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Application of waterborne coatings to railcars. For railcar fleet owners, operators, manufacturers, and repair personnel who use waterborne coatings.
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Over the past few decades, dramatic technology shifts have occurred in the coatings industry. Rapid changes in pigments, resins, and solvents have helped make environmentally friendly coatings possible; however, such changes have also created many technical hurdles.
Solventborne 2-pack (2K) epoxy-amine coating systems have for many years been commonly used to formulate high performance protective coatings such as metal anti-corrosion primers and concrete floor coatings. However, due to the concerns linked to their high volatile organic compounds (VOC) contents, waterborne alternatives with comparable performance are needed.
Cashew Nutshell Liquid (CNSL) is a non-edible, renewable biomaterial extracted from the honeycomb-like structure of the cashew nut. Its main component, cardanol, is produced by the decarboxylation of CNSL and it contains a highly hydrophobic aliphatic side chain. Cardanol is used in the synthesis of phenalkamines, which are widely used in marine, protective and industrial coatings applications. Historically, phenalkamines have been used in solvent systems, but recently, a new technology was developed that enables a very hydrophobic phenalkamine to be stably packaged in water.
Environmental, market, and cost pressures have led to the development of alternatives to conventional 2K polyurethane topcoats, including isocyanate-free binders. For example, 1- and 2K coating systems based on alkoxysilane chemistry find increased use in protective coatings.
As VOC regulations continue to drive coatings development, waterborne alkyds are progressively being utilized further due to their attractive environmental profile. Advancements in waterborne alkyd chemistry have provided the first waterborne biobased resin for pavement marking coatings. Through strategic selection of alkyd monomers and the appropriate balance of the emulsification aids, a shear stable alkyd latex resin that shows exceptional performance in waterborne traffic marking formulas has been developed.
A newly developed one-component waterborne polyurethane dispersion (PUD) topcoat, with VOC below 200 G/L, offers exterior durability, color and gloss retention and chemical resistance comparable to two-component solventborne and waterborne polyurethane coatings.
There are many factors to consider when optimizing your coating system for corrosion resistance. Waterborne coatings present a unique challenge due to their inherent hydrophilic nature and ability to readily conduct electrons. Waterborne resin technology has evolved greatly since its inception. If formulated properly one is able to meet and or exceed the performance of their solvent borne counterparts.
Coatings designed for heavy duty applications in the maintenance and protective coatings market are exposed to aggressive environments such as aggressive chemical solvents, marine atmospheres, UV light, abrasion, among others. In the US as well as other areas of the world, coatings designed for these applications have been primarily solvent-borne.
Polyurethane technologies have demonstrated their applications in a variety of seamless polymer flooring systems. Aliphatic polyurethanes are widely used as topcoats since they provide combinations of good color stability, gloss retention, abrasion resistance, chemical resistance, and weathering resistance. Recent development in polyaspartic chemistry offers more options in coating thickness, curing temperatures, and solids content.
Traditionally, a zinc-rich primer, epoxy midcoat and polyurethane topcoat have been the standard 3-coat solvent borne system used for coating structural steel, such as in the maintenance of bridges. This study describes the performance of waterborne acrylic coating systems in an accelerated testing protocol including corrosion resistance and cyclic weathering. A comparison of systems based solely on waterborne acrylic coatings, as well as hybrid systems (e.g., zinc rich primer with waterborne topcoats), to the industry standard will be discussed.
The twenty-first century presents a major challenge to coatings manufacturers. The amount of solvent allowable in many coatings has been reduced considerably. In order to attain these lower VOC’s, coatings formulators are searching for resins that have low VOC demand, as well as ways of formulating that can replace the high volumes of solvent used in the past