KIRBY BUILDING SYSTEMS – KUWAIT SOP No.

: QC – WI 03
REV. No. : 05
EFF. DATE : 23.07.15
SURFACE PREPARTION & PAINTING Page No. : 1 of 5
Quality Control Department
(Internal Use only)

QUALITY CONTROL

WORK INSTRUCTION
FOR

SURFACE PREPARATION AND PAINTING

COMPUTER GENERATED UNCONTROLLED COPY

FOR IMPLEMENTATION

ISSUE PREPARED BY REVIEWED BY APPROVED BY DATE

0 QA/QC SUPERVISOR QA / QC MANAGER DIRECTOR/SR. MANAGER 29.07.15

MFG
 KIRBY BUILDING SYSTEMS – KUWAIT SOP No. : QC – WI 03
REV. No. : 05
EFF. DATE : 23.07.15
SURFACE PREPARTION & PAINTING Page No. : 2 of 5
Quality Control Department
(Internal Use only)

TABLE OF CONTENTS

1.0 GENERAL

2.0 REFERENCE STANDARDS

3.0 SURFACE PREPARATION

4.0 INSPECTION & TESTING

5.0 PAINT APPLICATION

6.0 RECTIFICATION OF PAINT DAMAGE AREA

7.0 HANDLING & STORAGE

8.0 SAFETY
 KIRBY BUILDING SYSTEMS – KUWAIT SOP No. : QC – WI 03
REV. No. : 05
EFF. DATE : 23.07.15
SURFACE PREPARTION & PAINTING Page No. : 3 of 5
Quality Control Department
(Internal Use only)

1.0 GENERAL

This Work Instruction (WI) defines the minimum functional requirements related to coating works and
inspections of protective coatings for Pre Engineered steel Building components..

2.0 REFERENCE STANARDS

* Paint Manufacturer data sheet

* ISO 8501: Preparation of steel substrates before application of paints,
* American Standard Specification for surface texture, ANSI – B 46.1
* SSPC : The Society for Protective Coatings

3.0 SURFACE PREPARATION

The performance of protective coatings of paint and relative products applied to steel is significantly
affected by the state of steel surface prior to paint application. Surface preparation of components shall be
carried out by steel shots / Garnet blasting according to the recommendation of ISO 8504 – 2, and surface
preparation grade shall be as per project spec. in accordance with ISO 8501.The profile of blasted surface
shall be conformed to ISO – 8503 / ANSI – B 46.1.

The principal factors that are known to influence this performance are:

* The presence of rust and mill scale,

* The presence of surface contaminates, including salts, dust, oils / grease
* The surface profile.

Hence, prior to paint application ensure that the steel surface is free from above mentioned factors.
Surface preparation prior to paint shall be as per Project specification, if no particular surface preparation
specified in contract, and then kirby standard SP1,SP2 & SP3 shall be applicable for the job. The surface
shall be free from visible oil, grease and dirt, and from mill scale, rust, paint coatings and foreign matter.
Any remaining traces of contamination shall show only as slight strains in the form of spots or stripes.

4.0 INSPECTION & TESTING

Before the beginning of the works a pre-job meeting shall be arranged between paint supplier and plant
painting foremen, Operators and QC inspectors to clarify and agree the production procedures, checks and
inspections program, report forms and any other necessary requirements to achieve the correct job
execution.

4.1 Preliminary checks / Tests: Upon arrival of paints, the warehouse receiver and QC inspector shall
verify;

* Verify with the correspondence P.O., shipping documents and Identification of the containers,
* The containers integrity;
* The validity of shelf life of paint
* All the incoming Blasting / Coating consumables like Steel shots, Grits, Paints, Thinner and Cleaner
etc. shall be checked by QC to verify the P.O. requirements and T.C.
4.2 The prepared surface shall be inspected. The degree of cleanliness shall be SP1, SP2 & SP3 for
standard cleaning or as per project requirement (e.g SA1,SA2 SA2.5 etc.).
4.3 Profile (anchor pattern) prior to coating shall be measured and recorded.
 KIRBY BUILDING SYSTEMS – KUWAIT SOP No. : QC – WI 03
REV. No. : 05
EFF. DATE : 23.07.15
SURFACE PREPARTION & PAINTING Page No. : 4 of 5
Quality Control Department
(Internal Use only)

4.4 Visual standard for abrasive blast cleaning steel, SSPC VIS 1 - 89 shall be used as a guide for
inspecting the degree of cleanliness.
4.5 Surface profile gages, Keane-Tator surface profile comparator, Testex press-o-film, Replica Tape shall
be used to determine surface profile of blast cleaned surfaces.
4.6 In-process inspection is carried out to ensure that the correct coating material, mixing, application etc.
is as per the manufacturer product data sheet and project specification.
4.7 DFT of each coat shall be measured in accordance with SSPC-PA2 using an Elcometer-456 digital
coating thickness gage or its equivalent.
4.8 All the weather conditions such as Relative humidity, Substrate temperature, Dew Point etc. shall be
recorded for minimum 4 hours interval (depends on the weather condition).
4.9 All the inspection data shall be recorded in Kirby approved forms or client’s format.

4.10 The Inspector shall ensure that the blasting, coating procedure is followed properly.

5.0 PAINT APPLICATION:

5.1 PRIOR TO APPLICATION ENSURE FOLLOWING SHALL BE OBSERVED

* Painting shall be done as per Paint manufacturer Data Sheet.

* Painting process shall start only when the surface temperature is 3° C above Dew point or Relative
Humidity is less than 85 % and in Presence of sand storm visibility is 25 meter or more.

* Coating / paint application shall have full coverage of specified DFT, which shall be confirmed by
DFT (Dry Film Thickness) check gage i.e. Elcometer digital gage.

5.2 PROJECT SPECIFIED PAINTS SYSTEM AS BELOW;

Surface preparation & follow up coatings shall be as specified in contract with agreed DFT ,if no
particular paint system specified in contract, then kirby standard painting system shall be considered
(SP1 & SP3+ Alkyd primer @ 35µm) either with Red Oxide or Grey Oxide color.

5.3 PAINTER MUST MAINTAIN A REGISTER / LOG BOOKSHOWING FOLLOWING

INFORMATION:

* Supplier's name and paint Batch #

* Job # and piece mark,
* Ambient temperature and relative humidity,
* Quantity of steel members painted with that batch #
* Date and time of application.
NOTE: Packing and shipment of the steel members shall be done when the paint is fully cured.
5.4 Coatings that have gelled and exceeded their pot life shall be discarded.
5.5 The equipment, Air pressure, Tip sizes, Hose size etc shall be as per the paint manufacturer's product
data sheet.
5.6 Welds, edges, bolts, rivets shall be given a brush applied stripe coat before applying the full coat
whenever possible. All full coats shall be applied by airless spray, unless otherwise instructed.
 KIRBY BUILDING SYSTEMS – KUWAIT SOP No. : QC – WI 03
REV. No. : 05
EFF. DATE : 23.07.15
SURFACE PREPARTION & PAINTING Page No. : 5 of 5
Quality Control Department
(Internal Use only)

5.7 Re-coating intervals, mist coat if required and drying times shall be in accordance with the material
manufacturer’s published instructions.
5.8 Wet Film Thickness (WFT) shall be measured to ensure the required Dry Film Thickness (DFT) by
Painters.
5.9 The DFT shall be as per the job requirement and shall be measured

6.0 RECTIFICATION OF PAINT DAMAGE AREA. :

This Rectification Procedure applicable on area due to mud cracks observed on edges and corners due to
high DFT’s and due to mechanical damages in transit damage.

6.1 Surface Preparation Requirements:

6.1.1 Identify and mark the paint damage (crack) areas which are equal (or) greater than 0.1 square
meter shall be blasted to SA1 (SP7), SA2 (SP6) or SA2 ½ (SP10) as stated by the paint
manufacturers latest published instructions (or) blast clean to the standard originally specified.
6.1.2 The damaged areas which are less than 0.1 square meters, shall be power tool cleaned to ST2
(SP2) (or) spot blast to base metal. Feather edge the coating at least 50 mm beyond base metal.
6.1.3 Surface profile shall be as stated in the paint manufacturer’s published recommendations.

6.2 Painting:
6.2.1 All damaged areas and field weld connection areas of shop coated surfaces shall be repaired with
same coating system used in the initial coating (or) its equivalent. Substitution of an organic Zinc
primer for inorganic Zinc is permitted for field repairs. No substitution of top coats is permitted.
6.2.2 Clean the presence of surface contaminates, including salts, dust, oils / grease from the surface.
Scrape off loss paints by sharp knife. Roughen the affected areas.
6.2.3 Application paint touch up shall be by airless spray (or) brush /roller.
6.2.4 Re-coating intervals, drying times shall be in accordance with the material manufacturer’s
published instructions.

7.0 Handling & Storage:

7.1 Adequate packaging is to be ensured that the product is protected from contamination.
7.2 Since lower temperature during winter minimize the useful life, all paints to be stored in warm
surrounding.
7.3 Storage area should be isolated and well protected from heat and fire.

8.0 Safety:
Any surface preparation, painting or rectification shall be made under Kirby safety regulations. Safety in-
charge shall impart the rules and regulation & shall be randomly monitored the activities. Rectification
crews shall also follow the respective country’s Safety regulations.