Do you love metal and want to enjoy your objects for a long time? The main enemy of metal is rust, caused by the corrosion of iron in the presence of oxygen in the air, in a damp environment.
One technique for protecting metal is to apply an anti-rust paint. In this article, we take a closer look at this type of paint, the situations in which it can be used and how it is applied using a spray gun.
What is anti-rust paint?
It is a rust and weather resistant surface coating that can be used wherever a durable and effective protective layer is required.
It protects surfaces against moisture penetration and offers optimum protection against all types of corrosion, such as crevice corrosion, galvanic corrosion, stress corrosion cracking, rust, etc.
In addition, anti-rust paint can be used to design visually attractive surfaces or to recycle worn components. Its use is not limited to metal surfaces, as it is also suitable for wood, glass, ceramics, many plastics and other materials.
When should anti-rust paint be used?
The most common applications include :
- Railings
- Gates
- Drain pipes
- Garage doors
- Wrought iron balconies
- Garden lamps and other outdoor decorations
There are, of course, larger metal objects that are used in difficult conditions, such as containers or boat hulls. To see some photos of the renovation of a metal skip using airless spraying, click here.
What types of anti-corrosion materials are available on the market?
It is essential to match a type of coating to the substrate and the working environment to which it will be applied. With this in mind, most workplaces require several different types of coating. The right coating reduces corrosion, extends service life and facilitates future maintenance.
It is not uncommon to use these coatings as a base before applying other coatings to protect the surface.
Here are some of the best anti-corrosion coatings:
Fluoropolymer
Fluoropolymer is a blend of high performance resins combined with fluoropolymer lubricants. They are formulated with a superior solid film lubricant that controls abrasion by significantly reducing friction. Fluoropolymer is useful in very high and very low temperature environments.
Although chosen primarily for its corrosion resistance, fluoropolymer is also resistant to corrosive chemicals. It also has a certain degree of electrical resistance. This combination of characteristics makes it suitable for OEM fasteners and components, extending their service life.
Epoxy
Epoxy is one of the most common industrial coatings. It is often referred to in terms of epoxy flooring systems. However, it can be used throughout the industrial workplace. Different epoxy formulations have radically different conductivity and temperature resistance properties.
There are two main types of epoxy coating:
1. Air-dry epoxy coating
Air-dry epoxy coating is used exclusively for metal surfaces. It provides a high level of rust and chemical resistance. A single layer offers corrosion protection at a thickness of 4 to 6 millimetres. It is generally used in two- or three-layer systems in oil and gas installations.
2. Heat-curing epoxy coating
Thermoset epoxy coatings offer some of the best corrosion protection in demanding industrial environments. The high molecular weight allows exceptional impact and abrasion resistance to coexist. It is a popular coating in industries that use alkaline and caustic solutions.
Phosphate
Phosphate is a type of conversion coating for steel and other metals. It has a crystalline structure formed on ferrous metal substrates. It is used for pre-treatment prior to coating or painting an industrial surface. As well as protecting against corrosion, it improves the friction properties of sliding parts. With an appropriate oily topcoat, it can inhibit rust on threaded components.
Inorganic zinc
Inorganic zinc is an ideal form of corrosion protection for blasted metal surfaces. It offers some of the best corrosion protection on the market and is effective against weathering, salt attack and solvents. Coastal installations make extensive use of inorganic zinc coatings. Many ships have used this form of protection.
Inorganic zinc has the advantage of being compatible with a wide range of topcoats that can enhance its corrosion protection. It works with epoxies, phenolics, acrylics, silicones and many others. It should be considered for chemical plants and refineries, as well as silos and industrial tanks.
This is just a sample of the anti-corrosion coatings available today. Any painting plan should start with a full site assessment, detailing the environment and its hazards.
Spray with anti-rust paint
Metal protection materials can generally be sprayed mechanically. A low-pressure HVLP pump is more often used in this case. Why is this?
Because this type of machine is suitable for small quantities of material, for profiled surfaces and the atomisation is finer than with an airless spray gun.
The video below shows the Graco FinishPro 9.5 HVLP turbine used to paint iron fence ends. The low-pressure spray technique or HVLP works with a low working pressure and a high volume of air to atomise the paint. A turbine is used to supply the necessary volume of air. The turbine feeds the cup gun via an air hose.
This spraying method is suitable for painting objects in small quantities, in this case a metal fence. But radiators, doors or window frames can also be painted using the HVLP technique.
It’s also possible to paint larger objects like a bridge or a container using airless. To find out more about the advantages and characteristics of airless and HVLP spraying, we recommend you read our article on the subject (How to Choose Between an Airless, an AirCoat or a HVLP Spray Gun).
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Questions or queries?
For any further questions or if you would like to get your hands on one of these products seen in this article, you can contact us on +49 (0) 30 220 15436, fill out our contact form or email us. If you wish to purchase one of the products mentioned above, you can check them out in our online store. You can also visit us at our service base during office hours.
