UK MOD (Issue 3 Publication Date 20 September 2009) - Code of Practice For Protective Finishes

Ministry of Defence
Defence Standard 21-5

Issue 3 Publication Date 20 September 2009
Code of Practice
for
Protective Finishes
Category 3
DEF STAN 21-05 Issue 3
Contents
Foreword ...........................................................................................................................................................v
1 Scope ....................................................................................................................................................1
2 Warning..................................................................................................................................................1
3 Normative References .........................................................................................................................1
4 Health and Safety.................................................................................................................................1
4.1 Paint Remover.................................................................................................................................1
4.2 Cadmium..........................................................................................................................................2
4.3 Soluble Chromates .........................................................................................................................2
5 Corrosion ..............................................................................................................................................2
5.1 Types of Corrosion .........................................................................................................................2
5.2 Electrochemical Corrosion ............................................................................................................2
6 Surface Finishes ..................................................................................................................................3
6.1 General.............................................................................................................................................3
6.2 Decorative and Tactile Finishes ....................................................................................................3
6.3 Protective Finishes .........................................................................................................................3
6.4 Non – metallic Materials.................................................................................................................4
7 Guide to the Treatment of Non-corrosive Resisting (NCR) Steel ...................................................4
8 Guide to the Protective Treatment of Copper and Copper Alloys ...............................................14
8.1 General...........................................................................................................................................14
9 Guide to the Protective Treatment of Aluminium and Aluminium Alloys .....................................18
9.1 General...........................................................................................................................................18
10 Guide to the use of Paints and Powder Coatings..........................................................................23
10.1 Paint Policy....................................................................................................................................23
10.2 Paint Selection ..............................................................................................................................24
10.3 Required Paint Colours ...................................................................................................................25
11 Design Requirements/Guidance ......................................................................................................30
11.1 Design Factors................................................................................................................................30
11.2 Galvanic Hazards ..........................................................................................................................30
11.3 Design Considerations...................................................................................................................31
11.4 Hazards of Corrosion Due to Vapour.............................................................................................31
12 Pre-Treatment of Basic Metals..........................................................................................................31
12.1 General............................................................................................................................................31
12.2 Degreasing Hazard .........................................................................................................................32
12.3 Abrasive Cleaning ..........................................................................................................................32
12.4 Castings.........................................................................................................................................32
12.5 Waveguides ....................................................................................................................................32
ii
12.6 Hydraulic Systems..........................................................................................................................32

12.7 Metallic Substrates .........................................................................................................................32
13 Surfaces to be Painted.......................................................................................................................33
13.1 General............................................................................................................................................33
13.2 Inaccessible Steel Surfaces ...........................................................................................................33
13.3 Antennas.........................................................................................................................................33
13.4 GRP Mouldings and Fabrications ..................................................................................................33
13.5 Radomes.........................................................................................................................................34
13.6 Hydraulic Pipework ........................................................................................................................34
14 Paint Application ................................................................................................................................34
15 Paint Removers ..................................................................................................................................35
15.1 General ...........................................................................................................................................35
16 Process Drawings .............................................................................................................................35
16.1 General...........................................................................................................................................35
Annex A Normative References ....................................................................................................................36
Annex B Abbreviations, Definitions and Symbols......................................................................................38
Tables
Table 1 - 1a — Aluminium Sprayed or Cadmium Plated NCR Steel ............................................................5

Table 1 - 1b -Aluminium Sprayed or Cadmium Plated NCR Steel ...............................................................6
Table 1 - 2a - Chromium Plated, Lead Sprayed or Nickel Plated NCR Steel ..............................................7
Table 1 - 2b - Chromium Plated, Lead Sprayed or Nickel Plated NCR Steel ..............................................7
Table 1 - 3a - Phosphating NCR Steel ............................................................................................................8
Table 1 - 3b - Phosphating NCR Steel ............................................................................................................8
Table 1 - 4a - Silver Electroplated or Tin Plated NCR Steel..........................................................................9
Table 1 - 4b - Silver Electroplated or Tin plated NCR Steel..........................................................................9
Table 1 - 5a - Zinc Galvanised NCR Steel.....................................................................................................10
Table 1 - 5b -Zinc Galvanised NCR Steel .....................................................................................................10
Table 1 - 6a - Zinc Plated NCR Steel .............................................................................................................11
Table 1 - 6b -Zinc Plated NCR Steel ..............................................................................................................12
Table 1 - 7a - Zinc Sherardized or Zinc Sprayed NCR Steel.......................................................................13
Table 1 - 7b - Zinc Sherardized or Sprayed NCR Steel ...............................................................................13
Table 2 - 1a - Cadmium Plated or Chromium Plated Copper and Copper Alloys ....................................14
Table 2 - 1b - Cadmium Plated or Chromium Plated Copper and Copper Alloys ....................................15
Table 2 - 2a - Gold Plated or Rhodium Plated Copper and Copper Alloys ...............................................16
Table 2 - 2b - Gold Plated or Rhodium Plated Copper and Copper Alloys...............................................16
Table 2 - 3a - Silver Electroplated or Tin Plated Copper and Copper Alloys ...........................................16
Table 2 - 3b - Silver Electroplated or Tin Plated Copper and Copper Alloys ...........................................17
Table 2 - 4a - Tin/Lead Plated Copper and Copper Alloys .........................................................................17
Table 2 - 4b - Tin/Lead Plated Copper and Copper Alloys .........................................................................18
iii
Table 3 - 1a - Anodised Aluminium and Aluminium Alloys........................................................................19
Table 3 - 1b - Anodised Aluminium and Aluminium Alloys........................................................................20
Table 3 - 2a - Chromate Conversion Coatings on Aluminium and Aluminium Alloys ............................21
Table 3 - 2b - Chromate Conversion Coatings on Aluminium and Aluminium Alloys ............................22
Table 3 - 3a - Silver Electroplated Aluminium and Aluminium Alloys ......................................................22
Table 3 - 3b - Silver Electroplated Aluminium and Aluminium Alloys ......................................................23
Table 4 - 1a - Special Colours for Equipment, Gun Mountings and GW Launch Systems .....................25
Table 4 - 1b - Paint Sheen Requirements .....................................................................................................26
Table 4 - 2 - Air-Drying External Paints (201/202 Systems)........................................................................27
Table 4 - 3 - Air-Drying Internal Paints - (202 Systems)..............................................................................28
Table 4 - 4 - Air-Drying Internal Paint Systems (203, 204 and 205 Series)................................................29
Table 4 - 5 - Air-Drying GRP Paint Systems (206 Series) ...........................................................................29
iv
Foreword
AMENDMENT RECORD
Amd No. Date Text Affected Signature and Date
REVISION NOTE
This standard is raised to Issue 3 to update its content.
HISTORICAL RECORD
This standard supersedes the following:
Def Stan 21-05 Issue 2 dated 3 Dec 2004
Def Stan 21-05 Issue 1 dated 1 April 2000
NES 1005 Issue 2 dated 2 July 1993
Sponsorship
1. This Defence Standard (Def Stan) is sponsored by the DES SESea-MT Group, Ministry of Defence
(MOD).
2. The complete Def Stan Issue comprises;
Procedures for Code of Practice for Protective Finishes
3. If it is found to be unsuitable for any particular requirement the MOD is to be informed in writing of the
circumstances.
4. Any user of this Defence Standard either within MOD or in industry may propose an amendment to it.
Proposals for amendments that are not directly applicable to a particular contract are to be made to the
publishing authority DStan, and those directly applicable to a particular contract are to be dealt with using
contract procedures.
5. No alteration is to be made to this Defence Standard except by the issue of an authorised amendment.
6. Unless otherwise stated, reference in this Defence Standard to approval, approved, authorised or similar
terms, means the Ministry of Defence in writing.
7. Any significant amendments that may be made to this Defence Standard at a later date will be indicated
by a vertical sideline. Deletions will be indicated by 000 appearing at the end of the line interval.
8. Extracts from British Standards within this Defence Standard have been included with the permission of
the British Standards Institution.
v
Conditions of Release
General
9. This Defence Standard has been devised solely for the use of the MOD, and its contractors in the
execution of contracts for the MOD. To the extent permitted by law, the Crown hereby excludes all liability
whatsoever and howsoever arising (including but without limitation, liability resulting from negligence) for any
loss or damage however caused when the Defence Standard is used for any other purpose.
10. This document is Crown Copyright and the information herein may be subject to Crown or third-party
rights. It is not to be released, reproduced or published without written permission of the MOD.
11. The Crown reserves the right to amend or modify the contents of this Defence Standard without
consulting or informing any holder.
MOD Tender or Contract Process
12. This Defence Standard is the property of the Crown. Unless otherwise authorised in writing by the MOD,
it must be returned on completion of the contract or submission of the tender in connection with which it is
issued.
13. When this Defence Standard is used in connection with a MOD tender or contract, the user is to ensure
that he is in possession of the appropriate version of each document, including related documents, relevant
to each particular tender or contract. Enquiries in this connection may be made of the Authority named in the
tender or contract.
14. When Defence Standards are incorporated into contracts, users are responsible for their correct
application and for complying with contractual and other statutory requirements. Compliance with a Defence
Standard does not of itself confer immunity from legal obligations.
Categories of Maritime Defence Standard
15. The Category of this Maritime Defence Standard has been determined using the following criteria:
a) Category 1. If not applied, may have a Critical effect on the following:
⎯ Safety of the vessel, its complement or third parties.
⎯ Operational performance of the vessel, its systems or equipment.
b) Category 2. If not applied, may have a Significant effect on the following:
⎯ Safety of the vessel, its complement or third parties.
⎯ Operational performance of the vessel, its systems or equipment.
⎯ Through-life costs and support.
c) Category 3. If not applied, may have a Minor effect on the following:
⎯ MOD best practice and fleet commonality.
⎯ Corporate experience and knowledge.
⎯ Current support practice.
vi
Related Documents
16. In the tender and acquisition processes the related documents in each Section (and Annex A) can be
obtained as follows:
a) British Standards British Standards Institution,
389 Chiswick High Road,
London,
W4 4AL
b) Defence Standards Defence Equipment and Support
UK Defence Standardization,
Kentigern House
65 Brown Street,
Glasgow,
G2 8EX
c) Other documents Tender or Contract Sponsor to advise.
17. All applications to Ministry Establishments for related documents are to quote the relevant MOD
Invitation to Tender or Contract Number and date, together with the sponsoring Directorate and the Tender
or Contract Sponsor.
18. Prime Contractors are responsible for supplying their sub-contractors with relevant documentation,
including specifications, standards and drawings.
Health and Safety
Warning
19. This Defence Standard may call for the use of processes, substances and procedures that may be
injurious to health if adequate precautions are not taken. It refers only to technical suitability and in no way
absolves either the supplier or any user from statutory obligations relating to health and safety at any stage
of manufacture or use. Where attention is drawn to hazards, the list of those quoted may not necessarily be
exhaustive.
20. This Defence Standard has been written and is to be used taking into account the policy stipulated in
JSP430: MOD Ship Safety Management System Handbook.
Process Drawings
21. Process and procedure details which are to be adopted in order to provide corrosion protection are
contained in drawings related to and supporting this standard.
22. Proposals to use any finish other than those indicated by this standard are to be submitted to the
relevant Project Manager for prior approval and possible inclusion in this standard.
vii
This Page is Intentionally Blank
Standards for Defence -

Code of Practice for Protective Finishes
1 Scope
a) This standard outlines the principal types of Naval Equipment and recommends procedures and
processes to be used to provide adequate protection against corrosion. Design features, which assist in
preventing the formation of corrosion, are highlighted and suitable protective finishes are indicated for
the majority of the metals in common use.
b) Guidance on Hull Preservation Processes is given in BR3939, as amended by the current issue of
"Warpaint" publication, to which this standard will refer for current painting systems.
2 Warning
The Ministry of Defence (MOD), like its contractors, is subject to both United Kingdom and European laws
regarding Health and Safety at Work. Many Defence Standards set out processes and procedures that could
be injurious to health if adequate precautions are not taken. Adherence to those processes and procedures
in no way absolves users from complying with legal requirements relating to Health and Safety at Work.
3 Normative References
3.1 The publications shown in Annex A are referred to in the text of this standard. Publications are
grouped and listed in alpha-numeric order.
3.2 Reference in this Standard to any normative references means in any Invitation to Tender or contract
the edition and all amendments current at the date of such tender or contract unless a specific edition is
indicated. For some standards the most recent editions shall always apply due to safety and regulatory
requirements. Examples of these are Flight Order AvP 67 and Statutory Instruments (SI’s).
3.3 In consideration of clause 3.2 above, users shall be fully aware of the issue, amendment status and
application of all normative references, particularly when forming part of an Invitation to Tender or contract.
Responsibility for the correct application of standards rests with users.
3.4 DStan can advise regarding where to obtain normative referenced documents. Requests for such
information can be made to the DStan Helpdesk. Details of how to contact the helpdesk are shown on the
outside rear cover of Defence Standards.
4 Health and Safety

Particular attention is drawn to the following hazards(s) although the list may not be exhaustive.
4.1 Paint Remover

a) The inhaled vapours of trichloroethylene and dichloromethane are toxic and appropriate precautions are
to be taken during use. Containers must carry an additional warning that the contents are toxic and also
a reference to avoidance of contact with eyes and skin. Users are not to cover large areas of painted
surface with paint remover in one application when the remover is used in a confined space.
b) 1,1,1,- trichloroethane (also called methyl chloroform, and available under trade names Genklene,
Inhibisol, Chlorothene and others) can present hazards to health. In accordance with the Montreal
Protocol and EC Regulation 3952/92 its use was phased out in January 1996.
1
c) A range of water-based paint removers is now available for most tasks, and these products are to be
employed whenever practicable. Product details are given in the current issue of "Warpaint".
4.2 Cadmium
a) Cadmium and its corrosion products are a potential health hazard to personnel and contribute to toxic
pollution. It is only to be used where there is no acceptable alternative and only then when the written
permission of the MOD Project Manager has been obtained in advance.
b) A report detailing alternatives to cadmium is available from SESea-MT. Cadmium is also particularly
susceptible to organic vapour corrosion; see BS 7195 for further information.
4.3 Soluble Chromates
Use of soluble chromate pigments in paint is hazardous to health. The predecessor to this standard
(NES1005) contained various references to paints containing these substances, but suitable alternatives have
now been approved for MOD use and are listed in the current issue of "Warpaint". Consequently, the use of
paints containing soluble chromate is prohibited.
General guidance on precautions to be taken when handling products and their suitability for particular
applications is to be sought from:
a) Institute of Naval Medicine, Alverstoke for RN and MOD(N) or
b) Safety Services Organisation, St Mary Cray, Nr Orpington, Kent for MOD (DES)
5 Corrosion
All materials, by varying degrees, are vulnerable to the corrosive effects of their containing environment. This
environment may be natural in origin (e.g. water or air) or manufactured (e.g. funnel and flue gases).
5.1 Types of Corrosion

There are various types of corrosion, typical examples being:
a) Electro-chemical (Galvanic) corrosion.
b) Selective phase corrosion where only one of the constituent metals of an alloy is affected, e.g. de-
zincification, de-aluminification, etc.;
c) Stress corrosion;
d) Impingement corrosion;
e) Cavitation corrosion;
f) Crevice corrosion;
g) Chemical corrosion (e.g. exposure to organic vapours).

In the case of metals, the presence of an electrolyte (e.g. seawater, salt-laden air, etc.) will greatly
increase both the rate and the amount of the corrosion. Materials such as castings are further prone to
corrosion owing to the porous or retentive nature of their surfaces. For more detailed information on
corrosion, reference is to be made to BR 2203 Part 2, and Def Stan 03-30.
5.2 Electrochemical Corrosion
a) In a marine environment, the most destructive type of corrosion encountered by equipment or

structure is the electro-chemical (Galvanic) type. This is caused by the flow of a current between two
materials- usually metallic and dissimilar- with subsequent transfer of ions from one to the other.
b) For MOD design work the electro-potential Datum Reference used is the electrical charge produced
by immersing a Standard Calomel Half Cell in Standard Sea Water.
2
c) Materials can be compared electro-potentially using this datum reference. The greater the potential
difference between two materials, the greater is the electro-motive force driving the current and, usually,
the greater the corrosion in the cathodic material which degrades at the expense of the anodic or less
noble material.
d) Data Sheets in BR3008 give values of electrode potentials of most metal and alloys in common usage
within MOD. These potentials, whilst giving a useful guide to the selection of materials, are to be used
with care as other factors can play a large part in causing or increasing corrosion.
e) This standard deals mainly with protection against electro-chemical corrosion.
6 Surface Finishes
6.1 General
a) A surface finish provides an attribute, which is not otherwise inherent in the basis material. It may be
metallic, a paint system or a combination of both. It must be compatible with the basis material,
preferably being cathodic to it, and must not of itself cause any degradation.
b) For good adhesion, pre-treatment of the basis material is usually necessary, e.g. fettling, grit blasting,
sealing, etc. and this pre-treatment is to be considered with any high finish required by the design.
c) The function of a surface finish may be any or all of the following:
1) Decorative;
2) Tactical (e.g. for camouflage);
3) Protective.
6.2 Decorative and Tactile Finishes
a) Requirements for these finishes depend largely on:
1) The position of the item within a vessel, e.g. whether sited visibly above the water line or in offices
where reflective surface are prohibited;
2) The function of the item, e.g. whether a warning label or a protective radome.
b) These finishes must not impair the correct operation of an item or equipment (e.g. incorrect use of lead-
based paint; thickness of a paint finish in respect of the wavelength of transmitted energy) nor enhance
the corrosive effects of the environment.
c) Colour requirements for equipment are listed in Table 4.1 a. Paint sheen requirements are listed in Table
4.1b.
6.3 Protective Finishes
a) A protective finish may be either exclusive or sacrificial. Exclusive finishes are those which provide
overall protection to an item. They are effective only whilst no break occurs in the finish. Should a break
occur, the intrusion of a hostile environment or an electrolyte would attack the base material underneath
its protective coating and, being starved of oxygen, will cause enhanced corrosion.
3
b) Sacrificial coatings, e.g. zinc, aluminium, etc., are preferred for Naval equipment as slight mechanical
damage will not seriously affect their anti-corrosion properties. Cadmium will also give good protection;
however its use should only be considered if there is no other alternative. It must not be used without the
specific prior written permission of the MOD Project Manager.
c) The quality of any protective finish is always to be related to the expected functional life of an item in its
given environment. Over-protection increases cost and is to be avoided where possible.
d) Approved protective finishes for the metals commonly used within MOD (Navy) are summarised in the
current issue of "Warpaint" publication.
e) For equipment fitted on Weatherdecks, and in or near corrosive atmospheres, e.g. funnel uptakes or
battery compartments, an alternative finish of nylon or suitable plastic coating is to be considered.
Attention is drawn with respect to recommended maximum temperature limits when considering these
materials. Any proposals for using these types of finish are to be discussed with the equipment sponsor.
6.4 Non-metallic Materials
Insulating materials and painted wiring boards often need no additional protective finish. However, if the
materials used are hygroscopic, cut edges and other moisture absorbing places will need sealing. The choice
of insulating material and any sealant used will depend not only on the required electrical characteristics
but also on the finish applied to the components and other metal items attached. Zinc and cadmium are
especially vulnerable to corrosion vapours. In well-ventilated enclosures, sealing is to be effected using a
varnish conforming to BS EN 60464 Part 3. In poorly ventilated enclosures, sealing is to be effected using a
synthetic resin coating. In all cases the coating is to be hard dry before any handling.
7 Guide to the Treatment of Non-corrosive Resisting (NCR) Steel

a) The tables contained in this section provide a guide to the degree of protection against corrosion which
is afforded to NCR steel by various treatments.
b) Each table is divided into two parts with "a" presenting, alphabetically, a broad picture of complete
treatments and "b" a summarised description of the metallic finishes quoted, in numerical order.
c) Where additional paint finishes are required, these are detailed in Tables 4-2, 4-3 and 4-4.
d) A greater degree of protection can generally be obtained by selecting a system intended for a worse
environment than expected to be encountered by the equipment.
e) Sprayed aluminium is normally more protective than zinc, but zinc may be better in enclosed industrial
environments.
f) Passivation processes are to be omitted when using epoxy-resin based paints or powder coatings or
where soldering or electrical conductivity is required.
4
Table 1 - 1a — Aluminium Sprayed or Cadmium Plated NCR Steel

Environment and Process Code Number
Protective Standard of
Treatment Exposed Exposed Protection
Protected Controlled
(Funnel Gas) (Weather)
Aluminium Sprayed 1-1 plus 202-7 1-1 plus any one 1-1 plus any one Very good
from from
201-4 202-3
202-3 202-4
202-7 202-7
202-10 (for S/M 202-8
only) 203-2
1-2 1-1 Good to Very Good

1-3
Cadmium Plated 4-2 plus any one 4-2 plus any one Good to Very Good
and Passivated (see from from
notes on Table 1-1b) 201-3 202-1
202-1 202-2
202-5 202-5
202-9 (for S/M only) 202-6
203-1
204-1
205-1
4-2 plus 202-5 4-1 Fair to Good

4-3 (for fasteners)
4-2 Poor to Fair
5
Table 1 - 1b -Aluminium Sprayed or Cadmium Plated NCR Steel
Process Key to symbols: EC — Electrical Conductivity; S — Solderability; AR — Abrasion
Drawing Thickness Resistance; VG — Very Good; G — Good; F — Fair; P — Poor
Type of Finish
Def Stan (µm)
EC S AR Guidance Notes
21 -005
1-1 Aluminium, Sprayed to: 100 (Nominal) P P Suitable finish for frameworks, chassis, large structures,
BS EN ISO 2063(Al 4) or where close conformity to dimensions is not important.
1-2 Aluminium, Sprayed to: 175 (Nominal) Ideal key for paint. For explosive store it is permitted as
BS EN ISO 2063 (Al 7) an undercoat for an external paint scheme.
1-3 Aluminium, Sprayed to: 250 (nominal) Account must be taken of liability to distortion of thin
BS EN ISO 2063( (Al 10) sheets or damage to delicate parts by the grit blast pre -
treatment.
For surfaces, which are to be painted, use 1-1.
For surfaces, which are not to be painted, use 1-2.
or exposure to elevated temperatures, use 1-3.
4-1 Cadmium Plated and 14 (Average) F-G F P Gives good protection in exposed maritime situations and
Passivated to Def Stan 10 (Local) in tropical conditions of high humidity.
03-19 and BS 6338
4-2 Cadmium, Plated and 1 0 (Average) F-G F P Gives fair to good protection in situations protected from
Passivated to: BS EN 7,5 (Local) the weather. A suitable finish for ISO metric screw
12330Cd3 and BS threads above 20mm (nominal) diameter and unified
6338 screw threads above %" (nominal) diameter.
4-3 Cadmium, Plated and Varies F-G F P Optimum protection for threaded fastenings. Finish
Passivated to according to designed to avoid undue interference fits, yet afford
Def Stan 03-19 diameter of adequate protection to steel screw threads up to and
screw thread including %" (nominal) diameter. For screw thread
diameters above these ranges, use 4-2 above.
NOTE 1 Cadmium plating, due to the toxic nature of both cadmium and the salts formed by oxidation, is only to be used when
alternative finishes, such as zinc plating, are unacceptable, and then only with the prior written permission of the MOD Project
Manager.
NOTE 2 Cadmium plating is NOT to be used:
a) For items likely to come into contact with foodstuffs or drink.
b) Where its presence may contaminate oils used for lubrication, preservation, hydraulic systems, etc. Advice on this
matter may be obtained from the Defence Fuels Group, Westmoors (Advice may not be free.)
Where corrosion may arise as a result of exposure of the plated surface to vapour from certain organic materials. BS 7195.
NOTE 3 Cadmium plating may cause embrittlement of the part when used in temperatures exceeding 250°C.
NOTE 4 Passivation is to be omitted in the following circumstances:
a) When followed by epoxy resin paint coat.
b) Where soldering or electrical conductivity is required.
NOTE 5 Welding of plated surfaces is undesirable because of:
a) Liability to corrosion of basis metal beneath area of plating damaged by welding process.
b) Emission of toxic fumes from heated cadmium.

c) Impairment of welded joints, due to formation of oxides during welding process.
6
Table 1 - 2a - Chromium Plated, Lead Sprayed or Nickel Plated NCR Steel

Exposed Exposed
Treatment Protected Controlled Protection
Chromium Plated 7-1 Fair to Good
7-3 Fair
7-2 Poor to Fair
Clean (Bright 8-2 plus any one 8-2 plus 203-1 Poor to Fair
Uncoated) from 201-2 201-3
203-1
Lead, Sprayed 11-1 plus 201-5 11-1 Good to Very Good
11-1 11-1 Fair to Good
Nickel, Plated 12-1 Fair to Good
Table 1 - 2b - Chromium Plated, Lead Sprayed or Nickel Plated NCR Steel

To invoke any Metal Finish, quote relevant Process Drawing Number
Drawing Thickness Resistance; VG — Very Good; G— Good; F— Fair; P— Poor
Type of Finish
Def Stan (µrn)
21 -005
7-1 Chromium, Plated For decorative purposes. Not normally painted; standard
(Dull) to: BS EN 0.3 (Local) F VG processes applied where so required. Requires undercoating
12540 of nickel (40µm). See Note.
7-2 Chromium, Plated
(Satin) to: BS EN
12540
7-3 Chromium, Plated Applied to moving parts for protection against wear, or the
(Wear Resistant) building up to worn parts, 15µ chromium will give satisfactory
to: Def Stan 03- 15 (Local) F VG performance under mild sliding conditions of wear, but more
14/3 severe conditions, e.g. under heavy loading or in the
presence of abrasives, may necessitate a thickness of 250µ.
7-4 Chromium, plated Used when both corrosion and wear resistance are required.
(Wear and Requires undercoating (60µ) of copper or copper and nickel.
Corrosion See Note. Corrosion resistance of chromium plated parts can
resistant) to: Def 15 (Local) F VG be influenced greatly by the surface finish of the base metal.
Stan 03-14/3 Protection is by exclusion and increases with thickness.
When appreciable rust has started, galvanic effects
accelerate it.
8-2 Clean. (Bright, Used where, due to location or size, it is impossible to apply
Uncoated) and BS a metallic or phosphate treatment. Must be painted in
6338 addition. Use only on protected equipment and ship's
F P weatherwork, e.g. gun mountings, launchers, fire control.
Plates and sections above 5mm thick to meet requirements
of BS EN ISO 8504. Below 5mm, they are to be pickled and
not abrasive blasted.
11-1 Lead, Sprayed Restricted to surfaces requiring a sulphuric acid resisting
500-750 P F P finish. Adhesion poor for coating thicker than 500-750µm.
Surface breaks may accelerate corrosion.
12-1 Nickel, Plated Use to be limited to essential application owing to:
a) difficulty in supply position;
(Dull) to BS EN 30 (Local) F P G b) any break in the continuity of the plating may result in
12540
accelerated corrosion. Not suitable for soldering. See Note.
NOTE Nickel plating is to be avoided where possible. When it is a requirement, the maximum deposit of copper plate
permitted in accordance with BS EN 12540 is to be specified in order to reduce the required thickness of the nickel plating.
7
Table 1 - 3a - Phosphating NCR Steel
Exposed Exposed
Phosphating 13-2 plus any one 13-2 plus any one Fair to Good
from from
201-5 202-4
202-3 202-7
202-7 202-8
202-10 (for S/MS 203-2
only)
13-3 13-4 Fair
13-1 13-1 Poor to Fair
13-2 plus 202-7 Poor
NOTE 1 Phosphate treatment is cheap.
NOTE 2 It can be used on a wide variety of parts, large and small e.g. springs, holding down bolts, moving parts, etc.
Table 1 - 3b - Phosphating NCR Steel

Drawing Coating Resistance; VG — Very Good; G— Good; F— Fair; P— Poor
Type of Finish
Def Stan Weight
21-005 EC S AR Guidance Notes
2
13-1 Phosphating (Class I) 7.5 gm⎯ Heavy or deep phosphating. Used for fabricated gear-boxes,
to Def Stan 03-11 (minimum) bearing or sliding surfaces in conjunction with oil or grease.
Not applicable to ferrous surfaces in contact with steam
turbine lubricating oil.
2
13-2 Phosphating (Class II) 4.5 gm⎯ General purpose finish under paints. For use on external
to Def Stan 03-11 (minimum) surface of steel pipes in Hydraulic systems.
2
13-3 Phosphating (Class III) 1.5-4.5 gm⎯ For light gauge sections, followed by paint, varnish or coatings
to Def Stan 03-11 of high protective value.
2
13-4 Phosphating (Class IV) 0.2-1. 5gm⎯ For thin sections, fabricated or formed after application of
to Def Stan 03-11 paint, varnish or lacquer.
NOTE 1 Phosphate treatment is cheap.
NOTE 2 It can be used on a wide variety of parts, large and small e.g. springs, holding down bolts, moving parts, etc.
8
Table 1 - 4a - Silver Electroplated or Tin Plated NCR Steel

Treatment Exposed (Funnel Protection
Exposed (Weather) Protected Controlled
Gas)
Silver, Electroplated Good to Very

15-3 15-3
Good
15-1 15-1 Fair
15-2 Poor to Fair
15-2 Poor
Tin, Electro-plated 16-3 Poor to Fair
Tin, Hot Dipped 16-4 Poor to Fair
Table 1 - 4b - Silver Electroplated or Tin plated NCR Steel
Key to symbols: EC — Electrical Conductivity; S — Solderability; AR — Abrasion

Process
Thickness Resistance; VG — Very Good; G— Good; F— Fair; P— Poor
Drawing Def Type of Finish
(µm)
Stan 21-005
15-1 Silver, 5 (Local) VG VG P For radio and other electrical purposes where solderability
Electroplated to is a requirement. Requires an undercoating of nickel
BS EN ISO 4521 (10µm) or copper (8µm) and nickel (8µm). See Note.
15-2 Silver, 8-40 VG VG P For use where good electrical contact is required. Requires
Electroplated to (Average) an undercoating of nickel (10µm) or copper (8µm) and
BS EN ISO 4521 nickel (8µm). See Note.
15-3 Silver, 10 (Local) VG VG P For use where good surface conductivity is required.
Electroplated to Requires an undercoating of nickel (10µm) or copper (8µm)
BS EN ISO 4521 and nickel (8µm). See Note.
16-1 Tin, Electroplated 5 (Local) F VG P Use to facilitate soldering, solder tags, etc. Use on
to BS 1872 fabricated articles. May be used to reduce potential of steel-
copper junction. For use on threads below 6,25mm diameter
(nominal). Requires an undercoating of nickel (10µm) or
copper (8µm) and nickel (8µm). See Note.
16-2 Tin, Electroplated 20 (Local) F VG P Suitable for corrosion protection.

to BS 1872
16-3 Tin, Electroplated 30 (Local) F VG P Suitable for corrosion protection and abrasion
to BS 1872 resistance.
16-4 Tin, Hot Dipped 12,5 (Local) F VG P Used to facilitate soldering, solder tags, etc.
NOTE 1 Nickel plating is to be avoided where possible.
NOTE 2 When it is a requirement, the maximum deposit of copper plate permitted in accordance with BS EN 12540 should be
specified in order to reduce the required thickness of the nickel plating.
9
Table 1 - 5a - Zinc Galvanised NCR Steel
Standard of
Protective Treatment Exposed Exposed
Protected Controlled Protection
Zinc, Paint, Priming (Cold Galvanised) 19-1 plus any Good
Refer to Warpaint Section – Specialist one from
Coatings and Paint removers 202-3
202-4
202-7
202-8
203-2
19-1 plus any Fair to Good
one from
201-5
202-3
202-7
202-10 (for
S/MS only)
Zinc, Hot Dipped, (Galvanised) 19-2 plus 19-2 plus Good to Very Good
anyone from anyone from
201-3 202-1
202-1 202-2
202-5 202-5
202-9 (for 202-6
S/MS only) 203-1
204-1
19-2 19-2 19-2 Fair to Good
Table 1 - 5b -Zinc Galvanised NCR Steel

Key to symbols: EC — Electrical Conductivity; S — Solderability; AR —
Process
Abrasion Resistance; VG — Very Good; G— Good; F— Fair; P— Poor
Drawing Coating
Def Stan Type of Finish
Weight
Zinc, Paint, For use as a primer and for application to mating

Priming (Cold, surfaces that are to be subsequently spot-welded
Galvanised) Refer or riveted and which cannot receive
to Warpaint 2 subsequent protective treatment. May be used
19-1 Section – 120-1 50gm⎯ P P P to touch up damaged zinc coatings or zinc
Specialist sprayed surfaces or as a primer for antennas.
Coatings and
Paint Removers
Zinc, Hot Dipped For use on parts that can withstand the heat
(Galvanised) to involved (450°C) in the process. Provision for
BS EN ISO 1461 305-6 10gm⎯ .
2 venting and draining is essential for fabrication
Varies with assemblies. Galvanised surfaces are not to be
type and welded. Where welding is unavoidable, the
19-2 thickness of F P-F P coating is to be removed in the vicinity of the joint,
the item e.g. by grinding, and the subsequent welded joint
concerned coated with zinc paint. Refer to Warpaint Section –
Specialist Coatings and Paint Removers.
10
Table 1 - 6a - Zinc Plated NCR Steel

Treatment Exposed Exposed Protection
Protected Controlled
Zinc, Plated & 19-5 plus any one Good

Passivated from
201-3
202-1
202-5
202-9
(for S/MS only)
19-4 19-3 plus any one Fair to Good

from
19-6 (both for
202-1
fasteners) 202-2
202-5
202-6
203-1
204-1
205-1
19-3 Fair
19-5
19-4
19-6
(both for fasteners)
19-3 plus 202-5 19-3 19-3 Poor to Fair
19-4
19-6
(both for fasteners)
11
Table 1 - 6b -Zinc Plated NCR Steel

Process Resistance; VG — Very Good; G— Good; F— Fair; P— Poor
Thickness
Drawing Def Type of Finish
Stan 21-005 (µm)
19-3 Zinc, Plated 14 (Average) F P-F P Gives Fair to Good measure of protection in situations
and protected from the weather.
10 (Local)
Passivated to:
Def Stan 03-
20 and BS
6338
19-4 Zinc, Plated 12,5 (Average) F P-F P Gives Fair to Good measure of protection in situations
and Passivated protected from the weather. A suitable finish for ISO
5 (Local) metric screw threads above 20mm (nominal) diameter
to: BS EN
12329 Fe/Zn5 and unified threads above 3/4" (nominal) diameter.
and BS 6338
19-5 Zinc, Plated 40 (Average) F P-F P Gives good protection in exposed marine situations and
and Passivated tropical conditions of high humidity.
25 (Local)
to: BS EN
12329 Fe/Zn5
and BS 6338
19-6 Zinc, Plated and Varies F P-F P Optimum protection for threaded fastenings. Finish
Passivated to Def according to designed to avoid undue interference fits, yet
Stan 03-20 diameter of afford adequate protection to steel screw threads.
screw thread Suitable for ISO metric threads up to and including
20mm (nominal) diameter and unified threads up to
and including 3/4" (nominal) diameter. For screw
thread diameters above these ranges, use 19-4
above.
NOTE 1 Zinc plating is the preferred finish wherever possible for all steel fasteners exposed to the weather.
NOTE 2 Zinc plating is NOT to be used:
a) Where its presence may contaminate oils used for lubrication preservation, hydraulic systems, etc. Advice on this
matter may be obtained from the Defence Fuels Group, Westmoors (Advice may not be free.)
b) Where corrosion may arise as a result of exposure of the plated surface to vapours from certain organic materials.
BS 7195 gives guidance on this subject.
NOTE 3 Zinc plating may cause embrittlement of the part when used in temperatures exceeding 350°C.
NOTE 4 In a corrosive environment at temperatures above 60°C, zinc no longer protects steel but actively promotes rusting.
a) When followed by epoxy resin paint coat,
NOTE 6 Welding of plated surfaces is undesirable because of:
a) Liability to corrosion of basis metal beneath area of damage by welding process,
b) Emission of toxic fumes from heated zinc,
c) Impairment of welded joints, due to formation of oxides during welding process
12
Table 1 - 7a - Zinc Sherardized or Zinc Sprayed NCR Steel

Exposed Exposed
Zinc, Sherardized 19-7 plus any one Good
from
201-5
202-1
202-5
202-9
(for S/MS only)
19-7 19-7 plus anyone Fair to Good
from
202-1
202-2
202-5
202-6
203-2
204-1
205-1
19-7 plus 202-7 19-7 19-7
19-6 (for small
unpainted parts and
threaded parts)
Zinc, Sprayed 19-8 19-8 plus any one 19-8 plus anyone Good to Very Good
plus 202-7 from from
201-5 202-3
202-3 202-4
202-7 202-7
202-10 203-2
(For SIMS only)
19-9 Fair to Good
Table 1 - 7b - Zinc Sherardized or Sprayed NCR Steel

Process
Resistance; VG — Very Good; G — Good; F — Fair; P — Poor
Drawing Thickness
Type of Finish
Def Stan (µm)
19-7 Zinc, Sherardized to 30 P P P For hinges, clips and small castings. For fasteners. This is a
2
BS4921, Class 1 (or 210gm⎯ ) dry method of applying a zinc coating of controlled
thickness for use on small parts that can withstand the
heat involved (up to 425°C) in the process.
19-8 Zinc, Sprayed to BS 100 (Nominal) P P P Suitable finish for frameworks, chassis, large structures
EN ISO 2063 Zn 4 or where close conformity to dimensions is not important.
Ideal key for paint. Account must be taken of liability
to distortion of thin sheets or damage to delicate parts by
19-9 Zinc, Sprayed to BS 175 (Nominal) the grit blast pre-treatment. Note: Less vigorous grit
EN ISO 2063 Zn 7 blasting is required than for aluminium spraying. Ideal finish
where steel is joined to aluminium.
13
8 Guide to the Protective Treatment of Copper and Copper Alloys
8.1 General
8.1.1 The Tables contained in this Section provide a guide to the degree of protection against
corrosion, which is afforded to copper and copper alloys by various treatments.
8.1.2 Each Table is divided into parts with "a" presenting, alphabetically, a broad picture of complete
treatments and "b" a summarised description of the metallic finishes quoted, in numerical order.
8.1.3 Where additional paint finishes are required, these are summarised in the current issue of
"Warpaint".
8.1.4 For precise information on the protective treatments invoked in these Tables, refer to the
related Process Drawings.
8.1.5 A greater degree of protection can generally be obtained by selecting a finish intended for a
worse environment than planned for the equipment.
8.1.6 Passivation processes are to be omitted when using epoxy-resin paints or where soldering or
electrical conductivity is required.
8.1.7 To invoke a protective treatment listed in this Section, quote the Process Drawing Numbers of
both:
a) The relevant metal finish and
b) The relevant paragraph of "Warpaint".
Table 2 - 1a - Cadmium Plated or Chromium Plated Copper and Copper Alloys

Exposed Exposed
Cadmium Plated 4-4 Good to Very Good
and Passivated 4-4 Fair to Good
(see Health &
Safety Warning)
Chromate 18-1 Good
Passivation
18-1 Fair to Good
Chromium Plated 7-5 Good to Very Good

7-7
7-5 7-6 (for fasteners) Fair to Good
7-7
Clean, 8-3 plus 202-5 8-3 8-3 Very Good
(Bright, Uncoated) plus any one from plus any one from
201-3 202-1
202-1 202-2
202-5 202-5
202-9 202-6
(for only S/MS only) 204-1
205-1
8-3 Fair to Good
8-3 Poor to Fair
14
Table 2 - 1b - Cadmium Plated or Chromium Plated Copper and Copper Alloys

Process
Resistance; VG — Very Good; G — Good; F — Fair; P — Poor
Drawing Def Type of Finish Thickness (µm)
Stan 21-005 EC S AR Guidance Notes
4-4 Cadmium, Plated and 12 (Average) G G F Not normally used but may be applied to limit potentials at
Passivated to Def Stan 10 (Local) bi-metallic contacts. Requires undercoating of nickel (2
03-19 and BS 6338 µm). See Notes 1 to 6 below.
18-1 Chromate Passivation For brass cartridge cases, fuse components, etc. Normally
to Def Stan 03-12 a final process before assembly or packaging. Resists
staining by handling residues and atmosphere
contaminants.
7-5 Chromium, Plated 0,3 G P G Requires undercoating of nickel (30 µm). Use limited to
(Dull) to BS EN 12540 essential applications owing to difficult supply position of
nickel. See Note 6 below.
7-6 Chromium, Plated to Varies G P G Finish designed to prevent undue interference fits in
BS7371 -12 according to threaded components. Suitable for ISO metric screw
diameter of threads up to and including 20mm (nominal) diameter and
screw thread unified thread up to and including %" (nominal) diameter.
For screw thread diameters above these ranges, use BS
EN 12540.
7-7 Chromium, Plated 0,3 G P G Requires undercoating of nickel (5O µm). Use limited to
(Satin) to BS EN essential applications owing to difficult supply position of
12540 nickel, see Note 5 below.
8-3 Clean. (Bright, G-VG G F-G Not to be used where good electrical contact is required.
uncoated) to Def Stan Can be used:
03-2, Section 4. a) When followed by a paint system; b) For springs where
conditions permit; c) Where a degree of corrosion is
acceptable; d) Prior to soldering; e) When followed by
electroplating.
NOTE 1 Cadmium Plating, due to the toxic nature of both cadmium and the salts formed by oxidation is only to be used when
alternative finishes, such as zinc plating, are unacceptable, and then only with the prior written permission of the MOD
Project Manager. Cadmium Plating is NOT to be used:-
a) for items likely to come into contact with food stuffs or drink,
b) Where its presence may contaminate oils used for lubrication, preservation, hydraulic systems, etc. Advice on
this matter may be obtained from the Defence Fuels Group, Westmoors (Advice may not be free.)
c) Where corrosion may arise as a result of exposure of the plated surface to vapour from certain organic
materials. BS 7195 gives guidance on this subject.
NOTE 2 Cadmium plating may cause embrittlement of the part when used in temperatures exceeding 250°C.
a) When followed by epoxy resin paint coat,

NOTE 4 Welding of plated surfaces is undesirable because of:-
a) liability to corrosion of basis metal beneath area of plating damaged by welding process,
b) emission of toxic fumes from heated cadmium,
c) impairment of welded joints, due to the formation of oxides during welding process.
NOTE 5 Nickel plating is to be avoided where possible. When it is a requirement then the maximum deposit of copper plate
permitted in accordance with BS EN 12540 is to be specified in order to reduce the required thickness of the nickel
plating.
15
Table 2 - 2a - Gold Plated or Rhodium Plated Copper and Copper Alloys

Protective Treatment Standard of Protection
Exposed (Funnel Gas) Exposed (Weather) Protected Controlled
Gold, Plated 10-2 10-1 Good to Very Good
14-2 14-2 Good to Very Good
Rhodium, Plated
14-1 14-1 Fair to Good
Table 2 - 2b - Gold Plated or Rhodium Plated Copper and Copper Alloys

Process Key to symbols: EC — Electrical Conductivity; S — Solderability; A — Abrasion
Type of Finish
Def Stan (µm) EC S AR Guidance Notes
21-005
10-1 Gold, Plated to 0.5 (Local) VG G P For prolonged protection of conductor track of printed wiring and to
Def Stan 03-1 7, assist in solderability, e.g. mounting of flat packs, dual-in-line, TO'
Class Au (98) cans and wire lead components. Good shelf life. Prior to final
0.5 selection, see Tin/Lead 60/40 (17-1, 17-2& 17-3).
10-2 Gold, Plated to 5 (Local) For consistently low contact resistance with low contact pressure,
Def Stan 03-17, e.g. for edge connector contacts of printed wiring.
Class Au (98) 5
14-1 Rhodium, Plated 0.375 (Local) G VG Applied where an untarnishable, wear-resisting surface is required
to DTD 931 for electrical contact surfaces, when applied over silver or nickel
Class Rh 15 plating. Thick coatings are liable to give trouble due to crazing; they
14-2 Rhodium, Plated 2.5 (Local) are to be used only when specified by the Responsible Authority
to DTD 931 and are to be limited to essential areas.
Class Rh 100
Table 2 - 3a - Silver Electroplated or Tin Plated Copper and Copper Alloys

Exposed
Treatment Exposed (Weather) Protected Controlled Protection
(Funnel Gas)
Silver, Electroplated 15-3 15-3 Good to Very Good
15-4 (for fasteners) Fair to Good
15-1 15-1 Fair
15-4 (for fasteners) 15-2 Poor to Fair
15-2 Poor
Tin, Electroplated 16-3 16-3 Good to Very Good
16-7 16-5 (for Fair
fasteners)
16-7 16-5 (for 16-1 Poor to Fair
fasteners)
Tin, Hot-Dipped 16-6 16-6 Fair to Good
16
Table 2 - 3b - Silver Electroplated or Tin Plated Copper and Copper Alloys

Type of Finish
Def Stan (µm)
21-005
For rf and other electrical purposes where solderability is a
Silver, Electroplated requirement. Not suitable for printed wiring boards or other
15-1 5 (Local) VG VG P
to ISO 4521 applications where silver migration may reduce insulating
qualities.
For use where good electrical contact is a requirement. Not
Silver, Electroplated 8-40
15-2 suitable for printed wiring boards or other applications where
to ISO 4521 (Average)
silver migration may reduce insulating qualities.
For use where good surface conductivity is a requirement for rf
or other electrical purposes. To prevent tarnishing, it should
Silver, Electroplated
15-3 10 (Local) be lacquered or rhodium flashed. Not suitable for printed
to ISO 4521
wiring boards or other applications where silver migration may
reduce insulating qualities.
Finish designed to avoid undue interference fits yet provides a
Varies with measure of protection. Suitable for ISO Metric screw threads up
Silver, Electroplated
15-4 diameter of to and including 20mm (nominal) diameter and unified threads
to BS 7371-12
screw thread up to and including 3/4" (nominal) diameter. For screw thread
diameter above these ranges, use BS EN ISO 4521.
Used to facilitate soldering, solder tags, etc. For use on
fabricated articles. For use on threads below 6,25mm diameter
Tin, Electroplated
16-1 5 (Local) F VG P (nominal). May be used to reduce potential of steel copper
to BS1872
junctions. For brass, requires an undercoating (2,5mm) of
copper, bronze or nickel to retain solderability.
Tin, Electroplated
16-3 30 (Local) Suitable for corrosion protection and abrasion resistance.
to BS 1872
Finished designed to avoid undue interference fits yet provide
a measure of corrosion protection. Suitable for ISO Metric
Varies with
Tin, Electroplated Screw threads up to and including 20mm (nominal) diameter
16-5 diameter of
to BS 7371-12 and unified threads up to and including 3/4" (nominal) diameter.
screw thread
For screw thread diameters above these ranges, use BS
1872.
Suitable for solder tags. Requires flash under-coating of
16-6 Tin, Hot-Dipped 12,5 (Local) G G F
nickel (1,25 µm maximum).
Tin, Electroplated
16-7 8 (Local) Suitable for corrosion protection.
to BS1872
NOTE Nickel plating is to be avoided where possible. When it is a requirement; the maximum deposit of copper plate
permitted in accordance with BS EN 12540 is to be specified in order to reduce the required thickness of the nickel plating.
Table 2 - 4a - Tin/Lead Plated Copper and Copper Alloys

Standard of
Protective Treatment Exposed Exposed
Protected Controlled Protection
Tin, Lead 60/40 Electro-plated 17-1 17-1 Good
17-2 17-2
Tin/Lead 60/40 Hot tin Process Good
17-3 17-3
17
Table 2 - 4b - Tin/Lead Plated Copper and Copper Alloys

Type of Finish
Def Stan (µm)
21-005
17-1 Tin/Lead 60/40, 25 G VG P For protection of conductor track of printed wiring and to assist in
Electroplated (Nominal) solderability, e.g. mounting of flat packs, dual-in-line, TO' cans and wire
load components. Requires an undercoating of tin/nickel electroplate
(10 µm). Shelf lifeless than that of gold. 17-1 suitable but 17-2 and 17-3
not suitable for through-plated holes or where conductor clearance is
critical. Prior to final selection, see Gold (10-1 ).
17-2 Tin/Lead 60/40, 25
Hot Tin Process (Nominal)
(Wave
Soldering)
17-3 Tin/Lead 60/40, 12, 5
Hot Tin Process (Nominal)
(Roller tinning)
9 Guide to the Protective Treatment of Aluminium and Aluminium Alloys

9.1 General
9.1.1 The Tables contained in this Section provide a guide to the degree of protection against corrosion
which is afforded to aluminium and aluminium alloys by various treatments.
9.1.2 Each Table is divided into two parts with "a" presenting, alphabetically, a broad picture of
complete treatments and "b" a summarised description of the metallic finishes quoted, in numerical
order.
9.1.3 Where additional paint finishes are required, these are summarised in "Warpaint".
9.1.4 For precise information on the protective treatments invoked in these Tables, refer to the related
Process Drawings.
9.1.5 A greater degree of protection can generally be obtained by selecting a finish intended for a worse
environment than planned for the equipment.
9.1.6 To invoke a protective treatment listed in this Section, quote the Process Drawing Numbers of
both:
a) The relevant metal finish
b) The required paint system plus its colour code reference.
18
Table 3 - 1a - Anodised Aluminium and Aluminium Alloys

Exposed (Funnel
Treatment Exposed (Weather) Protected Controlled Protection
Gas)
Anodised 2-1 or Good to Very
2-2 or Good
2-3 or
2-4 or
2-5 plus any one
from
202-3
202-4
202-7
202-8
203-2
2-1 or 2-1 or Good
2-2 or 2-2 or
2-3 or 2-3 or
2-4 or 2-4 or
2-5 plus 2-5 plus any one
202-7 from
201-5
202-3
202-7
202-10
(for S/M only)
19
Table 3 - 1b - Anodised Aluminium and Aluminium Alloys
Resistance; VG — Very Good; G— Good; F— Fair; P— Poor
Drawing
Type of Finish Thickness (µm)
Def Stan EC S AR Guidance Notes
21-005
2-1 Anodised 8 to 13 G Normally suitable for general protective purposes. Not suitable
(Sulphuric Acid for use on parts containing riveted, lap or folded joints. Must
Process) to be stipulated where normal protection is required for
Def Stan 03-25 aluminium parts used in contact with concentrated hydrogen
peroxide (HTP).
2-2 Anodised 2 (Approx.) G Preferred process for the treatment of castings of suitable
(Chromate Acid composition and for providing a bonding surface for plastic
Process) to material or where one or more of the following considerations
Def Stan 03-24 are paramount:-a) Minimising loss of fatigue strength due
to anodising; b) Detection of flaws by subsequent seepage of
yellow electrolyte; c) Treatment of parts which are to be in
contact or near contact with explosives; d) Treatment of
material less than 250mm thick; e) Remove of electrolyte
from crevices or blind holes may be difficult.
2-3 Anodised, Hard to 100 (Approx.) VG Harder and thicker coatings than those provided by 2-1 and
BS 5599 2-2 above provide greater resistance to abrasion, corrosion
and electrical breakdown. If used on parts liable to contact with
concentrated hydrogen peroxide (HTP), the electrolyte is to
consist of a simple sulphuric acid solution.
2-4 Anodised to: Def Mixed coating VG Used only where certain areas require greater resistance to
Stan 03-25 and thickness 8 to 13 abrasion, corrosion or electrical breakdown. If used on parts
BS 5599 and 100 liable to contact with concentrated hydrogen peroxide (HTP),
(Approx.) the electrolyte is to consist of a simple sulphuric acid solution.
Not suitable for use on parts containing riveted, lap or folded
joints.
2-5 Anodised to: Def Mixed coating VG Used where only certain areas require greater resistance to
Stan 03-24 and thickness 2 abrasion, corrosion or electrical breakdown. Not to be used
BS 5599 (Approx.) and for parts liable to contact with concentrated hydrogen
100 (Approx.) peroxide (HTP).
20
Table 3 - 2a - Chromate Conversion Coatings on Aluminium and Aluminium Alloys

Exposed Exposed
Chromate 3-2 plus any one Good to Very Good
Conversion Coating from
202-3
202-4
202-7
202-8
203-2
3-1 plus any one Good
from
201-5
202-3
202-7
202-10 (for S/Ms
only)
Clean (Bright, 8-1 plus 202-5 8-1 plus any one 8-1 plus any one Very Good
Uncoated) from from
201-1 202-1
201-3 202-2
202-1 202-5
202-5 202-6
202-9 (for S/Ms 203-1
only) 204-1
205-1
8-1 Fair to Good
8-1 Poor to Fair
21
Table 3 - 2b - Chromate Conversion Coatings on Aluminium and Aluminium Alloys
Type of Finish
Def Stan (µm)
21-005
3-1 Chromate Conversion P* P P Non-elecrolytic treatment which produces a protective
Coating, (Immersion) coating on a l u m i n i u m a n d i t s a l l o ys . Processing
to Def Stan 03-18 times are short and operating temperatures are low.
Gives good paint adhesion. There is no appreciable
change in the dimensions of the treated work.
3-2 Chromate Conversion P P P Non-electrolytic treatment which produces a

Coating, (Brush or protective coating on aluminium and its alloys. May
Swab) to Def Stan 03- be used for the treatment of surfaces, which are too
18 large for immersion or where the scale of production
does not justify the installation of immersion
equipment. Gives paint adhesion and does not
appreciably change the dimensions of the treated
work. Used also to touch up damage anodised
surfaces.
8-1 Clean (Bright, VG P Used for:
a) Protected parts where electrical bonding is a
Uncoated) to Def Stan
requirement,
03-2, Section 3
b) Parts subsequently to be painted
NOTE ELECTRICAL RESISTANCE
To minimise the effect on surface electrical resistance, light to medium Alocrom coatings are recommended. The contact electrical
resistance for Alocrom 1200 is less than 5000 micro-ohms per square inch measured under an electrode pressure of 200 Ibs per square
inch (MIL-C-5541 method). These figures should satisfy general EMC and Tempest conditions for RN equipment. Henkel Metal
Chemicals, may be able to advise on electrical resistances achievable for various coating thicknesses. Generally, best
conductivity is realised when protection against corrosion is poorest.
Table 3 - 3a - Silver Electroplated Aluminium and Aluminium Alloys

Exposed Exposed
Silver, Electro- 15-3 15-3 Good to Very Good
plated 15-1 15-1 Fair
15-2 Poor to Fair
15-2 Poor
22
Table 3 - 3b - Silver Electroplated Aluminium and Aluminium Alloys

Type of Finish
Def Stan (µm) EC S AR Guidance Notes
21-005
15-1 Silver, Electroplated 5 (Local) VG VG P For rf and other electrical purposes where solderability is
to BS EN ISO 4521 a requirement. Requires an undercoating of nickel (20µm).
See Note.
15-2 Silver, Electroplated 8-40 For use where good electrical contact is required. Requires
to BS EN ISO 4521 (Average) an undercoating of nickel (20µm). See Note.
15-3 Silver, Electroplated 10 (Local) For use where good surface conductivity is required.
to BS EN ISO 4521 Requires an undercoating of nickel (20µm). See Note.
NOTE NICKEL PLATING
Nickel plating is to be avoided where possible. When it is a requirement, the maximum deposit of copper plate permitted in accordance
with BS EN 12540 is to be specified in order to reduce the required thickness of the nickel plating.
10 Guide to the use of Paints and Powder Coatings
10.1 Paint Policy

10.1.1 Following MOD adoption of a "Smart Acquisition Policy", and increasing emphasis on Health &
Safety at Work and environmental regulations in recent years, methods of specifying and procuring paint for
RN ships have changed. This section lists the changes, and their effect on paint specification, procurement
and use.
10.1.2 One emphasis of "Smart Acquisition" is to procure and use materials in accordance with national or
international standards, rather than Defence Standards, and to require the supplier, and/or the painting
contractor, to shoulder the risk of material failure. This entails MOD setting "Design Life Targets" for paint
systems, and also "Performance Criteria" (which must include H&S and any Environmental aspects), and the
paint supplier warranting that his commercially available products will meet these criteria. In submitting
coating systems to MOD, the supplier warrants that they will be "Fit for Purpose". In passing the risk to the
supplier and painting contractor, MOD must allow the supplier to specify how his products are to be used.
10.1.3 MOD (N) will no longer specify paint manufactured to Defence Standards. Instead, "Design Life
Targets" will be published in "Warpaint", and general paint "Performance Criteria" are included in BR 3939
Issue 2.
10.1.4 Paint suppliers are now required to be capable of supplying sufficient types of paint to coat an entire
warship at refit and/or new build. The very few specialist coatings, which are the exceptions to this rule, are
listed separately in "Warpaint". Approved suppliers' specifications for each area are listed as "Whole Ship
Specifications (WSS)", extracts of which are published 6-monthly by SESea – MT in "Warpaint". Paint
systems recommended in this standard will be indicated by the quotation of the relevant paragraph of the
WSS in "Warpaint". Full WSS, including specified thickness and number of paint coats required, are held in
electronic form by SESea – MT . These are the only paint specifications authorised for use on HM Ships,
and contractors are responsible for ensuring that the specification offered by their paint supplier matches that
held by SESea – MT. Where certain materials in a supplier's WSS have been published in advance of their
gaining full MOD approval, the appropriate line in the WSS will be lightly shaded. Users are to check the
actual status of these materials with SESea – MT prior to first use.
10.1.5 The "Approved Firm's Schedule (AFS)" system has lapsed with the changes in MOD policy.
However, in the event of dispute following a paint failure, there will still be a requirement to confirm that the
paint used was, in fact, the paint specified. In place of AFS, paint suppliers will be required to provide "Paint
Identification Characteristics", which will suffice to confirm the identity of the paint in use. To save
unnecessary recording, this information is likely to be the batch test results already in use by the supplier.
The information will be held by SESea –MT, and treated as confidential.
23
10.1.6 All paints specified are to be used strictly in accordance with the manufacturer's Health & Safety
and product data sheets. All paint application is to be by the manufacturer's recommended method, except
that cutting-in, stripe coating or touch up may be by brush.
10.1.7 Overcoating times and pot life, relevant to the ambient temperature, are to be observed. No
variations are permitted without prior approval from the appropriate Integrated Project Team.
10.2 Paint Selection
10.2.1 This Section tabulates paint systems suitable for use on Naval equipment and lists the available
colours of each finishing coat. For convenience, each colour has been allocated a reference number
appropriate to BS 381C (unless Black or White).
10.2.2 Painting is to be considered as a complete system inclusive of any required pre-treatment.
10.2.3 The selection of a paint system is governed by the metal substrate concerned and any protective
treatment which has been given to it. This Section is to be used in conjunction with the current issue of
Warpaint.
10.2.4 Paint Colours and Performance Characteristics are to comply with the requirements of the
appropriate table in BR 3939, Issue 2, and the table in this Section.
10.2.5 For environmental reasons, manufacturers are encouraged to use Powder Coatings, which must
be chosen from those approved by MOD –SESea –MT, and listed in Warpaint. The use of stoving paints
has, in general, been superseded by powder coatings.
24
10.3 Required Paint Colours
Table 4 - 1a - Special Colours for Equipment, Gun Mountings and GW Launch Systems
Use or Function Colour

Surfaces Ships; external surfaces of equipment exposed to the weather Light Weatherwork Grey to BS381C No 676
(excluding antennas and radomes)
Submarines : External surfaces of equipment exposed to the weather (including Black or Dark Green to BS381C No 241
Radomes and encapsulated antennas)
Antennas, Surface Ships Light Weatherwork Grey to BS381 C No 676 or White

a) Not exposed to Funnel Gases (Nuclear Radiation Reflecting)
b) exposed to Funnel Gases Black
Radomes; Surface Ships Light Weatherwork Grey to BS381C No 676 or White

(Nuclear Radiation Reflecting)
Fire Control equipment (not exposed to weather) Light Admiralty Grey to BS 381 C No 697
External Surfaces of all Electrical and Weapon equipment fitted in offices Light Admiralty Grey to BS 381C No 697
External surfaces of all Electrical and Weapon equipment fitted in positions other Light Admiralty Grey to BS 381C No 697 unless the
than Offices, but protected from the weather equipment has been designed for a specific
requirement and it can be proved that colour will
affect efficiency
External surfaces of all Electrical and Weapon equipment fitted in positions other Light Weatherwork Grey to BS381 C No 676
than Offices, but not protected from the weather
Analytical test equipment (free standing, mobile) Dark Admiralty Grey to BS381 C No 632
Inside surfaces of equipment (where necessary) Black White or as for external surfaces
a) Optical
b) Other than optical
Fittings e.g. escutcheons, handles, etc. on front surfaces of equipment Dark Admiralty Grey to BS381C No 632
Fittings, e.g. escutcheons, handles, etc. on front surfaces of Test Equipment Light Admiralty Grey to BS381C No 697
Access fasteners temporary covers or part to be removed during installation Brilliant Green to BS381C No 221
Nameplates and operational labels Dark Admiralty Grey to BS381C No 632 Letters:
White
Nameplates for Test Equipment Light Admiralty Grey to BS381 C No 697 Letters:
White
Air Weapon handling trolleys used on aircraft carrier flight decks Dark green gloss to BS381C No 241
Warning Labels Colour to be in accordance with Section 'E' of

Def Stan 05-34
All emergency stop pushes, power control switches, stop buttons -Gun Mountings Signal Red to BS381C No 537
& GWS Launchers
Hazards to Personnel: All dangerous parts of machinery (i.e. sights, elevating Canary Yellow to BS381C No 309
mass, hoist doors, loading trap, gun breeches, etc.). See Note 1.
All non-dangerous parts of machinery (i.e. hoists, motors, gearboxes, etc.), Mid Brunswick Green to BS381C No 26
except where a light reflecting surface is required
All light reflecting surfaces (i.e. interior surfaces of gun house, gun bay, White
magazine, missile storage check room, etc.)
NOTE 1 These colour schemes are intended to emphasise those parts that are liable to cause injury to crew members.
NOTE 2 Air bottles are normally supplied coloured French Grey (i.e. to BS 381C No 630). THEY MUST NOT BE
OVERPAINTED.
25
Table 4 - 1b - Paint Sheen Requirements
Use or Function Paint Sheen
SURFACE SHIPS Gloss
All external surfaces of equipment exposed to the weather with the exception of items
listed in 3(b) and (d) below.
SUBMARINES Matt Solar Heat Reflecting

(SHR)
All external surfaces of equipment exposed to the weather with the exception of items
listed in 3(b) and (d) below
ALL VESSELS
a) External surfaces of equipment protected from the weather Semi-Gloss
b) Operational and warning labels: nameplates; access fasteners /parts to Semi-Gloss

be removed during installation. Fittings such as handles, escutcheons
etc., fitted to front surfaces of equipment
c) Internal surfaces of equipment, (where required) Gloss or Semi-Gloss to

restrict reflection
d) Control and Stop buttons, switches, emergency stop pushes, etc. Semi-Gloss, Fire Retardant
Machinery parts such as hoists, motors, gearboxes etc.
e) All light reflecting surfaces such as interior walls of magazines, missile Semi-Gloss, Fire Retardant
storage check rooms, gun bays, etc.
f) Optical Semi-Gloss, Fire Retardant
26
Table 4 - 2 - Air-Drying External Paints (201/202 Systems)

Consult "Warpaint" Paragraph Substrate
Process Finishing Coat Guidance Notes
Copper Aluminium
Undercoat
Drawing
Primer
and and
Def Stan Colour NCR Steel
Para & Type Sheen Copper Aluminium
21-005 Ref
Alloys Alloys
201-1 Z J(iii) J(l) Gloss 677, Galvanised Clean Ship's weatherwork paint
Waterbased 676 or system suitable for painting
or silicone White the hull and superstructure
alkyd of HM Ships, Gun
Mountings, Launchers,
Antennas, etc., and other
items made of aluminium or
aluminium alloys.
201-2a G J(iii) J(l) Gloss White Blast to Sa System for grit-blasted steel
Waterbased 2½
or silicone
201 -2b H alkyd Clean to St 3 General purpose finish
employed where only
imperfect cleaning can be
achieved, e.g. St 3.
201-3a G N/A J(l) Epoxy Gloss 676, Blast to Sa A heavy duty ship's
Acrylic White 2½ weatherwork paint system.
Suitable for painting the
weatherwork areas of
201-3b Z Cadmium, Clean Clean Service
Plated. Zinc, Telecommunications
Hot Dipped. Equipment, Antennas, etc.,
Zinc, Plated. made of NCR Steel,
Zinc, copper and copper alloys,
Sherardized. or aluminium and aluminium
Zinc alloys, which have had
Sprayed previous surface conversion
treatment or metallic
coatings, applied.
201-4 As 201- 3b Aluminium, As above
Sprayed
201-5 As 201- 3b Phosphated Anodised As above
Chromate
Conversion
202-9 Z Def Stan 80- Matt Black Cadmium, Clean Clean Solar heat reflecting paint
schemes suitable for
111 Plated. Zinc,
periscopes, masts and
Hot Dipped, externally mounted
Zinc, Plated, submarine equipment.
Zinc,
Sherardized, NOTE: No Warpaint
Zinc, equivalent available
Sprayed.
202-10 Z Def Stan 80- Matt Black Aluminium, Anodised
111 Sprayed. Chromate
Phosphated conversion
27
Table 4 - 3 - Air-Drying Internal Paints - (202 Systems)
Consult "Warpaint" Paragraph Substrate
Process
Finishing Coat Copper Aluminium
Drawing
Under- and and
Def Stan Primer Para & Colour NCR Steel Guidance Notes
coat Sheen Copper Aluminium
21-005 Type Reference
Alloys Alloys
202-1 Z O Gloss 697; 632; Aluminium, Clean Clean An equipment
Waterbased 537; 309; Sprayed. paint system
Epoxy 221; Cadmium, suitable for service
Black; Plated. Zinc, Telecommunication
White Hot Dipped. Equipment, Fire
202-2 Z O Semi- 697; 632; Zinc, Plated. Control
Waterbased Gloss 537; 309; Zinc, Instruments,
Epoxy 221; Sherardized. Motors, Starters,
Black; Zinc, etc. Semi-gloss
White Sprayed. paint to have a
202-3 L O Gloss 697; 632; Phosphating, Anodised specular
Waterbased 537; 309; Class II. Chromate reflectance value
Epoxy 221; Clean conversion of 55-60 units
Black; measured at
White 60°angle.
202-4 L O Semi- 697; 632;
Waterbased Gloss 537; 309;
Epoxy 221;
Black;
White
202-5 Z O Gloss 697; 676; Cadmium, Clean Clean Gloss and
Semi-gloss air-
Waterbased 632; 537; Plated. Zinc,
drying paint
Epoxy 309; 221; Hot Dipped. schemes suitable
Black; Zinc, Plated. for Motors, Starters
White Zinc, and other metal
surfaces.
202-6 Z O Semi- 697; 632; Sherardized.
Waterbased Gloss 537; 309; Zinc,
Epoxy 226; 221; Sprayed
Black;
White
202-7 Z O Gloss 697; 632; Aluminium, Anodised
Waterbased 537; 309; Sprayed. Chromate
Epoxy 221; Phosphating, conversion
Black; Class II.
White Zinc,
202-8 Z O Semi- 697; 632; Sprayed.
Waterbased Gloss 537; 309; Clean
Epoxy 221;
Black;
White
28
Table 4 - 4 - Air-Drying Internal Paint Systems (203, 204 and 205 Series)
Process Consult "Warpaint" Paragraph Substrate

Drawing Finishing Coat Copper Aluminium
Def Stan Under and and
Primer -coat Colour NCR Steel Copper Aluminium Guidance Notes
21-005 Para & Type Sheen
Ref Alloys Alloys
203-1 Z O Gloss 697; Cadmium, Clean An interior paint
Waterbased Plated. Zinc, system suitable for
537;
Epoxy Hot Dipped steel, aluminium and
309; Zinc, Plated aluminium alloy
226; surfaces of Ships,
White (Gun Mountings,
O Aluminium, Launchers, Fire
203-2 Z Gloss 697; Anodised Control Equipment,
Waterbased Spray
537; Chromate etc.) intended for
Epoxy Phosphating,
309; Class II. Conversio use as a protective
226; Zinc, n and fire retardant
Sherardized. coating which will
White not propagate fire
Zinc, due to transmission
Sprayed. of heat through
metalwork (e.g.
ship's bulkheads).
Will withstand
repeated washing
down.
204-1 Z U Epoxy Semi- Any light Cadmium, Clean Clean An oil-resistant paint
for internal surfaces
Gloss shade Plated. Zinc,
of oil filled
Hot Dipped gearboxes.
Zinc, Plated.
Zinc,
Sherardized.
205-1 Def Stan Def Stan Matt Black Cadmium, Clean Clean For internal surfaces
80-113 80-113 Plated. Zinc, of optical
Plated Zinc, instruments.
Sherardized. Applicable to all
environments.
NOTE: No Warpaint
Equivalent available.
Table 4 - 5 - Air-Drying GRP Paint Systems (206 Series)

Process Consult "Warpaint" Paragraph:
Drawing Finishing Coat
Def Stan Primer Undercoat Para & Colour Guidance Notes
Sheen
21-005 Type Reference
206-1 Z J(l) Epoxy Gloss 676; White Applicable to glass reinforced plastic. A paint system for
Acrylic use on external surfaces of radomes (Surface Ships only).
206-2 Z Def Stan Matt Black Applicable to glass reinforced plastic resin ('Cenosphere'
80-111 or similar, loaded epoxy resin) for use on external
surfaces of radomes or encapsulated antennas
(Submarines only).
206-3 Z J(iii) J(l) Gloss 677, 676 or Applicable to glass reinforced plastic resin (GRP). General
Waterbased White purpose finishes for GRP fabrications which are exposed
or silicone to the weather.
alkyd
29
11 Design Requirements/Guidance
11.1 Design Factors
11.1.1 When designing an item, equipment or structure, various factors need to be taken into
consideration. Briefly these are:
a) The function and detail of each item concerned;
b) The choice of basis material, i.e. a material in its natural unprotected state;
c) The environment;
d) Juxtaposition of items, support structures, etc.
e) Avoidance, as far as possible, of electro-chemical corrosion.
11.1.2 Careful design contributes as much towards the minimisation of corrosion as any superficial
protective coating. The following clauses offer advice in the design technique of avoiding corrosion.
11.1.3 Any design features, which encourage the deposition or retention of electrolyte or hostile
element, are to be avoided. Exterior surfaces are to be as smooth as possible to minimise the collection of
stagnant electrolyte, castings being fettled, sealed etc. to avoid absorption. Unnecessary holes pockets
and other moisture traps are to be "designed out".
11.1.4 Where a construction employs devices such as folded seams, beading or screwed fasteners, the
application of anti-corrosive primer is to be considered, preferably prior to final stages of assembly.
11.1.5 Adequate ventilation and other arrangements are to be provided to prevent condensation in
equipment. Drainage holes are to be provided for inaccessible places, e.g. double-skin constructions. For
larger box-plate constructions, access holes with cover plates are to be provided to allow the painting
of interior surfaces.
11.1.6 Some materials, e.g. aluminium, corrosion-resisting steels, etc., can control the rate of corrosion by
forming a surface oxide film which tends to impede further degradation (Passivity). To enable this surface
protection to be maintained it is important that the surfaces of these metals should not be deprived of a
source of oxygen.
11.2 Galvanic Hazards
11.2.1 Contact of materials having a wide difference in electro-potential is to be avoided wherever

possible; alternatively, the use of an intermediary material of a mean potential is to be considered to
minimise the flow of current. Reduction of potential difference can be achieved by coating one or both
materials with a third material, e.g. by electroplating, metal spraying and similar.
11.2.2 The use of a sacrificial cathode is to be considered, the larger more expensive items being
made anodic with respect to smaller replaceable items.
11.2.3 Where submerged equipment or structures are involved, cathodic protection techniques may
need to be employed. Typically, these techniques involve either:
a) Introduction of a third material (sacrificial anode) which has an electro-potential higher than either of
the other two materials; or
b) Passing a dc current from an external source in the direction opposite to the flow of galvanic
current. Care is to be taken when using this technique, for should the external current flow in the
same direction as the galvanic current, then the rate of corrosion will be greatly increased.
11.2.4 The flow of galvanic current can also be reduced or even nullified by the insertion of an
insulating material which is not moisture absorbent. For full information on Cathodic Protection,
reference is to be made to BS 7361.
30
11.3 Design Considerations
11.3.1 There are many factors which affect the rate of corrosion in an item, e.g. ambient temperatures,
transient polarity etc; whilst some may be beyond the control of a designer, the majority are
interdependent and are to be jointly considered, including the following:
a) The site e.g. Mast Head, Hull, Protected Compartment, etc.;
b) The environment to be encountered at that site e.g. rain, snow, ice, strong sunlight, salt-laden air,
funnel gases etc. (see Def Stan 08-123 for further information);
c) The basis material, its position on the galvanic scale and its method of construction e.g. thin sheet
metal fabrication, porous casting, inaccessible areas, moisture traps etc.;
d) The cost of the envisaged protection in relation to total cost of the item.
e) The penalty to the equipment, system or ship of degradation of the item concerned.
11.3.2 Design considerations are also to encompass the packaging and storage of an item. Moisture
absorbing materials are to be avoided and desiccation of the package is to be given careful
consideration.
11.4 Hazards of Corrosion Due to Vapour
Some organic materials, e.g. certain encapsulating compounds, woods, glues, paints, etc., emit organic or
inorganic vapours- or even both- which may cause corrosion of associated metal parts, especially in
confined conditions of high humidity and elevated ambient temperature. Organic materials likely to emit
vapour which could cause metal corrosion are to be avoided; however should their use be essential, details
of material properties and recommendations for corrosion prevention can be obtained form BS 7195.
12 Pre-Treatment of Basic Metals
12.1 General
12.1.1 The painting of any item or structure is to be considered as a complete system inclusive of pre-
treatment (e.g. cleaning, degreasing, preparation of surfaces etc., paint application, choice of paint and
choice of colour and sheen. See also Def Stan 03-30. Surfaces to be given a protective finish will require pre-
treatment. Care is to be taken that such pre-treatments are suitable and will not damage the surface of the
substrate.
12.1.2 Before commencing any painting, all metal surfaces are to be clean and free from pits,
intergranular attack, oxide scale, machining fluids or other foreign matter (visible or invisible). Care is to be
taken during cleaning to avoid damage to plated surfaces, anodic coatings, screw threads, surfaces with
high finishes, conducting surfaces and similar. For methods of cleaning, see Def Stan 03-2.
12.2 Degreasing Hazard
Instances have occurred of corrosion of aluminium alloys on degreasing in 1,1,1-Trichloroethane as

cold solvent or as vapour when there is movement of one surface over another. It is recommended, therefore
that all aluminium alloy components undergoing degreasing in chlorinated hydrocarbon solvent are to be
kept separated. If this is not possible, positive evidence will be required that corrosion has not occurred e.g.
by 100% examination of all surfaces at X10-15 magnification.
31
12.3 Abrasive Cleaning
12.3.1 Grit blasting, shot blasting or other mechanically severe pre-treatments are not to be administered
to thin sheet-metal fabrications.
12.3.2 Abrasive cleaning of aluminium alloys is to be limited to those items that cannot be chemically
cleaned, due to the risk of retaining chemical residues, i.e. partly closed fabrications.
12.3.3 Abrasive used on any metal or alloy item is only to be re-used on other items of similar material.
12.4 Castings
All castings are to be fettled and thoroughly cleaned. Those castings which, owing to their application or
working pressure, suffer through micro-porosity but are acceptable in other respects, may be reclaimable. All
such cases are to be referred to the Design Authority and Project Manager.
12.5 Waveguides
Special care is to be taken when cleaning metal fabrications used in waveguide systems to ensure that
electrical characteristics are not impaired. The conducting surfaces of these fabrications, as far as possible,
are to retain the same quality of surface texture as specified on drawings or other specifications. For
suitable cleaning methods see Def Stan 21-50.
12.6 Hydraulic Systems
Cleanliness of a hydraulic system is essential to its efficient operation and reliability. Special care is to be
exercised during manufacture and handling of the various items comprising that system.
12.7 Metallic Substrates
12.7.1 The basic metals in common usage in Naval equipment have been divided into three main
groups;
a) Non-corrosion resisting (NCR) Steel
b) Copper and Copper alloys
c) Aluminium and Aluminium alloys
12.7.2 The various environments which equipment can be expected to encounter have also been divided
into groups;
a) Exposed (Funnel Gases)
b) Exposed (Weather)
c) Protected
d) Controlled
For an explanation of these terms, see Annex B.
12.7.3 Suitable protective finishes for each group of metals to combat these environments are
tabulated for the appropriate metal together with a brief description of each finish. Greater protection can
generally be obtained by choosing a finish intended for a more severe environment.
12.7.4 When choosing a finish, due consideration is to be given to the size, fragility, method of
construction, etc. of the items to be protected.
32
12.7.5 Any finishing process applied to a Waveguide fabrication is to take into account the possibility of
deleterious effects arising from that process, e.g. impairment of surface texture, uneven electro-
deposition; changes in metallurgical properties of the basis metal; blocking of air-vent holes etc. See
Def Stan 21-50 for further information.
13 Surfaces to be Painted
13.1 General
13.1.1 Except for insulators, earths and continuity surfaces, and some GRP surfaces, the following are to
be painted:
a) The external surfaces of all equipment
b) The internal surfaces of all equipment other than that mounted in dry interior atmospheres of
air-conditioned cabinets or compartments.
13.1.2 Painting is not to be employed on working parts where the paint is liable to interfere with the
operation of items such as pivots and plungers.
13.2 Inaccessible Steel Surfaces
13.2.1 The internal surfaces of double-skin constructions are to be protected by paint preceded by a
suitable pre-treatment. Drainage holes are to be provided and must not be blocked by the protective finish.
13.2.2 All plates forming pockets in steel structures are to be de-scaled and cleaned and, where not
rendered airtight, are to be painted via the access holes provided.
13.2.3 Deck plating hidden by secured equipment is to be periodically examined, cleaned and painted,
readily removable equipment being removed to provide access.
13.3 Antennas
During manufacture, an antenna is to be provided with a protective finish that has a life commensurate
with the mechanical and electrical components involved. Repainting should not be necessary before the
antenna is overhauled.
13.4 GRP Mouldings and Fabrications
13.4.1 GRP is inert to electro-chemical corrosion and hence needs no protective finish. If it is to be
used unpainted, any colouring requirements can be incorporated in the gel coat during manufacture. The gel
coat colours are to match as far as possible the colour shades shown in BS 381C.
13.4.2 A GRP item, when exposed for long periods to ultra-violet radiation, suffers damage to the
pigmented gel. For this reason, all GRP items, which are exposed to the weather, are to be painted in
addition to their pigmented gel coatings.
13.4.3 Useful information on the painting, marking and repair of GRP Gun-shields is contained in
BR 2921, Part 5A. See also Table 4 - 5 in this Def Stan.
13.5 Radomes
13.5.1 For radomes constructed from GRP, Section 12.4 applies. However, as energy is usually
transmitted through a radome, certain qualifications are to be made.
13.5.2 The dielectric constant of the paint to be used is to be, ideally, the same as that of the substrate and
the paint is not to contain large quantities of filler or pigment.
33
13.5.3 If the wavelength of the transmitted energy is equal to the thickness of the radome wall, then the
effect of coats of paint could be critical especially in the case of sandwich type radomes where the skin
thickness is related electrically to the core thickness. In such cases, painting may have to be omitted and
the required coloured weatherproof surface obtained by other means.
13.6 Hydraulic Pipework
External surfaces of steel pipes exposed to the weather are to be painted to within 50mm of the coupling and
identification tape applied. See Def Stan 05-34:
a) Heat-treated aluminium alloys;
b) Electrified parts;
c) Where acid-resisting paints are specified.
14 Paint Application
14.1 Paint finishes are to be preceded, wherever possible, by a specified combination of cleaning (or
other pre-treatment), a metal finish and a pre-paint treatment. Passivation of zinc or cadmium plated
surfaces is to be omitted if the subsequent paint coat is of the epoxy resin-based type.
14.2 Where gear-box interiors are required to be painted, it is important that the paint is compatible
with the oil. It is to be noted that some oils have detergent or other properties which react with certain types
of paint.
14.3 For painted radomes fitted on the fin or masts of submarines, low sheen paints with acceptable
transmission losses are to be specified.
14.4 Painting of equipment can be effected by spraying, brushing or dipping as relevant, or as specified
on the Process Drawings related to this Def Stan. Where detailed instructions are not stipulated for the
application of paint, it is to be applied in conformance with the requirements of BR 3939.
14.5 Gun mountings and launchers are normally to be painted by brush to avoid paint mist from spray
guns entering the working parts. Spray painting can be used for external surfaces such as gun shields etc.,
but care is to be exercised, by masking or similar, to keep lubricators clear of paint.
14.6 Dry film thickness (dft) measurements are to be taken in the manner specified in "Warpaint".
14.7 When painting waveguide fabrications and similar, care is to be taken to prevent paint mist or runs
entering internal spaces, cavities or venting apertures.
34
15 Paint Removers
15.1 General
15.1.1 The following specifications for paint removers are no longer permitted for Naval use:
a) DEF 1443 - Paint Remover, Trichloroethylene, Water Rinsable Brushing Type.
b) Def Stan 80-16 - Paint Remover, Dichloromethane (methylene chloride), Water Rinsable, Special -
Brushing Type.
c) Def Stan 80-14 - Paint Remover, Dichloromethane (methylene chloride), Water Rinsable -
Brushing Type.
15.1.2 The only paint removers approved for Naval use are the waterbased products listed in the current
issue of "Warpaint".
16 Process Drawings
16.1 General
16.1.1 Protective finishes have been compiled to form Process Drawings (Tabulated in Sections 5, 6, 7
and 8) which are to be used in conjunction with this Def Stan. To assist invocation on manufacturing
drawings and drawing lists, finish code references, prefixed by Def Stan 21-005 to show their allegiance to
this Def Stan, are used to comprise the Process Drawing numbering system e.g.: Def Stan 21-005/19-2 is
the number of the Process Drawing which gives particulars of a Zinc, Hot-Dipped (Galvanised) protective
finish for non-corrosive resisting steel. Def Stan 21-005/201-1/677 is the reference, which gives particulars of
an air-drying, gloss paint system for external areas, having a finishing coat colour of Dark Weatherwork
Grey.
16.1.2 Where an item of equipment needs both a metallic finish and a paint finish, both Process Drawing
numbers are to be quoted on the manufacturing drawing of the item.
35
Annex A
Normative References
BR2203 Ships Husbandry Manual

Handbook for 4,5 Mk 8 Gun. Pt SA general stripping, re-assembly and
BR2921
maintenance instructions
BR 3008 Material and processes mechanical engineering
BR3939 Issue 2 The preparation and painting of surface ships
BS381C Specification for colours for identification coding and special purposes.
BS 1336 Specification for knotting
BS 1872 Specification for electroplated coatings of tin
Method for specifying electroplated coatings of silver and silver alloys for
BS EN ISO 4521
engineering purposes.
BS7371 - 12 Specification for electroplated coatings on threaded components.
BS4921 Specification for sherardized coatings on iron or steel.

Specification for hard anodic oxidation coatings on aluminium and its alloys for
BS 5599
engineering purposes
Specification for chromate conversion coatings on electroplated zinc and
BS 6338
cadmium coatings.
D2: Preparation of steel substrates before application of paints and related
BS EN ISO 8504
products. Surface preparation methods. Abrasive blast cleaning
Guide for prevention of corrosion of metals caused by vapours from organic
BS7195
materials
BS 7361-1 Cathodic Protection. Code of practice for land and marine applications
Corrosion protection of metals. Electro-deposited coatings of zinc with
BS EN 12329
supplementary treatment on iron and steel
Corrosion protection of metals. Electro-deposited coatings of cadmium on
BSEN 12330
iron and stand steel
Corrosion protection of metals. Electro-deposited coatings of nickel, nickel
BS EN 12540
plus chromium, copper plus nickel and copper plus nickel plus chromium
Metallic and other inorganic coatings. Thermal spraying. Zinc, aluminium
BS EN ISO 2063
and their alloys
Varnishes used for electrical insulation. Part 3 Specifications for individual
BS EN 60464
materials. Ambient curing finishing varnishes
Hot dip galvanised coatings on fabricated iron and steel articles.
BS EN ISO 1461
Specifications and test methods.
Def Stan 03-2 Cleaning and preparation of metal surfaces
Def Stan 03-1 1 Phosphate treatment of iron and steel
Def Stan 03-1 2 Chromate passivation of brass articles
Def Stan 03-1 4 Electro-deposition of chromium for engineering purposes
Def Stan 03-1 7 Electro-deposition of gold
Chromate conversion coatings (chromate filming treatments), standard and
Def Stan 03-1 8
brushing, for aluminium and aluminium alloys
Def Stan 03-19 Electro-deposition of cadmium
36
Def Stan 03-20 Electro-deposition of zinc

Def Stan 03-24 Chromic acid anodising of aluminium and aluminium alloys
Def Stan 03-25 Sulphuric acid anodising of aluminium and aluminium alloys
Treatments for the protection of metal parts of service stores and equipment
Def Stan 03-30
against corrosion
Def Stan 05-34 (1) Marking of service materiel
Requirements for design and testing of equipment to meet environmental

Def Stan 08-1 23
conditions, Category 2
Def Stan 21-50(1)
Requirements for waveguide installation
Def Stan 80-111(1) Paint finishing, low sheen, black, brushing
Def Stan 80 -113(1) Paint System, Optical Instruments, Matt Black
DTD931(1) Rhodium plating

Metallic coatings- electro-deposited silver and silver alloy coatings for
BS EN ISO 4521
engineering purposes
Warpaint Bi-annual paint publication by MOD- DES SESea -MT
(1)
This standard is obsolescent and shall not be used in new applications, designs or procurement.
37
Annex B
Abbreviations, Definitions and Symbols
A number of parts or sub-assemblies or any combination thereof joined together

Assembly
to perform a specific function.
The document signed by the Design Authority to certify that the material to which it
Certificate of Design relates complies with the requirements of the approved specification except as
otherwise stated.
Chassis The framework upon which components are mounted to form a unit.
The electrical and electronic components and conductors designed to satisfy the
Circuit
functions required of the equipment.
Code of Practice A publication containing design features and methods of manufacture, etc.
Component The smallest discrete item.
Component, Major An individual component, normally large, considered repairable when defective.
An individual component, usually small, normally not considered repairable
Component, Minor
when defective.
A process for enveloping a part or an assembly of discrete parts within a
Conformal Coating protective material which is normally not greater than 2,5mm thick and does not
require a mould or container.
The process of originating a conceptual, technical solution to a requirement;
Design performing necessary calculations; adjusting the concept as necessary; expressing
the final result in the form of drawings from which the product could be made.
The establishment or Authority responsible for the detailed design of materiel to
Design Authority approved specifications and authorised to sign a certificate of design or to certify
sealed drawings.
Drawings in this context also include all item lists, drawing lists, etc., associated with
a drawing or group of drawings. These drawings may be conventional, photographic
Drawings
material, computer-produced and/or photocopied or may convey the required
information without pictorial representation.
The metal cabinets, consoles, panels, cases, frameworks, etc. which provide the
Enclosure
mechanical protection and support for their contents.
Environment The aggregate of all conditions and influences to which an equipment is subjected.
Environment
The dry interior atmospheres of air-conditioned cabinets.
(Controlled)
The conditions generated by the forces of nature whose effects are experienced by a
Environment (Natural)
system when it is at rest as well as when it is in operation.
Environment
The conditions generated as a result of the operation of a system.
(Self-Induced)
A specific condition or influence, natural or otherwise, that may be encountered in
Environmental Hazard transport, stowage, installation, operation and maintenance and which may prove
detrimental to the performance or physical structure of the equipment.
A device capable of performing a specific functions by itself or with other items of

equipment and may be mechanical or electrical in operation or a combination of
Equipment
both. Note: The term 'Mechanical' includes hydraulic, heat or manual operation. The
term 'Electrical' includes electrical, electronic or other physical means of operation.
Exposed (Funnel
Equipment exposed to weather, salt-water spray and funnel gases.
Gases)
Equipment mounted above deck level, exposed to weather and salt-water spray
Exposed (Weather)
but not subject to funnel gases.
38
A substance or mixture which, as a result of a chemical re-action, can rapidly

Explosive produce hot gases at a high temperature. The term explosive covers high
explosives, propellants, primary explosives and pyrotechnics.
The process by which equipment is fitted in a ship, shore establishment,
Installation
training establishment, trials site or any other situation.
Item A component, sub-assembly, assembly or equipment.
Materiel A generic term covering equipment, stores, supplies, spares and specifications.
A specific type of component defined as a single composite device, not intended for
Module subdivision, which performs functions that would otherwise require two or more
components e.g. integrated circuit.
An expression used to describe a group of assemblies, units and components. An
Outfit
outfit by itself will not necessarily perform a complete operational function.
The term 'packaging' embraces preservation and package marking, as well as the
actual packing. It does not embrace special containers such as cases for drawing
Packaging
instruments or micrometers or containers of frequency-changing crystals but does
embrace the packaging of such containers with their contents.
The material produced as a result of manufacture: e.g. a component,
Product
item, equipment, system or ship.
The individual within the MOD to whom responsibility has been assigned for the
Project Manager overall management of technical, time and cost aspects of a project or group of
projects and the motivation of all those involved.
Equipment installed in offices and enclosed spaces completely protected from the
Protected Equipment
weather.
The totality of features and characteristics of a product or service or its ability to
Quality
satisfy a given need.
Quality Assurance All activities and functions concerned with the attainment of quality.
Quality Assurance
The Project Manager is the Quality Assurance Authority (QAA) for his project.
Authority
Quality Assurance The QAR is the Principal Directorate Pricing and Quality Services (PD/PQS),
Representative (QAR) representative at the contractor's works.
Responsible Authority The Integrated Project Team (IPT) Leader as appropriate.
A term which encompasses all the outfits, assemblies and units (excluding power
Set supplies common to other services) necessary to the performance of a specific
operational function.
In Quality Assurance, the document, which prescribes in detail the requirements to
Specification which supplies or services, must conform. It may refer to drawings, patterns or other
relevant documents.
A number of components mounted together, e.g. on a sub-chassis in or on the
Sub-Assembly Sub-
outside of a unit which can be removed for repair or replacement, but which is not
Unit suitable for independent use without the unit.
System A combination of Weapon and/or Ship equipment.
A number of components and/or sub-units mounted on a chassis and housed in a
drawer, case, cell or other enclosure. It may be suitable for mounting independently
Unit
or grouped with other units in an assembly. Note: A unit includes any sub-units,
which are mounted in or on it.
39
©Crown Copyright 2009
Copying Only as Agreed with DStan
Defence Standards are published by and obtainable from:
Defence Equipment and Support
UK Defence Standardization
Kentigern House
65 Brown Street
GLASGOW
G2 8EX
DStan Helpdesk
Tel: 44 (0) 141 224 2531/2
Fax: 44 (0) 141 224 2503
Internet e-mail: enquiries@dstan.mod.uk
File Reference
The DStan file reference relating to work on this standard is D/DStan/21/005
Contract Requirements
When Defence Standards are incorporated into contracts users are responsible for their correct
application and for complying with contractual and statutory requirements. Compliance with a Defence
Standard does not in itself confer immunity from legal obligations.
Revision of Defence Standards
Defence Standards are revised as necessary by an up issue or amendment. It is important that users
of Defence Standards should ascertain that they are in possession of the latest issue or amendment.
Information on all Defence Standards can be found on the DStan Website www.dstan.mod.uk,
updated weekly and supplemented regularly by Standards in Defence News (SID News). Any person
who, when making use of a Defence Standard encounters an inaccuracy or ambiguity is requested to
notify UK Defence Standardization (DStan) without delay in order that the matter may be investigated
and appropriate action taken.

UK MOD (Issue 3 Publication Date 20 September 2009) - Code of Practice For Protective Finishes

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UK MOD (Issue 3 Publication Date 20 September 2009) - Code of Practice For Protective Finishes

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Ministry of Defence

Defence Standard 21-5

12.6 Hydraulic Systems..........................................................................................................................32

Table 1 - 1a — Aluminium Sprayed or Cadmium Plated NCR Steel ............................................................5

Amd No. Date Text Affected Signature and Date

This standard is raised to Issue 3 to update its content.

This standard supersedes the following:

Def Stan 21-05 Issue 2 dated 3 Dec 2004

Def Stan 21-05 Issue 1 dated 1 April 2000

NES 1005 Issue 2 dated 2 July 1993

2. The complete Def Stan Issue comprises;

Procedures for Code of Practice for Protective Finishes

MOD Tender or Contract Process

Categories of Maritime Defence Standard

a) Category 1. If not applied, may have a Critical effect on the following:

⎯ Safety of the vessel, its complement or third parties.

⎯ Operational performance of the vessel, its systems or equipment.

b) Category 2. If not applied, may have a Significant effect on the following:

⎯ Safety of the vessel, its complement or third parties.

⎯ Operational performance of the vessel, its systems or equipment.

⎯ Through-life costs and support.

c) Category 3. If not applied, may have a Minor effect on the following:

⎯ MOD best practice and fleet commonality.

⎯ Corporate experience and knowledge.

⎯ Current support practice.

a) British Standards British Standards Institution,

389 Chiswick High Road,

b) Defence Standards Defence Equipment and Support

c) Other documents Tender or Contract Sponsor to advise.

Health and Safety

Standards for Defence -

4 Health and Safety

4.1 Paint Remover

4.3 Soluble Chromates

5.1 Types of Corrosion

a) Electro-chemical (Galvanic) corrosion.

g) Chemical corrosion (e.g. exposure to organic vapours).

5.2 Electrochemical Corrosion

a) In a marine environment, the most destructive type of corrosion encountered by equipment or

e) This standard deals mainly with protection against electro-chemical corrosion.

c) The function of a surface finish may be any or all of the following:

2) Tactical (e.g. for camouflage);

6.2 Decorative and Tactile Finishes

a) Requirements for these finishes depend largely on:

6.3 Protective Finishes

6.4 Non-metallic Materials

7 Guide to the Treatment of Non-corrosive Resisting (NCR) Steel

Table 1 - 1a — Aluminium Sprayed or Cadmium Plated NCR Steel

1-2 1-1 Good to Very Good

4-2 plus 202-5 4-1 Fair to Good

4-2 Poor to Fair

NOTE 2 Cadmium plating is NOT to be used:

a) For items likely to come into contact with foodstuffs or drink.

NOTE 4 Passivation is to be omitted in the following circumstances:

a) When followed by epoxy resin paint coat.

b) Where soldering or electrical conductivity is required.

NOTE 5 Welding of plated surfaces is undesirable because of:

b) Emission of toxic fumes from heated cadmium.

Table 1 - 2a - Chromium Plated, Lead Sprayed or Nickel Plated NCR Steel

Table 1 - 2b - Chromium Plated, Lead Sprayed or Nickel Plated NCR Steel

13-3 13-4 Fair

13-1 13-1 Poor to Fair

13-2 plus 202-7 Poor