SURFACE PREPARATION & COATING

1. INTRODUCTION.
1.1.Scope
This specification covers the minimum requirements for surface preparation,
priming, painting & inspection relating to new construction projects.

1.2 Applicable International standards

The following standards and standard forms are referred in this specification and
shall be used.
SIS 05 59 00

-Swedish standard pictorial surface preparation standard

for Painting Steel Surfaces.

BS 4232

- Surface Finish of Blast-Cleaned Steel for painting.

SSPC

- System and Specifications Steel Structures Painting

Council.

BS 410

- Specification for Test Sieves.

2. DEFINATIONS.
Cure

-The hardening of recently applied paint by chemical reaction, solvent

evaporation, oxidation, heat curing ect.

High build -Describes a paint that can be applied to a surface in thick coats (of more
than 100 micron thickness) without the paint sagging.
Passivated

-The resistance to corrosion of a steel surface has been increased by the

formation of an adherent nonreactive surface layer of a ferrous salt such
as ferrous phosphate. This is normally achieved by treating the steel in a
phosphoric acid solution.

Phenolic

-A paint in which the resin incorporates the hydroxyl derivative of

benzene and produced as a distillate from coal tar.

Ester-based -A paint in which the resin is a compound of an alcohol (glycol) and an

acid (usually long-chain, e.g., linolenic or stearic).
Pot-Life

-The length of time following induction that 2 Pack paint remains in an

applyable condition as per manufacturers instruction.

NOTE: An ambient temperature in excess of that for which the pot-life has been
stated will substantially reduce pot-life.
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Shelf-Life

-The period of the time stipulated by the paint manufacturer between

manufacture and use during which the paint shows no marked
deterioration.

Thinners -The solvents for cleaning, painting equipment, or for mixing with paint in
small quantities if a decrease in paint viscosity is require.
Thixotropic -The property of a paint to decrease in viscosity when stirred and
conversely increase in viscosity when left standing.-The property is
important to maintain good pigment dispersion within a paint and to
prevent pigment sedimentation.

3. PAINTING MATERIALS.
2.1 Storage
Paint that has exceeded its marked shelf life shall not be used. Additionally shall
not be used if it has thickened to such extend that more than 5% by volume.
(10% by volume for primers) of the correct thinner is required to bring it to
application consistency.

3.2 Preparation for use

31.2.. Homogenizing.
Mixing of painting and coating materials is critical and should be carried
out under close supervision to ensure correct results. The drum should
be opened and the bulk of the liquid portion poured into a clean drum of
similar size with an open top. Stirring shall then break up the residual
stiff or lumpy paste with a wide strong wooden paddle. If the residue
cannot be worked into a smooth and uniform paste by this treatment, the
paint shall not be used. If the residue can be worked into a smooth and
uniform paste by this treatment, the liquid portion originally poured off
shall be replaced in small quantities while stirring with a power driven
stirrer moving with a figure-of-eight (8) motion.
When the paint appears to be completely uniform, it shall be boxed by
pouring repeatedly from one drum to the other. Before use, the paint
shall be strained through 100-mess metal gauze to BS-410 to remove
any skin or small lumps.
Only thinner supplied, recommended or approved by the paint
manufacturer for the particular paint type shall be used.

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Where coatings are being used containing metallic or heavy pigments
that have a tendency to settle, a power driven stirrer shall be used in a
pressure pot, or fitted in the supply drum for an airless spray pump.

32.2.. Mixing of Two component paints.

Paints, which are supplied as two components in separate containers,
shall be mixed together immediately before use and shall be applied
within the time limits specified by the manufacturer. The methods of
preparing these types of paints before use shall be as follows.
1) Oil based aluminum paints are supplied as powder or paste and
vehicle, packed in separate container in the correct proportions for
mixing. Mixing shall be carried out thoroughly and a quantity only
sufficient for 1 days work shall be mixed. Oil based aluminum
paint, unused for more than 48 hours after mixing, loses luster and
becomes grayish in color. It is then unsuitable for use as a finishing
coat. The epoxy ester based aluminium paint is supplies ready
mixed.
2) Epoxy resin based paints, high-build epoxy paints and coal-tar epoxy
paints are supplied as two components in separate container in the
correct proportion for mixing. These components shall be mixed in
the correct proportion since curing takes place by chemical reaction.
Once mixed, the paint shall be used within the time limits (Pot life)
specified by the supplier. When the base material is thixotropic, it
shall be stirred thoroughly in order to reduce its viscosity before
adding the curing agent.
3) Wash primer (Phenolic modified wash primer) is supplied as two
separate components. The hardener or accelerator is acidic and
normally supplied in plastics, glass or stoneware bottles. After
mixing, this material shall be used within specified Pot life.
4) Zinc silicate paints and graphite stack paints are supplies as separate
powder and vehicle in the correct proportions for mixing. They shall
be mixed thoroughly before use and stirred frequently during
application.
5) Product from different manufacturers shall not be used in the same
coating system, although in maintenance painting, this may be
permitted at the discretion of the company, when new system are to
be applied over existing sound coating.
3.2.3

Thinning.
Brushing paints, with the exception of emulsion paints, are
manufactured to the correct consistency for use.

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Thickening is usually due to prolonged storage. If thickening prevents
proper application by brush, not more than 5% by volume of thinner
shall be added. For oil-based primers, containing red lead thinning by up
to 10% by volume shall be acceptable. For enamels, which are applied
by spraying, special enamel thinners shall be used. On all occasions
thinners recommended or approved by the paint manufacturer shall be
used.
Emulsion paints normally require thinning with up to 10% by volume of
clean fresh water. The addition of more water than 10% to obtain a
satisfactory brushing consistency shall be avoided.
Gasoline, kerosene or gas oil shall not be used to paint.

4. EQUIPMENTS.
4.1 Compressors.
Air compressors shall comply with the safety regulations in chapter 9.0 of this
specification. The compressed air supply used for blasting shall be free from
water and oil. Adequate driers separators and traps shall be provided and these
shall be kept emptied of water and oil. Accumulation of water and oil shall be
removed from the air receiver by regular purging.
Air compressors shall not deliver air at a temperature greater than 110 o C.

4.2 Blast cleaning equipments.

All blasting equipment shall comply with the safety regulations in chapter 9.0 of
this specification. Blasting equipment shall be earthed and conductive hoses
used to prevent build-up of static electricity.
The blasting abrasive shall be discharged with a pressure at the nozzle
(measured with a hypodermic pressure gauge) of 700 kPa(g) (100 psi) and shall
not under any circumstances fall below 550 kPa(g) (80 psi).
Tungsten Carbide venturi nozzles shall be used and discarded when wear
reaches 50%.
The blasting operators hood or headgear shall be ventilated by clean cool air
served through a regulator/filter to prevent blasting residues from being inhaled
by the operator.
Ventilation shall meet the requirements laid down in BS 4275.

4.3 Abrasives.
Abrasives that may be used in blast cleaning are:- Child Iron Grit or Shot.
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- Steel Grit or Shot.
- Copper slag.
- Aluminium oxide.
- Glass bead.
High Silica sand and other material containing free Silica shall not be used.
Abrasive shall be free from oil, grease, moisture and salts and shall not be rusty,
noticeably worn or dull when compared with fresh material.
Abrasive specified as non-reusable shall be no account is reused without prior
approval of the company.

4.4 Spraying Equipment.

The spraying equipment to be used shall meet the recommendations and
instruction set forth by the paint manufacturer for each specific paint or coating
system. For airless spray the correct tip range and fluid pressure setting shall be
used.
An adequate moisture trap shall be placed between the air supply and pump or
pressure pot feed to the gun. The trap shall bleed off continually any water or oil
from the air supply.
Suitable working regulators and gauges shall be provided for the air supply to
the pump or pressure pot.
Spraying units shall be earthed and precautions taken to prevent build-up of
static electricity.

4.5 Scaffolding, Staging and Accessibility.

Fixed scaffolding or staging shall be used to provide adequate access for surface
preparation and painting and shall comply with the safety regulations and in
accordance with chapter 9.0of this specification. Operator shall be able to stand
up with body and arms free of scaffolding or staging and the structure being
worked on.
The contractor shall provide all rigging and scaffolding equipment needed to
complete the work in accordance with the specification.
Scaffolding shall not be removed until after the final inspection of the coating.

5. SURFACE PREPARATION.
5.1 Solvent Cleaning.
When solvent cleaning is specified, this shall be in accordance with SSPC: SP-1
Solvent Cleaning of the Steel Structure Painting Council (USA). Solvent
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cleaning shall normally be carried out prior to blast or power tool cleaning. Any
traces or smudges of oil or grease discovered on the blast cleaned surface shall
be removed by solvent washing and the whole area shall be re-blast.
All boltholes shall be solvent-cleaned prior to blast cleaning.
All surfaces to be painted, which do not require blast cleaning, or power tool
cleaning shall be cleaned down thoroughly by scrubbing with 2% approved
emulsifier or diluted ammonia solution, followed by washing down with
copious amount of potable water. A high-pressure cleaning unit is particularly
effective in this application.
Acid washes, or other cleaning solution, or solvents shall be used on metal
surfaces after they are blast or power tool cleaned prior to paint application.
This includes inhibitive washes intended to prevent rusting.

5.2 Blast Cleaning.

5.2.1 Environmental Conditions.
Blast cleaning shall not be conducted when the temperature of the
surface is less than 3 0C above dew point of the surrounding air or when
the relative humidity of the air is greater than 80%.
It is essential to ensure that no condensation occurs on blasted surface.
To prevent dust and abrasive contamination, blast cleaning shall not be
done in open areas close to painting operation or wet coated surface.
Blast cleaning shall be permitted only during daylight hours, except that
rough blasting shall be allowed during the night providing that the
surface is given a light blasting to the specified standard in daylight
thereafter.
When blast cleaning is in enclosed spaces, such as tanks and vessels,
adequate ventilation shall be provided. The direction of ventilation shall
normally be away from the blast site, i.e. in tanks from bottom to top.

5.2.2 Blast Cleaning Techniques.

Maximum speed and the most effective cleaning is obtained by
systematic, even blasting. Blasting the work in squares may be helpful.
Blast cleaning shall overlap by a minimum of 25mm into any adjacent
coated areas. Any surface not primed and/or wetted by rain or moisture
shall be blasted again prior to being painted.
Wet abrasive blast cleaning shall not be allowed without prior
permission of the company.
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5.2.3 Prior to Blast Cleaning.
Grease oil, etc, shall be removed by means of solvent cleaning (see 5.1)
or by high pressure water jetting or steam cleaning with, if necessary, an
alkaline cleaning agent. Excessive rust scale shall be removed using
impact-cleaning tools.
When using high pressure water jetting to clean a lined or coated
surface, the nozzle pressure must be controlled to prevent coating
damage, and should generally be less than 7000 kPa (1000 psi).
All bolts holes shall be solvent cleaned prior to blast cleaning. All sharp
ages shall be removed or rounded off.
To prevent damage during blast cleaning valve steams, gauges,
nameplates, area to be welded, etc, shall be protected using suitable
covers of adhesive masking tape. Such items and area shall remain
protected until the painting is completed.

5.2.4 Grade of Surface Finish.

Mill scale, rust, corrosion products, paint or any other foreign matters
shall be removed by blast cleaning to one of the grades specified.
For each painting and coating system the grades of surface finish by
blast cleaning shall be specified using the Swedish Standard SIS 05 59
00 (1967), as shown in Table-1 and cross-reference to other national and
professional standards is also given in Table-1.

BS 4232

SSPC

ISO 8501-01
SIS05 59 00
SA 3
1st QUALITY SSPC SP-5

SA 2.5

SA2

TABLE 1 - Surface Finish International Standards

INDIAN
CLEAN
EXTENT OF GENERAL DESCRIPTION FOR QUALITY
IS-1477-1971
BARE METAL
RESIDUE
OF BLASTING.
WHITE METAL
FULL SURFACE
NIL
BLAST CLEANING TO PURE METAL.VERY
THOROUGH REMOVAL OF MILL SCALE,
RUST, FOREIGN MATTERS.

2nd QUALITY SSPC SP-10 NEAR WHITE METAL 95% SURFACE MAX. 10% IN
UNIT AREA VERY THOROUGH BLASTING, REMOVAL
OF MILL SCALE, RUST, FOREIGN MATTER
TO THE EXTENT THAT ONLY SLIGHT
TRACES ARE REMAINING AS STAINS IN
THE FORM OF SPOTS AND STRIPS.
3rd QUALITY SSPC SP-6

COMMERCIAL

80% SURFACE MAX. 10% IN

UNIT AREA

THOROUGH BLAST CLEANING.ONLY

LIMITED MILL SCALE AND RUST ARE
REMOVED.

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5.2.5 Degree of Roughness.
The require degree of surface roughness or peak to valley height after
blast cleaning depends on the type of paint to be applied. Surface
roughnesses of 30 to 80 microns usually require.

5.2.6 Post Blasting Cleaning.

A dry abrasive blast cleaned surface shall be brushed with clean brushes
made of hair, bristles or fiber, blown off with compressed air(free from
oil and moisture)or vacuum cleaned to remove all traces of blast cleaned
products from the surface or from pockets and corners.
No surface shall be blast cleaned which cannot be painted within the
same working day. Any time constraints between blasting and the
application of paint coatings as specified by paint manufacturers shall be
strictly applied. Should delay between blasting and painting cause flash
rusting of the steel surface, that surface shall be given a sweep blasting
before painting proceed.

5.3 Power Tool Cleaning.

Power tool cleaning shall be carried out to a visual standard in accordance with
Swedish Standard SIS 05 95 00 St 3.
Metal surface for which blast cleaning is specified but which because of their
location cannot be open blasted shall be prepared wherever practicable by
vacuum blasting. Where this is not possible such areas shall be 100% power
disc sanded using a cross technique to provide good adhesion. Where welds
occur within these areas a Jason needle gun shall be used to prepare them.
Power tool cleaning shall extend to a minimum of 25mm into adjoining coated
areas.
Areas prepared for painting by power and hand tool cleaning shall be primed
within four hours and never left unprimed overnight.
Needle gun shall have needles of small cross section. When using a needle gun
the profile of the surface shall not exceed 50-micron differential and no sharp
edges, craters, etc, shall be left on the metal surface. All rough peaks shall be
removed.

5.4 Pickling.
5.4.1 General.
Pickling shall be carried out preferably under controlled workshop
condition. The surface produced shall be in accordance with SSPC-SP 8.
The minimum requirements for the process shall be: Page 8 of 21
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- Immersion in a warm dilute sulphuric acid or phosphoric acid bath to
remove mill scale and rust.
- Washing in a bath of warm water to remove all traces of sulphuric
acid. This water wash may be omitted when phosphoric acid is used.
- Immersion in a bath of hot dilute phosphoric acid to provide a
passivated surface suitable for painting.
- Rinsing in fresh water between 21 0C and 50 0C.
Contents of all acid bath shall be discarded when the concentrations fall
below that indicated specifically for each bath or if accumulation of
sediment causes staining of the work.
The pickling process is detailed in the following.
1) Descaling bath
The descaling bath shall consist either of sulphuric acid or
phosphoric acid.
- Sulphiric acid bath: - The bath shall contain a solution of sulphuric
acid of 5% to 15% by Weight in water. An inhibitor shall be used
to prevent undue attack on the steel. The temperature shall be
maintained at 50 0C to 65 0C. Acid from the treated material shall
be allowed to run back into the bath. The sulphuric acid in the bath
shall be discarded when the concentration of dissolved iron reaches
approximately 70 grams per liter.
- Phosphoric acid bath: - The bath shall contain a solution of
phosphoric acid of 10% to 20% by weight in water. The
temperature shall be maintained at 60 0C to 85 0C and a suitable
inhibitor shall be incorporated. The concentration of phosphoric
acid should be maintained by regeneration or the solution changed
whenever the concentration drops below 7% by weight and/or the
iron content exceed 30 grams per liter.
2) Intermediate water wash bath.
The water bath shall be maintained with clean fresh water at a
temperature of 60 0C to 65 0C. The steel shall be dipped twice in the
water bath before being passed into the final (phosphoric acid) bath.
The total acidity of the water bath, expressed as H2SO4, shall not
exceed 1gram per liter. This intermediate water wash can be omitted
when a phosphoric acid descaling bath is used.
The chloride concentration of all wash waters should be limited to a
maximum of 500 ppm.
3) Dilute phosphoric acid bath.
The bath shall contain a concentration of approximately 2% of free
phosphoric acid initially, and shall be maintained at a concentration
of 1.5% to 2% by weight by occasional addition of phosphoric acid.
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The iron content shall not be allowed to exceed 0.5% by weight. The
temperature shall be maintained at not less than 85 0C. Immersion
time shall be 3 to 5 minutes.
The appearance of treated steel leaving the final phosphoric acid
bath shall be free from any powdery deposit on the surface and shall
be dull gray in colour. A brown colour indicates that the temperature
of the final bath is too low.
4) Final water rinse bath.
This water bath shall be maintained with clean fresh water at a
temperature between 21 0C and 50 0C.

5.4.2 Protection after pickling.

Unless otherwise specified a coat of oil based red lead type primer shall
be applied, preferably by brush, as soon as the pickled steel is dry.
For pickled tank plates, the steel shall be primed as described above,
with the exception of approximately 50mm margins around the edge,
which shall be painted with an approved lead free primer. The material
shall then be stacked under cover in such a way that there is free access
of air to the paint coating. Packing or assembly shall not be take place
until the primer is hard enough to handle.

5.5 Chemical Cleaning.

Chemical cleaning is subjected to prior consultation with and approval of the
company.

6. COATING APPLICATION.
6.1 Environmental Condition during Coating.
6.1.1 Weather Conditions.
Cleaning, surface preparation, or coating work shall not be undertaken in
unsuitable environmental conditions, includes:- High wind speeds (greater than 15 knots).
- Airborne dust or sand.
- Rain, fog, mist or when there is free moisture on the prepared surface.
- Steel temperature/air temperature less than 5 0C.
- Steel temperature less than 3 0C above due point of the surrounding air
or relative humidity greater than 80%.
- Where there is likelihood that weather condition will change within 2
hours such that the above conditions apply.
The company shall reserve the right to stop the work when such
conditions prevail.
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6.1.2 Weather Protection.
Where environmental circumstances and/or contractors program and/or
construction methods require weather protection of all or part of the
structure to be painted, the contractor shall provide and equipment such
as tents, heating burners, ventilation, and equipment for
dehumidification, scaffoldings, screening, etc.

6.1.3 Ventilation.
When painting is carried out in enclosed spaces, adequate ventilation
shall be provided. The capacity of the ventilation shall be sufficient to
keep the concentration of solvent vapor in the air below 10% of the
lower explosion limit at all areas within the workspace. This is
considered adequate for personnel health protection, avoidance of
explosion hazards and to ensure adequate evaporation of solvent from
the paint.
Direction of ventilation shall be from top to bottom to withdraw vapors,
which are heavier than the air, where access at the bottom of the space is
not available, suction ducts shall be suspended from the roof with
opening near to the bottom of spaces served.

6.2 Application Technique.

6.2.1 General.
Application of coatings shall be in accordance with the manufacturers
recommendations. Application of primer shall normally be by brush or
by airless spray, except in the case of stripe coats, which shall be by
brush only. Brush marks shall be avoided as these indicate low DFT in
the valley of the marks.
Each coat shall be allowed to dry for at least the time recommended by
the manufacturer.
Paint shall not be applied within 50mm of an edge prepared for a field
weld and care shall be taken to ensure this by masking off. On
completion of finish coating the plant identification marks, flow
direction arrows, pipe identification color bands, etc, shall be applied as
requested and directed by the company.

6.2.2 Protection of Equipment.

The contractor shall protect all equipment and structures, and any other
areas required by the company from mechanical damage from paint
droppings or over spray.
Equipment or structure to be protected shall include the following.
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Valve spindles, gauge glasses, nameplates, giving makers specification,
etc, on vessels, motors, etc, motors, cables, stainless steel pipe work,
gratings, near by vehicles or buildings or any other area of the structure
not being painted at that particular time. Special attention shall be paid
to protecting equipment that operating at the time of painting.

6.2.3 Airless Spray.

All liners and pots shall be thoroughly cleaned before any addition is
made of new materials. The spray gun shall be held not closer than
450mm from the work surface and not further than 600mm, and shall
always be held at right angle to it. Even, parallel passes shall be made,
each pass overlapping the other by 50%.
Large surface shall be cross coated by receiving passes in two
directions at right angles to each other. The gun shall not be operated
continuously but will be triggered before and after each pass to obtain
the correct spray pattern and avoid runs and sags. Spray width
adjustment on the gun and readjustment of atomizing pressure at the
regulators shall be made until the desire spray pattern is obtained.
Each coat shall be applied uniformly and completely over the entire
surface. Great care shall be taken to avoid areas of low DFT and
misses. All runs and sags shall be brushed out immediately, or the paint
shall be removed and the surfaces resprayed.
Before spraying each coat, all areas such as corners, angles, edges,
welds, flanges, brackets, bolts, nuts and interstices shall be given a brush
coat to ensure that these areas have at least the minimum specified film
thickness.
Paint spraying from a single boatswains chair shall not be permitted.

6.2.4 Brush.
Coating shall be brushed on to all areas, which cannot be adequately
spray coated, e.g., difficult access, complex shape, etc.
Surface not accessible to brush shall be painted by company-approved
means to ensure a uniform paint film of adequate thickness.

6.2.5 Roller.
Application by roller shall only be done on large flat or slightly curved
surfaces where application by spray is not possible. This method is not
suitable for painting rough areas of crevices.

7. INSPECTION.
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The contractor shall ensure that qualified personnel inspect all painting working line
with the following requirements.

7.1 Environmental Conditions.

7.1.1 Steel Temperature.
The surface temperature of the steel at a representative area shall be
checked before application of any coating, and shall be within the range
specified by the paint manufacturer. Inspector may extend the minimum
and maximum recoat intervals for low surface temperature and reduce
for high surface temperatures.
The inspector to measure steel temperature may commonly use two
methods, namely a battery operated thermocouple or thermistor with
digital read out, or a contact thermometer that is simply clamped to the
surface with a magnet.
With both instruments time must be allowed for the device to reach a
stable temperature.

7.1.2 Air Temperature.

The contractor shall measure air temperature and relative humidity at
least twice daily and before coating or blasting operation start.
Measurement shall be done using a sling Hygrometer.
The due point shall be determined using the approved chart. All results
shall be recorded and submitted to the inspector.

7.1.3 Ventilation.
Before and during blasting and coating work in enclosed spaces,
adequate ventilation shall be established. During coating operations the
vapour concentration shall be monitored at regular intervals using
approved equipment and should never exceed 10% of lower explosion
limit.
The TLV (Threshold Limit Valve) or MAC (Maximum Allowable
Concentration) of the product being used must be known. Ventilation
shall be such as to maintain, wherever practical, a safe atmosphere
below the TLV.

7.2 Surface Preparation.

Before any surface preparation commences, the surface shall be inspected to
ensure it is free of oil and grease, other foreign matter and any substrate defects.

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After surface preparation, the surface shall be visually inspected and the degree
of cleanliness and surface character evaluated with standard or comparators.

7.2.1 Blasting Abrasive Quality.

If there is any doubt about the quality of the blasting grit, the contractor
shall provide a specification covering sieve grading, chemical analysis
and physical properties. If such a specification is not available, the
contractor shall take samples, of minimum 1 kg each, from each batch of
abrasive and arrange for analysis by an independent third party. Such
analysis shall include: - Sieve grading.
- Physical and chemical analysis.
Specification and/or analysis results shall be submitted to the company
for comparison with accepted values. If the abrasive has been wetted by
salt water, rain or condensation, or if its moisture content is considered
too high, it shall not be further used. The inspector shall reject any blast
cleaning done with such abrasive.

7.2.2 Surface Contamination and Cleanliness.

The contractor shall ensure that dust or dirt has been removed from the
surface prior to painting.
Contamination of the blasted surface by large embedded abrasive
particles, which cannot be brushed off using a stiff brush, shall not be
accepted. If such contamination is detected, no further blasting shall be
performed, using the same batch of abrasive. Tightly adherent embedded
fine particles, however, need not be a cause for rejection.
Work may be allowed to continue using a different batch, make or type
of abrasive approved by the company.
Removal of contamination by wire brushing shall not be allowed.
When using copper slag abrasive under high ambient temperature
condition, the visual standard SA2.5 may not be obtained due to
embedded fine particles causing a different shade. If there is any doubt
on the acceptability of the prepared surface the company shall be
requested to provide a dedicated visual standard for SA2.5 using copper
slag under these conditions.

7.2.3 Residual Mill scale and Corrosion Products.

Standard of preparation shall be established by visual comparison of the
steel surface with the appropriate photographic standard included in
Swedish Standard SIS 05 59 00.
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Visual examination will normally indicate the presence of residual mill
scale. If required by the inspector, a copper sulphate test shall be carried
out.

7.2.4 Surface Profile.

Contractor shall measure the surface profile after blasting using an
optical method or needle probe. Approved methods using a profile
comparator are Keane Tator or Rugotest no.3.

7.3 Coating Materials and Applications.

7.3.1 Materials.
Coating materials records shall be maintained by the contractor and
made available to the company. These records shall include, but not be
limited to information on the: - Type of coating system.
- Batch numbers (which shall relate to paint production date).
- Manufacture/expiry date.
- Numbers and sizes of paint containers or coating packages.
- Quantity of coating materials consumed during each day.

7.3.2 Wet Film Thickness (WFT).

The contractor shall, at all stages of paint application, as required by the
inspector measure the WFT as often as necessary to obtain the specified
Dry Film Thickness (DFT). WFT shall be determined using an
appropriate comb gauge.

7.4 Dry Film Thickness Inspection.

After the film is sufficiently dry or cured the contractor shall perform an
examination.

7.4.1 Visual Inspection.

After each coat the coating shall be inspected visually. The paint system
applied should have the correct shade, degree of gloss and evenness and
be free from thickness after drying/curing and free from cracks,
holidays, runs, sags, wrinkles, patch ness, brush or roller marks or other
defects that may deleterious to the quality of the coating.
Finishing coat shall be even in colour and gloss.

7.4.2 Dry Film Thickness (DFT).

DFT shall be measured after each coat at randomly chosen location. The
density of measuring points shall be at the discretion of the inspector but
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shall normally be once every 4 square meters for large areas and once
every 1 square meter for small areas or structures.
DFT shall be measured using a magnetic pull-off gauge or an electronic
instrument working on magnetic flux or eddy current principles. The
instruments working range shall be adequate for the specified coating
thickness and shall cover a minimum of 150% of the expected DFT.
The instruments which shall be checked or calibrated before each set of
measurements using a substrate of similar material and thickness to the
work, and shims of the expected coating thickness, shall have an
accuracy of better than + 10%.
Records shall be kept of all DFTs measured. Average, minimum and
maximum values shall be reported.
DFTs of each paint film shall be within + 25% of the specified thickness.
The total DFT shall never be less than the specified total DFT.
If coating is performed over existing paint layers, DFT of the existing
coating shall be measured before application so that the thickness of the
new layer of coating may be determined.
DFT of different layers of a paint system may be measured using a paint
inspection gauge utilizing calibrated cutters and microscope. This
however is a destructive test and nor suitable for production painting.

7.4.3 Pinhole Detection (Wet Sponge Method).

Pinhole detection shall be conducted on all conventional thin film and
coal tar epoxy coating system using a method approved by the company.
Refer to the system specification for details. Pinhole detection is carried
out after the final coat has been applied and fully cured/dried.
The wet sponge method shall be used.
For tanks and vessel internals, 100% of the surface shall be tested.
Special attention shall be paid to welds, edges and irregular surface.
For external surfaces, random inspection, which shall be representative
of the entire surface, shall be conducted.

7.4.4 Holiday Detection (High Voltage Spark Test).

Holiday detection shall be conducted on all heavy-duty systems
including FBE, GRE, heavy coal tars, asphalts and polyurethylene
coatings. A high voltage (spark) detector shall be used. The type of brush
shall be suitable for the surface to be inspected. The voltage setting shall
be according to the manufacturers recommendations or as given in the
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system specification. Normally 100% of the surface shall be tested.
Special attention shall be paid to welds, edges and other irregular
surfaces.

7.4.5 Degree of Cure.

An indication regarding the cure of two component materials such as
zinc silicates or epoxies can be obtained by solvent swabbing. The
curing test shall consist of rubbing the laminate surface for one minute
with a clean rag soaked in a suitable solvent. If cure is complete the
surface shall not be softened as indicated by scratching it with fingernail.
The test shall be conducted at a number of representative places on the
surface.

7.5 Reporting.
All inspection results shall be recorded daily, at site a standard Daily Painting
Record together with all inspection/repair report shall be recorded.

8. SAFETY.
8.1 General.
When paints containing volatile solvents are applied in enclosed or confined
spaces, two hazards exist: Fire & Explosion hazards and Toxic hazard.
Precautions must be taken to eliminate these dangers.

8.2 Fire and Explosion Hazard.

When the following factors are presents, there is a high risk of creating a fire or
an explosion; they are: - When the concentration of vapour in air is between the lower explosion limit
(LEL) and the upper explosion limit (UEL).
- When a flammable liquid, in contact with air (open container) is at a
temperature above its flashpoint.
- When there is a source of ignition with high enough temperature and energy to
initiate the explosion reaction.
These conditions shall be avoided at all times during the handling and
application of paints or coatings.

8.2.1 Ventilation and Extraction.

Adequate ventilation and extraction must be provided in the workroom
to prevent a potentially flammable concentration of vapours by
maintaining the concentration of vapour in air at no more than 10% of
the Lower Explosion Limit. The use of solvents with a flashpoint below
the working temperature is prohibited.
Booths and similar enclosures should be designed, installed and
maintained to prevent any vapours, over spray and droplets escaping into
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the general atmosphere of the workplace. The exhausts from such booths
should be designed to minimize external environmental pollution.
All booths and ducts shall be fire resistant structures and shall be
subjected to regular cleaning to prevent the accumulation of solid paint
residues.

8.2.2 Source of Ignition.

All potential sources of ignition shall be strictly controlled. Smoking
shall be prohibited in all areas where paint is stored, handled or used.
Sparks, hot surfaces, flames and all other sources of ignition must be
absolutely prevented. Flameproof lighting and electrical equipment must
be used, spark proof tools and clothing shall be used, all hot work in
adjacent compartments shall be prohibited.

8.2.3 Storage.
Special storage precautions are necessary for products with a flashpoint
below 32 0C. Storerooms shall be separated from workshops and
constructed to company approved standards. The amount of paint stored
in the workshop or working area shall be limited to one working days
requirements. All containers of paint and thinners not in use shall be kept
securely closed. Paint stored in workshops shall be kept in bins or
cupboards of fire resistant materials.

8.2.4 Cleanliness.
Strict attention to cleanliness shall be observed. All places where dry
paint deposits can accumulate shall be cleaned regularly and any brushes
used shall be of non-ferrous metal or non-sparking material. All
scrapings and sweepings must be placed immediately in metal container
with suitable covers, wetted down and removal from the building.
All spillages shall be cleaned up as they occur by absorption into sand,
earth or other suitable inert material. Any rags or other combustible
materials used for minor cleaning or any other work area cleaning must
be deposited immediately after use in a metal container having a suitable
cover, wetted down and removed without delay to a safe place outside
the building. If combustible material is used to protect floors or other
surfaces from paint drips or spillages, it should be removed daily and
deposited in a safe place for disposal.

8.2.5 Firefighting Equipment.

Adequate fire prevention and firefighting equipment shall be provided
and maintained in all areas where paint is used, handled or stored.
Guidance regarding the type and amount of equipment to install shall be
obtained the PDO safety department.
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8.3 Toxic Hazards.
8.3.1 General.
Application of paint containing a high proportion of solvents may, in
poor conditions of ventilation, result in high atmospheric concentrations
of solvent vapour. Overexposure may cause adverse physiological
effects. Certain paints may give rise to additional specific hazards, which
shall be indicated, on the label and in the manufacturers literature.
Particular care must be taken when handling and using paints containing
heavy metals, e.g., lead, and precautions taken to protect against skin
contact and fume inhalation.

8.3.2 Inhalation.
Inhalation of fumes, dust or sprays during surface preparation,
application of paint and sanding processes shall be avoided. Employees
shall be protected against the inhalation of dust, fumes or sprays during
any of the above activities by the provision of adequate ventilation at all
times and where appropriate, local extraction and dust masks or
respirators. A cartridge respirator should be worn, and fitted with a
vapour/particulate cartridge designed for paint spray and light fume
protection. In some cases a higher degree of protection from an air-line
breathing apparatus may be advisable, and where this is so it will be
stated in the manufacturers technical literature and marked on paint and
solvent containers. For dry sanding operations a cartridge respirator shall
be worn. In the open air, work or operations down wind of the spraying
area shall be restricted as necessary or personnel protection devices
worn.
When working in workshop areas, spraying shall be confined, so far as
possible, to spray booths which are designed, installed and maintained to
prevent any vapours escaping into the general atmosphere of the
workplace.
In an emergency resulting in
shall be moved to a fresh air
warm until medical attention
patients breathing should be
when breathing stops.

personnel injury or sickness, the patient

location as quickly as possible and kept
arrives. In case of unconsciousness the
checked and artificial respiration given

8.3.3 Ingestion.
Accidental ingestion (swallowing) of paint may cause irritation of the
mouth, throat and digestive tract, resulting in vomiting and abdominal
pain. Significant absorption of paint containing a high proportion of
solvents may cause drowsiness or loss of consciousness.
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Ingestion of paint must always be avoided. Food should not be brought
into, stored, prepared or consumed in workshop or work areas where
paint is handled or stored. Receptacles and utensils, which could be used
for food or drink, should also be excluded. Washing facilities should be
provided and their use encouraged before food is consumed or handled.
In an emergency, vomiting shall not be induced because of the risk of the
introducing solvents into the lungs by inhalation of vomit. This cans
result in severe lung damage. The spontaneous vomiting occurs, the
patient shall be turned on to his face if unconscious.

8.3.4 Skin Contact.

Some substance used in paint may cause irritation after repeated or
prolonged contact with the skin and in certain cases there is a risk of
dermatitis.
Operatives with a history of skin sensitivity should not be employed in
processes where skin contact cans occur. Prolonged or repeated contact
with the skin should be avoided. Barrier cream shall be provided and
used gloves and overalls shall be worn.

8.3.5 Eye Protection.

Splashes of paint products will irritate the eyes and goggles shall be
worn whenever possible to prevent this occurrence. Emergency
treatment shall consist of irrigation of the eyes with copious amount of
clean water until medical attention has been obtained.

8.4 Safe working Conditions in confined areas.

Safe working is of the greatest importance, but especially so during the
application of internal tank coatings.
The following principal measures will ensure safe working.

)1 Blast Cleaning.
When voice communication between the blast cleaner and blast operator is
not practical a reliable system of communication by signals shall be
established.
The blast cleaner shall be provided with an air-fed helmet and ear
protection.
A safety valve control operating by a dead mans handle principle shall be
provided for the blast cleaner.
All blasting equipment shall be electrically earthed to the mass of the tank,
vessel or structure being cleaned.
All scaffolding shall be provided with safety rails.
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)2 Painting.
All mixing of paints shall be performed outside the confined area.
Exhaust and fresh air ducts and fans shall be provided. The fresh air shall be
directed to the bottom of the tank and exhaust duct shall be close to the
bottom of the tank.
All spraying equipment shall be electrically earthed to the mass of the
structure being painted.
Warning signs shall be provided around the structures being painted
indicating that spraying is in progress.
A supervisor shall be in continuous contact with painters and shall have his
own safety outfits.
Unauthorized personnel shall not enter the tank or vessel during spraying.
All hoses shall be checked regularly for damage.
Safety lights and other electrical equipment shall be suitably certified for use
in hazardous areas likely to be encountered during paint spraying.
Painters shall be provided with lifelines, where necessary.

)3 Drying.
A fresh dry air supply shall be provided. The end of the exhaust duct shall be
installed close to the bottom of the tank.

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