Education Network Programs
Nye Miller
714.337.1953

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