high-performance protection...substrate covering options paint systems (aesthetic appeal) coating...
TRANSCRIPT
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High-Performance Protection Coating Selection for Interior and
Exterior Architectural Applications
AIA Wyoming Fall Conference
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Learning Objectives
After viewing this presentation, participants will be able to:
• Identify the coating environments applicable for architectural applications
• Understand what generic coating type should be used for a particular environment
• Identify what generic coating type should be used for interior and/or exterior applications
• Understand a complete coating system includes a primer, intermediate and topcoat
• Identify where floor coatings can fit into a particular project scope
• Understand what coatings may be used on environmentally focused projects
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Our Core Markets
• Water Storage Tank Market
• Water and Wastewater Market
• Specialty Architectural Market
• Processing & Manufacturing Market
• Industrial Market
Water Tank
WWTP Civic Building Manufacturing Plant Fuel Storage Tank
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PROTECTION Choosing the appropriate covering for your project
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Substrate Covering Options
Paint Systems
(Aesthetic appeal) Coating Systems (Protection)
Interior office spaces Exterior uses (color and gloss retention)
Low-traffic areas Areas subject to abuse
Traditional painted items Corrosion prevention
Aesthetic purpose Aesthetic value with long-term substrate
protection
Frequent repaints due to
color trends Life cycle cost value
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COATING ENVIRONMENTS Applicable for Architectural Applications
High Rise – CA
Natatorium - MA
Gateway - CA
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Protection For…
• Steel
• Aluminum
• Cast Iron
• Galvanized
• Non-Ferrous Metal
• Wood
• Concrete
• Masonry
• Stucco
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High Rise Buildings
High Rise Building - Chicago, IL
• Corrosion protection
• Color and gloss performance
• Overcoating of aged panels (refurbishment) or new construction
• Life Cycle Savings
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Sports & Recreation Facilities
Stadium - Atlanta, GA
• Color and gloss retention for exterior substrates
• Brand or logo color performance
• Durable floor and wall systems
• Water repellents
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War Memorial Stadium
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Processing & Manufacturing
Printing Facility – Kansas City, MO
• Structural steel
• Tanks
• Interior floors and walls
• Equipment
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Healthcare Facilities
Medical Center - Bailey, OK
• Operating rooms
• Clean rooms
• Ceilings
• Abrasion resistant, floor and wall systems
• Non-staining
• Frequent cleaning
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Educational Facilities
School District - Marion County, FL
• Steel, masonry and concrete protection
• Interior floors and
walls
• Roof coatings
• Graffiti protection
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Correctional Facilities
County Jail - Hamilton, OH
• High abuse wall and floor systems
• Interior and exterior steel & masonry
• Kitchen
• Shower areas
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Transportation
Airport - Indianapolis, IN
• High performance protection from UV and freeze/thaw cycling
• Interior and exterior steel & masonry
• Chemical resistance
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DIA Canopy 2001
No Corrosion, No color/gloss loss
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Natatoriums
Fieldhouse - Columbia, MO
• Overhead deck and
truss/joint protection
• Walls and floors in chemical environments
• Pool coatings
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Properly Prepared and Primed Vulcraft
Pool OH
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Parking Garages
Parking Garage -
Milwaukee, WI
• Light reflectant ceiling coatings
• Structural steel and concrete protection
• Water Repellents for chloride protection
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Auraria Parking Garage, Original 2006
- still looking great
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Local Coating Failures
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DU Parking Garage – Original 2005
Faded Color
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Union Station Canopy
Galvanized metal failure
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RTD Dry Creek Ped Bridge
Same application time – two different
Manufacturers
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COATING SELECTION Specifying the right coatings for your project
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Volatile Solvents
Resin (Binder)
Pigment
SOLIDS
VEHICLE
Costs of Paints & Coatings • Resins: The framework on
which the coating’s
performance is built – Most
expensive part - FLORINE
• Pigments: Color, hide & anti-
corrosion Next Most
Expensive – Quality
important
• Solvents: Workability and
wetting
PERFORMANCE = HIGH QUALITY RESINS & PIGMENTS + HIGH
QUALITY SOLIDS CONTENT.
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$230,625
$140,625
$96,000
$77,625
$71,250
20-Year Life-Cycle Cost of 30,000 sq.ft. (Based on acceptable aesthetics of topcoat only)
Alkyd
Acrylic
Polyurethane
Polysiloxane
Fluoropolymer
20 years
3-4 yrs. 3-4 yrs. 3-4 yrs. 3-4 yrs. 3-4 yrs.
4-6 yrs. 4-6 yrs. 4-6 yrs.
7-10 yrs. 7-10 yrs.
10-15 yrs.
15-20 yrs.
Polymer Type Applications Finish App. Cost
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How Primers Protect Steel
Protective coatings and primers provide economical
protection to steel in two basic ways:
• A PHYSICAL BARRIER –
• Several coats of Epoxy
• SACRIFICIAL METALS –
• Zinc Rich primers offer galvanic protection as
sacrificial metals
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Types of Primers
• Alkyd
• Acrylic
• Epoxy
• Urethane
• Zinc-Rich
Zinc-rich primer being applied in shop
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Levels of Corrosion Protection
Unprimed
32 hrs.
Alkyd
500 hrs.
Epoxy
4,000 hrs.
Zinc-Rich Urethane
10,000 hrs.
Testing Standard: Salt Fog (ASTM B 117)
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GENERAL PRIMER CONSIDERATIONS
• PART OF COATING SYSTEM
• SAME MANUFACTURER AS TOPCOATS
• USUALLY MUST BE TOPCOATED FOR DURABILITY
• BINDING TOPCOATS TO SUBSTRATE
• Div 5 – 05120, 05500 Spec sections must call out prep
and primer type – depending upon exposure
• Example: Interior Exposed versus Exterior Exposed
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FAILURES?
• POOR SUBSTRATE PREPARATION
• IMPROPER APPLICATION
• WRONG MATERIAL – OFTEN DUE TO DIV 5 PRIMER
WAS WRONG MATERIAL FOR EXPOSURE
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Alkyd & Acrylic Primers
• Application ease
• One-component
• Designed for shop and field applications
• Provide basic corrosion protection
• Suitable for steel fabricators, OEM’s
and field applications.
Often for INTERIOR EXPOSURES
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Epoxy Primers
• Two-component, chemical cross-
linking
• Provide barrier protection
• Steel protection in field and during
erection
• Allows for high-performance
topcoat application
• Chemical-resistant
• Often used as primer or mid-coat
in shop-applied systems for
EXTERIOR EXPOSURE
Westat, Inc. – Rockville, MD
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Galvanic Protection
• Primers are used to provide protection for a substrate
• Zinc-Rich Primers offer galvanic protection. GREAT
substitute for HDG when cost or size prohibited.
– The coating will sacrifice itself before allowing the steel
to corrode
– Used as part of a complete protective coating system
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Extended Protection with Zinc Testing Standard: Salt Fog (ASTM B 117)
Test Method Salt Fog (ASTM B 117)
System 3 mils Moisture Cured, Organic
Zinc-Rich Urethane
Test Duration 30,000 hours
Report Measuring of corrosion on the
plane and at the scribe
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• Results after 8,000 hrs
• Same barrier protection
provided by epoxy
• Different protection
provided by primer
Testing Standard: Salt Fog (ASTM B 117)
Extended Protection with Zinc
Epoxy (3 cts) Zinc-Rich Primer (1 ct)
Epoxy (2 cts)
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Intermediate/Topcoat Protection
Performance and life expectation can vary significantly
based on topcoat selection.
• Alkyds
• Acrylics
• Epoxies
• Polyurethanes/Polyurethane Hybrids
• Fluoropolymers
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Alkyds
• One component
• Easy application
• Provide basic UV protection
• Basic color and gloss retention
• Aged technology that requires frequent touch-ups, done by maintenance personnel
University - Georgetown, MD
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Acrylics
• One component
• Easy application
• Provides basic UV protection
• Basic color and gloss retention
• Advanced technologies can
provide dry-fall and hydrophobic
characteristics
Airport, Concourse B - Boise, ID
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Acrylic Finish – Laramie Ped Bridge
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Epoxies
• Two-component, chemical cross-linking
• Excellent adhesion to the substrate
• Chemical and abrasion resistant
• Barrier protection from corrosion
• Epoxies should be top coated when
subjected to UV exposure
Gateway - Los Angeles, CA
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Polyurethane/Polyurethane Hybrids
• Two-component, chemical cross-linking
• Superior color and gloss retention
• Topcoat over epoxies
• Resistance to abrasion
• Provides long-tern protection from
exterior weathering
TABLE MESA BRIDGE
BOULDER CO
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Fluoropolymers
• “Gold” standard in protection against UV and weathering
• Provide exceptional color & gloss performance
• Air-dried version can be shop or field applied
• Alternative to a clearcoat system
• Many colors contain energy saving infrared reflective pigments
• Extended life cycle similar to factory applied fluoropolymer coil coatings
Aquarium - Baltimore, MD
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Water Tank Exteriors
• Swan Ranch EWT
• 2012 with Hydroflon
finish by TNEMEC
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Extreme Weathering Tank - Kauai, HI
Color and Gloss after 13 years
• Painted in 2000
• Only 1.05 Delta E (FMC II) color difference after 13 years of moist tropical
salty air and hot tropical sun! AMAZING!!!!
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ZCMI Façade
City Creek Skylights
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Aesthetic Performance
Fluoropolymer
Polyurethane
10,000 hrs.
QUV-A Exposure
Test Method: QUV (ASTM D 4587)
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INTERIOR COATING SYSTEMS Specifying the right coatings for your projects
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Interior Coating Systems
• Carbon Steel
• Concrete and Masonry
• Galvanized Steel
Natatorium - Chattanooga, TN
Dept. Store - Omaha, NE
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Galvanized Steel
• Overhead decking
• Conduit and ducting
• Interior/exterior UV
• Passivated/Non-Passivated Steel
Fitness Center - Walla Walla, WA
Coating System (generic)
Primer/Finish Self-Crosslinking Hydrophobic
Acrylic Dry-Fall
Typical System May Include:
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CU Boulder Hockey Rink OH
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EXTERIOR COATING SYSTEMS Specifying the right coatings for your projects
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Exterior Coating Systems
• Ferrous metal
• Non-ferrous metal
• Concrete & masonry
Stadium - State College, PA
Manufacturing - St. Peters, MO
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Bridges
Pedestrian Bridge – Contra Costa County, CA
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JHR Tram Building 2008
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Exposed Steel Structures
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ADAMS STATE COLLEGE
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Lincoln Park Stadium, Grand Junction
Colorado
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Series 626 Dur A Pell
GS
RTV Silicone Rubber
Series 680 Mark A Way
Dual Purpose Water
Repellent and Graffiti System
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Product/Technology
Types of Anti-Graffiti
– Sacrificial
• A portion of or all of the protective coating is
removed during the cleaning of unwanted
graffiti.
• Does not crosslink chemically with the
substrate
• Can degrade do to weathering
• Must be reapplied after clean down, leaving
substrate unprotected while substrate dries
– Remember, speed of removal
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Product/Technology
Types of Anti-Graffiti (cont.)
– Non Sacrificial
• Protective Coating remains after graffiti has been
cleaned
– Coating may chemically bond to the substrate
– Coating may mechanically bond to the
substrate
– No exposure after clean down
– May minimize MVT
– May substantially alter the look of substrate
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Product/Technology
Definitions:
– Anti-Graffiti
• Clear or opaque coating formulated to deter
adhesion of graffiti and resist repeated
scrubbing and exposure to solvents, cleaners
or scouring agents used to remove graffiti
– Water Repellent
• Retards & reduces water intrusion
• Used in areas of intermittent hydrostatic
pressure
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Before Tagging
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Tagged Block
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Cleaning Process
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After Cleaning
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Floor and Wall Coatings
• Offer durability, cleanability and seamless protection
• Easy application
• Stand up to impact, abrasion, aggressive cleaning, thermal shock and chemical exposure
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WALL COATINGS Intended Uses and Types
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AREA WITHIN FACILITIES
• Kitchens/food preparation
• Locker rooms and showers
• Laboratories
• Hygienically controlled rooms
• Restroom/wash rooms
• Coolers/freezers
• Battery charging area
• Anywhere concrete is exposed to physical and/or
chemical attack.
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Spec-Finish®
Coated Concrete Masonry Wall Systems
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SPEC FINISH BLOCK
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Uncoated Standard CMU Wall
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Coated Spec-Finish CMU
Pinhole free surface
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Level I – Standard Block Finish
Prime Coat
Waterborne Filler
Intermediate Coat
Modified Polyamide Epoxy
Finish Coat
Aliphatic Polyurethane
Application: Roller-Applied
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Level II – Orange Peel Block Finish
Prime Coat
Waterborne Filler
Intermediate Coat
Modified Polyamide Epoxy
Finish Coat
Aliphatic Polyurethane
Note: Prime Coat must be back-rolled and squeegeed
Application: Roller-Applied
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Leprino Foods 2012
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Atlanta Humane Society
Level II – Orange Peel Block Finish
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Level III – Smooth Block Finish
Prime Coats (2 coats)
Waterborne Filler
Intermediate Coat
Modified Polyamide Epoxy
Finish Coat
Aliphatic Polyurethane
Note: Prime Coats must be back-rolled and squeeged
Application: Spray-Applied
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Level III Finish 1 coat of block filler
2 coats Latex Finish
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Level IV – Joint-Filled,
Fiber Reinforced Finish
Skim Coat (troweled)
Epoxy Filler and Surfacer
Fiberglass Mat
Fiberglass Reinforcing Mat
Saturation Coat
Modified Polyamine Epoxy
Intermediate Coat
Modified Polyamine Epoxy
Finish Coat
Aliphatic Polyurethane
Application: Roller-Applied
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Level II Finish Level IV Finish
Georgia State University
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LEVEL IV VIVARIUM WITH
SEAMLESS FLOORING
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Common Substrates
• Wallboard
• Concrete Masonry Units (CMU)
• Existing Tile
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Don’t Forget The Floors
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Remember
• Every project needs a qualified
applicator in order to be successful
• Qualified applicator responsibilities:
– Perform substrate testing
– Address surface preparation
– Address environmental conditions
(i.e. temp, humidity)
– Mixing and application of coatings
per manufactures instructions
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Wall Coatings
• Physical contact
• Public areas frequently
cleaned and wet
• Provides impermeable
surface over entire wall
• Easily cleaned and
maintained
• System can be tied into floor
system with cove base
Detention Facility Showers - TN
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FLOOR APPLICATIONS Common Generic Coating Types
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Types of Flooring Systems
• Thin-film flooring
• Thick-film flooring
– Laminate
– Mortar
Bakery Floor – San Antonio, TX
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Other Environments
• Areas where floor coatings are typically found:
– Automotive service
– Transit authority
– Aircraft hangers
– Bus terminals
Airplane Hanger
Dealership
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Corporate Hanger
Thin-Film Epoxy Systems
Repair Facility
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Knight Transportation Denver CO.
2012
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Common Resin Types for
Seamless Floor Applications
• Epoxies
• Urethanes
• Acrylics (MMA)
• Vinyl Ester
• Urethane modified concrete
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Why Install Resinous Floor Systems?
• To protect concrete from physical and chemical abuse
• To provide a cleanable, sanitizable surface
• To create a seamless monolithic surface
• To beautify and protect
• To create non-slip properties
• To improve lighting
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Quartz Aggregate
• Example of quartz/fleck aggregate added for visual
appeal
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Mortar Floor System
Before After
Rescue Mission Kitchen
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Various air districts throughout the
U.S. and Canada have VOC content
regulations, which must be followed in
regards to paints and coatings.
Specifications VOC Considerations for Coatings
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Where to specify High Performance
Coatings • Division 4
– Masonry - 4205
• Division 5
– Structural Steel – 5120
– Steel Decks – 5310
– Metal Fabrications: Shop Primers - 5500
• Division 8
– Steel Doors & Frames - 8111
• Division 9
– High Performance Coatings - 9960
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This concludes the educational content of this presentation.
Developed by Tnemec Company, Inc.
1-800-TNEMEC1 or www.tnemec.com
QUESTIONS?