Presentasi Coating Indr 26 Juli 2016 New 4

PENANGGULANGAN KOROSI STRUKTUR BAJA DI
LINGKUNGAN ATMOSFIR DENGAN LAPIS LINDUNG CAT
SUNDJONO
PUSLIT METALURGI - LIPI

E-mail : sundjono.dalil@gmail.com
Hp : 081399625845
INDOKOR
DAFTAR RIWAYAT HIDUP
NAMA : SUNDJONO
PENDIDIKAN : SARJANA KIMIA 1983 UNIVERSITAS PADJADJARAN
BANDUNG
PEKERJAAN
TAHUN 1984 – SEKARANG : STAF PENELITI DIVISI KOROSI – METALURGI LIPI
PENGALAMAN KERJA :
TAHUN 1985 – 1986 : KERJASAMA PENELITIAN - HANKAM :
KOROSI ATMOSFERIK - CAT
TAHUN 1987 – 1989 : STUDI DI JERMAN : KOROSI & CAT
TAHUN 1990 : KERJASAMA PENELITIAN - JEPANG : SSC
TAHUN 1991 : KERJASAMA PENELITIAN - PILIPINA :
KOROSI ATMOSFER & CAT
TAHUN 1992 : KERJASAMA PENELITIAN - JEPANG : SSC
TAHUN 2000 – 2001 : KERJASAMA PENELITIAN - NEW ZEALAND
MONITORING KOROSI PADA UNIT HE PABRIK PUPUK
TAHUN 1985–SEKARANG : PENELITIAN DAN JASA UJI DI BIDANG KOROSI
KOROSI
STRUKTUR MIKRO LOGAM BAJA
perlit (Fe3C) ferit
LOGAM BAJA MEMPUNYAI 2 FASA :
FASA PEARLITE Fe3C ( HITAM )
BERTINDAK SEBAGAI KATODA
C: 0.5384
FASA FERRITE % )
( PUTIH
BAJA KARBON BERTINDAK SEBAGAI ANODA.
C: 0.1799 % UKURAN BUTIRAN PEARLITE TERGANTUNG :

KADAR KARBON ( CC)1045
BAJA :
Adanya 2 fasa pada logam baja menyebabkan logam baja

tersebut cenderung mudah terkorosi
Laju korosi logam baja juga dipengaruhi oleh ratio antara
jumlah perlit & ferit.
Semakin besar jumlah fasa perlit, semakin mudah terkorosi,
tetapi sifat mekaniknya ( strength ) semakin tinggi.
Semakin rendah kadar karbon , semakin tahan terhadap
korosi, tetapi sifat mekaniknya ( strength ) semakin rendah.
Redox Potential of Metals
METAL REDOK POTENSIAL mv

Active End
Magnesium ( ACTIVE ) Mg2+ + 2e ---------- Mg -2.38
Alummunium Al3+ +3e ---------- Al -1.66
Zinc Zn2+ + 2e ---------- Zn -0.76
Chromium Cr3+ + 3e ---------- Cr -0.71
Iron Fe2+ + 2e ---------- Fe -0.44
Nickel Ni2+ +2e ---------- Ni -0.23
Hydrogen 2H+ + 2e ---------- H2 0.00
Copper Cu2+ +2e ---------- Cu +0.34
Silver Ag+ + e ---------- Ag +0.80
Platinium Pt2+ +2e ---------- Pt +1.2
Gold ( NOBLE ) Au3+ +3e ---------- Au +1.42
Noble of Passive End
PROSES KOROSI
O2 O2
LAPISAN AIR /
ELEKTROLIT
BAJA
 Baja terekpose di udara terbuka, permukaannya akan dibasahi

oleh air
 Ketebalan lapisan air , tergantung tingkat kelembaban relatif udara

disekitarnya
 Air pada permukaan baja akan melarutkan oksigen, patikel-partikel

garam & gas-gas korosif dari udara & membentuk lapisan elektrolit
PROSES KOROSI
O2 O2
LAPISAN AIR/
ELEKTROLIT
KATODA KATODA
e ANODA
e
BAJA
REAKSI ELEKTROKIMIA : Simultan - Stochometry & Closed Circuit
PADA ANODA : 4 Fe -------------- 4 Fe 2+ + 8 e ( OKSIDASI )

PADA KATODA : 4 H2O + 2 O2 + 8 e ---------- 8 OH- ( REDUKSI )
4 Fe 2+ + 8 OH- ------- 4 Fe ( OH )2
4 Fe( OH )2 + O2 -------- 2 Fe2O3. 2H2O ( KARAT )
LAJU KOROSI
 KONDUKTIVITAS ELEKTROLIT
 TEMPERATUR & pH ELEKTROLIT
 POTENSIAL LOGAM ( emf )
PENGARUH RH DENGAN KANDUNGAN 0.I % GAS SO2
TERHADAP LAJU KOROSI BAJA
CORROSION RATE µm PER YEAR

LAJU KOROSI vs KONSENTRASI LARUTAN NaCl
2
Relative corrosion rate 1
0
0 3 5 10 15 20 25 30
Conc NaCl ( wt % )
PENGARUH KELARUTAN ION Cl- TERHADAP KOROSI BAJA
80
Corrosion weightloss ( mg )
70 With oxygen
60
50
40
30
20
10
0 Without oxygen
0 500 1000 1500 2000
Chloride ion ( mg/l )
Redox Potential of Metals
METAL REDOK POTENSIAL mv

Active End
Potasium ( ACTIVE ) K+ + e ---------- K -2.92
Magnesium Mg2+ + 2 e ---------- Mg -2.38
Alummunium Al3+ +3e ---------- Al -1.66
Zinc Zn2+ + 2e ---------- Zn -0.76
Chromium Cr3+ + 3e ---------- Cr -0.71
Iron Fe2+ + 2e ---------- Fe -0.44
Nickel Ni2+ +2e ---------- Ni -0.23
Hydrogen 2H+ + 2e ---------- H2 0.00
Copper Cu2+ +2e ---------- Cu +0.34
Silver Ag+ + e ---------- Ag +0.80 1.63 0.44
Platinium Pt2+ +2e ---------- Pt +1.2
Gold ( NOBLE ) Au3+ +3e ---------- Au +1.42 0.84
Noble of Passive End
REDOX Potential of Cathodic Reactions
Reaction REDOK POTENSIAL mv
Hydrogen ion reduction 2H+ + 2e ------- H2 0.00

Oxygen reduction, in acid solution O2 + 4H+ + 4e ------ 2H2O +1.23
Oxigen reduction in base/neutral solution O2 + 4H2O + 4e ------ 4OH- +0.40
Metal iron reduction Fe3+ + e ------ Fe2+ +0.77
Metal deposition Cu2+ + 2e ------- Cu +0.34
PERSYARATAN KOROSI
 PROSES KOROSI SECARA ELEKTROKIMIA

 DAERAH ANODA
 DAERAH KATODA
 ELEKTROLIT
 SIRKUIT ELEKTRIK
Katagori korositivita atmosferik ISO 12944 -2
Kehilangan berat/tebal per

satuan permukaan
Kategori (setelah 1 tahun terekspos) Tipikal lingkungan
korosifitas Baja karbon-rendah
Kehilangan Kehilangan
Berat (g/m2) Tebal (μm)
Lingkungan pedesaan dengan tingkat

C2 >10 - 200 > 1,3 - 25 polutan rendah.
rendah
Lingkungan perkotaan & Industri
C3 dengan polusi SO2, area pantai
menengah > 200 - 400 > 25 - 50 dengan tingkat salinitas rendah
C4 Lingkungan industri & pantai

tinggi > 400 - 650 > 50 - 80 dengan tingkat salinitas menengah
C5-I Area industri dengan kelembaban &

sangat tinggi > 650-1500 > 80 - 200 polusi SO2 tinggi
(industrial)
C5-M
sangat tinggi > 650-1500 > 80 - 200 Area pantai dengan tingkat salinitas
(laut/pantai) tinggi
KONVERSI LAJU KOROSI
1.44
mdd mpy = --------------------- x mdd = ( mil /year )
berat jenis logam
Berat jenis baja = 7,86 g/cm3

1 mdd = 0,182 mpy = 36,50 g/m2.tahun
1 mpy = 1 / 0.182 = 5.5 mdd
Contoh :
10 g/m2.tahun = 10 / 36.50 = 0.274 mdd = 0,05 mpy
0,05 mpy = 0,05/1000 x 25,4 mm = 0,00127 mm /th= 1,27 μm/th
1500 g/m2.tahun = 1500 / 36.50 = 41.09 mdd = 7,47mpy

7,47mpy = 7,47/1000 x 25,4 mm = 0,19 mm = 190,0 μm
9
MEKANISME KOROSI BAJA
LINGKUNGAN INDUSTRI LINGKUNGAN PANTAI

Sulphur Dioxide SO2 Chloride Cl
Fe Fe
Fe IRON OXIDE Fe
IN LARGES VOLUMES
FeSO4 / FeCl2 CORROSION

PRODUCT
KOROSI CELAH
( keling, flange, sambungan ulir, & lasan )
DAERAH KRITIS KOROSI PADA TANKI TIMBUN BBM
Kondensasi moisture
Kondensasi moisture
Udara masuk karena tanki

tekanan tangki turun
Korosi disebabkan oleh

1. Korosi disebabkan oleh
kondensasi moisture
2. Korosi dinding kondensasi moisture
dalam sel pada Daerah uap
daerah bidang batas
H2S, CO2 & SO2 EVOLUTION
H2S, CO2, dan SO2 evolution
evolution
5. Korosi akibat
lingkungan Mild-attack
atmosferik
Air
6. Korosi akibat
lingkungan tanah 3. Korosi
Korosidibawah deposit
dibawah deposite 4. Korosi akibat
Korosi karena akumulasi air
akumulasi air
MEKANISME KOROSI PADA DINDING TANKI TIMBUN BBM
PENGENDALIAN KOROSI
1. PEMILIHAN MATERIAL
2. PROTEKSI KATODIK : IMPRESSED CURRENT

ANODA KORBAN.
3. PENAMBAHAN INHIBITOR : KOROSI,

ANTI SCALE
BIOCIDE
4. LAPIS LOGAM
5. LAPIS LINDUNG CAT

The use of protective coatings
1. Tranportation
2. Industry plant
3. Pipeline,
4. Storage tank.
5. Bridge.
6. The interior of a house or office building
PAINT FUNDAMENTAL
SISTEM LAPIS LINDUNG CAT
TOP COAT
UNDER COAT
PRIMER
Sand blast Sa 2,5 Anchor pattern 50 - 75 µm
PERSIAPAN PERMUKAAN
PAINT FUNDAMENTAL
FUNGSI & SIFAT - SIFAT CAT
FUNGSI CAT :
 PROTEKTIF & DEKORATIF
 PROTEKTIF
 DEKORATIF ( ESTETIKA )
 KHUSUS LAINNYA
SIFAT - SIFAT CAT :

 SIFAT - SIFAT DASAR
 SIFAT - SIFAT SPESIFIK
SIFAT - SIFAT DASAR:
SIFAT - SIFAT YANG HARUS DIMILIKI OLEH SEMUA CAT UNTUK

MENJAMIN FUNGSINYA SEBAGAI PROTEKTIF & DEKORATIF :
 DAYA ADESI
 LAPISAN TERINTEGRITAS
 KUALITAS TETAP
 MUDAH DIAPLIKASIKAN
SIFAT - SIFAT SPESIFIK :
SIFAT - SIFAT YANG DIPERLUKAN CAT UNTUK PENGGUNAAN AKHIR
YANG SPESIFIK :
 CAT TAHAN AIR / ZAT KIMIA

 CAT TAHAN AKSI MEKANIK
 CAT TAHAN SINAR UV
 CAT TAHAN API
 CAT TAHAN TEMPERATUR TINGGI
 CAT TAHAN JAMUR – ANTI FOULING
PAINT PAINT
KOMPONEN - KOMPONEN UTAMA CAT
1. RESIN / BINDER
2. PELARUT
3. PIGMEN
4. EXTENDER
TOP COAT
5. ADDITIVE
FUNGSI KOMPONEN - KOMPONEN CAT
RESIN / BINDER
FUNGSI
 MENGIKAT PIGMEN & KOMPONEN -KOMPONEN CAT LAINNYA
 MEMBERIKAN DAYA REKAT PADA SUBSTRAT & LAPISAN CAT

SEBELUMNYA
 MENENTUKAN SIFAT KIMIA, FISIK DAN MEKANIK :
RESIN / BINDER :
 CHLORINATED RUBBER  POLYURETHANE
 VINYL  EPOXY
 ACRYLIC  ETHYL ZINC SILICATE
 ALKYD
PELARUT :
FUNGSI :
 MELARUTKAN RESIN DALAM PROSES PEMBUATAN CAT
 KONTROL VIKOSITAS UNTUK MEMUDAHKAN DALAM APLIKASI
 KONTROL PROSES PENGERINGAN LAPISAN CAT
PELARUT:
 HC. Aliphatic  Alcohol
 HC. Aromatic  Esters
 Ketones  Toluene
 Aceton  Xylene
PIGMEN
FUNGSI :
DALAM LAPISAN PRIMER :
1. MENYEDIAKAN ANCHOR UNTUK MENGIKAT LAPISAN CAT
BERIKUTNYA
3. MENDISTRIBUSIKAN GAYA PENGKERUTAN LAPISAN CAT
DIATASNYA SELAMA PROSES PENGERINGAN
4. SEBAGAI PROTEKTIF ( INHIBISI KARAT / KOROSI )
PIGMEN :
AKTIF : PASIF :
 SERBUK Zn  Fe2O3
 Zn KROMAT  TiO2
 PbOPbO2
 CaPbO4
PIGMEN
DALAM LAPISAN CAT AKHIR :
1. Menyokong sifat – sifat spesifik tertentu :
• Memberikan daya tahan terhadap sifat mekanik, fisik &
kimia dalam coating film :
 Menurunkan permeabilitas
 Proteksi dari efek sinar UV & cuaca
2. Sebagai dekoratif :
A. WARNA
B. DAYA PENUTUP/ HIDING POWER
C. KILAPAN ( GLOSS ) :
PIGMEN:
 < 25 % : GLOSS
 25 - 70 % : SEMI- GLOSS
 > 70 % : NON- GLOSS
GLOSS & HIDING POWER
Definition of gloss from AS/NZS 2310

Prefered Term Description Alternative Term
Flat / Non gloss Equal or < 5 gloss units Matte
Low gloss > 5 – 20 gloss units

Low sheen or egg shell
Semi - gloss > 20 - 50 gloss units
Satin
Gloss > 50 -- 85 gloss units -
Full gloss > 85 gloss units High gloss
Hiding power of white pigments
Pigment Hiding Units

Basic lead carbonates 15
Basic lead sulfate 15
Zinc oxide 20
Antimony oxide 28
Anatase titanium dioxide 100
Rutile titanium dioxide 125-135
Pigment Shapes
The shape of pigments is an important characteristic & can influence
the physical properties of the coating
Some common shapes are : nodular, needle, lamellar
 Nodular
 titanium dioxide ( add color )
 metallic zinc ( cathodic protection ).
 Acicular needle – shaped )

 zinc oxide ( to provide color )
 glass fibers ( to reinforce the coating film )
 Lamellar ( plate – like )

 mica,
 aluminum flake,
 glass flake,
Decrease the permeability of the film to moiture
PENGARUH PIGMEN
EXTENDER
FUNGSI :
 UNTUK MENURUNKAN BIAYA PRODUKSI
 MENYOKONG SIFAT - SIFAT TERTENTU
CHEMICAL RESISTANCE
EXTENDER ACID ALKALI
1. BARITES ( BaSO4 ) E E
2. SILICA ( SIO2 ) E E
3. LIMESTONE ( CaCO3) P E
4. MICA ( K2O.3Al2O3.6SiO2.2.H2O ) E E
5. CLAY ( Al2 ( SiO3 )3 ) G G
6. TALC ( MgSiO3) G G
ADITIF
FUNGSI :
 MEMBERIKAN SIFAT - SIFAT TERTENTU YANG DIINGINKAN
1. ANTI SETTLING
2. ANTI SKINNING / OXIDANT
3. ANTI FLOATING
4. PLASTICIZER
5. GLOSSING AGENT
6. UV SCREENER
7. DRYER AGENT
8. ANTI BIOCIDE DAN FOULING
PEMILIHAN SISTEM CAT
UNTUK STRUKTUR BAJA

Sistem pengecatan baja untuk kategori korosifitas C2 ( 12944-5 2007 )
Surface preparation : For Sa 2½, from rust grade A, B or C only (see ISO 8501-1)
Cat akhir Perkiraan umur
Cat dasar (primer) ( Subsequent Sistem cat pelayanan
coat ) ( Expected durability )
No. sistem
Tot.
Jenis Jlh Lap. NDFT Jenis Jlh lap.
Binder NDFT
primer cat (μm) binder cat R M T
(μm)
A2.01 1 40 AK 2 80
A2.02 1-2 80 AK 2-3 120
AK
A2.03 1-2 80 AK, AY, CR, PVC 2-4 160
A2.04 Misc. 1-2 100 - 1-2 100
A2.05 AY, CR, PVC 1-2 80 AY, CR, PVC 2-4 160
A2.06 EP 1-2 80 EP; PUR 2-3 120
A2.07 EP 1-2 80 2-4 160
A2.08 EP; PUR; ESI Zn (R) 1 60 - 1 60
Water-borne
Water-borne Binder untuk cat selanjutnya Tipe
Binder untuk cat primer Tipe possible
possible ( top coat )
AK = Alkyd 1 pack X AK = Alkyd 1 pack X
CR = chlorinated rubber 1 pack CR = chlorinated rubber 1 pack
AY = Acrylic 1 pack X AY = Acrylic 1 pack X
PVC = Polyvinyl chloride 1 pack PVC = Polyvinyl chloride 1 pack
EP = Epoxy 2 pack X EP = Epoxy 2 pack X
1 pack / 1 pack / X
ESI = Ethyl silicate X PUR = Polyurethane aliphatic
2 pack 2 pack
PUR = Polyurethane aromatic or 1 pack/ X
aliphatic 2 pack
Note : Zn (R) = Zinc rich primer

R = rendah; (2- 5 thn); Misc. : Primers dengan bermacam - macam jenis
M = menengah (5-15 thn); pigmen anti korosi
T = tinggi (>15 thn);
Surface preparation : For Sa 2½, from rust grade A, B or C only (see ISO 8501-1)
No. sistem coat ) ( Expected durability )
Tot.
Jenis Jlh Lap. NDFT Jlh lap.
Binder Jenis binder NDFT R M T
primer cat (μm) cat
(μm)
A3.01 1-2 80 AK 2-3 120
A3.02 1-2 80 AK 2-4 160
AK
A3.03 1-2 80 AK 3-5 200
A3.04 1-2 80 AY, CR, PVC 3-5 200
A3.05 AY, CR, PVC Misc. 1-2 80 AY, CR, PVC 2-4 160
A3.07 EP 1 80 EP; PUR 2-3 120
A3.08 EP 1 80 EP; PUR 2-4 160
A3.09 EP 1 80 EP; PUR 3-5 200
A3.10 EP; PUR;ESI Zn (R) 1 60 - 1 60
A3.11 EP; PUR;ESI Zn (R) 1 60 EP; PUR 2 160
A3.12 EP; PUR;ESI Zn (R) 1 60 AY, CR, PVC 2-3 160
A3.13 EP; PUR Zn (R) 1 60 AY, CR, PVC 3 200
Water-borne Binder untuk cat akhir Water-borne
Binder untuk cat primer Tipe Tipe
possible ( top coat ) possible
1 pack / 1 pack / X
2 pack 2 pack
aliphatic 2 pack
Note : Zn (R) = Zinc rich primer

R = rendah; (2- 5 thn); Misc. : Primers dengan bermacam - macam jenis pigmen anti korosi
M = menengah (5-15 thn);
Surface preparation: For Sa 2½, from rust grade A, B or C only (see ISO 8501-1)
No. sistem coat ) ( Expected durability )
Tot.
Jenis Jlh Lap. NDFT Jlh lap.
Binder Jenis binder NDFT
primer cat (μm) cat R M T
(μm)
A4.01 1-2 80 AK 3-5 200
A4.02 AK 1-2 80 AY, CR, PVC 3-5 200
A4.03 1-2 80 AY, CR, PVC 3-5 240
A4.05 AY, CR, PVC Misc. 1-2 80 AY, CR, PVC 3-5 240
A4.06 EP 1-2 160 AY, CR, PVC 2-3 200
A4.07 EP 1-2 160 AY, CR, PVC 2-3 280
A4.08 EP 1 80 EP; PUR 2-3 240
A4.09 EP 1 80 EP; PUR 2-3 280
A4.14 EP; PUR;ESI Zn (R) 1 60 EP; PUR 2-3 200
A4.15 EP; PUR;ESI Zn (R) 1 60 EP; PUR 3-4 240
A4.16 ESI Zn (R) 1 60 - 1 60
1 pack / 1 pack / X
2 pack 2 pack
aliphatic 2 pack
Note :
R = rendah; (2- 5 thn); Zn (R) = Zinc rich primer
M = menengah (5-15 thn); Misc. : Primers dengan bermacam - macam jenis pigmen anti korosi
Sistem pengecatan baja untuk kategori korosifitas C5-I –C5-M (12944-5 2007)
Surface preparation: For Sa 2½, from rust grade A, B or C only (see ISO 8501-1)
coat ) ( Expected durability )
No. sistem
Jlh Tot.
Jenis Jlh Lap. NDFT Jenis
Binder lap. NDFT R M T
primer cat (μm) binder
cat (μm)
C5-I
A5I.01 EP; PUR Misc. 1-2 120 AY, CR, PVC 3-4 200
A5I.02 EP; PUR Misc. 1 80 EP; PUR 3-4 320
A5I.03 EP; PUR Misc. 1 150 EP; PUR 2 300
A5I.04 EP; PUR;ESI Zn (R) 1 60 EP; PUR 3-4 240
A5I.05 EP; PUR;ESI Zn (R) 1 60 EP; PUR 3-5 320
A5I.06 EP; PUR;ESI Zn (R) 1 60 AY, CR, PVC 4-5 320
C5-M
A5M.01 EP; PUR Misc. 1 150 EP; PUR 2 300
A5M.02 EP; PUR Misc. 1 80 EP; PUR 3-4 320
A5M.03 EP; PUR Misc. 1 400 - 1 400
A5M.04 EP; PUR Misc. 1 250 EP; PUR 2 500
A5M.05 EP; PUR;ESI Zn (R) 1 60 EP; PUR 4 240
A5M.06 EP; PUR;ESI Zn (R) 1 60 EP; PUR 4-5 320
A5M.07 EP; PUR;ESI Zn (R) 1 60 EPC 3-4 400
A5M.08 EPC Misc. 1 100 EPC 3 300
EP = Epoxy 2 pack X EP = Epoxy 2pack X
EPC = Epoxy combina-tion 2 pack EPC = Epoxy combination 2 pack
1 pack / 1 pack /
ESI = Ethyl silicate X PUR = Polyurethane aliphatic X
2 pack 2 pack
PUR = Polyurethane aromatic or 1 pack /
X CR = Chlorinated rubber 1 pack
aliphatic 2 pack
AY = Acrylic 1 pack X
PVC = Polyvinyl chloride 1 pack
Note :
R = rendah; (2- 5 thn); Zn (R) = Zinc rich primer
M = menengah (5-15 thn); Misc. : Primers dengan bermacam - macam jenis pigmen anti korosi
SISTEM PENGECATAN PADA BAJA
LINGKUNGAN INDUSTRI SANGAT KOROSIF
TOP COAT Polyurethane
UNDER COAT Polyurethane
PRIMER Zinc rich
LINGKUNGAN LAUT SANGAT KOROSIF
TOP COAT Epoxy
UNDER COAT Epoxy
PRIMER Inorganic Zn silicate

The functions of a primer include :
1. To adhere to the substrate
2. To adhere to subsequent adhesion of coatings
3. To protect the substrate against corrosion by acting :
I. Inhibition effect:
- Red lead
- Zinc phosphate
- Zinc chromate
II. Galvanic effect
- Zinc dust
III. Barrier effect
- cross-linked of binder (epoxy types)
MEKANISME PENGENDALIAN KOROSI DENGAN LAPISAN CAT
1. BARRIER EFFECT
Memisahkan permukaan logam dengan lingkungannya
2. INHIBITOR EFFECT
Air yang terdifusi sampai ke lapisan primer akan melarutan
pigmen & membentuk lapisan protektif
Contoh : Zinc Phosphate, Zinc Chromate,
3. GALVANIC EFFECT
Air yang terdifusi sampai ke lapisan primer akan menyebabkan
logam baja terpotreksi secara galvanik
Contoh : Zinc rich primer
The functions of a Intermediate Coats (Mid-Coats)
1. to improve the barrier of the system.
2. to adhere to subsequent adhesion of topcoats
The functions of a Finish Coats
1. their appearance.
o Good color retention,
o Good gloss
o A smooth finish
2. resistance to
o Chemical or solvent
o Sinar ultraviolet (UV)
o Physic
o Mechanic
o Anti jamur atau anti fouling
COATING CURE
Two categories of cure are generally recognized by the
coating manufacturers
1. Nonconvertible coatings
2. Convertible coatings
Nonconvertible ( Solvent- Evaporation Cure ) Coatings :
1. Chlorinated rubber ( solvent : xylene & toluene )
2. Vinyl ( solvent : ester, ketone & aromatik HC)
3. Acrylics
COATING CURE
Convertible ( Polymerization Cured ) Coatings :

1. Oxygen - induced
2. Chemically induced
3. Heat - induced
4. Moisture - induced
Oxygen - Induced Polymerization Coatings
1. Alkyds
2. Urethane alkyd
3. Epoxy Ester
Chemically induce
1. Epoxies
2. Polyurethanes
Heat-Induced Polymerization Coatings ( 95 to 245°C )
1. Phenolics
2. Epoxy - modified phenolics
3. Silicones
Moisture – induced ( Coatings are cured by hydrolysis )

1. Some urethanes
2. some inorganic zinc coatings
PROSES PENGERINGAN CAT
EVAPORASI
PELARUT
POLIMERISASI OKSIDASI UDARA

/PEMANASAN
POLIMERISASI KIMIAWI PADA TEMP.

NORMAL /OVEN
SIFAT CAT BERDASARKAN PROSES PENGERINGAN
PENGERINGAN MELALUI PENGUAPAN PELARUT :.

 REVERSIBLE
 SENSITIF TERHADAP PELARUT
 KURANG TAHAN TEMPERATUR > 60 oC
 THERMOPLASTIC
PENGERINGAN MELALUI REAKSI KIMIA :
 IRREVERSIBLE
 TAHAN TERHADAP PELARUT
 RELATIF TAHAN TERHADAP TEMPERATUR 70 - 120 oC
 NON-THERMOPLASTIC
JENIS – JENIS CAT
1. ALKYD
 TIDAK COCOK UNTUK LINGKUNGAN KOROSIF
 TIDAK TAHAN TERHADAP ALKALI
 TIDAK TAHAN TERHADAP S0LVENT KUAT ; ester , aseton ,
keton , etil asetat, metil etil keton, aromatik HC
 THINER : hydrokarbon
2. CHLORINATED RUBBER
TERMASUK JENIS HEAVY DUTY COATING :
 TAHAN TERHADAP ASAM, BASA, DAN CUACA

 THINER : xylene & toluene
JENIS - JENIS CAT
3. VINYL
TERMASUK JENIS HEAVY DUTY COATING
 TAHAN TERHADAP ASAM, BASA, DAN CUACA
 LEBIH ULET DARI CHLORINATED RUBBER & BERSIFAT DEKORATIF

 PELARUT : ester , ketone, aromatik HC
4. EPOXY
TERMASUK HEAVY DUTY COATING
 TAHAN TERHADAP MINYAK, BAHAN KIMIA , AIR & SOLVENT
 LAPISANNYA KERAS
 PELARUT : ester , ketone & glycol
 MAINTENANCE PERLU PERMUKAAN KASAR
JENIS - JENIS CAT
5. POLYURETHANE
TERMASUK HEAVY DUTY COATING
 SIFAT – SIFAT SAMA DENGAN EPOXY
 JENIS : AROMATIK & ALIFATIK
1. AROMATIK : KURANG GLOSSY & TIDAK TAHAN SINAR MATAHARI
2. ALIFATIK : GLOSSY & TAHAN SINAR MATAHARI
 PENGENCER : CAMPURAN aromatik HC, ester & ketone.
6. SILIKAT
 TIDAK TAHAN ASAM & ALKALI
 TAHAN ABRASI & PANAS
 ZINC RICH PAINT : SERBUK ZN > 92 % BERAT
 TWO CONTAINER : SERBUK Zn & SILIKAT
General properties of different generic types of paint
Combination
Suitability :
Chlorinated
urethane
Zn silicate
urethane
Poly (viny
Good
chloride)
rubber
Poly
Acrylic
Epoxy
Epoxy
Limited
Alkyd
Poly
Ethyl
Poor (PUR) (PUR)
Not relevant (PVC) (CR) (AY) (AK) Aromatic Aliphatic (EZS) (EP) (EPC)
Gloss retention
Colour retention
Resistance to chemical :
Water immersion
Rain / condensation
Solvents
Solvents (splash)
Acids
Acids (splash)
Alkalis
Alkalis (splash)
Resistance to dry heat :

up to 70 °C
70 °C to 120 °C
120 °C to 150 °C
> 150 °C but ≤ 400 °C
Physical properties :
Abrasion resistance
Impact resistance
Flexibility
Hardness
JENIS - JENIS CAT
7. ANTI FOULING
BIOCIDE ANTI FOULING :
 Cu2O & ZnO
BINDER :
1. CHLORINATED RUBBER & VINYL
 UMUR PELAYANAN 1 - 2 TAHUN
 DAPAT DICELUPKAN SETELAH KERING
2. ROSIN
 UMUR PELAYANAN 6 - 9 BULAN
 HARUS DILECUPKAN DALAM KONDISI MASIH BASAH
PERTUMBUHAN FOULING TERGANTUNG :
 TEMPERATUR AIR LAUT
 INTENSITAS SINAR MATAHARI
 KADAR SALINITAS
PERSIAPAN PERMUKAAN
PERSIAPAN PERMUKAAN
TUJUAN :
 MEMBERSIHKAN PERMUKAAN SUBTRAT : MINYAK, DEBU,
KARAT, KERAK LOGAM & CAT LAMA.
 MEMBUAT PENGKASARAN PADA SUBSTRAT LOGAM
SUPAYA LAPISAN CAT DAPAT MELEKAT KUAT PADA SUBTRAT
METODA PERSIAPAN PERMUKAAN

1. CARA KIMIA :
 DEGREASING ( PELARUT ALKALI & ORGANIK )
 PICKLING ( ASAM MINERAL H2SO4 & HCl )
2. CARA MEKANIK :
 HAND TOOL CLEANING

 POWER TOOL CLEANING
 ABRASIVE BLAST CLEANING
Hand Tool Cleaning
Power Tool Cleaning

power wire brushing Grinders & Sanders
Needle Scaler Piston Scaler

PERSIAPAN PERMUKAAN
1. HAND TOOL CLEANING

Untuk menghilangkan karat & lapisan cat lama yang
tidak melekat kuat
2. POWER TOOL CLEANING

Untuk menghilangkan karat dan lapisan cat lama yang
melekat cukup kuat
3. ABRASIVE BLAST CLEANING

Untuk menghilangkan karat, kerak logam & lapisan cat
lama yang melekat kuat dengan udara tek. 90 – 100 psi
PERSIAPAN PERMUKAAN
4. STEAM CLEANING
Pembersihan kotoran dengan steam boiler p = 14 kg/cm2
konsumsi air 750 l / jam
KEUNTUNGAN :
 Tidak menimbulkan debu & merubah dimensi
KERUGIAN :
 Tidak bisa menghilangkan karat, lapisan cat & kotoran

yang melekat cukup kuat
 Air dapat terjebak dalam celah - celah.
PERSIAPAN PERMUKAAN
5. FLAME CLEANING
Untuk membersihkan karat & lapisan cat yang melekat cukup kuat.
Penghilangannya berdasarkan perbedaan koefisien ekspansi antara
karat - logam
6. WATER BLAST CLEANING
Sangat efektik untuk menghilangkan kontaminan yang tidak melekat
kuat dengan pompa tek. tinggi :
- Tekanan 2500 – 5000 psi
- Konsumsi air 20 - 90 l / menit
- Air harus bersih & dapat dicampur detergen
- Penambahan inhibitor korosi
- Jarak nozzle ke permukaan 6 – 10 inchi
PERSIAPAN PERMUKAAN
Jenis - jenis Abrasif

1. Metallic Abrasives
2. Non-metallic Abrasives ( Oxides, Natural, / Manufactured )
3. Slag Abrasives
4. Abrasives Containing Free Silica
5. Agricultural Abrasives
PERSIAPAN PERMUKAAN
Types of Abrasives
1. Metallic Abrasives :
i. Cast steel
ii. Cast iron
iii. Malleable iron
iv. Steel grit
v. Steel shot
2. Hard Nonmetallic Abrasives ( Oxides, Natural, / Manufactured )

i. Garnet ( oxide )
ii. Silicon carbide (oxide).
iii. Al. Oxide ( natural / Manufactured)
PERSIAPAN PERMUKAAN
3. Slag Abrasives
i. Refractory Slag
ii. Mineral Slag:
iii. byproducts of burning coal, refining copper, and nickel.
4. Abrasives Containing Free Silica

i. Sand
ii. Flint
iii. Quartz (SiO)
5. Agricultural Abrasives
 Crushed walnut shells
STANDAR TINGKAT KEBERSIHAN PERMUKAAN
SSPC ISO 8501-1 NACE BS - 4232
SP - 1 - - -
SP - 2 st - 2 - -
SP - 3 st - 3 - -
SP - 4 - - -
SP - 5 Sa - 3 No.1 1st quality
SP - 6 Sa - 2 No.3 3rd quality
SP - 7 Sa - 1 No.4 -
SP - 8 - - -
SP - 10 Sa - 2,5 No.2 2nd quality
SP -11
SPESIFIKASI PERSIAPAN PERMUKAAN
SSPC ISO 8501-1 DESCRIPTION

SP - 1 - SOLVENT CLEANING
SP - 2 St.2 HAND - TOOL CLEANING
SP - 3 St.3 POWER - TOOL CLEANING
SP - 4 - FLAME CLEANING OF NEW STEEL
SP - 5 Sa. 3 WHITE METAL BLAST CLEANING
SP - 6 Sa 2 COMMERCIAL BLAST CLEANING
SP - 7 Sa. 1 BRUSH - OFF BLAST CLEANING
SP - 8 - ACID PICKLING
SP - 10 Sa. 2.5 NEAR - WHITE BLAST CLEANING
SP - 11 POWER TOOL CLEANING TO BARE METAL
STANDAR TINGKAT KEBERSIHAN PERMUKAAN
1. NACE No. 1 / SSPC - SP 5, “White Metal Blast Cleaning”

when viewed without magnification, shall be free of
all visible
2. NACE No. 2 / SSPC – SP 10, “Near - White Metal Blast
Cleaning”
staining shall be limited to no > 5% of each unit
area of surface approx. square 80 x 80 mm
3. NACE No. 3 / SSPC-SP 6, “Commercial Blast Cleaning”
staining shall be limited to no more than 33% of
each unit area approx. square 80 x 80 mm
. NACE No. 4 / SSPC - SP 7, “Brush - Off Blast Cleaning”
4.
tightly adherent mill scale, rust, & coating may remain
on the surface.
JENIS - JENIS DAN UKURAN BAHAN ABRASIVE
ANCHOR JENIS BAHAN ABRASIVE

PATTERN PASIR SILIKA GARNET Al2O3 STEEL GRIT
(µm) (MESH) (MESH) (MESH) (MESH)
12,7 80/120 100 120 G – 200

25.4 30/60 80 100 G- 80
38 20/50 36 50 G- 50
50.8 16/40 30 36 G- 40
63,5 12/30 20 24 G- 25
76.2 8/20 16 16 G- 16
1. TINGKAT KEBERSIHAN TERGANTUNG :
 PICTORIAL STANDARD ( ISO 8501-1)
TINGKAT KEKASARAN TERGANTUNG :


 PROFILE COMPARATOR
KARAKTERISTIK PROFIL PERMUKAAN
Silica abrasives
Sharp-graded sand
16-X 35 – mesh Shape
1.5 -mil anchor pattern
Round-grain pure silica

1-mil anchor pattern
Ungraded silica sand

Black mineral slag
Black mineral slag
Shape
8 - X 40 – mesh
Aluminum oxide
Aluminum oxide Shape

36- mesh
Garnet
Garnet Shape
30- mesh
Crushed flint
Shape
Crushed flint
8 - X 30 – mesh
GR-25 steel grit

GR-16 steel grit
50 Rockwell C hardness Shape
Sharp-etched surface
S-280 steel shot
S-280 steel shot

50 Rockwell C hardness Shape
Smooth surface
UNIFORM PATTERN :
Proper surface preparation
Surface 0f 3-mil dry protective coating
NON UNIFORM PATTERN :

Nonproper surface preparation
Exposed base metal Coating surface
0.001 in. = 1 mils = 25.4 um

SURFACE PROFILE GAGES
Comparator & Dial gauge depth Micrometer

coupons
( profilometer )
( ISO 8503 comparators
for grit and shot.) ASTM D 4417, Method B.
SURFACE PROFILE GAGES
Replica Tape
Two types of tape are commonly used :

coarse for 20 to 50 μm surface profile
extra coarse 37 to 112μm surface profile
NACE Standard RP 0287

ASTM 4417, Method C.
Surface Preparation Selection
Some should be taken into account in selecting a surface
Preparation :
1. The kind of surface metal to be cleaned

2. Size & shape of object to be cleaned
3. Type of cleaning facility :
outdoor, indoor with cabinet or blast room
4. Existing surface conditions
5. Conditions desired after cleaning
6. Desired surface profile
7. Types of coating to be applied
KEGAGALAN LAPIS LINDUNG CAT
FAKTOR - FAKTOR YANG DAPAT MENGAKIBATKAN KEGAGALAN

LAPIS LINDUNG CAT :
1. KEGAGALAN DESAIN / FABRIKASI :

 Skip welds,
 Rough Welds
 Weld slag
 Weld spatter
 Weld porosities
 Sharp edges,
 Crevices / gap
2. PERSIAPAN PERMUKAAN
3. KONDISI LINGKUNGAN
4. BAD APPLICATION PROCEDURES & WORKMANSHIP
5. PEMILIHAN SITE M CAT YANG URANG TEPAT
Skip Welds
Rough Welds
Welds slag
Weld Spatter
Overlapping plates
Crevice Gaps
Riveted and Bolted Construction
Sharp edges
Not rough enough
Surface 0f 3-mil dry protective coating
very rough
Coating surface
Exposed base metal
0.001 in. = 1 mils = 25.4 um

Many factors in surface preparation affect the
life of a coating :
1. Residues of oil, grease, and soil :
which can prevent adhesion of the paint to the surface
2. Residues of ( nonvisible ) chemical salts,
which can induce corrosion after coating
3. Rust on the surface,
which interferes with the coating bonding to the surface
4. Millscale on the surface,
which can cause later failure
Sources, sites, and effects of osmotic blistering in coating films
From From From
From From components components contamination
substrate contamination of paint film of lower paint films of lower paint
(e.g., of substrate (e.g., inhibitive (e.g., inhibitive films
metallic (e.g., salts) pigments, pigments, (e.g., salts)
corrosion solvents, solvents,
product) additives, etc.) additives, etc.)
Aqueous
environment
Finish coat
oooooo
oooooo
oooooo
oooooo
oooooo
Soluble oooooo
oooooo
species oooooo Primer oooooo

oooooo
o
Steel
substrate
1. Blistering, 2. Blistering, 3. Blistering, 4. Blistering, 5. Blistering,

delamination, delamination, reduced cohesion, reduced cohesion, intercoat
substrate corrosion film splitting, delamination, delamination
deterioration delamination corrosion
Indicates location of failure

PENGELUPASAN LAPIS LINDUNG CAT
KEGAGALAN ADESIF
Adhesion Coating separates cleanly

failure from substrate
STEEL
KEGAGALAN KOHESIF/ DELIMINASI
Coating breaks within itself

Cohesive
And not all all substrate
failure
STEEL
FAKTOR-FAKTOR LINGKUNGAN YANG DAPAT MENGAKIBATKAN

KEGAGALAN LAPIS LINDUNG CAT :
1. UAP LEMBAB / AIR

2. SINAR MATAHARI
3. MEKANIK, FISIK & KIMIA
KERUSAKAN LAPIS LINDUNG CAT
 Dissolution Chemical Reaction :

 Extraction Oxidation
Hydrolysis
Dissolution by alkali etc
Penetration of Solvation Swelling Solution
Environmental CAT Swelling
Agent
Craze Crack
Dynamic Condition :
 Change in Appearance  Stress
 Decrease in Mechanical properties  Temperature Gradient
 Decrease in Physical Properties
PENGARUH SINAR RADIASI UV
AESTHETICS MECHANICAL
1. Color change 1. Change in flexibility
2. Fading of color 2. Change in elongation
3. Yellowing 3. Change in hardness
4. Chalking 4. Change in abrasion resistance.
5. Loss of gloss
5. Change in internal stress
PERFORMANCE CHEMICAL
.
Alligatoring
1. Oxidation
Checking
2. Hydrolysis
Crazing
3. Change in solubility
Cracking 4. Increased wettability of surface
Loss adhesion / Delamination :
 Blistering,
 Peeling,
 Flaking
Corrosion process in osmotic blister
a.) Electrolite H2O O2 Oxygen - rich water is drawn to interface

osmotically, accumulating in layers until
Paint film film delaminates.
Steel substrate
H2O O2 Ferrous corrosion product
b.) Iron dissolves, going into solution as
ferrous ions &, in the presence of oxygen,
forming soluble ferrous corrosion product.
Cathode Anode Cathode
Rust layer Fe++ corrosion products are rapidly oxidized to

H2O O2
Fe+++ products, which are deposited as rust
c.) layer on underside of blister dome, cutting off
Oxygen supply to blister interior.
Cathode Anode Cathode At periphery of blister, oxygen availability

through paint film is higher, allowing cathode
reaction.
H2O O2
d.) Cathodic hydroxyl at periphery of blister
Causes film to delaminate, so that blister
expands, rust forms, and cathode sites
Cathode Anode Cathode advance outward.
Bad Application Procedures & Workmanship
is a major factor in coating failure :
1. Improper thickness
a. Pinpoint rusting
b. mudcracking, alligatoring, cracking, checking, wrinkling
2. Pinholes
3. Overspray
4. Dry spray
5. Cratering ( fisheyes )
6. Blistering / delaminasi
7. Chalking : amine-cured epoxies & epoxy esters
8. Erosion
Pinholes
Pinholes are small holes in a coating, often caused :
1. by application of a thicker coating over a porous surface
(coating epoxy over inorganic zinc ).
2. Coatings with the extra or the wrong thinners so
inability of solvent to escape from the rapidly curing
coating.
3. High ambient temperatures : the fast – drying surface
does not the solvents to escape, such as vinyl or
chlorinated rubber.
4. Holding the spray gun too close to the surface which
can force bubbles into the coating.
Pinholes
Overspray
PAINTING INSPECTION
PAINTING INSPECTION
PERSYARATAN INSPEKTOR
1. MENGETAHUI DASAR – DASAR KOROSI
2. MEMAHAMI METODA STANDAR PENGECATAN
3. MAMPU MEMBACA & MENGINTERPRESTASI SPESIFIKASI

DOKUMEN
4. MENGETAHUI JENIS & PENYEBAB KEGAGALAN LAPIS

LINDUNG CAT
5. MAMPU MENGEVALUASI HASIL PENGECATAN
6. BISA MENJAGA HUBUNGAN DENGAN KELOMPOK –

KELOMPOK LAINNYA & MENILAI HASIL PENGECATAN
SECARA BENAR – OBJEKTIF
PERALATAN INSPEKSI PENGECATAN
1. SIEVE TEST FOR ABRASIVE MATERIALS

2. pH PAPERS
3. SIEVE FOR COATING MATERIALS
4. VISCOSITY CUP & STOP WATCH
5. TERMOMETER , HYGROMETER & ANEMOMETER
6. PICTORIAL STANDARD ISO 8501 - 1. ( TINGKAT KEBERSIHAN )
7. PROFILE COMPARATOR ( TINGKAT KEKASARAN )
8. ELCOMETER WFT & DFT
9. HOLYDAY DETECTOR & GLOSS METER
10. ADHESIVE & HARDNESS TESTER
11. ALAT PEMBESAR & KAMERA
PAINTING INSPECTION
TUJUAN : UNTUK MENCEGAH / MEMPERBAIKI KESALAHAN &

KEKELIRUAN SELAMA PELAKSANAAN PENGECATAN
LANGKAH - LANGKAH INSPEKSI MELIPUTI :
1. SEBELUM PERSIAPAN PERMUKAAN
2. SELAMA PERSIAPAN PERMUKAAN
3. SEBELUM PENGECATAN
4. SELAMA PENGECATAN
5. SETELAH PENGECATAN
PAINTING INSPECTION
1. SEBELUM PEKERJAAN PELAKSANAAN PERSIAPAN PERMUKAAN

 KONDISI LOKASI PEKERJAAN :
penerangan, ventilasi & prasarana pendukung kesehatan & peralatan kerja
 KONDISI OBJEK :
desain konstruksi / fabrikasi
 TINGKAT KARAT :
A, B, C & D sesuai dengan Standar ISO 8501 - 1.
 KONTAMINASI PADA PERMUKAAN :
minyak & garam2. debu, air,
 PERALATAN APLIKASI :
blasting machine : spray gun, kompresor, hose, coupling hose & blast pot
 BESARNYA & KUALITAS UDARA TEKAN :
bebas minyak & air
 BAHAN ABRASIF :
jenis, ukuran, bentuk dan kualitas bahan abrasif : kebersihan & kekerasan
 KONDISI LINGKUNGAN
RH , temp. Udara & permukaan substrat logam, dew point, arah angin
TINGKAT KARAT :
Standard identifies conditions for steel : A,B,C,D ISO 8501-1
Steel surface largely covered with

A adherent mill scale but little, if any, rust.
Steel surface which has begun to rust

B and from which the mill scale has begun
to flake.
Steel surface on which the mill scale has

rusted away or can be removed by
C scraping, but with slight pitting visible
under normal vision
Steel surface on which the mill scale has

D rusted away and on which general
pitting is visible under normal vision.
Volume of air required at various pressures
to feed different sizes of nozzles.
Blast Nozzle Orifice Size Volume of air required ( l/ min)
4.1 4.8 5.5 6.2 6.9

bar bar bar bar bar
6.3 mm #4 1900 2150 2400 2660 2920
9.45 mm #6 4280 4840 5410 5980 6570
12.6 mm #8 7590 8610 9630 10650 11700

Nozzle Air Pressure ( Needle Gauge )
The needle gauge is used to measure the air

pressure at the nozzle.
 A hypodermic needle is inserted into the blast
hose just behind the nozzle while the blast unit
is in operation.
Nozzle gauge
Abrasives Checks
The inspector & the operator should ensure that :

1. Type & size of abrasive being used are as specified.
2. Abrasives are clean and free of moisture and oil.
3. Abrasive Hardness
4. Contaminants ( fines dust, paint, and mill scale ) must
be removed from the abrasive materials if they are to
be recycled.
2. Abrasive Cleanliness Test
the abrasive is dropped into a small vial of distilled water
and shaken.
Typically, the ratio volume of abrasive to water (1 : 2 )
 The top of the water is inspected for a film of oil.
 The water can be visually checked for turbidity
 A pH paper test of the water in the vial
3. Abrasive Hardness
Hardness is also a significant factor.
 Harder abrasives have a greater cutting effect,
 Softer abrasives have less cutting effect.
 Hardness of metallic chilled iron grit ( HRC 50 - 55 )
 Hardness of copper slag abrasive ( range 6 to 7 Mohs )
Abrasives Checks
Particle size Test

SAE Grit Specifications
S.A.E. MAX. LIMIT SCREEN NOMINAL SCREEN MIN. LIMIT SCREEN
Grit Max.Grit Screen Num. Min.Grit Screen Max. Screen
Num. Retained and Aperture Retained Num.and Grit to Num.and
% % Aperture Pass, Aperture
%
G-10 0 7 (0.111) 80 10 (0.0787) 10 12 (0.0661)
G-12 0 8 (0.937) 80 12 (0.0661) 10 14 (0.0555)
G-14 0 10 (0.0787) 80 14 (0.0555) 10 16 (0.0469)
G-16 0 12 (0.0661) 75 16 (0.0469) 15 18 (0.0394)
G-18 0 14 (0.0555) 75 18 (0.0394) 15 25 (0.0280)
G-25 0 16 (0.0469) 70 25 (0.0280) 20 40 (0.0165)
G-40 0 18 (0.0394) 70 40 (0.0165) 20 50 (0.0117)
G-50 0 25 (0.0280) 65 50 (0.0117) 25 80 (0.0070)
G-80 0 40 (0.0165) 65 80 (0.0070) 25 120 (0.0049)
G-120 0 50 (0.0117) 60 120 (0.0049) 30 200 (0.0029)
G-200 0 80 (0.0070) 55 200 (0.0029) 35 325 (0.0017)
G-325 0 120 (0.0049) 20 325 (0.0017) -
JENIS - JENIS DAN UKURAN BAHAN ABRASIVE
JENIS BAHAN ABRASIVE

ANCHOR
PATTERN PASIR SILIKA GARNET Al2O3 STEEL GRIT
( UM ) (MESH) (MESH) (MESH) (MESH)
12,7 80/120 100 120 G – 200
25.4 30/60 80 100 G- 80
38 20/50 36 50 G- 50
50.8 16/40 30 36 G- 40
63,5 12/30 20 24 G- 25
76.2 8/20 16 16 G- 16
SIEVE TEST FOR ABRASIVE MATERIALS
You have taken a 1,000 g sample of abrasive &

performed a sieve test.
The amount of abrasive retained at each sieve is listed
in column A.
Sieve Size A B
( NBS Screen # ) Grams Retained Percentage
12 25 2.5
16 750 75.0
18 100 10.0
Passed through 125 12.5
Check sum 1000 100%
Environmental Conditions
Affecting the Coating Job

Environmental conditions that can affect a coating job are:
1. Surface & air temperature
2. Relative humidity
3. Dew point
4. Wind velocity
5. Airborne contaminants ( e.g., chemical fumes, auto
haust, salt spray )
ENVIRONMENT CONDITION
SURFACE TEMPERATURE
Direct Reading Thermocouple
ENVIRONMENT CONDITION
Sling psychrometer /
a whirling hygrometer
This used to measure dew point & relative

humidity.
ANEMOMETER
Ambient conditions
Electronic Hygrometers
Electronic instruments are available

to determine relative humidity,
air temp., and dew - point temp.
Dew point
DEW POINT
30 30
30
Lowest acceptable surface temp.
25 25
Ambient temperature oC
25
20 20
20 44 2
15 3 15
15
10 10
10
5 5
5
0 1 0
0 10 20 30 40 50 60 70 80 90
Relative humidity %
1. relative humidity in ambient air : 80 %

2. Measure temperature of ambient air : 20 oC
3. Read the dew point in the table : 16,4 oC
4. Surface temperature must exceed the dew point by
at least 3 oC immediately prior to & during application
and curing i.e in the example : 19, 4 oC
Surface temperature
A. Surface temperature is at or below the dew point

moisture may condense :
1. flash rusting of blasted steel,
2. solvents do not readily evaporate, ( BLOOMING )
B. Surface temperature is too high.

1. too rapid solvent release ( PINHOLES )
2. poor wetting of the surface ( HOLIDAY )
Air temperature
A. Air temperatures are too low,

1. solvents do not readily evaporate,
2. reduced adhesion,
3. an irregular surface.
B. Air temperatures are too high,

1. coatings may not wet the surface ( HOLIDAY )
2. too rapid solvent release ( PINHOLES )
Relative Humidity ( RH )
When the RH is too high,

1. solvents do not readily evaporate,
2. malfunction of the coating cure reaction
Wind Effects
Wind can affect the coating job in several ways:
1. Causing overspray of sprayed coatings
2. Accelerating solvent evaporation contributing to
formation of dry spray
3. Blowing contaminants, such as sea spray, salt, blast
abrasive, dust, or sand, onto the work surface
PAINTING INSPECTION
2. SELAMA PEMBERSIHAN.
 TINGKAT KEBERSIHAN PERMUKAAN
 PICTORIAL STANDARD ( ISO 8501-1)
 TINGKAT KEKASARAN PERMUKAAN

 PROFILE COMPARATOR
PAINTING INSPECTION
3. SEBELUM PENGECATAN
 KONDISI LOKASI PEKERJAAN :
penerangan, ventilasi ; prasarana pendukung kesehatan & keselamatan kerja
 KONDISI PERMUKAAN :
tingkat kebersihan & kekasaran permukaan
 KONTAMINASI PADA PERMUKAAN :
asam- alkali, minyak, ion Fe, millscale & garam - garam.
 PERALATAN APLIKASI :
painting machine : spray gun, compressor, hose, mixer, viscometer, sieve
 BESARNYA & KUALITAS UDARA TEKAN :
bebas minyak & air
 PRODUK CAT :
merek , jenis & warna dari primer, under - topcoat, kode & batch number
 KONDISI CAT :
penggumpalan, pengkulitan & warna.
 JENIS & PROPORSI THINER.
 SPESIFIKASI CAT :
viskositas, flash point, drying time, pot life
 KONDISI ATMOSFIR :
temp. udara & permukaan, RH & titik embun ( dew point )
The corresponding photographs show levels of corrosion,
preparation grades of unprotected steel substrates and steel
substrates after completely removing previous coatings.
A GRADE Sa 2 1/2 B GRADE Sa 2 ½ C GRADE Sa 2 1/2 D GRADE Sa 2 1/2
A GRADE Sa 3 B GRADE Sa 3 C GRADE Sa 3 D GRADE Sa 3

KONTAMINASI PADA PERMUKAAN
The presence of certain chemicals :

1. Acid or alkaline, ( pH paper )
2. Soluble iron ( lar. K. Ferrycyanida )
3. Soluble sulfates ( lar. BaCl2 )
4. Soluble chloride ( lar. AgNO3 )
5. Mill scale ( lar. CuSO4 )
6. Oils, grease, and fingerprints contaminant :
( sinar UV atau solvent )
1. PERIKSA KONTAINER CAT & BUKA KONTAINER PERIKSA ISINYA
2. SEBELUM DIAPLIKASIKAN CAT DIADUK DENGAN BAIK &

TIDAK BOLEH ADA GELEMBUNG UDARA
3. SARING DENGAN UKURAN SESUAI DENGAN VISKOSITASNYA
4. GUNAKAN JENIS & JUMLAH THINNER YANG SESUAI & UKUR
VISKOSITASNYA
PERALATAN APLIKASI :
Selection of Airless Spray Tips
AIRLESS SPRAY COMPARATIVE TIP CHART
Material Approximate Typical Available Fan Width
Orifice Size (30 cm. from spray tip)
Low-viscosity coatings 0.28 mm 15, 20 or 25 cm
Wash primers, shop primers 0. 17 to 0.27 mm 15, 20 or 25 cm
Lacquer, varnish, enamel, 0.28 to 0.38 mm 15, 20, 25, 30 cm
finish coatings
Industrial primers 0.38 to 0.53 mm 15, 20, 25, 30 cm
Note: 100-mesh filter screens should be used with the above tips.
Medium, or heavy viscosity :
vinyls; acrylics, latex, alkyds approx. 0.43 mm 15, 20, 25, 30 cm
High-build coatings 0.48 to 0.63 mm 20, 25, 30, 35 cm
Glass-flake coatings 0.63 to 1.0 mm 25, 30, 35 cm
Note: 60-mesh filter screens should be used with above tips
Airless Spray Guns : Selection of Tips
Tip Orifice Spray Angle Fan Width Fluid Flow Rate

(°)
(mm) (mm) L/min
0.23 10 to 50 70 to 225 0.39
0.28 10 to 80 70 to 350 0.57
0.33 10 to 80 70 to 350 0.76
0.38 10 to 80 90 to 350 1.3
0.45 20 to 80 140 To 350 1.6
0.58 20 to 80 140 to 350 2.3

Airless Spray Guns : Selection of Tips
Use the following guidelines when selecting tips :

1. Thin materials require small orifice size; thick materials
require large orifice size.
2. The greater the tip angle, the wider the fan pattern.
3. The larger the tip – orifice diameter, the greater the
fluid flow and the faster the coverage.
4. The larger the orifice, the larger the pump & air
supply volume required
SPRAYING APPLICATION
FAN WIDTH
(FAN TOO NARROW)
FAN WIDTH
( NORMAL FAN )
15 - 35 cm
30 CM
FAN WIDTH
(FAN TOO WIDE)
AIRLESS SPRAY : 1000 – 6000 psi

HEAVY
FILM
DRY
FILM
DON’T TIP AT AT ANGLE
PENYARINGAN COATING
VISCOSITY CUP ASTM D-1200

During mixing & thinning, the inspector should ensure that
 Coating is mixed thoroughly.
If it is not :
1. non - uniform cure,
2. poor film - forming
3. reduced protective qualities
 Correct amount of thinner is used.

 Too much thinner may result in :
reduced dry – film thickness, together with runs & sags.
 Too little thinner may cause the coating to
1. dry spray,
2. a non - uniform film ( pinholes).
PAINTING INSPECTION
4. SELAMA PENGECATAN .
1. KETEBALAN CAT BASAH ( WFT ).
2. TENGGANG WAKTU PENGECATAN ANTARA LAPISAN
3. KONDISI LAPISAN CAT :

pelepuhan, sagging , orange peel, cracking, holiday & dry spray
5. SETELAH PENGECATAN.
1. KETEBALAN CAT KERING ( DFT ).
2. KONDISI LAPISAN CAT :
kehalusan lapisan cat, warna , gloss, adesi , hardness
3. KERUSAKAN AKIBAT MEKANIS
WFT GAGE
ASTM D 1212
WFT COMB GAGE

ASTM D 1212
MATERIAL LOSS DURING APPLICATION PROCESS :
BRUSH 4– 8%
ROLLER 4– 8%
CONVENTIONAL SPRAY 20 – 40 %
AIRLESS SPRAY 10 – 20 %
WET FILM THICKNESS ( WFT )
1000 X VOL. SOLID

THEORICAL COVERAGE ( TH. COV. ) = ------------------------- m2/l
DFT (µm)
PRACTICAL COVERAGE = TH. COV. - ( TH. COV. X LOSSESS )
AREA
CONSUMPTION = -----------------------------
PRACTICAL COVERAGE
DFT
WET FILM THICKNES ( WFT ) = --------------------------------
% SOLIDS by VOLUME
DFT ( 1 + % THINNER by VOLUME [ TBV] )

WET FILM THICKNES ( WFT ) = -------------------------------------------------------
% SOLIDS by VOLUME
EXAMPLE
The coating specification
DFT : 100 to 125 µm.

The coating has 35 % solids by vol.
What range of wet – film thickness ?
Low WFT : 100 µm DFT = 285.7 µm

0.35 solids by vol.
High WFT : 125 µm DFT = 357.1 µm

0.35 solids by vol.
DFT
WET FILM THICKNES ( WFT ) = --------------------------------
% SOLIDS by VOLUME
The coating specification
DFT : 75 to 100 μm.
The coating has 35% solids by vol.
The coating has been thinned by the add. of 0.5 L of solvent / 5L
What range of wet – film thickness ?
Step 1 : Calculate % volume thinner.
0.5 liters / 5 liters = 1/10 = 10 %
Step 2 : Calculate WFT range.
Low WFT = 75 μm x ( 1 + 0.10 ) = 82.5 μm = 236 μm

(0.35) 0.35
High WFT = 100 μm x ( 1 + 0.10) = 110 μm = 314 μm

0.35 solids by volume 0.35
DFT ( 1 + % THINNER by VOLUME [ TBV] )

WET FILM THICKNES ( WFT ) = ----------------------------------------------------
% SOLIDS by VOLUME
Example : Consider a coating that is 100 % solids by volume.
How many liters of material are required to coat an area of 100 m2
if the average DFT is 300 μm?
1 liter covers 1,000 m2 at a WFT of 1 μm.
At a WFT of 300 μm, the area covered ( by one liter ) is :
1,000 = 3.3 m2/l

300
To cover 100 m2 at this same thickness, volume required is :
100 = 30.3 liters
3.3
Example : Consider a coating that is 60 % solids by volume.
1000 X 0.60 = 600 m2 @ 1 μm dry

If the applied DFT of the same coating was 300 μm, the spread rate would be
:
600 m2 @ 1 μm = 2 m2/L
300 μm
To cover 100 m2 at this same thickness, volume required is :
EXAMPLE
Recommended DFT = 150 μm

% Solids by volume = 60 %
A loss of 20 %.
Theoretical spreading rate ( m2/L )

1,000 X 60 %
= ------------------- = 4 m2/L
150 μm
Practical spreading rate

= 4 m2/L – ( 4 m 2 / L x 0.2 ) = 3.2 m2 / L
PRACTICAL COVERAGE = TH. COV. - ( TH. COV. X LOSSESS )

WET FILM THICKNES ( WFT )
2
EXAMPLE :
1. Solids by volume : 50 %
2. DFT : 40 um
3. Yields : 80 um WFT
THINNING
2
EXAMPLE : 3
1. Solids by volume : 50 %
2. Thinner : 10 %
3. Yields % solid : 45 %
Magnetic Constant - Pressure DFT Gauge
Pencil - Type Magnetic Pull - Off DFT Gauge

Number of Spot DFT Readings Required by
Different Standards for Flat Areas
SSPC-PA 2 Total AS 3894.3 ISO 19840 PSPC Minimum

Total Area (Sq M)* number of spot Recommended Minimum number of spot
to be tested measurements number of spot number of spot measurements
measurements measurements
<1 5 3 5 1
1–3 5 3–9 10 1
3–10 5 9–30 15 1–2
10–20 10 10 20 2–4
20–30 15 15 20 4–6
30–100 15 15 30 6–20
>100 15 plus 5 per 15 plus 5 per 30 plus 10 for 1 for each 5

each additional each additional each additional square meters
100 square 100 square 100 Square
meters meters meters
Fig. 1: A suggested inspection plan according to SSPC-PA 2 or AS 3894.3 for
500 square meters of flat surface area. Figures 1–5 courtesy of the author.
Fig. 2: A suggested inspection plan according to ISO 19840

for 500 square meters of flat surface area
Fig. 3: A suggested inspection plan according to PSPC for 500

square meters of flat surface area
Inspect coating thickness DFT
Measurement of DFT ( 10 m2 for areas 100 m2 )

with magnetic gauges is SSPC - PA 2.
● ●
● A ● ● B ●
●
● C ●
● ●
● E ●
● D ●
Measurement of dry - film thickness ( DFT )
Specified range = 12 to 15 mils DFT
Calculate allowed spot measurements.
80 % of 12 mils = 9.6 mils, 120 % of 15 mils = 18 mils
Any single spot measurement must be > 9.6 mils & < 18 mils.
Reading ( Total
mils )
Area 1 2 3 (1+2+3) Area */ 3 = Average Complies (Y/N)?
A 10 12 12 34 11.3 YES
B 12 14 13 39 13.0 YES
C 15 14 14 43 14.3 YES
D 14 13 13 40 13.3 YES
E 12 13 12 37 12.3 YES
Overall Average 12.8 mill YES
HOLYDAY TESTER
NACE Standard RP 0188
Low Voltage DC ( Wet Sponge )
Output voltages ranging from 5 to 120 V DC
Coating film less than 500 μm ( 20 mils ) thick.

SHEET INSPECTION
Report Form
Inspector Name : Ambient Conditions Time Time Time
Date : ______________ at Worksite
Site Location : ______________
Client NAME : _______________ Air Temperature
Relative Humidity
Dew Point
Steel Temperature
Abrasive Blasting : Type /Grade of Abrasive ---------

Specified Standard -----------
Abrasive Checked for cleanliness (Y/N) ----pH: -----
Surface Profile minimum Maximum Average Hrs. left Comments

Measurements Uncoated
Location mils/μm mils/μm mils/μm

SHEET INSPECTION
COATINGS
Location Manufacturer Batch App. Avg. DFT WFT DFT

Name & Num. Method Color before Coat Coat
description Min. Max. Min. Max
1.
2.
3.
Coat # Mixing & Storage Holiday Defects/Comments

thinning Test ?
1.
2.
3.
PENGUJIAN CAT
TUJUAN :
UNTUK MENGETAHUI SIFAT-SIFAT & FUNGSI CAT SEHINGGA DAPAT
MEMPREDIKSI UNJUK KERJA DARI MASING – MASING LAPIS
LINDUNG CAT DALAM KONDISI LINGKUNGAN TERTENTU
RUANG LINGKUP PENGUJIAN :
1. UJI DAYA TAHAN TER HADAP CUACA

2. UJI DAYA TAHAN TERHADAP ZAT KIMIA
3. UJI DAYA TAHAN TERHADAP MEKANIK
4. UJI ADESI
5. UJI FUNGI DEKORATIF
6. UJI FUNGSI - FUNGSI SPESIFI
RUANG LINGKUP PENGUJIAN :
1. DAYA TAHAN TER HADAP CUACA :

 Salt spray chamber Test ASTM B 117
 Humidity Test ASTM D1748
 Sinar UV Test , ASTM G53
2. UJI DAYA TAHAN TERHADAP ZAT KIMIA :

 Spot & Immersion test ASTM D 1308
3. UJI DAYA TAHAN TERHADAP MEKANIK :

 Taber abrasive, ASTM D 4060
 Falling sand, ASTM D 968
 Scratch, ASTM D 2197
 IMPACT , ASTM G 14
 Bending Test ASTM D - 522-60
PENGUJIAN FUNGSI DEKORATIF
1. UJI warna ASTM D 2244 & E 308

2. Uji kilapan / Gloss, ASTM D 523
3. Uji Hiding power, ASTM D 344, D 2805
PENGUJIAN SIFAT - SIFAT DASAR
UJI ADESI :
 CROSS HATCH TEST, ASTM D 3359
 DIRECT PULL TEST, GSA 6301.1
PENGUJIAN FUNGSI SPESIFIK
 FIRE RETARDANCY TEST, ASTM D 1360 & D 1361

 HEAT RESISTANCE TEST, ASTM D 2244 & D 2485
 UJI DAYA T AHAN MIKROORGANISME, ASTM D 2547 & D3273
PERALATAN TEST CAT DI LABORATORIUM
Humidity chamber
SALT SPRAY CHAMBER
ASTM B117
SAMPEL SAMPEL
NOSEL
QUV CHAMBER
3
4 2 TABER ABRASIVE
5 1 13
6 11
8 1. Vacum hose
14 2. Counterweight stud of abrasion wheel
3. Abrasion wheel mounting shaft arm
12 4. Dust suction arm
5. Dust suction arm height adjusting device
6. Weight
7. Air flow adjusting device for dust remover
10 7 9 8. Turnable
9. Dust remover ON-OFF SW
10. Turnable ON-OFF SW
11. Abrasion wheel
12. Automatic counter
13. Dust remover
14. Speed setting knob
IMPACT TESTER FALLING SAND ABRASION TESTER

ASTM D - 809 ASTM D - 968
CONICAL MANDREL BEND TESTER

ASTM D-522-60
DUR-O-TEST HARDNESS PENCIL HARDNESS GAGE

TESTER ASTM-D-3363
LEAD GRADE 1 2 3 4 5 6 7 8
POSITION 6B 4B 2B HB 2H 4H 6H 8H
SOFTEST HARDEST
GLOSSMETER
ASTM D 523
ADHESION TESTER
PAINT ADHESION TEST KIT

ASTM D-3359
SURFACES OF GREATER
CROSS - CUT NONE THAN
AREA 65 %
CLASSIFICATION 5 4 3 2 1 0
KESIMPULAN
Persyaratan yang harus dipenuhi untuk
memperoleh sistem lapis lindung cat yang baik
1. PERENCANAAN YANG BAIK

2. TENAGA KERJA YANG BERPENGALAMAN & MAHIR
3. PEMILIHAN SISTEM CAT DISESUAIKAN DENGAN LINGKUNGANNYA
4. PERSIAPAN PERMUKAAN YANG MEMADAI & DISESUAIKAN
DENGAN SISTEM CAT
5. KONDISI LINGKUNGAN YANG MEMADAI SELAMA PERSIAPAN
PERMUKAAN & PENGECATAN
6. PERALATAN & TEKNIK APLIKASI YANG MEMADAI
7. KETEBALAN LAPISAN YANG MEMADAI
8. DAYA REKAT BAIK PADA SUBSTRAT & LAPISAN SEBELUMNYA
9. INSPEKSI DENGAN SEKSAMA & TELITI SELAMA PERSIAPAN
PERMUKAAN & PENGECATAN
PAINTING COSTS
PAINTING COSTS
PORTION OF JOB PERCENTAGE OF TOTAL

PAINT APPLICATION 25 - 60
SURFACE PREPARATION 15 - 40
CLEAN UP 5 - 10
ACCESORY PRODUCTS 3 - 6
PAINT 10 - 20
MATERIAL LOSS DURING APPLICATION PROCESS :

BRUSH 4– 8%
ROLLER 4– 8%
CONVENTIONAL SPRAY 20 – 40 %
AIRLESS SPRAY 10 – 20 %
PAINTING COST
How many liters of material are required

WHERE : AREA = 455 m2
THICKNESS = ± 50 µm
% VOL. SOLID = 50 %
APPLICATION METHOD : AIRLESS SPRAY.
1000 X VOL. SOLID 1000 x 0,5

THEORICAL COVERAGE = ------------------------- = -----------------
DFT (µm) 50
= 10,0 m2 / l
ALLOWANCE FOR SPRAY LOSS 20 %
10,0 m2 / l X 80 % = 8,0 m2 / l
AMOUNT OF PAINT NEEDED : PRACTICAL COVERAGE =

455 m2
-----------------= 56,875 l
TH. COV. - ( TH. COV. X LOSSESS )
8,0 m2 / l
PAINTING COST
COST MATERIAL
COST/GAL VOL. SOLID DFT
COATING A $ 4.50 30 % 4 mils ( 101,6 um )
COATING B $ 4.10 25 % 4 mils ( 101,6 um )
1604 X VOL. SOLID

THEORICAL COVERAGE ( TH. COV. ) = ------------------------- ft2/gal
DFT (mils)
COATING A
1604 X 0.3
----------------- = 122 ft2 / gal ( 2.9 m2 / l )
4 mils
$ 4.50/gal
------------------= $ 0.037 / ft2 ( $ 0.398 / m2 )
122 ft2 / gal
COATING B
m = 3,2 ft
1604 X 0,25 m2 = 10,76 ft2
------------------ = 100 ft2 / gal ( 2.5 m2 / l )
4 mils Gal = 3,8 l
$ 4.10/gal
------------------ = $ 0.041 / ft2 ( $ 0.441 / m2 )
100 ft2 / gal
INPEKSI RUTIN DALAM UPAYA
PEMELIHAHARAAN DAN PERBAIKAN
LAPIS LINDUNG CAT
Coating rust grades and respective rust surface areas.
ISO 4628-3
Rust grade Rusted surface area
Ri 0 0%
Ri 1 0,05 %
Ri 2 0,5 %
Ri 3 1,0 %
Ri 4 8,0 %
Ri 5 40-50 %
In rust grades Ri 1 – Ri 3 :maintenance

In rust grades Ri 4 and Ri 5 : total repainting.
SCALE AND DESCRIPTION OF RUST GRADE
ASTM
RUST ASTM DESCRIPTION
GRADES
10 No rusting or < 0,01 % of surface rusted No corrosion
Minute rusting < 0,03 % of surface rusted 1-2 pinpoints of rust per ft2
9
8 Few rust spots < 0,1 % of surface rusted 3-7 pinpoints of rust per ft2
7 < 0,3 % of surface rusted 20 pinpoints of rust per ft2
6 Extensive rust spots, < 1 % of surface rusted 30 pinpoints 1/32 of rust per ft2
5 Rusting to extent of 3% of surface rusted 30 pinpoints 1/16 of rust per ft2
4 Rusting to extent of 10 % of surface rusted 50 pinpoints 1/8 of rust per ft2
Approximately 1/6 of surface rusted APP. ¼ of surface rusted with

3 1/32 to 1/8 in rust spots
2 Approximately 1/3 of surface rusted APP. 1/3 of surface rusted with
1/32 to 1/8 in rust spots
1 Approximately 1/2 of surface rusted APP. 1/2 of surface rusted
with 1/32 to 1/2 in rust spots
Approximately 100 % of surface rusted Approximately 100 % of

0 surface rust
SCALE AND DESCRIPTION OF RUST GRADE
9 < 0,03 % 8< 0, 1% 7< 0, 3%
6 < 1% 5 to 3 % 4 to 10 %
Note :
10 < 0,01 %
0 = 100 %
3 ± 1/6 2 ± 1/3 1 ± 1/2

PENENTUAAN TINGKAT KOROSIVITAS (RATING)
Rating kira-kira 0 s/d 1 % korosi very low

I corrosion
Rating kira-kira 1 s/d 3 %, korosi

II kondisi lapis lindung cat masih baik. low corrosion
Rating kira-kira 3 s/d 10 %, permukaan middle
III logam sudah rusak. corrosion
Rating kira-kira 10 s/d 30 %, korosi berat &
IV permukaan logam sudah rusak dan high corrosion
banyak berkarat
Rating korosi sudah sangat parah, 30 - 100 % very high
V dari permukaan logam sudah berkarat corrosion
TINGKAT KOROSI & PRIORITAS PENGENDALIAN KOROSI
RATING PRIORITAS
I. 0-1% very low corrosion V. Masih bisa bertahan 6 -10 tahun
II. 1-3% low corrosion IV. Masih bisa bertahan 5 - 8 tahun
kondisi cat masih baik survey dilakukan setiap 1 tahun
III. 3-10% fairly low corrosion III. Masih bisa bertahan 3 - 6 tahun
kondisi cat masih agak survey dilakukan maks. 1 tahun
baik sekali
IV.10-30% high corrosion II. Pengecatan harus dilakukan
kondisi cat sudah 1 - 2 tahun kedepan
kusam
V. > 30% excessive corrosion I. Pengecatan harus dilakukan
Permukaan sudah sangat parah dengan segera
REPAINTING
1. MENENTUKAN TINGKAT KOROSIVITAS

2. MENENTUKAN URUTAN PERIORITAS PENGECATAN
3. MENENTUKAN VOLUME PENGECATAN & JENIS CAT
4. MENENTUKAN ANGGARAN BIAYA
5. MENENTUKAN JADWAL & WAKTU PENGECATAN
MASALAH PENGECATAN ULANG PADA CAT LAMA :
PENGELUPASAN
LAPISAN CAT BARU DAPAT MERUSAK LAPISAN CAT LAMA
SEBELUMNYA
ALLIGATORING
LAPISAN CAT LAMA TIDAK DAPAT MENAHAN PENGKERUTAN
DARI CAT BARU SELAMA PROSES PENGERINGAN
CRACKING ( RETAK )
 SISTEM CAT TOTAL AKAN MENJADI LEBIH TEBAL
MENYEBABKAN RETAK AKIBAT KONTRAKSI & EKPANSI
TERMAL.
MAINTENANCE & REPAIR
DILAKUKAN UNTUK MENJAGA KONDISI LAPISAN DALAM KEADAAN BAIK
1. REPAIR HARUS SEGARA DILAKUKAN PADA ATMOSFIR SANGAT AGRESIF
2. BILAMANA DAYA ADESI MASIH BAIK, LAKUKAN REPAIR SETEMPAT
3. BILAMANA DAYA ADESI KURANG BAIK, COATING HARUS DIHILANGKAN
4. PERSIAPAN PERMUKAAN HARUS DISESUAIKAN,
5. BLASTING HARUS DILAKUKAN DENGAN HATI-HATI
6. KASARKAN PERMUKAAN
7. ULASKAN PRIMER DENGAN KUAS, MINIMAL 25 µm
8. ULASKAN TOPCOAT DENGAN KUAS MINIMAL 50 µm

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PENANGGULANGAN KOROSI STRUKTUR BAJA DI

LINGKUNGAN ATMOSFIR DENGAN LAPIS LINDUNG CAT

PUSLIT METALURGI - LIPI

C: 0.1799 % UKURAN BUTIRAN PEARLITE TERGANTUNG :

Adanya 2 fasa pada logam baja menyebabkan logam baja

METAL REDOK POTENSIAL mv

 Baja terekpose di udara terbuka, permukaannya akan dibasahi

 Ketebalan lapisan air , tergantung tingkat kelembaban relatif udara

 Air pada permukaan baja akan melarutkan oksigen, patikel-partikel

REAKSI ELEKTROKIMIA : Simultan - Stochometry & Closed Circuit

PADA ANODA : 4 Fe -------------- 4 Fe 2+ + 8 e ( OKSIDASI )

CORROSION RATE µm PER YEAR

Relative corrosion rate 1

METAL REDOK POTENSIAL mv

REDOX Potential of Cathodic Reactions

Reaction REDOK POTENSIAL mv

Hydrogen ion reduction 2H+ + 2e ------- H2 0.00

 PROSES KOROSI SECARA ELEKTROKIMIA

Kehilangan berat/tebal per

Lingkungan pedesaan dengan tingkat

C4 Lingkungan industri & pantai

C5-I Area industri dengan kelembaban &

Berat jenis baja = 7,86 g/cm3

1500 g/m2.tahun = 1500 / 36.50 = 41.09 mdd = 7,47mpy

LINGKUNGAN INDUSTRI LINGKUNGAN PANTAI

FeSO4 / FeCl2 CORROSION

Udara masuk karena tanki

Korosi disebabkan oleh

H2S, CO2 & SO2 EVOLUTION

H2S, CO2, dan SO2 evolution

2. PROTEKSI KATODIK : IMPRESSED CURRENT

3. PENAMBAHAN INHIBITOR : KOROSI,

5. LAPIS LINDUNG CAT

Sand blast Sa 2,5 Anchor pattern 50 - 75 µm

FUNGSI & SIFAT - SIFAT CAT

SIFAT - SIFAT CAT :

SIFAT - SIFAT YANG HARUS DIMILIKI OLEH SEMUA CAT UNTUK

 CAT TAHAN AIR / ZAT KIMIA

KOMPONEN - KOMPONEN UTAMA CAT

 MENGIKAT PIGMEN & KOMPONEN -KOMPONEN CAT LAINNYA

 MEMBERIKAN DAYA REKAT PADA SUBSTRAT & LAPISAN CAT

 MENENTUKAN SIFAT KIMIA, FISIK DAN MEKANIK :

 KONTROL VIKOSITAS UNTUK MEMUDAHKAN DALAM APLIKASI

 KONTROL PROSES PENGERINGAN LAPISAN CAT

Definition of gloss from AS/NZS 2310

Low gloss > 5 – 20 gloss units

Full gloss > 85 gloss units High gloss

Hiding power of white pigments

Pigment Hiding Units

 Acicular needle – shaped )

 Lamellar ( plate – like )

UNTUK STRUKTUR BAJA

Note : Zn (R) = Zinc rich primer

Note : Zn (R) = Zinc rich primer

LINGKUNGAN INDUSTRI SANGAT KOROSIF

TOP COAT Polyurethane

UNDER COAT Polyurethane

PRIMER Zinc rich

Sand blast Sa 2,5 Anchor pattern 50 - 75 µm

LINGKUNGAN LAUT SANGAT KOROSIF

TOP COAT Epoxy

UNDER COAT Epoxy

PRIMER Inorganic Zn silicate