Teknos
Teknos
Teknos
2012, Teknos Oy Publisher: Teknos Oy Layout design: Mainostoimisto Dynastia Oy Printers: Offsetpaino Tuovinen Ky Acknowledgements: Pinteco Oy (Elcometer) Tallberg Roboma Oy Ab (DeVilbiss, Ransburg, Binks) S.O. Strmberg Oy (Byk) Photographs on the inside covers: Sandvik Mining and Construction Avant Tecno Ponsse VR Normek, Sonera Stadium Ruukki, Swedbank Stadium Neste Oil WinWind
7. EXECUTION OF PAINT WORK..............................................................................................................31 Painting methods......................................................................................................................................31. Brush application .................................................................................................................................31 Roller application..................................................................................................................................31 Spray application..................................................................................................................................31 Dip application......................................................................................................................................37 Application conditions ..............................................................................................................................37 Relative humidity and dew point...........................................................................................................37 Temperature and curing........................................................................................................................40 Film thickness and associated measurement.............................................................................................40. Film thickness.......................................................................................................................................40 Measurement of wet lm thickness.......................................................................................................40 Measurement of dry lm thickness........................................................................................................41 Non-destructive methods................................................................................................................41 Destructive methods........................................................................................................................42 Calculation of paint consumption..........................................................................................................43 Tables for estimation of paint consumption...........................................................................................44 8. QUALITY CONTROL OF CORROSION PROTECTION PAINTING.......................................................45 Quality plans...............................................................................................................................46 Quality assurance objects..........................................................................................................................46 Personnel.............................................................................................................................................46 Steel structure......................................................................................................................................47 Surface preparations............................................................................................................................47 Conditions............................................................................................................................................47 Application methods, tools and implements..........................................................................................48 Substances used in paint work.............................................................................................................48 Painting work ......................................................................................................................................48 Finished coating...................................................................................................................................48 Inspection tools and implements...............................................................................................................49 Reference areas........................................................................................................................................49 Documentation of the painting work and site conditions............................................................................49 Documents existing prior to commencement of paint work...................................................................49 Documents issued during paint work....................................................................................................49 Inspection records................................................................................................................................49 9. MAINTENANCE PAINTING.....................................................................................................................51 Evaluation of coating degradation..............................................................................................................51 Time for maintenance painting...................................................................................................................51 Determination of the maintenance paint.....................................................................................................52 Execution of maintenance paint work........................................................................................................53
10. OCCUPATIONAL SAFETY GUIDELINES APPLICABLE TO PAINTING WORK...................................54 11. LIST OF STANDARDS.............................................................................................................................56 12. PAINTING PROBLEMS TROUBLESHOOTING...................................................................................60 13. FUTURE OF CORROSION PROTECTION PAINTING...........................................................................63 FORMS ........................................................................................................................................................65
Local corrosion pairs (-) anode Fe > Fe2+ + 2e(+) cathode 2H+ + 2e- > H2 O2 + 2H2O + 4e- > 4OH-
Image 1.1 The formation of local pairs onto a metal surface, and the anode and cathode reactions.
Combining the anode and cathode reactions provides the total reaction: Fe2+ + 2OH- > Fe(OH)2 4Fe(OH)2 + O2 > 2H2O + 2Fe2O3*H2O hydrous iron oxide, i.e. rust The corrosion protection mechanism in metal is based on - the inhibition of formation of local pairs on a metal surface, and - the inhibition or retardation of anode and/or cathode reaction
In conclusion
Corrosion of the metal surface to be protected can be inhibited or retarded by applying: - corrosion protection paint containing corrosion protection pigments, which passivates the anode and/or cathode reaction, or - a coating, which generates sufcient resistance against an ion current - a primer giving cathodic protection
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Classication of environments
Atmospheric corrosivity and special corrosion stresses inuence the durability of the structures corrosion protection painting and the planning of paint work in an important way. Pursuant to ISO 12944-2, atmospheric corrosivity is divided into six categories: C1 very low C2 low C3 medium C4 high C5-I very high (industrial) C5-M very high (marine) The classication is based on the corrosion rate of steel and zinc during the rst year in exposure. ISO 12944-2 denes three corrosivity categories for structures immersed in water or buried in soil: lm1 immersion in fresh water, such as structures in rivers, hydropower plants lm2 immersion in sea or brackish water, such as port structures lm3 burial in soil, such as subterranean containers, steel beams and similar structures
Paint systems
The protective paint system is composed of the substrate, surface preparation, and the combination of paints used for coating. ISO 12944-5 presents the most common types of corrosion protection paints and protective paint systems. The markings for the paint types are: Acrylic AY Alkyd AK Epoxy EP Chlorinated rubber CR Polyurethane, aliphatic PUR Polyurethane combinations, puried urethane tar PURC Ethyl zinc silicate ESI Zn (R) Epoxy zinc EP Zn (R) Polyvinyl chloride PVC In 2007, a new edition of standard ISO 12944-5 was issued. Under ISO 12944-5:2007, the paint systems are marked as follows: ISO 12944-5/A1.01, where A1 = the table in which the system is included 01 = the sequence number of the paint system in the table The standard has eight tables (A1 A8), which present the paint systems for the various corrosivity categories for steel and zinc surfaces, thermally coated, sherardised, and zinc-electroplated steel surfaces. The table indicates for each paint system - the number - binder type of the primer, the number of coats, and nominal lm thickness - binder type for the intermediate and top coats - total number of coats, and nominal dry lm thickness of the paint system - expected durability The footnotes of the tables indicate the binder types and provide further information on the paints.
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Testing of paints
Part 6 of ISO 12944 is designed to facilitate the suitability assessment of new paint systems. Suitability is assessed in laboratory conditions using the humidity condensation test (ISO 6270), the neutral salt spray (fog) test (ISO 9227), and the test method used for determining resistance to the effects of water and chemicals (ISO 2812-1 and 2812-2). The standards inform that the aforementioned methods are not applicable to the testing of water-borne paints. Nevertheless, some water-borne paint systems are amenable to testing and evaluation using the procedures described in the standards, and the results could be taken taken into account. Testing paints in real-life conditions is regarded as the optimum method, and using well-known conventional paint systems as a reference in all testing operations is highly recommendable.
Reference areas
Upon a separate agreement, the contractor will prepare reference areas in conformity with the paint work specication in the presence of representatives of the purchaser and the manufacturer. The reference areas are used to establish the personnels professional skills and the acceptable quality of the work while monitoring whether the specications provided by the manufacturer and the contractor are correct. The performance of the coating can also be monitored by means of the reference area. The reference areas are not used for guarantee purposes, unless otherwise agreed to the contrary. The reference areas are to be prepared in locations in which the corrosive stresses are typical for the structure concerned. The size and number of reference areas are to be selected in proportion to the total surface area of the structure and criticality of its components. Annex A of ISO 12944-7 contains informative instructions on the reference areas. All reference areas are to be marked on the structure and the records must be stored (see form 187).
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Project specication
The project specication describes the project and associated requirements (ISO 12944-8). The party issuing the project specication can be the owner of the structure being coated, or the principal contractor, for example. The main headings in the project specication are: 1. General information 2. Type of project 3. Type of structure and constituent element 4. Description of each constituent element 5. Description of the environment of each constituent element 6. Durability 7.-10. Protective paint systems particular constraints 11. Quality management 12. Inspection and assessment 13. Reference areas 14. Health and safety; environmental protection 15. Special requirements 16. Meetings 17. Documentation
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15
16
Bad
Good
Image 3.1 On the left-hand side, examples of structures not suitable for corrosion protection painting. On the right-hand side, examples of suitable solutions (ISO 12944-3).
d 1 mm
r 2 mm
Image 3.2 In terms of painting, rounded corners and edges are ideal, since coating thickness is uniform (ISO 12944-3). Sharp corners are to be avoided.
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4. Substrate preparation
Determination of the preparation method and the quality grade for metal working and surface preparation
The surface preparation methods are described in parts 1 3 of ISO 8504 and in part 4 of ISO 12944. The determination is based on the following parameters, among others: - relevant working conditions - state and condition of surface - quality grade requirements of surface preparation - surface preparation of the entire surface area or only part thereof - economical considerations - special requirements or constraints The preparation degree and quality grade of surface preparation is determined based on the paint system to be used. The paint system is determined based on the protection requirements, taking into consideration surface preparation and surface preparation conditions. The quality grade for metal working and surface preparation is indicated in the paint system specication. The mechanical surface preparation methods and associated quality grades for blast-cleaned and prefabrication primer-treated steel surfaces are described in ISO 8501-3. If only the surface preparation quality for the metal working is being determined, the rst part of the table can be applied: STEEL WORK.
Rust removal
Rust removal is used for removing rust and mill scale from metal surface. The rust removal methods are divided into mechanical, thermal and chemical cleaning methods. The mechanical cleaning methods include wire brushing and blast cleaning, which are described in ISO 8504. Wire brushing (St) is performed using hand tools, or wire-brush or grinder power tools (ISO 8504-3). In abrasive blast cleaning (Sa), abrasive granular material is blasted onto the surface using pressurised air or water or a centrifugal blaster (ISO 8504-2). In hydro-blast cleaning (Wa), ultra-high pressure water, over 70 MPa, is sprayed onto the surface. Hydro-blast cleaning is based on the impact energy of water directed against the surface. No abrasive material is used in hydro-blast cleaning (ISO 8501-4 and SSPC VIC-4).
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The thermal method is the ame cleaning, where an acetylene-oxygen ame is used to remove previous paint coats, mill scale, and rust from steel surface. Hereafter, the surface is cleaned using wire brushing (ISO 9501-1). In chemical rust removal, i.e. acid pickling, mill scale and rust is dissolved in a suitable acid or acid-mixture bath.
Rust grades
The surface of hot-milled steel has a layer of mill scale generated during milling. The quantity of rust on steel surface varies according to how long, and in what environment, the steel has been unprotected. The rust grade of an uncoated steel surface inuences the determination of the rust removal method, cleaning costs and durability of the coating. ISO 8501-1 species four rust grades for hot-milled steel. The rust grades, designated and marked as A, B, C, or D, are dened verbally together with illustrative example photographs. In the photographs, the marking A depicts a steel surface covered largely by a rmly adherent layer of mill scale, and rust is minimal or absent. B depicts a steel surface where the formation of rust is at an initial stage and where the layer of mill scale has started to ake off. C depicts a steel layer where the mill scale has rusted off or can be scraped off, and where minor pitting corrosion can be detected through visual inspection. D depicts a steel surface where the mill scale has rusted off and where generalized pitting corrosion can be detected through visual inspection.
Preparation grades
Standard ISO 8501-1 species the surface preparation grades by describing verbally, together with illustrative photographs, the visual texture of the surface. Surface preparation with hand or power tools scraping or wire brushing manually, or wire brushing or grinding using power tools is designated with the marking St. The number following the marking indicates the degree of cleanliness from mill scale, rust, and previous coats. The most common preparation grades of wire brushing are St 2 and St 3. For example: St 2 = Careful cleaning by hand or power tools. With visual inspection, the surface may not contain dust, grease or oil, nor weakly adherent mill scale, rust, paint material or foreign substances. See photographs BSt 2, CSt 2 and DSt 2 in the standard.
Surface preparation performed using abrasive blast cleaning is designated with the marking Sa. The preparation grades for abrasive blasting are Sa 1, Sa 2, Sa 2 and Sa 3. For example: Sa 2 = Very careful abrasive blast cleaning. With visual inspection, the surface may not contain dust, grease, oil, mill scale, rust, paint material or foreign substances. The contaminants remaining on the surface must be rmly adherent to the substrate. See photographs ASa 2, BSa 2, CSa 2 and DSa 2 in ISO 8501-1. The term foreign substance refers to water-soluble salts and welding medium residue, for example. These contaminants cannot be entirely removed using dry blast cleaning. Standard ISO 8502 describes the test methods for detecting water-soluble iron salts and chlorides, dust and condensates.
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Hydro-blast cleaning is a surface cleaning method, which uses only high-pressure water. Hydro-blast cleaning is based on the impact energy of water directed against the surface. Advantages of hydro-blast cleaning include: - no solid abrasive granules or associated dust - removes soluble salts - removes grease and oil - leaves no granules or dust on the surface - does not prevent simultaneous execution of other trades in the immediate vicinity Disadvantages of the method include - does not remove mill scale - does not form surface prole The following hydro-blast cleaning methods are in common use: - high-pressure hydro-blast cleaning (34 MPa 70 MPa) - ultra-high pressure hydro-blast cleaning (over 70 MPa) In the determination of rust grade, the least acceptable rust grade discovered is to be recorded. In the determination of the surface preparation degree, the degree corresponding most closely under visual inspection to the steel surface being assessed is to be recorded. In cases where painting is carried out as patching and only part of the surface is prepared, the letter P can precede the marking for the surface preparation degree to indicate that the surface preparation is only partial, e.g. PSa 2, surface cleaned partially to surface preparation degree Sa 2, ISO 8501-2.
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Image 4.1 ISO surface prole reference comparators for tests under ISO 8503-1 and ISO 8503-2.
Table 4.1 Nominal values and deviation range for the surface proles of the different sectors of the ISO surface prole reference comparator.
3 m 10 m 15 m
4 150 m 20 m
1 25 m 3 m 2 40 m 5 m 3 70 m 10 m 4 100 m 15 m
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Different hot dip galvanised structures must be prepared after cleaning as follows: - hot dip galvanised steel structures are to be sweep blast-cleaned so that the entire surface becomes dull. Suitable cleaning agents are aluminium oxide, natural sand and quartz, for example. Painting is not recommended for galvanised structures intended for immersion. - New galvanised steel-plate structures are sweep blast-cleaned lightly. For preparation of surfaces dimmed by oxidation, alkali wash emulgation and rinsing with fresh water is sufcient. Surfaces coated with zinc-rich paint are prepared prior to subsequent coating according to the technical data sheet of the product.
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Table 4.2 Compatibility of pre-fabrication primers with paint systems (standard ISO 12944-5).
Epoxy 2)
Polyurethane
Zinc silicate
+ 3)
2. Polyvinylbutyral Miscellaneous + + + 3. Epoxy 4. Epoxy 5. Silicate Miscellaneous + Zinc dust Zinc dust + + + + + +
+ + + + + + + + + +
+ +
NOTE Paint formulations vary. Checking compatibility with the paint manufacturer is recommended. Including epoxy combinations, e.g. Hydrocarbon resisns Sweep-blasting is required
Table 4.3 Suitability of pre-fabrication primers, used with a related paint systems, in various exposure conditions (standard ISO 12944-5).
Pre-fabrication primer
Suitability to exposure conditions 1) Immersion without cathodic with cathodic protection protection + + + +
Binder type Anticorrosive C2 C3 C4 C5-I C5-M pigment 1. Alkyd 2. Polyvinylbutyral 3. Epoxy 4. Epoxy 5. Silicate Acrylic (water-borne) + = Suitable = Not suitable
1)
+ + + + +
+ + + + + +
+ + + + + +
+ + +
+ + +
Miscellaneous +
NOTE Paint formulations vary. Checking compatibility with the paint manufacturer is recommended.
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Binders
A binder forms a coating which bonds to the substrate, containing pigments bound to one another by the binder. The binder largely determines the characteristics and performance of the coating, such as adhesion, cohesive strength and durability. The curing mechanism of the paint is a binder-dependent property. The binders in paints are for the main part organic macromolecule polymers (plastics), or reactionable resins, which form polymers in the curing process. Synthetic polymers and resins are the most important group of binders. Based on the curing mechanism of the binder, paints are divided into reversible coatings (physically curing paint) and irreversible coatings. Irreversible coatings are further divided into air curing paints, water-borne dispersion paints and chemically curing paints. A paint product is named by the binder used, e.g. alkyd, epoxy, chlorinated rubber, polyurethane, acrylic or vinyl paints.
Solvents
The purpose of solvents is to dissolve the solid resins and polymers, and to reduce viscosity of the binder. In water-borne paints, solvent are also used for lm formation. Although solvents evaporate from the coating after application, they contribute in an important way to lm formation and properties. Solvents are ammable liquids, and most of them produce vapours and fumes harmful to health. Based on the solvents ash point, the paints are divided into ammable (and combustible) liquid classes as follows: Extremely ammable (symbol F+): ash point < 0C Flammable (symbol F+): ash point 0 21C Ignitable: (no symbol) ash point 21 55C If the ash point exceeds 55C, the paint product is not classied as ammable liquid. If the ash point is in the range of 55 100C, only the regulations on the warehousing permits of combustible liquids are relevant. The EUs new regulation on classication, labelling, and packaging of substances and mixtures, the CLP Regulation (EC) No 1272/2008 species the classication criteria applicable to solvents in a new way. The Regulation enters into force in phases in 2010 and 2015. Some of the solvents used in paints are classied as volatile organic compounds (VOC).
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Thinner
Thinner is a volatile liquid added to paint for thinning, which can be either a solvent or water. Paints are also referred to as water-thinnable or solvent-thinnable. In thinning a paint product, the instructions provided by the paint manufacturer must always be adhered to.
Additives
Paints usually contain a number of additives in small quantities. Additives are required to produce certain properties associated with shelf life, viscosity and curing. In water-borne paints, for instance, the usage of additives is very important.
Paint types
Paints can be classied in many ways, for example, by - physical state (solid/liquid) - lm formation - binder type - pigment - coat order in the paint system - designed use In this handbook, the paint types are classied according to binder types, and acronyms are used in accordance with ISO 12944-5.
Reversible coatings
In reversible coatings (formerly: physically curing paint), the binder is a complete polymer. Film is formed without any chemical reaction required when the molecules of the binder agent are attached to one another once the volatile paint component has evaporated from the lm, or a fused lm cools down. The lm can be dissolved at any point using the original solvent contained in the used paint Chlorinated rubber paint CR In the chlorinated rubber paints, the binder is a mixture of either chlorinated rubber and chemical-resistant plasticizer or of chlorinated rubber and resin. Chlorinated rubber paints are used for priming, intermediate and top coats on metal and concrete composite substrates. The chlorinated rubber lm withstands chemicals in splash form and water in immersion. Its weather resistance is good. Acrylic paints AY In acrylic paints, the binder is a mixture of acryl polymers and a suitable plasticizer. Acrylic paints are used for priming, intermediate and top coats in weather-resistant paint systems. Polyvinyl chloride paints PVC In polyvinyl chloride paints, the binder is a mixture of copolymers of polyvinyl chloride and plasticizers. Polyvinyl chloride paints are used for priming, intermediate and top coats in weather-resistant paint systems.
Irreversible coatings
Initially, the coating cures physically through the evaporation of volatile solvents (if a solvent is used), followed by a chemical reaction or coalescence of binder particles (in water-borne dispersion paints). The process is irreversible, which means that the lm cannot be dissolved after curing using the original solvent or, in solvent-free paints, using a solvent typical for the paint type in question. Air curing paints (oxidation) In air curing paints (i.e. the curing mechanism is based on oxidative cross-linking), the binder is a curable oil substance or a derivative thereof. Oxygen in the ambient air binds to the double bonds of the binder, and the cross-linking process starts. Alkyd paints AK In alkyd paints, the binder is an oil-modied polyester, epoxy or urethane resin.
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Alkyd paints (like epoxy esters and urethane oils) cure when exposed to oxygen in the ambient air once the solvent has evaporated from the lm. Film formation requires a temperature of over +5C. Alkyd paints can be either solvent-borne or water-borne. Alkyd primers utilise corrosion protection pigments. Alkyd paints are used both indoors and outdoors in environment classes C1 C4. Water-borne dispersion paints (one-pack) In water-borne dispersion paints the binder is a polymer in aqueous dispersion form (minuscule balloons of 0,05 0,25 m). Once water has evaporated from the lm, the polymer balloons fuse together to form an integral lm. The curing process is irreversible, and the coating cannot be dispersed or dissolved in water after hardening. Paints designed for metal surfaces utilise corrosion protection pigments and corrosion inhibitors. The most commonly used polymers are acrylic resin (AY), vinyl polymers or polyurethanes (PUR). The weather resistance of dispersion coating is good. The lm is thermoplastic, and it has good resistance to solvents and water. Chemically curing paints Film formation in chemically curing paints results from a reaction where a liquid resin of small molecule size becomes cross-linked and increases in molecule size. The cross-linked coating does not dissolve after hardening in the original solvent and does not substantially soften when exposed to heat. In two-pack paints, the cross-linking reaction of the paint components, the base component and the curing agent takes place Two-pack epoxy paints EP Two-pack epoxy paints are coatings where amine is used for cross-linking the epoxy resin. After combining the components, the coating mixture has a limited pot life. Film formation usually requires a temperature of over +10C. Lower temperatures are also possible when special curing agents are used. The epoxy lm does not dissolve in solvents, has good adhesion to the substrate, and is hard, which signies good mechanical properties. The coating withstands alkalis, salt solutions, weak acids, oils, greases and solvents well. When exposed to weather stress, the epoxy coating chalks easily on the inuence of UV light. Epoxy pains are available in solvent-borne, water-borne and solvent-free versions. Epoxy resin and a curing agent are used as binders in epoxy coatings, which are solvent-free or contain solvent only in minimal quantities. The coating has a short pot life. The coating is usually applied using a two-pack sprayer. A single application produces a dry lm of 250 - 1000:m in thickness Epoxy coating reinforced with glass bre is marked using the acronym EPGF. Epoxy combinations (EPC) can be modied using, for example, hydrocarbon resin, coal tar, acryl or vinyl. Coal tar-based epoxy coatings are used for subterranean or submarine structures intended for an immersion environment. Two-pack polyurethane paints PUR Polyurethane coatings are two-pack paints. The binder is a resin containing hydroxyl groups (i.e. polyol), such as acrylic or polyester resin. Using aliphatic isocyanate compounds as a curing agent will produce excellent durability of gloss and colour in outdoor conditions. Using aromatic isocyanates allows for shorter curing times and better chemical resistance, but the coating turns yellow and chalks when exposed to UV light.
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Film formation requires a temperature of over 0C. Polyurethane combinations (PURC) can be modied using, for example, hydrocarbon resin, or coal tar. The coatings are used for subterranean or submarine structures intended for an immersion environment. Oxirane ester paints (national acronym OX) Oxirane ester paints are solvent-borne coatings with a high content of solids. In two-pack oxirane ester paints, the binder is oil containing oxirane groups, cured using resin containing carboxylic acid groups. The lm hardens at a slow rate at room temperature and, therefore, curing is usually accelerated by stoving the coating at a temperature of +60 +150C. Adhesion of the oxirane ester coating to steel surfaces is good and, in combination with a primer, the paint is suitable for application on other metal surfaces. The chemical and weather resistance of the coating are rather good. The lm is exible and mechanically strong. Oxirane ester paint applied without priming onto metal surface usually contains corrosion protection pigments. Moisture curing paints The lm forms though the evaporation of the solvents. Chemical cross-linking occurs when the binder is exposed to ambient humidity. Moisture curing polyurethane paints Cross-linking takes place at or even below 0C, if ambient humidity is sufcient. Ethyl zinc silicate paints ESI (one or two-pack ethyl silicate) The binder for ethyl zinc silicate paint is an organic silicate and the pigment is zinc powder. Ethyl zinc silicate paint is able to withstand high temperatures, mechanical stress, and pH neutral solvents well. The paint is suitable for priming in environment classes C4, C5-I, and C5-M.
Stoving paints The lm formation of stoving paints takes place at a high temperature (+120 +180C), when the components of the binder react with one another. Alkyd stoving paints The binder is a short-oil alkyd resin and amino resin. Polyester stoving paints The binder is a polyester and amino resin. Powder coatings Powder coatings are paints in powder form. The binder for chemically curing powder coating is epoxy, acryl, polyester, polyurethane, or silicone. The powder is usually applied using an electrostatic spray. The nal lm forms in an oven, when the powder melts and polymerises into a coating at a temperature of +140 +200C (for 5 to 20 min). Coil coatings Coil coating is a continuous process for coating metal in an industrial coating line using stoving paints. The material to be coated is metal sheet: cold-rolled steel (CRS), hot dip-galvanised steel (HDG) or aluminium. Usually, a double-coat system, comprising the primer and topcoat, is used. The most commonly used binders are polyester (PE), polyurethane (PUR), and PVDF (domestic acronym PVF2). The sheet back is usually coated using epoxy paint. The coatings weather well and are highly pliable (e.g. proled roong sheets).
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6. Paint systems
A paint system comprises the substrate, substrate preparation, and the coating formed by the protective paints applied to the substrate. A paint system can comprise only a single paint, which is applied one or multiple times until a sufcient lm thickness is accomplished. In most cases, the paint system comprises multiple paints, which have properties supplementing one another. Based on the application sequence, the paints are divided into primers, intermediate coats and top coats. The corrosion protection mechanism of a corrosion protection paint system is based on electric potential displacement inhibition, anodic or cathodic inhibition, or cathodic protection. The system paints usually utilise two of these three mechanisms. For example, a top coat can utilise electric potential displacement inhibition and the primer cathodic inhibition. In certain cases, corrosion protection pigments are used in all coats.
In cases where multiple or alternative generic paint types are included under the same system number, the identier must contain the binder type, to be presented in the following form (system A2.06 of table A.2 as example): EN ISO 12944-5/A2.06-EP/PUR Tables A.1 A.8 present the listed paint systems: - substrate (Fe/Zn) and preparation grade of the surface - generic paint types, number of coats, and nominal dry lm thickness - total number of coats, and total nominal lm thickness of the paint system - estimated service life category under the corrosivity category indicated in the table In some countries, the paint system markings are more detailed. In Finland, for instance, it is recommended to mark the paint systems using a designation composed of the marking specied in part 5 of ISO 12944, supplemented (in brackets) by the paint type identier, total nominal lm thickness, number of coats, substrate material and the identier for substrate preparation. The binder type identiers are presented pursuant to part 5 of ISO 12944. The substrate preparation grades are presented according to the grades specied in ISO 8501-1 (see Chapter 4 Substrate preparation of this document). Nominal dry lm thickness is presented in micrometres. Substrate material is presented using the chemical symbol for the main constituent compound of the metal structure, for example: Fe = iron Zn = zinc Marking recommendation applicable in Finland: SFS-EN ISO 12944 5/A2.02 (AK 120/2 Fe Sa 2) ISO 12944 requires that if a paint system does not correspond to any of the combinations described in tables A.1 A.8, the designation must contain all information on substrate preparation, general paint type, nominal dry lm thickness and the number of coats. In such a case, the designation for the paint system can be presented using the designation method specied in the above recommendation (without reference to the identier of the table).
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Corrosivity categories
The paint type is selected primarily based on the protection required in the environment of the structure. The paints must also withstand any stress due to manufacture or installation. In the description of the environment relevant to the structure, the provisions in part 2 of ISO 12944 are to be used, where the environments are divided into corrosivity categories C1 C5 and lm1 lm3 based on the parameters contributing to corrosion in metals. Indoor environments in most cases fall into corrosivity categories C1 and C2, unless corrosivity parameters other than humidity are present to a signicant degree. Outdoor environments fall into corrosivity categories C2 C5. Based on the quality and quantity of atmospheric contaminants, local environments can be divided into rural, urban, maritime and industrial environments. In addition to the aforementioned corrosivity categories, there are a number of special stresses, such as those associated with chemical plants, paper and pulp mills, bridges, and subterranean or submarine structures. Corrosivity parameters typical for special environments include corrosive gases, chemical dust, splashes, biological, mechanical and thermal corrosion, and immersion in water or burial in soil. The paint systems for special environments are described in the Teknos Manual Paint Systems for Industrial Coating and Corrosion Protection Painting. In particular, the corrosivity parameters in the structures immediate environment must be considered in the determination of the relevant corrosivity category. This immediate atmospheric environment (microclimate) is more important in terms of corrosion protection than the general atmospheric environment of the locality (macroclimate). For instance, the Finnish climate is cool and humid by nature and, in comparison to most industrialised counties, clean. Because the performance and durability of coatings of the same type may, in principle, differ from one another, it is increasingly important to choose a time-proven paint system. The most commonly used Teknos paint systems with a good service history are described in the Teknos Manual Paint Systems for Industrial Coating and Corrosion Protection Painting.
Economical considerations
Corrosion protection by a paint system is an investment targeted to provide, at an optimal cost, a coating that will serve the designed purpose throughout the projected service life. Although the share of the paints is usually only 15 30 per cent of the overall costs, the determination of the paint system may have signicant economical effects. For example, in industrial coating and shop application fast-curing paints shorten process times and thus increase the output capacity of the facility.
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Painting methods
Paints can be applied onto the surface using a number of different painting methods. Spraying, brush application, roller application, dipping, ow coating, industrial ow coating and industrial roller coating are the most common painting methods. In the determination of the painting method, the following must be considered, among others: - painting site - shape, size and number of structures being coated as well as manufacture process cycles - paint type - number of colours - safety and environmental considerations - compatibility of the painting tools and implements used with the paint system
Brush application
Brush application is the oldest painting method in common use today. The advantages of brush application include the paints good penetration in the surface pores. Brush application is a slow process and a relatively expensive one. On large surfaces, brush application does not produce a sufciently uniform and good-quality lm. Film thickness is thinner than in airless spray coating.
Roller application
Roller application is often preferred to brush application because of the speed of the method. In roller application, the paint is rolled onto the surface instead of rubbing as in brush application. A paint roller is not an appropriate tool for painting small, poorly cleaned or uneven surfaces, especially in cases where the surface contains rust or dust. In such a case, the coating rests on the contaminants and cannot bond properly to the substrate. Furthermore, achieving a uniform and sufcient lm thickness is rather difcult. Hence, the paint roller is primarily a paint application tool for the application of top coats on large and smooth board surfaces, and is not recommended for priming use.
Spraying
Spraying is the most commonly used painting method for large surfaces today. Different types of sprayers have been developed for various purposes of use. Low pressure (conventional) air spray The side mount gravity sprayer, i.e. air atomising sprayer, is the oldest of the sprayer types. This sprayer type is still in extensive use, for example, for painting cars and the top coating of small structures. (image 7.1) In low pressure air spraying, the liquid is injected, either under hydrostatic pressure or slight overpressure, into the middle of the sprayer gun nozzle. The liquid from the nozzle is then atomised into ne mist by air jets directed at different angles to the paint material being ejected. The volume of the liquid ow to the nozzle can be adjusted using the needle valve or by adjusting the nozzle orice size. The spray pattern is determined based on the angle and volume of the air jets. The method requires the availability of pneumatic air and thinning of the paint material. The quality of the nish is uniform and smooth. The method is not suitable for forming thick coatings, since thinning in used to regulate the coating nish. Conventional spraying is not recommended for coating complex structures. Atomising prevents paint material from entering tight corners and the surface pores (image 7.5). Air atomising spraying is also called low-pressure spraying because of the low operating pressure used.
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The main advantages of low pressure air spraying include the following: - adjustable spray pattern - no movable parts - high-quality nish - low purchase price - allows for rapid change of colours Disadvantages include: - not suitable for all paint types - painting corners and other complex structures is difcult - thinning of paint required
Airless i.e. high-pressure spraying Airless spraying is the most commonly used painting method in corrosion protection painting (image 7.2). The splitting of paint liquids in airless spraying is based on the great pressure difference induced by conveying the liquid under high pressure though a small nozzle orice. The resulting paint mist is rather ne in quality and the droplets hit the surface at a high velocity. Because there is no air lock to overcome (see conventional spraying), the paint enters freely into corners and to the bottom of the surface pores. The pressure required for airless spraying is supplied by a high-pressure pump, which increases the pressure by tens of times, depending on the surface area ratio between the air-side pistons and the liquid-side pistons. There are also sprayers supplied by diaphragm or piston pumps, powered by electricity or a combustion engine. These sprayers are used on sites where pneumatic air is not available. The volume of sprayed paint (l/min) depends upon the nozzle size and the pressure used. The width of the spray pattern depends upon the split angle of the nozzle. Over the course of usage, the diameter of the nozzle orice wears and becomes larger and, thus, the spit angle increases. The technical data sheets of the paint products describe the design nozzle sizes for the product used in airless spraying. For spraying paint without thinning, a nozzle pressure of 120 250 bar is usually required. Using too high a spraying pressure should be avoided, since this will increase the volume of spray dust and, thus, the visual texture of the nish. As low a pressure as possible should be applied to achieve a cost-effective outcome. The operating pressure can also be signicantly reduced by using an appropriate paint warmer as an auxiliary device.
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The main advantages of airless spraying include: - suitable for most paint materials - high performance and capacity - only minimal thinning required - high dry lm thickness - minimum volume of paint mist Disadvantages include: - high hose pressure required - visual texture of nish may not be as satisfactory as in low pressure air spray - not suitable for application of small volumes of paint
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Airless pump
Spray gun
Filter unit
Image 7.5 High-pressure spraying (on the left) provides better nish than conventional spraying (on the right), especially in the corners.
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Air-assisted airless spraying The nish produced by airless spraying can be enhanced using a spray gun where compressed air is introduced into the spray from the airless nozzle to improve atomisation. Various spray gun manufacturers offer air-assisted airless spray guns under different brand names, such as Airmix, Aircoat, Airow, Airassistant, and so on. They all share the same feature, namely that the characteristics of the spray fan generated by the gun can be adjusted and modied by separately adjusting the compressed atomisation air. This allows for an improved nish and high-viscosity paints can be sprayed without creating a stencilling effect. These spray guns can be used as regular airless spray guns if compressed atomisation is not required. Because air-assisted spray guns allow for a reduction of spray pressure, they are well suited for electrostatic coating. Electrostatic spraying Electrostatic sprayers have been developed for the application of both liquid paint (image7.3) and powder coatings (image 7.7). High direct-current eld (60 100 kV) is formed using a transformer between the coated surface and the sprayer. The liquid paint or powder coating is atomised in the spray gun using centrifugal force, compressed atomisation air or high-pressure pneumatic air. The liquid or powder becomes electrically charged in the eld and is attracted to the surface of the grounded structure. Powder coating is charged using one of two methods, based either on high voltage (image 7.7) or triboelectricity (image 7.8). In powder coating, the powder drifting off target can be recovered and recycled for further use. Two-pack spraying In certain two-pack coatings, the curing reaction time is so short that dedicated two-pack spray applicators have been developed (image 7.6.). The applicators pump the curing agent and the base component from separate containers and mix the components to the correct proportion before the liquid reaches the spray gun.
Compressed air intake Decompression valve Feeding pump Electric paint pre-heater
Air valves
Feeding pumps
Base
Base
Hardener
Solvent pump
Mixing element
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Fluidising air
Powder particles
Charged particles
Fluidising air
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Dipping
Dipping is a method used for serial products, providing short cycle times and minimal waste of coating material. The objects being coated are dipped into the dipping pool individually, in bundles, coating racks or smaller objects in a mesh basket or similar conguration. The dipping pool is sized according to the size of the objects being coated. Larger dipping pools are equipped with pumps, which keep the coating material in constant ow so as to prevent settling of the paint. Dipping requires special paints designed for the purpose, curing either physically or through oxidation, or stoving paints. Two-pack reaction paints are not usually used because of the limited pot life. In most cases, lm thicknesses varying at about 30 m are achieved in one dip. If the object is very complex, dipping does not usually produce a ne nish because of sagging due to holes, cantilevers and other similar shapes. Electric dip coating Electric dip coating (electrophoresis, i.e. cathaphoresis) is a coating method where the object being coated is connected to a DC circuit either as an anode or a cathode and the basin being the opposite pole. The coating material is water-borne paint designed for the purpose. The paint particles become charged and are attracted to the surface being coated, then precipitate and form a uniform lm of approximately 30 m in thickness. The method is used for priming in the automotive and white consumer goods industries. Electrostatic uidized bed coating The object being coated is dipped into a pool of uidised powder. The pool has electrodes, creating an electrostatic charge to uidized powder which attaches to grounded object run through the cloud of charged powder. Film thickness can be controlled by adjusting the voltage.
Application conditions
Surface preparation and coating must be performed under the conditions specied by the manufacturers instructions. For instance, application onto a moist, wet or icy surface can cause peeling of the paint surface. The ambient temperature during application and drying must be sufciently high to allow for curing.
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When ambient temperature is below 0C, the surface must be checked for ice. A surface thermometer is the best device for measurement of surface temperatures. Generally, the temperature of the surface being coated should exceed the dew point of ambient air by at least 3C immediately before, and during, application and during curing, unless otherwise specied by the manufacturer. By using a dewpoint dial (Image 7.9) it is easy to make sure that the painting work can be carried out, if the ambient temperature, relative humidity and surface temperature are known. Image 7.10 presents, as a function of ambient temperature and relative humidity, the lowest acceptable surface temperature for the structure, as well as the respective dew point.
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18 15
Relative humidity, % () Example calculation for determination of the lowest acceptable surface temperature using the table above: 1 2 3 4 Measure relative humidity in ambient air: Measure temperature of ambient air: Read the dew point in the table: Surface temperature must exceed the dew point by at least 3 C immediately prior to and during application and curing, i.e. in the example: 80 % 20 C 16,4 C
19,4 C
Image 7.10 Ratio between ambient temperature, relative humidity, dew point, and acceptable surface temperature.
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V (1) Kk = Km 100
(m)
where V is the percentage of solids by volume. The percentage of solids content in the paint (V) is given in the technical data sheet, and the wet lm thickness Km is provided by the measurement.
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Image 7.11 Comb-type wet lm thickness metering device. The measurement is read from the furthermost tooth coming into contact with the paint when the comb is pressed through the paint lm so that the rst and last tooth come into contact with the substrate.
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Image 7.12a The dry lm metering gauge is used for the tests under ISO 1461, ISO 19840, ISO 2063, ISO 2360, ISO 2808-7C, ISO 2808-7D and ISO 2808-12.
Image 7.12b The magnetic pull-off lm thickness gauge is used on explosive sites, such as oil-drilling platforms, reneries and other similar facilities. The gauge is also known as the banana and is suitable for tests in accordance with ISO 2178 and ISO 2808-7A .
The standards, e.g. ISO 19840, specify the number of measurements by test area and the tolerance for deviation from the NDFT. For example: For each 100 m of the total area of the typical surface, one test area of 10 m is to be determined and 20 measurement points specied for such test area. Three readings are to be obtained for each measurement point. Film thickness may be no less than the NDFT in all but one of the measurement points of the test area. Such downward deviation may not exceed 20 per cent of the NDFT. The measurement record must indicate the standard(s) applied, agreed or other deviation from the standard, test measurements (arithmetical mean, maximum and minimum values), the measurement method and the metering device. Destructive measurement methods The dry lm thickness can also be measured using a destructive method where desired. ISO 2808 describes the measurement of dry lm thickness using a micrometre (method 3A), rollback dial (method 3B), and cutting tool making a V-groove incision (method 5B). All the methods cut through the lm into the substrate. On-site measurements are made using a cutting device, which comprises an illuminated scaled magnier and cutting tip. The tools hardened steel tip makes a V-groove though the coating. The scale of the magnier can be used to determine the lm thickness of the coating, because the tip angle of the blade is a known constant. The number of the coats can also be studied (images 7.13a, 7.13b, and 7.13c).
Image 7.13a The cutting tool making a V-groove incision is used for tests in accordance with ISO 2808-6B.
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Image 7.13b Film thickness is determined by cutting a V-groove through the coating into the substrate and, then, measuring the width a (or b), which is in relation to lm thickness a (or b).
(2) Mt =
where Mt Kk A V
Kk* A 10 * V
(I)
= theoretical paint consumption (l) = dry lm thickness (m) = surface being coated (m) = percentage of solids by volume (%)
The quantity of paint material required for painting is in all cases greater than the theoretical consumption indicated in the technical data sheet. In real-life conditions, paint material is consumed for lling prole valleys, non-uniform coating and overspray. Small quantities of paint material remain in the containers, pots, tools, and implements. The effective material consumption Mk can be calculated using the formula:
3) Mk =
10 * Kk* A V (100 H)
(I)
H = waste percentage of material (%) In actual painting work, the waste percentage is approximately 40 70 per cent. In other words, effective material consumption Mk is 1.7 3 times theoretical consumption.
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Tables for estimation of paint consumption All values in the tables are for reference only, and may vary according to actual circumstances.
Table 7.1 Determination of coating thickness based on the percentage of solids by volume.
Solids by volume %
Traversal lines represent examples of the solids by volume. Start from the top of the relevant solids by volume. Follow the line downward until it meets the vertical line representing the required dry film thickness (at the bottom). Then, from the point where the traversal and vertical lines meet, follow the horizontal line to the left-hand side and read the value that corresponds to the required dry film thickness. Example: 1. Solids by volume 50 per cent 2. Dry film thickness 40 m 3. Yields 80 m wet film thickness.
Thinning/volume -% Traversal lines represent example thinning percentages. Follow the horizontal line, which indicates solids by volume prior to thinning, starting from the left-hand side edge until the traversal line, which indicates the quantity of thinner added. The vertical line indicates the new percentage of solids by volume. Example: 1. Solids by volume 50 per cent 2. Thinner by volume 10 per cent 3. Yields the new percentage of solids by volume = 45 per cent Solids by volume -% prior to thinning Solids by volume -% when thinner is used
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The purpose of quality assurance of corrosion protection work is to provide the painting under the agreement (EN ISO 8402). Quality control comprises the inspection and recording of all operations, materials, implements, methods and procedures, conditions relating to corrosion protection work, and the associated corrective action and elimination of deviations. The quality control of corrosion protection work is made easier if the supplier or contractor has a quality system in place (see ISO 9001 and ISO 9002). The quality assurance of corrosion protection work and the main parameters to be taken into account therein are described in part 7 of ISO 12944.
Personnel
The applicators of corrosion protection paint must be qualied for the work. Work requiring particular care can be performed only by personnel who have appropriate professional training or are certied by a recognised organisation, unless otherwise agreed by the parties Where necessary, a meeting is convened prior to commencing paint work. The purchaser, the supplier, and the paint manufacturer must be represented in the meeting. The parties discuss in the meeting, among other subjects: - the paint system specication, the paint work specication, and the standards applicable to the paint work - the supplier must demonstrate its capability of delivering, during all process steps, the specied quality level - the diary maintained during the paint work and the party responsible - any ambiguities or conicts of the specications or standards, e.g. how to paint a difcult spot, which cannot be painted on-site in compliance with the paint system specication
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Steel structure
If the parties agree that the structure is manufactured according to the structural requirements of part 3 of ISO 12944, this will be veried where necessary. The rust grade of an uncoated steel surface is determined based on ISO 8501. Unless otherwise agreed to the contrary, only surfaces of rust grades A, B, or C are acceptable. The quality of metal working is inspected pursuant to standards, while validating that the welds and edges are nished to the agreed quality degree. The applicators must have unobstructed access to the work object (ISO 12944-3) and surface illumination must comply with the paint work specication. The inspection results are recorded.
Surface preparations
The surface must be cleaned to the required surface preparation grade under the paint system specication. Contaminants hampering rust removal, such as salts, oils, and greases must be washed from the surface before wire brushing or blasting. Where necessary, the parties agree on the type, size, and purity of blasting abrasives (ISO 11124 - ISO 11127). The cleaning equipment must comply with the agreement and be in good operational condition, the output of the air compressor must be sufcient and the pneumatic air free of contaminants. Ambient temperature, the temperature of the work object and relative humidity must be in compliance with the agreement during cleaning. The readings obtained are recorded. The surface preparation grade is assessed using ISO 8501-1, and the results are recorded. Where necessary, the surface prole is determined based on ISO 8503. After blast cleaning, the surfaces of rust grades C and D may contain water-soluble ferrous salts, chlorides, and dust not visible to naked eye. ISO 8502 describes the methods for the determination of such contaminants. A number of salt measurement devices are depicted in image 8.1. The surface preparation grades of coated structures are specied in ISO 8501-1 and ISO 8501-2. In blast cleaning, disturbing an intact coat is to be avoided. The borderline between the cleaned surface and the intact coating must be feathered. The surface preparation work must be scheduled so that the surface can be coated as soon as possible after preparation, before it becomes soiled. Work lighting must be sufcient.
Conditions
Surface preparation and painting must be performed under the conditions specied in the paint working specication or the applicable standards. The conditions during surface preparation, application and curing must not deviate from the ambient air and surface temperature range indicated by the paint supplier. Where necessary, the conditions are reorganised to comply with the requirements, or the work is suspended until requirements are met. The following parameters of the environment must be measured, monitored and recorded to the agreed extent: - ambient temperature - substrate temperature - relative humidity in ambient air - dew point - wind conditions - temperature of paint material - lighting conditions - any operations in the vicinity disturbing application
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The application methods and procedures as well the tools and implements, in good operating condition, specied in the paint work specication or applicable standards must be adhered to in the paint work. The selected application method must be appropriate for the structure and may not cause harm or hazard to the environment. The application methods and the execution of paint work are described in ISO 12944-7.
Only paints and thinners specied in the paint system specication may be used in painting, and such substances must be available in sufcient quantities. The paints and thinners must be warehoused appropriately. The containers and other packaging must be original and in good condition. The labels must be legible. In the warehousing of paints, the requirements and constraints associated with safety and usage conditions provided in the material safety data sheets and technical data sheets must be taken into account, as well as the limitations to shelf life. Paint products should ideally be warehoused in constant, cool indoor conditions. Paints warehoused in colder conditions should be brought to the site conditions sufciently in advance to ensure the appropriate temperature of the materials. The brand names and production batch numbers of the paints, curing agents, and thinners are recorded in the protocol.
Application
Application must be performed in compliance with the requirements of the paint work specication and the applicable ISO 12944-7. The applicators must be familiar with the usage instructions and the material safety data sheets of the paints used. The surface being painted must be prepared to the required surface preparation grade, and the surface may not be exposed to contaminants or oxidation before painting. Any paint skinning must be removed, and the paint must be blended until uniform. The components of two-pack paints must be mixed in correct proportion, and the permitted pot life of the mixture may not be exceeded. Where a thinner is used, the quality and added quantity of the thinner must comply with the paint system specication and the technical data sheet. During application, it must be ensured that the required lm thickness is achieved, that no sagging is produced or unpainted areas remain. The volume of applied paint is veried using a wet lm measurement gauge. Sharp edges, corners and welds must be reinforced by extra overcoating, where required. Before application of a subsequent paint, the previous coat must be dry. If the time between applications exceeds the maximum overcoating interval allowed for the paint, the surface must be prepared using solvent washing or be sanded to ensure adhesion. Surfaces remaining hidden after assembly are painted before assembly. Surfaces to be placed against one another must be dry to handle before installation. A structure may not be handled after painting until the paint is dry to handle. Patch painting refers both to corrective action during the application process and to patching damages caused to pre-painted surfaces during transport. Patch painting must take into account the paint system specication and the technical data sheets.
Finished coating
After curing, the coating is checked for unpainted areas or other defects deteriorating the performance of the coating, such as sagging, craters, pinholes, cracking, orange peel effect, or unbonded spray dust. Both the gloss and colour of the nish must be in compliance with the agreement. The agreements require in many cases thickness measurement of the nished coating. The lm thickness requirements are presented as the required nominal dry lm thickness. The denition of nominal lm thickness varies to some extent in the different standards. Measurement of lm thickness is described in Chapter 7 (pp 40-42). Carrying out a porosity inspection is recommended for insulating coatings exposed to immersion or burial corrosivity stress. The inspection is used to discover any pores, pinholes or other weak spots in the coating. A porosity inspection requires a minimum coating thickness of 300 m (image 8.2).
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The lm thickness can also be measured using a destructive method. The lm thickness measurements are described in ISO 2802. Bonding of the coating is tested using the pull-off test under ISO 4624 (image 8.3), or validated using the cross-cut test of ISO 2409 (image 8.4).
Reference areas
Where necessary, the supplier prepares a reference area in accordance with the paint system specication, and the purchaser accepts the coating of the reference area, the paints and coating equipment used, the applicators and application methods. The reference area is used to establish the minimum acceptable quality of the paint work, to verify the information provided by the manufacturer or supplier (contractor), and to enable validation of the performance of the coating at any time after application (ISO 12944-7). All reference areas must be recorded meticulously, and can also be marked permanently on the structure (ISO 12944-8). The size and number of the reference area must be in reasonable proportion, both in practical and economical terms, to the total surface area of the structure (ISO 12944-8).
For the purposes of quality assurance and quality control of the paint work, a number of different documents are issued and obtained, such as the specications, drawings, inspection guidelines, work instructions, quality assurance procedures, technical data sheets and material safety data sheets. All the documents must be legible, dated, in good condition and maintained in an orderly fashion. Documents management is used to ensure that up-to-date versions of the relevant documents are available on all sites, where process steps substantial to coating quality are being performed.
The person responsible for the paint work maintains a site log. The daily conditions, events and measurements are entered in the log, such as - weather conditions of the day, both on the application and surface preparation sites - tool and equipment checks - rust grade and surface preparation grade of the substrate - the brand names and production batch numbers of the paints, curing agents and thinners, as well as the pot lives and application times of two-pack paints - readings of lm thickness measurements The actions taken due to defects discovered and notices submitted, as well as the results of the re-inspection, are entered in the site log. The name of the person responsible for the paint work and the inspection time are recorded.
Inspection records
An inspection record is issued for all inspections, such as the nal inspection, the acceptance inspection and other similar inspections.
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Image 8.1 Salt content measurement devices for the tests under ISO 8502-6 and ISO 8502-9.
Image 8.2 Porosity probe for the tests under ISO 2746.
Image 8.3 Adhesion probe for measurement of lm adhesion using the pull-off test under ISO 4624 and ISO 16276-1.
Image 8.4 Cross-cutting tool for determination of lm adhesion under ISO 2409
Image 8.5 Probe for determination of relative humidity, ambient temperature and dew point under ISO 8502-4.
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9. Maintenance painting
Maintenance painting refers hereinafter to patch painting and overcoating of metal structures.
Table 9.1 Coating rust grades and respective rust surface areas.
Rust grade
Ri 0 Ri 1 Ri 2 Ri 3 Ri 4 Ri 5
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The durability range is not a guarantee range. Durability is a technical consideration that can help the owner set up a maintenance programme. A guarantee period is a major issue and is subject to dedicated clauses in the contract. The guarantee time is usually shorter than the durability range. There are no rules that link these two periods of time.
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53
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Safety gloves must be thin cotton gloves. Skin cleaning is easier when suitable skin creams are used. Fire and explosion hazards are often present in spray painting operation. The hazards can be eliminated by using appropriate earthing both during application and when washing the sprayer. Sanding All sanding dust, especially of fresh paint, can irritate the respiratory tract, skin and eyes. Well-designed exible extraction arms or extraction connected directly to the sander signicantly reduce the generation of dust. Wet sanding also substantially reduces the quantity of dust. Where necessary, respirators featuring dust ltration must be used as well as suitable protective clothing. Blast cleaning In blast cleaning work, a protective helmet-cape conguration featuring a window and supplied-air function must be used. Exposed areas of skin must be protected using heavy protective clothing, special safety gloves and safety boots. Dust from abrasive material should be prevented from entering underneath the clothing, e.g. by taping or tightening the sleeve and trouser leg openings. Personal protective equipment In painting work, the areas of the body to be protected are usually the eyes, respiratory tract and skin: - Safety glasses: If no air-purifying respirator providing protection for the eyes is used in painting work, using safety glasses is recommended. - Safety gloves: When handling paints, thinners or resins, chemical-resistant gloves must be used, made either of nitrile or butyl rubber. Underneath the safety gloves, the use of thin cotton gloves is recommended to prevent skin irritation due to perspiration. In blast cleaning, special gloves designed for the purpose must be used. - Protective clothing: In most cases, regular protective overalls can be used and in premises where re or explosion hazard is present, preferably those made of cotton. Where necessary, impermeable aprons, safety helmets and knee or wrist safeguards can be applied. Where necessary, a disposable protective suit can be used on top of the working overalls. - Protective creams: Use of protective cream is recommended where skin may be exposed. Protective creams make skin cleaning easier and prevent skin from becoming too dry. - Respirators: To be used if harmful dust and fume contents cannot be eliminated sufciently by ventilation at the workstation. - in sanding work, air-purifying respirator with dust ltration, type P2 or P3 - in washing work and brush, roller and putty knife application, air-purifying respirator with fume ltration, type A - in spraying work, air-purifying respirator with combined ltration, e.g. type A2P3 - in spraying, pneumatic or gravitational supplied-air respirator mask or hood; in blast cleaning, a blast cleaning helmet Detailed information on the safety and protection equipment required when handling the products is available in the relevant material safety data sheet. Personal hygiene Good personal hygiene forms an integral part of occupational safety. When transferring from the workstation to another space, personal cleaning and a change of clothes is recommended. Use of protective creams makes skin cleaning easier. At the end of the working day, clean hands should be lubricated with skin cream so as to prevent skin from becoming too dry. Further information For further information on safe handling of chemicals; ECHA, European Chemicals Agency (www.echa.europa.eu)
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ISO 8504-1 Preparation of steel substrates before application of paints and related products Surface preparation methods Part 1: General principles ISO 8504-2 Preparation of steel substrates before application of paints and related products Surface preparation methods Part 2: Abrasive blast-cleaning ISO 8504-3 Preparation of steel substrates before application of paints and related products Surface preparation methods Part 3: Hand- and power-tool cleaning Standards for the determination of substrate characteristics (roughness, and presence of dust, salts or other contamnants) ISO 8502-3 Preparation of steel substrates before application of paints and related products Tests for the assessment of surface cleanliness Part 3: Assessment of dust on steel surfaces prepared for painting (pressure-sensitive tape method) ISO 8502-6 Preparation of steel substrates before application of paints and related products Tests for the assessment of surface cleanliness Part 6: Extraction of soluble contaminants for analysis. The Bresle method ISO 8502-9 Preparation of steel substrates before application of paints and related products Tests for the assessment of surface cleanliness Part 9: Field method for the conductometric determination of water-soluble salts ISO 8503-2 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 prole of abrasive blast-cleaned steel. Comparator procedure Standards for the determination of lm thickness, adhesion and other performance properties ISO 19840 Paints and varnishes. Corrosion protection of steel structures by protective paint systems Measurement of, and acceptance criteria for, the thickness of dry lms on rough surfaces ISO 2808 Paints and varnishes. Determination of lm thickness ISO 2409 Paints and varnishes. Cross-cut test ISO 4624 Paints and varnishes. Pull-off test for adhesion ISO 2813 Paints and varnishes. Determination of specular gloss of non-metallic paint lms at 20 degrees, 60 degrees and 85 degrees Standards for the determination and evaluation of the degradation of coatings ISO 4628-1 Paints and varnishes. Evaluation of degradation of coatings Designation of quantity and size of defects, and of intensity of uniform changes in appearance Part 1: General introduction and designation system
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ISO 4628-2 Paints and varnishes. Evaluation of degradation of coatings Designation of quantity and size of defects, and of intensity of uniform changes in appearance Part 2: Assessment of degree of blistering ISO 4628-3 Paints and varnishes. Evaluation of degradation of coatings Designation of quantity and size of defects, and of intensity of uniform changes in appearance Part 3: Assessment of degree of rusting ISO 4628-4 Paints and varnishes. Evaluation of degradation of coatings Designation of quantity and size of defects, and of intensity of uniform changes in appearance Part 4: Assessment of degree of cracking ISO 4628-5 Paints and varnishes. Evaluation of degradation of coatings Designation of quantity and size of defects, and of intensity of uniform changes in appearance Part 5: Assessment of degree of aking ISO 4628-6 Paints and varnishes. Evaluation of degradation of coatings Designation of quantity and size of defects, and of intensity of uniform changes in appearance Part 6: Assessment of degree of chalking by tape method ISO 4628-7 Paints and varnishes. Evaluation of degradation of coatings Designation of quantity and size of defects, and of intensity of uniform changes in appearance Part 7: Assessment of degree of chalking by velvet method ISO 4628-8 Paints and varnishes. Evaluation of degradation of coatings Designation of quantity and size of defects, and of intensity of uniform changes in appearance Part 8: Assessment of degree of delamination and corrosion around a scribe ISO 4628-10 Paints and varnishes. Evaluation of degradation of coatings Designation of quantity and size of defects, and of intensity of uniform changes in appearance Part 10: Assessment of degree of liform corrosion Standards in use in Sweden BSK-07 Boverkets handbook om stlkonstruktioner In Sweden, the process industry applies the standards adopted by Skogsindustriella Standardiseringsgruppen (SSG). SSG 1000E-8 Design and procurement of protective paint systems. General regulations SSG 1001E Instructions for the design and procurement of protective paint systems SSG 1005E Systems for initial painting of metallic materials SSG 1006 Frger fr korrosionskydd av metalliska material. SSG 1007E-6 Colours of nishing paint on metallic materials
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SSG 1008E-2 Project planning and procurement of single item hot dip galvanising SSG 1009E-9 Systems for initial painting of hot dip zinc coated steel SSG 1010E-8 Systems for maintenance painting (repainting) of metallic materials SSG 1011E-6 Maintenance painting on metallic materials. Cleaning methods for surface treatment prior to painting SSG 1012E-9 Choice of painting system SSG 1017E-5 Recommendations for the inspection of painting SSG 1021E-5 Paints for protection of metallic materials. Two-pack epoxy or polyurethane primer GA, GK, GS SSG 1022E-5 Paints for protection of metallic materials. Zinc powder pigmented epoxy primer GB, GZ SSG 1023E-5 Paints for protection of metallic materials. Acrylic or vinyl primer GE, GL SSG 1024E-5 Paints for protection of metallic materials. Surface tolerant oil or long-oil alkyd primer GM, GP SSG 1025E-4 Paints for protection of metallic materials. Two-pack oxirane ester primer GR SSG 1026E-4 Paints for protection of metallic materials. Two-pack epoxy or polyurethane top paint TA, TB, TD SSG 1027E-4 Paints for protection of metallic materials. Acrylic or vinyl top paint TE, TL SSG 1028E-4 Paints for protection of metallic materials. Alkyd top paint TM, TP SSG 1029E-4 Paints for protection of metallic materials. Two-pack oxirane ester top paint TR SSG 1030E-4 Paints for protection of metallic materials. Solvent-free epoxy, vinyl ester or polyester top paint TF, TG
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Skinning
Paint warehoused in a non-vacuum container for too long Storage temperature too high.
Part of paint wasted. Unsatisfactory nish, if skinning becomes mixed with paint. Clogging of sprayer lters.
Application and lm Orange peel Inappropriate thinner, method or viscosity applied in spraying. The lm is not smooth. After selecting a thinner suitable for spray application, apply the thinner in a quantity that provides suitable spraying viscosity and thus results in appropriate atomisation. Use a suitable thinner in a suitable proportion, taking into account the application method, conditions and lm thickness. On a porous substrate, apply primer with thinner using the shrouding technique.
Porosity Pinholing
Unsuitable thinner. Air in the paint, Humidity in the sprayer supply air. Film thickness too thin or thick. Accelerated drying. Porous/pinholed substrate.
The pores in the lm degrade coating performance and the coating stains more easily.
Uneven gloss
Unsuitable thinner. Uneven substrate (lled spots). Uneven application. Porous, absorbent substrate.
Use a suitable thinner in a suitable proportion. Filled or otherwise more porous spots must be patch painted before overcoating. Uniform application.
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PROBLEM POTENTIAL CAUSE CONSEQUENCE Too fast drying Thinners used are too fast. Relative humidity too low (water-borne paints). Film formation disturbed; checkering or uneven gloss. Paint dust.
SOLUTION TO PROBLEM Add retarding thinner to the paint. Increase relative humidity (water-borne paints). The paint must be stored, blended and applied in accordance with the manufacturers instructions. Allow the priming cure to dry well. Apply the paint in the correct viscosity onto a dry substrate and under the required conditions. Adhere to the instructions on application conditions and lm thickness. Apply the shrouding technique. Increase volume of ventilation. Use the correct type of topcoat. Do not use thinners that are too strong. Sieve the paint. Wash the tools properly. Clean the substrate. Use suitable thinner. Stir the paint thoroughly before application. Avoid spraying mist from drifting to the surface being coated.
Curing agent missing or incorrect quantity thereof. Film thickness too thick. Applied onto a fresh coating. Rain, fog, humidity or cold weather. Uneven or greasy substrate. Substrate contains plasticisers. Cool or humid application conditions, lm thickness too thick or insufcient inhibition in the paint used.
Immediately after application, water-borne lm may cause slight spot rusting in steel, which becomes visible in the lm as brown spots.
Lifting
The primer cannot withstand the thinners of the topcoat, swells, and works loose from the substrate. Unclean paint and/or painting tools used. Unclean, dusty substrate. Unsuitable thinner used, which can cause occulation of the paint components. Spray coating applied to a previously coated surface. Sand-blasting dust or similar in the environment. Too fast drying. Film thickness too thick.
Rough surface
Wrinkling
Use the correct type of primer. Apply the correct lm thickness and curing time. Apply a thinner lm. Store the paint in warm conditions before application. Apply less thinner to the paint. Select a suitable topcoat or apply an insulating coat. Bituminous coating must not be overcoated using any other type of paint.
Sagging
Film thickness too thick. Temperature of paint too low. Excessive thinning.
Bleeding
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PROBLEM POTENTIAL CAUSE CONSEQUENCE Durability and performance Cracking The paint is too hard (fragile) for the specic substrate. Temperature variation. Unsuitable paint system. The paint has been applied onto a moist or greasy surface. The paint has been applied onto mill scale or rust. Application has been performed in poor conditions. The paint has been mixed or thinned incorrectly. The paint system is unsuitable for the substrate. The previous coat has been soiled or the hardening process is excessive. Unsuitable paint. Incorrect application interval. The lm cracks into the substrate or into the previous coat. The lm, or part of it, works loose from the substrate and corrosion protection capacity of the coating is compromised
SOLUTION TO PROBLEM
Check the suitability of the selected paint system with the paint manufacturer. Clean the surface well. Apply paint on a dry substrate at a sufciently high ambient temperature. Comply with the paint manufacturers instructions on mixing ratio, application interval and lm thickness. Select a paint system suitable for the substrate. Before application of a subsequent coat, clean the surface form soil, grease and salts. Hard or glossy surfaces must be sanded to a dull nish. Select a topcoat suitable for the primer. Apply the required application intervals. Apply paint only in good conditions. Clean the surface carefully. Use paints that withstand the relevant environment or special stresses well. In connection with cathodic protection mechanism, only paints compatible with said protection mechanism can be used. Choose a paint capable of weathering the UV exposure. Choose a suitable paint system for the structure and comply with the manufacturers instructions on surface preparation, application and application conditions. Choose a suitable paint system for the structure and comply with the manufacturers instructions on surface preparation, application and application conditions. Select a suitable paint type/ hue for the structure being coated.
Flaking
Delamination
The lm becomes entirely loose from the precedent coat. Appearance and durability are degraded.
Unsuitable thinner. The lm works loose from Humid conditions. the substrate in blister form. Film thickness too thick or too thin. Moisture has permeated underneath the lm. Rust formation under the coat. Blistering due to cathodic protection. Unclean substrate. UV exposure too powerful for the paint. Unsuitable paint system. Film thickness too thin. Inadequate surface preparation. Poor application conditions. Unsuitable paint system. Drying time too short.
Chalking
The pigments become loose from the surface due to decomposition of the binder agent. Premature rust formation.
The lm chalks. A property of the pigment (e.g. certain bright red hues).
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Powder coatings
The entirely solvent-free and environmentally friendly INFRALIT powder coatings have been on the market for over 40 years. The INFRALIFT powder coatings contain no organic volatile compounds, and are fully compliant with the VOC directive of the European Union (1999/13/EC). The INFRALIT powder coatings are also in compliance with European Union directive 2002/95/EC, as amended and endorsed by directive 2005/618/EC, which sets forth restrictions applicable to the products of the electrical industry, concerning the content of lead, chromium (VI) compounds, mercury, cadmium, polybrominated biphenyl (PBB), and polybrominated diphnenyl ether (PBDE). Zinc-rich powder coatings, as they are known (INFRALIT EP 8026-05 and INFRALIT PE 8316-05) are an exception to the above, since they can contain, in the form of zinc impurity, cadmium over 0.01 weight per cent and/ or lead over 0.1 weight per cent. As well as in industrial coating, the INFRALIT powder coatings are a cost-effective and high-quality option in corrosion protection painting. Teknos Oy has developed powder coating paint systems that have been tested accordant with Standard ISO 12944. The foregoing Teknos powder coating paint systems offer a true alternative to a number of recognized wet paint systems in domestic and international use.
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Paint system No.: Required durability (ISO 12944-5) (ISO 12944-5) SHOP APPLICATION Surface preparation grade: Type of prefabrication primer (if used): Paint manufacturer: Area, m: PROTECTIVE PAINT SYSTEM Nominal dry lm Overcoating interval thickness min., h max., h m 1st coat 2nd coat 3rd coat 4th coat Total NOTE: For touch-up of damage, see site application below. SITE APPLICATION Surface preparation grade: Touch up: Complete: Paint manufacturer: Area, m: PROTECTIVE PAINT SYSTEM 1st coat 2nd coat 3rd coat 4th coat 5th coat 6th coat Nominal dry lm Overcoating interval thickness min., h max., h m Drying time at ............C,h Drying time at ............C,h
Total
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Condition of substrate (see ISO 12944-8, Annex K) Protective paint system Paint system No.: for maintenance (ISO 12944-5) Required durability (ISO 12944-5)
MAINTENANCE Surface preparation grade of damaged surface: Surface preparation of undamaged surface: Area, m: Area, m:
Touch-up: Area, m: Complete: Area, m: Paint Manufacturer: Protective paint system Touch-up Complete Nominal dry Overcoating interval Drying time at lm thickness min., h max., h ............C,h m 1st coat 2nd coat 3rd coat 4th coat 5th coat 6th coat Total
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Comments Painted by
Temperature
Air
Date Time Type of work Method General (i.e. surface preparation used weather application of priming conditions C
Structure/ constituent element C
Signature/ initials
Relative air Dew Blast cleaning Paint batch Colour Remarks humidity point abrasive No. (e.g. ISO standard, (abrasive surface preparation, designation/ grade, irregularities) % C material No.)
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Place
Date
1st signature
2nd signature
3rd signature
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Company Vastuuhenkil
Size, in m
Original condition of the surface: Uncoated surface (information in accordance with ISO 8501-1) Rust grade A B Supplementary information:
Zinc-coated steel surface, if any: Hot-dip-galvanized surface Thermally sprayed surface Electroplated surface Zinc corrosion (e.g. white rust) Supplementary information:
YES
NO
Painted surface Type(s) of coat (including thickness and age, if known): Degree of rusting in accordance with ISO 4628-3: Degree of blistering in accordance with ISO 4628-2: Degree of cracking in accordance with ISO 4628-4: Degree of aking in accordance with ISO 4628-5: Supplementary information: Surface preparation: Preparation grade (ISO 8501-1 / ISO 8501-2) Sa 1 PSa 2 PSt 3 Sa 2 PSa3 PMa Sa 2 St 2 Fl Sa 3 St 3 PSa 2 PSt 2
Remarks:
1) 2)
Fill in a new sheet for each reference area. For example for preparation grades St 2 and St 3, whether hand tools or power tools were used.
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Paint material Manufacturer Brand name Batch and/or production No. Colour 4)
Application method 5)
Air temperature, C
Relative humidity, %
Surface temperature, C
Dewpoint, C
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6) 7)
Date Time
Company name(s)
3)
Possible further operations, e.g. application of further coats, edge protection. See ISO 12944-8, sub-clause 5, table 1
4)
List the individual measurements on a separate sheet. E.g. steel mill, workshop or on site.
Teknos is an innovative paint manufacturer and a pioneer in anti-corrosive paints and coatings. High-quality Teknos products are held in high esteem by both the wood and metal industry, and the retail and architectural coating market. Our ability to produce cost-effective solutions providing clear added value has formed the basis of our guarantee of customer satisfaction for over 60 years. Teknos is a familyowned business. Our background as a family-run enterprise is reflected in our long-term business relations and customer-oriented approach. Our technical competence and continuous investments in research and product development will continue to boost our status as one of the leading European operators in our industry.
www.teknos.com