Maincote AE-58/ProSperse 3001 Acrylic Epoxy TM toxicity, and odor and a performance profile similar to conventional solvent borne 2-pack epoxy finishes. MAINCOTE TM ProSperseAE-58

Technical Data Sheet

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Page 1 of 17 December 2010

MaincoteTM AE-58/ProSperseTM 3001 Acrylic Epoxy

For Waterborne 2K Light Duty Maintenance and Institutional Coatings

Regional Product

Availability

North America

Description MAINCOTETM AE-58 acrylic emulsion is a high Tg, hard acrylic binder containing functionality

allowing it to react with the epoxy dispersion ProSperseTM 3001 providing coatings with low VOC, toxicity, and odor and a performance profile similar to conventional solvent borne 2-

pack epoxy finishes. MAINCOTETM AE-58/ ProSperseTM 3001 is designed for general-purpose acrylic/epoxy paints which can be used on a variety of substrates such as exterior and interior metal and concrete where outstanding hardness, chemical resistance, and resistance to UV degradation are required.

Features and

Benefits

High hardness

Excellent chemical, stain, and solvent resistance

Rapid dry film property development

Low VOC and odor

Good exterior durability i.e. UV resistance and resistance to color change

Easy water clean-up

One-day pot life

Typical Physical

Properties

MaincoteTM

AE-58 Acrylic Binder*

Solids Content, % 42.5

pH 7.5

Viscosity, cP 700

Density. Lbs/gal 8.6

Bulking Value, gal./lbs

Dry 0.111

Wet 0.116

Equivalent Weight (solids basis) 1,700

MFFT (°C) 40

ProSperseTM

3001 Epoxy Dispersion

Solids Content, % 64

Density, Lbs/gal 9.1

Viscosity, cP 3000-9000

Epoxy Equivalent Weight (g/eq) on Solids 193-204

Epoxy Equivalent Weight (g/eq) as Supplied 297-324

pH 6.0 min.

Appearance Milky White

*Not to be considered specifications




Performance

Comparisons

Pot-Life/Property Retention

Unique to MAINCOTETM AE-58/ ProSperseTM 3001 two-part formulations is the excellent pot-life when compared to typical polyamide/ epoxy paints; see Table 1. After mixing the two components, the paint has a usable pot-life of one day, thereby reducing waste of paint which has exceeded its pot life. During the usable period, paints retain excellent application characteristics with little increase in viscosity or change in gloss in dried films toward the end of their usable pot-life.

Also, no appreciable degradation of coating performance occurred when paints were applied 24 hours after mixing, even when samples were aged at 100 ºF. However, blends that were aged 24 hours at 120 ºF became too viscous for use. We recommend that blends not be held for more than 24 hours because of the potential for intraparticle cross linking and a corresponding attrition of properties.

Table 1. Change in Viscosity after Mixing Acrylic Epoxy Coating

Acrylic-Epoxy Formulation Epoxy Polyamide Stormer Viscosity 86 70 After 24 hours Room Temperature 93 Gelled 100 °F 93 120 °F Very viscous

Hardness Development

Chart 1 demonstrates the hardness development at 25 °C and 50% humidity of MaincoteTM AE-58/

ProSperseTM 3001 starting point formulations in comparison with a conventional high gloss acrylic and commercial WB epoxy amine coatings. The acrylic epoxy coating develops hardness over 3 weeks whereas the conventional acrylic shows no increase in hardness after 2 weeks. The acrylic epoxies are significantly harder than a conventional acrylic but not as hard as the WB epoxy amine coating.

Chart 1. Hardness Development of Acrylic Epoxy, High Gloss Acrylic, and a Commercial Epoxy Amine Films as a Function of Cure Time (2-3 mils on untreated Aluminum).

0

20

40

60

80

100

120

140

3 7 14 21

Cure Time (RT, Days)

Ko

nig

Ha

rdn

es

s (

se

c)

High Gloss

Semi Gloss

High Gloss Rapid

Cure

Semi Gloss Rapid

Cure

High Gloss Acrylic

Commercial WB

Epoxy/Amine

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Exterior Gloss/Color Change Resistance

Coatings based on MAINCOTETM AE-58/ ProSperseTM 3001 have been exposed to accelerated weathering in a QUV chamber and show improved gloss retention and yellowing resistance over a typical solvent borne or water borne polyamide/epoxy coatings See Table 2. After 1000 hours of QUVA exposure the change in yellowness is 0.56 for the High Gloss Rapid Cure whereas the Commercial WB Epoxy Amine shows an increase of yellowness of 3.81. The largest change in 60 gloss (-9.9) is also for the High Gloss Rapid Cure Coating whereas the Commercial WB Epoxy dropped more than 55 in this period. By comparison a 100% acrylic dropped 3.7 units.

Table 2. Change in Color and Gloss after 1000 hours QUVA Dry Exposure

High Gloss

Semi Gloss

High Gloss Rapid Cure

Semi Gloss Rapid Cure

High Gloss Acrylic

Commercial WB Epoxy Amine

ΔL* -0.08 -0.22 -0 -0.5 -0.01 -0.98

Δa* 0.05 0.04 0.1 0.03 0.01 -0.35

Δb* -0.27 0.02 1.2 0.81 -0.61 3.81

ΔGloss (20°) -10 -0.5 -16 -1 -0.8 -72.8

ΔGloss (60°) -3.8 -2.5 -11 -3.1 -3.7 -55.29

ΔGloss (85°) -2.1 -4 -4 -0.8 -2.5 -5.6

Stain and Solvent Resistance

Waterborne acrylic/epoxy coatings based on MAINCOTETM AE-58/ ProSperseTM 3001 resist stains and solvents better than standard solvent borne polyamide/epoxy coatings or industrial alkyd coatings; see Table 3. After a 15 minute spot test with various solvents, the acrylic/epoxy coatings softened comparably to the solvent epoxy except where they were more resistant to Butyl Cellosolve. Both epoxy coatings outperformed the alkyd.

A number of staining agents were tested by leaving the stain in contact with the coating for 24 hours prior to removal with household cleanser. The most severe stains tested were mustard, coffee, red ink, coke, and grape juice. The red ink stained the alkyd heavily and lightly stained the polyamide/epoxy coating whereas the acrylic/epoxy coating was untouched. Mustard also discolors the polyamide/epoxy and the alkyd coatings but has little staining effect on the aqueous system.

CORROSION RESISTANCE

Acrylic/epoxy coatings have good flash rust and early rust resistance which makes them good direct-to-metal coatings. Topcoats offer barrier corrosion resistance comparable to their solventborne counterpart while primers exhibit adequate X-scribe (damaged) protection.

Photographs 1 through 3 are five year ocean front exposures showing the performance of MAINCOTETM AE-58/ ProSperseTM 3001 by itself and in mixed systems. Photograph 1 shows the

MAINCOTETM AE-58 barrier resistance while Photograph 2 shows its X-scribe corrosion resistance.

In both cases, the WB acrylic/epoxy compares favorably to a commercial solvent borne polyamide epoxy system. Photograph 3 shows waterborne as well as solvent borne topcoats over WB

acrylic/epoxy as a universal primer. MAINCOTETM AE-58/ ProSperseTM 3001 can also be used as a

topcoat over solvent borne primers.

https://ecenter.rohmhaas.com/webrvr/Doc/0/J7NM8PQ07EFKFAJCE89DGNR907/technical%20literature.htm#Table 4

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Table 3. Resistance Properties of Acrylic Epoxy, SB Epoxy Polyamide, and Alkyd Paints to Solvents and Staining

3-Weeks Air Dry

Solvent Resistance AE-58/3001 Epoxy Polyamide Alkyd

MEK Rubs to Remove >300 >300 120 Lifted

15-Minute Spot Tests

MEK Mod. Soft Mod. Soft Lifted

Toluene Mod. Soft Mod. Soft Lt. Soft

Gasoline Lt. Soft Lt. Soft Lt. Soft

Butyl Cellosolve Lt. Soft Mod. Soft Mod. Soft

Stain Resistance

24-Hour Spot Tests

Mustard OK Lt. Stain Med. Stain

Coffee OK Ok Ok

Red Ink OK Lt. Stain Heavy Stain

Soda Ok OK OK

Grape Juice OK OK OK

24-hr immersion on concrete

HCl No Effect No Effect No Effect

NaOH No Effect No Effect Dissolved










Formulation

Effects

Coalescent and Co-solvent Effects

The type and level of coalescents and co-solvents in a formulation can be critical to the balance of properties attained, particularly the early film properties. Water-soluble coalescents such as butyl Cellosolve™ or butyl Carbitol™ are generally not recommended as the sole coalescent for direct-to-metal maintenance paints because they do not develop rapid corrosion resistance, particularly early rust resistance. The recommended coalescent package, DowanolTM DPnB/Optifilm 400, gives good early water resistance and corrosion properties. The temperature at which a latex forms a continuous film is termed the minimum film formation temperature (MFFT) and is strongly dependent upon the coalescent used. Table 4 gives the MFFT for MaincoteTM AE-58 for a variety of widely used coalescent solvents at 10% on resin solids. The most efficient coalescents are Dowanol DPnB, Optifilm 400, and Texanol. The epoxy cross linker is also an effective reactive coalescent at the recommended formulation levels.

Table 4. Effect of Coalescent Solvent on Minimum Film Formation Temperature.

Coalescent Solvent Level (%) On Resin Solids MFFT (visual, °C)

None 0 47.0

Dowanol DPnB 10 21.2

Methyl Carbitol 10 39.5

Texanol 10 21.9

Optifilm 400 10 21.5

Dowanol DPM 10 30.1

Dowanol diEPH 10 25.4

ProSperse 3001 24 25.8

Dowanol DPnB and ProSperse 3001 10 & 24 5.4

Texanol and ProSperse 3001 10 & 24 9.0

Optifilm 400 and ProSperse 3001 10 & 24 6.9

Formulations with polymer-partitioning coalescents need water soluble co-solvents, such as DPM or propylene glycol to obtain freeze/thaw resistance. Excessive levels of propylene glycol or ethylene glycol detract from early rust resistance in direct-to-metal applications. The choice of coalescent and cosolvent can affect drying times, low-temperature film formation, gloss, heat stability, etc. of the paint.

Drying/Cure Times/Hardness Development

Drying times can be increased by the use of faster-evaporating coalescents or co-solvents or by lowering the epoxy content, but the effects of these on other properties, such as gloss and early rust, should be examined.

Heat Stability

All formulations pass accelerated heat age stability tests (i.e., 14 days aging at 40 ºC, See Table 5). Changes in coalescent and co-solvent can also change a paint's stability due to a change in the swellability of the polymer. Any change in solvent should be evaluated for its effect on paint stability. Dispersing agents and their level may be critical to the early rust performance and overall corrosion protection of a coating. The level of dispersing agent should be no higher than that necessary for adequate dispersion/paint stability. Tamol® 165 dispersant is a good starting dispersant for finishes




based on MAINCOTETM AE-58. Other dispersant types could diminish corrosion resistance.

Table 5. Properties of Acrylic Epoxy Starting Point Formulations.

Property High Gloss

Semi Gloss

High Gloss Rapid Cure

Semi Gloss Rapid Cure

High Gloss Acrylic

Commercial WB Epoxy Amine

Gloss (20°) 55 4 25 3 48 79

Gloss (60°) 82 25 66 23 76 94

Gloss (85°) 96 66 88 66 96 94

Change in KU Viscosity (2-Week @ 40 °C)

-2.7 -1.3 12.3 7.4 NA NA

Konig Hardness (3-Week Cure) 56 54 82 94 18 131

MEK Double Rubs (1-Week Cure) >300 >300 >400 >400 71 >300

Reactive Pigments

Many variables can affect the stability of a paint containing a reactive pigment. Following is a list of factors that can have a significant impact on the paint stability of a formulation.

1. Extender types and levels (soluble components) 2. Dispersant type 3. Coalescent type and level 4. PVC 5. Degree of stability required

Our technical literature provides starting points that meet our criteria for metal protection and heat-age stability. These starting points are intended to demonstrate the potential for a formulation approach. If factors such as the level of reactive pigment or the level of coalescent are changed, instability may occur and the consequences of any change must be checked by the formulator. Also, imparting excessive shear due to color shading or working in a “hot” plant can impact the viscosity stability of a paint and these conditions should be evaluated before the actual production of paint on a large scale.

Thickeners

Nonionic urethane thickeners, such as ACRYSOLTM RM-2020NPR, ACRYSOLTM RM-8W or ACRYSOLTM RM-845, and ACRYSOLTM RM-12W are a must to maintain good corrosion resistance. ACRYSOL RM-2020NPR is recommended for brushing/roller applications. ACRYSOL RM-845 and ACRYSOL RM-12W, which give a lower high shear viscosity, are more suitable for airless spray formulations.

Acrylic/Epoxy Ratio

The formulations presented in this brochure contain elevated levels of epoxy to improve corrosion resistance and film formation. Lower epoxy levels, near stoichiometric, give slightly faster drying times and slightly higher gloss but sacrifice corrosion resistance and film formation.




Co-Curing Agents

The amine hardener, D.E.H.TM 39 can be used to increase the rate of cross linking and the cross link density in the acrylic epoxy film. Results (See Chart 1) show that hardness and solvent resistance develop more rapidly and reach higher ultimate levels as well. In some cases, performance approaches standard conventional solvent borne epoxy polyamides. These gains, however, come at the slight expense of salt-spray corrosion resistance, acid resistance, yellowing, and decorative durability. The overall effect of an amine accelerator is the movement of the balance of properties towards that of a conventional solvent borne epoxy coating. An amine accelerator provides the coating manufacturer with more latitude to create formulations tailored to specific applications.




Standard Maintenance Gloss Topcoat/DTM - Formulation 83792-33

Material Name Pounds Gallons

Part A

Grind

Water 83.19 9.97

Dowanol DPnB 34.02 4.46

Ammonia (28%) 3.36 0.45

Tamol 165A 7.59 0.86

Triton CF-10 2.85 0.33

Tego Foamex 1488 1.50 0.18

Ti-Pure R-706 217.65 6.52

Water 17.29 2.07 Grind at 2000 RPM for 10 minutes

Grind Sub-total 367.45 24.82

LetDown

Maincote AE-58 519.66 60.33

Tego Foamex 1488 2.11 0.25

Sodium Nitrite (15%) 12.29 1.35

Acrysol RM-2020 NPR 5.23 0.60

Acrysol RM-8W 1.25 0.14

Part A Total 908.00 87.50

Part B

Premix

Water 19.07 2.28

ProSperse 3001 92.92 10.21

Part B Total 111.99 12.50

Totals 1019.99 100.00

Property Value

Total PVC (%) 18

Volume Solids (%) 37

Weight Solids (%) 49

VOC (g/L) 96

Mix Ratio 7:1

pH 8.7

KU Viscosity 94.7

ICI Viscosity 1.3

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Fast-Curing Maintenance Gloss Topcoat - Formulation 83792-35C


Part A

Grind

Water 81.67 9.78


Ammonia (28%) 3.30 0.44

Tamol 165A 7.45 0.84

Triton CF-10 2.80 0.32

Tego Foamex 1488 1.47 0.18

D.E.H. 39 14.87 1.82

Ti-Pure R-706 213.69 6.40

Water 15.11 1.81 Grind at 2000 RPM for 10 minutes


LetDown

Maincote AE-58 510.21 59.23

Tego Foamex 1488 2.07 0.25





Part B

Premix

Water 20.62 2.47

ProSperse 3001 91.23 10.03


Totals 1016.34 100.00

Property Value

Total PVC (%) 17



VOC (g/L) 92

Mix Ratio 7:1

pH 10.0

KU Viscosity 97.2

ICI Viscosity 1.5






Standard Semi Gloss Topcoat/DTM - Formulation 83792-29


Part A

Grind

Water 101.97 12.22


Ammonia (28%) 3.74 0.50

Tamol 165A 11.48 1.30

Triton CF-10 3.18 0.36

Tego Foamex 1488 1.67 0.20

Microtalc MP 12-50 85.63 3.80

Ti-Pure R-706 242.20 7.25 Grind at 2500 RPM for 15 minutes


LetDown

Maincote AE-58 442.16 51.33

Water 33.14 3.97

Tego Foamex 1488 2.50 0.30





Part B

Premix

Water 30.13 3.61

ProSperse 3001 80.91 8.89


Totals 1089.56 100.00

Property Value

Total PVC (%) 30



VOC (g/L) 87

Mix Ratio 7:1

pH 8.8

KU Viscosity 101

ICI Viscosity 1.6




Fast-Curing Semi Gloss Topcoat - Formulation 83792-35A


Part A

Grind

Water 100.40 12.03


Ammonia (28%) 3.69 0.49

D.E.H. 39 12.55 1.53

Tamol 165A 11.30 1.28

Triton CF-10 3.13 0.36

Tego Foamex 1488 1.64 0.20

Microtalc MP 12-50 84.32 3.74

Ti-Pure R-706 238.48 7.14 Grind at 2500 RPM for 15 minutes


LetDown

Maincote AE-58 435.37 50.54

Water 31.05 3.72

Tego Foamex 1488 2.46 0.29





Part B

Premix

Water 31.22 3.74

ProSperse 3001 79.66 8.76


Totals 1084.25 100.00

Property Value

Total PVC (%) 29



VOC (g/L) 83

Mix Ratio 7:1

pH 10.0

KU Viscosity 89.9

ICI Viscosity 1.4





Anticorrosive Maintenance Primer - Formulation 83792-23


Part A

Grind


Water 116.02 13.90

Tamol 165A 17.43 1.97

Ammonia (28%) 2.99 0.40

Tego Foamex 1488 2.67 0.32

Surfynol 104PG50 3.10 0.37

Microtalc MP 12-50 63.30 2.81

Halox SZP-391 79.13 3.15

Shieldex AC5 26.31 1.75

Ti-Pure R-706 103.34 3.09

Water 48.08 5.76 Grind at 2500 RPM for 10 Minutes


LetDown

Maincote AE-58 409.38 47.52


Tego Foamex 1488 1.85 0.22




Part B

Premix

ProSperse 3001 67.90 7.46

Water 42.07 5.04


Totals 1033.68 100.00

Property Value

Total PVC (%) 31



VOC (g/L) 99

Mix Ratio 7:1

pH 8.5

KU Viscosity 84

ICI Viscosity 0.4

https://ecenter.rohmhaas.com/webrvr/Doc/0/J7NM8PQ07EFKFAJCE89DGNR907/technical%20literature.htm#Formulation P-58-6

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Raw Material Suppliers and Web Addresses

Raw Material Supplier Name Web Address

Acrysol RM-2020 NPR Dow Chemical www.dow.com/coatings

Acrysol RM-8W Dow Chemical www.dow.com/coatings

D.E.H. 39 Dow Chemical www.dow.com/coatings

Dowanol DPnB Dow Chemical www.dow.com/coatings

Halox SZP-391 Halox www.halox.com

Maincote AE-58 Dow Chemical www.dow.com/coatings

Microtalc MP 12-50 Minerals Technology www.mineralstech.com

Shieldex AC5 W. R. Grace and Company www.grace.com

Sodium Nitrite GFS Chemicals www.gfschemicals.com

Surfynol 104PG50 Air Products www.airproducts.com

Tamol 165A Dow Chemical www.dow.com/coatings

Tego Foamex 1488 Tego www.tego.us/

Ti-Pure R-706 DuPont Titanium Technologies

www.dupont.com/titanium_techno

logies

Triton CF-10 Dow Chemical www.dow.com/coatings

XZ 92598 Dow Chemical www.dow.com/coatings

Handling

Precautions

Before using this product, consult the Material Safety Data Sheet (MSDS)/Safety Data Sheet (SDS) for details on product hazards, recommended handling precautions and product storage.

Storage Store products in tightly closed original containers at temperatures recommended on the product label.

Disposal

Considerations

Dispose in accordance with all local, state (provincial) and federal regulations. Empty containers may contain hazardous residues. This material and its container must be disposed in a safe and legal manner. It is the user's responsibility to verify that treatment and disposal procedures comply with local, state (provincial) and federal regulations. Contact your Dow Coating Materials Technical Representative for more information.

Product

Stewardship

Dow has a fundamental concern for all who make, distribute, and use its products, and for the environment in which we live. This concern is the basis for our product stewardship philosophy by which we assess the safety, health, and environmental information on our products and then take appropriate steps to protect employee and public health and our environment. The success of our product stewardship program rests with each and every individual involved with Dow products - from the initial concept and research, to manufacture, use, sale, disposal, and recycle of each product.

Customer Notice Dow strongly encourages its customers to review both their manufacturing processes and their applications of Dow products from the standpoint of human health and environmental quality to ensure that Dow products are not used in ways for which they are not intended or tested. Dow personnel are available to answer your questions and to provide reasonable




technical support. Dow product literature, including safety data sheets, should be consulted prior to use of Dow products. Current safety data sheets are available from Dow.

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Notice: No freedom from any patent owned by Dow or others is to be inferred. Because use conditions and applicable laws may

differ from one location to another and may change with time, Customer is responsible for determining whether products and

the information in this document are appropriate for Customer's use and for ensuring that Customer's workplace and disposal

practices are in compliance with applicable laws and other government enactments. The product shown in this literature may

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Documents

Maincote AE-58/ProSperse 3001 Acrylic Epoxy TM toxicity, and odor and a performance profile similar to conventional solvent borne 2-pack epoxy finishes. MAINCOTE TM ProSperseAE-58