N°: S-A-3-310-014 - Rev.

F
CORROSION PROTECTION
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The English translation is to be considered as a help to understand the present

instruction. In case of inconsistency between the French and the English translation,
the French text always prevails.

SCOPE: PAINTING TECHNICAL SPECIFICATION FOR

CORROSION PROTECTION OF CMI MACHINES.

APPLICATION FIELD: PAINTING FOR ALL MACHINES

REFERENCE DOCUMENTS: ISO 2409

ISO 8501-1
ISO 12944-1
ISO 12944-2
ISO 12944-3
ISO 12944-4
ISO 12944-5

F 10/06/2016 A. DARE E. GOREUX E.SCHIMANSKI E.SCHIMANSKI Entire document

Mentioned by
E 13/10/2015 F. BLANCO E. GOREUX E.SCHIMANSKI E.SCHIMANSKI
E

D 01/03/2013 F. BLANCO E. AUVRAY E.SCHIMANSKI E.SCHIMANSKI Entire document

C 27/02/2001 BAILLET E. AUVRAY E.SCHIMANSKI PREAUX

B 15/02/1995 BAILLET E. AUVRAY R. PONCIN WAROUX Add SIGMA

A 25/11/1994 BAILLET

Engineering Erection Q.A.

Rev Date Redaction Reference
CMI Approval
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TABLE OF CONTENTS

1. SCOPE ------------------------------------------------------------------------------------------------------------------------------------------------- 3
2. PAINT SYSTEMS ----------------------------------------------------------------------------------------------------------------------------------- 3
2.1. SURFACE PREPARATION ---------------------------------------------------------------------------------------------------------------------- 9
2.2. PRIMER COATING ------------------------------------------------------------------------------------------------------------------------------- 14
2.3. TOP COATING ------------------------------------------------------------------------------------------------------------------------------------ 16
2.4. FILM THICKNESS -------------------------------------------------------------------------------------------------------------------------------- 16
2.5. PROTECTIVE COATING ----------------------------------------------------------------------------------------------------------------------- 17
2.5.1. Standard protection ------------------------------------------------------------------------------------------------------------------ 17
2.5.2. Long-term protection ---------------------------------------------------------------------------------------------------------------- 17
2.6. TOUCH-UP OF THE PAINT SYSTEM ------------------------------------------------------------------------------------------------------- 17
2.7. USE OF HEAT-RESISTANT PAINT SYSTEMS ON STEEL STRUCTURES ----------------------------------------------------- 18
3. FILLING JOINTS AND GAPS ----------------------------------------------------------------------------------------------------------------- 18
4. INTERNAL PROTECTION OF GEAR-BOX ------------------------------------------------------------------------------------------------ 19
5. INSPECTIONS ------------------------------------------------------------------------------------------------------------------------------------- 19
5.1. Surface ---------------------------------------------------------------------------------------------------------------------------------------------- 19
5.2. Painting adhesion ------------------------------------------------------------------------------------------------------------------------------- 19
5.2.1. Cross-Cut Test ------------------------------------------------------------------------------------------------------------------------- 19
5.2.1.1. Apparatus ---------------------------------------------------------------------------------------------------------------------------- 20
5.2.1.1.1. Cutting tools -------------------------------------------------------------------------------------------------------------------- 20
5.2.1.1.1.1. Single-blade cutting tool ------------------------------------------------------------------------------------------------ 20
5.2.1.1.1.2. Multi-blade cutting tool -------------------------------------------------------------------------------------------------- 21
5.2.1.1.2. Pressure-sensitive adhesive tape---------------------------------------------------------------------------------------- 21
5.2.1.1.3. Viewing lens --------------------------------------------------------------------------------------------------------------------- 22
5.2.1.2. Procedure ---------------------------------------------------------------------------------------------------------------------------- 22
5.2.1.3. Evaluation and expression of results -------------------------------------------------------------------------------------- 22
5.2.2. X-Cut Test ------------------------------------------------------------------------------------------------------------------------------- 23
5.2.2.1. Apparatus ---------------------------------------------------------------------------------------------------------------------------- 23
5.2.2.2. Procedure ---------------------------------------------------------------------------------------------------------------------------- 24
5.2.2.3. Evaluation and expression of results -------------------------------------------------------------------------------------- 24
5.3. Painting thickness ------------------------------------------------------------------------------------------------------------------------------- 25
5.4. RAL --------------------------------------------------------------------------------------------------------------------------------------------------25
6. SUPPLIER’S RESPONSIBILITIES ----------------------------------------------------------------------------------------------------------- 26
7. PERFORMANCE TERMS AND CONDITIONS ------------------------------------------------------------------------------------------- 26
7.1. Paint -------------------------------------------------------------------------------------------------------------------------------------------------- 26
7.2. Personnel ------------------------------------------------------------------------------------------------------------------------------------------- 26
7.3. Walkway gratings and structural elements --------------------------------------------------------------------------------------------- 26
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1. SCOPE
This specification defines the general instructions for the anti-corrosion protection system of
CMI machines.
All steel surfaces, with exception of stainless or acid-resistant steels, shall be provided with
paint coats.
Suppliers are required to carry out a surface pre-treatment before applying protection painting
on the CMI machines.
Anti-corrosion protection system of piping, fastening materials and tanks are not concerned by
this specification.

2. PAINT SYSTEMS
Unless otherwise specified by CMI, a paint system is composed of:

Surfaces preparation

Either at workshop or supplier's site

Primer coating

Intermediate coating is usually required on machines or

machine parts which are exposed to fumes and splashes
Intermediate coating of chemicals. Intermediate coating shall be applied after
completion of workshop assembly or functional or
acceptance inspection, immediately before the application
of the top coating

The final coating will be defined in the specific technical

Top coating
specification attached to the purchase order
To select the appropriate paint system:
1. Determine the corrosivity category of the environment (macroclimate) where the
structure will be located (see §5 of ISO 12944-2 for more details). Six atmospheric
corrosivity categories are defined:

C1 very low
C2 low
C3 medium
C4 high
C5-I very high (industrial)
C5-M very high (marine)

To determine the corrosion categories, the exposure of standard specimens is strongly

recommended. Table 1 of ISO 12944-2 defines the corrosivity categories in terms of
mass or thickness loss of such standard specimens made of low-carbon steel and/or
zinc after the first year of exposure. If it is not possible to expose standard specimens in
the actual environment of interest, the corrosivity category may be estimated by simply
considering the examples of typical environment given in Table 1 of ISO 12944-2.
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Unless otherwise specified (i.e.: following the results of the exposure of standard
specimens described above), CMI machines shall operate in one of the two atmospheric
corrosivity categories: C3 and C4.

2. Establish whether special conditions (microclimate) exist which can result in a higher
corrosivity category (see ISO 12944-2).

3. Table 1 provides different types of paint system for corrosivity category C3 and C4, and
some special environments (i.e.: heat resistant paint system, oil resistant paint
system,...) for steels. Primer, intermediate and finish coatings recommended by CMI are
listed in Table 1. In case of using any coating not specified in Table 1, CMI approval is
mandatory.

4. Identify a suitable paint system with the required durability.

Alkyd primers are not recommended for atmospheric corrosivity categories C3 and C4
as they are usually applied for slightly corrosive environment. Modified alkyd based
primer containing zinc phosphate can be used as oil resistant external paint.
Acrylic water-borne paint has a good anticorrosive properties in mildly to moderately
corrosive environment (C3 or less).
Epoxy paints are pigmented. Based on the zinc content, zinc paints can be divided into
two categories: Zinc-rich primers (Zn(R)) and Zinc primers (Misc).
Zinc-rich paints (Zn(R)) are paints in which zinc powder is the only active pigment, and it
is present in levels above 80 wt% in the dry paint film. Because of these high levels of
zinc powder, the paint has the qualities of a metallic zinc film, which allows the paint to
protect the steel by an additional mechanism—cathodic protection. Zinc-rich paints
provide excellent corrosion protection in heavy-duty environments. Zinc phosphate
epoxy primers (Misc) are the most frequently encountered and give the best durability.
Unless otherwise specified, the expected durability of a paint system selected for CMI
machines is Medium (M) that is between 5 and 15 years.

5. Select the optimum one, taking into account the surface preparation (§2.1) method that
will be used.

6. Consult the paint manufacturer in order to confirm the choice and have any further
recommendation.

To ensure maximum performance of a paint system, the majority of the coats of the system or, if
possible, the complete system, should preferably be applied in the workshop.
Identification plates of accessories, as well as all moveable parts and guide-way surfaces, shall
not be allowed to be covered by paint or damaged by abrasive blasting work.
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NOTE:
i. All new welds must be abrasive blasted and then coated using the full coating system as
specified.
ii. All worn areas must be thoroughly dusted before any paint is applied.
iii. Sharp edges must be rounded off (according to ISO 12944-3, pp. 12–13: 2-mm radius
for all cut and welded edges, drilled holes, etc.).
iv. All joints, welds, edges, signs, pits and sharp corners (inside and outside corners) must
first be painted using a brush before starting to paint parts of an installation using spray-
painting or roller painting (if approved). This applies to all coats of the paint system.
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Corrosivity Priming coat(s) Intermediate coat(s) Finish coat(s)

Paint category/ Surface Max Service
Example of
System Expected preparation (2) Product (2) Product (2) Product Temperature
NDFT N° of NDFT N° of NDFT N° of application
No. durability grade (1) Binder Pigments Name/ Binder Pigments Name/ Binder Name/ (°C) (4)
(ISO12944-5) (m) coats (m) coats (m) coats
Colour Colour Colour
Apecoat Apecoat Mio Acrydur Finish
Sa 2½ zinc rich Epoxy E93/ Aliphatic
Epoxy Zinc dust 40 1 MIO (3) 80 1 40 1 A5456/ 120
or primer E8/ Grey and polyurethane Wide range
Be Zinc grey red-grey
Hempadur Hemphatane
Sa 2½ Zinc Aliphatic
Epoxy 80 1 47960/ - - - - - 80 1 HS 55610/ 120
or phosphate polyurethane
Grey Wide range
Be

Hemudur Hemuthane
Sa 2½ Zinc Polyurethane Enamel
Epoxy 100 1 18500/ - - - - - 60 1 120
or phosphate enamel 58510/
Grey
Be Wide range
1 C3/M
Apecoat
Sa 2½ primer E81/ Apecoat Mio
Acrydur Finish
or Red-brown, E93/ Aliphatic
Zinc Epoxy MIO (3) 70 1 40 1 A5456/ 100
Be Epoxy 60 1 light grey, Grey and polyurethane  Frame,
phosphate Wide range
or oxide red-grey Framework,
St3(5) yellow Supports, ...
Hemucryl Hemucryl
Sa 2½ primer HB
or Acrylic - 80 1
- - - - -
Acrylic - 80
primer HB 120  Movable parts
18032/ 58030/
Be Grey Wide range
Apecoat Apecoat Mio
Acrydur Finish
Sa 2½ zinc rich E93/ Aliphatic
Epoxy Zinc dust 40 1 Epoxy MIO (3) 80 2 40 1 A5456/ 120
or primer E8/ Grey and polyurethane
Wide range
Be Zinc grey red-grey

Hempadur Hemphatane
Sa 2½ Zinc Aliphatic
Epoxy 140 1 47960/ - - - - - 100 1 HS 55610/ 120
or phosphate polyurethane
2 C4/M Grey Wide range
Be

Hemuthane
Hemudur
Sa 2½ Zinc Polyurethane Enamel
Epoxy 200 2 18500/ - - - - - 40 1 120
or phosphate enamel 58510/
Grey
Be Wide range
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Corrosivity Priming coat(s) Intermediate coat(s) Finish coat(s)

Paint category/ Surface Max Service
Product Product Example of
System Expected preparation NDFT(2) NDFT(2) N° of Name/ NDFT(2) N° of Name/
Temperature
application
No. durability grade (1) Binder Pigments (m) Binder Pigments
(m) coats
Binder
(m) coats (°C) (4)
Colour Colour
(ISO12944-5)
Hempadur
Hempadur Aliphatic Hemphatan
Sa 2½ Zinc 17360/ Zinc
Epoxy Zinc dust 40 1 Epoxy 100 1 47960/ polyuretha 60 1 e HS 55610/ 120
or Reddish phosphate
Grey ne Wide range
Be grey

Hemuthane  Frame,
Hemudur Hemudur
Sa 2½ Zinc Polyuretha Enamel Framework,
Epoxy Zinc dust 40 1 Zinc 18560/ Epoxy 110 1 18500/ 50 1 120
or phosphate ne enamel 58510/ Supports, ...
Grey Grey
2 C4/M Be Wide range

Apecoat  Movable parts

Sa 2½ primer E81/ Apecoat Acrydur
Aliphatic
or Red-brown, Mio E93/ Finish
Zinc Epoxy MIO (3) 70 2 polyuretha 40 1 100
Be Epoxy 60 1 light grey, Grey and A5456/
phosphate ne
or oxide red-grey Wide range
St3(5) yellow

Hempel's
Hempel's
Sa 2½ Silicone
Galvosil Silicon
or Silicate Zinc dust 75 1 - - - - - 25 2 Acrylic 200
15700/ Acrylate
Be 56940/
Metal grey
Light grey
Hempel's
Hempel's Silicone
Sa 2½
or Silicate Zinc dust 75 1
Galvosil
- - - - - Silicon 25 2 Aluminium 500  Machines or
15780/ 56910/ machine
Be
Metal grey Aluminium components
3 Heat resistant
exposed to high
Hempel's temperature
Sa 2½
Galvosil
or Silicate Zinc dust 80 1 - - - - - - - - - 500
15700/
Be
Metal grey
Hempel's
Sa 2½ Silicone
or Silicon Aluminum 25 3 Aluminium - - - - - - - - - 600
Be 56910/
Aluminium
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Priming coat(s) Intermediate coat(s) Finish coat(s)

Paint Surface Max Service
Special Example of
System preparation Product N° of Product NDFT(2) N° of Product Temperature
Environment NDFT(2) N° of Binder Pigments NDFT(2) Name Binder Name application
No. grade (1) Binder Pigments Name coats (m) coats (°C) (4)
(m) coats (m) (example) (example)
(example)
Sa 2½
Hemulin Hemulin
or
Oil resistant Zinc Primer Alkyd Enamel  All machines
4 St3 Alkyd 40 1 - - - - - 40 1 120
External coat phosphate 18310/ enamel 58380/
or
Grey Wide range
Be
 Gear housings
and gear internals
Oil resistant
5 Select from the Paint System No.1 or 2 paint systems with two-component epoxy resin primer. such as welded
Internal coat
gear wheels and
oil flingers
 Machines or
machine parts
Select from the Paint System No.1 or 2 paint systems with two-component epoxy resin primer with zinc phosphate and two-component epoxy resin with zinc phosphate (or which are
Chemical
6 MIO) intermediate coat. exposed to fumes
Resistant
or splashes of
chemicals

Table 1 – Paint systems for steels

(1) From rust grade A, B or C only;

(2) NDFT= Nominal Dry Film Thickness. See §5.4, ISO 12944-5 for further details;
(3) MIO= Micaceous iron oxide;
(4) Max Service Temperature is the minimum among the max service temperatures of the paints used in the paint system;
(5) Apply the first coat with a brush to obtain good penetration of the paint.
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2.1. SURFACE PREPARATION

The performance and durability of any paint coating are significantly affected by the surface
preparation. Different types of surface preparation can be selected depending upon the
condition of the substrate, the paint system selected, the exposure and required durability of the
coating.
1) Residues of oil, grease, marking inks, cutting oils, etc. after fabrication operations will
seriously affect the adhesion of applied coatings and must be removed. Failure to remove
these contaminants before blast cleaning (or hand or power tool cleaning) results in them
being distributed over the steel surface and contaminating the abrasive. The supplier must
thoroughly wash and degrease the surface before performing any sort of de-rusting
treatment. This is to be done using water under high pressure (p= 60–80 bar, T = 60 °C)
and a detergent, following which the treated area is to be thoroughly rinsed with clean
water.
Remove from all the surfaces which shall be painted all contaminations that could impair
the coating adhesiveness such as:
 Marking inks
 Oil
 Grease
 Previous coatings
 Lubricants
 Salts
 Dust
 Weld spatters
 Etc.

If the surface of the steel is exposed to a polluted environment, such as an atmosphere

containing a high concentration of salts, it shall first be cleaned with pure water before any
other surface preparation is performed, such as de-rusting or abrasive blasting.
The weld bead area is cleaned very carefully, since the alkaline or acid particles from the
welding materials attacks the undercoat or promote rusting.

2) Four categories of ‘rust grades’ are described in ISO 8501-1 (see Figure 1) :
A - Steel surface largely covered with adhering mill scale, but little if any rust.
B - Steel surface which has begun to rust and from which mill scale has begun to flake.
C - Steel surface on which the mill scale has rusted away or from which it can be scraped,
but with slight pitting under normal vision.
D - Steel surface on which the mill scale has rusted away and on which general pitting is
visible under normal vision.
The majority of new steel parts usually conforms to A and B conditions and occasionally C
condition. In either case, the substrates can be prepared to an equally good standard by
abrasive blast cleaning.
As mentioned in Table 1, the acceptable rust grades from which the surface shall be
prepared are A, B and C only.
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Figure 1 - Four categories of ‘rust grades’ (ISO 8501-1)

3) SURFACE CLEANING
Various types of surface preparation are possible, such as manual derusting, grit blasting,
wet blasting, etc. CMI prefers grit blasting unless otherwise specified.

Abrasive blast cleaning (Sa Grades)

By far the most significant and important method used for the thorough cleaning of mill-
scaled and rusted surfaces is abrasive blast cleaning. This method involves
mechanical cleaning by the continuous impact of abrasive particles (grit) at high
velocities onto the steel surface. Uniform cleaning of steel surfaces by means of grit
blasting in order to provide the appropriate degree of cleanliness and roughness for
eliminating:
 Rust
 Mill scale
 Impurities
 Previous painting
 Inorganic coating
 Etc...
and to prepare them before painting.
Various methods and grades of cleanliness are presented in ISO 8501-1. This standard
refers to the surface appearance of the steel after abrasive blast cleaning (dry blasting)
and gives descriptions with pictorial references of the grades of cleanliness.
(1) If the machine (or any part of it) is exposed to a general atmospheric condition,
the required purity grade is Sa 2 ½:
Sa 2½: Very thorough blast-cleaning.
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When viewed without magnification, the surface shall be free from visible oil,
grease and dirt, and from mill scale, rust, paint coatings and foreign matter. Any
remaining traces of contamination shall show only as slight stains in the form of
spots or stripes.
Finally, the surface is cleaned with a vacuum cleaner, clean dry compressed air
or a clean brush.
Surface appearance must correspond to SA 2½ pictures (see Figure 2).

A SA 2 ½ B SA 2 ½

C SA 2 ½ D SA 2 ½

Figure 2 - SA 2½ blast cleaning (ISO 8501-1)

(2) For aggressive atmospheric conditions, the purity grade required is Sa 3:

Sa 3: Blast-cleaning to visually clean steel.
Grit blasting to such an extent that a perfectly clean metal surface is obtained.
Mill scale, rust and foreign matter shall be removed completely.
Finally, the surface is cleaned with a vacuum cleaner, clean dry compressed air
or a clean brush. Then, It shall have a uniform metallic colour and correspond in
appearance to Figure 3.
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A SA 3 B SA 3

C SA 3 D SA 3

Figure 3 - SA 3 blast cleaning (ISO 8501-1)

The abrasive media is to be selected to obtain a surface roughness compliant with the
paint system to be applied. Grit blasting shall be performed using compressed air free
of water and oil such that inspection of the surface using a magnifying glass or CuSO 4
test does not reveal the slightest trace of rust, mill scale or other contamination after it
has been treated.
NOTE:
In order to reach a standardized Sa 2½ or Sa 3 purity grade, the abrasive media to be
used is a chilled-iron grit type:
Abrasive ISO 11124 M/CI/G70
With the aforementioned grit blasting media, the average roughness value of Ra =
12,5 m (equivalent to N10) may be slightly higher. However, the impact energy and
the blasting angle shall be taken into account.
It is essential to avoid condensation of water on the abrasive-blasted surface.

Hand and power tool cleaning (St Grades)

Surface cleaning by hand tools such as scrapers and wire brushes is relatively
ineffective in removing mill scale or adherent rust. Power tools offer a slight
improvement over manual methods and these methods can be approximately 30% to
50% effective. Power wire brushes, impact tools such as needle guns, grinders and
sanders are all commonly used. Care should be taken, particularly with power wire
brushes, not to polish the metal surface as this will reduce the key for the subsequent
paint coating.
Where it is not possible to clean by abrasive blasting, hand and power tool methods
may be the only acceptable alternative methods.
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For machines (or any part of it) which cannot be grit blasted due to size or weight, the
purity grade required is St 3.
St 3: Very thorough hand and power tool cleaning.
The treatment shall thoroughly remove loose mill scale, rust and foreign matter. This
treatment must never cause the treated areas to become polished; in other words, a
certain amount of surface roughness must always be retained (50µm<Rz<80µm).
Finally, the surface is cleaned with a vacuum cleaner, clean dry compressed air or a
clean brush. After removal of dust, the surface shall have a pronounced metallic sheen
and will correspond to Figure 4.

B St 3 C St 3 D St 3

Figure 4- St 3 hand and power tool cleaning (ISO 8501-1)

Pickling
Instead of grit blasting, it is also possible, under certain conditions, to prepare the
surface by means of acid pickling in accordance with ISO 12944-4. This process
involves immersion of the component (usually small parts) in a bath containing a
suitable inhibited acid which removes mill scale and rust.
For carbon steel, sulphuric acid (H2SO4) is used in most batch pickling operations,
whereas hydrochloric acid (HCl) has become the pickling agent for continuous
operations with wire and strip. Acids other than HCl or H2SO4 have been used to
remove rust and scale from carbon steel. Citric acid, oxalic acid, formic acid,
hydrofluoric acid, fluoboric acid, and phosphoric acid are all capable of removing mill
scale from steel, but the rates of removal are generally not regarded as useful or
economical for most commercial applications, especially continuous operations.
The surface preparation grade is Be.
Be: Mill scale, rust and residues from paint coatings are removed completely (no
visual standard is available).

Removal of previously painted material

If existing paint coatings are not abrasive blasted, they must be thoroughly scoured
and/or brush-off blasted, with deep blasting on already corroded areas.
Here again various types of pre-treatment are possible. CMI preference is for thorough
manual de-rusting and/or brush-off blasting, or otherwise specified.
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Thorough manual de-rusting

The surface of the material must be cleaned down to solid metal by fully removing all
corrosion products (powdery, scabby and scaly rust, loosely bonded mill scale, etc),
old paint in poor condition (poorly attached, flaking, blistered, cracked, etc.) and the
various sorts of contamination.
The treatment consists of:
- Whitening the steel to grade St 3 at all eroded and heavily damaged locations
using all suitable means, whether manual or mechanical, including scrapers,
hammers with rotary brushes, sanding sponges, scaling hammers with needles,
etc. These treatments can be replaced by brush-off blasting the surface to be
painted, with deep blasting to SA 2½ on corroded areas. Putty knives are
prohibited.
- Lightly smooth the entire surface using sandpaper or steel wool.
- Remove the dust using vacuum or dry compressed air.
The paint is to be applied, either in the form of touching up or coating the entire
surface, within a short period but always within the same day on which the de-rusting
is done. All areas that are manually de-rusted must be fully coated with paint on the
same day.
NOTE:
The supplier must thoroughly wash and degrease the surface before starting manual or
mechanical de-rusting. This is to be done using water under high pressure (p = 60–80 bar,
T = 60 °C) and a detergent, following which the treated area is to be thoroughly rinsed
with clean water.

2.2. PRIMER COATING

Paint can only be applied to completely clean, dry, degreased and dust free surfaces. This
applies to the application of each layer.
Before painting, handling of parts with bare hands is forbidden. Handling of parts and masking
operations shall be accomplished using clean cotton, nylon or rubber gloves. Parts to be
painted shall be examined for cleanliness and absence of all contaminations (including
fingerprints) prior to paint.
After surface preparation by abrasive blasting, the primer coating is applied within 3 to 6 hours
in order to avoid a further rusting.
In addition, primer coating prevents penetration of cooling lubricants during the machining
stage.
If the surface has been prepared in a phosphate acid bath, the primer coating is applied after 48
hours (in order to provide a total reaction of the phosphoric acid and to avoid a chemical
decomposition of the initial coating) and within 72 hours.
The necessary precautions must be taken to avoid contamination of the freshly applied paint by
dust or grit arising from de-rusting.
Unless otherwise specified in the order, all coats of paint must be applied using paintbrushes in
good condition that are compatible with the type of paint used and which have very short
handles (50 cm max.).
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The paint coats should always be applied using spray-painting methods. To obtain good
covering of surface irregularities, the primer coats must always be applied using a brush.
Rollers can only be used for the second coat and following coats. Spray painting can be used
with the approval of the order administrator in consultation with the paint supplier.
The paint is to be mixed mechanically with full dispersion of the pigments until the composition
of the paint is fully homogeneous. It is prohibited to pour paints before the pigments have been
thoroughly mixed with the binder.
When mixing two-component paints, the ratio shall be very strictly observed. Only the amounts
that can be used on the same day are to be mixed. Inspections shall be made to verify this.
Paints shall be used and applied according to paint supplier’s rules. If it is found that the ratio is
incorrect or too much paint has been prepared, the supplier shall provide an additional amount
of paint to replace the amount squandered in that manner.
Thinning the paint with white spirit or any other thinner of any sort is strictly prohibited, except
following formal approval by the paint supplier.
The various successive primer paint coats of a coating system must come from the same paint
supplier.
The paint must be applied in accordance with the instructions of the paint supplier, in such a
manner that a homogeneous and coherent film is achieved. Any paint coat that has an inferior
or deficient appearance due to poor performance of the work or negligence must be removed at
supplier’s expenses.
Paint is always to be applied starting from the highest point and working downward to the lowest
point.
According to the severity of damage caused to the primer coating, during machining or welding
stage, touch-up or re-apply primer coating.

Touch-up repair procedure:

1) Clean the surface with a compatible thinner;
2) Remove salts and other contaminants using pressure water cleaning;
3) Mechanical abrasive cleaning, St3 grade;
4) Touch-up coating (Phosphate Conversion Coating).

Regions that are not to be primed shall be masked as required by applicable drawing with
appropriate paper and adhesive tape.

NOTE:
Dry film thickness of the reworked area shall not exceed the maximum authorized.
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2.3. TOP COATING

Apply top coating after having duly followed the instructions mentioned in §2.1 and §2.2 and
thoroughly removed greases, oil, impurities and dust which can impair a good adhesion of top
coating.
Prior to apply the top coating on surface the supplier shall:
- Check the adherence of the primer coating (see §5.2);
- Clean or/and degrease the application area;
- Select the top coating from Table 1 according to the selected paint system and primer
coating. For any other top coating not specified in Table 1, CMI approval is mandatory.
- Check the compatibility of the top coating colour with that of primer coating.
For preparation and application of top coating refer to the top coating technical specification of
the specific project.
In case of accessibility limitation to the surfaces to be painted, apply top coating before
assembling.

2.4. FILM THICKNESS

Before each coat of the various paint coats of a system is applied, the necessary thickness
measurements shall be made on the previous coat by the inspector of the party performing the
work.
Before starting the painting work, the supplier shall provide his site manager with the following
items:
1) wet-film thickness gauge;
2) dry-film thickness gauge;
3) relative humidity gauge;
4) contact thermometer for coatings.
The equipment above is mandatory and must be shown before starting the work.
Before applying the next coat, the supplier shall ascertain that the specified film thickness has
been adequately achieved and shall record this thickness in the daily log.

Dry-film thickness measurement

Unless otherwise specified, the specified coating thicknesses (NDFT’s) are to be regarded as
minimum coating thicknesses, with the 80–20 rule being applicable as the criterion for
acceptance of the dry-film thickness. The work shall be approved only if 80% of the
measurements are in the range equal to or greater than the thickness stated in the
requirements specification document (NDFT).
Individual dry film thicknesses between 80% of the NDFT and the NDFT are acceptable
provided that the number of these measurements is less than 20 % of the total number of
individual measurements taken.
The maximum thickness must not exceed the value specified in the technical specifications of
the paint supplier.
‘Alligator skin’ and wrinkles due to excess thickness shall not be tolerated, nor shall skins
resulting from oxidation of the paint (if the paint is not filtered after mixing and comes from a
previously used container) be tolerated. If air bubbles are enclosed in a dry film of paint, the
affected areas shall be sanded and recoated.
The supplier is to have the wet film measured in order to monitor the film thickness while the
paint is being applied.
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2.5. PROTECTIVE COATING

The protective coating is applied to the surfaces free of primer coating (generally machined
surfaces), after the last coating and touch-up operations, and after assembling or
functional/acceptance testing of the machine has been completed.
Grease, oil, impurities, rust and dust shall be thoroughly removed prior to protective coating
application and, to avoid formation of rust under the coat, the surfaces shall be dry before the
preserving compound is applied.
The inner protective coating for piping, fastening and tanks is not concerned by this
specification.

2.5.1. Standard protection

If the parts are not stored outdoors and if the storage time (if any) does not exceed 12
months, one layer of Valvoline Tectyl 506 shall be applied.

2.5.2. Long-term protection

For long-term protection, a painting system of 3 superimposed layers shall be applied. i.e.:
 1 layer of Shell Ensis Fluid SDB
 1 layer of Shell Ensis Fluid HA
 1 layer of Shell Ensis Fluid HB
The antirust protection of the parts treated has duration of:
  18 months indoor,
  9 months outside under cover,
 3 to 6 months outdoors.
The protection type, either §2.5.1 or §2.5.2 must be defined in the technical specification of the
purchase order.

2.6. TOUCH-UP OF THE PAINT SYSTEM

Touch-up repair procedure of the primer coating is described in §2.2. Touching up a paint coat
or a paint system consists of repairing the paint coat or system in question, such that the full
integrity of the coat or system is achieved. If the order includes touch-up work, execution of the
work must satisfy the following conditions:
- Touching-up is only allowed if its extent is less than 40% of the surface area to be
restored; otherwise the entire surface must be painted;
- Regardless of the condition of the paint, all edges and strapping must be touched up;
- The touch-up coat must overlap the intact portion of the old paint by several centimetres,
or in other words, up to 5 cm past the edges of the de-rusted areas, which are to be
prepared using sandpaper before the paint is applied. The painter shall always ensure
that the touched-up areas have neat borders. If loose edges of residues of the old paint
are present, they must be completely removed and then repainted with an overlapping
coat.
- A paint coat that has been restored by touching up must no longer show the least sign of
corrosion. Before the intermediate and/or final coats are applied, the already painted
surfaces are to be cleaned if contamination is present, such as dust, sand, etc. This can
be done using compressed air, possibly by wiping clean with solvents, or by light
sanding. Old paint coatings must always be lightly sanded before being painted.
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2.7. USE OF HEAT-RESISTANT PAINT SYSTEMS ON STEEL

STRUCTURES
The procedure for use of heat-resistant paint systems on steel structures is the following:
1) Surface preparation
- Remove oil and grease using a suitable detergent
- Break sharp edges using mechanical tools.
- Blast to SA 2½ with a minimum surface roughness corresponding to Ry=80µm and a
Rz ≥50µm.

2) Applying the paint system

Apply a suitable paint system according to the temperature (See System Paint No. 3 of
Table 1).

NOTE:
- The zinc silicate coat must always be fully cured before the painted item is overcoated or
transported. Curing must be verified using the MEK test, which involves rubbing the painted
surface with a saturated wad (40). The paint must not dissolve.
- The mixing ratio specified by the paint supplier must always be observed.
- The specified film thickness must always be maintained, since excessive thickness creates a
risk of cracking (breaking of the paint film). None of the measured values may be greater
than the value stated in the requirements specification plus 20% (e.g., for 75 microns the
largest allowable value is 90 microns).
- Surface preparation is very important with regard to both cleanliness and roughness.
- The atmospheric humidity must be at least 75% when zinc silicate is applied, since this
coating cures by reacting with moisture. Elevated humidity accelerates curing. It may be
necessary to spray the painted surface with water to obtain full curing.
- The zinc dust must be added to the liquid portion, rather than the other way around.
- Continuous mechanical stirring is necessary.
- Poorly accessible locations, corners and welds must always be pre-painted (25 micron DFT).
This thickness must be taken into account when overspraying.
- It is very important for trapped gasses, air bubbles and solvents to be able to escape from
the paint film, since otherwise blistering of the paint film will occur.
- The silicone top coat must be held at a temperature of 200 °C for five days to achieve full
curing.

3. FILLING JOINTS AND GAPS

Special attention is to be given to joints, gaps and strapping. Following thorough de-rusting and
inspection to verify that they are completely dry, they are to be coated with the primer coats
using brushes specially designed for this purpose as necessary. Narrow joints and gaps where
the paint cannot be properly applied shall be filled using a filling compound, sealing caulk or
adhesive putty that is compatible with the paint system, and whose composition must always be
reported to the principal.
The filling must be uninterrupted and regular, and the filling compound or putty shall have a
smooth surface such that no seepage of water is possible. The filling compound or putty applied
to the corners of the strapping joints shall be ground to a bevel. After filling has been completed,
the paint system can be further applied.
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4. INTERNAL PROTECTION OF GEAR-BOX

For long-term storage, gear-boxes must be filled with preservation oil (anti-corrosion and anti-
oxidation properties). Ensure to close hermetically all openings of the gearbox and replace the
draining with a screw cap.
After ± 200 hours of service, drain the gear-box and then refill with recommended oil.

5. INSPECTIONS
The following inspections shall be carried out by the supplier prior to CMI inspections.

5.1. Surface
Prior to the application of primer coating, the surface shall be checked and prepared in
accordance with §2.1.
Prior to the application of top coating, the surface shall be checked in accordance with the
requirements and procedure defined in §2.3 and Top Coating specification related to the
specific project.

5.2. Painting adhesion

The resistance of coating systems to adhesive and cohesive failures is assessed using either
the cross-cut test or the X-cut test, whereby it is assessed qualitatively using a scale from 0 to
5, minimum to maximum damage, for each method (see ISO 2409 and Annex A).
The cross-cut test is suitable for film thicknesses up to 250 μm. The X-cut test is not
limited by thickness.
As cross-cut and X-cut tests are destructive test methods, repair work will be necessary
when they are used on coated structures.
NOTE:
To avoid damage to the coated structure, test panels can be used (see §5.2.1 and §5.2.2).

5.2.1. Cross-Cut Test

The painting adhesion shall be checked in accordance with ISO 2409.
The cross-cut test is a simple and easily practicable method for evaluating the adhesion of
single- or multi-coat systems.
The test shall be carried out on finished products (or, if required, on specially prepared test
specimens according to ISO 2409, §4 and §5) .
NOTE:
The method is not suitable for coatings of total thickness greater than 250 μm or for
textured coatings.
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5.2.1.1. Apparatus

5.2.1.1.1. Cutting tools

It is particularly important to ensure that the cutting tool has a defined shape and
that the cutting edges are in good condition.
Suitable tools are shown in Figures 6 and 7. The tools are suitable for manual use
(see Figure 5).

Figure 5 - Cross-Cut Testers

5.2.1.1.1.1. Single-blade cutting tool

Single-blade cutting tool is the preferred tool in all cases, i.e. with all kinds of
coating on hard substrates. In order to space the cuts correctly, a series of
guiding and spacing edges is necessary when using a single blade cutting tool
(see ISO 2409, §3.3 for more details).

Figure 6 - Single-blade cutting tool

A single-blade cutting tool shall have a 20° to 30° edge and a blade thickness of
0,43mm (+/- 0,03mm) as shown in Figure 6.
When the cutting edge has worn to 0,1 mm it shall be reground.
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5.2.1.1.1.2. Multi-blade cutting tool

The multi-blade cutting tool is not suitable for thick (> 120 μm) or hard coatings.
A multi-blade cutting tool shall have six cutting edges spaced 1 mm, 2 mm or 3
mm apart (see Figure 7).
The width across the six cutting edges, a, shall be 5 mm for a tool which has a
cutting-edge spacing of 1 mm, and 10 mm for a tool which has a cutting-edge
spacing of 2 mm.
When the cutting edge has worn to 0,1 mm it shall be reground.
The guide edges and the cutting edges shall lie on the same diameter.

Figure 7 - Multi-blade cutting tool

5.2.1.1.2. Pressure-sensitive adhesive tape

Unless otherwise agreed, adhesive tape with an adhesive strength between 6 N per
25 mm width and 10 N per 25 mm width (determined in accordance with
IEC 60454-2) shall be used. The tape shall be at least 50 mm wide.
NOTE: Transparent tape is recommended.

Figure 8 - Pressure-sensitive adhesive tape

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5.2.1.1.3. Viewing lens

Use a hand-held lens with a magnification of x2 or x3 (ISO 2409).

Complete kits are also available (see Figure 9)

Figure 9 – Complete kits

5.2.1.2. Procedure
Follow ISO 2409, §6 and §7 instructions, taking into account field test and hard substrates
(metals) conditions.

5.2.1.3. Evaluation and expression of results

Evaluate the results immediately following removal of adhesive tape.
Carefully examine the cut area of the test coating in good lighting using normal or corrected
vision or, if agreed between the interested parties, using a viewing lens (§5.2.1.1.3). During
the viewing process, rotate the panel so that the viewing and lighting of the test area are not
confined to one direction. It can be useful to examine the tape in a similar manner.
Classify the test area in accordance with Table 2, by comparison with the illustrations.
In Table 2, a six-step classification is given: the first two steps are satisfactory and are
used for a pass/fail assessment.
For a multi-coat system, report the interface at which any flaking occurs and the site of
separation (between coats or between coating and substrate).
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Classification Description Appearance of surface of cross-cut Acceptance

area from which flaking has occurred criteria
(Example for six parallel cuts)

The edges of the cuts are

completely smooth; none of
the squares of the lattice is
0 detached. OK

Detachment of small flakes of

the coating at the intersections
of the cuts. A cross-cut area
not greater than 5 % is
1 OK
affected.

The coating has flaked along

the edges and/or at the
intersections of the cuts. A
2 cross-cut area greater than 5 NOK
%, but not greater than 15 %,
is affected.

The coating has flaked along

the edges of the cuts partly or
wholly in large ribbons, and/or
it has flaked partly or wholly on
3 different parts of the squares. NOK
A cross-cut area greater than
15 %, but not greater than 35
%, is affected.
The coating has flaked along
the edges of the cuts in large
ribbons and/or some squares
4 have detached partly or NOK
wholly. A cross-cut area
greater than 35 %, but not
greater than 65 %, is affected.
Any degree of flaking that
cannot even be classified by
5 classification 4. NOK

Table 2 — Classification of test results

5.2.2. X-Cut Test

The X-cut method requires that an X-cut (two cuts are made at an angle to form an X) be
made through the coating using a sharp blade. Adhesive tape is applied with a firm force to
remove coating that is poorly attached. The result of the test is expressed as a rating
according to the damage observed. For the rating scale, see Figure 10.

5.2.2.1. Apparatus
Single-blade cutter and transparent pressure-sensitive adhesive tape shall be in
accordance with ISO 2409.
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5.2.2.2. Procedure
Follow ISO 16276-2, §6 instructions, taking into account the X-Cut test.

5.2.2.3. Evaluation and expression of results

Determine the rating by inspection, using the information given in Figure 10.

Figure 10 - Classification of results of X-cut test

In reference to the ISO 16276-2, §6.6.4 (Minimum number of measurements), for the
acceptance of an inspection area, the appropriate criterion of the following two shall be
fulfilled:
1. For less than five tests, each test rating shall be equal to or better than the rating
required by the specification.
2. For five or more tests, 80 % of the test ratings shall be equal to or better than the
rating required by the specification. For each of the remaining 20 %, only test
ratings equal to the specified rating plus one rating level are acceptable.
For each 1000 mm2 or part thereof, only one test which has given a failure result shall be
re-done, and it shall be re-done only once.
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5.3. Painting thickness

The supplier shall inspect:

a) primer coating thickness

b) If required, total intermediate coating thickness (primer + intermediate)
c) total coating thickness (primer + intermediate+ topcoat)

The required thicknesses shall be defined in:

d) Table 1 in accordance with the selected Paint System, or
e) topcoat technical specification related to the project, or
f) drawing(s) related to the specific project.

The coatings thicknesses shall be checked in accordance with the requirements and procedure
defined in §2.4.
The measurement of the thicknesses shall be performed by means of Mikrotest device (or
equivalent) in accordance with ISO2808 Method 2 specification.

Figure 11 – Mikrotest device

5.4. RAL
The colour of the top coating shall be compliant with the RAL requested by the customer (see
technical specification enclosed in the purchase order).

NOTE:
The RAL of the primer coating may influence the final colour of the paint system.
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6. SUPPLIER’S RESPONSIBILITIES
The supplier shall comply with the requirements of this specification.
The supplier shall at all times monitor and measure the following parameters and record them in
the daily log:
 relative humidity (before starting work and when the work is started);
 dew point (as above);
 metal temperature (as above);
 the film thicknesses of the applied coatings (wet and dry film thickness)
Note that it is essential to have good meteorological conditions, and in all cases comply with the
Technical Data Sheet of the paint manufacturer (humidity, dew point, metal temperature, layer
thickness), before starting the work, and these conditions must be recorded in the daily log,
along with the time when they were measured, before the work is actually started.
The technical specifications and material safety data sheets for the products being used by the
supplier must be available and must remain on the work site as long as the work is in progress.
Prior to CMI inspections, the supplier must carry out his own internal inspection and deliver the
corresponding reports to CMI.

7. PERFORMANCE TERMS AND CONDITIONS

7.1. Paint
The supplier for the painting work shall purchase and store the necessary quantities of paint
(stored in a dry, frost-free, cool and well ventilated location).
When delivering the paint to the site, the supplier shall first have the delivered paints inspected
by CMI supervisor with regard to quantity and proper condition of the packages and labels.
Containers must not be opened before actual use. All containers must be sealed when they are
delivered to the site.
Paint containers must be clearly marked by the supplier, and the markings must remain legible
until after the containers have been used.
When they are delivered, these packages must be labelled in conformance with the applicable
statutory provisions. The individual components of multi-component paints are to be stored
separately.

7.2. Personnel
On confirmation of the order, the supplier shall submit for approval the names of the site
supervisor and painters he intends to employ to perform the work.
CMI reserves the right to question the supplier’s site supervisor with regard to the requirements
imposed on performing the assigned work.
If this does not yield a satisfactory result, the supplier shall be notified that he is in default in this
regard, and consideration may be given to the option of suspending the work.

7.3. Walkway gratings and structural elements

All structural elements that must be removed or loosened before painting shall always be
replaced and securely fastened by the supplier at the end of each day’s work and on completion
of the work.
Loose parts shall be clearly marked in a highly visible manner in order to prevent accidents.