Journal of Architectural Coatings - PaintSquare

Journal ofArchitecturalCoatingsV olume 1 / Number 1 January 2005GUIDE TOLIQUID-APPLIEDAIR BARRIERSGLITTERING REVIEWSFOR METALLICSAT THE OPERACONCRETE STAINGENERATES REACTIONIN LANDMARK CHAPEL

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january 2005journal of architectural coatings / contents18Innovations for repairingconcrete buildings in saltenvironmentsKen Tator, KTA-Tator Inc.project profilesState-of-the-art technologies forrepairing concrete buildings locatedin harsh, salt-laden coastalenvironments are examined.1538Design team prescribes resin-basedmaterial for hospital expansionReactive stain breathes life intolandmark chapel’s concrete32All that glitter is silverJoe Maty, editorThe ambitious makeover ofSeattle’s McCaw Hall has wonrave reviews; the supporting castincludes sparkling metallic finishes.42It’s westward ho for air barriersJAC staffThe barrier movement is gainingmomentum, and liquid-appliedmaterials figure prominently in thetechnology parade.3columnsEditorial Comment: Magazinelaunches into dynamic environment50Less pricey protectionJeff Schmucker, Carboline Co.Surprise: More steel, less intumescentcoating might save moneyin specifying fire-resistant constructionmaterials.263041Durability:Change in the air in test methodsGetting it Right: Successful paintingof galvanized steelThe Concept Stage:R&H plants seed of greener paintnews8New VOC rules arrive in Mid-Atlanticstates; Launch of building-enclosurecouncils commencesOn the cover: Seattle’s McCaw HallCourtesy of Tnemec5656CalendarAdvertisers IndexJournal of Architectural Coatings / January 2005 1

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editor’swordLaunching into a dynamic environmentWhen I first began planning this journal, it was 1991and George Herbert Walker Bush was President.Now, a generation later, the launch is finally here.Normally, I am slow in getting things done, but this lag seems abit excessive, even for me, so I’d like to try to explain myself, andin so doing, to explain the rationale for this new journal.In 1991 I decided to write about architectural coatings for anaudience of architects, specifiers, building owners, and contractors,after having seen that a void existed in communicatingobjective information to this audience about the use of coatings.But while I had found a niche in which to operate, I soonlearned there was not enough technical complexity in the subjectto interest the audience I wanted to pursue.So what happened between 1991 and 2005 to change mymind? As with other technologies, like computing and the Internet,plenty happened in the coatings industry, driven by forces such asenvironmental and safety regulations, the green movement in buildingtechnology, the drive for energy independence in the U.S.,and advances in nanotechnology and the chemistries of coatings.One simple fact of life makes it necessary to improve the communicationabout coatings materials to individuals who mustselect them: every type of coating is different now than it was 15years ago, having been reformulated to achieve compliance withregulations. And the pressure to reformulate to meet more andmore stringent regulations persists, as the story (in this issue on p.8) about new VOC regulations demonstrates.Evaluation of coatings performance becomes very important inthis environment of change. We believe users ought to have abasic understanding about the methodologies of performanceevaluation, and perspective about the validity of test data. To thisend, we will publish a column in every issue dealing with thesesubjects. Called “Passing the test,” the inaugural installment canbe found on p. 26.Green building initiativesOrganizations issuing certifications in the green building movementjudge coatings to be “green” based mainly on VOC content,so they impose further pressures on coatings formulations inthis area. A story on p. 10 in this issue describes recent actionsby the National Paint & Coatings Association to respond to coatingsrequirements set out by these organizations and by the EPA’sDraft Federal Guide for Green Construction Specifications.This magazine will cover the topic of green coatings continuouslyand will attempt to advance the dialogue between proponents ofgreen buildings and the coatings industry.Energy conservationThere is a strong movement by both government and industry to pursueenergy conservation in buildings. Here, special-purpose coatingsare required—as air and vapor barriers, waterproofing materials,roofing membranes, insulation, etc.—and many new coatings havebeen developed for these functions. We will cover all aspects ofcoatings for energy efficiency, as illustrated by the article on air barrierson p. 42. Note also in “The Concept Stage” we describeRohm & Haas research supported by the Department of Energy todevelop coatings materials requiring less energy to manufacture.Advances in chemistryThis month’s conference on nano and hybrid coatings technology inthe UK, organized by the Paint Research Association, exemplifies thedynamism in coatings chemistry as new materials based on theseand other technologies are developed and commercialized. The performancepromise of these new materials includes greater durability,strengthened resistance properties, and emerging functionalities. Wewill certainly devote significant attention to new coating materials.Not to mention aestheticsRecently developed coating materials offer aesthetic effects thatarchitects and others need to know about. In this issue, we describethe creation of a stunning silver in Seattle’s McCaw Hall, as well asthe innovative use of acid stain on the vertical surfaces of a chapelto create the beauty normally associated with stone. As we dealwith high-performance architectural coatings, we also deal with highperformance in aesthetic effects.DynamismSo, as this launch issue demonstrates, we are operating in a dynamicenvironment, with emerging materials, a vigorous green-buildingmovement, and significant technical advances in building science.There is now much to communicate about with our chosen audienceof architects, specifiers, building owners, and contractors.PublisherJournal of Architectural Coatings / January 2005 3

ContributorsAllen ZielnikAllen Zielnik (Passing thetest, p. 26) leads the technicalconsulting operation ofAtlas Materials Testing LLC,where he also serves as thedirector of strategic sales. Inaddition, Zielnik is a memberof the AmericanChemical Society, theSociety of Plastics Engineers, the Institute for EnvironmentalSciences, and the Federation of Societies for CoatingsTechnology (FSCT). He is an active member of numeroustechnical committees in ASTM International dealing with theweathering and durability of materials, and he frequentlyadvises standards and trade groups on technical issues.Ken TatorKen Tator (Innovations for repairing concrete buildings in saltenvironments, p.18) is the CEO of KTA-Tator, a coatings consultingfirm. Throughout his career, he has been active in thetechnical committees of theSociety for ProtectiveCoatings (SSPC) and NACEInternational. He is a pastchairman of SSPC Researchand Zinc-Rich Committees,and chairman or a memberof various NACE and SSPCAdvisory Committees. Hewas a member of the firstSSPC Board of Governors,and has been a director ofNACE. He is the UnitedStates delegate to the International Standards Organization(ISO) Technical Committee on Surface Preparation Prior toPainting, and the Convenor of ISO TC35/SC12, WG-5, “Saltsand Other Contaminants Beneath an Applied Paint Film.” Inaddition to NACE and SSPC, he is a member of ASTM, ASM,FSCT, and other industry technical organizations. He holds aBS in Chemical Engineering from Lafayette College and anMBA from Columbia University.Jeff SchmuckerJeff Schmucker (Less pricey protection: reducing the installedcost of intumescent fireproofing, p. 50) is a technical salesrepresentative for Carboline Company, where he has workedfor 23 years in the areas of highperformance coatings and fireproofing,an area in which hehas specialized. He has alsobeen employed by PenningtonManufacturing as manager ofbusiness development, wherehe oversaw the technicalaspects of the company’s paintingand tank lining operations.He serves on the Board ofDirectors of NACE Internationaland is a member of SSPC. Heholds an associate degree in mechanical engineering technologyfrom Penn State University.Jayson HelselJayson Helsel (Getting itright, p. 30), a senior coatingsconsultant with KTA-Tator,manages failure investigationsand coating projectsand is involved with coatingsurveys and inspection ofindustrial structures. Heholds an MS in chemicalengineering from theUniversity of Michigan, is aregistered professional engineer,and a NACE CoatingsInspection Technician.4 Journal of Architectural Coatings / January 2005

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NewsNew coatings VOC limitsgo into effect in Mid-AtlanticWASHINGTON—Newvolatile organic compound(VOC) limits on architecturaland industrial maintenancecoatings were scheduled togo into effect Jan. 1 in sixMid-Atlantic states and theDistrict of Columbia. Lower-VOC coatings over the nextseveral months will replaceinventories manufactured priorto Jan. 1, which are exemptfrom the new limits due to a“sell-through” provision in theregulations.The region, one of the mostdensely populated and developedparts of the country,represents a significant marketfor architectural coatings.The six states, members of the12-state Ozone TransportCommission (OTC), areimposing VOC limits as lowas 100 grams per liter, effectiveJan. 1. The states areNew York, New Jersey,Pennsylvania, Delaware,Maryland, andWashington D.C., withseveral counties in northernVirginia also joining thegroup in enacting a VOCrule. Some of the OTC’s sixother member states in NewEngland are expected toapprove VOC rules, but nonewere finalized in time to gointo effect Jan. 1.The National Paint &Coatings Association (NPCA),Washington, D.C., is pursuinglegal challenges to the newVOC rules in Delaware andNew York, with lawsuits thatcontend the rules presentunreasonable technologicalrequirements that couldadversely affect coatings performance.A court in Delawarehas ruled against the association’schallenge, but the NPCAhas appealed to the state’sSupreme Court, where a decisionis pending. Legal chal-Product pipelinelenges to the new VOC rulesalso are being pursued by TheSherwin-Williams Co.Key VOC limits imposed inthe six Mid-Atlantic states onJan. 1 include 100 grams perliter (g/L) for flat interior andexterior coatings, 150 g/L fornon-flat interior and exteriorcoatings, 250 g/L for non-flathigh-gloss coatings, 340 g/Lfor industrial maintenance coatings,and 200 g/L for primersand undercoaters.A range of VOC limits willgo into effect for nearly 50Cold weather sealersother categories of coatings.Among the limits viewed asproblematic is a 250 g/L standardfor clear, semitransparentand opaque stains, industryrepresentatives said.Coatings manufacturers saidthey were prepared for thecompliance challenge posedby the new regulations, butcautioned that coatings userswill see a difference in cost.“They (coatings products) willbe more expensive as a result ofincreased R&D costs,” said JohnSchutz, president and CEO ofcoatings and wood-finishes manufacturerSamuel Cabot Inc.,Newburyport, MA. Schutz, currentchairman of the NPCA’sArchitectural CoatingsDegussa Building Systems introduced two waterproofing sealersdesigned for cold-temperature application to exterior walls. Thoro20 is a solvent-based, high-build copolymer sealer formulatedfor application at temperatures as low as 20 F; Thoro 20Block Filler is a solvent-based first-coat product for applicationover porous blocks. The sealer is offered in three base colorsfor local tinting, 48 standard colors and unlimited custom colors,and can be applied to a variety of commercial buildings.Application can be done by spray, roller or brush, with applicationrecommended after seven days of cement curing. The productsare offered in smooth and fine textures, and are formulated to provideresistance to wind-driven rain and for breathability to prevent peeling and blistering caused bytrapped moisture, the company says. The fine-texture formula is reported to minimize the appearanceof minor substrate imperfections.Degussa Building Systems (www.degussabuilding systems.com), Shakopee, MN.8 Journal of Architectural Coatings / January 2005

AIA-NIBS agreement forges startto a network of building-enclosure councilsCommittee, said customers will begin tosee the effects of higher prices as inventoriesof pre-Jan. 1 products are depleted.Shutz said that while coatings producershave succeeded in formulating productsthat will comply with the VOC limitsand meet performance demands, coatingsusers should read product directionscarefully to ensure successful application.He also said some coatings makersare likely to abandon certain productlines in response to the new regulations.Schutz said the industry has madegreat strides in producing water-basedcoatings that equal or exceed the performanceof solvent-based products.Peter Flood, chairman and CEO ofcoatings manufacturer The Flood Co.and chairman of an NPCA policy committeethat has been formed to addressa growing array of architectural-coatingsVOC issues, agreed that coatings supplierswill be able to offer products thatcomply with the new VOC rule in theMid-Atlantic states. But he said someconcern exists in the industry that regulationswill go further, possibly duplicatingthe technology-forcing VOC limits adoptedby California regulators.Flood also echoed Shutz’s commentsthat coatings users will see higherprices, and also agreed that some coatingsmanufacturers will discontinue certainproduct lines rather than incur heftyfinancial outlays for reformulation.The NPCA is recommending that companiesand other interested partiesobtain copies of regulations enacted byeach of the states that have enactedrules, due to differences in the provisions.More information also is availablefrom the Ozone Transport Commission.The commission’s website is located atwww.otcair.org.The first local chapter of a planned networkof building-enclosure councils waslaunched recently in Pittsburgh following anagreement announced by the leadership ofthe American Institute of Architects (AIA) andthe National Institute of Building Sciences(NIBS).The agreement, signed by the AIA-NIBSBuilding Environment and Thermal EnvelopeCouncil, is designed “to reinforce the designcommunity’s leadership in the crucial area ofbuilding enclosures”—also known as buildingenvelopes—the NIBS said.Building-enclosure councils are in theprocess of being organized in Seattle,Chicago and Texas, said officials with theAir Barrier Association of America (ABAA), akey participant in efforts to develop buildingenvelopetechnologies, standards and speci-fications. Other cities targeted for the launchof building-enclosure councils areWashington, DC, New York, Boston,Philadelphia, Dallas, St. Louis, and SanFrancisco.“The establishment of building-enclosurecouncils across the U.S. under the auspicesof NIBS and the AIA will provide the constructionindustry a forum to discuss issues ofcommon concern,” said Richard Kelleher,AIA Building Science KnowledgeCommunity representative. “It will also affordarchitects the opportunity to take back leadershipin the design of the building enclosure,which is so intimately involved with thebuilding design itself.”The AIA-NIBS agreement’s objectivesinclude plans for “knowledge forums” opento all interested parties, where “an intensifiedJournal of Architectural Coatings / January 2005 9

Newsfocus on the building enclosure can takeplace,” the NIBS said. The forums will:• Provide a focus/forum at the local levelfor those with an interest in the enclosure(envelope) of buildings (all buildings) andthe related building science;• Promote and encourage discussion, training,education, technology transfer, and theexchange of information about local andnational issues and cases, relevant weatherconditions, etc.;• Initiate and promote cross-disciplinary andcross-responsibility dialogue among professions,designers, consultants, educators,manufacturers, suppliers, fabricators,builders, building operators, developers,insurance, etc.• Facilitate improvements in relation toprocess, namely inspection, approvals, regulations,standards, liability, etc.The agreement was engineered byWagdy Anis, AIA, a board member of theBuilding Environment and Thermal EnvelopeCouncil and chairman of the ad-hoc committeefor the venture; Dr. Eric Burnett, chairmanof the council; and David Altenhofen,AIA, past chairman of the Building ScienceKnowledge Community Advisory Council.The NIBS said the Building Environmentand Thermal Envelope Council will be modeledon a successful program initiated bythe Boston Society of Architects—the Bostonchapter of the AIA—and will be similar tothe network of existing councils in Canada.The NIBS said a priority of the council isto forge networks among the building-envelopecouncils across North America andwith similar international groups.Those interested in participating in thecouncils are advised to send an e-mail topcichowski@nibs.org stating name and contactinformation.NPCA initiates launchof ‘green building’ panelWASHINGTON—The National Paint &Coatings Association (NPCA) recently invitedcoatings manufacturers to join an industrytask force to address a growing numberof “green building” initiatives that couldplace a range of new environmentaldemands on coatings products.The NPCA said the panel will present theviews of coatings formulators and producerson “green building” programs being pursuedby the EPA, state governments andindependent organizations. The associationhas voiced criticism that the initiatives arebeing pursued with little or no considerationof industry views on crucial performanceand technical issues.In addition to an EPA draft green-buildingguide, the NPCA is calling attention to othergreen-building programs being developedcontinued on page 1210 Journal of Architectural Coatings / January 2005

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continued from page 10Newsby the EPA, state agencies and theNational Association of Home Builders(NAHB). The programs include recommendationsby the North American GreenBuilding Coalition (NAGBC); the“Environmentally Preferable PurchasingDatabase” of the California Office ofArchitect; the U.S. Green Building Council’s“Green Building Rating System ForCommercial Interiors”; and several otherprograms at the federal level and inCalifornia and Massachusetts.In comments submitted recently to the EPAon the agency’s Draft Federal Guide forGreen Construction Specifications, theNPCA said it is important that such recommendations“take into consideration industryperformance standards, which the currentdraft guide does not.”In seeking participants in a new industrywork group that would submit comments onthese and future green-building initiatives, theNPCA cited “the sheer number of ongoingactivities” in the green-building arena, andconcerns voiced by coatings-industry representativesabout the initiatives.More information about this subject is availableat www.paint.org.NEWS: Product PipelineColor systemDunn-Edwards Corp. introduced the “PerfectPalette” color system, consisting of 1,696colors that include 1,400 “core colors,” 100shades of white, 96 “deep, rich accent colors”and 100 “classic colors” that are continuedfrom popular tints in the company’s previoussystem. The system also includes “supersized”five-by-eight-inch color chips and anine-binder color library containing colorchips, fandeck and color album with oneinchcolor swatches grouped by family. Thecompany says the color system was developedover a three-year period in a processinvolving architects, designers, contractors,and color experts.Dunn-Edwards(www.dunnedwards .com), Los Angeles.Concrete primerRust-Oleum Industrial Brands’ flooring division,Concrete Protection Systems, introduced“Green Concrete Prime & Seal,” described asa high-performance epoxy coating system thatcan be applied within hours of pouring concrete.The company says the product combinesthe functions of a curing agent, sealerand permanent primer, and can be applied asearly as eight hours after the pouring of a concreteslab. Topcoating is said to be possibleafter an additional eight hours of dry time.Rust-Oleum (www.rustoleum.com),Vernon Hills, IL.JAC12 Journal of Architectural Coatings / January 2005

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Flooring ProjectProfileDesign teamprescribes resin-based materialfor hospital expansionPhotos courtesy of StonhardWhen Cook Children’s Medical Center in Fort Worth,Texas, undertook a $53 million expansion, thehospital placed top priority on materials and servicesfrom companies with a reputation for innovationand an appreciation for the importance of creating a childfriendlyenvironment. But the team that directed the project—thearchitect, interior designer, builder, and hospital—faced some importantchallenges when it came time to select flooring.The designer’s goal was to use colors and patterns in the flooringthat would appeal to children, soften the sterile hospital environment,distinguish one area from another, and help traffic flow.The team also needed a product that met the hospital’s requirementsfor hygiene, stain resistance, a seamless surface, low maintenance,acoustical dampening, superior durability, slip resistance,and scuff resistance.At the same time, the building-expansion team sought a productoffering design and appearance that would please both the childrenand the medical staff. Realizing that the vinyl flooring used in the pasthadn’t lived up to expectations, project architect Anne Mullins, FKPArchitects Inc., conducted an extensive search for the right flooring.At a “lunch and learn” event sponsored by Stonhard, Mullins wasfamiliarized with “Stonblend RTZ,” a resin-based flooring materialthat appeared to meet the requirements of the Cook Medical Center.In addition to reduced maintenance needs, Stonhard says the productoffers at least a 15-year service life—durability that can translateinto considerable lifecycle cost savings over traditional vinyl flooring.The product consists of the following three components:• Urethane mortar base composed of urethane resin, curing agent,and coarse rubber aggregate;• Clear, 100% aliphatic urethane grout coat; and• Water-borne flat aliphatic polyruethane coating topcoat.All three parts are multi-component materials. The manufacturerrecommends use over properly prepared concrete, wood, or steelsurfaces. Asphalt, mastic, gypsum-based products, brick, or paintedsurfaces must be removed mechanically to expose the substrate.Project priorities: aesthetics, durabilityIn the Cook Medical Center project, a top priority for architectMullins was the creation of the ideal environment for children. Shearranged for the design team to begin experimenting with colorsand patterns. Aside from aesthetics, Mullins pondered whether theproduct would stand up to the rigorous needs of a hospital.Mullins took a sample of the Stonblend product to the medicalcenter’s environmental services staff with the instructions to “try todestroy it.” The staff poured betadine, a commonly used antisepticthat leaves tough stains, on the flooring sample and left it for aweek. The betadine was then wiped off, revealing a clean surface.That clinched the decision to specify the product.Tom Greene, an architect with David M. Schwarz, the firmresponsible for the medical center’s interior design, said the flooringallowed the designers to “create a playful pattern thatappealed to the children while meeting rigorous hospital specifications.”The flooring plan included nurses’ stations, corridors, isolationrooms, patient rooms, and restrooms. With changes in colors andpatterns, the flooring could be used to identify hallway intersections,help traffic flow and distinguish one area from another.continued on page 16Journal of Architectural Coatings / January 2005 15

continued from page 15Installation issuesThe selection of the resin-based flooringrather than vinyl posed installation challengesfor LINBECK, the project manager andbuilder. Rebecca Pospisil, project managerfor LINBECK, was required to revise thesequence of the construction schedule toaccommodate the casting in place of theresin-based flooring. Application is chiefly bypower trowel, with some handwork for tightspots.The flooring results in a smooth finish,The “Ins” and “Outs” ofKTA’s Design ServicesKTA-Tator, Inc.’s consultants and engineers, added to your design team,provide the critical (and often missing) link to stop coatings, corrosion,and air barrier problems before they occur by preventing costly failures.For coating failures that start from the Outside, KTA offers:Coating Condition AssessmentsCoating Failure AnalysisSpecifications for New Constructionor RehabilitationConstruction InspectionFor building facade failures or mold and mildewproblems that start from the Inside, KTA offers:Air/Vapor Barrier AssessmentsBuilding Facade Failure AnalysisMold and Mildew EvaluationsSpecifications for Air/VaporBarrier Installation-New Constructionor RehabilitationConstruction InspectionKTA-Tator, Inc., 115 Technology Drive, Pittsburgh, PA 152751-800-245-6379/FAX (412) 788-1306Email: info@kta.com/Website: www.kta.comQuality & Integrity Since 1949Coating FailureFacade FailureKTA is an industry leader in coating consulting and air barrier/buildingenvelope construction consulting with senior-level professionalsspecializing in various substrates (i.e., concrete, wood and metallic).Our staff also includes Professional Engineers, Certified IndustrialHygienists, chemists, environmental specialists, SSPC C.3 Supervisor/Competent Persons, SSPC Protective Coatings Specialists, CertifiedWeld Inspectors, and NACE Certified Coatings Inspectors.Call us today to learn more about the benefits of having KTA on yourproject team, preserving your capital investment, and preventingfailures initiated from both the outside and inside.Patterns and colors in the flooring are used to distinguish onearea from another and guide traffic flow.which is then topcoated with a clear sealer.Stonhard says it works with the client to createcustom colors and patterns.Almost a year after installation, Pospisilsays the extra effort was worth it, thanks tothe flooring product’s performance andappearance.Hospital staff members also are impressed.Barbara Greer, RN, BSN, and director,NICU, Medical Floor, said the flooring meritsa “wow” in terms of its visual impact on childrenand their families, thanks to its colorfulappearance. Also a plus, she said, is a relativelysofter surface that is easier on the medicalstaff’s legs and lower back.The addition to the hospital houses 81additional beds for children treated by thePediatric Intensive Care Unit, NewbornIntensive Care Unit, and general medicaland surgical areas. The team directing theexpansion project expressed confidence thatit had achieved a goal of creating a childfriendlydesign that meets grown-up performanceexpectations.Stonhard, based in Maple Shade, NJ, is adivision of StonCor Inc., a part of RPM Inc.More information is available from the websitelocated at www.stonhard.com.JAC16 Journal of Architectural Coatings / January 2005

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Kenneth B. Tator, P.E.KTA-Tator Inc.Fig. 1: Placide, Boca Raton, FL. Photos courtesy of the authorInnovations for repairing concretebuildings in salt environmentsPaint deterioration on buildingsexposed to moist andsalt-laden environmentsallows water and salt penetrationto reach reinforcing steel(rebar) within the building’s concrete.Corrosion of this steel creates expansiontension on the concrete, crackingand spalling it. Patching repairs, evenwhen properly done, may fail withinonly a few years, often requiring additionalexpensive rework.This article describes the reasons forsuch patching failure, and presentssome innovative practices that haveshown promise to significantly extendthe life of a concrete structure in a saltenvironment—up to 15 to 35 or moreyears compared to past concrete repairand recoating methods.Nature of the problemHomes, condominiums and apartments,offices, and industrial and commercialbuildings in or near coastalenvironments, or these same types ofbuildings adjacent to heavily traveledhighways and other roads where deicingsalts are used, are often contaminatedwith salt.Water combined with salt acts as anelectrolyte and aggressively increasesthe rate of corrosion attack on mostmaterials, including steel reinforcementin concrete. Moreover, many coastalareas, particularly in southern climates,are both warm and sunny. The combi-18 Journal of Architectural Coatings / January 2005

Fig. 2: Placide (land-side),Boca Raton, FLFig. 3: Paint deterioration on the exteriorof a balcony in a condo.nation of sun and water (moisture)degrades many organic materials andmost paints (Fig. 3).When paint deterioration occurs on aconcrete surface, wind-driven salts canbe deposited on exposed concrete andsubsequently carried into that relativelyporous surface by permeating water. Intime, the salt-laden water will reach thesteel reinforcement buried in the concrete,causing it to corrode. Corrosion ofthe steel causes expansion, with anincrease in volume from 2 to 6.4 timesthe volume of the original steel, 1Fig. 4: Progression of cracking leading to spallingIllustration courtesy of Corrprodepending on the corrosion conditions.Expansion of the buried steel reinforcementplaces a tensile stress on the concrete,ultimately causing it to crack andspall (Fig. 4).It is cheaper to touch up and repaintdefective areas than it is to chip outconcrete and replace rebar at a laterdate. Managers of large buildings incoastal environments contemplaterepainting every seven or eight yearsand conduct maintenance-paintingtouch-up more frequently.Sometimes, for a variety of reasons,touch-up and repair of deterioratedpaint may be delayed, and the corrosionprocess accelerates until crackingand spalling of concrete goes beyondthe point where repainting is sufficientto preserve, restore, and protect. At thistime, large cracks must be routed outand repaired, spalled concrete removed,Fig. 5: Cracking and spalling of concrete at perimeterof patched area caused by rebar corrosionreinforcement steel (rebar) cleaned andpainted, and patches made to the concrete.Only after these steps are completedcan the patched areas and theentire structure be repainted.In some cases where proper concreteand coating repairs have been done,rapid deterioration to the repairedareas can still occur within only a fewyears. Failure of patched areas of concreteoccurs as a result of differentialchloride concentrations between theold concrete and the newly patchedareas (Fig. 5).Journal of Architectural Coatings / January 2005 19

Concrete deteriorationCorrosion of reinforcement steel occursprincipally due to initial deteriorationof the original paint or protective layeron the surface of the concrete, allowingcarbonation of the concrete substrate.Water-containing chloride salts thenpenetrate to the embedded rebar, causingit to corrode.Carbonation is the reaction of thealkalis in the concrete with carbondioxide in the air. The CO 2 permeatesthe concrete and hydrolyzes with thewater present to form carbonic acid,which reacts with the alkalinity, reducingit from initial levels above a pH of12 (where embedded steel is passivatedand does not corrode) to a pH of 10 orless (where steel does corrode). Thisprocess is relatively slow, and in theabsence of chlorides, may take manyyears to reduce concrete alkalinity tothe level where rebar corrosion commences.In chloride-containing atmospheres,however, water penetration of the concretebrings dissolved chlorides intocontact with the rebar, and the chloridesbreak down the passivating ironoxidelayer on the steel, allowing corrosionto commence even at a high pH(Fig. 6). Additionally, chlorides aggressivelyaccelerate corrosion that mayalready be proceeding at a lower pH. Achloride threshold concentration ofabout 0.026% (by weight of concrete) issufficient to break down the passivefilm and subject the reinforcing steel tocorrosion. This equates to 260 parts permillion (ppm) of chloride, or approximately1.0 lb/yd 3 of concrete. 2Fig. 6: Failed caulking at a joint between a balcony floor slaband wall allows moisture penetration and rebar corrosionInnovations in protectionof concrete structuresRecent innovative practices in protectingconcrete bridges in salt environmentshave spawned technologies thatare practical in protecting rebar steel inconcrete buildings. Even with thesenew methods, it remains necessary toremove and replace deteriorated andspalled concrete, repair cracks, andexpose and clean corroded rebar toremove chlorides. The use of a passivesacrificial anode system, however, maysubstantially stop or slow rebar corrosionfor up to 14 years or more. 4Migrating corrosion inhibitors (MCIs)will also slow or stop corrosion for proridesin contact with rebar steel willestablish a corrosion cell; areas of higherchloride concentration will becomeanodic; and the rate of corrosion deteriorationwill accelerate. Such differentialchloride concentrations may occuraround the perimeter of a previouspatch repair (Fig. 7).The rebar embedded in the old concretewill have a higher chloride levelthan that of the adjacent patch, wherethe newly embedded rebar has beencleaned and perhaps repainted. Theshort distance between the anode(higher chloride concentration) and thecathode (lower chloride concentration)ANODICApproximately 0.1–0.2 lbs. of chloridesper square foot are deposited on buildingsurfaces each year along the coastline.This threshold value usuallyoccurs within 8–12 years along thecoastline for unprotected balconies. 3Differential concentrations of chloonthe rebar at the interface of thepatch and old concrete, and the relativedifference in chloride concentrations,will accelerate corrosion of the rebar atany pinhole or discontinuity in thenewly applied rebar coating. As a result,spalling at the edges of patched concretemay be seen after only a fewyears, particularly on horizontal surfaceswhere water may pond.Fig. 7: Differential chloride concentrations cause accelerated corrosion aroundthe perimeter of a concrete patch. Arrows denote electron (e-) movement of corrosion cell.Illustration courtesy of Corrpro20 Journal of Architectural Coatings / January 2005

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longed periods. MCIs are either mixedinto the patching repair mortar as anadmixture or applied by spray, brush,or roller to the repaired mortar surface,where the inhibitors can migrate to theembedded steel.Additionally, hydrophobic treatmentsof the concrete surface can keepwater from penetrating into the concreteor into concrete cracks, thus preventingcorrosion.The use of these three technologies,alone or in combination with properpainting and timely touch-up of deterioratedpaint, will substantially extendthe life of a concrete structure.Passive sacrificial anode systemsThere are two types of cathodic protectionsystems: active (use of animpressed current) and passive (use ofdissimilar metals). Both are employedsuccessfully to protect reinforcementsteel in concrete, but the passive systemis most practical for inhabitedbuildings.There are three types of passiveanodic protection systems:• a thermally sprayed metal consistingof aluminum and zinc alloys applied tothe concrete surface and attached tothe rebar at exposed ends, or by connectingwires;• a zinc-foil hydrogel adhesive anodesystem applied as a laminate onto aconcrete surface and attached to therebar by connecting wires; and• embedded zinc anodes attacheddirectly to the rebar and subsequentlyembedded within the patching mortar.These systems all protect by utilizingmetals (usually magnesium, zinc, andaluminum) which are more electronegativethan steel. These metals anodicallysacrifice themselves by making steelthe non-corroding cathode in the corrosioncell that inevitably occurs whenwater (with or without chlorides) penetratesinto concrete.The cathodic protective current of agiven anodic material is predeterminedand will not exceed that level until theanode is consumed and needs to bereplenished. The current level, size, andarea of the anode can be adjusted toprovide maximum service life.Thermal sprayThe concrete surface must be abrasiveblastcleaned to provide a suitablecleanliness and roughness for the thermal-sprayapplication of the anodicmetal alloy. Guidelines for properpreparation of the concrete may befound in “Surface Preparation ofConcrete,” Joint Surface PreparationStandard NACE 6/SSPC 13. 5Electrical continuity of the steel reinforcementmust exist within the concrete.Exposed rebar or wire-mesh segmentsmay be tested for electrical conductivityby connecting them to astandard DC voltmeter. Readingsgreater than 1.0 millivolt indicate electricaldiscontinuity, requiring that theFig. 8: Schematic of a thermal-spray coating or azinc-foil hydrogel system protecting rebar.steel be bonded back into the steel networkby welding or wire ties.The metallic spray should be appliedto the concrete surface (over both thepatched area and cleaned old concrete)to a minimum thickness of 300microns (12 mils). An aluminum-zincindiumalloy, superior to other alloys,has been developed under a FHWAresearch contract. 6 Indium is its keycomponent, and keeps the anodeactive even under drier, less-humidconditions. 7Zinc-foil hydrogeladhesive anode systemThis system is similar in fashion andfunction to the thermally sprayedanode application described above,except that a zinc foil with a hydrogeladhesive is laminated to the cleanedconcrete surface, and the anodic foil isattached to the underlying rebar usingwires. This system is relatively easilyinstalled by maintenance staff. 8 Fig. 8depicts thermal spray and foil hydragelanodic protection of rebar.22 Journal of Architectural Coatings / January 2005

Coming in the April Issue...Journal ofArchitecturalCoatingsNEW JOURNALTARGETS ARCHITECTS,BUILDING OWNERS,AND CONTRACTORSSIMULTANEOUSPRINT, ELECTRONICVERSIONS OFFEREDFOCUS ONSELECTING HIGH ENDARCHITECTURALCOATINGSV olume 1 / Number 1 January 2005GREEN COATINGS•What makes a coating "green?" Views from thecoatings industry, from specifiers and owners, andfrom green building organizations.• Top products in the category of green coatingsSUNLIGHT RESISTANCE• Specifying the right generic types for durability andcost-effectiveness•Testing for sunlight resistanceALSO IN THIS ISSUE• Coatings for office exteriors•Writing specifications•Coating metallic substratesOrder your subscription now, by faxing or mailingthe bound-in subscription card (Fax 412-431-5428).Or subscribe online at www.paintsquare.comJournal ofArchitecturalCoatingsVisit us at World of Concrete Booth S-12506Journal of Architectural Coatings / January 2005 23

(a) (b) (c)Fig. 10: Drop of water on (a)an untreated surface, (b) ahydro- phobic-treated concretesurface, and (c) hydrophopictreatedcrack edges. Photoscourtesy of L. Wolff and ProfM. RaupachEmbedded anodesAn embedded anode (Fig. 9) is a relativelysmall, self-contained unit consistingof a zinc alloy sacrificial coreembedded within an active cementitiousmatrix. An attachment wireActiveCementitiousMatrixConnectionWireSacrificialZinc CoreFig. 9: Example of an embedded zinc anode.extends from the anode. Followingattachment to the rebar, the entire unitis embedded within the patching concrete.The anodic unit has a cylindricalpuck shape, with the diameter andheight of the puck dictating the designlife of the anode.Migrating corrosion inhibitorsCommercial corrosion inhibitors havebeen added to concrete since the 1970sin Japan and were introduced in theUnited States in 1978. 9 Considerableimprovements based on calcium nitritehave since been made to the originaltechnology.The more recent inhibitors are basedon amine carboxylates and amino alcohols.They function by forming anamine monomolecular film on the rebarsteel that inhibits the onset of corrosion.The inhibitors can be applied as anadmixture in the original concrete or inpatching grouts. Additionally, they areformulated to be brush-, roller-, orspray-applied to the surface of concrete.The inhibitor migrates through theconcrete capillary structure, first by liquiddiffusion by means of the moisturethat is normally present in concrete,then by its high vapor pressure, andfinally, by entering hairline and microcracks.The diffusion process requirestime to reach the rebar surface andform a protective layer.Migrating corrosion inhibitor treatmentwill increase life expectancy bymore than 10 to 15 years compared tountreated concrete. 10Hydrophobic treatmentsHydrophobic (water-hating) treatmentscan be roller- or spray-applied to concretesurfaces in order to repel waterand keep it from penetrating concrete.Silanes or siloxanes in liquid form canpenetrate into the pore structure of theconcrete, covering the surfaces but notclosing the pores or forming a surfacefilm.Due to the orientation of the molecules,these materials react with thesurface and form a silicone resin. Thesilicone chains (Si-O-Si) attach to themineral pore walls of the concrete andthe organic side groups orient themselvestowards the pores. Due to theorganic nature of the side groups,water beads on the surface and doesnot penetrate the concrete or smallcracks in the concrete. 11Solvent-based hydrophobic treatmentsystems penetrate approximatelytwice as deeply into the concrete aswater-borne (emulsion or dispersion)systems. Gels and creams containingthe hydrophobic agents increase thepenetration depth because they are incontact longer than less-viscous liquidsolutions are.The hydrophobic treatments shouldbe applied to thoroughly dried surfaces.They will repel water over mostsubstrates, including wood, metal, andsurface paints. Such treatments can beused in addition to the other protectiontechnologies described above todeter water penetration into the concrete.The treatments that penetrateless completely may need to be reappliedevery few years to maintain waterrepellency.It should be emphasized, however,that most paints cannot be appliedover these hydrophobic treatments,although the treatments can be appliedover intact paint. Paint applied overhydrophobically treated surfaces, particularlyif the paints are water-borne,will not adhere. Accordingly, if repaintingis to be done, the treatment mustbe removed from the concrete surface.The concrete surface can be tested bya water break test, which shows ifwater beads on the surface (Fig. 10).Another procedure is the muriatic-acidtest (application of a dilute 5%hydrochloric acid). With this test, a“fizzing” reaction of the acid and concretealkali will indicate that a contaminateis not present to prevent acidcontact with the concrete.If a hydrophobic treatment, oil contamination,or clear membrane concrete-curingcompound is present on24 Journal of Architectural Coatings / January 2005

the concrete, beading and fizzing willnot occur. These materials will interferewith paint adhesion.References1. “What Happens With ReinforcedConcrete Structures when theReinforcement Corrodes,” Palle Thoft-Christensen, www.civil.auc.dk/i6/publ/srpaper202.PDF2. “Understanding Corrosion andCathodic Protection of ReinforcedConcrete Structures,” Steven F. Daily;www.corrpro.com/library/CP48.pdf.3. “Chloride-related Concrete Damage,”Dave Colston; Managers Report, FloridaCommunity Association Journal,Advantage Publishing Co., Little RockAR 72211, Dec. 2003; pp. 20-23.4. “Fighting Corrosion in ReinforcedConcrete Bridge Decks andSubstructures: Galvanic CathodicProtection and ElectrochemicalChloride Extraction,” Gerry Clemenaand Paul Vermani, The Road Ahead;Sept. 2001, Virginia TransportationTechnology Transfer Center.www.vtrc.net/vtttc/newsletters/RA_5-3_Final.pdf.5. NACE, 1440 South Creek Drive,Houston, TX 77084; SSPC, 40 24 thStreet, Pittsburgh, PA 15222.6. “Development of a New SacrificialCathodic Protection System for SteelEmbedded in Concrete,” FHWA ReportFHWA-RD-96-171, June 1997.7. “Galvanic Cathodic Protection ofReinforced and Prestressed ConcreteStructures using Corrspray — aThermally Sprayed Aluminum Alloy,”CP-51; Steven F. Daily and Warren K.Green; www.corrpro.com/Concrete/CP51%20-%20CORRSPRAY.pdf.8. Clemena and Virmani (4).9. “What’s New in CorrosionInhibitors,” Neal S. Berke, Antonio J.Aldykiewicz Jr., and Lianfang Li;Structure; July/August 2003; pages 10-12,www.structuremag.org.10. “Improving Durability of ReinforcedConcrete Structures Using MigratingCorrosion Inhibitors,” Behzad Bavarianand Lisa Reiner, Corrosion 2004 paper04323; NACE, 1440 South Creek Drive,Houston, TX 77084.11. “Hydrophobic Treatment onConcrete—Investigations on Efficiencyand Durability,” Prof. Dr.-Ing. MichaelRaupach and Dipl.-Ing. Lars Wolff,Protective Coatings Europe, TechnologyPublishing Co., Pittsburgh, PA 15203,June 2004. JACJournal of Architectural Coatings / January 2005 25

DurabilityThis is the first in a series of columnson assessing the durability of coatingsby Allen Zielnik, Atlas MaterialTesting Technologies L.L.C.Congratulations! Your designhas been selected by “TheDonald” for his newest luxuryhigh-rise building. As onewould expect, the timeline on the project willbe intense and your new customer expectsthat the materials specified for the project willnot only bring your dramatic vision to life, but will also maintain itsstructural integrity for the next 100 years.In essence, your task is no different than it has been on countlessother occasions. You will be concerned with the aesthetic aspects ofcolor and appearance, as well as the protective ability of the coatingsto guard both structural and decorative elements.The coatings sales reps line up outside your door, all armed witha wide range of test data to show their products are the best, andthe amount of data available is staggering. So, how do you sort outthe claims to make the right choice? Is there a specific, standard testingmethodology that is reliable for your needs? What, specifically,do you need to know about corrosion test methods to make the rightdecision?The quick answer to these questions is that there are numerous stan-Corrosion anddurability testing:changes in the airAdvances in methods offer greater ‘real-world’ correlationAdvanced cyclic corrosion cabinets such as the model pictured are commonly used to evaluatethe performance of decorative and protective architectural coatings applied totest panels or parts such as door and window profiles.Photos courtesy of Atlas Material TestingPassing the test–Allen Zielnikdards currently in place with no universalagreement on which producethe most accurate results. Further,many of the current testing standardsthat have been used to validateperformance of materials donot necessarily produce reliableresults. This is creating a challengefor the coatings industry, especiallyas manufacturers are forced toaddress new environmental regulationsthat change the way productsare made and, thus, make historicaltrack records of their products lessreliable.The following are two approachesto testing, however, that are gainingpopularity in the coatings industry because theyhave been proven to greatly increase the probabilityof accuracy in predicting real-world application performance.1. Samples must be exposed to intensive testing which replicate myriadcombinations of stresses on materials, particularly those that occurduring the transitions between relatively steady state conditions (e.g.,from wet to dry and back again).2. An increasing array of innovative new testing equipment is beingutilized to set the benchmark on how materials react to a wide rangeof stress variables, leading exponentially to more reliable test data.To put these two approaches into perspective, it is important toreview the paradox surrounding varying testing standards, to evaluatecurrent testing approaches, and to explain why innovations incyclic corrosion testing (CCT) testing are producing better results.This column will examine some important issues related to testmethods for anticorrosion performance. Future columns will addresscoatings durability and appearance issues as well.Conflicting reports on varying standardsCoatings manufacturers can no longer rely on the long-term track26 Journal of Architectural Coatings / January 2005

tinuously subjected to a neutral 5% sodiumchloride salt solution which is atomized at atemperature of 95 F (35 C).The history of this test dates back to1914, and the test was codified as B117in 1939 when coatings were very different.The B117 test may be somewhat usefulSalt-fog testing, pictured here, provides a highly corrosive environmentto accelerate performance evaluations of coatings.Experts generally agree that test systems alternating betweenwet and dry cycles at elevated temperatures provide the bestcorrelation to "real-world" conditions.Flash it Right the First TimeBecause You’re Not in the Callback Businessfacturers have routinely provided corrosiontest results showing performance vs. hours oftest exposure to a “salt fog.” The most commonlyreferenced of such methods is theASTM B117 test, in which coated metal testpanels, usually scribed to provide a defect,are suspended in a sealed chamber and conrecordsof their products to convince customersof their performance because manytraditional products are being phased outdue to VOC, heavy-metal, and other environmentalregulations. New formulations arebeing introduced at such a rapid pace thatthe emphasis has shifted to highly acceleratedlaboratory testing of these new coatingmaterials.A large number of performance-basedspecifications and test methods have beendeveloped by recognized standards organizationssuch as ASTM International, theInternational Standards Organization,NACE International, and various governmental,trade, and other organizationsaround the world. But at present, no specificationor test standard is universally recognizedor accepted.There are, in fact, considerable differencesof opinion on coatings test methodologies.The key to successful laboratorytesting is to predict, or correlate with, somereal-world outdoor performance and provideassurance of expected service life.But, just as there is no one outdoor environment,there is also no one “universal”test that will accurately predict performanceand service lifetime for all types of decorativeand protective coatings.In a Williams BuildingDiagnostics investigationof 100 North Carolinasingle family homes, it wasdiscovered that approximately50% of all moisturedamage incidents weretraced to areas below thewindows.Fortunately, avoidingprofit draining callbackslike these are now easy.Contact CCW today aboutthe new EZ Pan systemfor windows, and startsaving your companymoney today.For more information visitus at www.carlisle-ccw.comor call 800.527.7092.Current testing approachesCan historical laboratory corrosion tests serveas a guide? For decades, coatings manu-PACE Booth #713, 715Journal of Architectural Coatings / January 2005 27

for a marine environment, but historically it has shown little andsometimes even reverse correlation to actual coatings performancein other applications such as architectural uses. The standardprovides no pass/fail criteria, and exposure times canrange from 24 to 6,000 hours or more. The fact that several differentcoatings can all pass a 500-hour (or other length) test providesno guidance to the customer about actual long-term performance.There are other variations of this “continuous fog” type of test,some with modified solutions containing acids, copper, or othersalts, to try to improve correlation with performance, but all havelimitations. A guiding principal of modern laboratory acceleratedtesting is to try to simulate the conditions of the in-service environmentas closely as possible.One reason that these historical tests don’t seem to work well isthat they do not capture the stresses caused by cycles of the outdoorenvironment (hot/cold, wet/dry, sunlight/dark, etc.). Wehave come to understand that it is during these transitions thatcoatings are most stressed and when the degradation principallyoccurs, not during the steady-state conditions, harsh though theymay be.Multiple tests are the key to more accurate dataAccelerated cyclic corrosion testing, or CCT, is fast becoming thenorm for evaluating the anti-corrosion properties of protective coatings.This innovative approach to accelerated testing exposesmaterials to numerous variables that can cause stress on coatings.In particular, CCT can be programmed to emphasize stressesthat typically occur in transitional periods such as exposure to wettingand drying and rewetting, temperature ramps and cycles,freeze and thaw, night and day—transitional periods that are criticalcomponents of the corrosion process.These tests were largely pioneered by the automotive industry,which essentially makes “small buildings that move.” The U.S.Federal Highway Administration has also compared CCT testingto parallel outdoor exposure testing on bridge coatings.Previously, tests were conducted in accordance with traditionalB117 salt-fog methodologies, but the new practice of using CCTin place of B117 has shown much better correlation to the outdoorresults and generated a vast improvement in predictiveaccelerated test results for the industry.The success that CCT has demonstrated in these industries isone of the reasons why it is now being adopted more frequently

in the architectural protective-coatings industry as well.There are quite a few, slightly differing CCT methods, but mostnormally include a salt-fog period, a dry or freeze period, andwith some a UV and moisture-condensation period; examples canbe found in the ASTM G85 Annex document. Some methods alsoincorporate gas injection, such as sulfur dioxide, and acid-rainsprays.The best CCT devices on the market incorporate the followingthree mechanisms: 1) advanced cycle options for immersion, variable-controlledhumidity, gas injection, and temperature cyclingfrom below freezing to near 100 C; 2) solution sprays to providedirect impingement of samples with various electrolytes, such asto simulate acid rain; and 3) the ability to automatically switchfrom salt fog to dry-off or controlled temperature with humidityfrom ambient to saturated RH.The adoption of these new testing methods for architecturalcoatings, particularly by smaller coatings producers, has beenslower to occur than might be expected. This most likely is due tothe fact that many manufacturers are not aware that such data canbe made available to them. Another reason may be that it takesanywhere between two weeks and 10 months or more to completea full cycle of testing on protective coatings, and the coatingssupplier has not yet finished or committed their line to this procedure.Conclusion—cyclic methodsmay offer best correlationSince no single test can be absolutely predictive for all coatingtypes and service environments, you may want to consider evaluatingcoatings based on the results of several different test methodsand make sure that there is strong emphasis placed on durabilityduring short-term (diurnal) and long-term (seasonal) stresstransitions.Time permitting, you may want to insist that CCT proceduresare used before you make a decision. Perhaps a collaborativeeffort between you and your coatings vendor will help move theprocess of CCT along in the industry, leading to a wide range ofproducts that are proven winners in the field.By doing so, the vision of your design will ultimately be manifestedby a good architectural-coating selection that will stand thetest of time.JAC

GettingItRightCoating selection, surface preparationhold key to successful paintingof galvanizedsteelBy Jayson L. Helsel, P.E.Successfullypaintinggalvanized steel canpresent a challenge.First, one must differentiatebetween paintingnew and existinggalvanized surfaces,since the approach topreparing each will differ.This article will address paintingnew galvanized steel. The key to paintinggalvanized steel is proper surfacepreparation and coating selection.It helps to first understand exactly what galvanizingis. It is the application of a zinc layer to steel by a varietyof methods such as hot-dip galvanizing, continuous galvanizingor electrogalvanizing. Newly galvanized surfaces, whichshould be shiny and smooth, can be difficult to paint becausecoatings may not achieve good mechanical adhesion to thesmooth surfaces, or because galvanizing post-treatments caninterfere with coating adhesion.The most common post-treatments that cause problems forcoatings are water quenching and chromate quenching. Inwater quenching, freshly galvanized steel is dipped into a waterbath to help accelerate the cooling process and stop the reactionbetween the iron and zinc. A consequence of waterquenching is that the water often becomes contaminated with oilor dirt that then gets deposited on the zinc surface. These contaminantswill interfere with adhesion if they are not adequatelyPhotoDisc©removed before paint is applied.Chromate quenching is usedto slow the oxidation of zincsurfaces during transportationor storage of the galvanizedsteel. Although the chromatetreatment can prevent this oxidation,it will also interfere withadhesion if paint is later applied,and should not be specified if paintingis intended.Galvanized surfaces should be testedfor chromates unless there is certainty thatchromate treatment was not completed. A field testusing an acid solution can be used to detect the presence ofchromate coatings, as described by J. F.H. van Eijnsbergen inDuplex Systems, published by Elsevier Science B.V. (page 63).The solution can be prepared from 40 milliliters (mL) distilledwater, 60 mL concentrated acetic acid, 1 gram diphenylcarbazide,15 mL hydrochloric acid (38%), 30 mL hypochloritesolution (2% in water), and 5 mL hydrogen peroxide (30%). Adroplet should be placed on the galvanized surface, and if chromatesare present, the color will change to red or purple withinone minute.Surface preparation of the galvanized steel should begin withcleaning in accordance with SSPC-SP 1, “Solvent Cleaning.”Further surface preparation can be accomplished by light abrasiveblast cleaning or chemical treatment of the surface.Abrasive blast cleaning of galvanized surfaces is best per-30 Journal of Architectural Coatings / January 2005

formed in accordance with SSPC-SP 7, “Brush-off BlastCleaning.” With blasting, great care must be taken to onlysuperficially etch the surface while minimizing damage to theprotective zinc. Consequently, blasting with “softer” abrasivesversus harder abrasives such as steel grit is recommended.Softer abrasives include aluminum/magnesium silicate, corncobs, walnut shells, limestone or some mineral sands.Additional changes such as decreasing blast-air nozzle pressuresand/or increasing stand-off distance while blasting arealso recommended. Brush-off blasting will expose fresh zinc,which will begin forming zinc oxides upon exposure to the airin as little as 24 to 48 hours. Therefore, it is generally recommendedthat the blasted galvanized surface be coated within24 hours.Galvanized surfaces can also be prepared for painting bychemical treatment. A common way to accomplish this is byspecifying phosphating post-treatment. Phosphating galvanizedsteel forms a non-reactive zinc phosphate layer over the zinc surface.The surfaces should first be cleaned and degreased (solventcleaning), and then immersed in a phosphating solution. Thephosphating prevents corrosion products from forming and promotesgood adhesion with a subsequently applied paint layer.Similar chemical treatment can be accomplished by applyingmildly acidic cleaning solutions, often referred to as “pre-paint”cleaners. These products are typically mixed with warm or hotwater, sprayed over the galvanized surfaces, left to sit for ashort period, and then rinsed off. With some products, scrubbingof the surfaces is recommended. As with blasting, preparedsurfaces should be painted within 24 hours.The final key to painting galvanized surfaces is the properselection of coatings. There are various coating systems thatdemonstrate a successful performance history on galvanizedsteel. Typical systems include acrylic coatings, epoxy/polyurethane coatings or moisture-cure urethanes. A zinc-richspot primer is recommended for touch-up of any damagedareas of the galvanized surface where steel is exposed.Although many coatings will work successfully in painting galvanizedsurfaces, alkyd oil-based coatings should not be used.Alkyds can react with alkaline zinc surfaces, leading to coatingdegradation and failure.JACWe partner with our customers to developcomplete weathering test solutions that mostaccurately predict their materials’ service life.We’ve made a science out ofseeing the future.We understand weathering inside and out. With theworld’s most accurate line of accelerated weatheringtest instruments and the largest outdoor exposurenetwork spanning the globe, we can tailor a solutionto answer your unique weathering needs. All of ourinstruments, services and facilities are designed to helpour customers reach their ultimate goals – a qualityproduct, a competitive edge, a faster time to market.For a representative in your area visithttp://www.atlas-mts.com/contactsExperience.The Atlas Difference.Journal of Architectural Coatings / January 2005 31

All that Glitter IsSILVER(Aluminum Metallic, Actually)by Joe Maty, Editor, JACDazzling reflective finish helps transform Seattle opera32 Journal of Architectural Coatings / January 2005

house to shimmering show palaceWhen the operators of theSeattle Opera andPacific Northwest Balletdecided it was time fora renaissance of the twogroups’ longtime homein the Seattle Centercomplex, they went forthe silver—aluminummetallic, actually—for asoaring design element in the redevelopedfacility’s striking entrance area.The new entrance and lobby areascomprise noteworthy portions of anambitious redevelopment of the onetimeCivic Auditorium building thatoriginally opened in 1928. Part of theSeattle Center complex that also featuresthe landmark Space Needle andserved as the site of the 1962 World’sFair, the auditorium was remodeled andre-christened the Seattle Opera Houseseveral decades ago. Then came thedecision for a complete overhaul, whichbegan in 2001 and was completed lastA daytime view of steel columns and the glass curtain wall of the grand lobby of Seattle’s McCaw Hallyear.For their $127 million tab, the city ofSeattle and the opera and ballet companiestransformed the Opera House intothe Marion Oliver McCaw Hall, a shimmeringshow palace that serves as thecenterpiece of the city’s performing-artsdistrict. And the crown jewel of the newMcCaw Hall would have to be thegrand lobby, a dramatic entry to thefacility that greets the eye with a fivestory-high,undulating—curvilinear,technically speaking—glass wall.This sweeping design focal point,combined with a series of three-dimensionalstainless-steel, descending metalscrims, or screens, and a cast of supportingcolor and light patterns deliver avisual effect that connects the lobbywith the adjacent urban setting.The effect, according to designersLMN Architects Inc., Seattle, is a “floodingof the artistry into the streetscape,”a phenomenon that “invites the entirecommunity to participate.” It wouldseem to follow that dancing in thestreets is strongly encouraged.In reality, the architects envisionedthat the dancing in the lobby was to bedone by the light—that of the reflectedvariety. In looking to choreograph theproduction of this effect, LMN enlistedthe technical and artistic talents of anumber of key contributors, includingthe paint and coatings developer andmanufacturer Tnemec Co. Inc. (KansasCity, MO). Tnemec, in turn, called onGudmundson Co. (Renton, WA), forapplication expertise.If the lobby can be called the McCawHall crown jewel, then the 38 circular,carbon-steel columns that support thelobby’s 60-foot-high glass facade wallwere looked to by the designers as offeringthe potential for reflected glory. ToTnemec and Gudmundson fell the taskof supplying and applying a metallic finishthat would justly serve this purpose.“We were looking for a metallic finishand a site-applied finish as well,” saidLMN project architect Peter Locke.“Typically when we do exposed steelwork, we have a coating applied in thefactory, but only a primer.” A finish coatis applied later, to avoid damage to thecoated surface during construction.In choosing a product for the final finishcoat, Locke said the designers “havean aesthetic we’re looking for. We wanteda coating that could be matched insideJournal of Architectural Coatings / January 2005 33

from a projected-light system that alternatesamong four different programsequences that span several minuteseach. The lighting is actually projectedonto the stainless-steel scrim elements inthe exterior promenade entryway, butadjacent design elements—including thesilver metallic-finished columns—catchsome of the reflected light as well, givingdifferent hues to the glittering surfaces.Varied lighting generates different visual effects in the metallic finishes in the McCaw Hall grand lobby. Acrylic-polyurethane metalliccoatings were used for the lobby’s 60-foot-high circular steel columns.and outside, and would be robust tostand up to exterior exposure.”The steel columns are located on bothsides of the curtain wall. Exterior exposurein this case includes the corrosiveagents encountered in an urban setting,with nearby Mercer Street and its fourlanes of heavy traffic contributing to theatmospheric mix.Torin Mowbray, a Tnemec representativefor many years in the Seattle area,said LMN’s specifications for thecolumns also required spray applicationto provide the desired uniform appearance.Still, spray application presentedthe challenge of painting from “edge toedge” and not applying the coating overan area that had already been sprayed.This problem was addressed by simultaneouscoating application by two technicians,with each applicator spraying aside of the column as both traveledupward on separate lift devices.At the same time, Mowbray said,Gudmundson was faced with the needto avoid overspray onto nearby MercerStreet or onto the lobby’s newly installedterrazzo floor.“The coordination was really the keywith this job,” Mowbray said. “It was avery difficult job, and the field painterspulled the rabbit out of the hat.”Mark Taylor, project manager forpainting contractor Gudmundson Co.,said the McCaw Hall project’s “aggressiveschedule” presented challenges to thecoatings-application process. The sprayapplicationwork was carried out in themidst of a multimillion-dollar renovationand construction program that involveda range of building trades, leaving littlemargin for error or overspray complaints.As for the metallic coating itself,Taylor said a key application parameterwas uniform film thickness, crucial toobtaining the desired reflective effect.The process required multiple spraypasses with a light touch on the volumegauge, “almost a mist,” Taylor said.Prevention of sags, runs and overlap waspivotal to producing the correct finish.Taylor, though, also is dazzled by thevisual effect that results, an end that justifiesthe painstaking means involved.“When the sun hits it you almostneed sunglasses,” he said of the silvermetallic finish. “It really is incrediblyreflective.”Come darkness, the color of the coatedsurfaces also varies due to reflectionAluminum finishes evolveto provide aesthetic appealThe coating system used for the carbonsteelcolumns comprised a Tnemec-suppliedsystem of urethane primer,polyamide epoxy intermediate coat andsilver metallic aliphatic acrylicpolyurethane topcoat. The system wasspecified by Mowbray in consultationwith LMN project manager OwenRichards.For the shop-applied primer, the productchosen was a two-component, moisture-curedzinc-rich urethane. The intermediatecoat product was the polyamideepoxy, a high-build material. The acrylicpolyurethane finish coat with “sparklealuminum pigment” is billed by Tnemecas highly durable, resistant to abrasion,wet conditions and exterior weathering.UV absorbers are added to boost colorand gloss retention.Elaborating on the silver metallic finish’scomposition, Tnemec Supervisor ofColor Technology Steven Patton said theformulation includes a small amount ofpearl mica pigment to enhance hide,whiteness and brightness, and to boostthe reflective effect of the coating’s aluminumflake pigment. Besides color andsparkle, the aluminum also imparts protectiveproperties due to a barrier mechanism.Completing the color mix is a34 Journal of Architectural Coatings / January 2005

Polyaspartics• Fast cure• Corrosion protection• High film build (25 mils) • Aliphatic topcoat• Non yellowing• Ultra-high solids• Color and gloss retention • High productivitywww.PolyasparticCoatings.com2K Waterborne Polyurethane Resins• Odorless• UV light stable• 4-hour cure time • High gloss• Abrasion resistant • Ultra-high solids• 0-250 g/l VOC • Weatherabilitywww.WaterbornePolyurethanes.comCall your coatings supplier for more information on polyaspartic andwaterborne polyurethane coatings.Visit us at the World of Concrete, booth S 11541, and Paint and Coatings EXPO, booth 805.Bayer MaterialScience LLC100 Bayer Road • Pittsburgh, PA 15205-9741 • Phone: 1.800.662.2927© 2004, Bayer MaterialScience LLC

small quantity of translucent yellowoxide pigment, which Patton said offsetsa bluish tint that can develop with theuse of aluminum.Patton said interest in metallic finishesfor architectural applications can beattributed at least in part to color directionspioneered by the automotiveindustry, which introduced the phenomenonof color shift—sometimes called“flop” or “travel”—in metallic and special-effectcoatings. The terms refer tovariation in color perception dependingon the viewing angle and difference inlight.Tnemec says metallic finishes such asthe Series 1077 Enduralume used for theMcCaw Hall project were developed as aresponse to the exposed-metal andmetallic-aluminum look that camestrongly into vogue in architecturaldesigns in the 1990s. The Series 1077Enduralume was commercialized inFluoropolymer-based metallic aluminum coatings were used inthe restoration of bronze and cast iron art-deco figures on theexterior of the historic George Fuller Building in Manhattan.Fluoropolymer metallic finishes were used for the turrets ofthe Excalibur Hotel in Las Vegas.1999; more recently, Tnemec introducedits Series 1078 Fluoronar Metallic, a thermosetsolution fluoropolymer metallicaluminum coating.Tnemec hails the Series 1078 productas the “ultimate” metallic coating due tothe long-term exterior durability andcolor-retention properties of the fluoropolymerchemistry involved.Metallic finishesare catching onBefore its application in the McCawHall project, Tnemec’s Series 1077 acrylicpolyurethane had seen use on a numberof notable architectural sites, including a30-story Ernst & Young sign in New YorkCity. There, architects Kohn PedersonFox wanted to match the look of theglass and steel curtain walls of the company’shigh-rise headquarters in TimesSquare.Also in Gotham, the Series 1078 fluoropolymermetallic was employed in therestoration of bronze and cast-iron artdecofigures on the historic GeorgeFuller Building in Manhattan, in a projectshepherded by New York-basedConservation Associates.Mark Thomas, Tnemec’s director ofmarketing, said the exposed-metal and“chrome-metal” effect conveyed bymetallic finishes has caught the fancy ofdesigners of various commercial buildings,including retail and office structuresand even educational facilities and condominiumcomplexes.In response to the fascination withmetallic effects, aluminum-pigmentedcoatings have evolved from an original,utilitarian service as protective paints to adual role of substrate protection and aestheticappeal. Gone are the days of specifyingan aluminum-pigmented coating inany color you want, as long as it’s a flatsilver finish like the paint on the oldwater tower on the hill.While Tnemec bills the Series 1077acrylic polyurethane as its McCaw Hall“star performer,” the company also supplieda high-performance acrylic coatingfor interior exposed steel that was used inthe facility’s new fly loft.The McCaw Hall redevelopmenthas gotten positive reviews since thefacility opened in 2003. The SeattlePost-Intelligencer, referring to the site’sprevious auditorium and opera-housestints, called the reincarnation of thefacility “a coming of age for the city, a21 st -century realization of the hope projectedby its predecessors.” The old lobby“has been opened up—triple the size,with a five-story glass wall extendingfrom the Seattle Center campus toMercer Street.”The architects, in turn, were impressedwith the metallic coatings that havegiven the McCaw Hall makeover an extradegree of sparkle.“I think everyone’s very happy withthe result,” said Project Architect Locke.As for Seattle’s opera and ballet productions,they’ll have to earn any glitteringreviews on their own.JAC36 Journal of Architectural Coatings / January 2005

PLIOTEC LATICES: FOR DURABLE CONCRETE FLOORCOATINGS, SEALERS AND STAINS WITH UV,CHEMICAL AND TIRE PICK-UP RESISTANCEPliotec latices are produced using a unique technology that ensures a waterbornepaint formulation with high performance. Chemical and water resistance, hardnessand abrasion resistance, and strong adhesion are among the key strengths of the Pliotectechnology. Pliotec resins have been very successful for many years in the floor coatingmarket in the U.S.THE PLIOTEC ® LOGOIS THE SIGNATURE OF PAINTSMEETING HIGH QUALITY ANDPERFORMANCE TESTS.Floor coating paints, particularly for driveways and garage floors, areover exposed to traffic, water, UV rays, oil, hot tire pick-up, and gasoline. Concrete stainsand sealers need to protect from UV rays, alkali & acid, and water while at the same timeprovide excellent adhesion. Coatings formulated with durable Pliotec can withstand theassaults of these tough environments.Let’s share the future. Eliokem is a global company with manufacturing,sales & marketing, research & development all across the world. New product andapplication developments are primary focuses of Eliokem. Our expertise and commitment toproduct innovation make Eliokem the best partner for all its customers.Contact: Valerie Johnsonvalerie.johnson@eliokem.comPhone: + 1 330-734-1223Fax: + 1 330-734-1151

ProjectProfileConcrete FinishingReactive stain breathes life intolandmark chapel’s concrete BY Joe Maty, Editor, JACSeattle University’s prizewinning St. Ignatius unites ‘ancient and new’n seeking to achieve a confluenceof the modern and the ancient, theparticipants in the design and constructionof the landmark St. IgnatiusChapel at Seattle University settledon striking contemporary stylingaccented with natural hues andmaterials inspired by the stone-builtarchitectural monuments of Catholicism’s capital city.A key challenge for these participants—the Jesuit, CatholicSeattle University; Steven Holl Architects, New York; and BaughConstruction, Seattle—was the achievement of this ambitiousobjective within the limitations of budgetary constraints. Early in theconceptual discussion phase, those limitations made it clear thatthe genuine article was not an option for the exterior façade.With stone cladding toppled from the design plans by cost, thearchitects looked to precast concrete for the chapel exterior. Theyevaluated coatings technologies that would produce the desiredappearance—one that would add “warmth” to the inherent coldgray of concrete and help convey the “materiality” of stone, in thewords of project architect Tim Bade of Holl Architects.The product selected for this purpose was a reactive, penetratingconcrete stain supplied by L.M. Scofield Company, Los Angeles.The product, LITHOCHROME® Chemstain Classic, is formulatedto react chemically with the concrete and generate translucent orother intriguing color effects. Scofield says the product penetratesand permanently stains new or existing concrete and cementitioussubstrates, and wears only as the concrete itself weathers or is otherwisedegraded.In visual terms, the “antique amber” tint chosen for St. Ignatius38 Journal of Architectural Coatings / January 2005

produced the desired color—and animpression akin to stone.“We were looking for a warmerochre limestone color, to provide acontrast with the gray of Seattle,”Bade said, referring to the region’spredominant climatic feature.The 6,100-square-foot chapelopened in 1997 and serves as one ofthe “anchors” of the student pedestrianmall at the urban Seattle Universitycampus.Stone without the rockThe designers examined a variety offinishing materials for the concreteexterior, including pigmented paint.But Bade said an opaque finish woulddisguise, rather than enhance, the variedsurface of the concrete, which wascast on-site and installed by means ofthe “tilt-up” construction method.Bade said the university “was interestedin having a contemporary building,but one with a sense of permanence,”a multifaceted design conceptthat was well-served by the choice of exterior materials and colors—concreteminus the concrete look.For this project, the stain was applied by multiple spray passesto achieve the desired color intensity. Application guidelines fromL.M. Scofield call for the stain to be “scrubbed into the surface” bybrush. Rinsing of excess, unreacted acid stain is recommended,followed by application of a clear sealer.Rev. Jerry Cobb, S.J., a Seattle University English professor, wasappointed by former university President Rev. William J. Sullivan,S.J., to serve as chairman of the committee that directed the St.Ignatius building project. Rev. Cobb said architect Holl took fromthe many churches of Rome the idea of a “Roman ochre” colorationfor the exterior of St. Ignatius.“The stain gave a warm, variegated hue to the walls, a colorthat seems to convey the solidity of stone and the humility of earth,”Rev. Cobb said. The three-part chapel site of “green field, reflectionpool and building in a sense ‘interrupt’ or engage passersby, callingthem to a moment of engagement,” Rev. Cobb said. “It’s a wayof invoking the old color of Rome, but with new technology.”Architect Bade describes the chapel exterior as “kind of a limestonelook,” although he adds that the designers were not seekingto duplicate a specific stone species or deposit.“This wasn’t about replication with contemporary building methods.It’s more of a tectonic, emotional response, an attempt to conveya substantial materiality,” he said. “When you rely on a naturalmaterial, you have to loosen your normal restrictions, but thatgives it its character,” he said, adding that concrete, like stone, isnot “monolithic.”Rev. Cobb said the chapel succeeds in blending the “new andancient,” with elements such as hand-carved cedar doors presentinga marked contrast to the contemporary concrete façade andoverall design motif.Recalling the university’s initial vision for the chapel, Rev. Cobbsaid Rev. Sullivan wanted a chapel that would constitute an “architecturalgift” to the city of Seattle. “He hoped it would not onlymeet our campus need to have a spiritual home, but that it wouldalso be inviting to people from Seattle and from all over theworld.”Rev. Sullivan, now chancellor at the university, is credited withsaying that visitors to Seattle should make sure they include twonotable landmarks when on tour—the signature Space Needleand St. Ignatius.Steven Holl Architects secured the St. Ignatius commission followingan “intensive” selection process that included—in authenticJesuit tradition—lecture presentations at the university by representativesof four finalists for the project. The university’s priority was a“distinctive, contemporary approach to the chapel’s design,” Rev.Cobb said.For its winning chapel design, Holl Architects captured a numberof awards, including an American Institute of ArchitectsNational Design award, an AIA National Religious Architectureaward, and a New York City AIA Design award. The scalemodel of the chapel also was chosen to become part of the permanentcollection of the Museum of Modern Art in New York,according to Seattle University.The Washington Aggregate and Concrete Association namedthe chapel construction project a “tilt-up project of the year” awardwinner, in recognition of effective use of the building processemployed with the precast concrete panels.In a commentary on the chapel, Seattle University says HollArchitects adopted as the guiding concept for the chapel “AGathering of Different Lights,” a metaphor said to represent the university’smission while invoking Jesuit founder St. Ignatius’ thoughton the spiritual life. In this interpretation, the varied light and darknessin the chapel’s interior—“seven bottles of light in a stonebox,” in Holl’s words—represent the “consolations and desolations”of spirituality as defined by Ignatius.The chapel design, which involved significant input from students,is described by Holl as “forward looking, but anchored inthe past.”JACJournal of Architectural Coatings / January 2005 39

TheConceptStageDevelopment project seeks to employ‘biomass-derived’ materials in coatingsArmed with a $3.75 million grant from theU.S. Department of Energy, Rohm andHaas Co. recently launched a program todevelop technologies that could reduce byup to 30 percent the amount of raw materials used to manufacture avariety of waterborne paint and coatings.Rohm and Haas, a major supplier of resins used in the manufactureof architectural and other coatings, said it will spend approximately$5.5 million during the five-year R&D program. At the top ofthe list of objectives is the development of architectural-coatings resintechnologies that will offer low levels of volatile organic compounds(VOCs), the company said.Waterborne coatings use polymer emulsions to bind color pigmentsand other paint ingredients together, and to help the resultingpigment-binder film adhere to the substrate. Rohm and Haas noted,however, that only the outer surface of each emulsion particle is actuallyinvolved in this function.“With over 700 million gallons of paint sold annually in NorthAmerica alone, there is significant opportunity to improve efficiencyand reduce waste,” the company said.Rohm and Haas said it will work with Archer Daniels Midland Co.(ADM), the University of Minnesota, and the Department of Energy tocombine novel water-based polymeric binders with new biomassderivedcoalescing agents to develop architectural paint and coatingsmaterials. The coatings will be designed to offer performance,environmental friendliness, and cost efficiencies, the company said.Rohm and Haas and ADM will be responsible for more than 30percent of the total cost, with the remainder to be funded by theDOE’s Industrial Technologies Program.Andrew Swartz, project leader, Rohm and Haas Architectural andFunctional Coatings Research, said the company will seek to developcoatings that provide low odor and are “environmentally acceptable.”He said such a coating product “must adhere to a substrate aswell as it does today, and still hold up to environmental elements.”Rohm and Haas said the development program will initially targetthe North American architectural-coatings market, but will expandinto other markets including industrial coatings, paper, carpet, textiles,and construction.Kenneth Smith, Rohm and Haas global research manager, architecturalcoatings, said during an interview with the Journal ofArchitectural Coatings that the research project will focus on combi-nations of resin materials with film-forming additives produced byADM, the agricultural-products giant based in Decatur, IL. ADM inrecent years has introduced biomass-, or plant-derived, film-formingaids for paint and coatings.“They have clearly demonstrated that they can deliver chemistriesin biomass-based materials, so we will be exploring that capability,”Smith said. “The initial focus has more to do with additives—thingsthat might help us as we look to change binder technology, to makethem more complementary and work better with these new film-formingmaterials.“Why not takeadvantage of the GOING FOR THE GREENtechnology to delivercoalescing aids that Rohm and Haas said theare not petroleumbased?”Smith said. project will focus on theSmith added, however,that coatings resinsdevelopment of technologiesemployed in these that could reduce by up to 30new technologies willpercent the amount of rawcontinue to be madewith monomers derivedfrom petroleum-materials used to manufacturea variety of waterborne paintbased raw materials.Rohm and Haas and coatings.enjoys a dominantposition in acrylicresintechnologies for architectural coatings, and Smith said coatingsmakers and their customers can logically expect that these new binderchemistries will involve acrylics. “But we believe that this should applyto all binder chemistries,” he said.Smith declined to speculate on when new these new materialsmight make their commercial debut, but said product introductions arelikely to come in stages as advances in specific types of coatings takeplace. End-use candidates will include a range of architectural coatingsfor interior and exterior application and coatings with variousgloss levels, he said.More information about the Department of Energy’s IndustrialTechnologies Program can be found on the website located atwww.eere.energy.gov/industry.Journal of Architectural Coatings / January 2005 41JAC

ProductSpotlightPhotos courtesy of Carlisle Coatings & WaterproofingIt’s westward ho for air barriersBy JAC StaffFrom Boston’s BeaconHill to the Back Bay andon to the Berkshires, theair-barrier movementhas commenced withnearly the resonance of the proverbialshot heard ‘round the world. For pointswest and south of Lexington andConcord, the early salvos of the air-barrierrevolution can definitely be discerned,but remain a distant rumble on the easternfront.That may not completely describe thecurrent geographic domain of the air barrierin building design and construction.But industry insiders agree that when itcomes to the specification and use of airbarriers in building construction,Massachusetts remains the undisputedchampion of this still relatively newbuilding-envelope element. The stateowes this distinction to the establishmentin 2001 of building-code requirementsfor air barriers in buildings of 10,000square feet or more in size.Suppliers of air-barrier systems alsoagree that New England is not likely toremain the exclusive realm of the air barrierfor long, what with the spiraling costof energy for heating and cooling andevidence that air barriers can significantlyreduce those costs.The advent of the air-barrier era hasattracted a variety of suppliers of materialsto this emerging market, some ofthem well-known names such asDuPont, BASF and Dow, and others withrelatively lower profiles. These barriersinclude sheet-type products such asmembranes made of bituminous materials,polystyrene, urethane insulation,phenolic insulation board, cementboard, foil-backed gypsum board, andothers.The liquid-applied products, mean-Liquid-appliedsystems vie forsignificant shareof Expandingexpandingmarket for keybuilding-envelopecomponentwhile, include offerings from coatingsand polymer companies, which haveintroduced spray, roller and trowelappliedmaterials that are thought of asbeing akin to coatings and elastomerics.Many suppliers offer both liquid andsheet products.Brian Carey, product manager, Air andVapor Barrier Systems, with CarlisleCoatings, said the air-barrier marketplaceoffers an array of different products fordifferent applications. Liquid-type barriersystems, he says, offer the potential forsignificant labor savings in applicationcompared to sheet-applied barriers. ButCarey says quality control during applica-42 Journal of Architectural Coatings / January 2005

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tion is crucial to barrier performance.“With spray-applied barriers, a keyissue is uniform thickness,” Carey says,adding that inspection of the finishedapplication job is important in ensuringthe work is done right. The Air BarrierAssociation of America (ABAA), anindustry group launched in 2001, hasdeveloped an inspection training andcertification program that provides aframework for quality assurance in theinstallation of air barriers.The key component of Carlisle’s airbarrierproducts is a water-borne asphaltemulsion that can be applied with along-nap roller, although a speciallydesigned spray system is recommended.Carey says performance of liquid-typebarrier systems should be comparable tosheet-applied materials if the material isuniformly and properly applied.The ABAA—located, not surprisingly,in the hub of the air-barrier movement,Boston—acts as something of an arbiterof air-barrier ways and means. The associationpursues a mission of spreadingthe gospel of air-barrier education andpreferred methodology. This questincludes efforts to bring some order tothe industry in terms of standards onhow air barriers are marketed and used.Lavergne Dalgleish, the ABAA’s executivedirector, said there is no questionthe liquid-applied air-barrier segment isexperiencing the fastest growth curve,with speed of application viewed as aplus for the technology. A clear indicationthat liquid-applied products aregaining ground is evidence that makersof sheet-applied materials are alsoentering the liquid-applied productmarket, he said.The ABAA was launched in the wakeof Massachusetts’ enactment of the stringentbuilding code requirements thatnew construction of 10,000 square feetor more in size have air barriers. Mostresidential housing, thus, is exempt.Versions of barrier-type requirementsare on the books in Minnesota,Michigan and Wisconsin, but theMassachusetts law is the most specific inrequiring air barriers, Dalgleish says. Theother states allow other means to ensureair “tightness” in construction.While air barriers are viewed as offeringenergy-efficiency benefits in variousclimates, complications come into playin the use of air barriers that also providevapor-barrier functionality, theABAA points out. In colder, northern climates,the use of a vapor barrier is ratherstraightforward: the barrier is installedon the “winter-warm” side of the exteriorbuilding-wall construction to preventvapor from condensing and lingering asmoisture. Essentially, the air/vapor barrieris installed on the outside of the interiorwall system, with insulation placedon the outside of the barrier followed bythe exterior wall construction—masonry,for example.In Texas or Florida, on the other hand,the vapor barrier logically would beplaced outside the insulation — thewarm side of the wall system for muchof the year. The problem, Dalgleish says,arises “in between” these contrasting climates—inregions such as the Mid-Atlantic and Midwestern states and largeportions of the South and West.“There is no good answer for Ohio, forexample,” Dalgliesh says. What mightwork is a thick vapor barrier that stopsmoisture from either side—a combinedinsulating, air-barrier and water-impermeablesystem. Economic considerations,however, can come into play in specifyingsuch an all-encompassing envelopesystem.Education is the key issue with air barriersand related products, Dalgleish said.“The farther west andsouth you go, the lessawareness you see.”But, he adds, “That ischanging extremelyrapidly.”Approximately 15–20percent of new-buildingspecificationsissued in New York, heestimates, include airbarriers, in the expectationthat such requirementsare on the horizon.Air-barrier requirementsare also in varyingstates of development in the state ofWashington and in the Carolinas,Georgia and the city of Chicago.Liquid-Applied BarriersVary with Performance NeedsSuppliers of liquid-applied barrier systemsoffer a variety of air-barrier productsdesigned to meet different applicationand performance needs.Representatives of these companies,however, voice identical opinions aboutthe importance of proper choice of product,the use of trained application personnel,proper application methods, andcareful inspection of the finished job.Henry Co., based in Los Angeles, laysclaim to being the biggest supplier of airbarriersystems in North America, andcontinued on page 4744 Journal of Architectural Coatings / January 2005

continued from page 44entered the market by way of acquisitionof the Canadian company Bakor in 1998.Cary Robertson, Henry Co. productmanager, Building Envelope Systems,says the company offers a range ofacrylic liquid-applied barrier systems thatare tailored to meet the needs of differentclimate zones and application needs.Robertson says a dew-point analysisof the building wall system is crucial todetermining proper installation of theair-barrier system, particularly in situationswhere a vapor barrier is part of thesystem being applied. Henry Co.’s airbarrierproduct line includes bothvapor-barrier and vapor-permeablefunctionality.“The vapor-permeable barrier allows alittle more latitude,” Robertson says, inthat it can be employed in different climateswhere condensation points canvary due to seasonal temperature andhumidity swings.Robertson agrees that sales of air-barriersystems are experiencing theirstrongest growth in the Northeast, buthe says other regions are jumping on thebandwagon. “We’re seeing growth everywhere.Architects are realizing the importanceof having an air barrier, what withthe interest in energy efficiency andmold mitigation.”Tom Harris, product manager forBASF Corp.’s Spray-AppliedPolyurethanes business (Wyandotte,MI), says the business’s liquid-appliedair-barrier system “is a little different”in that it provides insulation functionalityas well as air- and vapor-barrierproperties. The isocyanate/polyhydroxylresin foam is applied in a thick coatingof 3 inches or more.Harris says overall sales are expandingat a rate of 20% annually, with growthof more than 100% being recorded inthe industrial and commercial segments.Sales are growing fastest in anorthern tier of states extending fromNew England to the Dakotas, withincreasing interest being seen in theMidwest and Mid-Atlantic states.Sto Corp., another major air-barriersupplier, offers a system that consists ofelastomeric materials that are spray- orroller-applied. The barrier system thatresults prevents air and moisture penetration,but is designed for “breathability”and is not a vapor barrier.Tnemec Co. (Kansas City, MO) is successfullymarketing an air barrier coatingoriginally used as a high-performance,elastomeric concrete coating,says Terry Wallace, director, architecturalproducts. The product, a modifiedwater-borne acrylic, was tested andfound to meet air-barrier code requirementsin Massachusetts when applied intwo coats and a total thickness of 8mils, Wallace says.Wallace says the Tnemec product,which is vapor-permeable, can functionas both a protective and decorative coatingand an air barrier, and can be usedas an interior or exterior finish. He saysthe product’s touch-up and recoat capabilitiesalso are viewed as a plus in suchapplications, where the finished coatingis located on the exterior façade or interior-wallsurface.Wallace cautions, however, that whenused as an exterior finish, the product’seffectiveness as an air barrier is dependenton geographic location and climateconditions.More information on liquid-appliedair-barrier products and their suppliers isprovided in the listings accompanyingthis article on p. 48.JACJournal of Architectural Coatings / January 2005 47

Air Barrier Buying GuideLiquid Air BarriersCompanyCarlisle Coatings & WaterproofingCorbond CorporationDow ChemicalEPRO Services, Inc.W.R. Grace & Co.Henry CompanyW.R. Meadows, Inc.RectorsealResin Technology Co.Rubber Polymer CorporationSto CorporationTnemecTremcoGeneric Typerubberized asphalt emulsionpolyurethane foampolyurethane foampolymer-modified asphaltsynthetic rubber latexelastomeric liquid membranepolymer-modified asphalt emulsionnon-asphaliticpolymerpolyurethane foamthermoplastic rubberacrylicacrylicelastomeric asphaltBrand NamesBarriseal-R Barriseal-SClimate Isolation SystemDow SPF Wall Insulating SystemECOFLEX-R ECOFLEX-SPerm-A-Barrier LiquidAir-Bloc® 06, 07, 21, 21 FR, 31, 32, 33AIR-SHIELD LMGreen-Tite Green-Tite WBSprayed Polyurethane Foam, closed cellRub-R-Wall AirtightSto Guard®Series 156 Enviro-CreteExoAir 120Recommended DFT40 mils2.5 inches1.5 inches40–60 mils60 mils40–60 mils45 mils20 mils 30 mils2–5 inches40 mils35–42 mils4–8 mils40 milsVOC Content30 g/L0 g/L0 g/L25 ppm75 g/L

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Exposed structural steel in this walkway is a key design element. Photos courtesy of the David L. Lawrence Convention Center, PittsburghReducingthe installed costof intumescentfireproofingrotectionJeff SchmuckerCarboline Co.The incorporation of exposedstructural steel as a designelement in contemporarybuildings provides architects and designerswith the ability to convey multipleimpressions to building occupants andvisitors. Often, these structural elementsfall within the building-code enveloperequiring fire protection.Thin-film intumescent fireproofing canprovide the required hourly fire ratingwhile preserving the desired appearance.Historically, the primary impediment tothe widespread use of exposed structuralsteel protected by intumescent fireproofinghas been the high cost.This article reviews the basic protectionmechanism of intumescent coatings andthe positive cost impact made possible byincreasing steel sections used in exposeddesigns.Intumescent coatings protect steel byinsulating the substrate from the heat ofthe fire and are rated by the number ofminutes, or hours, that they can maintainthe steel below 1,000 F, the point atwhich structural integrity is compromised.At temperatures above 300 F, intumescentcoatings swell, creating an insulatingchar that interferes with heat conductionand keeping the steel coollonger.With a heat capacity of 0.12 btu/lb/degree F, unprotected steel offers someinherent fire resistance. Therefore, it followsthat by using heavier steel sections,advantage can be taken of the heatcapacity of steel and less intumescentcoatingthickness is required. By reducingcoating thickness, less coating materialand less application labor are required,resulting in cost savings.Structural engineers are taught fromearly in their college curriculum todesign with the lightest practical structuralsteel member. The thinking is thatsteel costs money and is sold by weight,so the lighter the member the lower thecost. This is true unless thesteel will be part of an exposed designelement requiring fire protection. Inthese cases, the cost of steel becomes lesssignificant compared to the applied costof intumescent fireproofing.Consider the following example: Anarchitect decides to place an 18-foot-highglass wall in the spacious foyer of a newoffice tower, affording a view of an adjacentriver. The interior designer decidesthat exposed hollow structural steelshould comprise the framing to providethe desired interior visuals. The structuralengineer calculates that 4-in. x 4-in. x 5 ⁄16(HSS) is more than adequate for thecolumns and X bracing. The fire marshalrequires a 1 1 ⁄2-hour fire rating for thestructure, so intumescent fireproofingapplied in accordance with UnderwritersLaboratories Design No. X633 is specified.This design requires 292 mils (0.292in.) of intumescent coating to achievethe 1 1 ⁄2-hour rating. The painting contrac-Journal of Architectural Coatings / January 2005 51

tor calculates that there are 1,605 squarefeet of surface to be coated, requiringapproximately 480 gallons of intumescentcoating applied in seven coats. Thework will require four men 12 days tocomplete at a total cost of $49,500, or$30.85 per square foot. More steel, less moneyA few days after the cost estimates forthis job are submitted, the structuralengineer finds himself seated on a flightfrom Pittsburgh to St. Louis next to atechnical representative of the intumescentcoating manufacturer. They strikeup a conversation and the engineer’sjust-completed, intumescent-protectedglass curtain wall design project comesup. He comments that everyone wasshocked at the cost of the fireproofing.The technical representative asks if anyoneinvestigated the potential cost savingsby using heavier-walled structuraltubing for the project. Fortunately, it’snot too late.The architect issues an addendum withthe design changed to 4 x 4 x 1 ⁄2 HSS, anincrease of 3 ⁄16 in. in the wall thickness ofthe tubing. A 1 1 ⁄2-hour fire rating for thesame intumescent coating applied perthe same UL design now requires a thicknessof 166 mils (0.166 in.). The paintingcontractor recalculates his costs and findsthat he now needs four men workingeight days to apply 275 gallons of intumescentcoating at a total cost of$30,650, or $19.10 per square foot. Theresult is an initial cost savings of$18,850.The original design required 17,884pounds of tube steel, while the reviseddesign required 26,085 pounds, or anincrease of 8,201 pounds. At the timethis article is being written, small lotsof structural tubing cost $0.60 perpound, resulting in an increased steelcost of $4,921. Subtracting thisincreased cost from the initial savingsresults in a net reduction in the overall52 Journal of Architectural Coatings / January 2005

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cost of $13,929, or 28 percent less thanthe original design.Move work to the shopArchitects and general contractors canpursue another avenue to reduce the costof intumescent applications by movingthe majority of the application from thefield to specialized shop applicators. Thishybrid approach can result in substantialsavings but requires closer communicationamong the structural engineer, generalcontractor or construction manager,erector, shop applicator, and the fieldpainting contractor.Ideally, the intumescent fireproofingcontract should be between the generalcontractor or construction manager andthe field painting contractor, who thenretains the specialized shop as a subcontractor.Under this scenario, theCommercial and IndustrialCoatings/Fireproofing/Concrete FloorSystemsV U L C A NP A I N T E R SVulcan Painters, Inc.205-428-0556field painter and erection contractor areultimately responsible for the finishedquality.The general contractor must communicatewith the steel-erection contractor toassure that handling damage is held to aSee the DifferenceBirmingham, Alabama www.vulcan-group.comUse of heavier than required sections, shown above, reduces cost.minimum. Additionally, the structuralengineer can contribute to the success ofthis approach by designing lifting lugs inobjects of complex geometry such asspace frames, so that slings and chokersneed not be used when performing siteinstallation.By applying the majority of therequired film thickness of the intumescentcoating in a shop, lower labor costsare realized and job-site trade conflictsand schedules are reduced.In most situations it is advisable toshop-apply all but the last coat of material,which is then applied in the field aftererection scars and connection areas havebeen addressed. This contributes to amore uniform appearance prior to finishpainting.As general contractors, constructionmanagers, structural engineers, andapplicators become more familiar withthe benefits and limitations of intumescentfireproofing, the technology will seemore prolific use and costs will be furtherreduced.AcknowledgementThe author would like to thank Mr. SteveDobrosielski, Manager of Engineering andEstimating with John B. Conomos Inc.,Bridgeville, PA, for providing an accurateestimate of the costs described above.JAC54 Journal of Architectural Coatings / January 2005

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Albi Mfg. . . . . . . . . . . . . . . . . . . . . . . .52Ameron Int. - Prot. Ctgs Group . . . . . . . . . .7The ArmaKleen Company . . . . . . . . . . . .12Atlas Material Testing Technology . . . . . . .31Bayer . . . . . . . . . . . . . . . . . . . . . . . . .35Blastrac . . . . . . . . . . . . . . . . . . . . . . . . .6Carlisle Coatingsand Waterproofing, Inc. . . . . . . . . . . . . .23Coronado Paint / Insl-X . . . . . . . . . . . . .14Crown Polymers, LLC . . . . . . . . . . . . .28-29DuPont Industrial Coatings . . . . . .Back CoverEliokem, Inc. . . . . . . . . . . . . . . . . . . . . .37AdIndexGraco Inc. . . . . . . . . . . . . . . . . . . . . . .11ICI Paints . . . . . . . . . . . . .Inside Back CoverInside Paint . . . . . . . . . . . . . . . . . . . . . .46Journal of Architectural Coatings . . . . . . . .23KTA-Tator, Inc. . . . . . . . . . . . . . . . . . . . .16Kelly Moore . . . . . . . . . . . . . . . . . . . . .43Key Resin Co. . . . . . . . . . . . . . . . . . . . .23Muralo . . . . . . . . . . . . . . . . . . . . . . . .13P&AT Labor Management Corp. . . . . . . . .17PDCA . . . . . . . . . . . . . . . . . . . . . . . . .45PPG . . . . . . . . . . . . . . . . . . . . . . . . . . .5Paint BidTracker . . . . . . . . . . . . . . . . . . .49PaintSquare StoreFronts . . . . . . . . . . . . . .55PolySpec . . . . . . . . . . . . . . . . . . . . . . .25Rubber Polymer Corporation . . . . . . . . . .10SSPC . . . . . . . . . . . . . . . . . . . . . . . . . .53Sawtec . . . . . . . . . . . . . . . . . . . . . . . . .6Sherwin-Williams . . . . . . . .Inside Front CoverSto Corp . . . . . . . . . . . . . . . . . . . . . . .21Titan Tool, Inc. . . . . . . . . . . . . . . . . . . .40Tnemec Company . . . . . . . . . . . . . . . . . .2United Coatings . . . . . . . . . . . . . . . . . . .9Vulcan Painters . . . . . . . . . . . . . . . . . . .54ZRC Products . . . . . . . . . . . . . . . . . . . .52Jan. 25Exotic Coatings Mini-SymposiumASTM Committee D01 on Paint and RelatedCoatings, Materials, and ApplicationsEmbassy SuitesFort Lauderdale, FL610/832.9729www.astm.orgJan. 24-25Nano and Hybrid Coatings ConferencePaint Research AssociationManchester Conference CenterManchester, UK+44.0.20.8614.4800www.pra.org.ukFeb. 2-4Annual International Waterborne, High-Solids,and Powder Coatings SymposiumUniversity of Southern MississippiNew Orleans MarriottNew Orleans601/266.4475www.waterborne@usm.eduFeb. 16-18Smart Coatings 2005 ConferenceEastern Michigan UniversityDisney World ResortLake Buena VistaOrlando, FL734/487-2203www.emich.eduFeb. 28-March 3SWRI Annual MeetingSealing, Waterproofing and Restoration InstituteWyndham El Conquistador ResortPuerto Rico816/472-7974www.swrionline.orgCalendarMarch 3-4ICRI 2005 Spring ConventionInternational Concrete Repair InstituteBoston Park PlazaBoston847/827-0830www.icri.orgMarch 7-9Computer Modeling Workshop for Wall Design andPerformanceNational Institute of Building Sciences (NIBS)La Mansion del Rio HotelSan Antonio, TX202/289-7800www.nibs.orgMarch 8-10PDA Annual ConferencePolyurea Development AssociationGrand CasinoBiloxi, MS816/221.0777www.pda-online.orgMarch 15-17National Facilities Management and TechnologyConference/ExpositionMaintenance Solutions National ExpoTrade Press Publishing Co.Baltimore Convention Center414/228-7701www.nfmt.comMarch 16-17Hygienic Coatings & Surfaces ConferencePaint Research AssociationParis Expo, Porte de VersaillesParis+44.0.20.8614.4800www.pra.org.ukApril 20-23Annual CSI Show and ConventionConstruction Specifications InstituteMcCormick PlaceChicago800/689-2900www.csinet.orgMay 19-21The AIA National Convention and Design ExpositionAmerican Institute of ArchitectsMandalay Bay Convention CenterLas Vegas800/242-3837www.aiaconvention.comJune 8-10Nanotechnology in Coatings: Realizingthe Potential conferenceFederation of Societies for Coatings TechnologyFSCT)Seattle610/940-0777www.coatingstech.orgfax: 610.940.0292; email: fsct@coatingstech.org).June 10-11BETEC 2004 Spring SymposiumMembranes in Enclosure Wall SystemsBuilding Environment & Thermal Envelope CouncilNational Institute of Building SciencesCrystal City Marriott HotelArlington, VA202/289-7800www.nibs.orgJune 25-28BOMA International Congress and Office BuildingShowBuilding Owners and Managers AssociationInternational and RealcommAnaheim, CA202/408-2662www.boma.orgNov. 6-9Biennial Western Coatings Symposium and ShowWestern Coatings Societies and Federation ofSocieties for Coatings Technology (FSCT)Westin Casuarina Hotel & SpaLas Vegas610/940-0777www.coatingstech.org56 Journal of Architectural Coatings / January 2005

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