Professional Documents
Culture Documents
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Volume 1
IBSN 0-938477-81-1
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DISCLAIMER
The techniques, procedures, regulations and other in-
formation presented in this volume have been reviewed by
experts in each field and are believed to represent good cur-
rent practice. They are monitored and revised as practices
improve, and suggestions for revision are welcome.
SSPC is not responsible for the application, interpreta-
tion, or administration of the information outlined here. SSPC
specifically disclaims responsibility for the use or misuse of
any product, procedure or technology or misinterpretations
of any regulations referred to in this manual. The supplying
of details about patented formulations, treatments, or
processes is not to be regarded as conveying any right or
permitting the user of this manual to use or sell any patent-
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ed invention.
When it is known that the subject matter of the text is
covered by patent, such patents are reflected in the text.
Table of Contents
Page
Foreword
Chapter 1.O INTRODUCTION
SSPC Staff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter 1.1 CORROSION OF STEEL - SIMPLIFIED THEORY
byF.L.LaQue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 1.2 PAINTS FOR ANTI-CORROSION SERVICE
byCliveH.Hare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 2.0 SU RFAC E PREPARATION
b y H . W i l l i a m Hitzrot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Chapter 2.1 MECHANICAL SURFACE PREPARATION
byA.W.Mallory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Chapter 2.2 M ETALLIC ABRASIVES
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byEinarA.Borch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Chapter 2.3 NO N-METALLIC ABRASIVES
by H. William Hitzrot.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Chapter 2.4 ABRASIVE AIR BLAST CLEANING
b y J i m Bennett . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Chapter 2.5 WATER BLAST CLEANING
b y J i m Bennett . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Chapter 2.6 HAND AND POWER TOOL CLEANING
by Preston S. Hollister and R. Stanford Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Chapter 2.7 FIELD SURFACE PREPARATION COSTS
byRobertB.Roth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Chapter 2.8 OTHER METHODS AND FACTORS IN SURFACE PREPARATION
by Bernard R. Appleman and John D. Keane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Chapter 2.9 CHEMICAL CLEANING
by Melvin H. Sandler and Sam Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Chapter 3.1 SPECIAL PRE-PAINT TREATMENTS: PHOSPHATING
bySamspring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Chapter 3.2 PICKLING STEEL SURFACES
by D. W. Christofferson . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Chapter 4.1 PAINT MATERIALS
by Sidney B. Levinson and Saul Spindel. ....................................... 117
Chapter 4.2 ZINC-RICH PRIMERS
byCharlesG.Munger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Chapter 4.3 CORROSION INHIBITIVE PIGMENTS AND HOW THEY FUNCTION
byArnoldJ.Eickhoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Chapter 5.1 PAI NT APPLICATION
by Sidney B. Levinson and Saul Spindel.. ...................................... 150
Chapter 5.2 SCAFFOLD ING
by Sidney B. Levinson and Saul Spindel. ....................................... 168
Chapter 5.3 SAFETY IN PAINT APPLICATION
by Sidney B. Levinson and Saul Spindel. ....................................... 176
Chapter 6.0 INSPECTION
by Kenneth B. Tator and Kenneth A. Trimber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
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byJ.R.Foster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Chapter 14.1 PAINTING STEEL TANKS
byW.J.Wallace,Jr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Chapter 14.2 THE LINING OF STEEL TANKS
by Wallace P. Cathcart and Albert L. Hendricks ................................. 320
Chapter 15.0 PAINTING HYDRAULIC STRUCTURES
byJ.L.Kiewit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Chapter 16.1 COATINGS FOR PIPELINES AND OTHER UNDERGROUND STRUCTURES
by R. N. Sloan and A. W. Peabody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Chapter 16.2 CATH ODIC PROTECTION
byA.W.Peabody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Chapter 17.0 PAINTING OF INDUSTRIAL PLANTS
by William F. Chandler.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
Chapter 17.1 WASTE TREATMENT PLANTS
byThomasP.Delany . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Chapter 17.2 PAINTING OF COKE AND STEEL PLANTS
by Arthur R. Thompson and S. C. Frye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
Chapter 17.3 PETROLEUM REFINERY COATINGS
byW.E.Stanford . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
Chapter 17.4 PAINTING CHEMICAL PLANTS
by J. Roy Allen and David M. Metzger. ......................................... 412
Chapter 17.5 PAINTING PULP AND PAPER MILLS
by C. Edwin Wilkins and William F. Chandler ................................... 420
Chapter 17.6 PAINTING FOOD PLANTS
bySteven L.Schmidt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
Chapter 17.7 POWER GENERATION FACILITIES
byRonald R.Skabo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
Chapter 18.0 GOVERNMENT PAINTING PRACTICES
by Richard W. Drisko and Howard G. Lasser .................................... 448
Chapter 19.0 TRAINING PROGRAMS FOR PAINTING
byJayl.Leanse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
Chapter 20.0 THERMAL SPRAYED COATINGS
by S. J. Oechsle and J. N. Childs, Jr. ........................................... 456
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FOREWORD
Coatings for structural steel have been called the prin- new realities. Because the list of specifications in the back
cipal means of protecting our principal construction of Volume 2, Systems and Specifications has been enthusias-
material-steel-from its principal weakness-corrosion. tically received, we have added such a list to Volume 1.
This technology has been the subject of an intensive pro-
gram by the Steel Structures Painting Council since 1950. Like its predecessors, the third edition is written from the
The purposes of the SSPC are to assess and advance the coating end user’s point of view and not that of the paint tech-
technology of surface preparation and coating of industrial nologist or scientist. Volume 1 should be considered a com-
structures by conducting research, developing standards, panion to Volume 2. Volume 1 was intentionally designed
and disseminating information: More specifically: to include some duplication between chapters. This tends
to make each chapter as complete as possible for the indus-
1. To instigate and carry on laboratory and field investiga- try being covered, to present shades of opinion with regard
tions of techniques to mitigate corrosion through the use of to various controversial matters, and to spare the reader the
protective coatings; necessity of large amounts of cross-referencing. When such
2. To develop standards, specifications, and guides cover- cross-referencing is necessary, however, it is expedited by
ing techniques and materials of surface preparation and coat- the detailed Index, Glossary, Table of Contents and Specifi-
ing of structures; and cation list. Each chapter attempts to be a balanced presen-
3. To organize and communicate information intended to fur- tation in which each author has been given the benefit of the
ther improve and make more effective the protection of in- viewpoints of the outstanding leaders in his particular
dustrial structures. specialty, usually representing buyer, supplier, applicator,
manufacturer, contractor, maintenance engineer and
I. THE THIRD EDITION engineer-architect. The focus, of course, has been on coat-
The first undertaking of the Council was the preparation ings for structural steel rather than factory-applied enamels.
of Volume 1 of the Steel Structures Painting Manual. It has
been revised since then to incorporate new information. This II. ABOUT THE SSPC
third edition of Volume 1, Good Painting Practice is primari- The SSPC is a professional technical society whose
ly an editorial revision and update. A complete technical re- primary objective remains to improve the technology and
vision of the volume will take several years. In the interim, practice of protecting structures through the application of
several chapters have been added and several have been coatings. Headquarters and laboratories of the SSPC are lo-
revised to reflect changes in the industrial painting industry cated in Pittsburgh. SSPC membership is open to both in-
since 1982. dividuals and organizations, but SSPC services are not
restricted to its membership. These services include consen-
One of the most important changes since that time has sus standards developed by technical committees, to help
been the increased attention health and safety and environ- industry define and use good painting practice, a wide range
mental regulators have focused on the industry. In addition of publications, and annual national conference and specialty
to their other duties, specifiers and users must now be conferences and tutorials offered throughout the year.
familiar with hazardous waste, air pollution control and other SSPC’s laboratory evaluates new materials and application
regulations. Worker safety has also become a concern. In techniques and develops procedures for coating performance
recognition of the increased importance of these issues to evaluation and surface characterization. SSPC’s Painting
painting concerns, an environmental chapter and a health Contractor Certification Program (PCCP) is a national, pre-
and safety chapter have been added to the third edition. qualification service developed for facility owners who hire
contractors. The PCCP confirms that an industrial painting
Concern about environmental and health effects has also contractor has met the standards for quality set forth in
led to major changes in the kinds of paint the industry uses. SSPC-QP-1, “Standard Procedure for Evaluating Qualifica-
Lead- and chromate-based paints, once a mainstay of the tions of Painting Contractors: Field Application to Complex
industry, are being rejected in favor of less toxic paints. Most Structures”.
military and federal specifications for lead- and chromate-
based paints have been canceled. SSPC has recently pro- 111. ORGANIZATION
posed to withdraw its specifications for lead-based paint and The affairs of the Steel Structures Painting Council are
is re-examining specifications for paints containing chromate managed by a Board of Governors composed of sixteen (16)
pigments. At the same time, paints are being reformulated elected members, a non-voting Secretary and Treasurer, and
to meet air pollution control requirements, and the recent additional ex-officio members appointed by the President.
amendments to the Clean Air Act will accelerate this process. The board of Governors annually elects a five-person Execu-
The tables in this volume have been revised in light of these
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C.A
- ADMINISTRATIVE
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BIOGRAPHY BIOGRAPHY
Dr. Bernard R. Appleman
has been the Executive Director Dean M. Berger received his
of the Steel Structures Painting B.S. degree at North Central
Council since 1984. In this posi- College and did advance studies
tion, he is responsible for or- at the University of Wisconsin.
ganizing and managing He has had over 20 years of
operations of a technical socie- research experience at PPG
ty whose activities encompass Industries, and eight years at
research, development of indus- Union Carbide Research. Be-
try standards, and dissemination ginning in 1974, he worked for
of technical information via GilbetVCommonwealth,advising
reports, presentations, training engineers and architects on the
programs and conferences. He application and use of coatings.
has directed and coordinated In 1988 Mr. Berger retired from
numerous projects in coatings performance evaluations, surface Gilbert Associates and formed
preparation techniques, development of specifications and guides, his own coatings consulting firm, Berger Associates Inc., of Leola,
and lead paint removal and abatement. Pennsylvania. He has attained specific expertise in zinc rich coat-
His past work experience includes work as a CorrosionlCoat- ing technology, epoxy, coal tar epoxy, urethane, and vinyl coating
ings Specialist for Exxon Research and Engineering Company. From systems.
1977 to 1982, he was Project Manager, Coatings, for the Federal He has been a member of the Steel Structures Painting Council
Highway Administration. He also worked as a Research Chemist since 1960, chairman of the Epoxy Advisory Committee, and Co-
for the Naval Ship Research and Development Center. Chairman of both the Research Committee and the Inspection Com-
mittee. He was chairman of the American Society for Testing and
Materials (ASTM) Subcommittee 0-1.46 on Industrial Protective
Coatings. He is the Executive Director of the Board of Registration
BIOGRAPHY of Nuclear Safety-related Coating Engineers and Specialists, and
a member of ASTM Committee D-33 on Coatings for Power Gener-
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BIOGRAPHY
de Nemours and Company.
Mr. Keane is a member of various honorary societies, includ-
ing Tau Beta Pi, Phi Lambda Upsilon, Pi Nu Epsilon and Alpha Chi
Sigma. He has served as director of several civic and religious or-
ganizations and is the author of approximately 60 scientific and tech-
nical publications and 30 technical disclosures. He has represented
the United States at three international symposia and conferences
on coatings.
He served as a consultant, advisor, chairman, or active com-
mittee member in many societies, including the American institute
of Steel Construction, the American Iron and Steel Institute, the
Canadian Instituteof Steel Construction,the Painting and Decorating
Contractors of America, the Steel Plate Fabricators Association, the
Federation of Societies for Coatings Technology, the American So-
ciety of Association Executives, the National Paint and Coatings As-
sociation, the National Association of Corrosion Engineers (NACE),
the American Society for Testing and Materials, the Transportation
Research Board, the International Organization for Standardization,
and the American National Standards Institute. He is a Certified
Manufacturing Technologist (Coatings), a NACE Corrosion
Specialist, and a registered professional engineer (by examination)
in the states of Illinois, Pennsylvania and California.
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XII
Copyright The Society for Protective Coatings
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No reproduction or networking permitted without license from IHS Not for Resale