Professional Documents
Culture Documents
Surface Preparation
Surface Preparation
To obtain the best results from a paint system the best possible surface
preparation consistent with the degree of sophistication of the system is required.
The quality of the paint and surface preparation (i.e. the removal of rust, scale,
salt, grease, dirt and loose paint) are the most important factors in determining
the lifetime of the paintwork, and therefore the length of time the surface will be
protected. First class preparation has the potential to extend the protective life of
any paint system.
What is surface preparation?
Coating performance is directly affected by surface preparation.
Coating integrity and service life will be reduced because of
improperly prepared surfaces.
As high as 80% of all coating failures can be directly attributed to
inadequate surface preparation that affects coating adhesion.
The majority of paintable surfaces are concrete, ferrous metal,
galvanizing and aluminum.
They all require protection to keep them from corroding in
aggressive environments.
Selection of the proper method for surface preparation depends
on the substrate, the environment, the coating selected and the
expected service life of the coating system.
The greater the
DFT the greater
the Surface
Profile
SURFACE CONTAMINANTS
Mill Scale :The complete removal of mill scale and rust is critical in order to limit its corrosive
properties. Mill scale is generally found on new steel as a hard brittle coating – it consists of
distinct layers of various iron oxides and is formed during the hot rolling process in the
manufacture of steel. Painting over mill scale is not satisfactory, as mill scale is not firmly or
permanently bonded to the steel. Eventually the scale will lift off, causing paint coatings to
flake and corrosion to occur.
Rust: Rust is a form of hydrated ferric oxide formed by the action of water and oxygen on
iron and steel surfaces and occupies a much greater volume than the original steel. It is for
this reason that rust forming beneath a paint layer is able to rupture a coating. All areas of
rust should be completely removed – any rust remaining will act as a nucleus for further
rusting.
Oil, Grease Fat and Perspiration : Oil, grease, fat and perspiration deposits cannot be
removed by mechanical methods of cleaning. The simplest method of removal is to use a
solvent emulsifiable degreaser or biodegradable detergent. Apply the degreaser liberally
to the contaminated surface, allow to stand for a short time, then hose off with fresh
water.
Prepare surface for subsequent processing, such as a coating application or adhesive
bonding
Improve hygiene conditions for workers and customers
Remove contaminants that might chemically react with the surface
Enhance appearance and performance of the product
Factors in Selecting a Cleaning
Method
Contaminant to be removed
Degree of cleanliness required
Substrate material to be cleaned
Purpose of cleaning
Environmental and safety factors
Size and geometry of the part
Production and cost requirements
Contaminant to be Removed
Various contaminants build up on part surfaces, either due
to previous processing or factory environment
Principal surface contaminants found in factory
Oil and grease, e.g., lubricants in metalworking
Solid particles such as metal chips, abrasive grits, shop dirt,
dust, etc.
Buffing and polishing compounds
Oxide films, rust, and scale
What are Non-Ferrous Metals?
Non-ferrous metals refer to metals that are not derived from iron ore, such as
aluminium and its alloys, copper, brass and bronze. Whilst iron (mild steel) will readily
oxidize to red rust (iron oxide), non-ferrous metals usually exhibit only tarnishing
(surface corrosion). Aluminum finds ready use in window- and door-frames, handrails,
balustrades and architectural work generally. Copper is used in water pipes and
guttering.
.
Primary Substrates
• Steel
– Carbon Steel – Easily attacked by the
environment in which it is placed and will
begin to revert back to iron ore.
– Stainless Steel - Stainless steel does not stain,
corrode, or rust as easily as ordinary steel.
Non-Ferrous Metal Surfaces
Aluminum
Remove all oil, grease, dirt, oxide and other foreign material
by cleaning per SSPC-SP1, Solvent Cleaning.
Galvanized Metal
Allow to weather a minimum of six months prior to coating.
Clean per SSPC-SP1 using detergent and water or a
degreasing cleaner, then prime as required. When weathering
is not possible or the surface has been treated with chromates
or silicates, first Solvent Clean per SSPC-SP1 and apply a test
area, priming as required. Allow the coating to cure at least
one week before testing per ASTM D3359. If adhesion is poor,
Brush Blast per SSPC-SP7/NACE 4 is necessary to remove these
treatments.
Ductile Iron
National Association of Pipe Fabricators, Inc. www.napf.com NAPF 500-03 Surface
Preparation Standard for Ductile Iron Pipe and Fittings in Exposed Locations Receiving
Special External Coatings and/or Special Internal Linings This standard summarizes the
surface preparation requirements for ductile iron. Included within this standard are the
following:
NAPF 500-03-01 Solvent Cleaning
NAPF 500-03-02 Hand Tool Cleaning
NAPF 500-03-03 Power Tool Cleaning NAPF 500-03-04
Abrasive Blast Cleaning for Ductile Iron Pipe
NAPF 500-03-05 Abrasive Blast Cleaning for Cast Ductile Iron
NOTE:
Recommended Coating Systems for Non-Ferrous Metals :
A surface tolerant epoxy primer is the preferred primer for most non-ferrous
metals.
Concrete
Concrete - used more than any other man-made material in the
world and is easily attacked when placed in chemical
environments.
.
METHODS OF SURFACE PREPARATION
Depending upon conditions of the concrete one or more methods of surface
preparation may be required. It is common for decontamination to precede
mechanical preparation, and if necessary a second decontamination to follow
Protection Mechanisms
• Barrier Protection
– The coating/lining isolates the electrolyte from
the anode, cathode, and metallic pathway.
• Rust Inhibitive
– The slightly water-soluble pigments permeate
to steel/coating interface and passivate the
substrate.
• Sacrificial
– The coating/lining contains pigments that are
more active than the metal and sacrifice
themselves to protect the substrate.
Chemical Cleaning Processes
Alkaline cleaning
Emulsion cleaning
Solvent cleaning
Acid cleaning
Ultrasonic cleaning
Alkaline Cleaning
Uses an alkali to remove oils, grease, wax, and
various types of particles (metal chips, silica,
light scale) from a metallic surface
Most widely used industrial cleaning method
Alkaline solutions include sodium and
potassium hydroxide (NaOH, KOH), sodium
carbonate (Na2CO3), borax (Na2B4O7)
Cleaning methods: immersion or spraying
followed by water rinse to remove residue
Emulsion Cleaning
Chemistry:-
Chromate coating on aluminium may contain the compound
AL2O3.Cr(OH)3.CrOH.CrO4.
On zinc as basis metal, ZnCrO4 has been claimed to appear
Mechanical Cleaning