Coating procedure

Following coating procedure refers to Siemens D Ineos Project, manufactured by

Hydac PL (PL 2653)

1. Scope and Purpose

The International Paint Coating Procedure have been prepared and revised in line with the
Worldwide Protective Coatings product range. The purpose of this procedure is to ensure
that a coating system, as applied, provides adequate protection against corrosion.

Successful in-service performance of a coating system depends upon both the correct choice
of coating and the adoption of the correct procedures for surface preparation and paint
application.

The responsibilities for achieving the specific standards outlined and for carrying out surface
preparation and paint application rest with the Contracting Company. The role of the
International Paint Technical Service Representative is advisory only unless otherwise
specified in the terms and conditions of the contract.

Procedures in this document are drawn up to comply with current standards of surface
preparation as well as paint system application. Any deviation from these recommendations
should be consulted with paint manufacturer in order to obtain acceptance prior the
commencement of paint work.

This document shall always be used with reference to relevant product Technical Data
Sheets (TDS) and Material Safety Data Sheets (MSDS).

2. Surface preparation
Proper surface preparation is essential for the success of any protective coating scheme.
The importance of removing oil, grease, old coatings and surface contaminants cannot be
over emphasised.
The performance of any paint coating is directly dependent upon the correct and thorough
preparation prior any paint work. The most expensive and technologically advanced coating
system will fail if the surface preparation is incorrect or incomplete.
On course of pre-treatment and initial blast procedures, steelwork should be carried out to
min P2 grade (ISO 8501-3).
2.1. Washing/degreasing
It is essential to remove all soluble salts, oil, grease and other surface contaminants prior to
further surface preparation. The most common method is by solvent washing, followed by
wiping dry with clean rags.
High pressure water cleaning also can be used (using fresh water or water with suitable
detergents) followed by rinsing with fresh water. Cleaning with alkaline detergent followed by
hosing with fresh water is recommended for galvanized steel parts.
2.2. Abrasive blast cleaning
Abrasive blast cleaning to Sa2½ (PN ISO 8501-1:2007). If oxidation has occurred between
blasting and application of paint system the surface should be reblasted to the specified
visual standard. Surface defects revealed by the blast cleaning process should be ground,
filled or teated in the appropriate manner.
A surface profile of 40-75 µm is recommended.
All galvanized parts should be sweep blasted using non-ferrous abrasive. A surface profile
min. 25 µm is recommended for these parts.
2.3. Compressed air
The air, used for abrasive blasting, must be clean, degreased and dry. Air cleanliness can
be easily check, applying Blotter test acc. to ASTM D 4285 . The air pressure to processing
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abrasive blasting should be at least of 6 atm. at nozzle output (less for sweep blasting).
2.4. Weather conditions
Abrasive blasting should be carry out when relative humidity stabilized at below 85% and
the temperature stays above 00C. Steel temperature has to be at least of 30C above dew
point temperature of surrounding air. Working outside, bad weather conditions may cause
fast appearing of secondary flush rust on worked surfaces, what, with rule the process of
cleaning, disqualifies elements already prepared. Secondary cleaning is mandatory.
2.5. Health & Safety
Always carefully read and completely follow the health and safety procedures and
instructions recommended by manufacturers of surface preparation devices, application
equipment, media or products and the job site safety measures.
Always carefully read and follow the manufacturer’s health and safety procedures and
instructions concerning materials used to surface preparation.
These are general statements to alert you to the importance of specific warnings and
instructions on individual products. These statements are not intended to be specific
warnings or advice.

3. Paint application

The success of any paint application will be governed by a number of parameters,

including:
- Surface preparation,
- Film thickness applied,
- Methods of application,
- Conditions during application.
Coating system application should be carry out on surface already prepared in accordance
with standards written in section 2.

3.1. Paint System Application

Surface prior to application has to be carefully cleaned and dry. Paints should be applied as
films at even thicknesses. Overcoating interval with subsequent coat (when specified dry film
thickness will be not achieved in one coat) has to be adequate to complete drying or curing
time of the paint according to manufacturer’s advice. Touch dry, hand dry times and
overcoating intervals are given in proper technical data sheets.
Each coat on painted areas should be inspected and approved prior to application of
subsequent coat. All the paint work should be performed by applicators, who can apply
coating layers without holidays, sagging, slumping, orange peel, dry spray and other film
defects. Paints can be thinned strictly regarding to technical data sheet advices.
3.2. Stripe coat
Stripe coat is a very important element of good painting practice. It should be executed in
places of damages of previous layers and in places where covering becomes to be hard,
including:
- edges, screws,
- weld seams,
- hard accessible spaces.
Stripe coat must be done with suitable brush type, trying to reach as thick layers, as possible,
to meet specified thicknesses after spray application. Overcoating times should be in
accordance to appropriate Technical Data Sheets
3.3. Application conditions
Ambient conditions should be monitored during paint application and curing. The following
parameters should be measured and recorded: air temperature, surface temperature, relative
humidity and dew point . Ambient conditions should be measured at regular intervals typically
twice per day (or shift). If conditions are subject to change, measurements should be taken
more frequently, depending on speed of change. Optimum application temperature is
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between +5°C and +30°C. Do not apply at temperatures below 5°C. Steel temperature must
always be 30C above dew point. Application should stop when substrate temperature falls to
within 30C of the dew point.
Throughout application and curing, ensure adequate ventilation and air flow are present, in
order to prevent “dead spots”, especially when application is in confined spaces.
Application should be carried out under cover from the elements. Painting film should be
protected from rain, fogg and dampness during application and cure.
3.4. Paint mixing
Paints are supplied as two component material. The base component (Part A) should be
mixed thoroughly by mechanical agitation and then the curing agent (Part B) poured in and
the composite agitated thoroughly. Do not mix more material than can be used within its pot
life.
3.5. Airless spray
Airless spray is recommended application method allowing to achieve optimal properties of
coat. The airless spray equipment should be in good working order. Pump ratios of 48:1 up
to 73:1 can be used, or any pump capable of producing an output pressure of 190 kg/cm2.
Recommended tip size range is 0,33-0,63 mm as stated on the technical data sheets.
International thinners GTA series should be used for pump cleaning. Thinning is not normally
required. Maximum recommended thinning 5%.
All equipment should be cleaned immediately after use. It is good working practice to
periodically flush out spray equipment during the course of the working day. Frequency of
cleaning will depend upon amount sprayed, temperature and elapsed time, including any
delays.
Airless spray of paints should be carried out very carefully to attain wet film at specified
thickness and without holidays. Wet film should be applied at specified thickness to achieve
required dry film thickness. Wet film comb should be used to measure wet film thickness
during application.
When the material is theoretically up to specified thickness, dry film thickness readings must
be taken. Any low areas should be brought up to the specification.
It is necessary during application any subsequent coat:
• compliance with overcoating intervals (see 3.1)
• checking if previous coat is free from contaminations and removing of
contaminants.
Prolonged stoppages in the time of application of subsequent coats can need to measure of
ionic contaminations. When ionic contaminants are present on the surface then must be
removed by high pressure fresh water washing.
Stoppages during application of subsequent coats longer than these recommended on
technical data sheet can result in requirement of surface abrading prior to application
subsequent coat.
Coating film after curing should not contain any holidays, sagging, slumping, pinholes,
cracking’s, orange peel, dry spray and other film defects.
3.6. DFT measurements
Dry film thickness measurement must be taken according to ISO 19840. Dry film thickness
should be measured using non-destructive gauge (with separate or integral probe).
Measuring gauge should be calibrated on smooth surface. Calibration should be carried out
using measured foils (samples) on a value similar to the expected thickness of the coating.
The procedure for checking of nominal dry film thicknesses should be agreed between the
interested parties. Unless agreed otherwise individual values between 80% and 100% of the
nominal dry film thickness are acceptable provided that the overall average (mean) is equal
to or greater than the nominal dry film thickness (rule 80/20). Unless agreed otherwise,
individual dry film thicknesses of less than 80% of the nominal dry film thickness are not
acceptable.

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Care should be taken to achieve the nominal dry film thickness and to avoid areas of
excessive thickness. Specific requirements apply for limitations of maximum dry film
thickness in the case of some paints.
3.7. Coating systems

3.7.1 For carbon steel No.2.20:

Interzinc 52 - 80µm
Intergard 345 - 160µm
Interthane 990 - 80µm RAL 9002
320 µm DFT

3.7.2 For galvanized steel No. 2.15:

Intergard 269 - 40µm
Intergard 345 - 130µm
Interthane 990 - 70µm RAL 6019, 7030, 7032, 1018
240 µm

3.8. Supervision
Direct supervision of work quality is conducted by applicator’s quality control department.
Engineer carries out random supervision of application, documentation review and approve
stages of work. Executive documentation (quality control plan) should be agreed prior to start
of work. The main contractor shall be responsible for approval of the critical stages as below:
• Assessment of surface preparation
• Control of application conditions
• DFT measurements according to compliance with specification.
Work execution and supervision should meet requirements of Technical Acceptance Criteria
set out in reference document.
3.9. Health & Safety
Always carefully read and completely follow the health and safety procedures and
instructions recommended by manufacturers of surface preparation devices, application
equipment, media or products and the job site safety measures.
Always carefully read and follow the manufacturer’s health and safety procedures and
instructions concerning materials used to surface preparation.
These are general statements to alert you to the importance of specific warnings and
instructions on individual products. These statements are not intended to be specific
warnings or advice.

4. Coating repairs
Repair of the coatings must be done in case of mechanical damages and defects listed on
the table 1. The acceptance of the other defects (not listed at the table 1) must be confirmed
by AkzoNobel (based on the material nature and recipe), as well with Customer (based on
the technical requirements for the project)

Table 1 Defects and remedial actions

Type of Acceptance Remedial action recommended
defect
Gaps Not accepted Must be identified and remediated before
commissioning and remedied in-shop
conditions.

Apply extra layer(s) up to NDFT

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 Not accepted if DFT on the
Runs & Sags sag point is more than max
allowed for this exact
product
Dry spray over the blasted
Dry Spray surface to be coated,
primer coat and mid-coat is
not accepted. Dry spray
over the top-coat surface
might be accepted, but it
should be clarified by the
project requirements for
coating appearance
Rusting Not accepted
Bubbling Not accepted
Not accepted
Over
thickness
Must be identified and remediated before
commissioning and remedied in-shop
conditions.
If necessary, grind or sand away; apply
extra layer(s) according to current
technical specification
Dry spray over the blasted steel surface
must be removed by mechanical tools or
by abrasive blast cleaning.
Dry spray over the coat must be sanded
down by abrasive paper or similar. Touch
up or full coat application must be done
further
Must be identified and remediated before
commissioning and remedied in-shop
conditions.)
Blast or mechanical cleaning and
reapplication of the extra layer(s)
Blast or mechanical cleaning and
reapplication of the extra layer(s)
Must be identified and remediated before
commissioning and remedied in-shop
conditions.

Sand with fine sandpaper and apply extra

layer(s)
Not Not accepted Blast clean the surface; apply extra layer(s)
acceptable
adhesion
Cracking Not accepted
Unless otherwise stipulated Must be identified and remediated before
Dirt & foreign by the project requirements commissioning and remedied in-shop
particles and confirmed – only 4 conditions.
pcs/dm2 (dimension not
bigger than 2 mm) are Clean the surface according to the current
allowed technical specification; apply extra layer(s)
Delamination Not accepted up to NDFT
Pores, craters Not accepted
Mechanical Not accepted Clean the surface according to the current
damages technical specification; apply extra layer(s)
up to NDFT

When the size of the defect is less than 50 cm2 – the defected area must be treated locally
by sanding (aluminum abrasive for galvanized steel, Р60-Р80). The sanding media must be
changed frequently to avoid the surface polishing. SSPC SP11 and Rz not less than 25µm
are recommended.

When the size of defect is more than 50 cm2 the local abrasive blast cleaning (to PSa2½ ISO
8501-2) must be applied.

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For galvanized steel, Interzinc 52 is suitable as a repair primer.

Normative references:
• ISO 8501-1,
• ISO 8501-2,
• ISO 8501-3,
• EN ISO 8502-4
• EN ISO 12944
• EN ISO 19840
• ASTM D 4285