In high-performance protective coating applications, traditional systems often require three distinct layers of different composition/formulation for optimal protection of the structure against degradation. Polyurethane topcoats have been widely used as high performance and durable coatings in these applications; however, they typically contribute little to corrosion protection and therefore are not useful as primers. In these applications, a two-coat system providing similar performance as the three-coat system would yield labor and material savings as well as reduced environmental impact. Advances in understanding the compatibility between silicone and organic resins has led to the development of a new isocyanate-free hybrid resin technology that combines the advantages of silicones (e.g., outstanding weather resistance, hydrophobicity) with the benefits of an organic binder (e.g., corrosion protection, adhesion). Excellent corrosion resistance is observed after 3000 hours (as a two-coat system) or 1000 hours (as a single coat system) salt fog exposure with no evidence of blistering, cracking or rusting. Weathering tests show exceptional gloss retention over 4000 hr QUV A or Q-Sun exposure and after >2 years South Florida exposure. The hybrid technology also has low VOC and favorable hazard labelling when compared against those of standard PU coatings.
The impact of corrosion on society is enormous. The National Association of Corrosion Engineers (NACE) estimated that the global total cost of corrosion is ~$2.5 trillion (USD), approximately 3.4% of global GDP.1 In 2016, NACE released the "International Measures of Prevention, Applications, and Economics of Corrosion Technology" which estimates that implementing corrosion prevention best practices could result in global savings between 13-15 percent of the cost of damage, or a savings between $375-875 billion (USD) annually on a global basis.2 One important aspect of this strategy is implementing state-of-the art corrosion control through advanced painting/coating technology and use of corrosion-resistance materials, resulting in competitive advantages and warranties against corrosion. A second study noted that if indirect costs of corrosion (costs incurred by lost productivity, taxes, and costs of others than the owners and operators) were also accounted for in these calculations, the total estimated cost is closer to 6% GDP.3