A SUSTAINABLE APPROACH TO INDUSTRIAL AND

MODERN COATING TECHNOLOGY

PROTECTIVE COATINGS
 A Sustainable Approach to
Modern Coating Technology

Patcham FZC is a well-established manufacturer of specialty additives headquartered in the

United Arab Emirates. Since its inception, Patcham has steadily grown into a leading supplier
of specialty additives for the Paint & Coatings, Ink, PVC and Composite industries.

The companys Pat-Add range of coating additives includes wetting & dispersing agents,
defoamers, slip & leveling agents, rheology modifiers. Whilst keeping focus on environmental
sustainability, the company produces products using green raw materials that are APEO free
and have low or no VOC.

These products are multi functional and multi compatible, which simplifies the production
process, reduces the chance of errors and minimizes inventory thus improving cost effective-
ness.

Patcham has built a strong manufacturing and R&D infrastructure that enables the rapid
transition from concept to products. The company has strategically located technical service
laboratories, offices and representatives around the world to provide the most efficient
customer service. In addition, a well-developed robust supply chain network enables it to
deliver its products and services to customers around the globe with minimal lead-time.

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 Contents

Introduction 1

Pat-Add additives for high performance industrial coatings 2

Industrial high performance primers 3

2K PU and Epoxy primer

Industrial high performance topcoat 7

Topcoat based on Alkyd, PU and Epoxy systems

Topcoats for high end application
Alkyd topcoats

Additives for waterborne epoxy systems 12

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 Introduction
An industrial coating is a paint or coating defined by its protective, rather than its aesthetic
properties. The most common use of industrial coatings is for corrosion control of steel
structures such as offshore platforms, pipelines, OEM machineries, engineering civil
structures and other various substrates. The occurrence of corrosion is a universal
phenomenon and defined as the deterioration of a material, usually a metal, because of a
reaction with its environment. The ingress of water through the coating on a metal surface,
can lead to the start of corrosion which if not corrected can weaken the metal structures.

The coating (both liquid and final dried film) has to have over all high performance in terms
of superior flow, sag resistance, high build, hiding, gloss and above all provide corrosion
resistance.

Furthermore, various pigments such as zinc phosphate are included in coating formulations
in order to further alleviate the chance of corrosion. Due to the high specific gravity of these
kind of pigments, very efficient wetting and dispersing agents are required to provide optimal
stabilisation and avoid the possibility of settling. It also requires multicompatible additives that
can work through systems such as polyurethane, epoxy, alkyds, thermo plastic, thermo
setting acrylics, etc.

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 Pat-Add additives for industrial coatings
Patcham offers a package of additives, that can help to improve the appearance and
durability of industrial and protective coating by providing optimum mill base viscosity,
efficient grinding, flow, leveling, improved gloss and DOI. Efficient dispersion of the
pigmented coatings further enhances the barrier properties, particularly against corrosion.
This further boosts the performance of the coating system.

Pat-Add additive package for industrial applications includes dispersing agents, anti settling
agents, leveling agents and defoamers. These multifunctional and multicompatible additives
can be incorporated in Epoxy, PU, alkyds and other solventborne formulations.

A selection of Pat-Add additives for Solventborne (SB) systems are illustrated below in
Table 1.
Table 1: Patcham additives for solventborne industrial applications.

Additive for solventborne primers and topcoats

Additive Features Dosage on total

formulation (%)

Uniquely designed multifunctional polymer with multi

compatibility with different types of resin systems. 0.3 - 0.8
Pat-Add DA 1666 Grinding / Letdown
Acts as wetting and dispersing agent, anti settling
agent, anti sagging agent and anti flocculating agent.

Amphoteric dispersing agent effective in alkyd

0.3 1.0
Pat-Add DA 707 paints. Strongly adsorbed onto inorganic and black
Grinding stage
pigments, contributing steric stabilization against
re-flocculation.

Efficient dispersing agent for alkyd system and 0.3 - 0.8

Pat-Add DA 1808 suitable for organic, inorganic and black pigments Grinding stage

Water incorporation additive offers excellent gloss

0.5 1.0
Pat-Add DA 786 retention, stable viscosity, anti-settling and
anti-sagging properties Grinding stage

High Molar Volume technology polymeric dispersing

agent for all kind of carbon blacks, organic pigments 1.0 - 4.0
Pat-Add DA 932 and inorganic pigments. Enables high pigment 10.0 - 15.0 (PC)
loading for pigment concentrates (PC) and supports Grinding stage
stabilization of pigments
Polyether modified polysiloxane surface modifier 0.05 - 1.0
Pat-Add LE 1020
improves flow, leveling, DOI and gloss Letdown stage

Pat-Add AF 62 Silicone free defoamer for both clear and pigmented 0.05 - 0.4
systems. Suitable for all kinds of SB resin systems Grinding / Letdown

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 Industrial high performance primers
The primers are formulated generally with high levels of Zinc dust, Zinc phosphate or other
anti-corrosive extenders to enhance the corrosive barrier. One of the draw backs of using
high levels of these types of pigments is that these pigments are more prone to settling issues
and require an efficient dispersing and stabilizing agent to overcome this problem.

Pat-Add DA 1666 is a special additive compatible with all solventborne systems such as PU,
Epoxy, Alkyd, TPA, etc. The key features are:

Excellent wetting and dispersing agent for fillers, anti-corrosive pigments, inorganic and
organic pigments
Reduced mill base viscosity and milling time
Prevention of flocculation and floatation in pigment blends
Acts as a compatibilizer
Good anti sagging property and eliminates settling thereby enhancing the stability

2K PU and epoxy primer

Table 2: Formulation of 2K PU red oxide primer

2K PU Red oxide zinc phosphate primer

Raw materials Weight (%)
Part A Mill base viscosity of 2K PU primer
Pat-Add DA 1666/Reference 0.25 822

Red oxide 8.00 820 814

Zinc phosphate 8.00

810
CaCO3 22.00
Talc 10.00 800
Viscosity (cP)

Acrylic polyol 18.00 790

Xylene 10.00
780
Butyl acetate 4.50
Letdown 770
Acrylic polyol 12.00
1% Patcat 3001 (DBTDL ) 0.20 Reference Pat-Add DA 1666

Butyl acetate 7.05 Figure 1: Mill base viscosities of 2K PU

Total 100.00 red oxide zinc phosphate primer

Part B
Aromatic isocyanate 10.00
Mixing ratio part A:B (weight) 10:1

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 Industrial high performance primers
Table 3: Viscosity and grinding parameters

Properties Reference Pat-Add DA 1666

Mill base viscosity (cP) 822 814
Paint viscosity (cP) 342 325
Fineness of grind (m) 30 25
Grinding time (hour) 2 2

Reference Pat-Add DA 1666

Figure 2: Representation of de flocculation in 2K PU red oxide primer with Pat-Add DA 1666

Figure 3: Sag resistance test - 2K PU and alkyd red oxide zinc phosphate primer

Reference Pat-Add DA 1666

Figure 4: Pictorial representation of stability of alkyd primer with Pat-Add DA 1666

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 Industrial high performance primers
The formulation of 2K PU primer surfacer and epoxy zinc rich primer are given in
Tables 4 & 5.
Table 4: Formulation of 2K PU surfacer white Table 5: Formulation of epoxy zinc rich primer

2K PU surfacer white Epoxy zinc rich primer

Raw materials Weight (%) Raw materials Weight (%)
Part A Part A
Pat-Add DA 1666 0.50 Pat-Add DA 1666 0.50
Silica 15.00 Moisture scavenger 1.00
Titanium dioxide 8.00 Epoxy resin (75%) 12.00
Barytes 14.00 Organoclay thickener 0.50
Talc 10.00 Fumed silica 0.30
Acrylic polyol 32.80 Zinc dust 77.00
Solvesso 100 9.00 Butyl cellosolve 4.00
MIBK 3.00 Butanol 2.70
Butyl acetate 7.00 Xylene 2.00
Pat-Add AF 70 0.50 Total 100.00
1% Patcat 3001 (DBTDL) 0.20 Part B
Total 100.00 Polyamide 125 (50%) 6.00
Part B Xylene 4.00
Aromatic isocyanate 10.00 Total 10.00
Mixing ratio 10:1 Mixing ratio (w/w) 10:1

Pat-Add DA 1666 provides excellent stabilization of pigments and extenders that increases
the stability of the system. The reference sample showed hard settling whereas DA 1666 did
not have any settling. It also enhances the anti sagging property of the primer, wherein the
reference sample sags from 100 microns WFT, while there is no sagging observed up to 225
microns WFT. The anti settling and anti sagging properties are evident in Figure 5 and 6
below.

Heavy settling WFT in

Reference Pat-Add DA 1666
microns
75 m
100 m
125 m
150 m
175 m
200 m
225 m
250 m
275 m
300 m
Reference Pat-Add DA 1666
Sagging limit

Figure 5: Stability test for 2K PU surfacer white Figure 6: Sagging test for 2K PU surfacer white

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 Industrial high performance primers
Table 6: Formulation of epoxy zinc phosphate red oxide primer

Pat-Add DA 1666 in Epoxy zinc phosphate primer

Raw materials Weight (%)
Part A
Epoxy resin (75%) 23.23
Pat-Add DA 1666 0.60
Organoclay thickener 0.30
Red oxide 5.75
Talc 8.00
CaCO3 19.25
Zinc phosphate 7.00
Xylene 5.79
Butyl cellosolve 10.08
Letdown
Epoxy resin (75%) 14.00
Butyl cellosolve 3.00
Xylene 3.00
Total 100.00
Part B
Polyamide 125 hardener 10.00
Mixing ratio A:B (w/w) 10:1

As can be seen from the results for sag resistance, adhesion and bend test (Figure 7) from
a formulation based on an epoxy zinc phosphate primer (Table 6), the addition of Pat
Add-DA 1666 helps to optimise the overall performance of the epoxy zinc phosphate primer.

Figure 7: Performance of epoxy red oxide primer

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 Industrial high performance topcoat

The function of a topcoat in an industrial coating is not only to provide the final barrier to the
substrate but also to give an appealing and aesthetic appearance to the substrate.
Top coat based on alkyd, PU and epoxy systems
Specially designed multicompatible and multifunctional Pat-Add DA 1666 can be used in a
formulation for industrial topcoat to provide the required characteristics such as stabilization
of the pigments, good flow and improved final appearance such as gloss in a high
performance coating.
Table 7: Formulation for 2K PU white topcoat

2K PU white topcoat
Raw materials Weight (%)
Part A
Acrylic polyol 30.00
Organoclay thickener 0.50
Pat-Add DA 1666/Reference 0.50
Titanium dioxide 22.00
PU solvent 4.00
Letdown
Acrylic polyol 30.00
Pat-Add LE 1020 0.30
1% Patcat 3001 (DBTDL) 0.20
PU solvent 12.50
Total 100.00
Part B
Aliphatic isocyanate 28.00
Mixing ratio A:B (w/w) 100:28

Pat-Add DA 1666 shows better coloristic values with PU direct grinding systems due to their
efficient wetting and dispersing properties and compatibility with the system. Figure 8 shows
that white paint made using this additive gives better brightness, low yellow index and good
gloss values.

Yellow index L* Gloss value

90.4 90.9
93.05
0.81

0
20
83.4
0
81.5 60
92.35
0.16

Reference Pat-Add DA 1666 Reference Pat-Add DA 1666 Reference Pat-Add DA 1666

Figure 8: L* value, yellow index and gloss value in polyurethane white paint

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 Industrial high performance topcoat
The same trend of higher brightness, low yellow index and good gloss values are possible
with Pat-Add DA 1666 in Alkyd, PU, Epoxy and other solventborne systems. It has the ability
to reduce the mill base viscosity and improve the grinding efficiency. Mill base viscosity of
Alkyd, PU and Epoxy systems are shown in Table 10.

Table 8: Formulation of epoxy white topcoat Table 9: Formulation of 2K PU co-grinding system

Epoxy white topcoat 2K PU co-grinding system

Raw materials Weight (%) Raw materials Weight (%)
Part A Part A - Mill base
Epoxy resin (75%) 20.00 Acrylic polyol 30.00
Organoclay thickener 0.50 Pat-Add DA 1666 1.40
Pat-Add DA 1666 0.50 Titanium dioxide 18.00
Titanium dioxide 22.00 Yellow PY 42 0.90
Epoxy solvent (xylene, butanol) 10.00 PB 15:3 0.60
Letdown Black oxide 0.10
Epoxy resin (75%) 25.00 Organoclay thickener 0.50
Pat- Add LE 1040 0.20 PU solvent 8.00
Epoxy solvent (xylene, butanol) 21.80 Letdown
Total 100.00 Acrylic polyol 30.00
Part B Pat-Add LE 1020 0.30
Polyamide 115 (60% solution) 30.00 Pat-Add AF 62 0.20
Mixing ratio Part A:B (w/w) 100:30 1% Patcat 3001 (DBTDL) 0.20
PU solvent 9.80
Total 100.00
Part B
Aliphatic isocyanate 28.00
Mixing ratio (w/w) 100:28

Gloss @ 60 - 96 units
0

Figure 9: Flow behaviour of 2K PU co-grinding system

Table 10: Mill base viscosity of alkyd, PU and epoxy white paint

Alkyd white PU white Epoxy white

Properties
Pat-Add Pat-Add Pat-Add
Reference Reference Reference
DA 1666 DA 1666 DA 1666

Mill base viscosity (cP) 359 402 860 865 536 549
Paint viscosity (cP) 160 232 481 550 225 370

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 Industrial high performance topcoat

Topcoats for high end application

Pat-Add DA 932 is a dispersing agent based on High Molar Volume technology. The higher
volume occupied by the dispersant results in a thicker adsorbed layer around the pigments
which increases resistance to attractive forces and therefore gives a more stable pigment
dispersion. It has wide compatibility with PU, epoxy, TPA, NC and other solventborne
systems. High performances can be achieved in co-grinding, direct grinding, resin free and
resin minimal pigment concentrates. The key features are:

Dense network of anchoring groups stabilize black, organic and inorganic pigments
Contributes to optimum mill base viscosity and reduced milling time
High jetness and blue under tone for black pigments
Provides excellent long term stability of pigment dispersions
Superior gloss and transparency
Table 11: Formulation of 2K PU black

2K PU black topcoat 25
Fineness of grind vs grinding time
Raw materials Weight (%)
20

Part A Mill Base

Particle size (m)

Acrylic polyol 17.14 15

Organoclay thickener 0.20

10
Pat-Add DA 932 2.00
Carbon black FW 200 2.00 5

Butyl acetate 3.00

Xylene 3.00
0

30 mins 1 hr 1 hr 30 2 hr 3 hr

Letdown
Grinding time
Acrylic polyol 52.86
Reference Pat-Add DA 932
Butyl acetate 3.00
Figure 10: Grinding time vs particle size of PU black topcoat
Pat-Add LE 1020 0.20
MPA 4.00
Xylene 12.40
As shown in Figure 10, Pat-Add 932 helps
1% Patcat 3001 (DBTDL) 0.20 in reducing the grinding time of pigments.
Total 100.00 It also helps in obtaining stable dispersions
Part B and enriching the coloristic values.
Aliphatic isocyanate 33.00
Mixing ratio A:B (w/w) 100:33

NB: For optimum performance of Pat-Add DA 932 in grinding of pigments, it is advised to grind pigments till the required particle size is
achieved in terms of Hegman gauge and color strength. Over grinding may lead to change in coloristic properties

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 Industrial high performance topcoat
Reference Pat-Add DA 932
287.14
286.23
285.58
284.72
283.56
1.8 1.7

1.6 1.4
1.4 276.56
277.35

1.2 274.12
274.67
L* values

1
271.35
0.8
0.6
0.4
0.2
0

Reference Pat-Add DA 932 30 mins 1hr 1hr 30 2hrs 3hrs

mins

Figure 11: L* value of 2K PU black topcoat Figure 12: Mc values of 2K PU black topcoat

Pat-Add DA 932 shows less L* values and higher Mc values for 2K PU black with FW 200
which indicates higher jetness and bluish under tone of black is obtained.

Reference Pat- Add DA 932

Figure 13: Jetness of 2K PU black topcoat

Alkyd topcoats

Pat-Add DA 1808 shows excellent compatibility with most alkyds including long, medium,
short and other modified alkyd systems used on different types of substrates such as plastic,
and steel structures. Key benefits that Pat-Add DA 1808 can bring to the formulation
includes
Optimization of the milling process
Provides excellent color development
Prevention of floating and flocculation
Excellent compatibility with Alkyd resin systems

Formulation of Alkyd paint based on Pat-Add DA 1808 is shown in Table 12. It can be seen
to bring out and enhances the jetness of carbon black in Alkyd black topcoat (Figure 14).

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 Industrial high performance topcoat
Table 12: Formulation of alkyd black topcoat

Alkyd black topcoat

Raw materials Weight (%)
Long oil alkyd 20.00
Pat-Add DA 1808 1.00
Carbon black N 330 2.00
White spirit 10.00
Letdown
Long oil alkyd 40.00
Patcom 24 (Combination drier) 1.40
Patox 1 (MEKO) 0.20
White spirit 25.40
Total 100.00

Alkyd black paint made with Pat-Add DA 1808 shows better jetness as can be seen in
Figure 14. A stable black dispersion is achieved and is shown in Figure 15 with lower E
values for rubbed and unrubbed areas.

Figure 14: Jetness of alkyd black topcoat

Rub out test results

0.3
0.26
0.25

0.2
E values

0.15

0.1
0.06
0.05

0
Reference Pat-Add DA 1808

Figure 15: Rubout test of alkyd black topcoat

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 Additives for waterborne epoxy systems
Waterborne industrial epoxy coatings offer exceptional performance as a barrier to
corrosion along with other performance properties, whilst being environmentally friendly.
Applicators however come across issues of dewetting of substrate and foam. It is well under-
stood that wetting agents (surfactants) help to increase substrate wetting, flow and to some
extent leveling.

Surfactant

Foam
De wetting generation

Anti
foaming
agent

Figure 16: Competition cycle of conventional surfactants and defoamers

The challenge has always been to find the right wetting agent that does not lead to foam
generation and if at all it does, a right defoamer to destroy this foam generated due to the
presence of the wetting agent. The selection of a suitable surfactant and defoamer
combination becomes critical to formulators.

Patcham has developed a package of additives (Table 13), for waterborne epoxy system
which can overcome the issues related to these systems. It consists of

Dispersing agent with anti settling properties

Leveling agent with excellent flow, leveling and substrate wetting
Defoamer with excellent balance between defoaming and compatibility with the system

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 Additives for waterborne epoxy systems
Table 13: Additives for WB epoxy topcoat

Waterborne epoxy system

Dosage on total
Additive Features
formulation (%)

Efficient dispersing optimizes the milling process and 0.3 - 3.0

Pat-Add DA 817 strong prevention of pigment flocculation, floating and Grinding stage
settling issues. Compatible with all WB and SB systems.

Easily dispersible and very effective anti foaming agent 0.1 - 0.4
Pat-Add AF 31 with optimum compatibility Grinding / Letdown

Polyether modified polysiloxane surface modifier provides

Pat-Add LE 1030 excellent flow and leveling enhances substrate wetting, 0.05 - 0.4
Letdown stage
avoids pinholes and craters.

Table 14: Formulation of waterborne epoxy grey

Waterborne epoxy grey

Raw materials Weight (%)
Part A Mill base
Epoxy amine adduct 20.00
Pat-Add DA 817 0.85
Pat-Add AF 31 0.10
Barytes 16.00
Talc 10.00
Titanium dioxide 8.00
Iron oxide black 0.46
Iron oxide yellow 0.24
Fumed silica 0.20
Butyl carbitol 2.00
Butyl cellosolve 0.60
MPA 3.00
Water 10.00
w w w. pa tc h a m l t d . c o m

Letdown
Epoxy amine adduct 18.00
Water 10.35
Pat-Add LE 1030 0.20
Total 100.00
Part B
Liquid epoxy resin 25.00
Mixing ratio A:B (w/w) 4:1
Pat-Add DA 817 optimizes the viscosity of waterborne epoxy paint whilst the leveling and
anti foaming agents provide the synergistic effect to avoid issues of dewetting and foaming.
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 Additives for waterborne epoxy systems

Pat-Add DA 817 is a unique dispersing agent that also acts as an anti-settling agent. The
electrostatic repulsion created by charged polymeric dispersants adsorbed on the surface of
the pigments helps to reduce particle aggregation. This in turn reduces the chances of
flocculation while continuing to maintain the smaller particle size.
Reference Pat-Add DA 817

Figure 17: Stability of WB epoxy primer

The stability of waterborne epoxy primer is represented in Figure 17. Epoxy primer has
optimum viscosity with no settling whereas, the reference sample shows settling of pigmnets
during the stability test.
The package of Pat-Add additives have an excellent balance of compatibility and do not
show any side effects such as de wetting (Figure 18), craters, fish eyes and intercoat
adhesion issues (Figure 19).
Reference Pat-Add LE 1030

Figure 18: Substrate wetting of waterborne epoxy primer with Pat-Add LE 1030

Performance properties such as flexibility and adhesion tests showed no intercoat adhesion
failure. These findings are illustrated in Table 15 and Figure 19.

Table 15: Performance of waterborne epoxy paint

Physical properties
Dry film thickness 55-60m
Gloss value @600 90 units
Flexibility by conical mandrel 7mm Passes
Adhesion test after 24 hrs (1.5 mm) 5B passes
Adhesion test after 7 days (1.5 mm) 5B passes Figure 19: Adhesion and bending test results of WB epoxy paint

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 Notes

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 Notes

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PATCHAM (FZC) PATCHAM INDIA

P.O. Box: 7753, B-52, Pravasi Industrial Estate

Saif Zone, Sharjah, UAE Vishweshwar Nagar, Off Aarey Road
Tel: +971-6-5570035 Goregoan (E), Mumbai - 400 063 (India)
Fax: +971-6-5570038 Tel: +91-22-29272471
Email: patcham@emirates.net.ae Email: india@patchamltd.com

PATCHAM EUROPE BV PATCHAM USA LLC

Klavermaten 65-1 10 Commerce Road

7472 DD Goor Fairfield, New Jersey 07004
Netherlands Tel: (201) 293-4282
Email: eu@patchamltd.com Fax: (201) 820-0818
Email: info@patchamusa.com

w w w . p a t c h aThe
m l tinformation
d.com given in this booklet is intended for technical guidance without obligation. Ver. 1.0
17