SSPC Painting Manual

Volume 1
Good Painting Practice
Fourth Edition
Executive Editor
Dr. Richard W. Drisko
Production Editor
Pamela Groff
Technical Illustrator
Renee Zmuda
SSPC: The Society for Protective Coatings
40 24th Street, 6th Floor
Pittsburgh, PA 15222
The fourth edition of SSPCs Painting Manual Volume 1: Good Painting Practice represents the first
comprehensive update of this key title in many years. More than 30 industry leaders have contributed over 40
chapters that cover every aspect of industrial paintingfrom the fundamentals of surface preparation for steel,
concrete, and other surfaces to the complexities of painting particular facilities and structures. Over 20 new
chapters have been added to address the coating industrys constantly evolving technologies and procedures.
It has been nearly 50 years since the release of the first edition this book. SSPC remains committed to
assisting todays protective coating specialists as they strive for improved performance and economics, while
conforming to government requirements concerning health, safety, and the environment. We thank our authors for
sharing their knowledge with colleagues through this important work and look forward to a future of continued
cooperation in developing quality standards and publications for the protective coatings industry.
William L. Shoup
Executive Director
Society for Protective Coatings
Pittsburgh, PA
Foreword
The information in this book is provided at a
basic level to permit personnel with limited technical
training to address current problems with the best
available materials, equipment, and technologies. The
scope of this book has been broadened to include
information on the coating of concrete and the
management of coating projects. These are areas that
have not received needed attention in the past. The
books intended audience remains contractors,
engineers, specifiers, formulators, suppliers,
technicians, maintenance painters, users, and
manufacturers who are looking for state-of-the-art
technologies to meet specific requirements.
This book is intended to be a companion to
SSPC Painting Manual Volume 2: Systems and
Specifications. Volume 2 can be used effectively to
implement the recommendations of this book and
facilitate the incorporation of SSPC specifications into
procurement documents.
Presentation of Chapters
This book is divided into sections in which
related topics are grouped for the convenience of the
reader.
Section 1. Corrosion
Control of metal corrosion is probably the chief
reason for applying coatings. Thus, it is important that
coatings personnel have a basic understanding of the
impact of corrosion and the systems available for its
control.
Chapter 1.1. Corrosion of Metals describes
the causes and mechanisms of metal corrosion. It also
describes the most commonly found types of industrial
corrosion.
Chapter 1.2. Designing Structures for Good
Painting Performance describes how corrosion on
metal structures can be minimized by avoiding those
features that promote both corrosion and deterioration.
Chapter 1.3. Mechanisms of Corrosion
Control by Coatings describes the basic mechanisms
by which coatings may be used to control metal
corrosion. It also describes the requirements for each
mechanism.
Chapter 1.4. Properties of Coating Generic
Types describes the general chemical and physical
properties of different generic coatings and how these
properties contribute to the total corrosion control
process.
Chapter 1.5. Organic Coatings:
Composition and Film Formation discusses the
components of organic coatings and their functions in
providing the protective film that guards against
corrosion.
Chapter 1.6. Cathodic Protection of Coated
Structures describes the basic mechanisms and
applications of cathodic protection to coated metal
structures. It describes the environments in which
cathodic protection can be effective and emphasizes
the synergistic effects of using cathodic protection in
conjunction with protective coatings in a total corrosion
control program.
Chapter 1.7. Coating Galvanized Steel
describes hot dipping of galvanized steel for industrial
service and surface treatment and coating to provide
additional years of protection to the steel.
Section 2. Surface Preparation
Surface preparation is perhaps the most
critical part of coating operations and typically also the
most expensive.
Chapter 2.1.Overview of Steel Surface
Preparation describes the practical and economic
effects of obtaining the recommended levels of surface
preparation of steel before application of coatings.
Introduction
Chapter 2.2. Hand and Power Tool Cleaning
describes both the oldest processes for preparing
surfaces prior to painting and those power tools
common in cleaning operations.
Chapter 2.3. Nonmetallic Abrasives
describes when and how these abrasives can be used
most effectively.
Chapter 2.4. Metallic Abrasives describes
how to use these abrasives most efficiently (including
recycling) to achieve desired levels of cleanliness and
profile.
Chapter 2.5. Abrasive Air Blast Cleaning
describes recommended techniques to achieve
optimum cleaning rates and levels of cleanliness and
profile.
Chapter 2.6. Centrifugal Blast Cleaning
describes the techniques used and advantages and
disadvantages of this process.
Chapter 2.7. Wet Abrasive Blast and
Pressurized Water Cleaning (Waterjetting)
describes the techniques used and advantages and
disadvantages of this process.
Chapter 2.8. The Effect of Soluble Salts on
Protective Coatings describes different techniques
for removing soluble salts from contaminated surfaces
and analyzing the problems inherent with the presence
of such salts. It also describes possible adverse
effects on coating performance, if removal is
inadequate.
Chapter 2.9. Other Methods of Surface
Preparation describes pickling, chemical stripping,
baking soda blast cleaning, pliant media blasting, dry-
ice blasting, and electrochemical stripping.
Chapter 2.10. Solvent and Pre-Cleaning
describes removing any contaminants that cannot be
removed by subsequent mechanical cleaning and
surface profiling.
Chapter 2.11. Dehumidification During
Coating Operations describes the technology of
dehumidification and temperature control in enclosed
spaces and the importance of such equipment during
surface preparation and coating application and
curing.
Section 3. Surface Preparation of Concrete and
Other Surfaces for Coating
Surface preparation of concrete and other
surfaces requires special techniques as described in
these chapters.
Chapter 3.1. Concrete Surface Preparation
describes recommended methods of preparing
concrete surfaces to achieve the desired levels of
cleanliness and surface profile.
Chapter 3.2. Surface Preparation of
Nonferrous Surfaces describes techniques for
preparing aluminum, copper, and nickel alloys,
stainless steel, and wood and polymer resin-based
composites for coating application and optimum
performance.
Section 4. Coating Materials
An understanding of the basics of coating
materials is essential for their proper utilization.
Section 4 describes the different coatings available for
a variety of purposes.
Chapter 4.1. Coatings for Industrial Steel
Structures presents general information on the use of
coating systems for the protection of steel surfaces.
Chapter 4.2. Coatings for Concrete
describes how coating concrete surfaces differs from
coating steel.
Chapter 4.3. Powder Coatings describes
powder coating materials, application methods,
substrates, and curing techniques.
Chapter 4.4. Thermal-Spray (Metallized)
Coatings for Steel describes how metallizing is used
to protect steel from corrosion. It also describes
sealing and topcoating to provide optimum corrosion
protection.
Section 5. Application Methods and Equipment
Section 5 describes different methods of
coating application and the equipment used in
the shop and field.
Chapter 5.1. Application of Industrial
Coatings describes all coating application methods
and the advantages and limitations of each.
Chapter 5.2. Contractor Equipment: An
Overview describes the types of equipment typically
used for successful industrial maintenance painting.
Chapter 5.3. Shop Painting of Steel
describes different types of industrial and light
industrial/commercial paint shops, their methods of
operation, and their advantages and limitations when
compared to on-site field painting.
Section 6. Coating Specific Structures
Section 6 describes how to prepare surfaces
and apply coatings to specific structures. It also
describes the special problems associated with
coating each of these structures.
Chapter 6.1. Painting Highway Bridges and
Structures describes recommended materials and
methods for coating steel bridges in the field.
Chapter 6.2. Corrosion Protection of Water
and Fuel Tanks provides an overview of the industry
guidance in this area and examples of practical
experience in applying this guidance.
Chapter 6.3. Linings for Vessels and Tanks
describes accepted practices for selecting and
applying protective coatings to the interior surfaces of
steel tanks.
Chapter 6.4. Painting Chemical Plants
describes the recommended methods for coating
equipment and structures located in these harsh
environments.
Chapter 6.5. Painting Waste Water
Treatment Plants describes the coating systems used
for various areas of waste water treatment plants.
Chapter 6.6. Painting Petroleum Refineries
describes the recommended coating methods for
these facilities.
Chapter 6.7. Painting Power Generating
Facilities describes the common methods for
generating electrical power and the best coating
systems for each type of power facility.
Chapter 6.9. Painting Steel Surfaces in Pulp
and Paper Mills provides a framework for establishing
and executing successful maintenance coating
programs in pulp and paper mills with associated
guidelines for ensuring quality coatings work.
Chapter 6.10. Painting Hydraulic Structures
describes the coating materials and methods used to
protect locks, dams, and other components of
hydraulic structures.
Chapter 6.11. Coatings for Buried and
Immersed Metal Pipelines describes the
fundamentals of selection, application, inspection, and
performance of coatings buried in soils or immersed in
water.
Chapter 6.12. Painting Ships describes
problems with ship corrosion and new construction
and maintenance coating systems for various ship
components.
Section 7. Inspection of Coating Operations
Section 7 describes standard industry
inspection methods used in all coating operations to
ensure that job specification requirements are fully
met.
Chapter 7. Inspection describes all commonly
used inspection practices and tools.
Section 8. Safety and Health
Section 8 describes the many health and
safety concerns in the coatings industry and the
actions that should be taken to protect workers and the
environment.
Chapter 8. Safety and Health in the
Protective Coatings Industry addresses OSHA
safety regulations as well as directives from NIOSH
and other organizations.
Section 9. Government Regulation Affecting the
Coatings Industry
Section 9 reviews those government
regulations impacting the coatings industry. A general
knowledge of these regulations is necessary to
conduct coating operations.
Chapter 9.1 Air Quality Regulations
addresses the Clean Air Act, national ambient air
quality standards, and hazardous air pollutants.
Chapter 9.2 Waste Handling and Disposal
covers sources of waste in painting activities and
relevant federal and state regulations.
Chapter 9.3 Other Regulations Affecting
Protective Coatings describes the impact of water
quality standards, CERCLA (Superfund), and lead
abatement programs.
Section 10. Programmed Painting
Section 10 describes various aspects of
designing programmed painting systems to provide for
structural protection at minimal expense.
Chapter 10.1 Total Protective Coatings
Programs describes how to prepare and manage a
total protective coatings program for an industrial or
government activity.
Chapter 10.2. Comparative Painting Costs
presents guidance in cost estimating coating
operations in various regions of the U.S.
Chapter 10.3. Using Plant Surveys to
Maintain Coating Protection of Structures
describes how minimum, mid-level, and detailed field
surveys can be used to resolve various maintenance
painting challenges.
Chapter 10.4. Preparing a Specification for
a Coating Project summarizes the Construction
Specifications Institute (CSI) format for preparing job
specifications.
Chapter 10.5. Maintenance Painting
Programs describes the elements of a maintenance
painting programwhen to start and how to
accomplish the steps.
Sections 11 and 12. Coating Performance and
Failures
Sections 11 and 12 describe quality control
methods for good coating performance and those
coating failures that may occur when quality control is
lacking.
Chapter 11. Quality Control for Protective
Coatings Projects provides an overview of quality
control inspection procedures and roles.
Chapter 12. Coating Failures addresses the
common causes of coating defects on industrial
structures and the associated preventative or
corrective actions.
Dr. Richard W. Drisko
Executive Editor