HOW TO SELECT THE RIGHT PAINT SYSTEM

How to select the right paint system Guidelines for coating protection in accordance with ISO 12944

How to select the right paint system

Introduction

The purpose of this guide is to help you select the best Hempel coating system to protect your structure against corrosion. All steel structures, facilities and installations, exposed to atmosphere, staying under water or in soil, suffer because of corrosion and require protection. Throughout this guide you will find important information regarding paint technology, criteria for right paint selection and surface preparation requirements. This guide has been prepared in accordance with the latest edition of the International Standard ISO 12944 “Paints and varnishes – corrosion protection of steel structures by protective paint systems”. Outlined at the end of this document are generic coating systems recommended by ourselves for different corrosive environments. This document is to be considered as a guide only.

2


1. How to select the right paint system A. Environmental corrosivity B. A type of protected surface C. The durability required for a paint system D. Planning the paint application process

6-9 6 9 9 9

2. Surface preparation 10-12 2.1 Surface preparation grades 10 A. Grades of a surface according to the ISO 8501-1 standard 10 B. Surface preparation grades after high pressure water cleaning 12 2.2 Types of surfaces 14 1. Steel surfaces 14 2. A bare steel structure with no previous protective coatings 14 3. A steel surface covered with shopprimers 15 4. A steel surface coated with a paint system which needs to be maintained 16 B. Hot dipped galvanised steel, aluminium and stainless steel surfaces 16 1. Hot dipped galvanised steel 16 2. Aluminium and stainless steel 16 3. Maximum service temperatures

17

4. Useful definitions A. Waviness of paint film B. Size and shape of the surface C. Surface roughness of the substrate D. Physical losses

18 19 19 19 19

5. Guide specification according to ISO 12944 C1/C2 Corrosivity category C3 Corrosivity category C4 Corrosivity category C5-I Corrosivity category C5-M Corrosivity category Immersed structures

20-41 20-23 24-25 26-29 30-33 34-37 38-41

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World-leading coatings supplier Hempel was founded in 1915 and is today one of the world’s leading manufacturers and suppliers of coating solutions. Our advanced protective and decorative coatings can be found on millions of surfaces around the globe. From the world’s longest bridges and tallest skyscrapers to airports, sports stadia and civil structures our coatings protect your assets against corrosion in many different and challenging environments. Our history is rooted in protective coatings for the extreme conditions experienced in the Marine, Decorative and Protective industries, so you can be assured that we offer trusted technology, expert technical service and reliability. With our vast expertise and knowledge, you know we are the trusted protective coatings partner for many customers around the world.

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Global service We want to give you the right products on site, on time, every time. With the support of our 28 manufacturing plants and over 150 stock points worldwide, we offer a flexible service to all our customers. A service that we believe is second to none.

Proven performance Our range of high performance protective coatings offer advanced protection and optimised application for a durable finish that looks good for longer, in even the most challenging climates. With our proven track record, we are a trusted protective coatings partner for customers around the world.

Professional support Our customers know that specifying the right products is crucial, to ensure corrosion and fire protection, good appearance and minimum maintenance. Our multinational, globally based teams are uniquely positioned to ensure the smooth running of your project. From planning to completion, specification to application, we have key people to support you both off and on site.

Innovative solutions With 15 global research and development facilities, we work locally with you to provide the right solution for your project. Our research and development teams are committed to continuous development of innovative and effective speciality coatings to give you durable protection whilst ensuring environmental responsibilities are met.

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1. How to select the right paint system

Selecting the correct paint system for protection against corrosion requires a variety of factors to be taken into account to ensure that the best technical solution is achieved. For each project the most important factors to consider before selecting a protective coating are: • environmental corrosivity • surface preparation grades after high pressure water cleaning A. Environmental corrosivity When selecting a paint system it is vitally important to work out the conditions in which the structure, facility or installation is to operate. To establish the effect of environmental corrosivity, the following factors must be taken into account: • humidity and temperature (service temperature and temperature gradients) • the presence of UV radiation • chemical exposure (e.g. specific exposure in industrial plants) • mechanical damage (impact, abrasion etc.) 6

In the case of buried structures their porosity must be considered and the ground conditions which they are subject to. The dampness and pH of the terrain and biological exposure to bacteria and micro-organisms are of critical importance. In the case of water, the type and chemical composition of the water present is also significant. The corrosive aggressiveness of the environment will have an effect on: • the type of paint used for protection • the total thickness of a paint system • the surface preparation required • minimum and maximum recoating intervals


Note that the more corrosive the environment, the more thorough the surface preparation required. The recoating intervals must also be strictly observed. Part 2 of ISO 12944 standard gives the corrosion classifications for atmospheric conditions, soil and water. This standard is a very general evaluation based on the corrosion time for carbon steel and zinc. It does not reflect specific chemical, mechanical or temperature exposure. However the standard specification may still be accepted as a good indicator for paint system projects as a whole.

ISO 12944 distinguishes 5 basic atmospheric corrosivity categories: C1

Very low

C2

Low

C2

Low

C4

High

C5-I

Very high (Industrial)

C5-M

Very high (Marine)

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Corrosivity category C1 Very low

Environment examples Exterior -

Interior Heated buildings with a clean atmosphere such as offices, shops, schools, hotels.

Page 20-23

C2 Low

Atmosphere contaminated to a small extent, mainly rural regions.

Buildings which are not heated, where condensation may occur e.g. storehouses, sports halls.

20-23

C3 Medium

Industrial and urban atmosphere with an average sulphur oxide (IV) contamination level. Inshore areas of low salinity.

Production space of high humidity and certain air contamination e.g. foodstuff plants, laundries, breweries, dairies.

24-25

C4 High

Industrial areas and inshore areas of medium salinity.

Chemical plants, swimming pools, ship repair yards.

26-29

C5-I Very high (Industrial)

Industrial areas of high humidity and aggressive atmosphere.

Buildings and areas of almost constant condensation and high contamination.

30-33

C5-M Very high (Marine)

Inshore areas and offshore areas of high salinity.


34-37

The categories for water and soil according to the ISO 12944 standard are shown as:

Im1

Fresh water

Im2

Sea or brackish water

Im3

Soil

Corrosivity category

Environment

Examples of environments and structures

Im1

Fresh water

River installations, hydroelectric power plants.

Im2

Sea or brackish water

Seaports with the following structures: sluice gate, locks (water steps), water stilts, piers, offshore structures.

Im3

8

Soil

Underground tanks, steel stilts, pipelines.

Page

38-41


B. A type of protected surface Designing a coating system normally involves dealing with constructional materials such as steel, hot dipped galvanised steel, spray-metallised steel, aluminium or stainless steel. The surface preparation, the paint products used (particularly the primer) and the total system thickness will depend mainly on the constructional material to be protected. C. The durability required for a paint system The lifetime of a paint system is assumed to be the period of time which passes until maintenance is required for the first time after application. ISO 12944 specifies a range of three time frames to categorise durability: Property

Standard

Low - L

2 to 5 years

Medium - M

5 to 15 years

High - H

More than 15 years

D. P lanning the paint application process The building schedule and the various stages of construction of any particular project determine how and when the paint system needs to be applied. Consideration needs to be given to materials at their prefabrication stage, when components are being prefabricated both off and on site and when building stages are complete. It is necessary to plan the job so that surface preparation and the drying/curing time of paint products in relation to temperature and humidity are considered. Also if one stage of construction takes place in a protected workshop environment and the next stage then takes place on site, recoating intervals must also be taken into account. Our skilled personnel are always available to assist our customers in selecting the most adequate coating system for the customer’s needs and requirements. For further information, please contact your local Hempel representative.

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2. Surface preparation for metal 2.1 Surface preparation grades There are many ways to classify steel surface preparation grades but this document focuses on those outlined below. A. Grades of a surface according to the ISO 8501-1 standard Standard surface preparation grades for primary surface preparation by abrasive blasting methods Sa 3

Blast-cleaning to visually clean steel When viewed without magnification, the surface shall be free from visible oil, grease and dirt, and shall be free from mill scale, rust, paint coatings and foreign matter1. It shall have a uniform metallic colour.

Sa 2 ½ Very thorough blast-cleaning When viewed without magnification, the surface shall be free from visible oil, grease and dirt, and from mill scale, rust, paint coatings and foreign matter1. Any remaining traces of contamination shall show only as slight stains in the form of spots or stripes. Sa 2

Thorough blast-cleaning When viewed without magnification, the surface shall be free from visible oil, grease and dirt, and from most of the mill scale, rust, paint coatings and foreign matter1. Any residual contamination shall be firmly adhering2.

Sa 1

Light blast-cleaning When viewed without magnification, the surface shall be free from visible oil, grease and dirt, and from poorly adhering mill scale, rust, paint coatings and foreign matter1.

Standard preparation grades for primary surface preparation by hand cleaning St 3

Very thorough hand and power tool cleaning As for St 2, but the surface shall be treated much more thoroughly to give a metallic sheen arising from the metallic substrate.

St 2

Thorough hand and power tool cleaning When viewed without magnification, the surfaces shall be free from visible oil, grease and dirt, and from poorly adhering mill scale, rust, paint coatings and foreign matter3.

Notes: 1. The term ‘foreign matter’ may include water-soluble salts and welding residues. These contaminants cannot always be completely removed from the surface by dry blast cleaning, hand and power tool cleaning or flame cleaning; wet blast cleaning may be necessary. 2. Mill scale, rust or a paint coating is considered to be poorly adhering if it can be removed by lifting with a blunt putty knife. 3. Preparation grade St 1 is not included as it corresponds to a surface unsuitable for painting.

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B. Surface preparation grades after high pressure water cleaning Surface preparation grades by high pressure water cleaning should not only include the cleanliness grade but also the flash rust grade, since flash rusting may occur on cleaned steel during the drying period. There are several ways to classify the degree to which a steel surface is prepared after high pressure water cleaning.

This guide has used the ISO 8501-4 surface preparation grade standard using high pressure water jetting: “Initial surface conditions, preparation grades and flash rust grades in connection with high pressure water jetting”.

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The standard applies to surface preparation by high pressure water cleaning for a paint coating. It distinguishes three levels of cleanliness with reference to visible contaminants (Wa 1 – Wa 2½) such as rust, mill scale, old paint coatings and other foreign matter. Description of the surface after cleaning Wa 1

Light high-pressure water jetting When viewed without magnification, the surface shall be free from visible oil and grease, loose or defective paint, loose rust and other foreign matter. Any residual contamination shall be randomly dispersed and firmly adherent.

Wa 2

Thorough high-pressure water jetting When viewed without magnification, the surface shall be free from visible oil, grease and dirt and most of the rust, previous paint coatings and other foreign matter. Any residual contamination shall be randomly dispersed and can consist of firmly adherent coatings, firmly adherent foreign matter and stains of previously existent rust.

Wa 2½

Very thorough high-pressure water jetting When viewed without magnification, the surface shall be free from all visible rust, oil, grease, dirt, previous paint coatings and, except for slight traces, all other foreign matter. Discolouration of the surface can be present where the original coating was not intact. The grey or brown/black discolouration observed on pitted and corroded steel cannot be removed by further water jetting.

Description of the surface appearance relating to three grades of flash rust L

Light flash rust A surface which, when viewed without magnification, exhibits small quantities of a yellow/brown rust layer through which the steel substrate can be seen. The rust, (seen as a discolouration) can be evenly distributed or present in patches, but it will be tightly adherent and not easily removed by gentle wiping with a cloth.

M

Medium flash rust A surface which, when viewed without magnification, exhibits a layer of yellow/brown rust that obscures the original steel surface. The rust can be evenly distributed or present in patches, but it will be reasonably well adherent and it will lightly mark a cloth that is gently wiped over the surface.

H

Heavy flash rust A surface which, when viewed without magnification, exhibits a layer of red yellow/brown rust that obscures the original steel surface and is loosely adherent. The rust layer can be evenly distributed or present in patches and it will readily mark a cloth that is gently wiped over the surface.

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2.2 Types of surfaces 1. Steel surfaces To guarantee that a coating system delivers long lasting protection, it is essential to ensure that the right surface preparation is carried out before any paint is applied. For this reason the initial surface condition of the steel needs to be evaluated. Generally speaking, the condition of a steel surface prior to painting falls into one of the three following categories: 1) a bare steel structure with no previous protective paint coatings 2) a steel surface coated with a shopprimer 3) a steel surface coated with a paint system which needs to be maintained

ISO 8501-1 standard identifies four initial conditions for steel: A, B, C, D A Steel surface largely covered with adherent mill scale but little, if any, rust.

B Steel surface which has begun to rust and from which the mill scale has begun to flake.

2. A bare steel structure with no previous protective coatings Steel surfaces which have never been protected by paint coatings may be covered to a varying extent by rust, mill scale or other contaminants (dust, grease, ionic contamination/soluble salts, residues etc.).

C Steel surface on which the mill scale has rusted away or can be removed by scraping, but with slight pitting visible under normal vision.

The initial condition of such surfaces is defined by ISO 8501-1 standard: “Preparation of steel substrates before application of paints and related products. Visual assessment of surface cleanliness”.

D Steel surface on which the mill scale has rusted away and on which general pitting is visible under normal vision.

The corresponding photographs show levels of corrosion, preparation grades of unprotected steel substrates and steel substrates after completely removing previous coatings.

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A Grades - A 2½

B Grades - Sa 2½

C Grades - Sa 2½

D Grades - Sa 2½

A Grades - Sa 3

B Grades - Sa 3

C Grades - Sa 3

D Grades - Sa 3


3. A steel surface covered with shopprimers The main purpose of applying shopprimers is to protect steel plates and structural components used in the prefabrication stage, or in storage before a main paint system is applied. A shopprimer film thickness normally equals 20 - 25μm (these figures are quoted for a smooth test panel). Steel plates and structural components coated with shopprimers can be welded. We offer the following shopprimers: Hempel’s Shopprimer 15280 (protection period - 3 to 5 months) is a solvent-borne epoxy shopprimer pigmented with zinc polyphosphate. It is designed for automatic spray application or manual application. Hempel’s Shopprimer ZS 15890 (protection period - 4 to 6 months) is a solvent-borne zinc silicate shopprimer designed for automatic spray application. Hempel’s Shopprimer ZS 15820 (protection period - 3 to 5 months) is a solvent-borne zinc silicate shopprimer, designed for automatic spray application. Hemucryl Shopprimer 18250 (protection period - 3 to 5 months) is a waterborne acrylic shopprimer. It is designed for automatic spray application or manual application.

Surfaces coated with a shopprimer must be prepared correctly prior to the application of a finishing paint system; this is termed, ‘second surface preparation’. A shopprimer may need to be partially or completely removed. The second surface preparation will be determined, by the finishing paint system and two key factors need to be taken into account: • the compatibility of an applied shopprimer and a finishing paint system • the surface profile achieved during preparation prior to a shopprimer application, i.e. whether the profile is suitable for a finishing paint system A surface coated with a shopprimer should always be thoroughly washed with water and detergent, (e.g. Hempel’s Light Clean 99350) at 15-20 MPa, and then rinsed carefully prior to a paint system application. Corrosion and damage due to welding spots must be cleaned to the preparation grade as specified in the ISO 8501-1 standard.

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4. A steel surface coated with a paint system which needs to be maintained The condition of an existing paint system must be assessed using the degradation grade according to the standard and this must be done each time maintenance work is carried out. It will need to be determined whether the system should be completely removed or whether parts of the coating can remain.

For the different amounts of surface preparation required refer to ISO 8501-2 standard: “Preparation of steel substrates before application of paints and related products. Visual assessment of surface cleanliness. Preparation grades of previously coated steel substrates after localised removal of previous coatings”.

B. H ot dipped galvanised steel, aluminium and stainless steel surfaces In addition to standard steel, other non-iron materials can be used in construction such as hot dipped galvanised steel, aluminium or high-alloy steels. All of them require a separate approach in terms of surface preparation and the selection of a paint system. 1. Hot dipped galvanised steel When galvanised steel is exposed to the atmosphere, zinc corrosion products form on its surface. These products vary in their composition and adhesion and influence therefore the adhesive properties of applied paint systems. It is generally considered that the best surface for painting is one of pure, (within hours of the galvanisation process) or seasoned zinc. For stages in between it is recommended that the zinc corrosion products are removed by washing the surface with Hempel’s alkaline cleaner. This can be carried out using a mixture of 20 litres of pure water to half a litre of Hempel’s Light Clean 99350 detergent. The mixture must be applied to the surface and then rinsed off after half an hour, preferably at high pressure.

If necessary, washing should be combined with scrubbing using a special hard nylon bristle brush, abrasive paper or the surface cleaned by an abrasive, (glass balls, sand, etc.). For coating systems in lower corrosion classes, special adhesion primers are recommended. For coating systems in higher corrosion classes, surface preparation should include mechanical preparation of the surface, preferably by abrasive sweep blasting with a mineral abrasive. 2. Aluminium and stainless steel In the case of aluminium and stainless steel, the surface should be cleaned with fresh water and a detergent, then rinsed off thoroughly by pressure washing with fresh water. To obtain better adhesion for the paint system, it is recommended that abrasive blasting is carried out with a mineral abrasive or special brushes are used.

For further information and thorough explanations on processes and procedures of surface preparation, contact your local Hempel representative.

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3. Maximum service temperatures Paint products have different resistances to temperatures depending on the binder and pigments used. The temperature resistance of individual paint types is shown below.

Temperature °C -50

-40

-30

-20

-10

0

10

20

30

40

50

60

70

80

90

100 110 120 140 200 400 600

alkyds bitumen acrylics epoxies polyurethanes silicates silicones

Suitable for continuous dry service Suitable for short temporary service only Suitability will depend on pigmentation. Above 400°C only aluminium pigment is suitable

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4. Useful definitions

There are several useful definitions and terms used in coating protection technology. Here we provide you with a few necessary terms that you should be acquainted with when dealing with paints. Volume solids The volume solids (VS) figure expresses as a percentage the ratio of: Dry film thickness Wet film thickness The stated figure has been determined as the ratio between dry and wet film thickness of the coating applied in the indicated thickness under laboratory conditions, where no paint loss has been encountered.

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Theoretical spreading rate The theoretical spreading rate of the paint in a given dry film thickness on a completely smooth surface is calculated as follows: Volume solids % x 10 = m2/litre Dry film thickness (micron) Practical consumption The practical consumption is estimated by multiplying the theoretical consumption with a relevant consumption factor (CF). The consumption factor or the practical consumption cannot be stated in the Product Data Sheet because it depends on a number of external conditions.


A. Waviness of paint film When paint is manually applied, the film will show some waviness on the surface. It will also have an average thickness higher than the specified dry film thickness in order to fulfil the 80:20 rule for example. This means the paint consumption will be higher than the theoretically calculated amount if you want to reach the minimum specified film thickness.

C. Surface roughness of the substrate When a substrate has a particularly rough surface this creates a “dead volume” which uses more paint than if the surface was smooth and this will affect any theoretical calculations. In the case of shopprimers with a thin film, this has the effect of seemingly larger surface causing higher consumption as the paint film covers irregular surface hollows.

B. Size and shape of the surface Complex and small-sized surfaces will lead to higher consumption through overspray, than the square, flat area which was used to work out the theoretical calculation.

D. Physical losses Factors such as residues in cans, pumps and hoses, discarded paint due to exceeded pot life, losses due to atmospheric conditions, insufficient skills of a painter etc. will all contribute to a higher consumption.

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5. Guide specification according to ISO 12944 C1/2 Corrosivity category Sample systems corresponding to C1/C2 Corrosivity categories* Lifetime Top Coat

Topcoat 2nd Coat Primer

2-5 Years

System no. 1

System

DFT (μm)

Recommended use

1× Hempel's Speed-dry Alkyd 43140/1

40

As a single/double coat anticorrosive primer/finish for steel structures, general steel work has a multitude of applications for heavy and light steel industry, where quick drying properties are required. It is for general use, in exterior and interior steel surfaces. Suitable for protection of steel in mild to medium atmospheric corrosive environments.

1× Hempaquick Enamel 53840

40

As a topcoat on steel in mild to moderately corrosive environment. In case of line application of small items to be packed together, Hempalin Enamel 52140 is recommended.

Total DFT

80


40



40


Total DFT

80

1× Hemulin Primer 18310

40

As a fast drying primer on interior and exterior steelwork, machinery parts etc. in mildly to moderately corrosive environment.

1× Hemulin Enamel 58380

40

As a fast drying topcoat on steel in mildly to moderately corrosive environment.

Total DFT

80

1× Hempathane HS 55610

80

Total DFT

80

Surface

Top Coat

2-5 Years

Topcoat 2nd Coat

2

Primer

Surface

Top Coat


2-5 Years

3

Surface

Topcoat

2-5 Years

4

Surface

20

As a VOC compliant, high building finishing coat for protection of structural steel in severely corrosive environment. May be specified as a one coat "direct to metal" system in environments classified as C2 and C3.


Paint type

Finish

Volume solids

VOC

Dry to touch 20° C


SB Alkyd

Flat

49 ± 1

442 g/L

15 minutes

SB Alkyd

Glossy

41 ± 1

519 g/L

45 minutes

SB Alkyd

Flat

49 ± 1

442 g/L

15 minutes

SB Alkyd

Flat

49 ± 1

442 g/L

15 minutes

WB Alkyd

Flat

41 ± 1

1 g/L

1 hour approx

WB Alkyd

Glossy

40 ± 1

4 g/L

30 minutes approx

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours

Exterior

Interior

C1 Very low

-

Heated buildings with a clean atmosphere such as offices, shops, schools, hotels.

C2 Low


Buildings which are not heated, where condensation may occur. e.g. storehouses, sports halls.

* For the places where blasting as secondary surface preparation is not possible after production, the use of shopprimed steel is an option. Zinc silicate based shopprimers e.g. Hempel’s Shopprimer ZS 15890 or 15820 are preferred – especially for later overcoating with zinc containing paints – Epoxy based shopprimers e.g. Hempel Shopprimer 15280 can also be used in case of later overcoating with non-zinc containing paint. Ask Hempel for more specific guidelines regarding optimum choice of shopprimer and need for secondary surface preparation. SB = Solvent-borne WB = Waterborne DFT = Dry Film Thickness

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C1/2 Corrosivity category Sample systems corresponding to C1/C2 Corrosivity categories* Lifetime

Topcoat

5 - 15 Years

System no. 1

Surface Topcoat

5 - 15 Years

2

System

DFT (μm)

Recommended use

1× Hempadur Fast Dry 45410

120

As a fast curing topcoat in mild to severely corrosive environment. As one coat direct to metal in mild corrosive environment. As a topcoat where the usual cosmetic performance of epoxy coatings is acceptable.

Total DFT

120


120

Total DFT

120


60

As a single/double coat anticorrosive primer/finish for steel structures, general steel work add a multitude of applications for heavy and light steel industry, where quick drying properties are required. It is for general use, in exterior and interior steel surfaces. Suitable for protection of steel in mild to medium atmospheric corrosive environments.


60


1× Hempaquick Enamel 53840

40

As a topcoat on steel in mild to moderately corrosive environment. In case of line application of small items to be packed together, Hempalin Enamel 52140 is recommended.

Total DFT

160


80



80


Total DFT

160

1× Hempadur Mastic 45880

160

Total DFT

160

1x Hempadur Fast Dry 17410

100


60

Total DFT

160


Surface

> 15 Years

Topcoat

1

2nd Coat Primer

Surface

> 15 Years Top Coat

2


Surface

> 15 Years

Topcoat

3

Surface

Top Coat

> 15 Years

Topcoat 2nd Coat

4

Primer

Surface

22

As a self-primed, surface tolerant paint system or as an intermediate or finishing coat in heavy duty paint systems where low VOC and high film build are required. For immersed areas Hempadur Mastic 45880 is only recommended for minor repairs. Can be specified where extended recoating properties for polyurethane topcoats are requested (typically travel coating). May be used directly on cured zinc silicate (Galvosil products) or spray metallised surfaces to minimise popping.

Is suitable for the protection of new build and maintained steel structures where fast dry to handle and short overcoating times are required, such as in industrial halls, stadiums, exhibition halls, airports, bridges, power plants, refineries, chemical and petrochemical.


Paint type

Finish

Volume solids

VOC

Dry to touch 20° C


SB Epoxy

Semi flat

65 ± 1

331 g/L

1 hours approx

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours

SB Alkyd

Flat

49 ± 1

442 g/L

15 minutes

SB Alkyd

Flat

49 ± 1

442 g/L

15 minutes

SB Alkyd

Glossy

41 ± 1

519 g/L

45 minutes

SB Alkyd

Flat

49 ± 1

442 g/L

15 minutes

SB Alkyd

Flat

49 ± 1

442 g/L

15 minutes

SB Epoxy

Semi gloss

80 ± 1

216 g/L

3 hours

SB Epoxy

SB Polyurethane

Flat

75 ± 1

235 g/L

1 hour approx

Exterior

Interior

C1 Very low

-

Heated buildings with a clean atmosphere such as offices, shops, schools, hotels.

C2 Low


Buildings which are not heated, where condensation may occur. e.g. storehouses, sports halls.


23


C3 Corrosivity category Sample systems corresponding to C3 Corrosivity category* Lifetime

Top Coat

2-5 Years

Topcoat 2nd Coat

System no. 1

Primer

System

DFT (μm)

1× Hempalin Primer 12050

80

General purpose for primer for Hempalin systems for protection of steel in mild to medium atmospheric corrosive environments.

1× Hempalin Enamel 52140

40

As a general purpose finishing coat in alkyd systems on exterior and interior steel and woodwork in mildly to moderately corrosive environment. As a finishing coat in engine rooms including tank tops, main engines and auxiliary machinery.

Total DFT

120


120

Total DFT

120


100



60


Total DFT

160

1× Hemudur 18500

100

As a general purpose primer on steel constructions.

1× Hemuthane Enamel 58510

60

As a durable topcoat in waterborne epoxy systems.

Total DFT

160


140

As a self primed, surface tolerant paint system or as an intermediate or finishing coat in heavy duty paint systems where low VOC and high film build are required. For immersed areas where Hempadur Mastic 45880 is only recommended for minor repairs. Can be specified where extended recoating properties for polyurethane topcoats are requested (typically travel coating). May be used directly on cured zinc silicate (Galvosil products) or spray-metallised surfaces to minimize popping.

1x Hempathane HS 55610

60

As a VOC-compliant, high build finishing coat for protection of structural steel in severely corrosive environment. May be specified as a one coat "direct to metal" system in environments classified as C2 and C3.

Total DFT

200


120

As a primer in mild to medium atmospheric environments. As an intermediated or finishing coat in epoxy systems in medium to severely corrosive atmospheric environments.

1x Hempathane HS 55610

80

As a VOC-compliant, high build finishing coat for protection of structural steel in severely corrosive environment. May be specified as a one coat "direct to metal" system in environments classified as C2 and C3.

Total DFT

200

1× Hempadur Avantguard 750

60

As a versatile primer for long-term protection of steel in severely corrosive environments.


100


Total DFT

160

Surface

Topcoat

2-5 Years

2

Surface

5 - 15 Years Top Coat

1

Recommended use

Topcoat 2nd Coat


Primer

Surface

Top Coat

5 - 15 Years

Topcoat 2nd Coat

2

Primer

Surface

> 15 Years Top Coat

1


Surface

Top Coat


> 15 Years

2

Surface

Top Coat


Surface

24

> 15 Years

3


Paint type

Finish

Volume solids

VOC

Dry to touch 20° C


SB Alkyd

Flat

49 ± 1

407 g/L

45 minutes

C3 Medium

SB Alkyd

Glossy

46 ± 1

429 g/L

3 hours

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours

SB Epoxy

Flat

75 ± 1

235 g/L

1 hour approx

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours

WB Epoxy

Semi flat

50 ± 1

22 g/L

2 hours approx

WB Polyurethane

Glossy

48 ± 1

50 g/L

20 minutes

Exterior

Interior

Industrial and urban atmosphere with an average sulphur oxide (IV) contamination level. Instore areas of low salinity.

Production space of high humidity and certain air contamination e.g. foodstuff plants, laundries, breweries, dairies.


SB Epoxy

Semi gloss

80 ± 1

216 g/L

3 hours

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours

Solvent Based Epoxy

Semi gloss

74 ± 1

238 g/L

45 minutes

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours

SB Zinc Epoxy

Flat

65 ± 1

315 g/L

10 minutes

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours

25


C4 Corrosivity category Sample systems corresponding to C4 Corrosivity category* Lifetime 2-5 Years Top Coat

System no. 1

System

DFT (μm)

Recommended use


120



80


Total DFT

200


90



90



60


Total DFT

240

1x Hemudur 18500

90


1x Hemudur 18500

90


1× Hemuthane Enamel 58510

60

As a durable topcoat in waterborne epoxy systems.

Total DFT

240


60



80



60


Total DFT

200


Surface

5 - 15 Years

Top Coat

1


Surface

Topcoat

5 - 15 Years

2nd Coat

2

Primer

Surface

5 - 15 Years Topcoat

2nd Coat

3

Primer

Surface

26


Paint type

Finish

Volume solids

VOC

Dry to touch 20° C


Exterior

Interior

SB Epoxy

Semi gloss

74 ± 1

238 g/L

45 minutes

C4 High

Industrial areas and instore areas of medium salinity.


WB Acrylic

Glossy

67 ± 1

336 g/L

3 hours

SB Epoxy

Semi gloss

74 ± 1

238 g/L

45 minutes

SB Epoxy

Semi gloss

74 ± 1

238 g/L

45 minutes

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours

WB Epoxy

Semi flat

50 ± 1

22 g/L

2 hours approx

WB Epoxy

Semi flat

50 ± 1

22 g/L

2 hours approx

WB Polyurethane

Glossy

48 ± 1

50 g/L

20 minutes

SB Zinc Epoxy

Flat

65 ± 1

315 g/L

10 minutes

SB Epoxy

Semi gloss

74 ± 1

238 g/L

45 minutes

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours * For the places where blasting as secondary surface preparation is not possible after production, the use of shopprimed steel is an option. Zinc silicate based shopprimers e.g. Hempel’s Shopprimer ZS 15890 or 15820 are preferred – especially for later overcoating with zinc containing paints – Epoxy based shopprimers e.g. Hempel Shopprimer 15280 can also be used in case of later overcoating with non-zinc containing paint. Ask Hempel for more specific guidelines regarding optimum choice of shopprimer and need for secondary surface preparation. SB = Solvent-borne WB = Waterborne DFT = Dry Film Thickness

27


C4 Corrosivity category Sample systems corresponding to C4 Corrosivity category* Lifetime > 15 Years

Topcoat

System no. 1

2nd Coat Primer

System

DFT (μm)

1× Hempadur Mastic 45880/1

110

As a self primed, surface tolerant paint system or as an intermediate or finishing coat in heavy duty paint systems where low VOC and high film build are required. For immersed areas where Hempadur Mastic 45880 is only recommended for minor repairs. Can be specified where extended recoating properties for polyurethane topcoats are requested (typically travel coating). May be used directly on cured zinc silicate (Galvosil products) or spraymetallised surfaces to minimise popping.


110



60


Total DFT

280


60



120



60


Total DFT

240

1× Hempel's Galvosil 15703

60

As a general purpose, heavy duty, rust preventing primer. As a single, complete coating for long-term protection of steel exposed to moderately to severely corrosive environment and to abrasion. As a tank lining in accordance with the Cargo Protection Guide. In compliance with SSPC-Paint 20, type 1, level 1 and ISO 12944-5.


120



60


Total DFT

240

Surface

> 15 Years

Topcoat

2

Recommended use

2nd Coat Primer

Surface

> 15 Years

Topcoat

2nd Coat

3

Primer

Surface

28


Paint type

Finish

Volume solids

VOC

Dry to touch 20° C


Exterior

Interior

SB Epoxy

Semi gloss

80 ± 1

216 g/L

3 hours

C4 High

Industrial areas and instore areas of medium salinity.


SB Epoxy

Semi gloss

80 ± 1

216 g/L

3 hours

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours

SB Zinc Epoxy

Flat

65 ± 1

315 g/L

10 minutes

SB Epoxy

Semi gloss

80 ± 1

216 g/L

3 hours

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours


SB Zinc Silicate

Flat

64 ± 1

432 g/L

30 minutes

SB Epoxy

Semi gloss

80 ± 1

216 g/L

3 hours

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours

29


C5-I Corrosivity category Sample systems corresponding to C5 Industrial Corrosivity category* Lifetime 5 - 15 Years

System no. 1

System

DFT (μm)

Recommended use


150



150


Total DFT

300


60



120

As an intermediate high build fairing surfacer in an epoxy system where the cosmetic finish is important.


60


Total DFT

240


Surface

5 - 15 Years Topcoat

2nd Coat Primer

Surface

30

2


Paint type

Finish

Volume solids

VOC

Dry to touch 20° C


Exterior

Interior

SB Epoxy

Semi gloss

80 ± 1

216 g/L

3 hours




SB Epoxy

Semi gloss

80 ± 1

216 g/L

3 hours

SB Zinc Epoxy

Flat

65 ± 1

315 g/L

10 minutes

SB Epoxy

Semi gloss

63 ± 1

359 g/L

1 hour

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours

* For places where blasting as secondary surface preparation is not possible after production, the use of shopprimed steel is an option. Zinc silicate based shopprimers e.g. Hempel’s Shopprimer ZS 15890 or 15820 are preferred, especially for later overcoating with paints containing zinc. Epoxy based shopprimers e.g. Hempel Shopprimer 15280 can also be used in the case of later overcoating with paint not containing zinc. Ask Hempel for more specific guidelines regarding the optimum choice of shopprimer and the need for secondary surface preparation. SB = Solvent-borne WB = Waterborne DFT = Dry Film Thickness

31


C5-I Corrosivity category Sample systems corresponding to C5 Industrial Corrosivity category* Lifetime > 15 Years

Topcoat

System no. 1

2nd Coat Primer

System

DFT (μm)


130



130



60


Total DFT

320


60



200



60


Total DFT

320


60

As a general purpose, heavy duty, rust preventing timber. As a single, complete coating for long term protection of steel exposed to moderately to severely corrosive environment and to abrasion. As a tank lining in accordance with the Cargo Protection Guide in compliance with SSPC-Paint 20 type 1, level 1 and ISO 12944-5.


200



60


Total DFT

320

Surface

> 15 Years Topcoat

2

2nd Coat Primer

Surface

> 15 Years

Topcoat

2nd Coat

3

Primer

Surface

32

Recommended use


Paint type

Finish

Volume solids

VOC

Dry to touch 20° C


Exterior

Interior

SB Epoxy

Semi gloss

80 ± 1

216 g/L

3 hours




SB Epoxy

Semi gloss

80 ± 1

216 g/L

3 hours

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours

SB Zinc Epoxy

Flat

65 ± 1

315 g/L

10 minutes

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours

SB Zinc Silicate

Flat

67 ± 1

535 g/L

30 minutes approx

SB Epoxy

Semi gloss

80 ± 1

216 g/L

3 hours

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours


33


C5-M Corrosivity category Sample systems corresponding to C5 Marine Corrosivity category* Lifetime 5 - 15 Years

System no. 1

System

DFT (μm)


150



150


Total DFT

300


60



120



60


Total DFT

240


Surface

5 - 15 Years

Topcoat

2nd Coat

2

Primer

Surface

34

Recommended use


Paint type

Finish

Volume solids

VOC

Dry to touch 20° C


SB Epoxy

Semi gloss

80 ± 1

216 g/L

3 hours


SB Epoxy

Semi gloss

80 ± 1

216 g/L

3 hours

SB Zinc Epoxy

Flat

65 ± 1

315 g/L

10 minutes

SB Epoxy

Flat

75 ± 1

235 g/L

1 hour approx

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours

Exterior

Interior

Marine areas and offshore areas of high salinity.



35


C5-M Corrosivity category Sample systems corresponding to C5 Marine Corrosivity category* Lifetime > 15 Years

Topcoat

System no. 1

System

DFT (μm)


130



130



60


Total DFT

320


60



100



100



60


Total DFT

320


60

As a general purpose, heavy duty, rust preventing timber. As a single, complete coating for long term protection of steel exposed to moderately to severely corrosive environment and to abrasion. As a tank lining in accordance with the Cargo Protection Guide in compliance with SSPC-Paint 20 type 1, level 1 and ISO 12944-5.


100



100



60


Total DFT

320

2nd Coat Primer

Surface

> 15 Years

Topcoat

2

3rd Coat 2nd Coat Primer

Surface

> 15 Years

Topcoat

3

3rd Coat 2nd Coat Primer

Surface

36

Recommended use


Paint type

Finish

Volume solids

VOC

Dry to touch 20° C


SB Epoxy

Semi gloss

80 ± 1

216 g/L

3 hours


SB Epoxy

Semi gloss

80 ± 1

216 g/L

3 hours

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours

SB Zinc Epoxy

Flat

65 ± 1

315 g/L

10 minutes

SB Epoxy

Flat

75 ± 1

235 g/L

1 hour approx

SB Epoxy

Flat

75 ± 1

235 g/L

1 hour approx

SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours

SB Zinc Silicate

Flat

64 ± 1

535 g/L

30 minutes approx

SB Epoxy

Semi gloss

80 ± 1

216 g/L

3 hours

SB Epoxy

Semi gloss

80 ± 1

216 g/L

3 hours

Exterior

Interior

Marine areas and offshore areas of high salinity.



SB Polyurethane

Glossy

67 ± 1

336 g/L

3 hours

37


Immersed structures For steel structures immersed in water (excluding potable water) or buried in soil Lifetime 5 - 15 Years

Topcoat

System no. 1

System

DFT (μm)

1x Hempadur Quattro 17634

190

As a universal epoxy and self primed high performance coating system for atmospheric or in water service, including water ballast tanks and cargo oil tanks to be coated according to IMO-PSPC requirements. It is intended for all year application down to -10°C/15°F.


190


Total DFT

380

1x Hempadur Mastic 45880/1

190


1x Hempadur Mastic 45880/1

190


Total DFT

380

1x Hempadur Multi-strength GF 35870

400

Total DFT

400

Primer

Surface

5 - 15 Years

2


Surface

Topcoat

Surface

38

5 - 15 Years

3

Recommended use

As a self primed, high build coating primarily for areas subject to abrasion and/ or to a highly corrosive environment, e.g. splash zones, jetty pilings and working decks. Can be used as interior lining for crude oil and fuel oil storage tanks.


Paint type

Finish

Volume solids

VOC

Dry to touch 20° C

Epoxy

Semi flat

72 ± 1

275 g/L

2 hours

Epoxy

Semi flat

72 ± 1

275 g/L

2 hours


Epoxy

Semi gloss

80 ± 1

216 g/L

3 hours

Epoxy

Semi gloss

80 ± 1

216 g/L

3 hours

Epoxy GF

Glossy

87 ± 1

188 g/L

4 hours

39


Immersed structures For steel structures immersed in water (excluding potable water) or buried in soil Lifetime > 15 Years

Topcoat

System no. 1

2nd Coat Primer

Surface

> 15 Years

Topcoat

2

2nd Coat Primer

System

DFT (μm)

Recommended use


150



175



175


Total DFT

500

1x Hempadur Multi-strength 45751/3

150

As a heavy duty coating for areas exposed to abrasion and aggressive corrosive climate such as ramps, ship hulls and holds of bulk carriers. As a ballast tank coating for special purposes where pure epoxy coating is requested. As a finishing coat where a cosmetic appearance is less important. 45751 is intended for use in warm climates. 45753 for use in cold climates.


175

As a heavy duty coating for areas exposed to abrasion and aggressive corrosive climate such as ramps, ship hulls and holds of bulk carriers. As a ballast tank coating for special purposes where pure epoxy coating is requested. As a finishing coat where a cosmetic appearance is less important. 45751 is intended for use in warm climates. 45753 for use in cold climate.


175

As a heavy duty coating for areas exposed to abrasion and aggressive corrosive climate such as ramps, ship hulls and holds of bulk carriers. As a ballast tank coating for special purposes where pure epoxy coating is requested. As a finishing coat where a cosmetic appearance is less important. 45751 is intended for use in warm climates. 45753 for use in cold climate.

Total DFT

500


300



300


Total DFT

600

1x Hempadur 87540

800

Total DFT

800

Surface

> 15 Years

Topcoat

3

Primer

Surface

Topcoat

Surface

40

> 15 Years

4

As a self primed, high build coating for the protection of the exterior of buried steel pipes, valves, fittings etc. operating at elevated temperatures in severely corrosive environments. As a repair system for pipelines.


Paint type

Finish

Volume solids

VOC

Dry to touch 20° C

Epoxy

Semi flat

72 ± 1

275 g/L

2 hours

Epoxy

Semi flat

72 ± 1

275 g/L

2 hours

Epoxy

Semi flat

72 ± 1

275 g/L

2 hours

Epoxy

Semi gloss

79 ± 1

45751 250 g/L

45751 7-8 hours

45753 235 g/L

45753 8-10 hours

45751 250 g/L

45751 7-8 hours

45753 235 g/L

45753 8-10 hours

45751 250 g/L

45751 7-8 hours

45753 235 g/L

45753 8-10 hours

188 g/L

4 hours

Epoxy

Epoxy

Epoxy

Semi gloss

Semi gloss

Glossy

79 ± 1

79 ± 1

87 ± 1

Epoxy

Glossy

87 ± 1

188 g/L

4 hours

Epoxy

Glossy

100

5 g/L

1 hour


41


Winning solutions 2014 World Cup Stadia, Brazil Although the 2014 FIFA World Cup officially kicked off on 12th June 2014 when host nation Brazil played Croatia, we had been actively involved in the country’s intense stadium preparation programme for the previous 3 years.

Stadiums including: Arena Fonte Nova Stadium Castelao Stadium Arena do Gremio Stadium

Hempel was a natural choice for this project. With our global facilities and flexible service offering, it was possible to assist our customer efficiently both in Portugal, for the initial build and in Brazil for subsequent touch up and repair work after the long crossing. The huge metal structures for all 3 stadiums were manufactured and fully coated in Portugal, before being shipped to Brazil and erected on site. Our systems were chosen to resist the corrosive salty ocean crossing, the hard knocks that happen during transportation and protect against the Brazilian climate for many years to come. With a reputation among steel constructors as an extremely reliable product that combines excellent mechanical resistance with high productivity, Hempadur Fast Dry 15560 was integral to this durable protective coating system. Arena Fonte Nova in Salvador da Bahia, with a capacity for 55,000 spectators, and coated with 40,000 litres of Hempel, was awarded the 2013 European Steel Design Award by ECCS (European Convention for Construction Steelwork). Part of the legacy of Brazil 2014, these three stadia continue to play an important role as major sporting venues and our coatings systems continue to protect a combined 6,220 tonnes of steel that form their roofs.

Products Hempadur Zinc 17360 Hempadur Fast Dry 15560 Hempathane HS 55610

42

Photo: Fábio Lima


Vestas, Denmark 140 metres high, the Vestas’ wind turbine produces electricity for around 7,500 homes. It is protected with our two-coat system that Vestas use as standard on their offshore wind towers. As well as excellent anti-corrosive performance and rapid application properties, the system delivers excellent abrasion resistance to protect during transportation and installation, and lasting weather and UV resistance. Products Hempadur 4774A Hempathane HS 5561B

Elco, Oman Elco, a leading engineering and fabrication company, identified Hempel as the right coatings supplier for the onshore Khazzan and Makarem processing facility, to give the best corrosion protection available. The system that Elco are using includes Hempadur Avantguard 750, an activated zinc primer that is ideal for use in severely corrosive environments.

Products Hempadur Avantguard 750 Hempadur MIO 47950 Hempathane HS 55610

VW Manufacturing Plant, Russia When constructing a new factory for a leading German automotive manufacturer, our customer needed a coating system that not only delivers excellent corrosion protection, but could also be applied extremely quickly. Hempel's Speed Dry Alkyd met these tough conditions, as it is engineered for C2 corrosive environments and dries in less than two hours.

Products Speed-Dry Alkyd 4314 (primer) Speed-Dry Alkyd 4314 (topcoat) 43

hempeldecorative.me

Since 1915 Hempel has been a world-leading coatings specialist, providing protection and inspiration to the world around us. Today we have over 5,500 people in 80 countries delivering trusted solutions in the protective, decorative, marine, container, industrial and yacht markets. This includes many recognised brands like Crown Paints, Schaepman and Jones-Blair. Hempel is proudly owned by the Hempel Foundation, which supports cultural, humanitarian and scientific causes across the world.

Hempel Qatar Block 212, Street 16 Salwa Industrial Area P.O.Box 3484, Doha State of Qatar Tel: +974 4455 9000 Fax: +974 4460 0901 Hempel Emirates Interchange 8 Al Dhaid Road Plot 698/G, Sajaa Area P.O.Box 2000, Sharjah United Arab Emirates Tel: +971 6 531 0140 Fax: +971 6 531 0141 Hempel Oman Ghala Industrial Area Beside Komatsu Building No 1280 Way No 5217 P.O.Box 1260, PC 112 Muscat, Sultanate of Oman Tel: +968 24592759 Fax: +968 24596895

Hempel Abu Dhabi Plot No 37, Sector M-15 Mussafah Industrial Area P.O.Box 47006 Abu Dhabi United Arab Emirates Tel: +971 2 5552279 Fax: +971 2 5553379

Hempel Riyadh Bldg. No. 6371 King Abdulaziz Road P.O.Box 3977, Riyadh 11481 Kingdom of Saudi Arabia Tel: +966 11 810 7780 Fax: +966 11 214 4664

Hempel Dammam First Industrial Area Fourth Road, Bn Zheer Street P.O.Box 1077, Dammam 31431 Kingdom of Saudi Arabia Tel: +966 3 847 1616 Fax: +966 3 847 1816

Hempel Bahrain Mina Salman Industrial Area Building 314, Road 4306, Block 343 P.O.Box 997, Manama Kingdom of Bahrain Tel: +973 1772 8668 Fax: +973 1782 7327

Hempel Jeddah Al Suhaili Commercial Centre, Siteen Street, Al Rabwah District, P.O.Box 6783, Jeddah 21452 Kingdom of Saudi Arabia Tel: +966 2 257 4567 Fax: +966 2 275 2828

Hempel Kuwait Shuwaikh Industrial Area Block B, Street No. 30, Plot No. 119 P.O.Box 3400, Safat 13034, State of Kuwait Tel: +965 2 202 0700 Fax: +965 2 484 3307

Hempel Syria Industrial City, Hassia P.O.Box 11613, Damascus Syrian Arab Republic Tel: +963 31 5360150/8 Hempel (Decorative Paints) in Egypt Tel: +20105298886

V1_DEC_16

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