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Document No10004-KGOLPage (excluding attachment)11 of 20
RevisionB0Date Issued21-09-2014
SURFACE PREPARATION
&
PAINTING PROCEDURENotes:Client Approval:
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Fax : Web :
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2. Approved Submit Certified Final
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3. Approved as Noted Revise and Resubmit
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DATE:SIGN:
0210-09-2014IFASh.YazdaniV.NaderianA.Heforezai
REVISSUE DATEDESCRIPTIONPREPARED BYCHECKED BYAPPROVED BY
DEFINITION :
IFI : ISSUED FOR INFORMATION, IFA : ISSUED FOR APPROVAL, APP :
ISSUED FOR FINAL
LIST OF CONTENT
1.0INTRODUCTION
2.0REFERENCES
3.0 GENERAL3.1 Equipment3.2 Coating Material4.0SURFACE
PREPARATION
4.1General4.2 Pre-Cleaning of Surfaces and Solvent Cleaning4.3
Surface Preparation by Blast Cleaning4.4 Blasting Abrasives4.5
Techniques and Constraints4.6 Surface Preparation by Hand and Power
Tool Cleaning5.0PAINT APPLICATION
5.1 Pre Application Procedures5.2Scheduling5.3Application
Methods5.4Repair of Defects6.0 PAINTING AND COATING SYSTEM7.0 FLOW
CHART FOR INSPECTION OF BLASTING AND PAINTING ACTIVITIES7.1 Before
Blasting7.2After Blasting7.3Before coating7.4After coating8.0
INSPECTION AND TESTING9.0 DOCUMENTATION10.0SAFETY11.0ATTACHMENT11.1
Attachment 1Blasting and Painting Inspection Report
11.2Attachment 2Proposed Paint Technical
Datasheet1.0INTRODUCTION1.1 Scope
This Procedure covers the requirement surface preparation and
coating on steel surface for
2.0REFERENCES 2.1Reference document shall be the specification
herein and painting specification
a.
b.
3.0GENERAL 3.1 EquipmentThe compressed air supply for Blast
Cleaning equipment shall be free of water and oil. Adequate
separators and traps shall be provided and these shall be kept
emptied regularly of water and oil. Accumulations of oil and
moisture shall be removed from the air receiver by regular purging.
Air compressors shall not be allowed to deliver air at a
temperature in excess of 110 C. The grit shall normally be
discharged with a pressure of 7 bar measured at the nozzle using a
hypodermic pressure gauge and shall not under any circumstances
fall below 5.6 bar for normal cleaning operations.The coating
spraying equipment to be used shall meet the recommendations and
instructions set forth by the paint manufacturer for each specific
coating system. Airless Spray is normally the choice of application
method but if conventional air spray is used, an adequate moisture
trap shall be placed between the air supply and the pressure pot
feed to the gun. The trap shall continuously bleed off any water or
oil from the air supply.3.2 Coating MaterialStorage, thinning,
mixing and handling of paint materials shall be in accordance with
the Paint Manufacturers recommendation. All paint materials and
solvents shall be supplied in the paint manufacturers original
containers, durably and legibly marked with clear description of
the contents. This shall include the specification number, the
color reference number, the method of application for which it is
intended, the batch number, date of manufacture, the shelf life
expiry date and the paint manufacturers name or recognized
trademark.
Different brands or different make of paints shall not be
inter-mixed. Similarly, mixing of different brands or generic types
of paint material is not permitted. The Manufacturers pot-life
requirements shall be strictly and diligently followed. The same
shall be said for the minimum and maximum over-coating time as
recommended by paint manufacturerOnly thinners as specified by the
paint manufacturer shall be used. Mixing and thinning directions as
furnished by the paint manufacturer shall be followed. Statutory
requirements for levels of volatile organic compound are to be
met.4.0SURFACE PREPARATION
4.1GeneralFor optimum paint performance, surfaces to be painted
or coated shall be completely dry and free from burrs, weld
spatter, flux, rust, loose scale, dirt, dust, grease, oil and other
foreign matter deleterious and harmful to paint. After preparation
of substrate surface, any grit or dust shall be removed and a layer
of primer applied before any corrosion or recontamination occurs,
normally within four (4) hours after blasting. Surface preparation
shall be subjected to inspection before the primer coat is applied
to ensure all traces of dust and foreign matter have been removed
by brushing, blowing with dry clean compressed air or vacuum
cleaning.4.2 Pre-Cleaning of Surfaces and Solvent CleaningThis
cleaning process is mandatory before further cleaning or surface
preparation. Prior to the actual cleaning operation, surface
contaminants such as oil, grease, hydrocarbon etc. shall be removed
preferably by degreasing with suitable degreaser or solvent
cleaning according to SSPC-SP1. The degreased surface shall be
further washed or rinsed down with fresh water to remove all traces
of the degreaser chemicals. The surface shall be allowed to dry
thoroughly before proceeding with any further coating work. This
process also applies to all metal surfaces to be coated that do not
require blast cleaning or power tool cleaning.
Excessive rust scale shall be removed by impact cleaning tools
or high pressure water jetting. All edges shall be ground to a
minimum radius of 2 mm. Flame cut areas shall be ground
flush.4.3Surface Preparation by Blast CleaningBlast cleaning shall
be carried out through ISO 8504-2:1992 to the required visual
standard in accordance with ISO 8501-1:1988 or equivalents. All
surfaces, where accessible shall be prepared by abrasive blast
cleaning to a minimum of SA 2.5 ISO 8501-1(SSPC-SP10)4.4Blasting
AbrasivesBlasting abrasives for use in blast cleaning carbon steel
and low alloy steel are specified in ISO 8504-2. Recommended
blasting abrasives are as follows, but not limited to:a)Chilled
iron grit or shot
b) Steel and malleable iron grit or shot
c) Natural mineral abrasives
d) Non metallic abrasives (aluminium oxide, garnet etc)
All blasting abrasives shall be tested and qualified in
accordance with the procedures described in SSPC-AB1 Abrasive
Specification No.1; Mineral and Slag Abrasives.
Abrasives that are classified as Scheduled Waste under the
Environmental Quality Act (EQA) 1974 shall not be used. Sand or
other materials producing silica dust shall not be used. The
abrasives shall be free from oil, grease, moisture, salt, dust etc.
Re-used abrasives shall be clean, sharp and free from contaminants
and re-qualified to SSPC-AB 1 requirements. The blast profile and
angular anchor pattern shall be that recommended by the paint
manufacturer to suit the minimum requirements of their respective
primers. The acceptable peak-to-valley height range shall be
between 50 ~ 75 microns.4.5Techniques and ConstraintsBlast cleaning
shall not be carried out when the temperature of the surfaces to be
coated is less than 3 Celsius above the dew point or when th e
relative humidity of the air is greater than 85 %.
Abrasive blasting shall not be done in open areas close to
painting operations or wet coated surfaces to prevent dust and grit
contamination. Normally grit blasting shall be permitted only
during daylight hours except that rough grit blasting will be
allowed during the night provided that the surface is subsequently
blasted to the specified standard under good light conditions. The
illumination of the surface during final blasting shall be at least
500 Lux and all environmental restrictions are observed.
All welded areas and appurtenances shall be given special
attention for removal of welding flux in crevices. Welding
spatters, slivers, laminations and underlying mill scale not
removed during fabrication and exposed before and during blast
cleaning operations shall be removed by the best mechanical means
and the edges smoothed or rendered flush. Where rectification is
necessary on abrasive blast cleaned surfaces, the dressed areas
shall be re-blasted to remove all rust, slag and grit and to
provide an adequate anchor pattern.
Blasting shall continue a minimum of 25 mm into any adjacent
coated areas and the edges shall be feathered. After dry blast
cleaning, no acid washes, cleaning solutions, solvents or other
chemical treatment shall be used on metal surfaces. This
restriction includes inhibitive washes to prevent rusting. Any
blast-cleaned steelworks on which rust develops shall be re-blasted
prior to being painted.4.6Surface Preparation by Hand and Power
Tool CleaningThe most technically effective surface preparation
method is blast cleaning. Manual preparation shall only be used
when blast cleaning is either not feasible or not strictly required
eg. galvanize steel and stainless steel.
Manual cleaning shall be performed using hand wire brushes or
mechanically operated tools (grinders, chippers, wire brushes) in
accordance with ISO 8504-3. Where welds occur within these areas or
when these areas cannot accommodate a power disc, power impact
tools shall be applied (vibratory and rotary hammers, needle guns,
chisels) followed by brush cleaning.
If the surface being prepared lies adjacent to a coated surface
which is not to be refurbished, the power tool cleaning shall
overlap the coated surface by at least 25 mm. The minimum
requirement for successful coating application is St 3 ISO 8501-1
(SSPC-SP3) at the time of coating. Care shall be taken to ensure
that the substrate surface does not become polished during power
tool cleaning.5.0PAINT APPLICATION5.1 Pre Application
Procedures
5.1.1 GeneralAny surfaces to be coated shall be dry and rendered
dust free prior to application of primer coat. This can be
accomplished by blowing off the surface with clean dry air or using
an industrial vacuum cleaner together with a clean dry stiff brush.
The blasted surfaces shall be examined for traces of smudge, oil,
grease or other contamination and also tested for the presence of
soluble salts. If present they shall be removed by solvent washing
or for salts by water washing or steam cleaning and the areas
re-blasted.5.1.2 Mixing and ThinningAll coating materials shall
be thoroughly stirred in a pressure pot with a power mixer for a
time sufficient to thoroughly remix the pigments and vehicles.
Sufficient agitation to maintain good mixing shall be applied until
the product is used. Coatings containing heavy or metallic pigments
that have a tendency to settle shall be kept in continuous
suspension in the
pressure pot by a mechanical agitator or stirrer
If during mixing / stirring air is entrapped in the product,
sufficient time should be allowed for air bubbles to escape, before
application is started. This is to reduce the risk of pin-holing of
the coating layer to be produced
Thinner shall not be added to primer or paints unless necessary
for proper application according to the paint manufacturers
recommendation. The type of thinner used must comply with same.If
the coating material requires the addition of a catalyst, the pot
life under application conditions shall be clearly stated on the
label. The pot life shall not be exceeded. When the pot life limit
is reached, the spray pot shall be emptied, the material discarded,
the equipment cleaned and new material catalyzed.
Hydrostatic and other testing of welds shall be completed prior
to painting weld lanes, ends of pipe and related components that
will require subsequent welding at site shall be masked off after
blast cleaning and left uncoated for a distance of 50 mm from all
areas requiring welding.5.1.3 Other Miscellaneous RequirementsFor
multi-coat system, a mist coat shall be applied over inorganic zinc
primer to avoid surface defects. Necessary care shall be exercised
to ensure a smooth and uniform coating is applied over inorganic
zinc primer
Extra coats of paint shall be applied on areas where shape
and/or plane of application results in thinly applied coatings;
example at edges, weld behind angles, corners etc and areas not
fully accessible by spray in order to obtain the specified coverage
and thickness. A stripe coat of paint shall be brush applied before
applying the subsequent coat.5.2 SchedulingUnless otherwise
recommended by the paint manufacturer and accepted by the Customer,
paints shall NOT be applied when:5.2.1Incomplete surface
preparation or oil, grease and dust still present on substrate to
be painted.5.2.2 The surface temperature is less than 3C above Dew
point.
5.2.3 The air or surface temperature is below 5C as it would
adversely affect curing of Paint.
5.2.4 The relative humidity of air is greater than 85% except
for inorganic zinc silicate up to 90%.
5.2.5 The metal substrate temperature is higher than that
recommended by the paint manufacturer for application
5.2.6 There is a likelihood of an adverse change in weather
conditions within two hours after application that would result in
a drastic drop in air temperature below those as specified
above.
5.2.7 There is a deposition of moisture in the form of rain,
condensation etc. upon the surface.
5.2.8 The available light is less than 500 Lux
Blast cleaned or power disc grinded surfaces shall be coated
with the primer specified within four (4) hours after blasting or
power grinding or within such other limits as may be specified and
before any visible rusting occurs. Each coat of paint shall dry for
a time period within the limits prescribed by the Paint
Manufacturer before the next coat is applied (minimum and maximum
over-coating time).5.3 Application Methods5.3.1 GeneralCoatings
shall be uniformly applied without runs, sags, solvent blisters,
dry spray or other blemishes. All blemishes and other
irregularities shall be repaired or completely removed and
recoated. Special attention shall be paid to crevices, corners,
edges, weld lines, bolt heads, nuts and small brackets to apply the
specified minimum dry film thickness by brush
application if spray will not completely cover all
surfaces.Edges of existing coating shall be feathered towards the
substrate prior to over-coating Primers should not be over-coated
with the second coat paint until the specified minimum over-coating
time is achieved
Inter-coat contamination shall be minimized by maintaining
proper cleanliness and by applying the intermediate and finish
coats within the over-coating time recommended by the paint
manufacturer. If contaminants are present, they shall be removed
before applying succeeding coats. Contrasting color shall be used
for each coat of paint.5.3.2 Spray ApplicationPaints shall be
applied by Air Spray (Conventional) or Airless Spray
Hose and containers, lines and pots shall be thoroughly cleaned
before addition of new materials. The spray gun shall be held no
closer than 200 mm (between 450 mm to 600 mm) from the surface to
be coated at right angles to the surface. Uniform parallel passes
should be made with the spray gun. Each spray pass shall overlap
the previous pass by 50%. Large surfaces should always receive
passes in two directions at right angles to each other.
Each coat is to be applied uniformly and completely over the
entire surface. All runs and sags shall be brushed out immediately
or the paint removed and the surface re-sprayed. Before spraying
each coat, all areas such as corners, edges, welds, small brackets,
bolts, nuts and interstices shall be pre-coated, usually by brush
to ensure that these areas have at
Least the minimum specified film thickness.5.3.3 Brush
ApplicationBrush application may be used under the following
circumstances:
a)When spraying for any reasons cannot properly coat areas
b) When spray application is deemed to be difficult, adverse to
the required quality finish, uneconomical or may affect other
plant, equipment property, personnel etc. due to location of work
accessibility
c) For the application of self-etching primers
d) For touch-up or repair to localized damaged paint areas or
areas of incorrectly applied paint
e) For application of initial stripe coat of paint to corners,
edges, crevices, holes, welds or other irregular surfaces
Paint brushes used shall be of a style and quality that will
permit proper and appropriate application of paint. Good quality
hog bristle is preferred and nylon or other synthetic bristle types
are prohibited. Round or oval brushes are considered most suitable
for rivets, bolts, irregular surfaces etc. Wide flat brushes are
suitable for large flat areas but not to exceed
Width of 120 mm. Brushes shall be kept in good condition at all
times and discarded if damaged or excessively worn. The brushing
shall be done so that a smooth coat, as uniform in thickness as
possible is obtained. There should be no deep or detrimental brush
marks.
Paint shall be worked into all crevices and corners. Runs and
sags shall be brushed out. 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 coating5.3.4 Roller ApplicationRoller
application shall be discouraged and shall be subject to the
specific approval of customer. If allowed, it will only be used on
relatively large surface areas provide the first primer coat of
paint is applied by brush and its use in accordance to Paint
Manufacturers instructions. Rollers shall be manufactured from good
quality carpet pile or lambs wool.5.4 Repair of Defects5.4.1
GeneralA specific paint system or scheme for the repair and/or
touch-up painting of each generic type shall be submitted for
approval from customer
Before application of any further coat of material, all damages
to previous coats shall be repaired. All loose paint shall be
removed to a firm edge. All surface irregularities and contaminants
shall be removed. Hard glossy surfaces may require abrading to
obtained suitable surface for painting.
If the surface being prepared lies adjacent to a sound coated
surface which is not to be repaired, the surface preparation shall
overlap the coated surface by at least 25 mm.5.4.2 Inadequate
Coating ThicknessAreas with inadequate coating thickness shall be
thoroughly cleaned and if necessary abraded and additional
compatible coats applied shall blend in with the final coating on
adjoining areas.5.4.3 Coating Damage not exposing steel surface
substrateThe damaged area shall first be washed down to remove all
contamination, followed by rinsing with clean fresh potable water
and left to dry. The coating around the damaged area shall be
feathered or chamfered by sanding down to ensure continuity of the
patch coating. The full coating system shall then be re-applied
strictly in accordance with specification5.4.4 Coating Damage
exposing steel surface substrateThe damaged area shall be
re-cleaned as originally specified for that item and the full
coating system re-applied in accordance with paint technical data
sheet. The re-cleaning shall carry over on to the secure
surrounding coating for not less than 25mm all round and the edges
shall be feathered or chamfered by sanding down to ensure
continuity of the patch coating.5.4.5 Repair of Zinc Silicate
primerDamaged surfaces of zinc primer shall be cleaned to remove
all loose materials and blast cleaned with a portable vacuum blast
cleaning unit. The surfaces shall be coated with one coat of the
primer which is the same as the damaged primer. If blast cleaning
is not possible, power tool cleaning may be used subject to
customer agreement.5.4.6 Repair of Fully Cured Epoxy coatingsIn
case of repairing damage to fully cured epoxy coatings, the coating
work shall only be carried out after the surface of the fully cured
epoxy to be coated has been suitably abraded to provide an adequate
tooth for the coating to be applied. The repair coating shall be
compatible with the existing coating.6.0 PAINTING AND COATING
SYSTEM
6.1 Painting material will be applied according to the design
temperature and services condition. Selection of paint material is
also confirmed by Paint Manufacturer. 6.2Painting coating system
shall be in accordance Table 2 & Table 3 in this procedure.
7.0 FLOW CHART FOR INSPECTION OF BLASTING AND PAINTING
ACTIVITIES7.1 Before Blasting
7.2 After Blasting
7.3 Before coating
7.4 After coating
8.0 INSPECTION AND TESTING
8.1The following inspection shall be carried out after in
accordance with Table 1 in this procedure. Surface shall be
accessible until final inspection is carried out. 8.2Individual
coat and completed coating shall be visually inspected for
appearance. Coatings shall be smooth and free from run, cracking,
blistering, dry spray, over spray, pinholes, crater and
sagging.
8.3During coating, the wet film thickness shall be spot-checked.
Specified total minimum DFT shall be spot-checked by thickness
gauge. Dry film thickness shall also be measured on individual
coats. WFT and DFT measurements shall comply with ASTM D 4414 and
SSPC-PA2 respectively.8.4Temperature and relative humidity shall be
measured by means of a temperature gauge and hygrometer. Reading
shall be taken at regular intervals, depending on change in
climatic condition8.5Coating shall be removed and repainted if the
specification reveals the following:
a)Coating not adhering to surface to which it is applied
b)Surface has not been properly blasted and/or clean
c) Loose or scaling paints remains
d)Foreign matter (contamination) embedded into coated
surface.
e)Freshly coating surface is wet from rain, high humidity or low
dew points.f)Previously applied coating has not cured.
e)For other reason that will impair the coating performance.9.0
DOCUMENTATION9.1Inspection results for surface preparation and
coating shall be recorded in Painting Inspection Report as per
Attachment 2.10.0 SAFETY10.1 All safety and regulations of
Malaysian and local laws and insurance underwriterRegulations shall
be adhered to in the storing, handling, use and application of
paints, thinners, solvents, etc.10.2Smoking, open fires, or sparks
will not be permitted in confined areas that are being or recently
have been painted and are emitting flammable solvents.10.3All
equipment recommended lifting up by using the lifting lug attached
due the painting work to avoid any damage or uneven distribution of
paints on the equipment main body.
10.4The following documentation shall be provided and used when
evaluating coating systems:a)Chemical name of organic solvent, OAR
number, and VOC content in g/l;
b)Percentage of low molecular epoxy (molecular weight <
700);
c)Content of hazardous substances;
d)Specification of hazardous thermal degradation components;
e)Combustibility;
f)Special handling precautions and personal protection.
10.5Use of Personal Protective Equipment (PPE) shall be
mandatory to avoid any incident / accident / health hazard during
blasting and painting activities.
11.0 ATTACHMENT11.1 Attachment 1Blasting and Painting Inspection
Report
11.2Attachment 2Proposed Paint Technical DatasheetTable 1 -
Inspection & Testing
Test TypeMethodFrequencyAcceptance CriteriaConsequence
EnvironmentalconditionsAmbient and steel temperature, relative
humidity,Dew pointBefore start of each shift and minimum twice per
shiftIn accordance with specified requirementsNo blasting or
coating
Visual examinationVisual for sharp edges weld spatter, slivers,
rust grade etc100% of all surfaceNo defects, see specified
requirementsDefects to be repaired
Cleanlinessa) ISO 8501-1b) ISO 8502-3 a) 100% visual all
surfacesb) Spot checksa) In accordance
with specified
requirementsb) Maximum quantity
& size is rating 2a) Re-blastingb) Re-cleaning
and retesting
until
acceptable
Salt testISO 8502-6 and ISO 8502-92 every 1m2Soluble salts
(NaCl) less than 3mg/cm3Repeated washing with potable water and
retesting until acceptable
RoughnessComparator or stylus instrumentISO 8503Each component
or once per 10m2In accordance with specified paint
systemRe-blasting until acceptable
Curing test
(for Zn silicate)ASTM D4752Each component or once per
100m2Rating 4-5Allow to cure
Visual examinationVisual to determine curing, contamination,
solvent retention, pinholes/popping,sagging and surface defects100%
of surface after each coatIn accordance with specified
requirementsRepair of defects and retesting
Wet film thickness (WFT)SSPC-PA2Systematically during any
applicationIn accordance with specified paint systemRepair or
re-coating as appropriate
Dry film thickness (DFT)SSPC-PA2Each coat, when coating system
are curedIn accordance with specified paint systemRepair or
re-coating as appropriate
AdhesionASTM D4541(on test panel)Spot checks when coating system
are curedMinimum value
3 MpaCoating to be rejected
Table 2 Painting system for carbon steel substrateSurface
MaterialCarbon SteelOperating Temp-
ApplicationExternalPart -
Painting System No3.1InsulationN/A
Paint ManufacturerBAJAKSurface PreparationSA 2 and above
Coat NoPaint TypePaint ProductColorDFT
1Self-cured Inorganic Zinc (Primer) BAJAPOX ZINC 15360L
Red-grey
75
2Epoxy High Build (Tie oat)BAJAPOX HI-BUILD 45200
grey100
3Aliphatic Polyurethane (Top Coat) BAJATHANE * TOPCOAT 55210
* White/Blue50
Total DFT225