Painting and Coating - SKG15 Slides

INSPECTION AND MATERIALS ENGINEERING
SG 15
SG 15.5
PAINTING AND COATING
INSTRUCTOR'S MANUAL
( LEVEL 3 )
SG 15.5 PAINTING AND COATING
SG 15
OBJECTIVE :
At the end of the program, participants will be able to
evaluate
various types of paint defects, identify the root

causes and determine solutions.
performance of new paint and coating materials.
suitable paint systems for various applications.
quality control for paint applications
SG 15
CONTENTS :
Paint defects.
Selection of coating systems.
Case study of coating systems.
Quality control.
Coating survey.
SG 15
How does a coating system protect the substrate?

• Barrier Protection
3 categories of paint defects:
– Insulation of substrate from external environment by paint film
-- Low permeability to corrodents
-- Prevention of rusting & corrosion
•
In can defects.
Inhibitive Action
– Certain special pigments inhibit or interfere with corrosive reactions at steel surface
– Typical examples are zinc phosphate alkyds and zinc phosphate acrylics
– Defect during application.
Moisture which escapes the physical barriers dissolve these pigments hence interfering the
corrosion process once the solution reaches steel substrate
• Sacrificial Action
– Defect after
Example : Zinc application.
rich primers.
– Corrosion is not prevented, rather Zn takes on the corrosion, protecting the steel
SG 15
3 categories of paint defects:

• ESSENTIAL PROPERTIES OF COATING
-- Strong adhesion with substrate
-- Excellent wetting of substrate
In can defects.
-- Low permeability
-- Cohesive & Adhesive strength to withstand stress
-- Defect duringproperties
Good mechanical application.
and chemical
resistance
Defect after application.

SG 15
Common types of Paint

Inorganic Zinc Primer
Epoxy Zinc Rich Primer
High Solids Epoxy
Surface tolerant Epoxy
Epoxy Primer
Coal Tar Epoxy
Amine Adduct Epoxy
Aliphatic Polyurethane
Glass Flake Epoxy
Glass Flake Polyester
Silicone Acrylic
Silicone Aluminium
ATERIALS ENGINEERING
G 15
COATING SYSTEM
A coating system is a functional unit that provides

protection to the substrate. A system can consist of
one, two, three or more coats of paint.
A typical system consists of 3 coats:-

A primer
An intermediate coat
A topcoat
SG 15
Functions of a primer
Prevent corrosion by
Barrier
Inhibitive
Electrochemical activities
A base for subsequent coating to adhere.
Prevent undercutting.
SG 15
Functions of an Intermediate
Coat.
Seal the primer and fill in any pinholes, voids or
porosities.
Additional barrier coat.
Provide a surface to which a subsequent coating

will adhere.
SG 15
Functions of a Topcoat.
To protect the primer and intermediate coats.
Enchance weathering resistance and wear

resistant
Provide colour and gloss.

SG 15
Coating Selection Process

To identify :
Limiting Parameters.
Corrosives and Eposures.
Substrate Conditions.
SG 15
Limiting Parameters
Surface preparation method.
Blast cleaning or power tool cleaning?
Environmental conditions.
Location
Field or shop?
Application methods
Spray, brush or roller?
Local regulations.
SG 15
Corrosives and
Exposures
General weathering .
Chemical fumes.
Chemical splash and spillage.
High temperature.
Salt spray.
Intermittent immersion.
Total immersion.
SG 15
Substrate Condition
type of substrate materials.
new or painted substrate.
blast cleaning or power tool.
existing coatings.
SG 15
Areas to be protected
1. Exterior (Atmospheric Zone)
I. non-sulated (<110ºC)
II. isulated (<110ºC)
III. temperature (110-250ºC)
IV. temperature (250-450ºC)
2. Interior.
3. Platform Deck.
4. Tidal and Splash Zone.
5. Tank Lining.
SG 15
1. (I) EXTERIOR NON-INSULATED - Includes

various applications and surfaces such as
leg, bracing, cranes, piperacks, ladders
handrails and tank exteriors.
New Painting
1st Coat : Inorganic Zinc or Epoxy Zinc (75mm)
2nd Coat : High Solids Epoxy (150mm)
3rd Coat : Aliphatic Polyurethane (50mm)

SG 15
Maintenance (Blast Cleaning)
1st Coat : Epoxy Zinc (75 mm)
2nd Coat: High Solids Epoxy (150 mm)
3rd Coat : Aliphatic Polyurethane (50 mm)
Maintenance (Power Tool Cleaning)
1st Coat : Surface Tolerant Epoxy (125 mm)
2nd Coat: Surface Tolerant Epoxy (125 mm)
3rd Coat : Aliphatic Polyurethane (50 mm)

SG 15
1 (ii) Exterior Insulated

New Painting
1st Coat : Inorganic Zinc or Epoxy Zinc (75 mm)
2nd Coat : High Solids Epoxy (150 mm)
Maintenance (Blast Cleaning)

1st Coat : Epoxy zinc (75 mm)
2nd Coat : High Solids Epoxy (150 mm)
Maintenance (power tool Cleaning)

2nd Coat : Surface Tolerant Epoxy (125 mm)
SG 15
1 (iii) Exterior 110ºC - 250ºC

Insulated or Non-insulated
New Painting and Maintenance
1st Coat : Inorganic Zinc (75 mm)
2nd Coat : Silicone Acrylic (30 mm)
3rd Coat : Silicone Acrylic ((30 mm)

SG 15
1 (iv) Exterior 250ºC - 450ºC

Insulated or Non-insulated
New Painting and maintenance
1st Coat : Inorganic Zinc (75 mm)
2nd Coat : Silicone Aluminium (25 mm)
3rd Coat : Silicone Aluminium (25 mm)

SG 15
2. INTERIOR - living
quarters, control rooms, work
area.
New Painting and Maintenance.

SG 15
3. PLATFORM DECK - including

primary and secondary structures.
1st Coat : Glass Flake Polyester or Glass Flake Epoxy (400 mm)
2nd Coat : Glass Flake Polyester or Glass Flake Epoxy (400 mm)
(Anti-skid aluminium oxide 20-30 mesh)

SG 15
4. TIDAL AND SPLASH

ZONE
1st Coat : Glass Flake Polyester or Glass Flake

Epoxy (500 mm).
2nd Coat : Glass Flake Polyester or Glass Flake

Epoxy (500 mm)
SG 15
5. (i) TANK LINING

(Roof and Shell Plate)
Crude / Condensate sweet and sour,
naptha, jet fuel, lube oil, gasoline.
New Painting and Maintenace.
1st Coat : Amine Adduct Epoxy (125 mm)
2nd Coat : Amine Adduct Epoxy (125 mm)

SG 15
5.(ii) TANK LINING

(Bottom Plate And Vessels)
Crude / Condensate sweet and sour
New Painting And Maintenance.
3rd Coat : Amine Adduct Epoxy (100 mm)

SG 15
5. (iii) TANK LINING

Potable water, Sea water
(aerated and non-areated)
New Printing and Maintenance

SG 15
FACTORS AFFECTING THE

SELECTION OF BALSTING
ABRASIVES.
• type / materials
• size
• shape
• impurities
• consumption rate
• environmental & health impact
SG 15
Steps for Coating Application

STEP 1 - Pre-surface preparation
inspection
STEP andpreparation
1 – Pre-Surface testing.inspection and testing
STEP 2 – Surface
To examine and Preparation
test surface to determine if it is
acceptable and meets specifications.
STEP 3 – Inspection and Acceptance of Prepared Surface
• welds
STEP must beofground
4 – Approval flush
Prepared Surface
• weld spatter removed
• sharp
STEP edge rounded
5 – Testing during Application of Surface
STEP 6 – Testing Cured Film

SG 15
STEP 1 - Pre-surface preparation

inspection and testing.
To examine and test surface to determine if it is
acceptable and meets specifications.
• welds must be ground flush

• weld spatter removed
• sharp edge rounded
SG 15
STEP 2 - Surface Preparation.
To assure the specifiction requirements are

complied.
• relative humidity
• dew point
• air supply to be free from oil and water
SG 15

complied.
• dew point
SG 15

complied.
• dew point
SG 15

complied.
• dew point
SG 15
STEP 3 - Inspection and Acceptance of

Prepared Surface.
Perform specified tests on prepared surfaces:-
• Degree of surface cleanliness - visual

comparison to reference standards.
• Surface Profile.
- Surface profile gauge
- Testex tape & thickness gauge
- Surface profile comparator
SG 15
STEP 4 - Approval of Prepared

Surface.
• Non-conforming area are marked with grease
free chalk.
• Corrective actions.
• Re-inspect.
• Approval in witten memo. Specifying area

approved and signature.
SG 15
STEP 5 - Testing During Application of

Paints.
Confirmation of :
• proper coating materials.

• materials within usable shelf life.
• temperature and pot life.
• proper application equipment.
• proper thinner.
• proper application techique
• ambient and surface conditions within limits
• applied film without sags ans record wet film
thickness with wet film thickness comb.
SG 15
STEP 5 - Testing During Application of

Paints.
Confirmation of :
• proper coating materials.

• materials within usable shelf life.
• temperature and pot life.
• proper application equipment.
• proper thinner.
• proper application techique
• ambient and surface conditions within limits
• applied film without sags ans record wet film
thickness with wet film thickness comb.
SG 15
STEP 6 - Testing Cured Film.

Final inspection shall include :-
• checking dry film thickness with dry film

thickness gauge.
• visual check for paint defects such as

mud-cracking, dry spary, holidays, sags.
• approval given in written memo and signed.

SG 15
STEP 6 - Testing Cured Film.

Final inspection shall include :-
• checking dry film thickness with dry film

thickness gauge.
• visual check for paint defects such as

mud-cracking, dry spary, holidays, sags.
• approval given in written memo and signed.

Reasons For Coating Failure
• POOR SURFACE PREPARATION
• APPLICATION RELATED FAILURES
• STRESS RELATED FAILURES
• ENVIRONMENTAL EFFECTS
-- Microbial Growth
• IMPROPER DESIGN
-- Formulation related issue
-- Selection of improper coating systems
Poor Surface Preparation
• 75% failures attributed to faulty surface preparation.
• Service life of coating system is enhanced by 50-100%

between manual vis-à-vis blast cleaned steel.
• Coating fails miserably if there is underneath mill scale, rust,

soluble salts, oils & greases.
• Surface contaminants
– Impairs wetting
– Affects adhesion
– Promotes blisters / rusting
– Causes de-lamination
Adhesion Failure
Causes :
Surface contamination
Substances which can cause adhesion
failure are left on the substrate (e.g. oil,
grease, rust, sanding residue,
etc.) An unsuitable primer was applied
to the substrate.Primer or base coats
were applied too thin.
Remedies :
Remove all coats with poor adhesion.
Thoroughly sand and clean the
substrate.
Repaint using the correct choice of
Primer and/or surfacer and/or top-coats.
Crinkling
Causes :
Substrate not thoroughly dried
Coating are not thick enough
( sprayed too thin or sanded
down to far.
Remedies :
Sand down the paintwork back
to a sound substrate.
Rework using suitable Primer
And Top Coats.
(If necessary be prepared to
strip back to a sound substrate).
Causes :
Poor coverage
Substrate not coloured to similar
even shade
Top coat over thinned
Top coat not stirred before used
Remedies :
After drying, sand down and
repaint.
Causes :
Water marking
Insufficient drying of fresh
paintwork prior to being left in
the rain.
Poor drying of paint due to
thick coat application.
Incorrect hardener or quantity
of hardener.
Remedies :
If the damage is minor, first try
washing with
clean water; For severe damage,
sand the surface, ensure it is
thoroughly cured and repaint.
Dust contamination
Causes :
Poor cleaning of substrate prior to
painting.
Lint containing overalls or clothes.
Remedies :
For severe faults, sand out the
problem and repaint
Blistering
Causes :
Improper surface cleaning or preparation.
Tiny specks of dirt left on a surface can
act like a sponge and hold moisture.
When the finish is exposed to the sun or
abrupt changes in atmospheric pressure,
Moisture expands and builds up pressure.
If the pressure is great enough, blisters
form.
Remedies :
Sand down and remove the paint
layers back to a sound substrate.
Be prepared to strip the areas back to
bare metal where necessary.
Refinish with the correct choice of primers
fillers and top-coats.
Brush Marks
Causes :
Viscosity of material may be too high
for brush application.
Incorrect thinners used in the paint.
Inadequate mixing or poor application
technique.
Two-pack paints may have exceeded
application pot-life.
Remedies :
• Use brushing grade of paint and
apply adequate thickness.
• Thin paint to brushing viscosity.
• Use within pot-life.
Chalking
Causes :
Disintegration of the binder

on exposure to weathering
and /or UV light.
Remedies :
Apply a topcoat having high

resistance to chalking, such
as a polyurethane coating or
acrylic coating.
Cracking/Crazing
Causes :
Cracking is generally a stress related
failure and can be attributed to surface
movement, ageing and lack of
flexibility of the coating.
The thicker the paint film the greater
the possibility it will cracks.
Remedies :
• Use correct coating systems,
application techniques and dry film
thickness.
• Alternatively, use a more flexible
coating system.
Holidays
Causes :
Poor application
techniques.
Lack of quality control.
Remedies :
• Use correct application

techniques.
• Apply good painting
practices.
• Carry regular inspection.
Causes :
Orange Peel
Spray gun held too far from object.
Spray pressure too low (poor atomization).
Paint film too thin.
Viscosity to high.(paint too thick).
Spray nozzle too small.
Remedies :
Keep spray gun within the recommended
distance from the object.
Ensure spray pressure is as recommended.
Always apply wet coats.
Adjust paint viscosity as recommended.
Choose correct hardener
See tech data for correct choice of spray
nozzle.
SG 15
Laboratory Tests
For Coating Systems:-
(i) Salt spray test (ASTM B117)
(ii) Adhesion test (ASTM D4541 / ASTM D3359)
(iii) Impact test (ASTM D2749)
(iv) Abrasion test (ASTM D4060)
(v) Acclerated weathering (ASTM G26)

Painting and Coating - SKG15 Slides

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Painting and Coating - SKG15 Slides

Uploaded by

Copyright:

Available Formats

INSPECTION AND MATERIALS ENGINEERING

various types of paint defects, identify the root

How does a coating system protect the substrate?

3 categories of paint defects:

Defect after application.

Common types of Paint

A coating system is a functional unit that provides

A typical system consists of 3 coats:-

A base for subsequent coating to adhere.

Additional barrier coat.

Provide a surface to which a subsequent coating

Enchance weathering resistance and wear

Provide colour and gloss.

Coating Selection Process

Corrosives and Eposures.

new or painted substrate.

blast cleaning or power tool.

4. Tidal and Splash Zone.

1. (I) EXTERIOR NON-INSULATED - Includes

1st Coat : Inorganic Zinc or Epoxy Zinc (75mm)

2nd Coat : High Solids Epoxy (150mm)

3rd Coat : Aliphatic Polyurethane (50mm)

Maintenance (Blast Cleaning)

1st Coat : Epoxy Zinc (75 mm)

2nd Coat: High Solids Epoxy (150 mm)

3rd Coat : Aliphatic Polyurethane (50 mm)

Maintenance (Power Tool Cleaning)

1st Coat : Surface Tolerant Epoxy (125 mm)

2nd Coat: Surface Tolerant Epoxy (125 mm)

3rd Coat : Aliphatic Polyurethane (50 mm)

1 (ii) Exterior Insulated

Maintenance (Blast Cleaning)

Maintenance (power tool Cleaning)

1 (iii) Exterior 110ºC - 250ºC

New Painting and Maintenance

1st Coat : Inorganic Zinc (75 mm)

2nd Coat : Silicone Acrylic (30 mm)

3rd Coat : Silicone Acrylic ((30 mm)

1 (iv) Exterior 250ºC - 450ºC

New Painting and maintenance

1st Coat : Inorganic Zinc (75 mm)

2nd Coat : Silicone Aluminium (25 mm)

3rd Coat : Silicone Aluminium (25 mm)

New Painting and Maintenance.

1st Coat : Surface Tolerant Epoxy (150 mm)

3. PLATFORM DECK - including

New Painting and Maintenance.

(Anti-skid aluminium oxide 20-30 mesh)

4. TIDAL AND SPLASH

New Painting and Maintenance.

1st Coat : Glass Flake Polyester or Glass Flake

2nd Coat : Glass Flake Polyester or Glass Flake

5. (i) TANK LINING

New Painting and Maintenace.

1st Coat : Amine Adduct Epoxy (125 mm)

2nd Coat : Amine Adduct Epoxy (125 mm)

5.(ii) TANK LINING

New Painting And Maintenance.

1st Coat : Amine Adduct Epoxy (100 mm)

2nd Coat : Amine Adduct Epoxy (100 mm)

3rd Coat : Amine Adduct Epoxy (100 mm)

5. (iii) TANK LINING

New Printing and Maintenance