Steel structures, bridges, machinery, pipes, and other components require protection against corrosion. The environment and its aggressiveness (e.g., chemical composition) play a key role in the deterioration of steel structures and industrial equipment during their operation. Mechanical and thermal impact on a given steel component also significantly influences corrosion. To counteract this, appropriate anti-corrosion systems should be used.

selection of anti-corrosion painting systems for the Grunwaldzki Bridge

When selecting the appropriate anti-corrosion system, the following steps should be followed:

STEP 1 Determining the type of substrate:

  • Black steel , also known as carbon steel, is the most susceptible material to corrosion. To protect it, it must be coated with an anti-corrosion pigment.
  • Galvanized steel is steel protected against corrosion by the application of a zinc layer. Galvanized steel does not require additional protection, however, if the zinc coating is damaged or worn, we recommend additionally protecting the steel with a suitable primer (anti-corrosion primer). For aesthetic reasons, galvanized steel can be painted with paints designed for this purpose. Please note that not all paints can be applied directly to galvanized steel.
  • Aluminum is used in construction due to its lightness and durability, and it doesn't corrode. Aluminum is painted primarily for aesthetic reasons.
  • Cast iron is an extremely durable material, but cast iron elements exposed to increased humidity or weather conditions (lamps, etc.) should be painted with anti-corrosion paints.

Call us - we will help you choose the anti-corrosion system: +48 717 026 346

STEP 2 How will the structure, machine or tank be used?

  • Is the structure inside or outside the building?

Coatings are susceptible to weathering, so for outdoor structures, for example, polyurethane paints are used, which are characterized by excellent resistance to moisture and UV radiation. In such cases, epoxy primers . Epoxy coatings cannot be used as a standalone coating outdoors, as they are not UV-resistant and chalk, so they should always be protected with a topcoat.

  • Will the steel tank be painted? What substances will be used to fill the tank?

Anti-corrosion paint must provide protection, sealing, and resistance to water (or other liquid) pressure in the tank. The paint must be chemically resistant to chemical spills.

Valuable information for the consultant will include: – What liquid will be in the tank? – For acids, what are the concentrations? – Is a certificate required for the coating to come into contact with food or drinking water? The more information we receive from you, the better the solution will be selected for you.

  • Is the structure susceptible to mechanical impacts, friction from objects, or pedestrian traffic?

To ensure high mechanical resistance, we offer systems with an epoxy or polyurethane flooring resin as the final coating (epoxy for interiors, polyurethane for exteriors). A carefully selected primer provides the first layer of protection against corrosion and serves as a bonding agent to the resin.

STEP 3 Determining the corrosive environment and the durability of the coating.

The corrosion class is determined according to the table below. This is a very important factor, as the class determines, among other things, the appropriate coating thickness or coatings that will comprise the anti-corrosion system.

Commonly used environmental terms Environmental Corrosion Classification

according to PN-EN ISO 12944-2

 Basic corrosion factors
Dry interior C1 Very small Indoor steel structure with the possibility of moisture condensation on the surface of the paint coating.
Damp interior C2 Small Steel structures in rooms where internal condensation is common. Additional corrosive factors may include salt aerosol (sea atmosphere) or aggressive gases absorbed in moisture (e.g., sulfur dioxide in industrial atmospheres).
Rural and urban exteriors C3 Medium Steel structure outdoors, in an atmosphere free of heavy pollution resulting from proximity to sources of industrial gas emissions and dust; additional corrosive factors are present.

Corrosion exposure resulting from:

  • Atmospheric waste,
  • Temperature changes due to sunlight,
  • Effects of solar radiation,
  • Emissions of aggressive, corrosive gases (e.g. sulfur dioxide from home furnaces and local boiler rooms),
  • Periodic splashing of the structure (e.g. from vehicle traffic)
Industrial and coastal with medium salinity C4 Large Steel structure outdoors in an atmosphere with significant air pollution.

Corrosion exposure resulting from:

  • Atmospheric precipitation with salt content resulting from the proximity of the sea,
  • High relative air humidity resulting from the proximity of water bodies,
  • Air pollution with industrial dust (soot, fly ash, etc.),
  • The presence of SO2 in the air causing so-called acid rain,
  • Temperature changes and radiation exposure due to sunlight
Chemically aggressive C5-I Very large (industrial) Steel structure outdoors and indoors in an aggressive atmosphere with a high degree of air pollution with aggressive, chemically corrosive gases: sulfur dioxide, sulfuric acid vapors, hydrogen chloride, hydrogen sulfide, ammonia; dust with inorganic salts, etc.
Very strong chemically aggressive CX Very large (marine) Steel structure outdoors and indoors in aggressive atmospheres with almost constant moisture condensation and heavy pollution; coastal and remote areas with high salinity.

Additional information is the required durability period. The client should specify the warranty period; this information is often included in designs or tender specifications.

According to the PN-EN ISO 12944-1:2001 standard, three durability periods of anti-corrosion paint coatings are distinguished:

  • Short (L) – up to 7 years,
  • Medium (M) – from 7 to 15 years old,
  • Long (H) – from 15 to 25 years,
  • Very long (VH) – over 25 years.

STEP 4 Choosing the right paint: product division, characteristics and sample systems in our offer

Anti-corrosion paints are available as products:

  • two-component (hardener + base – require mixing – have a specific shelf life of the mixture)
  • one-component (ready to paint)

Anti-corrosion paints can be divided, for example, according to the content of anti-corrosion pigment:

  • Primers and enamel – primer and enamel in one, contains anti-corrosive pigments, which makes it softer than typical topcoats.
Telkyd S 220
 polyvinyl primer Telpur S 210
 two-component polyurethane primer Peganox is an elastomeric, water-based anti-corrosion paint 
           
  • Primer – also known as undercoat, contains anti-corrosive pigment, the primer requires painting with topcoat paint (enamel or primer-enamel) because it degrades under the influence of the environment.
Telpox P 100 two-component anti-corrosive epoxy primer
Telkyd P 100S
one-component anti-corrosive alkyd primer, especially recommended for painting large surfaces, e.g. containers Epodux Primer is a quick-drying, two-component epoxy-polyamide primer
 
  • Enamel – a topcoat paint, does not contain anti-corrosive pigment, a primer should be applied under it.
Telpox T 300
 industrial epoxy enamel with a high gloss Telpur T 300
 is an industrial polyurethane enamel, available in high gloss or matt Telkyd T 330 is a one-component alkyd topcoat, particularly recommended for painting large surfaces, e.g. containers.
Examples of painting systems depending on the environmental corrosivity class and the durability of the coating.

The prices listed below are list prices. We offer additional discounts for contractors and larger orders. The price depends on the color and is different for each RAL color.

Our technical advisors will help you choose the optimal system - call: +48 717 026 346

Corrosion class C1/C2

Durability time : short, up to 7 years
 Product: Telkyd P 100 S
 primer Telkyd T 300 topcoat Short description: alkyd system, primer + 1 layer of topcoat

The products are characterized by excellent weather resistance and very fast drying. The system is ideal for environments with moderate corrosion (industrial areas, steel structures, pipes, workshops, laundries, basements), metal and steel structures and halls, metal elements, metal furniture, doors, and agricultural machinery. Suitable for both interior and exterior use. Total dry film thickness: 80µm.

Product Layer thickness Number of layers Theoretical efficiency Net price 1l Net price per 1m2
[-] [µm] [-] [m 2 /kg] [PLN/l] [PLN/m2]
Telkyd P 100S 40 1 9 21,42 2,38
Telkyd T 300 RAL7040 40 1 9,5 25,83 2,72
5,1

Durability : Average, 7 to 15 years.
Product: Telpox P 100
 high-build epoxy paint. Brief description: Telpox P 100 is an industrial, anti-corrosive epoxy primer for steel. It provides excellent protection against corrosion and contains zinc phosphate as an anti-corrosion pigment. At a thickness of 120µm, it can be used as a standalone coating (primer-enamel) indoors.

Product Layer thickness Number of layers Theoretical efficiency Net price per 1kg Net price per 1m2
[-] [µm] [-] [m 2 /kg] [PLN/kg] [PLN/m2]
Telpox P 100 60 2 9,7 28,1 5, 79

Corrosion class C3

Durability : medium, 7 to 15 years
 Product:  Telkyd S 220
 Brief description: Polyvinyl primer, can be applied directly to bare black steel, aluminum, and galvanized steel. Total dry film thickness: 160µm. Recommended application in two coats.

Product Layer thickness Number of layers Theoretical efficiency Net price per 1kg Net price per 1m2
[-] [µm] [-] [m 2 /kg] [PLN/kg] [PLN/m2]
Telkyd S 220 RAL7040 160 1 1,79 25,06 14,00

Durability : up to 15 years
 Product:
 Telkyd P 100S primer Telkyd T 330 topcoat Short description: alkyd system, primer + 2 layers of topcoat

Designed for large-scale painting, these thixotropic products do not bleed at edges. They are perfect for spray painting shipping containers. Total dry film thickness: 160µm.

Product Layer thickness Number of layers Theoretical efficiency Net price 1l Net price per 1m2
[-] [µm] [-] [m 2 /kg] [PLN/l] [PLN/m2]
Telkyd P 100S 80 1 5,9 21,42 3,63
Telkyd T 330 RAL7040 40 2 11 23,67 4,3
7,93

Durability : Average, 7 to 15 years.
 Product: Telpur S 210.
 Brief description: Two-component polyurethane primer/finish. Can be spray-applied in a single, 120µm thick layer. Can be applied directly to mild steel, galvanized steel, or aluminum. Total dry film thickness: 120µm.

Product Layer thickness Number of layers Theoretical efficiency Net price per 1kg Net price per 1m2
[-] [µm] [-] [m 2 /kg] [PLN/kg] [PLN/m2]
Telpur S 210 RAL7040 120 1 4,1 37,98 9,26
telkyd t330 container paint3
telkyd t330 container paint

Corrosion class C4

Durability : average, from 7 to 15 years
 Product: Telpox PM 150 primer + Telpur S 210

Brief Description: Two-component polyurethane primer/finish. Can be applied directly to mild steel, galvanized steel, or aluminum. Total dry film thickness: 180µm.

Product Layer thickness Number of layers Theoretical efficiency Net price 1l Net price per 1m2
 [-] [µm] [-] [m 2 /kg] [PLN/l] [PLN/m2]
Telpox PM 150  100 1 7,68 31,33 4,08
Telpur S 210 RAL7040
 80 1 6 37,98 6,33
10,41

Durability time : short, up to 7 years
 Product: 2 layers of
 Telpox P 100 Telpur T 320 polyurethane topcoat Short description: Anti-corrosion epoxy-polyurethane system, total dry layer thickness 160µm.

Product Layer thickness Number of layers Theoretical efficiency Net price per 1kg Net price per 1m2
[-] [µm] [-] [m 2 /kg] [PLN/kg] [PLN/m2]
Telpox P 100 80 1 5,2 34,56 6,65
Telpur T 320 RAL7040 40 2 10,4 31,81 6,12
12,77

Corrosion category C5 and CX

Corrosion class: C5
 Durability time : medium, from 7 to 15 years
 Product: 1 layer of Telpox P 170 epoxy primer + 2 layers of Telpur T 330HS polyurethane topcoat
 Short description: Anti-corrosive epoxy-polyurethane system, total dry layer thickness 220µm.

Product Layer thickness Number of layers Theoretical efficiency Net price per 1kg Net price per 1m2
[-] [µm] [-] [m 2 /kg] [PLN/kg] [PLN/m2]
Telpox P 170
 160 1 4,6 24,12 5,24
Telpur T 330 HS RAL7040
 80 1 3,3 41,31 12,52
17,76

Corrosion class: C5
Durability time : long, over 15 years
 Product: 1 layer of Telpox P 170 epoxy primer + 2 layers of Telpox PM 150 epoxy primer with iron mica + 1 layer of Telpur T 330 HS polyurethane topcoat
 Short description: Anti-corrosion epoxy-polyurethane system, total dry layer thickness 300 µm.

Product Layer thickness Number of layers Theoretical efficiency Net price per 1kg Net price per 1m2
[-] [µm] [-] [m 2 /kg] [PLN/kg] [PLN/m2]
Telpox P 170 100 1 6,3 24,12 3,45
Telpox PM 150
 120 1 6,33 31,33 4,89
Telpur T 330 HS RAL 7040
 80 1 3,3 41,31 12,52
20,86

Corrosion Class: C5 and CX
Durability: Up to 10 years
Product: Noxyde, two coats
Brief Description: Elastomeric, water-based anti-corrosion paint. Can be applied directly to rust; no sandblasting required. Total dry film thickness: 320µm.

Product Layer thickness Number of layers Theoretical efficiency Net price per 1kg Net price per 1m2
[-] [µm] [-] [m 2 /kg] [PLN/kg] [PLN/m2]
Noxyde 160 2 0,4 50,00 40,00
Telpurt T 320 polyurethane enamel application
Telpurt T 320 polyurethane enamel application

STEP 5 Painting

Once you've chosen your paint, it's worth paying attention to the application requirements listed in the product's technical data sheet. Each paint has a recommended surface temperature, air temperature during application and drying, and a specified curing time at specific temperatures. Therefore, painting outdoors in unfavorable weather conditions should not be planned.

To sum up, our offer includes:

Peganox : Provides excellent anti-corrosion protection for structures such as bridges, metal roofs, metal facades, and steel structures. The paint withstands highly corrosive environments, including industrial and marine environments (classes C5-I and C5-M). Ideal for use in industrial environments. Sandblasting is not required; it can be applied directly to flash rust.

Epoxy paints : Designed for use as a topcoat in interior anti-corrosion paint systems. Can also be used on mineral substrates, such as masonry.

Polyurethanes : They are characterized by excellent resistance to moisture and chemicals. They are UV-resistant. They are primarily used for painting steel, wood, and concrete surfaces. They are slightly flexible and exceptionally abrasion-resistant.

Polyvinyls : Designed primarily for painting steel and galvanized steel structures for corrosion protection. Due to their flexibility, they are primarily used for steel roofs and metal facades.

Alkyd paints : Designed for interior and exterior painting in mildly corrosive environments where very long durability is not required. Also suitable for wood and paneling.

Acrylics : They are characterized by excellent adhesion to steel, galvanized steel (including fresh galvanized steel), aluminum, and copper. For undemanding, economical work.

Chlorinated rubbers : Designed for interior and exterior painting, except in chemically aggressive environments. They can be used to protect:
 – steel and cast iron surfaces for corrosion protection and decorative purposes, machines, equipment, industrial and construction structures, barriers, poles, fences, streetlights, etc.
 – wood and wood-based materials for aging protection and decorative purposes.

Heat-resistant paints and varnishes : They can be applied to new, clean or sandblasted steel surfaces or to pre-treated surfaces, e.g. exhaust pipes, boiler equipment, fireplaces, radiators, etc. They provide anti-corrosion and heat-resistant protection.

Zinc-rich paints : These paints contain a high zinc dust content and provide excellent corrosion protection thanks to their excellent bonding to the substrate.