IMO Performance Standard For Protective Coating and IACS Common Structural Rules

IMO Performance Standard for
Protective Coating and IACS

Common Structural Rules

2
nd
Day Training
For the benefit of business and people
2
BV Internal use only
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1 > Terms and definitions

2 > Corrosion basis

3 > Protective Coatings

4 > Coating Process
SUMMARY
3
> Terms and definitions
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Abrasive: the agent used for abrasive blast cleaning; for example, garnet, grit, shot etc.
Adhesion: The bonding strength; the attraction of a coating to the substrate.
Airless Spraying: An application method by which the paint is forced to a great pressure (up
to 350 kg/sq. cm.) and is atomized by forcing it through a tiny nozzle.
Ambient temperature: The room temperature or temperature of surroundings.
Blast cleaning: Cleaning with propelled abrasive.
surface cleanliness : One free of contamination (including non-visible contamination such as
soluble salts).
Coating system: A number of coats separately applied, in a predetermined order, at suitable
intervals to allow for drying and curing, resulting in a completed job.
Curing Time: Time required by a coating to reach its complete properties and mechanical
characteristic
Dew point is the temperature at which air is saturated with moisture.
DFT is Dry Film Thickness.
Dust is loose particle matter present on a surface prepared for painting, arising from blast-
cleaning or other surface preparation processes, or resulting from the action of the
environment.
Terms and definition
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5
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Edge grinding is the treatment of edge before secondary surface preparation.
Epoxy based: Film formers based on generic resins (binders) cross linked by amines,
polyamides or isocyanates.
Film thickness: The thickness of a coating layer or a multilayer coating system. Minimum
and maximum values are the only relevant numbers when dealing with corrosion protection.
Humidity: Measure of moisture content; relative humidity is the ratio of the quantity of water
vapour in the air to the greatest amount possible at the given temperature. Saturated air is
said to have a humidity of 100%.
Material Safety Data Sheet: Document published by paint manufacturer in which
components of the paints and all the safety requirements are given.
Primer: General term used to define the first coat of a paint system applied to provide
adhesion and/or corrosion protection.
Profile depth: Average distance between tops of peaks and bottom of valleys on the surface.
Power Tool Preparation: Surface preparation method carried out by mechanical tools,
pneumatic or electric such as abrasive discs, wire brush, sandpaper etc.
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Recoat time: Time interval required between application of successive coats.
Shop-primer is the prefabrication primer coating applied to steel plates, often in automatic
plants (and before the first coat of a coating system).
Stripe coating is painting of edges, welds, hard to reach areas, etc., to ensure good paint
adhesion and proper paint thickness in critical areas.
Thinners: Volatile organic liquids for reducing viscosity; diluents.
Target useful life is the target value, in years, of the durability for which the coating system is
designed.
Technical Data Sheet (TDS) is paint manufactures Product Data Sheet which contains
detailed technical instruction and information relevant to the coating and its application.
Touch-up: Operation of repair of spot damage coated surface.
Two-Pack Paints: Paints stored in two separate containers and that have to be mixed in the
correct proportion before application.
Wet Film Thickness: The thickness of paint film just applied and before evaporation of the
volatile part.
Zinc silicate: Inorganic zinc coating.

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Corrosion basis

Definition and causes
Factors influencing the
corrosion rate
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Corrosion and coating
2-1 Definitions and causes
Steel Corrosion is the deterioration of the steel
caused by its interaction with the environment
The Metal tend to return to a more stable
thermodynamic state: iron oxide (rust) for steel
The Standard Electrode Potential
*
E
0
measure the
difference of potential at the equilibrium state
between the metal and the electrolyte* :
The more E
0
is negative the more the metal is electronegative (i.e.
release electrons) and corrode easily
*E
0
is calculated compared to the Hydrogen electrode

Basic Knowledge 2
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Electrolyte
Ions Migration
2-1 Definitions and causes
Four essential elements must be present to make the corrosion
process likely to occur:

2
Metal oxidation (i.e. corrosion)
Fe Fe
++
+ 2e
-
Anode
+
1
Reduction of Ions or oxygen:
O
2
+2H
2
O +4e
-
4OH
-
Cathode

2
Electron Migration
3 Metallic Pathway or external conductor
ACME
Basic Knowledge
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Electrolyte
Ions Migration
2
Anode
+
1
Cathode

2
Electron Migration
ACME
Rust
2-2 Factors influencing corrosion rate
[NaCl]
Basic Knowledge
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The principal factors influencing corrosion rate are:
Electrolyte salinity [NaCl]: A high level of salinity (ex. 3.5% for
seawater) increase electrolyte conductivity and so promotes corrosion
and localised attacks. Chlorides produce breakings in the protective oxide
films and so reduce metal corrosion resistance.
[NaCl] (g/L)
Corrosion rate
www.Pilebuckinternational.com
2
Basic Knowledge
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Electrolyte
Ions Migration
2
Anode
+
1
Cathode

2
Electron Migration
ACME
Rust
[O
2
]
Basic Knowledge
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2
Electrolyte salinity [NaCl]
Oxygen concentration [O
2
]: A increase in [O
2
] causes a rise in
corrosion rates.
www.Pilebuckinternational.com
Corrosion rate
(Mils/yr)
[O
2
] (Parts per Billion)
Basic Knowledge
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Electrolyte salinity [NaCl]
Oxygen concentration [O
2
]
Electrolyte temperature T: Generally corrosion increase with
temperature.
Bacteria: Bacteria present in seawater can cause local changes in
corrosive conditions, and are therefore baneful for most metals.
Basic Knowledge
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Difference in potential DE
0
: Particularly for galvanic corrosion when two
metals or alloys are electrically in contact in a corrosive environment.
Relative surface areas of anodic and cathodic zones
Distance between anode and cathode
Basic Knowledge
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Protective Coatings
Definition and main components
Coating families- a brief overview
Concept of a coating system
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Protective Coating
3
3-1 Definitions and main components
Electron Migration
Cathode

Anode
O
2
H
2
O

Ions

Suitable Protective Coatings are used to prevent or retard corrosion in
ballast tanks :
They act as a physical barrier that reduces corrosion rate
Protective coating
Low permeability
(Controlled Thickness
and suitable formulation)
Good Adhesion with
Substrate
Basic Knowledge
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Protective Coating 3

Conventional coatings have two major components :
Pigment
Vehicle
Basic Knowledge
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Pigments are discrete particulate solids used to provide
specific:
protective
or decorative properties (color, opacity and gloss)
to the coating.
They are Organic / Inorganic chemical products.
Basic Knowledge
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Decorative Pigments:
iron oxide (yellow, red etc.),
titan oxide(white),
candium compounds(red and yellow).
Basic Knowledge
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Fillers are organic/inorganic particulates which allow the paint to be
applied in thick layers, improve coating impermeability, adjust rheologic,
gloss and mechanical properties, reduce cost formulation. (Silicium oxide,
calcium carbonate, aluminum silicate, talc)
Main coating properties are controlled by the Pigment Volume
Concentration (PVC).

Basic Knowledge
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Vehicle is the liquid part of the coating. It consists of the binder, solvent
and any liquid additives.
Binders (Resins) are part of nonvolatile film-forming components. It
provide internal cohesion and flexibility and adhesion with substrate and
gives the chemical resistance:
Solvents
Long
Hydrocarbonate
chains
(binder)
Vehicle Scheme
Basic Knowledge
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Solvents are volatile components. They may be classified as:
Primary solvent (active): dissolves the resin to form a liquid solution
Latent solvent: often used together with the primary solvent (easiness
of application, evaporation rate control, enhance film properties)
Diluents are used with active solvents to dilute the coating. In some
cases diluents may improve smoothness and toughness of the film
Generally, paint formulators use a mixture of solvents to optimize the binder
solubilisation, evaporation, viscosity etc.
The main use volatiles compounds are : white spirit, Xylen, Toluen, Methyl
ethyl ketone (MEK), Metyl isobutyl ketone (MiBK).
Basic Knowledge
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The two major characteristics of solvents, which influence their use
are:
Solvency power: their ability to dissolve other chemical compounds
Volatility: their ability to quit the coating (it governs the evaporation
rate)
Solvent safety is concerned with two types of hazards:
Fire hazards: Flash Point
LEL = Lower Explosive Limits: is the lowest concentration of solvent
vapor in air that can be ignited
UEL = Upper Explosive Limits : is the highest concentration of solvent
vapor in air that can be ignited
(The lower is the flash point of a solvent, the more highly flammable
the solvent will be ! )
Health hazards
all solvents to be handled with care (ventilation, breathing apparatus,
protective clothing, etc.)

Protective Coating
Basic Knowledge
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Additives which confer special properties to the paint:
Rheological agent
Anti-foaming agent
Anti-settling agent
Anti-skinning agent
UV absorber
Platicizer

Rheological agent
Protective Coating
3
Basic Knowledge
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Paint production
Raw
materials
Premix
(millbase)
dispersion
(grinding)
Final mix
packaging
storehouse
Site
application
Part of vehicle and
pigment, extender mixed
Agglomerates be divided
into primary particles and
wetting
the rest of the binders and
additives are added, adjust
viscosity and color
Protective Coating
Basic Knowledge
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3-2 Coatings families: a brief overview
Others systems
( Polyurethane,
Polyester etc.)
Coatings Families
Shop Primer
(Ethyl Zinc Sillicate,
Zinc reach epoxy)
Soft Coatings
Physical drying
(Chlorinated rubber,
Vinyl Paint )
Hard Coatings
Chemical drying
Dry by oxidation
(Oil, Alkyd Paints)
Epoxy base
Coating
PSPC
Protective Coating
Basic knowledge
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Paint which dry by chemical reaction: Curing is obtained by mixing the
base and the hardener in clearly defined proportions. A chemical reaction
then occurs, causing crosslinking of the molecular chains. After curing,
these paints provide a very hard film.

Base +Hardener
Crosslink reaction
Crosslink Network
Protective Coating
Basic knowledge
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Basic knowledge 3
Paint which dry by chemical reaction: Curing is obtained by mixing the
base and the hardener in clearly defined proportions. A chemical reaction
then occurs, causing crosslinking of the molecular chains. After curing,
these paints provide a very hard film.

The ratio Epoxy/Hardener is crucial for the final properties of the
coating
Temperature and Dry time have to comply with Manufacturer
instruction to guarantee optimal conversion (To avoid solvent
entrapment, crosslink default, vitrification etc.)

To ensure optimum coating properties
Protective Coating
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3-3 Notion of Coating System

In addition to protect the substrate against corrosion, coating have to
ensure others functionality such as adhesion, UV resistance, anti-fouling
action etc. So we talk about Coating System.
Steel
Primer: (Adhesion and/or active corrosion protection)
Undercoats: barrier effect, ajusting thickness,
compatibility with upper and below layers
Finish layer: Surface aspect, gloss, color, UV resistance
Each coat layer is applied at a specified film thickness.
Protective Coating
Basic knowledge
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Coating Process
Environmental factors
Surface preparation
Coating application
Coating inspections
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4-1 Environmental factors: Definitions and Influences
In order to obtain the optimum properties of a Coating System the applicator
need to control the Coating Process
Drying time Drying time
Surface Preparation Surface Preparation
Surface Preparation
(eventually)
Surface Preparation
(eventually)
Coating Preparation Coating Preparation
Overlap time delay Overlap time delay
1
st
Coating
Application
1
st
Coating
Application
x Coating
Application
x Coating
Application
Repairs
(eventually)
Repairs
(eventually)
Process applicated x
times until to obtain
the required thickness
Measurement and control of
environnemental
parameters (T, NaCl, HR%)
Coating Process
Basic knowledge
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4-1 Environmental factors: Definitions and Influences
Environmental conditions affecting the coating job are mainly:
Surface temperature of the substrate (Condensation, Drying and Curing times)
Ambient conditions, including:
Temperature (Drying and Overlap times),
Relative humidity (RH) (Drying and Overlap times, Conversion rate),
Wind velocity (Drying and Overlap times, Health and Safety)
Airborne contaminants (dust, chemical fumes, salt spray, oil,)
(Adhesion loose, initiation of corrosion, failures)
Dew point is the temperature at which air is saturated with moisture. Below it
condensation occurred and forbidden coating application.
Rust Scale if it is not remove prior to coating application will cause early
failure. The loose top-scale is easy to remove, however the inner (black) hard
scale is much more adherent.

Coating Process
Basic knowledge
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4-2 Surface preparation
Surface preparation is the essential first stage treatment of a substrate
before the application of any coating.
Correct paint application, ballast tank condition
after 13 years (bulk carrier double bottom tank)
Poor paint application, ballast condition after 13
years (bulk carrier top side tank)
About 75% of coating failures would be caused
by bad surface preparation
Coating Process
Basic knowledge
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The objective of surface preparation is:
To ensure good adhesion properties between coating and
substrate
Surface cleanliness: to remove any contaminants which may be
harmful to the performance of coating.
Surface profile: create an anchor pattern and control it.

Coating Process
Basic knowledge
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Sequence of cleaning and usual applicable methods
Oil, grease emulsifying solution or solvent.
Soluble salts water hosing, water jetting
Mill scale, rust abrasive blasting, water jetting, grinding, etc.
Dust blowing, vacuum cleaning
Moisture heating, ventilation

Coating Process
Basic knowledge
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Cleaning method:
Chemical: emulsifying solutions, solvents, pickling, etc. oil/grease, or Mill
scale & rust (pickling) .
Thermal: flame cleaning Mill scale & rust.
Mechanical: by far the most widely used
Manual and power tool - rust & old coating
Wire brushes, scrapers, etc.
Disc sanding
Grinding tools
Chipping and needle gunning.
Abrasive blasting Mill scale, rust & old coating
The degree of surface cleanliness required, is determined by the generic
type of paint, the aggressiveness of the environment and the projected
service life/maintenance cycle of the structure
Manual and power tool cleaning:
Low work efficiency , tiresome and maybe used in maintenance work or for
preparation of substrate in non-aggressive environment.
Coating Process
Basic knowledge
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Surface cleanliness is to be checked:
Before any surface preparation activities
After surface preparation, before coating begins

remove sharp edges
remove weld spatter
suitable anchor profile
anchor profile
(Base Metal Reading)
Hammer scale,
Contaminants
cleaning
anchor profile
(Base Metal Reading)
Hammer scale,
Contaminants
cleaning

ISO 8501-2,3:1998: preparation grades of previously coated steel/
welds, and other areas with surface imperfections.
Correspond to the surface preparation standard, other exists, like the
US Steel Structure Painting Council SP Standard
Coating Process
Basic knowledge
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INTERNATIONAL STANDARD ISO 8501-1 : 1988 (E)
RUST GRADES
A
B
C
D
Coating Process
Basic knowledge
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The text of the individual Standards are quoted literally

Coating Process
Basic knowledge
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Joint Surface Preparation Standard NACE No. 5/SSPC-SP 12 - surface
preparation method using high pressure water for cleaning.

Coating Process
Basic knowledge
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Suitable Anchor Profile:
Commercial
Blast Cleanning
NACE 3
SSPC-SP 6
Sa 2
Brush off Blast
Cleanning
NACE 4
SSPC-SP 7
Sa 1
*
Near White Metal
Blast Cleaning
NACE 2
SSPC-SP 10
Sa 2.5
White Metal
Blast Cleaning
NACE 1
SSPC-SP 5
Sa 3
*ISO -8501-1:1988/suppl 1994
ISO -8503-1/3
Coating Process
Basic knowledge
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*ISO -8504-1:2001
Blasting is a collective name to describe methods using projection of
abrasive particles at high velocity against the surface of a work piece. It is
widely used and efficient.
Employed method :
Dry blasting:
Automatic mechanical methods: where the centrifugal force will
actuate the abrasive directly when it is fed from the center and out
to the wheel.
Open nozzle blasting methods: the dry abrasive is mixed with
compressed air in a mixing valve .
Vacuum blasting: is a method by which the abrasive and dust are
immediately removed by suction.
Wet blasting
Water blasting: use water, at pressures ranging from 200-700 bar,
as the propellant for the abrasive.
Hydro blasting (high pressure water jetting): at pressure more than
700 bar.
Wet abrasive blasting and slurry blasting.
Coating Process
Basic knowledge
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Different types of abrasives:
The type and size of the abrasive used in blast cleaning have a significant effect on
the profile or amplitude produced.
Mineral Abrasives (ISO 11126/ 11127):
Sand abrasives: which have the highest emission rate of particles
Funace Slags (burning coal), Smelter Slags: The level of associate
polluants vary depending upon the source of the coal.
Mettalic Abrasives (ISO 11124 / 11125): They have the lowest particles
emission rates.
Iron and steel shot, Iron and steel grit.
Organic plastic etc.
Open nozzle abrasive blasting:
Compressor (capacity, pressure, separator etc); sand pot (abrasive
size, salts, pressure gauge); nozzle and hose.
*ISO -8504-1:2001
Coating Process
Basic knowledge
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3
4-3 Coating Application
Mixing the different components (base, hardener, thinner )
Measure and control of Atmosphere and Substrate Temperature (/Dew
point), HR%, Ventilation, Salt concentration*
1rst layer
2nd layer
3rd layer
O
2
H
2
O O
2
H
2
O
Cleanness of coating surface before
recoating
To avoid discontinuities between
layers and defaults
To insure good adhesion between
layers

Measure and control NDFT is the Nominal
Dry Film Thickness*

Control Drying and Overlap time
To be conform with TDS
To avoid solvent entrapment

**ISO 19840:2004 *ISO 8502-9
SSPC-PA2
Coating Process
Basic knowledge
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Application workmanship:
Preparation of paint
Check the information of the can, such as type, colour, pot life, mixed ratio etc.
Stirring, mixing and the volume of thinner mixed.
Stripe coat (sometimes applied after paint application)
Check spray preparation of equipment : power, hose, nozzle; flush out the old
thinner, etc.
Spraying technique:
Spray pattern,
spray distance to the substrate
Crossing spraying,
avoiding defect such as overspray and dry spray etc.
Wet Film Thickness measured with regular.

Coating Process
Basic knowledge
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Application methods
Brush Application (for limited access zones, for small surfaces,
welding, angles)

Advantage
Disadvantage
Use for limited access zones

Long time application and high
costs
Coating Process
Basic knowledge
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Application methods
Roll Application (for plane and width surfaces)

Advantage
Disadvantage
Four to Five times faster than brush
application

Not to be used for primer
application
Not adequate for aluminium
filled paints, vinyl and rubber
chlorinated paints
Coating Process
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Application methods
Pulverised Application
Airless
Conventional Spraying
The paint is provided by thrust,
aspiration or gravitation until the fluid
nozzle, then atomised by the air flux

The paint is applied under
pressure
Its atomisation is due to the
suction pressure.

Coating Process
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Application methods
Conventional spraying
Advantage
Disadvantage
Faster than roll and brush
applications
Uniform and reproductible thickness

Important looses
Dry pulverisation (fog paint)
Defaults applications in angles etc.

Coating Process
Basic knowledge
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Airless Pulverisation
Advantage
Disavantage
Better efficiency (until 300 m
2
/h)
High viscosity paint could be applied
Lower paint losses

Dry pulverisation (fog paint)
Defaults applications in angles etc.

Coating Process
Basic knowledge
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Airless spray equipment :
power source: air-driven, electrical-driven and
other.
Pump, check point: ratio, pressure of
compressed air, oil separator, lubricating oil
around piston rod, paint filter, paint filter, paint
pressure .
Nozzle: size of orifice and fan angle.
Airless spray
equipment
Coating Process
Basic knowledge
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4-4 Coating Inspections

Ensure that the work carried out is of a very high quality by
Inspection.
The tasks of coating inspection are:
Prevent errors and mistakes to occur.
Correct if do occur.
the inspection routines can be divided according to the progress of
coating work:
Before surface preparation
surface preparation
Before coating application
Coating application
Final control
document

Coating Process
Basic knowledge
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Coating Process parameters have to be controlled

Selection of the coating products: complete number and types of coats applied
to a substrate in a predetermined order
Primary and Secondary surface preparation (including cleanness before and
after surface preparation)
Mixing and thinning operations regarding each type of coat
Checking of environmental conditions during all coating operations
Coating application manner, wet film thickness (uniformity of film thickness),
dry film thickness (per layer, and for the total multi-coat)
All these items are to make reference to specific standards to clearly
define the Coating System
The Technical Data Sheet (TDS) is coating manufactures Product Data
Sheet which contains detailed technical instruction and information relevant
to the coating and its application. It is part of the Coating System definition.
Coating Process
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Instruments used to measure environmental conditions are mainly:

Surface-contact thermometer (magnetic surface-contact
thermometer, direct-reading thermocouple / thermistors)

Electronic Hygrometers are used to determine RH, Air temperature,
and Dew Point temperature.

Coating Process
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Sling psychrometer (whirling
hygrometer), used to measure the ambient
air temperature (dry-bulb temperature) and
wet-bulb temperature at the work site

Psychrometric charts, are used to
determine the RH and Dew Point
temperature of the air, based upon dry-
bulb and wet-bulb temperature
readings. The wet bulb depression is
the difference between the dry and wet
bulb temperatures.
RH =65
Dew T =11 C +3C
Dry =18 C
Wet =14 C
b_d =4 C
Dry =18 C
Wet =14 C
b_d =4 C
Coating Process
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Dust Rating:
ISO 8502-3:1993
provides pictorial ratings for
the assessment of the
average quantity of dust,
rating:1,2,3,4,5;
and also provides
descriptive classed for the
assessment of the average
size of the dust particles.
class 0 ~ class 5.

Coating Process
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Assessment of visual cleanliness:
Oil/grease determination:
many methods are described for detection of oil
and grease, unfortunately most of these are
unsuitable for on-site use
a simple method using a piece of chalk can
often quickly decide if degreasing is necessary,
as the figure.
Dust grades:
Reference standard: ISO 8502-3:1993.
Preparation of steel substrate before
application of paints and related products
Test for the assessment of surface cleanliness.
Evaluation of dust grades: generally according
to the dust size and quantity to determine with
the pressure-sensitive tape method. (not
suitable to the plate of rust grade D)

Coating Process
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Solutions test and conductimeter (for Salts
detection):

To detect water-soluble salts, the most user-friendly
method available today is to dissolve the salts that are
present at the surface and to measure the conductivity
of the water sample.
The sampling is given by ISO 8502-6, "Extraction
soluble contaminants for analysis", the Bresle sampler.

The analysis is described by ISO 8502-9, "Field
method for soluble salts by conductometric
measurement".

Coating Process
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procedure to determine the soluble
salts, as the figure.

Coating Process
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The standard for assessment of visual cleanliness:
The standard of ISO 8501-1: identifies three preparation grades, the
various grades are defined by written together with pictures that are
representative examples. (text see surface preparation)
Blast cleaning: Sa1, Sa2 , Sa2.5, Sa3
Hand and power tool cleaning, St2, St3
Flame cleaning, FL
Some pictures of the sample, as follows:
Surface preparation standards for water jetting. See the previously
mentioned : Joint Surface Preparation Standard NACE No. 5/SSPC-SP
12.

Coating Process
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Anchor profile Inspection:

Rugotest No.3: has specimens for
round and sharp profiles collected in
one comparator. For greater
roughness values there is even a
division in fine and coarse grained
finish.
Keane-Tator Surface Profile
Comparator: has three different
discs, designed by S (sand), G/S
(steel or metallic grit), and SH (shot),
respectively. As right figure

Coating Process
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Anchor Profile Roughness :
In ISO 8503, two comparators are specified;
one with profiles corresponding to blast
cleaned surfaces using grit abrasive (reference
comparator G) and one corresponding to blast
cleaned surfaces using metallic shot abrasives
(reference comparator S).

The nominal values for these profiles, identify
the limits of the three grades fine, medium, and
coarse.
(Sa 3, Sa 2.5, Sa 2)

Coating Process
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Instruments used to measure film thickness:

Wet Thickness measurements :
The wet film gauge (ISO 2808) is a useful tool
to measure wet film thickness on flat, even
surfaces. When measuring the second coat, a
soft first coat or, if the first coat is of a resoluble
paint type, the results may be inaccurate.

Dry Film Thickness measurements
*
:
The most used instrument in the field is the
electromagnetic dry film thickness gauge. It is
important to calibrate the instruments to zero
and thickness similar to be measured.

*SSPC-PA2 : 2004

Coating Process
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Magnetic induction instrument, based on a principle of a low-frequency
voltage in the probe create a magnetic field.
The accuracy is within the range of + 3-5% of the reading.
Keep the probe clean and free of paint and fillings
Measurement should not be made too close to edges and corners.
Adjustment:
It is important to adjust the instrument according the
manufactures
instructions using calibrated shims.
Recommend to check adjustment of the instrument.
Keep the steel plate clean and free of rust.
Coating Process
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Permanent magnet instruments (banana gauge)
When measured: dial is turned forward to allow the magnet to contact
with the film, then turn backward the dial slowly and evenly, until the
sound of the magnet pull off, and the DFT can be read on the scale.
The accuracy is within the range of + 5% of the reading.
Measurement may be inaccurate when take on the underside of
horizontal surface, or in area with vibration.

Coating Process
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Instruments used to measure adhesion:

Pull-off test
*
:
The pull-off test (ISO 4624:2002): Dollies are
connected to the painted surface with glue. The
force needed to loosen the dolly, is measured
by the instrument.
Cross cut test, ISO2409.

Cohesive rupture
Mixed rupture
Adhesive rupture
Coating Process
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4

After Coating application and drying Inspections are taken in order to note
defects zones and undertaken Repairs.

The main paint defaults are:
Delamination : Loss of paint adhesion
Causes : bad surface preparation, incompatibility between primer
and paint layers, no adequate overlap time application
Chalking : Separation between the pigments and the binder
Causes : UV ageing, Bad paint mixing, no adequate thinners
Blistering :
Causes : Presence of contaminants (oil, rust, salts) on the metal
surface, solvent entrapment.

Coating Process
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4


Cracking :
Causes : Application/drying temperature
too important, too short overlaptime,
formulation problems.
Checking :
Causes : Thickness of zinc rich primer
too important
Flaking :
Causes : Following to paint cracking
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4


Cracking :
Causes : Application/drying temperature
too important, too short overlaptime,
formulation problems.
Checking :
Causes : Application/drying
temperature too important, too short
overlaptime, formulation problems.
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4


Rusting :
Causes : Presence of holes, film porosity, substrate roughness too
important.
Orange peel :
Causes : Bad paint atomisation due to low pressure,
nozzle near to the surface, fast solvent evaporation.
Fish-eye :
Causes : Application onto oil, dust, water
condensation, or incompatibility between paint layer.
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Coating Process 4

Paint default:

ISO 4628 Paint and varnishes-Evaluation of degradation of paints coatings-
Designation of intensity, quantity and size of common types of defect indicate
the designation of degree of:
blistering (Part 2),
rusting (Part3),
cracking (Part 4)
flaking (Part 5).

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-
Conclusion

The ability of the coating system to reach its target useful life depends on :

The type coating system

Steel preparation,

Application and Coating inspection,

Coating maintenance.

Basic knowledge
4
74
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Conclusion
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coatings
4

Record and report
Pre-job meeting (minutes):
analyze, discuss the problem during the whole application process, and appropriate
solutions adopted
Daily log by inspector:
Object ID: including site location, name etc.
Work locations and date/time: details on area, etc.
Ambient condition during blasting cleaning and painting.
All data, reading, measurements etc. necessary to complete the required reporting of
the project
Non conformity reports
Deviation description and reference document.
Correct action
Progress reports
Work locations and date/time: details on area, etc.
Initial condition/application details inspection result
Remarks: deviation/ non-conformity.
75
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Conclusion 4

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Thank you for your attention

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