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HEMPEL ACADEMY
October 2012
INDEX
Chapter 1 ............................................................................................................................................................5
1.1 The history of paint ................................................................................................................................7
1.2 Reasons for painting ..............................................................................................................................8
1.3
Chapter 2 ......................................................................................................................................................... 11
2.1 Definition of paint ................................................................................................................................ 13
2.2 Constituents ............................................................................................................................................ 14
2.3 Production ............................................................................................................................................... 15
2.4 Control ....................................................................................................................................................... 17
Chapter 3 ........................................................................................................................................................... 19
3.1
3.2
3.3
3.4
Chapter 4 ........................................................................................................................................................... 39
4.1
Anticorrosives ................................................................................................................................... 42
4.2
4.3
Antifoulings ........................................................................................................................................ 53
4.4
Chapter 5 ........................................................................................................................................................... 67
5.1
Background ........................................................................................................................................ 69
5.2
Objective .............................................................................................................................................. 69
5.3
Contaminants .................................................................................................................................... 69
5.4
5.5
5.6
Chapter 6 ........................................................................................................................................................... 79
6.1
Planning ............................................................................................................................................... 81
6.2
6.3
Microclimate ...................................................................................................................................... 81
6.4
6.5
Workmanship .................................................................................................................................... 86
Chapter 7 ......................................................................................................................................................... 89
7.1 Product data sheets ............................................................................................................................. 90
Chapter 8 ........................................................................................................................................................... 91
8.1
8.2
8.3
8.4
8.5
8.6
9.2
9.3
9.4
10.2
10.3
Chapter 1
INTRODUCTION
PAINTOVERVIEW
1. INTRODUCTION
1.1 The history of paint
1.2 Reasons for painting
1.3 Key factors in using paint
1.1
One of the first to use paint not only for decoration but also for protection was Noah, who
according to the Bible, was ordered by God to: "Make thee an ark of gopher wood, - - and pitch it within and without with pitch".
The developing process in paint technology has moved slowly through wood oils, linseed oil
mentioned 63 A.D., colophonium, glues extracted from animals in the Middle Ages,
copals (a fossil resin), shellac (secretion from insect), etc., all raw materials found in
nature.
In 1903, the first synthetic binder was marketed; it was a novolac intended for use as
a shellac substitute. The alkyd industry developed just before 1920; chlorinated
rubber, vinyl, acrylics entered the market during the 1930s; dispersions (waterborne
paints) were introduced in the 1940s, zinc silicates, epoxies and polyurethane
followed in the 1950s.
1.2
against
Corrosion
Wood
against
Ship bottoms
against
Fouling
Commodities
e.g. in tanks
against
Contamination
e.g. from steel or corrosion products
Concrete
against
Carbonation
Ship decks
against
Abrasion
The list is not complete, but it does give the major areas where paint would be the first
and often the only practical choice for economical protection.
1.3
(2)
The environment.
(4)
(5)
(6)
To obtain the optimum results from coating systems is the primary objective of
Hempel's Coating Inspection Course; consequently, the main contents or subjects of the
course will be the factors listed above.
Chapter 2
PAINT
CONSTITUENTS
and
PRODUCTION
Premix
Dispersion (Grinding)
Final mix
2.4 Control
2.1
Definition of paint
In the paint industry, paint is often defined as "a liquid material which can be applied to
a surface and which after drying forms a thin, cohesive film with good adhesion to the
surface".
2.2
Constituents
Paint is a liquid material. It consists of a medium (vehicle) which is the actual liquid
part of the paint, pigments and extenders (small insoluble particles dispersed in the
medium); plus various additives (in minor amounts).
Mixing of these ingredients, in the right manner and proportion, is really what paint
production is all about. It is not, however, quite as simple as it may sound.
On an average, some 500 different raw materials are used in a typical size paint
manufacturing facility. From a user's point of view, it may be convenient to divide these
many different ingredients into groups, according to their function in the paint.
2.2.1 Binders
The binder, or resin, forms the non-volatile part of a paint's medium; it
ensures adhesion to the substrate and cohesion within the paint film.
Film formation, the manner in which a paint changes from its liquid to its solid state,
is determined by the binder. Most of a paint's more prominent properties are
directly related to the binder used in that paint (see also chapter 3).
2.2.2 Solvents
Solvents serve to liquefy the binder, facilitating production and application of
the paint. They form the volatile part of a paint's medium, and should evaporate
during application and film formation.
(Solvent free paints are, of course, an exception to the foregoing; here, the
binder itself is a liquid and no solvent is required to liquefy the paint).
The choice of solvents influences among others a paint's application properties
and drying time, and in determining its flash point.
2.2.3 Pigments
Pigments give the paint colour and opacity (hiding power), i.e. hide the
underlying surface, they are present as solid particles in the dried/cured paint
film.
Of particular interest are those pigments that prevent or retard corrosion;
and the bio-active pigments used in antifouling paints.
2.3 Production
Quality paints are produced in accordance with detailed, tested and proven formulas,
recipes if you like.
In accordance with the formula, the raw materials for a given batch of paint are assembled
from the raw material stock. Anywhere from about ten to twenty odd different ingredients
may be used in the production of a single paint.
2.3.1 Premix
To start production, part of the binder(s) and solvents, all the pigments and extenders
and possibly some of the additives are mixed to a premix (or millbase) in a large
mixing vat.
Making an optimal millbase is the key point in an efficient production.
2.3.2 Dispersion (grinding)
The millbase can be described as a liquid medium (binder and solvents) plus insoluble
powder, the pigments and extenders. These pigment/ extender powders consist of
primary particles cemented together forming small lumps, agglomerates.
The specified dry film thickness is the upper limit for the size of the agglomerates
which is acceptable in a paint - in principle, as the limit often is specified safely
below.
High-speed disperser
The fastest, but by no means finest, dispersion
is achieved in the high-speed disperser.
It works on the same principle as an ordinary
kitchen blender, although on a somewhat
different scale.
Pearl mill
Undoubtedly the most efficient and most used
grinding mill in modern paint production is the
pearl mill, either the older vertical or the latest
horizontal types.
The millbase is pumped into the mill under
pressure, and is ground by the milling of
numerous small glass beads, the "pearls", set in
motion by a number of rotating discs. Due to
higher pressure, the absence of air in the
mixture
and
a
different
discharge
arrangement, the horizontal pearl mill yields a
better and faster grind than the traditional,
upright type. The most common horizontal pearl
mill is the Dyno mill.
2.4
Control
Quality is monitored throughout the production. A production laboratory checks the
quality of the raw materials before approval for production.
A control laboratory checks the finished paint. Before filling in cans, each batch is
checked for: specific gravity, viscosity, fineness of grind, drying time.
Other control items will be colour (by colour computer), gloss, hiding power,
application properties, sag index, etc., depending on the type of paint in question.
In most (if not in all) paint manufacturing facilities, a production retain sample of each
batch - usually 1/2 liter - is kept for a definite period. In the unlikely event of product
complaints, the production retain sample plays a key part in the investigation process.
Chapter 3
CLASSIFICATION
and
PROPERTIES
of
PAINT
Solvent-borne paints
Waterborne paints
Classification
3.2.1
Physically drying
3.2.2
Chemically curing
3.2.2.1
3.2.2.2
3.2.2.3
Oxidative curing
Two-component curing
Other curing mechanisms
Physically drying
3.4.2
Chemically curing
3.4.2.1
Oxidative curing
3.4.2.2
Two-component curing
3.4.2.3
Alkyds
Modified Alkyds
Epoxy
Polyurethane
Polysiloxane
3.1
polymer chains
polymer chains
with cross-linking
The size and shape of the binder polymer will influence the properties of the final
paint film. Longer chain molecules will generally give a more flexible coating,
while smaller molecules will result in a more dense network.
3.1.1
Solvent-borne paints
The binders are dissolved in solvents.
Along with the evaporation of solvents, the binder molecules get closer and
closer together, and will in the dry film be intertwined and attracted to
each other and to the substrate.
If the binder needs a cross-linker (or a hardener) to make the film this will
typically also be dissolved in the solvents.
3.1.2
Water-borne paints
The binders can be dispersed in water by encapsulating them by a soaplike compound. Very large binder molecules can be incorporated in the
binder phase by utilising the dispersion technology.
Water evaporates. The binder particles deform and coalesce (or melt
together) assisted by coalescing agents (powerful solvent for the
binder particles) - until they form a continuous film, attached to the
surface.
If the binder needs a cross-linker (or a hardener) to form the film,
this will typically also be dispersed in water.
3.2
physically drying
chemically curing
Solvent sensitive.
The solvent-borne physically drying paints will even years after
application be redissolved by its own or stronger solvents, and are
for that reason called reversible.
The water-borne physically drying paints, will be dissolved by
solvents similar or stronger in dissolution power to the coalescing
agent in question.
However, just adding water will not result in a re-dispersion of the
paint film. Re-dispersion is never possible.
Thermoplastic.
Physically drying coatings become soft at elevated temperatures.
Like other molecules, the polymers become more mobile at higher
temperatures and, as they are not cross-linked to each other, they have
a certain freedom of movement, resulting in a softening of the coating.
Excellent recoatability.
A main difference between solvent-borne and water-borne physically
drying paints is the minimum temperature of application. The solventborne can typically be applied down to -100C, whereas water-borne
can only be applied at temperatures higher than about 50C.
Non-thermoplastic. The binder molecules in the tight crosslinking are not able to vibrate or move even at high temperature,
ie the paint film does not become softer at higher temperatures.
Oxidative curing
Binders which are most often dissolved in solvents and which
form the final binder with oxygen in the air, eg oleoresins,
alkyds, modified alkyds.
Film formation:
3.2.2.2
Two-component curing
Binders which are often dissolved in solvents and consist of
two components that react with each other after mixing,
forming the final binder, eg epoxy, polyurethane, unsaturated
polyester, or polysiloxane
Filmformation:
3.2.2.3
3.3
Classification Diagram
(most important binder types only)
P
A
I
N
T
P
A
I
N
T
Physically
drying
Chemically
curing
One-pack
Tars
Bitume
n
Chlorinated
Rubbers Acrylics
Vinyl
Oxidation
Oleoresinous
Alkyds
Modified Alkyds
Two-pack
Epoxies
Polyurethan
Polyesters
Others
Polyurethane
Zinc Ethyl Silicates
Zinc Alkali Silicates
Silicones
3.4
Chlorinated Rubbers
As the name indicates chlorinated rubber resin is formed by adding
chlorine to rubber. In the early days only isoprene from natural rubber was
utilised but, nowadays, most of the isoprene is extracted in the oil industry.
After application and the evaporation of its solvent, chlorinated rubber
leaves a dense but very brittle film. A softening agent, a plasticizer, is
therefore always incorporated in a chlorinated rubber-based paint.
Chlorinated rubber-based paints are today of limited use, and largely
replaced with acrylic.
Some main advantages and limitations of chlorinated rubber coatings
are:
Acrylics
Acrylic resins are produced by polymerising different acrylic monomers.
Through the use of different monomers the properties of the acrylic resin
can be varied to a very large extent. Properties are also influenced by the
often incorporated plasticizer.
Acrylics are extensively used on concrete, in antifoulings (chapter 4) and
as topcoat on atmospherically exposed structures.
General advantages and limitations of acrylic coatings are:
animal
and
vegetable
Vinyl
Vinyl resins are mainly based on a copolymer consisting of vinyl chloride
monomers and vinyl acetate monomers, but other monomers can occur
too.
Vinyl form fairly brittle films, so plasticizers might be incorporated into
vinyl-based paints.
Solvent-borne vinyl-based paints are today of limited use, because
of relatively low solid content and consequently high amount of
(strong) solvents, and they have largely been replaced by acrylics
and epoxies.
Water-borne vinyl paints are, however, still in use, see below.
The main advantages and limitations of vinyl coatings are:
Polyurethane water-borne
The reaction product between isocyanate and the hydroxyl containing
binder, ie the polyurethane (ref . 3.4.2.2), is present as complete binder
particles in the dispersion. Paints based on a polyurethane dispersion are
consequently one-component products.
They are used as sole binder or in combination with acrylic as wood
varnish, floor varnish or paint, and paints for plastics.
Special properties are:
Modified Alkyds
Alkyds may be modified with a wide range of other binders to provide
new binders with specific properties.
Epoxy
Epoxy may cure at normal room temperatures through the addition of
curing agent (certain amines or poly amides, or adducts(1) of the same).
The curing agent reacts with the epoxy groups in the base resin, building
a three-dimensional network (ref. 3.2.2.2).
Polyurethane (two-pack)
Polyurethane is formed through a reaction between isocyanates and
hydroxyl containing binders (eg alcohols), creating a network
structure. They are usually two-pack products, have better weathering
properties and cure at lower temperatures than epoxies (ie in general
down to -10C, epoxies normally down to 5-10C). During the curing
process however, polyurethane is much more sensitive to humidity.
(The curing agent, isocyanate, can react with water, resulting in foam in
the applied paint film).
The isocyanates are either aromatic (ie containing a benzene ring) or
aliphatic (without the benzene ring). Both types give tough, wear resistant
films with good resistance to chemicals and solvents.
Aromatic isocyanates dry faster than aliphatic, but when used externally they chalk and yellow rapidly.
Aliphatic isocyanates possess superior colour retention and UV resistance (ie the ultraviolet radiation in sunlight); they are frequently
recommended for exterior finishing coats.
Like epoxies, polyurethane may be produced in a wide range of
molecular sizes, some small enough to allow their use in solvent-free or
solvent-less coatings.
Polyurethane is used as a finishing coat above the water line in epoxy
systems, heavy duty coating, floor and boat finishes.
General advantages and limitations of polyurethane coating are:
Excellent weathering
Excellent gloss retention (aliphatic types only)
Excellent colour retention (aliphatic types only)
High abrasion resistance
Good chemical resistance
Difficult application
(low relative humidity and trained painters required)
Low temperature curing
Two components (attention to mixing and pot life)
Comparatively expensive.
Polysiloxane
Polysiloxane is a relatively new binder on the market for use where
isocyanate is not feasible.
Polysiloxane is made from functional silane molecules which are
cross-linked with each other in the presence of moisture. Alcohol is
formed during the reaction. The functional silanes may also contain
other functional groups such as e.g. amines which can cross-link with
epoxy binder or unsaturated acrylic binder forming hybrid epoxy
polysiloxane or hybrid acrylic polysiloxane.
Used on exterior steel work as finishing coat above waterline.
General advantages and limitations of polysiloxane coatings are:
Excellent weathering
Excellent gloss and colour retention
Very good chemical resistance
High solids (low VOC)
Fast dry to handle
High cost
Humidity curing
Humidity curing binders polymerise and form films through a
reaction with water, usually in the form of vapour contained in the
surrounding air. Binders of interest are ethyl silicate and
moisture curing (one-pack) polyurethane.
Polyurethane (one-pack)
The tendency of the isocyanate group to react with water
can be utilised by employing isocyanates with relatively
large molecules. After application the paint or varnish cures
by absorbing moisture from the air.
Moisture curing polyurethane has properties similar to
two-pack polyurethane. Its major limitation is its
dependence on humidity in the surrounding air, plus special
care should be exercised in their storage when they are
pigmented - as pigments may contain a certain amount of
moisture.
Also, the production of moisture curing polyurethane is an
exceedingly tricky business. Manufacture often has to take
place under a "nitrogen blanket", to avoid humidity coming
in contact with the binder until curing is desired.
Zinc Silicates
Silicate binders owe their special properties to a high
content of silicon-oxide in their composition. In the
protective coatings field, silicate binders are exclusively
pigmented with zinc as zinc silicates. As such they offer the
best corrosion protection obtainable with a paint.
Heat curing
Silicones
While almost all other polymers (with the obvious
exception of inorganic zinc silicates) have a more or less
branched backbone of carbon atoms, silicones have
backbones of alternating silicon and oxygen atoms and
carbon containing side groups.
Condensation at high temperatures, approx. 200C,
produces networks, and this is the mechanism by which
curing is effected.
General properties:
Comparatively expensive.
Silicones can and are being modified with a number of
other resins (typically alkyds, acrylics, etc.) in order to
reduce cost and improve mechanical properties in the
uncured stage.
Chapter 4
PAINTS
for
PURPOSES
4.1 Anticorrosives
4.2 Shopprimers/Holding Primers
4.. 3 Antifoulings
4.4 Coating Concrete
4.1 Anticorrosives
4.1.1 Corrosion
4.1.1.1Corrosion in humid environments
4.1.1.2 Corrosion in acidic environments
4.1.1.3 Galvanic corrosion
4.1.2 Anticorrosives
4.1.2.1 Barrier effect
4.1.2.2 Inhibitor effect
4.1.2.3 Galvanic effect
4.1
Anticorrosives
Anticorrosives is a collective term for paints designed to prevent the corrosion of
metals, particularly steel.
In order to understand the design of such paints it is necessary to know the basic
principles of corrosion.
4.1.1 Corrosion
Corrosion is here defined as a breakdown of a metal through interaction
with the environment.
The corrosion may be due to a chemical action, or it may be due to a
mechanical action.
4.1.1.1 Chemical corrosion
In their natural states metallic atoms are most often found in
metallic ores as salts or oxides of said metals.
The metallic atom in the metallic ores will exist on a lower level of
energy than if they are processed into pure metals.
Atoms with a high "unnatural" level of energy will strive to revert
to a lower level of energy and this is the reason for chemical
corrosion.
This is true for all metals, but the different metals have different
tendency to revert to their natural state of lower energy as
exemplified below:
Low tendency to corrode
Noble
Gold
Titanium
Stainless steel
Copper
Iron (steel)
Zinc
Both iron and zinc will corrode if immersed in f.ex. seawater. But if
the two metals are in metallic contact, only zinc will corrode, and
thereby the zinc protects iron.
All surfaces exist in equilibrium with their surroundings. Atoms will
leave the surface and other atoms or molecules will enter the surface,
a constant process taking place all over the surface.
Some of the steel has been eaten away, and a brown deposit has
appeared around the attached area. At the edge of the water drop,
the water has become more alkaline. This cannot immediately be
seen, but it can be measured.
The observations can be explained as follows:
The iron atom gives off negative electrons and is thereby
transformed to a positive particle, a so-called iron ion which can
move in water.
The electrons react with water and oxygen forming a negative
particle, a so-called hydroxide ion, which also can move in water.
The hydroxide ions are alkaline.
The positive iron ions and the negative hydroxide ions combine and
form the brown deposit, the rust.
The area where electrons are released, and where the attack of iron
takes place, is called the anode. The area where electrons are
consumed is called the cathode.
The water carrying the ions is called the electrolyte.
Fig. 2
The steel has been eaten away in the whole area exposed to acid,
and a gas is evolving.
The observations can be explained as follows:
The iron atom gives off negative electrons and is thereby
transformed to a positive iron ion which can move in water.
The electrons react with a positive particle from the acid, a so-called
hydrogen ion, forming hydrogen gas.
The iron ions substitute the hydrogen ions in the aqueous solution,
and no corrosion products are seen.
In this case, the anode and the cathode are not separated from each
other, they appear at one and the same place.
4.1.2
Corrosion prevention.
Considering the economical consequences of corrosion, estimated to be some
3.5% of GNP, protection of the substrate a must.
The mechanical corrosion can in most cases be minimized or eliminated by
proper design and material selection.
For the chemical corrosion, the crucial issue is to prevent electrons from
leaving the steel surface. Based on the above descriptions of the three
possible corrosion principles, corrosion of steel can be retarded or prevented
by
4.1.2.1 Anticorrosives
Barrier effect
A barrier effect is obtained by applying thick coatings, 250-500 m, of
paints with very low water permeability. These paints are usually,
but not always, based on bitumen, tar and/or epoxy. Typical
representatives are:
Bitumen
Epoxy.
By adding flake-formed pigments, eg leafing aluminium or
micaceous iron oxide, a barrier effect can be achieved even at
low film thicknesses.
The flake-pigments orientate parallel to the steel surface, so water and
oxygen, when trying to pass through, are forced to pass the more
complicated and longer passage around the pigments.
For permanently immersed steel, the first, and often the only,
choice of protection through coatings, would be to utilise the
barrier effect.
If a barrier coating is damaged, the areas of damage lie open for
corrosion, which can proceed both down, into the steel, and
outwards under the intact coating (underrusting). Thus, where there
is a risk of mechanical damage, additional protection, in the form of
cathodic protection, is often provided.
Inhibitor effect
The rate of corrosion can be reduced by using primers containing
so-called inhibitors. These are soluble basic pigments designed to
suppress the corrosion process. The only one used today is:
Zinc phosphate 1
Inhibitors are, and must be, somewhat water soluble. To prevent them
from being washed out of the primer coats, topcoats without inhibitors
are applied to provide the barrier necessary for the inhibitive primer
to last.
Due to the water solubility of the pigments used, primers with
inhibitors are not suited for prolonged immersion; such an exposure
would result in blistering and early breakdown of the coating system.
When damaged, a certain protection against rust-creeping
(underrusting) is afforded, but the damaged area itself is not
protected.
Galvanic effect
Protection of steel through the galvanic effect can be achieved with
paints containing metallic zinc. A condition for protection is that
there is metallic contact between the individual zinc particles and
between the zinc particles and the steel.
The zinc has a higher tendency to corrode than steel, and by a damage
to steel, zinc will therefore become the anode and steel the cathode
the steel is said to be cathodically protected
Typical binders for zinc dust paints are:
Epoxy
Ethyl silicate
Alkali silicate
Graphite
Gold
Titanium
Stainless steel (passive)
Bronze
Copper
Mill scale
Brass
Stainless steel (active)
Iron (steel)
Aluminium
Zinc
Ignoble Magnesium
Even though they are non-metallic, graphite and mill scale are
included in the series, because they willingly partake in the cathodic
reaction.
4.2
Shopprimers
Holding primers
Blast primers.
4.2.1 Shopprimers
These primers are often referred to as prefabrication primers. They
are anticorrosives designed for application in automated plants, to plates
or profiles prior to fabrication (cutting and welding) and storage.
Demands
The special demands to such primers are:
They must not evolve noxious or toxic fumes during the welding or
cutting process
They should form a suitable base for the widest possible range of
coatings systems.
Properties
Consequent to the requirements listed above, shopprimers possess
properties not normally found in paints designed for other purposes;
notably:
They are applied in comparatively low film thicknesses, 15-25 microns, in
order not to interfere with the speed of cutting and welding.
Offering reasonable protection at such low film thicknesses can only be
achieved if the coating follows the contours of the blasted steel, and
shop-primers are designed to do just that.
Property
zinc epoxy
Delivery
two-pack
Solvent and
thickeners
esters,
ketones,
aromatics
zinc
silicate
two-pack
or onepack
water or
alcohols
epoxy
iron oxide
two-pack
esters,
ketones,
aromatics
PVB
two-pack
or onepack
alcohols,
ketones,
aromatics
Dry film
thickness
15-25 pm
15-25 pm
20-25 pm
20-25 pm
Anticorrosive
properties
very good
excellent
good
good
Mechanical
properties
very good
excellent
good
good
Recoatabiliy
sometimes
critical
sometimes
critical
less critical
less critical
good
limited
Resistance to
ICCP*
not usually
not usually
used with ICCP used with ICCP
4.3
Antifoulings
Painting a vessel's underwater hull serves two main purposes:
4.3.1 Fouling
The number of fouling organisms is estimated to be in the region of 4-5000
different species. They can be split into two groups:
micro-organisms
macro-organisms
Among the animals the most dominant as ship fouling organisms are:
soft forms:
hydroids
tunicates
Distribution
The highest concentration of fouling organisms occurs in harbours
and coastal areas where hard naturally surfaces, stones and rocks, are
present. Here the bottom of a ship will easily be infected by algae spores
and animal larvae. Algae spores settle in a matter of hours, whereas
animal larvae normally require a couple of days to settle.
The speed of the vessel, if it is idle and slow steaming, will also
influence the fouling severity.
As a rule of thumb, most fouling organisms will not settle at speeds
above 4 knots.
The distribution of fouling organisms on a hull is seldom uniform. This
is due partly to the different flow conditions on the hull and partly to
differences in the settling pattern of the organisms.
Thus, there is often a very well defined horizontal division:
The area from the waterline and 1 - 4 metres down is dominated by
algae, and perhaps a few barnacles. This "algae belt" is the area which
is first and most heavily fouled.
Further down the vertical side, some scattered fouling of
barnacles, encrusting bryozoans, tubeworms and goosenecks may
occur. The flat bottom is dominated by hydroids, barnacles, mussels,
tunicates, bryozoans, and in some cases goosenecks.
Start of lifetime
1/2 lifetime
End of lifetime
General properties:
Protection rather limited, 12 - 15 months only
Only antifouling type that can be safely applied over soft
(bituminous) primers
The binder oxidises and is sensitive to sunlight, i.e. the
vessel must be launched/floated soon after application
Sensitive to oil pollution (both mineral and fish oils)
Due to the low mechanical strength of the binder, subject to cold
flow
Insoluble matrix antifoulings are based on a physically
drying, seawater insoluble binder The mechanical strength
of the binder is high, allowing a high loading of antifouling
pigments. As the binder is insoluble in seawater, the toxic
particles (pigments) must be in direct contact with each other
in order to be dissolved by the seawater and release the toxic
content.
The release rate is very high at the beginning of the service life,
but will decrease slowly during service, leaving a honeycomb
structure (the empty matrix) consisting of the insoluble binder.
This empty matrix contributes to roughness development.
Start of lifetime
1/2 lifetime
End of lifetime
At the end of the service life for the specified antifouling, the
concentration of biocides is so far below the threshold value,
that fouling of the hull can no longer be prevented.
General properties:
Environmental concern
In recent years the growing environmental awareness within the shipping
industry has highlighted the harmful effects of organotin compounds on
marine organisms in areas with high shipping activity and poor water
exchange. As a result the demand for tin-free antifoulings has increased,
which has led to the development of tin-free self-polishing antifoulings,
keeping the self-polishing properties known from the tinbased, self-polishing paints without the use of tin-containing groups in the binder.
From 1. Janaury 2003 IMO (International Maritime Organization) the
application of tin containing anti-foulings was banned. And from 2008
there was a ban on presence in contact with seawater. From July 2003 EU
flaggesd ships must not apply organotin containing A/F systems. And from
2008 vessels irrespective of their flag could not enter EU ports with active
tin containing A/F.
SEA
WATER
O C A O C B OC A
O
O
O
H2O
NaCl, pH
8
x
CHEMICAL
REACTION
O C A O C B OC A
O
O
O
Na
Na
Start of lifetime
H2O
O C A O C B OC A
O
O
O
EROSION/
SOLUBILITY
1/2 lifetime
Na
Na
End of lifetime
Copolymer
Toxicant
General properties:
Light weight.
Fouling Release coatings are generally applied onto a suitable
anticorrosive system. A tie coat is then applied which provides the
adhesion between the anticorrosive and the non-stick top coat.
The best of the fouling release coatings today may be specified for ships
sailing down to 8 knots.
4.4
Coating Concrete
4.4.1
What is concrete?
Concrete is a mix of cement, gravel, aggregate (stone) and water; the
amount of each component in the mix depends upon the type and purpose
of the structure to be cast. The mix hardens through a chemical reaction
between the cement and the water.
Typical properties of concrete are its easy manufacture and casting; high
resistance to impact and its compressive strength; tensile strength is
obtained by incorporation of metal bars (rebars) to produce reinforced
concrete.
Concrete is very strongly alkaline, having a pH of 12-13 when freshly cast. The
highly alkaline water in the pores of the concrete passivates the surface of
the rebar, protecting them against corrosion. The passivation will protect
the rebars against corrosion as long as pH > 9.
The rebars may also be protected by a coating (typically powder coating)
or by ICCP.
Concrete, pH <9
Corrosion
This will lower the pH, resulting in corrosion of the rebars, and in
addition the formed gypsum will reduce the mechanical strength of
the concrete.
Alkali silica reactions: Reaction between reactive silica and alkali ions
in the pore liquid. The alkali metal ions come from the cement or
from de-icing salts. The alkali-silica reactions might result in
expansion of the
concrete, and cracking. By decreasing the water content in the concrete,
the deterioration can be decreased.
Blow holes, cracks and other surface defects must be filled with a
cement based mortar or epoxy filler, which must cure before paint is
applied. Plasters should only be used indoors, as they tend to absorb
moisture.
Laitance, the thin layer of cement sludge that rises to the surface during
vibrating and floating, must be removed as its cohesive strength is too
low to serve as a substrate for the coating system.
abrasion resistance
non-skid properties
4.4.6 Constructions
The build-up of paint systems will, as described above, depend on the
environment to which the coating system is exposed eg:
Open air constructions. Bridges above water level, the exterior of
buildings, and many other constructions exposed to normal
atmospheric conditions, may often be adequately protected by a water
repellent.
Where decoration (colour) is desired, an acrylic dispersion paint over
an acrylic sealer would provide a very flexible solution. This would
also suit the requirements for interior, decorative painting.
For exposure in a polluted atmosphere, an epoxy sealer followed by a
full epoxy, or an epoxy + polyurethane system would provide tough and
durable protection.
In addition the coating must be able to "breathe", allowing water
vapour to pass through the coating from both sides.
Reinforced concrete may in some environments need a coating, which
prevents intrusion of carbon dioxide, chloride and liquid water (ref.
4.4.2).
Floors. A solvent free epoxy system, will protect concrete floors against
wear and abrasion. For superior chemical and wear resistance,
combined with easy cleaning, a sealer + an epoxy + a polyurethane
coatings system should be considered.
Chapter 5
SURFACE
PREPARATION
5. SURFACE PREPARATION
5.1 Background
5.2 Objective
5.3 Contaminants
5.4 Cleaning Processes
5.4.1 Abrasive blasting
Dry blasting
Wet blasting
Inhibitors
Abrasives
5.4.2 Manual and Power Tool Cleaning
Chipping and needle gunning
Wire brushing
Disc sanding
Grinding tools
5.4.3 Water Jetting
5.5 Surface Preparation Standards
Surface cleanliness
Surface profile
5.6 Preparation of other Metals than Steel
5.6 Inspection and Painting of Steel Surfaces Prepared by Water Jetting
5.1
Background
The protective value of a coating system is proportional to the cleanliness of
the surface of the substrate to which the coating system is applied. Experience
from practice has established that some 85% of all paint failures can be traced
back to insufficient surface preparation.
Tests made in connection with the establishment of Swedish Standard, SIS 05 59
00 (grading cleanliness of steel) clearly demonstrated the relationship between
surface cleanliness and coating life and also between surface profile and lifetime.
The conventional, oil and alkyd, systems lasted several times longer on a well
cleaned (Sa 3) surface, than on a superficially cleaned surface. For the
tougher, more
advanced but also more demanding, coatings of today, the difference in lifetime
would be even more pronounced.
5.2
Objective
The objective of surface preparation is to ensure adhesion of a paint film to a
substrate:, this being the necessary condition for a long lifetime.
The adhesion is ensured in two ways, by cleaning the surface and by
roughening the surface:
Surface cleanliness:
This involves the removal of any substance on the surface detrimental to the
performance of paints. The enemies of paint performance are especially mill
scale, rust, soluble salts, dust, oil and grease.
Surface profile:
This involves the creation of a profile, an "anchor pattern", of the
substrate,.suitable for the specific coating system to be applied.
This will enlarge the contact area between paint and substrate
5.3
Contaminants
Mill scale. Surface oxides (mainly iron oxides), mill scale, formed during the hot
rolling of steel, expands and contracts at a rate different to that of steel. It
cracks, breaks and flakes, damaging any coating applied over it. Also, since
it is more noble than steel, mill scale can give rise to galvanic corrosion of the
steel.
Rust. Rust is porous and mechanically weak, too weak to support a paint
coating. Due to its porosity, rust tends to attract moisture, and old rust
would always contain soluble salts (sulphates and chlorides). Paints applied
over rust will break down very quickly.
Oil/grease. Most paint binders are repelled, rather than attracted by oil
and grease. Failure to remove such contaminants can consequently result
in poor adhesion and detachment. Even coatings attracted would fail,
due to poor cohesion in the oil and grease.
Dust. As opposed to oil and grease, most paints adhere well to dust, but in
doing so will lift the dust from the substrate. The result being detachment of
both dust and paint coating.
Old paint system. Several reasons will demand removal of the previous paint
system: lack of adhesion and/or cohesion, decision to change to another
generic type, not being compatible with the present.
5.4
Cleaning Processes
For cleaning of structural steel, mechanical cleaning methods like abrasive
blasting, hand or power tool cleaning are by far the most widely used.
Mechanical cleaning methods, however, do not remove oil, grease and salts.
The
cleaning processes must therefore take place in the following succession:
Degreasing. Oil and grease are most effectively removed by the use of an
emulsifier (possibly preceded by scraping and solvent wash). Hot water
steam cleaning and/or scrubbing enhances the effect of emulsifiers. The
emulsified contaminants are removed by high pressure (75-150 bar/1,1002,200 psi) hosing with fresh, clean water.
Degreasing with rags soaked in solvent or thinner, tends to redistribute rather
than remove oil and grease.
Removal of rust, mill scale and old paint. When larger constructions are
considered, rust and mill scale are usually removed by mechanical
means. Fastest and most effectively by abrasive blasting.
The degree of surface cleanliness required, is determined by the generic type
of paint to be applied, the aggressiveness of the environment and the
projected service life/maintenance cycle of the structure.
The choice of mechanical cleaning method is usually dictated by factors such as:
condition of substrate, degree of completion of structure, area sizes, accessibility,
availability of equipment and operators etc. The different methods are
described in 5.4.1 below.
Dust is most often removed by clean (without oil and water) high pressure
air, but the best method is vacuum-cleaning.
Dry blasting
Automatic plants are usually based on a number of
centrifugal wheels, throwing the abrasive onto the work
pieces, which are placed on a moving conveyor.
Production rates are high; humidity and
temperature can be easily controlled, and the
dust problem contained. Automatic blasting
plants are usually coupled to facilties for
automatic
application
of
shopprimer
(shopprimer plants).
However, automatic plants lack flexibility, and
both investment and maintenance costs are high.
Wet blasting
The many methods, and variations of methods, referred to as "wet
blasting" may be conveniently divided into four broad categories:
Wet abrasive blasting (the "original" or traditional method)
where water is added (pressure 5-50 bar/73-725 psi, amount 0.510 l/min.) at the nozzle, to a stream of air propelled abrasive
(pressure at nozzle as for open nozzle dry abrasive blasting, 6-7
bar/90-100 psi).
Inhibitors
Inhibitors are water soluble chemicals retarding corrosion by
passivation of the steel surface; added to the water in wet blasting,
they may delay flash rusting for hours.
When drying, inhibitors tend to form crystalline materials which, if
not removed, may cause osmotic blistering. As a rule, inhibitors
should not be used in areas that are to be immersed for any length
of time.
Abrasives
The abrasive giving the required profile and the greatest
efficiency should be chosen; these factors are determined mainly
by:
Size. A large size abrasive will cut deeper but clean slower than a
small or fine abrasive, when comparing same amount of abrasive.
Using too fine abrasive, however, will result in the desired anchor
pattern not being achieved. Grain sizes in the range 0.2-1.8 mm are
considered the most advantageous for cleaning of structural steel.
Hardness. Abrasive hardness influences both surface roughness
and the rate of work. Hard abrasives cut deeper and faster than
soft or brittle ones. The abrasive used must, obviously, be harder
than the work piece.
Non-metallic abrasives
Slag abrasives, copper slag, nickel slag, etc. are byproducts of the ore and power industries. They are fast
cutting but have a relatively high breakdown rate, and
are not normally recycled.
5.4.2
5.4.3
Water jetting
Water jetting is a process by which water at a pressure higher than
700 bar (10,000 psi) is forced through a nozzle with the purpose of
cleaning a surface of old coating and rust.
The typical employed pressure is around 2,500 bar.
Rust and old coating are removed at approximately the same rate as
by abrasive blasting, and salts are removed very effectively, all
without creating any dust.
All operations needed during repair (removal of rust and old coating,
feathering of edges and possibly roughening of surrounding intact
coating) can be done by changing the distance between nozzle and
surface.
These characteristics make water jetting an attractive alternative to
the other surface preparation methods for repair and maintenance,
because no dust is created.
Two immediate limitations are, that no roughness is created and that
the surface will flash rust:
In most cases, however, these limitations can be overcome by a
suitable choice of coating and by proper planning of the job.
5.5
5.5.1
Abrasive blasting
Cleanliness.
ISO 8501-1 defines descriptively and by photos, four
preparation grades for abrasive blasting, Sa 1, Sa 2, Sa2 and Sa3,
correlated to four initial rust grades A, B, C and D.
Surface profile
ISO 8503 defines descriptively and by reference to a comparator
three roughness levels, fine, medium and coarse, correlated to
respectively a grit and a shot blasted surface.
A roughness comparator is a small plate exhibiting definite peak to
valley depth, shape and density of peaks. Comparison is both visual
and by touch.
Flash rust for wet abrasive methods
Please see 5.5.3
5.5.2
5.5.3
Water jetting
Cleanliness
ISO 8501-4 defines descriptively and by photos three
preparation grades, Wa 1, Wa 2 and Wa 2, for water jetting
correlated to five initial conditions DC A, DC B, DC C, DC I and DC
Z.
Flash rust
ISO 8501-4 defines descriptively and by photos three flash rust
degrees, Light, Medium and Heavy.
5. 6
Aluminium. Anodised aluminium will not accept paint. The anodising must
be removed completely by abrasive blasting with non-metallic abrasive before
paint can successfully be applied.
Hot-dipped galvanizing. Degreasing and removal of sags, runs and zinc ashes
embedded in the galvanizing can, for more than mild service conditions, be
followed by sanding or abrasive blast sweeping with fine non-metallic
abrasive. This is the only acceptable method where epoxy systems are to be
applied.
Coatings of chromate or oil sometimes applied to hot-dipped galvanized work
pieces, to prevent formation of white rust must be removed before any further
treatment.
Chapter 6
PAINT
APPLICATION
6. PAINT APPLICATION
6.1 Planning
6.2 Working conditions
6.3 Microclimate
Temperature of substrate
Dew point
Ambient temperature
Relative humidity
Temperature of paint
Brush
Roller
Air spray
Airless spray
Air-mix spray
Electrostatic spray
Pluri-component spray
6.5 Workmanship
Proper planning
Proper working conditions
Favourable microclimate
Correct choice of application method
Operator skill
6.1
Planning
Based on the painting specification, a time schedule reflecting the progress
of surface preparation and paint application should be established.
In the schedule, adequate allowance must be made for the erection and moving of
scaffolding and the time required for rigging, moving and maintaining lighting
and possibly ventilation equipment. Drying, curing and recoating intervals,
including
pot life of mixed two-pack products should be considered in the schedule.
Anticipated temperatures and weather conditions must be considered.
It should be considered whether possible construction or cleaning work may
delay the application of paint or cause damage to, or contamination of, the
painted surface. Rate of work calculations should be based on past experience,
with similar painting crew on similar construction and under similar conditions.
6.3
Microclimate
By microclimate is understood the climatic conditions in that small, well defined
area, where paint gets in contact with the surface of the substrate.
Dew point. The dew point is the temperature at which the humidity in the air
will condense, and settle as moisture on the substrate.
6.4
Relative humidity. With very few exceptions, paints perform best when
applied below 85% relative humidity (RH), and some paints, e.g. many
polyurethane paints, require even lower relative humidity during
application and curing if they are to perform as designed. For water-borne
paints a RH higher than 65-70% will affect the drying and thereby the
filmformation.
Application Methods
Choice of application method will influence not only the rate, but also the quality
of paint work. Major advantages and limitations of the most commonly employed
application methods are given in the following:
Brush
Advantages. The brush is a versatile, low cost tool; old fashioned, perhaps,
but still often the most suitable for painting complex objects, such as
lattice structures, pylons, rods, small diameter piping, etc.
Brush application tends to displace dust, and to some
extent even moisture, from the surface; this makes
brush application particularly well suited for
application of first coat of primer.
For rough or pitted surfaces, the penetration offered
by brush application, when done correctly, is not
surpassed by any other application method.
Roller
Advantages. Low cost tool, mobility and independence of a power source,
are advantages that the paint roller has in common with the brush.
Roller application is particularly advantageous on
broad, even surfaces and on wire netting.
Limitations. Regardless of operator skill, roller
application leaves a thin, uneven film, often with misses
and pinholes; for this reason, and because penetration is
very poor, the roller should never be considered for
application of the first coat of primer.
Thick coats are particularly difficult to obtain, and roller application is
therefore not a method that can be recommended for high builds.
Air spray
Advantages: The low pressure and mist-like atomisation of air spray enables
the skilled operator to achieve superior finishes; painting of motor cars,
furniture, refrigerators, etc. are examples of this.
From a protective coatings point of view, the air spray is of limited use.
Limitations: Limitations stemming from the fine atomisation and low
pressure are risk of overspray and dry spray, much paint fog and, often,
loss of material. Low pressure, combined with the emission of a large volume
of air, also results in poor penetration..
Airless spray.
In airless spray atomisation is achieved through the sudden
release from high pressure, as the liquid is forced through
a narrow orifice.
The high pressure is afforded by a hydraulic pump,
usually driven by compressed air, but air has no part in
the atomisation of the liquid.
Airless spray offers good penetration and is well suited for application of
the first coat of primer provided the output pressure and the distance
between nozzle and work piece are correct (30-40 cm/12-16 in).
Limitations: Airless spray does introduce a certain element of hazard,
due to the very high operating pressures which, at the nozzle, may be as high
as 300 bar/4,500 psi.
Because of the high pressure, operators are often tempted to spray at
excessive distances (sometimes several metres/yards from the work piece).
This causes overspray and/or dry spray with subsequent loss of material,
thin films and poor film formation; the end result being reduced protection.
Air-mix spray.
The desire to combine the high quality finish of air spray with the high
output of airless spray has led to the air-mix spray.
In principle, air-mix spray is an airless using compressed air to assist the
atomisation at the nozzle.
The penetration and the rate of work are better than for air spray, and the
finish almost as good. Compared to airless spray, the method is slower and
the equipment more complex.
Electrostatic spray.
Electrostatic spray is based on the law that particles of opposite polarity
attract one another. The work piece may be positively charged (earthed), and the
paint particles negatively charged through the gun, being connected to a
generator.
The electrical charge to the paint
particles may be applied by either
of two processes:
The paint is electrically atomised and
charged as it leaves the edge of a
spinning bell or disc.
The electrical charge is applied to
paint particles already atomised.
Plural-component spray.
The introduction of modern high performance coatings of two, or more,
components, high viscous with no or little solvent, and with a short pot
life of only minutes, has necessitated the development of plural-component
spray systems.
The components, two or more, are either mixed immediately upstream from
the gun, in the gun itself or, indeed, immediately in front of the gun nozzle.
6.5
Workmanship
Knowledge about the application equipment, how to maintain it and how to use
it are characteristics of good workmanship, which is of utmost importance to get
a well adhering, sound paint film in the specified thickness.
Fan width shall be appropriate for the work piece and its configuration.
Narrow fan for narrow areas and wide fans for extended areas. Overspray,
dryspray and an unnecessary uneven film, may otherwise result.
The tip orifice size shall be chosen with regard to the specified DFT, the
complexity of the area to be painted and by consulting the product data sheet.
In an area where a wide fan width is suitable will call for a bigger orifice to achieve
the DFT.
The atomising pressure shall ensure a continuous fan with straight sharp
edges and with minimum paint mist some 30-40 cm/1-1.3 ft from the nozzle
Filters, on both pump and gun, shall be clean and intact, to avoid stoppages
and loss of time.
The spraying distance between substrate and gun tip shall be about 30 cm/1
ft with an allowance of 30%. This is what the spray guns are designed for to
ensure optimum penetration and freedom from dry spray.
The gun should be held perpendicular to the substrate at all times, also at the
end of each gun pass.
Chapter 7
PRODUCT
DATA
SHEETS
Chapter 8
PAINTING
SPECIFICATIONS
8. PAINTING SPECIFICATIONS
8.1 Selection of Coatings System
8.1.1 Primary Requirements
8.1.2 Secondary Requirements
8.1.3 Feasibility
8.2 Inspection and Documentation
8.3 Cost
8.4 Allocation of Responsibilities
8.5 The Working Specification
8.6 ISO 12944 : Corrosion Protection of Steel Structures
by Protective Paint Systems
Introduction
A specification is a document defining the required outcome of a given job, and defining
what shall be done to achieve the outcome.
The specification thereby defines the required quality.
To make the specification more precise and thereby to avoid meaningless discussions, and
to allow for a realistic estimate of the duration of the job and thereby the cost, the
specification must also define the required procedures, often with reference to a standard.
A procedure is a detailed description of how work processes and tests defined in the
specification shall be carried out
Contract specification
Project specification
The general part of the contract specification, of interest and importance for all parts of the
total job, and
the project specification, are sent to a limited number of suppliers for their branded match
and pricing.
Quotation specification
For a paint job, we distinguish between a Paint system specification and a Painting
specification, also called a Working specification.
A paint system specification specifies:
(a) the project, the area,
(b) brands and colour of primer, midcoat(s) and topcoat(s),
(c) minimum, maximum and specified DFTs,
(d) specified WFTs,
(e)minimum and maximum overcoating intervals and
(f) application method, pressure and nozzle sizes.
A painting specification, same as a working specification is a paint system specification
plus procedures for surface preparation and application, plus recommended conditions
during surface preparation, application and drying.
Virtually all specifications for new constructions made by owner and contractor are wellproven specifications.
Most of the specifications made by the paint supplier are made as an answer to a project
specification. Due to the nature of the project specification, this may seem a straight
forward thing to do, but that is far from being true.
The inherent constraints in the project specification are not always compatible with the
required performance, and it does as a minimum require a very detailed knowledge about
advantages and limitations of the products in the product range.
For those making specifications, ISO 12944-1 to -8 is a must read:
Part -1 to -4 give the necessary background knowledge.
Part -5 lists possible generic systems inclusive DFTs and the expected lifetime of the
systems in various service environments.
Part -6 specifies laboratory testing and the required results for systems in various
service environments. This part is only of occasional use.
Part -7 deals with inspection and execution of work.
Part -8 gives recommendations on what to include in a specification, and checklists
on what to consider.
In some cases an owner (or a contractor) may, due to production facilities or for other
reasons, need a specification made from scratch, and this will typically be done in close
cooperation with a paint supplier.
Some help may be found in ISO 12944, but generally it will require a thorough analysis of
all the specific needs and requirements to make a suitable selection of the system.
The steps in such an analysis is sketched in the following:
8. 1
Protection
What are the protection requirements of the various parts of the
structure? Some of the major protection requirements to keep in
mind are:
Corrosion prevention
Prevention of the settlement of fouling organisms
Protection of commodities against contamination
Prevention of the general deterioration of construction materials other than
steel (eg concrete)
Resistance
The exposure of the various locations on the structure must be considered:
Water
condensation
brackish water
fresh water
sewage
Oil/fat
Solvents
Alkali/acid
Abrasion/impact
Temperature (eg welding)
UV light (weather)
Industrial atmosphere
Etc.
Substrate
Steel.
The initial condition of the steel should be known, and the following taken
into consideration:
Concrete.
Also for concrete the initial condition of the substrate should be known and
the following taken into consideration:
State of curing
Cracks and holes to be repaired with mortar or filler
Coated.
For surfaces previously coated, compatibility with the chosen protective system
must be taken into consideration.
Surface Preparation
A good painting specification prescribes the methods for removal of
contaminants such as salts (always present on rusty steel) and oil or grease.
Before prescribing mechanical cleaning, the specifier should focus on:
Degreasing method
Flame volatilising
Blast cleaning methods, both wet and dry
Acidic etching
High pressure water jetting
Power tool cleaning
Possible repair of reinforcement bars
Possible repair of cracks or filling of holes occurring as a result of
surface preparation
Methods for the removal of dust, etc.
8.1.3 Feasibility
The paint specifier possessing adequate knowledge of paint technology and a
reasonable amount of practical experience, will now have chosen (for each major
area or location on the structure) the best possible coating system.
This is not as far too many would believe the end of the painting specification. Now
comes the hard and tedious work of determining whether the chosen coatings
systems can be applied and applied correctly.
Logistics. Are the coatings chosen available at all?
Environmental constraints.
Allowance may have to be made for:
Safety, health and environment (eg special local legislation)
Anticipated climatic conditions during work, anticipate the effect on:
Working conditions. Due considerations must be given to the possible need for:
Staging
Working light
Dehumidifiers
Forced ventilation
Application. Consider:
other
Joints. Some joints, e.g. friction bolted joints, may require special treatment, and
allowance should be made for this.
Time. How much time is available for surface preparation and paint application?
To what degree can other "behind schedule" trades be expected to delay
painting? And can the job be done in the time available?
Workforce. For the specifying designer or engineer, there are many aspects of
both main and sub-contractors to be considered, for the painting contractor,
mainly these are:
Adequacy of workforce
(also to meet peak demands if work is behind schedule)
Adequacy of equipment
(sufficient in number, correct type, standard of maintenance)
Skill of workers
(ratio between skilled workers, laborers, foremen and supervisors)
Reputation
8.3
Cost
Cost must be seen in relation to the expected life of the structure, the amount and
frequency of maintenance, and the cost of possible downtime in connection with
maintenance painting.
Comparatively easily calculated are the costs of:
8.4
Allocation of Responsibilities
Responsibilities can now be allocated. They span from who is responsible for the
removal of spent abrasives, to who pays the telephone bill. From who provides the
heaters and who pays for fuelling the heaters, to who is responsible for checking paint
quantities and qualities.
Allocation of responsibilities is obviously a matter for the contract and not the painting
specification. But many of the critical, and costly, areas where responsibility must be
allocated can be pinpointed only by the author of the painting specification.
8.5
A painting specification has a much wider readership than most other specifications;
it spans from the owner and his engineers over consultants, suppliers and main
contractors, to sub-contractors and their operatives.
The art of writing a working specification, ie a painting specification that is actually
workable, is to extract, from all the foregoing conclusions, that which is relevant for the
painting contractor and his operatives. Then to formulate it in clear, concise and
preferably brief terms.
The less paper a paint foreman is given to read, the greater the chance that he will
actually read it. A one-sheet painting specification is ideal. Much of what has
otherwise been considered, evaluated and desired upon in the foregoing, is really for
inclusion in the General Conditions of Contract.
Chapter 9
PAINTCOATING
INSPECTION
Provided the painting specification is a good and workable one (see the foregoing chapter),
quality assurance is simply a question of ensuring that the specification is being followed.
The higher the demands to protection, the more advanced the coating system and painting
specification. This in turn increases the demands to the execution of the work and consequently
the degree of quality control/paint coating inspection.
9.1
Levels of Inspection
Hempel operates with three levels of inspection as follows:
(1) Premium. All operations observed by a coating inspector and passed as
complying with the specification before the next stage is started. (For larger
projects this may require a team of coating inspectors).
(2) Standard. Part of all operations observed by a coating inspector to ensure
compliance with the specification before the next stage is started.
(3) Basic. All operations observed initially by a coating inspector for setting
standards of workmanship. Ad hoc visits by a coating inspector thereafter.
9.2
Checking
Advising
To prevent errors and mistakes to occur, and to correct should they occur.
Reporting
As a minimum on possible deviations and on the corrective advices given.
During all phases of the job relevant for the level of inspection agreed.
The multitude of tasks belonging to paint coating inspection may be conveniently
divided according to the progress of work. Seven distinct phases, some of them
recurrent, require the coating adviser's attention.
Ref.: Hempels Coating Reference Handbook.
9.2.1 Before surface preparation
Before the start of any surface preparation, it is important to examine
Depending on the actual situation and the job to be done, several additional
checks may be relevant:
welds
corrosion traps
It is also at this point, as early as possible, relevant to check if the paint and
thinner has been delivered in the right quality and the right amount, and
if it is all stored correctly. Also batch numbers shall be checked to ensure
the shelf life has not been exceeded.
9.2.2
9.2.3
9.2.4
9.2.6
9.2.7
Final inspection
The previous three phases are repeated for each coat applied, and
After paint application for the last coat will therefore be identical
with Final inspection. It is, however, not in all jobs all the phases are
inspected as described above, but a final inspection is always done.
Relevant inspection points may be:
general condition
total DFT
adhesion test if required by specification
film defects
mechanical damages
9.3
Inspection Equipment
From the listing of the paint coating inspector's duties and main checkpoints, it should
be evident that his most vital equipment is his eyes and ears, his common sense and a
wide experience in paints and allied technologies.
Some checkpoints, however, demand a degree of accuracy not easily afforded by the
human senses, and electronic measuring instruments are called for. But not all the
tools of the inspection trade are that sophisticated.
An electric torch and an angled mirror with telescopic handle enable the
coating inspector to look into things in a thorough manner.
Standard to aid the assessment of surface preparation degree; f.ex. ISO 8501-1
or as dictated by the specification.
Comparators for determining surface roughness and roughness profile, f.ex. ISO
8503 or as dictated by the specification.
Tape for checking and documenting dust or other deposits, and for X- and #-cut
test.
Wet film gauge of the comb type and made of steel, not plastic, for measuring
and monitoring wet film thicknesses.
X- and #-cut template and thin bladed knife for adhesion testing
Special Equipment
Special, less frequently used, inspection equipment worth mentioning, could be:
Pinhole detector, used when checking the dried/cured system for continuity (free
from pinholes, macro pores, misses and holidays). The high voltage types, up to
about 15 kV, reveal also inadequate overpeak protection.
This listing of standard and special inspection equipment does not claim to be absolute
or complete, but in the hands of a skilled and experienced paint coating inspector, the
equipment listed will assist in completing and documenting all vital checks.
9.4
Full inspection. Where full inspection is warranted, it is customary also to record items
such as:
Chapter 10
MAINTENANCE
and
REPAIR
Roughening
Spot cleaning
Compatibility
Other considerations
Most structures are designed for a life well beyond that of their protective coatings systems
and, sooner or later, the protective coating must be restored.
Operators of processing plants, rigs, ships and many other structures, are becoming
increasingly aware of the role of coatings maintenance in trouble-free operations of their
structures, and realise the advantages of providing preventive maintenance in advance of failure.
When. The maxim for economical maintenance of protective coatings is: "Do it before it is too
late", or to be a little more precise: Do it while the breakdowns are still local. When breakdowns
have spreaded to all-over repair is not a solution, a total refurbishment is called for.
The need for maintenance or repair may present itself through local:
The amount of work involved is determined by the condition of the existing coatings system.
b)
If recoating is not required; wash down only. This to remove soot, salts and
other corrosion promoting impurities.
Coatings exhibiting blisters and/or pinhead rusting less than Ri 3 (ISO 4628-3).
a)
If the paint film, apart from damaged areas, is otherwise sound and adequate;
spot clean broken down areas and touch up to full film thickness.
b)
If the paint film is thin, inadequate; apply, after cleaning and touching up, one full
coat of undercoat and one or two finishing coats.
Grit sweep blasting, when done correctly, is not necessarily faster than blasting,
but it does save the application of a new, complete coatings system.
In grit sweep blasting, the nozzle is to the extent
possible held at a more oblique angle to the
work piece than in abrasive blasting. The most
important is, however, the use of a smaller
particle size (0.2-0.8 mm) and a pressure at the
nozzle reduced to about 4 bar/60 psi.
This all results in a dense but not very severe
impact of abrasives on the coating to be
roughened.
Spot cleaning. Far too often problems occur at the border between existing
coating and spot repairs. The problems usually manifest themselves as either
premature rusting, or the lifting and curling of the paint film. Such problems are
avoided by:
o
Cleaning to bare metal, not just the visible corroded area, but also
adjacent area, where corrosion (underrusting), although not yet visible,
may have started.
This is best done by sanding, blasting or water jetting.
Chemically curing paints, with the exception of newly applied oil and
oleoresinous, can normally be overcoated with physically drying paints.