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Graphite + 0.25 v
Silver - 0.1 v
Nickel 200 - 0.15 v
Copper - 0.35 v
Mill Scale - 0.4 v
Mild Steel - 0.7 v
Aluminium Alloys - 0.9 v
Zinc - 1.0 v
Magnesium - 1.6 v
Surface preparation - 2
a) Dry Abrasive Blast Cleaning
b) Water Blasting
c) Hand and Power Tool Cleaning
d) Flame Cleaning
e) Pickling
f) Vapour Degreasing
g) Weathering
Molecular Interference.
Rough and uneven blasted surface and wet paint locks, Analogy Velcro. Physical.
Molecular Attraction.
Negatively charged particles attracted to positive areas, and vice versa. Analogy Magnet (sometimes
called Ionic Bonding). Chemical.
Hackle – A small surface lamination, which stands upright like a needle after blasting.
Approximately ≤ 13 mm. Easily removed.
Lamination (slivers) – Appears to be a longitudinal ‘crack’, one lip curling back, any laminations
found must be referred to engineer for ultrasonic check.
1 mm = 1000 um
1 thou = 25.4 um
25.4 mm = 1 inch
2.54 cm = 1 inch
Properties of an abrasive
Size of the particles, Hardness of the material, Density of the material, Shape of the particle
A Steel surface largely covered with adherent mill scale with little if any rust.
B Steel surface, which has begun to rust and from which the mill scale has begun
to flake.
C Steel surface on which the mill scale has rusted away or from which it can be
scraped, but with slight pitting visible under normal vision.
D Steel surface on which the mill scale has rusted away and on which general
pitting is visible under normal vision.
Sa 1 Light Blast Cleaning. When viewed without magnification, the surface shall be
free from visible oil grease and dirt and from poorly adhering mill scale, rust,
paint coatings and foreign matter.
Sa 2 Thorough Blast Cleaning. When viewed without magnification, the surface shall
be free from visible oil grease, dirt, and most of the mill scale, rust, paint
coatings and foreign matter. Any residual contamination shall be firmly
adhering.
Sa 21/2 Very Thorough Blast Cleaning. When viewed without magnification, 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 stains in the form of spots or stripes.
Sa 3 Blast Cleaning to Visually Clean Steel. When viewed without magnification the
surface shall be free from visible oil grease and dirt, and shall be free from mill
scale, rust, paint coatings and foreign matter. It shall have a uniform metallic
colour.
Pickling is a general term relating to the chemical removal of oxides (rust), from a metal substrate.
Pickiling and passivation
Oil or grease needs to be removed by using a suitable solvent
Immerse in a bath of Sulphuric Acid, 5 – 10% concentration at a temperature of 65 – 70oc. Time can
vary from 5 to 25 minutes depending on degree of contamination
Rinse using clean warm water to remove the layer of soluble salts formed
Immerse in a bath of phosphoric/chromic acid, 2% solution at 80oc for approximately one to two
minutes with iron filing (0.5%)
Rinse in clean water, and check for pH values
Compressors
Every 10C raise in temperature the airs capacity to hold water doubles.
Every 1-psi drop in pressure results in an efficiency drop of 11/2%. 80 psi blasting pressure
results in 70% efficiency.
¼" nozzle will need 103 cfm to maintain 100 psi,
½" nozzle will need 413 cfm.
Wheel abrators
Advantages;
When viewed without magnification the surface shall be free from visible oil, grease and dirt and
from poorly adhering mill scale rust, paint coating and foreign matter.
There are no wires brushing grades for Rust Grade A as the mill scale is much harder than the
bristles on the brushes, which are of non sparking alloys such as phosphor bronze and beryllium
bronze.
Surface contamination and test - 3
N3 Watman filter paper is soaked in 5-10% solution of potassium ferricyanide and distilled water
and let dry the colour shall be lime green
The distilled water shall be sprayed the blasted area leave few second allow the water to dissolve
with salt
The test paper is applied on the sprayed area the paper will drew the solution on capillary action
If salt in present the paper colour will be blue spots on the lime green background
Dust on substrate
Piece of self adhesive tape stick on the blasted area and then snatched off, and then place on white
paper the dust and finings are easily visible
Moisture on substrate
Sprinkle chalk powder or talc on the blasted surface and then lightly blow away, powder will stick if
moisture present
Spray the solvent on the suspected area and pressing the wat man paper strips on the sprayed area
Take the paper away the solvent will evaporate and the grease will be shown inDarker appearance
Binder properties
Short oil paints – less than 45% oil to resin, faster drying material, suitable for steelwork. More
brittle with shorter over coating time.
Linseed oil and tung oil used to be referred to as rapid drying oils
Rust inhibitive pigments are added into primers to protect the steel substrate by passivation.
a) Red lead *
b) Calcium plumbate *
c) Coal tar *
d) Zinc chromate *
e) Zinc phosphate
f) Barium metaborate
g) Zinc phosphosilicate
Opaque pigments are inert particles with excellent light scattering properties in order to give
covering power, (opacity) and colour.
1. Carbon Black
2. Compound of Cobalt Blue
3. Compound of Chromium Greens, Yellows and Oranges
4. Compound of Iron Browns, Reds and Yellows
5. Compound of Calcium Reds and Yellows
6. Titanium Dioxide White
Extender pigments
Clays e.g. Kaolin, China clay
Chalk Calcium carbonate
Talcum Magnesium silicate
Slate flour Aluminium silicate
Laminar pigments
Plate like pigments such as MIO (Micaceous Iron Oxide), Aluminium Flake, Glass Flake, Mica and
Graphite, provide excellent barriers
High resistance to water permeability
Glass Flake as a laminar pigment is usually for abrasion resistance,
Aluminium Flake and MIO have good ultra violet A and ultra violet B reflectance properties,
Flash point
In minimum temperature the solvent vapours are flammable if a source of ignition is introduced.”
The higher flash point, the safer the solvent
Anti settling agent
An anti settling agent is an aid to shelf life. It is a thixotrope, a thickener, which also allows a higher
film thickness.
Thixotropic paints are jelly paints, non- drip, and if stirred change to normal liquid consistency.
When left they slowly revert to thixotropic consistency.
bentones and waxes, I.e. stop settlement.
Plasticiser
A plasticiser basically gives paint flexibility, reduces brittleness,
Castor Oil, Coconut Oil and some Palm Oils fall into this category.
Driers
Also known as oxidants, these are heavy metal salts, rich in oxygen, which are added to the paint
during manufacture.
Common salts are, manganese and zirconium e.g. cobalt naphthanate.
Acids producing the salts are Octoic Acid and Naphthanic Acid
Solution
Solvent is a liquid, which will dissolve another material, liquid or solid.
Solute is the material dissolved by the solvent.
Solution is the resulting liquid. Salt and water, sugar and water are solutions; a binder and
Solvent are also a solution.
Dispersions
Suspension
Solid particles are dispersed with in liquid, e.g. pigment and extenders are dispersed within a
liquid,
Emulsion
An emulsion is a liquid dispersed in another liquid, when there is no solubility
Solvent Evaporation
The drying mechanise is solvent evaporation
Non-convertible reversible
The coatings are dry by solvent evaporation only. No chemical changes take place while
drying, after curing the paint would be softened or damaged if it contact with its own solvent
Acrylics, Vinyls, Chlorinated Rubber, Asphalt and
Coal Tars and Cellulosic Resins.
Oxidation
The dry first by solvent evaporation and then by oxidation
Convertible or non-reversible
Convertible or non reversible paints under go chemical changes upon drying. After drying the
paint cannot be softened or damaged if it contact with its own solvent
Natural oil , resins, epoxy, and urethane
Chemical curing
Chemical curing paints need curing agents to get drying
Chemically curing paints are convertible or non – reversible
The second material, the activator, is supplied in a can, hence the term 2 packs or Multi Component
Liquid.
Induction time
The length of time paint has to stand after mixing and before application
An exothermic reaction. Giving off heat, the container will warm up
An endothermic reaction. Taking in heat, the container will cool forming condensation
Pot life
The period of time after mixing in which the paint must be used
Amides – Epoxy curing agents, usually quote seven days to full cross-linking at 20 oC.
Paint system - 7
Primer
Low volume solid materials
Provides excellent adhesion and also provides a key
Passivation layer
Mid-coats
Mainly barrier coats
Primers to prevent further water passing into the film
Mid-coats also build up the film thickness
Finishing coats
Mainly aesthetic
Colour and appearance
Gloss finish the surface must be perfectly smooth, removal of dust and dirt, and natural drainage or
shedding of water
Solar reflective properties
Non-ferrous substrates such as Wash or Mordant primers
Moisture Tolerant Systems
This system is used in above ground gas pipe lines, due to the gas temperature the out side of the
pipe will always damp and wet,
Application
After Surface preparation if excess water in the surface shall be swabbed off and then brush
application of moisture curing polyurethane or high solid epoxy on blasted surface
The more moisture there is presents in the atmosphere, the faster the cure. The criteria with this type
of material is not high RH, 100% is no problem, but low humidity. Some manufacturers state 35% as
minimum RH criteria.
Thermosetting
Thermosetting means the material will cure with the application of heat
Convertible or non-reversible.
Powders are electro statically sprayed onto a preheated substrate, approximately 245oc.
As soon as the powder hits the heated steel, it melts, undergoes a chemical cure and is fully cross-
linked in approximately three minutes.
Thermoplastic
Thermoplastic materials soften with the application of heat,
Are linear polymer and therefore reversible or non-convertible.
Polyethylene and Polypropalene being examples of these materials.
Usually flame sprayed as repair systems on existing thermoplastic coatings
Sacrificial coatings
This classification of materials sacrifices itself to protect the underlying substrate.The sacrificial
component must be less noble (more electronegative) than the substrate.
In this situation the zinc works as a barrier coat initially and undergoes atmospheric corrosion itself
forming corrosion products such as Zinc Sulphates and Zinc Carbonates.
In order to hold the high concentration of zinc particles together, a very strong binder is required.
This is usually an organic epoxy.
High temperature coatings
Inorganic binders such as Ethyl or Methyl Silicates are zinc pigmented but are primarily designed for
high temperature service and need sealers such as aluminium or carbon pigmented silicones.
When weight added will cause the paddle start rotating inside the paint, more weight added the
paddle speed will increasing
Add more weight until the paddle rotate 200Rpm speed note the reading
Viscosity unit is poise or centi -poise
Flow viscometers
Flow cups
Place the finger over the nozzle orifice and fill the paint up to brim, scrap the excess paint in to the
overflow rim by using scale
Start the stopwatch the same time remove finger from the orifice , the paint run continual stream at
first distinctive break or start drip stop the watch and note down the time
Units of viscosity
For dynamic viscosity is, Newton-second per square metre (N.s/m2)
Although on many machines the poise is still used (cgs. unit).
Poise has ten subdivisions called centi-poise.
Water has a viscosity of approximately one centi-poise.
One poise is equal to one dyne second per cm2.
Volatile and non volatile test
Weight the clean watch glass and stir rod add 2 gm of paint re weight, place the watch glass in hot
air oven stir the volatile drive away
Weight the dry paint with watch glass and stir rod, Deduct from the initial weight, a simple
calculation give us volatile and Non volatile Ratio
Flash point (closed able cup)
Place the thermometer, solvent, agitator, Spark electrode in the water bath as shown the figure
Gently heat the water which will turn heat up the solvent,
Every 0.5 Dec rise the temperature activate the high frequency spark
The flash point reached blue flame flashes over the solvent, this temperature is called flash point of
the solvent
Density cup
Weight the clean empty cup and lid cover on sensitivity scale, fill the paint up to brim allow
entrapped air bubbles burst place the lid on the top
Wipe of any Excess paint from the vent and weight
Deduct the weight of the cup from the final weight and divide by 100
Hegman grind gauge or fineness gauge
The Hegman Grind Gauge is a stainless steel block approximately 17.5cm x 6.5cm x 1.4cm and is
highly polished
Two grooves are precision ground tapering from 100 um deep to zero along the total length of the
gauge, 10um increment scale is engraved along the length of the groove
Paint is added to the deepest point of the scale and drawn along to totally fill the groove using a
specially profiled scraper bar. Within three seconds the scale should be placed so that the eye looks
almost parallel along the groove,
To observe a point along the groove where, within a 3mm band, five to ten aggregates break through
the surface of the paint.
Magnetic
Tinsley Pencil or Pull of Gauge
The Magnetic Horseshoe gauge (suitable for hot surfaces)
Banana gauge
Accelerated testing
Humidity cabin, salt spray cabin, water soak test, temperature cycling, Prohesion testing
BK drying recorders,
It gives stage wise drying detail like solvent evaporation, surface drying time, final drying time ,
motor driven needles are fixed on the painted glass panels, when the paint wet the needle penetrate
through the glass after solvent evaporation the needle will cut the paint, after drying the scratch is
not visible based on this we will able to know the correct time was taken each stages
Dolly test
Clean the surface to be checked, rough with medium emery paper, mix the regular araldite and stick
the dolly to the surface for 24 hrs at 25 Deg C Cut araldite around the dolly with the help of special
cutter, attach pull of instrument and apply pull of force to detach the dolly from the surface reading
shall be note The detached surface shall be interpret
Coating condition
Relative Humidity,
The amount of water vapour in the air expressed as a Percentage of the amount of water vapour,
which could be in the air at that same temperature
Dew Point,
This is the temperature at which water vapour in the air will condense
Every 11oc drop in temperature results in the airs capacity to hold water halving
Hygrometer should be rotated quickly about a horizontal axis in front of the operator at a speed of
4m/sec for 30 – 40 seconds as fast as possible and then first read wet bulb and than dry bulb
This operation should be repeated until the readings should be within 0.2oc, the wet bulb and dry
bulb temperatures recorded and then determine the RH and DP from scales
Thermometer, pyrometer
To measure the steel substrate temperature
Paint application -16
Brush application, Roller application, and Spray application
Spray application
Conventional spray.
Suction feed
Paint container is underneath the gun, paint is drawn up by venturi principle to the gun
Gravity feed
The paint container is above the gun and paint feeds to the gun by gravity
Remote pressure pot
Air from a compressor is fed into the top of the pot and the paint is forced out through a line to the
gun when the trigger is operated, the paint exits in a continual stream.
Airless spray.
Conventional Airless
Slow application due to fluid delivery.
Excellent application rates.
Low air pressure 40 – 75 PSI
Can need 100 PSI to operate the pump.
Delivery pressures greater than 6000 PSI,
Delivery pressure greater than 20 PSI dependant on pump ratio.
Airless spray
Airless spray the paint is pressurised by hydraulic pumps OR compressed air pump in
Of two pistons on a common shaft For instance, if an air driven piston has a surface area of 35
Square inches and is exposed to a pressure of 100 psi, a piston at the other end of the shaft with a
surface area of one square inch will exert a pressure of 3500 psi.As the piston is driven down to
pressurise the paint, the one-way valve at the paint inlet is forced to close position and the paint out
port is opened. When the piston reached the bottom of its stroke, the air circuit reverses and forces
the piston back upwards. This happens the outlet port is closed and the inlet port opens to refill the
cylinder with paint. At the top of the stroke the air circuit reverses again and drives the piston down
again.
The outlet pressure can be adjusted by reducing the inlet pressure from the compressor.
These systems are called airless because air is not used for atomization.
Atomization occurs by forcing the paint at extremely high pressure, usually 2000 to 2500 psi through
a very small aperture, 12 to 23 thou diameter, into a volume of air offering a resistance to the paint
flow. As the air and paint meet, the paint atomies.
Most tips used on airless spray equipment have a facility for reversing the flow of paint through the
tip type of airless spray tip exists with an adjustable aperture size, called a Titan Tip.
Pigments and extenders, especially MIO and metallic pigments can be quite abrasive and the tips are
subject to wear
Some are sleeved with tungsten carbide to give a loner life.
Galvanising
The components are acid cleaned washed and fluxed, then totally immersed in a vessel containing
molten zinc at approximately 450oc average thickness of approximately 100 um
Sheradising
After cleaning the components are tumbled in the powdered zinc, impact fuses the zinc onto the
components and in effect, “cold welds” the powder onto the metal.
Calorising
Component is dip it into molten aluminium at a temperature of 625oc or also be done by
immersing a component in a mix of fine sand and aluminium powder and heating.
Electro-plating
Current is released from an item into a metal salt solution through to a cathode, the metal salts ionise
and deposit the metal ions on the cathode bar
Powdered metal is fed into a heat source (usually butane or propane and pure oxygen burning) and
propelled onto the substrate
Anodising;
A treatment for aluminium, anodising is an electrolytic method of coating which results in the
formation of a dense oxide. The component is immersed in a weak acid bath and oxidation is
induced electrically
Painting faults-18
Bittiness
The presence of particles of gel flocculated material
Bleeding
Diffusion of a soluble coloured substance. Discolouration
Blistering
Formation of dome shaped projections
Bloom
Loss of gloss and dulling of colour.
Chalking
Powdery layer on the surface
Cissing
Coating material reduced Leaving holidays in the film.
Cracking
Usually as a result of ageing
Hair cracking
Fine cracks
Checking
Fine Cracks on the finish coat not penetrate top coat
Crocodiling/alligatoring
Producing a pattern resembling the hide of a crocodile
Mud cracking
Network of deep cracks
Cratering
Formation of small bowl shaped depressions
Curtaining/sagging
Coat having a thick lower edge
Run
Narrow downward movement of a coat
Dry spray
Production of a rough or slightly bitty film
Efflorescence
Salt crystal on the substrate shall shown Whitish crystalline formation
Flaking
Lifting of the coating materials
Flocculation
Development of loosely cohesive pigment
Grinning through
Inadequate hiding power of the coating material.
Holidays
Insufficient thickness or complete absence of coating on random areas
Lifting
Swelling or separation from the substrate
Orange peel
Uniform pock marked appearance
Pinholing
Minute holes in the film
Ropiness
Brush marks
Saponification – the formation of soap by the reaction of a fatty acid Easter and an alkali
long term exposure limits are averaged over an eight hour reference period and short term exposures
over ten minute reference periods.
Symbol
Toxic or Very Toxic
Black symbol of skull and crossbones on an orange square with the words Toxic or Very Toxic
printed below
Harmful or Irritant
Black diagonal cross on an orange square with the words Harmful or Irritant printed below.
corrosive
Black symbol showing a tilted test-tube dripping onto a hand with a chunk out, adjacent to a test
tube dripping onto a stone flag. Orange background with the word corrosive printed below.
Dräger tube and Dräger bellows
TABLE SPA1a - Operations chart for use with clauses 13 and 15 for uncoated or unsuitably
Coated surfaces
TABLE SPA1b - Operations chart for use with clauses 14 and 15 surfaces with limited coating
damage
TABLE SPA3a - Operations chart for hot duty surfaces from 100 0 C to 149 0 C
TABLE SPA3b - Operations chart for hot duty surfaces from 150 0 C to 340 0 C
TABLE SPA3c - Operations chart for hot duty surfaces operating above 340 0 C
NOTE – Thermally sprayed aluminium is the preferred system and will provide the longest
service life.
Alternative coating systems to thermally sprayed aluminium are:
4a i) Inorganic zinc Apply in accordance with 25.2.2
silicate manufacturers’ instructions
ii) Apply sealer Apply in accordance with 25.2.4
manufacturers’ instructions.
Not required for polysiloxane
coatings
iii) Apply heat to cure In accordance with 25.2.4
sealer manufacturers’ instructions.
Check plant operating
conditions
4b Polysiloxane Apply in accordance with 25.2.2
inorganic coating manufacturers’ instructions
TABLE SPA4a - Operation chart for painting damp metal surfaces
IS-8501-1 Photographs
Rust grade – A,B,C,D
Blast grade – ASa2.5,ASa3, BSa1, BSa2, BSa2.5,BSa3, CSa1, CSa2, CSa2.5,
CSa3, DSa1,DSa2,DSa2.5,DSa3
Hand and power tool cleaning – BSt2, BSt3, CSt2, CSt3, DSt2
Flame cleaning - Af1, Bf1, Cf1, Df1