CHAPTER 8

SURFACE COATING
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• Learning outcomes:
I. Comprehend the types of surface coating materials
such as paints, varnish and lacquer.
II. Distinguish the differences between paints, varnish
and lacquer.
III. Explain the composition of paints and its function.

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 Introduction
• Surface coating operations involve applying a thin
layer of coating (e.g., paint, lacquer, varnish, etc.) to
an object for decorative or protective purposes.
✓ Decoration – to enhance the aesthetic appeal
(surface features) - colour, glossy and texture.
✓ Protection – from corrosion, erosion and fire
retardant.

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• The process of applying coating materials can be
accomplished by brushing, rolling, spraying, dipping,
flow coating, electrocoating, or specialized
combinations or variations of these methods.
• Most paints are either oil-based or water-based and
each have distinct characteristics.

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 Paints
• Paint is a coating applied to the surface in form of a
liquid dispersion, which is then hardens forming a
solid film.
• Paint composed of solid coloring matter suspended in
a liquid medium - applied as a coating various types of
surfaces (eg: canvas, paper, wood, metal, glass etc.)
• Function of paint:
i. Protection of the part surface from the environmental
factors (Oxygen and other chemically active gases,
moisture, dissolved salts and other chemicals,
temperature, bacteria, fungi). 5
ii. Corrosion protection is the most important
function of paints.
iii. Aesthetic appearance provided by the paint color
and sheen (eggshell, satin or gloss).
iv. Providing a desired ability of reflection-absorption
of heat and light.
v. Changing the surface properties: ant-friction,
hardness, electrical conductivity.
vi. Identification of products
according to the color of the paint.

Color code for pipelines

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• Paints are classified by gloss.
• Gloss – luster, shininess or
reflecting ability of a surface.
• The gloss of paint is controlled
by the amount of pigment/
extender pigment. (i.e, the
greater the pigment content –
the lower the gloss).
• Most paints fall into one of the
general categories of eggshell,
semi-gloss, flat or gloss.

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 Paints
• Primer/undercoater - aid the adhesion
of top-coat to surface and prevent top-
coat adsorption to porous surface and
prevent corrosion of metal surface.
• Fillers/surfacers – primer type that fills
the scratches and surface imperfections.
• Final coat – Finish coats/top-coats.

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 Types of Paints

• Outdoor house paint

• Indoor house paint
• Concrete paint
• Asphalt roof paint
• Floor paint
• Indoor flat paint
• Indoor glossy paint

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 Recommended
Application Methods
Although latex- and oil-based paints can be applied with rollers
or pads as well as brushes, cleaning them after using oil paints is
difficult and will require lots of white spirit or thinner (oil-based
paint)
• Primer: Use a brush, roller or pad.
• First Coat: Use a brush, roller or pad.
• Flat: Use a brush, roller, pad or sprayer.
• Eggshell: Use a brush, roller or pad.
• Gloss: Use a brush.
• Floor Paint (on Wood): Use a brush.
• Floor Paint (on Concrete): Use a brush or roller.
• Metal Paint: Use a brush. 10
(alkyd paint)

*An extender pigment is a naturally occurring chemical substance

(usually having a white color) that is added to a paint or coating to
improve its properties such as durability, cost, and resistance to
corrosion or wear.
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 Pigments
- Insoluble, fine particle-size materials that confer on
a paint its color and opacity.
- Used in paint formulation to:
i. Provide color
ii. Hide substrates and obliterate previous colors
iii. Improve the strength of a paint film
iv. Improve the adhesion of the paint film
v. Reduce gloss
vi. Reduce cost
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• Ideal pigment:
✓ Chemically inert
✓ Free of soluble salts
✓ Insoluble in all media used
✓ Unaffected by normal temperature
✓ Easily dispersed
✓ Non-toxic
✓ Low oil-absorption characteristics

Q: What is the differences between pigment and dye??

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• Pigments can be classified as: inorganic and organic.
• Inorganic pigments are usually more opaque and
more insoluble than organic pigments.
• Example of Inorganic pigments: White, Filler
(Extender), Colors, Black, Metallic.
• All white pigments are inorganic compounds of
titanium, zinc, lead or antimony.
• Eg: TiO2 (good hiding power, RI= 2.70), antimony
oxide (fire-retardant properties).
• Fillers is special type of pigment that serve to thicken
the film, support its structure and increase the
volume of the paint. Not all paints include fillers.
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• Colored inorganic (natural or synthetic) such as; iron
oxides, ultramarine blues, chrome oxide green
(Cr2O3) etc.
• Black pigment – created from carbon.
• Organic pigment – generally have lower hiding power
but exhibit higher color strength and gloss.
• They are mainly based on carbon, hydrogen, and
nitrogen.
• Organic pigments can be classified in three main
groups: azo pigments, polycyclic pigments, and
anthraquinone pigments.

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 Binders / Resin
• Binders are polymers (resinous) or resin-forming
constituent of a paint that binds together the pigment
particles and hold them on the surface.
• It is the only component that must be present in a
paint.
• The binder imparts properties such as gloss, durability,
flexibility, and toughness.
• Binders include synthetic or natural resins such as
alkyds, acrylics, vinyl-acrylics, vinyl acetate/ethylene
(VAE), polyurethanes, polyesters, melamine resins,
epoxy, silanes or siloxanes or oils. 18
 Binders / Resin
• The three most important binders used in modern
paints are: alkyd, acrylic and epoxy polymers (resins)
• Alkyd resin – used in oil-based paint. Has an excellent
pigment wetter and dispersers. Also have good
durability, flexibility, solvent resistance, gloss and color
retention and low in cost.
• Acrylics resin – used in latex @ water based-paint.
Acrylic paint has water as the vehicle for
an emulsion (suspension) of acrylic polymer, which
serves as the binder.
• https://www.cabinetswarehouse.com/water-and-oil-based-
paints-pros-and-cons/ 19
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 Solvents / Vehicle
• Solvents are volatile liquids added to dissolve or
disperse the film-forming constituents of a paints
and allied products – to adjust the viscosity of the
paint.
• They evaporate during drying@ volatile (do not
become a part of the paint film).
• The type of binder determines the type of solvent or
thinner used in a paint formulation.
A paint thinner is a solvent used to thin oil-
based paints or clean up after their use,
although all such solvents have other uses.
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• Solvents can be divided in three classes:
i. Hydrocarbons solvents – most commonly used
solvents. Divided into aliphatic, naphthenic and
aromatic. Preferred type of solvent is an odorless
aliphatic hydrocarbon (mineral spirit).
ii. Oxygenated solvents – example; ketone, esters,
glycol esters and alcohols. Offer much stronger
solvency and widely used as active solvents for
synthetic binders.
iii. Water – main vehicle for water-based paints.

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• Solvents should be:
1. Regulate application properties
2. Control consistency and character of finish
(minimizes defects)
3. Control evaporation rate
4. Adjust solid level that influence film application
thickness
5. Adjust and influence coating viscosity (thickness
of paint)
6. Are used in resin manufacturing
7. Should have an acceptable odor, minimal
toxicity and reasonable cost.
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 Additives
• Additives are substances that are added in small
quantities to a paint to improve or to modify certain
properties of the finished paint coatings.

1. Thickening agents.
- influence the rheological properties of paint by
increasing the viscosity. Example; organoclays
(inorganic thickeners)

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2. Surface active agent.
- Consists of wetting and dispersing agents, antifoam
agents and adhesion promoters.
- Wetting and dispersing agents – facilitate the very
important process for pigment and extender
dispersion and stabilization in paints and coatings.
- Defoamers – avoid or improve the bursting of
bubbles during drying of the paint film.
- Adhesion promoters – improve adhesive strength of
paints in term of resistance against mechanical
separation from the painted surface.

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3. Surface modifiers.
- Control the mechanical (eg. surface slip, scratch
resistance) and optical properties (eg. gloss) of a
coated surface.

4. Leveling agents and coalescing agents.

- Used to control flow and leveling of a paint during and
after the application and before the film is formed.

Improper
The paint is
leveling -
properly leveled
swirls
and polished
problem
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5. Catalytically active additives.
- Includes paint driers and other catalysts that are
used to accelerate a chemical reaction occur during
the film-forming process.

6. Special-effect additives.
- Examples: anti-skinning agents, light stabilizers,
corrosion inhibitors, biocides (antifungals), flame
retardants.

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Paint Production Process

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 The Manufacturing Process
1. Making the paste
• Pigment manufacturers send bags of fine grain pigments to paint plants.
• There, the pigment is premixed with resin (a wetting agent that assists in
moistening the pigment), one or more solvents, and additives to form a
paste.

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 The Manufacturing Process
2. Dispersing the pigment

• For most industrial – send to sand mill, a large cylinder that agitates tiny
particles of sand or silica to grind the pigment particles, making them
smaller and dispersing them throughout the mixture. The mixture is then
filtered to remove the sand particles.
• Up to 90 percent of the water-based latex paints designed for use by
individual homeowners are instead processed in a high-speed dispersion
tank.
• There, the premixed paste is subjected to high-speed agitation by a
circular, toothed blade attached to a rotating shaft. This process blends
the pigment into the solvent.

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The Manufacturing Process

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 The Manufacturing Process
3. Thinning the paste
• Whether created by a sand mill or a dispersion tank, the paste must now be
thinned to produce the final product.
• Transferred to large kettles, it is agitated with the proper amount of solvent for
the type of paint desired.

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 The Manufacturing Process
4. Canning the paint
• The finished paint product is then pumped into the canning room. For the
standard 8 pint (3.78 liter) paint can available to consumers, empty cans are
first rolled horizontally onto labels, then set upright so that the paint can be
pumped into them.
• A machine places lids onto the filled cans, and a second machine presses on the
lids to seal them. From wire that is fed into it from coils, a bailometer cuts and
shapes the handles before hooking them into holes precut in the cans.
• A certain number of cans (usually four) are then boxed and stacked before
being sent to the warehouse.

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 Quality Control
• A finished paint is inspected for its density, fineness of grind, dispersion,
and viscosity. Paint is then applied to a surface and studied for bleed
resistance, rate of drying, and texture.
• In terms of the paint's aesthetic components, color is checked by an
experienced observer and by spectral analysis to see if it matches a
standard desired color.
• Resistance of the color to fading caused by the elements is determined by
exposing a portion of a painted surface to an arc light and comparing the
amount of fading to a painted surface that was not so exposed.

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 Quality Control
• The paint's hiding power is measured by painting it over a black surface
and a white surface. The ratio of coverage on the black surface to
coverage on the white surface is then determined, with 0.98 being high-
quality paint.
• Gloss is measured by determining the amount of reflected light given off a
painted surface.

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 Quality Control
• Tests to measure the paint's more functional qualities include one for mar
resistance (@ scratch resistance), which entails scratching or abrading a
dried coat of paint. Adhesion is tested by making a crosshatch, calibrated
to 0.07 inch (2 millimeters), on a dried paint surface. A piece of tape is
applied to the crosshatch, then pulled off; good paint will remain on the
surface.

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 Quality Control
• Scrubbability is tested by a machine that rubs a soapy brush over the
paint's surface. A system also exists to rate settling. An excellent paint can
sit for six months with no settling and rate a ten. Poor paint, however, will
settle into an immiscible lump of pigment on the bottom of the can and
rate a zero.
• Weathering is tested by exposing the paint to outdoor conditions. Artificial
weathering exposes a painted surface to sun, water, extreme temperature,
humidity, or sulfuric gases.
• Fire retardancy is checked by burning the paint and determining its weight
loss. If the amount lost is more than 10 percent, the paint is not
considered fire-resistant.

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 Failure of a Paint
• The main reasons of paint failure after application on
surface are the applicator and improper treatment of
surface.
• Dilution
– This usually occurs when the dilution of the paint is
not done as per manufacturers recommendation.
There can be a case of over dilution and under
dilution, as well as dilution with the incorrect diluent
(solvent).

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• Contamination
– Foreign contaminants added without the
manufacturers consent which results in various film
defects.
• Peeling/Blistering
– Most commonly due to improper surface treatment
before application and inherent moisture/dampness
being present in the substrate.
• Erosion
– Erosion is very quick chalking. It occurs due to
external agents like air, water etc. 39
• Chalking
– Chalking is the progressive powdering
of the paint film on the painted surface.
– This can be caused by:
i. extended exposure to the combined effects of
moisture and the ultraviolet rays of the sun.
ii. Using a low-grade paint.
iii. Over thinning the paint.
iv. Overspreading the paint.
v. Not priming and sealing a porous surface.
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• Cracking
– Cracking of paint film is due to the unequal
expansion or contraction of paint coats. It usually
happens when the coats of the paint are not allowed
to cure/dry completely before the next coat is
applied.

• Blistering
– Blistering is due to improper surface
exposure of paint to strong sunshine.

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 Varnishes
• Varnish is a clear transparent hard
protective coating or film applied to
wood (primary application), metal, or
other surfaces to enhance their
durability and appearance.
• It usually has a yellowish shade due to
the manufacturing process and
materials used, but it may also be
pigmented as desired.
• Varnish are designed to penetrate the
wood, bringing out and enhancing the
wood's natural beauty while protecting
it from water, dirt, and sunlight. 42
 Varnishes
• The type of varnish mainly depends on the types of solvents
used and they are as follows :
- Oil varnishes - Water varnishes
- Flat varnishes - Spar varnishes
- Spirit varnishes - Asphalt varnishes
- Turpentine varnishes

• Spar varnishes (also called marine varnish)

is high quality, waterproof, and sunlight-
resistant varnish named for its use on ship
or boat spars and other woodworks.

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 Components of Varnish

Resins
solvents (hardness)
The solvent may be alcohol, Most resin or "gum" varnishes
turpentine, or petroleum-
varnish
consist of a natural, plant- or
based (i.e., mineral spirit or insect-derived eg., amber, kauri
paint thinner) gum, dammar, copal, rosin
Drying oils (pine resin), etc. Synthetics
(elasticity) resin – phenolic resin
http://upload.wikimedia.org/wikipedia/commons/thumb/b/b6/Amber2.jpg/220px-Amber2.jpg

Substances that hardens on

exposure to oxygen. Eg., linseed oil,
tung oil, and walnut oil.
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 Varnish Application
Wood varnish

Sand the wood Clean the wood and your work space Apply the first coat Sand the first coat and wipe it with a
with fine-grit with a damp cloth and let it dry of thinned varnish damp cloth.
sandpaper. and let it dry.

Wait for the varnish to finish curing. Continue applying more varnish and Apply the next coat of varnish and
sanding between coats. allow it to dry. 45
 Varnishes
• The natural varnishes are produced by heating the resins,
adding natural oils such as linseed oil, cooking the mixture to
the desired viscosity, and then diluting it with solvent like
turpentine.
• Varnish dry to a hard-gloss, semi-
gloss or flat transparent film by a
process comprising evaporation of
solvent, followed by oxidation and
polymerization of the drying oils and
resins.

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 Varnishes
• The type of oils and resins and the ratio of oil to resins are the
principal factors which determine the properties of varnish.
• In oleoresinous varnishes, the ratio of oil to resin is expressed
as the number of gallons of oil that are combined with 100
pounds or resin – commonly referred as the “length” of the
varnish.
• Ratio (oil/resin)
i. Short-oil varnish <20 gal/100 lbs
ii. Medium-oil varnish 20-30 gal/100 lbs
iii. Long-oil varnish >30 gal/100 lbs

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Classification of Varnish

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 Lacquers
• Lacquer is a protective coating which dries by evaporation of
volatile components (solvent).
– nonconvertible coatings – meaning the lacquer film
formation does not depend upon any chemical reaction.
– film formation is dependent only upon the evaporation of
solvents, and the formed film remains soluble in the parent
solvent blend (eg. Lacquer thinner).
• Lacquer is usually made with shellac and alcohol – make
surface more resistant to damage and scratches.

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Shellac is a resin that is secreted by an insect onto tree trunks.
 Lacquers
• Lacquer comes in a wider variety of shades than varnish
finishes and dries much quicker. It also has distinctive odor –
usually based on high MW polymers (low-boiling solvents of
high solvency power) such as alcohols, ketones, and esters.
• Lacquers are usually applied by spraying.
• The use of lacquers: automobile finishes, furniture finishes,
metal finishes, and plastic, rubber, paper and textile finishes.

Lacquerware - objects decoratively covered with lacquer.

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• Lacquers types – pigmented (major use) or
colorless.
• Examples of lacquers:
1. Nitrocellulose lacquers can form glossy
coatings having excellent adhesion – eg. in
car refinish and the wooden furniture.
2. Chlorinated rubber lacquers are used
principally as protective coatings for steel and
other vulnerable materials in harsh
environments.
3. Vinyl lacquers are mainly used where a high
degree of chemical resistance is required –
this lacquers are based on vinyl chloride and
vinyl acetates. 51
4. Acrylic lacquers are based on methyl methacrylate
and methyl acrylate polymers and copolymers –
principal uses are fluorescent and metallic paints
for car refinish applications, clear lacquers and
sealers for metals and protective coatings for air-
craft components.

Lacquer fabric red 52

Japanese lacquered Yuzen paper
 Lacquer Application
1 2 3 4 5

Choose the piece of Sand the surface with Wipe the furniture Purchase a lacquer Buy cans of colored
furniture that you want extra fine sandpaper. thoroughly with tack base/primer. lacquer spray
to lacquer. cloths

6 7 8 9

Wear a mask, safety Shake the can according to

Sand the surface of Cover the entire surface with
goggles and gloves when package directions. Hold the
the primer with fine- a coat of lacquer. It will take
you apply all paint and can between 10 and 18
grit sandpaper and a half hour or less to dry, but
lacquer. inches from the surface of
wipe it clean. 48 hours to cure. Let each
the furniture. Spray it in small coat cure before you apply
horizontal strokes another layer.
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