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51314-3979-Novel Zinc Rich Primers for Corrosion Protection

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Product Number: 51314-3979-SG
ISBN: 3979 2014 CP
Author: Santiago Codolar
Publication Date: 2014
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Zinc rich primers both organic and in-organic coatings are extensively used in the marine and offshore industry. During the 60’s and the 70’s zinc rich epoxy primers were dominating the market. Later zinc ethyl silicate primers took over this role but nowadays it looks as if zinc epoxy primers have made a comeback. Some of the advantages of zinc epoxies compared to zinc silicates are the less demanding curing conditions (epoxies will cure at low humidity) they are easier to overcoat and they are less demanding to substrate preparation prior to application. Zinc epoxies are typically formulated with high loads of zinc dust. According to ISO 12944 a zinc rich coating contains more than 80% zinc by weight in the dry film.The protecting mechanism of zinc rich coatings is believed mainly to be based on cathodic protection provided by the zinc dust in the paint.  When a coating system containing a rich primer is exposed to e.g. the marine environment rust creep and blistering are amongst the most important failure mechanism to be considered. Many accelerated exposures will not within their exposure time show the defects visually on intact coated surfaces. Therefore behaviour of the coatings around artificially made damages i.e. scores are given significant considerations in the development of efficient anticorrosive primers and many prequalification tests (e.g. ISO 2034 NORSOK M501 Rev.6) are based amongst others on rust creep and blistering as well as detachment from scores. The increasing demands to the performance of zinc rich primers (low rust creep) has addressed even more focus on maximizing the utilization of the zinc dust in the paint. In addition to this the recent developments in the market prices of zinc dust suggest new developments in this area. Is it possible to achieve the same cathodic protection with a lower content of zinc dust?The purpose of this paper is to describe the protecting mechanisms of a new generation of zinc rich primers with enhanced protection properties and to set up the design criteria for a well working system. Results from different corrosion tests (ISO 12944 ; NORSOK M501 Rev.6) will be presented as well. 

Zinc rich primers both organic and in-organic coatings are extensively used in the marine and offshore industry. During the 60’s and the 70’s zinc rich epoxy primers were dominating the market. Later zinc ethyl silicate primers took over this role but nowadays it looks as if zinc epoxy primers have made a comeback. Some of the advantages of zinc epoxies compared to zinc silicates are the less demanding curing conditions (epoxies will cure at low humidity) they are easier to overcoat and they are less demanding to substrate preparation prior to application. Zinc epoxies are typically formulated with high loads of zinc dust. According to ISO 12944 a zinc rich coating contains more than 80% zinc by weight in the dry film.The protecting mechanism of zinc rich coatings is believed mainly to be based on cathodic protection provided by the zinc dust in the paint.  When a coating system containing a rich primer is exposed to e.g. the marine environment rust creep and blistering are amongst the most important failure mechanism to be considered. Many accelerated exposures will not within their exposure time show the defects visually on intact coated surfaces. Therefore behaviour of the coatings around artificially made damages i.e. scores are given significant considerations in the development of efficient anticorrosive primers and many prequalification tests (e.g. ISO 2034 NORSOK M501 Rev.6) are based amongst others on rust creep and blistering as well as detachment from scores. The increasing demands to the performance of zinc rich primers (low rust creep) has addressed even more focus on maximizing the utilization of the zinc dust in the paint. In addition to this the recent developments in the market prices of zinc dust suggest new developments in this area. Is it possible to achieve the same cathodic protection with a lower content of zinc dust?The purpose of this paper is to describe the protecting mechanisms of a new generation of zinc rich primers with enhanced protection properties and to set up the design criteria for a well working system. Results from different corrosion tests (ISO 12944 ; NORSOK M501 Rev.6) will be presented as well. 

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