Surface Preparation Methods and Standards If the products of the corrosion reactions, and other contaminants, were left on a substrate and paint applied over them, the adhesion of the coating and thus the coatings life would be far from satisfactory. Surface preparation involves removing these contaminants, and in some instances increasing the area available for adhesion by roughening up the substrate. A good surface preparation grade (degree of cleanliness) along with a suitable surface profile Gan’ give 10 years life froma “Typical four coat paint system. The same system applied over a substrate with litle oF “To profile and contaminiant remaining might give four to six years, or even less. Therefore two factors need to be considered when inspecting a surface preparation 1 Degtea of cleantiness/_ 2 Sar ess ngtres)/ If a specification gives criteria for both of these factors, then quality is not achieved until both criteria are satisfied. Surfaces can be prepared for paint application in several different ways, each one varies in cost, efficiency, ease and suitability. a) Dry abrasive blast cleaning _ ») Water blasting Dry abrasive blast cleaning Dry abrasive blast cleaning involves compressing air and forcing it along a hose and out of a small aperture called a nozzle. A pre: of 100psi results in the air exitit the nozzle at approximately 450mphyIf abrasive particles are mixed in with the air and travel at the same speed, they will carry a lot of work energy. This energy is used in chipping away millscale and other detritus from the substrate. With some abrasives part of the energy is used in shattering into small pieces and with others all the energy is used in impinging into the ste! surface, roughening the surface and increasing the surface area to increase adhesion properties. Because all standards refer to the amount of contamination remaining on the surface, the longer the time spent on this operation, the higher the degree of cleanliness. Abrasives Abrasives come in many forms and can be classified in several different ways, as shown below. Rev 2 January 2010 - Surface Properaton a Copyright © TW Ltd 2010 LMT ‘sewer ee.0cv_Ptone metallic (mineral) expendable Metallic (recyclable) Agricultural by-product Copper slag— ‘ACI (angular chilled iron) Walnut shell {Mickel slag Steel grit Coconut shell ~Boiler slag Steel shot Eggshell 1_ Glass bead Grit and shot mix Com cob husk [Aquamarine (olivine) Gamet Peach husk It can be seen that the recyclable abrasives are the more costly, and therefore justify a cleansing operation before re-use. In the context of this course we are considering the following: ey” Sand _Y'It is not permitted to use sand. S| 1657 states that any mineral used as an abrasive S11657 must release less than 1% free silica on impact. (Silica causes pneumonicosis_or is.) COSHH regulatior “of sand containing silica for dry fing. Sand itself is perfectly safe, but shattering on impact releases silica which can be inhaled ‘by’ Copper slag Although the name implies metallic content the amount of copper in the structure is extremely minute. Minerals smelted with the copper, liquefy and form a protective cover over the molten copper to prevent reaction with the atmosphere like slag on a weld. When the copper metal is run off the slag is rapidly cooled in cold running water, which causes it to shatter. The material is supplied in grit form (random, sharp edges, amorphous) and is very brittle, _ shatters into smaller pieces on 1 impact, and should be used only once and itis class is xpendable)) _ - ss) Garnet~ A natural mineral classed as being of diamond type hardness, can be either ‘expendable GP recyclable. If the situation justifies, cleansing units are available to extract contamination so that the material can be reused, usually up to three times. Doesn't shatter on impact but does suffer some wear, supplied in grit form. BY Metalic art Crsect ont the Prtlile F arey Relves Guckece In this context, steel and iron are both metallic. Cast steel grit being the softer of the two tends to round off on impact and loses its sharp edges. Angular chilled iron chips off small slivers on impact to produce sharp cutting surfaces on its next cycle. The finings so produced are extremely abrasive and cause extreme wear on moving parts of the recovery systems. Metallic abrasives are recyclable because the particles reduce in size slowly. Hence it can be re-used many times and still perform a useful function in a working mix. A Rev 2 January 2010 Surface Preparation Copyright © Twit Ltd 2010 TWI wonocenrre For MATERIALS Soma TECHNOLOGYoo Q working mix is an accepted ratio of large and small particles, where the large particles cut the profile and the smaller particles clean out the troughs. we} “Metalic shot > conjrole te Feaks. Shot is spherical and doesn't shatter (otherwise it would form grit). When supplied the particles are virtually uniform in size and shape, (not a working mix) but like the grit they wear down slowly in size. Regular addition of new abrasive as, with grit, will then maintain a working mix. The particles are worn down eventually to finings, and are drawn out of the system during cleansing. AT” Metallic shot and grit mixed ‘A mix of shot and grit results in a more uniform profile. The grit cuts the profile and the shot, being unable to enter the troughs produced, controls the peak height and so greatly reduces the number of rogue peaks. A rogue peak is one, which is well proud of the acceptable profile range, and if painted over due to contraction of the paint, will leave bare metal in contact with the atmosphere, thus allowing corrosion to occur. When rogue peaks are in concentrated area the effect is of a rash, hence rust rashing or rust spotting, ‘WA typical mix ratio of shot to grit as used in a pipe coating mill would be 70-80% shot to.20-30% arit Other properties of an abrasive have an effect on the resulting substrate also, these being. Size of the particles. Hardness of the material. Density of the material Shape of the particle. For example steel has a density of approximately 7.6gm/cc and copper slag, depending on composition, approximately 4.2gmicc. If one particle of each material, of identical size, hit a steel substrate, then it would be logical to say that the steel would impinge further into the substrate, resulting in a deeper trough. A spherical particle would not impinge as deeply because the large smooth surface area would use its energy up in peening or work hardening the surface rather than cutting into it. So a shot blasted surface is different in appearance and texture to that of a grit blasted surface. ing of abrasives * G prefix = grit_amorphous, points and cutting edges, irregular profile. « S prefix = shot_spherical, smoother profile. The G or S notation is followed by a number, which denotes the particle size. eg G24 or $330. From system to system the number can represent vastly different values, eg with the now defunct BS 2451 the 24 means nominally 24 thousandths of an inch where as in the Spe system it represents '/zs inch = approximately 40 thou. The new # Qrvit. Society by Aatometite Soy Rev 2 January 2010 — Surface Preparation TIWI wonncenrne Copyright © TW La 2010 MT ei eto.oorY¥.BS 7079 pt E uses a different method again, in metric units. G140 would mean a nominal particle size of 1.4mm, Adhesion and profile A commonly used definition of adhesion is tne force required to separate two surfacesiin touch.” A newly rolled plate, perfectly smooth, 1m x 1m has an apparent surface area of 4m? and an actual area of 1m*. Abrasive blasting roughens the surface and increases the actual area, (the apparent area is still 1m’), thus increasing the adhesion. Two theories of adhesion are: 1 Molecular interference: Because the surface is rough and uneven the paint wets, and Tocks into the profile, analogy velcra. Physical ° se velcro e crainsype dink - 2 Molecular attraction: Negatively charged particles “rected to positive areas, and vice versa. Analogy magnet (sometimes called ionic bonding). Chemical. 1A omgmet Profile err a Surface profile, anchor pattern, key, peak to trough height and amplitude are all expression meaning the cross section of a blasted area, as measured from the top of the peaks to the bottom of the troughs. The surface profile requirements are given on the specification for the job, eg for’BGAS 30-75 microns’ Actual sample size: 0.5mm x 0.5mm. Profile height 28.5 microns. Blasted with grit. ‘Rev 2 January 2010 a SisacePreperaton TWI ror pcone Copyright © TWI Ltd 2010 CM ‘own ceno.0Shot blasted profile Also amplitude, key, anchor pattern, surface profile. Peak to trough Figure 2.1 Terms relating to preparing surfaces. Other terms relating to preparing surfaces are illustrated below. _ Peau peak \ Surface Lamination Goer Figure 2.2 Grit blasted profile. lackld: A small surface lamination, which stands upright like a needle after blasting. Foximately < 13mm. Easily remover Lamination:-Appears to be a longitudinal crack, one lip curling back, any laminations (slivers) found must be referred to engineer for ultrasonic. check. Profile measurement If a profile requirement is specified, it is the inspector's duty to ensure that the specification requirements are met. This can be done in two ways. a) Measuring using gauges with and without replica tape. b) Assessing using surface comparators, Digital gauges are common nowadays, but refineries, gas plant, etc have stringent safety requirements and batteries can produce sparks, so the dial gauges are still very often used. The dial gauges fall into two categories, surface profile needle gauge and dial micrometers and replica tape. c jauge: The gauge is applied to the blasted substrate and the needle can be felt to locate a trough. Then by applying a slight pressure to allow the flat ‘foot’ of the gauge to sit firmly on the peaks of the blasted substrate, the needle will pass into the trough as far as it can Rev 2 January 2010 WI. Surface Preparation TWI wonscenrne Copyright © TW Lid 2010 WIM ‘coo eenoorTo measure the difference from peak to trough we need to zero the gauge when the point of the needle is on the same plane as the flat foot, ie on a smooth piece of glass. This is done by applying slight pressure to the foot to ensure that it is perfectly flat on the glass, By loosening the locking screw, the bezel can now be moved easily in any direction, Still applying the slight pressure, the bezel should be moved so that the zero on the gauge is immediately behind the needle, then tighten the locking screw and the gauge is ready for use. When using this type of gauge it is normal to work to an average figure. Several readings are taken, usually more than ten, in random positions over the substrate, and the average calculated. This type of gauge is not ideally suited for curved areas such as pipes. calabowte y mag so vending eed 42 ow Figure 2.3 Surface profile needle gauge. \_- Bilal micrometer and replica tape: Replica tape, more often referred to by its trade name Testex, is also sometimes called corn plaster method. Although more costly than the needle gauge this method provides a permanent record and the traceability required from quality systems. The tapes are supplied in two grades: Coarse and extra coarse grade, to cover two different ranges of blasted profiles. sina for measuring profiles 0.8 to 2 thou inch. oso 15pm Ext coarse grade for measuring profiles 1.5 to 4.5 thou inch Co um > Rev 2 January 2010 TWI wonscere Surface Preparation won comms Copyright © TWI Ltd 2010 LMI cnmerervoo0rThe correct tape should be selected otherwise the readings will not be accurate. Mylar tough transparent / polyester plastic 7 x Paper Testex paste Figure 2.4 Cross section of a replica tape. The procedure for using replica tape is: Zero the dial micrometer. Clean the anvils (paper or fingers) and allow the contacts to come together, release the locking screws and adjust the bezel so that the zero is immediately behind the large needle. Remove the backing paper from the replica tape, ensuring that the small white disc with the black ring is detached also. Stick the replica tape to the area to be measured. A _ Using a pen or pencil end, or the specially provided plastic stick, rub firmly and evenly all over the area of the mylar. This causes the testex paste to pass into the troughs and the peaks of the blast will butt up to the transparent mylar. 4” Remove the replica tape and check. The mylar area shauld no longer-be white (now grey), and pinpricks of light should be visible through the mylar when held up to the light. & Place the testex paste area between the anvils of the micrometer and allow them to gently close together. From the final reading on the gauge deduct two thou if using an imperial gauge or 50um if using a metric gauge, The balance figure is the peak to trough height of the profile. Rev 2 January 2010 Surface Preparation TW mono cenree Copyright © TWI Ltd 2010 JOWING TECHNOLOGY2um, 104m Replica tape (60um of plastic _< 3 backing) Figure 2.5 Metric micrometer for testex measurement in microns. 4mm = 1000um 25.4um = 0,001 inch (1 thou.) 40 thou inch = 1mm 25.4mm = 1 inch Example: Micrometer is reading 93m, subtract 50um for testex plastic backing. The surface amplitude is therefore 434m Rev 2 January 2010 —— Surface Preparation TWI won cenne Copyright © TWI Ltd 2010 Sonne TECHNOLOGY100 microns Testex {allow 50 microns 0.05mm for plastic backing) Micrometer is reading 80 microns (0.080mm) subtract 50 microns (0.050mm) for testex plastic backing, the surface amplitude is therefore 30 microns. Rev 2 January 2010 — ‘Surface Preparation TWI worn cou Copyright © TW Ltd 2010 MT ‘ewe reenso.00%Testex Micrometer is reading 4.6 thou (rOee tne) for plastic (0.0046 inch), subtract 2 thou backing (0.002 inch) for testex plastic backing, the surface amplitude is therefore 2.6 thou (0.0026 inch) Figure 2.7 Imperial micrometer for testex measurement in 1000 of an inch. Reading the gauges There are four common scales for dial micrometers, one of which, the 2um scale is also used on the needle gauge. The common scales are: 0.01mm 10 microns/small division 0.002mm 2 microns/small division 0.001 inch = 1 thou/small division 0.0001 inch= "/;o thou/small division With all four scales the value given represents the smallest increment on the periphery of the large scale. The small dial at 11 or 1 o-clock position gives the number of complete revolutions of the needle on the main scale. Typically the 2um scale is 200m per full revolution. Most profiles are around 75-100ym. Therefore the small dial can be virtually ignored for normal use. =~ s Asses: ing a profile to BS 7079 Pt C ISO 8503. Grit and shot abrasives produce different surface profiles, therefore two comparators are specified. One for grit blasted profiles, G. and one for shot blasted profiles, S. When a mix has been used then the reference comparator should be G. In all 2 entire area should be blasted to SA2"/ or SA3 grade (discussed later). Rev 2 January 2010 Surface Preparation TWI wonuncenrae Copyright © TWI Ltd 2010 Sonne TECHNOLOGYUse of the comparators Three methods can be employed to assess the roughness characteristics of blast cleaned steel. 1 Naked eye 2 Visual aid, not exceeding 7x magnification 3 Tactile (Note: The comparators are not for assessing cleanliness.) The comparators to BS 7079 are approximately 8cm square with a 2cm diameter hole in the middle, and are divided into four segments, by smooth strips. On each strip is an arrow indicating the segment number. Segment one is the smoothest and the degree of roughness progressively increases up to segment four. Using the comparators With all three methods it is important to remember that the prepared surface should Not be touched (contamination). For the tactile method the fingernail or a clean wooden stylus may be used. The principle is to compare the surface profile of the blasted steel with the segments ‘on the ISO/BS comparator, looking for two segments between whose profile the test surface lies. The grading used sing -Profes equal to segment one and up to, but excluding segment two. edi -Profiles equal to segment two and up to, but excluding segment three. (omre -Profiles equal to segment three and up to, but excluding segment four. Any profile below the lower ‘Any profile above the upper limit for coarse grading is referred to-as-coarser than coarse, Because the blasted surface is considered to be a secondary profile, the primary profile is the surface of the steel prior to abrasive blasting. The primary profile is therefore going to have an effect on the secondary profile. It is customary to report on the condition of the substrate before preparation in the following manner. Rev 2 January 2010 Surtace Preperation WY vosscouts Copyright © TWI Ltd 2010 JOINING TECHNOLOGY