Choosing a Qualified Contractor and

Surface Preparation & Coatings

Presented
P
t db
by:
David Van Zee
NACE Certified Coating Inspector # 9285
SSPC CCI # 21145
Brian Huffman
Protective & Marine Coatings Rep
Sherwin-Williams Protective Coatings
SSPC CCI # 21154

What is corrosion?
According
g to the National Association of Corrosion
Engineers, (NACE):
Corrosion is the deterioration of a material, usually
a metal, because of a reaction with its
environment.
environment
The cost of corrosion in the United States was
estimated at $300 Billion in 1994, representing
4.5% of the GNP.

Causes of corrosion in W&WW

A corrosion cell on steel in comprised of 4
components and all must be present for
corrosion to take place
Anode
Cathode
Metallic Pathway
Electrolyte

Causes of corrosion in W&WW

Since an anode and cathode can exist on
the same piece of steel, the only
protection mechanism is to remove the
electrolyte from the equation. Coatings
protect by three basic principles
principles.
Barrier Protection
Inhibitive Protection
Sacrifical Protection

Causes of corrosion in W&WW

Concrete degradation can take place
through many different factors. Some of
the key factors are:
Chemical Attack
Erosion
Microbial Induced Corrosion
Poor Construction

Causes of corrosion in W&WW

Concrete degradation can be reduced or
stopped by protecting the structure from it
environment through barrier
barrier protection
protection
methods

Rust issues in a pipe gallery

More close up examples

Steel tanks and corrosion

Concrete issues on a clear well

Close up of concrete tanks

Concrete degradation on a clarifier

You have corrosion now what?

Have project specified by a qualified
professional
Manufacturer / material supplier
Engineering group
Qualified industrial painting contractor
Previous coating specification

What is a written specification?

Websters 20th Centuryy Dictionaryy defines a
Specification as:
A particular and detailed description of a thing:
specifically a statement of particulars describing
the dimensions
dimensions, details
details, or peculiarities of any
work about to be undertaken as in architecture,
building, engineering, etc.

A typical specification includes:

General description
p
Reference standards
and codes
Scope of work
Safety / Insurance
Pre-job conference
Coating materials
Sampling
S
li coatings
i
Workmanship

Substrate p
preparation
p
Repairs / remediation
Material selection
Coating application
Mil thickness
Work schedule
Inspection
Documentation

Why is the specification

important?
When developing or writing any
specification, the goal should be to
produce a clear
clear, concise and technically
correct document. This goal is seldom
more difficult
difficult, nor the risk so great as
when writing specifications for HighPerformance Coatings
Coatings, Tank Linings or
Corrosion Protection Systems for steel
and concrete surfaces
surfaces.

Why is a specification so important

to the
h ffacility
ili owner?
?
Shifts responsibility to a professional more
qualified to access problems and solutions
Most important step toward a quality
completed project
Allows for apples-to-apples
apples to apples proposal
comparison
Outlines to contractors exactly what is
required to complete the job
Guarantees a predictable end result

How to choose a quality contractor

Certifications: NACE Coating
g Inspector
p
Program,
g
Society for Protective Coatings program
Experience level references from other municipalities
Insurance coverage
Quality Assurance program What does the contractor
do to ensure a quality end-result
Safety program Compliance with OSHA and EPA
standards
Request list of approved industrial contractors from
manufacturer

What to consider in managing a

coatings
i
project
j

Timing / scheduling / down time

Budget / pricing
Service life of asset
Disruptions to operations
Environmental impact
Removal of existing coatings facility owner disposal
or contractor disposal
p
Lead concerns is there lead present?

Safety

When things go wrong

a case study
d
Neutralization tank at WWTP needed repair
Plant manager received multiple proposals
to fix problems internal and external
Different solutions were offered
Bids were approximately $1,000 apart
Contractor was chosen,, repairs
p
were
completed

Tarboro NC -- February 2008

Tarboro,

Steel tank with concrete floor

A leak was noticed; the tank was

d i d revealing
drained
li the
h ffailed
il d lilining
i

6 months later
later summer 2008

Failure: 100% - floor,

floor 50% - walls

Exposed aggregate on tank floor

Wholesale failure of lining system

N
Now
what?
h ?
Plant manager requested new proposals
based on current situation
NACE certified coating inspector consulted
to conduct failure analysis and manage
project
Original contractor currently on site
removing
i coating
ti and
d starting
t ti over

Impact of these problems:

Headaches for p
plant manager
g to deal with
problem again
Additional expenses:
Down time to take tank out of service again
Charges for coating inspector to consult and manage
project
Expenses to repair exterior damage

Fortunately the rake arm and other equipment

was not damaged with the failure of the system
Potential legal issues

Benefits of hiring a quality

contractor

Partner to help solve maintenance problems

Anticipate possible issues
Manage project around your operation
Long-lasting, quality finished project
Assume some of the risks
Stand behind their workmanship
You get the project done right the first time
saving you time, money, etc.

Painting: Its
It s all in the prep!
60% - 80% of premature coating
failures are due to poor / substandard
surface
f
preparation
ti

Surface preparation
Purpose

Considerations

Clean surface
Remove rust
Provide anchor profile
Promote adhesion

Exposure conditions
Generic type coating
Economics
Environmental and
safety

Surface prep note

Paints adheres to the surface by mechanical
and / or chemical bond
Whatever interferes with that bond will also
i t f
interfere
with
ith adhesion
dh i

Surface preparation standards

The basic standards for preparing metal
substrates are a joint effort between:
The Society for Protective Coatings,
(SSPC)
National Association of Corrosion
Engineers, (NACE)

Standards and Methods

SSPC-SP 1
SSPC-SP 2
SSPC-SP 3
SSPC-SP 5 / NACE 1
SSPC SP 6 / NACE 3
SSPC-SP 7 / NACE 4
SSPC-SP 8
SSPC-SP 10 / NACE 2
SSPC-SP 11
SSPC-SP 12 / NACE 5
SSPC-SP 13 /NACE 6

Solvent cleaning
Hand tool cleaning
Power tool cleaning
White metal blast cleaning
Commercial blast cleaning
Brush-Off blast cleaning
Pickling
g
Near-white blast cleaning
Power tool cleaning to bare metal
Surface p
preparation
p
and cleaning
g
of steel and other hard materials by
high and ultra-high water jetting
Surface Preparation of Concrete

SSPC SP1
SSPC-SP1
Solvent Cleaning
Removal of oil, grease, dirt, soil and
contaminants by cleaning with solvent
solvent,
vapor, alkali, emulsion or steam
This is the first step dictated by all surface
preparation methods!

SSPC SP2
SSPC-SP2
Hand tool cleaning
Removal of loose rust, loose mill scale and
loose paint by hand chipping
chipping, scraping
scraping,
sanding and wire brushing
Loose is described as what can be
removed with the edge of a dull putty knife

SSPC-SP
SSPC
SP 3
Power tool cleaning
Removal of loose rust, loose mill scale and
loose paint by power tool chipping
chipping,
descaling, sanding, wire brushing and
grinding
Loose is described as what can be removed
with the edge of a dull putty knife

SSPC-SP6
SSPC
SP6 / NACE 3
Commercial blast cleaning
Removal of all visible oil grease, dust, dirt,
mill scale, rust, coating, oxides, corrosion
products, and other foreign matter when
g
for at least
viewed without magnification
66.6% of a 9 square inch area
Random staining shall be limited to no more
than 33% of each unit area

SSPC-SP
SSPC
SP 10 / NACE 2
Near white blast cleaning
g
Removal of all visible oil, grease, dust, dirt, mill
scale, rust, coating, oxides, corrosion products,
and other foreign matter when viewed without
magnification for at least 95% of a 9 square inch
area.
Staining consisting of light shadows, slight streaks,
or minor
o
o d
discolorations
sco o at o s caused by sta
stains
so
of rust,
ust,
mill scale, or previously applied coatings shall be
limited to 5% of area.

SSPC-SP
SSPC
SP 12 / NACE 5
Surface preparation and cleaning of steel and
other hard materials by high and ultra-high
pressure water jetting prior to recoating
Level of standard is determined by amount of
pressure.

SSPC-SP12 / NACE 5
4 llevels
l off pressure cleaning
l
i
Low pressure water cleaning:
cleaning performed at pressure less than 5,000 PSI

High pressure water cleaning:

cleaning performed between 5,000 and 10,000 PSI

High pressure water jetting:

cleaning performed between 10,000 and 30,000 PSI

Ultra-high
g pressure water jjetting:
g
cleaning performed at pressures above 30,000 PSI

SSPC-SP13
SSPC
SP13 / NACE 6
Surface Preparation of Concrete
Gi
Gives
the
th requirements
i
t for
f surface
f
preparation of concrete by mechanical,
chemical,
h i l or th
thermall method
th d prior
i tto
the application of bonded protective
coating or lining systems
systems.
A minimum concrete surface strength
strength,
maximum moisture vapor emission rate, and
surface profile range should be specified in
the specification.

Coating Inspection
Someone once wrote
wrote, inspect
inspect what you
expect.
A certified professional coating inspector can
be the most cost effective insurance policy
that an owner can purchase.
p

Coating Inspection
With todays
today s technically advanced
coatings and application methods this is a
task that should not be left to a general
construction inspector or the
consequences could be enormous
enormous.
Certified professional coatings inspectors
use tools specifically design to insure
compliance with your specification.

Replica Tape for Measuring

Surface Profile

SSPC-VIS
SSPC
VIS 1
1-89
89

VIS 1-89
Initial Conditions
Mill Scale

Mill Scale & Rust

Uniform Rust

Uniform Rust & Pitting

SP6 Commercial Blast

Start With Rust Grade B

Start With Rust Grade D

SSPC-VIS
SSPC
VIS 3

SSPC VIS 4
SSPC-VIS

Sling Psychrometer

Surface Thermometer

ICRI No. 03732 CSP Surface

Profile Replica Coupons
ICRI
C Concrete
Co c e e Surface
Su ce Profile
o e
Replicas

Before

After

No more rust
rust

Look at those nuts, bolts and

fl
flanges!
!

Rust

No Rust

Before and after of a steel tank

And heres
here s another one

5MG clear well cleaned and

painted
i d

Clear well and back wash tank

Beautiful finish on this clear well

It sure was ugly!

Repaired and coated clarifier

And another shot or two

Questions?
For more info contact:
David Van Zee
Carolina Management
Team, LLC
PO Box 1409
Enka, NC 28728
828-648-7708
828
648 7708 office
919-414-8867 mobile
g
www.CMTcoatings.com

For more info contact:

Brian Huffman
Sherwin-Williams Co.
Protective Coatings
113 Oakwood
O
Dr
Winston Salem NC 27103
336 558 3335 mobile
336-558-3335
336-725-3066 fax
Swrep6254@sherwin.com