Formulation
Pwd:
Process SOP (Water-borne)
- Sanitize & charge water (70–80% of total). Start agitation (6–8 m/s tip speed).
- Add dispersant, wetting agent, defoamer. Mix 5 min.
- (White grade only) Slurry TiO₂ with part water → high-shear disperse to Hegman 6–7; add to main.
- Add acrylic emulsion slowly; avoid air.
- Add wax emulsion. Mix 10 min.
- Introduce coalescent and thickener; mix 10–15 min.
- Adjust pH to 8.0–8.5 with AMP-95.
- Add preservative. Finish with water to batch weight.
- De-air 15–20 min; filter through 100–150 µm bag.
QC & Compliance
- NV % (105 °C, 1 h): spec ±1.5% of target
- Viscosity (Brookfield or Ford cup) within window
- pH (water-borne): 8.0–8.5
- Density: record (for coverage calc)
- Moisture-loss test (ASTM C156) & Curing compound performance (ASTM C309)
- Drying time (ASTM D5895)
- Reflectance (white): ≥ 60% at 570 nm (or ASTM E1347 Y-value ≥ 70)
- Freeze–thaw (3 cycles, water-borne)
- VOC by calculation or EPA Method 24 as required
- Storage: 5–40 °C; protect from frost (water-borne)
Application Guidelines
- Surface: fresh concrete, bleed water disappeared, sheen damp—not dry.
- Spray: 0.4–0.6 mm tip, low-pressure fan; Do not over-apply (puddling causes dusting/soft films).
- Coverage: Clear 160–250 mL/m²; White 200–330 mL/m².
- Second coat (hot/windy): perpendicular pass after 30–60 min.
- Compatibility: If future coatings planned, use dissipating grades (lower wax, oxidizing acrylic), and pressure-wash + light mechanical abrasion before topcoating.
- Cleanup: Water for water-borne; suitable solvent for solvent-borne.
Raw-Material Suggestions (generic)
- Acrylic emulsion: self-crosslinking, ~50% solids, MFFT ≤ 10 °C (e.g., styrene-acrylic outdoor grade).
- Wax emulsion (optional – when there is no top coat) : oxidized PE or paraffin, 30–40% solids, anionic/non-ionic type compatible with your latex.
- Coalescent: 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate (Texanol) or DPnB.
- Preservatives: MIT/BIT per local biocide law.
- TiO₂: Rutile, alumina/silica treated for water systems.
Process (concise)
- Grind: Water → dispersant → wetting agent → defoamer (small) → TiO₂; high-shear to Hegman 6–7.
- Let-down: Add acrylic emulsion slowly (low air), then wax emulsion (for wax based formulation only), coalescent, thickener, preservative.
- Adjust pH (8.0–8.5), top with water, de-air 15–20 min, filter 100–150 µm.
NOTE
Wax improves curing (moisture retention) but interferes with adhesion of later coatings. Here’s how it works and how the industry handles it:
Why Wax is Used
- Forms a hydrophobic barrier → reduces evaporation of mix water → better cement hydration.
- ASTM C309 often requires wax-modified emulsions to pass the moisture retention limit.
- Gives “guaranteed cure” in hot/windy climates.
Why Wax is a Problem for Recoating
Even after weathering, residual wax may block bonding unless mechanically or chemically removed (shot-blast, power-wash with detergent/alkali, light grinding).
Waxy surface is water-repellent and “slippery.”
Paints, sealers, tile adhesives, and screeds often show poor adhesion, peeling, or fish-eyes.
| Raw material (non-wax white, recoatable) | Example grade / trade name | Indicative Indian suppliers / contacts |
|---|---|---|
| Styrene-acrylic binder (non-crosslinking) | BASF Acronal® range | BASF India makes/distributes acrylic dispersions; Prakash Chemicals is an authorized BASF distributor. |
| Dow RHOPLEX™ acrylics | Dow RHOPLEX binder family; engage via Dow India/distributors. | |
| Arkema ENCOR® acrylics | Arkema Coating Resins India/Mumbai contacts listed. | |
| Titanium dioxide (rutile) | KMML KEMOX® RC series | Kerala Minerals & Metals Ltd (India producer). |
| Tronox TiONA®/TiKON® | Tronox India offices (Hyderabad/Mumbai). | |
| Venator TIOXIDE® | Venator in India via authorized distributors (e.g., Prakash Chemicals; S S India/Meet Marketing). | |
| Chemours Ti-Pure™ | Chemours distributor finder for India. | |
| Pigment dispersant (polycarboxylate) | BASF Dispex® AA 4040 | BASF Dispex; BASF/Prakash Chemicals supply in India. |
| Wetting agent (low-foam, silicone-free) | Evonik TEGO® Wet 500/296/288 | Evonik Coating Additives; TEGO Wet product pages/launches. |
| Dow TERGITOL™ 15-S-9 | Dow India distributors such as K.K. Chem list TERGITOL 15-S series. | |
| Coalescent | Eastman Texanol™ ester alcohol | Eastman Chemical India (New Delhi) sales office; Texanol product page. |
| Co-solvent / flow aid (glycol ether) | Dow DOWANOL™ DPnB | Dow product page; Indian distributor examples (K.K. Chem). |
| HEUR thickener (associative PU) | BASF Rheovis® PU series | BASF HEUR rheology modifiers. |
| Arkema Coapur™ HEUR | Arkema Coating Resins; Coapur HEUR range; India contact listed. | |
| Defoamer (silicone-free, recoatable) | BYK BYK-1642 / BYK-015 | BYK silicone-free defoamers; BYK defoamer range overview. |
| Evonik TEGO® Foamex 805/8850 | Evonik Coating Additives defoamers (including bio-based/non-siloxane options). | |
| In-can preservative (MIT/BIT) | LANXESS Preventol® BIT grades | BIT preservatives for aqueous coatings. |
| Arxada Proxel™ | Proxel industrial biocides; Arxada products. | |
| pH adjuster / amine | Advancion AMP-95™ | Advancion (formerly ANGUS) AMP-95; India regional contact; Brenntag India lists AMP-95. |
| pH adjuster (alkali) | Aqueous ammonia (25–28%) | Indian suppliers such as TCI India; Mysore Ammonia / Jaysons Chemical for bulk. |
Notes
- All brands shown are typical, not exclusive. Confirm local availability, grade fit (APEO-free, VOC limits), and regulatory approvals with the supplier.
- For recoatable curing compounds, keep wetting agent silicone-free and prefer silicone-free defoamers to minimize topcoat cratering/adhesion risks.
