GreenAlternativestoUsingZincPotableWaterSystems

AuthoredbySteveHarrison,DonFutch,andMitchConnor

Prelude
Duringthemid1990s,severalprominentcoatingsmanufacturersstartedtopromoteand
endorsetheuseofzincrichcoatingsasalinerforpotablewaterimmersionservice.This
wasconsideredanewfrontierandwasmetwithresistancebytheremainingcoatings
manufacturersthatchosenottoparticipateinthisnewarenaforzincrichcoatings.Atthat
pointintime,thewatertankindustrywasinthemidstofremovingleadbasedwatertank
linings.Somecoatingsmanufacturersfeltthatreintroducinganotherheavymetalback
intothisenvironmentwasafuturerecipefordisasterandrefusedtoenterthisfight.
Othersfeltthatthescienceofthistechnologydidntmakesenseandthereforeavoidedthe
fightaltogether.
Overtime,somemanufacturersreluctantlyenteredthismarketwithanofferingtocompete
forbusiness,concernedthattheymightmissout.Othercoatingssuppliersthathad
enteredthemarketsuddenlywithdrewtheirofferingsovertechnicalissuesandleftthis
controversialfight.Onethingthathascomefromthiseventisthateverycompany,
inspector,andprofessionalorganizationthatisinvolvedinthisarenahasastrongopinion
andhasanexplanationtodefendormaketheircase.
Inthisarticle,wewillbepresentingsomebackgroundaboutthezincinimmersion
technologyitselfwhileaddressingsomeoftheimportantquestionswherethetwo
opposingsidescommonlyclash.Adiscussionoverfailuremodes;reasonsforfailure;and
alternatetechnologieswillbediscussed.Additionalinformationwilldetailwhatfactors
andfeaturesareneededtodevelopagoodliningtoprotectsteelwatertanks.Thepaper
willconcludebydiscussingalternativecoatingoptionsthatexist(includinggreener
versions)andtheexpectedperformancelevelsthesecoatingsareanticipatedtoprovide.

Introduction
Thegalvaniccorrosionprotectionaffordedwhenusingzincmetalcoupledtocarbonsteel
iswelldocumentedwithdecadesofsuccessfulperformance.Oneneedonlylookatthe
historyofgalvanizedstructuresandtherevolutionarydevelopmentofsprayonzinc
primerstoseetheeffectthatzinchashadinhelpingindustrysavebillionsofdollarsthat
wouldotherwisebeenspentoncorrodedassetreplacement.Indeed,MotherNaturehas
providedsomewonderfulpropertiesinzincmetal.Ourownbodiesneedacertainamount
forsurvival.Whentheworldsfirstselfcuringinorganiczincprimerwascommercialized
inthelate1950s(Patentedin1962byLopataandKeithler)thepaintingofsteelstructures
hasneverbeenthesame.Largesteelmembersusedintheconstructionoftheworlds
infrastructure(bridges,powerplants,refineries,chemicalplants;thelistisendless)were
easilyprotectedwitheasytousesprayonzincprimers.Theirperformancehasbeen
undeniablyprovenovertheyears.
Inmorerecentyearssomesuppliershavepromotedtheuseofzincrichprimers
(topcoatedwithotherorganicfilmslikeepoxies)forpotablewaterimmersionservice.The
appealofusingzincrichprimersforuseasacorrosionresistantcoatingiswellunderstood
andquiteappealing.Theireffectivenessinpreventingcorrosionandtheirundercutting
resistanceisoutstanding.Theyhavebeenconsideredpermanentprimersforstructures
exposedtoweatheringforliterallydecades.Theyhavebeenshowntobeaseffectiveas
galvanizinginlongevity;andhaveactuallyoutperformedgalvanizinginsaltladen
environments.Theeconomicsofzinccoatedsteelforcorrosionprotectionisbasedon
manyyearsofactualfieldperformance.
Extendingtheirusefromatmosphericexposures(structuralsteel,tankexteriors)and
movingthemfromoutsidethetanktoinsidethetankcanbeveryintoxicatingeven
seductive.Iftheirperformanceissogoodontheoutsideofthetank;itislogicaltoassume
theywilldojustaswellontheinside.Whiletheyhavebeenusedquitesuccessfullyfor
immersionandstorageofalltypesofsolvents(inorganiczincsonly)ithasalwaysbeen
untopcoated.Thispaperwilllookatthepotentialproblemswhenzincprimersare
topcoatedforimmersionserviceinwaterexposuresandsuggestalternatemethodsand
systemstoprotectsteeltanksfromcorrosionandmaintainwaterpuritythroughtheuseof
greenalternativesinliningselectionandapplication.

CorrosionProtectionfromZincPrimers(General)
Zincrichprimershavebeenexcellentchoicesfortheprotectionofsteelinatmospheric
exposures.Zincmetalhasinherentpropertiesthatareperfectforthisuse.Zincisanactive
metal,andinmostatmosphericandwaterimmersioncondition,itisanodictosteel.Zinc
primersaredesignedtoreactwiththeirenvironment,andtosacrificethemselvesto
protecttheunderlyingsteelsubstratefromcorrosion.Thisprotectiveprocessisaformof
cathodicprotection.Inmoistneutraloralkalineconditions,andinthepresenceofoxygen,
thisprotectiveprocessresultsintheformationofzinchydroxide,asdepictedinthe
reactionbelow.

2Zn+2H2O+O2=2Zn(OH)2
Inthepresenceofwaterandoxygen,oxidizationofthezincoccurs,andeachatomofzinc
releases2electrons.Subsequently,anoxidationreductionreactionoccurs,andwiththe
electronsdonatedfromtheoxidationofthezincatoms,formhydroxylions(OH).These
hydroxylionsarequicklyconsumedinreactionwiththepreviouslyformedzincions,to
formthezinchydroxide,asdepictedinthebalancedformulaabove.Theadditional
presenceofcontaminants(chlorides;sulfides)suchastypicallyfoundinanindustrial
environmentcanandwillacceleratethisprocess,formotherzincsaltsandcompounds
resultinginfurtherdegradationofthezincmetal.Thisisalldesignedpurposelyto
consumethezincratherthanthesteelsubstrate.
Thezinchydroxidewillcontinuetoreactwithcarbondioxideintheatmosphereandcreate
zinccarbonatecompounds(apassivatingandwaterinsolublesalt).Thisisanaturally
occurringphenomenon.Thesezinccarbonatecompoundswillineffectsealanybreakin
thefilmandpreventundercutting.Thus,thisgalvanicactionofzinccoupledwiththe
carbonsteelsubstratewillpreventcorrosionofthesteel.Themechanismfortheir
protectioniswellunderstood.
Variablesaffectingthecorrosionrateofzincrichprimersincludewater;pHlevels(toohigh
ortoolow);dissolvedoxygenandcarbondioxidecontent;waterpurity;andsalt
(chlorides)content.Increasinglevelsofthesevariablecanandwillacceleratethe
corrosionrateofzinc.Thepresenceofchlorideswillreactwithzinctocreatezincchloride
saltsthatarehygroscopic(theabilityofasubstancetoattractandholdmoisturefromits
environment).

InorganicZincPrimers
Inorganiczincprimersreadilyprovidecathodicprotectionbecausethereisexposedzinc
metalinintimatecontactwiththesteelsubstrateandwiththeotherzincparticles.They
formanelectricpathwaytoprovidecathodicprotection.Theseprimersareoutstanding
foratmosphericexposuresandwillsealanybreakinthefilmandpreventundercutting.
Theyperformextraordinarilywellforthistypeapplication.
Ifinorganiczincprimersaretopcoated(withsayepoxies)andplacedinimmersionservice,
waterdoesfinditswaythroughtheepoxyfilm,eventually.Allcoatingsaresemi
permeablemembraneswhichallowmoisture;albeitsmall;topassthroughthefilm.The
zincsaltsthatforminthepresenceofmoistureandoxygenandeventuallycarbondioxide
willpullwaterthroughthefilmandcauseosmoticblistering.Thisisaverypowerful
drivingforce.Intheend,whatwasanadvantageforIOZprimersinatmosphericexposure,
isnowadisadvantagefortheminimmersionservicewhentopcoated.Thereisnostopping
it,zincisanactivemetalandwillreactwithitsenvironment.Thisiswhyzincprimers
worksowellinatmosphericexposureswithorwithouttopcoatsbutnotnecessarilyfor
immersionwhentopcoated.
Thepicturesbelowdepictthedifferencesinthefilmsbetweenanorganicandinorganic
zincprimer.Theinorganicfilmisfilledwithporositiesandshowsintimateandnumerous
zinctozincmetalcontact.Bycontrasttheorganiczincfilmshowsveryfewporositiesand
muchmoreencapsulationofzincparticleswiththeorganicpolymerresin.

OrganicZinc

InorganicZinc

OrganicZincPrimers
Somesuppliersarepromotingorganiczincsforimmersionwhentopcoatedwithepoxies.
Organiczincsarealsocommonlyusedasprimersforatmosphericsystems.Againtheydo
verywellinatmosphericexposures.Organiczincsdoprovidesomecathodicprotection
buthow?Ifwelookatafilmofaninorganiczincprimer,weseethatthezincparticles
areinintimatecontactwithoneanother,aswellasthesteelsubstratebecausethereis
barelyenoughbindertogluethemtogether.Intheorganiczincfilmeachzincparticleis
encapsulated(intheory)byitsorganicresinsystem.Andaslongasitisencapsulated,it
should(intheory)notexhibitanyzinctozincparticlecontactorcontactwiththesteel
substrate;andthereforenotprovideanygalvanicprotection.Ofcourseweknowthatin
factorganiczincrichprimersdoinfactprovidesomecathodicprotectionaslongasthe
zinccontentissufficientlyhigh.Figure3depictstheconductivityofinorganicversus
organiczincprimers.Onecanseethatthepercentzincinthedriedfilmforanorganiczinc
primermustbehigherthananinorganiczincprimerinordertocreateanelectrical
pathway(lessresistance)tooccur.Thechoiceofresinandotherformulationparameters
willalsoaffecttheconductivityandultimateeffectivenessofthezincprimer.When
sufficientconductivityoccurs,ittranslatesintoacathodicprotectionmechanism.So,in
realitythereisenoughzinctozincparticlecontactandzinctosteelcontacttoatleast
providesomecathodicprotectionaffordedbythezincwithorganiczincsystems.Ifnot,the
zincwouldbeanexpensivefillertousewithoutbenefit.

Figure3:Conductivityofinorganicandorganiczincfilmsasapercentofzincbyweightinthedried
film.

So,ratherthanbeingshieldedfromtheenvironment;asonewouldhaveexpected;the
organiczincsdoinfacthavesufficientzincavailablesothatsomecathodicprotectionis
achieved.Theamountofexposedzincinorganicbindersisobviouslylessthanwith
inorganicbindersandconsequentlyreactstoalesserextentwithitsenvironment.Assuch,
organiczincsdoultimatelyallowmoisture,oxygen,andcarbondioxidetoreachandthen
reactwiththezincmetalalbeitinamorerestrictivemannerthaninorganiczincprimers.

WhyUseZincRichPrimersforImmersionServiceinPotableWater?

Directtometalepoxysystems(alsocalledselfprimingepoxysystems)havebeenused
successfullyforover60years,longbeforezincrichprimerswereintroducedintothis
market.Someoftheearlierversionsofpotablewatertankliningsdidcontainleadinthe
primer(andsometimesinthefinishaswell),butleadfreeepoxy,polyureaand
polyurethanecoatingshavebeenproviding30+yearsofsatisfactoryservicelifesincethe
1970s,whenleadcoatingsweredeclaredathreattothepublichealth.
Thequestionthenbecomes,whyreinventthewheel?Whatarethebenefitstobegainedby
installingzincrichcoatingsinpotablewaterservice?
Thereactivemechanismthatzincundergoesin
atmosphericexposure(withtheresultantcathodic
protectionmechanism)isoftenappliedto
immersionexposuresaswell.Letsexaminethis
argument.Weknowthatzincwillreactwithits
environment;afterallzincisareactivemetal.
Whenexposed,itwillreactwithitsenvironment
andformzinccorrosionbyproducts.Theby
products(atleastinatmosphericexposures)serve
tosealanybreakinthefilm.Intheory,thezinc
beneaththefilmlaysdormantuntilcalleduponto
reactwithitsenvironment.Thisisthelogicbut
thereisaflawintheargument.

Osmosis: Thediffusionofwaterthrougha
semipermeablemembrane.Morespecifically,
itisthemovementofwateracrossasemi
permeablemembrane(thetopcoat)froman
areaofhighwaterpotential(lowsolute
concentration)toanareaoflowwater
potential(highsoluteconcentration).
ElectroOsmosis:Themovementofwater
throughasemipermeablemembraneasa
resultofapotentialgradient.
VolumetricExpansion:Thezincsaltsthat
areyourcoatingsallywhenuntopcoatedare
yourcoatingsystemsenemywhentopcoated.
Undertherightconditionsthezincsalt
reactionproducts,Zn(OH)2,ZnO,ZnCO3,and
ZnCldevelopatthezincprimer/topcoatinter
phaseandaretheprimarycausefortopcoat
blisteringbyosmosisandorvolumetric
expansion.

Sowhathappenswhentheorganiczincprimers
aretopcoated,withsayanepoxy?Epoxy
formulationsaretypicallygreatbarriersagainst
chemicals;includingwater.Theyarechemically
curedresinswithahighdegreeofcrosslinking
makingitdifficultforchemicalstopenetratethe
filmorbreakthebondsbetweenthemoleculeswithinitspolymermatrix.Thatsaid,these

filmsareneverthelesssemipermeablefilmsthatinfactdoallowwaterandgasestopassin
(andout)ofafilm.Dependingontheformulaofthespecificliningthismovementcanbe
relativelyrapidorveryslow.(Liningformulationswillbediscussedlaterinthispaper).As
longasthereisnothinginthefilmtoholdwater,themoistureandgasesflowintoandout
ofafilm.Whenmoistureflowsinatarategreaterthantherategoingout,ablisteroccurs.
Thequestionthenbecomes,Underwhatconditionswillmoisturelingerinafilmorbeheld
withinthefilm?
Thereareseveralconditionswheremoistureispulledortrappedwithinapaintfilm.
1)Ifthesteelsurfacebeneaththefilmhascontaminationsuchaschlorides,salts,dirt,(worker
sweat);contaminatedrinsewater;etc;waterispulledintothefilmbyosmosis.Waterwantsto
dilutethesaltsandwilldrivethroughthefilmtotryandequalizetheconcentrationsacrossthe
membrane(film).
2)Thebacksidesteeltemperaturehasasufficienttemperaturegradient(colder)thanthe
commoditycarriedinsidethetank.Thisphenomenonisknownasthecoldwalleffectandexplains
whysomeapplicationsfailbyblistering(waterwantstocondenseonthecoldwalllikeasodacan
sweatingonawarmsummerday);or
3)Contaminantsorwatersolublecompoundsarepresentwithinthecoatingthatpullsandholds
waterinthefilmbyosmosis(similarto#1).
Whenzincprimersaretopcoatedandplacedinwaterimmersionthepotentialforblisteringis
present.Weknowthatzincisanactivemetalandwillreactwithitsenvironment.Weknowthat
filmsaresemipermeablemembranesthatallowmoistureandgasestopassthrough.Weknowthat
thezincmetalisavailabletoreactwithmoistureandoxygenregardlesswhetherthezincisinan
inorganicbindersystemoranorganicone.Withtheformationofzinchydroxideandotherzinc
salts,apowerfulosmoticcelliscreated.Withthecontinuedmovementofwaterthroughthe
topcoatfilmduetoosmosis,blistersforminthetopcoat.Volumetricexpansionofthesezinc
compoundscausesthetopcoattodisbond,blister,andeventuallydelaminate.Ifthezincprimer
functionsasintended,thenblisteringwilloccur.Otherwise,thezincisnotneeded.

Thisprocessisinevitable;itisnotaquestionifblisterswilloccur,onlywhen.Inspiteof
thispotentialfailurebyblistering;suppliershavereportedprojectswheretheyhavethus
farperformedsuccessfully.Claimsofdoublingtheexpectedservicelivesofliningsusing
zincprimersarenotuncommon.Thepracticeofusingtopcoatedzincinimmersionfor
potablewaterliningsgoesbackapproximatelytenyears.Sotheclaimsaboutlongevityare
farfromrealitysincemany2coatepoxyliningshavebeenknowntolast1520+years.
Nevertheless,someuserscontinuetousethisapproacheventoday.

Inpractice,whenepoxycoatingsystemsareappliedinthefield,variationsinfilmthickness
arecommonplaceandhardtoavoid.Thinnerareasofferlessbarrierprotection.Breaksor
discontinuities(pinholes)allowmoisturetoeasilypenetrate.Theabilityofaliningsystem
toretardorresistmoisturepenetrationisdirectlyrelatedtoitsformulation,filmthickness
applied,anddegreeofcure.Liningsystemsthatcontainsolventcanbeparticularly
problematicifthesolventshavenottotallyleftthefilmpriortoservice.Knowingallthese
potentialproblemsonlyservestoemphasizetheimportanceofspecifyingandapplyinga
liningsystemsothattheseproblemsdonotoccurwhichmightotherwiseleadtolining
failure.

LiningFailures
Whatconstitutesaliningfailure?Thesimpleansweriswheneveritfailstoperformitsintendedfunctionofprotectingthesteel
from corrosion or protecting the cargo. There may be some linings that partially disbond from the surface; but do not cause
corrosionorimpartanynegativeimpacttothecargo.Noharmdonenofailureatleastyet!Atsomepointtheliningmay
continuetodisbond;corrosionbeneaththefilmbegins;andsoonerorlaterthecargoisaffectedbypiecesofliningorcorrosion
productsfromthesubstrateinthecommodity.
Themostcommontypesofliningfailuresare;

delaminationbetweencoats;
delaminationfromthesubstrate;
blistering;
cracking;
surfacebreakdown(chemicalattack);and
Contaminationofthecargo.

One can grade the performance of lining systems by evaluating the presence of or degree of rusting (ASTM D610), blistering
(ASTMD714)bothsizeandfrequency,delamination,surfaceattack,softening,ordiscolorationofcoatingfilmorcommodity.In
addition;onecanalsoconductweightgain/lossevaluationsonthecoatingfilm;wetadhesion(postexposureadhesioncompared
topretestconditions);orachemicalanalysisofthecommodity(lookingforcontamination).Thislastevaluationisparticularly
importantforfoodgradesolutionswherecontamination,taste,orodorisofprimeimportance.
Thechartbelowisacommonlyusedperformanceevaluationtodeterminesuitabilityofliningsystemsthattakesintoaccounta
weightingofmoreimportantperformanceelements.Higherscorerepresentsbetterperformance.

Coating
Perfect
Performance
CoatingA
CoatingB
CoatingC

Penetration
orBlistersto
substrate

Surface
Attackor
topcoat
blisters

Softening

40

25

15

10

10

100

40
20
40

25
25
0

12
15
12

9
8
10

9
6
5

95
74
67

Solution
Coating
Discoloration Discoloration

CoatingAwouldbeacceptableifveryslightcoatingdiscolorationorsolutiondiscolorationisacceptable.
CoatingBwouldnotbeacceptablesincethesolutionpenetratedtothesubstrateresultinginblistering.
CoatingBwouldnotbeacceptablesincesurfaceattackwasevidenteventhoughitdidnotpenetratetosubstrate.

Total

WhatMakesaGoodTankLining?

Goodperformingtankliningssharesomecommoncharacteristicsorcombinationsof
characteristics.Manyprovideexcellentbarrierprotectionagainstthecommodityorcargo.
Thedegreeofcrosslinking(inthecaseofepoxies)helpsdefineorquantifythelevelof
barrierprotection.Thechoiceofresinandcurativewilldeterminetheoverallchemical
resistanceofthepolymerandwhetheritissuitablefortheservice.Theselectionoffillers
andpigmentshasadramaticeffectonperformance.Watersolublepigmentswould
obviouslynotbeawisechoiceforliningsinwaterservice.Barrierpigmentsthatmaybe
flakelikeorlamellarthatstacktogetherinafilmcanbedesirabletoslowdownthe
penetrationofwaterorothercargos.Fillerslikemicaormicaceousironoxide(MiO)are
inert,nonreactive,flakelikepigmentsthatdonotreactwithwater,oxygenorcarbon
dioxide;areexcellentchoicestocoatingsinthesetypeexposures.Zincbycontrast,isan
activemetalandsphericalinnature.Itisjusttheoppositeofwhatonewouldchooseto
formulateatankliningproduct.Topcoatingitforimmersion,createsapotentialproblem
thatwilleventuallysurface.
Throughout history, water tank linings were formulated as a barrier coating. Barrier coatings are
designed to limit the permeability of water and oxygen to the substrate which could cause
corrosion of the substrate. What makes a good formula for a water tank lining? Coating
formulations consist of four parts: binder (resin), pigment, additives and solvents. Each of these
parts is critical to a good formula. Let us look at each part:
Binder is normally associated with resins. Resin provides a large portion of the physical
properties in a coating. The choice of resin provides properties that include cure rate, hardness,
impact resistance, flexibility, chemical resistance, adhesion, recoatability, water absorption, and
permeability. Resins normally used in water tank linings are typically epoxies but there has been
a growing interest and use of polyurethanes, hybrid polyurethanes and polyureas. In general, a
formulator is looking for a resin that provides both application properties desired by an
applicator and physical properties desired by the ultimate customer, the tank owner.

Pigmentshavemultiplepurposesinaformulation.Thosepurposesincludehiding,color,
fillers,reinforcing,andcorrosioninhibitingpigments.Thechoiceandtheamountpigments
usedareimportantdependingonthepropertiesdesired.Fillerandreinforcingpigments
canimprovecertainphysicalpropertiesandimprovebarrierproperties.Pigmentsyou
mightwanttoavoidarewatersolublepigmentsorpigmentstocouldreactwithwater.
Inhibitivepigmentscanbewatersolubleandhavebeenknowntocauseosmoticblistering.
Pigments,likezincdust,areusedinprimerstoprovideprotectionofthesteel.Theproblem
isthatalltopcoatcoatingsarepermeabletosomedegreesowhenwaterandoxygen
penetratesthefilmitreactswiththezincpigment.Thisreactionformszinchydroxideand

createsanosmoticcell.Thatcellisknowntocauseosmoticblisteringinthepresenceof
water.
Additivesaresubstancesthatareaddedinsmallquantitiestousuallyimprovecertain
properties.Normallyadditivesarenotaddedunlesstheyareneeded.Propertiesmodified
byadditivescanbeflow,wetting,filmbuildanddrytime.
Solventsareliquidsthatarevolatileandareusedtolowertheviscosity,regulate
applicationpropertiesandcontroltheconsistencyofthefinish.Duetoregulationsthat
limitVOCandHAPsincoatings,paintformulationsaremovingtowardshigherandhigher
solids.Thechoiceontheselectionofaparticularsolventinvolvestheevaporationrate,the
watersolubility,anditsstrength(abilitytocuttheresin).Akeyfactorinitsselectionis
whetherornotitwillremaininthefilmforlongperiodsandthusinfluencethethreshold
limitwhenextractiontestingisdoneforpotablewaterevaluation.Normallyaformulator
willavoidslowandwatersolublesolvents.
Awellformulatedliningforwatertankswillprovideagoodbarrierthatisstableoverthe
servicelife.

IsZincaHeavyMetal?
WearenottalkingaboutMetalicaorBlueOysterCult.Acommonargumentforopponents
ofthezincinimmersiontheoryhasbeenthereintroductionofaheavymetal(zinc)into
drinkingwatercomponentsrightafteroursocietyhasjustaboutremovedallofthelead
primeroffofthewatertanks.Proponentsmaketheclaimsthatgalvanizedmetalhasbeen
usedinpotablewatertanksfordecades(althoughweusedleadaswell).Allgradesofzinc
dustcontainlevelsofleadandothertraceheavymetals.Somemanufacturersshowthem
onMSDSsheets,whereasotherschoosenottorevealthisbecausethelevelsareverylow
andarenotmandatedbytheFederalGovernmenttoprovidethisinformationtothe
consumerorunsuspectingcoatingsapplicator.
Inrecentyears,wehaveseenourNationsVOC(VolatileOrganicCompound)emissionlaws
becomemorestringent,especiallyintheStateofCalifornia.AsourNationandtheworld
becomemoreawareandsensitiveoftheenvironment,willthisconstrictingtrendleadto
tightercontrolsoverourwatersupplies?Ifso,itisreasonabletoassumethathavingsome
ofthesecontaminantsinthepresenceofourdrinkingwatersuppliesmaybefrowned
uponandremoval,encapsulation,orremediationofthesecoatingsmaybecome
mandatory.
Thereisalonglistofalternativecoatingsthatcanbeusedinlieuofzincrichcoatingsthat
providewhatcouldbeviewedbysomeasgreenalternatives.

GreenAlternatives
WhatmakesalinerGreen?

Aliningsystemcanbeconsideredagreenalternativetoazincrichcoatingifit:

Isconsideredasolventfreelining.

Hasaloweramountofsolventsand/orrequiresaloweramountofsolventtothinor
cleanupequipmentduringand/orafterapplication.

Containsalternativefiller(s)thatprovidethesameorsimilarfeaturesandbenefits
ofazincrichcoatingwithoutthedetrimentalsideeffects.

Canbeappliedinafewernumberofcoats(preferablyone)whichreduceslabor
costsandenergyexpendedduringinstallation.

Hasahigherfilmthickness,whichwillprovidealongerlastingcoatingsystem,
therebyreducingthefrequencyofrelining.

Acombinationoftwoormoreoftheseconditions.

Solventfreelinings

Theidealgreencoatingwouldbealiningfreeofanychemicalsorsolvents.However,itis
impracticaltolinewatertankswithdesertsandorforestmulch,sosolventfreeliningsare
thenextbestchoice.Thistypeofliningsystemtypicallyconsistsof2componentsthat
haveliquiditybeforetheyaremixedtogether.Whenmixed,theyreactandtheirliquidityis
convertedintoasolid,solventlessfilm.Thisreactioncantakeseconds,asinthecasewith
manypolyureas,orseveralhours,aswithmany100%solidsepoxylinings.Theremaybea
traceamountofsolvent(usuallylessthan1%)presentduringthereactionthatevaporates
orisconsumedduringthereaction,butthesecoatingsarestillclassifiedassolventfree
linings.AnadditionalbenefittotheenvironmentisthelittleifanyVOCsemittedfrom
thesecoatingsduringinstallation.Besidesthe100%solidsepoxiesandpolyureasalready
mentioned,elastomericpolyurethanesandpolyurethanepolyureahybridsalsofallinto
thiscategory.

LowerSolventVersions

Traditionalepoxyliningshadhoveredaroundthe5060%volumesolidsrangefordecades.
ThistypeofcoatinghadhighVOClevelsandcontained4050%solvent.Inaddition,upto
30%solventwouldbeaddedtothecoatingmix.Allofthissolventdidnotmakethistype
ofcoatinggreen!
Inthepastfewdecades,effortsbycoatingscompaniescreatedlowersolventcoatingsthat
alsorequiredlittleifanyadditionalsolventfortheirapplication.Pushedbygovernmental
mandatestolowerVOClimits,coatingcompaniesincreasedepoxyliningsvolumesolids
levelsfromthe50%levelallthewayupto100%.Thecoatingsthatfallinthiscategory
primarilyepoxyliningsystemstypicallyhoveraroundthe7590%volumesolidslevel.
Someofthe100%solidsmaterialsrequiretheadditionofsomesolvent(35%)toapply
thecoatingproperly.Pluralcomponentappliedepoxies,polyureas,andpolyurethanes
requiresomesolventstoflushequipment.Thesearetypicallysmallamountsandpalein
comparisontothelevelsofsolventrequiredtoinstallthetypicalzincrichprimerand
subsequentepoxytopcoat(s).

NonReactiveBarrierPigments(MiO)

MicaceousIronOxide(MiO)isagreenersolutiontothezincinapotablewaterlining.MiO
hasbeenwidelyusedoverseas,particularlyinEurope,asanalternative(andasanadditive
orahybrid)tozinc.ThebenefitsofusingMiOoverzincarenumerous:

MiOhasbeenusedinpaintstoprotectsteelforoveracentury,twiceaslongaszinc.

MiObasedprimers(andintermediates)havebeenfoundtoexhibitimproved
adhesionofepoxytopcoatsthanoverzincbasedprimers

MiOprovidessuperiorresistancetoblisteringasopposedtozincrichcoatings

MiOisanaturallyoccurringmineralwhereaszincmetalhastobemined,refined
andprocessed.

MiOisinsolubleinwater,Zincisnot.

MiOisinertandnonconductive,unlikezinc.

MiOwillnotincreasethecurrentdemandofacathodicprotectionsystemunlike
zincprimers

MiOisnontoxicandnonoxidizing;thesamecannotbesaidaboutzinc.

MiOnoncorrosive,andnonflammable;Zincdustis.

MiOislamellarflake,whichprovidessuperiorbarrierprotectiontothespherical
zincdustfoundinthezincrichcoatings.Thisprovides2.53timestheamountof
barrierprotection.

Aliningspurposeistoprovideabarrierbetweenthecargoandthesubstratetoprotect
cargopurityand/orpreventdeteriorationofthesubstrate.Bycontrollingthechemistryat
thecoatingsteelinterface,liningscanprovidelongtermservicelives.Havingareactive
pigment(zinc)atthisinterfacedoesnotofferthiscontrol.Nonreactivepigments(like
MiO)do.

Singlecoatsystems(laborsavings)

Theargumentthatsinglecoatsystemsarelessexpensiveduetofewercoats(labor)is
intuitiveprovidedtheyarejustaseasytoapply,inspectandrepairasmulticoatsystems.
Productsthatarecommonlyrecommendedassinglecoatsystemsaretypicallyhigher
solids(lessVOC)andthereforegreenerthanmultiplecoatsystems.Theyarealso
typicallyhighfilmbuildandoffermorebarrierprotection.Thesehighersolidsresins
haveshownexcellentflowandlevelingthatminimizespinholestypicallyencounteredwith
somelowersolidsformulationsandthereforefewerrepairs.Whilethereisstillsome
reluctancebysomeownerstomoveawayfrommulticoatsystems,thesinglecoatsystems
aregainingground.

Thickfilmsystems(longevity)

Inordertogetextrathicknessinatankanextracoathadtobeapplied.Threecoatsystems
providedthatextrathicknessbutattheexpenseofanadditionallaborcost.Thickfilm
systemsprovidedthatextrabarrierprotectionresultinginlongercoatinglivesthan
thinnerliningsystems.Thelongeracoatingsystemcanprotectthesteelsubstrate,the
greeneritisconsidered.Relinescostmoney,energy,labor,anddowntime.Thenewer
highsolidsorsolventfreesystemsarethickfilmliningsoftenappliedinasinglecoat.On
ownercangetthelongevityhewantsinfewercoatswithlesscost.

Summary
Thefactsaboutzincrichcoatingstopcoatedforpotablewaterservicehavebeenclearly
presented.Alogicalargumenthasbeenmaderegardingtheireffectiveuseinthisregard,
butthelogicisflawed.Theirreactivenatureisidealforatmosphericexposuresbutthat
samereactivityposesaliabilitywhentopcoatedforwaterimmersion.
Therearemanysuitable,greeneralternativesavailabletodaythathaveproven
performance.Thesegreeneralternativesarebetterfortheenvironmentandprovide
outstandingprotectionofsteelwatertanksinwhichtheyareused.Nonreactivebarrier
pigments,solventfreelinings,singlecoatlinings,andthickerfilmcoatingsofferlongevity
ofservice,easeofapplication,andgreeneradvantagestotankowners.