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KCC

KCC. The World Leader. in Container Coatings. Accumulated data of Container Projects (by Year). Total : 11,721,807TEU , As of Dec. 31, 2015. ◈ Reference list of Container Projects. ◈ Reference list of Container Projects. By Builder’s Country.

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  1. KCC TheWorldLeader inContainerCoatings

  2. Accumulated data of Container Projects (by Year) Total : 11,721,807TEU, As of Dec. 31, 2015 ◈ Reference list of Container Projects

  3. ◈ Reference list of Container Projects By Builder’s Country Total : 11,721,807TEU, As of Dec. 31, 2015 Accumulated data (by Major Owners)

  4. ◈ Reference list of Container Projects Accumulated data of Container Projects (by Major Owners) Total : 11,721,807TEU, As of Dec. 31, 2015

  5. PaintingSystem for NewbuildingContainer

  6. Products for Container Coating ♣ ♣ ♣ ♣ EpoxyZincPrimer EpoxyPrimer EpoxyTopcoatforinterior(FDA-Compliant) Topcoatsofvariousresinbasis; ModifiedAcrylicTopcoat ChlorinatedRubberTopcoat VinylTopcoat PolyesterTopcoat UrethaneTopcoat Non--chalkingEpoxyTopcoat

  7. Environmental Friendly Coatings ♣Highsolid&VOCcompliantpaints -KorepoxZincRichPrimerEZ1750 -KorepoxH.B.EH2351 ♣CTCFreepaint -KoraborH.B.RH247N -KoclacH.B.AH2470 ♣Waterbornepaints -KosumelZincPrimerWZ3300 -KosumelPrimerWP3400 -KosumelTopcoatWT3500 -KosumelTopcoatWT3600

  8. ◈GeneralCoatingSystemforNewbuildingDry-CargoContainers ForExteriorSurfaces(Substrate:Steel) DFT(μ) System1System2System3 Coating Productname Generictype Primer Middle EpoxyZinc(Rich)Primer EpoxyZinc-phosphatePrimer 10∼40 30∼70 30∼40 - - 30∼50 EZ175C,EZ175orEZ1750 EP170ST Basedonorderingspecification. (RefertoKCC’sexteriortopcoatingmaterialsasbelow.) TotalDFT(DryFilmThickness,microns) Topcoat 40∼50 110∼120 70∼80 110∼120 40∼50 80∼90 System1:Three(3)coatingsystem(Substrate:Generalsteel) System2:Two(2)coatingsystem(Substrate:Generalsteel) System3:Coatingsystemincasethatsubstrateisanon-ferrousmetals(MGSS,SUS,etc.) “EP1720orEP1730”canbeusedinsteadof“EP170ST”asasamethickness. KCC’sexteriortopcoat Generictype Acrylic Vinyl CRor Acrylic+CR Productname AH2470,AH2470(S) VH4233,VH4233(S) RT547,RH247, RH247(N),RT546(D) Generictype Epoxy Urethane Polyester Productname ET5730 UT6581(C) MT340

  9. ◈GeneralCoatingSystemforNewbuildingDry-CargoContainers ForInteriorSurfaces(Substrate:Steel) DFT(μ) Coating Primer Productname EZ175C,EZ175orEZ1750 EP170ST Generictype EpoxyZinc(Rich)Primer EpoxyZinc-phosphatePrimer System1 10∼40 - System2 10∼40 40∼70 Topcoat EpoxyHighBuild 40∼70 - EH270 60∼80 60∼80 TotalDFT(DryFilmThickness,microns) ForUnderStructureSurfaces(Substrate:Steel) Coating Primer Productname EZ175C,EZ175orEZ1750 Generictype EpoxyZinc(Rich)Primer DFT(μ) 10∼40 BituminouspaintorBasedonorderingspecification. SameasExteriortopcoatingsystem. - - Topcoat

  10. ◈GeneralCoatingSystemforNewbuildingReeferContainers ForExteriorSurfaces(Substrate:MGSSorHGSS) Coating Primer Productname EP170ST,EP1720 Generictype EpoxyPrimer DFT(μ) 40∼50 Basedonorderingspecification. (RefertoKCC’sexteriortopcoatingmaterials) TotalDFT(DryFilmThickness,microns) Topcoat 50~60 90∼110 ForUnderStructureSurfaces(Substrate:Steel) DFT(μ) Coating Productname EZ175C,EZ175orEZ1750 Generictype EpoxyZinc(Rich)Primer System1 10∼30 System2 - Primer EpoxyPrimer - 30∼40 EP170ST,EP1720 BituminouspaintorBasedonorderingspecification. SameasExteriortopcoatingsystem. - - Topcoat

  11. Waterborne Coatings For Containers

  12. Contents Introduction of KCC’s New Waterborne Coatings I Technology & Performance II Recommended Working Procedure & Condition III Application References IV

  13. I. Introduction of KCC’s New Waterborne Coatings

  14. , KCC s R&D History for WB Container Coatings 1990s The 1st generation WB coating system. Suitable for low-speed production line at container manufacturers. 2008 W-series Organic-inorganic hybrid technology. Excellent weatherability, anti-contamination property Finish for new building & refurbishing containers. New tech. Waterborne Top coat The 2nd generation WB coating system. Good anticorrosive property Good resistance to abrasion & impact Very Low VOC contents Full waterborne 3coat system The 3rd generation WB coating system. Non-zinc primer but, excellent anti- corrosive property. Highly economic & good workability. 2009~2011 Full waterborne 2coat system ~2013

  15. New Waterborne Coating System # For Dry Container Exterior 3coat 2coat Top40~50㎛ Top45~50㎛ Mid40㎛ Mid45~50㎛ Primer20㎛ Shopprimer10㎛ Shopprimer 10㎛ Interior 2coat 1coat Top40~50㎛ Top50~60㎛ Primer 20㎛ Shopprimer 10㎛ Shopprimer 10㎛

  16. New Waterborne Coating System # For Reefer Container SUS substrate Top50㎛ Mid40㎛ Steel parts Metallizing Zinc primer Top50㎛ Top50㎛ Mid40㎛ Mid40㎛ Primer 20㎛ Zinc metalizing Shopprimer 10㎛

  17. New Waterborne Coating System 1. For Dry Container 2. For Reefer Container

  18. II. Technology & Performance

  19. Organic-Inorganic Hybrid Top Coat for Ext. Organic-Inorganic Hybrid Emulsion structure Surfactants layer Polymer Core Silicone-modified acrylates Organic part Inorganic part

  20. Organic-Inorganic Hybrid Top Coat for Ext. Strong Bonding Energy Siloxane (Si-O-Si) Structure -- Strong Bonding -- Stable for UV & Heat than Organic Coatings

  21. Organic-Inorganic Hybrid Top Coat for Ext. Novel Technology Conventional Good Weatherability : QUV-B, 600hours - Color differance : Max. 0.5 - Gloss retention : Min. 80% Novel Technology Conventional Good Dirt pickup resistance : Carbon black solution test - Very easy to remove contamination

  22. Long term Protection technology Conventional WB epoxy Novel WB epoxy Uniform film formation - Enhance barrier property - High cross-linking density Cathodic protection & passivation - Long term protection technology - Electro-chemical corrosion control

  23. Performance Test Results a. Anti-corrosive performance Novel Technology Conventional Novel Technology Conventional Excellent anti-corrosion properties - Salt fog 1000hours - No blister Good temporary protection(Shop primer) - Salt fog 150hours - No blister, No rust

  24. Performance Test Results b. IICL Paint test result Exterior 2coat system Interior 1coat system

  25. VOC Emission Full waterborne coating system can reduce substantial amount of VOC emission in painting process. Dry Container Reefer Container

  26. III. Recommended working Procedure & Condition

  27. Recommended Procedure & Conditions Interior Topcoat/ Exterior Midcoat Zinc-Rich Primer coat • Setting • Setting • Dry oven • Cooling Decal and Flooring Exterior Topcoat • Setting • Dry oven

  28. Shop priming line Stacking Cooling Setting Spray Dry oven Temp. : Ambient Humid : 20~80%RH Time : - * Air blowing Temp. : Ambient Humid : 20~80%RH Substrate temp. : Min. 10℃ Temp. : 60~80℃ Humid : 20~80%RH Time : 80~120sec. *Hot air blowing *Ventilation required Temp. : Ambient Humid : 20~80%RH Time : 60~120sec. * Air blowing Temp. : Ambient Humid : 20~80%RH ※ Thisprocedure & conditions were set up based on our actual experiment. It can be changed by each painting line’s structure & condition.

  29. Main Painting Line • Dry container 3coating system • & Reefer container steel parts zinc primer system Zinc Primer coat Dry oven Setting Exterior middle /Interior top Setting Temp. 10~35℃ Humid 40~80%RH *Ventilation required Temp. 20~40℃ Humid ~80%RH Air blow 1.0~1.5m/s Time10min *Warm air blowing *Ventilation required Temp. 10~35℃ Humid 40~80%RH *Ventilation required Temp. 15~40℃ Humid ~75%RH Air blow 1.0~1.5m/s Time6~10min *Warm air blowing *Ventilation required Temp. 40~50℃ Humid ~45%RH Air blow 1.0~1.5m/s Time15~20min *Hot air blowing *Ventilation required cooling Final dry oven 1st dry oven Exterior top coat Setting Temp. 60~70℃ Humid ~30%RH Air blow 1.0~1.5m/s Time 20min *Hot air blowing *Ventilation required Temp. 40~50℃ Humid ~45%RH Air blow 0.5~1.0m/s Time 10min *Hot air blowing *Ventilation required Temp. 20~40℃ Humid ~75%RH Air blow 0.5~1.0m/s Time10min *Warm air blowing *Ventilation required Temp. 10~35℃ Humid 40~80%RH *Ventilation required Temp. ~30℃ Humid ~80% RH Air blow 3.0m/s Time 10min *Ventilation required *Air blowing ※ Thisprocedure & conditions were set up based on our actual experiment. It can be changed by each painting line’s structure & condition.

  30. Main Painting Line b. Dry container 2coating system Dry oven Exterior middle /Interior top Setting cooling Exterior top coat Temp. 40~50℃ Humid ~45%RH Air blow 1.0~1.5m/s Time15~20min *Hot air blowing *Ventilation required Temp. ~30℃ Humid ~80% RH Air blow 3.0m/s Time 10min *Ventilation required *Air blowing Temp. 10~35℃ Humid 40~80%RH *Ventilation required Temp. 15~40℃ Humid ~75%RH Air blow 1.0~1.5m/s Time6~10min *Warm air blowing *Ventilation required Temp. 10~35℃ Humid 40~80%RH *Ventilation required Final dry oven 1st dry oven Setting Temp. 60~70℃ Humid ~30%RH Air blow 1.0~1.5m/s Time 20min *Hot air blowing *Ventilation required Temp. 40~50℃ Humid ~45%RH Air blow 0.5~1.0m/s Time 10min *Hot air blowing *Ventilation required Temp. 20~40℃ Humid ~75%RH Air blow 0.5~1.0m/s Time10min *Warm air blowing *Ventilation required ※ Thisprocedure & conditions were set up based on our actual experiment. It can be changed by each painting line’s structure & condition.

  31. Main Painting Line c. Reefer container coating system for SUS substrate Dry oven Exterior middle Setting cooling Exterior top coat Temp. 10~35℃ Humid 40~70%RH *Ventilation required Temp. ~35℃ Humid ~80% RH Air blow 1.0~1.5m/s Time 10~15min *Ventilation required *Air blowing Temp. 10~35℃ Humid 40~70%RH *Ventilation required Temp. 20~40℃ Humid ~70%RH Air blow 1.0~1.5m/s Time10~15min *Warm air blowing *Ventilation required Temp. 50~60℃ Humid 15~30%RH Air blow 0.5~1.0m/s Time15~20min *Hot air blowing *Ventilation required Final dry oven 1st dry oven Setting Temp. 60~80℃ Humid 20~30%RH Air blow 1.0~1.5m/s Time 20~30min *Hot air blowing *Ventilation required Temp. 35~40℃ Humid ~40%RH Air blow 0.5~1.0m/s Time 10~15min *Hot air blowing *Ventilation required Temp. 20~40℃ Humid ~70%RH Air blow 0.5~1.0m/s Time10~15min *Warm air blowing *Ventilation required ※ Thisprocedure & conditions were set up based on our actual experiment. It can be changed by each painting line’s structure & condition.

  32. Waterborne Paint Drying Mechanism It is the reason why modification is necessary for some CT manufacturing line. Emulsion particle Coalescent Water Capillary force a) Wet paint b) Evaporation of water : The capillary forces press the particles against one another ※ depending on Temperature, humidity and airflow c) Coalescing stage : There is interdiffusion or Cross- linking of polymer chains. ※ depending on Temperature and airflow d) Continuous film formation

  33. Waterborne Paint Drying Mechanism High humidity makes water evaporation rate slower! It affect step b during the WB paint film formation humidity control is essential!! Water Time to Complete Evaporation Solvent % Relative Humidity

  34. Recommended conditions : Spray zone RH • South China needs to control humidity • Middle China needs to control humidity • in rainy season • North China needs to control Temperature • Generally, spray workability can be • advanced slightly by adding some kinds • of solvents. • However, these raw materials cause • decreasing long term performances and • increasing VOC contents. Reduce drying speed, it can cause sagging ↑ → Poor appearance (Dust, crack, orange peel etc) ← Can cause film formation failure ↓ Dust spray (It can be solved by thinning more water, but sagging.) Temperature

  35. Recommended conditions : Setting zone Zinc primer Ext. middle & Int. topcoat Ext. topcoat RH Air flow rate : 1.5m/s Air flow rate : 1.0m/s Air flow rate : 1.0m/s Dew point gap below 3℃ ↑ Dew point gap below 3℃ ↑ Dew point gap below 3℃ ↑ Flash rust ↑ Flash rust ↑ Insufficient dry corrugated area ↑ → Crack, pinhole bubling → Difficult to cooling down → Crack, pinhole bubling ← Mud cracking ← Mud cracking ← Mud cracking Temperature • Generally, containerpainting lines have no zinc primer oven. Zinc primer should be almost dried • in the setting stage. • Ext. middle, topcoat and Int. topcoat should be touch dry before going in dry oven. • In the setting stage, • Temperature is too high, it may cause poor appearance like crack, pinhole, etc. • Temperature is too low, it may cause mud cracking and insufficient film performance. • Humidity is too high, it may cause insufficient dry before dry oven and make flash rust in a few minutes. • Low humidity doesn’t matter in the setting zone. • Proceeding the paint work, the internal space of painting line is getting increasingly wet. • So, humid control is necessary. • - Too fast air flow may cause cracking of film surface.

  36. Recommended conditions : Dry oven Ext. middle & Int. topcoat dry oven Ext. topcoat 1st dry oven Final dry oven RH Air flow rate : 1.5m/s Air flow rate : 1.5m/s Air flow rate : 1.0m/s Dew point gap below 3℃ ↑ Insufficient dry corrugated area ↑ → Difficult to cooling down → Crack, pinhole, bubling Insufficient cure ← can cause decal work failure ← Hard to reduce humidity Hard to reduce humidity ← ← Hard to reduce humidity Temperature • Preceding two dry ovens make each film tack free and final dry oven make hard dry film. • Low humidity doesn’t matter in the dry ovens. • Ext. middle, topcoat and Int. topcoat should be touch dry before going in dry oven. • In the preceding two dry oven, • Temperature is too high, it may cause poor appearance pinhole, bubbling, etc. • Temperature is too low, it may cause insufficient dry for succeeding coat. • Humidity is too high, it may cause insufficient dry for succeeding coat. • Inthe final dry oven, • Temperature is too high, it may cause poor appearance pinhole, bubbling, etc. • Temperature is too low, it may cause decal work failure like peel off during decal sticker removal. • Humidity doesn’t matter. However, continuous humidity control and ventilation are necessary. • if not, we may meet finnish steam ‘Sauna’.

  37. Summary of working conditions

  38. IV. Application References

  39. 1st Generation Field References(1990s)

  40. 2nd Generation Field Test Results(2008~2016) • Showed good appearance • Showed good workability

  41. 2nd Generation Field Test Results(2008~2016) • Main defect during the waterborne paint application 1) Metalizing bubble 2) Fish eye • Metalizing bubbles are caused by reacting between • bare zinc metal and water contained in WB paints. • Zn + H2O → ZnO + H2 • Because of above reaction, some bubbles occurs • during the paint film dry and captured in the film • like a ‘Balloon’ • Fish eye like film defect occurs on stainless steel • surface which contaminated by zinc metal dust • during the metalizing. • There is much different surface tension between zinc metal • and stainless steel. That kinds of surface contamination cause • Fish eye. Zinc contaminant Hydrogen gas Paint film Paint film Stainless steel panel Zinc metalizing

  42. 2nd Generation Field Test Results(2008~2016) • Solutions 1) Metalizing bubble a. Reducedrying time : By using middle coat dry oven b. Prohibit excessive metalizing film : ~40㎛ metalizing film shows no bubbles 70㎛~ metalizing bubbles can cause bubbles 2) Fish eye a. Masking onthe metalizing border line : Preventzinc metal contamination. (Thisis the sure method to avoid fish eye) b. Cleaning : Cleaning by power tool(etc. brass brush) can reduce fish eyes evidently. ※ Refer to the test report

  43. 2nd Generation Field Test Results(2008~2016) • Showed good appearance • Showed good compatibility with • solventborne middle coat • Minor pinhole, popping phenomena • occurred in excessive film thickness area

  44. 2nd Generation Field Test Results(2008~2016) • Appearance was generally good. • Some boxes showed top coat cracking • cause by high D.F.T

  45. 2nd Generation Field Test Results(2008~2016) • Appearance was generally good. • Some boxes showed top coat cracking • cause by high D.F.T

  46. 2nd Generation Field Test Results(2008~2016) • Shows good appearance • Good workability

  47. 2nd Generation Field Test Results(2008~2016) • Shows good appearance • Good workability

  48. 2nd Generation Field Test Results(2008~2016) • Shows good appearance • Good workability Solvent borneWaterborne

  49. 2nd Generation Field Test Results(2008~2016) • Shows good appearance • Good workability Solvent borneWaterborne

  50. 2nd Generation Field Test Results(2008~2016) • Shows good appearance • Good workability • Shop primer shows fast dry property Solvent borneWaterborne

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