Analysis of Resin Coatings and Paints: Case Study
Premature Corrosion in the Presence of a Coating
A construction company specializing in industrial infrastructure recently encountered issues with premature corrosion on painted metal structures. To address the problem, they turned to our laboratory for an in-depth analysis of the resin coatings and paints used.
Objectives of the Analysis
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Identify coating defects: Determine the causes of premature corrosion.
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Evaluate the quality of base components and hardeners: Check the compliance of the materials used.
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Optimize formulations: Propose improvements to enhance coating durability.
Methodology
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On-Site Analysis
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Visual Inspection: Identification of corroded areas and visible defects
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On-Site Testing and Measurements: Verification of thickness, material nature, and alloy through XRF and ATR-FTIR spectroscopy
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Aging Tests: Evaluation of coating durability under simulated environmental conditions.
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Laboratory Analysis
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Mass Spectrometry (ICP-MS): Detection of heavy metals and pollutants in the coatings.
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Gas Chromatography (GC-MS): Analysis of volatile organic compounds present in the paints.
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Infrared Spectroscopy (FTIR): Identification of chemical components in resins and paints.
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Scanning Electron Microscopy (SEM): Analysis of the structure and morphology of the coatings.
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Dry Extract Analysis: Measurement of the amount of solid matter remaining after solvent evaporation.
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Ash Content: Determination of the amount of inorganic residue after incineration.
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Pycnometer: Measurement of the density of bases and hardeners.
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Results
The analysis revealed several issues:
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Poor application of coating layers: Thickness not in accordance with specifications, non-compliant grain size distribution, presence of corrosion due to interaction with chlorides
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Inadequate paint formulation: The bases and hardeners used had densities and ash contents that did not meet specifications.
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Structural defects: Electron microscopy revealed microscopic cracks in the coatings, facilitating moisture penetration.
Recommendations
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Formulation Review: Use of bases and hardeners that comply with standards.
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Improved Application Processes: Optimization of painting techniques to avoid cracking.
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Ongoing Monitoring: Implementation of regular tests to ensure the durability of the coatings.
Conclusion
Thanks to our in-depth analysis, the company was able to resolve its corrosion issues and improve the quality of its coatings. Our recommendations allowed for optimized formulations and application processes, thus ensuring better protection of the metal structures.