Corrosionpedia Explains Epoxy Primer

Epoxy primer is a sealer that produces a good surface finish on applied top coats. A two-part epoxy primer contains zinc phosphate, which acts as a corrosion-inhibiting pigment. Epoxy primers can be used to waterproof materials that consequently protect the bare metal from oxidation. A dry, very clean surface is needed before applying epoxy primer. Two-part epoxy primer needs to be mixed thoroughly before applying.

The term epoxy refers also to the epoxy resins that usually appear after curing, curing being a term that refers to a chemical process in which a material hardens due to air, heat, or chemical additives exposure. Curing occurs with the help of a catalyst in epoxy, which works as a chemical additive that increases the rate of a chemical reaction. An exothermic reaction is the result, creating a cross-linkage in the polymer. This resulting cross-linkage proves to be responsible for the rigidity and strength seen in epoxy materials.

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Since paints in the automobile and marine industries are very important for resisting corrosion (rusting), epoxy coatings are widely used as primers to improve the adhesion of the metal surface. Epoxy primers are also used in structural steel coatings for high-build thickness with the application of only one or two coats.

A two-part epoxy primer is known as a structural steel primer. It needs two components that are cured chemically through cross-linking. This two-part epoxy primer produces a film that is resistant to abrasion, chemicals and moisture. It is very suitable for use on properly prepared steel and concrete. This primer is also recommended for power plants, marine applications, water treatment plants and tank exteriors. Filler can be applied directly over epoxy primer and more epoxy applied over the filler to completely encase it in epoxy.

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Epoxy also provides some build so it can be used exclusively without any other primer/surfacer. Epoxy can be reduced 50% and used as a sealer before a base coat.

The degradation of epoxy coatings having various filler materials has been studied under natural and accelerated environmental conditions. ZnO-containing epoxy coatings show more pronounced UV stabilization characteristics, which could extend the service life of the epoxy coating compared to other filler materials exposed to same environmental conditions. The relatively minor decrease in the adhesion strength by ZnO-containing coatings indicated its better mechanical integrity and UV resistant characteristics compared to coatings containing TiO2, Fe2O3 and graphite filler materials. The addition of antioxidants and photo-stabilizers in the epoxy coatings shows excellent resistance during aggressive salt spray tests with a negligibly minor loss in the adhesion strength without any blistering.

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