Dr.

J RANGARAJAN
MEMS
IIT B
Disclaimer: This presentation is only for teaching purpose. No part of the
presentation can be distributed or uploaded to any other website.

The Figs. Presented are for teaching purpose only and orginal Pictures belong to
respective authors only.

This presentation cannot be used by students for purposes other than learning.

The slides should not be shared or uploaded to any other web sites.
PAINT CHARACTERISTICS

Prof. J . RANGARAJAN
METALLURGICAL ENGINEERING AND
MATERIALS SCIENCE
IIT Bombay
 Various Kinds of Tests for paint Coatings
• Paint Characterization
– Volume solid, Density, viscosity, drying and curing
properties, in case of two components – mixing ratio, pot
life
• Mechanical Properties
– Hardness, abrasion, scratch, adherence, pullout strength,
flexibility
• Chemical Resistance Properties
– Salt Spray
– weathering,
– Humidity
– Immersion tests
• Permeability
Typical crosslinked epoxy
Tri amine is used as hardener
• To make the cured resin more cross-linked

• The curing agent must have more than three active

hydrogen atoms and two amino groups in a molecule.
• For optimal loading of curing agent

• The number of moles of hydrogen should be equal to

the number of moles of epoxy
Paint Characterization
 NON VOLATILE MATTER
Significance

• Indicates the weight solids in paint

• Higher solids means higher coverage

Stoving Method (IS 101 - Part 2/Sec 2)

• Weight 2 gms of sample in lid. Spread it across

• Place in oven at 105 Deg. C / 3 hrs or 120 Deg.C/1 hr
• Calculate the weight retained in percentage
 DENSITY
Mass of a unit volume of a material at a specified
temperature.

Weight per litre cup (IS 101 - Part 1/ Sec 7)

• Cylindrical cup which can hold 100 ml of paint is used
• Determine the weight of the empty cup.
• Fill the cup with the paint and determine the weight.
• The difference in weight multiplied 10 gives WPL ( weight
per litre)

Significance
• If density is not within spec, then there is a good chance that
there can be some error in charging of the batch.
• Can act as a check on the solids of paint.
 VOLUME SOLIDS
It is defined as the total volume of non volatile
solids present in one litre of paint

Significance
• A measure of spreading capacity of paint
• Higher volume solids product will give higher coverage at a
given DFT
• It gives an indication of the amount of volatile solvents used
in the paint
• Higher volume solids product are being preferred due to
VOC regulations in developed countries
• High build products are designed with higher volume solids
for higher thickness deposition per coat
 VOLUME SOLIDS

Volume solids - (ASTM D 2697)

• Initially determine the % NVM by weight and
WPL of the paint
• Take circular disc of 60 mm dia. and take its
weight in air and in water.
• Apply the paint to the disc and allow it to dry.
• Take weight of coated disc in in air & in water.
• Volume solids is then calculated by formula .
 VOLUME SOLIDS
• W1 = weight of disc in air, g : W2 =weight of disc in water
• D = Density of water , g/ml
• Volume of disc G = (W1– W2) /D

• W3 = weight of coated disc in air, g

• W4 = weight of coated disc in water , g
• Volume of coated disc H = (W3– W4) /D

• Volume of wet coating = F = H-G

• Volume of dry coating =

V = (W3 - W1) / ( % NVM * WPL)
 VOLUME SOLIDS

The volume solids is then calculated as below by

Formula

Volume of dried coating

V.S. = -------------------------------- X 100
Volume of wet coating
 COVERAGE CALCULATION
THEORETICAL COVERAGE
Volume solids X 10
Theo. Coverage (M2 / lit) = ------------------------
DFT (Microns)
For a paint with 80% VS
Theo. Coverage at 100 µm DFT = 80 x 10/100
= 8 [Link] / lit
PRACTICAL COVERAGE

Actual coverage of paint after taking into account

all possible loss factors involved during the
painting process
 TYPES OF LOSSES
DURING APPLICATION

• Paint loss during application may be due to :

a) Apparent losses
-- Effect of blast profile
-- Paint distribution losses

b) Actual losses
-- Application losses
-- Paint wastage
 APPARENT LOSS
DUE TO EFFECT OF BLAST PROFILE

Surface Blast Profile DFT Loss *

Unblasted steel 0 0
Steel blasted using 0 - 50 µ 10 µ
round shot
Fine open blasting 50 - 100 µ 35 µ
Coarse open blasting 100 - 150 µ 60 µ
Old pitted steel – 150 - 300 µ 125 µ
reblasting

* DFT Loss - Addl. DFT required to Compensate blast

profile
 ACTUAL LOSS
DUE TO APPLICATION METHOD

For Brush / Roller Application -- 5 - 10%

For Air Spray -- 50-60%
For Airless Spray -- 45-50%
For Electrostatic Air Assisted Spray -- 30%

The loss factor will also depend on :

• Shape of structure
• Atmospheric Condition - Wind velocity
• Painting location e.g. Height
 APPARENT LOSS
DUE TO PAINT DISTRIBUTION
Application Method Type of Structure Estimated Loss
(%)
Brush & Roller Simple Structure 5%
-- do -- Complex 10-15%
Structure
Spray Simple Structure 20%
-- do -- Complex 40%
Structure

Higher DFT against minimum stated DFT due to uneven paint

distribution / over deposition during application
 ACTUAL LOSS
DUE TO PAINT WASTAGE
This is losses due to

-- Paint spillage due to handling

-- Retention in container / brush / spray line etc
-- Premature gelling during application (e.g. improper
mixing ratio, high temperature etc)

Estimated Loss factor for

-- 1K Paint -- Max 5%
-- 2K Paint -- 5-10%
 CALCULATION OF
PRACTICAL COVERAGE
Application of 2K High Solid Epoxy Paint :

• 2 coat application / airless spray

• 100 microns / coat
• Sandblasted substrate - Sa 21/2 - 50 microns profile
• Complex object (confined space inside tank)
• Volume Solid - 80%
• Theoretical Coverage - 4 [Link] / lit at 200 microns DFT
WHAT IS THE PRACTICAL COVERAGE ?
 CALCULATION OF
PRACTICAL COVERAGE
First Coat
Required DFT 100 microns
Loss due to blast profile 10 microns
Loss due to distribution @ 40% 40 microns
(100 x 0.4) --------------
150 microns
Loss due to application @ 5% 7.5 microns
(150 x 0.05)
Loss due to wastage @ 10% 15 microns
(150 x 0.1) ---------------
172.5 microns
Extra Paint used -- 72.5%
 CALCULATION OF
PRACTICAL COVERAGE
Second Coat
Required DFT 100 microns
Loss due to blast profile Nil
Loss due to distribution @ 40% 40 microns
(100 x 0.4) --------------
140 microns
Loss due to application @ 5% 7 microns
(140 x 0.05)
Loss due to wastage @ 10% 14 microns
(140 x 0.1) ---------------
161 microns
Extra Paint used -- 61%
 CALCULATION OF
PRACTICAL COVERAGE

72.5 + 61
Total loss for 2 coats = ------------ = 66.75%
2

This means 66.75% extra paint is required w.r.t. theoretical

quantity i.e. 1.67 lit paint is actually required to
compensate all the losses.
 CALCULATION OF
PRACTICAL COVERAGE
Theo. Coverage / Lit
Practical Spreading Rate = ---------------------------
Actual Paint Required

= 4 / 1.67 = 2.39 [Link]. / lit

Overall Loss Factor = (4 - 2.39) x 100 / 4

= 40.25%

Utilisation Efficiency = 60%

 VISCOSITY
Viscosity is the force per unit area that resists the
flow of two parallel fluid layers
Significance
• Flow and leveling properties
• Anti-sag properties

Efflux Viscometers - Ford Cup (ASTM D 1200)

• Brass cup - conical bottom - 4.12 mm orifice
• Used for low viscosity materials
• Measures the time taken for discharge in seconds
 VISCOSITY

Stormer viscometers - (ASTM D 562)

• Paddle is immersed in the paint and load in

weight applied through string
• Load required to produce 200 revolutions in
60 seconds is recorded
• Stroboscopic timer will indicate the
motionless lines when 200 rpm is achieved
 DRYING TIME
Indicates the rate of drying / film formation
of the paint film
Significance
• Drying time depends on resin chemistry

• Can detect wrong mixing ratio / improper mixing in case

of two pack products

• Slower drying time than specified - indicate slow curing

and delayed / inadequate resistance properties
 DRYING TIME

Set to touch - (ASTM D 1640)

• Lightly touch the paint film with the tip of a
clean finger
• Immediately place the finger tip against a piece
of clean glass.
• A film is set-to-touch when no coating is
transferred to the glass plate
 DRYING TIME

Dust Free - (ASTM D 1640)

• Cotton fibers are dropped on the paint film from a
height of 1 inch

• The film is considered dust-free when a gentle current

of air removes the fibre from the surface
 DRYING TIME
Tack Free - (ASTM D 1640)
• Tack is the ability of a coating to hold an object
• Test paper is placed on the paint film
• Steel cylinder (2 inch dia, 2.85 kgs) is placed on the
paper
• After 5 secs remove the weight and invert the test
specimen
• If the paper falls within 10 secs the paint is said to be
tack free.
 DRYING TIME

Dry Hard - (ASTM D 1640)

• Involves pressing the paint film with thumb
• If no noticeable mark is seen after the paint film is lightly
rubbed with a soft cloth, the coating is said to be hard dry

Dry Through - (ASTM D 1640)

• Involves pressing the paint film with thumb and turning
the thumb through an angle of 90 Deg.
• If no loosening, detachment, wrinkling is noticed, the paint
is said to be dry through
 Some other Important Properties

• Sag Resistance
• Dispersion of pigment
• Flash Temperature
Paint Coating Evaluation
 Wet Film Thickness Measurement

DFT = WFT x % Vol. Solid

 Thickness
Measurement
Magnetic adhesion

spring balance
principle

Coating

Steel
Magnetic adhesion

balance beam
principle
Coating

Steel
 Magnetic induction

Steel
Eddy-currents
Ultrasonics principle

Ultrasonic
Wave
Layer 1

Layer 2

Layer 3

Substrate
MikroTest
non-magnetic coatings on
steel

Nickel on steel

Nickel on non-ferrous
metals
MiniTest Series
non-magnetic coatings
on iron and steel

insulating coatings on
non-ferrous metals

non-ferrous metal
coatings on insulating
substrates
Dual Gauge

Magnetic induction

Eddy-currents
Mechanical Properties of Paint Coatings
 Blast Clean Test

The Potassium Ferricyanide Test for International Standard BS

water-soluble iron salts that form at the 5493
bottom of rust pits after blast-cleaning.

ferrous iron salts + potassium

ferricyanide

ferric hexacyano ferrate (Blue)

Any soluble iron salts present are drawn

out of the rust pits by capillary action
and react with the potassium ferricyanide
to form blue spots. The presence of blue
spots on the test paper indicates that the
surface should be re-blasted.
Potassium Ferricyanide Papers
.
 The Dust Test Tape
BS 8502-3

Magnifying glass

adhesive tape

Why ????:---Dust on blast-cleaned steel surfaces may reduce the

adhesion of applied coatings and by absorbing moisture, may
promote the corrosion of the blast-cleaned steel surface.
 Hardness Measurement

Shore Hardness D
• Barcol Hardness
• • ASTM D2583
• Fiberglass
Aluminum
Aluminum Alloys
Soft Metals
Plastics
 Scratch Hardness- (IS 101 - Part 5/Sec 2) BS 3900
Hardness can be defined as resistance to
indentation or scratching
• The scratching needle is a hardened steel
hemispherical tip of 1 mm dia.
• Clamp the panel on the DC circuit panel
• Place weights on the holder above the
needle
• Start the motor to make a scratch on the
coating
• Observed the scratch for penetration
upto the substrate
• Failure of the coating is indicated by
deflection in the current needle due to
completion of the circuit.
 Pencil
Hardness Tester
The Pencil Hardness evaluates the hardness
and resistance to scratching of coatings.

The principle of operation uses the pressure

applied to allow the pencil lead to just crush
and therefore repeatable results of the
hardness of the coating can be obtained.

The pressure or weight applied relates to

pencil lead crushing and therefore can be used
for vertical coating evaluation to achieve
repeatable results.

These pencils when passed for a specified

number of times on the coating will also allow a
wear factor to be determined which is related
to the hardness of the pencil used

Supplied with a set of 14 pencils (6B to 6H)

Impact Testing ASTM 2794
Abrasion Resistance
Flexibility – Conical Mendral
(ASTM D552)
•Tape Test (ASTM D3359)
Adhesion Test

• Pulloff Adhesion
( BS 4624)
Pull off Test ASTM D 4541
Tensile Properties
ASTM E8 / D 638

• UTS
• YS ( 0.2% Proof
Stress)
• % Elongation
• Modulus of Elasticity

• Composite Panel
• Skin
 HOLIDAY DETECTOR

• PINHOLES IN COATINGS
• INVISIBLE TO NAKED EYES
• DETECTOR COUNTS PINHOLES AND
SOUNDS ALARM
• ALLOWS INSTANT REPAIR OF
PINHOLES
Working Principle

electrically conductive
rubber electrode

paint coating

metal substrate
Holiday Detector
Outside-tube testing

Large
diameters:
Especially suitable
for large diameters,
the ringelectrode
enables reliable
testing of the
complete tube in
one or two
operations only.
• HOLIDAY
DETECTOR
• NEW MODEL
POROTEST7
DIGITAL
• LATEST
TECHNOLOGY
 ASTM G-62
Stanadrd Prcatice for Holiday Detection in Pipeline Coatings

• If the coating thickness is less than

1.016mm then V ( test Voltage) = M (Tc)½
Where M = 3294 if Tc is in mm
Tc = Coating thickness
• If the coating thickness is more than 1.016
mm then V ( test Voltage) = K (Tc)½
Where K = 7843 if Tc is in mm
ASTM D5162 Holiday Testing of Non conductive protective
coating on Metallic Substrate

Thickness (mils) Thickness (mm) Inspection Voltage (KV)

8-12 0.20-0.31 1.5
13-18 0.32-0.46 2.0
19-30 0.47 – 0.77 2.5
31-40 0.78 – 1.03 4.0
41-60 1.04 – 1.54 5.0
61-80 1.55 – 2.04 7.5
81-100 2.05- 2.55 10.0
101-125 2.56 – 3.19 12.0
126-160 3.20 – 4.07 15.0
161-200 4.08 – 5.09 20.0
201-250 5.10- 6.35 25.0
 Relative
Humidity Meter
• Allows the determination of the:
• relative humidity,
• dew point and
• air temperature
before the application of a coating.

• Polyethylene filter on the sensor provides

sensor protection against dust and high air
velocity, Clear, backlit graphic display.
Complies with International
Standards: BS 7079-B4, ISO 8502-4
 The Digital Surface
Thermometer

Allows the measurement of the

substrate temperature to be
immediately measured. And
ensures that the substrate can be
maintained at a temperature
sufficiently above the dew point to
prevent moisture forming on the
uncoated surface.
Salt Testing Kit
 Bresle Test
This Chloride Test on steel
 The Bresle Test is one of the most popular tests for extracting and
measuring the salt contamination on blast-cleaned substrates.

 Easy to use, pour 10mls of distilled water into the beaker and
determine the conductivity using the Conductivity Meter.
Take a Bresle Patch and apply to the test surface. Fill the syringe
with 2.5mls of test water and insert through the adhesive foam
into the test chamber. Inject the contents, then extract back into
the syringe.
 Repeat ten cycles of injecting and extracting, then transfer the test
water back into the beaker. Measure the test water with the
Conductivity Meter and deduct the initial conductivity reading
from the result. Multiply the readings by 0.4 to give the quantity
of salts in µg/cm² also known as ppm, or by 4 for the quantity of
salts µg/m².
 .Complies with International Standards: ISO 8502-6 and ISO 8502-
Chemical Resistance Properties
Humidity Test ASTM –D2247
 Immersion Tests

• Immersion in various solutions for

• 72 hours
• 7 days
• 1 month
• Change in appearance, Blisters, change in
dimensions, weight
 Salt Spary Test ASTM – B117

• Resistance to
corrosion
• Blistering ASTM
D714
( Size & Density)
• Delamination
• Creeping of defects
 Accelerated Weathering

ASTM G-53-96

Resistance to
•Sunlight
•Chalking
•Cracking
 GLOSS
The relative luminous reflectance factor of a specimen
or the shiny appearance of the coating is GLOSS .

Significance
• Gloss increases as the PVC of the product decreases
• Primers have lower gloss levels than topcoats
• Gloss levels increases as the fineness of grind of the
product increases
• Higher DFT will give higher gloss reading
 60 Degree Gloss Measurement

Reflected Light Incident Light

60

• GLOSS VALUES are not percentages, the numerical scale is based on

highly polished black glass = 100 (or a perfect mirror surface = 1000)
• GLOSS RETENTION VALUES are percentages because they are
ratios of gloss values
 GLOSS
Gloss - (ASTM D 523)
• Glossometer with various angular geometry are available
i.e. 20 / 60 / 85 Deg.
• Incidence angle and viewing angle are same for a
particular geometry
• Calibrate the glossometer on the black tile with specified
gloss level. Gloss levels are different for different angles
• Place the glossometer on the coated panel
• Measure the values at various locations and calculate the
mean / range.
 GLOSS RANGES
(IS :101 PART-4 / SECTION – 4)

FINISH GLOSS – R

MATT 0 – 10
EGG SHELL 11 – 20
SATIN 21 – 40
SEMI GLOSS 41 – 70
GLOSSY > 70

NOTE :
•FOR HIGH GLOSS USE 200 HEAD GLOSSOMETER
•FOR LOW GLOSS USE 850 HEAD GLOSSOMETER
 Colour Retention & Gloss Retention
Measurement

Portable Spectrometer
Software for measuring
Colour Retention and Gloss
Colour Retention Results
 Cathodic Disbondment Test

ASTM G-8 -96

Resistance to disbondment
Due to cathodic reaction
At the defect
Weight Loss Permeability ASTM D 1653

Time in Days
THANK YOU