Release Date:2026-09-14 14:41:00
News Category: Company News
With growing demand for long‑term anti‑corrosion performance from infrastructures such as steel‑structure bridges, storage tanks and offshore engineering, conventional anti‑corrosion coatings are confronted with common challenges in formulation and application: zinc powder sedimentation, sagging under high film‑thickness build‑up, and adverse impacts of surface active agents on topcoat weather resistance. Based on analysis and testing of interfacial behaviors among resins, pigments & fillers and additives, TAIGA provides a full‑range additive matching solution covering primer, intermediate coat and topcoat, to support high‑quality development for anti‑corrosion coating manufacturers
01 Analysis of Application Pain Points for Anti‑Corrosion Coatings
Anti‑corrosion coating is a multi‑coat synergistic system: the primer delivers cathodic protection and substrate adhesion; the intermediate coat offers barrier performance and builds film thickness; the topcoat provides weather resistance and decorative properties. Nevertheless, typical failure risks emerge for each layer in real‑world formulation and construction. Three core common challenges are illustrated below.
Pain Point ① Hard Sedimentation of Zinc Powder in Zinc‑Rich Epoxy Primer
During the storage process of epoxy zinc rich primer, the zinc powder density can reach ≈ 7.1 g/cm, and it settles to the bottom to form a hard settlement/block. During construction, the distribution of zinc powder in the paint film is uneven, and the local zinc content is insufficient, which will significantly reduce the anti-corrosion effect; If a large amount of zinc powder is not sufficiently dispersed, the equivalent particle size of zinc powder particles will be larger after agglomeration, further accelerating sedimentation.
Merely increasing viscosity to resist zinc powder settling is not enough. This solution constructs a suitable thixotropic network using polyamide wax rheology agent (Tech-9020): that is, under low shear conditions (such as storage, volatilization, and drying), a three-dimensional network structure of polyamide wax (hydrogen bonds) is formed, providing sufficient yield stress to "support" the zinc powder and solve the problem of hard settling; Under high shear conditions (such as spraying and stirring), the hydrogen bond network is broken down, and the viscosity of the slurry rapidly decreases, ensuring workability. At the same time, 0.1% wetting and dispersing agent (Tech-5108) is used to anchor and wet the surface of zinc powder, preventing agglomeration and flocculation between zinc powders and reducing the risk of settling
Difficulty 2: Flow hanging and shielding issues of intermediate paint in Yuntie
During the construction of epoxy cloud iron intermediate paint facade, sagging and uneven coating thickness often occur, resulting in poor local shielding effect and affecting anti-corrosion performance. The main reason is that the flake like mica iron oxide (MIO flake like α - Fe2O3) has a large diameter to thickness ratio and is prone to slip under the influence of gravity in a wet film state
The advantage of the TAIGA solution lies in providing a more suitable rheological relaxation time for anti-corrosion coating construction: through the synergistic combination of polyamide wax (Tech-9020) and bentonite, the relaxation time of epoxy mica iron is adjusted to achieve thick coating under low construction viscosity; Corresponding defoamers and leveling agents complete the defoaming and leveling of the paint film within the relaxation time; And polyamide wax fibers act on sheet-like mica iron oxide, promoting parallel arrangement and enhancing shielding effect. The plan achieves the ideal state of "thick coating without sagging and parallel arrangement of mica iron oxide" by adjusting the various properties of the coating under different shear conditions
Difficulty ③ Surface activity affects the chemical resistance of topcoat
Surfactants (such as dispersants, wetting leveling agents, etc.) may affect the water resistance, salt spray resistance, and weather resistance of anti-corrosion topcoats while reducing the viscosity of colorants and improving the leveling performance of coatings, resulting in substandard anti-corrosion performance. Especially for low molecular weight hydrophilic surfactants, although they have a strong wetting effect on inorganic fillers, they will accumulate on the surface of the paint film (solid gas interface), leading to the following defects :
● Insufficient cross-linking density on the surface of the topcoat : The surface is attacked by ultraviolet rays and oxygen, resulting in loss of gloss and powdering; Corrosive substances (salt spray, acid, alkali) are prone to infiltration, leading to foaming and decreased adhesion● Surface water absorption of topcoat : Some surfactants add hydrophilic groups (such as EO, carboxylate salts, sulfonate salts, quaternary ammonium salts, etc.) to the chain segments to improve product versatility. They absorb water in high humidity environments and will significantly bubble in salt spray tests;
By using hydrophobic groups and special structural designs, and controlling the dosage, the negative effects of surfactants on anti-corrosion coatings (such as Tech-598, Tech-5041, etc.) are avoided, and various resistance verification tests are strictly conducted in accordance with standards (such as HG/T 2454-201).
02 Anti corrosion coating color paste scheme and effect display
This scheme aims to address the differences in surface charge and polarity of titanium dioxide, carbon black, and phthalocyanine pigments. Different dispersant structures are selected to minimize the impact of resistance while improving grinding efficiency and reducing viscosity; Through the synergistic effect of thixotropic agent (Tech-9010L) and bentonite, while ensuring high solid content and color saturation, it significantly alleviates storage settlement and construction floating color problems
● Basic formula for anti-corrosion color paste
● State of anti-corrosion color paste
03 Epoxy Zinc Rich Primer Scheme and Effect Display
In the epoxy zinc rich solution, to address the issue of sedimentation of rust resistant pigments such as zinc powder, a composite thixotropic system of Tech-9020+gas-phase silica+bentonite is used to construct a three-dimensional network structure and design a relaxation time more suitable for anti-corrosion coatings. After film formation, the surface appears uniform and delicate, with dense distribution of zinc powder/phosphorus iron powder without pinholes, effectively enhancing the adhesion between the coating and the steel substrate, and significantly improving the corrosion resistance of buried and outdoor steel structures● Basic formula for epoxy zinc rich primer
● Epoxy zinc rich primer status
● Epoxy zinc rich primer testing
Attention : The surface of the steel must undergo Sa2.5 sandblasting and rust removal treatment to ensure the cleanliness of the substrate.
04 Epoxy cloud iron intermediate paint scheme and effect display
● Basic formula for epoxy cloud iron intermediate paint
● Epoxy cloud iron intermediate paint state
● Epoxy cloud iron intermediate paint test
05 Steel Structure 2K Two Component Acrylic Polyurethane Topcoat Scheme
● 2K two-component acrylic polyurethane topcoat basic formula
● 2K two-component acrylic polyurethane topcoat status
Epoxy zinc rich primer+epoxy mica iron intermediate paint+acrylic polyurethane topcoat
● 2K two-component acrylic polyurethane topcoat testing
06 Summary
This scheme balances and synergizes the anti-corrosion additive system of "epoxy zinc rich primer+epoxy cloud iron intermediate paint+acrylic polyurethane topcoat". Better achieve cathodic protection of primer, physical shielding of intermediate paint, weather resistance and decorative properties of topcoat, and jointly construct a three-layer anti-corrosion coating system
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