INSPECTA MIDDLE EAST

TECHNICAL PROCEDURE

FOR

Carbon Steel Structures

Add.: 12 st. # 1 branched from El Nasr St. in front of Green Plaza, Semouha, Alexandria – Egypt.

Tel. No.: +2 03 4265180 Fax No.: +2 03 4280961 Lab. No.: +2 03 4200185 mob: 01276132866

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SUMMARY
1. Scope of work……………………………………………………………………….2
2. Quality Requirements..……………………………………………………….….2
3. Area to be painted…………………………………………………………….……2
4. Surface preparation…………..………………………………………………. ..2
4 -1 General requirements before Preparation …………….……….…..2
4 -2 Methods of preparation for Carbon steel..………………………….3
4-3 General consideration after Preparation …………………………..3
5. Paint application...…………………………………………………………….….4
5.1 Methods of Application..…………………………….……….…….4
5.2 Paint System. …….…………………………………………….…....5
6. Repair Procedure…………………………………………………………………..5
7. Inspection and testing…… ………………………………………………….....5
7.1 Preliminary inspection……………………………………………………..5
7.2 Inspection test during application……………………………………..5
7.3 Inspection after application………………………………………………6
7.4 Inspection Equipment..…………………………………………………….6
7.5 Paint application….............................................................…....7
7.6 Acceptance criteria.………………………………………………………….7
8. Reporting………………….……………………………………………………….…8
9. Health and safety............................................................................8

Add.: 12 st. # 1 branched from El Nasr St. in front of Green Plaza, Semouha, Alexandria – Egypt.

Tel. No.: +2 03 4265180 Fax No.: +2 03 4280961 Lab. No.: +2 03 4200185 mob: 01276132866

web: www.inspectame.com E-mail: info@inspectame.com , gm@inspectame.com

1. Scope of work
This procedure was designed to govern all surface preparation
and painting activities for steel structures

2. Quality Requirments
Surface preparation and paint application for that project should be in
accordance to this recommended procedure and respecting Inspecta
Middle East instructions & Products Technical Data Sheet, using the
paints and paint systems specified in the project.
3. Area to be painted
Carbon Steel structure.

4. Surface preparation
4.1 General requirements before Preparation:
4.1.1 Substrate to be painted must be dry, clean, and free from Oil,
Grease, Salts, welding fumes, fine carbon dust and contaminants.
Otherwise substrate has to be washed by means of suitable
Detergent/Solvent after removing heavy contaminants – Grease/Mud
then high pressure fresh water wash(outlet pressure 120 to 150 bar}.

4.1.2 All weld areas are to be given special attention for removal of
welding flux in crevices. Welding spatter, slivers, laminations, all
surface irregularities, Sharpe edges and underlying mill scale not
removed during fabrication, shall be removed using mechanical
power means. Also rough edges should be smoothed.
4.1.3 Blast cleaning operation not be carried out when surface to be
blasted is at temperature less than 3 ºC above dew point, when relative
humidity of the air exceeded 85% or when raining.
4.2 Methods of preparation for Carbon steel:
Various areas have different paint systems and method of preparation,
therefore each of which has to be prepared according to the specified
method which is limited to Sa2 ½, prior Paint Application.

Add.: 12 st. # 1 branched from El Nasr St. in front of Green Plaza, Semouha, Alexandria – Egypt.

Tel. No.: +2 03 4265180 Fax No.: +2 03 4280961 Lab. No.: +2 03 4200185 mob: 01276132866

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 4.2.1 Blasting
(a)-Blasting shall fulfill the following requirements either it’s
performed manually
-Cleanliness: Sa 2 ½ (ISO 8501-1) exactly prior Paint Application.
Roughness Ry: 40 - 80 Micron ( ISO 8503 ) or equivalent.
(b)-The pressurized air source (compressors) should be in a good
condition to satisfy the following requirements:
Air Quality: Clean and dry ( oil and moisture filters to be fixed )
Air Pressure: In the range : 6.00 - 7.00 Kg/cm2 -before Nozzle
Fitting & Hoses: In sound and safe conditions.
Nozzles: To be of the Venture type and to be replaced when wearing
reaches 30% from inner diameter.
(c)The period of blasting must not exceed 8 hours.
(d) Blasting and painting activities must be performed in Daylight.
(e)Blasting Media (Abrasives)
4.2.2 Abrasive

The following are the minimum requirements for the used abrasive
Cleanliness:-
The abrasive should be dry, free from clay, dirt, Oil and any other
contaminants. Sodium Chloride salts test will be carried out for sand
to ensure that results are within the accepted limits (1000 µs)Salts on
blasted surface measured with the Bristle conductivity meter within
accepted limits (max.50 mg/m2)

4.2.3 Power tool Preparation:

(a) Power Tool Preparation Method used in different areas for
touch up and repairs only with approval from INSPECTOR.
4.3 General consideration after Preparation

4.3.1 Climatic conditions

● Application operation should not be carried out when surface
to be painted is at temperature less than 3°C above the Dew
point ,Also when the relative Humidity of the air exceeds 85%.
● Maximum Substrate Temperature must not exceed 50ºC
4.3.2 Windy and rainy conditions should stop painting activities

Add.: 12 st. # 1 branched from El Nasr St. in front of Green Plaza, Semouha, Alexandria – Egypt.

Tel. No.: +2 03 4265180 Fax No.: +2 03 4280961 Lab. No.: +2 03 4200185 mob: 01276132866

web: www.inspectame.com E-mail: info@inspectame.com , gm@inspectame.com

5. Paint application
5.1 Methods of Application
5.1.1 Spraying
(a) Airless spraying is the most preferable method for all paints
to be painted. Conventional spraying is not allowed for all
areas to be painted .
(b) Airless M/C has to be cleaned by suitable thinner when
applying different types of paints subsequently, ensuring that
no mix could happen between paints.
(c) Airless M/C should have a satisfactory pressure ratio.
(d) A range of different nozzle-tip sizes should be available during
Paint application.
(e) Source Air Pressure In the range : 6.00 - 7.00 Kg/cm2
(f) Mechanical mixer should be use for mixing two pack paint.

5.1.2 Roller
Rollers should never be used for first coat , also usage of rollers for
second and finish coat areas and upon approval from JOTUN Rep.
5.1.3 Brushes
(a) Brush usage is limited for inaccessible areas and stripe coats
on weld seem and edges only.
(b) Brushes used should be clean and in a good
condition.

5.1.4 Personnel
(a) Qualified and skilled personnel for blasting and application.
(b) Qualified and skilled supervisors to supervise paint and
blasting activities
5.2 Paint System:
According to specification and position.

Add.: 12 st. # 1 branched from El Nasr St. in front of Green Plaza, Semouha, Alexandria – Egypt.

Tel. No.: +2 03 4265180 Fax No.: +2 03 4280961 Lab. No.: +2 03 4200185 mob: 01276132866

web: www.inspectame.com E-mail: info@inspectame.com , gm@inspectame.com

6 .Repair procedure

6.1 damaged to metal surface:

Power tool cleaning to St 3 according to ISO 8501-1, the surface
is cleaned with compressed air.
Using sand paper for polishing the edges of the existing paint in
the damaged area
Making an overlap of at least 50mm between the damaged area
and the existing paint
Reapply the repair painting system with the required dry film
thickness
6.2 damage to paint coating:
Removing coating local to the damaged area with sand paper or
any power tool cleaning acceptable to client
Using sandpaper for polishing the edges of the existing paint in
the damaged area
Making An overlap of at least 50mm between the damaged area
and the existing paint
6.3 In case of subsequent coat have exceeded interval time, Substrate
must be dry, clean, free from Oil, Grease, Salts, and any
contaminants. Abrade down surface by sand paper followed by
fresh water high pressure washing with minimum 120 Bar.

6.4 Repair system

According to specification and position.

Add.: 12 st. # 1 branched from El Nasr St. in front of Green Plaza, Semouha, Alexandria – Egypt.

Tel. No.: +2 03 4265180 Fax No.: +2 03 4280961 Lab. No.: +2 03 4200185 mob: 01276132866

web: www.inspectame.com E-mail: info@inspectame.com , gm@inspectame.com

7.Inspection and Teating
7.1 Preliminary inspection:
• Check certificates & batch identification for paint.
• Check storage condition.
• Confirm application method according to paint supplier.
• Calibration for instruments, equipment’s with their
certificates.
7.2 Inspection test during application:
• Visual inspection
• Check atmospheric ambient condition.
• Check for degree of surface cleaning.
• Check salt contamination once per main item in accordance
withISO-8502-6&9
• Inspection of surface roughness, ISO-8503-2.
• Check of wet paint film thickness.
• Confirm overcoat interval according to requirements of the
paint supplier data sheet.
• Check washing between subsequent coats.

7.3 Inspection after application:

• Visual inspection.
• Check of dry film thickness.( the minimum ,maximum ,
average and number of reading will record in the daily
report )
• Porosity test.(holiday detector)in accordance with NACE RP
0274
• Adhesion test (pull off) one test plate per main item in
accordance with ASTM 4541

Add.: 12 st. # 1 branched from El Nasr St. in front of Green Plaza, Semouha, Alexandria – Egypt.

Tel. No.: +2 03 4265180 Fax No.: +2 03 4280961 Lab. No.: +2 03 4200185 mob: 01276132866

web: www.inspectame.com E-mail: info@inspectame.com , gm@inspectame.com

7.4 Inspection Equipment
The inspector should equipped with all the necessary equipments
to ensure that all the above mentioned operations are applied
exactly as stated and to report immediately any deviation that
might occur during different project stages.

7.4.1 Weather conditions

7.1.1 Relative humidity : Hygrometer ISO 8502-4
7.1.2 Dew Point : ISO 8502-4
7.1.3 Steel temperature : Thermometer ISO 8502-4
7.4.2 Surface Preparation
7.4.2.1 Surface cleanliness from dirt's, oil, grease is checked visually.
7.4.2.2 Surface preparation and rust grade will be evaluated ISO 8501-1
7.4.2.3 Blasting pressure for nozzle will be measured by needle
gauge
7.4.2.4 Oil and water contamination will be checked by white cotton
rag
7.4.2.5Salts contamination test on surface will be test using
7.4.2.6Bristle method ISO 8502-6.(max.50 mg/m2) Salts
contamination in Sand will be tested by means of conduct-meter
ASTM-D4940.(max. 1000µS)
7.4.2.7 Dust rating on blasting substrate will be measure according to
ISO 8502-3 rating accepted No 2.
7.4.4.8Surface roughness will be evaluated according to ISO 8503.
7.4.2.9Abrasive test according to ISO 11126 &ISO 11127.
7.4.2.10 Compressed air test according to ASTM –D4285
7.5 Paint application
7.5.1 Wet Film Thickness and Dry Film Thickness will be
controlled through wet comb ISO 2808

Add.: 12 st. # 1 branched from El Nasr St. in front of Green Plaza, Semouha, Alexandria – Egypt.

Tel. No.: +2 03 4265180 Fax No.: +2 03 4280961 Lab. No.: +2 03 4200185 mob: 01276132866

web: www.inspectame.com E-mail: info@inspectame.com , gm@inspectame.com

 7.6 Acceptance criteria

Checkpoint Reference Limits

Method

Abrasive Lab Analysis ISO 11127 As item 4.2.1.e

Air Compressor White Rag Method ASTM D 4285 Oil Free

Pressure at Nozzle Needle gage 7 Bar
Airless Pressure Ratio Min. 1 : 46
Rust Grades Visually ISO 8501-1,2
Oil and Grease Water Break Test DIN 55 928-4 Oil Free
Preparation Grades Visually ISO 8501-1,2
Anchor Pattern Testex Imprint Tape ASTM D 4417 30-70µ
Saline IS0 8502-6,9
Salt Contamination Max. 50 mg/m2
Conductmeter ASTM D 4940
Pressure-Sensitive Rating No. 2 “External”
Dust on the Substrate ISO 8502-3
Tape Rating No. 1 “Internal”
Sling Psychrometer RH < 85%
Climatic Conditions ISO 8502-4
Thermometer S.T-D.P.T >3ºC
Wet Film Thickness Comb Gauge ASTM D 4414
Dry Film Thickness Eddy Current SSPC- PA2

Pull off Test using

Adhesion ISO 4624 3MPa
Adhesion Test ASTM D 4541
Holiday Low Voltage Test ASTM D 5162 Holiday Free

Add.: 12 st. # 1 branched from El Nasr St. in front of Green Plaza, Semouha, Alexandria – Egypt.

Tel. No.: +2 03 4265180 Fax No.: +2 03 4280961 Lab. No.: +2 03 4200185 mob: 01276132866

web: www.inspectame.com E-mail: info@inspectame.com , gm@inspectame.com

8. Reporting
Daily reports to be issued by the painting inspector representing all paint
activities and signed by all partners.

9. Health and Safety

Wear mask, safety glasses, and gloves when applying the different
products. We shall refer to the product Material Safety Data Sheet to
ensure that all safety procedures are followed.
Site Safety Instructions shall be respected and taken in consideration
by all workers.

Add.: 12 st. # 1 branched from El Nasr St. in front of Green Plaza, Semouha, Alexandria – Egypt.

Tel. No.: +2 03 4265180 Fax No.: +2 03 4280961 Lab. No.: +2 03 4200185 mob: 01276132866

web: www.inspectame.com E-mail: info@inspectame.com , gm@inspectame.com