Surface Preparation and protective

coating

Classification 0f Surface preparation

Solvent cleaning
Hand tool cleaning.
Power tool cleaning.
Brush off blast.
Commercial blast.
Near white metal blast.
White metal blast.

Blasting Equipment Selection.

Compressors.
Nozzle.
Abrasive

General

Material Specification

Coating application
1.

Spray equipment

2.

Spray application

3.

Brush application

1. Good house keeping

Clean and orderly work area
Storage and issue area
Mixing utensils and container
Wet coating safe guards
2. Surface preparation
Prior to surface cleaning
Blast cleaning equipment
Abrasive medium.
Final inspection

1.

Coating application.
Application procedure
Equipment.

2. Coating inspection
Wet film thickness.
Dry film thickness.
Holiday detection.

General

Good housekeeping.

Sand blasting.

Coating application

1.

Coating specification

2.

Contractor selection

3.

Job scheduling

4.

Coating job progressive inspection.

What is Corrosion?

Corrosion is the result of a conversion process that takes place when

oxygen and moisture come in contact with metal.

The oxygen and water combine with iron to create a brown coating
(hydrated ferric oxide) on the surface of the metal.

The interaction between the water and iron is accelerated if salts are
added to the mix.

Because the oxide that is created is bulky and porous, it allows oxygen
access to the iron below, causing additional oxidation.

If allowed to continue, the iron metal will be completely converted to

ferric oxide or solid rust, which is weak and flaky.

How can we protect against corrosion

This chemical process can be stopped if water and moisture are not allowed to contact
the metal surface.

Typically, metal is coated with some substance to seal it off from oxygen and water.

These coatings can be as simple as oil and grease or chemically complex primers
and paint.

Coatings are effective as long as the separation between the metal and oxygen and
water is maintained.

If the oil or grease is wiped off or dries out, rust begins to form. In the case of paints,
they begin to shrink and crack over time.

When this happens, cracks develop in the coating, allowing rust to start.

Even a deep scratch in a painted surface will expose the metal.

Once the rust starts, it travels under the paint forcing the paint away from the metal,
allowing more moisture and oxygen to come in contact with the metal surface.

How can we protect against corrosions?

Generally the only way to reseal the surface is to

mechanically or chemically remove all the rust
before the surface can be sealed again.

If any rust remains, and paint is applied over the

surface, enough moisture and oxygen will travel
through the paint molecules to start the rusting
process again.

For this reason, most paints directions require you

to remove all rust before you paint the surface.

Why do we prepare Surface?

For application of Coating, required a

particular type of Surface cleanliness and
roughness

Surface - How do we prepare?

Solvent Cleaning

(SSPC-SP-1)

Hand Tool Cleaning

(SSPC-SP-2, SIS St. 2)

Power Tool Cleaning

(SSPC-3, SIS St.3).

Brush-off Blast

(SIS Sa-1, SSPC-SP-7, NACE 4).

Commercial Blast

(SIS Sa 2, SSPC-SP 6, NACE 3).

Near White Metal Blast (SIS Sa 2.5,SSPC SP10,NACE- 2).

White Metal Blast

(SIS Sa-3, SSPC SP-5, NACE 1).

Surface - How do we prepare?

1. Solvent Cleaning. (Also called SSPC SP 1)

This involves removal of oil, grease, dirt, soil, salt, and other contamination by cleaning with so
vapor, alkali, emersion, stream, or detergent

2. Hand tool cleaning (also called SSPC-SP-2, SIS St-2)

This type of cleaning requires removal of loose rust, mill scale, and paint by hand chipping, scr
sanding or wire brushing. The resulting surface has a faint metallic sheen. The cleaned surface a
corresponded to the Swedish standard designated as St-2.

3. Power tool Cleaning (Also called SSPC- SP-3, SIS St-3)

This requires removal of loose rust, mill scale, and paint by power tool chipping, sanding wire b
and grinding. The speed of surface preparation is higher than hand tool cleaning, and the resulti
has a pronounced metallic sheen. It appearance corresponded to the Swedish Std designated as

4. Brush-off Blast (also called SIS Sa-1, SSPC-SP 7, NACE 4 ).

This is a surface preparation method in which all oil, grease, dirt, rust scale, loose mill scales, lo
and loose paints and coating are removed completely, but tightly adhered rust, paint, and coatin
permitted to remain provided that all mill scale, and rust have been exposed to abrasive blast pa
sufficiently to expose numerous flecks of underlying metal fairly uniformly distributed over the
surface.

Surface - How do we prepare?

5. Commercial Blast (also called SIS Sa-2, SSPC-SP 6, NACE 4).

This is a surface preparation where at least 2/3 of each element of area is in white metal conditi
oil, grease, dirt, rust scale, and foreign matter shall be completely removed from the surface and
mill scale, and old paint shall be completely removed except for slight shadows, streaks, or slig
discoloration caused by rust stain, mill scale oxides, or slight, light residues of paint or coating
remain. If the surface is pitted slight residues of rust or paint may be found in the bottom of the

6. Near White Metal Blast (also called SIS Sa-2.5, SSPC SP-10, NACE 1).
This is a surface preparation where at least 95% of each element of area, is in white metal cond
oil, grease, dirt, mill scale, rust, corrosion products, oxides, paint or other foreign matter shall b
completely removed from the surface except for very light shadows, very light streaks, or sligh
discoloration caused by rust stain, mill scale oxides, or slight, tight residues of paint or coating
remain.

7. White Metal Blast (also called SIS Sa-3, SSPC SP-5, NACE 1).
This is the degree of surface cleanliness required to achieve a surface with a greywhite, unifor
metallic color, slightly roughened to form a suitable anchor pattern for coating adhesion. The su
when viewed without magnification, shall be free of oil, grease, dirt, mill scale, rust, corrosion p
oxides, paint or may other foreign matter.

Corrosion Grades?
A?
B?
C?
D?

How we define the Corrosion Grades.

A.

Steel surface covered completely with adherent mil

scale with little, if any, rust.

B.

Steel surface, which has begun to corrode, and from

which the mill scale has begun to flake.
How we define the Corrosion Grades.

C.
Steel surface on which the mill scale has corroded
away or from which it can be scraped, but with little pittin
visible to the naked eye.
D.
Steel surface on which the mill scale has corroded
away and on which considerable pitting is visible to the
naked eye.

Pre-treatment
According to SIS 055900,
Pre-treatment for these degrees of corrosion is respectively wire
brushing and blast cleaning to the following quality scale:1. Bad.

(Light brushing or light scraping).

2. Middle

quality (thorough scraping with hard metal

scrapper and wire brushing or thorough blast
cleaning).

3. Thorough

scrapping or wire brushing till distinct metal lust

is obtained or blast cleaning to clean gray steel.

Blast Cleaning

SIS 055900 Standard

St.

(Standard tool)

Sa.

(Standard abrasive)

Sa3

St1
St3

St2

Sa1

Sa2
Sa2.5

Profile Gauge

Press-O-Film Gauge

Testex Tape / Press-O-Film

Testex Tape is popularly called as Press-O-Film.

Press-O-Film provides surface profile of a blasted cleaned surface.

It can produce virtually exact replicas of the blasted surface

profile, which can be measured, using a snap gauge.

Testex offers a simple and very accurate method of measuring

blasted profiles.

Press-O-Film consists of layer of crushable plastic micro

coated onto a pollster film of highly uniform thickness.

foam

Testex Tape (Press-o-film) complies with ASTM, NACE and SSPC

methods measurement

Sand Blasting - History

Sandblasting is nothing new; the occupants of deserts around

the world have had to deal with natural sandblasting as a part
of everyday life.

Artificial sandblasting, however, was created and patented by

Benjamin Chew Tilghman on October 18th in 1870.

By using sand of uniform size through sieving, operators of

sandblasting equipment could have predictable results.

Over time it was discovered that silica dust that was produced
as a byproduct of the sandblasting process caused silicosis
long-term inhalation of the dust.

after

Compressor

All pots require air compressors.

The volume of air the compressor
can disperse and the pressure at
which it operates are important
considerations. For the most basic
of needs, the compressor should be
able to handle ninety cubic feet per
minute at a hundred pounds per
square inch.

Pot

The pot is the vessel that holds and

discharges the material used in the blasting,
often referred to as sand regardless of its actual
composition.

and

There are two pot types, the pressure-pots

the siphon system pots.

Siphon systems are similar in operation to

paint sprayers, with the sand being sucked out
(or siphoned out) from the pot via a
connecting hose, mixed with air and blasted
out of the nozzle onto the surface.

Siphon systems are slower than pressure-pots

and require a large amount of air to draw the
sand from the pot.

METHOD

RESULT

1. Blast-cleaning

Ideal

2. Mechanical wire
brushing

Risk of polishing

3. Mechanical disk
sending

Some risk of polishing

4. Needle chipping

Some risk of indentations

5. Mechanical rust- chipping

Not good heavy indentations

6. Mechanical scraping
(air powered)

Combined with other methods

7. Hand brushing

Poor

8. Hand scraping

Only to be used with in

combinations other methods

Selection of Blasting Equipment?

Compressors

The ideal working pressure for air blast cleaning equipment is 90 100 psi is at
the abrasive discharge nozzle.

This can be verified by utilizing a hypodermic needle gauge inserted through the
blast hose immediately behind the nozzle when the equipment is under normal
operation, discharging the abrasive.

Compressor shall deliver the volume and pressure of air required to perform
work effectively and safely. Oil-lubricated compressors shall have an overheat
sensor or carbon monoxide sensor if a respirator (other than air-supplied) is used
in poorly ventilated areas.

A regulator valve shall be used at the compressor, set to manufacturer

specifications, to provide adequate air pressure to abrasive blast
equipment.
Inspect the compressor starting sand blasting.
Open the air discharge valve and put a white paper in front of valve (for 30
Second) to check that: -

Oil in air. Purification of air. Any other contamination.

Nozzle.

The abrasive blast cleaning nozzle

shell be equipped with an operating
valve which must be held open manually.
The sizing of the abrasive discharge nozzle
should be correctly matched with the
discharge volume capacity of the compressor.
To conform in optimum conditions, a compressor
should not be required to operate above 75% of its
rated capacity.
Sand Blasting Nozzles are made of alumina, tungsten carbide
or boron carbide, used for sand blasting purpose as required
in many industries, such as machinery, bearing, electric and
electronic, etc. There are two kinds:
Straight bore nozzles and venture bore nozzles.
,

Abrasives

Garnet

Glass Beads

Copper Slag

Steel Abrasives

Silica Sand

Aluminum Oxide

Blast Cleaning Equipment?

Correct Nozzle Size

Correct Air Hose

Blasting Machine with Dead man

Coupling

Traps

Nozzle Pressure

PPE

Abrasive

Skilled Labor

Compressors

Inspection equipment

Rules to be followed
Correct Pressure
Removal of Lose Paint and Rust
Check the hardness of abrasive
Use Lab tested correct abrasive
(Free of chloride and Iron)
Use good quality sharp quartz abrasive
Check the salt contamination level

How to perform Test

Select a fresh, clean surface on the specimen to be tested.

Hold the specimen firmly and attempt to scratch it with the point of an object of
own hardness. In this example, we use a sharp quartz (H=7) crystal.
Press the point of the crystal firmly against the surface of the unidentified specimen.
If the "tool" (in this case the quartz crystal) is harder, you should feel a definite "bite"
into the surface of the specimen.

Look for an etched line. It is a good idea to rub the observed line with your finger to
ensure that it is actually etched into the surface of the specimen. In this case, the
ystal left a deep, definite scratch in the surface. Because the specimen was scratched
the quartz crystal, we know its hardness is less than that of the quartz - less than H=7.

If there is any question about the result of the test, repeat it being sure to use a
arp point and a fresh surface.

Salt Contamination

ECIFICATION OF SALT LEVELS.

Ideally, the salt level remaining on steel surface after surface cleaning and prior to painting
or any other construction operation should be zero.

In practice it is not possible to achieve this due to various environmental factors and a
orking salt level need to be specified.
In the case of painting, this level is matter for discussion between the client, the applicator
and the paint manufacturer and it will depend on the working conditions, the paint system
used the required service life and what can be economically achieved.

Consequently, it is not possible to specify in these instructions which salt standards are
est suited to all industries.

However, during the development salt contamination meter, the effect of salt
ontamination on the life of coatings under a range of realistic and accelerated environmental
onditions for a number of common generic coating systems was assessed.

It cant be recommended as a specification that which limit is suitable for coating. The
ork has shown that a salt level of better than 4g. cm is a sensible working limit.

Salt Contamination Meter

Soluble salts on the surface are taken into solution by placing a wetted 11 cm dia Elcometer 130
CM 400 high purity sample paper on the area to be sampled. By leveling the paper in contact for
timed period, salt removal from the surface is maximized. Using a paper of known size allows
ontamination to be expressed in terms of surface area. These papers retain a known amount of
water because of their consistent absorbency characteristics and therefore the concentration of the
olution formed is related to the quantity of soluble salt remover. The sample paper containing the
alt solution is placed over the electrodes on the meter and its resistivity is determined. This is
chieved by measuring the minimum resistance of the solution over a fixed solution path length and
ross section, governed by the electrode spacing and paper thickness respectively. The solution
onsideration is inversely proportional to its resistivity. The meter release the latter to a calibration
with known concentrations of sodium chloride solution and the known surface area sampled, to
ive surface salt levels in g. cm

Salt Contamination Meter

Object:
Determination of chloride salts on steel surface after blasting
Test Details:
Sample
Blasting Standard: Sa 2
Test Area:
1 ft
Test Temperature: Ambient
Procedure:1.
100 ml distilled water is used to swab 1 ft of steel surface (Pipe, steel plate or
structure) with clean cotton. After blasting.
2.
Swabbing is carried out 2 3 time within 5 minutes.
3.
Piece of cotton is dipped-n-mixed in water with a glass rod so that expected salt can
be well diluted in water.
4.
Finally Quantab strip is approximately half dipped in water till yellow string of
strip turns brown. Meanwhile white color appears from bottom indicating salt
connection.
5.

Always use rubber gloves before performing the test.

Whirling & Sling Hygrometer

Climatic Condition Testing. During the application of a coating, the presence of
moisture in the environment, or on the work surface, often results in a poor quality
finish. Problems such as poor adhesion of the coating or premature corrosion of the
substrate can occur. To determine the likelihood of moisture affecting the quality of the
finish, it is essential that the surface temperature, air temperature, relative humidity
(RH) and dew point are all measured.

Dew point Calculator

This provides accurate values of Relative Humidity (RH) and Dew point from the wet
and dry bulb temperatures measured by a Whirling or Sling Hygrometer - such as
the Elcometer 116 range.
The range of the Elcometer 114 is -10C to 50C (14F to 122F) and it has an
accuracy of 1% of standard tables.

Dew meter
Has been designed to incorporate all the needs required for climate condition
monitoring, in a single gauge. This simple to use dew check measures all the parameters
required to determine if the climatic conditions are correct for coating to commence including - air temperature, relative humidity, surface temperature, dew point
temperature and delta - the difference between dew point and surface temperature.

Coating Material

Adequate facilities for storage

Quality

Application Surface

Mixing (With agitator)

Shelf Life (Check Expiry Date)/Pot life

Humidity

Manufacturers recommendation

1. Paint is a liquid material, which, when applied on a substrate, turns into a solid, adhering film
that forms a protective and / or decorative coating. Its main constituents are binder and
pigments (and filler). In its liquid form the binder is usually diluted by a solvent to render the
paint fir for application. The combination of binder and solvent is called the vehicle.
2. The BINDER determines the film formation and the general performance of the paint
coating. In most cases it is of a rather complex nature, which is determined by the specific
conditions the paint has to be used under and to withstand. Because of the wide variety of
conditions, the universal binder does not exist, and most likely never will.
3. The PIGMENT is responsible for the decorative value, including color, hiding power, , gloss,
light fastness, etc. Certain types are used for other purposes. Such as corrosion inhibition and
resistance to biological attacks, e.g. Fouling under water. Like the binder, the pigmentation
of a paint represents a balance of properties.
4. The FILLERS are non coloring pigments especially used to influence some of the physical
properties of the paint.
5. The SOLVENT act as a servant for the other two. It is responsible for the viscosity and for
the application properties. When the paint is applied the solvent has served its purposes and
disappears by evaporation.
6. Paint can be divided into two main groups according to their solidification or film formation
which may be either a physical or a chemical process.

Paint can be divided into two main groups according to their solidification or film
formation which may be either a physical or a chemical process.
1. Physical film formation.
This mechanism can also be described as evaporation drying. The solidification safely relies
on the evaporation of the solvent which is a physical process. The binder in the dry
film is chemically the same as it was in the paint can. The principle binders are of
widely different nature, ranging from bitumen to vinyl. Acrylics and chlorinated
polymers. Physically drying paints are thermoplastic. They are also sensitive to
solvents, including their own solvents.
2. Chemical film formation.
The chemical process differ which accounts for the division in to sub groups:Oxidative drying.
The drying mechanism is due to the fact that the binder contains drying oil. When
exposed to air the binder takes up oxygen and is thus converted into a
chemically new material. The most widely used type of oxidative drying
binder is alkyd, but many others exist.
II. Chemically curing.
In chemically curing paints the film is formed by chemical reactions in the binder.
By definition the reactions do not include oxygen uptake. Ordinarily, the

There are three specified painting zones

1. Atmospheric Zone.
2. Splash Zone (High Tide).
3. Submerge Zone (Low Tide).

Enamel/Polyurethane
High Build Epoxy
Coal Tar Epoxy

1
Weather Condition

HT

LEVEL

LT

1.Minimum 5 C
2.Maximum 55 C
3.Maximum Humidity 85%
4. Dew Point
5. Surface Temp Max 70 C

Epoxy history
The
wordepoxy
epoxy
derived
from
Greek
prefixes
- epi,means
which"upon"
meansand
"upon"
The word
is is
derived
from
two two
Greek
prefixes
- epi, which
oxy,
and oxy,
which
means "sharp/acidic".
which
means
"sharp/acidic".
The history of epoxy chemistry probably began in the early 1900s, when the
The
history
of epoxyPrileschajev
chemistry probably
beganthat
in the
early 1900s,
the Russian
Russian
chemist
discovered
olefins
react when
with peroxybenzoic
chemist
Prileschajev
discovered
that olefins react
with peroxybenzoic
to form
acid to form
epoxides.
In the mid-1930s,
the German
P. Schlockacid
applied
for a
epoxides.
In
the
mid-1930s,
the
German
P.
Schlock
applied
for
a
patent
on
the
preparation
patent on the preparation of high molecular weight polyamines by making the
of high molecular weight polyamines by making the amines react with peroxide
amines
react with peroxide compounds that contain more than one peroxide
compounds that contain more than one epoxide group. The patent was described as the
group.
patent was
described
as the peroxide
compounds'
reaction of
epoxide The
compounds'
reaction
of epichlorohydrin
with bisphenol
A.
epichlorohydrin with biphenyl A.
The
epoxychemistry
chemistry
know
theof
fields
of and
marine
and
The epoxy
thatthat
we we
know
todaytoday
withinwithin
the fields
marine
industrial
industrial was
protection
protection
recognized
wassimultaneously
recognized simultaneously
by P. Castan fromby
Switzerland
P. Castanand
from
S. Greenlee
from
USA. These
chemists applied
for various
in the lateapplied
1930s. The
Switzerland
andtwo
S. Greenlee
from USA.
Thesepatents
two chemists
for first type
of
epoxy patents
resin wasincommercialized
byThe
Cibafirst
in 1946.
various
the late 1930s.
type of epoxy resin was
commercialized by Ciba in 1946.
Hempel launched its first epoxy products in the mid-1950s, under the names Tanker Protect
Hempen launched its first epoxy products in the mid-1950s, under the names
Primer and Tanker Protect Topcoat. Epoxy has since grown to become the most important
Tanker
Primer protection
and Tanker
Protectand
Topcoat.
Epoxy
has since grown to
product Protect
used as surface
in marine
industrial
applications.
become the most important product used as surface protection in marine and
industrial applications.

Coating Application

Spray Equipment
Spray Application
Brush / Roller Application

Spray Equipment

The compressor should be capable of supplying continuous volume of 20 cfm at

a minimum of 80 psi to each nozzle. A supply of tips with varying spray angles
and washers, as recommended by paint suppliers for each specific steel
configuration to be coated should be available.

Lines and pots must be cleaned with solvent / thinner before adding new coating
material.

Adequate moisture trap shall be placed between the air supply and the pressure
Pot feed to the gun. Water or oil from the air supply should be continuously bled
off.

Suitable working regulator and gauges should be provided for air supply to
pressure pot, and air supply to the pressure gun. Spray equipment should be
grounded and non conducting hoses should be used.

For air less spray, equipment should use a 28:1 or 30:1 pump ratio. Air supply
should be 80 100 psi. For conventional air spray, equipment should include
pressure pot with mechanical agitator and separator atomizing and fluid
pressure regulators.

Spray application

The gun should held at right angles to the surface. For airless spray, the spray gun
should be held no closer than 1 ft, and no further than 2 ft from the surface.

For air spray the spray gun should be held no closer than 6"and no further than
10" from the surface.

Even and parallel passes should be made with the spray gun. Each spray should
overlap the previous by 50%. Large surface should be always receiving passes in
two directions at right angles to each other.

Each coat should be applied uniformly and completely over the entire surface. All
runs and sags should be brushed out immediately or the coating/paint should be
removed and the surface resprayed.

Before spraying each coat, all areas such as corners, edges, welds, small brackets,
bolts, nuts, etc. should be recoated by brush to ensure that these areas have at
least the minimum specified film thickness.

Airless Pump

Spray Gun

Brush / Roller application.

Brushes used in brush application should be of a style quality and will permit proper
application of the paint. Round or oval brushes Generally are considered most suitable
for rivets, bolts, irregular surfaces, and rough or pitted surfaces. Wide flat brushes are
suitable for large flat areas, but they should not have a width of over 4.5". No
extending handles should be allowed on paint brushes.

Brushing should be done that a smooth coat as nearly uniform in thickness as possible, is
obtained. There should be no deep or detrimental brush marks. Paint/coating should be
worked into all crevices and corners.

Runs or sags should be brushed out.

Successive coats should be applied by cross hatching the Previous Coat In brushing of
the solvent base coatings, care must be taken so that no lifting of formers coats occur.

During application of each coat, all areas such as corners, edges, welds, Small brackets,
bolts, nuts, and interstices shall receive additional coating material to ensure that these
areas have at Least the minimum specified film thickness and to ensure continuity of the
coating.

Inspection Hold Points

Visual Inspection

Enclosed areas

Inside Corners

Inside / Outside Edges

Weld seams (Stripe Coat)

Large Horizontal Surface

Large Vertical Surface

Around Fittings

Sagging / Over spray

Masked Off Areas

Ambient conditions (Pre-Preparation)

TD

TD

Pre-surface preparation conditions (Weld, rust, edges, etc.)

VD

VD

VD/TP

RD/VO/TP

Abrasive cleanliness

TP

RP/TP

Compressed air cleanliness

TD

RD/TP

Soluble salt contamination

TD

RO/TP

Soluble salt remediation

VO

VO

Ambient conditions (Pre-Mixing and application)

TD

TD

Mixing and material (Batch No. Shelf Life, Pot life, Thinner ratio, etc.)

VD

RO/TP

VD/TP

VD/TP/RD

Compressed air Cleanliness (Spray/application)

TD

RD/TP

Wet Film Thickness

TO

RO/TP

Stripe Coat, Caulking, Intercoat cleanliness, etc.

VO

RO/VO

Dry Film Thickness

TO

TO

Visual appearance (runs, sags, etc.)

VO

VO

Repairs. (Procedure, method)

VO

VO

Pre-surface preparation conditions (grease, dust, , etc.) and / or SP 1

Surface Preparation equipment operation and abrasive size/type

Application equipment operation (Pressure, agitation, type, etc.)

Legend
Type of Verification

Frequency of Verification.
D = Daily

V = Visual

O = Occurrence - Base

T = Testing

P = Periodic

R = Review of QC report or testing

House Keeping

House Keeping

Work Area

Storage Area

Mixing utensils & containers

Wet Coating Safe Grades

Painting Defects

Sagging & Curtaining

Orange Peel Effect

Wrinkling or Lifting

Rough Surface Finish

Pin Holing

Thin Areas

Over Spray

Sagging

Figure 2. Second cut

Figure 1. First cut

Figure 4. Apply tape

Figure 3. Remove debris by brush

Figure 5. Remove tape at 60 or 180

Surface

Description

I
S
O

The edges of the cuts are completely smooth; none of the squares of the lattice is detached

A
S
T

5B

Detachment of flakes of the coating at the intersections of the cuts. A cross cut area not
significantly greater than 5% is effected

4B

The coating has flaked along the edges and/or at the intersections of the cuts. A cross cut
area not signifanctly greater than 5% but not significantly greater than 15% is effected

3B

The coating has flaked along the edges of the cuts in large ribbons and/or some squares
have detached partly or wholly. A cross cut area significantly greater than 35%, but not
significantly greater than 65%, is affected.

2B

The coating has flaked along the edges of the cuts partly or wholly in large ribbons, and/or it
has flaked partly or wholly on different parts of the squares. A cross cut area Significantly
greater than 15%, but not significantly greater than 35%, is affected.

1B

Any degree of flaking that cannot be classified even by classification 4 (1B).

0B

Coating Application

Procedure

Material Inspection

Homogeneous Mixing

Thinning

Material Wastage Control

Spray Equipment

Spray Gun and Tip (Reversible)

Airless Pump

Fluid Hoses

Air Hoses

Filter & Strainers

Water Separators

Pressure Gauges

Spray Equipment

Coating Inspection

Proper Application

Runs & Sages

Wet Film Thickness

Dry Film Thickness

Holiday Detection

Wet Film Thickness

Dry Film Thickness Gauge

Holiday Detector

Holiday Detector

Holiday Detector is a portable quality control inspection

instrument used to electrically locate defects in protective coatings up
to 30 mils applied to metallic or concrete structures.

The detector converts low voltage direct current (rechargeable

batteries) into regulated high voltage pulses.

Output voltage is selectable from 1,000 to 3,000 volts in 10

settings.

This versatile unit can be used to inspect protective coatings

applied to pipelines, tanks, pilings or any similar conductive
surface.

The solid state capacitor discharge circuit provides genuine

regulated output voltages that ensure unchanged inspection
voltages regardless of weather conditions, type or size of exploring
electrode or structure.

COATING INSPECTORS KIT

Coating specification.
Manufacturers data sheet.
Blasting and coating equipment check list.
Inspection Report.
Anchor pattern measurement device. (Profile Gauge) Dial indicator. Press o film.
Wet film thickness gauge (Comb)
Dry film thickness gauge. Magnetic gauges, Elcometer.
High intensity battery powered light.
White coverall.
Gloves lint free.
Rubber soled shoes.
Thermometer. For air temperature.
Humidity gauge. Or sling psycho meter.
Contact thermometer. Metal temperature gauge.
Sharp knife.
Hypodermic needle pressure gauge.

CONTRACTORS EQUIPMENT CHECK LIST

Date: ______________
Project: ____________
Contractor/Maintenance crew Leader.____________________ Job Location ________
Compressor Size-cfm.____ Manifold outlet size. __ Gauges. __No. of outlets. ___ Oil Leaks ____
General Condition. ______________________________________________________________
Remarks: ______________________________________________________________________
Dead man, Handle and hoses fitted / not fitted. ________________________________________
Remarks: Air Hood. Air hoses, purifiers type _____ size______ condition. __________________
Blasting Nozzle size. _______condition._______ Type. ________. Remarks.
Blast Pots. Quantity. Type. _____ Size. _______ Condition. ___
Moisture Trap. ________Air Hoses,_____ size.________ Condition_______ Remarks.
Air less spray pump. Type.___ Ratio. ___No. of spare filters.___ Mesh size._________
Hand set. _____ Condition. ______Liquid line size. ______coupling ________________
gauges. ______ Tip Size. ______ Reversible tip condition. __________________________
No of machines on site. ________ Spare Hand set. ________ Spare Tips. ____Tools.
Remarks. ___________________________________________________________________
Paint mixer type _______________________ size _______________________
Inspectors Name ____________________ Signature. _____________________________
Contractors Representative Name _________________________Signature._________________

INSPECTION & TEST REPROT: PAINTS & COATING

PLANT #___________________ PLANT NAME ___________________________________
Previous Coating _______________
Shop /field applied ___________________________
Contractor/Coating Crew Name _______________ Reg. #____________ Phone # ___________________
Work Started at ___________am/pm
work completed at _____________________am/pm
BLAST CLEANING / HAND TOOL / POWER TOOL
NACE / Sa _______ Profile Depth ________
Started ________________am/pm Date _________Finished ____ am/pm Date ___________
Compressor size ____cfm, Nozzle Pressure ___ psi, Nozzle Size_____ Air Hose Size _____ Length _____ Blast Hose Size ______Length _______
COATING SPECIFICATION
Primer Prod # _________________
Mfg. Date ____________________
Expire Date ___________________
Batch #_______________________
Color # ______________________
Stock # ______________________
Amount at site ________________

Top Coat Prod # ___________________________

Mfg. Date ________________________________
Expire Date ______________________________
Batch # __________________________________
Color # __________________________________
Stock # __________________________________
Amount at site _____________________________

COATING APPLIED BY (Brush, Airless or conventional)

Date____________1st Coat ____________am/pm
Air Temp ________
Date __________ 2nd Coat ____________am/pm
Air Temp ________
Date ___________ 3rd Coat ____________ am/pm
Air Temp _______
W.F.T.

Metal Temp______
Metal Temp______
Metal Temp ______

1st Coat _____________ 2nd Coat ____________ 3rd Coat ___________________

D.F.T.
1st Coat _____________ 2nd Coat _____________ 3rd Coat ___________________
Remarks______________________________________________________________________
Inspector: NAME ---------------------------------------------------

SIG ----------------

Steps for Sandblasting

Dead man with remote control

No loose dress + safety shoes

Air Fed Face Shield

Leather Gloves

Trained & Skilled workforce

Lighting Explosion Proof In Confined Space

Scaffolding (if required)

Communication

Sand Blasting.
1.

Provide dead man or remote control valve fitted at the blasting nozzle
for
safety. Adequate grounding for static should be provided. Provide sufficient
number of dust evacuators, and provide canvas screen around the work area.

2.

Provide air-fed head shield for blast nozzle operators, which must be in Good
Operating condition. No blasting should be allowed without this device.

3.

Always use respirators in dusty atmosphere, especially when silica sand is in use
For surface preparation. Always check the wind direction and never allow the
worker to sit in dusty environment. Properly trained, certified, physically fit, and
alert blast cleaning equipment operators and support personnel must be used.

4.

Unnecessary peoples should keep away of the blasting area.

5.

Adequate lighting (Explosion Proof) should be provided especially for blasting

inside of the tanks and vessels. Battery operated flash light (24 V DC) should be
used. Two men as stand by should be used at entrance to vessel.

6.

Secure and adequate scaffolding should be placed to assure the inspector

And the blasting equipment operator sufficient vantage point from which to
operate.

1.

Always follow the Occupational Health and Safety Act. (OHSA).

2.

Acute Silicosis is a lung disease that develops rapidly.

3.

This occurs through inhalation of small airborne particles of

silica dust, mainly in the range of 0.5 which are not expelled
from the lung when inhaled. Instead, they remain in the lung
and are deposited in lymph nodes, where over time, calcium can
deposit in those nodes and settle along the rim of lymph node.

4.

The condition is known as egg-shell classification. In some

cases, silica particles are carried into the lungs where a scar
may form around the particles. Over time, the hardened scars
gradually start to show up on the chest x-ray as fibrosis of the
lung.

Sand Blasting Equipment

Coating Application

No Careless move with spray gun

Keep Clear Area
Never Point the gun toward any one
Never Put Finger in front of gun
Use apron Eye & Ear Protection
Never Leave the Gun un-attendant
Never Exceed the Air Pressure
Never Clean the Tip with Pressure
Never Flush Thinner in the Direct Sun
Always use Low Pressure

What are the implementations for

Sandblasting & Coating?

Coating Specification

Contractor Selection

Job Scheduling

Coating Job Progressive Inspection

Coating Specification
2.1 MATERIALS
2.2 PAINT APPROVAL
2.3 PAINTING CONTRACTOR
Manufacturer.
3. SURFACE PREPARATION
3.1 GENERAL
3.2 SURFACE PREPARATION BY BLAST CLEANING
3.2.1 General
3.2.2 Blast cleaning equipment
3.2.3 Abrasives
3.2.4 Grades of surface finish
3.2.5 Performance and application conditions
3.3 SURFACE PREPARATION BY HAND AND POWER TOOL CLEANING
4. PAINT APPLICATION
4.1 GENERAL
4.2 PAINT APPLICATION REQUIREMENTS
4.2.1 Spray application
4.2.2 Brush application
4.2.3 Roller application
5. PAINTING SCHEDULES AND PAINT SYSTEMS
5.1 GENERAL
5.2 GENERIC PAINT CHARACTERISTICS
6. INSPECTION AND TESTING

Contractor Selection
The painting Contractor shall be responsible for:
1. The quality of workmanship, which shall be performed in accordance with this DEP and all
other relevant documents such as site regulations, safety rules, referred standards and codes,
etc.
2. Obtaining the Principal's assurance that the equipment is certified safe and available and that
all appropriate tests are completed before starting any painting work.
3. The protection of all equipment, structures and any other areas from mechanical damage,
environmental damage, damage caused by abrasives during blast cleaning, paint droppings, or
overspray.
4. The earthling of electrical equipment.
5. Taking all necessary precautions to avoid interference with the execution of work of other
contractors
6. Maintenance of the paint work until completion of the contract. This shall include the repair of
any damages caused by third parties.
7. The characteristics of the paints and paint materials obtained from the paint

Job Scheduling
PAINTING SCHEDULES
Table 1-1
PIPING, VESSELS, COLUMNS, EXCHANGERS, REACTORS,
STRUCTURAL STEEL AND FIRE-FIGHTING SYSTEMS
ITEM
OPERATING TEMP (C)
SUBSTRATE
PAINT SYS NUMBER
Table 1-2
TANKS AND LPG STORAGE
ITEM OPERATING TEMP (C) SUBSTRATE
CRUDE OIL TANKS
STORAGE TANKS

Primer

Inter-coat

PAINT SYS

NUMBER
(see Appendix

Top coat

Table 1-3
FURNACES, STACKS, FLARE STACKS, FLUE DUCTS, OFFSHORE
RUCTURES, TOPSIDE FACILITIES
ITEM OPERATING TEMP (C)
SUBSTRATE
PAINT SYS NUMBER
(see Appendix 2)
APPENDIX 2 PAINT SYSTEMS
SYSTEM NUMBER
SURFACE PR

PAINT SYSTEM
Primer

Inter-coat

Top coat

Code and Standards

SIS
Swedish Institute of Standards.
ANS I
American National Institute of Standards.
JIS
Japan Institute of Standards.
BSI
British Institute of Standards
SSPC
Steel Structure Painting Council
N AC E
National Association of Corrosive Engineering
ASM E
American Standard for Mechanical Engineering
A W W AAmerican Water Works Association
SSPC Vol 1 & 2. Specification of SSPC
NACE RP 0178-95 Fabrication details, Surface finish requirements and proper design considerations for Tanks and
Vessels to be lined for immersion.

SSPC SP-!-91
SIS 055 900
ISO 9000 2000.

Solvent cleaning (SSPC Manual Chapter 2 Surface Preparation Specification.

Surface Preparation Standard for Painting Steel Structure.

Quality System

Acid
Alkaline
Binder
Blistering
Drier

Having a pH of less than 7; turns blue litmus paper red

Having a pH of more than 7; turns red litmus paper blue
The non-volatile part of a medium
Isolated convex deformation of a paint film in the form of blisters arising
from the detachment of one or more of the coats
A compound, usually organic-metallic and soluble in organic solvents and
binders, which is added to paint to accelerate drying by catalytic

oxidation
Dry film Thickness (DFT) The thickness of a coating after all the solvent has evaporated and the
coating has cured
Evaporate
To convert from a liquid into vapor

Filler
A composition used for filling fine cracks and indentations to obtain a smooth f
preparatory to painting
Gloss

The visual impression created by the reflecting properties of a surface

Hardener

A cross-linking agent used to cure a resin or paint system

Holidays

Defects characterized by a film having areas of insufficient thickness, even to

the point where parts of the surface may remain uncoated
A material used in small proportion to slow a chemical reaction
The pock-marked appearance of a sprayed film due to its failure to flow out
to a level surface

Inhibitor
Orange Peel

Overspray
Pigment

Sprayed paint which misses the surface to be coated

A substance, generally in fine powder form, which is practically insoluble in
media and which is physically dispersed in the binder to impart specific
physical and chemical properties (optical, protective, decorative, etc.)
Pinholes
Minute holes in a dry film which form during application and drying of paint
Polymer
A chemical compound or mixture of compounds formed by polymerization
Primer
The first coat of a painting system that helps bind subsequent coats to the
and which may inhibit its deterioration
Resin
A natural or synthetic material used to bind pigments together and to the
substrate
Spreading Rate
Refers to the area, in square feet, which can be covered by one gallon of
coating at a given Wet Film Thickness (WFT)
Solvent
liquid, single or blended, which is volatile under normal drying conditions
and in which the binder will dissolve completely
Teardrops
Drops of paint which collect on the bottom edges of items painted by dipping
Thinner
A volatile liquid, single or blended, added to paint to facilitate application by
lowering the viscosity
Vehicle
The total sum of the constituents of the liquid phase of the paint
Wet Film Thickness (WFT) The thickness of a coating immediately after application, before any
solvent has evaporated