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High-performance organic coatings

Edited by A S Khanna 
Woodhead Publishing  July 2008  



Hardcover  472 pp  ISBN 9781845692650      £160.00
  • reviews the factors affecting the success of a coating
  • describes the main types of coating and how their performance can be enhanced, including epoxies, polyester and waterborne coatings
  • examines applications in such areas as reinforced concrete pipelines and marine engineering

Paint coatings remain the most widely used way of protecting steel structures from corrosion. This important book reviews the range of organic paint coatings and how their performance can be enhanced to provide effective and lasting protection.

The book begins by reviewing key factors affecting the success of a coating, including surface preparation, methods of application, selecting an appropriate paint and testing its effectiveness. It also discusses why coatings fail, including how they degrade, and what can be done to prevent these problems. Part two describes the main types of coating and how their performance can be enhanced, including epoxies, polyester, glass flake, fluoropolymer, polysiloxane and waterborne coatings. The final part of the book looks at applications of high-performance organic coatings in such areas as reinforced concrete, pipelines, marine and automotive engineering.

With its distinguished editor and international team of contributors, High-performance organic coatings will be a valuable reference for all those concerned with preventing corrosion in steel and other metal structures.

Contents

PART 1 GENERAL ISSUES

Key issues in applying organic paint coatings A S Khanna, Indian Institute of Technology Bombay, India
- Introduction - Primers - Intermediate and top coats - Curing mechanisms - Pigments - Additives - Alkyds - Epoxies - Coal tar epoxies - Poly urethane coatings - Moisture-cured polyurethanes - High performance coatings - References

Surface preparation for organic paint coatings A S Khanna, Indian Institute of Technology Bombay, India
- Introduction - Blast cleaning - Measurement of anchor profile - Measuring the impurities on the lasted surface - Sponge jetting - Hydrojetting (water blasting) - Summary - References

Techniques for applying organic paint coatings A S Khanna, Indian Institute of Technology Bombay, India
- Introduction - Application by brush and roller - Spray application - Transfer efficiency - Mixing components - Summary - References

Characterisation, evaluation and testing of organic paint coatings A S Khanna and S Kumar, Indian Institute of Technology Bombay, India
- Introduction - Tests carried out prior to application - Identifying non-volatile matter (NVM) - Density - Practical coverage calculations - Viscosity - Volatile organic component - Pigment volume concentration - Critical PVC (CPVC) - Wettability - Tests carried out on coatings after they are applied to a substrate - Testing during the drying process - Corrosion resistance tests - Evaluation of physical properties - Summary - References

Selecting an appropriate organic paint coating A S Khanna, Indian Institute of Technology Bombay, India
- Introduction - The decision-making process - Keysteps in the decision-making process - Coating selection criteria for offshore structures - Service environment - Regulatory requirements - Substrate compatibility - Application alternative - Cost of painting - Summary

Causes and assessment of failures in organic paint coatings B P Mallick, Asian Paints Ltd, India
- Introduction - Causes of coating failure - Surface preparation-related failure - Design-related failures - Improper system selection - Stress-related failure - Application-related failure - Common types of coating failure and remedial measures - Conclusion - Bibliography

Mechanical degradation of organic paint coatings S Rossi and F Deflorian, University of Trento, Italy
- Introduction: paint damage produced by mechanical action - Mar degradation - Reduction of protection properties due to mechanical damage - Understanding damage morphology - Conclusion - References

PART 2 TYPES OF ORGANIC COATING

High performance epoxies and solvent-less epoxies for corrosion protection S Kanitkar, Aditya Birla Chemicals (Thailand) Ltd., Thailand
- Introduction - Epoxy basics - Curing agents - Epoxy reactive diluents - Corrosion - High performance coatings - Solventless epoxy systems - Epoxy waterborne coatings - Summary - Bibliography

Polyester coatings for corrosion protection K VSN Raju, Indian Institute of Chemical Technology, India, D K Chattopadhyay, North Dakota State University, USA
- Introduction - Polyester resin - Raw materials and reactions - Polymerization methods - Determination of hydroxyl value and acid value - Backbone modification polyester resin for high solid coatings - Polyester-melamine coatings - Polyester-urethane coatings - Other type of polyester coatings - Conclusion - References

Glassflake coatings for corrosion protection G Greenwood-Sole, Corrocoat Ltd, UK
- Introduction - The development of glassflake coatings - Factors affecting the effectiveness of glassflake coatings - Testing the performance of glassflake coatings - Applications of glassflake coatings

Fluoropolymer coatings for corrosion protection in highly aggressive environments A S Hamdy, Boise State University, USA
- Introduction - Corrosion protection of aluminium metal matrix composites - Application of fluoropolymer as corrosion resistant coatings - Evaluating coating performance using electrochemical impedance spectroscopy - Salt spray chamber and adhesion performance tests - Conclusion - References

Polysiloxane coatings for corrosion protection K-H Kaesler, Momentive Performance Materials Inc, Germany
- Introduction: what is a polysiloxane? Direct method for producing polysiloxane - Grignard method for producing polysiloxane - Olefin addition method for producing polysiloxane - Polymerization - Siloxanes for protective coatings - Concrete protection - Siloxanes as paint additives - How do the modified siloxanes work?

Waterborne coatings for corrosion protection S S Pathak and A S Khanna, Indian Institute of Technology Bombay, India
- Introduction - Alternative to solventborne coatings - Waterborne coatings - Classification of waterborne coatings - Water properties influencing coating formulation - Technology behind development of waterborne coatings - Development of resin for waterborne coating formulation - Additives in waterborne coating - Film formation - Application methods - Performance evaluation of waterborne coatings - Application of waterborne coatings - Conclusions - References

PART 3 APPLICATIONS OF HIGH-PERFORMANCE ORGANIC COATINGS

Organic coatings for concrete and rebars in reinforced concrete structures A S Khanna, Indian Institute of Technology Bombay, India
- Introduction - Deterioration of reinforced concrete - Corrosion of steel reinforcement in concrete - The corrosion process - Corrosion initiation and propagation mechanism - Methods of corrosion control and protection - Modification of steel composition - Admixtures in concrete - Corrosion inhibitors in concrete - Cathodic protection - Protective coatings - Concrete coatings - Galvanic coatings - Epoxy coatings - Modified FBE coatings - Cement polymer composite coatings (CPCC) - References

Organic coatings for underground pipelines N Kumar, Gail (India) ltd, India
- Introduction - History and importance of pipelines - Pipeline and corrosion - The need for pipeline coatings - Types of coatings for pipelines - Characteristics of good coatings - Selection of coatings - Coal-tar coatings - Single-layer fusion bonded epoxy coatings - Dual-layer FBE coating - Three-layer polyethylene/polypropylene coatings - Surface preparation and its importance in coating - Comparison of various coatings - Coatings and cathodic protection - Coating failures - Future trends - Coating standards - Bibliography

Organic coatings for marine and shipping applications J H W De Wit and J M C Mol, Delft University of Technology, W Bos and G Ferrari, TNO Science and Industry, The Netherlands
- Introduction - Types of application - Coatings for corrosion protection - Coatings for antifouling protection - Inspection, monitoring and maintenance - Conclusions and future - References

Organic coil coating of metal M De Souza, University of Campinas, Brazil
- Introduction - Understanding the coil coating process - Substrates and paints - Coil coating uses - Future of coil coating - References

High performance organic coatings for wastewater treatment plants D Dhage, EWAC Alloys Limited, India
- Introduction - Categories of waste treatment plants - Materials of construction and their deterioration - Protection of materials by coatings - Glassflake-filled coating system - Different resin systems for glassflake coatings - Application of various resins - Formulation aspects - Advantages with glassflake coatings - Performance of glassflake-filled coatings against conventional coatings - Application of glassflake coating to wastewater treatment plant - Conclusion - References

Anticorrosion organic coatings for the automotive industry M G Mehrotra, Kansai Nerolac Paints Ltd, India
- Introduction: automotive coatings - Types of automotive coating - Sequence for coating the automobile body shell - Primers, base coats and topcoats and metallic finishes - Anti-scratch and anti-mar coatings - Special coatings for plastic and other non-metallic components - Future developments in automotive coatings - Application and process systems - Nanomaterials as additives in coatings - Nanocomposites in surface coatings - Incorporation of inorganic particles and clusters for hybrid coatings - Self-cleaning paint layer - Abrasion-resistance coatings - Non-chromate corrosion inhibitors - Conclusions - References

Using organic coatings for repainting and maintenance of steel components and structures N Wilds, International Paints Ltd, UK
- Introduction - Conventional systems - Developments in conventional coatings - 'High performance' coatings - Alternative approaches - Complete surface tolerance - Urethane surface tolerance - Epoxy €mastics€ - Current developments - Moisture-cured urethanes (MCUs) - Rust converters - Conclusions

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