Chemical-Resistant Coatings & Tank Linings — Formulation Guide
About this book
Chemical-Resistant Coatings & Tank Linings — Formulation Guide is a comprehensive technical reference covering 40 validated starting-point formulations across every major chemical-resistant coating and lining system — from economy solventborne BPA epoxy through premium epoxy novolac, glass flake-reinforced epoxy, vinyl ester, furan resin, aliphatic polyurethane (both solventborne and waterborne), potassium silicate inorganic coatings, and glass-fibre reinforced polymer (GRP/FRP) tank laminates. Written for protective coatings formulators, paint manufacturers entering the chemical-resistant segment, and plant engineers specifying linings for chemical storage, process vessels, and secondary containment.
The technology
The handbook develops the resistance mechanism of each binder system from first principles. Epoxy systems: DGEBA/EPN novolac chemistry, EEW/AHEW stoichiometry, glass flake barrier extension, phenalkamine cold-cure and phenolic-amine high-temperature curing options. Vinyl ester: free-radical polymerisation, BPA vs novolac backbone, styrene vs reactive diluent tradeoffs, MEKP/cobalt initiation and MEKP safety sequencing. Furan resin: acid-catalysed condensation, SiC aggregate for abrasion, antistatic carbon for conductive linings. Aliphatic PU: HDI/IPDI trimers, NCO:OH stoichiometry, WB PUD dispersion film formation, UV/HALS stabilisation for outdoor service. Potassium silicate: inorganic condensation cure, fluorosilicate 2-pack chemistry, zinc-silicate galvanic protection. FRP: resin/glass fibre selection, Vf calculation, hand lay-up sequence, post-cure requirements.
Inside the formulations
All 40 formulations span Economy, Mid-range, Premium and Specialty tiers across 10 sub-categories. Every 2-pack block provides IUPAC-named Part A and Part B component tables with % w/w and sourcing tier, EEW/AHEW or NCO:OH stoichiometric check, PVC/CPVC analysis, VOC per EPA Method 24, condensed manufacturing SOP, QC targets with test method citations (ISO 2812, ASTM C581, ISO 4624, NACE SP0188), DFT recommendation, pot life, cure schedule, stability and shelf life, variants and modifications, and a scientific basis paragraph. FRP laminates replace DFT with laminate thickness and Vf, and potassium silicate entries note inherent water-mixed inorganic chemistry.
What you get
- 40 starting-point formulations across 10 chemical-resistant binder systems
- All 2-pack systems as Part A + Part B with EEW/AHEW stoichiometric verification
- PVC/CPVC analysis and VOC per EPA Method 24 for every coating formulation
- Glass flake epoxy formulations with 15–25% loading and squeegee high-build options
- Styrene-free vinyl ester alternative and explicit MEKP/cobalt safety sequencing
- FRP laminate formulations with hand lay-up SOPs, Vf calculations and post-cure schedules
- Potassium silicate 1-pack, fluorosilicate 2-pack and zinc-silicate variants
- Chemical resistance matrix: acids, alkalis, solvents, hydrocarbons, oxidising agents by binder
- QC targets tied to ISO 2812, ASTM C581, ISO 4624, ISO 16443, NACE SP0188
- REACH SVHC flagging: styrene, crystalline silica, BPA, TETA, IPDA throughout
- Appendix C chemical resistance compatibility matrix across all 10 binder systems
Technical details
- Format
- A4 PDF · instant digital download
- Extent
- ~300 pages · 40 formulations · 10 sub-categories
- Chemistry
- SB & WB BPA Epoxy · Epoxy Novolac · Glass Flake · Vinyl Ester · Furan · Aliphatic PU (SB & WB) · Potassium Silicate · FRP/GRP
- Standards
- ISO 2812-1 · ASTM C581 · ISO 4624 · ISO 16443 · NACE SP0188 · IMO PSPC Res.MSC.288 · EPA Method 24 · ISO 9227
- Tiers
- Economy · Mid-range · Premium · Specialty
- Audience
- Protective coatings formulators · industrial paint manufacturers · corrosion & plant engineers · tank lining contractors
- Series
- Paints & Coatings Handbook Series · Volume 2 · Industrial Protective Coatings · Book 2.06
Chemical storage tanks, process vessels and secondary containment fail when the coating chemistry is wrong — get 40 validated starting-point formulations across every major chemical-resistant binder system, from BPA epoxy to furan resin and FRP laminates, engineered for immersion service in acids, alkalis, solvents and hydrocarbons.
Who is this book for?
Protective Coatings Formulator
You develop or adapt chemical-resistant coatings for tank linings, pipe coatings, secondary containment and process vessel interiors — and need complete 2-pack formulations with EEW/AHEW stoichiometry, PVC/CPVC analysis, VOC calculations, and immersion-grade QC specs already worked out across BPA epoxy, novolac, vinyl ester, furan and aliphatic PU chemistries.
Industrial Paint Manufacturer
You manufacture protective coatings and want to enter the high-value chemical-resistant segment — from economy solventborne BPA epoxy through premium glass flake laminates, styrene-free vinyl esters and potassium silicate inorganic coatings — with manufacturing SOPs, REACH/SVHC compliance notes, and raw material sourcing tiers.
Plant & Corrosion Engineer
You specify coatings for chemical plant tanks, pharmaceutical vessels, water treatment structures and petroleum storage — and need formulation-level understanding of binder chemistry, chemical resistance mechanisms, NACE/AMPP SP0188 holiday detection, ISO 2812 immersion testing, and IMO PSPC tank coating standards to evaluate products and prevent in-service failures.
Table of Contents
- Product category overview: immersion service, splash/spillage, atmospheric chemical exposure
- Chemistry of 10 binder systems: BPA epoxy, novolac, glass flake, vinyl ester, furan, aliphatic PU, potassium silicate, FRP/GRP
- Core raw materials: resins, curatives, glass flake, SiC, fibres, pigments, solvents and catalysts
- Functional additive classes: adhesion promoters, anti-settling agents, anti-skin agents, HALS/UVA stabilisers
- Specifications and grade structure: economy to specialty, immersion vs splash service, temperature service limits
- Sub-cat 01: SB BPA Epoxy (F1–F4) — polyamide, IPDA adduct, phenalkamine, PACM adduct curatives
- Sub-cat 02: WB BPA Epoxy (F5–F8) — economy WBE, mid-range, premium fast-cure, high-build mastic
- Sub-cat 03: Epoxy Novolac SB (F9–F12) — economy, mid-range phenolic amine, premium TETA-cured, 100%-solids plural-component
- Sub-cat 04: Glass Flake Epoxy (F13–F16) — 15% to 25% glass flake loading; squeegee ultra-high-build specialty
- Sub-cat 05: Vinyl Ester (F17–F20) — isophthalic PE, BPA VE, novolac VE, styrene-free BPA VE
- Sub-cat 06: Furan Resin (F21–F24) — silica-filled, SiC-filled, conductive, furan-epoxy hybrid
- Sub-cat 07: SB Aliphatic PU (F25–F28) — HDI trimer, IPDI trimer, low-VOC, fluoropolymer-modified
- Sub-cat 08: WB Aliphatic PU (F29–F32) — OH-acrylic/HDI, PUD/aliphatic, WB floor coating, self-crosslinking
- Sub-cat 09: Potassium Silicate (F33–F36) — 1-pack, SiC grade, 2-pack fluorosilicate, zinc-silicate
- Sub-cat 10: FRP/GRP Tank Linings (F37–F40) — isophthalic PE, BPA VE, novolac VE, carbon-hybrid
- Surface preparation: abrasive blast to Sa 2½, anchor profile, salt contamination, moisture limits
- Application methods: airless spray, brush/roller for repair, squeegee for high-build, hand lay-up for FRP
- Pot life management: induction, mix ratios, ambient temperature effects
- Holiday detection: NACE SP0188 wet sponge and high-voltage spark testing
- Curing: temperature correction, gradient cure for thick films, post-cure for FRP
- Inspection and QC: DFT measurement, adhesion pull-off (ISO 4624), crosshatch (ISO 2409)
- Immersion testing: ISO 2812-1 chemical immersion, ASTM C581 coupon immersion
- Adhesion: ISO 4624 pull-off, ISO 2409 crosshatch; cathodic disbondment ISO 15711
- Chemical resistance matrix: acids, alkalis, solvents, hydrocarbons, salts, oxidising agents
- Holiday detection: NACE SP0188 procedures and acceptance criteria
- Film properties: DFT (SSPC-PA 2), hardness (ISO 2815 Persoz), flexibility (ISO 6860)
- Accelerated aging: ISO 9227 salt spray, UV/condensation QUV, ISO 16443 cathodic disbondment
- REACH SVHC: styrene (IARC 2A), crystalline silica (IARC Group 1), BPA, TETA, IPDA
- VOC compliance: EPA Method 24, EU Directive 2004/42/EC, LEED credit thresholds
- Isocyanate handling: SAR mandatory for spray, IE COSHH, ATEX considerations for MMA
- IMO PSPC Res.MSC.288: dedicated seawater ballast tank coating requirements
- Waste disposal: solvent waste streams, MEKP peroxide disposal, fibre-containing FRP waste
- SDS requirements: GHS/CLP for 2-pack systems, combined SDS approach
- Appendix A — Glossary of 35+ technical terms (AHEW, CPVC, EEW, PVC, Vf, MEKP, EPN, PSPC…)
- Appendix B — Standard Test Method Index (20+ standards from ASTM, ISO, NACE, IMO)
- Appendix C — Substrate & Chemical Resistance Matrix (acid, alkali, solvent, hydrocarbon, salt service by binder)
See what's inside
Frequently asked questions
They are validated starting points. You will need to bench-test and adapt treat rates to your specific raw material lots, but you start from a working formulation — not a blank sheet.
The handbook is a PDF — high-resolution A4, printable, with bookmarks and a linked table of contents. You receive an instant download link and it is also available in your library indefinitely.
Up to 3 downloads are included with your purchase. If you need more, contact us and we will reset your download limit.
Yes. The handbook opens with a fundamentals section that explains the underlying chemistry and ingredient functions before presenting formulations — so beginners can follow the rationale, not just the recipe.
Yes. All 2-pack epoxy, PU, and vinyl ester formulations are presented as Part A (resin base) and Part B (curative/crosslinker) with complete % w/w component tables for each part, weight mix ratio, stoichiometric verification (EEW/AHEW for epoxies, NCO:OH for PUs), pot life at 25°C, and cure schedule.
Yes. Sub-category 05 includes F20 — a Styrene-Free BPA Vinyl Ester Premium formulation that uses a reactive diluent system in place of styrene monomer, meeting emerging workplace exposure limits while maintaining chemical resistance comparable to a standard BPA VE. The formulation notes the EHS driver and performance trade-offs clearly.
The handbook includes a full chemical resistance matrix (Appendix C) covering acids, alkalis, solvents, hydrocarbons, salt solutions, and oxidising agents for all 10 binder systems. In general: epoxy novolac and furan resin offer the broadest acid/alkali coverage; vinyl ester excels in oxidising acid service; aliphatic PU provides superior solvent and UV resistance; potassium silicate handles high-temperature inorganic acid service; FRP laminates allow custom resistance through resin selection.
Yes — Sub-category 10 covers FRP laminates (glass-fibre reinforced thermoset) across four formulations. Unlike coatings applied at 75–500 µm DFT, FRP laminates are built up in 2–6 mm thickness using glass cloth/mat and resin systems. The formulation blocks replace DFT with laminate thickness and Vf (fibre volume fraction), and include hand lay-up SOPs, gel coat/barrier coat/lamination sequence, and post-cure requirements.
These two chemicals must never be brought into direct contact — the combination is exothermic and can ignite or explode. The vinyl ester and FRP formulations include an explicit warning: pre-dilute MEKP in resin first, then add cobalt-promoted resin separately. This sequencing is included in every relevant SOP in the handbook.
