| 1 | Metal surface preparation | Abrasion or abrasive blasting removes loose rust, mill scale, oil, and weak surface layers. The process also creates a roughened profile that improves mechanical anchoring. | Common preparation level: ISO 8501-1 Sa 2½ for blasted steel. A typical surface-profile range is approximately 25–75 µm. | The surface becomes clean, uniformly rough, and free from visible oil, dust, and loose corrosion. | Check dust, salts, surface cleanliness, and flash rust before priming. The steel should be dry and above the calculated dew point. |
| 2 | Primer and solidify-agent mixing | The epoxy resin component is combined with a curing agent, commonly an amine, polyamide, or amine-adduct type. The curing agent supplies reactive hydrogen atoms that can open epoxy rings. | Use the specified mass or volume ratio. Mix until color and consistency are uniform, normally at about 15–30 °C. | The two liquid components form a uniform coating mixture. Viscosity may gradually increase after mixing. | Incorrect ratio can leave unreacted resin or curing agent, causing softness, poor adhesion, amine blush, or reduced chemical resistance. |
| 3 | Initial epoxy-ring reaction | Amine nitrogen attacks the electrophilic carbon of an epoxy group. The epoxy ring opens and forms a stable carbon–nitrogen bond plus a hydroxyl group. | The reaction proceeds at ambient temperature and accelerates as temperature rises. Excessive heat shortens working time. | The mixed primer begins to lose flow and becomes progressively more viscous. | Observe the pot life stated for the formulation. Do not apply material that has become stringy, excessively viscous, or noticeably warm in the container. |
| 4 | Network formation | Additional epoxy groups react with primary and secondary amine sites. Multifunctional resin and curing-agent molecules create a three-dimensional cross-linked polymer network. | Typical practical application temperatures are approximately 10–35 °C, subject to the product’s technical requirements. | The wet film changes from liquid to a gel-like state and then to a firm solid. | Apply the primer within its usable pot life and maintain a uniform wet-film thickness to avoid solvent entrapment and uneven curing. |
| 5 | Film wetting and adhesion | The liquid primer wets surface irregularities and penetrates the anchor profile. Polar groups in the cured binder can interact with the oxide or hydroxide layer on prepared metal. | A common dry-film-thickness range for a single primer coat is approximately 50–100 µm, depending on the coating system. | The coating levels the surface while retaining enough texture to form a continuous protective film. | Avoid application over condensation, oil, soluble salts, or dust. Excessive thickness may increase solvent retention and curing time. |
| 6 | Surface dry and handling strength | Cross-link density increases as more epoxy and amine functional groups react. Residual solvent leaves the film while the polymer becomes less mobile. | Typical touch-dry time may be about 2–6 hours at approximately 20–25 °C, depending on film thickness and formulation. | The surface is no longer easily marked by light contact, although the film may not yet have full chemical resistance. | Protect the coating from rain, condensation, dust, and mechanical damage during the early cure period. |
| 7 | Moisture and humidity effects | Water does not normally replace the primary epoxy–amine reaction, but high humidity can cause surface blush, localized whitening, or reduced intercoat adhesion in some amine-cured systems. | A commonly controlled application range is approximately 40–70% relative humidity, with the metal temperature at least 3 °C above the dew point. | The film may appear hazy, waxy, cloudy, or uneven if moisture condenses during cure. | Measure air temperature, metal temperature, relative humidity, and dew point before and during application. |
| 8 | Full cure and protection | The cross-linked network approaches its final hardness and chemical resistance. The cured primer acts as a barrier that limits water, oxygen, and ionic movement toward the metal. | Full cure is commonly reached in approximately 5–7 days at room temperature, while lower temperatures generally extend the cure time. | The film reaches stable hardness, adhesion, and resistance to handling and many service chemicals. | Confirm cure before overcoating or placing the metal into service. Use adhesion, hardness, dry-film-thickness, and visual inspections as applicable. |