Chokwang Jotun Ltd.

Jotun Paint School

Welcome to Jotun Paint School

Prepared by Astin (JS) Park

Technical Support

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Jotun Paint School

1. Introduction of Jotun
2. Corrosion
3. Paint technology
4. Coating Failures
5. Standard (ISO 12944)

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Jotun Paint School

1. Introduction of Jotun
2. Corrosion
3. Paint technology
4. Coating Failures
5. Standard (ISO 12944)

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Definition of corrosion

Corrosion is a chemical reaction between

a metal
and
its surrounding environment
under the formation of corrosion products.

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Production and degradation of steel

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Corrosion reaction

Steel

Water

Oxygen

Remember this illustration, as removal of

the oxygen or water will result in the
elimination of corrosion

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Parameters influencing the corrosion speed

Humidity

Temperature

Concentration of salts

Amount of air pollution, including acid rain,

soot and dust particles

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Corrosion
Acidity/pH:
The pH scale (0-14) is used as a measure of acidity. The scale is based on the
concentration of hydrogen ions in a solution. A value of 1 refers to the highest acidity,
while 14 is the most basic (alkaline) and 7 is neutral.
Steel
Corrosion increases in acidic solutions
Strong alkaline solutions prevent corrosion (pH 10 and higher)

Zinc and Aluminium

Slow corrosion in near neutral solutions (pH 5-8)
Heavy corrosion in acidic and alkaline solutions

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Galvanic Series
The galvanic series is a table used to
demonstrate the reactivity of different metals.
When two metals are in contact with each
other, the more reactive metal will corrode in
preference to the less reactive metal.
Aluminum will therefore corrode in preference
to iron when the two are connected.
The galvanic series is important when
considering design with different materials.

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Factors needed for corrosion

To achieve corrosion we need a galvanic cell
A galvanic cell consist of:

A Cathode:
The noble metal / alloy (or part of metal)

An Anode:
The less noble metal / alloy

An electrical connection
between the two metals, conducting electrical current (by electrons)

An electrolyte:
Conducting electrical current (by ions)

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Corrosion
The corrosion rate depends on the
electrolyte conductivity
Steel corrodes at different speed in fresh
water and seawater
Seawater conducts the corrosion current
better than fresh water, and gives more
corrosion

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Corrosion
Single piece of metal showing the anodic
and cathodic sites.
Corrosion occurs at the anodic sites. If the
steel was all cathodic corrosion would
stop.
A piece of steel has thousands of anodic
and cathodic sites.
It is, however, unusual to find them
uniform as various factors such as
contaminants will cause different types of
corrosion rates on a single piece of metal.

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Corrosion Protection by coatings

Barrier effect
Creates a barrier that stops the ionic current
(i.e. corrosion current) Example: epoxy-coatings

Inhibitive/passivizing effect
The coating passivizes the steel surface
Example: coatings mixed with anti corrosive pigments
(lead, chromates or phosphates)

Cathodic effect
The coating itself acts as an anode (galvanic effect)
Example: zinc rich coatings

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Barrier effect
Most paints protect the steel by forming a
barrier to the surrounding environment.

A barrier will increase the resistance in the

galvanic circle.

A thick barrier will give better protection

than a thin.

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Inhibitor effect
In inhibitive coatings, moisture may penetrate
to reach the inhibitive primer where the
reactive pigments are activated, which in turn
passivizes the metal substrate at the
coating/metal interface.
Example of Inhibitive pigments:
Red Lead (not used)
Lead/zinc chromate (not used)
Zinc phosphate
Product with inhibitive pigments are not suited
for immersed substrates.

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Cathodic effect

Some paints offer the same cathodic

protection effect as sacrificial anodes.

A zinc-rich primer reacts to protect the

steel substrate when the topcoat is
damaged.

The CP type of paints is not an inert paint

film as the barrier coatings.

The paints contain active, metallic

pigments.

The pigments react with moisture and the

steel and creates a calcareous deposit on
bare spots of the steel substrate.

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Jotun Paint School

1. Introduction of Jotun
2. Corrosion
3. Paint technology
4. Coating Failures
5. Standard (ISO 12944)

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Paint consists of:

Binder
Colour pigments
Extenders
Solvents

Additives

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Types of binders
Synthetic resin:

Natural resin:

Drying oil
Wood rosin
Coal Tar
Bitumen
Nitro-cellulose

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Alkyd
Chlorinated rubber
Vinyl
Acrylic
Epoxy
Polyurethane
Silicate
Polyester
Polysiloxane

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What is a Binder ?

A binder is a fluid or a solution that forms a film during drying or curing.

Describes the generic type of paint/coating.
Bind pigments and extenders to a solid film.
Provides the adhesion to the substrate.
Provides the water, chemical, solvent and UV resistance.

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What is the purpose of Pigments?

Colour
Corrosion inhibiting effect

Barrier effect
Anti-Fouling effect

Cathodic Protection effect

Abrasion

Gloss control

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Colour Pigments

Natural or synthetic pigments

Organic or inorganic pigments
Gives colour to the film
Hides the substrate (opacity)
Almost all colours consist of a blend
of pigments
Individual colours can be changed or
adjusted by altering the pigment blend

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Active / Reactive pigments

Take an active role in ensuring that the paint performs as expected:
Anticorrosive (inhibitive or galvanic)

Red Lead
Lead chromate
Zinc chromate
Zinc phosphate
Zinc dust

For health reasons, no longer

used in Jotun products

Barrier pigments (flakes shaped pigments)

Glass, aluminum and micaceous iron oxide (MIO)

Antifouling
Cuprous oxide

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What is the purpose with Solvents?

Dissolve the binder

Give lower viscosity
Give application properties for brush, roller, spray
Once the paint has been applied, there is no more need for the solvent.
Examples:
Water
White Spirit
Xylene
Toluene
Ketones
Glycol
Alcohols

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Some thinner types are a mixture

of solvents and diluents

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Thinning
The paint is generally supplied with the correct
viscosity.

Usually there is no reason to thin the paint.

The paint is supplied at its optimal viscosity

for being applied.

Excessive thinning may lead to several

problems.

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Thinning
Thinning is primarily only recommended in three situations:

Very cold paint (becomes thick)

Very warm conditions / substrate (keep the film open longer)

Painting very porous substrates (tie coat or mist coat technique)

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Types of Additives and Extenders

Wetting & Dispersing Agents

Rheological Additives (Viscosity Adjustment)

Driers

Anti-foaming/Air release additives

UV absorbers/Light Stabilizers

Adjust the gloss level (Extenders)

Anti-Settling Additive

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Paint production video

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Drying / Curing Mechanism

The properties of a paint film is closely related to how the binder dries or cures.
The three most common drying / curing mechanisms are:
1. Solvent evaporation (physically drying)
2. Reaction with oxygen in the air (oxidation)
3. Chemical reaction between resin and hardener

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Physical drying

Chlorinated rubber
Vinyl
Acrylic
Silicone
Bitumen
Tar
Antifoulings

The solvents evaporate.

Molecules pack and melt together to form
a paint film.
No chemical bonds.
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Physical drying properties

Advantage

Limitation

Single component
Not temperature dependent for drying
(solvent borne)
Easy to recoat, good inter-coat
adhesion
Relatively good water resistance
Reasonably good chemical resistance

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Poor solvent resistance

Low solid content
Relatively poor wetting properties
Thermoplastic
Dry heat resistance 60 70C
Emulsion paint (water borne) +5C

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Oxidative drying/curing
Alkyd

The solvents evaporate.

Oxygen enter the paint and the reaction
starts.
The binder molecules link together
through a chemical reaction with oxygen.

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Curing (drying) by oxidation properties

Advantage

Limitation
Poor chemical resistance (especially
against alkaline / caustic)
Limited water resistance (submerged)
Limited solvent resistance
Limited film thickness per coat

Single component
Good application properties
Good weather resistance
Good wetting properties
Good recoatability
Good levelling / flow
Good gloss retention

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Chemically curing

Epoxy (solvent and water borne)

Zinc epoxy
Epoxy Mastic
Polyurethane
2-pack Acrylic
Zinc Silicate
Polysiloxane
Polyester
Vinylester

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Chemically curing
The solvents evaporate.
Component A and Component B
molecules moves towards each other.
They link together through a chemical
reaction.
A three dimensional network is formed
which give the solid paint film.

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Chemically curing

Insufficient mixing results in:

Poor curing

Reduced protective properties of

the paint system

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Epoxy paint properties

Advantage

Limitation

Chemical curing
Very good chemical resistance
High alkali resistance
Moderate resistance to acids
Good adhesion
Very low permeability
High mechanical strength
Dry heat resistant up to 120C

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Chalking
Temperature dependent
2 - component
Requires blast cleaning
Over-coating time

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Jotun Paint School

1. Introduction of Jotun
2. Corrosion
3. Paint technology
4. Coating Failures
5. Standard (ISO 12944)

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Most common paint failures

Holidays, too low DFT

Sags and runs
Orange peel
Dry spraying
Pinholes
Popping
Fish-eyes
Lifting
Sweating and carbonisation

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Bloom and blush

Osmotic blistering
Pinpoint rust penetration
Checking/cracking
Alligatoring/crocodiling
Mud cracking
Delamination
Chalking
Bleeding
Formation of vacuoles

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Holidays
Appearance
Primer/undercoat shining through topcoat
Caused by

Uneven film thickness of the last applied coat

Repair
Apply another coat

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Non - Systematic Spraying

Unskilled personnel
Non systematic spraying of a
large surface
Several holidays
Uneven spraying and paint film
thickness

Helligdag
Rd maling
0589 - 54

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Sags and runs

Appearance
Paint running or hanging like curtains on vertical surfaces

Caused by
Too high Wet film thickness
Too much thinner added to the paint
Airless spray gun too close to surface

Repair
Avoid above
Use paint brush to smoothen or remove excessive paint

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Sags / Runs
Paint applied in too heavy coats
May be caused by:
Wrong application technique
(Overlapping)
Too short recoating interval
Too high wet film thickness
Too much thinner added to the paint
Airless spray too close to the surface

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Runs inside a Tank (1 of 3)

Inside a tank
Heavy runs/sags
Paint collects at the
weld/corner, forming a
very thick paint film
Has to be removed, or the
paint will break up and
cause corrosion

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Runs leading to Cracking of Paint (2 of 3)

Inside a tank
Paint has collected in
the corner
Several mm thick
paint
The paint cracked,
corrosion will develop

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Flaking of Paint. Corrosion (3 of 3)

The paint has been applied
too thick
The film cracks and breaks
up.
Corrosion has developed on
the steel after a short period
of time

Too thick film is just as

damaging as too thin
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Orange Peel
Appearance

Paint surface is rough, like an orange peel

Caused by

Poor flow / levelling properties of the paint

(Paint too thick or too low temperature)
Poor atomisation of the paint
Too fast evaporation of the thinner
Airless spray gun too close to surface

Improve application technique

Use correct thinner
Grind surface and apply new paint

Repair

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Orange Peel
Paint surface is rough, like an orange peel.

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Dry spray
Appearance

Porous, sandpaper like surface of the paint

Caused by

Poor atomisation of the paint

Spray gun too far away from the object
High air temperature and low relative humidity: Too fast evaporation of
the solvents
Strong wind during application

Remove loose dust, sandpaper to smooth surface, apply topcoat

Repair

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Dry spray
Application of a white paint in a paint shop
During painting of the lowest pipe, dry

spraying of the two upper pipes has

occurred.
Their surface look like a sandpaper
Wrong spray technique
Plan the work thoroughly to avoid overspraying (Shielding)
Too high pump pressures increase the dryspraying

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Pinholes
Appearance
Tiny holes through one or more coats, or even down to the substrate, as if
perforated by a needle
Caused by
Dry spraying
Entrapped solvents or air
Porosity of previous coat
Incorrect application technique or viscosity of the paint
Repair
Grind top layer of the paint
Recoat

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Pinholes

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Popping

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Fisheyes
Appearance
Spots of paint on the surface with no wetting of the surface around
the spots. Appearance of a fisheye.
Caused by
Paint applied on oil, silicone or other contaminants
Painted on incompatible paint (Glossy paint giving poor wetting)
Repair
Grind top layer of the paint
Recoat

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Fish-eyes

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Lifting / Wrinkling
Appearance
Small wrinkles through the paint film
Caused by
Softening and raising or swelling of a previous coat by the
application of an additional coat
Normally when overcoating Alkyd
Lifting often caused because the solvents in the new coat is too
strong for the previous coat
Repair
Remove the paint
Recoat

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Lifting / Wrinkling

The strong solvents will resolve the

relatively fresh conventional paint.

May also occur if Alkyd paint is

applied too thick. The paint will
Skin dry, (wrinkling) particularly
at high temperature differences
between steel and air.

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Sweating & carbonisation

(Amine blooming)
Appearance
Tacky and sweating film, often with white stains
Caused by
High humidity, particularly on Epoxies during curing
Poor ventilation
The Amines react with CO2 and humidity and form Amine carbomate.
Too low temperature
Repair
Wash with warm water or thinner, using rags
Preventive measure: Induction time before application start

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Amine blooming - Sweating

Steel painted with Epoxy
Tacky surface

Tacky surface
C22/2-19
with white stains

C22/2-17

Tacky, shining surface

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Osmotic blistering
Appearance
Smaller or bigger blisters in the paint film
Caused by
Salt and other water soluble contamination on the metal
surface or between coats
Repair
Remove existing system
Fresh water clean
Apply new paint system

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Blisters Close to Weld

Blisters forming at the area close
to the weld
Most probably due to welding
smoke remaining on the steel
Welding smoke is resoluble in
water and will create osmotic
blistering
Galvanic difference between
steel plate and weld may
aggravate the attack

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Rd bl ring sveis

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Blistering
Blisters inside a tank
Blisters sometimes contain water
As long as the blister are intact no rust
will be formed inside. This is due to the
high pH
As soon as the blisters break corrosion
will start
Use cathodic protection to back up the
paint system.

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Pinpoint rust penetration

Appearance
Points of rust
Caused by
Small pores (pinholes), openings or defects in the paint
film down to bare steel
Holidays due to overspray, dry spraying etc.
Too high substrate roughness
Repair
Grind down to bare steel
Recoat

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Corrosion. Too Thin Paint Film

Corrosion of steel on a flat area.

Paint film is too low. This is
verified by film thickness
measurements.

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Checking / cracking
Appearance
From fine cracks in the topcoat to more severe cracks down to
the substrate.
Caused by
Stress in the paint film
Entrapment of solvent
Too soft primer compared to the softness of the topcoat
Too high thickness
Repair
Abrade to remove cracked paint
Apply new suitable coating system

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Cracking / Flaking
Mechanical stress in steel.
Old, thick paint not sufficiently
flexible to follow the steel movements.

Most frequently observed on paints

that becomes hard, such as Alkyds.

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Cracking & Flaking

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Flaking of Alkyd on Zinc

1. Coat: Zinc rich coatings
2. Coat: Alkyd
Never use Alkyd on top of Zinc
Alkyd on Zinc will give
saponification

Gjerde flaker
1-8
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Mud-cracking
Appearance
Cracks occurring during the drying process of the paint
Appearance of the surface of cracked mud
Caused by
Particularly for inorganic Zinc applied at a too high film
thickness
Repair
Re-blast to Sa 2 or grind off
Apply the inorganic Zinc

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Mud Cracking
Mud cracking on a Zinc silicate paint.
This is a fast drying paints.
Has been applied in a too high film
thickness.

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Delamination (Adhesion failure)

Appearance
Loss of adhesion:
Intercoat delamination: Between coats
Substrate delamination : Between primer and
substrate
Caused by
Primer not compatible with subsequent coat
Contamination of substrate or between coats
Recoating interval too long
Blooming / sweating
Repair
Remove loose paint layer or down to substrate
Recoat
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Flaking. Too long Recoating Interval

Flaking of Epoxy
Poor adhesion between coats
Too long recoating interval

Check the maximum recoating

interval: Technical data Sheet

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Chalking
Appearance

Almost like dust on top of the coat

The gloss will be reduced

Caused by

Repair

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Pigments and extenders exposed on the paint

surface, due to
Exposure to sun / UV light
Degradation of the binder
Weathering of the paint
Insufficient mixing of the paint

Grind and/or wash top layer of the paint

Recoat

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Chalking
Promoted by UV-light
Causes loss of gloss
Darker colours appear to fade
Light colours will be self-cleaning

May happen to all types of paint to a

greater or lesser degree. Paints based on
epoxy binder are worst affected.

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Jotun Paint School

1. Introduction of Jotun
2. Corrosion
3. Paint technology
4. Coating Failures
5. Standard (ISO 12944)

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Can we use a paint for all environments and surface?

Various paint can be used to protect construction.

However, the selection may be not always effective.
Three generic types of paint to be used here:
Alkyd
Epoxy
Polyurethane
Different results show in different exposure:
Sunlight
Water
Chemical

What_is_paint2.mpg

There is no paint can be used in all environment!

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What factors give influence to select a paint system?

Customers expectation (durability)

Service environment

Paint and/or other protective materials

Substrate

Structure design

Surface preparation

Paint application

Maintenance

Cost

Health, safety and environmental

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Customer expectation
In the industry, customer expectation is mainly for
preventing corrosion.
They may always consider a long term protection
period of a paint system.

Durability is defined as the expected life of a

protective paint system to the first major
maintenance painting according to ISO 12944-1.

Low (L)

2 to 5 years

Medium (M)

5 to 15 years

High (H)

Durability is not same word as guarantee.

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Corrosivity of environment

Corrosivity of environment may be various as influence parameters absence in nature.

Artificial environment is built with a lot of different materials (metals).

It is critical to identify corrosivity of an environment since it can relate to:

Corrosion rate

Material selection
Determine proper corrosion protection method

ISO 12944-2 define the classification of environment by corrosivity.

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Corrosivity of environment ISO 12944/2

Atmospheric condition
C1

Very low

C2

Low

C3

Medium

C4

High

C5-I

Very high (industrial)

C5-M Very high (marine)

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Immersion
Im 1

Fresh water

Im 2

Sea or brackish water

Im 3

Soil

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Atmospheric condition
C1 Very low

C2Low
Low
C2

C3 Medium

Exterior:

Exterior:
Interior:
Heated buildings with
clean atmospheres, e.g.
offices, shops, schools,
hotels

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Atmospheres with low

level of pollution. Mostly
rural areas.

Urban and industrial

atmospheres, moderate
sulfur dioxide pollution.
Coastal areas with low
salinity.

Interior:

Interior:
Unheated buildings where
condensation may occur,
e.g. depots, sports halls.

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Production rooms with

high humidity and some air
pollution, e.g. foodprocessing plants,
laundries, breweries,
dairies.

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Atmospheric condition
C4 High

Exterior:
Industrial areas and
coastal areas with
moderate salinity.

Interior:
Chemical plants,
swimming pools, coastal
ship- and boatyards.

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C5-I Very high (Industrial)

C5-M Very high (Marine)

Exterior:

Exterior:
Industrial areas with high
humidity and aggressive
atmosphere.

Interior:
Buildings or areas with
almost permanent
condensation and with
high pollution.

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Coastal and offshore areas

with high salinity.

Interior:
Buildings or areas with
almost permanent
condensation and with
high pollution.

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Immersion condition
Im1 Fresh water

River installations,
hydro-electric power
plants

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Im2 Sea or brackish water

Harbor areas with

structures like sluice
gates, locks, jetties;
offshore structures

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Im3 Soil

Buried tanks, steel

piles, steel pipes

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C2 environment
Areas with low level of pollution, rural or dry areas

Example: Interior of an airport

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C3 environment
Moderate and Industrial atmosphere
Exterior areas inland, with limited humidity and pollution

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C4 environment
Industrial and coastal areas with moderate salinity

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C5 I: Industrial areas with high humidity and aggressive atmosphere

Refineries, HPI, harbours, heavy polluted areas

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C5-M: Very high (Coastal & marine)

Offshore and harbors: Consider using ISO 20340

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Select a paint system according to ISO 12944/5

ISO 12944/5 is common industrial standard can be referred to find a suitable system
for new construction.
There are list of typical systems categorized by:
Substrate (low-alloyed carbon steel, galvanized steel and metallized steel).
Corrosivity of environments (C1, C2, C3, C4, C5-I, C5-M, Im 1, Im 2, Im 3).
Durability (low, medium and high).

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Example
Table A.5 Paint systems for low-alloy carbon steel for corrosivity categories
C5-I and C5-M

Paint system for

external of a
windmill located at
coast of Baltic Sea.
Customer expect
service life should
be 20 years.
Construction
material is mild
steel.

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Build-up a paint system

There are no magic paint can do everything, hence, multi-layers
systems are normal in most cases.
Primer
Intermediate coat

Topcoat

However, one coat system may be specified:

Paint is specially designed for a single coat.

Constant environment.
Minor job such as maintenance.

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A paint system may be compared to a house

First:
The basement - Primer coat

Second:
One or several stories - Midcoats

Finally:
The roof - Top coat

They all have a special function

In the house
In the paint system

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How can we know the characteristics of all paints?

It is impossible to know all different paint products.
Through technical datasheet (TDS) of supplier is a well-suited way.
Information in right may list in a TDS:

Product description
Recommended use and typical paint system
Film thickness and spreading rate
Approvals
Physical properties
Surface preparation (methods and requirements)
Application (ambient condition, methods, technical
parameters)
Drying time
Brief HSE requirements
Packing size
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Special environment than ISO 12944/2 defined

Corrosivity environment in ISO 12944 doesnt cover all situations.

Some influences in the environment will cause more aggressive to corrosion.

Heat (high)
Chemical
Stray current
Mechanical stress

To find proper paint system for these environments is not easy.

We can always consult paint supplier and also confirm with pre-qualification testing.

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