SURFACE PREPARATION & PAINTING PROCEDURE

QCP- M109

03 QCP-REV-03 SARATH 13/05/20 SM 13/05/20 KK 14/05/20

02 QCP-REV-02 SM 30/04/18 KK 30/04/18 SJ 01/05/18
01 QCP-REV-01 PKV 15/01/14 ACK 15/01/14 SJ 15/01/14
00 QCP-00 SNKR 12/20/10 SR 12/20/10 PK 12/20/10
Rev. Description Prepared by Date Checked by Date Approved by Date
QA/QC Manager

Document Title SURFACE PREPARATION & PAINTING PROCEDURE FOR INDUSTRIAL COATING

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Document No QCP- M109 1 of 18
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 TABLE OF CONTENTS

1. INTRODUCTION

2. REFERENCES

3. GENERAL

4. SURFACE PREPARATION

5. PAINT APPLICATION

6. PAINTING AND COATING SYSTEM

7. FLOW CHART FOR INSPECTION OF BLASTING AND PAINTING

ACTIVITIES
8. INSPECTION AND TESTING

9. FLOW CHART FOR INSPECTION OF BLASTING AND PAINTING

ACTIVITIES

10. SAFETY

11. TABLES & ATTACHMENTS

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 1.0 INTRODUCTION

1.1 SCOPE

This Scope covers the Quality requirements and work procedure of external
surfaces blasting and painting control for pipelines, storage tanks, equipment’s
and structural steel in industrial facilities This procedure is applicable for shop and
field painting work.

1.2 PURPOSE

The purpose of this is to define the minimum requirements for the selection of
painting materials, surface preparation, application, and inspection of painting for
steel structures, equipment and piping.

2.0 REFERENCE

Industry Codes and Standards

SSPC - Steel Structures Painting Council

SIS 05-59-00 - Pictorial Surface Preparation Standards for Painting Steel

Surfaces

Saudi Aramco Total Refining and Petrochemical Co. Specifications

JERES-H-001- Coating Selection & Application Requirements for Industrial

Plants & Equipment

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 3.0 GENERAL

3.1 Equipment

The compressed air supply for Blast Cleaning equipment shall be free of
water and oil. Adequate separators and traps shall be provided and these shall
be kept emptied regularly of water and oil. Accumulations of oil and moisture
shall be removed from the air receiver by regular purging. Air compressors shall
not be allowed to deliver air at a temperature in excess of 110 ° C. The grit shall
normally be discharged with a pressure of 7 bar measured at the nozzle
using a hypodermic pressure gauge and shall not under any circumstances fall
below 5.6 bar for normal cleaning operations.

The coating spraying equipment to be used shall meet the recommendations and
instructions set forth by the paint manufacturer for each specific coating system.
Airless Spray is normally the choice of application method but if conventional air
spray is used, an adequate moisture trap shall be placed between the air supply
and the pressure pot feed to the gun. The trap shall continuously bleed off any
water or oil from the air supply.

3.2 Coating Material

Storage, thinning, mixing and handling of paint materials shall be in accordance

with the Paint Manufacturer’s recommendation. All paint materials and solvents
shall be supplied in the paint manufacturer’s original containers, durably and
legibly marked with clear description of the contents. This shall include the
specification number, the color reference number, the method of application for
which it is intended, the batch number, date of manufacture, the shelf life expiry
date and the paint manufacturer’s name or recognized trademark.

Different brands or different make of paints shall not be inter-mixed. Similarly,

mixing of different brands or generic types of paint material is not permitted. The
Manufacturer’s pot-life requirements shall be strictly and diligently followed.
The same shall be said for the minimum and maximum over-coating time as
recommended by paint manufacturer

Only thinners as specified by the paint manufacturer shall be used. Mixing and
thinning directions as furnished by the paint manufacturer shall be followed.
Statutory requirements for levels of volatile organic compound are to be met.

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 4.0 SURFACE PREPARATION

4.1 General

For optimum paint performance, surfaces to be painted or coated shall be

completely dry and free from burrs, weld spatter, flux, rust, loose scale, dirt, dust,
grease, oil and other foreign matter deleterious and harmful to paint. After
preparation of substrate surface, any grit or dust shall be removed and a layer of
primer applied before any corrosion or recontamination occurs, normally within
four (4) hours after blasting. Surface preparation shall be subjected to inspection
before the primer coat is applied to ensure all traces of dust and foreign matter
have been removed by brushing, blowing with dry clean compressed air or
vacuum cleaning.

4.2 Pre-Cleaning of Surfaces and Solvent Cleaning

This cleaning process is mandatory before further cleaning or surface preparation.

Prior to the actual cleaning operation, surface contaminants such as oil, grease,
hydrocarbon etc. shall be removed preferably by degreasing with suitable
degreaser or solvent cleaning according to SSPC-SP1. The degreased surface
shall be further washed or rinsed down with fresh water to remove all traces of the
degreaser chemicals. The surface shall be allowed to dry thoroughly before
proceeding with any further coating work. This process also applies to all metal
surfaces to be coated that do not require blast cleaning or power tool cleaning.
Excessive rust scale shall be removed by impact cleaning tools or high pressure
water jetting. All edges shall be ground to a minimum radius of 2 mm. Flame cut
areas shall be ground flush.

4.3 Surface Preparation by Blast Cleaning

The method the of surface preparation will done accordance to JERES-H-001 Table-
A1 for Non-Insulated material & Table- A2 for Insulated material.

Blast cleaning shall be carried out through ISO 8504-2:1992 to the required visual
standard in accordance with ISO 8501-1or equivalents. All surfaces, where
accessible shall be prepared by abrasive blast cleaning to a minimum of SA 2.5
ISO8501-1(SSPC-SP10)

4.4 Blasting Abrasives

Blasting abrasives for use in blast cleaning carbon steel and low alloy steel are
specified in ISO 8504-2. Recommended blasting abrasives are as follows, but not
limited to:

a) Chilled iron grit or shot

b) Steel and malleable iron grit or shot
c) Natural mineral abrasives
d) Nonmetallic abrasives (aluminum oxide, garnet etc.)

All blasting abrasives shall be tested and qualified in accordance with the
procedures described in SSPC-AB1 Abrasive Specification No.1; Mineral and
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 Slag Abrasives. Abrasives that are classified as Scheduled Waste under the
Environmental Quality Act (EQA) 1974 shall not be used. Sand or other materials
producing silica dust shall not be used. The abrasives shall be free from oil,
grease, moisture, salt, dust etc. Re-used abrasives shall be clean, sharp and free
from contaminants and re-qualified to SSPC-AB 1 requirements. The blast profile
and angular anchor pattern shall be that recommended by the paint manufacturer
to suit the minimum requirements of their respective primers. The acceptable
peak-to-valley height range shall be between 50 ~ 75 microns.

4.5 Techniques and Constraints

Blast cleaning shall not be carried out when the temperature of the surfaces to be
coated is less than 3° Celsius above the dew point or when the relative humidity
of the air is greater than 85 %.

Abrasive blasting shall not be done in open areas close to painting operations or
wet coated surfaces to prevent dust and grit contamination. Normally grit blasting
shall be permitted only during daylight hours except that rough grit blasting will be
allowed during the night provided that the surface is subsequently blasted to the
specified standard under good light conditions. The illumination of the surface
during final blasting shall be at least 500 Lux and all environmental restrictions are
observed.

All welded areas and appurtenances shall be given special attention for removal of
welding flux in crevices. Welding spatters, slivers, laminations and underlying mill
scale not removed during fabrication and exposed before and during blast
cleaning operations shall be removed by the best mechanical means and the
edges smoothed or rendered flush. Where rectification is necessary on abrasive
blast cleaned surfaces, the dressed areas shall be re-blasted to remove all rust,
slag and grit and to provide an adequate anchor pattern.

Blasting shall continue a minimum of 25 mm into any adjacent coated areas and
the edges shall be feathered. After dry blast cleaning, no acid washes, cleaning
solutions, solvents or other chemical treatment shall be used on metal surfaces.
This restriction includes inhibitive washes to prevent rusting. Any blast-cleaned
steelworks on which rust develops shall be re-blasted prior to being painted.

4.6 Surface Preparation by Hand and Power Tool Cleaning

The most technically effective surface preparation method is blast cleaning.

Manual preparation shall only be used when blast cleaning is either not feasible
or not strictly required e.g. Galvanize steel and stainless steel.

Manual cleaning shall be performed using hand wire brushes or mechanically

operated tools (grinders, chippers, wire brushes) in accordance with ISO 8504-3.
Where welds occur within these areas or when these areas cannot accommodate
a power disc, power impact tools shall be applied (vibratory and rotary hammers,
needle guns, chisels) followed by brush cleaning.

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 If the surface being prepared lies adjacent to a coated surface which is not to be
refurbished, the power tool cleaning shall overlap the coated surface by at least
25 mm. The minimum requirement for successful coating application is St 3
ISO 8501-1 (SSPC-SP3) at the time of coating. Care shall be taken to ensure
that the substrate surface does not become polished during power tool cleaning

5.0 PAINT APPLICATION

5.1 Pre Application Procedures

5.1.1 General

Any surfaces to be coated shall be dry and rendered dust free prior to
application of primer coat. This can be accomplished by blowing off the
surface with clean dry air or using an industrial vacuum cleaner together
with a clean dry stiff brush. The blasted surfaces shall be examined for
traces of smudge, oil, grease or other contamination and also tested
for the presence of soluble salts. If present they shall be removed by
solvent washing or for salts by water washing or steam cleaning and the
areas
Re-blasted.

5.1.2 Mixing and Thinning

All coating materials shall be thoroughly stirred in a pressure pot with

a power mixer for a time sufficient to thoroughly remix the pigments
and vehicles. Sufficient agitation to maintain good mixing shall be applied
until the product is used. Coatings containing heavy or metallic
pigments that have a tendency to settle shall be kept in continuous
suspension in the pressure pot by a mechanical agitator or stirrer

If during mixing / stirring air is entrapped in the product, sufficient

time should be allowed for air bubbles to escape, before application is
started. This is to reduce the risk of pin-holing of the coating layer to be
produced Thinner shall not be added to primer or paints unless
necessary for proper application according to the paint manufacturer’s
recommendation. The type of thinner used must comply with same.

If the coating material requires the addition of a catalyst, the pot life under
application conditions shall be clearly stated on the label. The pot life
shall not be exceeded. When the pot life limit is reached, the spray pot
shall be emptied, the material discarded, the equipment cleaned and new
material catalyzed.

Hydrostatic and other testing of welds shall be completed prior to painting

weld lanes, ends of pipe and related components that will require
subsequent welding at site shall be masked off after blast cleaning
and left uncoated for a distance of 50 mm from all areas requiring
welding.

5.1.3 Other Miscellaneous Requirements

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 For multi-coat system, a mist coat shall be applied over inorganic zinc
primer to avoid surface defects. Necessary care shall be exercised to
ensure a smooth and uniform coating is applied over inorganic zinc primer
Extra coats of paint shall be applied on areas where shape and/or plane
of application results in thinly applied coatings; example at edges, weld
behind angles, corners etc. and areas not fully accessible by spray in
order to obtain the specified coverage and thickness. A stripe coat of
paint shall be brush applied before applying the subsequent coat

5.2 Scheduling

Unless otherwise recommended by the paint manufacturer and accepted by the

Customer, paints shall NOT be applied when:

5.2.1 Incomplete surface preparation or oil, grease and dust still present on
substrate to be painted.
5.2.2 The surface temperature is less than 3°C above Dew point.
5.2.3 The air or surface temperature is below 5°C as it would adversely affect
curing of Paint.
5.2.4 The relative humidity of air is greater than 85% except for inorganic zinc
silicate up to 90%.
5.2.5 The metal substrate temperature is higher than that recommended by the
paint manufacturer for application
5.2.6 There is a likelihood of an adverse change in weather conditions within
two hours after application that would result in a drastic drop in air
temperature below those as specified above.
5.2.7 There is a deposition of moisture in the form of rain, condensation etc.
upon the surface.
5.2.8 The available light is less than 500 Lux

Blast cleaned or power disc grinded surfaces shall be coated with the primer
specified within four (4) hours after blasting or power grinding or within such other
limits as may be specified and before any visible rusting occurs. Each coat of paint
shall dry for a time period within the limits prescribed by the Paint Manufacturer
before the next coat is applied (minimum and maximum over-coating time).

5.3 Application Methods

5.3.1 General

Coatings shall be uniformly applied without runs, sags, solvent blisters,

dry spray or other blemishes. All blemishes and other irregularities shall
be repaired or completely removed and recoated. Special attention shall
be paid to crevices, corners, edges, weld lines, bolt heads, nuts and small
brackets to apply the specified minimum dry film thickness by brush
application if spray will not completely cover all surfaces.

Edges of existing coating shall be feathered towards the substrate prior to

over-coating Primers should not be over-coated with the second coat
paint until the specified minimum over-coating time is achieved

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 Inter-coat contamination shall be minimized by maintaining proper
cleanliness and by applying the intermediate and finish coats within the
over-coating time recommended by the paint manufacturer. If
contaminants are present, they shall be removed before applying
succeeding coats. Contrasting color shall be used for each coat of paint.

5.3.2 Spray Application

Paints shall be applied by Air Spray (Conventional) or Airless Spray

Hose and containers, lines and pots shall be thoroughly cleaned before
addition of new materials. The spray gun shall be held no closer than
200 mm (between 450 mm to 600 mm) from the surface to be coated at
right angles to the surface. Uniform parallel passes should be made with
the spray gun. Each spray pass shall overlap the previous pass by 50%.
Large surfaces should always receive passes in two directions at right
angles to each other.

Each coat is to be applied uniformly and completely over the entire

surface. All runs and sags shall be brushed out immediately or the paint
removed and the surface re-sprayed. Before spraying each coat, all areas
such as corners, edges, welds, small brackets, bolts, nuts and interstices
shall be pre-coated, usually by brush to ensure that these areas have at
least the minimum specified film thickness.

5.3.3 Brush Application

Brush application may be used under the following circumstances:

a) When spraying for any reasons cannot properly coat areas

b) When spray application is deemed to be difficult, adverse to the
required quality finish, uneconomical or may affect other plant,
equipment property, personnel etc. due to location of work
accessibility
c) For the application of self-etching primers
d) For “touch-up” or repair to localized damaged paint areas or areas
of incorrectly applied paint
e) For application of initial stripe coat of paint to corners, edges,
crevices, holes, welds or other irregular surfaces

Paint brushes used shall be of a style and quality that will permit proper
and appropriate application of paint. Good quality hog bristle is preferred
and nylon or other synthetic bristle types are prohibited. Round or oval
brushes are considered most suitable for rivets, bolts, irregular surfaces
etc. Wide flat brushes are suitable for large flat areas but not to exceed

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 Width of 120 mm. Brushes shall be kept in good condition at all times and
discarded if damaged or excessively worn. The brushing shall be done so
that a smooth coat, as uniform in thickness as possible is obtained. There
should be no deep or detrimental brush marks.

Paint shall be worked into all crevices and corners. Runs and sags shall
be brushed out. During application of each coat, all areas such as
corners, edges, welds, small brackets, bolts, nuts and interstices shall
receive additional coating material to ensure that these areas have at
least the minimum specified film thickness and to ensure continuity

5.3.4 Roller Application

Roller application shall be discouraged and shall be subject to the specific

approval of customer. If allowed, it will only be used on relatively large
surface areas provide the first primer coat of paint is applied by brush and
its use in accordance to Paint Manufacturer’s instructions. Rollers shall be
manufactured from good quality “carpet pile” or lamb’s wool.

5.4 Repair of Defects

5.4.1 General

A specific paint system or scheme for the repair and/or touch-up painting
of each generic type shall be submitted for approval from customer
Before application of any further coat of material, all damages to previous
coats shall be repaired. All loose paint shall be removed to a firm edge. All
surface irregularities and contaminants shall be removed. Hard glossy
surfaces may require abrading to obtained suitable surface for painting.
If the surface being prepared lies adjacent to a sound coated surface
which is not to be repaired, the surface preparation shall overlap the
coated surface by at least 25 mm.

5.4.2 Inadequate Coating Thickness

Areas with inadequate coating thickness shall be thoroughly cleaned and

if necessary abraded and additional compatible coats applied shall blend
in with the final coating on adjoining areas.

5.4.3 Coating Damage not exposing steel surface substrate

The damaged area shall first be washed down to remove all

contamination, followed by rinsing with clean fresh potable water and left
to dry. The coating around the damaged area shall be feathered or
chamfered by sanding down to ensure continuity of the patch coating. The
full coating system shall then be re-applied strictly in accordance with
specification

5.4.4 Coating Damage exposing steel surface substrate

The damaged area shall be re-cleaned as originally specified for that item
and the full coating system re-applied in accordance with paint technical
data sheet. The re-cleaning shall carry over on to the secure surrounding

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 coating for not less than 25mm all round and the edges shall be feathered
or chamfered by sanding down to ensure continuity of the patch coating.

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 5.4.5 Repair of Zinc Silicate primer

Damaged surfaces of zinc primer shall be cleaned to remove all loose

materials and blast cleaned with a portable vacuum blast cleaning unit.
The surfaces shall be coated with one coat of the primer which is the
same as the damaged primer. If blast cleaning is not possible, power tool
cleaning may be used subject to customer agreement.

5.4.6 Repair of Fully Cured Epoxy coatings

In case of repairing damage to fully cured epoxy coatings, the

coating work shall only be carried out after the surface of the fully cured
epoxy to be coated has been suitably abraded to provide an adequate
tooth for the coating to be applied. The repair coating shall be compatible
with the existing coating.

6.0 PAINTING AND COATING SYSTEM

6.1 Painting material will be applied according to the design temperature and
services condition. Selection of paint material is also confirmed by Paint
Manufacturer.

6.2 Paint coating system shall be in accordance to JERES-H-001 Table-A1

for Non-Insulated material & Table- A2 for Insulated material.

6.3 The colour scheduling and coding will follow accordance to JERES-H-001
Appendix C

7.0 FLOW CHART FOR INSPECTION OF BLASTING AND PAINTING ACTIVITIES

7.1 Before Blasting

 CONDITION OF RUST GRADE A ,

TO CHECK
B,C&D
INSPECTION OF  OIL AND GREESE REMOVED
STEEL WORK  REMOVE OF SHARP EDGES ,
WELD SPATTER

TO CHECK
INSPECTION OF  SALT FREE AND GENERAL
ABBRASIVE UTILITY
 GRADE / MESH SIZE /TYPE ISO
8504-2

INSPECTION OF TO CHECK

TEST RUN THE EQUIPMENT
BLASTING 
COMPRESSED AIR FREE FROM
EQUIPMENT OIL AND MOISTUFRE
 PRESSURE AT BLAST HOSE
NOZZLE
Document Title SURFACE PREPARATION & PAINTING PROCEDURE FOR INDUSTRIAL COATING
CHECKING Page TO CHECK
Document No QCP- M109 WHEATHER  NO
12 BLASTING
of 18 SHALL BE
CONDITION DONE BEFORE CHECKING
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WHEATHER
 7.2 After blasting

INSPECTION OF TO CHECK  STANDARD ISO 8501-1, 8502 ,

SURFACE PROFILE 8503
AND CLEANESS  SURFACE PROFILE 50-75
MICRONS

7.3 Before painting

TO CHECK  NO COATING APPLIED SURFACE

WEATHER CHECKING TEMPERATURE LESS THAN 3°C
CONDITION ABOVE DEW POINT OR RELATIVE
HUMIDITY MORE THAN 85%

TO CHECK  DUST FREE SURFACE TO BLOW

INSPECTION OF
OFF
SURFACE
 DUST/ POLLUTION FREE
ENVIRONMENT

 CORRECT PAINT AS PER

TO CHECK PAINT SYSTEM
INSPECTION OF PAINT
 BATCH NUMBER
MATERIAL
 CORRECT COLOUR AS PER
PAINT SYSTEM


7.2 After painting

TO CHECK
INSPECTION OF  MANUFACTURES SPECIFIED
PAINTED SURFACE WFT
 ADHESION TEST
 MINIMUM DFT ACHEIVED

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 8.0 INSPECTION AND TESTING

8.1 The following inspection shall be carried out after in accordance with Table 1 in
this procedure. Surface shall be accessible until final inspection is carried out.

8.2 Individual coat and completed coating shall be visually inspected for appearance.
Coatings shall be smooth and free from run, cracking, blistering, dry spray, over
spray, pinholes, crater and sagging.

8.3 During coating, the wet film thickness shall be spot-checked. Specified total
minimum DFT shall be spot-checked by thickness gauge. Dry film thickness shall
also be measured on individual coats. WFT and DFT measurements shall comply
with ASTM D 4414 and SSPC-PA2 respectively.

8.4 Temperature and relative humidity shall be measured by means of a temperature

gauge and hygrometer. Reading shall be taken at regular intervals, depending on
change in climatic condition

8.5 Coating shall be removed and repainted if the specification reveals the following:

a) Coating not adhering to surface to which it is applied

b) Surface has not been properly blasted and/or clean
c) Loose or scaling paints remains
d) Foreign matter (contamination) embedded into coated surface.
e) Freshly coating surface is wet from rain, high humidity or low dew points.
f) Previously applied coating has not cured.
e) For other reason that will impair the coating performance.

9.0 DOCUMENTATION

9.1 Inspection results for surface preparation and coating shall be recorded in Painting
Inspection Report as per Attachment 2.

10.0 SAFETY

10.1 Smoking, open fires, or sparks will not be permitted in confined areas that are
being or recently have been painted and are emitting flammable solvents.

10.2 All equipment recommended lifting up by using the lifting lug attached due the
painting work to avoid any damage or uneven distribution of paints on the
equipment main body.

10.3 The following documentation shall be provided and used when evaluating coating
systems:

a) chemical name of organic solvent, OAR number, and VOC content in g/l;
b) percentage of low molecular epoxy (molecular weight < 700);
c) content of hazardous substances;

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 d) specification of hazardous thermal degradation components;
e) combustibility;
f) special handling precautions and personal protection.

10.4 Use of Personal Protective Equipment (PPE) shall be mandatory to avoid any
incident / accident / health hazard during blasting and painting activities.

11.0 TABLES & ATTACHMENTS

11.1 Table 1 - Inspection & Testing

11.2 Attachment 1 Blasting and Painting Inspection Report

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 Table 1 - Inspection & Testing

Test Type Method Frequency Acceptance Criteria Consequence

Environmental Before start of In accordance with No blasting or
conditions Ambient and steel each shift and specified coating
temperature, relative minimum twice requirements
humidity, Dew point per shift
Visual Visual for sharp 100% of all No defects, see Defects to be
examination edges weld surface specified repaired
spatter, slivers, requirements
rust grade etc
a) In accordance a) Re-blasting
Cleanliness a) ISO 8501-1 b) a) 100% visual all with specified b) Re-cleaning
ISO 8502-3 surfaces requirements and retesting
b) Spot checks b) Maximum quantity until
& size is rating 2 acceptable
Repeated
Salt test ISO 8502-6 and 2 every 1m2 Soluble salts (NaCl) washing with
ISO 8502-9 less than 3mg/cm3 potable water and
retesting until
acceptable
Comparator or Each component In accordance with Re-blasting until
Roughness stylus instrument or once per 10m2 specified paint acceptable
ISO 8503 system

Curing test ASTM D4752 Each component Rating 4-5 Allow to cure
(for Zn silicate) or once per
100m2

Visual to determine
Visual curing, 100% of surface In accordance with Repair of defects
examination contamination, after each coat specified and retesting
solvent retention, requirements
pinholes/popping,
sagging and surface
defects

Wet film SSPC-PA2 Systematically In accordance with Repair or re-

thickness (WFT) Using WFT Gauge during any specified paint coating as
application system appropriate

Dry film SSPC-PA2 Each coat, when In accordance with Repair or re-
thickness (DFT) Using Elcometer coating system specified paint coating as
are cured system appropriate

Adhesion ASTM D 3359

(Tape Test) Spot checks Rating 4A and 5A Coating to be
when coating rejected
system are
ASTM D4541 cured Minimum Value 3MPa
(test panel)

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*NOTE : TABLE BELOW FOR EXAMPLE ONLY.