Professional Documents
Culture Documents
Section
General
Section
Scope
Section
Surface Preparation
3.1
3.2
Section
3.3
Miscellaneous.
Coating Material
4.1
General
4.2
Material Specification
4.3
Coating application
4.3.1
4.3.2
4.3.3
Section
Solvent Cleaning.
Hand tool cleaning
Power tool cleaning
Brush off blast
Commercial blast
Near white metal blast
White metal blast
Compressor
Nozzle
Abrasive
Spray equipment
Spray application
Brush application
Inspection
5.1
5.2
Surface preparation
5.2.1
5.2.2
5.2.3
5.2.4
5.3
Coating application
5.3.1
5.3.2
Application procedure
Equipment
5.4
Coating Inspection
5.4.1
5.4.2
5.4.3
Section
Section
Attachment A
Attachment B
Attachment C
Attachment - D
Attachment - E
Safety
6.1
6.2
6.3
6.4
General
Good housekeeping
Sand Blasting
Coating application
Implementation
7.1
7.2
7.3
7.4
Coating specification
Contractor selection
Job scheduling
Coating job progressive inspection.
;
;
;
:
:
Coating Inspection
Equipment check list
Inspector Test report.
Paint Failure Causes
Standard Terminology for Paint and other coating materials.
Epoxy history
The word epoxy is derived from two Greek prefixes - epi, which means "upon" and oxy, which
means "sharp/acidic".
The history of epoxy chemistry probably began in the early 1900s, when the Russian chemist
Prileschajev discovered that olefins react with peroxybenzoic acid to form epoxides. In the mid1930s, the German P. Schlock applied for a patent on the preparation of high molecular weight
polyamines by making the amines react with epoxides compounds that contain more than one
epoxides group. The patent was described as the epoxide compounds' reaction of epichlorohydrin
with biphenyl A.
The epoxy chemistry that we know today within the fields of marine and industrial protection was
recognized simultaneously by P. Castan from Switzerland and S. Greenlee from USA. These two
chemists applied for various patents in the late 1930s. The first type of epoxy resin was
commercialized by Ciba in 1946. Hempel launched its first epoxy products in the mid-1950s,
under the names Tanker Protect Primer and Tanker Protect Topcoat. Epoxy has since grown to
become the most important product used as surface protection in marine and industrial
applications.
Section
General
What is corrosion
Corrosion is the result of a conversion process that takes place when oxygen and moisture
come in contact with metal. The oxygen and water combine with iron to create a brown
coating (hydrated ferric oxide) on the surface of the metal.
The interaction between the water and iron is accelerated if salts are added to the mix.
Because the oxide that is created is bulky and porous, it allows oxygen access to the iron
below, causing additional oxidation. If allowed to continue, the iron metal will be completely
converted to ferric oxide or solid rust, which is weak and flaky.
How can we protect against corrosion?
What do we required to prevent iron and steel from rusting? Rust is an insidious enemy, and costs the owners
enormous sums every year, but by modern painting, it can be fought effectively. We have seen that air (Oxygen) and
moisture are needed to initiate the rusting process; therefore if one of these factors or, for the matter, both, is
prevented from coming into contact with steel, we will counter act rusting. We can do this by
mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm
mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm
mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm
mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm
mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm
mmmmmmmmmmmmmmmmmputting a barrier or membrane on the steel-if this barrier is impermeable to moisture
and oxygen we will have prevented all rust-formation and corrosion. In order to make this possible, it is important that
oxygen or water are not allowed to penetrate underneath the barrier or membrane.
A paint film will give us such a barrier. From what we have seen, a paint film must have the following property to be
able to give effective protection. It must be as impermeable as possible. Naturally, a thick film is more impermeable
than a thin paint film. Therefore, within practical limits, the paint film must be sufficiently thick. We have said there
must be no oxygen or moisture present under the paint film so that corrosion cannot be initiated here with out a supply
of these from outside.
For protection against corrosion, to chief principals are followed
1. We have paints, which form barriers between air and moisture on the one side and steel on the other side. The
following are the examples of barriers-forming coatings. Conventional paints, epoxy paints, vinyl paints,
polyurethane paints, and chlorinated rubber paints. This kind of corrosion protection is most common.
2. The other chief principal is based on the use of active rust preventing zinc-rich paints. This kind of corrosion
protection is widely used because of its effectiveness. The old fashioned red lead paint and, for example, zinc
chromate primer stops corrosion primarily by forming a barrier. In addition the special pigments (lead
compounds and zinc chromate) act as a corrosion inhibitor. This effect is partly based on the lead compound
reacting with linseed oil and partly on water dissolving the pigment by penetrating the paint. Corrosion
inhibition is therefore obtained through a chemical reaction. This kind of corrosion prevention is now of less
importance, lead compounds, for example, make the paint poisonous (danger during spraying); whilst at the
same time the increasing use of water resistance binders has reduced the importance of these pigments types
and principles. Further more, using linseed oil as a binder is impractical because of the long drying time
required. Use of quick drying binders reduces to a large extent the effect of the red lead pigments.
Section
Scope
These guide lines shall govern the design, materials, surface preparation, application, and inspection requirements of
all maintenance painting and coating jobs pertaining to surface piping and flow lines, storage tanks, and process
vessels. Guide lines for internal re-coating of salt water tanks, gun barrels, and separators are also included.
The details specified here are minimum guide lines only. Depending on availability of materials and equipment, the
coating contractor or maintenance crew may recommend different systems than the ones outlined in this report. Full
details must be provided to the corrosion engineer for review and approval prior to using a different system all work
will be subject to inspection by the corrosion engineer or his designate, which shall be given advanced notice prior to
work commencement. Each coating job will require a thorough step by step inspection by a trained and certified
coating inspector such an inspector can be hired on a daily rate basis for the duration of each job it will be the
inspectors responsibility to get the job done in accordance with these guide lines.
A contractor having adequate equipment and trained people for each activity should do coating jobs requiring sand
blasting and use of air or air less spray. A number of such contractors having vast experience with local petroleum
refinery/marketing organization are locally available. A bid specification can be easily prepared for such contractors
using these guide lines. A special task force created from the maintenance crew can do coating job requiring manual
cleaning and brush application. Such a task force will consist of two peoples one of which will be team leader. The
team leader can be trained in basic inspection techniques applicable to manual cleaning/ application. This training can
be organized in house by the corrosion engineer. Since the volume of work involving manual cleaning/application is
very large and needs to be covered in a reasonable time. The in house coating task force can get trained during this
period and can handle future maintenance coating requirements.
THE FOLLOWING SURFACES ARE NOT COVERED IN THESE GUIDELINES AND DONOT REQUIRE
PAINTING/COATING.
1. Non ferrous metals.
2. Plastic or plastic coated surfaces.
3. Instrument cases, watch glasses, junction boxes, threaded or machined surfaces and other factory painted
items.
Section
Surface Preparation
A surface preparation is the most critical part of the coating job. Each type of coating requires a particular type of
surface cleanliness and roughness (also called anchor pattern). Before a particular type of surface preparation
technique is used, the following preparation is recommended:1. All rough welds, wells spotters, identification, and all other sharp surface projections shall be grounded
smoothed prior to further surface preparation. Any grinding done after sand blasting shall be reblasted to
obtain proper anchor pattern. Grinding should not decrease weld wall thickness.
2. All bore holes shall be drilled and smoothed before sand blasting.
3. Oil, Greece, tar, or other contamination shall be removed using clean rags and a non oily solvent such as
xylan prior to surface preparation. Gasoline shall never be used.
PRE-TREATMENT.
How important is pre-treatment?
Because of its prime importance it is necessary to set a quality standard of pre-treatment cleanliness. The most
important internationally used standard is that describe in SWEDISH STANDARD SIS 055900. We have seen that
pre-treatment is of prime importance for the result obtained with respect to anti corrosive action and thus the cost.
When deciding on the type of pre-treatment and the paint system to be used, the large sum of money involved must
always be come in mind.
The pre-treatment norms are based on four different grades of corrosion, A, B, C, D, which represent respectively:A. Steel surface covered completely with adherent mil scale with little, if any, rust. This condition of the steel is
after a short time after roling.
B. Steel surface, which has begun to corrode, and from which the mill scale has begun to flake.
C. Steel surface on which the mill scale has corroded away or from which it can be scraped, but with little pitting
visible to the naked eye.
D. Steel surface on which mill scale has corroded away and on which considerable pitting is visible to the naked
eye.
According to SIS 055900, pre-treatment for these degrees of corrosion is respectively wire brushing and blast
cleaning to the following quality scale:1. Bad. (Light brushing or light scraping).
2. Middle quality (thorough scraping with hard metal scrapper and wire brushing or thorough blast cleaning).
3. Thorough scrapping or wire brushing till distinct metal luster is obtained or blast cleaning to clean gray steel.
St indicates wire brushing and Sa blast cleaning. Thus the norm will be the following:St 1, St 2, St 3, and Sa1, Sa2, Sa 3.
After the norms had been in use for a while, a norm line between Sa 2 and Sa 3 was found necessary. The steel had to
be thoroughly sand blasted and all mill scale, rust and foreign particles removed, but faint shadows or strips were
allowed on the surface. An extra norm was thus made Sa2,. The norms can be found in a book published by the
Swedish Standard Institution. In this book the norm describe by a text explaining how the work should be done, and
illustrated by color photos which can be compared to the finish treatment to see whether this is unto the specified
standard.
It has been proved that SIS 055900 is an excellent aid in connection with treatment in workshops. When the pretreatment norm have been agreed upon, there is little basis for discussion. Afterward regarding the quality of the work.
Maintenance, however, does not consist of painting alone, but also --- as repeatedly infancies ---- of pre-treatment,
washing and cleaning process.
There are many things to consider when planning a maintenance job, and for the pre-treatment we must choose:1. Method
2. Tool.
Depending on the following: Degree of damage to the surface. If the whole surface is more or less destroyed by rust, certain
method and tools are chosen. If there is only smaller spots of rust, for instance on a welding seam or
bolt head, and method and tools will be chosen.
What kind of tools is available? Unfortunately, in our country not every contractor has all the
necessary equipment.1. Large, mobile blast cleaning equipment.
2. Vacuum blasting equipment.
3. Air-driven grinding equipment.
4. Rotary wirebrush.
5. Needle gun.
6. Air driven descaler.
7. Manual scraper with exchangeable hard metal edge.
8. Hand wire brushes of various sizes.
Which paint system is to be used? As modern, sophisticated paint systems are in use in many
countries, required different pretreatment norms.
The nature of the surface --- different methods and tools are used for pretreatment.
Previous treatment --- If for instance epoxy paint has been used, it is necessary to flatten the surface
mechanically to obtain good adhesion for the next coat. If chlorinated rubber paint has been used, this
is not necessary.
Result required--- In certain cases durability is the most important factor. On the other hand it is
necessary to do the work quickly. Pretreatment includes far more than wire brushing or scraping. A
well done maintenance job includes a rule most of the following operations :1. Removal of loose rust, loose paint, and mill scale.
2. Removal of grease, oil, and dirt.
3. Removal of unwanted paint (if the former coat of paint is so thick that it has lost its protection properties
--- if a more advanced system is desired or if the original coat of paint is of poor quality).
4. Abrasion of sharp edges.
5. Roughening of glossy paint.
6. Thorough washing down with fresh water to remove dust and salt.
The following methods can be used to remove and loosen under-rusted paint.
METHOD
1. Blast-cleaning
2. Mechanical wire brushing
3. Mechanical disk-sanding
4. Needle chipping
5. Mechanical rust-chipping
6. Mechanical scraping (air-powered)
7. Hand brushing
8. Hand scraping
RESULT
Ideal
Risk of polishing
some risk of polishing
some risk of indentations
not good heavy indentations
Good combined with other methods
Poor
only to be used with in combinations
With other methods
Nothing can compete with blast-cleaning to obtain the best result. Air powered (mechanical) tools generally give
better results to obtain the best result than hand tools. There is no doubt about the superiority of the blast cleaning
method. This method gives an ideal foundation for paint , and blast cleaning combined with a modern, correctly used
paint system will make the paint last 4-5 times as long . Result have been obtained with blast cleaned surfaces that
have lasted 10 times as long as corresponding surfaces pretreated in a conventional way and painted with the same
paint system.
3.1
3.1.2
Hand tool cleaning (also called SSPC-SP-2, SIS St-2)
This type of cleaning requires removal of loose rust, mill scale, and paint by hand chipping,
scraping, sanding or wire brushing. The resulting surface has a faint metallic sheen. The
cleaned surface appearance corresponded to the Swedish standard designated as St-2.
3.1.3.
Power tool Cleaning (Also called SSPC- SP-3, SIS St-3)
This requires removal of loose rust, mill scale, and paint by power tool chipping, sanding wire brushing,
and grinding. The speed of surface preparation is higher than hand tool cleaning, and the resulting surface
has a pronounced metallic sheen. Its appearance corresponded to the Swedish standard designated as St-3.
3.1.4
Brush-off Blast (also called SIS SA-1, SSPC-SP 7, NACE 4).
This is a surface preparation method in which all oil, grease, dirt, rust scale, loose mill scales, loose rust,
and loose paints and coating are removed completely, but tightly adhered rust, paint, and coating and
permitted to remain provided that all mill scale, and rust have been exposed to abrasive blast pattern
sufficiently to expose numerous flecks of underlying metal fairly uniformly distributed over the entire
surface.
3.1.5
Commercial Blast (also called SIS SA-2, SSPC-SP 6, NACE 4).
This is a surface preparation where at least 2/3 of each element of area is in white metal condition. All oil,
grease, dirt, rust scale, and foreign matter shall be completely removed from the surface and all rust, mill
scale, and old paint shall be completely removed except for slight shadows, streaks, or slight
discoloration caused by rust stain, mill scale oxides, or slight, light residues of paint or coating that may
remain. If the surface is pitted slight residues of rust or paint may be found in the bottom of the pit.
3.1.6
Near White Metal Blast (also called SIS SA-2.5, SSPC SP-10, NACE 1).
This is a surface preparation where at least 95% of each element of area, is in white metal condition. All
oil, grease, dirt, mill scale, rust, corrosion products, oxides, paint or other foreign matter shall be
completely removed from the surface except for very light shadows, very light streaks, or slight
discoloration caused by rust stain, mill scale oxides, or slight, tight residues of paint or coating that may
remain.
3.1.7
White Metal Blast (also called SIS SA-3, SSPC SP-5, NACE 1).
This is the degree of surface cleanliness required to achieve a surface with a grey white, uniform
metallic color, slightly roughened to form a suitable anchor pattern for coating adhesion. The surface,
when viewed without magnification, shall be free of oil, grease, dirt, mill scale, rust, corrosion products,
oxides, paint or may other foreign matter.
The following main rules should be followed:
Use correct pressure. Correct nozzle pressure is 7 7.5 kg/cm. (100 107 psi). Reducing the pressure to 4
4.5 kg/cm. *57 65 psi) often leads to doubling of the amount of sand needed per m.
Loose paint and rust must be removed prior to sandblasting. Using driven chisel or hard metal scraper does
this. This removal of coarse impurities prior to blast cleaning has, in some cases, reduced the sand consumption
to a quarter.
Use the correct properties of sand/grit and air. Note that it is often good economy to pay more for the sand, as
poor quality sand gives dust problems and low effect. The sand should not be used more than twice (preferably
only once).it is important to remove dust from the blasted surface with oil free compressed air or a special
vacuum cleaner, or alternatively sweep the surface prior to applying the first coat of paint. At 100 psi.
Blast-clean a small area at a time. Protect this with primer, as they are finished. Zinc rich primer gives the best
protection and allows the rust area to blast little by little and covered by zinc rich primer. After completion of this
practice whole the area can be painted with the selected paint system. This is the most effective work procedure. Zinc
rich primer dries rapidly after it has been applied, and the blast cleaning can be carried out side by side with the
freshly painted areas without sand sticking to the surface. (Hard Dry 1 hr).
3.2
Blasting Equipment Selection. Abrasive blast equipment shall be inspected before use. All fittings and hoses
shall be in good condition and tightly attached. The air intake shall be remotely located from all
vehicles/equipment exhaust system to ensure harmful emissions are not taken into the work area.
Contamination of inlet air to the compressor can adversely affect purifier performance. The compressor intake
shall be located to avoid intake of contaminated air and to ensure air with adequate oxygen contents.
3.2.1
3.2.2
Compressor. The ideal working pressure for air blast cleaning equipment is 90 100 psi is at the
abrasive discharge nozzle. This can be verified by utilizing a hypodermic needle gauge inserted
through the blast hose immediately behind the nozzle when the equipment is under normal operation,
discharging the abrasive. Compressor shall deliver the volume and pressure of air required to perform
work effectively and safely. Oil-lubricated compressors shall have an overheat sensor or carbon
monoxide sensor if a respirator (other than air-supplied) is used in poorly ventilated areas. A regulator
valve shall be used at the compressor, set to manufacturer specifications, to provide adequate air
pressure to abrasive blast equipment.
Nozzle. The abrasive blast cleaning nozzle shell be equipped with an operating valve which must be
held open manually. The sizing of the abrasive discharge nozzle should be correctly matched with the
discharge volume capacity of the compressor. To conform in optimum conditions, a compressor
should not be required to operate above 75% of its rated capacity. The correct sizing of nozzle
discharge orifice versus compressor discharge capacity is as follow:
Compressor rated at 125 cfm at 100 psi.
a.
one orifice of " dia, delivering delivering 81 cfm or
b.
Two orifices of 3/16" dia, delivering 80 cfm.
3.2.3
Abrasive. The quality of the cleaned surface following an abrasive blast is strongly influenced by the
size and the shape of the abrasive used. The preferred abrasives for most high performance coatings
and the ones, which provide the most generally accepted surface, are:
16 - 40 mesh silica sand or minerals grit.
G 50 irons grit.
These materials provide a surface profile from 1.5 to 3.5 mils (36 to 87 ), and are able to produce whatever
degree of surface cleanliness is required. In field application such as maintenance painting, sandblasting or
synthetic blast media are the preferred choice due to wastage factor.
3.3 Miscellaneous.
3.3.1
3.3.2
3.3.3
3.3.4
Use dry abrasive, free from dust, salt and other impurities. Laborarory test is the better way to check.
Keep moisture, oil, grease, or other organic matters off the cleaned surface, before priming. Spot
reblast to remove any contamination. Solvent wiping is unsatisfactory.
Applying coating as soon as possible to prevent the blasted surface from rusting. Cleaning
should be discontinued each day in sufficient time to permit cleaned surface to be inspected and
primed before the end of the working day. The maximum time between blasting and priming for
systems requiring blast cleaning shall be for four hours.
Dry blast cleaning shall not be done in rain, mist or fog, or when the relative humidity is above 85%
or when other conditions exist which would prevent the crew from painting the cleaned surface at the
end of the working day. Due to the possibility of rains, major coating jobs should not be scheduled in
the month of July and August near the sea.
Most of the coatings used consist of multiple layers called coatings. The first coat is called primer coat and is different
from intermediate or finish coat. Some coating systems consist of only one coat, which act as both primer and top
coat.
4.1.7
Adequate facilities should be provided to store coating materials on site to protect them from rain,
dust and sun.
Coating materials shall be inspected when opened for use. Any material that has gelded, or otherwise
deteriorated during storage shall not be used.
All surfaces to be coated shall be rendered dust free prior to primer coat application except when
surface tolerant coatings are used. This shall be accomplished by blowing the surface with clean dry
air or with clean rags if the area is small.
All coating materials are thoroughly stirred in a pressure pot with power mixer for a time sufficient to
thoroughly re-mix the pigments and vehicles. Only thinners as specified by the manufacturer should
be used. Mixing directions as furnished by the manufacturer should be followed.
Pot life of catalyzed coating should not be exceeded. When the pot life limit is reached, the spray pot
must be emptied material discarded, the equipment cleaned and new material is catalyzed.
No coating should be applied when surfaced are less than 5 F above due point, and the relative
humidity is above 80%, when the air temperature is below 40 F, or if there is a likelihood of changes
in weather conditions within two hours after application which would result in condensation upon the
surface. Normally, paint/coating is not to be applied to surface exceeding 120 F at the time of
application. Dew point can be determined in accordance with the table attachment C.
Manufacturers recommendations should be followed with regard to minimum and maximum curing
time between various coats.
Enamel/Polyurethane
Weather Condition
1.Minimum 5 C
2.Maximum 55 C
3.Maximum Humidity 85%
4. Dew Point
HT
LEVEL
3
LT
What Is Paint?
1. Paint is a liquid material, which, when applied on a substrate, turns into a solid, adhering film that
forms a protective and / or decorative coating. Its main constituents are binder and pigments (and
filler). In its liquid form the binder is usually diluted by a solvent to render the paint fir for
application. The combination of binder and solvent is called the vehicle.
2. The BINDER determines the film formation and the general performance of the paint coating. In
most cases it is of a rather complex nature, which is determined by the specific conditions the paint
has to be used under and to withstand. Because of the wide variety of conditions, the universal
binder does not exist, and most likely never will.
3. The PIGMENT is responsible for the decorative value, including color, hiding power, gloss, light
fastness, etc. Certain types are used for other purposes. Such as corrosion inhibition and resistance to
biological attacks, e.g. Fouling under water. Like the binder, the pigmentation of paint represents a
balance of properties.
4. The FILLERS are non coloring pigments especially used to influence some of the physical
properties of the paint.
5. The SOLVENT act as a servant for the other two. It is responsible for the viscosity and for the
application properties. When the paint is applied the solvent has served its purposes and disappears
by evaporation.
6. Paint can be divided into two main groups according to their solidification or film formation which
may be either a physical or a chemical process.
Paint can be divided into two main groups according to their solidification or film formation which
may be either a physical or a chemical process.
1. Physical film formation.
This mechanism can also be described as evaporation drying. The solidification safely relies
on the evaporation of the solvent which is a physical process. The binder in the dry film is
chemically the same as it was in the paint can. The principle binders are of widely different
nature, ranging from bitumen to vinyl. Acrylics and chlorinated polymers. Physically drying
paints are thermoplastic. They are also sensitive to solvents, including their own solvents.
2.
the paint is delivered in two parts to be mixed prior to use. The best known
types are epoxy and urethane.
4.2
Material specification.
The type of coating system used will depend upon the service requirements as well as factors
determining
the degree of surface preparation achieved in a particular situation. The service requirements may vary from general
atmospheric exposure to total immersion in salt water or
produced petroleum. Prior to using, all coating
materials must be checked to ensure thay they meet
US health, safety, and environmental standards.
4.3 Coating application.
4.3.1. Spray equipment.
Lines and pots must be cleaned with solvent / thinner before adding new coating material.
Adequate moisture trap shall be placed between the air supply and the pressure pot feed to the
gun. Water or oil from the air supply should be continuously bled off.
Suitable working regulator and gauges should be provided for air supply to pressure pot, and air
supply to the pressure gun.
Spray equipment should be grounded and non conducting hoses should be used.
For air less spray, equipment should use a 28:1 or 30:1 pump ratio. Air supply should be 80
100 psi.
For conventional air spray, equipment should include pressure pot with mechanical agitator and
separator atomizing and fluid pressure regulators. The compressor should be capable of
supplying continuous volume of 20 cfm at a minimum of 80 psi to each nozzle.
A supply of tips with varying spray angles and washers, as recommended by paint suppliers for
each specific steel configuration to be coated should be available.
4.3.2
Spray application
For airless spray, the spray gun should be held no closer than 1 ft and no further than 2 ft from
the surface.
For air spray the spray gun should be held no closer than 6"and no further than 10" from the
surface.
Even and parallel passes should be made with the spray gun. Each spray should overlap the
previous by 50%. Large surface should be always receiving passes in two directions at right
angles to each other.
Each coat should be applied uniformly and completely over the entire surface. All runs and sags
should be brushed out immediately or the coating/paint should be removed and the surface
resprayed.
Before spraying each coat, all areas such as corners, edges, welds, small brackets, bolts, nuts,
etc. should be recoated by brush to ensure that these areas have at least the minimum specified
film thickness.
4.3.3
Brush application.
Brushes used in brush application should be of a style quality at will permit proper application
of the paint. Round or oval brushes generally are considered most suitable for rivets, bolts,
irregular surfaces, and rough or pitted surfaces. Wide flat brushes are suitable for large flat
areas, but they should not have a width of over 4.5". No extending handles should be allowed
on paint brushes.
Brushing should be done that a smooth coat as nearly uniform in thickness as possible, is
obtained. There should be no deep or detrimental brush marks. Paint/coating should be worked
into all crevices and corners.
In brushing of the solvent base coatings, care must be taken so that no lifting of formers coats
occurs.
11
During application of each coat, all areas such as corners, edges, welds, small brackets, bolts,
nuts, and interstices shall receive additional coating material to ensure that these areas have at
least the minimum specified film thickness and to ensure continuity of the coating.
Section
Inspection
No coating specification can fully be describing the application procedure. An inspector must inspect and ensure
quality of the work at each stage. The corrosion engineer or his designated will act as an inspector for all maintenance
coating jobs.
12
Q.C
TD
VD
V
VD/TP
TP
Q.A
TD
VD
V
RD/VO/TP
RP/TP
TD
RD/TP
RO/TP
VO
TD
RO/TP
VD/TP/RD
RD/TP
RO/TP
RO/VO
TO
VO
VO
5.1.2
5.1.3
5.1.4
5.1.5
13
5.2
5.1.6
5.1.7
Whenever possible, all surface coatings should be removed in a shot blast booth or outside, as it
is difficult to completely capture and remove airborne dust within a building.
Surface preparation.
5.2.1
5.2.2
14
5.2.3
5.2.4
5.3
Secure, adequate scaffolding placed to assure the inspector and the blasting equipment
operator sufficient vantage points from which to operate.
Dry and secure storage facility for abrasives. Unless abrasives are to be used
immediately, storage under clean canvas sheeting is recommended.
Polyethylene sheeting is not recommended, as moisture will condense on the underside of
such sheeting causing materials stored to be subjected to dampness.
Blast pots must be kept under cover throughout the blasting operation to forestall wind
blown debris, communication of the blasting medium.
Abrasive medium
Grit / sand should be inspected carefully to ensure that it is clean, free of foreign matters, dry,
and the specified mesh (i.e. particular size).
Final Inspection
All phases of surface preparation procedure, including the removal of all the dust and
debris from the immediate area of the prepared surface, must be completed prior to final
inspection and approval for the application of coatings to proceed.
The maximum allowable time lapse between the completion of blast cleaning and final
inspection / approval prior to coating application is two hours. If the time lapses,
surfaces must be reinspected and all evidence of oxidation must be removed by flash
blast.
Do not use rags or cleaning cloth either to inspect the surface or to remove any dust
detected. Clean cotton gloves, soft shoes, and clean coveralls are required items of
clothing which must be worn by all personnel entering any vessel or tank which has been
freshly clean blasted.
The inspector must monitor the condition of freshly blasted and cleaned surfaces prior to
the application of the primer coat. The surface should be covered with primer prior to the
onset of sever blush oxidation.
Inspection of surface cleanliness will include presence or absence of dust debris, degree
of steel cleanliness, and anchor pattern (surface roughness). Degree of cleanliness can be
determined by confirmation to a pre agreed surface texture and shade or by using visual
standards adhering to Swedish SIS 055900. The type and size of abrasive used determine
the anchor pattern. If necessary, it can be determined by surface profile meter. This is
normally not necessary in the field.
Coating application.
5.3.1
Application procedure.
Preliminary inspection.carefuly inspects each new batch of coating material. Note under
setting of pigments, objectionable skinning, the amount of clear medium, color, amount
of ullage. Record these observations for future purpose. Reject any unsuitable material.
Homogenous mixing. Power mixture must be used for two component coating
compounds. The mixing process must be closely observed to verify that the correct
quantities of each component are combined. If zinc rich coatings are used, the paint pot
must be equipped with smoothly functioning mechanical agitator.
Thinners. Only thinners recommended by the manufacturers for a particular coating
used. All thinners are very volatile material and should be stored and used carefully.
Dont expose thinner cans to heat or direct sun. keep in mind that all the solvents are
not thinners, but all the thinners are good solvents
Site control of material. Prior to start up of the job, carefully document the following on
site:The amount of coating materials in hand, and noted damage to the containers, label
description, and date of manufacture. Containers that are badly damaged or which bear
labels not corresponding to specification
15
Equipment
A.
Inspection. The equipment intended for spray application must be inspected to verify
that it confirms to the manufacturers recommendations for the type of coating used
and that it will meet the production schedule.
Inspect the air gun carefully.
Are the atomization holes in the air cap open?
Are adequate grounds provided for static charge?
Are the fluid tips and guns in good condition or are they oval or worn to the point
that needle will not seat properly when the guns trigger is released?
Are the fluid hoses caked with old coating material?
If so, either get the hoses changed or get them cleaned / flushed with thinner or similar strong
solvent.
5.4
B.
C,
Brush application. Brush application over large areas are seldom specified, it is
normally used small areas where utilization of spray equipment will be ineffective.
Brushes if required or present on the job site should be inspected carefully, as they
constitute an easily overlooked source of contamination to an otherwise acceptable
job.
Coating Inspection: coating must be done before, during, and following the finished coating
application. Proper inspection begins with an inspection of the prepared surface. Once the, surface
has been satisfactorily prepared in the manner specified for a particular coating, it should be
thoroughly vacuumed. Only then it is ready for coating. Each coat should be carefully inspected
before the succeeding coat is applied. The time between the two coats should be according to the
coating manufactures recommendations. Overspread and dust should be removed. Runs and sags are
to be avoided. Water spotting as manifested by the appearance of drops or spots of water in freshly
applied coating film is an unacceptable condition. Observations pertaining to these surface defects
should be recorded and remedial action should be taken in addition wet film thickness measurement
on freshly applied coating as well as dry film thickness of dried coating film should be measured as a
quality control measure.
5.4.1
Wet Film thickness. Wet film thickness is used as a spot check during film deposition to get
a rough idea of each coat. This enables the applicators to immediately correct any application
faults. This is measured by sinking the wet film thickness gauge into wet coating film and
16
taking a reading. As solvent evaporates, the dry film thickness becomes lower. Thus, wet film
thickness reading should be more than dry film thickness (DFT) specified in the specification
by a factor depending upon volume of solids in coating material.
5.4.2
Dry film thickness. This is measured after the coating film has dried up and can be measured
between the coats. Various types of dry film thickness measuring instruments are available in
the market.
5.4.3
Holiday deduction. This is required to be done critical cases such as immersion services. A
wet sponge low voltage detection of these film coatings would reveal any breaks in the
coating film. This should be done when specified in the coating specification.
Section
Safety
6.1 General. Operating machinery and power tolls within a production facility poses potential danger from
fire or explosion. A safety meeting involving the Operation Manager, Safety coordinator, Corrosion
Engineer, and the coating contractor must be conducted at the location to be painted prior to
commencement of the job. During the meeting, the contractor must provide a complete list of all the
equipment, materials, and personnel that will be required for the job. The location will be inspected
determine the most suitable location for every piece 0f equipment; determination will be made of the
proper method of isolating the vessel to be worked on. If necessary, from other vessels, at the facility. The
Safety Coordinator will be responsible for determining the fire fighting equipment required during the
job.
6.2 Good House Keeping. Good house keeping on site is very necessary and important of view of personnel
safety. Empty cans, unnecessary tools, etc. should not cause an obstacle in the way of craftsmen or their
equipment. Unnecessary personnel also constitute a hazard by causing obstruction to craftsmen and
machinery in use.
6.3 Sand Blasting.
Provide dead man or remote control valve fitted at the blasting nozzle for safety. Adequate grounding
for static should be provided.
Provide sufficient number of dust evacuators, and provide canvas screen around the work area.
Provide air-fed head shield for blast nozzle operators, which must be in good operating condition. No
blasting should be allowed without this device.
Always use respirators in dusty atmosphere, especially when silica sand is in use for surface
preparation.
Always check the wind direction and never allow the worker to sit in dusty environment.
Properly trained, certified, physically fit, and alert blast cleaning equipment operators and support
personnel must be used.
Unnecessary peoples should keep away of the blasting area.
Adequate lighting (Explosion Proof) should be provided especially for blasting on inside of the tanks
and vessels. Battery operated flash light (24 V DC) should be used. Two men as stand by should be
used at entrance to vessel.
Secure and adequate scaffolding should be placed to assure the inspector and the blasting equipment
operator sufficient vantage points from which to operate.
Always follow the Occupational Health and Safety Act. (OHSA). Acute Silicosis is a lung disease
that develops rapidly. This occurs through inhalation of small airborne particles of silica dust,
mainly in the range of 0.5 which are not expelled from the lung when inhaled. Instead, they
remain in the lung and are deposited in lymph nodes, where over time; calcium can deposit in
those nodes and settle along the rim of lymph node. The condition is known as egg-shell
calcification. In some cases, silica particles are carried into the lungs where a scar may form
around the particles. Over time, the hardened scars gradually start to show up on the chest x-ray
as fibrosis of the lung.
17
SECTION 7: IMPLEMENTATION
Each facility and piece of equipment will require detailed custom tailored coating specification, based on
present coating condition, desired service life, aggressiveness of local environment, and cost of coating
systems. All surface preparation and coating application steps will be closely monitored and inspected by a
qualified coating inspector. An experienced contractor having adequate equipment and trained staff for each
activity will do coating jobs requiring sand blasting and use of air or air less spray equipment. Due to high
18
pressure involved, use of airless spray will be avoided as much as possible in any case, prior approved by
Divisional Manager, Operation and engineering will be required for using air less spray coating application.
7.1 Coating SpecificationCoating Specifications for each coating job, giving details of surface, preparation, inspection standard, type of
coating material, application method, safety requirement etc., will be prepared separately, as and when
required by the Corrosion Engineer and approved by Division Manager, Operation and Engineering. The
various coating system will last between 2 6 years. The coating specification will include expected life of
the recommended coating system and the approximate date the next coating job will be required. The most
cost-effective system for each an area component will be used.
7.2 Contractor SelectionContractors will be selected on the basis of there past experience, availability of adequate equipment, skilled
personal reliability, safety consciousness, and cost. The coating specifications referred to 7.1 will serve as
technical specifications of the bid documents for contractor selection. The biding process will be initiated by
the Corrosion Engineer and the bids receive from contractors will be evaluate jointly by Maintenance
Manager and the Corrosion Engineer to finalize the selection. The Divisional Manager, operation and
Engineering will approve the selection of the contractor. Small jobs requiring manual cleaning and brush
application can be done in house by maintenance crew are coating task force.
7.3 Job SchedulingOnce a contractor have been selected, he will meet Operation Manager, Construction & facilities Manager,
Corrosion Engineer, and safety Co-coordinator to discuss the job. Things that will be needed to be discussed
during the meeting include equipment and personal requirements, safety and environment issues, and any
specific operational matters that may affect the job. The Operational Manager will schedule the field safety
meeting discussed in section 6.1. The Operational Manager will make the final decision on the date for the job
to begin.
7.4 Coating Job Progressive InspectionSurface preparation by using blasting equipment and coating application by roller, air spray, or air spray will
require inspection by a qualified inspector at each step during the job. Such a contractor will be hired
temporarily or on a daily rate basis for each job. It will be inspectors responsibility to ensure that all surface
preparation and coating application steps confirm to the coating specification outlined in section 7.1. He will
coordinate between the maintenance and production groups and the contractor for all matters related to the
coating job and submit technical reports of his inspection to the Corrosion Engineer.
The Corrosion Engineer will do the search and the selection of the inspector.
Inspection of manual cleaning and brush painting of piping, structures, etc. will be done by the maintenance crew
coating task force especially trained for this purpose. The Corrosion Engineer will do this training in this house. This
task force will consist of 2 workers, lead by a supervisor, who will act as the inspector.
ATTACHMENT -
Electronic gauges.
ATTACHMENT :
20
condition. ______
Type. ________.
_________________________________________________________________________
ATTACHMENT
DATE ______________________
FINSHED ____________________AM/PM
DATE ______________________
Batch #_______________________
Batch # __________________________________
Color # ______________________
Color # __________________________________
Stock # ______________________
Stock # __________________________________
Metal Temp______
Metal Temp ______
W.F.T. 1st Coat _____________ 2nd Coat ____________ 3rd Coat ___________________
D.F.T. 1st Coat _____________ 2nd Coat _____________ 3rd Coat ___________________
Remarks______________________________________________________________________
Inspector: NAME ---------------------------------------------------
22
SIG -------------------------------
23
Designation: ASTM
D 16 03
(for coatings)the ability of a coating to resist being worn away and to maintain its original
appearance and structure when subjected to rubbing, scraping, or wear. D 968, D01.23
Acid number, n
(for coatings)the number of milligrams of potassium hydroxide (KOH) required to neutralize the
free acids in 1 g of an oil, resin, varnish, or other substance; generally reported on the nonvolatile
content
Acid value
see acid number.
Acrylic resin
under resin, synthetic, see acrylic resin.
Additive, n
a substance added in small quantities to another substance, usually to improve specific properties (for
example, a drier, mildewcide, etc.).
Adhesion promoter, n
a material built into a binder or added to a paint to form primary bonds to either the substrate or the
previously applied coating, with the specific aim of improving the dry or wet adhesion, or both.
D01.23
Alkyd resin
under resin, synthetic, sees alkyd resin.
Architectural coatings, n coatings intended for on-site application to interior or exterior surfaces of residential, commercial,
institutional or industrial buildings.
Asbestos
see industrial talc and industrial talc, no asbestos type.
Associative thickener, n water-soluble polymers containing hydrophobic groups that are capable of nonspecific hydrophobic
association similar to surfactants that elevate viscosity presumably by association between thickener
particles or thickener and dispersed particles that may be present in the aqueous system such as latex
particles rather than through high molecular weight or chain stiffness of the thickener molecules
themselves.
Auto deposition, n
a single-step immersion metal finishing process in which an organic coating is applied by means of
unique surface chemical reactions carried out in an aqueous latex dispersion, also referred to as
chemiphoresis. Components within the bath give rise to chemical reactions that slightly solubilize the
metallic surface and lead to destabilization, deposition, and coalescence of the dispersed latex particles
at that surface. ISCUSSIONthe deposition rate of the latex is controlled by the rate of surface solubilization. The recess
does not require any pretreatments such as phosphating, needs no external energy input, and gives rise to deposition
wherever the solution wets the substrate. Irregularly shaped parts can be uniformly coated.
Baking finish, n
a paint or varnish that requires baking at temperatures above 150F (65C) for the development of
desired properties.
Baking temperature, n a temperature above 150F (65C).
Batch, n
the total quantity of a material produced in a single final mixing operation after all production
processes are complete, or just prior to filling.
Bituminous varnish
under varnish, see bituminous varnish.
Bleeding, n
the diffusion of coloring matter through a coating from the substrate; also, the discoloration arising
from such diffusion. In the case of printing ink, the spreading or running of a pigment color by the
action of a solvent such as water or alcohol.
blistering resistance, n the ability of a coating to resist the formation in the film of dome-shaped, liquid- or gas-filled
projections resulting from local loss of adhesion and lifting of the film from the previously applied
coating or the substrate.
blocking, n
for coatings other than powder coatings, the sticking of a coated surface to an adjacent surface when
the two surfaces have been in contact for an extended period of time. D01.42
brush-drag, n
resistance encountered when applying a coating by brush, directly related to the high-shear viscosity of
the coating. D 4958, D01.42
bulking value, n
solid volume of a unit weight of material, usually expressed as gallons per pound. For practical
urposes this is 0.120 divided by the specific gravity.
caulking compound, n a soft, plastic material, consisting of pigment and vehicle, used for sealing joints in buildings and
other structures where normal structural movement may occur.
cellulose lacquer see lacquer.
24
chalking resistance, n
checking resistance, n
chipping resistance, n
coating, n
Color of an object, n
the ability of a pigmented coating to resist the formation of a friable powder on its surface caused
by the disintegration of the binding medium by degradative weather factors.
the ability of a coating to resist slight breaks in the film that do not penetrate to the previously applied
coating or to the substrate. The breaks should be called cracks if penetration extends to the previously
applied coating or to the substrate. See cracking resistance.
the ability of a coating or layers of coatings to resist removal, usually in small pieces, resulting from
impact by hard objects or from wear during service.
a liquid, liquefiable or mastic composition that is converted to a solid protective, decorative, or
unctionaladherent film after application as a thin layer.
the aspect of the appearance of an object dependent upon the spectral composition of the incident light,
the spectral reflectance or transmittance of the object, and the spectral response of the observer.
hue, n The attribute of color perception by means of which a color is judged to be red, orange,
yellow, green, blue, purple, or intermediate between adjacent pairs of these, considered in a
close ring, red and purple being an adjacent pair. (White, gray and black colors possess no
hue). E 284
DISCUSSION The short end of the spectrum is violet, with purple by definition being a nonspectral combination of red and
violet. The practice of replacing violet by purple in the roster of object colors is apparently a practical
accommodation to color-order requirements, as described in the Munsell system. See Practice D 1729.
contrast ratio, n
cracking resistance, n
crawling, n
curtaining
density, n
lightness, n (1) The attribute by which a perceived color is judged to be equivalent to a member of a
series of graysranging from black to white. (2) The attribute of color perception by which a
non-self-luminous body is judged to reflect more or less light. E 284
saturation attribute of a visual sensation that permits a judgment to be made of the proportion of
pure chromatic color in the total sensation. E 284
ratio of the reflectance of a dry paint film over a black substrate of 5 % or less reflectance, to the
reflectance of the same paint, equivalently applied and dried, over a substrate of 80 % reflectance.
coverage, coverage rate, covering powerambiguous terms that are used in some instances to refer to
hiding power and in others to mean spreading rate. The precise terms hiding power and spreading
rate are preferred.
the ability of a coating to resist breaks of the film where the breaks extend through to the surface
painted and the previously applied coating or the substrate is visible. The use of a minimum
magnification of 10 diameters is recommended in cases where it is difficult to differentiate between
cracking and checking. See checking resistance.
defect in which the wet film recedes from localized areas of the substrate (usually caused by
insufficient wetting) leaving those areas uncoated. D 1848, D01.42
see sag or sagging.
the mass per unit volume of a substrate at a specified temperature and pressure; usually expressed in
g/mL, kg,L, g/cm3, g/L, kg/m3 or lb/gal. See specific gravity. D01.23, D01.24
DISCUSSION(1) g/mL = kg/L = g/cm3; g/L = kg/m3. (2) Density lb/gal) = Density (g/mL) 3 8.345405 ... (3) The
temperature should be 25C for best conformance with Test Method D 1475. For liquids andsolids, which are
the usual concerns of Committee D-1, the pressure need not be specified. (4) Density of water at 25C =
0.997044 g/mL = 8.32 lb/gal.
dirt
dirt resistance, n
drying oil, n
durability, n
edge-tracking, n
efflorescence, n
an oil that possesses to a marked degree the property of readily taking up oxygen from the air and
changing to a relatively hard, tough, elastic substance when exposed in a thin film to the air.
a relative term indicating degree of permanency. It may be applied to individual protective, decorative,
or functional properties, for example, the durability of gloss, but if used in a general way, for
example, the excellent durability of a paint, implies the ability of the described coating to retain, to
the indicated degree, all the properties required for the continued service of the coating.
residual, discernible pattern in a rollerapplied coating, characterized by trails from either or both
ends of the roller.
a condition that occurs when soluble salts in a dry coating or the substrate migrate to the surface due to
the movement of water through the film; characterized by a (commonly) white, nonuniform powder or
crystalline incrustation,not removable with neutral water but usually removed with dilute mineral acid.
D 1736, D 1848, D01.42
DISCUSSIONThe previously water-soluble salts become insoluble at the surface of the film due to reaction with carbon
dioxide of the air.
emulsion paint
25
enamel, n
erosion resistance, n
ester gum
extended pigments, n
facade paint, n
filiform corrosion resistance, n the ability of a coating to resist that type of corrosion of metal substrates characterized
by a definite thread-like structure and directional growth that occurs under coatings.
filler, n
a pigmented composition for filling pores or irregularities in a surface preparatory to application of
other finishes.
finish, n
(1) final coat in a paint system; at the termination of cure or drying
( 2) sometimes refers to the entire coating system: the texture, color, and smoothness of a surface, and
other properties affecting appearance.
fire-retardant, adj
a descriptive term which implies that the described product, under accepted methods of test, will
significantly:
(a) reduce the rate of flame spread on the surface of a material to which it has been applied, or
(b) resist ignition when exposed to high temperatures, or
(c)insulate a substrate to which it has been applied and prolong the time required to reach its ignition,
melting, or structural weakening temperature.
fire-retardant coating, n a coating that will do one or more of the following:
(1) reduce the flame spread on the substrate over which the coating is applied, sometimes at the
sacrifice of the coating (see intumescent coating);
(2) resist ignition of the substrate when exposed to high temperature; or
(3) insulate the substrate to which the coating is applied and thereby prolong the time required to reach
its ignition, melting or structural-weakening temperature.
flaking resistance, n
the ability of a coating to resist the actual detachment of film fragments either from the previously
applied coating or the substrate. Flaking is generally preceded by cracking, checking, or blistering and
is the result of loss of adhesion. Also known as scaling resistance.
flatting agent, n
a material added to paints, varnishes, and other coating materials to reduce the gloss of the dried film.
forced drying temperature, n
a temperature between room temperature and 150F (65C).
fossil resin, n
under resin, natural, see fossil resin.
gallon, U. S., n
a volume equal to 231 in.3 For paint, varnish, lacquer, and related products this is measured at 77F
(25C).
glaze, n
a very thin coating of a paint product usually a semi-transparent coating tinted with Van Dyke brown,
burnt sienna, or a similar pigment, applied on a previously painted surface to produce a decorative
effect.
glazing compound, n
a dough-like material consisting of pigment and vehicle, used for sealing window glass in frames. It
differs from putty in that it retains its plasticity for an extended period.
grain, n
an inch-pound unit of weight, equal to 0.002285 avoirdupois oz (0.0648 g). CED
grinding japan
see japan, grinding.
grit, n
coarse foreign particles in paint materials and coatings, often of irregular shape, that are hard, abrasive,
and resistant to disintegration.
hiding power, n
the ability of a paint, or paint material as used, to hide or obscure (see opacity) a surface to which it
has been uniformly applied.
DISCUSSIONWhen expressed numerically, it is generally in terms of the number of square feet over which a gallon of
paint, or pound of pigment, as used, can be uniformly spread to produce a specified contrast ratio (see contrast
ratio). The term covering power has no specific relationship to hiding power, and actually has no precise
meaning.
Hue
hydroxyl number, n
impact tester, n
industrial talc, n
26
latex paint
leveling, n
27
mud-cracking, n
an irregular broken network of cracks in the film, which occurs due to volatile loss while drying or
curing. D 1848, D01.42
natural resin
see resin, natural.
natural spreading rate, n the spreading rate that occurs when a coating is applied in a manner natural to the operators technique,
perceptions, and expectations, as they relate to coating tools, substrate, and characteristics of the
coating itself.
DISCUSSIONSuch a spreading rate can vary widely with the same paint applied under similar conditions by different
operators, but a series of paints applied by different operators under the same conditions will tend to have
approximately the same rank order.
nondrying oil, n
nonvolatile content, n
nonvolatile vehicle, n
OEM coatings, n
oil color, n
oil paint
oil varnish
opacity, n
open time, n
over-tone
paint vb
paint n, general
paint n, specific
emulsion paint
latex paint
oil paint
paste paint
water paint
paint brush, n
an oil that does not of itself possess to a perceptible degree the power to take up oxygen from the air
and lose its liquid characteristics.
the portion of a coating that does not evaporate during drying or curing under specified conditions,
comprising the binder and, if present, the pigment. (The percent volatile content is obtained by
subtracting the nonvolatile content from 100.)
the liquid portion of a paint excepting its volatile thinner and water.
original equipment manufacturers coatings, which include automotive, marine, furniture, appliance,
as well as many other miscellaneous consumer and industrial applications.
an oil paint containing a high concentration of colored pigment, commonly used for tinting paint.
under paint, see oil paint.
under varnish, see oil varnish.
the degree of obstruction to the transmission of visible light. In this sense opacity is a relative term, it
being considered that given a film sufficiently thin, in paint technology at least, there is no absolutely
opaque substance.
length of time a coating remains wet enough to allow for brushing-in at the laps; also called wet edge
time.
see mass color.
to apply a thin layer of a coating to a substrate by brush, spray, roller, immersion, or any other suitable
means.
a pigmented coating. See coating. D 16 03
a classification sometimes employed to distinguish pigmented drying oil coatings (paints) from
synthetic enamels and lacquers.
a paint, the vehicle of which is an emulsion of binder in water. The binder may be oil, oleoresinous
varnish, resin, or other emulsifiable binder.
a paint containing a stable aqueous dispersion of synthetic resin, produced by emulsion
polymerization, as the principal constituent of the binder. Modifying resins may also be present.
a paint that contains drying oil or oil varnish as the basic vehicle ingredient.
a paint in which the pigment is sufficiently concentrated to permit a substantial reduction with vehicle
before use.
a paint, the vehicle of which is a water emulsion, water dispersion, or ingredients that react chemically
with water.
a paint application tool consisting of a flexible brushing part composed of long filamentary material
(brushing material) bound to a handle.
DISCUSSIONTypical types include designs for varnish, enamel, sash and wall painting. They are manufactured in a range
of shapes and sizes.
28
penta resin
phenolic resin
picking, n
picture framing, n
for a specified decrease in oscillation (swing) amplitude; the shorter the damping time the lower the
hardness. D 4366, D01.23
under resin, synthetic, see penta resin.
under resin, synthetic, see phenolic resin.
a rolling up in the lap (see lap) when the previously applied paint film is in a semisolid (gel-like) state
of drying, causing a tacky resistance to the brush or roller and resulting in an unsightly nonuniform
appearance in the final dried film.
a perimeter thickness or color difference (usually darker) relative to the rest of the painted surface.
DISCUSSIONThis problem could be due to various mechanisms:
(a) architectural paintsthe greater shear of a brush used around the perimeter of a wall or ceiling compared
to the lower shear of a roller used on the rest of the wall or ceiling;
(b) industrial finishesthe flow of a finish during baking resulting in the build-up of the coating on the edge
of the substrate;
(c) roofinga rectangular pattern of ridges in a membrane over insulation or deck joints;
(d) cement-asbestos shingles (on exposure fences)the darker color of the coating on the perimeter due to
carbonation of the edges (from the carbon dioxide in the air).
pigment, n
the fine solid particles used in the preparation of paint or printing ink and substantially insoluble in the
vehicle. Asphaltic materials are not pigments except when they contain substances substantially
insoluble in the vehicle in which they are used.
pigment volume, n
the percent by volume of pigment in the nonvolatile portion of a paint or printing ink, as calculated
from bulking value and composition data. The letters PV are commonly used as an abbreviation.
pinholes, n
small pore-like flaws in a coating that extend entirely through the applied film and have the general
appearance of pin pricks when viewed by reflected light.
pin holing, n
the presence of a series of fine holes or voids in a film. D 1848, D01.42
plasticizer, n
a substance added to paint, varnish, or lacquer to impart flexibility.
primer, n
the first of two or more coats of a paint, varnish, or lacquer system.
printing ink, n
a colored or pigmented liquid or paste composition that dries to a solid film after application as a
thin layer by printing machinery.
print resistance, n (coatings)the ability of a coating to resist taking on the imprint due to the pressure of another surface
placed against it.
putty, n
a dough-like material consisting of pigment and vehicle, used for sealing glass in frames, and for
filling imperfections in wood or metal surfaces. See glazing compound.
resin, natural, n
a solid organic substance, originating in the secretion of certain plants or insects, which is
thermoplastic, flammable, nonconductive of electricity; breaks with a conchoidal fracture (when hard);
and dissolves in certain specific organic solvents but not water.
fossil resin
a natural resin of ancient origin usually found in the earth.
resin, synthetic, n
a synthetic substance physically similar to natural resin. D 16 03
acrylic resin
a synthetic resin made from derivatives of acrylic acid.
alkyd resin
a synthetic resin made from polyhydric alcohols and polybasic acids; generally modified with resins,
fatty oils or fatty acids.
ester gum
a resin made from rosin or rosin acids and a polyhydric alcohol, such as glycerin or pentaerythritol.
maleic resin
a resin made from a natural resin and maleic anhydride or maleic acid.
melamine resin
a synthetic resin made from melamine and aldehyde.
penta resin
ester gum made from rosin and pentaerythritol.
phenolic resin
a synthetic resin made from phenols and aldehydes.
styrene resin
a synthetic resin made from vinyl benzene.
urea resin
a synthetic resin made from urea and an aldehyde.
vinyl resin
a synthetic resin made from vinyl compounds.
roller spatter resistance, nthe ability of a paint to resist the formation of various size droplets generated during paint
roller application, which results in undesirable spots splashing on areas that are not being painted
including the person applying the paint.
rust, n (coatings)
the reddish material, primarily hydrated iron oxide, formed on iron or its alloys resulting from
exposure to humid atmosphere or chemical attack. See white rust.
rust resistance, n (coatings)the ability of a coating to protect the substrate of iron or its alloys from rusting.
sag or sagging, n
nonuniform downward flow of a wet paint film that occurs between the times of application and
setting, resulting in an uneven coating having a thick lower edge.
DISCUSSIONThe sags usually occur at a local, thick local area of a vertical film and may have the characteristic
appearance of a draped curtain, hence the synonym curtaining.
29
shade, n
sheepskin paint roller cover, na cover in which the paint applicating material is wool fleece still attached to its tanned
natural skin.
size, n
usually a liquid composition to prevent excessive absorption of all paints into plaster, old wall paint,
and similar porous surfaces; also a liquid composition used as a first coat on metal to improve adhesion
of succeeding coats (latter usage is limited to the metal decorating industry). The terms sealer and size
are almost synonomous, but usage has established certain differences. A sealer is ordinarily a thin
varnish or clear lacquer and is usually applied on wood and metal surfaces. Ordinary painters size is a
thin solution of glue, starch or other water-soluble substance and is usually applied on plaster surfaces,
but size used in metal decorating is a thin varnish.
spar varnish
under varnish, see spar varnish.
spirit varnish
under varnish, see spirit varnish.
soil, n
of coatings, disfiguring foreign materials such as dirt, soot, or stain, other than microorganisms,
deposited on or embedded in a dried film of applied coating material; also called dirt.
soilant, n
a discoloring substance with a dispersed color component that is not in solution, and therefore can
cling to the surface of a coating without penetrating into the film. D 3450, D01.42
DISCUSSIONA soilant differs from a stain in that the colorant of a stain is in solution and therefore can penetrate into the
film.
solid, n
specific gravity, n
(flammability regulations) a substance that has a viscosity greater than 1 3 103 St (1 3 101 m2s1) at
104F (40C) or an equivalent viscosity at an agreed upon temperature. (This includes powders and
granular materials.)
(1) ratio of the weight of a given volume of substance to the weight of an equal volume of water.
(2) ratio of the density of a substance at a specified temperature to the density of water. See density.
D01.23, D01.24
DISCUSSION(1) Specific gravity measurements are generally made with the test substance and water at the same
temperature, which should be 25C for best conformance with Test Method D 1475. This value multiplied by
the density in g/mL of water at 25C (0.997) is the specific gravity relative to water at 4C and numerically
equal to the density in g/mL of the test substance at 25C, within normal test precision. (2) Conventionally
abbreviated:
spreading rate, n
the area covered by a unit volume of coating material frequently expressed as square feet per
gallon.
stain, n
a discoloration, arising from foreign materials, that penetrates into the coating.
stain, n
a penetrating composition that changes the color of a surface, usually transparent and leaving
practically no surface film.
styrene resin
under resin, synthetic, see styrene resin.
surfacer, n
a pigmented composition for filling minor irregularities to obtain a smooth uniform surface preparatory
to applying finish coats; usually applied over a primer and sandpapered for smoothness.
synthetic paint roller cover, na cover in which the paint applicating material is man-made material.
synthetic resin
see resin, synthetic.
Talc
see industrial talc and industrial talc, non asbestos type.
temporary coating, n
a coating designed to protect or decorate a substrate for a limited time that can be readily
removed either by mechanical or chemical means.
thinner, n
the portion of a paint, varnish, lacquer, or printing ink, or related product that volatilizes during the
drying process.
tint, n
a color produced by the mixture of white pigment or paint in predominating amount with a colored
pigment or paint, not white. The tint of a color is, therefore, much lighter and much less saturated than
the color itself.
tinting strength, n
the power of coloring a standard paint or pigment.
toner, n
an organic pigment that does not contain inorganic pigment or inorganic carrying base.
undertone, n
the color of a thin layer of pigment-vehicle mixture applied on a white background.
urea resin
under resin, synthetic, see urea resin.
urethane coatings, n
coatings based upon vehicles containing a minimum of 10 percent by weight (nonvolatile vehicle
basis) of a polyisocyanate monomer reacted in such a manner as to yield polymers containing any
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Varnish, n
Oil varnishes
Spar varnish
Spirit varnishes
Vehicle, n
vernonia oil, n
Vinyl resin
under resin, synthetic, see vinyl resin.
Volatile thinner
see thinner.
Volume percent solids, n the portion of a coating that remains as part of the dry film expressed as percent by volume.
DISCUSSIONThis contrasts to another convention of expressing solids content by weight percent. Often a percent is given
without specifying whether it is volume or weight. This is confusing and leads to errors in coating calculations.
Water-based coating, n
Waterborne coating, n
a coating in which the principal volatile constituent is water. See also water-reducible coating.
DISCUSSIONFor government regulatory purposes related to the analysis of coatings for VOC and water content, if the
volatile constituent contains more than 5 % by weight of water, the coating is arbitrarily classified by the EPA
as waterborne. For a full explanation refer to: EPA document 450/3-83-013R, Glossary for Air Pollution
Control of Industrial Coating Operations, EPA, Method 24 (40 CFR PART 60, Appendix A), and ASTM
Manual 4 Determination of VOC Content of Paint, Coatings and Printing Inks.
water paint
under paint, see water paint.
Water-reducible coating, n a coating that can be reduced in viscosity by the addition of water. D01.55
DISCUSSIONAlthough all waterborne coatings are water-reducible, the reverse is not true because there are industrial
coatings that contain little or no water in their pre-application storage condition, but are reducible with either
water or a suitable organic solvent. Thus prior to actual reduction with water, a coating of this type might not
strictly be referred to as waterborne, and might never become such. Since the vast majority of water-reducible
coatings are waterborne the latter term tends to be used inclusively, unless there is a specific need to make a
distinction.
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water vapor permeance (WVP), nthe steady state rate of water vapor movement through a free film induced by a vapor
pressure difference (Dr) of one unit between the two surfaces of the film, where Dr is expressed in
inches or millimetres of mercury. Thus: WVP = WVT/Dr. See WVT. D 1653, CED, D01.23
DISCUSSIONThe unit of permeance is the perm or the metric perm, thus: perm (U.S., inch-pound unit) = grain per
square foot per hour per inch of Hg (gr/ft2 hin), metric perm (S.I. unit): = gram per square metre per day per
millimetre of Hg (g/m2d mm) DISCUSSION 1 perm (U.S.) = 0.659 metric perms permsee water vapor
permeance, unit of
water vapor transmission (WVT) rate, nthe steady state rate of water vapor movement through a free film under specific
conditions of temperature and humidity at each surface; customarily expressed in grains per square
foot per hour (gr/ft2h) or grams per square metre per day (g/m2d). D 1653, CED, D01.23
DISCUSSION1 gr/ft2 h = 16.74 g/m2 d.
DISCUSSIONCoatings that are too brittle or otherwise unsatisfactory for handling as free films are sometimes tested on a
porous support surface, although such a support can have an effect on test results.
Weight percent solids, n the portion of a coating that remains as part of the dry film expressed as weight.
DISCUSSIONAnother convention of expressing solids content is by volume percent.
Wet adhesion, n
Wet edge, n
the ability of a coating film to adhere tightly to the substrate directly beneath it under wet conditions
such as rain, dew, washing, etc.
the edge of a wet, painted area that remains workable for continued painting.
DISCUSSIONWhen painting large surfaces, it is generally necessary to join up to the edge of a paint film that has been left
to dry for some period of time. When this can be done by blending this edge with free-working paint, without
any lap mark between the drying and freshly painted area, the paint is said to present a wet edge.
high boiling liquids such as propylene glycol added to latex or water-based paints to reduce the
evaporation rate and thereby extend the (open) time that they are wet enough to brush into.
DISCUSSIONThese wet edge extenders are used to minimize lapping problems.
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