Steel structures, bridges, machines, pipes and other elements require protection against corrosion. The environment and its aggressiveness (e.g. chemical composition) play the main role in the destruction of steel structures of buildings or industrial equipment during their operation. The mechanical and thermal impact on a given steel element also has a significant impact on the course of corrosion. To counteract this, appropriate anti-corrosion systems should be used.

selection of anti-corrosion painting systems for the Grunwaldzki Bridge

To select the appropriate anti-corrosion system, follow the steps listed below:

STEP 1 Determining the type of substrate:

  • Black steel , also known as carbon steel, is the raw material most susceptible to corrosion. To protect black steel, it should be coated with an anti-corrosion pigment.
  • Galvanized steel is steel protected against corrosion by applying a layer of zinc. Galvanized steel does not require additional protection, however, if the zinc coating is broken or worn out, we recommend additionally protecting the steel with an appropriate primer (anti-corrosion primer). For aesthetic reasons, galvanized steel can be painted with paints intended for this purpose. Please remember that not all paints can be applied directly to galvanizing.
  • Aluminum is used in construction due to its lightness and durability, this material does not corrode. Aluminum is painted mainly for aesthetic reasons.
  • Cast iron is an extremely durable material, however, cast iron elements exposed to increased humidity or weather conditions (lanterns, etc.) should be painted with anti-corrosion paints.

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

  • Is the structure inside or outside the building?

Coatings are susceptible to weather conditions, which is why, for example, in the case of outdoor structures, polyurethane paints are used, which are characterized by excellent resistance to moisture and UV rays. epoxy primers as a primer . Epoxy coatings cannot be used as a stand-alone exterior coating because they are not resistant to UV radiation and chalk, so they must always be protected with a topcoat.

  • Will the steel tank be painted? What substances will the tank be flooded with?

Anti-corrosion paint must provide protection, tightness and resistance to the pressure of water (or other liquid) in the tank. When flooded with chemicals, the paint must be chemically resistant.

Valuable information for the advisor will be: – What liquid will be in the tank? – For acids, what are the concentrations? – Is a certificate for contact of the coating with food or drinking water required? The more information we get from you, the better the right solution will be for you.

  • Is the structure susceptible to mechanical impacts, friction of objects, and pedestrian traffic?

To ensure high mechanical resistance, we propose systems in which the final coating is epoxy or polyurethane flooring resin (epoxy indoors, polyurethane outdoors). The first layer that protects the steel against corrosion and bonds with the resin is a properly selected primer.

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

We determine the corrosion class according to the table below. This is a very important factor because the class determines, among other things, the selection of the appropriate thickness of the coating or coatings that the anti-corrosion system will consist of.

Commonly used environmental terms Classification of environmental corrosivity

according to PN-EN ISO 12944-2

 Basic corrosion factors
The interior is dry C1 Very small Steel structure indoors with the possibility of moisture condensing on the surface of the paint coating.
The interior is damp C2 Small Steel structure inside rooms with frequent internal condensation of water vapor. An additional corrosive factor may be the presence of salt aerosol (marine atmosphere) or aggressive gases absorbed in moisture (e.g. sulfur dioxide in industrial atmosphere).
Rural and urban outdoors C3 Average Steel structure outdoors, in an atmosphere free from strong pollutants resulting from the proximity of industrial gas and dust emission sources; additional corrosive factors occur.

Corrosion exposure resulting from:

  • atmospheric waste,
  • Temperature changes due to sunlight,
  • Actions of solar radiation,
  • Emissions of aggressive and corrosive gases (e.g. sulfur dioxide from home furnaces and housing estate 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:

  • Precipitation with salt content resulting from the proximity of the sea,
  • High relative air humidity resulting from the proximity of water bodies,
  • Air dusting with industrial dust (soot, fly ash, etc.),
  • The presence of SO2 in the air causing the so-called acid rain,
  • Changes in temperature and radiation exposure as a result of 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 chemically aggressive and corrosive gases: sulfur dioxide, sulfuric acid vapors, hydrogen chloride, hydrogen sulphide, ammonia; dusting with inorganic salts, etc.
Very strong chemically aggressive CX Very large (marine) Steel structure outdoors and indoors in an aggressive atmosphere with almost constant moisture condensation and heavy pollution; coastal and inland areas with high salinity.

Additional information is the required shelf life. The customer should specify how long the guarantee is to be granted, and this information is also often included in designs or tender specifications.

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

  • Short (L) – up to 7 years,
  • Medium (M) – from 7 to 15 years,
  • 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:

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

The prices given below are net catalog prices as of July 28, 2020. We offer additional discounts for contractors and larger orders. The price depends on the color and is different for each RAL color.

Corrosion class C1/C2

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

The products are characterized by very good resistance to weather conditions and dry very quickly. The system works perfectly in environments with moderate corrosion (industrial areas, steel structures, pipes, workshops, laundries, basements), metal and steel structures and halls, metal elements, metal furniture, doors, agricultural machinery. Used inside and outside buildings. Total dry layer thickness 80µm.

Product Layer thickness Number of layers Theoretical performance Net price 1l Net price per 1m2
[-] [µm] [-] [m2 / 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, from 7 to 15 years
Product: thick-layer epoxy paint
 Telpox P 100 Short description: Telpox P 100 is an industrial, anti-corrosion epoxy primer for steel. Perfectly protects steel against corrosion, contains zinc phosphate as an anti-corrosion pigment. With a thickness of 120µm, it can be used as an independent coating (primer enamel) indoors.

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

Corrosion class C3

Durability : average, from 7 to 15 years
 Product:  Telkyd S 220
 Brief description: Polyvinyl primer, can be applied directly to clean black steel, aluminum and galvanized steel. Total dry layer thickness 160µm. Recommended application in two layers.

Product Layer thickness Number of layers Theoretical performance Net price 1 kg Net price per 1m2
[-] [µm] [-] [m2 / 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 Brief description: alkyd system, primer + 2 layers of topcoat

Products designed for large-surface painting, thixotropic, do not run on the edges. Perfect for spray painting shipping containers. Total dry layer thickness 160µm.

Product Layer thickness Number of layers Theoretical performance Net price 1l Net price per 1m2
[-] [µm] [-] [m2 / 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, from 7 to 15 years
 Product: Telpur S 210
 Short description: Two-component, polyurethane primer enamel. It can be sprayed in one thick layer of 120µm. Can be applied directly to black steel, galvanized steel or aluminum. Total dry layer thickness 120µm.

Product Layer thickness The number of layers Theoretical performance Net price 1 kg Net price per 1m2
[-] [µm] [-] [m2 / 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. Can be applied directly to black steel, galvanized steel or aluminum. Total dry layer thickness 180µm.

Product Layer thickness Number of layers Theoretical performance Net price 1l Net price per 1m2
 [-] [µm] [-] [m2 / 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 : short, up to 7 years
 Product: Telpox P 100
 epoxy primer Telpur T 320 polyurethane topcoat Brief description: Anti-corrosion epoxy-polyurethane system, total dry layer thickness 160µm.

Product Layer thickness The number of layers Theoretical performance Net price 1 kg Net price per 1m2
[-] [µm] [-] [m2 / 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

Corrosivity category C5 and CX

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

Product Layer thickness The number of layers Theoretical performance Net price 1 kg Net price per 1m2
[-] [µm] [-] [m2 / 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 : long, over 15 years
 Product: 1 layer of Telpox P 170 epoxy primer + 2 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 The number of layers Theoretical performance Net price 1 kg Net price per 1m2
[-] [µm] [-] [m2 / 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 layers
Brief description: Elastomeric anti-corrosion paint, water-soluble. It can be applied directly to rust, it does not require sanding the surface. Total dry layer thickness 320µm.

Product Layer thickness Number of layers Theoretical performance Net price 1 kg Net price per 1m2
[-] [µm] [-] [m2 / 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 we have chosen the paint, it is worth paying attention to the application conditions specified in the product's technical data sheet. Each paint has a recommended temperature of the coated substrate, air temperature during application and drying, and indicated hardening time of the coating at given temperatures. Therefore, you should not plan to paint outdoors when the weather is unfavorable.

To sum up, our offer includes:

Noxyde/Peganox : They provide excellent anti-corrosion protection for objects such as bridges, metal roofs, metal facades, steel structures. The paints withstand highly corrosive environments, including industrial and marine environments (classes C5-I and C5-M). Perfect for use in industrial areas. They do not require sanding the substrate and can be applied directly to flash rust.

Epoxy Paints : Intended for use as a topcoat in interior, anti-corrosion painting systems. It can also be used on mineral substrates, e.g. walls

Polyurethanes : characterized by excellent resistance to moisture and chemicals. They are resistant to UV rays. They are used primarily for painting steel, wooden and concrete surfaces. They are slightly flexible and at the same time extremely resistant to abrasion.

Polyvinyls : Intended mainly for painting steel and galvanized steel structures, for anti-corrosion protection. Due to its flexibility, it is mainly used for steel roofs and metal facades.

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

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

Chlorinated rubbers : Intended for painting indoors and outdoors, outside chemically aggressive environments.
 They can be used to protect: - steel and cast iron surfaces to protect against corrosion and for decorative purposes of machines, devices, industrial and building structures, barriers, poles, fences, street lamps, etc.
 - wood and wood-based materials for protection against aging and for decorative purposes.

Heat-resistant paints and varnishes : They can be used for new, clean or sandblasted steel surfaces or for surfaces after preliminary treatment, e.g. exhaust pipes, boiler room equipment, fireplaces, radiators, etc. They provide anti-corrosion and heat-resistant protection.

Zinc-rich paints : They have a high content of zinc dust. They provide excellent anti-corrosion protection thanks to excellent bonding to the substrate.