JOTUN

COURSE

Jotun.ico
Jotun

In Protective
Coating
Lecturer
Eng. Hamed Mespah

1/45
By Eng- Hazem Wassel
 JOTUN COURSE

Protection Coating Theory & Practice

Contents

1) corrosion & cathodic Protection ------------------- (4)

2) Surface Preparation ------------------ (13)
3) Paint Technology ------------------ (21)
4) Painting data Sheet & Calculation------------------ (26)
5) Generic type of Paint ----------------- (30)
6) Inspection and control ----------------- (35)
7) Introduction to paint failure analysis -------------- (41)

2/45
By Eng- Hazem Wassel
Corrosion
&
Cathodec
Protection

3/45
By Eng- Hazem Wassel
 Corrosion
Mechanism of uniform corrosion Steel ٍUnstable State

1) Anodc Reaction = Fe26 ‫ﺗﺄﻳﻦ‬ Fe++ + 2(e) Energy Energy loss

2) Cathodic Reaction = H2O + O2 + ( 2e ) OH-

3) Corrosion Cell Reaction = Fe++ + OH- Fe (OH) 2

Rust

4) Fe(OH)2+H2O Fe2 O3 H2 Fe2 O3 + Fe3 O4mH2O.Fe3O4

Magnotite 65% Hematite 35%

Corrosion

Pitting Catotrophic failure Corrosion Prodcute

1- rust (steel )
2- white zinc rust
(galvanized)
3- verdgress (copper)
4- Patina (alominum

Corrosion is an electrochemical Reaction Which Detnio rate ( degreed ) materials

Condition for corrosion cell
1) Anode 2) cathode 3) Oxygen 4) electrolyte

Note strong electrolyte 1- sea water 2 – soil

Relation between Anode and Cathode

1- one metal and one non metal
2- two metals
3- one metal in two different condition

Example
Which of this metals will be rust first in two conditions 1st at sea water 2nd at air and
arrangement for this metals and gire the reason for the different arrangement (AL,
copper , steel, zinc , )
Sol
At Sea water Aluminum – Zinc – Steel – copper
At Air Steel – copper - Aluminum – Zinc

4/45
By Eng- Hazem Wassel
 The condition
Weakness of air as a electrolyte makes the porosity takes the frats property

Energy Metal/alloy Potential corrosion

Lest Energy Gold +.500 Least Corrosion

Reguired For Silver -0.205
Filling Titanume -0.225
Stanles steel -0.235
NI-AL-Bronze -0.380 Nability Resiston
Potentialty Copper -0.435 Corrosion
Carbon Steel -0.600
Aluminum -0.800
High Energy Zinc (Anode Alloy) -1.080
Reguired For Aluminum (Anode Alloy) -1.04 Very Corrosion
refilling Magnesum (Anode Alloy) -1.550

A B
Anode Cathod
Need Oxygen (O2) P(A) > P(B)
Electrolyte

Potentialty
Is a measure of material ability to shaein chemical Reaction
Nability
Is a measureof energy Consumed in extracting from its ore
Galvanize Series
Is a measure ranking according to corrosion resistance potentialty –Nability

Factors affecting corrosion rate

1- Potential defference between anode & cathode
2- Prorortional dimensions between anode & cathode welding
3- Electrolyte condution
4- Oxygen content (corrosion of blasted surface under sea water
5- Environment

5/45
By Eng- Hazem Wassel
 A) Salinty Corrosion

Salinty mg/litre

B) Acidity Corrosion

After PH=10 NO Corrosion PH

7 10

C) Temperatures Corrosion

B A

a) supstrate
b) Inviromement ( Sea Water)

Temp

D) Humidity Corrosion

``

20 40 60
Humidity %

Note Corrosion Allownce used to choose the thickness of steel at design according to
Humidity

6/45
By Eng- Hazem Wassel
How to measure the corrosion potential of a structure ?

Steel Stricter
voltmeter
+ -

Sea Water

Reference
Electrode

Stander Reference Electrode

• Standard hydrogen electrode
• Cal mel
• CU/CU So4 "Copper –copper –sulphate "
• Ag /Ag CL " silver – silver – chloride "

Gold Nobility Corrosion

Silver Resistance
Titanume
Stanles steel
NI-AL-Bronze
Copper
Carbon Steel
Aluminum
Zinc (Anode Alloy)
Aluminum (Anode Alloy)
Magnesum (Anode Alloy) Potentiality

1) Anodic reaction
2) Cathodic reaction
3) Corrosion cell reaction
4) Rust formulation

Fe2O3 .N H2O .Fe2O3 = Hematite 65%

Fe3O4 .N H2O .Fe3O4 = Magnetite 35% =Rust

7/45
By Eng- Hazem Wassel
 Corrosion Protection by paints principles

‫( ﺑﻜﺴﺮ اﻟﺘﻔﺎﻋﻞ ﻓﻲ اﻟﺨﻄﻮة اﻷوﻟﻰ وذﻟﻚ ﻋﻦ ﻃﺮﻳﻖ ﺗﻮﺻﻴﻞ اﻟﺤﺪﻳﺪ ﺑﻤﻌﺪن ﻳﻌﻮض اﻟﺤﺪﻳﺪ ﺑﺎﻷﻟﻜﺘﺮوﻧﺎت اﻟﺘﻲ ﻳﻔﻘﺪهﺎ أي‬1
Cathodic Protection ‫ﻳﻜﻮن اﻟﺤﺪﻳﺪ آﺎﺛﻮد وﻳﻜﻮن اﻟﻤﻌﺪن أﻧﻮد وهﻮ ﻳﺴﻤﻰ ﺑﺎﻟﺤﻤﺎﻳﺔ اﻟﻜﺎﺛﻮدﻳﺔ‬
1) the cathodic effect
a) sacrificial anodes ‫اﻟﻘﻄﺐ اﻟﻤﻀﺤﻲ‬
b) Impressed current ‫اﻟﺘﻴﺎر اﻟﻤﻀﻐﻮط‬
c) Intimate contact ‫اﻷﺗﺼﺎل اﻟﻤﺒﺎﺷﺮ‬
Must by pure zinc pure metallic

Steel in seawater Potentials in Volt

Ag/Ag CL Cu/Cu SO4

Rapid Corrosion
-0.55 -0.60
General Corrosion
-0.80 -0.85
100% Cathodic Protection
-1.05 -1.10
Increasing Polarisation
-1.10 -1.15
Overprotection possible coating damage
-1.30 -1.35

Potential versus zinc & Ag/Ag cL Reference electrodes

‫( ﺑﻜﺴﺮ اﻟﺘﻔﺎﻋﻞ ﻓﻲ اﻟﺨﻄﻮة اﻟﺜﺎﻧﻴﺔ ﺑﻌﻤﻞ ﺡﺎﺟﺰ ﺑﻴﻦ ﺑﺨﺎر اﻟﻤﺎء و اﻷآﺴﺠﻴﻦ اﻟﻤﻮﺟﻮد ﻓﻲ اﻟﻬﻮاء واﻟﺤﺪﻳﺪ‬2
2) Barrier effect
Buids a Barrier that prerents seawater or other corrosion agents from
coming in to contact with the substrate.
a) Painting minimum VS % 96
b) Coating VS % up to 96%
c) Wrapping
d) Lining Any reinforcing with paint by GFR , CFR
Note Solvent less No solvent with VOC
Solvent Free No solvent with out VOC
VOC Volatile Organic Compound

8/45
By Eng- Hazem Wassel
‫‪Note for Lining‬‬
‫‪• Epoxy polymide primer‬‬
‫‪• Amine adduct cured epoxy primer‬‬
‫‪• Non- Pegmented Solvent free epoxy‬‬
‫‪• Culking‬‬ ‫) ‪Leveling ( 450 or 300‬‬

‫‪ (3‬ﺑﻜﺴﺮ اﻟﺘﻔﺎﻋﻞ ﻓﻲ اﻟﺨﻄﻮة اﻟﺜﺎﻟﺜﻪ وهﻲ ﺗﻜﻮﻳﻦ ﻃﺒﻘﺔ ﺥﺎﻡﻠﺔ ﺑﻴﻦ اﻻﻧﻮد واﻟﻜﺎﺛﻮد وﻳﺤﺪث ذﻟﻚ ﺑﺘﻜﻮﻳﻦ‬
‫ﻃﺒﻘﺔ ‪ Sealed‬ﻡﻐﻠﻔﺔ ﻋﻠﻲ اﻟﺤﺪﻳﺪ وﻳﺤﺪث ذاﻟﻚ ﺑﺎﺱﺘﺨﺪام أﻡﻠﺢ اﻟﺰﻧﻚ ﻡﺜﻞ اﻟﺰﻧﻚ ﻓﻮﺱﻔﺎت أو اﻟﺰﻧﻚ‬
‫آﺮوﻡﺎت ‪.‬‬
‫اﻟﺰﻧﻚ آﺮوﻡﺎت ﻳﺘﻔﺎﻋﻞ ﻡﻊ ﺑﺨﺎر اﻟﻤﻞء وﻳﺘﻜﻮن ﺡﻤﺾ اﻟﻜﺮوﻡﺎت وﻳﺘﻔﺎﻋﻞ ﺑﺪورة ﻡﻊ اﻟﺤﺪﻳﺪ ﻓﻴﻜﻮن‬
‫ﻃﺒﻘﺔ ﻡﻐﻠﻔﺔ ﺗﻤﺎﻡَﺎ‬
‫ﺱﻤﻚ ﻃﺒﻔﺔ اﻟﺰﻧﻚ ﻓﻮﺱﻔﺎت أو اﻟﻤﻜﺮوﻡﺎت ﺡﻮﻟﻰ ‪ 2‬إﻟﻰ ‪ 4‬ﻡﻴﻜﺮون‬

‫‪3) Inhibiting / aestivating effect‬‬

‫‪Example: Paints Incorporating Rust Preventing pigments‬‬
‫)‪(Red lead, chromates, and phosphates‬‬

‫‪9/45‬‬
‫‪By Eng- Hazem Wassel‬‬
Corrosion Types :
Corrosion

Corrosion Pitting Catastrophic

Products Failure

Rust & Patina

&verdigris

1) Uniform Corrosion
2) Galvanic "Bimetallic Corrosion "
3) Pitting Corrosion
4) Crevice Corrosion
5) Erosion Corrosion
6) Dealloying " Selective Leaching " Corrosion.
7) Microbial Corrosion
8) Stress Corrosion
9) Corrosion Fatigue.
1) Uniform Corrosion
• Uniformally Attack the surface
• Corrosion rate linear with time
• Approximately equal rust thickness
‫اﻟﻤﺴﺎﻡﻴﺔ ﻓﻲ اﻟﻤﻌﺎدن ﺗﺰﻳﺪ ﻡﻦ ﻡﻌﺪل اﻟﺘﺎآﻞ‬
2) Galvanic "Bimetallic Corrosion "

‫ﻳﺤﺪث ﻧﺘﻴﺠﺔ وﺟﻮد ﻡﻌﺪﻧﻴﻦ ﻡﺨﺘﻠﻔﻴﻦ أﺡﺪهﻤﺎ ﻳﻌﻤﻞ آﺎﺛﻮد واﻷﺥﺮ اﻧﻮد ﻓﻴﺤﺪث ﺗﺼﺎﻋﺪ ﻓﻲ ﻡﻌﺪل ﺗﺎآﻞ‬
‫ ﺑﻌﺰل‬Galvanic Corrosion ‫اﻻﻧﻮد وﻳﺤﺪث ﺗﻨﺎﻗﺺ ﻓﻲ ﻡﻌﺪل ﺗﺎآﻞ اﻟﻜﺎﺛﻮد وﻳﺘﻢ اﻟﺤﻤﺎﻳﺔ ﻡﻦ‬
.‫اﻟﻤﻌﺪﻧﻴﻦ آﻬﺮﻳﺒَﺎ وﺑﺬﻟﻚ ﻳﺘﻢ ﻋﺰل اﻻﻧﻮد ﻋﻦ اﻟﻜﺎﺛﻮد‬
3) Pitting Corrosion
• Locallized
• Mainly attack Non –Ferrous Metals
• Stainless steel 18/10
Note 18 = Nickel & 10= Carom
Nickel for Give Mechanical properties S.S
Carom for anti corrosive properties
The Passive Layer Not Continuous
From discontinuity Depth
‫ ﺗﻤﺎﻡَﺎ‬Sealed ‫ﻃﺒﻘﺔ أآﺎﺱﻴﺪ اﻟﺪرﻓﻠﺔ ﺗﺤﻤﻲ اﻟﺤﺪﻳﺪ وﺗﻜﻮن ﻃﺒﻘﺔ‬

Passive Layer
Chromium
Oxide
S.S

10/45
By Eng- Hazem Wassel
 4) Crevice Corrosion
Characterized By (O2) In Sufficiency
‫ﻡﺜﻞ وﺟﻮد ﺥﻂ ﻡﻮاﺱﻴﺮ ﻧﺼﻔﺔ ﻓﻲ اﻟﺘﺮﺑﺔ واﻟﻨﺼﻒ اﻷﺥﺮ ﻓﻲ اﻟﺨﺎرج وﻳﺸﺮط أن ﻳﻜﻮن ﻓﻲ ﻡﻨﻄﻘﺔ‬
.‫ﺱﺎﺡﻠﻴﺔ و اﻟﺘﺮﻳﺔ ﺗﻜﻮن ذات ﻧﻔﺎذﻳﺔ ﻋﺎﻟﻴﺔ ﺱﻮف ﻳﺤﺪث ﺗﺄآﻞ ﻓﻲ اﻟﺠﺰء اﻟﺬي ﻓﻴﺔ ﺗﻼﻡﺲ ﻡﻊ اﻟﺘﺮﻳﺔ‬
5) Erosion Corrosion
Re > 2000 Linear Flow
Combined Action Between erosion Resulting From Steel stress on
internal duct walls and corrosion resulting form swerly turbulence flow

Elbow Tee
The most Soft metal is Copper Erosion
6) Deploying Corrosion
.Brittle ‫ﻳﺤﺪث ﻓﻲ اﻻﺟﺰاء اﻟﻨﺸﻄﻪ ﻡﻦ اﻟﺴﺒﺎﺋﻚ ﻓﻲ اﻟﺒﺪاﻳﺔ ﻓﺒﻌﺪ ﺗﺎآﻠﻬﺎ ﺗﺘﺮك ﻓﺠﻮات ﻡﻤﺎ ﻳﺠﻌﻞ اﻟﺴﺒﻴﻜﺔ هﺸﺔ‬
Cast Iron = Carbon + Iron
Iron will be corrode at first and leave pores matrix

7) Microbial Corrosion

SRB = Sulpher Reducing Bacteria

MEB = Metal Eating Bacteria
8) Stress Corrosion Cracking

SCC = Tensile Stress + Corrosion in a specified environment

S E = Specified environment
Carbon steel NO3 Nitrate
Cooper NH3 Ammonia
Stainless Steel CL Colour

9) Corrosion Fatigue
Load
‫• هﻮ اﻟﻜﻠﻞ أي وﺟﻮد ﺡﻤﻞ ﻡﻊ ﺗﻐﻴﺮ اﻟﺰﻡﻦ‬
‫ أي ﻳﻜﻮن‬Fatigue Limit ‫• داﺋﻤَﺎ ﻳﻜﻮن اﻟﺘﺼﻤﻴﻢ ﻋﻨﺪ‬
‫ أي ﺛﺒﺎت ﺥﻂ اﻟﻜﻠﻞ‬Saturation ‫اﻟﺤﻤﻞ ﻓﻲ ﻡﺮﺡﻠﺔ‬
Fatigue Line
Fatigue
Limit
No Cycle
Time
11/45
By Eng- Hazem Wassel
 Surface
Preparation

12/45
By Eng- Hazem Wassel
 Surface Preparation
Surface Preparation to remove Mill scale & Foragen Material & Make
Roughness
Roughness
In the British standard 40 < R <75 Micron
In the NACE 40 < R <90 Micron
In the old NACE 1/6 D.F.T < R <1/3 D.F.T R< 120

Note
• High Build > 1000 micron
• Ultra high build < 1000 micron (the coat must be Reinforcement)

Why Roughness not increase 120 micron?

‫ﻻن اﻟﻄﺒﻘﺔ اﻟﻌﻠﻮﻳﺔ ﻓﻲ اﻟﺪهﺎن ﺱﻮف ﺗﺠﻒ ﻗﺒﻞ ﺟﻔﺎف ﺑﺪن اﻟﺪهﺎن أي اﻷﺥﺘﻠﻒ ﻓﻲ وﻗﺖ اﻟﺠﻔﺎف ﻓﻌﻠﻴﺔ‬
‫أن اﻟﻄﺒﻘﻪ اﻟﻌﻠﻮﻳﺔ ﺱﻮف ﺗﻘﻮم ﺑﺸﺪ اﻟﻄﺒﻘﻪ اﻟﺴﻔﻠﻴﺔ ﻗﺒﻞ اﻟﺠﻔﺎف وﺑﺎﻟﺘﺎﻟﻲ ﺱﻮف ﻻ ﻳﺤﺪث ﺗﻤﺎﺱﻚ ﻡﻊ‬
.‫اﻟﺤﺪﻳﺪ‬

Rust grades
Rust grades A Full mail scale completely corer surface with little if any rust
Rust grades B mail scale and rust
Rust grades C No mail scale completely corer slite superficial and little of
Pitting
Rust grades D General Pitting

Mechanical Pretreatment

Grinding Smoothing Refilling

Weld slag Sharp edges Under cut
Weld deposite Not ches Pitting >2 mm
Weld spatter Holes
Lamination Beam tips
Flame cute edges
Weld beads
Manual weld beads
Procity caused pinholes

Note
Sharp Edges: sharp tension make paints away of sharp edges

13/45
By Eng- Hazem Wassel
 Degreasing
Oils

Vegetable oil Crude oil Syntactical oil

To remove use To remove use To remove use
specification Emulsification Emulsification
Emulsifiers (mek) Emulsifiers (mek)

How to detected oil ?

1) water break test
2) fettrot test DIN 53928

Methods Of Surface Preparation

1) Blast Cleaning
2) Tool Cleaning
3) Chemical Cleaning
4) Fire Cleaning
5) Water jetting

(1) Blast Cleaning

Operation
1) open system
2) closed system

Water Oil Dry & Clean Air Pressured Air+ Abrasive

Compressor Pot Nozzle
trap trap

Abrasive
Monometer
Nozzles

The pressure 7 bar before nozzle 450

Stream

The nozzle types Voutlet

1) Straight Bore

2) Convergent – Divergent

Pressure
Pressure 7 bar

14/45
By Eng- Hazem Wassel
 Abrasives

Mineral abrasives Metallic abrasives Organic abrasives

Sand Shot chilled Iron Wall net shell
Garnet Grit chilled Iron Packing soda
Aluminum Silicate Mix Grit & Shot Water
Capper Slag Cylindrical Cat

Recycle 3 Recycle 20

‫ ﺗﺒﻌَﺎ ﻟﻨﻮﻋﻴﺔ اﻟﻤﻌﺪ اﻟﻤﺮاد ﺗﻨﻈﻴﻔﺔ ﻡﻦ إﺗﺠﺎة اﻟﻤﺮوﻧﺔ‬Abrasive ‫ﻳﺘﻢ ﺗﺤﺪﻳﺪ ﻧﻮﻋﻴﺔ اﻟـ‬
Mineral abrasives specifications ISO 11126
Mineral abrasives Test ISO 11127

Metallic abrasives specifications ISO 11124

Metallic abrasives Test ISO 11125

Standard of Blast Cleanliness Grades

IN ISO 8501-1
Sa 1 The Surface is free from oil, Greece, dirt and poorly adhered
Sa 2 The Surface is free from oil, Greece and most Rust, mille scale – Forager Material

Sa 2 ½ The Surface is free from oil, Greece and Free Rust, mille scale – Forager Material
and Substrate is a nearly white
Sa 3 The Surface is free from oil, Greece and Free Rust, mille scale – Forager Material
and Substrate is a white

IN British Standard

Sa 1 Light Blast Cleaning

Sa 2 Thorough Blast Cleaning
Sa 2 ½ Very Thorough Blast Cleaning
Sa 3 Blast Cleaning to white metal

IN SSPC

Sa 1 SSPC-SP7
Sa 2 SSPC-SP6
Sa 2 ½ SSPC-SP10
Sa 3 SSPC-SP5

15/45
By Eng- Hazem Wassel
IN NACE

Sa 1 NACE 4
Sa 2 NACE 3
Sa 2 ½ NACE 2
Sa 3 NACE 1

IN General
Sa 1 Brush of blasting
Sa 2 Commercial Blasting
Sa 2 ½ Near White Metal
Sa 3 White Metal
Note
Sa 2 ½ Max blasting 8 hour
Max waiting before painting 4 hour

Sa 3 Max blasting 4 hour

Max waiting before painting 0 hour
Structure of IOS 8501

A Sa 1 A Sa 2 A Sa 2 ½ A Sa 3
B Sa 1 B Sa 2 B Sa 2 ½ B Sa 3
C Sa 1 C Sa 2 C Sa 2 ½ C Sa 3
D Sa 1 D Sa 2 D Sa 2 ½ D Sa 3

Note
• Pitting is anodic for flat cell in pitting change the colure of surface metal
so re cant reach for the degree for white metal
• For steel grad (A) the minimum degree for blasting is ASa 2 ½

Sand Analysis
Chemical analysis
1- % Free Silica 90 % max
2- % Loss burning at 550oc 1 % max
3- % of calcium oxides 0.05% max
4- % of Sulfates SO3 100ppm = 0.01% max
5- % Chlorides CL 300ppm = 0.03% max
6- % Total dissolvent salts 500ppm 0.05% max
7- PH Value (6-8)
8- % moisture content 0.5% max
9- Conductivity of solution 25sµ/simins max
10- % Clay content 0.02% max

16/45
By Eng- Hazem Wassel
 Volumetric seize Analyses

Percentage of total residue on each mesh

total residue TRn = ∑ni=1 Ri 100
TR 80
50
30

Mesh
TR 1

TR 2 Mechanical Vibrate

TR1- TR2 ≤ 84
Fine Medium Coarse

0.3m 1.5m Mesh Size

(2) Tool Cleaning

Tools

Manual tools Power Tools

Scraper Power brush
Chisel Needle Gun
Wire Brush Disksander
Emery Paper

Manual tools
1) Scraper for remove the lamination And spatter
2) Wire Brush good quality bat very poor productivity
3) Emery Paper

Power tools
1) Power brush Cleaning bat don't make roughness
2) Needle Gun Cleaning bat make roughnepeaks
3) Disksander
Note
Spot blasting use in riper or small area bay vacuum blasting machine bat
avoid over blasting

17/45
By Eng- Hazem Wassel
 Standard of Tool Cleanliness Grades in ISO 8501-1
St 2 make by manual tool
Analogy Sa 2
St 3 make by Power tool

B St 2 B St 3
C St2 C St 3
D St 2 D St 3
Note
the colure of material is Black if make white colure this Grad SSPC- SP11
SSPC- SP11 power tool cleaning to bare metal

The difference between the sand sweep and sand blast

sand sweep sand blast

Not stander stander
Soft abrasive < 6 moh Soft abrasive > 6 moh
Pressure < 4 bar Pressure =7 bar
Distance between the nozzle and Distance Angle 30o to 60o
Steel between 1m to 1.25m
Angle equal 30o to 45o Angle near 90o
Abrasive is fine Abrasive is Medium or coarse
Fast and random Intensive and low speed

(3) Fire Cleaning

What can the fire cleaning?

• Rust Fe2 O3 H2 Fe2 O3 + Fe3 O4mH2O.Fe3O4 makes dehydration to rust
• Mile scale Coefficient of thermal expansion
• Foreign material organic to can burning ( Ash )

‫ أذا‬300 -180 Co ‫ ﻡﺜﻞ اﻟﺴﻴﺎرات وﻳﺤﺘﺎج إﻟﻲ‬1 mm ‫ﺗﻜﻮن هﺬة اﻟﻄﺮﻳﻘﺔ ﻧﺎﺟﺤﺔ ﻓﻲ اﻟﺼﺎج أﻗﻞ ﻡﻦ‬
‫ وهﺬا ﻳﺆﺛﺮ ﻋﻠﻲ اﻟﺨﻮاص اﻟﻤﻴﻜﺎﻧﻴﻜﻴﺔ ﻟﻠﺤﺪﻳﺪ‬3000Co ‫زاد اﻟﺴﻤﻚ ﻋﻦ ذاﻟﻚ‬

Standard of Fire Cleanliness Grades in ISO 8501-1

A FL B FL
C FL D FL
Note
4 Rust Grades
14 Blasting
6 Tool Cleaning
4 Fire Cleaning

18/45
By Eng- Hazem Wassel
 (4) Chemical Cleaning

Stapes for chemical cleaning

1) Degreasing
2) Pickling by HCL 10% Or H2 SO 45% to remove the mile scale & rust
3) Neutralizing by soda ash 2%
4) Aestivation by Zinc phosphate or Zinc chromate

SSPC-SP8
Note
Very limited and Standardized

(5) Water Jetting (U H W J)

( U H W J) Ultra High Pressure Water Jet

17.000 < P < 60.000
Psi = 14.7 bar
H Center force

Back
Pressure

Rotating Lance
Q
Pump chart aoristic

Property's
1. Environmental Friendly
2. High Productivity
3. No salts in the surface
4. low cost
5. the pressure water of emulsification

Defects
1. can't make roughness
2. make bad surface appearance
3. used in maintenance project
4. high fixed cost

19/45
By Eng- Hazem Wassel
 Paint
Technology

20/45
By Eng- Hazem Wassel
 Paint Technology
What is the paint?
Paint is liquid can be converted to a solid film upon dry .
Paints

Liquid paints powder paints

Composition of liquid paint

1- Binder
2- Pigments
3- Solvent
4- Additives

(1) Binder
BINDER physically clear soled
The function
1) film formation
2) adhesive & cohesive
3) the major role in mechanical & physical properties

1- Classification of binders according to resources

Resources

Natural Binders Synthetic Binders

Alkyd
Plant Non Drying oils Animal Epoxy
• Drying oil Simi Drying oils Shellac Vinyl
(linseed oil –castor oil Drying oils Acrylic
-Saiabeem oil –tang oil) Polyester
• Coal tar Polyurethane
• Rosin CR
• Dammar

Polymer is a collection of repeated units of chemical structure in a chain (polymer

ethane) related to each other By a force (Polymer Strength)

Polymerization is a physical process By which the molecules of the light gas are
gathered and repeated in a structure

21/45
By Eng- Hazem Wassel
 Classification of polymers:-

(1) According to Repeated units

Homo Polymer Co- Polymer Tar- Polymer

Repeated unit 2 Repeated unit 3 Repeated unit
(Epoxy) (Epoxy – Acrylic –Silicon) (Poly siay loxan)

(2) According to type of polymer chair

Linear Polymer Branched Polymer Cross linked Polymer

-Vinyl - Alkyd - any two component Paints
- Acrylic - Phenolic - Epoxy
- Tar - Drying oils - Polyurethane

(3) According to Heat Effect

Thermoplastic Thermosetting
- are Polymers fused up no heating - can't fused up no heating
All Linear Polymers - All Branched & Cross
(4) According to Solvent Resistance

Reversible Irreversible
- Are Polymers which can be - Are Polymers which can't be
Converted state Liquid State Dissolved Converted to liquid state
via strong solvent under effect any strong solvent
-All Linear Polymers - All Branched & Cross
(5) According to Drying Mechanism

Physical Drying Oxidation Chemical Curing

-In Linear Polymers - Branched Polymers - Cross linked Polymers
-by ventilation -by ventilation & percentage of O2 - by Temp
- Two component Paints
O2

Solvent Solvent A
B
Polymerization

22/45
By Eng- Hazem Wassel
 (6) According to Changing in chemical structure

Convertible Non Convertible

Changing in chemical structure - No Changing in chemical structure
Upon drying Upon drying

-What difference between the Physical Drying & Oxidation & Chemical Curing?

Physical Drying Oxidation Chemical Curing

Linear Branched Cross Linked
Thermoplastic Thermosetting Thermosetting
Reversible Irreversible Irreversible
Non Convertible convertible Convertible

(2) Pigments

PIGMENTS physically powder And give the paints colour & opacity

What the different between the dye stain and pigment?

Pigment is suspended in vehicle
Dye stain is dissolved in vehicle
Note
• Vehicle = Binder + solvent
• The different between the paints and ink in paints Pigment bat in ink dye stain

Types of Pigments
1. Colour Pigments
2. Cathodically Pigments
3. Rust inhibitive Pigments
4. Laminar Pigments
5. Biocides
6. Extender
(1) Colour Pigments
Example ( Titanium de oxide & Calcium & carbon Black
& Brouslan Blue & Hanza yellow )
(2) Cathodically Pigments
Example ( Zinc & micronized aluminum )

(3) Rust inhibitive Pigments

Example ( Zinc phosphate & Zinc chromate && Red oxide Red lead & coal tar )

23/45
By Eng- Hazem Wassel
 (4) Laminar Pigments
Example ( MIO Micaceous Iron Oxide & Aluminium flakes & Glass Flakes )

A) Enhance mechanical properties 2 to 7 µ

1- Compressive Strength 0.1 to 0.5

2- Abrasion resistance
3- Impact resistance 100 to 400 µ
4- Water resistance 28% min weigh in Paint
5- Chemical resistance
Before
T Daring

water
B) Reduce
1- Bending resistance After
T Daring
2- Flexibility

T Before Daring =
5000 T After Daring
(5) Biocides
Example (Cuo Coppcrus Oxide )

(6) Extender = Fillers

Example ( Barium sulphate & Calcium Carbonate & Bentonite & Silica Sand )

(1) Give capacity to paint

(2) Reinforce the paint film
(3) Control the gloss of the paint

( P.V.C ) Pigment Volume Concentration

PVC = Extender + Pigment / total Volume

PVC control 1- Permeability
2-Golss
3- Rust tendency
4- Blistering
Generic type
Pigment Binder
MIO Epoxy amide
Col tar Epoxy
Gloss Flake Vinyl ester
Zinc Ethyl silicate

24/45
By Eng- Hazem Wassel
 (3) Solvents
Solvents Inside Paint
Thinner Additive , Alcohol
Dileunt Like solvents

Type of Solvents
Strong Water Latex Paint
White Spirit Alkyd & Phenolic
Xylene CR
ACetone Epoxy
Solvent Strength Binder ‫ ﻋﻠﻰ أن ﻳﺤﻞ ﻥﻮع ﻣﻌﻴﻦ ﻣﻦ‬Solvent ‫• ﻳﻌﺒﺮ ﻋﻦ ﻗﺪرة‬

Note
For thinner change type of paint may be happen blastring or Bond Strength

(4) Additives
‫ﺗﻌﻤﻞ ﻋﻠﻰ رﻓﻊ ﺧﻮاص ﻣﺎدة اﻟﺪهﺎن ﺳﻮاء ﻗﺒﻞ اﻟﺪهﺎن أو ﺏﻌﺪة‬

(1) Anti Skinning ‫ﻟﻤﻨﻊ ﻇﻬﻮر اﻟﺘﺠﻠﺪ ﻋﻠﻰ ﺳﻄﺢ اﻟﺒﻮﻳﺎت وهﻲ ﻓﻲ اﻟﻌﺒﻮة‬
(2) Driens ‫ﻟﻌﻤﻠﻴﺔ اﻟﺠﻔﺎف‬
(3) Anti Settling agents ‫ﻣﺎﻥﻊ ﻟﻠﺘﺮﺳﻴﺐ‬
(4) thixotropic agents ‫ﺗﻌﻤﻞ ﻋﻠﻰ رﺏﻂ ﺝﺰﻳﺌﺎت اﻟﺪهﺎن ﻓﻲ اﻟﺴﻤﻚ اﻟﻌﺎﻟﻲ‬
(5) Leveling agents ‫ﻟﻤﻨﻊ اﻟﺴﻴﻼن‬
(6) Stabilizers Shelf Life ‫ﻳﻀﺎف ﻟﻠﺪهﺎن ﻟﺘﺤﺴﻴﻦ اﻟـ‬
(7) Plasticizers to Control mechanical Proparties Without it the Paint be brittle

(8) Antifoaming agents ‫ﻣﻨﻊ اﻟﺮﻏﻮة ﻋﻠﻰ ﺳﻄﺢ ﻟﺒﻮﻳﺎت ﻥﺘﻴﺠﺔ اﻟﺘﻘﻠﻴﺐ‬

25/48
By Eng- Hazem Wassel
 RelatIve HumIdIty Tables For WhIrlng Psychrometer
Dry Bulb Readings - Celsius
ºC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 ºC
0.5 RH% 91 92 92 92 93 93 93 94 94 94 94 94 95 95 95 95 95 95 95 96 96 96 96 96 96 96 96 96 96 96 96 97 97 97 97 97 97 97 97 97 97 97 98 98 98 98 98 98 98 99 RH% 0.5
DPºC 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 DPºC
RH% 83 84 84 85 86 86 87 87 88 88 88 89 89 90 90 90 90 91 91 91 91 92 92 92 92 92 92 93 93 93 93 93 93 93 93 94 94 94 91 94 94 94 94 94 94 94 94 94 94 94 RH%
1.0 1.0
DPºC -1 -1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 14 DPºC

RH% 75 76 77 78 79 79 80 81 82 82 83 83 84 84 85 85 86 86 86 87 87 87 88 88 88 88 89 89 89 89 90 90 90 90 90 90 91 91 88 91 91 91 92 92 92 92 92 92 92 92 RH%
1.5 1.5
DPºC -2 -1 0 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 DPºC

RH% 66 68 69 70 72 73 74 75 76 77 77 78 79 79 80 81 81 82 82 83 83 83 84 84 84 85 85 85 86 86 86 86 87 87 87 87 87 88 85 88 88 88 88 88 89 89 89 89 89 89 RH%
2.0 2.0
DPºC -3 -2 - 0 1 3 4 5 6 7 8 9 10 12 13 15 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 36 37 38 39 40 DPºC

2.5 RH% 58 60 62 63 65 66 67 69 70 71 72 73 74 74 75 76 77 77 78 78 79 79 80 80 81 81 82 82 82 83 83 83 83 84 84 84 85 85 85 85 85 86 86 87 87 87 87 87 87 87 RH% 2.5

DPºC -4 - - 0 1 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 20 21 22 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 DPºC
RH% 50 52 54 56 58 60 61 63 64 65 77 68 69 70 71 71 72 73 74 74 75 76 76 77 77 78 78 79 79 79 80 80 80 81 81 81 82 82 82 82 83 83 83 83 83 84 84 84 84 84 RH%
3.0 3.0
DPºC -5 - - - 0 1 3 4 5 6 7 8 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 DPºC

RH% 42 45 47 49 51 53 55 57 58 60 61 63 64 65 66 67 68 69 70 70 71 72 72 73 74 74 75 75 76 76 77 77 77 78 78 78 79 79 79 80 80 80 80 80 80 80 81 81 81 81 RH%
3.5 3.5
DPºC - - - - 1 2 3 4 5 6 7 9 10 11 12 13 14 16 17 18 19 20 21 22 23 24 25 26 28 28 29 31 32 33 34 35 36 37 38 DPºC

RH% 34 37 40 42 45 47 49 51 53 54 56 75 59 60 61 62 64 65 65 66 67 68 69 69 70 71 71 72 72 73 73 74 74 75 75 76 76 76 77 77 77 78 78 78 78 78 79 79 79 79 RH%
4.0 4.0
DPºC - - - - - 0 1 3 4 5 6 8 9 10 11 12 13 15 16 17 18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 34 35 36 37 DPºC

RH% 26 30 33 35 38 41 43 45 47 49 51 35 54 56 57 58 59 60 61 62 63 64 65 66 67 67 68 69 69 70 70 71 71 72 72 73 73 74 74 74 75 75 75 75 75 75 76 76 76 76 RH%
4.5 4.5
DPºC 1 3 4 5 6 8 9 10 11 13 14 15 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 36 37 DPºC

RH% 16 22 26 29 32 35 37 40 42 44 46 48 49 51 52 54 55 56 58 59 60 61 62 62 63 64 65 65 66 67 67 68 69 69 70 70 70 71 71 72 72 72 73 73 73 73 74 74 74 74 RH%

Depression OF Wet Bulb 0.5 To 20 C.

Depression OF Wet Bulb 0.5 To 20 C.

5.0 5.0
DPºC - 1 3 4 5 7 8 9 10 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 29 30 31 32 33 34 35 36 DPºC

RH% 15 17 20 23 24 29 31 34 36 39 41 43 45 46 48 50 51 52 54 55 56 57 58 59 60 61 62 62 63 64 64 65 66 66 67 67 68 68 69 69 70 70 69 70 70 70 71 71 71 71 RH%
5.5 5.5
DPºC - - 1 3 4 5 7 8 9 11 12 13 14 15 17 18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 34 35 DPºC

RH% 15 16 19 23 26 29 31 34 35 37 39 41 43 46 47 49 50 51 52 54 55 56 57 58 59 59 60 61 62 62 63 64 64 65 65 66 66 67 67 68 68 68 68 68 69 69 70 70 RH%
6.0 6.0
DPºC - - 0 1 3 4 6 7 8 10 11 12 13 15 16 17 18 19 20 22 23 24 25 26 27 28 29 30 31 33 34 35 DPºC

RH% 15 18 20 23 26 29 31 34 36 38 40 41 43 45 46 48 49 50 51 52 54 55 55 56 57 58 59 60 60 61 61 62 63 63 64 64 65 65 65 65 65 66 66 66 67 67 RH%
6.5 6.5
DPºC - - - 0 1 3 4 6 7 9 10 11 12 14 15 16 17 18 20 21 22 23 24 25 26 28 29 30 31 32 33 34 DPºC

RH% 10 12 14 18 21 24 26 29 31 33 36 37 39 41 43 44 46 47 48 49 50 51 52 53 55 56 57 57 58 58 59 60 60 61 61 62 62 63 63 63 64 64 65 65 66 66 RH%
7.0 7.0
DPºC 3 5 6 7 9 10 11 13 14 15 16 18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 DPºC

RH% 10 13 16 19 22 24 27 29 32 34 35 37 38 40 41 43 44 46 47 48 50 51 52 52 53 54 55 56 57 58 58 58 59 60 60 61 60 61 62 62 62 62 63 63 RH%
7.5 7.5
DPºC 2 3 5 6 8 9 10 12 13 14 16 17 18 19 23 22 23 24 25 26 27 28 29 31 32 33 DPºC

RH% 11 14 17 20 23 25 27 30 32 34 35 37 39 40 42 43 44 46 47 48 49 50 51 52 52 53 55 55 55 56 57 57 58 58 58 59 69 60 60 61 61 62 RH%
8.0 8.0
DPºC 0 2 3 5 6 8 9 11 12 13 15 16 17 18 20 21 22 23 24 25 27 28 29 30 31 32 DPºC

RH% 10 12 16 18 21 23 26 28 30 32 34 36 37 39 40 41 43 44 45 46 47 48 49 50 51 52 53 53 54 54 55 56 56 56 57 57 57 58 58 58 59 RH%
8.5 8.5
DPºC 15 16 17 19 20 21 22 23 25 26 27 28 29 30 31 DPºC

RH% 11 14 17 20 22 24 27 29 30 32 34 36 37 38 40 41 42 43 44 45 46 47 48 50 51 51 51 52 53 53 54 54 55 55 56 56 57 57 58 RH%
9.0 9.0
DPºC 14 15 17 18 19 20 21 23 24 25 26 27 28 30 31 DPºC

RH% 12 16 18 21 23 25 27 29 31 33 34 36 37 38 40 41 42 43 44 45 46 48 48 48 49 50 51 51 52 52 53 53 54 54 55 55 56 RH%
9.5 9.5
DPºC 13 14 16 17 18 19 21 22 23 24 25 27 28 29 30 DPºC

RH% 12 15 17 20 22 24 26 28 30 31 33 34 36 37 38 39 41 42 43 44 45 46 46 47 48 48 49 50 50 51 51 52 52 53 53 54 RH%
10.0 10.0
DPºC 12 13 15 16 17 19 20 21 22 23 25 26 27 28 29 DPºC

RH% 11 14 16 19 21 23 25 27 28 30 32 33 34 36 37 38 39 40 41 42 43 44 45 46 46 47 48 48 49 49 50 50 51 51 52 RH%
10.5 10.5
DPºC 11 12 14 13 16 18 19 20 21 23 24 25 26 27 29 DPºC

11.0 RH% 18 20 22 24 26 27 29 30 32 33 34 35 37 38 38 40 41 42 42 44 44 45 45 46 47 47 48 49 49 49 50 RH% 11.0

11.5 RH% 15 17 19 21 23 25 26 28 29 31 32 33 34 36 37 38 39 40 40 42 42 43 44 44 45 45 46 47 47 47 48 RH% 11.5
12.0 RH% 12 14 16 18 20 22 24 25 27 28 30 31 32 33 34 36 37 38 39 40 40 41 42 43 44 44 44 45 45 45 46 RH% 12.0
12.5 RH% 9 11 13 16 28 19 21 23 25 26 27 29 30 31 32 33 34 35 37 37 38 38 39 40 41 41 42 42 42 42 43 RH% 12.5

13.0 RH% 6 8 11 13 15 17 19 21 22 24 25 27 28 29 30 34 33 34 35 35 36 36 37 38 39 39 39 40 40 40 41 RH% 13.0

13.5 RH% 3 6 18 10 12 14 16 18 20 21 23 24 26 27 28 29 30 32 33 33 34 34 35 36 37 37 37 38 38 38 39 RH% 13.5
14.0 RH% 3 5 8 10 12 14 16 18 19 21 22 24 25 26 27 29 30 31 31 34 32 33 34 35 35 35 36 36 36 37 RH% 14.0
14.5 RH% 3 5 7 10 12 14 15 17 19 20 22 23 24 26 27 28 29 30 30 30 31 32 33 33 34 34 34 35 36 RH% 14.5

15.0 RH% 3 5 7 9 11 13 15 17 18 20 21 22 24 25 26 27 28 28 29 29 30 30 31 31 32 32 34 35 RH% 15.0

15.5 RH% 3 5 7 9 11 13 15 16 18 19 21 22 23 24 25 26 27 28 28 29 29 30 30 31 31 32 34 RH% 15.5
16.0 RH% 3 5 7 9 11 13 14 16 17 19 20 21 22 24 25 26 26 27 27 28 28 28 29 30 31 32 RH% 16.0
16.5 RH% 3 5 7 9 11 12 14 15 17 18 20 21 22 23 24 25 26 27 27 27 27 28 29 30 31 RH% 16.5

17.0 RH% 3 5 7 9 10 12 14 15 16 18 19 20 21 22 23 24 25 25 25 26 27 28 29 30 RH% 17.0

17.5 RH% 3 5 7 8 10 12 13 15 16 17 19 20 21 22 22 23 24 24 25 26 27 28 29 RH% 17.5
18.0 RH% 1 3 5 7 8 10 12 13 14 16 17 18 20 20 21 22 22 23 24 25 26 27 28 RH% 18.0
18.5 RH% 3 5 7 8 10 11 13 14 16 17 18 19 20 21 22 22 23 24 25 26 27 RH% 18.5

19.0 RH% 1 3 5 7 8 10 11 13 14 15 17 18 19 20 20 21 22 23 24 25 26 RH% 19.0

19.5 RH% 3 5 7 8 10 11 13 14 15 16 18 19 19 20 21 22 23 24 25 RH% 19.5
20 RH% 1 3 5 7 8 10 11 12 14 15 16 17 18 19 20 21 22 23 24 RH% 20

G. H. Zeal Ltd., 8 Deer Park Road, London SW19 3UU

instructions For Use.

Fill Cistern With Distilled Water And Ensure That Wick Is Clean Whirl Psychrometer
Rapidly For Aprrox 20 Saconds And Record Wet And Dry Bulb Temperatures
Immediately An Average of 3 readings should be taken to ensure Accuracy . The
Difference Between The Wet and dry bulbTemperatures gives Depression value. From
Chart Read Off Percentage Hwmidity.
N.B. If. at Temperatures Below Freezing. ice Forms on the wet bulb. extra Whirling Is
necessary to give a True Wet bulb Reading
Nots :
RH % & DPºC=Air Timp Dry - Air Timp Wit
RH ≤ 85 % OK
Stel Timp - DPºC ≥ 3 OK
 Painting
data Sheet
&
Calculation

25/45
By Eng- Hazem Wassel
Summary Of Formulas:
Dray Film Thickness = V.S% * Wet / 100
Wet Film Thickness = 100 * D.F.T / V.S%
Solid By Vol. (V.S % ) = 10 * D.F.T / W.F.T
Theoretical Rate ( m2/Ltr ) = V.S % * 10 / D.F.T
Theoretical (Cost/M2 ) = (Cost / Litr ) / ( m2 / Ltr )
Theoretical (Cost/M2 ) = ( D.F.T *(cost / ltr ) ) / (10 * V.S %)
Consumption ( Liters ) = ( D.F.T * Area ) / (10 * V.S % * Loss Factor)
Dead Volume = (Area * Dead Volume * 100 ) / ( V.S% * Loss Factor)
Loss Factor = (A.S.R / T.S.R ) * 100

Volume Solids (V.S) After Thinner :

Solid % 5% 7% 10% 15% 20% 25% 30% 35%

100% 95 93 91 87 83 80 77 74
95% 90 88 86 83 79 76 73 70
90% 85 83 82 78 75 72 69 67
85% 80 78 77 74 71 68 65 63
80% 75 73 73 70 67 64 62 59
75% 70 68 68 56 63 60 58 56
70% 65 63 64 61 59 56 54 52
65% 60 58 59 57 54 52 50 48
60% 55 53 55 52 50 48 46 44
55% 50 48 50 48 46 44 42 41
50% 45 43 46 44 42 40 39 37
45% 40 38 41 39 37 36 35 33
40% 35 33 36 35 33 32 31 30
35% 30 28 31 30 29 28 27 26
30% 25 23 27 26 25 24 23 22
25% 20 18 23 22 21 20 19 19

Loss in% and Dead Volume AS

sorrespondion Loss Factor : Function Of Surface Roughness:

Roughness Dead Volume

Loss In % Loss Factor
in Microns 1/m2

30 0.02 40 0.6

45 0.03 30 0.7

60 0.04 20 0.8

75 0.05 10 0.9

90 0.06
105 0.07

26/45
By Eng- Hazem Wassel
 Example:
(P P) Price lit for paint 40 LE
(D) Discount 30%
V.S 64%
Loss 45%
(P Th) Price lit for Thinner 15 LE
Mixing Ratio 10%
Total Aria 4000 m2
Tax 11%

I would like Total Price After Mixing Thinner & Tax and Total Qty Liters

• Price Before Discount = P .P – ((P*D)/100) * –1

= 40 – ((40*30)/100 *–1
= 28 LE

• Theoretical Spreading Rate for Paint = DFT / V.S % * 10

T S R P = 90 / 0.46 * 10
= 0.141 lit/ m2

• Actual Spreading Rate for Paint = T S R P / ( 1– ( loss / 100) )

A S R P = 0.141 / ( 1– ( 45 / 100) )
= 0.256 lit/ m2

• Price Par m2 For paint = P. P * A S R P

= 28 * 0.256
= 7.168 LE/ m2

• Actual Spreading Rate for Thinner = ( Mixing Ratio /100) * A S R P

A S R T = 0.10 * 0.256
= 0.0256 lit/ m2

• Price Par m2 For Thinner = ( P Th * A S R T) / 10

= ( 15 * 0.256 ) / 10
= 0.384 LE/ m2

• Total Price Before Tax LE/ m2 = (P Th + P.P) * ( 1+ Tax% )

= (0.384 + 7.168 ) * ( 1+ 0.11 )
= 8.38 LE/ m2
• Total Qty Pint Liters = A S R P * Aria
= 0.256 * 4000
= 1024 Lit

• Total Qty Thinner Liters = A S R P * Aria

= 0.0256 * 4000
= 102.4 Lit

27/45
By Eng- Hazem Wassel
Compression Ration

P1 Airless P2 P3
Compressor Nozzl
Spray

P3 = P2 / 1.15 - 1.2
Example:
P3= 150 bar Com. ration = 1 : 60

P3 = P2 / 1.2
P2 = 150 * 1.2 = 180
P1/P2 = 1 / 60
P1 * 60 = 1 / P2
P1 * 60 = 1 * 180
P1= 180 / 60 = 3 bar
P1= 3 bar

28/45
By Eng- Hazem Wassel
 Generic
Type of
Paint

29/45
By Eng- Hazem Wassel
 Generic Type of Paint
Selecting Criteria for Generic type In design criteria for coating
Design criteria for coating
1) Survey of environment
2) Assignment of corrosively grade ISO 12944
C1 Environment condition ( Heating Builds )
C2 Rural Environment ( Dray )
C3 Urban Environment
C4 Industrial Environment With low Pollution ( sulphur & Color aid )
C5 I Industrial Environment With Height Pollution ( sulphur & Color aid )
C5 M Marine Environment
3) Durability Expected life time up on the first major maintenance
Low --- 2 : 5 years
Medium --- 5 : 15 years
High --- > 5 years
4) Economic Considerations
5) Generic type Assignment

( Oxidation ) Alkyd
• Alkyd IS Made of Alcohol + Acid + Oil
• The chemical reaction need Polymerization
Alkyd Kinds depends on drying oil Percentage
• Short Alkyds < (40-45) % -----Fast dray Alkyd
• Medium Alkyds < (45-60) % -----Protective Coating
• Long Alkyds >60 % -----Decorative Coating
Alkyd Advantages
• Good Application Properties
• One Component
• Good weather Durability
• Good wetting Properties
• Good Recoat ability
• Good Levelling Resistance
• Good Heat Resistance 140 oC
Alkyd Limitation
• Very Bad Compatibility
• Bad Chemical Resistance
• Bad Mechanical Properties
• Very Bad Water Resistance
• Bad Mechanical Properties
• Bad Gloss Resistance
• Maximum DFT 40µ

30/45
By Eng- Hazem Wassel
 Physical Types

Physical Advantages
• Good weather Durability
• Good Recoat ability
• Good Chemical Resistance
• Good Mechanical Properties
• Very Good Water Resistance
• Very Good Adhesion

Physical Limitation
• Very Bad Compatibility
• Bad wetting Properties
• Bad Heat Resistance up to 70 oC

Chemical ( Epoxy )
Epoxy
Ioscynate Polyamine Polyamide Amine Aduct

Adhesion Excellent
Surface Tolerant Penetration Excellent

Elastic Excellent

Epoxy Advantages
• Good weather Durability
• Very Good Chemical Resistance
• Good Mechanical Properties
• Very Good Water Resistance
• Very Good Adhesion
• Very Good Compatibility
• Very Good Heat Resistance 120 oC

Epoxy Limitation
• Very Bad wetting Properties
• Very Bad Recoat ability
• Bad Levelling Resistance
• Very Bad Chalking Resistance
• Bad Gloss Resistance

31/45
By Eng- Hazem Wassel
 Chemical ( Polyurethane )
Polyurethane
Aliphatic Aromatic
Primer High Build
Polyurethane Advantages
• Good weather Durability
• Good Chemical Resistance
• Good Mechanical Properties
• Very Good Water Resistance
• Very Good Adhesion
• Very Good Heat Resistance 120 oC
• Very Good Chalking Resistance
Polyurethane Limitation
• Very Bad wetting Properties
• Very Bad Recoat ability
• Bad Levelling Resistance
• Bad Gloss Resistance
• Very Bad Compatibility

Oxidative Physical Chemical

Alkyd CR Vinyl Acrylic Epoxy PU
Anti Corrosive Properties Fair Fair Very good Bad Excellent Fair
Wetting Properties Excellent Bad Bad Bad Very Bad Bad
Recoat ability Excellent Excellent Excellent Excellent Bad Very Bad
Compatibility Very Bad Very Bad Very Bad Very Bad Excellent Bad
Weathering Resistance Excellent Good Good Excellent Good Excellent
Chalking Resistance No Meaning No Meaning No Meaning Excellent Very Bad Excellent
Very good Very good
Heat Resistance 140o Bad Bad Bad Up to 70o 120o Excellent
Levelling Resistance Excellent Fair Fair Fair Bad Good
DFT Imitation
Very Bad Very Bad Very Bad Very Bad Excellent Bad
(Dielectric Resistance)
Chemical Resistance
-Solvent Bad Nell Nell Nell Very Good Excellent
-Acids Bad Good Excellent Excellent Very Good Excellent
-Alkali Bad Very Good Very Good Very Good Very Good Excellent
Mechanical Properties
-Strength Bad Good Good Excellent Excellent Excellent
-Impact Bad Good Good Excellent Excellent Excellent
-Abrasion Bad Good Good Excellent Very Good Excellent
-Bending Bad Good Good Excellent Good Excellent
Water Resistance Very Bad Excellent Good Excellent Excellent Excellent
Colour & Gloss Resistance Bad Fair Fair Excellent Good Excellent
Adhesion &Cohesion Good Excellent Excellent Excellent Excellent Very Good
Levelling Resistance Excellent Fair Fair Fair Bad Good
32/45
By Eng- Hazem Wassel
Gloss% UV- Light Gloss Retenyion For Various Paints

100

90

80

70

60

50

40

30

20

10

0
400 800 1200 1600 2200
Hours Accelerated Testing
Epoxy ACrilic
Epoxy
Polyurethane
Alkyd

• Gloss is Measuring By Refreto Metilc

Gloss Digrys
Mat 0---5%
Velvet 5---10%
Eggsheal Gloos 10---20%
Stain Gloos 20---35%
Semi Gloos 35---65%
Gloos 65---85%
High Gloos > 85%

33/45
By Eng- Hazem Wassel
 Inspection
&
Control

34/45
By Eng- Hazem Wassel
 Inspection & Control
1) Speaks Specified
2) Personal Prequalification
3) Equipment Prequalification Sensor

4) Abrasive
• Conductivity Test ( Filed Test ) Salt Contamination
1) Bring 300ml of abrasive and 300ml of Distilled Water
2) Measure the Conductivity of the distilled water Adaptor

3) Add the abrasive to the water with continuous stirring Sleeve

25 ml
with agitator for 60 second after Finish adding
Conduct meter
4) Leave the solution 8 minutes for conduction
5) Stirring again for 60 second
Filtration Paper Funnel
6) Filtrate The Solution Or
A lot Layer Cotton
7) Measure Conductivity for sleeve Size
(L – Lo) < 1000µs

Sleeve size
15-25 ml
5) Oil Leakage from Compressor
White Rag Method to 3-4 bar

Monometer
6) Pressure At Nozzle
Hyprrdermic Needle 450
The standard 7 bar Stream

7) Airless Pressure Ratio

Compressor P1 Airless P2 P3
Nozzle
How to measure Airless Pressure Ratio ?
Working Pressure 250 bar

(Pr) Pressure Ratio ( deponds on designee of Airless machine and pump dimension)
(P1) Gage Airless
(P2) Main Plat Of Airless
(P3) From Data shits
P2=1.2*P3
Pr = P2 / P1
8) Rust Grades Visually

9) Oil and Grease

By Water Break Test Or Fettrot Test or UV Test

35/45
By Eng- Hazem Wassel
10) Preparation Grades

1) Roughness Comparator
2 1
1 - Finer Then Fine
1-2 1 < Roughness < 2 Fine 3 4
2-3 2 < Roughness < 3 Medium
3-4 3 < Roughness < 4 Coarse
4 Roughness > 4 Coarse Than Coarse

Roughness = 60 µ - 85µ

2) Roughness Comparator
Limitation
• Mecosure Single Point
• No document

3) Testex Imprint Tape

• Mecosure many Point

• document
Roughness = 40 µ - 90µ

4) Styless Method

11) Salt Contamination by (saling conduct meter )

• Bresle test – assmeut of salt contamination on blasted surfaces
Prepared for painting (ISO 8502-6,9 )

Polyester film
Sponge diaphragm
1- 15ml from distilled water
Test Past
2- Conductivity of distilled water
3- Retrieve 3ml from sleeve
4- Inject 3ml in and at in side the patch through sponged diaphragm
from 4 to 5 minute
5- 3ml in the sleeve again 12ml (L)
6- Measure the conductivity
7- Salt density (micro g/ m2) = 6(L-Lo)
36/45
By Eng- Hazem Wassel
12) Dust on the Substrate
Assessment of dust on blasted surfaces prepared for painting (ISO 8502-3)

1- clear Adhesive strength spec 1

Standard Tap 2
2- Press with firm pressure with thumb for 15sec
3
3- Take on tap white board 5cm
4- Compare with the master chart in standard 4

13) Climatic Conditions (ISO 8502-4 )

Sling Psychrometer & Thermometer & Dew Point Calculator
In ISO 8502-4
RH < 85%
S.T.- D.P.T >3 OC
S.T < 50 OC

14) Wet Film Thickness

By Comb Gauge

150 125 100

Paint Line

Unreal Line

Right reading = 125+150 /2

15) Dry Film Thickness ( ISO 2808 -ISO 19840 )&( SSPC-PA2)

Methods of DFT

Destructive Test Non-Destructive Test

(P.I.G)
Magnetic Magnetic Eddy
Paint
Pull- Off Induction Current
Inspection
Principle Principle Principle
Gauge

37/45
By Eng- Hazem Wassel
1) Destructive
(P.I.G) Paint Inspection Gauge
1. Make the selected Areas
2. Make Line by Black Marker
3. choose the suitable cutter according to paint specs
4. cut across the reference line,
5. Measurements can be taken by means of a graticule scale engraved on
one of the lenses of a focusable microscope.
6. DFT = No of spaces * Cutter Factor

Reference
line
View

Blade Damage View through lens with

graticule scale
2) Non Destructive

A. Magnetic Pull- Off Principle

• This Method need a Ferrous substrate & non Ferrous Coat
• The degree of resolution ± 15%
Non Ferrous Coat
Ferrous substrate

B. Magnetic Induction Principle

• This Method need a Ferrous substrate & non Ferrous Coat
• The degree of resolution ± 10%
Diamagentic Coat
Magentizble substrate

C. Eddy Current Principle

• This Method need a Ferrous substrate or non Ferrous substrate & non Ferrous Coat
• The degree of resolution ± 1%
Dielectric Coat
Electric –conductire Subsrate

Specs in SSPC-PA2
1- Take 5 spot reading for 100 Feet or 10 m2
2- Every spot reading Composed of three close triangular shape
3-each spot reading equal 80% of the nominal D.F.T
4- each drop equal 90% of the nominal D.F.T

38/45
By Eng- Hazem Wassel
16) Adhesion Test

1-Qualitative

A) tap Adhesion Test 1- ISO 2409 Cross Hatch Test 6 Plates

2- ASTM D3359

• ISO 2409 Cross Hatch Test

The Cuter Spacing Function in film thickness
1mm 0 - 50µ
2mm 50 - 125µ
1mm 125 -250 µ

• ASTM D3359
1. Method (B) Cross Hatch until DFT ≤ 125 µ
Class 0 = 5B
Class 1 = 4B
Class 2 = 3B

2. Method (A) cross-cut test DFT > 125 µ

30 o -- 45 o
5A No Effect
4A Trace Peeling a long cession 3cm – 4cm

3A Peeling with 1.6mm a long cession

2A Mast area under x cut removed

2-Qualitative Pull off test ISO 4624 & ASTM 4541

• Any thickness
• Full coat or any part of system
• Acceptance from SPEC or coating manufactory
• Adhesive must be regular high molecular solvent free epoxy
40/48
By Eng- Hazem Wassel
17) Holiday Test
Discontinuity test
Measure dielectric
• Low DFT
• Foreign materials Inside coat
• Mist Area
• Voides ( Popping & pin holing & air gaps )

Methods of Holiday Test

Low Voltage High Voltage
Spange 6.5 – 90 Volt 0 – 25 kV
0 – 500 µ to Any thicknes

41/48
By Eng- Hazem Wassel
 Scope Checkpoint Method Reference Limits
ISO 11127
ISO 11126
Abrasive Abrasive Lab Analysis ISO 11125
ISO 11124
SSPC – AB1
Oil Leakage from ASTM D
White Rag Method Oil Free
Compressor 4285
Equipment
Pressure At Nozzle Hyprrdermic Needle 7 bar

Airless Pressure
Min 1: 46
Ratio
Rust Grades Visually ISO 8501-1,2
Water Break Test DIN 55 928-4
Fettrot Test
Oil and Grease UV Test
Oil Free
Solvent Cleaning SSPC – SP1
Surface ISO 850-1,2
Preparation SSPC– SP 11
Preparation Grades Visually SSPC– SP 12
SSPC– SP 13
SSPC– SP 14
Testex Impriint tape ASTM D4417
Anchor Pattern Stylus Instrument ISO 8503
40-75µ
Saline Conduct ISO 8502-6,9
Salt Contamination Max 50 mg/m2
meter ASTM D 4940
Pressure-Sensitive Rating 2 External
Dust on the Substrate Tape
ISO 8502-3
Rating 1 Internal
Humidity Sling Psychrometer
RH < 85%
Climatic Thermometer
Temperature Dew Point
ISO 8502-4 S.T.- D.P.T >3 OC
Conditions S.T < 47 OC
Dew Point Calculator

Application Wet Film Thickness Comb Gauge ASTM 4414

Eddy Current
Dry Film Thickness Method
SSPC-PA2

Curing ZES
Curing Solvent Tast ASTM D 4752

X- Cut ISO 2409 B3 , A3

Adhesion
Testing Pull Of Test ISO 4624
High Voltage Test ASTM D 5162 Holiday Free
Holiday
Low Voltage Test ASTM D 5162 Holiday Free

42/48
By Eng- Hazem Wassel
 Paint
Failures

40/45
By Eng- Hazem Wassel
 Paint Failures
1) Holiday too law DFT
2) Sags and runs
3) Orange peel
4) Dry Spraying
5) Over spray
6) Pinholes
7) Popping
8) Fish eyes
9) Wrinkling
10) Lifting
11) Sweating (Amine)
12) Blisters
13) Cracking
14) Chalking
15) Discoloration / Bleeding
16) Delamination
17) PinPoint Rust

1) Holiday too low DFT

Mist Area

2) Sags and runs

Appearance: Paint running or hanging like curtains on vertical surface

Reasons: 1- High wet film thickness

2-Airspray 30-60 cm is near of substrate
3-High thinner Percentage
4-Sags for vertical substrate only
5-have something wrong in material disfunction Leveling against

Repair: 1- Avoid above

2- use paint brush to smoother or remove excessive paint Look to the photos

41/45
By Eng- Hazem Wassel
3) Orange peel
Reasons: 1- Poor atomization of the paint
2- Poor flow leveling Properties of the paint
(paint too thick or too low temp)
3- Too fast evaporation of thinner
4- Air less spray gun too closed to surface
5- low pressure or high pressure cause back pressure

Repair: 1- Improve application technique

2- use correct thinner
3- Grind surface and apply new paint Look to the photos
4) Dry Spraying
Appearance: Porous sand paper like surface of the paint
(The jet drying befor recch do surface)
(The surface is too rough like sand paper)
Reasons: 1- Poor atomization of the paint
2- High air temperature and low relative humidity too evaporation
of the solvent
3- Strong wind during application
4- The gun of spray too for of surface
Repair: 1- Inorganic zinc re blast and apply new paint
2- physically drying pints apply thinner on the painted surface
and apply a new coat
3- Oxidative drying paints remove loose dust and apply top coat
4- tow –pack paints remove loose dust by sand paper to smooth surface
and apply top coat Look to the photos
5) Over Spray – Dry Spray
Appearance: Secondary Dry Spray

Reasons: 1- High wind sped Look to the photos

6) Pinholes
Appearance: Tiny holes through one or more coats or even down to the substrate as
If perforated by a needle
Reasons: 1- Rough surface recoating
2- Recoating prose
3- Dry spraying
4- Entrapped solvent or air
5- Porosity of previous coat
6- Incorrect application technique or viscosity of the paint
Repair: 1- Grind top layer of paint
2- Recoat Look to the photos
42/45
By Eng- Hazem Wassel
 7) Popping
Appearance: air puppies

Reasons: 1- High temp surfers

Repair: 1- Grind top layer of paint

2- Recoat

Wht different between the pinholes And Popping ?

1- the repair pinholes so difficult then popping
2- the pinholes is the reservoir Solvent in dused itself and be appears
different coats
3- Pinholes caused pin point rusting Look to the photos
8) Fish eyes
Appearance: Spots of paint on the surface with on wetting of the surface
around the spots. Appearance of a fisheye
Reasons: 1- Paint applied on oil or silicone or other contamination
2- painted on incompatible paint
Repair: 1- Re blasting or Grind top layer of paint
2- Recoat

9) Wrinkling ( just happen for alkyd material )

Appearance: small wrinkles through of partly through the pint film

Reasons: Skin drying of the paint film which is usually applied too thick

Repair: Re blasting Look to the photos

10) Lifting
Appearance: small wrinkles through the paint film
Reasons: 1- Softening and raising or swelling of a previous coat by the
Application of an additional coat
2- Normally when over coating alkyd
3- Lifting often caused because the solvent in the new coat is too
strong for the previous coat
Repair: Re blasting

43/45
By Eng- Hazem Wassel
11) Sweating And Carbonization (Amine Blooming)
Appearance: Tacking and whiting and milking
Blooming – happen in epoxy amin only
Blushing – happen in another paint
Reasons: 1- Condensation on cold steel surfaces at humidity
2- Air pollution sulphur dioxide(so2 ) or (co2 ) and ammonia fuming
ammonium sulphate on the paint film
3- fast thinners

Repair: 1- Washing by hot water under pressure

2- Grind by sand paper and recoat Look to the photos

12) Blistering
Appearance: Cosmetic blisters
Dry blisters
Reasons: Solvent entrapped and dust contamination
Repair: 1- dry blisters –water missible sand paper and touch up
2- Osmosic Blisters- when we open it me find rust by sand paper and
touch up after good washing if the blisters too much reblast Look to the photos

13) Cracking
1-Cracking
Appearance:- deep and Visible
Reasons:- 1- High dry film thickness
2- Recoating a soft coat by harder coat
3- Temperature cycling

2-Checking
Appearance:- Visible
Reasons:- 1- Micro superficial Cracks
2- High Temperature in dry process

3-Micro cracking
Appearance:- Micro Invisible deep
Reasons:- High thickness on zinc ethyl silicate

4-Mud cracking
Appearance:- visible for only zinc
Reasons:- ethyl silicate and deep high thickness Look to the photos

44/45
By Eng- Hazem Wassel
14) Chalking
Appearance: - Almost like dust on top of the coat
- the gloss will be reduced
Reasons: Pigments and extenders exposed on the paint surface due to
1- Exposure to sun /UV light
2- weathering of the paint
3- Insufficient mixing stirring of the paint
4- use of wrong thinner

Repair: 1- Grind top layer of paint

2- Recoat Look to the photos
15) Bleeding
Appearance: - Discoloration of paint particularly in top coat
Reasons: 1- Colored ingredients in a previous coat or on the substrate is
dissolved by solvents in the subsequent coat
2- Soluble pigments (poor solvent resistance)
3- Tar Bitumen
4- Surface contaminants

Repair: 1- Re blasting
2- Recoat Look to the photos
16) Delamination
Appearance: - Loss of adhesion
Reasons: 1- Primer not compatible with subsequent
2- contamination of substrate or between coats
3- Recoating interval too long
4- Blooming /sweating
Repair: 1- remove loose paint layer or down to substrate
2- Recoat Look to the photos
17) PinPoint Rust
Appearance: - Point of rust
Reasons: 1- small pores (openings ) openings or defects in the point film down
to bare steel
2- holidays due to overspray , dry spray
3- too high substrata roughness
Repair: 1- Grind down to bare steel
2- Recoat Look to the photos

45/45
By Eng- Hazem Wassel