High-Performance Protection Coating Selection for Interior and
Exterior Architectural Applications
AIA Wyoming Fall Conference
Learning Objectives
After viewing this presentation, participants will be able to:
• Identify the coating environments applicable for architectural applications
• Understand what generic coating type should be used for a particular environment
• Identify what generic coating type should be used for interior and/or exterior applications
• Understand a complete coating system includes a primer, intermediate and topcoat
• Identify where floor coatings can fit into a particular project scope
• Understand what coatings may be used on environmentally focused projects
Our Core Markets
• Water Storage Tank Market
• Water and Wastewater Market
• Specialty Architectural Market
• Processing & Manufacturing Market
• Industrial Market
Water Tank
WWTP Civic Building Manufacturing Plant Fuel Storage Tank
Substrate Covering Options
Paint Systems
(Aesthetic appeal) Coating Systems (Protection)
Interior office spaces Exterior uses (color and gloss retention)
Low-traffic areas Areas subject to abuse
Traditional painted items Corrosion prevention
Aesthetic purpose Aesthetic value with long-term substrate
protection
Frequent repaints due to
color trends Life cycle cost value
COATING ENVIRONMENTS Applicable for Architectural Applications
High Rise – CA
Natatorium - MA
Gateway - CA
Protection For…
• Steel
• Aluminum
• Cast Iron
• Galvanized
• Non-Ferrous Metal
• Wood
• Concrete
• Masonry
• Stucco
High Rise Buildings
High Rise Building - Chicago, IL
• Corrosion protection
• Color and gloss performance
• Overcoating of aged panels (refurbishment) or new construction
• Life Cycle Savings
Sports & Recreation Facilities
Stadium - Atlanta, GA
• Color and gloss retention for exterior substrates
• Brand or logo color performance
• Durable floor and wall systems
• Water repellents
Processing & Manufacturing
Printing Facility – Kansas City, MO
• Structural steel
• Tanks
• Interior floors and walls
• Equipment
Healthcare Facilities
Medical Center - Bailey, OK
• Operating rooms
• Clean rooms
• Ceilings
• Abrasion resistant, floor and wall systems
• Non-staining
• Frequent cleaning
Educational Facilities
School District - Marion County, FL
• Steel, masonry and concrete protection
• Interior floors and
walls
• Roof coatings
• Graffiti protection
Correctional Facilities
County Jail - Hamilton, OH
• High abuse wall and floor systems
• Interior and exterior steel & masonry
• Kitchen
• Shower areas
Transportation
Airport - Indianapolis, IN
• High performance protection from UV and freeze/thaw cycling
• Interior and exterior steel & masonry
• Chemical resistance
Natatoriums
Fieldhouse - Columbia, MO
• Overhead deck and
truss/joint protection
• Walls and floors in chemical environments
• Pool coatings
Parking Garages
Parking Garage -
Milwaukee, WI
• Light reflectant ceiling coatings
• Structural steel and concrete protection
• Water Repellents for chloride protection
Volatile Solvents
Resin (Binder)
Pigment
SOLIDS
VEHICLE
Costs of Paints & Coatings • Resins: The framework on
which the coating’s
performance is built – Most
expensive part - FLORINE
• Pigments: Color, hide & anti-
corrosion Next Most
Expensive – Quality
important
• Solvents: Workability and
wetting
PERFORMANCE = HIGH QUALITY RESINS & PIGMENTS + HIGH
QUALITY SOLIDS CONTENT.
$230,625
$140,625
$96,000
$77,625
$71,250
20-Year Life-Cycle Cost of 30,000 sq.ft. (Based on acceptable aesthetics of topcoat only)
Alkyd
Acrylic
Polyurethane
Polysiloxane
Fluoropolymer
20 years
3-4 yrs. 3-4 yrs. 3-4 yrs. 3-4 yrs. 3-4 yrs.
4-6 yrs. 4-6 yrs. 4-6 yrs.
7-10 yrs. 7-10 yrs.
10-15 yrs.
15-20 yrs.
Polymer Type Applications Finish App. Cost
How Primers Protect Steel
Protective coatings and primers provide economical
protection to steel in two basic ways:
• A PHYSICAL BARRIER –
• Several coats of Epoxy
• SACRIFICIAL METALS –
• Zinc Rich primers offer galvanic protection as
sacrificial metals
Types of Primers
• Alkyd
• Acrylic
• Epoxy
• Urethane
• Zinc-Rich
Zinc-rich primer being applied in shop
Levels of Corrosion Protection
Unprimed
32 hrs.
Alkyd
500 hrs.
Epoxy
4,000 hrs.
Zinc-Rich Urethane
10,000 hrs.
Testing Standard: Salt Fog (ASTM B 117)
GENERAL PRIMER CONSIDERATIONS
• PART OF COATING SYSTEM
• SAME MANUFACTURER AS TOPCOATS
• USUALLY MUST BE TOPCOATED FOR DURABILITY
• BINDING TOPCOATS TO SUBSTRATE
• Div 5 – 05120, 05500 Spec sections must call out prep
and primer type – depending upon exposure
• Example: Interior Exposed versus Exterior Exposed
FAILURES?
• POOR SUBSTRATE PREPARATION
• IMPROPER APPLICATION
• WRONG MATERIAL – OFTEN DUE TO DIV 5 PRIMER
WAS WRONG MATERIAL FOR EXPOSURE
Alkyd & Acrylic Primers
• Application ease
• One-component
• Designed for shop and field applications
• Provide basic corrosion protection
• Suitable for steel fabricators, OEM’s
and field applications.
Often for INTERIOR EXPOSURES
Epoxy Primers
• Two-component, chemical cross-
linking
• Provide barrier protection
• Steel protection in field and during
erection
• Allows for high-performance
topcoat application
• Chemical-resistant
• Often used as primer or mid-coat
in shop-applied systems for
EXTERIOR EXPOSURE
Westat, Inc. – Rockville, MD
Galvanic Protection
• Primers are used to provide protection for a substrate
• Zinc-Rich Primers offer galvanic protection. GREAT
substitute for HDG when cost or size prohibited.
– The coating will sacrifice itself before allowing the steel
to corrode
– Used as part of a complete protective coating system
Extended Protection with Zinc Testing Standard: Salt Fog (ASTM B 117)
Test Method Salt Fog (ASTM B 117)
System 3 mils Moisture Cured, Organic
Zinc-Rich Urethane
Test Duration 30,000 hours
Report Measuring of corrosion on the
plane and at the scribe
• Results after 8,000 hrs
• Same barrier protection
provided by epoxy
• Different protection
provided by primer
Testing Standard: Salt Fog (ASTM B 117)
Extended Protection with Zinc
Epoxy (3 cts) Zinc-Rich Primer (1 ct)
Epoxy (2 cts)
Intermediate/Topcoat Protection
Performance and life expectation can vary significantly
based on topcoat selection.
• Alkyds
• Acrylics
• Epoxies
• Polyurethanes/Polyurethane Hybrids
• Fluoropolymers
Alkyds
• One component
• Easy application
• Provide basic UV protection
• Basic color and gloss retention
• Aged technology that requires frequent touch-ups, done by maintenance personnel
University - Georgetown, MD
Acrylics
• One component
• Easy application
• Provides basic UV protection
• Basic color and gloss retention
• Advanced technologies can
provide dry-fall and hydrophobic
characteristics
Airport, Concourse B - Boise, ID
Epoxies
• Two-component, chemical cross-linking
• Excellent adhesion to the substrate
• Chemical and abrasion resistant
• Barrier protection from corrosion
• Epoxies should be top coated when
subjected to UV exposure
Gateway - Los Angeles, CA
Polyurethane/Polyurethane Hybrids
• Two-component, chemical cross-linking
• Superior color and gloss retention
• Topcoat over epoxies
• Resistance to abrasion
• Provides long-tern protection from
exterior weathering
TABLE MESA BRIDGE
BOULDER CO
Fluoropolymers
• “Gold” standard in protection against UV and weathering
• Provide exceptional color & gloss performance
• Air-dried version can be shop or field applied
• Alternative to a clearcoat system
• Many colors contain energy saving infrared reflective pigments
• Extended life cycle similar to factory applied fluoropolymer coil coatings
Aquarium - Baltimore, MD
Extreme Weathering Tank - Kauai, HI
Color and Gloss after 13 years
• Painted in 2000
• Only 1.05 Delta E (FMC II) color difference after 13 years of moist tropical
salty air and hot tropical sun! AMAZING!!!!
Aesthetic Performance
Fluoropolymer
Polyurethane
10,000 hrs.
QUV-A Exposure
Test Method: QUV (ASTM D 4587)
Interior Coating Systems
• Carbon Steel
• Concrete and Masonry
• Galvanized Steel
Natatorium - Chattanooga, TN
Dept. Store - Omaha, NE
Galvanized Steel
• Overhead decking
• Conduit and ducting
• Interior/exterior UV
• Passivated/Non-Passivated Steel
Fitness Center - Walla Walla, WA
Coating System (generic)
Primer/Finish Self-Crosslinking Hydrophobic
Acrylic Dry-Fall
Typical System May Include:
Exterior Coating Systems
• Ferrous metal
• Non-ferrous metal
• Concrete & masonry
Stadium - State College, PA
Manufacturing - St. Peters, MO
Series 626 Dur A Pell
GS
RTV Silicone Rubber
Series 680 Mark A Way
Dual Purpose Water
Repellent and Graffiti System
Product/Technology
Types of Anti-Graffiti
– Sacrificial
• A portion of or all of the protective coating is
removed during the cleaning of unwanted
graffiti.
• Does not crosslink chemically with the
substrate
• Can degrade do to weathering
• Must be reapplied after clean down, leaving
substrate unprotected while substrate dries
– Remember, speed of removal
Product/Technology
Types of Anti-Graffiti (cont.)
– Non Sacrificial
• Protective Coating remains after graffiti has been
cleaned
– Coating may chemically bond to the substrate
– Coating may mechanically bond to the
substrate
– No exposure after clean down
– May minimize MVT
– May substantially alter the look of substrate
Product/Technology
Definitions:
– Anti-Graffiti
• Clear or opaque coating formulated to deter
adhesion of graffiti and resist repeated
scrubbing and exposure to solvents, cleaners
or scouring agents used to remove graffiti
– Water Repellent
• Retards & reduces water intrusion
• Used in areas of intermittent hydrostatic
pressure
Floor and Wall Coatings
• Offer durability, cleanability and seamless protection
• Easy application
• Stand up to impact, abrasion, aggressive cleaning, thermal shock and chemical exposure
AREA WITHIN FACILITIES
• Kitchens/food preparation
• Locker rooms and showers
• Laboratories
• Hygienically controlled rooms
• Restroom/wash rooms
• Coolers/freezers
• Battery charging area
• Anywhere concrete is exposed to physical and/or
chemical attack.
Level I – Standard Block Finish
Prime Coat
Waterborne Filler
Intermediate Coat
Modified Polyamide Epoxy
Finish Coat
Aliphatic Polyurethane
Application: Roller-Applied
Level II – Orange Peel Block Finish
Prime Coat
Waterborne Filler
Intermediate Coat
Modified Polyamide Epoxy
Finish Coat
Aliphatic Polyurethane
Note: Prime Coat must be back-rolled and squeegeed
Application: Roller-Applied
Level III – Smooth Block Finish
Prime Coats (2 coats)
Waterborne Filler
Intermediate Coat
Modified Polyamide Epoxy
Finish Coat
Aliphatic Polyurethane
Note: Prime Coats must be back-rolled and squeeged
Application: Spray-Applied
Level IV – Joint-Filled,
Fiber Reinforced Finish
Skim Coat (troweled)
Epoxy Filler and Surfacer
Fiberglass Mat
Fiberglass Reinforcing Mat
Saturation Coat
Modified Polyamine Epoxy
Intermediate Coat
Modified Polyamine Epoxy
Finish Coat
Aliphatic Polyurethane
Application: Roller-Applied
Remember
• Every project needs a qualified
applicator in order to be successful
• Qualified applicator responsibilities:
– Perform substrate testing
– Address surface preparation
– Address environmental conditions
(i.e. temp, humidity)
– Mixing and application of coatings
per manufactures instructions
Wall Coatings
• Physical contact
• Public areas frequently
cleaned and wet
• Provides impermeable
surface over entire wall
• Easily cleaned and
maintained
• System can be tied into floor
system with cove base
Detention Facility Showers - TN
Types of Flooring Systems
• Thin-film flooring
• Thick-film flooring
– Laminate
– Mortar
Bakery Floor – San Antonio, TX
Other Environments
• Areas where floor coatings are typically found:
– Automotive service
– Transit authority
– Aircraft hangers
– Bus terminals
Airplane Hanger
Dealership
Common Resin Types for
Seamless Floor Applications
• Epoxies
• Urethanes
• Acrylics (MMA)
• Vinyl Ester
• Urethane modified concrete
Why Install Resinous Floor Systems?
• To protect concrete from physical and chemical abuse
• To provide a cleanable, sanitizable surface
• To create a seamless monolithic surface
• To beautify and protect
• To create non-slip properties
• To improve lighting
Various air districts throughout the
U.S. and Canada have VOC content
regulations, which must be followed in
regards to paints and coatings.
Specifications VOC Considerations for Coatings
Where to specify High Performance
Coatings • Division 4
– Masonry - 4205
• Division 5
– Structural Steel – 5120
– Steel Decks – 5310
– Metal Fabrications: Shop Primers - 5500
• Division 8
– Steel Doors & Frames - 8111
• Division 9
– High Performance Coatings - 9960
This concludes the educational content of this presentation.
Developed by Tnemec Company, Inc.
1-800-TNEMEC1 or www.tnemec.com
QUESTIONS?