Important Factors and Aspects of Coating

IMPORTANT FACTORS AND ASPECTS OF
COATING
1. COATING SELECTION
1.1. The choice of protective paints systems should be

based on practical experiences and / or on the results of
standardized performance tests (see ISO 12944-5), in
particular when new coating technology is involved.
1.2 The Specified protective paint systems shall be tested

for compatibility with existing coatings on previously
coated surfaces.
Your Notes :
PT. STARIS GIROS INDONESIA / LINDUNG SILALAHI

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2. CLASSIFICATION OF ENVIRONMENTS
(derived from ISO 12944-2)
2.1 Atmospheric corrosivity categories for

atmospheric corrosion and associated types of
atmosphere.
2.2. Corrosivity Categories Your Notes :

C1 Very low
C2 Low
C3 Medium
C4 High
C5 1 Very high-Industry
C5 2 Very high-Marine

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2.3 Types of atmosphere
- Rural atmosphere
- Urban atmosphere
- Industrial atmosphere
- Marine atmosphere
2.4 Immersion of atmosphere

1. Immersion in fresh water
2. Immersion in sea or brackish water
3. Immersion in soil
2.5 Climatic Conditions Your Notes :

- Extremely cold
- Cold
- Cold temperature
- Warm temperature
- Warm dry
- Mild warm dry
- Extremely warm dry
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- Warm damp
- Warm damp, equable
2.6 Particular situations and special loads
2.6.1 Particular situations

- Corrosion inside buildings
- Corrosion in box members and hollow
Components
2.6.2 Special loads

- Chemical loads
- Mechanical loads
- Loads due to condensation
- Loads due to elevated or high temperature
- Increased Corrosion due to load combination

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3. Aspects to Manage Corrosion Problem with
Protective Coating
3.1 The main task of protective coatings is to

prevent or control corrosion.
Uncontrolled corrosion can cause serious
damage to capital investments and can endanger
human file.
Therefore, optimum selection and application of
protective coatings is of tremendous importance.
3.2 During its services life a protective coating

system deteriorates as a result of exposure to
ultraviolet light, moisture, fluctuating
temperatures, chemicals, abrasion and many
other factors.
3.3 Proper and timely maintenance is required to

obtain the optimum performance from protective
coating system. However, selection and
application of maintenance coating systems is
more complicated than for new construction.
Climatic conditions, chemical exposure, available
time, budget, health and safety, low-grade
surface preparation, these and other condition

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have an influence on the selection and
application of the optimum maintenance system.
3.4 A maintenance system intended for total repair

may often be the same as one for new construction,
but special construction and project requirements
met in new building may require alterations.
3.5 Coatings consideration
- 3.5.1 Maintenance systems

Recommended coating systems for maintenance
and total repair, including coatings specially
designed to cope with one or more of the
prevailing adverse conditions.
- 3.5.2 Compatibility
Recommended coating systems (generically) in
relation to exposure conditions and existing
coating systems.
- 3.5.3 Quality
Qualitative aspects of various generic-coating
types
- 3.5.4 Compendium

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A compendium providing information about
surface preparation, paint application, corrosion
phenomena, typical maintenance procedures and
other aspects needed to manage corrosion
problems.
- 3.5.5 Performance expectancy

The expected performance life related to the
coating system/surface preparation/dry film
thickness and exposure conditions.
- 3.5.6 Problem solving

Problem solving in the corrosion and coating
field.
4. SYSTEM SELECTION FOR

INTERNAL AND EXTERNAL EXPOSURE
4.1 The exposure definitions and compatibility table

are used as follows:
Firstly select the appropriate exposure condition.
Then compare this exposure condition with the
generic type of the existing coating system in the
following tables. This indicates the system types,

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which may be considered for maintenance.
4.2 GENERAL DESCRIPTION OF EXPOSURE

CONDITIONS
1). INTERNAL DRY EXPOSURE

Inside buildings with neutral atmosphere.
Relative humidity below 60%
2). INTERNAL WET (HUMID) EXPOSURE

Inside buildings where condensation may occur.
Atmosphere with low pollution and dry climate
Relative humidity up to 80%
3). RURAL ATMOSPHERIC EXPOSURE

The environment usually covers areas away
from the coast and industrial or urban activity.
Corrosive attack is governed mostly by humidity,
rainfall and ultraviolet radiation, but is normally
less aggressive than an industrial or coastal
environment.
Average sulphur dioxide content is lower than
10 g per m3 air.
Salt content in rainwater is lower than 12 mg per
litre rain.
4a). INDUSTRIAL POLLUTED ATMOSPHERE

EXPOSURE

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Conditions of high humidity, ultraviolet radiation
and chemical pollution will accelerate the
corrosion process and requires considerations
regarding increased acidic fall out. The main
effect is corrosion due to sulphur dioxide attack
and this environment is characterised by an
average sulphur dioxide content or more than
10 g per m3 air.
4b.) SEA, COASTAL ATMOSPHERE

EXPOSURE
Conditions of high humidity, ultraviolet radiation
and salt spray will accelerate the corrosion
process, aggravated by wind borne particle.
This environment is characterised by a salt
content in rain water of more than 12 mg per
litre air.

5). ATMOSPHERE EXPOSURE WITH

ABRASION/IMPACT
Same conditions as for industrial polluted
atmospheric exposure can be expected;
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additional abrasion and impact exposure is
expected. (See also 4a-4b)
6). HIGH TEMPERATURE

High temperature surfaces: The temperature
aspects are usually of greater importance than
the general atmosphere. Thermal shock may
need to be consider
7). IMMERSION IN WATER (with or without

cathodic protection)
Immersion in water in conjunction with or
without cathodic protection
Subsoil water and splash zone are considered
as immersion conditions.
8). IMMERSION IN WASTE WATER AND/OR

SLURRIES (cathodic protection)
Applicable to river installations, sewage-
treatment tanks, water tanks and domestic
water systems, with pH between 3 and 10 and
where abrasion can be expected.
9). IMMERSION IN CHEMICAL

Immersion in chemicals like acids, alkalis and
solvents.
Specific corrosion hazard from both liquid and
vapour.

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10). IMMERSION IN REFINED PETROLEUM
PRODUCTS AND CRUDE OIL
Immersion in aliphatic white petroleum products
and crude oil.
5. QUALITY ASPECTS OF MAJOR

MAINTENANCE COATINGS SPECIFICATION
GENERAL
Coating system specifications for new construction
and or maintenance are the result of a
techno/economic analysis. A maintenance system
is more than just the specified number of generic
coats.
5.1 The following items shall be counted :

- Cleaning procedure before mechanical surface
preparation.
- Standard of surface preparation of damaged
and/or corroded areas

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- Choice and specification of coating materials and
system composition in relation to the paint
system to repaired
- Data concerning acceptable limits for
environmental conditions during application and
drying of the coating materials
- Data concerning upper and lower limits for DFT
and minimum and maximum over coating times
- Expected exposure conditions in service
- Expected lifetime in relation costs involved
5.2 To ensure good coating adhesion it is essential

that the surface to be painted is dry and free form
rust, dirt, dust and debris that might prevent the
paints adhering to the surface. Roughening of the
surface in order to improve the adhesion may
required.
5.3 It is not always possible to obtain a perfect

coating application, therefore special attention
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should be given to areas of difficult access or which
have sharp edges, in order to obtain the specified
dry film thickness (DFT).
In practice no coating system is completely
impermeable and the rate at which oxygen water or
aggressive chemicals penetrate reflects the
durability of the coating system.
5.4 Water soluble matter, if left on the surface to be

painted, causes rapid deterioration (blistering) when
the coating is exposed to moisture (condensation or
immersed in water or chemicals).

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Performance properties of coatings
A classification of coatings based on generic type,
related to the film properties the mechanism of film
formation is given in the following tables.
7. COATINGS FUNCTION
Functional properties of individual coats

Basically a coating system is designed to protect
against corrosion by forming a barrier between the
steel and environment. For aesthetic or functional
reasons coating systems are made up of a number
of coats. Generally the types of materials are
grouped as primers, sealers/barrier coats
(undercoats and or intermediate coat), build coats
and top coats (finish coats).

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The function of the different types can be described
as follows :
7.1 Primers: Anticorrosive properties rely on the

presence of inhibitive pigments and/or on
the formation of a barrier. Primers should
give adhesion to sufficiently roughened,
cleaned metal and cleaned old coating,
providing a sound base for and offering
adhesion to the subsequent coating
system. They should provide corrosion
protection during the overcoating interval
and service life. Coats applied in the
correct dry film thickness will provide
sufficient protection against rust creep in
case of mechanical damage afterwards.
7.2 Sealers These coatings are used as an

Barrier coats
(tie coats):
intermediate coat in coating system to
enhance to overall protection and to
provide good intercoat adhesion.
Incorporation of pigments with a laminar
structure (aluminium flakes, talc or
micaceous iron oxide) reduces or delays
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moisture penetration of the binder. On a
porous substrate (e.g. zinc rich coatings)
suitable formulated sealers minimize
popping effect.
7.3 Build coats: These coatings are used as an

intermediate coat top coat in a coating
system to enhance the overall protection
by increasing the thickness, reducing or
delaying moisture penetration and
decreasing the permeability to oxygen.
When a build coat has to be finished with
a top coat it must provide recoatability.
Aesthetic or other functions to topcoats
(colour hiding) may be incorporated.
7.4 Top coats:

(finish coats:)
The top coat gives the required
colour, gloss and surface resistance of the
system, providing the first line of defence
against weather, sunlight, condensation
impact, abrasion and chemical attack. For
economic reasons top coats are
commonly applied in a low dry film
thickness. Sometimes topcoats need
special properties e.g. in non-skid, self-
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cleaning or chemical resistant systems. In
specific systems for immersed exposure a
very smooth finish is sometimes required
to obtain better cleaning of settlement of
bacteria.

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8. IMPORTANT ASPECTS FOR COMPRISING A
MAINTENANCE SYSTEM
Important aspect for composing a maintenance

system are :
8.1 Epoxies, chlorinated rubber, vinyl or

polyurethane in general should not be applied on
top of alkyd paints. In exceptional causes this can
be done after a through investigation in how the
proposed coating system behaves with respect to
softening and adhesion. However, due to the new
development by the coating manufacture,
epoxies, polyurethane and other coating system
can be applied on top sound well adhering old
alkyd paints.
8.2 Silicate based paints should never applied on

organic coating and shop primers (no inter coat
adhesion).
8.3 Alkyd based paints should not be applied on

chlorinated rubber or vinyl coatings (cracking)

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and also on zinc rich primers or galvanized steel
when exposed wet conditions (saponification).
8.4 Special consideration should be given to tar

bleeding effects when bituminous or tar based
coatings are top coated with solvent borne paints.
8.5 When choosing a paint system, geometry of

the structure to be coated and the application
conditions should be considered. Very fast drying
paints are not suitable for spraying complex
structures because of possible dry spray and
build up of too high dry film thickness.
Waterborne paints should not be used when
ventilation conditions are not good or when the
atmospheric conditions are cold and humid.

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9. TOOLS FOR MAINTENANCE MANAGEMENT
GENERAL ASPECTS
A maintenance specification is more complex than

a coating specification for new fabrication. In this
section a systematic approach is presented for
checking objects which are due for maintenance
painting in order to see if special measures have to
be taken to extend the service life of the object to
be protected by the maintenance coating system.
9.1 NOTE FOR METALLIC SUBSTRATES
Steel Mill Scale, corrosion, pitting

corrosion.
Cast iron Surface irregularities,
porosity, corrosion.
Corten steel Surface Corrosion , very
hard.
Stainless steel Contact corrosion, smooth
surface, chlorine/chloride
contamination.

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Non ferrous metals Zinc, copper, aluminium,
lead, contact corrosion, corrosion
product.
Zinc sprayed steel Surface irregularities,
porosity, zinc salts, corrosion.
Hot dipped galvanized steel Smooth surface,
zinc salts, corrosion.
Coil galvanized plate Smooth surface, zinc
salts, corrosion.
(Sendzimir)
Aluminium Anodised, aluminium salts, pitting
corrosion, contact corrosion.
Aluminium sprayed steel Surface irregularities,
porosity, aluminium salts.

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9.2 NOTE FOR STRUCTURAL DETAILS
Weld spatters rough welds, These cannot be

protected properly and must be ground Tack (skip)
welds, doublings, and/or repaired by welding.
Intermittent welding
Open connections, bolt and Moisture and dirt

collects on these sports.
nuts, crevices, sharp edges, Sharp edges must
be rounded by grinding.
wrong inclination See also “details prone to
corrosion attack”
Combination of different Avoid contact

corrosion by insulating properly.
metals
Inaccessible Seal with caulking

compounds.

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9.3 NOTE FOR ORIGINAL COATING SYSTEMS
For each maintenance specification the
compatibility of the maintenance paint with the
existing paint system should be given or checked a
by test patch. Main paint defect are corrosion,
checking and cracking, blistering and detachment.
Causes for paint defects should be detected,
especially when the paint system did not perform
well. See also “paint Defects”.

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9.4 note for physical and/or chemical attack
Extreme temperature changes, erosion, From practice it is known that in case of an
direct, sunlight, UV radiation, rain, early coating failure a wrong paint system
abrasion, impact, wear, condensation, was applied. If this has happened, the
humidity, moisture, chemicals, aggressive exposure conditions should be defined
fumes, contact corrosion, cathodic again another paints system should be
protection considered.
Your Notes :
9.5 Dry heat resistance of generic coating types

Bitumen 500 C (1200F) Powder coating 1500 C (3000F)
Chlorinated rubber 700 C (1600F) Epoxy, low solids 1500 C (3000F)
Vinyl 700 C (1600F) Alkyd aluminium 1750 C (3500F)
Alkyd 1200 C (2500F) Silicone acrylic 1750 C (3500F)
Stoving enamel 1200 C (2500F) Epoxy, high solids 600 C (1400F)
Tar epoxy 1200 C (2500F) Silicone 600 00 C (4800F)
Polyurethane 1200 C (2500F) silicate 5000 C (9300F)
Your Notes :

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9.6 NOTE FOR SURFACE PREPARATION
The methods for surface preparation in maintenance painting are often limited because
interference with other works ha to be avoided as well as damage to machines and
equipment. Nevertheless when the cause of paint defects was related to poor surface
preparation, this fault should not be repeated.
Full attention should be paid to the following points :

a. Removal of weld spatters by power tool chiselling and grinding.
b. Structural repair by welding.
c. Pitting to be cleaned in depth and filled.
d. Sharp edges to be rounded by grinding preferably to a radius of 2 to 3 mm.
e. Smooth surfaces should be roughened, polished surfaces should be avoided.
f. Measurements to be taken to avoid contact (galvanic) corrosion by using proper sealing
and insulation materials.
g. Removal of local rust by wire brushing and/or power tool disc cleaning.
h. Removal of rust and other corrosion products like zinc and aluminium salts is done by
scrapers, blast cleaning (wet, dry, vacuum), power tool disc cleaning or water jetting.
i. Contamination should be removed with detergents and/or high pressure fresh water
j. cleaning, solvent cleaning should be used only when this is unavoidable.
k. Old defective paint coats should be removed if the adhesion or the inter coat adhesion is
insufficient, The edges of old intact paint coats should be feathered.
l. Old intact paint coats should be sanded lightly to achieve good adhesion.

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9.7 Specific remedial actions
a. CHALKING: A(high pressure) wash with solution of detergent and water,followed by

thorough rinsing with fresh water.
b. MILDEW. Remove mildew with proper material or by scrubbing with solution of one part
of household bleach per three parts of water, followed by thorough rinsing with fresh
water.
c. FLAKING and PEELING. Depending upon severity of atmospheric exposure and extent
of flaking and peeling, minimum surface preparations light blast cleaning, high pressure
water cleaning, water abrasive blast cleaning, or power tool cleaning to remove all
loosely adhering paint.
d. HARD, GLOSSY or TOUGH SURFACES : to provide satisfactory adhesion, the surface
must be roughened by hand or power tool, by wet or by dry abrasive blasting.
e. BLEEDING. The surface should be sealed with a special coating (sealer)
f. UPGRADING of exiting coating systems. Due to strong solvents (swelling) upgrading
usually cannot be accomplished by direct application of high performance solvent based
coatings. Recommended tie coats should be applied first. Some water borne epoxies
may be applied directly to existing coating system.
g. BLISTERING OR RUSTING. Minor blistering and/or rusting should be removed by power
tool cleaning high pressure water cleaning or spot blast cleaning. When blistering and
rusting occurs in excess of 25 % of the total area. The existing coating should be
completely removed.

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9.8 NOT FOR PAINT APPLICATION
a. Spraying of paint is often limited because interference with other works has to be
avoided. So maintenance paints should be also fit for either roller or brush application.
Very complex structures should be painted by brush or roller instead or by spray gun to
avoid over spray. Dry spray and extreme paint losses.
b. For brush or roller applied paints the specified dry film thickness should be reached for
which extra coats might be needed. Sharp edges and complex structures should be
stripe coated with each coat of the system
c. The preceding (build) coat should be of a colour which allows the finishing coat to give
coverage.
9.9 PAINT APPLICATION CONSIDERATIONS
a. CONTAMINATION. The possibility of the contamination of substrate and the coating during
application and curing or drying will influence the selection and future performance of the
specific coating.
b. APPLICATION CONDITIONS. Specific information regarding temperature limitations is
given in the product data sheets. A low temperature may inhibit curing while a high
temperature may cause solvent popping and skin drying. A high wind velocity result in
excessive paint consumption, dry spray and skin drying.
C. HUMIDITY, Best results for most coatings are obtained at a relative humidity, below 85
%. The substrate temperature should be at least 30C above dew point.
d. SOLVENT AND THINNER SELECTION. Follow the recommendations given in the
product data sheets.
e. EXCESSIVE ZINC SALTS. Zinc salts may be removed by light blast cleaning, followed by
fresh water rinsing to remove dust. High pressure water cleaning may be suitable.
f. CONTAMINATION. Suitable solvents or emulsifying agents should be used to remove
surface or absorbed greasy contaminants.

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10. RELATION BETWEEN PRETREATMENT – PAINT SYSTEM –
EXPECTED LIFETIME
10.1 EXPECTED LIFETIME OF MAINTENANCE COATING SYSTEMS
In order to select and justify a coating system, it is extremely important for the specifying
engineer to have data available describing the expected service life. The service life of a
coating is related to the degree of surface pre-treatment and the exposure conditions the
coating is subjected to. Only in this way it will be possible to estimate real costs of a coating
system. The service life should not be mixed up with guarantee.
10.2 Surface pre-treatment: This includes the pre-treatment of old, sound, adhering
coatings and the pre-treatment of corroded areas and blistered, cracked or deteriorated
coatings. Pre treatment by means of blast cleaning or by means of mechanical tools should
be carried out according to internationally accepted standards such as the ISO standard
8501-01, the Japanese standard SPSS-1975, the German standard DIN 55928, part four, the
British standard BS 4232 or the American standard SSPC-Vis 1; NACE Standard and
Swedish Standard (SIS 055900)
10.3 Application and application conditions: The pre treated surface should be kept in a
conditions that it is not contaminated again. So special measures have to be taken if the work
is to be executed in a polluted or humid atmosphere. A real problem can be that build coats
can not be applied by airless spray for whatever reason. However the application of primers
by brush will often be advantageous due to better penetration and wetting of the surface with
the primer.
The use of rollers for the application of primers can have drawbacks like uneven or too low
DFT or holidays. The right kind of roller should be used and application should be done with
sufficient pressure. Special attention should be given to application of paint by roller onto
large surfaces under windy conditions. In that case the paint must contains a large amount of
slow evaporating solvent and should be ordered accordingly.
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Attention should also be given to sharp edges and complex shaped structures because
experience shows that the DFT on such spots is only 30 % of the DFT on flat surfaces, so
repeated stripe coating is necessary.
10.4 Coatings : To select a correct maintenance coating system knowledge of the

performance of the previous coating system is essential. One should also know what type of
paint is still present on intact areas. An analysis of existing exposure conditions is also very
important, especially when the old coating system did not perform as had been expected.
Upgrading of an existing coating system can only be considered when the intact coatings are
still adhering well and are not degraded to the extent that they cannot provide a sound base
for the maintenance coating system. If there any doubt it is recommended to check this by
treating a small area as a test patch.

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11. INDICATION OF RESISTANCE OF COATINGS
TO IMMERSION AND SPLASH
General:
To determine whether a system in suitable for immersion in chemicals, water, solvents or oils
and fatty acids a comparison is given of the different coating systems.
The indication are based on systems with the following characteristics.
11.1 High solids Epoxy system

Suitable for storage tanks and equipment continuously or intermittently exposed to a wide
range of chemical, salts, fatty acids, solvents and water.
Not suitable for potable water and foodstuffs.
Your Notes :
11.2 Phenolic Epoxy system

Suitable for transport tanks, storage tanks and equipment continuously or intermittently
exposed to a wide range of solvents, fatty acids, chemicals, monomers and water, including
fresh water, hot water and foodstuffs.
A resistance list is usually available from coating manufacture.
Your Notes :

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11.3 High solids Epoxy system
Suitable for storage tanks and equipment continuously or intermittently exposed to potable
water, aliphatic and aromatic hydrocarbons, and a limited range of solvent and chemicals. A
resistance list is usually available from coating manufacture.
Your Notes :
11.4 Solvent free Epoxy system

Suitable for storage tanks continuously or intermittently exposed to aliphatic and aromatic
hydrocarbons, crude oils, fresh and salt water and limited range of chemical. Can be applied
with single feed 60 : 1 airless spray.
Your Notes :
11.5. Two coat epoxy tar coating system

Excellent resistance to water even in conjunction with cathodic protection.
Suitable for storage tanks and equipment continuously or intermittently exposed to crude oil
and waste water.
Your Notes :

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11.6 One coat zinc ethyl silicate system
Suitable for storage tanks for aggressive solvents. The resistance to acidic or alkaline
chemicals is limited due to the zinc pigment.
Your Notes :

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4.1 INTERNAL DRY OR WET CONDITIONS

MAINTENANCE COATING SYSTEM
EXPOSURE INTERNAL DRY (1) INTERNAL WET (2)
SYSTEM ALKYD EP/ ACR CR ALKYD EP/ ACR CR
PUR DISP PUR DISP
EXISTING COATING
SYSTEM
ALKYD + θ + θ + θ + θ
EPOXY ESTER + + + θ + + + θ
URETHANE ALKYD + + +  + + + θ
CHLOR. RUBBER - θ + + - θ + +
VINYL - θ + + - θ + +
EPOXY + + + + θ + + +
ZC + EP + + + + - + + +
POLYURETHANE + + + θ θ + + +
ZC + PUR + + + θ - + + +
BARE METAL + + + + + + + +
ACR = Acrylic + = recommended

CR = Chlorinated Rubber θ = suitable, subject to detailed info
DISP = Dispersion - = not recommended
EP = Epoxy
PUR = Polyurethane
ZC = Zinc containing

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SYSTEM SELECTION FOR
4.2 RURAL CONDITIONS

EXPOSURE EXTERNAL RURAL (3)
ALKYD EP/ ACR CR HS/EP
SYSTEM
PUR DISP PUR
EXISTING COATING
SYSTEM
ALKYD + θ + - θ
EPOXY ESTER + + + θ +
URETHANE ALKYD + + + θ +
CHLOR. RUBBER - θ + + -
VINYL - θ + + -
EPOXY + + + + +
ZC + EP - + + + +
POLYURETHANE + + + + +
ZC + PUR - + + + +
BARE METAL + + + + +
POWDERCOATINGS
Epoxy θ + θ θ +
Epoxy-polyester θ + θ θ +
Polyester θ + θ θ +
Polyurethane θ + θ θ +
STOVING ENAMELS
Alkyd-amino + + θ θ +
COIL COATINGS
Acr-sil.polyester θ + θ θ +
Polyvinylydene-fluoride - - - - -
Polyvincylchloride - + θ θ +
Plastisols - - θ θ -

DISP = Dispersion - = not recommended
EP = Epoxy
PUR = Polyurethane
SIL = Silicone

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4.3 INDUSTRIAL OR COASTAL CONDITIONS

EXPOSURE EXTERNAL INDUSTRIAL/COASTAL (4)
ALKYD EP/ HS/EP CR
SYSTEM
PUR PUR
EXISTING COATING
SYSTEM
ALKYD + θ 0 -
EPOXY ESTER + + 0 θ
URETHANE ALKYD + + 0 θ
CHLOR. RUBBER - θ - +
VINYL - θ - +
EPOXY + + + +
ZC + EP - + + +
POLYURETHANE + + + +
ZC + PUR - + + +
BARE METAL + + + +
POWDERCOATINGS
Epoxy θ + + θ
Epoxy-polyester θ + + θ
Polyester θ + + θ
Polyurethane θ + + θ
STOVING ENAMELS
Alkyd-amino + + θ θ
COIL COATINGS
Acr-sil.polyester - + θ θ
Polyvinylydene-fluoride - - - -
Polyvincylchloride - + θ θ
Plastisols - - θ θ

EP = Epoxy - = not recommended
HS = High solids
MOD = Modified
PUR = Polyurethane
SIL = Silicone
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4.4 ATMOSPHERIC CONDITIONS + ABRASION OR IMPACT

EXPOSURE ATMOSPHERIC AND ABRASION OR IMPACT (5)
EP/ EP/
SYSTEM
SF HS
EXISTING COATING
SYSTEM
ALKYD - -
EPOXY + +
SAILIKONE - -
SILICATE θ θ
POLYURETHANE + +
BARE METAL + +
4.5 SYSTEM SELECTION FOR INTERNAL AND EXTERNAL EXPOSURES

HIGH TEMPERATURES
EXPOSURE HIGH TEMPERATURE (6)
1750 C 2000 C 2000 C 4500 C 5000 C
SYSTEM ALKYD ACRYLIC EPOXY SILICONE SILICATE
EXISTING COATING
SYSTEM
ALKYD + - + - -
EPOXY θ - + - -
SAILIKONE - - - θ -
SILICATE - + θ θ +
POLYURETHANE θ - - - -
BARE METAL + + + + +
EP = Epoxy + = recommended
HS = High solids θ = suitable, subject to detailed info
SF = Solvent free - = not recommended

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4.6 IMMERSION IN WATER – WASTE WATER - SLURRY

EXPOSURE IMMERSION WATER (7) MAX. TEMP.
700 C 500 C 500 C 500 C 400 C 400 C 1000 C
EPOXY EPOXY EPOXY EPOXY EPOXY BITU- PHEN
SYSTEM TAR TAR TAR TAR TAR MEN EPOXY
EXISTING COATING
SYSTEM
CHOLRINATED RUBBER - - - - - - -
EPOXY + + + + + + -
EPOXY TAR + θ θ θ θ θ -
BITUMEN - - - - - - -
BARE METAL
+ + + + + - +
4.7 SYSTEM SELECTION FOR INTERNAL AND EXTERNAL EXPOSURES

HIGH TEMPERATURES
EXPOSURE WASTE WATER – (8) SLURRY
EPOXY EPOXY EPOXY
SYSTEM
HS TAR HS
EXISTING COATING
SYSTEM
CHLORINATED RUBBER - - -
EPOXY + θ +
EPOXY TAR θ + -
BITUMEN - - -
BARE METAL
+ + +
HS = High solids + = recommended

PHEN = Pheonic θ = suitable, subject to detailed info
SF = Solvent free - = not recommended
SHS = Super high solids

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4.8 IMMERSION IN REFINED PETROLEUM PRODUCT – CRUDE OIL – CHEMICAL

REFINED PETROLEUM (10)
EXPOSURE IMMERSION CHEMICALS (9)
PRODUCT – CRUDE OIL
EPOXY PHEN EPOXY ZINC EPOXY EPOXY EPOXY
SYSTEM HS EPOXY SF SILICATE HS TAR SF
EXISTING COATING
SYSTEM
EPOXY-AMINE θ + θ - + θ θ
EPOXY-AMIDE + + + - + θ θ
PHEN-EP-AMINE θ + θ - + θ -
EPOXY-ISOCYANATE θ θ - - + θ -
POLYURETHANE θ θ - - + θ -
COAL TAR-EPOXY θ - θ - θ θ -
ZINC SILICATE + θ - + + θ -
BARE METAL + + + + + + +
EP = Epoxy + = recommended
HS = High solids θ = suitable, subject to detailed info
PHEN = Pheonic - = not recommended
SF = Solvent Free
6. QUALITY ASPECTS OF MAJOR MAINTENANCE COATING SYSTEM

Page 39 of 44
6.1 SOLVENT BORNE COATINGS
AK V CR EP PUR BIT ACR IOC
Drying mechanism OX PH PH CH CH(MC) PH PH MC
suitable as primer +++ ++ +++ ++++ ++ ++ ++ ++++

top coat +++ +++ ++ +++ ++++ ++ +++ ++
build coat - ++ ++ ++++ +++ +++ ++ -
tolerance to low grade
surface preparation ++ - - ++ ++ +++ + +
Gloss retention +++ +++ + + ++++ - +++ -
Colour retention +++ +++ + + ++++ - +++ ++
Corrosion prevention +++ ++ +++ ++++ +++ +++ ++ ++++
Heat resistance + - - +++ ++ - + ++++
Water immersion - ++ +++ ++++ ++ ++++ ++ +++
Solvent resistance + + + +++ +++ - + ++++
Acid resistance + ++ ++ +++ +++ + ++ -
Alkali resistance - +++ ++ ++++ +++ +++ ++ -
Abrasion resistance ++ +++ +++ ++++ ++++ + +++ +++
Impact resistance ++ +++ +++ ++++ ++++ + ++ ++
flexibility + +++ ++ ++ ++ ++ +++ -
Indications Type of coating
- = not good AK = Alkyd PUR = Polyurethane
+ = marginal V = Vinyl BIT = Bitumen
++ = acceptable CR = Chlorinated Rubber ACR = Acrylic
+++ = good
++++ = very good EP = Epoxy IOZ = Inorganic zinc
Notations used for drying mechanism :

CH = chemical curing, the film hardens by evaporation of solvents by chemical
reaction between base and hardener or by chemical reaction between base
hardener only if the product is solvent free.
MC = moisture curing, the film hardens by evaporation of solvents and by chemical
reaction with moisture from the air.
OX = oxidative, the film hardens by evaporation of solvents and uptake of and
reaction with oxygen from the air.
PH = physical drying, the film hardens by evaporation of solvents
6.2

Page 40 of 44
WATER BORNE –
SOLVENTS BORNE-
SOLVENTS FREE –
Acrylate Vinyl Epoxy
HIGH SOLIDS
COATING
Drying mechanism WB SB WB SB WB SF HS SB
suitable as :
primer + ++ ++ ++ ++ +++ ++++ ++++
top coat +++ +++ +++ +++ ++ ++ ++ +++
build coat ++ ++ ++ ++ ++ ++++ ++++ +++
tolerance to low grade - + - - ++ ++ +++ +++
surface preparation
gloss retention +++ +++ +++ +++ + + + +
colour retention +++ +++ +++ +++ + + + +
corrosion prevention + ++ + ++ ++ ++++ ++++ ++++
heat resistance - - - - ++ ++ +++ +++
Water immersion + ++ ++ ++ ++ ++++ ++++ ++++
Solvent resistance + + + + +++ +++ ++++ ++++
Acid resistance + ++ + ++ ++ ++ +++ +++
Alkali resistance ++ ++ ++ +++ +++ ++++ ++++ ++++
Abrasion resistance ++++ + ++++ + ++++ ++++ ++ +
Impact resistance ++++ ++ ++++ ++ +++ +++ ++ ++
flexibility - ++ - ++ - ++++ ++ ++
Indications
- = not good HS = High solids
+ = marginal SB = Solvents borne
++ = acceptable SF = Solvents free
++++ = very good WB = Water borne
Notations used for drying mechanism :
CH = chemical curing, the film hardens by evaporation of solvents by chemical
reaction between base and hardener
CO = coagulation, the film hardens by evaporation of water and film forming
(coagulation) of the dispersed binder
CO/CH = coagulation plus chemical curing, the film hardens by evaporation of water,
film forming (coagulation) of the dispersed binder components followed by
chemical reaction between base and hardener
PH = physical drying, the film hardens by evaporation of solvents
10.5 ATMOSPHERIC EXPOSURE

Page 41 of 44
I. Interior dry EP = Epoxy
II. Interior wet Pur = Polyurethane
III. Rural HS = High Solids
IV. Industrial + coastal
V. Industrial (abrasion or impact)
System Surface Min. Expected life time in years

preparation DFT I II III IV V
m
2 coat alkyd SSPS-Pt2 85 8
3 coat alkyd SSPS-Pt2 `120 10 3 3
SSPS-Pt3 120 10 5 5
4 coat alkyd SSPS-Pt2 150 5 5 3
SSPS-Pt3 150 7 7 5
2 coat chlorinated rubber SSPS-Pt2 100 8
3 coat chlorinated rubber SSPS-Pt2 150 10 5 5
SSPS-Pt3 150 10 6 6
4 coat chlorinated rubber SSPS-Pt2 200 6 6 5
SSPS-Pt3 200 7 7 6
2 coat recoatable EP/PUR SSPS-Pt2 90 10 5
3 coat recoatable EP/PUR SSPS-Pt2 150 11 6
SSPS-Pt3 150 12 9 9 7
ISO Sa21/2 150 10 10 8
3 coat modified HS epoxy SSPS-Pt2 195 8 8 6
3 coat surface tolerant SSPS-Pt2 225 8 8 6
EP/PUR SSPS-Pt3 225 11 11 9
ISO Sa 21/2 225 12 12 10
2 coat epoxy tar SSPS-Pt2 300 5 5 4

ISO-Sa2 300 6 6 5
SSPS-Pt3 300 8 8 7
ISO-Sa2 ½ 300 8 8 7
1 coat flint reinforced ISO-Sa2 ½ 3000 5
2 coat glassflake epoxy ISO-Sa2 1/2 475 8 8
2 coat waterborne acrylic ISO-Sa2 1/2 100 8
2 coat waterborne acrylic ISO-Sa2 1/2 150 10 5 5
10.6 High temperature and immersion exposure

VI. Heat mod. = modified
I. VII. Water

Page 42 of 44
II. VIII. Chemicals
III. IX. Hydro carbons
IV. X. Waste water/slurry
System Surface preparation Min. Expected life time in

DFT years
m VI VII VIII IX X
2 coat bitumen SSPS-Pt2 ISO-Sa2 500 3
3 coat high solids epoxy SSPS-Pt3 ISO-Sa21/2 500 4
2 coat epoxy tar ISO-Sa 21/2 375 10
SSPS-Pt2 ISO-Sa2 300 4
4 coat alkyd SSPS-Pt3 ISO-Sa21/2 300 7 8
ISO-Sa 21/2 400 9 7 7
2 coat high solids epoxy SSPS-Pt2 ISO-Sa21/2 300

SSPS-Pt3 ISO-Sa21/2 300 5 5
SSPS-Pt21/2 350 6 6
SSPS-Pt2 ISO-Sa21/2 450 6 6 5
SSPS-Pt3 ISO-Sa21/2 450 7 7 6
2 coat mod. Solvent free SSPS-Pt2 ISO-Sa21/2 300
epoxy SSPS-Pt3 ISO-Sa21/2 300
3 coat Phenolic Epoxy ISO Sa3 300 9 9 10

1 coat Solvent Epoxy ISO Sa 21/2 400 6 8
1 coat Zinc Silicate ISO Sa 21/2 75 8
4 coat Alkyd aluminium 1750C SSPS-Pt3 ISO-Sa2 1/2 110 3

3 coat Epoxy 2000C SSPS-Pt3 ISO-Sa2 1/2 180 3-4
1 coat silicone 4500C ISO-Sa2 1/2 *115 3-4
2 coat silicate 5000C ISO-Sa2 1/2 115 4-5
11.7 TABLE OF RESISTANCE LIST
I II III IV V VI
Demineralised water +++ +++ +++ +++ ++ ++

Page 43 of 44
Freshwater +++ +++ +++ +++ +++ ++
Seawater +++ +++ +++ +++ +++ ++
Sewage water +++ +++ +++ +++ +++ -
Industrial waste water +++ ++ + - - -
Crude oil (up to 700C) +++ +++ +++ +++ +++ ++

Aliphatic hydrocarbons +++ +++ +++ +++ - +++
Aromatic hydrocarbons +++ +++ +++ +++ - +++
Lubrication oil (up to 700C) +++ +++ +++ +++ - ++
Benzene, toluene, xylene +++ +++ +++ +++ - +++

Glycols +++ +++ + - - -
Aggressive solvent ++ +++ + - - +++
Styrene +++ +++ ++ - - -

Monomers ++ +++ - - - -
Animal and vegetable oils +++ +++ ++ ++ ++ -

(up to 700C)
fatty acids (up to 600C) +++ +++ - - - -
low molecular organic acids + - - - - -

inorganic acids ++ + + - - -
sodium or potassium +++ +++ +++ +++ +++ -

hydroxide
(up to 50% and 600C)
ammonia (up to 25%) +++ +++ - - - -
amines - + - - - ++
+++ = suitable for continuous immersion

++ = Under restrictions suitable for temporary immersion
+ = Only for temporary contact (splash and spillage)
g. = not suitable
For more detailed information about chemical resistance at a certain temperature or
concentration, coating manufacture should be contacted.

Page 44 of 44

Important Factors and Aspects of Coating

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Important Factors and Aspects of Coating

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IMPORTANT FACTORS AND ASPECTS OF

1.1. The choice of protective paints systems should be

1.2 The Specified protective paint systems shall be tested

PT. STARIS GIROS INDONESIA / LINDUNG SILALAHI

(derived from ISO 12944-2)

2.1 Atmospheric corrosivity categories for

2.2. Corrosivity Categories Your Notes :

PT. STARIS GIROS INDONESIA / LINDUNG SILALAHI

2.4 Immersion of atmosphere

2.5 Climatic Conditions Your Notes :

2.6 Particular situations and special loads

2.6.1 Particular situations

2.6.2 Special loads

PT. STARIS GIROS INDONESIA / LINDUNG SILALAHI

3.1 The main task of protective coatings is to

3.2 During its services life a protective coating

3.3 Proper and timely maintenance is required to

PT. STARIS GIROS INDONESIA / LINDUNG SILALAHI

3.4 A maintenance system intended for total repair

3.5 Coatings consideration

- 3.5.1 Maintenance systems

PT. STARIS GIROS INDONESIA / LINDUNG SILALAHI

- 3.5.5 Performance expectancy

- 3.5.6 Problem solving

4. SYSTEM SELECTION FOR

4.1 The exposure definitions and compatibility table

PT. STARIS GIROS INDONESIA / LINDUNG SILALAHI

4.2 GENERAL DESCRIPTION OF EXPOSURE

1). INTERNAL DRY EXPOSURE

2). INTERNAL WET (HUMID) EXPOSURE

3). RURAL ATMOSPHERIC EXPOSURE

4a). INDUSTRIAL POLLUTED ATMOSPHERE

PT. STARIS GIROS INDONESIA / LINDUNG SILALAHI

4b.) SEA, COASTAL ATMOSPHERE

4. SYSTEM SELECTION FOR

5). ATMOSPHERE EXPOSURE WITH

6). HIGH TEMPERATURE

7). IMMERSION IN WATER (with or without

8). IMMERSION IN WASTE WATER AND/OR

9). IMMERSION IN CHEMICAL

PT. STARIS GIROS INDONESIA / LINDUNG SILALAHI

5. QUALITY ASPECTS OF MAJOR

5.1 The following items shall be counted :

PT. STARIS GIROS INDONESIA / LINDUNG SILALAHI

5.2 To ensure good coating adhesion it is essential

5.3 It is not always possible to obtain a perfect

5.4 Water soluble matter, if left on the surface to be

PT. STARIS GIROS INDONESIA / LINDUNG SILALAHI

Functional properties of individual coats

PT. STARIS GIROS INDONESIA / LINDUNG SILALAHI

7.1 Primers: Anticorrosive properties rely on the

7.2 Sealers These coatings are used as an

7.3 Build coats: These coatings are used as an

7.4 Top coats:

PT. STARIS GIROS INDONESIA / LINDUNG SILALAHI

Important aspect for composing a maintenance

8.1 Epoxies, chlorinated rubber, vinyl or

8.2 Silicate based paints should never applied on

8.3 Alkyd based paints should not be applied on

PT. STARIS GIROS INDONESIA / LINDUNG SILALAHI

8.4 Special consideration should be given to tar

8.5 When choosing a paint system, geometry of

PT. STARIS GIROS INDONESIA / LINDUNG SILALAHI

A maintenance specification is more complex than