Performance of paint systems with polyurethane topcoats, proposed for atmospheres with very high corrosivity category

Abstract

The EN ISO Standard 12944-5 describes the types of paint and paint systems commonly used for corrosion protection of steel structures. In this work four paint systems, applied on steel, including polyurethane topcoats, recommended for atmospheres with high corrosivity (C5 category), codified by 1–4, were studied. Systems 1 and 4 include zinc rich primers and epoxy/polyamide intermediates, system 2 has solvent free epoxy/polyamide primer and intermediate and, system 3 is a hybrid system with vinyl–acrylic water based primer and a high solids epoxy/polyamide intermediate. Systems 2–4 have acrylic–polyurethane topcoats and, the topcoat of the system 1 was identified as an aliphatic polyurethane. According to EN ISO 12944-6, water condensation and neutral salt spray tests were performed. Three exposure times were considered taking into account the durability ranges of paint systems: low, medium and high, respectively. The paint systems were complementary submitted, during 30 days, to ultraviolet radiation with water condensation test according to ASTM G 154. At the same time, natural exposure was conducted in the marine atmosphere of Sines, with very high corrosivity (>C5). The paint adhesion, before and after artificial ageing, was evaluated by cross-cut test and, for the systems with dry thickness greater than 250 μm, by pull-off test. Visual inspections were carried out. For the exposure in UV radiation test chamber and at test site, gloss reduction, colour change and chalking were measured. Chemical changes on polyurethane topcoats exposed in the UV radiation test chamber were studied by Fourier transform infrared spectroscopy (FTIR). In spite of the higher aesthetic degradation by UV radiation, of the aliphatic polyurethane topcoat of the system 1 relatively to the acrylic–polyurethane topcoats of the other systems, system 1 with ethyl silicate zinc rich primer and epoxy intermediate, was the one that presented the best corrosion protection when exposed in artificial and natural salty environments. At the test site, the worst anticorrosive behaviour seems to be presented by the system 2 with two coats of solvent free epoxy paint.