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
PROTECTION
Choosing the appropriate covering for your project
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
Life cycle cost value
color trends
Natatorium - MA
High Rise – CA
Gateway - CA
COATING ENVIRONMENTS
Applicable for Architectural Applications
Protection For…
•
•
•
•
•
•
•
•
•
Steel
Aluminum
Cast Iron
Galvanized
Non-Ferrous Metal
Wood
Concrete
Masonry
Stucco
High Rise Buildings
• Corrosion protection
• Color and gloss
performance
• Overcoating of aged panels
(refurbishment) or new
construction
• Life Cycle Savings
High Rise Building - Chicago, IL
Sports & Recreation Facilities
• Color and gloss
retention for exterior
substrates
• Brand or logo color
performance
• Durable floor and wall
systems
• Water repellents
Stadium - Atlanta, GA
War Memorial Stadium
Processing & Manufacturing
•
•
•
•
Printing Facility – Kansas City, MO
Structural steel
Tanks
Interior floors and walls
Equipment
Healthcare Facilities
•
•
•
•
Operating rooms
Clean rooms
Ceilings
Abrasion resistant,
floor and wall systems
• Non-staining
• Frequent cleaning
Medical Center - Bailey, OK
Educational Facilities
• Steel, masonry and
concrete protection
• Interior floors and
walls
• Roof coatings
• Graffiti protection
School District - Marion County, FL
Correctional Facilities
• High abuse wall and
floor systems
• Interior and exterior
steel & masonry
• Kitchen
• Shower areas
County Jail - Hamilton, OH
Transportation
• High performance
protection from UV and
freeze/thaw cycling
• Interior and exterior
steel & masonry
• Chemical resistance
Airport - Indianapolis, IN
DIA Canopy 2001
No Corrosion, No color/gloss loss
Natatoriums
• Overhead deck and
truss/joint protection
• Walls and floors in
chemical environments
• Pool coatings
Fieldhouse - Columbia, MO
Properly Prepared and Primed Vulcraft
Pool OH
Parking Garages
• Light reflectant ceiling coatings
• Structural steel and concrete
protection
• Water Repellents for chloride
protection
Parking Garage Milwaukee, WI
Auraria Parking Garage, Original 2006
- still looking great
Local Coating Failures
DU Parking Garage – Original 2005
Faded Color
Union Station Canopy
Galvanized metal failure
RTD Dry Creek Ped Bridge
Same application time – two different
Manufacturers
COATING SELECTION
Specifying the right coatings for your project
Costs of Paints & Coatings
• Resins: The framework on
which the coating’s
performance is built – Most
expensive part - FLORINE
• Pigments: Color, hide & anticorrosion Next Most
Expensive – Quality
SOLIDS
important
• Solvents: Workability and
wetting
Volatile Solvents
VEHICLE
Resin (Binder)
Pigment
PERFORMANCE = HIGH QUALITY RESINS & PIGMENTS + HIGH
QUALITY SOLIDS CONTENT.
20-Year Life-Cycle Cost of 30,000 sq.ft.
(Based on acceptable aesthetics of topcoat only)
Applications
Polymer Type
Alkyd
Acrylic
Polyurethane
Polysiloxane
3-4 yrs.
3-4 yrs.
4-6 yrs.
3-4 yrs.
4-6 yrs.
7-10 yrs.
Finish App. Cost
3-4 yrs.
3-4 yrs.
4-6 yrs.
7-10 yrs.
$230,625
$140,625
$96,000
$77,625
10-15 yrs.
$71,250
Fluoropolymer
15-20 yrs.
20 years
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
Testing Standard: Salt Fog (ASTM B 117)
Unprimed
32 hrs.
Alkyd
500 hrs.
Epoxy
4,000 hrs.
Zinc-Rich Urethane
10,000 hrs.
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 crosslinking
• 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
Extended Protection with Zinc
Testing Standard: Salt Fog (ASTM B 117)
• Results after 8,000 hrs
• Same barrier protection
provided by epoxy
• Different protection
provided by primer
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
Acrylic Finish – Laramie Ped Bridge
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
Water Tank Exteriors
• Swan Ranch EWT
• 2012 with Hydroflon
finish by TNEMEC
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!!!!
ZCMI Façade
City Creek Skylights
Aesthetic Performance
Test Method: QUV (ASTM D 4587)
Polyurethane
10,000 hrs.
QUV-A Exposure
Fluoropolymer
INTERIOR COATING SYSTEMS
Specifying the right coatings for your projects
Interior Coating Systems
• Carbon Steel
• Concrete and Masonry
• Galvanized Steel
Dept. Store - Omaha, NE
Natatorium - Chattanooga, TN
Galvanized Steel
•
•
•
•
Overhead decking
Conduit and ducting
Interior/exterior UV
Passivated/Non-Passivated Steel
Fitness Center - Walla Walla, WA
Typical System May Include:
Coating System (generic)
Primer/Finish
Self-Crosslinking Hydrophobic
Acrylic Dry-Fall
CU Boulder Hockey Rink OH
EXTERIOR COATING SYSTEMS
Specifying the right coatings for your projects
Exterior Coating Systems
• Ferrous metal
• Non-ferrous metal
• Concrete & masonry
Manufacturing - St. Peters, MO
Stadium - State College, PA
Bridges
Pedestrian Bridge – Contra Costa County, CA
JHR Tram Building 2008
Exposed Steel Structures
ADAMS STATE COLLEGE
Lincoln Park Stadium, Grand Junction
Colorado
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
Before Tagging
Tagged Block
Cleaning Process
After Cleaning
Floor and Wall Coatings
• Offer durability, cleanability and seamless
protection
• Easy application
• Stand up to impact, abrasion, aggressive cleaning,
thermal shock and chemical exposure
WALL COATINGS
Intended Uses and Types
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.
Spec-Finish®
Coated Concrete Masonry Wall Systems
SPEC FINISH BLOCK
Uncoated Standard CMU Wall
Coated Spec-Finish CMU
Pinhole free surface
Level I – Standard Block Finish
Application: Roller-Applied
Prime Coat
Waterborne Filler
Intermediate Coat
Modified Polyamide Epoxy
Finish Coat
Aliphatic Polyurethane
Level II – Orange Peel Block Finish
Application: Roller-Applied
Note: Prime Coat must be back-rolled and squeegeed
Prime Coat
Waterborne Filler
Intermediate Coat
Modified Polyamide Epoxy
Finish Coat
Aliphatic Polyurethane
Leprino Foods 2012
Atlanta Humane Society
Level II – Orange Peel Block Finish
Level III – Smooth Block Finish
Application: Spray-Applied
Note: Prime Coats must be back-rolled and squeeged
Prime Coats (2 coats)
Waterborne Filler
Intermediate Coat
Modified Polyamide Epoxy
Finish Coat
Aliphatic Polyurethane
Level III Finish
1 coat of block filler
2 coats Latex Finish
Level IV – Joint-Filled,
Fiber Reinforced Finish
Application: Roller-Applied
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
Georgia State University
Level II Finish
Level IV Finish
LEVEL IV VIVARIUM
WITH
SEAMLESS FLOORING
Common Substrates
• Wallboard
• Concrete Masonry Units (CMU)
• Existing Tile
Don’t Forget The Floors
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
FLOOR APPLICATIONS
Common Generic Coating Types
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
Thin-Film Epoxy Systems
Corporate Hanger
Repair Facility
Knight Transportation Denver CO.
2012
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
Quartz Aggregate
• Example of quartz/fleck aggregate added for visual
appeal
Mortar Floor System
Before
After
Rescue Mission Kitchen
Specifications
VOC Considerations for Coatings
Various air districts throughout the
U.S. and Canada have VOC content
regulations, which must be followed in
regards to paints and 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?