paint and surface coatings

798 Pages·2003·7.18 MB·English

PAINT AND SURFACE
COATINGS

Theory and Practice

Second edition

Editors:
R LAMBOURNE and T A STRIVENS

Cambridge England

PAIPR 7/16/99 2:28 PM Page i

Published by Woodhead Publishing Ltd, Abington Hall, Abington, Cambridge CB1 6AH,
England

First published 1987 Ellis Horwood Ltd
Reprinted 1988
Reprinted in paperback 1993
Second edition 1999 Woodhead Publishing Ltd

© 1999 Woodhead Publishing Ltd
The authors have asserted their moral rights.

Conditions of sale
All rights reserved. No part of this publication may be reproduced or transmitted in any
form or by any means, electronic or mechanical, including photocopying, recording or any
information storage and retrieval system, without permission in writing from the publisher.

While a great deal of care has been taken to provide accurate and current information,
neither the author, nor the publisher, nor anyone else associated with this publication shall
be liable for any loss, damage or liability directly or indirectly caused or alleged to be
caused by this book.

British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library.

ISBN 1 85573 348 X

Typeset by Best-set Typesetter Ltd., Hong Kong.
Printed by TJ International, Cornwall, England.

PAIPR 7/16/99 2:28 PM Page ii

Contents

List of contributors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
x

Preface to first edition
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
xi

Preface to second edition . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
xiii

1
Paint composition and applications — a general introduction
R Lambourne
1.1
A short history of paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.2
Paint or surface coating? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1.3
The components of paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
1.4
Paint making . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
1.5
Methods of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
1.6
Paint markets
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18

2
Organic film formers
J Bentley
2.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
2.2
Natural polymers
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
2.3
Oils and fatty acids
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
2.4
Oleoresinous media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
2.5
Alkyd resins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
2.6
Polyester resins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
2.7
Acrylic polymers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
2.8
Emulsion and dispersion polymers
. . . . . . . . . . . . . . . . . . . . . . . . . .
54
2.9
Non-aqueous dispersion polymerization . . . . . . . . . . . . . . . . . . . . . .
60
2.10
Amino resins
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
2.11
Phenol formaldehyde resins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
2.12
Epoxy resins
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
2.13
Isocyanates
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70
2.14
Silicone resins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74

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2.15
Vinyl resins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
2.16
Water-borne systems
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
2.17
Resins for electrodeposition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80
2.18
High solids coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82
2.19
Radiation-curing polymers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84
2.20
Powder-coating compositions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85
2.21
Resin manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87
References
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87

3
Pigments for paint
A G Abel
3.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
91
3.2
Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
91
3.3
Required qualities of pigments
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
92
3.4
Pigment classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
105
3.5
Pigment nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
108
3.6
Further types of pigments and terms used . . . . . . . . . . . . . . . . . . . .
109
3.7
Particulate nature of pigments and the dispersion process . . . . . .
114
3.8
Manufacture of pigments
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
119
3.9
Toxicity and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
124
3.10
Choosing pigments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
125
3.11
Physical forms of pigment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
127
3.12
Notes on families of pigments
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
129
References
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
165

4
Solvents, thinners, and diluents
R Lambourne
4.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
166
4.2
The market for solvents in the paint industry . . . . . . . . . . . . . . . . .
167
4.3
Solvent power or solvency
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
168
4.4
Solvent effects on viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
178
4.5
Evaporation of solvents from coatings . . . . . . . . . . . . . . . . . . . . . . .
179
4.6
Flashpoint
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
180
4.7
Toxicity and environmental pollution . . . . . . . . . . . . . . . . . . . . . . . .
181
Acknowledgement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
183
References
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
183

5
Additives for paint
R A Jeffs and W Jones
5.1
Introduction
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
185
5.2
Anti-corrosive pigment enhancers . . . . . . . . . . . . . . . . . . . . . . . . . . .
186
5.3
Antifoams
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
186
5.4
Antisettling agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
187
5.5
Antiskinning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
188
5.6
Can-corrosion inhibitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
188
5.7
Dehydrators/antigassing additives . . . . . . . . . . . . . . . . . . . . . . . . . . .
189
5.8
Dispersion aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
189
5.9
Driers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
190

iv
Contents

PAIPR 7/16/99 2:28 PM Page iv

5.10
Electrical properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
192
5.11
Flash corrosion inhibitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
192
5.12
Floating and flooding additives
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
192
5.13
In-can preservatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
193
5.14
In-film preservatives
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
194
5.15
Insecticidal additives
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
194
5.16
Optical whiteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
195
5.17
Reodorants
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
195
5.18
Ultraviolet absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
195
5.19
Additive suppliers
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
196

6
The physical chemistry of dispersion
A Doroszkowski
6.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
198
6.2
Immersion and wetting of the pigment . . . . . . . . . . . . . . . . . . . . . . .
199
6.3
Deagglomeration (mechanical breakdown of agglomerates) . . . . .
203
6.4
Dispersion — colloid stabilization . . . . . . . . . . . . . . . . . . . . . . . . . . .
205
6.5
Steric (or polymer) stabilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
219
6.6
Depletion flocculation and stabilization . . . . . . . . . . . . . . . . . . . . . .
224
6.7
Adsorption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
227
6.8
Rate of flocculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
234
References
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
240

7
Particle size and size measurement
A Doroszkowski
7.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
243
7.2
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
243
7.3
Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
252
7.4
Methods of particle sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
257
7.5
The best method? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
280
References
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
283

8
The industrial paint-making process
F K Farkas
8.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
286
8.2
The use of dispersants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
286
8.3
Methods of optimizing millbases for dispersion . . . . . . . . . . . . . . . .
288
8.4
The instrumental formulating technique . . . . . . . . . . . . . . . . . . . . . .
290
8.5
Methods of dispersion and machinery . . . . . . . . . . . . . . . . . . . . . . . .
309
8.6
Mixing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
325
8.7
Control techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
327
Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
329
References
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
329

9
Coatings for buildings
J A Graystone
9.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
330
9.2
Formulating considerations and constraints . . . . . . . . . . . . . . . . . . .
331
9.3
Pigment–binder–solvent relationships . . . . . . . . . . . . . . . . . . . . . . . .
335

Contents
v

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9.4
The nature of paint binder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
350
9.5
Colour delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
359
9.6
Meeting the needs of the substrate . . . . . . . . . . . . . . . . . . . . . . . . . .
365
9.7
Masonry and cementitious substrates . . . . . . . . . . . . . . . . . . . . . . . .
383
9.8
Metallic substrates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
398
9.9
Plastic as a substrate
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
406
References
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
406

10
Automotive paints
D A Ansdell
10.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
411
10.2
Pretreatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
415
10.3
Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
419
10.4
Surfacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
431
10.5
Anti-chip coatings
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
438
10.6
Inverted or reverse process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
438
10.7
Automotive topcoats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
440
10.8
In-factory repairs
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
457
10.9
Painting of plastic body components . . . . . . . . . . . . . . . . . . . . . . . . .
459
10.10 Spray application
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
461
10.11 Stoving procedures
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
472
10.12 Performance/testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
477
10.13 Future developments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
483
Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
490
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
491

11
Automotive refinish paints
A H Mawby
11.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
492
11.2
Topcoat systems
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
494
11.3
Colour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
497
11.4
Future developments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
500
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
501

12
General industrial paints
G P A Turner
12.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
502
12.2
Factors governing the selection of industrial painting
processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
503
12.3
Industrial application and curing methods . . . . . . . . . . . . . . . . . . . .
509
12.4
Finishing materials and processes in selected industrial
painting operations
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
517
12.5
Developments and trends in general industrial finishing . . . . . . . .
526
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
528

13
The painting of ships
R Lambourne
13.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
529
13.2
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
530

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13.3
Surface preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
533
13.4
Blast primers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
534
13.5
Paint systems for ships
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
534
13.6
The painting of off-shore structures
. . . . . . . . . . . . . . . . . . . . . . . . .
547
References
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
549

14
An introduction to rheology
T A Strivens
14.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
550
14.2
History of viscosity measurements . . . . . . . . . . . . . . . . . . . . . . . . . . .
551
14.3
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
552
14.4
Methods of measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
560
14.5
Interpretation of results
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
567
References
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
574

15
The rheology of paints
T A Strivens
15.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
575
15.2
General considerations on paint rheology — paint application
processes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
575
15.3
Experimental methods for measuring paint rheology for
application and flow-out after application
. . . . . . . . . . . . . . . . . . . .
581
15.4
Paint rheology during manufacture and storage . . . . . . . . . . . . . . .
593
References
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
595

16
Mechanical properties of paints and coatings
T A Strivens
16.1
Introduction
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
598
16.2
Viscoelastic properties of polymers . . . . . . . . . . . . . . . . . . . . . . . . . .
599
16.3
Ultimate mechanical properties of polymers . . . . . . . . . . . . . . . . . .
603
16.4
Experimental methods for determining mechanical properties
of coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
605
16.5
Discussion of experimental methods . . . . . . . . . . . . . . . . . . . . . . . . .
611
16.6
Technological tests for mechanical properties . . . . . . . . . . . . . . . . .
612
16.7
Acoustic emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
615
16.8
Recent developments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
617
References
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
618

17
Appearance qualities of paint — basic concepts
T R Bullett
17.1
Introduction
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
621
17.2
Physics of reflection by paint/air interfaces . . . . . . . . . . . . . . . . . . . .
621
17.3
Light scattering and absorption by paint films . . . . . . . . . . . . . . . . .
624
17.4
Colour of pigment mixtures and pigmented films . . . . . . . . . . . . . .
629
17.5
Changes in paint films . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
634
17.6
Fluorescence and phosphorescence . . . . . . . . . . . . . . . . . . . . . . . . . .
636
17.7
Colour appreciation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
636
17.8
Further reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
639
References
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
640

Contents
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PAIPR 7/16/99 2:28 PM Page vii

18
Specification and control of appearance
T R Bullett
18.1
Gloss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
642
18.2
Opacity of paint films . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
647
18.3
Specification and control of colour
. . . . . . . . . . . . . . . . . . . . . . . . . .
652
18.4
Colour control in paint manufacture . . . . . . . . . . . . . . . . . . . . . . . . .
657
Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
657
References
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
657

19
Durability testing
R Lambourne
19.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
658
19.2
Chemical resistance testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
661
19.3
Testing mechanical properties of paints
. . . . . . . . . . . . . . . . . . . . . .
668
19.4
Accelerated weathering
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
675
19.5
Natural weathering
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
686
19.6
Suppliers of accelerated weathering test equipment . . . . . . . . . . . .
692
Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
692
References
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
693

20
Computers and modelling in paint and resin formulating
J Bentley
20.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
694
20.2
Software in the laboratory
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
695
20.3
Information technology and knowledge-based systems . . . . . . . . .
695
20.4
Modelling and mathematical techniques . . . . . . . . . . . . . . . . . . . . . .
696
20.5
Molecular modelling
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
700
20.6
Resin formulating and processes . . . . . . . . . . . . . . . . . . . . . . . . . . . .
701
20.7
Resin scale-up and manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
711
20.8
Polymer properties, curing, and network properties . . . . . . . . . . . .
712
20.9
Solvents and solubility properties
. . . . . . . . . . . . . . . . . . . . . . . . . . .
716
20.10 Paint formulation and manufacture, and coating performance . . .
718
20.11 Experimental analysis, design, and quality control . . . . . . . . . . . . .
719
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
719
References
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
720

21
Health and safety in the coatings industry
G R Hayward
21.1
Introduction
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
725
21.2
Raw materials and intermediates . . . . . . . . . . . . . . . . . . . . . . . . . . . .
726
21.3
Occupational exposure
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
729
21.4
Provision of information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
732
21.5
The approved supply list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
732
21.6
Hazard details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
738
21.7
Safety data sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
739
21.8
Labelling of substances and preparations . . . . . . . . . . . . . . . . . . . . .
740
21.9
Classification and labelling for transport (conveyance) . . . . . . . . .
745
21.10 Control of hazardous substances . . . . . . . . . . . . . . . . . . . . . . . . . . . .
750
21.11 New substances regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
752

viii
Contents

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21.12 Food contact coatings
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
753
21.13 Major accident hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
756
21.14 Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
759
21.15 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
761
References
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
762
Appendix 1: risk phrases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
762
Appendix 2: safety phrases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
764

Index
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
767

Contents
ix

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List of contributors

A G Abel
Industrial Manager (Technology), Clariant Specialties Ltd,
Calverley Lane, Horsforth, Leeds LS18 4RP, UK
D A Ansdell
Formerly Technical Manager, Automotive Products, ICI Paints
Division, Slough SL2 5DS, UK
J Bentley
Consultant, Paint Research Association, Teddington,
Middlesex, UK
T R Bullett
Formerly Research Director, Paint Research Association,
Teddington, Middlesex, UK
A Doroszkowski
Principal Research Scientist, Paint Research Association,
Teddington, Middlesex, UK
F K Farkas
Consultant, FKF & Associates
J A Graystone
Principal Research Scientist, Paint Research Association,
Teddington, Middlesex, UK
G R Hayward
Consultant, Hales End, Main Street, Laxton Village, E.
Northants NN17 3AT, UK
R A Jeffs
Formerly Research Department, ICI Paints Division, Slough
SL2 5DS, UK
W Jones
Formerly Research Department, ICI Paints Division, Slough
SL2 5DS, UK
R Lambourne
Formerly Research Department, ICI Paints Division and
Industrial Colloid Advisory Group, Bristol University, UK
A H Mawby
Director, Refinish Marketing, PPG Industries (UK) Ltd,
Ladywood, Birmingham B116 0AD, UK
T A Strivens
Formerly Divisional Research Associate, ICI Paints Division,
Slough SL2 5DS, UK
G P A Turner
Formerly Technical Manager, Industrial Coatings Research,
ICI Paints Division, Slough SL2 5DS, UK

PAIPR 7/16/99 2:28 PM Page x

Preface to first edition

For many years I have felt that there has been a need for a book on the science and
technology of paints and surface coatings that would provide science graduates
entering the paint industry with a bridge between academia and the applied science
and technology of paints.Whilst there have been many excellent books dealing with
the technology there have not to my knowledge been any that have sought to
provide a basic understanding of the chemistry and physics of coatings. Many of
the one-time standard technological texts are now out of date (and out of print),
so it seemed appropriate to attempt to produce a book that will, I hope, fill a gap.
Nevertheless, it was with some trepidation that I undertook the task of editing a
book covering such a diverse technology.The diversity of the technology is such that
rarely will an acknowledged expert in one aspect of the technology feel confident
to claim expertise in another. It therefore seemed to me that a work produced by
a single author would not meet the objectives I had in mind, and I sought the help
of friends and colleagues in the industry to contribute individual chapters on sub-
jects where I knew them to have the requisite expertise. Fortunately, I was able to
persuade sufficient contributions from individuals for whom I have the highest
regard in respect of their knowledge and years of experience within the paint indus-
try to satisfy myself of the ultimate authenticity of the book as a whole.
However, because of limitations of space it is impossible for a book of this kind
to be completely comprehensive. Thus I have had to make decisions regarding
content, and have adopted a framework which gives more space, for example, to the
physics of paint and the physical chemistry of dispersions than most books of this
kind. In doing so I have had to reduce the breadth (and in some cases the depth)
of treatment of specific technologies.Thus, whilst the chapters on automotive paint-
ing and architectural paints are fairly detailed, the treatment of general industrial
finishing is less an ‘in depth’ account of specific technologies, but is intended to illus-
trate the very wide range of requirements of manufacturing industry and the prob-
lems the paint technologist may encounter as a result of this.
In chapters dealing with the fundamental principles underlying the technology
authors have been invited to provide critical accounts of the science and technol-

PAIPR 7/16/99 2:28 PM Page xi

ogy as it stands today. This is reflected in the extensive lists of references to origi-
nal work mostly published within the last decade. It is hoped that readers wishing
to delve further to increase their understanding will find these references a valu-
able source of information.
It is important to record that apart from the authors, a number of individuals
have contributed to the production of this book. I would like to record my thanks
to Dr Gordon Fettis, Research Manager of ICI Paints Division, for his support and
encouragement from its inception, and for the use of many of the facilities of ICI
in the production of the manuscript. Thanks are also due to Mrs Millie Cohen (of
ICI) and Mrs Kate Slattery (of Bristol University) who between them typed the
major part of the manuscript.

R Lambourne

xii
Preface to first edition

PAIPR 7/16/99 2:28 PM Page xii

Preface to second edition

When I was invited to edit the second edition of this book, I took the decision to
retain as far as possible the original team of authors. In addition, valuable new chap-
ters (20 and 21) on the use of computers in the paint industry and health and safety
have been contributed by Mr J Bentley and Mr G R Hayward, respectively. Owing
to the unfortunate and untimely death of Miss J F Rolinson, Chapter 3 on pigments
has not been revised. Instead, thanks to Dr A G Abel, a completely new chapter on
this subject has been provided.
I believe this resulting new edition will provide a useful text for those wishing to
explore various aspects of paint technology and its underlying science, whilst its lit-
erature references will provide a useful start to the study of any particular aspect
of that technology.
I would like to pay tribute to the team of authors, who have provided me with
revised or new chapters, and for their support, help and encouragement in produc-
ing this second edition.

T A Strivens

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PAIPR 7/16/99 2:28 PM Page xiv

1

Paint composition and applications —
a general introduction

R Lambourne

1.1
A short history of paint

Primitive men are credited with making the first paints about 25000 years ago.They
were hunters and cave dwellers and were probably inspired by the rock formations
of their cave walls to outline and colour the shapes of the animals they hunted. It
is possible that by creating these images they thought their power over their prey
would be increased.
Chemical analysis of cave paintings discovered at Altamira (Spain) and Lascaux
(France) show that the main pigments used by Palaeolithic artists were based upon
iron and manganese oxides. These provide the three fundamental colours found
in most cave paintings, namely black, red, and yellow, together with intermediate
tints. Carbon from burnt wood, yellow iron carbonate, and chalk may also have been
used. Surprisingly, there is no trace of a white pigment (the commonest pigment
in use today) at Lascaux, where the natural colour of the rock was used as a pale
background. However, white pigments do occur in some prehistoric paintings in
Africa.
These earth pigments were ground to a fine powder in a pestle and mortar.
Naturally hollowed stones are thought to have been used as mortars and bones as
pestles, following the finds of such articles stained with pigments. The powdered
pigments were probably mixed with water, bone marrow, animal fats, egg white, or
vegetable sugars to form paints. They were applied by finger ‘dabbing’, or crudely
made pads or brushes from hair, animal fur, or moss. Cave paintings have survived
because of their sheltered positions deep in caves which were subsequently sealed
off. These paints have very poor durability, the binders serving merely to make the
pigments stick to the cave walls.
The Egyptians developed the art of paint-making considerably during the period
circa 3000–600 bc.They developed a wider colour range of pigments which included
the blues, lapis lazuli (a sodium silicate–sodium sulphide mixed crystal), and azurite
(chemically similar to malachite). Red and yellow ochres (iron oxide), yellow orpi-
ment (arsenic trisulphide), malachite green (basic copper carbonate), lamp-black,

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