Hempel Technical Guideline
Force Curing by Infrared Radiation
Epoxy and polyurethane coatings
Introduction
In many situations there is a need to speed up curing e.g to allow early shipping or fast return to service to minimize down time of a facility.
There are various technologies to accelerate the force curing of a coating such as; air movement, convection heat (oven) and infrared
radiation, besides addition of catalyst.
This can be done efficiently by heating the uncured coating with infrared (IR) heaters. The heaters may be fixed installation in a production
line or mobile units for field repair.
Infrared energy is a form of radiation, which falls between visible light and microwaves in the electromagnetic spectrum (Fig.1).
Figure 1: Electromagnetic Spectrum
The specific infrared absorption wave length of organic coatings is most efficient between 3 to 10 µm. It is not only the produced heat that
accelerates the curing process but also the energy from the specific wavelength that promotes the crosslinking reactions.
Typical benefits
Infrared offers many advantages over convection ovens:
• Increased line speed through-put
• Lower utility costs, less floor space – energy savings
• Enhance crosslinking polymerization and ensures the coating is of optimal hardness, mechanical adhesion and chemical resistance
• Unlike a convection oven the curing process is from the inside out. Curing from the inside out greatly reduces the chance of water or
solvent entrapment
• Very precise control compared to convection heat
• Generally the finish is smoother than other curing technologies
• Infrared modules can be portable and adjustable
• Significant reduction of VOC and CO2 emission observed in gas catalytic IR drying system as IR-panel using the VOC as fuel
• IR introduces less heat into the work environment
[Link] Issued by Hempel A/S – June 2023
1/4
Hempel Technical Guideline
Energy level of the IR emitter
Infrared curing is energy radiated directly on the surface by a source (emitter). IR-curing can be carried out by short, medium, or long
wavelength IR-radiation (Fig.2).
• Short wavelength IR (from 1µm to 3µm): is characterized by bright visible light which is also emitted. Most of the energy is transmitted
through the coating to be absorbed by the substrate. This type of cure is therefore best suited for complex part shapes (non line-of-sight
heating) where it is used to heat the substrate. The fastest heat up rate is possible with high energy IR.
• Medium wavelength IR (from 3µm to 8µm): is the most widely used for curing because the energy is absorbed directly by the coating.
• Long wavelength IR (from 8µm to 15µm): is not effective for cure. Much of the energy generated is lost to inefficient convection heating.
The fraction of IR energy which does reach the coating is absorbed at the surface, resulting in possible “skin formation” or other defects.
Since long wavelength does little for force curing, the curing process will mainly be carried out by medium and short wavelength. Short
wavelength is more intense and is the choice for pre-heating of metal substrate. Depending on the process requirements and design details,
an IR curing system might consist of only medium wavelength or a combination of medium and short wavelength.
Figure 2: How infrared curing technology works(1)
Infrared radiation can be generated from both ‘’electric’’ and ‘’gas catalytic’’ sources. Both technologies create heat in the form of infrared
energy (IR). The energy produces wavelengths– varying from long, medium, and short. However, the difference between the two depends
on these wavelengths. Electric Infrared systems rely on tungsten bulbs to produce a short wavelength of IR. In comparison, gas catalytic
systems create a flame-less heat at a medium wavelength.
Electric systems produce a short wave of infrared energy which is more likely to pass through the paint molecules and penetrate the substrate
(underlying metal) – causing an unwanted by-product of an over- heated metal panel before the paint is cured.
Gas catalytic equipment uses propane, methane, or a propane/butane mix to produce medium wavelengths. The gas is funneled through
the machine and interacts with a catalyst on the inside to produce a “flame-less burning.” By doing so, it sends the heat out across the
vehicle and heats the paint equally– all while avoiding heating the metal beneath.
IR-radiation process
If it is required a short period of flash-off can be considered for applied coat before using the IR. Apply IR at an optimum distance and energy
output. Thickness of steel influences the curing time, and higher thickness of steel requires more time to heat up the steel and achieve a
fully cured coating system. During the IR radiation, coating surface temperature should be closely controlled to avoid sagging of the applied
coat on vertical surfaces. When temperature reaches to a level which is close to the melting point of thixotropic agent, sagging is expected.
Hempel can advise for product specific temperature limit, or this can be found through experiment.
Vary the time and distance until you achieve the proper homogeneous cure or the surface. Time not temperature is the major factor in
determining full cure. A primary approach to determine the degree of curing can be achieved by using a wooden stick, as follows:
• Stage 1: paint is liquid and adhering to stick.
• Stage 2: paint is sticky (like chewing gum) or feels soft when pushing.
• Stage 3 (sufficient heat cycle): Paint is cured, and stick will only leave a tiny scratch.
[Link] Issued by Hempel A/S – June 2023
2/4
Hempel Technical Guideline
Depending on the intensity and distance from the IR-radiation source, curing time in the range of is 20 to 45 minutes with medium wavelength
is expected.
Table 1 provides some practical data regarding the time that coated object can be handled.
Table 1: Practical test – time before object can be handled/Used
Where tested Coating system Specified DFT (µm) IR Cure
Deck Hempadur Spray-Guard 35490 3000 45 minutes
Spot repair in-shop Hempadur 47140/ Hempathane Topcoat 55210 150/50 45 minutes
Repair of tank for drinking water 3 x Hempadur 35560 3 x 125 3x60 minutes
Panels coated in the lab 1 x Hempadur Mastic 45880 1 x 200 30 minutes
Panels coated in the lab Hempadur Multi-Strength 35840 1 x 750 75 minutes
Hempel has a successful track record of several coating systems which were cured by IR radiation. Figure 3 shows the IR heating unit
which was set up for curing Hempathane HS 5561B on a 6-meter tower section.
Figure 3: Setting up the IR heating unit
Limitation in using IR-curing process
In following circumstances, it is not recommended to force cure the applied coating system by IR:
• High-build paint with DFT higher than 300 µm and solid volume below 80%: Risk of solvent entrapment, therefore it is recommended to
do some test trial in such cases.
• Paint containing wax to be overcoated: Wax may migrate to surface and adhesion for next layer may be compromised if IR is not used
for curing process of the second layer
• Physical drying paint: The heat will speed up the drying, but it will not enhance performance.
• Moisture curing products: Some binder types, cure through reaction with moisture in the surrounding air. In such cases, IR-radiation
will do little to speed up curing. This is the case for inorganic zinc silicates (Hempel’s Galvosil range) and certain polysiloxanes
(Hempel’s Hempaxane range)
[Link] Issued by Hempel A/S – June 2023
3/4
Hempel Technical Guideline
Health and Safety
In general, infrared radiation from the most common sources such as lamps, or from most industrial applications, is harmless for the human
body provided the power, distance and duration are appropriate.
Infrared radiation will not penetrate the skin very deeply. Therefore, exposure of the skin to very strong IR may lead to local thermal effects
of different severity, and even serious burns.
Short infrared rays are very dangerous for the eyes and long-term exposure may lead to the development of cataract.
Always follow instruction of the provider of the IR-equipment and use suitable protective measures like shielding (eye shields) and protective
clothing.
References
1) Global Finishing Solutions. August 30, 2019. Minimal infrared curing integration for maximum results. Minimal Infrared Curing
Integration for Maximum Results ([Link])
This document is intended for professional use and provides generic advice in respect of the subject matter only. It is not intended to be used as a
comprehensive guide. The buyer/applicator should always read the relevant Product Data Sheet (“PDS”) and Safety Data Sheet (“SDS”) relating to the
Products ordered which are available for download on [Link] . If in doubt, please contact your local Hempel representative for further advice. To
the extent relevant, the disclaimer set out in the relevant PDS(s) applies to this document.
[Link] Issued by Hempel A/S – June 2023
4/4
