L 4A - 2b Tab of Factor

Table 2 Environments A & B: Typical Protective Systems
Interior dry and interior

with occasional
condensation
Dry film
thickness
Cost comp
Likely time to first

maintenance in years
(a)
prevent steel
corrosion
Comments upon initial

systems
Repaint - likely
system
Comments
upon repaint
system
Prepare and spot

prime - oil based
anticorrosive
Primer plus one
or two coats oil
based finish.
Spot
priming
should be
less than 1%
Top-coats
only
refurbished
overall so
maintenance
relatively
straightforward.
(b)
maintain
appearance
hygiene etc
P1
Off site:
Blast to Sa 2, ISO
8501-1
1. Ignore this DFT

in calculating total
thickness required
for protection.
Medium Profile
ISO 8503 Part 1
(1)
15
Coat 1 Blast Primer
Type 1, 11 or 111
2. Accurate costing
possible.
50
3. Controlled
environment for
preparation/priming.
(50)
4. Pre or post
fabrication priming
possible. If post
Coat 2 or Oil Based

Anticorrosive Primer
On site:
fabrication, omit
coat 1.
Rectify transit/erection
damage with Coat 2
Primer
25
Coat 3 Oil Based

Undercoat
110
20+
130
20+
7-12
35
5. Total system can

be applied on site
see (4) above. Cost
is likely to increase.
Quality control is
more difficult.
Coat 4 Oil Based Finish
Total DFT
150
Total DFT using
micaceous Iron oxide
pigmented undercoat
Total DFT using

Micaceous Iron oxide
pigmented undercoat
and finish
20+
7-12
6. The use of
micaceous iron
oxide pigmented
undercoat and finish
give better edge
protection.
7. Coats 3 & 4 can
also be replaced
with one coat of a
high build finish.

Interior dry and interior with
occasional condensation
Dry film
thickness
Cost
comp

(a)
prevent
steel
corrosion

systems
Repaint - likely system
Comments
upon repaint
system
Prepare spot prime oil

based Anticorrosive Primer
bring forward with oil
based under coat apply 1 or
2 coats of finish overall.
May require up
to 25% priming
& bringing
forward failure
due to millscale
detachment
unpredictable.
(b)
maintain
appearance
hygiene etc
P2
On site:
1. light millscale, rust
in pits will not be
removed. This may
cause paint
detachment before the
top coats need
refurbishing.
Manual/Mechanical
preparation to St 2, ISO 85011
50
Coat 1 Oil Based
25
Coat 2 Oil Based Undercoat
35
110
OR
20+
5(1)
Total DFT
130
20+
5+(1)
Total DFT using micaceous

iron oxide pigmented
undercoat
150
20+
2. Coats 2 & 3 can be

replaced with 1 coat
of a high build finish.
5-7(1)
3. The use of
micaceous iron oxide
pigmented undercoat
and finish will give
better edge protection.
1 coat high build finish.
Planned
maintenance
budgeting
difficult.

P3
On site:
1. This process is for

hollow encased
steelwork. It is not
decorative.
Manual/Mechanical
preparation to St 2, ISO 85011
Coat 1 Non oxidising 'grease'
paint or propriety
'anticorrosive' compound
100+
Total DFT
not
2. Check risks in the
event of fire.
100+
Coat 2 As coat 1
20+
200+
20+
app
3. Some
manufacturer's may
recommend a
'penetrating' primer.
Refurbish with original

material or similar.
Establish
consequence of
increasing the
total film
thickness in the
event of fire.

Interior dry and interior with
occasional condensation
Dry film Cost

thickness comp
m

(a)

systems
Comments upon
repaint system
Oil based anticorrosive

primer calcium plumate
pigmented (lead)
containing - T - Wash or 2pack etch primer similar to
Type 1 Blast primer 1 coat
oil based undercoat 1 coat
oil based finish.
Corrosion products
must be washed prior
to painting lead containing primers
impose limitations. T
Wash must be rinsed
off thoroughly.
Non lead containing oil

based anticorrosive primer
Corrosion products
must be removed
before priming.
(b)
prevent
maintain
steel
appearance
corrosion hygiene
etc
G1
On site:
Galvanize - pr EN 1029
85
20
not
Size limitations.
applicable
Not decorative.
Not readily cleaned in
service. *Life using
galvanized fasteners.
AS1/ZS1
Off site:
Zinc or aluminum spray to
BS 2569 - sealed
Aluminium, Unsealed zinc
100
100
20+
20+
not
No size limitations.
applicable
Not decorative, retains dirt,
oil etc., readily.
Not readily cleaned in
service. * assumes fasteners
treated to same standard.
1 coat oil based undercoat

1 coat oil based finish.
Table 2 Environment C: Typical Protective Systems

Interior frequent
condensation
Dry film
thickness
m
Cost
comp

(a)
(b)
prevent
steel
corrosion
maintain
appearance
hygiene etc

systems
Comments upon
repaint system
Prepare, prime with Onepack Chemical Resistant

Primer, bring forward with
one coat of Coat 3 type
undercoat and apply Coat 4
type finish overall
These products dry

by solvent
evaporation alone
when unmodified
with oil. Adhesion
of maintenance
systems usually
good therefore.
P4
Off site:
Blast to Sa 2, ISO 8501-1
1. Ignore this DFT

in calculating total
thickness required
for protection.
Medium Profile ISO 8503

Part 1
Coat 1 Blast Primer Type 11

or 111
15
Coat 2 One-pack Chemical
Resistant Primer
75
2. Zinc containing
(type III) primer
normally not used
where direct
chemical attack
predicted. Consult
manufacturer.
3. May be MIO
pigmented.
On site:
Rectify transit/erection
damage with One-pack
4. Small sections
Chemical Resistant Primer.
(75)
vulnerable to
'blocking' if bundled
together at this
thickness: consult
manufacturer.
75
Resistant Undercoat
75
225
15+

Resistant Finish
12
175
10+
10
Coat 4 Replacing with fill

gloss One-pack Chemical
Resistant Finish gives 25
:
6. Maximum
resistance to direct
chemical attack on
paint film and for
aesthetic reasons.
5

25 :

5. Total system can

be applied on site
see (4) above. Cost
is likely to increase
and quality control
is more difficult.
250
15+
12
7. Maximum
durability and
chemical resistance.
Table 2 Environment C: Typical Protective Systems

Interior frequent condensation
Dry film Cost

thickness comp
m

(a)
Comments upon initial systems
Repaint - likely
system
Comments
upon repaint
system
Prepare and
apply one or two
coats of coat 3,
two pack
chemical
resistant finish.
Preparation
may include
light blasting.
Remember
temperature
humidity and
intervals
between coats
are critical.
(b)
prevent
maintain
steel
appearance
corrosion hygiene etc
P5
Off site:
1. Ignore this DFT in

calculating total thickness
required for protection.
Medium Profile ISO 8503 Part 1

Coat 1 Blast Primer Type 1, 11 or
111
15
Coat 2 Two-pack Chemical
Resistant Primer
75
3. Coat 1 may be omitted if

blasting is post fabrication.
On site:
Rectify transit/erection damage with
Coat 2 type Primer.
2. Zinc containing (Type III)

primer normally not used
where direct chemical attack
predicted. Consult
manufacturer.
(75)
4. Epoxy or urethane pitch or

tar can be used for water
resistance.
OR
1 coat one-pack
chemical
resistant
undercoat
1 coat one-pack
Refurbishing
with one-pack
chemical
resistant
undercoat and
finish can be
considered.
Resistant Finish
75

Resistant Finish
75
15+
10+
5. Consult manufacturer for

min temperature & max
humidity requirements during
application and curing.
chemical
resistant finish.
223
6. Intervals between coats are
critical, consult manufacturer.
Ensure relevant information is
written into specification.
Total DFT
Note: System P1, page 1 using MIO pigmented undercoat and finish can be considered at dft's of 130-150 m. It will not resist direct chemical
attack or immersion. Likely time to first maintenance - 5 years (columns 'a' and 'b').
Consider also Galvanising - See system G1 (85 m dft). See page 22
Consider also Metal Spraying - See system AS1/ZS.1 (100 m dft). See page 22
Table 2 Environment D: Typical Protective Systems

Normal Inland
Dry film Cost

thickness comp
m

(a)
Repaint - likely
system
(b)
Comments
upon repaint
system
prevent
maintain
steel
appearance
P1
Off site:
Prepare and spot

calculating total thickness prime - oil based
anticorrosive
Primer plus one
or two coats oil
2. Accurate costing
based finish.
possible.
Coat 1 Blast Primer Type 1, 11 or 111
15
Coat 2 or Oil Based Anticorrosive Primer
50
3. Controlled
environment for
Onsite:
Rectify transit/erection damage with Coat
2 Primer
(50)
4. Pre or post fabrication

priming possible. If post
fabrication, omit coat 1.
Spot priming
should be less
than 1% Topcoats only
refurbished
overall so
maintenance
relatively
straightforward.
25
5. Total system can be

applied on site see (4)
above. Cost is likely to
increase. Quality control
is more difficult.
35
Total DFT
110
7+
5+
130
10+
7-12
150
10+
7-12
Total DFT using micaceous Iron oxide

pigmented undercoat
6. The use of micaceous

undercoat and finish give
Total DFT using Micaceous Iron oxide

pigmented undercoat and finish
7. Coats 3 & 4 can also
be replaced with one coat
of a high build finish.

Normal Inland
Dry film Cost

thickness comp
m

(a)
Comments
upon repaint
system
Prepare, spot prime with

coat 1 type primer, bring
forward with coat 2 type
undercoat, finish overall
with one coat type 2
undercoat and one coat type
3 finish OR 2 coats type 3
finish.
May require up
to 25% priming
& bringing
forward failure
due to millscale
detachment
unpredictable.
(b)
prevent
maintain
steel
appearance
P2
On site:
Manual/Mechanical
preparation to St 2, ISO
8501-1
Coat 1 Oil Based
50
25
35
110

Total DFT
undercoat
1. light millscale rust in

pits will not be
removed. This may
cause paint detachment
before the top coats
need refurbishing.
6-
3-
10
6-10
3-5
8-12
5-7
135
150
2. The use of
micaceous iron oxide
pigmented undercoat
and finish will give
OR 1 coat high build finish.
Planned
maintenance
budgeting
difficult.

Normal Inland
Dry film Cost

thickness comp
m

(a)
Repaint - likely
system
Comments
upon repaint
system
Prepare, prime
with One-pack
Chemical
Resistant Primer,
bring forward
with one coat of
Coat 3 type
undercoat and
apply Coat 4 type
finish overall.
These
products dry
by solvent
evaporation
alone when
unmodified
with oil.
Adhesion of
maintenance
systems
usually good
therefore.
(b)
prevent
maintain
steel
appearance
P4
Off site:


111
15

Resistant Primer

predicted. Consult
manufacturer.
On site:
3. May be MIO pigmented.
75
(75)
One-pack Chemical Resistant
Primer.
75
75
Coat 3 One-pack Chemical Resistant
Undercoat
225
7-10
15+
4. Small sections vulnerable

to 'blocking' if bundled
together at this thickness:
consult manufacturer.

Finish
175
10+
7+
5. Total system can be applied

on site. Cost is likely to
increase and quality control
be more difficult.
6. Maximum resistance to
direct chemical attack on
paint film and for aesthetic
reasons.
Coat 4 Replacing with full gloss

One-pack Chemical Resistant Finish
gives 25 m for final coat: Total
DFT becomes
7. Maximum durability and

OR
250
15+
7-10
Add Coat 5 - full gloss One-pack

Chemical Resistant Finish giving
additional 25 m:
Total DFT becomes
Consider also Galvanising - See system G1 (85 m dft). See page 22
Consider also Metal Spraying - See system AS1/ZS.1 (100 m dft). See page 22
Table 2 Environment E: Typical Protective Systems

Normal Coastal
Dry film Cost

thickness comp
m

(a)
Repaint - likely
system
Comments
upon repaint
system
Prepare, prime
with One-pack
Chemical
Resistant Primer,
bring forward
with one coat of
Coat 3 type
undercoat and
apply Coat 4 type
finish overall.
These
products dry
by solvent
evaporation
alone when
unmodified
with oil.
Adhesion of
maintenance
systems
usually good
therefore.
(b)
prevent
maintain
steel
appearance
P4
Off site:


Coat 1 Blast Primer Type 11 or 111
15

Primer
75

predicted. Consult
manufacturer.
On site:
One-pack Chemical Resistant
Primer.
Undercoat
(75)
75
75
4. Small sections vulnerable to

'blocking' if bundled together
at this thickness: consult
manufacturer.
Finish
225
15+
12
Coat 4 Replacing with full gloss

One-pack Chemical Resistant Finish
gives 25 m for final coat: Total
DFT becomes
175
10+
10

increase and quality control be
more difficult.
direct chemical attack on paint
film and for aesthetic reasons.
OR
Add Coat 5 - full gloss One-pack

Chemical Resistant Finish giving
additional 25 m:
Total DFT becomes
250
15+
12

Polluted Inland
Dry film Cost

thickness comp
m

(a)
Repaint - likely
system
Comments
upon repaint
system
Prepare and apply

one to two coats
of coat 4 type
Two-pack
Chemical
Resistant Finish.
Preparation
may include
light
blasting.
Remember,
temperature
and
humidity
and intervals
between
coats are
critical.
Refurbishing
with a Onepack
Chemical
Resistant
Finish can
be
(b)
prevent
maintain
steel
appearance
P6
Off site:

15
2. This coat can be omitted if

post fabrication blasting is
carried out.

Resistant Primer
75
125

Resistant Undercoat
Onsite:
(75)

predicted. Consult
manufacturer.
min temperature and max
application and 'curling'.
OR
one-pack
moisture curing
polyurethanes
Coat 2 Primer, bring forward primed (125)

areas with coat 3 type undercoat.
75
Coat 4 to-pack Chemical Resistant
Finish
275
OR
20
7-12
20
7-12
Total DFT
OR
75
substitute Coat 4 One-pack
Chemical Resistant Finish
275
Alternative process Total DFT
considered
i.e.
chlorinated
5. Interval between coats is
rubber, vinyl
critical consult manufacturer.
Ensure relevant information is Prepare and apply or acrylic
one or two coats resin based.
Also 1-pack
One-pack
moistureChemical
Resistant Finish. curing
urethane.
6. This is a useful alternative to
a 2-pack paint as the final coat
under cold conditions or where
there are likely to be delays on
site (includes 1-pack moisturecurling polyurethanes)
7. Glossy 1 or 2 pack Chemical
Resistant Finishes will give
lower DFT's (circa 25 m).

Polluted Inland
Dry film Cost

thickness comp
m

(a)
prevent
steel
corrosion
Repaint - likely
system
(b)
Comments
upon repaint
system
maintain
appearance
hygiene etc
P7
Off site:


15

Primer
100
On site:
(50)
Rectify transit/erection damage with 2 (50)
coats One-pack Chemical Resistant
Primer.
75
Undercoat
75
Prepare, prime
with One-pack
Chemical
Resistant Primer,
bring forward
with one coat of
2. Zinc containing (Type III) Coat 3 type
undercoat and
where direct chemical attack apply Coat 4
type finish
predicted. Consult
overall (1 or 2
manufacturer.
coats).

These
products dry
by solvent
evaporation
alone when
unmodified
with oil.
Adhesion of
maintenance
systems
usually
good
therefore.
Finish
75
15+

Finish
12
325
reasons.
Total DFT
255(6)
Replacing with full gloss One-pack
Chemical Resistant Finish gives 25
m for final coat:

applied on site. Cost is likely
to increase and quality
control be more difficult.
10+
15+
10
12

Total DFT becomes

G1
Offsite:
85
10+
Not
applicable
See notes under G1 page 22
zinc 15+
Not
applicable
See notes under AS1/ZS1 page 22
Galvanise - pr EN 1029
AS2/ZS2
Off-site zinc or aluminium spray to
BS 5269 - sealed
150
Aluminium
20
3 Coat one or
two pack
chemical
resistant paint
systems 150300 m dft
See notes
under G1
page 22
As noted in G1
above
See notes
under
AS1/ZS1
page 22
Table 2 Environment F: Typical Protective Systems

Normal Coastal
Dry film Cost

thickness comp
m

(a)
Repaint - likely
system
(b)
Comments
upon
repaint
system
prevent
maintain
steel
appearance
P1
Off site:
111
15
Coat 2 Oil Based Anticorrosive
Primer
50
1. Ignore this DFT in calculating Prepare, spot

total thickness required for
prime with coat 2
protection.
type primer.
Bring forward
with coat 3 type
2. Accruable costing possible.
undercoat. Finish
overall with coat
4 type finish.
3. Controlled environment for
Onsite:

Coat 2 type Primer.
(50)

increase. Quality control is more
Spot
priming
should be
less than
1%.
Bringing
forward
primed
areas with
undercoat
retains
original
thickness.
difficult.
25

35
Total DFT
3+
110
Total DFT using a micaceous iron

oxide pigmented undercoat
8+
130
3-5
Total DFT using micaceous iron

oxide pigmented undercoat and
finish
8+
150
5+
8-12
6. The use of micaceous iron

oxide pigmented undercoat and
finish will give better edge
protection.
Table 2 Environment F: Typical Protective Systems

Normal Coastal
Dry film Cost

thickness comp
m

(a)
Repaint - likely
system
(b)
Comments
upon repaint
system
prevent
maintain
steel
appearance
P5
Off site:


111
15
75
2. Zinc containing (Type

III) primer normally not
used where direct chemical
attack predicted. Consult
manufacturer.
(75)

Coat 2 Two-pack Chemical Resistant

Primer
On site:
coat 2 type Primer.
75
4. Epoxy or urethane pitch

or tar can be used for water
resistance.
min temperature & max
Preparation
may include
light
blasting.
Remember
temperature,
humidity
and intervals
between
OR
coats are
critical.
Refurbishing
with One1 coat One-pack
pack
chemical resistant
chemical
undercoat
resistant
undercoat
1 coat One-pack
and finish
chemical resistant
can be
finish.
considered.
Prepare and apply
one to two coats
of coat 3, Twopack chemical
resistant finish.
Finish
75
humidity requirements
during application and
curling.

Finish
15+
10+
225
6. Intervals between coats
are critical, consult
manufacture. Ensure
relevant information is
Total DFT
G1
Offsite:
85
20
Not
applicable
See notes under G1
20
Not
applicable
See notes under AS1/ZS1
AS2/ZS1
BS 5269 - sealed
150
3 Coat one or two See notes

pack chemical
under G1
resistant paint
As noted in G1
above
See notes
under
AS1/ZS1
Table 2 Environment G: Typical Protective Systems

Polluted Coastal
Dry film Cost

thickness comp
m

(a)
Repaint - likely
system
Comments
upon repaint
system
Prepare and
apply one to two
coats of coat 4
type Two-pack
Chemical
Resistant Finish.
Preparation
may include
light
blasting.
Remember,
temperature
and
humidity
and intervals
between
coats are
critical.
Refurbishing
with a Onepack
Chemical
Resistant
Finish can
be
(b)
prevent
maintain
steel
appearance
P6
Off site:
Blast to Sa 2, EN 8501-1

15
2. This coat can be omitted if

post fabrication blasting is
carried out.

Resistant Primer
75
125

Resistant Undercoat
Onsite:
(75)

predicted. Consult
manufacturer.
min temperature and max
application and 'curling'.
OR
one-pack
moisture curing
polyurethanes
Coat 2 Primer, bring forward

primed areas with coat 3 type
undercoat.
(125)
OR
75
Coat 4 two-pack Chemical Resistant 275

Finish
10+
10
5. Interval between coats is

critical consult manufacturer.
Ensure relevant information is
Total DFT
6. This is a useful alternative
to a 2-pack paint as the final
coat under cold conditions or
where there are likely to be
delays on site (includes 1-pack
moisture-curling
polyurethanes)
OR
75
substitute Coat 4 One-pack

Chemical Resistant Finish
Alternative process Total DFT
275
10+
7-12
7. Glossy 1 or 2 pack
Chemical Resistant Finishes
will give lower DFT's (circa
25 m).
Prepare and
apply one or two
coats One-pack
Chemical
Resistant Finish.
considered
i.e.
chlorinated
rubber, vinyl
or acrylic
resin based.
Also 1-pack
moisturecuring
urethane.
Table 2 Environment G: Typical Protective Systems

Polluted Coastal
Dry film Cost

thickness comp
m

(a)
Repaint - likely
system
(b)
Comments
upon repaint
system
prevent
maintain
steel
appearance
P8
Off site:
Blast to Medium Profile ISO 8503
Part 1


15
Primer
100
On site:
(50)
Rectify transit/erection damage with 2

coats One-pack Chemical Resistant
Primer.
(50)

Undercoat
75
Prepare, prime
with One-pack
Chemical
Resistant Primer,
bring forward
with one coat of
2. Zinc containing (Type III) Coat 3 type
undercoat and
where direct chemical attack apply Coat 4 type
finish overall (1
predicted. Consult
or 2 coats).
manufacturer.
75
75

These
products dry
by solvent
evaporation
alone when
unmodified
with oil.
Adhesion of
maintenance
systems
usually
good
therefore.
Finish
325
15+
12

Finish
reasons.
Total DFT
275(6)
Replacing with full gloss One-pack
Chemical Resistant Finish gives 25
m for final coat:

applied on site. Cost is likely
to increase and quality
control be more difficult.
10+
10
Total DFT becomes

G1
Offsite:
140
10+
Not
applicable
See notes under G1
15+
Not
applicable
See notes under AS1/ZS1
AS2/ZS2
BS 5269 - sealed
150
3 Coat one or two See notes

pack chemical
under G1
resistant paint
As noted in G1
above
See notes
under
AS1/ZS1

L 4A - 2b Tab of Factor

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Table 2 Environments A & B: Typical Protective Systems

Interior dry and interior

Likely time to first

Comments upon initial

Prepare and spot

1. Ignore this DFT

Coat 2 or Oil Based

Coat 3 Oil Based

5. Total system can

Coat 4 Oil Based Finish

Total DFT using

Table 2 Environments A & B: Typical Protective Systems

Likely time to first

Comments upon initial

Repaint - likely system

Prepare spot prime oil

Coat 2 Oil Based Undercoat

Coat 3 Oil Based Finish

Total DFT using micaceous

2. Coats 2 & 3 can be

1 coat high build finish.

iron oxide pigmented

1. This process is for

Refurbish with original

Table 2 Environments A & B: Typical Protective Systems

Dry film Cost

Likely time to first

Comments upon initial

Repaint - likely system

Oil based anticorrosive

Non lead containing oil

1 coat oil based undercoat

Table 2 Environment C: Typical Protective Systems

Likely time to first

Comments upon initial

Repaint - likely system

Prepare, prime with Onepack Chemical Resistant

These products dry

1. Ignore this DFT

Medium Profile ISO 8503

Coat 1 Blast Primer Type 11

Chemical Resistant Primer.

Coat 4 One-pack Chemical

Coat 4 Replacing with fill

5. Total system can

Table 2 Environment C: Typical Protective Systems

Dry film Cost

Likely time to first

Comments upon initial systems

1. Ignore this DFT in

Medium Profile ISO 8503 Part 1

3. Coat 1 may be omitted if

Coat 3 Two-pack Chemical

2. Zinc containing (Type III)

4. Epoxy or urethane pitch or

Coat 4 Two-pack Chemical

5. Consult manufacturer for

Table 2 Environment D: Typical Protective Systems

Dry film Cost

Likely time to first

Comments upon initial systems

Prepare and spot

Medium Profile ISO 8503 Part 1