COATING APPLICATION, EQUIPMENT,

MATERIAL CONSUMPTION AND SITE

INSPECTION
COATING MIXING

Coatings are mixed:

• To ensure all the ingredients are evenly dispersed in the container before application.
• To ensure the base and curing agent in two-pack products are evenly dispersed
together to allow for correct chemical reaction and complete cure to occur.

Procedure for Mixing Coatings:

• Avoid contamination during mixing, from dirty mixers, paint tins etc. Use a mechanical mixer when possible. Always use
a mechanical mixer with two pack products.
• For two pack products, use the correct base with the correct hardener. (confirm with product data sheets).
POT LIFE

All two-pack materials have a pot-life.

• This is the time period between mixing and curing when the paint is workable and can
• be applied.
• Pot-life is reduced when the temperature increases and vice versa. (Check product
• datasheet.)
• Never mix more paint than can be used before pot life expires.
• Never add thinner to extend the pot-life.
• Exceeding pot-life will waste paint, and will block up airless spray equipment.
COATING THINNING

Use thinners only when necessary

• Always use the correct thinners for the product. (confirm with Product datasheet).
• Limit thinning to 5% by volume (maximum).

Over-thinning can cause :-

• Solvent entrapment.
• Runs, sags, slumping etc.
• Inadequate cure of the film.
• Reduced volume solids and affect applied dry film thickness.
COATING APPLICATION AND INSPECTION

Methods of Application
• Brush ; Generally used for small or difficult access areas and for stripe- of weld seams, edges,
corners and cut-outs.Multiple coats may be required to achieve high film thickness
• Roller ; Roller Application is a faster method than brush but still is mainly used for touch-up areas.
Roller application will generally be used when spraying can not be done because of contamination by air-
borne spray particles. Multiple coats may be required to achieve high film thicknesses
• Conventional Spray ; This method of application is normally used to apply low viscosity coats and
sometimes inorganic zinc silicate coatings. Low pressure compressed air is used to atomize the coating
for spraying so conventional spray can not handle high-build, high-viscosity coatings
• Airless Spray ; The most common and fastest method of application of heavy-duty, high viscosity
coatings The system uses very high fluid or hydraulic pressures to atomize the coating. Application is
controlled by tip size, tip angle, input/output pressure and spray technique.
• Plural Pump Spray ; The most common and best method of application of short pot life coating
material.
COATING APPLICATION AND INSPECTION
Brush and Roller
COATING APPLICATION AND INSPECTION
Conventional Spray
COATING APPLICATION AND INSPECTION
Airless Spray
COATING APPLICATION AND INSPECTION
Plural Airless Spray
COATING APPLICATION AND INSPECTION

• Volume Solid : the ratio of the volume of its non volatile components to its
• initial wet film volume.
COATING APPLICATION AND INSPECTION

Example :
• Volume Solid stated in the TDS 60%, DFT expected is 100 microns.
• What is WFT ?
1. Without Thinner.
•WFT = DFT / VS = 100 / 0.6 = 167 microns
•2. With 5% Thinner.
•WFT = DFT x 1.05 / VS = 100 x 1.05 / 0.6 = 175 microns
COATING APPLICATION AND INSPECTION

• QUIZ :
• In the TDS stated that VS = 82%, suppose expected DFT is 150 microns.
• What is the WFT ? Without thinner and with 5% thinner.
• Answer :
1. Without thinner :
•WFT = DFT / VS = 150 / 0.82 = 183 microns
•2. With 5% thinner
•WFT = DFT x 1.05 / 0.82 = 150 x 1.05 / 0.82 = 191 microns.
COATING APPLICATION AND INSPECTION
Wet Film Thickness
COATING APPLICATION AND INSPECTION

• Critical to Quality :
1. Mixing ratio part A and part B à see Technical Data Sheet
2. Coating interval from one layer to next layer à see Technical Data Sheet
3. Typical thickness of each layer à See Technical Data Sheet
4. Surface preparation required
5. Pot life
6. Volume solid
COATING APPLICATION AND INSPECTION
Paint Consumption
COATING APPLICATION AND INSPECTION

• Example :
• We have 1500 m2 surface to be applied the paint.Volume solid of the paint is 82%, DFT
specified is 200 microns, Refer to the experience loss factor is 40%. How many liter paint required
for this job? (suppose adding 5% thinner)

• TSR = (VS / DFT ) x 10 = (82 / 200) x 10 = 4.1 m2/liter

• PSR = TSR ( 1 – loss) = 4.1 x ( 1-0.4) = 2.46 m2 / liter

• Liter = Area / PSR = 1500 / 2.46 = 609.7 liters.

COATING APPLICATION AND INSPECTION

• QUIZ
• A tank with surface area 2000 m2, a client’s specification mentioned the thickness of the
paint is 200 microns, if the VS = 75%, and loss factor is 30%, how many liter paints required ?
with thinner 10%.

• Answer :

• 762 liters
GENERAL COATING INSPECTION
GENERAL COATING INSPECTION

• 1. Dry Film Thickness.

• Common standard : SSPC PA2.
• Every 10m2, 5 Spot, each 3 reading.
• The DFT Range, Spec. +/- 20%
GENERAL COATING INSPECTION

• 2. Adhesion Test.
• ASTM D 3359
•For thickness <125 microns ; Cross Hatch test
•For thickness >125 microns ; X cut test
• ASTM D 4541.
•Pull Off Test.
•Min Value 3 MPa refer to SSPC No. 22.
GENERAL COATING INSPECTION
Pull Off Adhesion Tester
GENERAL COATING INSPECTION

• 3. Low and High Voltage Holiday Test

• Common standard : AS3894.1-2002,ASTM G62-07,ASTM D5162-08,ASTM D4748-08
• NACE RP0274-04, NACE SP0490-2007, NACE SP0188-2006,ANSI/AWWA C214-07,
• ANSI/AWWA C213-07,ISO 2746:1998