Table of contents
Table of contentsSection!;GeneralSection 2;Scope
Section3;Surface Preparation3.1 Classification of surface
Preparation3.1.1 Solvent Cleaning.
3.1.2 Hand tool cleaning
3.1.3 Power tool cleaning
3.1.4 Brush off blast
3.1.5 Commercial blast
3.1.6 Near white metal blast
3.1.7 White metal blast3.2 Blasting equipment selection
3.2.1 Compressor
3.2.2 Nozzle
3.2.3 Abrasive
3.3 Miscellaneous.
Section 4;Coating Material
4.1General4.2Material Specification
4.3Coating application
4.3.1Spray equipment
4.3.2Spray application
4.3.3Brush applicationSection5;Inspection
5.1Good house keeping5.1.1Clean and orderly work area
5.1.2Storage and issue area
5.1.3Mixing utensils and containers.
5.1.4.Wet coating safe guards.
5.2Surface preparation
5.2.1Prior to surface cleaning
5.2.2Blast cleaning equipment
5.2.3Abrasive medium
5.2.4Final inspection
5.3Coating application
5.3.1Application procedure
5.3.2Equipment
5.4Coating Inspection
5.4.1Wet film thickness
5.4.2Dry film thickness
5.4.3Holiday deductionSection6;Safety
6.1 General
6.2 Good housekeeping
6.3 Sand Blasting
6.4 Coating applicationSection7;Implementation
7.1 Coating specification
7.2 Contractor selection
7.3 Job scheduling
7.4 Coating job progressive inspection.
Attachment A;Coating Inspection Attachment B;Equipment check
list
Attachment C;Inspector Test report.
Attachment - D:Paint Failure Causes
Attachment - E:Standard Terminology for Paint and other coating
materials.
Epoxy history
The word epoxy is derived from two Greek prefixes - epi, which
means "upon" and oxy, which means "sharp/acidic".
The history of epoxy chemistry probably began in the early
1900s, when the Russian chemist Prileschajev discovered that
olefins react with peroxybenzoic acid to form epoxides. In the
mid-1930s, the German P. Schlock applied for a patent on the
preparation of high molecular weight polyamines by making the
amines react with epoxides compounds that contain more than one
epoxides group. The patent was described as the epoxide compounds'
reaction of epichlorohydrin with biphenyl A.
The epoxy chemistry that we know today within the fields of
marine and industrial protection was recognized simultaneously by
P. Castan from Switzerland and S. Greenlee from USA. These two
chemists applied for various patents in the late 1930s. The first
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 Primer and Tanker Protect Topcoat. Epoxy has since
grown to become the most important product used as surface
protection in marine and industrial applications.
Section 1:General
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?
What do we required to prevent iron and steel from rusting? Rust
is an insidious enemy, and costs the owners enormous sums every
year, but by modern painting, it can be fought effectively. We have
seen that air (Oxygen) and moisture are needed to initiate the
rusting process; therefore if one of these factors or, for the
matter, both, is prevented from coming into contact with steel, we
will counter act rusting. We can do this by
mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmputting
a barrier or membrane on the steel-if this barrier is impermeable
to moisture and oxygen we will have prevented all rust-formation
and corrosion. In order to make this possible, it is important that
oxygen or water are not allowed to penetrate underneath the barrier
or membrane. A paint film will give us such a barrier. From what we
have seen, a paint film must have the following property to be able
to give effective protection. It must be as impermeable as
possible. Naturally, a thick film is more impermeable than a thin
paint film. Therefore, within practical limits, the paint film must
be sufficiently thick. We have said there must be no oxygen or
moisture present under the paint film so that corrosion cannot be
initiated here with out a supply of these from outside.
For protection against corrosion, to chief principals are
followed
1. We have paints, which form barriers between air and moisture
on the one side and steel on the other side. The following are the
examples of barriers-forming coatings. Conventional paints, epoxy
paints, vinyl paints, polyurethane paints, and chlorinated rubber
paints. This kind of corrosion protection is most common. 2. The
other chief principal is based on the use of active rust preventing
zinc-rich paints. This kind of corrosion protection is widely used
because of its effectiveness. The old fashioned red lead paint and,
for example, zinc chromate primer stops corrosion primarily by
forming a barrier. In addition the special pigments (lead compounds
and zinc chromate) act as a corrosion inhibitor. This effect is
partly based on the lead compound reacting with linseed oil and
partly on water dissolving the pigment by penetrating the paint.
Corrosion inhibition is therefore obtained through a chemical
reaction. This kind of corrosion prevention is now of less
importance, lead compounds, for example, make the paint poisonous
(danger during spraying); whilst at the same time the increasing
use of water resistance binders has reduced the importance of these
pigments types and principles. Further more, using linseed oil as a
binder is impractical because of the long drying time required. Use
of quick drying binders reduces to a large extent the effect of the
red lead pigments.Section 2:ScopeThese guide lines shall govern the
design, materials, surface preparation, application, and inspection
requirements of all maintenance painting and coating jobs
pertaining to surface piping and flow lines, storage tanks, and
process vessels. Guide lines for internal re-coating of salt water
tanks, gun barrels, and separators are also included.
The details specified here are minimum guide lines only.
Depending on availability of materials and equipment, the coating
contractor or maintenance crew may recommend different systems than
the ones outlined in this report. Full details must be provided to
the corrosion engineer for review and approval prior to using a
different system all work will be subject to inspection by the
corrosion engineer or his designate, which shall be given advanced
notice prior to work commencement. Each coating job will require a
thorough step by step inspection by a trained and certified coating
inspector such an inspector can be hired on a daily rate basis for
the duration of each job it will be the inspectors responsibility
to get the job done in accordance with these guide lines.A
contractor having adequate equipment and trained people for each
activity should do coating jobs requiring sand blasting and use of
air or air less spray. A number of such contractors having vast
experience with local petroleum refinery/marketing organization are
locally available. A bid specification can be easily prepared for
such contractors using these guide lines. A special task force
created from the maintenance crew can do coating job requiring
manual cleaning and brush application. Such a task force will
consist of two peoples one of which will be team leader. The team
leader can be trained in basic inspection techniques applicable to
manual cleaning/ application. This training can be organized in
house by the corrosion engineer. Since the volume of work involving
manual cleaning/application is very large and needs to be covered
in a reasonable time. The in house coating task force can get
trained during this period and can handle future maintenance
coating requirements. THE FOLLOWING SURFACES ARE NOT COVERED IN
THESE GUIDELINES AND DONOT REQUIRE PAINTING/COATING.
1. Non ferrous metals.2. Plastic or plastic coated surfaces.
3. Instrument cases, watch glasses, junction boxes, threaded or
machined surfaces and other factory painted items. Section
3:Surface Preparation
A surface preparation is the most critical part of the coating
job. Each type of coating requires a particular type of surface
cleanliness and roughness (also called anchor pattern). Before a
particular type of surface preparation technique is used, the
following preparation is recommended:-
1. All rough welds, wells spotters, identification, and all
other sharp surface projections shall be grounded smoothed prior to
further surface preparation. Any grinding done after sand blasting
shall be reblasted to obtain proper anchor pattern. Grinding should
not decrease weld wall thickness.
2. All bore holes shall be drilled and smoothed before sand
blasting.
3. Oil, Greece, tar, or other contamination shall be removed
using clean rags and a non oily solvent such as xylan prior to
surface preparation. Gasoline shall never be used.
PRE-TREATMENT.
How important is pre-treatment?
Because of its prime importance it is necessary to set a quality
standard of pre-treatment cleanliness. The most important
internationally used standard is that describe in SWEDISH STANDARD
SIS 055900. We have seen that pre-treatment is of prime importance
for the result obtained with respect to anti corrosive action and
thus the cost. When deciding on the type of pre-treatment and the
paint system to be used, the large sum of money involved must
always be come in mind.The pre-treatment norms are based on four
different grades of corrosion, A, B, C, D, which represent
respectively:-
A. Steel surface covered completely with adherent mil scale with
little, if any, rust. This condition of the steel is after a short
time after roling.B. Steel surface, which has begun to corrode, and
from which the mill scale has begun to flake.
C. Steel surface on which the mill scale has corroded away or
from which it can be scraped, but with little pitting visible to
the naked eye.D. Steel surface on which mill scale has corroded
away and on which considerable pitting is visible to the naked
eye.
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
luster is obtained or blast cleaning to clean gray steel.
St indicates wire brushing and Sa blast cleaning. Thus the norm
will be the following:-
St 1, St 2, St 3, and Sa1, Sa2, Sa 3.
After the norms had been in use for a while, a norm line between
Sa 2 and Sa 3 was found necessary. The steel had to be thoroughly
sand blasted and all mill scale, rust and foreign particles
removed, but faint shadows or strips were allowed on the surface.
An extra norm was thus made Sa2,. The norms can be found in a book
published by the Swedish Standard Institution. In this book the
norm describe by a text explaining how the work should be done, and
illustrated by color photos which can be compared to the finish
treatment to see whether this is unto the specified standard.It has
been proved that SIS 055900 is an excellent aid in connection with
treatment in workshops. When the pre-treatment norm have been
agreed upon, there is little basis for discussion. Afterward
regarding the quality of the work.
Maintenance, however, does not consist of painting alone, but
also --- as repeatedly infancies ---- of pre-treatment, washing and
cleaning process.
There are many things to consider when planning a maintenance
job, and for the pre-treatment we must choose:-
1. Method
2. Tool.
Depending on the following:-
Degree of damage to the surface. If the whole surface is more or
less destroyed by rust, certain method and tools are chosen. If
there is only smaller spots of rust, for instance on a welding seam
or bolt head, and method and tools will be chosen. What kind of
tools is available? Unfortunately, in our country not every
contractor has all the necessary equipment.-1. Large, mobile blast
cleaning equipment.2. Vacuum blasting equipment.
3. Air-driven grinding equipment.
4. Rotary wirebrush.
5. Needle gun.
6. Air driven descaler.
7. Manual scraper with exchangeable hard metal edge.
8. Hand wire brushes of various sizes.
Which paint system is to be used? As modern, sophisticated paint
systems are in use in many countries, required different
pretreatment norms.
The nature of the surface --- different methods and tools are
used for pretreatment. Previous treatment --- If for instance epoxy
paint has been used, it is necessary to flatten the surface
mechanically to obtain good adhesion for the next coat. If
chlorinated rubber paint has been used, this is not necessary.
Result required--- In certain cases durability is the most
important factor. On the other hand it is necessary to do the work
quickly. Pretreatment includes far more than wire brushing or
scraping. A well done maintenance job includes a rule most of the
following operations :-
1. Removal of loose rust, loose paint, and mill scale.2. Removal
of grease, oil, and dirt.
3. Removal of unwanted paint (if the former coat of paint is so
thick that it has lost its protection properties --- if a more
advanced system is desired or if the original coat of paint is of
poor quality).
4. Abrasion of sharp edges.
5. Roughening of glossy paint.
6. Thorough washing down with fresh water to remove dust and
salt.
The following methods can be used to remove and loosen
under-rusted paint.
METHOD RESULT
1. Blast-cleaning Ideal
2. Mechanical wire brushing Risk of polishing
3. Mechanical disk-sanding some risk of polishing
4. Needle chipping some risk of indentations
5. Mechanical rust-chipping not good heavy indentations
6. Mechanical scraping (air-powered) Good combined with other
methods
7. Hand brushing Poor
8. Hand scraping only to be used with in combinations With other
methods
Nothing can compete with blast-cleaning to obtain the best
result. Air powered (mechanical) tools generally give better
results to obtain the best result than hand tools. There is no
doubt about the superiority of the blast cleaning method. This
method gives an ideal foundation for paint , and blast cleaning
combined with a modern, correctly used paint system will make the
paint last 4-5 times as long . Result have been obtained with blast
cleaned surfaces that have lasted 10 times as long as corresponding
surfaces pretreated in a conventional way and painted with the same
paint system.3.1 Classification of Surface Preparation 3.1.1
Solvent Cleaning. (Also called SSPC SP 1) This involves removal of
oil, grease, dirt, soil, salt, and other contamination by cleaning
With solvent, vapor, alkali, emersion, stream, or detergent.
3.1.2Hand 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, scraping, sanding or wire
brushing. The resulting surface has a faint metallic sheen. The
cleaned surface appearance corresponded to the Swedish standard
designated as St-2.3.1.3. 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 brushing, and grinding.
The speed of surface preparation is higher than hand tool cleaning,
and the resulting surface has a pronounced metallic sheen. Its
appearance corresponded to the Swedish standard designated as
St-3.3.1.4 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, loose rust, and loose paints
and coating are removed completely, but tightly adhered rust,
paint, and coating and permitted to remain provided that all mill
scale, and rust have been exposed to abrasive blast pattern
sufficiently to expose numerous flecks of underlying metal fairly
uniformly distributed over the entire surface.
3.1.5 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 condition. All oil, grease, dirt, rust
scale, and foreign matter shall be completely removed from the
surface and all rust, mill scale, and old paint shall be completely
removed except for slight shadows, streaks, or slight discoloration
caused by rust stain, mill scale oxides, or slight, light residues
of paint or coating that may remain. If the surface is pitted
slight residues of rust or paint may be found in the bottom of the
pit.
3.1.6 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 condition. All oil, grease,
dirt, mill scale, rust, corrosion products, oxides, paint or other
foreign matter shall be completely removed from the surface except
for very light shadows, very light streaks, or slight discoloration
caused by rust stain, mill scale oxides, or slight, tight residues
of paint or coating that may remain.3.1.7 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 grey white,
uniform metallic color, slightly roughened to form a suitable
anchor pattern for coating adhesion. The surface, when viewed
without magnification, shall be free of oil, grease, dirt, mill
scale, rust, corrosion products, oxides, paint or may other foreign
matter.The following main rules should be followed:-
Use correct pressure. Correct nozzle pressure is 7 7.5 kg/cm.
(100 107 psi). Reducing the pressure to 4 4.5 kg/cm. *57 65 psi)
often leads to doubling of the amount of sand needed per m.
Loose paint and rust must be removed prior to sandblasting.
Using driven chisel or hard metal scraper does this. This removal
of coarse impurities prior to blast cleaning has, in some cases,
reduced the sand consumption to a quarter. Use the correct
properties of sand/grit and air. Note that it is often good economy
to pay more for the sand, as poor quality sand gives dust problems
and low effect. The sand should not be used more than twice
(preferably only once).it is important to remove dust from the
blasted surface with oil free compressed air or a special vacuum
cleaner, or alternatively sweep the surface prior to applying the
first coat of paint. At 100 psi.Blast-clean a small area at a time.
Protect this with primer, as they are finished. Zinc rich primer
gives the best protection and allows the rust area to blast little
by little and covered by zinc rich primer. After completion of this
practice whole the area can be painted with the selected paint
system. This is the most effective work procedure. Zinc rich primer
dries rapidly after it has been applied, and the blast cleaning can
be carried out side by side with the freshly painted areas without
sand sticking to the surface. (Hard Dry 1 hr). 3.2Blasting
Equipment Selection. Abrasive blast equipment shall be inspected
before use. All fittings and hoses shall be in good condition and
tightly attached. The air intake shall be remotely located from all
vehicles/equipment exhaust system to ensure harmful emissions are
not taken into the work area. Contamination of inlet air to the
compressor can adversely affect purifier performance. The
compressor intake shall be located to avoid intake of contaminated
air and to ensure air with adequate oxygen contents.3.2.1
Compressor. 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.3.2.2 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. The
correct sizing of nozzle discharge orifice versus compressor
discharge capacity is as follow:-
Compressor rated at 125 cfm at 100 psi.a. one orifice of " dia,
delivering delivering 81 cfm or
b. Two orifices of 3/16" dia, delivering 80 cfm. Compressor
rated at 600 cfm at 100 psi.
i. One orifice of dia, plus one orifice of " dia.ii. Both
delivering a total of 419 cfm or
iii. One orifice of 7/16 dia, plus one orifice of 3/8 dia.
iv. Both delivering a total of 450 cfm.
3.2.3 Abrasive. The quality of the cleaned surface following an
abrasive blast is strongly influenced by the size and the shape of
the abrasive used. The preferred abrasives for most high
performance coatings and the ones, which provide the most generally
accepted surface, are:-
16 - 40 mesh silica sand or minerals grit. 20 40 mesh garnet
deep red color.
Crush iron slag.
G 50 irons grit.
These materials provide a surface profile from 1.5 to 3.5 mils
(36 to 87 ), and are able to produce whatever degree of surface
cleanliness is required. In field application such as maintenance
painting, sandblasting or synthetic blast media are the preferred
choice due to wastage factor.
3.3 Miscellaneous.3.3.1 Use dry abrasive, free from dust, salt
and other impurities. Laborarory test is the better way to
check.
3.3.2 Keep moisture, oil, grease, or other organic matters off
the cleaned surface, before priming. Spot reblast to remove any
contamination. Solvent wiping is unsatisfactory.
3.3.3 Applying coating as soon as possible to prevent the
blasted surface from rusting. Cleaning should be discontinued each
day in sufficient time to permit cleaned surface to be inspected
and primed before the end of the working day. The maximum time
between blasting and priming for systems requiring blast cleaning
shall be for four hours.
3.3.4 Dry blast cleaning shall not be done in rain, mist or fog,
or when the relative humidity is above 85% or when other conditions
exist which would prevent the crew from painting the cleaned
surface at the end of the working day. Due to the possibility of
rains, major coating jobs should not be scheduled in the month of
July and August near the sea.
Most of the coatings used consist of multiple layers called
coatings. The first coat is called primer coat and is different
from intermediate or finish coat. Some coating systems consist of
only one coat, which act as both primer and top coat.
Section - 4. Coating Material4.1 General 4.1.1 Adequate
facilities should be provided to store coating materials on site to
protect them from rain, dust and sun.
4.1.2 Coating materials shall be inspected when opened for use.
Any material that has gelded, or otherwise deteriorated during
storage shall not be used.
4.1.3 All surfaces to be coated shall be rendered dust free
prior to primer coat application except when surface tolerant
coatings are used. This shall be accomplished by blowing the
surface with clean dry air or with clean rags if the area is
small.
4.1.4 All coating materials are thoroughly stirred in a pressure
pot with power mixer for a time sufficient to thoroughly re-mix the
pigments and vehicles. Only thinners as specified by the
manufacturer should be used. Mixing directions as furnished by the
manufacturer should be followed. 4.1.5 Pot life of catalyzed
coating should not be exceeded. When the pot life limit is reached,
the spray pot must be emptied material discarded, the equipment
cleaned and new material is catalyzed.
4.1.6 No coating should be applied when surfaced are less than 5
F above due point, and the relative humidity is above 80%, when the
air temperature is below 40 F, or if there is a likelihood of
changes in weather conditions within two hours after application
which would result in condensation upon the surface. Normally,
paint/coating is not to be applied to surface exceeding 120 F at
the time of application. Dew point can be determined in accordance
with the table attachment C.
4.1.7 Manufacturers recommendations should be followed with
regard to minimum and maximum curing time between various
coats.
What Is Paint?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 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:-
I. 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 paint is delivered in two parts to
be mixed prior to use. The best known types are epoxy and
urethane.
4.2 Material specification.
The type of coating system used will depend upon the service
requirements as well as factors determining the degree of surface
preparation achieved in a particular situation. The service
requirements may vary from general atmospheric exposure to total
immersion in salt water or produced petroleum. Prior to using, all
coating materials must be checked to ensure thay they meet US
health, safety, and environmental standards. 4.3 Coating
application.
4.3.1. Spray equipment.
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. 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.
4.3.2 Spray application
The gun should hold 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.
4.3.3 Brush application.
Brushes used in brush application should be of a style quality
at 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 occurs.
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.
Section5:InspectionNo coating specification can fully be
describing the application procedure. An inspector must inspect and
ensure quality of the work at each stage. The corrosion engineer or
his designated will act as an inspector for all maintenance coating
jobs.
Hold Point - Inspection Q.C Q.A
Ambient conditions (Pre-Preparation) TD TD
Pre-surface preparation conditions (Weld, rust, edges, etc.) VD
VD
Pre-surface preparation conditions (grease, dust, , etc.) and /
or SP 1 V V
Surface Preparation equipment operation and abrasive size/type
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
Application equipment operation (Pressure, agitation, type,
etc.) 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
Legend
F frequency of Verification. Type of Verification
D = Daily V = Visual
O = Occurrence - Base T = Testing
P = Periodic R = Review of QC report or testing
The inspection work should include the following.
5.1 Good housekeeping.5.1.1 Clean and orderly work area.Areas at
the work face and immediately adjacent to the work face must be
free of dirt, blast cleaning residue, empty containers, tools not
in use, and other debris. Unnecessary personals should not be
allowed in the area. Canvas screen should be provided around the
work area.
5.1.2 Storage and issue area.Job site storage area for supplies
and accessories should be close enough to the work area to be
rapidly accessible but they should not constitute an obstacle to
access or to movement of personal or equipment.
5.1.3 Mixing utensils and containers.Containers utilizing to mix
coating compounds should not be allowed to sit open or unattended.
Utensils should be thoroughly cleaned and stored in a dirt/dust
free area for usage.5.1.4 Wet coating safe grades.Precautions
should be taken to prevent sand or dust being blown on freshly
coated should be screened to reduce the possibility of wind borne
dust/sand contaminating the freshly applied coatings. Access to the
interior of the vessel must be rigidly restricted following coating
applications.
5.1.5 For surface coatings that contain hazardous materials
(heavy metals).
For surface coatings that contain hazardous materials (heavy
metals), blast material and debris shall be cleaned up by using
dust free methods. Wet clean up methods and vacuum cleaners with
high efficiency particulate air filters are recommended.5.1.6
Blasting Is Performed Indoors.When abrasive blasting is performed
indoors, surface becomes contaminated with dust that may contain
hazardous materials. Contaminated surfaces shall be cleaned to
remove as much of this contamination as possible after each
abrasive blasting operation.
5.1.7 Whenever possible, all surface coatings should be removed
in a shot blast booth or outside, as it is difficult to completely
capture and remove airborne dust within a building.5.2 Surface
preparation.5.2.1 Prior to Surface Cleaning.The condition of steel
must be determined by careful examination and a record Made of the
inspectors observations. Burrs, surface defects of the steel,
Condition of welds, and reducing of edges must be noted and
necessary repair efforts instituted. A careful re-examination of
the effected areas must be conducted following the repair
completion. The surface to be coated must be thoroughly cleaned and
all traces of hydrocarbon and water.
5.2.2 Blast Cleaning Equipment.
The inspector should insure the following before starting an
abrasive cleaning operation: Correctly sized nozzle orifice for the
compressor is being used.
Minimum 2-inch internal diameter air hose and coupling.
Large enough blasting machine to do the job in the time allotted
with a properly ventilated enclosure.
Blast hose of sufficient size to maintain nozzle pressure i.e.
3/8 inch nozzle bore requires 1 / 1 inch I.D. blast hose. Adequate
length of hoses, properly clamped at ends, should be used.
All coupling should be the external types, no restrictions or
reductions in air or blast line internal diameter.
Dead man or remote control valves fitted at the blasting nozzle
for safety and economy.
Traps (oil, water separators) fitted on compressor discharge as
required to eliminate the possibility to substate contamination by
water / oil from the compressor.
Nozzle pressure staying with in the range of 90-100 psi.
A sufficient number of dust evacuators.
Air fed head shield, in good repair and in use, for blast nozzle
operator. This is a mandatory safety requirement, and no blasting
operation may be allowed to continue under any circumstances with
out this device.
Correctly graded and sized abrasive chosen for its suitability,
per the appropriate specification. Properly trained, certified, and
alert blasting equipment operators and supporting personals.
Adequate lighting.
Compressor drive engines, compressors, airlines, sand ports,
connectors, electrical lines, etc., in proper state of repair.
Black exhaust fumes from the compressor drive engine are in
indication of poor maintenances procedures. Excessive discharge of
this nature, particularly within a confine, presents a serious
hazard to the health of operating personnel. Additionally, these
fumes may be drawn into the air intake of the compressor causing
serious contamination through the blasting medium at the work face.
Reason able work surface temperatures. Discharge of high-pressure
air onto excessively hot or cold steel surface can cause the
condensation of moisture on the surface. Failure to remove all
traces of hydrocarbon or water vapor contamination through from
steel surfaces prior to coating application will result in total
coating failure. Secure, adequate scaffolding placed to assure the
inspector and the blasting equipment operator sufficient vantage
points from which to operate.
Dry and secure storage facility for abrasives. Unless abrasives
are to be used immediately, storage under clean canvas sheeting is
recommended. Polyethylene sheeting is not recommended, as moisture
will condense on the underside of such sheeting causing materials
stored to be subjected to dampness. Blast pots must be kept under
cover throughout the blasting operation to forestall wind blown
debris, communication of the blasting medium.
5.2.3 Abrasive medium
Grit / sand should be inspected carefully to ensure that it is
clean, free of foreign matters, dry, and the specified mesh (i.e.
particular size).5.2.4 Final Inspection All phases of surface
preparation procedure, including the removal of all the dust and
debris from the immediate area of the prepared surface, must be
completed prior to final inspection and approval for the
application of coatings to proceed. The maximum allowable time
lapse between the completion of blast cleaning and final inspection
/ approval prior to coating application is two hours. If the time
lapses, surfaces must be reinspected and all evidence of oxidation
must be removed by flash blast. Do not use rags or cleaning cloth
either to inspect the surface or to remove any dust detected. Clean
cotton gloves, soft shoes, and clean coveralls are required items
of clothing which must be worn by all personnel entering any vessel
or tank which has been freshly clean blasted. The inspector must
monitor the condition of freshly blasted and cleaned surfaces prior
to the application of the primer coat. The surface should be
covered with primer prior to the onset of sever blush oxidation.
Inspection of surface cleanliness will include presence or absence
of dust debris, degree of steel cleanliness, and anchor pattern
(surface roughness). Degree of cleanliness can be determined by
confirmation to a pre agreed surface texture and shade or by using
visual standards adhering to Swedish SIS 055900. The type and size
of abrasive used determine the anchor pattern. If necessary, it can
be determined by surface profile meter. This is normally not
necessary in the field. 5.3 Coating application.5.3.1Application
procedure.
Preliminary inspection.carefuly inspects each new batch of
coating material. Note under setting of pigments, objectionable
skinning, the amount of clear medium, color, amount of ullage.
Record these observations for future purpose. Reject any unsuitable
material. Homogenous mixing. Power mixture must be used for two
component coating compounds. The mixing process must be closely
observed to verify that the correct quantities of each component
are combined. If zinc rich coatings are used, the paint pot must be
equipped with smoothly functioning mechanical agitator. Thinners.
Only thinners recommended by the manufacturers for a particular
coating used. All thinners are very volatile material and should be
stored and used carefully. Dont expose thinner cans to heat or
direct sun. keep in mind that all the solvents are not thinners,
but all the thinners are good solvents Site control of material.
Prior to start up of the job, carefully document the following on
site:- The amount of coating materials in hand, and noted damage to
the containers, label description, and date of manufacture.
Containers that are badly damaged or which bear labels not
corresponding to specification Requirements must be rejected. A
description of storage facilities detailing the type of shelter and
protection from sun, rain and dust shall be recorded.5.3.2
Equipment A.Inspection. The equipment intended for spray
application must be inspected to verify that it confirms to the
manufacturers recommendations for the type of coating used and that
it will meet the production schedule.
Inspect the air gun carefully.
Are the atomization holes in the air cap open?
Are adequate grounds provided for static charge?
Are the fluid tips and guns in good condition or are they oval
or worn to the point that needle will not seat properly when the
guns trigger is released?
Are the fluid hoses caked with old coating material?
If so, either get the hoses changed or get them cleaned /
flushed with thinner or similar strong solvent.
B. Airless spray equipment. Preliminary inspection should
include these:
Filters and strainers should be free of old coating
particles.
Water separator (Regulator) installed between compressor and
hydraulic pump should be of adequate size and design to be
effective at normal operating air pressure.
Pressure regulators and gauges must be in good operating
condition.
The start up check list should include;
Is adequate air pressure and volume available?
Is the airless spray unit clean and in good operating
condition?
Is a variety of .tips, filters and tip gas kits readily
available? Are hand tools such as wrench, screwdrivers, and pliers
readily available?
Is sufficient supply of rags, solvents, and cleanup containers
provided?
Are the application craftsmen fully informed regarding the
nature of the coating material to be applied and the surface to
which it is to be applied?
C,Brush application. Brush application over large areas are
seldom specified, it is normally used small areas where utilization
of spray equipment will be ineffective. Brushes if required or
present on the job site should be inspected carefully, as they
constitute an easily overlooked source of contamination to an
otherwise acceptable job.5.4Coating Inspection: coating must be
done before, during, and following the finished coating
application. Proper inspection begins with an inspection of the
prepared surface. Once the, surface has been satisfactorily
prepared in the manner specified for a particular coating, it
should be thoroughly vacuumed. Only then it is ready for coating.
Each coat should be carefully inspected before the succeeding coat
is applied. The time between the two coats should be according to
the coating manufactures recommendations. Overspread and dust
should be removed. Runs and sags are to be avoided. Water spotting
as manifested by the appearance of drops or spots of water in
freshly applied coating film is an unacceptable condition.
Observations pertaining to these surface defects should be recorded
and remedial action should be taken in addition wet film thickness
measurement on freshly applied coating as well as dry film
thickness of dried coating film should be measured as a quality
control measure.
5.4.1Wet Film thickness. Wet film thickness is used as a spot
check during film deposition to get a rough idea of each coat. This
enables the applicators to immediately correct any application
faults. This is measured by sinking the wet film thickness gauge
into wet coating film and taking a reading. As solvent evaporates,
the dry film thickness becomes lower. Thus, wet film thickness
reading should be more than dry film thickness (DFT) specified in
the specification by a factor depending upon volume of solids in
coating material.
5.4.2 Dry film thickness. This is measured after the coating
film has dried up and can be measured between the coats. Various
types of dry film thickness measuring instruments are available in
the market.
5.4.3 Holiday deduction. This is required to be done critical
cases such as immersion services. A wet sponge low voltage
detection of these film coatings would reveal any breaks in the
coating film. This should be done when specified in the coating
specification.Section6 :Safety6.1 General. Operating machinery and
power tolls within a production facility poses potential danger
from fire or explosion. A safety meeting involving the Operation
Manager, Safety coordinator, Corrosion Engineer, and the coating
contractor must be conducted at the location to be painted prior to
commencement of the job. During the meeting, the contractor must
provide a complete list of all the equipment, materials, and
personnel that will be required for the job. The location will be
inspected determine the most suitable location for every piece 0f
equipment; determination will be made of the proper method of
isolating the vessel to be worked on. If necessary, from other
vessels, at the facility. The Safety Coordinator will be
responsible for determining the fire fighting equipment required
during the job.
6.2 Good House Keeping. Good house keeping on site is very
necessary and important of view of personnel safety. Empty cans,
unnecessary tools, etc. should not cause an obstacle in the way of
craftsmen or their equipment. Unnecessary personnel also constitute
a hazard by causing obstruction to craftsmen and machinery in
use.
6.3 Sand Blasting. 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.
Provide air-fed head shield for blast nozzle operators, which
must be in good operating condition. No blasting should be allowed
without this device.
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.
Unnecessary peoples should keep away of the blasting area.
Adequate lighting (Explosion Proof) should be provided
especially for blasting on 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.
Secure and adequate scaffolding should be placed to assure the
inspector and the blasting equipment operator sufficient vantage
points from which to operate. Always follow the Occupational Health
and Safety Act. (OHSA). Acute Silicosis is a lung disease that
develops rapidly. 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. The
condition is known as egg-shell calcification. 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.6.4 Coating
Application.A careless move with a conventional spray gun will
normally cause a messy situation, but the same slip with airless
spray gun kill somebody in the area since large hydraulic pressure
up to 5,000 psi, is involved.Due to danger of fires from sparks due
to static charge created by the high velocity of coating particles
during atomization, an inspector must insist on the following:
Adequate equipment grounds. Non-conductive hoses.
Any other protective device to control or criminate the danger
of static electric discharge.
In addition, the following list of safety dos and dont must be
observed when using an airless spray equipment.
Keep clear from spray stream.
Handle the spray gun as cautiously as you would a loaded
firearm.
Never, never point the gun at your self or anyone else.
Never put your hand or finger directly over the fluid tip. Wear
protective leather gloves when operating the gun. Use aprons, eye
and ear protection, and respiratory protection for personal
safety.
Never leave the gun unattended without engaging the trigger
safety catch. For extended periods, the system should be shut down
and the pressure bled off. Never exceed the maximum recommended air
or hydraulic inlet pressure to pump.
Be certain of the maximum working pressure recommended for the
particular hoses and / or accessories used with the gun, and DO NOT
EXCEED, to attempt to operate a gun rated at 5,000 psi at its
maximum rated pressure through hoses rated 3,000 psi maximum
working pressure in a disaster. Do not exceed 5,000 psi working
pressure in any case in paint line.
Never attempt to remove the gun, the gun tip, or the gun filter,
without shutting down the pump and bleeding off the system
pressure. Never attempt to clean the tip while it is installed on
the gun. Shut down the pump, bleed the system pressure, and remove
the tip from the gun to clean it.
Never operate airless spray equipment until you are certain that
all static electricity discharge ground (earths) are in place and
connected. Special grounded or any static, voltage-conducting hoses
are normally used with airless spray equipment. Make sure these are
in good condition. Never flush solvent into containers, which have
been sitting in the direct sun. The solvent normally used has a
very low flash point. The surface temperature of a metal container,
which has been exposed to the direct rays of the sun for any length
of time, may easily reach a temperature of 130-degrees F or more.
At atomized stream of high volatile (low flash point) solvent
striking the walls of such a container which probably result in
spontaneous ignition of the solvent vapor.
Always use the lowest pressure possible when flushing the
equipment. Hold the gun firmly against a cool metal waste
container. When a tank is out of service and unattended, all
accesses, i.e., manways, and vents must remained closed.
Vents/manways should be screened to restrict access of foreign
bodies after application of coating. In order to facilitate drying
up of coating. SECTION 7: IMPLEMENTATION
Each facility and piece of equipment will require detailed
custom tailored coating specification, based on present coating
condition, desired service life, aggressiveness of local
environment, and cost of coating systems. All surface preparation
and coating application steps will be closely monitored and
inspected by a qualified coating inspector. An experienced
contractor having adequate equipment and trained staff for each
activity will do coating jobs requiring sand blasting and use of
air or air less spray equipment. Due to high pressure involved, use
of airless spray will be avoided as much as possible in any case,
prior approved by Divisional Manager, Operation and engineering
will be required for using air less spray coating application.
7.1 Coating Specification-
Coating Specifications for each coating job, giving details of
surface, preparation, inspection standard, type of coating
material, application method, safety requirement etc., will be
prepared separately, as and when required by the Corrosion Engineer
and approved by Division Manager, Operation and Engineering. The
various coating system will last between 2 6 years. The coating
specification will include expected life of the recommended coating
system and the approximate date the next coating job will be
required. The most cost-effective system for each an area component
will be used.
7.2 Contractor Selection-Contractors will be selected on the
basis of there past experience, availability of adequate equipment,
skilled personal reliability, safety consciousness, and cost. The
coating specifications referred to 7.1 will serve as technical
specifications of the bid documents for contractor selection. The
biding process will be initiated by the Corrosion Engineer and the
bids receive from contractors will be evaluate jointly by
Maintenance Manager and the Corrosion Engineer to finalize the
selection. The Divisional Manager, operation and Engineering will
approve the selection of the contractor. Small jobs requiring
manual cleaning and brush application can be done in house by
maintenance crew are coating task force.7.3 Job Scheduling-
Once a contractor have been selected, he will meet Operation
Manager, Construction & facilities Manager, Corrosion Engineer,
and safety Co-coordinator to discuss the job. Things that will be
needed to be discussed during the meeting include equipment and
personal requirements, safety and environment issues, and any
specific operational matters that may affect the job. The
Operational Manager will schedule the field safety meeting
discussed in section 6.1. The Operational Manager will make the
final decision on the date for the job to begin. 7.4 Coating Job
Progressive Inspection-Surface preparation by using blasting
equipment and coating application by roller, air spray, or air
spray will require inspection by a qualified inspector at each step
during the job. Such a contractor will be hired temporarily or on a
daily rate basis for each job. It will be inspectors responsibility
to ensure that all surface preparation and coating application
steps confirm to the coating specification outlined in section 7.1.
He will coordinate between the maintenance and production groups
and the contractor for all matters related to the coating job and
submit technical reports of his inspection to the Corrosion
Engineer.The Corrosion Engineer will do the search and the
selection of the inspector.
Inspection of manual cleaning and brush painting of piping,
structures, etc. will be done by the maintenance crew coating task
force especially trained for this purpose. The Corrosion Engineer
will do this training in this house. This task force will consist
of 2 workers, lead by a supervisor, who will act as the
inspector.ATTACHMENT-A
COATING INSPECTORS KIT
1. Coating specification.
2. Manufacturers data sheet.
3. Blasting and coating equipment check list.4. Inspection
Report.
5. Anchor pattern measurement device. (Profile Gauge)
Dial indicator.
Press o film.
6. Wet film thickness gauge (Comb)
7. Dry film thickness gauge.
Electro physics. Coin (Micro test III) is the preferred
instrument.
Magnetic gauges. Nordson or Elcometer.
Electronic gauges.
8. High intensity battery powered light.
9. White coverall.
10. Gloves lint free.
11. Rubber soled shoes.
12. Thermometer. For air temperature.
13. Humidity gauge. Or sling psycho meter.
14. Contact thermometer. Metal temperature gauge.
15. Sharp knife.
16. Hypodermic needle pressure gauge.ATTACHMENT :B
CONTRACTORS EQUIPMENT CHECK LISTDate:
______________Contractor/Maintenance crew
Leader.______________________ Job Location
_____________________
Compressor Size in 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.________________________ATTACHMENT
:CINSPECTION & 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 ______________________
FINSHED ____________________AM/PM
DATE ______________________
COMPRESSOR SIZE _________cfm Nozzle Pressure _____ psi Nozzle
Size___________
Air Hose Size _______ Length _______ Blast Hose Size
___________Length _______
COATING SPECIFICATION
Primer Prod # _________________
Top Coat Prod # ___________________________
Mfg. Date ____________________
Mfg. Date ________________________________
Expire Date ___________________
Expire Date ______________________________Batch
#_______________________
Batch # __________________________________
Color # ______________________
Color # __________________________________
Stock # ______________________ Stock #
__________________________________
Amount at site ________________ Amount at site
_____________________________
COATING APPLIED BY (Brush, Airless or conventional)
Date____________1st Coat ____________am/pm Air Temp ________
Metal Temp______
Date __________ 2nd Coat ____________am/pm Air Temp ________
Metal Temp______
Date ___________ 3rd Coat ____________ am/pm Air Temp
_______Metal Temp ______
W.F.T. 1st Coat _____________ 2nd Coat ____________ 3rd Coat
___________________
D.F.T. 1st Coat _____________ 2nd Coat _____________ 3rd Coat
___________________Remarks______________________________________________________________________Inspector:
NAME --------------------------------------------------- SIG
-------------------------------
Designation: ASTM D 16 03
Standard Terminology for
Paint, Related Coatings, Materials, and Applications1
This standard is issued under the fixed designation D 16; the
number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last
revision. A number in parentheses indicates the year of last
reproved. A superscript epsilon (e) indicates an editorial change
since the last revision or reproved.
This standard has been approved for use by agencies of the
Department of Defense.Abrasion resistance, n (for coatings)the
ability of a coating to resist being worn away and to maintain its
original
appearance and structure when subjected to rubbing, scraping, or
wear. D 968, D01.23
Acid number, n
(for coatings)the number of milligrams of potassium hydroxide
(KOH) required to neutralize the
free acids in 1 g of an oil, resin, varnish, or other substance;
generally reported on the nonvolatile
content
Acid value
see acid number.
Acrylic resin
under resin, synthetic, see acrylic resin.
Additive, n
a substance added in small quantities to another substance,
usually to improve specific properties (for
example, a drier, mildewcide, etc.).
Adhesion promoter, na material built into a binder or added to a
paint to form primary bonds to either the substrate or the
previously applied coating, with the specific aim of improving
the dry or wet adhesion, or both.
D01.23
Alkyd resin
under resin, synthetic, sees alkyd resin.
Architectural coatings, n coatings intended for on-site
application to interior or exterior surfaces of residential,
commercial,
institutional or industrial buildings.
Asbestos
see industrial talc and industrial talc, no asbestos type.
Associative thickener, nwater-soluble polymers containing
hydrophobic groups that are capable of nonspecific hydrophobic
association similar to surfactants that elevate viscosity
presumably by association between thickener
particles or thickener and dispersed particles that may be
present in the aqueous system such as latex
particles rather than through high molecular weight or chain
stiffness of the thickener molecules
themselves.
Auto deposition, na single-step immersion metal finishing
process in which an organic coating is applied by means of
unique surface chemical reactions carried out in an aqueous
latex dispersion, also referred to as
chemiphoresis. Components within the bath give rise to chemical
reactions that slightly solubilize the
metallic surface and lead to destabilization, deposition, and
coalescence of the dispersed latex particles
at that surface. ISCUSSIONthe deposition rate of the latex is
controlled by the rate of surface solubilization. The recess
does not require any pretreatments such as phosphating, needs no
external energy input, and gives rise to deposition
wherever the solution wets the substrate. Irregularly shaped
parts can be uniformly coated.
Baking finish, n
a paint or varnish that requires baking at temperatures above
150F (65C) for the development of
desired properties.
Baking temperature, na temperature above 150F (65C).
Batch, n
the total quantity of a material produced in a single final
mixing operation after all production
processes are complete, or just prior to filling.
Bituminous varnish under varnish, see bituminous varnish.
Bleeding, n
the diffusion of coloring matter through a coating from the
substrate; also, the discoloration arising
from such diffusion. In the case of printing ink, the spreading
or running of a pigment color by the
action of a solvent such as water or alcohol.
blistering resistance, nthe ability of a coating to resist the
formation in the film of dome-shaped, liquid- or gas-filled
projections resulting from local loss of adhesion and lifting of
the film from the previously applied
coating or the substrate.
blocking, n
for coatings other than powder coatings, the sticking of a
coated surface to an adjacent surface when
the two surfaces have been in contact for an extended period of
time. D01.42
brush-drag, n
resistance encountered when applying a coating by brush,
directly related to the high-shear viscosity of
the coating. D 4958, D01.42
bulking value, n
solid volume of a unit weight of material, usually expressed as
gallons per pound. For practical
urposes this is 0.120 divided by the specific gravity.
caulking compound, na soft, plastic material, consisting of
pigment and vehicle, used for sealing joints in buildings and
other structures where normal structural movement may occur.
cellulose lacquer see lacquer.
chalking resistance, nthe ability of a pigmented coating to
resist the formation of a friable powder on its surface caused
by the disintegration of the binding medium by degradative
weather factors.
checking resistance, nthe ability of a coating to resist slight
breaks in the film that do not penetrate to the previously
applied
coating or to the substrate. The breaks should be called cracks
if penetration extends to the previously
applied coating or to the substrate. See cracking
resistance.
chipping resistance, nthe ability of a coating or layers of
coatings to resist removal, usually in small pieces, resulting
from
impact by hard objects or from wear during service.
coating, n
a liquid, liquefiable or mastic composition that is converted to
a solid protective, decorative, or
unctionaladherent film after application as a thin layer.
Color of an object, nthe aspect of the appearance of an object
dependent upon the spectral composition of the incident light,
the spectral reflectance or transmittance of the object, and the
spectral response of the observer.
hue, nThe attribute of color perception by means of which a
color is judged to be red, orange,
yellow, green, blue, purple, or intermediate between adjacent
pairs of these, considered in a close ring, red and purple being an
adjacentpair. (White, gray and black colors possess no
hue). E 284
DISCUSSIONThe short end of the spectrum is violet, with purple
by definition being a nonspectral combination of red and
violet. The practice of replacing violet by purple in the roster
of object colors is apparently a practical
accommodation to color-order requirements, as described in the
Munsell system. See Practice D 1729.
lightness, n (1) The attribute by which a perceived color is
judged to be equivalent to a member of a
series of graysranging from black to white. (2) The attribute of
color perception by which a
non-self-luminous body is judged to reflect more or less light.
E 284
saturation attribute of a visual sensation that permits a
judgment to be made of the proportion of
pure chromatic color in the total sensation. E 284
contrast ratio, n
ratio of the reflectance of a dry paint film over a black
substrate of 5 % or less reflectance, to the
reflectance of the same paint, equivalently applied and dried,
over a substrate of 80 % reflectance.
coverage, coverage rate, covering powerambiguous terms that are
used in some instances to refer to
hiding power and in others to mean spreading rate. The precise
terms hiding power and spreading
rate are preferred.
cracking resistance, nthe ability of a coating to resist breaks
of the film where the breaks extend through to the surface
painted and the previously applied coating or the substrate is
visible. The use of a minimum
magnification of 10 diameters is recommended in cases where it
is difficult to differentiate between
cracking and checking. See checking resistance.
crawling, n
defect in which the wet film recedes from localized areas of the
substrate (usually caused by
insufficient wetting) leaving those areas uncoated. D 1848,
D01.42
curtaining
see sag or sagging.
density, n
the mass per unit volume of a substrate at a specified
temperature and pressure; usually expressed in
g/mL, kg,L, g/cm3, g/L, kg/m3 or lb/gal. See specific gravity.
D01.23, D01.24
DISCUSSION(1) g/mL = kg/L = g/cm3; g/L = kg/m3. (2) Density
lb/gal) = Density (g/mL) 3 8.345405 ... (3) The
temperature should be 25C for best conformance with Test Method
D 1475. For liquids andsolids, which are
the usual concerns of Committee D-1, the pressure need not be
specified. (4) Density of water at 25C =
0.997044 g/mL = 8.32 lb/gal.
dirt
(for coatings)see soil.
dirt resistance, n (for coatings)the ability of a coating to
resist soiling by foreign material, other than microorganisms,
deposited on or embedded in the dried coating.
distinctness-of-image gloss, nthe sharpness with which image
outlines are reflected by the surface of an object.
dope, n
a composition, usually a cellulosic lacquer, for application on
textiles and leathers.
drier, n
an additive that accelerates the drying of an oil, paint,
printing ink, or varnish.
DISCUSSIONDriers are usually metallic compositions and are
available in both solid and liquid forms.
drying oil, n
an oil that possesses to a marked degree the property of readily
taking up oxygen from the air and
changing to a relatively hard, tough, elastic substance when
exposed in a thin film to the air.
durability, n
a relative term indicating degree of permanency. It may be
applied to individual protective, decorative,
or functional properties, for example, the durability of gloss,
but if used in a general way, for
example, the excellent durability of a paint, implies the
ability of the described coating to retain, to
the indicated degree, all the properties required for the
continued service of the coating.
edge-tracking, n
residual, discernible pattern in a rollerapplied coating,
characterized by trails from either or both
ends of the roller.
efflorescence, n
a condition that occurs when soluble salts in a dry coating or
the substrate migrate to the surface due to
the movement of water through the film; characterized by a
(commonly) white, nonuniform powder or
crystalline incrustation,not removable with neutral water but
usually removed with dilute mineral acid.
D 1736, D 1848, D01.42
DISCUSSIONThe previously water-soluble salts become insoluble at
the surface of the film due to reaction with carbon
dioxide of the air.
emulsion paint
under paint, see emulsion paint.
enamel, n
a paint that is characterized by an ability to form an
especially smooth film.
erosion resistance, nthe ability of a coating to withstand being
worn away by chalking or by the abrasive action of
water or windborne particles of grit. The degree of resistance
is measured by the amount of the coating
retained. See abrasion resistance.
ester gum
under resin, synthetic, see ester gum.D 16 03
extended pigments, norganic pigments diluted with an extender
(for example, alumina trihydrate, blanc fixe, or calcium
carbonate).
facade paint, n
a decorative and protective coating for exterior masonry
surfacesusually for buildings and walls.
DISCUSSIONThis is a term more commonly used in Europe.
filiform corrosion resistance, nthe ability of a coating to
resist that type of corrosion of metal substrates characterized
by a definite thread-like structure and directional growth that
occurs under coatings.
filler, n
a pigmented composition for filling pores or irregularities in a
surface preparatory to application of
other finishes.
finish, n
(1) final coat in a paint system; at the termination of cure or
drying
( 2) sometimes refers to the entire coating system: the texture,
color, and smoothness of a surface, and
other properties affecting appearance.
fire-retardant, adja descriptive term which implies that the
described product, under accepted methods of test, will
significantly:
(a) reduce the rate of flame spread on the surface of a material
to which it has been applied, or
(b) resist ignition when exposed to high temperatures, or
(c)insulate a substrate to which it has been applied and prolong
the time required to reach its ignition,
melting, or structural weakening temperature.
fire-retardant coating, na coating that will do one or more of
the following:
(1) reduce the flame spread on the substrate over which the
coating is applied, sometimes at the
sacrifice of the coating (see intumescent coating);
(2) resist ignition of the substrate when exposed to high
temperature; or
(3) insulate the substrate to which the coating is applied and
thereby prolong the time required to reach
its ignition, melting or structural-weakening temperature.
flaking resistance, nthe ability of a coating to resist the
actual detachment of film fragments either from the previously
applied coating or the substrate. Flaking is generally preceded
by cracking, checking, or blistering and
is the result of loss of adhesion. Also known as scaling
resistance.
flatting agent, n
a material added to paints, varnishes, and other coating
materials to reduce the gloss of the dried film.
forced drying temperature, n a temperature between room
temperature and 150F (65C).
fossil resin, n
under resin, natural, see fossil resin.
gallon, U. S., n
a volume equal to 231 in.3 For paint, varnish, lacquer, and
related products this is measured at 77F
(25C).
glaze, n
a very thin coating of a paint product usually a
semi-transparent coating tinted with Van Dyke brown,
burnt sienna, or a similar pigment, applied on a previously
painted surface to produce a decorative
effect.
glazing compound, na dough-like material consisting of pigment
and vehicle, used for sealing window glass in frames. It
differs from putty in that it retains its plasticity for an
extended period.
grain, n
an inch-pound unit of weight, equal to 0.002285 avoirdupois oz
(0.0648 g). CED
grinding japan
see japan, grinding.
grit, n
coarse foreign particles in paint materials and coatings, often
of irregular shape, that are hard, abrasive,
and resistant to disintegration.
hiding power, n
the ability of a paint, or paint material as used, to hide or
obscure (see opacity) a surface to which it
has been uniformly applied.
DISCUSSIONWhen expressed numerically, it is generally in terms
of the number of square feet over which a gallon of
paint, or pound of pigment, as used, can be uniformly spread to
produce a specified contrast ratio (see contrast
ratio). The term covering power has no specific relationship to
hiding power, and actually has no precise
meaning.
Hue
under color of an object, see hue.
hydroxyl number, nthe number of milligrams of potassium
hydroxide (KOH) equivalent to the hydroxyl content of 1 g
of sample.
impact tester, n
a device for dropping a cylindrical weight from a variable
height onto a coated metal test panel; the
greater the height required to produce cracks in the coating,
the greater its impact resistance. D 2794,
D01.23
industrial talc, n
a mineral product varying in composition from that approaching
the theoretical formula of talc, Mg
3Si4O10(OH)2, to mixtures of talc and other naturally associated
minerals, some of which may be
fibrous as defined in ASTM Definitions D 2946, Terms Relating to
Asbestos. These fibrous minerals
may or may not be asbestos.
industrial talc, nonasbestos type, nindustrial talc of which
less than 2 particles per 100 particles (by light microscopy)
are asbestos fibers, where asbestos fiber is defined as being
both a fiber by Definitions D 2946 and
one of the asbestiform varieties of serpentine, riebeckite,
cummingtonite (which are chrysotile,
crocidolite and amosite, respectively),anthophyllite, tremolite,
or actinolite. The nonasbestiform
varieties of these same minerals are not asbestos.
intumescent coating, na fire-retardant coating (which see) that
when heated forms a foam produced by nonflammable
gases, such as carbon dioxide and ammonia. This results in a
thick, highly insulating layer of carbon
(about fifty times as thick as the original coating) that serves
to protect the coated substrate from fire.
japan, n
a varnish yielding a hard, glossy, dark-colored film. Japans are
usually dried by baking at relatively
high temperatures.
japan, n
a vehicle for japan colors; frequently contains shellac.
japan color, n
a paste containing pigment and a grinding japan vehicle used for
lettering and decoration.
japan drier, n
a resinate-base liquid drier.
lacquer, n
a coating composition that is based on synthetic thermoplastic
film-forming material dissolved in
organic solvent that dries primarily by solvent evaporation.
Typical lacquers include those based on
nitrocellulose, other cellulose derivatives, vinyl resins,
acrylic resins, etc. D 16 03
lake, n
a special type of pigment consisting essentially of an organic
soluble coloring matter combined more
or less definitely with an inorganic base or carrier. It is
characterized generally by a bright color and a
more or less pronounced translucency when made into an oil
paint. Under this term are included two
(and perhaps three) types of pigment:
(a) the older original type composed of hydrate of alumina dyed
with a solution of the natural organic
color,
(b) the more modern and far more extensive type made by
precipitating from solution various coal-tar
colors by means of a metallic salt, tannin, or other suitable
reagent, upon a base or carrier either
previously prepared or coincidently formed, and
(c) a number combining both types in varying degree might be
regarded as a third class.
lap, n
(for coatings)the region where one area of a coated surface
merges into an adjacent freshly-coated
area during application of a single coat to the entire
surface.
DISCUSSIONThe objective of the painter is to avoid showing the
lap.
latex paint
under paint, see latex paint.
leveling, n
(1) the process whereby a film of liquid coating flows out after
application so as to minimize any
surface irregularities such as brush marks, orange peel, peaks,
or craters, that have been produced by
the mechanical process of application.
(2) a measure or rating of the leveling ability of a coating. D
4062, D01.42
lightness
under color of an object, see lightness.maleic resin
under resin, synthetic, see maleic resin.
liquid, n
(flammability regulations) a substance that has a definite
volume but no definite form, except such
given by its container. It has a viscosity of 1 3 10 3 to 1 3
103 St (1 3 10 7 to 1 3 101 m2 s1) at 104F
(40C) or an equivalent viscosity at agreed upon temperature.
(This does not include powders and
granular materials.) Liquids are divided into two classes:
Class A, low viscositya liquid having a viscosity of 1 3 103 to
25.00 St (1 3 107 to 25.00 3 10 4
m2s1) at 104F (40C) or an equivalent viscosity at an agreed upon
temperature.
Class B, high viscositya liquid having a viscosity of 25.01 to 1
3 10 3 St (25.01 3 104 to 1 3 10 1m2
s1) at 104F (40C) or an equivalent viscosity at an agreed upon
temperature.
mar resistance, n(1) ability of a coating to resist visual
damage caused by light abrasion, impact, or pressure.
(2) resistance of the surface of the coating to permanent
deformation resulting from the application of
a dynamic mechanical force. D 5178, CED, D01.23
mass color, n
the color, when viewed by reflected light, of a pigment-vehicle
mixture of such thickness as to obscure
completely the background. Sometimes called over-tone or
mass-tone.
mass-tone
see mass color.
melamine resin
under resin, synthetic see melamine resin.
metal marking resistance, nthe ability of a coating to withstand
streaking or marking when a metal object is rubbed
against or dragged across the surface of the coating.
MFFT, n
abbreviation of minimum film forming temperature.
mildew (fungus) resistance, nthe ability of a coating to resist
fungus growth that can cause discoloration and ultimate
decomposition of a coatings binding medium.
mildewstat, n
a chemical agent that inhibits the growth of mildew.
mohair paint roller cover, na cover in which the paint
applicating material is woven of short-pile velour that
contains
wool or angora goat hair.
mottling, vt
the presence in the surface of a film, of irregularly shaped,
randomly distributed areas that vary in
color, gloss, or sheen, causing the film to be non-uniform in
appearance, also known as blotching. D
1848, D01.42
mud-cracking, n
an irregular broken network of cracks in the film, which occurs
due to volatile loss while drying or
curing. D 1848, D01.42
natural resin
see resin, natural.
natural spreading rate, nthe spreading rate that occurs when a
coating is applied in a manner natural to the operators
technique,
perceptions, and expectations, as they relate to coating tools,
substrate, and characteristics of the
coating itself.
DISCUSSIONSuch a spreading rate can vary widely with the same
paint applied under similar conditions by different
operators, but a series of paints applied by different operators
under the same conditions will tend to have
approximately the same rank order.
nondrying oil, n
an oil that does not of itself possess to a perceptible degree
the power to take up oxygen from the air
and lose its liquid characteristics.
nonvolatile content, nthe portion of a coating that does not
evaporate during drying or curing under specified conditions,
comprising the binder and, if present, the pigment. (The percent
volatile content is obtained by
subtracting the nonvolatile content from 100.)
nonvolatile vehicle, nthe liquid portion of a paint excepting
its volatile thinner and water.
OEM coatings, n
original equipment manufacturers coatings, which include
automotive, marine, furniture, appliance,
as well as many other miscellaneous consumer and industrial
applications.
oil color, n
an oil paint containing a high concentration of colored pigment,
commonly used for tinting paint.
oil paint
under paint, see oil paint.
oil varnish
under varnish, see oil varnish.
opacity, n
the degree of obstruction to the transmission of visible light.
In this sense opacity is a relative term, it
being considered that given a film sufficiently thin, in paint
technology at least, there is no absolutely
opaque substance.
open time, n
length of time a coating remains wet enough to allow for
brushing-in at the laps; also called wet edge
time.
over-tone
see mass color.
paint vb
to apply a thin layer of a coating to a substrate by brush,
spray, roller, immersion, or any other suitable
means.
paint n, general
a pigmented coating. See coating. D 16 03
paint n, specific
a classification sometimes employed to distinguish pigmented
drying oil coatings (paints) from
synthetic enamels and lacquers.emulsion paint
a paint, the vehicle of which is an emulsion of binder in water.
The binder may be oil, oleoresinous
varnish, resin, or other emulsifiable binder.
latex paint
a paint containing a stable aqueous dispersion of synthetic
resin, produced by emulsion
polymerization, as the principal constituent of the binder.
Modifying resins may also be present.
oil paint
a paint that contains drying oil or oil varnish as the basic
vehicle ingredient.
paste paint
a paint in which the pigment is sufficiently concentrated to
permit a substantial reduction with vehicle
before use.
water paint
a paint, the vehicle of which is a water emulsion, water
dispersion, or ingredients that react chemically
with water.
paint brush, n
a paint application tool consisting of a flexible brushing part
composed of long filamentary material
(brushing material) bound to a handle.
DISCUSSIONTypical types include designs for varnish, enamel,
sash and wall painting. They are manufactured in a range
of shapes and sizes.
paint brush bristle, nhair of the swine (for example: pig, hog,
boar), used in brushing material.
paint brush ferrule, nouter band that joins the brushing
material to the handle.
paint brush filament, na synthetic polymer extrusion used in
brushing material.
paint brush head, nbrush without the handle.
paint brush length clear, n also called length out, the exposed
length of the brushing material from the ferrule to the tip
end.
paint brush thickness, nmeasurement of the brushing material
across the narrow opening of the ferrule.
paint pad, n a paint application tool consisting of short
filamentary material usually bonded to a flat, resilient
backing connected to a handle designed to apply paint by a
wiping action.
paint roller, n
a complete paint application tool consisting of a roller frame
and a roller cover designed to apply paint
by a rolling action.
paint roller core, na structural tube that forms the base of the
roller cover to which paint applicating material is attached.
paint roller cover, na tubular sleeve consisting of a paint
applicating material secured to a core.
paint roller cover pile