Bulletin 12-31

INDUSTRIAL
CHEMICALS
DIVISION
Bonding And Coating
Applications of PQ ®

Soluble Silicates
INTRODUCTION
Sodium and potassium silicates in aqueous solutions have physical and
chemical properties that are useful in bonding and coating applications.
THE PQ CORPORATION When applied as a thin layer on or between surfaces of other materials, the
silicate solution dries to form a tough, tightly adhering inorganic bond or film
CORPORATE HEADQUARTERS
which can exhibit the following characteristics:
PO Box 840
Valley Forge, PA 19482-0840 ● Low cost
Phone: 800-944-7411
● Non-flammable
IN CANADA ● Resistant to temperatures up to 3000oF
National Silicates ● Odorless and non-toxic
Phone: 416-255-7771
● Moisture resistant
IN MEXICO ● Bondable to metals, particles (e.g., refractory materials), fibrous materials
Silicates y Derivados, S.A. (e.g., paper, fiberglass), glass, ceramics
Phone: 011-52-55-5227-6801 ● Strong and rigid
IN EUROPE
PQ Europe Because of the low cost and versatile properties of PQ® sodium and potas-
Phone: 31-33-450-9030 sium silicates as coatings and binders, they are useful in a broad range of
applications. Typical applications include:
IN AUSTRALIA
PQ Australia Pty. Ltd. ● Adhesive for corrugated board, spiral or convolute paper tubing and fiber
Phone: 61-3-9708-9200 drums
IN TAIWAN ● Foil-to-paper lamination adhesive
PQ Silicates Ltd. ● Masonry coating/sealing
Phone: 886-2-2383-0515 ● Latex co-binder/extender
● Binders for forming fibrous materials into building products (e.g., ceiling
insulating materials, wallboard)
● Binders for briquetting, pelletizing, or agglomerating (e.g., detergents)
● Binders for ceramics or powdered metals for high-temperature coating
applications and welding rod coatings
● Paint vehicle

CHARACTERISTICS OF PQ® SOLUBLE SILICATES

Liquid sodium silicates are solutions of glasses which are made by fusing
varying proportions of sand (SiO2) and soda ash (Na2CO3). These propor-
tions are usually defined by the specific product’s SiO2/Na2O weight ratio.
PQ also offers KASIL® liquid potassium silicates in several SiO2/K2O weight
ratios. The potassium silicates are similar to sodium silicate but have proper-
ties that are better suited to some applications, e.g., when greater electrical
resistance is required.

® Registered trademarks of PQ Corporation

 The properties of the PQ liquid soluble silicates are summarized in Table I.
INDUSTRIAL Liquid silicates range in viscosity from very fluid, slightly sticky consistencies
CHEMICALS to thick substances that barely flow. As a general rule, the higher SiO2/Na2O
DIVISION ratio products (2.8 to 3.22) are used for adhesive applications.

Table II describes the properties of various powdered forms of PQ soluble

silicates used in dry mix adhesive and coating systems.

MECHANICS OF SILICATE FILM AND BOND FORMATION

Silicates are converted to solid films or bonds by two methods: (1) evapora-
tion of water (dehydration) or (2) chemical setting mechanism. These can be
used separately or in combination. Chemical setting is often used to improve
film moisture resistance, to reduce setting time, and to increase ultimate
bond strength as needed.

EVAPORATION DRYING
THE PQ CORPORATION
As water evaporates, liquid silicates become progressively tackier and more
CORPORATE HEADQUARTERS viscous. As shown in Table III, PQ’s N® sodium silicate, for example, has an
PO Box 840 initial water content of 62.4% and a viscosity (at 20oC) of 1.8 poises. With a
Valley Forge, PA 19482-0840 weight loss of 6% by evaporation the viscosity increases to 20 poises, and
Phone: 800-944-7411
after 12% weight loss, to 2,300 poises. When evaporation approaches 14%,
IN CANADA the viscosity is approximately 40,000 poises, at which point the silicate has
National Silicates in effect set. Further dehydration brings it to a final hardened condition.
Phone: 416-255-7771
Soluble silicates with higher SiO2/Na2O or SiO2/K2O ratios, such as N, O®,
IN MEXICO
Silicates y Derivados, S.A.
and KASIL #1, are more desirable for applications employing evaporation
Phone: 011-52-55-5227-6801 drying than are more alkaline, lower ratio grades. The higher ratio silicates
change from an almost waterlike condition to a semi-solid state when only a
IN EUROPE small amount of water is evaporated.
PQ Europe
Phone: 31-33-450-9030
Lower ratio silicates, such as K® and RU® sodium silicates, dehydrate more
IN AUSTRALIA slowly, because their higher alkali content creates a greater affinity for water.
PQ Australia Pty. Ltd. They may require heat for drying or treatment with chemical setting agents to
Phone: 61-3-9708-9200 achieve the desired set.
IN TAIWAN
PQ Silicates Ltd. Flexibility increase in lower-ratio silicates can also result from their tendency
Phone: 886-2-2383-0515 to hold onto water more tenaciously than higher ratio silicates and thus have
some degree of internal plasticization of the film by the residual water.
Because the low-ratio silicates tend to retain more water, they are less brittle
than the higher ratio silicates.

Curing. For silicate bonds or films to become impermeable and relatively

insoluble, water must be completely removed. Air drying alone usually is not
adequate for films or bonds that will be exposed to weather or high moisture
conditions. For such applications, heat curing is usually recommended.
Initially, the temperature should be increased gradually to 200-210oF to slow-
ly remove excess water. Then final curing can be done at 300 to 400oF.
Heating too quickly may cause steam to form within the film, resulting in blis-
tering or puffing when the steam is released. For some applications, where
an insulated coating is desired, this intumescent property can be useful.
Infrared and microwave heating have been used successfully for curing sili-
cate systems.
 CHEMICAL SETTING
INDUSTRIAL Liquid sodium and potassium silicates also can be reacted with a variety of
CHEMICALS acidic or heavy metal compounds to produce solid, insoluble bonds or films.
DIVISION
Neutralizing an alkali silicate with acidic materials (e.g., aluminum sulfate)
polymerizes the silica and forms a gel. This produces a bond or film on sur-
faces where gellation occurs. Chemical setting agents that can be used in
this manner include: mineral and organic acids, carbon dioxide (CO2) gas,
and acid salts such as sodium bicarbonate and monosodium phosphate
(NaH2PO4).

Multivalent metal compounds react with silicate solutions to form coatings or

bonds by precipitation of insoluble metal silicate compounds.

Chemical setting reactions generally occur rapidly, and these materials fre-
quently are applied as an after-treatment. Calcium chloride, magnesium sul-
THE PQ CORPORATION fate, aluminum sulfate, borax, and sodium metaborate used in this manner
CORPORATE HEADQUARTERS
are generally applied as 5 to 10% solutions.
PO Box 840
Valley Forge, PA 19482-0840 Chemical setting agents that dissolve slowly in water, such as finely divided
Phone: 800-944-7411 zinc oxide or sodium silico fluoride, can be used for silicate binders or coat-
ings that exhibit longer working lives. These agents usually are used at a
IN CANADA
National Silicates level of approximately 7% by weight based on the weight of liquid silicate.
Phone: 416-255-7771 Silico fluoride is particularly effective for ambient temperature curing proce-
dures. Excellent water resistance is obtained when zinc oxide is used and
IN MEXICO the bond or coating is cured at 200 to 220oF.
Silicates y Derivados, S.A.
Phone: 011-52-55-5227-6801
Some chemical setting agents will only react with the silicate at elevated
IN EUROPE temperatures. Kaolinitic clays and minerals, which decompose at 400 to
PQ Europe 500oF into acidic compounds, are examples of this type of setting agent.
Phone: 31-33-450-9030

IN AUSTRALIA PROPERTIES OF SILICATE BONDS AND FILMS

PQ Australia Pty. Ltd.
Phone: 61-3-9708-9200 Moisture Resistance
Silicate films and bonds are highly impermeable to moisture and weathering
IN TAIWAN
PQ Silicates Ltd. when proper curing or setting procedures are used. The use of zinc oxide as
Phone: 886-2-2383-0515 a chemical setting agent is especially desirable since, after curing at 200 to
220oF, it produces films capable of actually shedding water.

Heat Resistance
When silicate films are completely dehydrated, they provide excellent resist-
ance to high temperature. Most silicates used for coatings or binders have
softening points of approximately 1200oF and flow points of 1500 to 1600oF
(see Table IV).

Resistance to higher temperatures can be achieved by adding clay to the

formulation. Depending on the aluminum or magnesium content of the clay,
service temperatures up to 3200 to 3400oF are possible due to the formation
of a ceramic bond.

Mixtures of copper, nickel, chromium and stainless steel powders in the sili-
cate vehicle provide high temperature-resistant coatings for metals.
 TABLE 1. Typical Properties of PQ® Liquid Sodium and Potassium Silicates
INDUSTRIAL
SODIUM SILICATES
CHEMICALS
VISCOSITY DENSITY
PRODUCT WT. RATIO
DIVISION AT 20oC
SiO2/Na2O % Na2O % SiO2 o CHARACTERISTICS
(Poises) Be lb./gal
N® 3.22 8.90 28.7 1.8 41.0 11.6 Syrupy liquid
O® 3.22 9.15 29.5 4.0 42.2 11.8 Thick liquid
STIXSO® RR 3.25 9.22 30.0 8.3 42.7 11.8 Thick liquid
K® 2.88 11.00 31.7 9.6 47.0 12.3 Sticky, heavy liquid
RU® 2.40 13.85 33.2 21.0 52.0 13.0 Heavy syrup
D® 2.00 14.70 29.4 4.0 50.5 12.8 Syrupy, alkaline liquid
C® 2.00 18.00 36.0 700.0 59.3 14.1 Thick, alkaline liquid

POTASSIUM SILICATES
VISCOSITY DENSITY
PRODUCT WT. RATIO
AT 20oC
SiO2/Na2O % Na2O % SiO2 o CHARACTERISTICS
(Poises) Be lb./gal
KASIL® #1 2.50 8.30 20.8 0.4 29.8 10.5 Thin syrup
KASIL® #6 2.10 12.65 26.5 10.5 40.3 11.6 Syrupy liquid

The properties shown are typical values, not manufacturing specifications

THE PQ CORPORATION
®
TABLE II. Typical Properties of PQ Powdered Sodium Silicates
CORPORATE HEADQUARTERS
PO Box 840 PRODUCT WT. RATIO DENSITY
Valley Forge, PA 19482-0840 SiO2/Na2O % Na2O % SiO2 % H 20 lb./ft3 CHARACTERISTICS
Phone: 800-944-7411 SS® 65 Pwd. 3.22 23.1 74.4 0.0 88 Through 65 mesh
G® 3.22 19.2 61.8 18.5 44 Through 100 mesh
IN CANADA GA® 2.40 23.8 57.2 17.5 38 Through 100 mesh
National Silicates GD® 2.00 27.0 54.0 18.0 46 Through 100 mesh
Phone: 416-255-7771 The properties shown are typical values, not manufacturing specifications

IN MEXICO
Silicates y Derivados, S.A. ®
TABLE III. Effects of Evaporation on Viscosities of PQ Liquid Sodium Silicates
Phone: 011-52-55-5227-6801
PRODUCT
Viscosities at 200C (Poises) APPROXIMATE WT. LOSS
WT. RATIO
IN EUROPE NAME SiO2/Na2O INITIAL 6% WT. LOSS 12% WT. LOSS FOR INITIAL SET- %
PQ Europe N® 3.22 1.8 20 2,300 13.6
Phone: 31-33-450-9030 O® 3.22 4.0 120 20,000 11.2
K® 2.88 9.6 150 10,000 12.0
IN AUSTRALIA
PQ Australia Pty. Ltd.
Phone: 61-3-9708-9200 TABLE IV. High Temperature Properties of Soluble Silicates in Anhydrous State

IN TAIWAN APPROXIMATE APPROXIMATE

PQ® PRODUCTS SOFTENING POINT1 FLOW POINT2
PQ Silicates Ltd. 0F(0C) 0F(0C)
Phone: 886-2-2383-0515
N, O, N 38,
G, SS 65 Pwd. 1200(649) 1545(840)
K 1185(640) 1520(827)
RU 1140(615) 1455(790)
D, C, GD, SS-C Pwd. 1095(590) 1400(760)
B-W 1050(565) 1345(729)

KASIL #1 est. 1280/1360(693/738) 1660(904)

KASIL #6 est. 1280/1360(693/738) 1635(890)

1Viscosity reaches 4 x 107 poises

2Viscosity reaches 105 poises
 Electrical Properties
INDUSTRIAL
When completely dehydrated, sodium and potassium silicates exhibit good
CHEMICALS dielectric properties. PQ’s N sodium silicate (3.22 SiO2/Na2O ratio), when
DIVISION dehydrated, has a specific resistance of approximately 3 x 1010 ohm-cen-
timeters - about the same as common plate glass. Electrical resistance is
lower when more alkaline (lower SiO2/Na2O ratio) sodium silicates are used.

Potassium silicates, when fully dehydrated, exhibit greater electrical resist-

ance than sodium silicates. Maximum resistance is obtained by combining
selected proportions of potassium and sodium silicates.

UV Transmission
Silicate films are generally stable to UV light exposure. Specially clarified
sodium silicate solutions, such as PQ’s E® silicate, transmit 92 to 98% of
light in wave lengths ranging from 430 to 700 millimicrons. Below 400 mil-
limicrons transmission drops off rapidly, exhibiting a value of approximately
THE PQ CORPORATION 40% at 325 millimicrons.
CORPORATE HEADQUARTERS
PO Box 840 UV absorption is usually a function of the type of filler or pigment used in a
Valley Forge, PA 19482-0840 silicate film or adhesive. A potassium silicate coating pigmented with zinc
Phone: 800-944-7411 oxide proved satisfactory for use on space vehicles requiring solar radiation
IN CANADA
absorption and infrared emittance.
National Silicates
Phone: 416-255-7771 Opacity and Color
Silicate films can be made opaque by the use of titanium dioxide or alu-
IN MEXICO minum pigments. Fillers such as clay are used for semi-opaque films. Alkali-
Silicates y Derivados, S.A.
Phone: 011-52-55-5227-6801 resistant pigments are necessary for use with silicate vehicles. The follow-
ing are suggested: white—titanium dioxide; red—lime-free iron oxide;
IN EUROPE blue—ultramarine; green—chrome oxide; yellow—ochre; brown—umbers or
PQ Europe siennas; black—grease-free carbon black.
Phone: 31-33-450-9030

IN AUSTRALIA When silicate coatings are used on paper or other materials, the coating's
PQ Australia Pty. Ltd. alkalinity may darken the material's color. The addition of 0.5 to 5.0% hydro-
Phone: 61-3-9708-9200 gen peroxide, based on the weight of the silicate, may be helpful.
IN TAIWAN
PQ Silicates Ltd. Flexibility
Phone: 886-2-2383-0515 Silicate coverings or adhesives alone generally are not suitable where a
high degree of flexibility is required. However, a moderate degree of flexibili-
ty is obtained by the addition of plasticizers to the silicate solution. Typically,
1 to 5% by weight of sugar, glycerine or other polyhydric alcohols are used.
Up to 30% of sorbitol can be used, provided the silicate solution is diluted to
avoid excessive thickening. Rubber latices can also be employed as plasti-
cizers. Incorporation of finely ground clays and similar fillers will improve
flexibility to some extent.

Combinations with Latex Emulsions

Soluble silicates can be incorporated into latex-based coating or adhesive
formulations as part of the total binder solids. The advantages include sig-
nificant cost savings, increased flame retardancy, more stable formulations,
increased adhesive strength (depending on the substance), and increased
resistance to heat, light, oxidation, and microbial degradation. Rheology
modification is also possible when silicates are added to some latex emul-
 sions. Generally, the inorganic silicate will raise the apparent glass transition
INDUSTRIAL temperature (Tg) of the mixed latex/silicate binder system.
CHEMICALS
DIVISION Soluble silicates are generally compatible with alkaline aqueous emulsions
(pH above 8). They are compatible with aqueous dispersions of polymers
such as styrene-butadiene, polystyrene, neoprene, polyvinyl chloride,
polyvinyl acetate, acrylonitrile copolymers, acrylic polymers and copolymers.

BONDING AND COATING APPLICATIONS

Surface Characteristics
Since silicate coatings and adhesives are inorganic aqueous polymers
they perform most effectively on hydrophilic, non-oily surfaces, where they
achieve proper wetting and, hence, maximum adhesion. Generally, a thin
continuous silicate film between the surfaces to be bonded provides opti-
mum adhesion.
THE PQ CORPORATION

CORPORATE HEADQUARTERS
Coating Metals. In the coating or bonding of metals and similar rigid mate-
PO Box 840 rials, the difference in coefficient of thermal expansion between silicate and
Valley Forge, PA 19482-0840 the bonded surfaces may be a limiting factor. However, where temperatures
Phone: 800-944-7411 are relatively constant and there is no mechanical strain, ultrathin silicate
films which have been dehydrated by baking can hold permanently. A thin
IN CANADA
National Silicates silicate film has greater elasticity and is more serviceable than a thick one
Phone: 416-255-7771 for coating or bonding metal. A compatible surfactant in the amount of
0.05 - 0.1% by weight relative to the silicate will aid surface wetting. Good
IN MEXICO adhesion to metal often can be obtained after the surface has been thor-
Silicates y Derivados, S.A.
Phone: 011-52-55-5227-6801
oughly cleaned with alkali (e.g. with a PQ METSO® sodium metasilicate) or
solvent or is degreased or sandblasted.
IN EUROPE
PQ Europe Typical metal coating applications are:
Phone: 31-33-450-9030
● Thin silicate films on lithographic plates to render the surface area
IN AUSTRALIA hydrophilic and acceptable for further processing.
PQ Australia Pty. Ltd.
Phone: 61-3-9708-9200 ● Steel ingots coated with thin films of silicate to protect against corrosion.
● Silicate films on silver flatware to protect against scratches during manu-
IN TAIWAN facture.
PQ Silicates Ltd.
Phone: 886-2-2383-0515
● A thin coating of silicate - about .001" thickness - protects stainless steel
colored by controlled oxidation, rendering it resistant to atmospheric con
ditions, abrasion and fumes as well as to cleaning agents commonly
used on architectural or decorative finishes. The silicate film does not
change the color of the coated steel but rather adds a depth of color to
the steel sheet. Baking at about 480oF cures the silicate and considerably
delays any moisture uptake. The silicate coating is smooth, glossy and
resistant to scratching.
● A silicate coating to impregnate aluminum for ferrous castings by special
vacuum and pressure techniques to reduce their porosity.
● Anodized aluminum surfaces sealed with sodium silicate solutions.
● Sodium or potassium silicates used as a binder for zinc dust in the appli
cation of zinc-rich primers on metal surfaces exposed to moisture or
weather.
● Coating of the interiors of bulk rail cars that have been cleaned or sand
blasted, to act as a barrier for the metal from corrosive cargos such as
salts.
 Paper and Fibrous Products. Soluble silicates are ideal for bonding,
INDUSTRIAL laminating or impregnating cellulose and other types of fibrous materials,
CHEMICALS particularly in the manufacture of various building and insulating products.
DIVISION In addition to their fire-proofing qualities, silicate adhesives or coatings pro-
vide good wet strength as well as dry bond strength and excellent overall
adhesion.

Silicate has been used alone as a greaseproofing agent for coating paper
carton stock. It may be used as a priming coat on paper to prevent paraffin,
which provides water resistance, from soaking excessively into the paper.

Silicates have been used in combination with styrene-butadiene latex for

exceptional protection of clay-filled paper board and sulfite-lined cylinder
board against turpentine, cotton seed oil, and lard oil. A silicate-latex combi-
nation also protects against transmission of water vapor.

THE PQ CORPORATION Powdered or Granular Materials. For bonding powdered or granular mate-
CORPORATE HEADQUARTERS
rials a thin silicate film should envelop each particle. Depending on the parti-
PO Box 840 cle size and density of the material, this usually requires from 2 to 5% N sili-
Valley Forge, PA 19482-0840 cate relative to the weight of the solids to be agglomerated. Perlite wallboard
Phone: 800-944-7411 or acoustical tile and colored roofing granules are examples of the success-
ful bonding and coating of particulate materials with soluble silicates.
IN CANADA
National Silicates
Phone: 416-255-7771 SPECIAL ADHESION AND BONDING APPLICATIONS
IN MEXICO Information about several specific applications of PQ® soluble silicates are
Silicates y Derivados, S.A. provided in several detailed technical bulletins:
Phone: 011-52-55-5227-6801
Bulletin 12-30 - “Sodium Silicates: Versatile Inorganic Adhesives”
IN EUROPE
Bulletin 24-1 - “PQ® Soluble Silicates in Refractory and Chemical Resistant Cements”
PQ Europe
Phone: 31-33-450-9030 Bulletin 34-1 - “Treating Concrete with PQ® Sodium Silicates”

IN AUSTRALIA Environmental Acceptability

PQ Australia Pty. Ltd. Sodium silicates are made from sand and alkali and are universally judged
Phone: 61-3-9708-9200
to be nontoxic and ecologically harmless in fresh water environments. They
IN TAIWAN are completely inorganic and therefore do not present hazards of explosion
PQ Silicates Ltd. or flammability.
Phone: 886-2-2383-0515
Safety and Handling Information
Depending on their degree of alkalinity, soluble silicates may irritate or burn
the skin and eyes on contact. Precautions for handling, provided on the
labels of packages, should be observed. Material Safety Data Sheets are
available for all products for further guidance.

Application Assistance
For additional information and/or assistance, contact PQ’s Industrial
Chemicals Division. Our technical service representatives will be happy to
Information herein is accurate to the best of our
knowledge. Suggestions are made without war-
assist you in selecting and evaluating PQ® sodium silicates for your specific
ranty or guarantee of results. Before using, user application.
should determine the suitability of the product for
his intended use and user assumes the risk and
liability in connection therewith. We do not sug-
gest violation of any existing patents or give per-
mission to practice any patented invention with-
out a license.

12-31/1002