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Nye Miller Copyright Materials Learn about corrosion resistant coatings, coating selection for extending lifecycles thus reducing costs and infrared reflective pigments. Obtain broad knowledge of performance coating systems Learn about coatings performance in terms of lifecycle of generic types of coating systems Learn about infrared reflective pigments and how they can reduce energy costs, stress on structures and increase the lifecycle of commercial coating systems. Learning Objectives Coatings that Work Performance Coatings Protecting against corrosion Coatings lifecycle vs. cost IR reflective coatings…more than just cool savings Discussion NACE definition “The deterioration of a substance, usually a metal, or its properties, because of a reaction with its environment.” What is Corrosion? Steel to iron oxide, what stops this from happening? ◦ Sacrificial zinc Galvanized steel Inorganic zinc coating systems Organic zinc rich coating systems ◦ Zinc phosphate containing primer systems ◦ Barrier coating systems Ferrous Metal Corrosion Inorganic Zinc Coating System Organic Zinc Coating System Zinc Phosphate Coating System Barrier Coating System Purpose ◦ Establish a 10, 15 and 20 year lifecycle cost estimate per square foot for installed popular performance coating systems based on aesthetics and corrosion for the commercial architectural market. Coatings lifecycle versus cost Referenced documents and major contributors NACE Paper 98509 Cost consideration of different coatings Michael P. Reina, Kirk R. Shields, Michael F. McLampe, KTA-TATOR, Inc. ISO12944 Corrosion protection of steel structures by protective coatings AAMA 2605-05 Performance requirements and test procedures for high performance organic coatings on aluminum extrusions and panels Linda Marquez, Vice President, Global Infrastructure Systems The CHEMARK Consulting Group, Inc. Doug Hampton, Wilson and Hampton Painting Contractors, Painting and Decorating Contractors Association Paul Whitehead, Technical Service Manager North America PPG Protective and Marine Coatings Jeff Pearl, Technical Director and General Manager Precision Coatings, Inc. Coatings lifecycle versus cost Parameters ◦ $84.00 per hour labor rate for northern California ◦ 60 square feet per hour production rate per coat = $1.40 labor cost per square foot per coat. ◦ Establish commercial average cost per square foot of coating. ◦ Establish average lifecycle for each coating system. Coatings lifecycle versus cost Definitions Epoxy: surface tolerant epoxy primer Organic zinc: zinc powder in epoxy or urethane resin primer ◦ Minimum 19 lbs. of zinc per gallon Inorganic zinc: zinc powder in silicate matrix ◦ Minimum 14 lbs. of zinc per gallon Industrial urethane: acrylic aliphatic polyurethane with crosslink density of 600-800, industrial pigments, finish coat Automotive urethane: acrylic aliphatic polyurethane with crosslink density of 370-500, automotive pigments, finish coat Fluorinated acrylic: fluoro-polymer acrylic finish coat for field application Polysiloxane epoxy: oxidized silicone combined with an epoxy creating a weatherable epoxy finish coat Generic coatings Coating Surface Preparation Years before recoat commercial Alkyd SSPC-SP2 and SP3 4 Alkyd SSPC-SP10 5 Acrylic Emulsion SSPC-SP2 and SP3 6 Surface tolerant epoxy SSPC-SP2 and SP3 12 Surface tolerant epoxy SSPC-SP10 14 Organic zinc SSPC-SP3 16 Organic zinc SSPC-SP10 25 Inorganic zinc SSPC-SP10 35 to structural life Primers Finish Coat Stable Primer Years before recoat commercial Alkyd Alkyd 4 Acrylic emulsion Acrylic emulsion 6 Industrial urethane Epoxy 8 Industrial urethane Organic zinc/epoxy 8 Automotive urethane Epoxy 14 Automotive urethane Organic zinc/epoxy 14 Fluorinated acrylic (field) Epoxy 12 Polysiloxane epoxy Epoxy 16 Polysiloxane epoxy Organic Zinc 20 Polysiloxane epoxy Inorganic zinc 20 Finish Coats Minimal corrosive requirement Renovation of previously coated surfaces (intact) Barrier primers and finish coat Moderate corrosive requirement Exposed substrates and coastal environment SSPC-SP3 Mechanical surface preparation minimum, organic zinc primers, possible intermediate and finish coat Corrosive requirement Coastal location with exposure to salt laden air SSPC-SP10 near white abrasive blast, barrier and organic zinc primers with finish coats Very corrosive requirement Exposure to airborne chemical contamination as well as salt laden air SSPC-SP10 surface preparation with inorganic zinc, possible intermediate and finish coat Coatings lifecycle versus cost $12.00 $10.00 $8.00 $6.00 $4.00 Applied Cost $2.00 10 year cost $0.00 15 year cost 20 year cost Metropolitan minimal corrosive requirement $9.00 $8.00 $7.00 $6.00 $5.00 $4.00 $3.00 $2.00 $1.00 $0.00 Applied Cost 10 year cost 15 year cost 20 year cost Metropolitan moderate corrosive environment $16.00 $14.00 $12.00 $10.00 $8.00 $6.00 $4.00 $2.00 $0.00 Metropolitan corrosive requirement SSPC-SP 10 near white abrasive blast SSPC-SP10 Applied Cost 10 year cost 15 year cost 20 year cost $18.00 $16.00 $14.00 $12.00 $10.00 $8.00 $6.00 $4.00 $2.00 $0.00 Metropolitan very corrosive requirement SSPC-SP 10 near white abrasive blast SSPC-SP10 Applied Cost 10 year cost 15 year cost 20 year cost Surface preparation ◦ ◦ ◦ ◦ SSPC-SP2 & SP3 SSPC-SP3 power tool SSPC-SP6 shop blast SSPC-SP10 near white Primer ◦ Barrier ◦ Organic zinc ◦ Inorganic zinc Finish ◦ Resin system resistance ◦ Pigment resistance Coatings lifecycle versus cost Conclusion ◦ The specification establishes the coating lifecycle, coating costs and the future maintenance cycle and costs. Surface preparation selection Primer selection Finish coat selection Coatings lifecycle versus cost IR reflective pigments Benefits ◦ Reduce cooling costs ◦ Reduce structure stress ◦ Longer pigment life How they work How they are made Infra Red Reflective Coatings Study – UNLV Engineering ◦ Thermal Performance Analysis of Highly Reflective Coating on Residences in Hot and Arid Climates. ◦ By Samir F. Moujaes P. E., PH.D. and Richard Brickman PH.D. Study confirms a decreased load on air conditioning equipment …“On a typical day in the summertime, a 41% reduction is shown to exist where the roof and walls are coated…” “Roof plus wall combination reduces energy consumption by about 33.3%.” IR Reflective Coatings In the visible spectrum the color (light) reflected is black In the near infrared spectrum the color (heat) reflected is a white Visible vs. IR Spectrum Synthetic mineral inorganic pigments • Possess high infrared spectrum reflectivity • Reactions to create IR reflective pigment take up to 24 hours at 1800 to 2200 degrees Fahrenheit • Extremely stable against environmental degradation IR Reflective Pigments 30 Atlanta Heat Growth • Buildings using IR reflective technology on exterior walls and roofs use less energy, are cooler and more pleasant for the occupants. • Products utilizing reflective technology are likely to have a longer service life. Lower surface temperatures will lessen chemical and atmospheric degradation and also lessen expansion and contraction. For every 5% more reflectivity, a roof is approximately 4 degrees Fahrenheit cooler in direct overhead summertime sunlight. Advantages of IR Reflective Pigments This presentation and back-up data including the workable coatings lifecycle spreadsheet calculator is available on-line at: www.pacificsouthwest.net Paul Bethke of TAVCO Chemicals, representatives for Ferro IR reflective pigments is here to answer any questions you might have regarding IR reflective pigments. Nye Miller, Pacific Southwest Coatings 714.337.1953 nyemiller@pacificsouthwest.net This concludes The American Institute of Architects Continuing Education Systems and Construction Specifications Institute Construction Education Network Programs Nye Miller 714.337.1953