Zealcon Engineering

(Pvt.) Ltd
Method Statement for Surface
Preparation And Protective Coating

Zealcon-DGK-9000 TPD-MS003
Issue # 001

Issue Date

Page 1 of 11

16-06-2016

METHOD STATEMENT

SURFACE PREPARTION AND PROTECTIVE COATING

Client:

DG Khan Cement

Contractor:
(Pvt.) Ltd

Rev.
No
00

Zealcon Engineering

Description

By

Prepared
By

Reviewed
By

Approved By

MS for Control of
Surface Preparation
And Protective Coating

QHSE

Farhan
Ahmad

A. Hafeez
Khan

Sohail Rabbani

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Zealcon Engineering
(Pvt.) Ltd
Method Statement for Surface
Preparation And Protective Coating

Zealcon-DGK-9000 TPD-MS003
Issue # 001

Issue Date

Page 2 of 11

16-06-2016

CONTENTS
1. Purpose
2. References
3. Definitions
4. Responsibilities
5. Pre-blast Preparations
6. Ambient Conditions
7. Equipments
8. Abrasives
9. Cleanliness degree
10. Precautions
11. Mechanical Cleaning
12. Cleaning of surface between coats
13. Painting
14. Painting Applications
15. Application Equipment
16. Re coating interval
17. Handling of coated items
18. Dry Film Thickness
19. Repairing of coating
20. Quality Control
21. Blast Cleaning and Painting Inspection Report
1. PURPOSE
This Method Statement provides the guidelines for Blast Cleaning and Painting of
Fabricated structural steel materials & Mechanical equipment for D G Cement
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Zealcon Engineering
(Pvt.) Ltd
Method Statement for Surface
Preparation And Protective Coating

Zealcon-DGK-9000 TPD-MS003
Issue # 001

Issue Date

Page 3 of 11

16-06-2016

Project at Workshop as well as at Site.

2. REFERENCE DOCUMENTS
General Workshop Instructions 520530-8.0
EN ISO 8503-2:2012 Preparation of steel substrates before application of paints
and related products
Steel Structure Painting Council (SSPC)
ASTM D3335 Test Method for Low Concentrations of Lead, Cadmium and Cobalt
in Paint by Atomic Absorption Spectroscopy
AOAC 974.02, Lead in Paint, Atomic Absorption Spectophometric Method or
equivalent shall be used.
Design Drawings and Standards
Project application datasheets

3. DEFINATIONS

COMPANY
DG Khan Cement
CONTRACTOR
ZEAL Construction Engineering
CONSULTANT
FL Smidth
ITP
Inspection & Test Plan
QC
Quality Control
MS
Method Statements

4. RESPONSIBILITIES.
Project Manager shall be responsible to provide recourses for execution of the
activity.
Painting supervisor and Painting QC Inspector shall be the responsible persons for
blast cleaning & Painting activities in accordance with General Workshop
Instruction 520530-8.0 and this Method Statement.

5. PRE-BLASTING PREPARATIONS
Before shipment for blast cleaning of fabricated items, shall be checked for free
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Zealcon Engineering
(Pvt.) Ltd
Method Statement for Surface
Preparation And Protective Coating

Zealcon-DGK-9000 TPD-MS003
Issue # 001

Issue Date

Page 4 of 11

16-06-2016

from spatters, flux or other foreign matter.

All sharp edges, fillets, corners and weld seams shall be rounded or smoothed by
grinding, min. R= 2mm.
Any major surface defects, particularly surface laminations or scars likely to be
detrimental to the paint shall be removed by suitable dressing. All welds shall be
inspected and repaired if required prior to blast cleaning. Undercut and rough
geometry is not accepted.
All oil and grease traces shall be removed by solvent cleaning prior to starting
blast cleaning operations.

6. AMBIENT CONDITION
Blast cleaning shall not proceed on surfaces that are moist or may become moist
before the application of primer. Blasting shall not be permitted when metal
surfaces are less than 3 deg above the dew point or when the relative humidity of
the air is greater than 85%.

7. BLASTING EQUIPMENTS
The compressed air used for blasting shall be free of water and oil.

Adequate

coolers and separators/traps shall be fitted and these shall be kept emptied. The
discharge pressure shall be measured at the nozzle with a hypodermic pressure
gauge of 7 kg/cm (100 PSI) and not less than 5.5 Kg/cm (80Psi).

8. ABRASIVES
Abrasive for use on carbon steel and low alloy steel shall be in accordance with
General Workshop 520530-8.0
Abrasive used on stainless steel shall be free for chloride, zinc and iron
contaminants.
Company approval shall be required prior to use of abrasive.

9. CLEANLINESS DEGREE
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Zealcon Engineering
(Pvt.) Ltd
Method Statement for Surface
Preparation And Protective Coating

Zealcon-DGK-9000 TPD-MS003
Issue # 001

Issue Date

Page 5 of 11

16-06-2016

Blasting to Sa2 according to EN ISO 8501-1:2007 (Preparation of steel

substrates before application of paints and related products - Visual assessment
of surface cleanliness - Part 1\: Rust grades and preparation grades of uncoated
steel substrates and of steel substrates after overall removal of previous
coatings) is required. All dust must be completely removed before painting.
The roughness of the blasted surfaces shall conform to the demands made by the
paint manufacturer and at least grade fine to medium G according to EN ISO
8503-2:2012 (Preparation of steel substrates before application of paints and
related products - Surface roughness characteristics of blast-cleaned steel
substrates - Part 2: Method for the grading of surface profile of abrasive blastcleaned steel - Comparator procedure) or Rugotest No. 3 BN 9a if no other
requirements are specified by the paint manufacturer or in the paint
programmes.
For programme V the roughness of the blasted surfaces shall conform to "medium
G" or according to the paint manufacturer's requirements in the painting
specification

10.

PRECAUTIONS

Blasting shall be stopped sufficiently early to allow application of the primer on

the blast surfaces before sunset and before any oxidation develops. No visible
oxidation is acceptable on blast cleaned surface prior to painting.
A 25mm wide strip minimum around the blast cleaned surface shall not be
painted with primer unless adjacent surfaces are already painted or it is the last
part of the surface to be prepared.
The left strip of 25mm width shall also be blast cleaned next day to achieve the
required degree of surface preparation.
During blasting if any surface defects like laminations, cold-laps ect. detected,
shall be repaired and that surfaces shall be re-blasted.

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Zealcon Engineering
(Pvt.) Ltd
Method Statement for Surface
Preparation And Protective Coating

Zealcon-DGK-9000 TPD-MS003
Issue # 001

Issue Date

Page 6 of 11

16-06-2016

The surfaces which cannot be blast cleaned due to un-access or blast cleaning is
impracticable may be cleaned mechanically subject to Company approval.

11.

MECHANICAL CLEANING

Mechanical cleaning comprises power and hand tool cleaning method. Such surface
preparation methods shall be restricted to those areas where standard cleaning is
prohibited or impossible due to access or dust sensitive equipment presence and
shall be performed only with the acceptance of manufacturer approval procedure
and equipment used shall be recorded.

12.

CLEANING OF SURFACE BETWEEN TWO COATS

Oil, Grease, dirt, dust or any other contaminants shall be removed completely prior
to the application of any succeeding coat of paint system.

13.

PAINTING

13.1

Storage conditions

All material shall be stored under cover, preferably a warehouse. Outdoor

storage, for instance next to application site is acceptable only for quantities to
be used on a particular day and providing weather protection and provision for
cover are made.
If stored in an enclosed area, adequate ventilation must be provided for
precautions against fire and health hazards shall be taken, in keeping with local
regulations and normal safety practices.
All paint materials shall be stored in tightly sealed condition, and never stored
unprotected outdoors or exposed to direct sunlight. Recommended storage
temperature: 5 to 40 c.
Paint material cans shall only be opened immediately before use. Paints which
have gelled or in which sediments have formed during storage shall be discarded.
Paint materials shall be issued from storage on a first in first out base.
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Zealcon Engineering
(Pvt.) Ltd
Method Statement for Surface
Preparation And Protective Coating

Zealcon-DGK-9000 TPD-MS003
Issue # 001

Issue Date

Page 7 of 11

16-06-2016

Products which have reached their expiry date shall not be used unless checked
and approved by paint manufacturer.
13.2

Mixing & Thinning

Contents of paint shall be completely mixed and dispersed to obtain a

homogeneous blend. Only power mixer shall be used. Under no circumstances
shall hand mixing be allowed.
In case of Two Pack products, both components shall first be mixed separately
then together to ensure complete dispersion and mixing.
During application, the coating shall be agitated sufficiently often with a power
mixer to maintain pigments and extenders in suspension.
Continuous agitation during application shall be provided for:
a. Inorganic Zinc rich primer
b. Zinc rich epoxy primers
c. M.I.O pigmented coatings.
Powered agitators, either clamped on the rim of the paint containers of built in
agitator in the case of conventional spray equipment shall be used.
Paint which have been mixed in the original container shall not be transferred
before the settled pigment has been blended again into the binder may be
momentarily removed if required to ease mixing.
Paint shall never be mixed or maintained in suspension by means of air bubbles.
If a skin has formed in a can, it must be removed, if the shin is thicker than 1 mm,
the product will be discarded.
All pigmented coatings shall be filtered after mixing unless the painting
equipment used is fitted with adequate filters.
Only thinners recommended by the paint manufacturer shall be used.
Under particular conditions, thinning may however be necessary, this shall be
supervised by the manufacturers representative
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Zealcon Engineering
(Pvt.) Ltd
Method Statement for Surface
Preparation And Protective Coating

14.

Zealcon-DGK-9000 TPD-MS003
Issue # 001

Issue Date

Page 8 of 11

16-06-2016

PAINTING APPLICATIONS

14.1

Paint system

The type, number of coats and thickness of paint shall be as indicated in General
Workshop Instructions 520530-8.0 Para 5.5.6, 5.7 and 5.5.8
The primer and subsequent coats of each painting system shall be of the same
make.
The manufacturers instructions, including safety precautions, form part of the
present document and shall prevail over all other instructions in case of conflict.
The dry film thickness shall not be less 90% of the specified thickness
14.2

Ambient Conditions

Coating application shall not be performed when weather conditions are not as
per the Manufacturers recommendations, and particularly;
a. In dusty or windy weather, or dust laden air.
b. In areas where injurious particles are in suspension.
c. If the surface temperature is less than 3c above the dew point of the
ambient air.
d. If the relative humidity is in excess of 85% (95% for inorganic ethyl zinc
silicate primer application.)
Generally when adverse conditions are expected soon, outdoor painting shall be
stopped. If it is raining either during or immediately after paint application, proper
steps such as re-painting shall be taken. (Except for ethyl zinc silicate primer).
Paint application shall not be carried out if ambient temperature reaches or
exceeds 55c.
14.3

Precautions

Blast cleaned surface shall be given a coat of primer as soon as possible and not
later than 4 hours after surface preparation completion. If oxidation appears

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Zealcon Engineering
(Pvt.) Ltd
Method Statement for Surface
Preparation And Protective Coating

Zealcon-DGK-9000 TPD-MS003
Issue # 001

Issue Date

Page 9 of 11

16-06-2016

during application of painting, that affected portion shall be re-blasted as per

specification.
As for as possible each coat of paint shall be applied without break. Any part of
the surface that was missed or insufficiently painted shall be repainted. The next
coat shall not be applied before the preceding coat is dry.
After each coat is sufficiently dry or polymerized and before the next coat applied,
surface cleanness shall be checked. Fresh water rinsing/ washing of painted area
shall be performed between each coat until satisfactory cleanness is obtained.
Multi-coat systems shall have contrasting colors for each particular coat in order
to ensure proper coverage.
Surfaces of equipment and components in contact with structures (skid bottoms,
equipment base plates and the like) shall be painted.
Supports for items to be painted shall be designed so as to minimize contact
points.
Wet paint shall be protected from dust and other foreign matter that could result
in inclusions.

15.

APPLICATION EQUIPMENT

The application method shall be governed by the manufacturers recommendation

for the particular coating being applied. Spray equipment shall be in compliance
with manufacturers recommendation, i.e.; nozzles, spray tips, spray angles, air/
fluid pressure, etc. Roller application of the first primer coat is strictly prohibited.

16.

RE-COATING INTERVALS

Each coat shall be allowed to dry or cure for a time specified by the manufacturer
before the application of any succeeding coat.

If the specified period between coats has been exceeded, sweeping with abrasive
or the corrective actions as recommended by the manufacturer shall be carried
out.
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Zealcon Engineering
(Pvt.) Ltd
Method Statement for Surface
Preparation And Protective Coating

Zealcon-DGK-9000 TPD-MS003
Issue # 001

Issue Date

Page 10 of 11

16-06-2016

All products that have been exposed to weathering for any length of time shall
be carefully checked for chalking or surface contamination and cleaned by
appropriate means to obtain a sound, contamination free surface for subsequent
coat application.

17.

HANDLING OF COATED ITEMS

No handling shall be performed before the coating system is completely cured.

When handled, special precautions shall be taken to avoid to damaging the
coating system.
Where paint has been damaged in handling, repair shall be carried out according
to mentioned in section Repair of coating.
Before shipment and packing, Inspection shall be offered to CONSULTENT
/COMPANY.
Finished painted piping, steel structure shall be lifted, lowered or suspended by
using rubber or canvas belt with removable pin and clevis on one end to permit
removal of belt without damage to the paint.

18.

DRY FILM THICKNESS

The tolerance limits for dry film thickness for each coat and the total coating
systems shall be strictly followed. It shall be observed that excessive film thickness
may be determined due to solvent retention and improper curing.

19.

REPAIRING OF COATING

Repairs shall be performed as soon as possible and in accordance with the

relevant standards of surface preparation and specified coating system
mentioned in General Workshop Instruction 520530-8.0 Para. 5.5
All damaged and loosely adhering paint shall be removed and the surface cleaned
to the original specified standards. Edges of the surrounding intact paint shall be
feathered approximately 50 mm in from the damage area. Original paint system
shall be rebuilt as per specification.
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Zealcon Engineering
(Pvt.) Ltd
Method Statement for Surface
Preparation And Protective Coating

Zealcon-DGK-9000 TPD-MS003
Issue # 001

Issue Date

Page 11 of 11

16-06-2016

Painting after erection welding should be performed immediately after the

welding work is finished in order to minimize the cleaning work before painting.

20.

QUALITY CONTROL

During blast cleaning & painting the following instruments shall be available with
QC Inspector for inspection.
1. Wet Film Thickness Gauge.
2. Dry Film Thickness Gauge.
3. Humidity Gauge.

21.

BLEST CLEANING & PAINTING INSPECTION REPORT

Check List for blast cleaning

Surface Preparation & Protective Coating Report

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