Document Title SURFACE PREPARATION & PAINTING PROCEDURE

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SURFACE PREPARATION
&
PAINTING PROCEDURE

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Document Title SURFACE PREPARATION & PAINTING PROCEDURE
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Notes: Client Approval:

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LIST OF CONTENT
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1.0 INTRODUCTION

2.0 REFERENCES

3.0 GENERAL
3.1 Equipment
3.2 Coating Material

4.0 SURFACE PREPARATION

4.1 General
4.2 Pre-Cleaning of Surfaces and Solvent Cleaning
4.3 Surface Preparation by Blast Cleaning
4.4 Blasting Abrasives
4.5 Techniques and Constraints
4.6 Surface Preparation by Hand and Power Tool Cleaning

5.0 PAINT APPLICATION

5.1 Pre Application Procedures
5.2 Scheduling
5.3 Application Methods
5.4 Repair of Defects

6.0 PAINTING AND COATING SYSTEM

7.0 FLOW CHART FOR INSPECTION OF BLASTING AND PAINTING ACTIVITIES

7.1 Before Blasting
7.2 After Blasting
7.3 Before coating
7.4 After coating

8.0 INSPECTION AND TESTING

9.0 DOCUMENTATION

10.0 SAFETY

1.0 INTRODUCTION

1.1 Scope
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This Procedure covers the requirements for surface preparation and coating of the
steel surface for the project GE GEN8 (SQ-080410)

2.0 REFERENCES

2.1 Reference document shall be the painting specification of the customer GE

Hungary

a. Technical specification: Application of paint and protective coatings (GE Class II

(Internal) 95953 Rev AE (16.10.2015)

3.0 GENERAL

3.1 Equipment

The compressed air supply for Blast Cleaning equipment shall be free of water
and oil. Adequate separators and traps shall be provided and these shall be kept
emptied regularly of water and oil. Accumulations of oil and moisture shall be
removed from the air receiver by regular purging. Air compressors shall not be
allowed to deliver air at a temperature in excess of 110°C. The grit shall normally
be discharged with a pressure of 7 bar measured at the nozzle using a
hypodermic pressure gauge and shall not under any circumstances fall below 5.6
bar for normal cleaning operations.

The coating spraying equipment to be used shall meet the recommendations and
instructions set forth by the paint manufacturer for each specific coating system.
Airless Spray is normally the choice of application method but if conventional air
spray is used, an adequate moisture trap shall be placed between the air supply
and the pressure pot feed to the gun. The trap shall continuously bleed off any
water or oil from the air supply.

3.2 Coating Material

Storage, thinning, mixing and handling of paint materials shall be in accordance

with the Paint Manufacturer’s recommendation. All paint materials and solvents
shall be supplied in the paint manufacturer’s original containers, durably and
legibly marked with clear description of the contents. This shall include the
specification number, the color reference number, the method of application for
which it is intended, the batch number, date of manufacture, the shelf life expiry
date and the paint manufacturer’s name or recognized trademark.

Different brands or different make of paints shall not be inter-mixed. Similarly,

mixing of different brands or generic types of paint material is not permitted. The
Manufacturer’s pot-life requirements shall be strictly and diligently followed.
The same shall be said for the minimum and maximum over-coating time as
recommended by paint manufacturer

Only thinners as specified by the paint manufacturer shall be used. Mixing and
thinning directions as furnished by the paint manufacturer shall be followed.
Statutory requirements for levels of volatile organic compound are to be met.
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4.0 SURFACE PREPARATION

4.1 General

For optimum paint performance, surfaces to be painted or coated shall be:

completely dry, steel preparation shall be in accordance with ISO 8501-3 grade
??, free from rust, loose scale, dirt, dust, grease, oil and other foreign matter
deleterious and harmful to paint. After the preparation of the substrate surface,
any grit or dust shall be removed and a layer of primer applied before any
corrosion or recontamination occurs, normally within four (4) hours after blasting.
Surface preparation shall be subjected to inspection before the primer coat is
applied to ensure all traces of dust and foreign matter have been removed by
brushing, blowing with dry clean compressed air or vacuum cleaning.

4.2 Pre-Cleaning of Surfaces and Solvent Cleaning

This cleaning process is mandatory before further cleaning or surface preparation.

Prior to the actual cleaning operation, surface contaminants such as oil, grease,
hydrocarbon etc. shall be removed preferably by degreasing with suitable
degreaser or solvent cleaning according to SSPC-SP1. This process also applies
to all metal surfaces to be coated that do not require blast cleaning or power tool
cleaning.
Excessive rust scale shall be removed by impact cleaning tools before blasting
operations.

4.3 Surface Preparation by Blast Cleaning

Blast cleaning shall be carried out through ISO 8504-2:1992 to the required visual
standard in accordance with ISO 8501-1:1988 or equivalents. All surfaces, where
accessible shall be prepared by abrasive blast cleaning to a minimum of SA 2.5
according to ISO 8501-1.

4.4 Blasting Abrasives

Blasting abrasives for use in blast cleaning carbon steel and low alloy steel are
specified in ISO 8504-2. Recommended blasting abrasives are as follows, but not
limited to:

a) Chilled iron grit or shot

b) Steel and malleable iron grit or shot
c) Natural mineral abrasives
d) Non metallic abrasives (aluminium oxide, garnet etc)

Sand or other materials producing silica dust shall not be used. The abrasives
shall be free from oil, grease, moisture, salt, dust etc. Re-used abrasives shall be
clean, sharp and free from contaminants. The blast profile and angular anchor
pattern shall be that recommended by the paint manufacturer to suit the minimum
requirements of their respective primers. The acceptable peak-to-valley height
range shall be between 40 ~ 75 microns or equivalent to ISO 8503-1 grade
Medium (G) this is also correspondent to grades BN10a according to Rugotest No
3.
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4.5 Techniques and Constraints

Blast cleaning shall not be carried out when the temperature of the surfaces to be
coated is less than 3° Celsius above the dew point or when the relative humidity of
the air is greater than 85 %.

Abrasive blasting shall not be done in open areas close to painting operations or
wet coated surfaces to prevent dust and grit contamination. Normally grit blasting
shall be permitted only during daylight hours except that rough grit blasting will be
allowed during the night provided that the surface is subsequently blasted to the
specified standard under good light conditions. When blasting is done indoors in a
controlled environment, the blasting operations can be performed during the whole
day and night. The illumination of the surface during final blasting shall be at least
500 Lux and all environmental restrictions are observed.

All welded areas and appurtenances shall be given special attention for removal of
welding flux in crevices. Where rectification is necessary on abrasive blast
cleaned surfaces, the dressed areas shall be re-blasted to remove all rust, slag
and grit and to provide an adequate anchor pattern.

Blasting shall continue a minimum of 25 mm into any adjacent coated areas and
the edges shall be feathered. After dry blast cleaning, no acid washes, cleaning
solutions, solvents or other chemical treatment shall be used on metal surfaces.
This restriction includes inhibitive washes to prevent rusting. Any blast-cleaned
steelworks on which rust develops shall be re-blasted prior to being painted.

4.6 Surface Preparation by Hand and Power Tool Cleaning

The most technically effective surface preparation method is blast cleaning.

Manual preparation shall only be used when blast cleaning is either not feasible or
not strictly required eg. hot dip galvanized steel and stainless steel.

Manual cleaning shall be performed using hand wire brushes or mechanically

operated tools (grinders, chippers, wire brushes) in accordance with ISO 8504-3.
Where welds occur within these areas or when these areas cannot accommodate
a power disc, power impact tools shall be applied (vibratory and rotary hammers,
needle guns, chisels) followed by brush cleaning.

If the surface being prepared lies adjacent to a coated surface which is not to be
refurbished, the power tool cleaning shall overlap the coated surface by at least 25
mm. The minimum requirement for successful coating application is St 3 ISO
8501-1 at the time of coating. Care shall be taken to ensure that the substrate
surface does not become polished during power tool cleaning.

5.0 PAINT APPLICATION

5.1 Pre Application Procedures

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5.1.1 General

Any surfaces to be coated shall be dry and rendered dust free according
to ISO 8502-3 grade 2, prior to application of primer coat. This can be
accomplished by blowing off the surface with clean dry air or using an
industrial vacuum cleaner together with a clean dry stiff brush. The
blasted surfaces shall be examined for traces of smudge, oil, grease or
other contamination. If present they shall be removed by solvent washing
and the areas re-blasted.

5.1.2 Mixing and Thinning

All coating materials shall be thoroughly stirred in the paint container with
a hand held power mixer for a time sufficient to thoroughly remix the
pigments and vehicles. Sufficient agitation to maintain good mixing shall
be applied until the product is used. Coatings containing heavy or metallic
pigments that have a tendency to settle shall be kept in continuous
suspension in the paint container by a hand held mixer power mixer.

If during mixing / stirring air is entrapped in the product, sufficient time

should be allowed for air bubbles to escape, before application is started.
This is to reduce the risk of pin-holing of the coating layer to be produced
Thinner shall not be added to primer or paints unless necessary for proper
application according to the paint manufacturer’s recommendation. The
type of thinner used must comply with same.

If the coating material requires the addition of a catalyst, the pot life under
application conditions shall be clearly stated on the label. The pot life shall
not be exceeded. When the pot life limit is reached, the spray pot shall be
emptied, the material discarded, the equipment cleaned and new material
catalyzed.

Hydrostatic and other testing of welds shall be completed prior to painting

weld lanes, ends of pipe and related components that will require
subsequent welding at site shall be masked off after blast cleaning and
left uncoated for a distance of 50 mm from all areas requiring welding.

5.1.3 Other Miscellaneous Requirements

Extra coats of paint shall be applied on areas where shape and/or plane
of application results in thinly applied coatings; example at edges, welds
behind angles, corners etc and areas not fully accessible by spray in order
to obtain the specified coverage and thickness. A stripe coat of paint shall
be brush applied before applying the subsequent coat.

5.2 Scheduling

Unless otherwise recommended by the paint manufacturer and accepted by the

Customer, paints shall NOT be applied when:

5.2.1 Incomplete surface preparation or oil, grease and dust still present on
substrate to be painted.
5.2.2 The surface temperature is less than 3°C above Dew point.
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5.2.3 The air or surface temperature is below 5°C as it would adversely affect
curing of Paint.
5.2.4 The relative humidity of air is greater than 85% except for inorganic zinc
silicate up to 90%.
5.2.5 The metal substrate temperature is higher than that recommended by the
paint manufacturer for application
5.2.6 There is a likelihood of an adverse change in weather conditions within
two hours after application that would result in a drastic drop in air
temperature below those as specified above.
5.2.7 There is a deposition of moisture in the form of rain, condensation etc.
upon the surface.
5.2.8 The available light is less than 500 Lux

Blast cleaned or power disc grinded surfaces shall be coated with the primer
specified normally within four (4) hours after blasting or power grinding or within
such other limits as may be specified and before any visible rusting occurs. The
surface preparation quality shall meet the standard ISO 8501-1 grade Sa2,5 at the
time of coating application. Each coat of paint shall dry for a time period within the
limits prescribed by the Paint Manufacturer before the next coat is applied
(minimum and maximum over-coating time).

5.3 Application Methods

5.3.1 General

Coatings shall be uniformly applied without runs, sags, solvent blisters,

dry spray or other blemishes. All blemishes and other irregularities shall
be repaired or completely removed and recoated. Special attention shall
be paid to crevices, corners, edges, weld lines, bolt heads, nuts and small
brackets to apply the specified minimum dry film thickness by brush
application if spray will not completely cover all surfaces.

Edges of existing coating shall be feathered towards the substrate prior to

over-coating Primers should not be over-coated with the second coat
paint until the specified minimum over-coating time is achieved

Inter-coat contamination shall be minimized by maintaining proper

cleanliness and by applying the intermediate and finish coats within the
over-coating time recommended by the paint manufacturer. If
contaminants are present, they shall be removed before applying
succeeding coats. Contrasting color shall be used for each coat of paint.

5.3.2 Spray Application

Paints shall be applied by Airless Spray or Air Spray (Conventional) in

cases of small repair work. Hose and containers, lines and pots shall be
thoroughly cleaned before addition of new materials. The spray gun shall
be held no closer than
200 mm (between 300 mm to 400 mm) from the surface to be coated at
right angles to the surface. Uniform parallel passes should be made with
the spray gun. Each spray pass shall overlap the previous pass by 50%.
Large surfaces should always receive passes in two directions at right
angles to each other.
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Each coat is to be applied uniformly and completely over the entire

surface. All runs and sags shall be brushed out immediately or the paint
removed and the surface re-sprayed. Before spraying each coat, all areas
such as corners, edges, welds, small brackets, bolts, nuts and interstices
shall be pre-coated, usually by brush to ensure that these areas have at
least the minimum specified film thickness.

5.3.3 Brush Application

Brush application may be used under the following circumstances:

a) When spraying for any reasons cannot be properly implemented

b) When spray application is deemed to be difficult, adverse to the
required quality finish, uneconomical or may affect other plant,
equipment property, personnel etc. due to location of work
accessibility
c) For “touch-up” or repair to localized damaged paint areas or areas
of incorrectly applied paint
d) For application of initial stripe coat of paint to corners, edges,
crevices, holes, welds or other irregular surfaces

Paint brushes used shall be of a style and quality that will permit proper
and appropriate application of paint. Good quality hog bristle is preferred
and nylon or other synthetic bristle types are allowed. Round or oval
brushes are considered most suitable for rivets, bolts, irregular surfaces
etc. Wide flat brushes are suitable for large flat areas but not to exceed
width of 120 mm. Brushes shall be kept in good condition at all times and
discarded if damaged or excessively worn. The brushing shall be done so
that a smooth coat, as uniform in thickness as possible is obtained. There
should be no deep or detrimental brush marks.

Paint shall be worked into all crevices and corners. Runs and sags shall
be brushed out. During application of each coat, all areas such as
corners, edges, welds, small brackets, bolts, nuts and interstices shall
receive additional coating material to ensure that these areas have at
least the minimum specified film thickness and to ensure continuity of
coating

5.3.4 Roller Application

Roller application shall be discouraged and shall be subject to the specific

approval of customer. If allowed, it will only be used on relatively large
surface areas provided that the first primer coat of paint is applied by
brush and its use in accordance to the Paint Manufacturer’s instructions.
Rollers shall be manufactured from good quality “carpet pile” or lambs
wool.

5.4 Repair of Defects

5.4.1 General

A specific paint system or scheme for the repair and/or touch-up painting
of each generic type shall be submitted for approval from customer
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Before application of any further coat of material, all damages to previous

coats shall be repaired. All loose paint shall be removed to a firm edge. All
surface irregularities and contaminants shall be removed. Hard glossy
surfaces may require abrading to obtain a suitable surface for painting.
If the surface being prepared lies adjacent to a sound coated surface
which is not to be repaired, the surface preparation shall overlap the
coated surface by at least 25 mm.

5.4.2 Inadequate Coating Thickness

Areas with inadequate coating thickness shall be thoroughly cleaned and

if necessary abraded and additional compatible coats applied shall blend
in with the final coating on adjoining areas.

5.4.3 Coating Damage not exposing steel surface substrate

The damaged area shall first be washed down to remove all

contamination. The coating around the damaged area shall be feathered
or chamfered by sanding down to ensure continuity of the patch coating.
The full coating system shall then be re-applied strictly in accordance with
the specification

5.4.4 Coating Damage exposing steel surface substrate

The damaged area shall be re-cleaned as originally specified for that item
and the full coating system re-applied in accordance with the product data
sheet (PDS). The re-cleaning shall carry over on to the secure
surrounding coating for not less than 25mm all round and the edges shall
be feathered or chamfered by sanding down to ensure continuity of the
patch coating.

5.4.5 Repair of Fully Cured Epoxy coatings

In case of repairing damage to fully cured epoxy coatings, the coating

work shall only be carried out after the surface of the fully cured epoxy to
be coated has been suitably abraded to provide an adequate tooth for the
coating to be applied. The repair coating shall be compatible with the
existing coating.

6.0 PAINTING AND COATING SYSTEM

6.1 Painting material will be applied according to the design temperature and services
condition. Selection of paint material is also confirmed by the Paint Manufacturer.

6.2 The coating system is described in Table 1.

Position Coat # Manufacturer/Paint Nominal dry film

name thickness (NDFT)
(µm)
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1 PPG/Amercoat 68 G 75
OUTSIDE
2 PPG/PSX 700 100
1 PPG/Amercoat 68 G 75
INSIDE
2 PPG/PSX 700 100
Table 1.

7.0 FLOW CHART FOR INSPECTION OF BLASTING AND PAINTING ACTIVITIES

7.1 Before Blasting

i) Condition of rust Grade A, B, C and D

INSPECTION OF ii) Oil and grease removal as per SSPC-SP1
STEEL WORK iii) Steel preparation according to ISO 8501-3,
grade

i) Grade/ mesh size/ type ISO 8504-2

INSPECTION OF
ABRASIVE

INSPECTION OF i) Test runs of the equipment

BLASTING ii) Compressed air free from oil and moisture,
EQUIPMENT oil and moisture separator
iii) Pressure at blast hose nozzle

i) No blasting shall be done when the surface

CHECK WEATHER temperature is less than 3˚C above the Dew
CONDITION Point or the relative humidity (RH) is greater
than 85%

7.2 After Blasting

INSPECTION OF i) Quality achieved according to ISO 8501-1,

SURFACE PROFILE Sa2,5
AND CLEANLINESS ii) Surface roughness profile between 40-75µm
or equivalent to ISO 8503-1, Medium (G) or
BN10a according to Rugotest No. 3

7.3 Before coating

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i) No coating to be applied if steel temperature

CHECK WEATHER is less than 3˚C above the Dew Point or
CONDITIONS relative humidity is greater than 85%

i) Surface to be blown off with compressed air /

SURFACE vaccum cleaning to Grade 2 according to ISO
INSPECTION 8502-3
ii) Dust/pollution free environment. No painting
to be carried out when blasting work is
nearby

INSPECTION OF i) Correct paint as per paint specification

PAINT MATERIAL ii) Batch number
iii) Correct color as per paint specification
iv) Preparation as per Manufacturers
specification
v) Correct method of paint application

7.4 After coating

i) Specified WFT achived

INSPECTION OF ii) Minimum DFT achieved as per specification
PAINTED SURFACE

8.0 INSPECTION AND TESTING

8.1 The following inspection shall be carried out after in accordance with Table 1 in
this procedure. Surface shall be accessible until final inspection is carried out.

8.2 Individual coat and completed coating shall be visually inspected for appearance.
Coatings shall be smooth and free from run, cracking, blistering, dry spray, over
spray, pinholes, crater and sagging.

8.3 During coating, the wet film thickness (WFT) shall be spot-
checked. Specified total minimum dry film thickness (DFT) shall be spot-
checked by a thickness gauge (Elcometer 456). Dry film thickness shall
also be measured on individual coats. WFT and DFT measurements shall
comply with SSPC-PA2 restriction Level 2. The NDFT for this project is
175µm. Measurements taken shall be evaluated and approved according
to the standard SSPC-PA2 80/20 rule, restriction Level 2. In contrast to
the standard requirements (restriction Level 2) for maximum dry film
thickens (DFT), the maximum allowed DFT for this specific project is
400µm which was specified by the customer GE. The minimum DFT shall
be evaluated by the 80/20 with no additional requirements.

8.4 Temperature and relative humidity shall be measured by means of a temperature

gauge and hygrometer. Reading shall be taken at regular intervals, depending on
change in climatic condition

8.5 Coating shall be removed and repainted if the specification reveals the following:

a) Coating not adhering to surface to which it is applied

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b) Surface has not been properly blasted and/or clean

c) Loose or scaling paints remains
d) Foreign matter (contamination) embedded into coated surface.
e) Freshly coating surface is wet from rain, high humidity or low dew points.
f) Previously applied coating has not cured.
e) For other reason that will impair the coating performance.

Test Type Method Frequency Acceptance Criteria Consequence

Environmental Ambient and steel Before start of In accordance with No blasting or
conditions temperature, each shift and specified coating
relative humidity, minimum twice requirements
Dew point per shift
Visual Visual for sharp 100% of all ISO 8501-3 grade Defects to be
examination edges weld surface repaired
spatter, slivers,
rust grade etc
Cleanliness a) ISO 8501-1 a) 100% visual all a) In accordance a) Re-blasting
b) ISO 8502-3 surfaces with specified b) Re-cleaning
b) Spot checks requirements and retesting
b) Maximum quantity until
& size is rating 2 acceptable
Roughness Comparator or Each component In accordance with Re-blasting until
stylus instrument or once per 50m2 specified paint acceptable
ISO 8503/ system
Rugotest No 3
Visual Visual to 100% of surface In accordance with Repair of defects
examination determine curing, after each coat specified and retesting
contamination, requirements
solvent retention,
pinholes/popping,
sagging and
surface defects
Wet film SSPC-PA2 Systematically In accordance with Repair or re-
thickness (WFT) during any specified paint coating as
application system appropriate
Dry film SSPC-PA2 Each coat, when In accordance with Repair or re-
thickness (DFT) coating system specified paint coating as
are cured system appropriate
Table 2. Inspection and testing

9.0 DOCUMENTATION

9.1 Inspection results for surface preparation and coating shall be recorded in the
Inspection report document for the specific project.

10.0 SAFETY

10.1 All safety and regulations of Slovenian and local laws and insurance underwriter
regulations shall be adhered to in the storing, handling, use and application of
paints, thinners, solvents, etc.
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10.2 Smoking, open fires, or sparks will not be permitted in confined areas that are
being or recently have been painted and are emitting flammable solvents.

10.3 All equipment recommended lifting up by using the lifting lug attached due the
painting work to avoid any damage or uneven distribution of paints on the
equipment main body.

10.4 The following documentation shall be provided and used when evaluating coating
systems:

a) chemical name of organic solvent, OAR number, and VOC content in g/l;
b) percentage of low molecular epoxy (molecular weight < 700);
c) content of hazardous substances;
d) specification of hazardous thermal degradation components;
e) combustibility;
f) special handling precautions and personal protection.

10.5 Use of Personal Protective Equipment (PPE) shall be mandatory to avoid any
incident / accident / health hazard during blasting and painting activities.

Written by: Dominik Tafi

Technologist for corrosion protection