Professional Documents
Culture Documents
Contents
1. What is Coating?
2. Corrosion in Steel.
3. Surface Preparation for Maintenance- Non Blasting Type.
4. Importance of Stripe Coating(Practice).
5. Methods of applications(Brush /Roller /Spray).
6. Application techniques and Good painting practice.
7. Materials Handling.
8. Bad Painting Practice & Overconsumption.
9. Site Equipment Application & Painting Accessories.
10.
11. Safety Equipments.
What is a Coating?
What is a Lining?
A lining is a film material applied to interior and exterior
surfaces subject to immersion.
-Corrosion resistance
Binder
-Film formation
Solvent
Additive
-Application
-To improve
paint properties
2-Corrosion Steel
Corrosion of Steel
Basic principles of corrosion
Required conditions
Oxygen availability
Electrolyte
Electrical potential differenceCURRENT-CARRYING ELECTROLYTE
(i.e. SEA WATER)
Corrosion mechanism
ANODE (CORRODING AREA)
Types of Corrosion
General corrosion
Types of Corrosion
Galvanic
General corrosion
Types of Corrosion
Galvanic
Galvanic
General corrosion
Area with
high DFT
Types of Corrosion
Galvanic
Pitting
Galvanic
General corrosion
Types of Corrosion
Galvanic
Pitting
Galvanic
General corrosion
Types of Corrosion
Galvanic
Crevice Corrosion
General corrosion
Types of Corrosion
Galvanic
Fili form corrosion
General corrosion
Types of Corrosion
Galvanic
Steel exposed to Sulphuric
acid pH 2
General corrosion
CORROSION
Causes
- Removal of coating by detachment, mechanical forces.
- Low film thickness.
- Inadequate surface preparation before coating application.
- Poor coating performance, incorrect selection.
Coating life time exceeded
Remedial Action
- Scrape off rust scale and loose coatings.
- Prepare corroded areas to achieve the required standard.
Power tool / Hydro blast / Grit blast
- Feather edges of intact coatings and abrade overlap area.
- Patch prime and apply touch-up of finish.
BLISTERING
Liquid OR Gas exerts a pressure on coating greater than adhesional strength
causing localised detachment.
BLISTERING
Cause
- Solvent entrapment due to excessive coating thickness
- Solvent entrapment due to premature over coating
- Osmotic blistering due to soluble salts (paint or substrate)
- Electroendosmosis (Cathodic over protection)
- Low film thickness
- Air entrapment
- Premature exposure to water
Remedial Action
- Scrape open blisters, chasing back to a firm edge
- Fresh water wash to remove contamination
- Prepare corroded areas to achieve the required standard.
- Feather edges of intact coatings to give smooth overlap
- Patch prime and apply finish as appropriate
DETACHMENT
Delamination of coatings or entire scheme from undercoat
DETACHMENT
Causes
- Surface contamination on substrate prior to o/c:
Oil / Grease / Salts / Rust / Water
- Incorrect surface preparation:
Shot vs. Grit vs. Hydro Blasting profiles
- Cure conditions prior to over coating:
Temperature / Ventilation / UV Exposure
- Maximum over coating intervals exceeded
Build-up of coatings leading to internal stress
Remedial Action
- Scrape off loose scale and coating(s)
- Fresh water wash affected areas
- Prepare areas of corrosion to required standard
- Patch prime and apply touch-up of finish as appropriate
Hairline
Mud Cracking
Surface Preparations-SSPC
D-Acid Pickling
PARAMETERE
OUTCOME
STEP-1
C1/C2/C3/C4/C5
STEP-2
STEP-3
NB OR MAINTENANCE
STEP-4
NEW BUILDING
STEP-5
MAINTENANCE
STEP-6
COMMUNICATION
Stripe coating
Stripe coating
Stripe coat with paint brush:
Stripe coating
Stripe coating
Use a good quality paint brush
Work the paint well into the
substrate to wet the substrate
properly
Welds, edges, notches and
areas difficult to reach by spray
must be stripe coated
Stripe coating.
Welds, edges, notches and areas
difficult to reach by spray must be
stripe coated
Sigmaprime:
Note the contrast between stripe
coat and spray coat due to different
method of application
Stripe coating
Weld seams
Edges
Bulbs
Angels / bars
Notches etc.
inspection
Stripe coating-C.O.Tank
Stripe coating-Accommodation
Pipes
Supports
Windows
Reeling
Stripe coating.
5-Methods of Application
Coating application
Methods of application
Brush
Roller
Conventional Spray
Airless Spray
Methods of Application
Brush
Roller
Spray
Brush
Roller
Spray
Speed
Ease of application
Simplicity of equipment
Safety
Material conservation
Portability
Versatility
Initial economics
Long range economics
Hiding power
Uniformity
fair
fair
excellent
excellent
excellent
excellent
Good
excellent
fair
Good
Poor
Good
Good
excellent
excellent
Good
Good
fair
excellent
fair
fair
fair
excellent
Poor
Poor
Poor
Poor /good*
Poor
excellent
Poor
excellent
Good*
Good
Brush Application
Limitations
Slower production rates.
Low film built.
Requires applicator skills.
Roller application
Advantages
Faster method of application compared to brush.
Good on areas with poor accessibility.
For e.g.-Back of bars.
Good selection of roller gives good results
For e.g.- Thin rollers with glossy finishes
Disadvantages
Not suitable for application on bare steel.
May incorporate pinholes and voids.
Poor wetting on weld seams.
Low film built, many coats required.
Brush Vs Roller
Paint
Gun
Airless spraying
Wet end
Safety lock
Reversible
tip
Trigger
Airless Spray Gun
Conventional Spray
Conventional spray
On external surfaces soft spray creates little or no
overspray for minimal waste and cleaner, safer
operating environment.
Airless spray
Advantages
Fast application.
Higher production rates
High film built possible.
No bounce back or
overspray
High solid and high
performance coatings can
be applied
Start moving
the spray gun
before pulling
the trigger
Release
trigger before
stopping the
movement
Use as low
pressure as
possible to
obtain a
homogenous fan
Airless Spray-Application
Techniques
Airless Spray-Application
Techniques
Link
Long distance between spray gun and object will lead to Dry spray and Surface roughness
Overlap
by 50%
during
each pass
2
3
4
5
6
7
Begin application on
corners and complex
areas first
Coat each corner by
vertical strokes
The areas adjacent to
the corner should be
covered by vertical
strokes
Metal
90
50 cm
Pattern Size
Spray Techniques
Level Surfaces
Slender Parts
Round Parts
Small cylinder shapes, like furniture legs,
Are best sprayed with a narrow spray pattern,
using three vertical strokes. A vertical pattern
and stroke can be used, but the gun
movement must be quicker to prevent sags
and runs.
Spray smaller or medium diameter cylinders
with lengthwise strokes. Spray large cylinders like
a flat vertical surface, only with shorter
strokes.
Tip Size
Selection
Factors to Consider When Selecting a Tip
Material to be sprayed
Spray pump capacity
Final finish required
Painters experience level
GPM
.23
.30
.55
.77
1.00
1.25
1.75
2.50
LPM
.9
1.1
2.1
2.9
3.8
4.7
6.6
9.5
Material
Tip Size
.011 to .013
.013 to .015
.015 to .019
.021 to .025
.025 to .035 +
Pattern Size
517 Tip
17
X2
= 10 inch
fan width
= .017
orifice
needed
OPERATOR MAINTENANCE
Regular Maintenance
Shut Down
WARNING
Before servicing the tip or gun, and before
disassembling the gun, always shut off the
pump, trigger the gun, engage the trigger
safety and open the pump drain valve
(normally located below the filter) to relieve
pressure in the system. Disconnect the fluid
hose from the gun.
1. Relieve all fluid pressure in the system, and
soak only the tip of the gun in a compatible
solvent, or remove the entire fluid tip and soak it
in solvent.
Cd-4934-21
Accessibility
WRONG SCAFOLDING
CORRECT SCAFOLDING
To save costs.
To avoid material wastage and overconsumption.
To get a final product in line with coating specification.
To enhance coating quality.
To enhance customer satisfaction.
7-Material Handling
Paint handling at SY
Check packing
condition after paint
arrival
Paint shop
Paint Mixing
Mix component A
Slowly add component B while
mixing component A.
Empty component B
completely
Thoroughly mix component A
&B.
Always use mechanical stirrer.
Some 2 pack paint need
induction time
Pot life
Paint temperature
Note- Use heating bath under low temperature conditions instead of too much th
Thinning
Use thinners only when necessary
Always use the correct thinners for the product.
(confirm with Product datasheet).
Limit thinning to 5% by volume (maximum).
Over-thinning can cause : Solvent entrapment.
Runs, sags, slumping etc.
Inadequate cure of the film.
Reduced volume solids and applied dft
A rough surface
Too much paint dust
Pinholes in the paint film
Entrapped air
Entrapped solvents
High paint consumption
-Poor workmanship
-Painting under bad climatic conditions
Condition of surface
Maintenance required
if condition is below line
Time
Cd-4934-73
Bad result
Uneven film thickness
Cd-4934-52
Unsystematic
application
Overconsumption
ReasonsPoor workmanship
Inexperience.
Poor equipment.
Poor equipment maintenance.
Poor quality control.
Lack of proper coating facilities.
Overconsumption
Unskilled personnel.
Non - systematic spraying of bullwark
Several holidays
Uneven spraying and paint film thickness
Stripe coating is missing
Cd-4934-39
Overconsumption
Overconsumption
Overconsumption
Personnel training
Use correct application
techniques
Calculate quantities to be used
as per total area of object to be
coated
Example-Drum distribution in
dry-dock
Ensure good access to surface
before coating
Avoid excessive paint mixing
than required
Inspection equipment
Salt test
W.F.T Guage
Sling Psychrometer
Profile gauge
DFT Guage
Basic set
10-Site Equipment-Safety
SAFETY