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WaterborneProducts,
Systems,�AndApplication
Textbo
ok
Version:�11.5
©�2009�-�2014�Inter-Industry�Conference�On�Auto�Collision�Repair
REF07-STMAN1-E
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Waterborne�Products,�Systems,�And�ApplicationTextbook
Table�of�Contents 3
Contents
Introduction..............................................................................................................................7Obligations�To�The�Customer�And�Liability.......................................................................... 7
Module�1�-�Waterborne�Refinish�Materials.............................................................................13What� Is�Waterborne?.......................................................................................................... 13Why�Waterborne?............................................................................................................... 18Waterborne�At�The�OEM�Level...........................................................................................19Clearcoats........................................................................................................................... 20Module�Wrap�Up............................................................................................................... 20
Module�2�-�Waterborne�Refinish�Systems...............................................................................23Surface�Preparation�And�Equipment................................................................................... 23Spray�Guns......................................................................................................................... 32Primers................................................................................................................................37Application�Consideration.................................................................................................. 38Drying.................................................................................................................................42Air�Movement�Equipment...................................................................................................44Module�Wrap�Up............................................................................................................... 49
Module�3�-�Storage,�Waste�Disposal,�And�Waterborne�Conversions.......................................53Waterborne�Storage�Recommendations.............................................................................. 53Waterborne�Waste�Disposal�Considerations........................................................................55Converting�To�Waterborne..................................................................................................56Module�Wrap�Up............................................................................................................... 59
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Introduction
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IntroductionTextbook
Waterborne�Products,�Systems,�And�Application 7
Obligations�To�The�Customer�And�Liability
The�collision�repair�industry�has�anobligation�to�correctly�repair�thecustomer’s�vehicle.�Collision�repairs�mustbe�performed�using:
• recommended�or�testedprocedures�from�vehicle�makers,I-CAR,�and�other�research�andtesting�organizations.
• quality�replacement�parts�andmaterials.
• repair�processes�and�parts�aswritten�and�agreed�upon�in�therepair�order.�If�items�on�the�repairagreement�are�not�consistentwith�the�repair�order,�it�can�beconsidered�fraud.
Performing�proper�collision�repairsrequires�using�parts�and�procedures�thatkeep�remaining�warranties�intact.
Collision�repairs�must�restore:
• safety.• structural�integrity.• durability.• performance.
• fit.• finish.
Throughout�the�damage�analysis�andrepair�process�the�repairer�and�insurermust:
• communicate�with�each�other.• maintain�constant�communication
with�the�customer.• be�in�agreement�with�each�other
and�the�customer�on�how�repairswill�be�performed.
• inform�the�customer�of�anychanges�in�the�repair�plan�fromthe�original�repair�agreement,�andexplain�the�changes�and�why�theyhave�to�be�made.
To�reduce�liability:
• make�sure�that�all�repairs�areperformed�thoroughly,�correctlyand�as�listed�in�the�damage�report.
• follow�proper�procedures.• have�documentation�of�required
repairs�with�detailed�recordkeeping�available�for�customers.
IntroductionTextbook
Waterborne�Products,�Systems,�And�Application 8
Technicians�are�considered�theexperts�and�are�expected�to�beknowledgeable�on�how�to�performa�quality�repair.
Liability�insurance�that�covers�the�repairfacility�may�not�always�cover�all�damages.For�example:
• the�policy�may�not�coverfaulty�repairs,�leaving�liabilityresponsibility�completely�on�thefacility.
• a�shop�owner�may�find�that�repairfacility�liability�coverage�may�notcover�the�full�amount�awarded�ina�lawsuit.�The�shop�owner�wouldhave�to�pay�the�difference.
It�is�difficult�to�reduce�the�risk�of�liabilityexposure.�The�part�that�the�repairer�cancontrol�is�the�chance�of�being�found�atfault.�Chances�can�be�minimized�by:
• using�recommended�or�testedprocedures�from�the�vehiclemakers,�I�CAR,�or�other�researchand�testing�organizations.
• using�quality�replacement�partsand�materials�that�restore�fit,
finish,�durability,�and�perform�atleast�as�well�as�the�original.
• keeping�thorough�records.
Keeping�thorough�records�includes�morethan�recording�the�date,�mileage,�and�pre-existing�damage.�Record�keeping�alsoincludes:
• making�sure�all�notes�are�legible.• verifying�the�repairs�that�were
made�or�not�made.• having�the�customer�sign�a
waiver�for�repairs�that�they�donot�want�performed.�Repairersmust�determine�their�liability�onnot�repairing�safety�systems�suchas�restraint�and�anti-lock�brakesystems.
• keeping�computer�printouts�orworksheets�on�file�showing�wheelalignment�readings�or�vehicledimensions�before�and�afterrepairs.
• keeping�scan�tool�printouts�andrecords�of�computer�codes�forairbag,�anti-lock�brake,�emission,and�powertrain�control�module(PCM)�systems.
IntroductionTextbook
Waterborne�Products,�Systems,�And�Application 9
• attaching�the�OEM�or�other�testedprocedure�printout�to�the�vehiclerepair�order.
• keeping�receipts�for�all�subletwork�performed.
Refer�to�"Video:�Topics�Off�Limits"�in�thepresentation.�This�video�identifies�topicsthat�should�not�be�brought�up�in�class.
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Module�1�-Waterborne�Refinish
Materials
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Module�1�-�Waterborne�Refinish�MaterialsTextbook
Waterborne�Products,�Systems,�And�Application 13
What�Is�Waterborne?
Learning�objectives�for�this�moduleinclude:
• explaining�the�definition�ofwaterborne�refinish�material.
• identifying�differences�betweenwaterborne�and�solvent-bornerefinish�material.
• explaining�technicalcharacteristics�of�waterbornerefinish�material.
• explaining�what�waterbornerefinish�materials�are�available.
• explaining�why�waterbornerefinish�material�is�used.
• explaining�vehicle�makers�use�ofwaterborne�refinish�material.
Water�is�the�primary�ingredient�in�waterbornerefinish�materials.
Waterborne�refinish�materials�weredeveloped�to�reduce�the�amount�oforganic�solvent�content�in�refinishmaterials.�Water�is�also�a�solvent.Automotive�refinish�materials�described�aswaterborne�are�products�using:
• water�as�the�main�ingredient.�Solidingredients�are�dispersed�in�thewater.��
• reduced�amounts�of�organicsolvents.�Waterborne�finishes�stillcontain�some�organic�solvents(also�known�as�co-solvents).
Waterborne�refinish�materials�and�/�orsystems�may�be�called�water-based�bysome�sources.
Solvent-borne�refinish�material�contains�85%organic�solvents,�while�waterborne�contains�about10%�organic�solvents.
Some�characteristic�comparisons�betweenwaterborne�and�solvent-borne�refinishmaterials�are�that:��
• there�may�be�a�difference�in�solidcontent.�The�solid�content�insome�product�lines�is�higher�inwaterborne�refinish�materials�thanin�solvent-borne�refinish�materials.�
• there�is�a�difference�in�thereducers�that�are�used.�Solvent-borne�reducers�are�blends�ofsolvents.�Some�waterbornebasecoat�is�reduced�with�water
Module�1�-�Waterborne�Refinish�MaterialsTextbook
Waterborne�Products,�Systems,�And�Application 14
or�water�with�an�additive�that�isdesigned�to�slow�the�evaporationrate�in�hot�weather.��
• waterborne�refinish�materialstend�to�be�more�sensitive�tohumidity,�temperature,�and�surfacecontamination.
• the�flammability�risk�is�reduced.
Because�a�main�ingredient�is�water,�andthe�organic�solvent�content�is�lower,waterborne�refinish�materials�may�poseless�of�a�risk�of�flammable�issues�thansolvent-�borne�products.�However,�alwaysuse�caution�when�working�with�anyrefinishing�materials.
With�solvent-borne�refinish�material,many�of�the�recommendations�betweenpaint�makers�are�similar,�but�this�is�notthe�case�for�waterborne�refinish�materials.When�working�with�waterborne�refinishmaterials,�each�product�maker�hastheir�own�recommendations,�and�it�isimportant�not�to�generalize.�Refer�to�thetechnical�data�sheets�for�product-specificinformation.
Film�thickness�comparisons�between�waterborneand�solvent-borne�refinish�materials�vary.�Theproducts�may�be�thicker,�thinner,�or�about�the�samedepending�on�the�product�maker.
Other�characteristic�comparisons�betweenwaterborne�and�solvent-borne�refinishmaterials�are�that:
• waterborne�refinish�materialsmay�have�a�higher�pigmentationamount.�This�content�may�varydepending�on�the�product�andproduct�maker.�There�are�fewergaps�between�the�color�molecules.The�pigment�part�of�basecoatprovides�the�color,�and�givesthe�basecoat�the�ability�to�hidewhat�is�underneath.�Axaltawaterborne�refinish�materials�havea�slightly�higher�pigmentationamount�that�allows�the�waterbornebasecoat�to�cover�with�fewer�coatscompared�to�their�solvent-borneproduct.�Other�paint�makers,such�as�AkzoNobel,�have�acomparable�pigmentation�amountbetween�their�solvent-borne�andwaterborne�refinish�materials.
• there�may�be�a�difference�infinal�film�thickness,�as�it�maybe�thinner,�thicker,�or�aboutthe�same�thickness�as�solvent-borne�material.�For�example,PPG�states�that�the�film�thicknessof�their�waterborne�basecoat�isabout�half�of�their�solvent-borne.Axalta�states�that�their�waterbornebasecoat�is�thicker�than�theirsolvent-borne.�1.5�-�2.5�coats�ofAxalta�waterborne�results�in�a�filmthickness�of�20�-�30��m,�whereas�ittakes�2�-�4�coats�of�their�solvent-borne�to�achieve�the�same�filmthickness.�Others,�however,�statethat�the�film�thickness�of�theirwaterborne�and�solvent-borne
Module�1�-�Waterborne�Refinish�MaterialsTextbook
Waterborne�Products,�Systems,�And�Application 15
products�is�similar.�AkzoNobel,for�example,�states�that�the�filmthickness�of�their�two�productlines�is�about�the�same.
• there�is�a�difference�in�appearancewhen�wet,�compared�to�solvent-borne�materials.
Waterborne�refinish�materials�are�made�with�a�latexresin�that�binds�together�as�the�moisture�evaporates.
Waterborne�refinish�materials�containwater,�water-soluble�solutions,�and�resins.Most�solvent-borne�automotive�refinishproducts�can�be�divided�into�one�of�eithertwo�basic�resin�types,�thermoplastic�orthermoset.
A�thermoplastic�coating:��
• may�be�reflowed�using�heat�ora�solvent.�A�dried�thermoplasticcoating�can�be�softened,�orreturned�to�liquid�state,�byreintroducing�solvents.��
• cures�by�solvent�evaporation.��• does�not�change�chemically�after
it�has�cured.��• is�prone�to�environmental�damage,
cracking,�checking,�and�shrinking.
A�thermoset�coating:��
• cannot�be�reflowed�by�heat�orsolvent�after�it�has�cured.��
• cures�by�a�catalyst�such�as�oxygenor�an�isocyanate.��
• chemically�changes�as�it�cures.
With�waterborne�refinish�materials:��
• a�latex�resin�is�used.�Latex�resinis�neither�a�true�thermoplasticnor�thermoset,�but�showscharacteristics�of�both.�Accordingto�one�paint�maker’s�technicalinformation,�the�latex�resin�doesnot�“reflow”�with�heat�or�solvent,but�will�“wash�off”�with�water�orsolvent�when�fresh.�Also,�oncethe�coating�flashes,�it�will�not�turnback�into�a�liquid.��
• as�the�water�evaporates,�the�latexparticles�form�and�bind�together.There�are�also�co-solvents�leftbehind�to�help�melt�the�resinparticles�together.�The�latexparticles�are�cell-like�structureswith�a�solid�core.�The�cell,�or�core,dissolves�outwardly�to�an�outershell�with�threadlike�“fingers”�or“tendrils”�that�bind�together.
These�cells�are�made�of�binder,�pigment,and�co-solvent�and�are�dispersed�in�thewater�that�serves�as�a�carrier.�As�the�waterevaporates,�the�cells�align�on�the�surfaceand�the�co-solvent�will�start�to�evaporate,link�the�cells�together,�and�create�the�paintfilm.�These�cells�have�an�identical�weight
Module�1�-�Waterborne�Refinish�MaterialsTextbook
Waterborne�Products,�Systems,�And�Application 16
so�they�do�not�sink�or�move,�creatinga�mottling�effect.�Mottling�is�when�themetallic�flakes�are�not�oriented�uniformlyor�evenly�on�the�panel.�It�typically�occursin�metallic�colors�and�appears�as�darkspots�or�blotches�in�the�color.
Personal�SafetyDue�to�the�latex�resins�used�in�waterbornepaints�and�primers,�latex�allergies�may�bean�issue�when�working�with�waterbornematerials.
Reducers�are�water-based�and�used�to�make�surethe�refinish�material�has�the�correct�viscosity�to�beproperly�sprayed.
With�waterborne�basecoats:
• specific�water-based�reducersact�as�a�carrier,�so�the�refinishmaterials�can�be�transferred�fromthe�spray�gun�to�the�surface�to�berefinished.
• reducer�helps�with�final�levelingand�allows�suspended�materials,such�as�metallics,�to�orientproperly�and�distribute�evenlyacross�the�surface.�Reducers�mayalso�be�referred�to�as�thinners.
• tap�water�should�not�be�used�toreduce�waterborne�basecoatsfor�spraying�because�it�contains
various�minerals�that�will�affectfinish�durability.�This�durabilitymay�not�be�apparent�immediatelyafter�applying�the�finish�or�afterthe�finish�has�dried.�Improperbinding�that�can�result�fromwater�contamination�may�causebasecoat�failure�well�after�thevehicle�has�been�delivered�to�thecustomer,�causing�an�increasedvolume�of�paint-related�warrantyclaims.�It�is�also�important�to�notethat�using�tap�water�to�reduce�thebasecoat�may�void�the�paint�makerwarranty.
• specific�water-based�reducersare�recommended�by�some�paintmakers.�For�example,�the�water-based�reducer�used�with�thePPG�system�is�PH�balanced,�de-ionized,�de-mineralized,�and�hasan�added�anti-fungal�agent.
With�traditional�solvent-borne�refinishmaterials,�a�petroleum-based�thinner�orreducer�is�used.�The�solvent�acts�as�both�areducer�and�carrier.
This�is�one�type�of�waterborne�basecoat�andbasecoat�activator.
Module�1�-�Waterborne�Refinish�MaterialsTextbook
Waterborne�Products,�Systems,�And�Application 17
Waterborne�automotive�refinish�materialsare�available�to�collision�repair�facilitiesfor�various�applications�such�as:
• primer-surfacer.• primer-sealer.• basecoat.• clearcoat.
Waterborne�basecoats�may�require�aspecific�type�of�clearcoat.�Depending�onthe�paint�maker,�the�clearcoat�may�haveto�be�chemically�compatible,�and�/�orVOC�compliant.�Be�sure�to�reference�thetechnical�data�sheet,�or�consult�with�thelocal�jobber,�to�determine�which�clearcoatis�recommended.
Manufacturers�of�waterborne�clearcoatproducts�include,�but�may�not�be�limitedto:
• AkzoNobel�(Sikkens�AutoclearWB).
• Lechler�(Hydrofan�ClearcoatHF950).
• PPG�(D8186�WaterborneClearcoat,�NEXA�AUTOCOLORWaterborne�ClearcoatP910-5510).
Proper�personal�protection�equipment�includes(clockwise)�a�supplied-air�respirator,�a�full�bodypaint�suit,�and�chemical-resistant�gloves.
Personal�SafetyIsocyanates�are�contained�in�catalyzedmaterials,�have�no�smell�or�taste,�and�areconsidered�a�severe�irritant.
It�is�important�to�be�aware�of�all�safetyconsiderations�when�working�withwaterborne�refinish�materials.�Aspreviously�mentioned,�waterbornebasecoats�still�contain�some�solventsand�other�hazardous�materials,�whichmay�include,�but�are�not�limited�to,�2-Butoxyethanol,�Ethylene�Glycol,�andPropylene�Glycol.
National�/�local�regulations�will�requireemployers�to�provide�the�properpersonal�protective�equipment�(PPE)to�protect�the�workers�from�potentialhazards.�Recommended�PPE�for�refinishtechnicians�include:
• respiratory�protection.�Supplied-air�respirators�provide�the�bestprotection�and�are�mandated�inmost�states�when�applying�refinishmaterials.
• eye�protection.
Module�1�-�Waterborne�Refinish�MaterialsTextbook
Waterborne�Products,�Systems,�And�Application 18
• chemical-resistant�gloves,�such�asnitrile.
• a�full-body�paint�suit.
Always�read�all�instructions�andcautions�before�using�waterbornerefinish�materials.�Safety�data�sheets(SDS)�and�product�information�sheetsare�good�sources�to�determine�PPErequirements�when�using�waterbornerefinish�materials.
When�there�are�activators,�isocyanatesmay�be�present�depending�on�the�paintmaker�material�specifications.
Why�Waterborne?
Reducing�the�amount�of�volatile�organic�compoundsin�refinish�materials�results�in�fewer�hazardous�airpollutants�released�into�the�atmosphere.
The�U.S.�Environmental�ProtectionAgency�(EPA):��
• has�identified�paint�strippingoperations�and�product�surfacecoatings�as�sources�of�hazardousair�pollutants�(HAPs).�Collisionrepair�and�refinishing�facilities�areincluded�in�these�HAP�sources.��
• defines�an�air�pollutant�as�anysubstance�in�the�air�that�isharmful�to�humans�and�/�orthe�environment.�The�HAPsare�emitted�when�the�refinishmaterials�are�atomized�duringspray�application,�and�during�theevaporative�drying�process.��
• focus�is�to�reduce�the�amountof�HAPs�emitted�into�theenvironment�by�recommendingalternative�methods�and�materials,such�as�the�use�of�waterbornerefinish�materials.
Waterborne�basecoat�contains�almost�half�theamount�of�VOCs�per�gallon�of�material.
Advantages�of�using�waterborne�basecoatsover�solvent-borne�basecoats�include�that:�
• they�emit�fewer�volatile�organiccompounds�(VOCs)�than�solvent-borne�basecoats,�and�thereforehelp�collision�repair�facilities�to�bemore�compliant�with�increasinglystringent�VOC�regulations.The�VOC�level�is�reduced�byalmost�one-half�compared�to
Module�1�-�Waterborne�Refinish�MaterialsTextbook
Waterborne�Products,�Systems,�And�Application 19
conventional�solvent-bornebasecoats.�The�VOCs:• in�refinishing�products�are
released�into�the�environmentwhen�solvents�in�the�productevaporate�during�the�dryingprocess.
• contribute�to�depletionof�the�ozone�layer,�smogproduction,�and�causeadverse�health�effects.�Usingwaterborne�refinish�materialsis�an�obvious�solution�toreducing�the�amount�ofVOCs�being�emitted�into�theenvironment.
• waterborne�basecoats�mayflash�faster�than�solvent-bornebasecoats.��
• there�is�improved�metallic�control.
Waterborne�At�The�OEM�Level
This�2006�Chevrolet�HHR�has�a�waterborne�finishapplied�by�the�vehicle�maker.
Several�vehicle�makers�are�usingwaterborne�technology�during�vehicleproduction.�Vehicle�makers�that�usewaterborne�basecoats�at�the�productionlevel�include,�but�may�not�be�limited�to:�
• Audi.��• BMW.��• Chrysler.��• General�Motors.��• Honda.��• Mercedes-Benz.��• Toyota.
Vehicle�makers�have�claimed�that�the�use�ofwaterborne�material�has�reduced�the�amount�ofenergy�used�during�the�refinishing�process.
In�addition�to�reducing�HAPs,�vehiclemakers�are�realizing�other�benefits�fromusing�waterborne�refinish�materials.�Somevehicle�makers�see�a�reduction�in�energyuse�with�waterborne�systems�comparedto�solvent-borne�systems�by�adjusting�thebake�cycle�on�the�assembly�line.
Based�on�performance�at�the�productionlevel,�some�vehicle�makers�considerwaterborne�finishes�to�have�a�betterappearance�than�solvent-borne�finishes.
Module�1�-�Waterborne�Refinish�MaterialsTextbook
Waterborne�Products,�Systems,�And�Application 20
Clearcoats
When�choosing�a�clearcoat,�stay�within�thepaint�line.�Some�clearcoat�chemistry�may�not�becompatible�with�other�paint�makers’�waterbornebasecoats.
Clearcoat�is�the�final�step�for�refinishing.Clearcoat�provides�the�gloss�for�the�finish,and�protection�from�UV�and�chemicaldamage.�When�using�waterbornebasecoat,�considerations�for�clearcoatapplications�include�that:
• the�clearcoat�may�be�specific�tothe�paint-system�line.
• the�clearcoat�will�berecommended�by�the�paint�maker.
• some�clearcoats�used�for�solvent-borne�may�not�be�recommendedfor�waterborne�refinish�materials.
Because�of�the�different�chemistriesbetween�waterborne�basecoats�andsolvent-borne�clearcoats,�it�is�less�likelythat�the�basecoat�will�move�with�a�run�inthe�clearcoat.�Always�check�the�materialtechnical�data�sheet�or�ask�a�jobber�aboutproduct�compatibility.
Module�Wrap�Up
Topics�discussed�in�this�moduleincluded:
• the�definition�of�waterbornerefinish�materials.
• differences�between�solvent-borneand�waterborne�refinish�materials.
• technical�characteristics�ofwaterborne�refinish�materials.
• what�waterborne�refinish�materialsare�available.
• why�waterborne�refinish�materialsare�used.
• vehicle�makers�use�of�waterbornerefinish�materials.
Module�2�-Waterborne�Refinish
Systems
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Module�2�-�Waterborne�Refinish�SystemsTextbook
Waterborne�Products,�Systems,�And�Application 23
Surface�Preparation�And�Equipment
Learning�objectives�for�this�moduleinclude:
• identifying�proper�surfacepreparation�steps.
• identifying�consumable�productsspecific�to�waterborne�refinishmaterials.
• determining�how�waterbornerefinish�materials�are�affected�bytemperature�and�humidity.
• listing�the�requirements�forwaterborne�spray�guns.
• listing�proper�mixing�andapplication�techniques.
• determining�how�air�movementaffects�drying.
• identifying�the�different�types�of�airmovement�equipment.
The�key�to�a�quality�finish�is�ensuring�the�panelsurface�is�smooth.
When�preparing�a�surface�for�refinishing,the�surface�that�will�have�the�basecoatapplied�must�be�as�close�to�flawlessas�possible.�With�waterborne�finishes,surface�defects�such�as�sandscratchesare�typically�more�visible.�These�defects
will�cause�the�metallic�flakes�to�liein�an�orientation�that�will�show�theimperfection.�These�cannot�be�buried�withthe�basecoat�and�clearcoat.�There�are�noshortcuts�when�working�with�waterbornerefinish�materials,�and�creating�a�nearlyflawless�surface�will�ensure�the�repair�areais�hidden.
To�help�eliminate�this�problem,�surfacesthat�will�have�basecoat�applied�must�besanded�according�to�the�paint�maker’srecommendations.�Grit�recommendationswill�depend�on�the�surface�material�beingsanded,�such�as�existing�finishes,�baremetal,�primer,�etc.�Grit�recommendationsmay�also�depend�on�the�equipmentbeing�used.�For�example,�when�applyingCromax�Pro,�Axalta�recommends�P500grit�when�using�a�DA�sander,�P600�gritwhen�hand�sanding,�and�P800�or�finer�ifwet�sanding.�Blend�panel�areas�will�needfiner�preparation.�For�example,�Sherwin-Williams�AWX�recommends�a�randomorbital�sander�using�P800�-�P1000�grit�forblend�areas.
Surface�cleaners�that�have�a�water�base�areavailable.
When�working�with�waterbornerefinishing�materials,�surface�cleaners
Module�2�-�Waterborne�Refinish�SystemsTextbook
Waterborne�Products,�Systems,�And�Application 24
must�also�be�used�to�clean�contaminantsfrom�the�panel�surface.�These�cleaners:��
• are�used�on�freshly�preparedsurfaces�before�the�basecoat�isapplied.��
• typically�have�a�water�base.��• must�be�totally�removed�before
the�application�of�the�basecoat.Failure�to�do�so�may�cause�finishdefects.�Additionally,�the�cleanershould�not�be�allowed�to�drybefore�being�wiped�off�the�panel.If�this�occurs,�more�cleaner�shouldbe�applied�and�wiped�from�thepanel�surface.�Be�sure�to�followthe�directions�as�stated�on�thetechnical�data�sheet.
Tack�cloths�used�with�waterborne�refinish�materialare�made�from�a�specific�fabric�that�does�not�createany�wipe�marks�on�a�panel�surface.
Similar�to�working�with�solvent-bornerefinishing�materials,�tack�cloths:��
• are�used�to�remove�contaminantsfrom�the�surface�being�refinished.��
• recommended�for�waterbornerefinish�materials�are�designed�tohelp�remove�surface�contaminants
without�leaving�any�wipe�marksin�the�area�being�refinished.Waterborne�basecoats�are�moresensitive�to�contaminationcompared�to�solvent-bornebasecoats�and�the�wipe�marks�canshow�through�the�new�finish�orcause�finish�defects.��
• of�a�specific�type�may�berecommended�by�the�paint�maker.If�no�tack�cloths�are�specificallyrecommended,�use�tack�cloths�thatare�compatible�with�waterbornefinishes.�This�may�be�indicated�bythe�tack�cloth�maker.
Spraybooths�must�be�able�to�reach�a�minimumtemperature�of�68°F�for�application�of�waterbornerefinish�materials.
In�regards�to�spraybooth�requirementsneeded�for�spraying�waterborne�refinishmaterials,�existing�spraybooths�that�canbe�set�to�reach�temperatures�of�68�-�75°Fcan�be�retrofitted�to�meet�the�needs�ofrefinishing�materials.�Retrofitting�mayinclude�installing�new�air:
• movement�systems.• hoses.• filters�or�upgrading�existing�filters
for�the�sprayable�air.
Module�2�-�Waterborne�Refinish�SystemsTextbook
Waterborne�Products,�Systems,�And�Application 25
Spraybooths�that�are�being�purchasednew�may�already�be�equipped�with�thenecessary�air�movement�devices�andheaters.�Waterborne�finishes�are�alsomore�susceptible�to�dirt�and�debris.Therefore,�spraybooth�cleanliness�is�vital.Areas�where�dirt�and�debris�can�hideare�called�dirt�traps.�These�areas�mayinclude:
• air�hoses.�To�help�controlcontaminants�in�a�spraybooth,replacing�the�air�hoses�may�behelpful.�When�to�change�the�airhoses�in�a�spraybooth�is�a�decisionbased�on�use�of�the�sprayboothand�the�contaminants�on�thehoses.
• spraybooth�walls.• air�movement�devices.�Whenever
equipment�is�added�into�thespraybooth�environment,�itprovides�another�rest�area�for�dustor�dirt.�Periodic�cleaning�of�theequipment�is�recommended�toreduce�finish�contamination.
In�a�typical�downdraft�spraybooth(without�an�air�movement�system),there�can�be�areas�where�there�is�verylittle�air�movement.�Dirt�and�debriscan�rest�in�these�areas�during�normaloperation.�However,�when�the�retrofittedair�movement�devices�are�engagedfor�the�first�time,�contaminants�thathave�been�resting�in�these�areas�will�belifted�up�and�can�settle�on�the�newlyapplied�refinish.�For�this�reason,�it�isimportant�to�thoroughly�clean�all�areasof�the�spraybooth�during�a�conversion�towaterborne,�such�as�walls,�corners,�andhoses.
Compressed�air�must�be�clean�and�dry.
Compressed�air�for�spraying�or�dryingwaterborne�material:��
• must�be�clean�and�dry,�free�of�oildroplets�and�oil�vapors.��
• may�require�additionalcompressed�air�volume,depending�on�the�design�and�/�ormaker�of�the�drying�system.��
• requires�proper�in-line�filters.
Three-stage�filters,�such�as�these,�are�used�to�providehigh�quality�air�for�spraying�waterborne�refinishmaterials.
Filter�requirements�for�removing�moistureand�contaminants�from�compressed�airinclude�a:��
Module�2�-�Waterborne�Refinish�SystemsTextbook
Waterborne�Products,�Systems,�And�Application 26
• 2-stage�minimum�to�dry�the�air.�A3-stage�filter�offers�better�dryingability.�Beyond�a�3-stage�filteringsystem,�other�systems�might�beavailable�and�offer�drier�air�withreduced�oil�vapors.��
• regular�change-out�schedule.�Thisis�critical.��
• 6�-�12%�acceptable�humiditylevel.�In�some�cases,�this�ispreferred.�Some�desiccant�airdryers�can�achieve�a�0.5%�relativehumidity�or�-40°F�dew�point.�Thedrier�the�air,�the�lower�the�dewpoint.�Paint�maker�representativesmay�have�access�to�an�airlinemoisture�tester.�Sprayboothcompressed�air�should�be�testedfor�excessive�moisture�andcontaminant�levels.
Like�most�types�of�filters,�compressedair�filters�also�have�life�spans�andlimitations.�By�locating�the�filters�as�closeto�the�spraybooth�as�possible,�cleaner,drier�air�can�be�available.�Excessivewater�contamination�from�compressedairlines�can�cause�improper�binding�ofwaterborne�basecoats�that�will�resultin�long�term�failure.�The�problem�withexcessive�or�contaminated�moisture�is�notalways�apparent�when�spraying.�Problemswith�the�finish�may�appear�well�afterthe�vehicle�is�released�to�the�customer,potentially�creating�a�high�volume�ofpaint-related�warranty�claims.
Mixing�sticks�made�from�plastic�or�steel�arerecommended�for�mixing�waterborne�basecoats.
Mixing�sticks�for�waterborne�materialsshould:��
• not�be�wooden.�Wooden�mixingsticks�are�not�recommendedbecause�the�dry�wood�can�absorbparts�of�the�refinishing�materialand�alter�the�color.�Additionally,waterborne�basecoats�canpotentially�draw�sap�out�of�awood�mixing�stick�and�createcontamination�issues.��
• be�metal�or�plastic,�as�they�do�notabsorb�any�materials.
Paint�mixing�strainers�should�be�between�125�-�200microns.
Module�2�-�Waterborne�Refinish�SystemsTextbook
Waterborne�Products,�Systems,�And�Application 27
Choosing�the�proper�strainer�can�becritical�to�achieving�a�proper�waterbornefinish.�Strainers�that�have�screenswith�holes�that�are�larger�than�therecommended�micron�size�will�not�filterout�the�impurities.�These�impurities�willshow�up�in�the�finish.�Holes�that�are�toosmall�will�not�work�well�with�the�thickerviscosity�associated�with�waterbornematerials.
When�straining�waterborne�refinishingmaterials,�the�recommended�strainer�typeis�listed�on�the�paint�maker’s�technicaldata�sheet.�Most�strainers�for�waterbornefinishes�are�recommended�to�be�125�-�200microns.�Strainers�used�with�waterbornematerial�have�more�surface�area�thanthose�used�for�solvent-borne�material.
When�using�a�strainer�that�is�separatefrom�the�paint�cup,�such�as�a�typicalpaper�strainer,�make�sure�the�straineris�compatible�with�waterborne�refinishmaterials.�If�it�is�not,�the�glue�may�softenand�/�or�the�paper�may�get�soggy�as�therefinishing�materials�pass�across�thefilter.
Strainers�can�be�built�into�the�disposable�cup�lid,straining�the�material�as�it�is�being�delivered�to�thespray�gun.
Some�strainers�may�be�built�into�adisposable�cup�lid.�This�requires�specificlids�depending�on�the�paint�maker’srecommended�micron�size.�Other�systemswill�provide�the�screen�separate�from�thelid.
Some�built-in�strainers�may�be�specificto�a�paint�system,�spray�gun�maker,�orequipment�maker.
One�example�of�a�spray�gun�makerthat�has�a�built-in�strainer�is�3M.�SATAprovides�screens�separate�from�the�lid.
Masking�material�should�be�resistant�to�moisture.
The�recommended�masking�for�usewith�waterborne�materials�is�similar�tothat�used�for�applying�solvent-bornematerials.�The�main�concern�is�to�usemasking�material�that�will�not�becomewaterlogged.�This�can�cause�the�refinishmaterial�to�bleed�through�the�masking�andcontaminate�the�existing�finish.
To�avoid�this,�use�coated�or�treatedmasking�materials.
Module�2�-�Waterborne�Refinish�SystemsTextbook
Waterborne�Products,�Systems,�And�Application 28
Spray-on�masking�can�be�used,�however,generally�it�should�not�be�used�adjacent�tothe�panel�being�refinished.
Using�a�quality�masking�tape�ensures�the�tape�isdurable�against�the�high�moisture�content�of�thewaterborne�refinish�material.
Masking�tape�could�possibly�beoverlooked�as�a�critical�part�of�awaterborne�refinishing�process.�A�name-brand,�quality�masking�tape�should�not�beadversely�affected�by�waterborne�refinishmaterials.�Using�economy�masking�tapecan�lead�to�problems�with�adhesion.�Low-tack�tape�is�available�for�use�over�freshlyrefinished�surfaces.
Shaking�the�basecoat�material�by�hand�may�berecommended�by�the�paint�maker.�Refer�to�thetechnical�data�sheets�for�recommended�mixingtechniques.
Some�waterborne�refinish�material�mixingtechniques�to�consider�may�include:��
• determining�if�the�productcan�be�shaken�or�stirred.�Thisrecommendation�is�particularto�certain�paint�makers.�Somepaint�makers�do�NOT�recommendshaking�on�a�paint�shakingmachine�as�the�material�mayfoam.�The�technical�data�sheet�forNexa�Aquabase�Plus�waterbornebasecoat�states�to�NOT�shake�theproduct�after�the�toners�have�beenmixed.�Stir�only.��
• mixing�and�storing�in�corrosion-resistant�containers.��
• making�sure�additives�are�mixedin�the�proper�order.�Depending�onthe�product�maker,�failure�to�doso�may�cause�the�refinish�materialto�clump,�causing�problems�withsprayability.
Some�paint�makers�recommend�thebasecoat�be�shaken�and�/�or�stirredimmediately�after�the�additives�and�tintsare�poured�into�the�cup.�Letting�thematerial�sit�may�cause�the�different�partsto�separate�permanently.�For�materialsavings,�make�sure�to�mix�only�enoughrefinish�materials�for�the�panels�beingsprayed.�Some�paint�makers�providea�mixing�chart�that�shows�how�muchmaterial�to�make�based�on�the�panelsbeing�refinished.
Module�2�-�Waterborne�Refinish�SystemsTextbook
Waterborne�Products,�Systems,�And�Application 29
DuPont�and�PPG�waterborne�basecoats�areexamples�of�pre-mixed�basecoat�materials.
Waterborne�basecoats�may�be�providedas�pre-mixed�or�not�pre-mixed.�Basecoatsthat�do�not�have�the�reducer�/�mixingbase�added�are�not�pre-mixed.�Theyare�essentially�pigment�and�solvent.�Anadvantage�to�this�is�that�the�product�canbe�shipped�and�stored�without�potentiallyfreezing.�Reducer�/�mixing�base�must�beadded�during�the�mixing�process.
Waterborne�basecoats�that�are�shippedpre-mixed�have�the�reducer�/�mixing�baseadded.�This�saves�time�during�the�mixingprocess,�but�also�makes�the�productsusceptible�to�freezing�during�shippingand�storage.
For�example,�PPG�waterborne�basecoat�isprovided�pre-mixed,�while�the�BASF�90-Line�is�not�pre-mixed.
Both�types�of�products�(pre-mixed�and�notpre-mixed)�require�additional�reductionbefore�the�material�is�sprayed.�Theamount�used�is�dependent�on�the�ambienttemperature�and�humidity.
The�optimum�temperature�for�applying�waterbornerefinish�materials�is�68�-�75°F.
Temperature�considerations�include:��
• spraying�materials�in�an�optimumtemperature�range�of�68�-�75°F.However,�in�warmer�climateswhere�temperature�cannot�becontrolled,�the�basecoat�may�needadditional�or�a�different�reducer�tocompensate�for�the�effect�of�highertemperatures.��
• a�shorter�flash�time�with�highertemperatures.�Some�paint�makersstate�that�the�basecoat�may�skinover�with�higher�temperatures,�orif�forced�air�is�applied�too�quicklyafter�basecoat�application.�Toprevent�this�from�happening,�makesure�to�add�the�proper�type�andamount�of�reducer,�and�follow�theproduct�maker’s�recommendationsfor�applying�forced�air.�Sherwin-Williams�states�to�wait�1�-�2minutes�before�application�offorced�air�after�application�of�theirbasecoat.�This�allows�the�particlesto�come�in�close�contact�beforethe�solvent�begins�to�evaporate.Failure�to�do�this�may�result�insmall�voids,�which�will�show�upwhen�the�clearcoat�is�applied.��
Module�2�-�Waterborne�Refinish�SystemsTextbook
Waterborne�Products,�Systems,�And�Application 30
• a�longer�flash�time�with�lowertemperatures.�Realize�that�thechances�of�finish�contaminationincrease�with�a�longer�basecoatdry�time.
For�Aquabase�Plus�Basecoat�(metallic),�intemperatures�above�95°F,�an�additional10�-�15%�reducer�may�be�added�to�helpwith�application,�metallic�orientation,�andoverspray�absorption.
In�general,�cold�creates�more�applicationproblems�than�too�much�heat.
A�viscosity�cup�is�required�to�ensure�the�refinishmaterial�is�the�proper�viscosity�in�relation�to�thespraybooth�temperature�and�humidity.
When�spraying�waterborne�refinishmaterials,�the�vehicle�or�part�must�be�ator�above�the�recommended�temperature.The�refinish�material�may�not�dryefficiently�if�the�surface�is�not�at�therecommended�temperature.�A�noncontactthermometer�may�be�used�to�determinepanel�temperature.
If�the�vehicle�panel�or�ambient�air�isbelow�60°F,�the�refinish�material�may�taketoo�long�to�dry.�This�can�cause�the�newlyapplied�finish�to�run�or�sag.
Many�paint�suppliers�/�jobbers�can�supplya�chart�with�reducing�recommendationsthat�also�include�reducing�using�aviscosity�measuring�cup.�A�viscositymeasuring�cup�is�used�to�measure�theviscosity�of�refinish�materials.�This�isdone�by�the�refinish�technician�clockingthe�amount�of�time�it�takes�for�refinishmaterial�to�flow�through�the�hole�in�thebottom�of�the�viscosity�measuring�cup.�Forexample,�Standox�has�a�recommendationthat�in�lower�humidity�conditions,�therefinish�material�viscosity�should�take�20�-23�seconds.�In�high�humidity�conditions,the�refinish�material�viscosity�should�take24�-�26�seconds.
Makers�of�viscosity�measuring�cupsinclude:��
• Ford.��• FRIKMAR.��• Gardco�/�Fisher.��• SATA.��• Shell.��• Zahn.
Some�of�the�charts�also�denote�properneedle�and�cap�size�and�the�suggestedreduction�rate.
Module�2�-�Waterborne�Refinish�SystemsTextbook
Waterborne�Products,�Systems,�And�Application 31
Hygrometers�such�as�this�are�available�to�measurespraybooth�humidity.
Humidity�is�a�variable�when�sprayingwaterborne�refinish�materials.�Whenconsidering�humidity:��
• the�optimum�spraying�humidity�is30�-�60%.
• too�much�or�too�little�humidityaffects�the�drying�time.�Sincehumidity�in�the�sprayboothtypically�cannot�be�adjusted,�paintmakers�may�provide�charts�onthe�amount�of�reducer�to�addto�compensate�for�variations�inhumidity�and�/�or�temperature.Lower�humidity�may�requireadditional�reducer.�Followingthese�recommendations�willensure�the�refinishing�materialdries.
• remember�that�compressed�airthat�has�too�much�humiditycan�cause�increased�dryingtime.�Occasionally�test�thecompressor�air�to�determine�if�thefilters�and�dryers�are�operatingproperly.�Humidity�is�tested�usinga�hygrometer.
Also,�higher�viscosity�(thicker)�basecoatmay�be�recommended�in�humidsituations.
According�to�Standox,�relative�humiditybetween�30�-�60%�is�ideal�and�willrequire�the�addition�of�10%�reducer.Lower�relative�humidity�will�require�15%reducer,�while�a�higher�relative�humidityrequires�5%�reducer.
Refer�to�Module�2,�“Demonstration:Sherwin-Williams�AWX�Solvent�SelectionChart”�in�the�presentation�for�an�exampleof�the�Sherwin-Williams�AWX�solventselection�chart.
Refer�to�“Video:�Repair�FacilityEquipment”�in�the�presentation.�Thisvideo�shows�examples�of�equipment�and
Module�2�-�Waterborne�Refinish�SystemsTextbook
Waterborne�Products,�Systems,�And�Application 32
consumables�required�when�working�withwaterborne�refinish�materials.
Spray�Guns
This�spray�gun�has�corrosion-resistant�parts�so�canbe�used�for�waterborne�application.
There�are�special�considerations�whenselecting�a�spray�gun�for�waterbornerefinish�materials.�Waterborne�spray�guns:�
• must�have�corrosion-resistantparts.�Some�solvent-borne�sprayguns�may�be�retrofitted�withcorrosion-resistant�parts,�such�asthe�cap�and�needle,�rather�thanpurchasing�a�new�spray�gun.��
• may�be�used�to�spray�solvent-borne�materials�and�vice�versa.When�switching�between�solvent-borne�and�waterborne�refinishmaterials,�the�spray�guns�shouldbe�flushed�with�the�same�type�ofmaterial�that�will�be�sprayed,�anddried�thoroughly.�For�example,water�is�used�with�waterborne,solvent�is�used�with�solvent-borne.Interchanging�the�materials�willcause�sludge�to�form�inside�thespray�gun.�Having�dedicatedspray�guns�for�waterborne�refinishmaterials�may�be�the�best�way�to
avoid�cross-contamination�withsolvent-borne�refinish�materials.Do�not�use�compressed�air�duringthe�solvent-borne�flushing�processto�minimize�VOC�emissions.��
• must�have�fluid�tips�that�are�theproper�diameter.�Spray�gunsshould�be�cleaned�immediatelyafter�use.�If�waterborne�refinishmaterials�dry�inside�the�spray�gun,acetone�is�required�to�loosen�thedried�material.�Proper�cleaningof�the�spray�gun�can�ensurelongevity.
This�spray�gun�has�corrosion-resistant�parts�so�it�canbe�used�for�waterborne�application.
Spray�guns�for�waterborne�refinishmaterials:��
• have�a�needle�and�nozzle�typicallymade�of�stainless�steel.��
• have�paint�cups�that�are�plastic�orstainless�steel.�Most�plastic�paintcups�are�disposable,�reducing�theamount�of�cleanup�required.��
• are�typically�not�aluminum.Aluminum�may�corrode�overtime�from�repeated�exposure�towaterborne�refinish�materials.�It
Module�2�-�Waterborne�Refinish�SystemsTextbook
Waterborne�Products,�Systems,�And�Application 33
is�important�to�follow�the�spraygun�maker's�procedures�to�avoidpremature�corrosion.
Refer�to�“Video:�Spray�Guns”�in�thepresentation.�This�video�shows�a�typicalwaterborne�spray�gun�that�is�available�forspraying�waterborne�materials.
The�air�caps�on�spray�guns�may�be�nickel�plated�toprevent�corrosion.
Spray�gun:
• fluid�tips�are�1.2�mm�-�1.5mm.�According�to�SATArecommendations,�when�thetemperature�is�higher�than�90°F,with�less�than�10%�humidity,fluid�tip�size�should�be�increased
to�one�size�larger�than�normalrecommendations.
• air�caps�are�typically�coated�with�anickel�plating�on�the�outside,�andbrass�on�the�inside.�This�specialcoating�helps�when�cleaningwaterborne�refinishing�materialsfrom�the�spray�gun�in�addition�toproviding�corrosion�resistance.
• parts�are�specially�coated�to�helpwith�ease�of�cleaning.
Refer�to�Module�2,�“Demonstration:SATA�Fluid�Tip�Recommendations”�in�thepresentation�for�an�example�of�differentfluid�tip�recommendations.
Refer�to�“Video:�Spray�Gun�Fluid�Tips”�inthe�presentation.�This�video�shows�howfluid�tips�on�waterborne�spray�guns�differslightly�compared�to�spray�guns�used�forsolvent-borne�material.
Module�2�-�Waterborne�Refinish�SystemsTextbook
Waterborne�Products,�Systems,�And�Application 34
Use�the�recommended�waterborne�cleaning�solventto�clean�the�spray�gun.
When�cleaning�the�spray�gun:
1. Clean�the�spray�gun�immediatelyafter�use.�If�a�spray�gun�is�left�tosit�with�refinishing�material�stillinside,�the�waterborne�materialmay�etch�the�inner�surfaces,making�future�cleaning�difficult.�Itmay�be�recommended�to�preventcleaning�solution�from�enteringthe�air�passage.�This�prevents�anyetching�of�the�air�passage�walls.
2. Clean�the�spray�gun�with�the�paintmaker’s�recommended�solution.If�the�proper�solution�is�not�used,note�that�some�cleaning�solventsmay�cause�foaming�in�some�spraygun�washers.
3. Use�compressed�air�to�dry�theinside�and�outside�of�the�spraygun.
If�switching�from�solvent-borne�towaterborne�material,�or�vice�versa,�makesure�the�spray�gun�is�properly�flushed�anddried�thoroughly�before�use.�Failure�to�doso�can�alter�the�new�refinish�material�andcreate�sludge�in�the�spray�gun.
Spray�gun�washers�may�be�equipped�with�stainlesssteel�parts�so�they�are�compatible�with�waterbornematerial.
Spray�gun�washers�may�be�speciallydesigned�for�waterborne�material.�Theseinclude�automatic�or�manual�spray�gunwashers.
Some�spray�gun�washers�may�have�specialcleaning�features.�For�example,�BECCAautomatic�spray�gun�washers�come�withPower�Clean�and�Power�Clean�Plusfeatures,�which�use�pulsating�air�in�theair�passage�and�fluid�in�the�fluid�passageto�completely�clean�the�spray�gun.�Thiseffectively�cleans�the�needle�and�fluidnozzle�of�the�spray�gun�with�cleaningsolution�while�putting�compressed�air�intothe�air�passages.
Currently,�some�spray�gun�washerscan�be�used�to�clean�either�solvent-borne�material�or�waterborne�material,depending�on�which�material�the�systemis�set�up�to�clean.�It�is�important�that�spraygun�washers�used�to�clean�waterbornerefinish�materials�have�corrosion-resistantparts.
Module�2�-�Waterborne�Refinish�SystemsTextbook
Waterborne�Products,�Systems,�And�Application 35
Some�spray�gun�washer�makers,�suchas�BECCA,�and�paint�makers,�such�asAkzoNobel,�Axalta,�and�PPG,�recommendusing�separate�cleaning�machines,�one�forwaterborne�refinish�materials,�and�one�forsolvent-borne�refinish�materials.
Refer�to�“Video:�Spray�Gun�Cleaning”�inthe�presentation.�This�video�shows�theimportance�of�cleaning�the�spray�gunwith�the�proper�cleaning�methods�andmaterials.
Flocculating�powder,�also�called�coagulating�powder,is�used�with�spray�gun�washer�systems�to�removesolids�from�the�filtrate.
Flocculating�powder�can�be�used�to�helpseparate�solid�waste�from�the�spray�guncleaning�solution�(filtrate).�Flocculatingpowder�causes�paint�waste�to�clumptogether�(coagulate)�and�can�be�strained
from�the�cleaning�solution.�Removing�thepaint�waste�from�the�spray�gun�cleaningsolution�extends�the�life,�potentiallyreducing�hazardous�waste�disposal�costs.Cleaning�solution�can�be�reused�until�itbecomes�tacky�to�the�touch.�Flocculatingpowder�is�effective�for�the�treatment�ofwaterborne�waste�only�and�should�not�beused�with�solvent-borne�waste.
Steps�for�adding�flocculating�powder:
1. When�the�reservoir�is�full,�add�theappropriate�amount�of�flocculatingpowder�as�per�the�manufacturer’srecommendations.
2. Mix�thoroughly�with�a�rotarymixer�for�5�-�10�minutes.
3. Let�the�coagulated�solid�wastematerial�separate�from�thecleaning�solution�for�5�-�10minutes.
4. Filter�the�solid�waste�from�thecleaning�solution�and�follow�localwaste�handling�laws�for�disposal.
Clarification�chemicals�can�be�used�toseparate�solid�waste�from�the�cleaningsolution�in�systems�where�continuousfiltration�is�used.�A�clarifying�chemical�isadded�to�cause�the�remaining�pigment�inthe�material�to�become�heavy�and�settleto�the�bottom�of�the�collection�container.This�“clarifies”�the�cleaning�solution�forcontinual�use.
Steps�for�clarifying�the�cleaning�solutionin�an�automatic�spray�gun�washer�withfilters:
Module�2�-�Waterborne�Refinish�SystemsTextbook
Waterborne�Products,�Systems,�And�Application 36
1. Follow�the�equipment�maker’sinstructions.�When�theclarification�chemical�is�addedto�the�spray�gun�washer,�it�slowlydissolves�into�the�cleaningsolution,�allowing�the�clarifyingchemical�to�react�with�theremaining�solid�pigment.�Thismakes�the�pigment�heavy�andsettle�to�the�bottom,�providinga�clear�cleaning�solution�forcontinual�spray�gun�cleaning.
2. The�spray�gun�washer�may�be�usedduring�this�process.�It�typicallytakes�about�an�hour�for�theclarifying�process�to�occur.
3. Cleaning�of�the�collectioncontainer�will�be�necessary�afterbuildup�of�the�solid�material.Follow�local�waste�handling�lawsfor�disposal.
Bonny�Marlin�has�a�dual-purpose�gun�washer�thatallows�cleaning�either�solvent-borne�paint�guns�orwaterborne�paint�guns�in�the�same�cleaning�solution.
At�least�one�spray�gun�washer�is�marketedas�a�dual-purpose�machine.�Accordingto�the�equipment�maker,�with�thistype�of�system�both�solvent-borne�andwaterborne�refinish�equipment�may�be
cleaned�in�the�same�fluid.�There�is�nolacquer�thinner�required�to�clean�up�thesolvent-borne�materials.
The�solution�used�for�cleaning�is�neverdiscarded,�but�requires�about 2�quartsto�be�added�weekly.�According�tothe�equipment�maker,�this�results�in�acleaning�solution�that:��
• is�nonflammable.��• has�zero�HAPs.��• has�low�VOCs.
This�system�is�air�operated�and�requires�noelectric�hookup�or�venting.�The�cleaningsolution�is�filtered�while�it�is�being�used.
Every�1�-�2�months,�the�cleaning�solutionis�drained�into�buckets�so�the�basin�can�becleaned�and�the�pre-filter�changed.
Some�areas�of�the�U.S.,�such�as�southernCalifornia,�may�prohibit�the�use�ofthis�type�of�gun�washer�as�it�does�notmeet�specific�VOC�requirements.Research�local�and�state�regulations�whenpurchasing�a�gun�washer�to�ensure�VOCcompliance.
The�name�of�this�system�is�Bonny�Marlin.For�more�information�on�this�system,access�www.bonnymarlin.com.
Module�2�-�Waterborne�Refinish�SystemsTextbook
Waterborne�Products,�Systems,�And�Application 37
Primers
Waterborne�primers�that�are�available�includeprimer-surfacers�and�primer-sealers.
Some�waterborne�primers�include:
• primer-surfacer.• primer-sealers.
When�working�with�primer-surfacers,surface�preparation�is�key.�Make�sure�thepanel�surface�is�properly�cleaned�andsanded,�generally�using�P180�-�P320grit,�depending�on�the�product�maker’srecommendations�and�surface�type�(bodyfiller,�refinished�panel,�or�bare�steel).�Paintmakers�may�recommend�a�surface�prep,such�as�etch�primer,�before�applying�aprimer-surfacer.
For�application�of�primer-surfacers�orprimer-sealers,�inlet�air�pressure�of�35�-45�psi�on�conventional�spray�guns�is�fairlycommon,�and�around�30�psi�for�high-volume�low-pressure�(HVLP)�(around�10psi�at�the�air�cap).�Refer�to�the�productmaker’s�technical�data�sheet�for�specificrecommendations.
Generally�1�-�3�coats�of�primer-surfaceris�acceptable,�with�a�flash�time�betweeneach�coat.�Recommended�film�thicknessvaries.�Some�product�makers�recommend
1.6�-�1.8�mils�while�another�recommends2.0�-�2.5�mils.
For�primer-sealer,�such�as�Sherwin-Williams�Aqua�Seal,�one�medium�wetcoat�is�acceptable�with�a�film�buildof�0.5�-�1.5�mils.�If�a�second�coat�isdesired,�make�sure�the�first�coat�has�driedbefore�application.�There�are�similarrecommendations�for�Nexa’s�AutocolorHS�Plus.
Drying�time�for�primer-surfacers�or�primer-sealers�depends�on�the�drying�method–�either�air�dry,�forced�dry�(heat),�orinfrared.
Primer-surfacer�and�primer-sealer�are�available�as�awaterborne�product.
Waterborne�primers�may�be�able�to�beapplied�to�bare�steel,�or�used�as�a�barriercoat.�When�applying�to�bare�steel,�thesurface�is�cleaned�with�a�wax�and�greaseremover.�Sherwin-Williams�states�thattheir�Aqua-Fill�1K�waterborne�primer-surfacer�is�recommended�over�repairareas�where�there�is�the�chance�of�theundercoat�primer�lifting,�edge�mapping,�orsimilar�defects.
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If�an�etching�primer�is�used,�do�not�applywaterborne�basecoat�on�top�of�the�etchingprimer.�A�primer-sealer�should�be�appliedover�the�top�of�the�etch�primer.
Depending�on�the�paint�system�beingused,�waterborne�primers�may�betintable.
If�a�waterborne�basecoat�is�being�applied,a�waterborne�primer�is�not�required,�aslong�as�the�materials�being�applied�arecompatible�within�the�specific�system.
Application�Consideration
Spray�techniques�only�need�to�be�slightly�modifiedfor�spraying�waterborne�refinish�material.
Just�like�spraying�solvent-borne�materials,there�are�a�number�of�applicationconsiderations�for�waterborne�refinishmaterials.�Application�considerations�forspraying�waterborne�refinish�materialsare�similar�to�solvent-borne�materials,including:
• using�sprayout�panels�to�helpdetermine�color�match.
• surface�preparation.�Make�sure�thearea�to�be�refinished�is�properlysanded,�cleaned,�and�primed.
• overlap�percentage.• the�use�of�a�control�coat�when
spraying�metallics�or�pearls.
Using�proper�spraying�technique�will�helpachieve�proper�film�build�and�a�nearlyinvisible�blend�area�if�blending.
Blending�basecoats�for�waterborne�requires�similartechniques�to�those�used�for�solvent-borne.
Other�spray�application�considerationsinclude:
• understanding�how�the�color�ofthe�basecoat�will�change�as�itdries.
• having�the�correct�air�movementto�ensure�the�proper�dryingprocess.
• using�a�blending�techniquethat�the�refinish�technician�iscomfortable�with.�The�blendingtechniques�are�similar�to�solvent-borne�blending.
• using�a�clearcoat�that�isrecommended�for�the�refinishingsystem�being�used.
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Waterborne�Products,�Systems,�And�Application 39
Basecoat�material�should�be�applied�6�-�8"�from�thepanel�surface�using�a�75�-�80%�overlap.
Spray�gun�distance�when�sprayingwaterborne�refinish�materials�is�about�thesame�as�for�spraying�solvent-borne�refinishmaterials,�6�-�8".�This�may�be�true�for�mostproducts,�but�not�for�all.�Requirementsmay�differ�by�paint�maker.
Just�like�with�solvent-borne�refinishingmaterials,�most�paint�makers�recommendusing�a�75%�-�80%�overlap�when�sprayingwaterborne�basecoat.
A�control�coat�is�used�to�make�sure�the�metallicflakes�are�properly�oriented.
A�control�coat�is�used�when�sprayingmetallics�to�ensure�that�the�metallic�flakesare�properly�oriented.�A�control�coat�is
not�required�when�applying�solid�colorbasecoats.�Make�sure�the�basecoat�hasflashed�off�before�applying�the�controlcoat.�When�applying�a�control�coat:
• apply�the�material�at�85%�-�90%overlap,�and�reduce�inlet�airpressure�for�the�spray�gun�byabout�40%.�Requirements�maydiffer�by�paint�maker.
• the�spray�gun-to-work�piecedistance�is�about�10"�-�12".
• apply�the�material�for�completecoverage.
• the�finish�will�have�a�mottledappearance�until�the�materialdries.
• the�material�should�look�flat�anduniform�when�dry.
• some�paint�makers,�such�asSherwin-Williams�and�PPG,recommend�to�NOT�use�increasedairflow�for�drying.�Allow�thecontrol�coat�to�dry�naturally.
Waterborne�basecoat�sands�easily.
If�sanding�is�necessary,�waterbornebasecoat�sands�easily.�If�the�basecoatis�still�wet,�problems�may�be�washedoff�with�water.�However,�do�not�let�the
Module�2�-�Waterborne�Refinish�SystemsTextbook
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washed�off�refinish�material�drain�intothe�sewer.�The�best�method�is�to�wipe�therefinish�material�off�the�panel�surface�toavoid�waterborne�material�from�drippingon�the�floor.
According�to�PPG,�after�their�waterbornebasecoat�has�fully�flashed,�dry�sandingwith�P1000�-�P2000�grit�sandpaper�workswell�for�removing�imperfections.�Do�notuse�wet�sanding�with�PPG�waterbornebasecoat.�This�can�wash�off�the�freshwaterborne�basecoat.
According�to�Sikkens,�remove�dustparticles�from�their�waterborne�basecoatby�carefully�dry�sanding�with�P500�-�P600grit�sandpaper.�Dry�sanding�is�preferred.Wet�sanding�(although�not�recommended)can�be�done�using�a�minimum�amount�ofwater,�with�P1000�-�P1200�grit�sandpaper.Allow�sufficient�water�evaporation�timebefore�basecoat�application.
Make�sure�the�sprayout�panel�is�completely�drybefore�making�a�color�comparison.
Sprayout�panels�are�used�to:
• compare�basecoat�color�withthe�existing�color�on�the�vehicle.
Do�not�compare�wet�basecoatwith�dry.�Wet�basecoat�appearsdarker�than�dry�basecoat.�Somewaterborne�basecoats�may�havea�different�hue�when�applied,but�that�hue�disappears�when�thematerial�dries.�For�one�example,PPG�Envirobase�has�pigmentssuspended�in�a�blue�gel-likesubstance�that�gives�the�basecoat�alight-blue�tint�when�applied.�Afterthe�material�dries,�this�blue-liketint�disappears.
• make�new�in-house�color�chips.
When�using�waterborne�refinishingmaterials,�special�sprayout�cards�arerequired�that�are�resistant�to�water.�If�theseare�not�properly�coated�to�prevent�waterabsorption,�the�cards�tend�to�curl�as�theydry.
Do�not�use�a�covered,�wet�mixing�stick�toverify�color�match.�Many�basecoats�dryto�a�different�color,�using�a�wet�mixingstick�is�a�bad�choice�to�determine�colormatch.
Some�paint�makers�provide�pre-madesprayout�cards�/�color�variant�decks�tohelp�determine�color�match.�These�cardshave�the�color�match�code�on�the�card,which�is�used�with�the�paint�maker�systemto�determine�the�paint�formula.
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Refer�to�“Video:�Drying�WaterborneBasecoat”�in�the�presentation.�This�videodiscusses�on�how�waterborne�basecoatchanges�appearance�as�it�dries.
Blending�basecoats�requires�the�material�to�drybefore�applying�clearcoat.
When�blending�waterborne�basecoats:
• allow�the�basecoat�to�dry�beforeapplying�clearcoat.
• use�techniques�similar�to�thoseused�for�solvent-borne.
• apply�the�recommended�clearcoatfor�the�paint�system�being�used.
A�reverse-blending�technique�may�beconsidered.�Reverse�blending�is�done�byapplying�the�color�over�the�repair�areaand�blending�it�out�to�the�farthest�areas
on�the�first�or�initial�coat.�The�followingcoats�are�applied�in�smaller�sizes�insidethe�preceding�coats,�until�the�repair�areais�covered.�Determining�whether�or�notto�use�a�reverse�blend�is�specific�to�therefinish�technician’s�preference.�Somemay�feel�that�a�reverse�blend�works�best,while�others�may�have�success�with�atraditional�blending�technique.
Some�blends�may�require�a�blendingbed.�A�blending�bed�is�typically�atransparent�basecoat�with�no�pigment.It�is�applied�to�the�surrounding�areasand�adjacent�panels�where�blending�willbe�done.�The�blending�bed�is�typicallyapplied�to�the�complete�panel.�It�iscommonly�used�when�blending�metallicand�pearl�basecoats,�but�can�be�donewhen�blending�any�basecoat�color.
Refer�to�“Video:�Waterborne�FinishMixing�And�Application”�in�thepresentation.�This�video�shows�the�stepsand�techniques�for�mixing�and�applyingwaterborne�refinish�materials.
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Drying
This�shows�the�four�drying�phases�of�waterbornerefinish�material.
Drying�is�the�evaporation�of�carriermaterials�such�as�solvents�or�water,without�chemical�cross-linking�occurring.Waterborne�drying�occurs�as�the�carriermaterials�evaporate.�When�this�occurs,the�molecules�bind�together�to�form�asolid�film.
Curing,�which�occurs�in�solvent-basedrefinish�materials,�is�the�chemical�cross-linking�of�specific�particles�and�theevaporation�of�carrier�materials�such�assolvents.
Venturi�blowers,�handheld�or�mounted�on�a�stand,use�compressed�air�and�the�venturi�effect�to�createthe�necessary�air�movement�in�the�spraybooth.
For�the�drying�of�waterborne�basecoats�tooccur:
• large�volumes�of�air�movementare�required.�This�is�important�forimproved�cycle�times�since�lowerairflow�increases�the�evaporationtime.
• proper�turbulent�air�movementcan�reduce�dry�time�considerably.For�example,�airflow�at�250feet-per-minute�(fpm)�can�drywaterborne�basecoats�in�about�4minutes.�Sherwin-Williams�statesthat�when�their�AWX�product�drieswithout�the�forced�air,�it�may�takeup�to�10�minutes�to�dry�dust�free.With�venturi�blowers,�it�may�takeup�to�2�-�3�minutes�to�dry�dustfree.
• baking�of�the�basecoat�is�not�ascritical�as�air�movement.
• it�is�not�recommended�to�aim�theair�blowers�/�multipliers�directlyat�the�refinished�area�(90°�to�thepanel).�For�best�results,�angle�theblower�to�the�panel.
Air�movement�systems�should�not�beengaged�to�force�cure�solvent-basedclearcoats.�This�may�result�in�the�clearcoatskinning�over�and�cause�solvent�popping.Follow�the�curing�recommendations�thatare�stated�in�the�technical�data�sheets.
To�achieve�proper�drying�of�waterbornebasecoats,�there�are�various�types�ofdryers�available�for�moving�air.�Itemsto�consider�when�purchasing�airflowequipment�include�the:
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• cost�of�the�equipment.• energy�costs�for�operating�the
equipment.• acceleration�of�dry�times.• ease�of�use.• needs�of�the�paint�shop.�Choice�of
the�airflow�equipment�will�dependon�the�type�and�size�of�the�repair.For�example,�if�a�facility�spraysa�large�number�of�completes,�amore�elaborate�system�may�berequired.�But�if�most�of�the�work�isspot�repair,�a�more�modest�airflowsystem�may�be�adequate.
Infrared�heating�equipment�may�be�used�for�dryingwaterborne�refinish�materials.�Make�sure�the�paintmaker�recommendations�are�followed.
When�using�heat�for�drying�waterbornerefinishing�materials:
• follow�the�recommendationsby�the�paint�and�/�or�equipmentmaker�when�using�infrared�(IR)heating�equipment.
• heat�must�incorporate�airmovement.
• do�not�use�heat�lamps.�Heatlamps�can�cause�the�waterborne
basecoat�to�skin�over�and�trapwater�in�the�underlying�layer,causing�a�possible�blisteringproblem.
These�arrows�show�how�laminar�and�turbulent�airmovement�differ.
There�are�two�types�of�air�movement,�suchas:
• laminar.�Laminar�air�movementis�the�movement�in�a�uniformpattern�or�straight�path.�Laminarair�movement�is�the�type�foundin�the�traditional�sprayboothenvironment.
• turbulent.�Turbulent�airflow�isthe�erratic�and�non-uniformmovement�of�air.
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Refer�to�“Video:�Type�Of�Air�Movement”in�the�presentation.�This�video�shows�howturbulent�air�breaks�up�the�boundary�layerthat�seals�in�moisture�and�inhibits�thedrying�process.
Laminar�airflow�(top)�is�used�during�the�refinishmaterial�application,�and�turbulent�air�(bottom)�isused�during�the�flash�off�and�drying�cycle.
With�waterborne�refinishing�materials,there�are�guidelines�for�air�movementduring:
• application,�when�120�-�400�fpmof�laminar�air�is�recommended.
• the�flash�off�and�drying�cycle,when�200�-�600�fpm�of�turbulentair�movement�is�recommended.
Maintain�proper�distance�and�angle�to�ensuremaximum�efficiency�from�the�air�drying�system.
Not�enough�airflow�can�result�in�extendedwork�times�and�reduced�productivity.Another�negative�effect�of�extendeddrying�times�is�the�increased�possibility�ofcontaminants�in�the�wet�basecoat.
Too�much�airflow�may�displace�the�wetrefinishing�material.�Airflow�must�beproperly�directed�so�the�turbulent�air�doesnot�push�the�wet�refinishing�materials�outof�position.�The�air�movement�equipmentmust�also�be�a�specific�distance�from�thepanel�surface.
Air�Movement�Equipment
Wall-mount�air�multipliers�(left)�and�handheld�airmultipliers�(right)�provide�the�turbulent�air�necessaryfor�quick�drying�of�waterborne�refinish�materials.
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Types�of�air�movement�equipment�thatmay�be�used�for�drying�waterbornefinishes�include:
• handheld�air�multipliers�/�venturiblowers.
• high�speed�and�adjustable�ceilingfans.
• wall-mount�air�multipliers�ortowers,�which�also�have�venturiblowers.
Spray�guns�should�not�be�used�as�an�airmovement�system.�This�can�cause�thebasecoat�material�inside�the�spray�gunto�dry,�creating�a�spray�gun�maintenanceissue.
Compressed�air�is�required�for�operation�of�ahandheld�air�multiplier,�such�as�this,�which�mayrequire�upgrades�to�the�repair�facility�air�compressorto�handle�the�increased�load.
Handheld�air�multipliers�may�be�equipped�with�astand�(or�tree)�to�hold�up�to�two�air�multipliers.
Handheld�air�multipliers:
• make�use�of�compressedair,�therefore,�may�require�acompressor�upgrade�to�handleincreased�cfm�depending�on�howmany�multipliers�are�used.�If�thecompressor�is�able�to�handle�theincreased�cfm,�the�compressormay�run�longer�to�keep�up�withthe�increased�demand,�whichcan�cause�increased�wear�onthe�compressor.�One�equipmentmaker’s�ratings�are�that�each�airmultiplier�operates�at�a�rangeof�8�-�9�cfm�at�30�-�35�psi.�Thisvaries�slightly�according�to�eachequipment�maker.
• employ�the�venturi�effect�tomultiply�volume�/�velocity,which�can�be�up�to�12�times�theairflow�from�the�compressed�airsystem.�The�venturi�effect�can�bedescribed�as�an�increase�in�thevolume�/�velocity�of�air�passingthrough�a�constriction�due�tohigher�pressure�on�the�intakeside�of�the�constriction�and�lowerpressure�on�the�output�side�of�theconstriction.
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• are�moved�manually�over�thepanel�surface.�For�best�results,angle�the�air�multiplier�to�thepanel,�do�not�position�directly�atthe�panel.�Keep�the�air�multiplierapproximately�20"�-�40"�from�thepanel�surface.
• may�be�available�with�adjustablestands.
• have�a�debris�filter�in�back�of�themultiplier.
• are�generally�the�less�expensiveoption�compared�to�ceiling�fansand�the�wall-mounted�towers.
Refer�to�“Video:�Handheld�Air�MultipliersAnd�Compressed�Air�Requirements”�inthe�presentation.�This�video�discussesproper�techniques�for�using�a�handheldair�multiplier�and�the�considerations�forcompressed�air�requirements.
Refer�to�“Video:�Venturi�Effect”�in�thepresentation.�This�animation�shows�howthe�venturi�effect�multiplies�air�volume�/velocity.
Ceiling�fans�are�mounted�in�the�center�of�thespraybooth,�with�the�motor�located�outside�tocomply�with�fire�codes.
Spraybooth�ceiling�fans:
• have�bladed�fans�with�safetycages.�The�cages�provide�personalprotection�when�working�withhigher�profile�vehicles�such�astrucks�and�vans.
• move�around�ambient�air.• are�mounted�through�the�ceiling�in
the�center�of�the�spraybooth.• have�fan�motors�mounted�outside
of�the�spraybooth.
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• must�be�routed�around�thefire-suppression�system�in�thespraybooth.�Interference�withthe�fire-suppression�system�cantemper�the�effectiveness�of�thesystem.
• require�even�spacing�in�thespraybooth.�To�be�evenly�spacedduring�installation,�the�sprayboothair�plenum�in�the�ceiling�mayneed�to�be�modified.
The�fan�blades�can�be�dust�traps�and�should�becleaned�regularly�to�prevent�contaminants�fromfalling�on�a�freshly�painted�panel.
Considerations�for�spraybooth�ceiling�fansinclude�that:
• the�fan�blades�and�cages�shouldbe�cleaned�periodically.�Howfrequently�depends�upon�the�useof�the�spraybooth.
• they�should�not�be�run�whilespraying�waterborne�refinishmaterials.�This�can�affect�the�spraypattern�from�the�spray�gun.
Refer�to�“Video:�Ceiling�Fan�Installation”in�the�presentation.�This�video�will�showone�process�for�retrofitting�a�sprayboothwith�an�air�movement�system.
Wall-mount�air�multipliers�are�positioned�in�thecorner�of�the�spraybooth�and�have�adjustable�venturinozzles�that�should�be�positioned�to�optimize�airturbulence�on�the�vehicle�panels.
Wall-mount�air�multiplier�retrofits:
• are�installed�in�a�spraybooth,midway�between�the�floor�andceiling.
• generally�draw�from�ambient�air.A�squirrel�cage-type�fan�creates�airmovement�and�venturi�nozzles�areused�to�multiply�the�air�volume�/velocity.
• have�adjustable�nozzles.�Thenozzles�must�be�properly�directed
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to�optimize�drying�efficiency.In�some�instances,�nozzles�onopposite�sides�of�the�sprayboothcan�cancel�out�the�air�movement,creating�still�air�over�the�vehicle.
• are�typically�placed�in�thespraybooth�corners.
• should�be�cleaned�periodically.How�frequently�depends�upon�theuse�of�the�spraybooth.
Depending�on�the�requested�options,new�spraybooths�may�be�equipped�withthe�air�multiplier�systems�built�into�thespraybooth.
Wall-mounted�air�multipliers�installationconsiderations�include�the:
• wiring�requirements.• fire�code�considerations.
Infrared�lamps�are�typically�used�for�spot�repairoutside�the�spraybooth.
With�waterborne�systems,�infrared�(IR)lamps�are:
• combined�with�air�movementsystems,�but�not�inside�aspraybooth,�as�this�equipment�istypically�not�explosion�proof.
• generally�for�spot�repairs.• should�not�be�positioned
too�close�to�the�panel.Follow�the�equipment�makerrecommendations.�Triskrecommends�22�1⁄2"�-�24�1⁄2"�fromthe�panel.
Follow�the�paint�maker�recommendations�for�IRlamp�usage.
When�using�an�IR�lamp,�consider�that:
• PPG�states�that�if�using�IR�tocure�clearcoat,�the�basecoatshould�also�be�dried�with�IR.�Thisallows�any�residual�moisture�to�beremoved�from�the�basecoat�film.
• different�paint�makers�havedifferent�use�recommendations.For�example,�Sherwin-Williamsstates�that�a�waterborne�basecoatcan�be�dried�with�an�IR�lamp�at120°�-�140°F�for�5�-�10�minutes.For�waterborne�primer-surfacer,BASF�states�to�apply�IR�short�wave
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for�3�-�5�minutes,�and�apply�IRmedium�wave�for�10�-�15�minutes.
Module�Wrap�Up
Topics�discussed�in�this�moduleincluded:
• proper�surface�preparation�steps.• consumable�products�specific�to
waterborne�refinish�materials.• requirements�for�waterborne�spray
guns.• how�waterborne�refinish�materials
are�affected�by�temperature�andhumidity.
• proper�mixing�and�applicationtechniques.
• the�different�types�of�air�movementequipment.
• how�air�movement�affects�drying.
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Module�3�-�Storage,Waste�Disposal,And�Waterborne
Conversions
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Waterborne�Storage�Recommendations
Learning�objectives�for�this�moduleinclude:
• identifying�proper�storagetechniques�for�waterborne�refinishmaterials.
• identifying�problems�that�mayoccur�from�waterborne�refinishmaterials�stored�at�impropertemperatures.
• listing�proper�disposal�proceduresof�waterborne�waste.
• identifying�types�of�assistanceoffered�by�paint�companiesto�make�the�conversion�towaterborne.
• listing�steps�required�for�aconversion�to�waterborne.
When�storing�waterborne�refinish�material,�avoidexcessive�heat�and�cold.
When�choosing�a�storage�location�forwaterborne�refinish�materials,�note�that:
• the�optimum�storage�temperatureis�68°F.
• excessive�heat,�or�temperaturesbetween�102°�-�122°F�should�beavoided.
Proper�storage�of�waterborne�refinishmaterials�can�prevent�the�destruction�ofthese�materials�if�exposed�to�extremetemperatures.�For�example,�waterbornerefinish�materials�exposed�to�temperaturesover�140°F�may�be�unusable.
Because�of�the�water�factor,�waterbornerefinish�materials�are�packaged�and�storedin�corrosion-resistant�containers.
The�temperature�indicator�on�the�right�shows�whathappens�when�it�has�been�exposed�to�temperaturesbelow�freezing�for�a�short�period�of�time.
Because�of�the�high�water�content,�mostpre-mixed�waterborne�refinish�materialsare�susceptible�to�freezing�at�temperaturesbelow�32°F.�When�a�waterborne�materialhas�frozen,�a�change�in�the�productchemistry�occurs�that�typically�makesthe�product�unusable.�However,�someproducts�can�freeze�several�times�beforethe�product�should�not�be�used.�Forexample,�Sherwin-Williams�states�thattheir�product�can�freeze�and�thaw�upto�seven�times�before�the�product�isunusable.
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When�products�are�shipped,�they�may�beequipped�with�a�freeze�indicator�on�thebulk�packaging�that�changes�color�if�thematerials�were�exposed�to�below�freezingtemperatures�for�an�extended�period�oftime.�3M�makes�a�freeze�indicator�thathas�a�small�vial�of�red�material�that,�whenexposed�to�25°F�for�a�short�period�oftime,�the�vial�breaks�open�and�stains�thebacking�paper�red.
Some�products,�such�as�BASF,�are�shippedwith�no�water�added,�and�therefore�arenot�prone�to�freezing.�The�water�is�addedby�the�refinishing�technician�during�themixing�operations.�These�materials�maybe�called�“no-freeze”�or�“frost-resistant”products.
Basecoat�that�has�a�shift�in�color�or�hasstarted�to�gel�is�a�good�indication�that�thematerial�has�been�exposed�to�extremetemperatures.
This�is�a�mixing�bank�for�refinish�material�that�is�notpre-mixed.
As�with�solvent-borne�material,�a�mixingbank�stores�the�waterborne�toners.Depending�on�the�product�used,�themixing�bank�may�or�may�not�have�stir
paddles�to�agitate�the�toners.�Tonerswith�paddles�are�not�pre-mixed�withwater.�With�one�particular�mixing�banksystem�that�has�paddles,�the�paint�makerrecommends�engaging�the�stir�paddlesonce�every�4�hours�for�15�-�30�minutes.
If�the�product�is�pre-mixed�with�water,there�are�no�paddles,�and�the�mixing�bankresembles�a�bookshelf.�For�pre-mixedtoners,�a�simple�shake�of�the�canister�is�allthat�is�required�to�prepare�the�material�foruse,�rather�than�stirring�the�product.
Make�sure�to�check�with�the�technical�data�sheetregarding�the�shelf�life�of�reduced�and�not�reducedrefinish�materials.
As�a�general�rule,�the�shelf�life�forwaterborne�material�is�not�quite�as�longas�solvent-borne�material,�but�there�areexceptions.�Waterborne�shelf�life:
• varies�depending�on�each�productmaker.
• can�be�as�short�as�one�year,�to�avirtually�unlimited�shelf�life.
• is�considerably�shorter�after�thematerial�has�been�reduced.
Some�products�may�have�an�activator�/hardener�that�can�be�added.�When�this
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material�is�added�to�the�waterbornerefinish�material,�the�shelf�life�is�reducedto�minutes�or�hours�depending�on�thepaint�maker.
Refer�to�Module�3,�“Demonstration:�ShelfLife�Chart”�in�the�presentation�for�anexample�of�a�shelf�life�chart.
Waterborne�Waste�Disposal�Considerations
Waterborne�and�solvent-borne�waste�must�be�keptseparate.
Waterborne�refinish�material�waste�shouldbe�treated�like�a�hazardous�material.Waterborne�refinish�materials�still�containsolvents�and�other�hazardous�materials.When�disposing�of�waterborne�refinishmaterial:
• it�should�be�discarded�in�adesignated�corrosion-resistantwaterborne�waste�container.
• do�not�intermix�waterborneand�solvent-borne�waste.�The
processing�of�these�wastes�isvery�different.�Mixing�the�twotogether�may�create�a�wastethat�is�not�accepted�by�wastedisposal�companies.�For�example,aluminum�flakes�and�solvent-borne�refinish�materials�mixedwith�waterborne�refinish�materialsmay�form�hydrogen�gas�and�createan�explosion�risk.
Determining�disposal�methods�of�gun�washer�filtrateis�dependent�on�the�toxicity�of�the�filtrate�in�additionto�local�and�state�regulations.
The�spray�gun�washer�filtrate�will�vary�intoxicity�depending�on�if�a�flocculatingagent�is�used.�If�a�flocculating�agent�wasused�in�the�spray�gun�washing�system,�themajority�of�hazardous�refinish�materialshould�have�been�removed�by�filteringthe�filtrate.�In�some�instances,�this�wastecan�be�disposed�of�as�non-hazardouswastewater,�however,�state�and�localregulations�may�vary.�Regulations�mayrequire�the�wastewater�be�tested�todetermine�the�toxicity.
If�a�flocculating�agent�was�not�used,�thematerial�is�more�hazardous�and�should�betreated�as�controlled�waste.
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The�disposal�costs�between�solvent-borne�and�waterborne�may�differ,�withwaterborne�disposal�cost�generallyhigher.
Using�the�flocculating�agent�is�an�easyway�to�decrease�spray�gun�cleaner�costsand�hazardous�waste�disposal�costs.Coagulating�the�paint�waste�cleans�thefiltrate�in�the�spray�gun�washer,�allowingfor�the�filtrate�to�be�used�for�a�longerperiod�of�time�before�the�spray�gunwasher�is�drained�and�refilled.
Paint�sludge�collected�from�the�flocculating�processmust�be�treated�as�controlled�waste.
Paint�sludge�is:
• the�material�collected�after�thespray�gun�washer�filtrate�hasbeen�treated�with�the�flocculatingpowder.
• classified�as�“controlled�waste.”• disposed�of�in�accordance
with�local,�state,�and�regionalregulations.
Converting�To�Waterborne
Mixing�banks�and�air�movement�systems�may�besome�of�the�larger�investments�required�to�make�theconversion.
Converting�a�repair�facility�to�awaterborne�facility�is�not�a�complicatedprocess.�While�some�facilities�may�requirea�large�capital�investment,�most�are�ableto�do�it�with�little�to�moderate�expenseand�disruption.�The�amount�spent�varies,and�is�determined�by�a�facility’s�existingequipment.�Also,�there�are�different�toolsthan�traditionally�used,�such�as�strainers,mixing�sticks,�tack�cloths,�and�sprayoutcards.
Spray�guns�need�to�be�equipped�with�corrosion-resistant�parts.
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Filters�are�needed�to�remove�moisture,�oil,�and�oilvapors�from�the�spray�gun�airline.
Tack�cloths�used�with�waterborne�refinish�materialare�made�from�a�specific�fabric�that�does�not�createany�wipe�marks�on�a�panel�surface.
Waterborne�cleaning�solvent.
Masking�supplies�are�needed�that�hold�up�to�water.
Turbulent�air�may�be�supplied�with�venturi�blowersor�wall-mounted�air�multipliers.
Turbulent�air�may�be�supplied�in�the�form�of�ceilingfans.
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A�heated�spraybooth�is�needed�to�keep�thetemperature�consistent�for�waterborne�applications.
The�following�equipment�is�recommendedfor�a�waterborne�conversion:
• Spray�guns�equipped�withcorrosion-resistant�parts
• Filters�to�remove�moisture,�oil,and�oil�vapors�from�the�spray�gunairline
• Tack�cloths�that�do�not�leave�wipemarks
• Non-cellulose-based�wipes• Spray�gun�washer,�which
may�need�to�be�dedicated�towaterborne
• Cleaning�solvent• Masking�supplies�that�hold�up�to
water• Turbulent�air,�in�the�form�of�ceiling
fans,�venturi�blowers,�or�wall-mounted�air�multipliers
• Heated�spraybooth
The�conversion�process�can�take�verylittle�time�depending�on�the�equipmentbeing�installed.�In�some�instances,�theconversion�can�be�done�in�as�short�as�oneday.
On-site�support�is�often�provided�to�repair�facilitieslooking�to�make�a�changeover�to�waterborne�refinishmaterials.
Spraying�waterborne�material�is�not�muchdifferent�than�solvent-borne,�but�thereare�a�few�refinishing�techniques�that�areslightly�different.�All�paint�companies�offerproduct-specific�training�to�help�with�thistransition,�and�the�training�is�generallypart�of�the�I-CAR�Industry�TrainingAlliance,�meaning�I-CAR�credit�hours�canbe�obtained�upon�successful�completionof�the�training�and�submission�of�theIndustry�Training�Alliance�applicationform.
In�addition�to�the�training,�paintcompanies�offer�technical�support�hotlinesand�on-site�support.
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Refer�to�“Video:�Making�The�Conversion”in�the�presentation.�This�video�discusseshelpful�tips�that�can�be�used�if�consideringswitching�a�repair�facility�fromsolventborne�materials�to�waterbornematerials.
Almost�all�paint�makers�offer�waterborne�refinishmaterials�as�part�of�their�paint�line.
Makers�of�waterborne�refinish�materialsinclude,�but�are�not�limited�to:
• AkzoNobel.• BASF.• Axalta.• PPG.• Sherwin-Williams.• Standox.
Click�on�a�company�name�for�moreinformation.
Module�Wrap�Up
Topics�discussed�in�this�moduleincluded:
• proper�storage�techniques�forwaterborne�refinish�materials.
• problems�that�may�occur�fromwaterborne�refinish�materialsstored�at�improper�temperatures.
• proper�disposal�procedures�ofwaterborne�hazardous�waste.
• types�of�assistance�offered�bypaint�companies�to�make�theconversion.
• steps�required�for�converting�towaterborne.
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