Coating College

Rizal Tresna Ramdhani

Country Technical Service Manager
About Me, Married, 3 Daughters
Previous job ASTRA Group – Surface Treatment Engineering (10 years)
Process Engineering and Production Manager

Marine PC Technical service Manager - IP Indonesia (1 year)

Current Function Country PC Technical Service Manager ( 5 years)

PT International Paint Indonesia - Akzonobel

Education Background Bachelor Degree Chemistry Universitas of Airlangga - Surabaya

Bachelor Degree Chemical Engineering ITS - Surabaya
Master Degree Corrosion Universitas of Indonesia - Jakarta

Qualification NACE Certified Coating Inspector Level 3 – Peer Review

CIP No. 40242
NACE Instructor – Coating Inspector Program

Office Adress Intiland Tower

Jl. Jendral Sudirman Kav 32 Jakarta

Home Adress Perumahan Bumi Sentosa Blok C9/12

Cibinong Bogor

HP : 08121874890, 0818105412
Email : rizal.tresna@akzonobel.com
Agenda
1. Basic Corrosion

2. Coating Fundamental

3. Coating Technology

4. Environmental Control, Equipment and Inspection

5. Surface Preparation, Equipment and Inspection

6. Coating System

7. Coating Application , Equipment, Material consumption and

Inspection

8. Coating Defect

9. General Coating Inspection

10. Health and Safety

Basic Corrosion

1
Basic Corrosion
Basic Corrosion
Basic Corrosion
QUIZ

What is the corrosion ??

Basic Corrosion

Corrosion is basically:-

“The attack on metals by their environment.”

We normally see it as steel changing to rust.
Nature is simply returning steel from an unstable
man-made state to a stable natural state.
Video 2.
Basic Corrosion

STEEL
Iron Metal
Chemically Unstable
Structural

HEAT CORROSIO
(By N
Man) (By Nature)
IRON ORE RUST
Iron Oxide Iron Oxide
Chemically Stable Chemically Stable
Non-Structural Non-Structural
Basic Corrosion
Corrosion Cell :

Anode
Cathode
Metallic pathway (or external conductor)
Electrolyte
Basic Corrosion
Galvanic Series
Basic Corrosion
Factors that Affect the Rate of Corrosion :

Oxygen
Temperature
Chemical Salt
Humidity
Pollutan and Acid gases
Basic Corrosion
Type of Corrosion ; uniform corrosion, pitting corrosion, crevise corrosion, galvanic
corrosion, etc.
Basic Corrosion
Corrosion Control :
Design
Inhibitors
Material selection
Cathodic protection
Protective coatings
Splash zone systems
Alteration of the environment
Coating Fundamental

2
Coating Fundamental
Why we do paint the Steel ?
1) Corrosion Prevention
2) Fouling Control
3) Cosmetic Appearance
4) Cargo Storage
5) Abrasion Resistance
6) Skid Prevention
7) Fire Protection
8) Heat Resistance
9) Radar Absorption
Coating Fundamental
Properties of Coating :

Chemical Resistance
Water resistance
Easy to Apply
Adhesion to substrate
Cohessive Strength
Flexibility and Elongation
Impact and Abbrasion Resistance
Temperature Resistance
Dielectric Strength
Coating Fundamental
Modes of Protection :
Barrier coatings
Coating Fundamental
Inhibitive Coating
Coating Fundamental
Sacrificial Coating
Coating Fundamental

Adhesion : The most basic function of any coating is its ability to adhere to the
surface on which it is placed.
• Chemical Bond ; reaction between the coating and the substrate is the most
effective bond, ex : galvanizing process
• Polar Adhesion ; the most common type of bond for organic coatings. The resin
acts as a weak magnet with the north and south poles attracting opposite poles on
the substrate
• Mechanical Adhesion ; is associated with surface roughness (anchor pattern).
Coating Technology

3
Coating Fundamental

Coating Component :
Pigment
Additive
Binder
Solvent
Coating Technology
Curing Mechanisms :

• Nonconvertible Coatings ; Evaporation Cure, Coalescence

• Convertible Coatings ; Oxidation, Co-reaction (polymerization), Hydration, Fusion

Environmental Control and Inspection

4
Environmental Control and Inspection
“Rule of Thumb”

• Surface Temperature greater 3 deg C than Dew Point

• Surface Temperature ( 5o – 50o C) - ASTM D3276
• Relatif Humidity ( max 85%) - ASTM E337-02
Environmental Control and Inspection
“Rule of Thumb”
QUIZ

What is the Dew point ?

What is the relatif humidity ?

Environmental Control and Inspection
Ambient Condition Check
Environmental Control and Inspection
Ambient Condition Check
Example :

T wet = 24 deg C
T dry = 29 deg C See the Dew point Table
Steel Temp = 30 deg C

Dew Point = 22 deg C

RH = 66%

Result : OK for Painting

Environmental Control and Inspection
Ambient Condition Check
QUIZ :

T wet = 28 deg C
T dry = 30 deg C
Steel Temp = 32 deg C

OK or Not for Painting ?

Environmental Control and Inspection
Inspection Details — Ambient Conditions
Surface Preparation and Inspection

5
Surface Preparation, Equipment and Inspection
Many factors in surface preparation affect the life of a coating,
including:
• Oil/Grease : Reduce free energy of surface to below the free
energy of the caoting resulting on no displacement of the oil.
• Rust : Iron and steel corrosion products – Iron oxide, Iron
Chloride, Iron Sulphate powdery loose deposits.
• Soluble Salt : Chloride, Sulphates, Dried sea salt residues.
• Dust / Dirt / Soil : Air-borne deposits, blast cleaning operation,
etc.
• Water ; Condensation (dew point), Rain water, Humidity
• Mill scale : mixed surface oxides, magnetite Cathodic to stel,
instigates corrosion
• Rust Inhibitors ; watre soluble inhibitors, My cause blistering of
the coating by osmosis if not correctly remove
• Old loose coating : poorly adhere existing coatings
• Sharp ridges, edge, burrs, cuts from mechnical cleaning
equipment can prevent adequate DFT
Surface Preparation, Equipment and Inspection
Equipment
Solvent Cleaning
Surface Preparation, Equipment and Inspection
Equipment
Hand Tooling Cleaning
Surface Preparation, Equipment and Inspection
Equipment
Power Tooling Cleaning
Surface Preparation, Equipment and Inspection
Equipment
Dry Abrasive Blast Cleaning
Surface Preparation, Equipment and Inspection
Equipment
Water Jetting and Hydroblasting
Surface Preparation, Equipment and Inspection
Dry Process
Degree of Surface Preparation
Standard
Cleanliness Cleanlines
SSPC NACE ISO 8501-1
Solvent Cleaning SP1
Hand Tooling Cleaning SP2 Thorough Hand and Power
st2
Tooling Cleaning
Power Tooling Cleaning SP3 Very Thorough Hand and Power
st3
Tooling Cleaning
Power Tooling to Bare Metal SP11
Brush off Blast Cleaning SP7 No. 4 sa1 Light Blast Cleaning
Industrial Blast Cleaning SP14 No. 8
sa2
Thorough Blast Cleaning
Commercial Blast Cleaning SP6 No. 3
sa 2.5
Near White Metal Blast Cleaning SP10 No. 2 Very Thorough Blast Cleaning
White Metal Blast Cleaning SP5 No. 1 sa3 Blasting to Visually Clean Metal
Surface Preparation, Equipment and Inspection
Wet Process
1. Water Jetting : SSPC SP12 / NACE no. 5

• Low-Pressure Water Cleaning (LPWC): pressures below 5,000 psi (34 MPa)
• High-Pressure Water Cleaning (HPWC): pressures of 5,000 to 10,000 psi (34 to 70
MPa)
• High-Pressure Waterjetting (HP WJ): pressures of 10,000 to 30,000 psi (70 to 210
MPa)
• Ultrahigh-Pressure Waterjetting (UHPWJ): pressures above 30,000 psi (210 Mpa)

2. Water Blasting / Hydrobalasting / Slurry Blasting : SSPC TR2 / NACE 6G 198

• Pressurised Water Abrasive Blasting ; Abrasive added to High Pressure Water
• Air Abrasive Wet Blasting ; Water added to Compressed Air & Abrasive
Surface Preparation, Equipment and Inspection
Cleanliness Inspection
Surface Preparation, Equipment and Inspection
Cleanliness Inspection
Surface Preparation, Equipment and Inspection
Cleanliness Inspection
Surface Preparation, Equipment and Inspection
Surface Profile Inspection

You will often see a typical surface profile recommendation on

page 2 of product technical datasheets,example:-
Surface Preparation, Equipment and Inspection
Surface Profile Inspection & Standards

Surface Profile Gauges Testex Tape

ASTM D4417 Method B ASTM D4417 Method C

“Physical Measurement” Techniques

Pictures courtesy of Elcometer Instruments
Surface Preparation, Equipment and Inspection
Surface Profile Inspection & Standards

Grit / Shot
Rugotest
Comparators “Comparator”
ASTM D4417Techniques
Method A
ASTM D4417 Method A
ISO 8503-1 & 2 Pictures courtesy of Elcometer Instruments
Surface Preparation, Equipment and Inspection
Conductivity and Salt Contamination Test
1. Conductivity test for Abrasive Material ; ISO 11127-6
2. Salt test – Qualitatif
3. Salt test – Quantitatif
a. Bressle Method ; ISO 8502 – 6&9
b. Sleeve Method
Coating System

6
Coating System
General / Atmospheric coating
High temperature coating
Passive Fire proofing
Anti fouling coating
Splash zone coating
Lining/Internal tank coating
Under water application coating
Coating System
How to design ? – ISO 12944
Comprehensive “instructions” providing guidance for engineers,
consultants, contractors and coatings suppliers when dealing with the
corrosion protection of steel structures by protective paint systems.

“Instructions” divided into 8 separate parts :

• Defines “Durability” of coating systems

• Defines “Corrosivity Categories” of environments
• Provides guidance in coating system specifications
Coating System
How to design ? – ISO 12944
Expected Durability
Coating System
How to design ? – ISO 12944
Environment Clasification
Coating System
How to design ? – ISO 12944

Environment Clasification
Coating System
How to design ? – ISO 12944
Coating System Specification
Coating Application, Equipment, Material
Consumption and Inspection

7
Coating Mixing
Coatings are mixed:
• To ensure all the ingredients are evenly dispersed in the container before
application.
• To ensure the base and curing agent in two-pack products are evenly dispersed
together to allow for correct chemical reaction and complete cure to occur.

Procedure for Mixing Coatings:

• Avoid contamination during mixing, from dirty mixers, paint tins etc. Use
a mechanical mixer when possible. Always use a mechanical mixer with
two pack products.
• For two pack products, use the correct base with the correct hardener.
(confirm with product data sheets).
Pot Life
All two-pack materials have a pot-life.

This is the time period between mixing and curing when the paint is workable and can
be applied.

Pot-life is reduced when the temperature increases and vice versa. (Check product
datasheet.)

Never mix more paint than can be used before pot life expires.
Never add thinner to extend the pot-life.
Exceeding pot-life will waste paint, and will block up airless spray equipment.
Coating 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 affect applied dry film thickness.
Coating Application and Inspection

Methods of Application
• Brush ; Generally used for small or difficult access areas and for stripe- of weld seams,
edges, corners and cut-outs.Multiple coats may be required to achieve high film thickness
• Roller ; Roller Application is a faster method than brush but still is mainly used for touch-up
areas. Roller application will generally be used when spraying can not be done because of
contamination by air-borne spray particles. Multiple coats may be required to achieve high film
thicknesses
• Conventional Spray ; This method of application is normally used to apply low viscosity
coats and sometimes inorganic zinc silicate coatings. Low pressure compressed air is used to
atomize the coating for spraying so conventional spray can not handle high-build, high-viscosity
coatings
• Airless Spray ; The most common and fastest method of application of heavy-duty, high
viscosity coatings The system uses very high fluid or hydraulic pressures to atomize the coating.
Application is controlled by tip size, tip angle, input/output pressure and spray technique.
• Plural Pump Spray ; The most common and best method of application of short pot life
coating material.
Coating Application and Inspection
Brush and Roller
Coating Application and Inspection
Conventional Spray
Coating Application and Inspection
Airless Spray
Coating Application and Inspection
Plural Airless Spray
Coating Application and Inspection
Volume Solid : the ratio of the volume of its non volatile components to its
initial wet film volume.
Coating Application and Inspection
Example :
Volume Solid stated in the TDS 60%, DFT expected is 100 microns.
What is WFT ?

1. Without Thinner.

WFT = DFT / VS = 100 / 0.6 = 167 microns

2. With 5% Thinner.

WFT = DFT x 1.05 / VS = 100 x 1.05 / 0.6 = 175 microns

Coating Application and Inspection
QUIZ :

In the TDS stated that VS = 82%, suppose expected DFT is 150 microns.
What is the WFT ? Without thinner and with 5% thinner.

Answer :

1. Without thinner :
WFT = DFT / VS = 150 / 0.82 = 183 microns

2. With 5% thinner
WFT = DFT x 1.05 / 0.82 = 150 x 1.05 / 0.82 = 191 microns.
Coating Application and Inspection
Wet Film Thickness
Coating Application and Inspection
Critical to Quality :
1. Mixing ratio part A and part B  see Technical Data Sheet
2. Coating interval from one layer to next layer  see Technical Data Sheet
3. Typical thickness of each layer  See Technical Data Sheet
Coating Application and Inspection
Paint Consumption
Coating Application and Inspection
Example :

We have 1500 m2 surface to be applied the paint. Volume solid of the paint is 82%,
DFT specified is 200 microns, Refer to the experience loss factor is 40%. How many
liter paint required for this job? (suppose adding 5% thinner)

TSR = (VS / DFT ) x 10 = (82 / 200) x 10 = 4.1 m2/liter

PSR = TSR ( 1 – loss) = 4.1 x ( 1-0.4) = 2.46 m2 / liter

Liter = Area / PSR = 1500 / 2.46 = 609.7 liters.

Coating Application and Inspection
QUIZ

A tank with surface area 2000 m2, a client’s specification mentioned the thickness
of the paint is 200 microns, if the VS = 75%, and loss factor is 30%, how many liter
paints required ? with thinner 10%.

Answer :

762 liters
Coating Defect

8
Coating Defect
Modes of Failure
Coating Defect
Cause of Coating Defect

1) Poor Surface Preparation

Surface contamination  salt contamination, oil, etc
Surface profile  not adequate profile
2) Poor Application
Mixing (1-pack & 2-pack)
Over/less application (too thick/thin)
Use of spraying (low or high dft per coat)
Coating Defect
3) Incompatible Paint Systems  Maintenance and
Repair

eg 2-pack over 1-pack systems

4) Incorrect system for the environment
eg Anticorrosive or Antifouling performance needs
5) Poor Engineering Design
• Inherent design defects (eg stitch welding)
General Coating Inspection

9
General Coating Inspection
1. Dry Film Thickness.
Common standard : SSPC PA2.
• Every 10m2, 5 Spot, each 3 reading.
• The DFT Range, Spec. +/- 20%
General Coating Inspection
2. Adhesion Test.
• ASTM D 3359
For thickness <125 microns ; Cross Hatch test
For thickness >125 microns ; X cut test
• ASTM D 4541.
Pull Off Test.
Min Value 3 MPa refer to SSPC No. 22.
General Coating Inspection
Pull Off Adhesion Tester
General Coating Inspection
3. Low and High Voltage Holiday Test
Common standard : AS3894.1-2002, ASTM G62-07, ASTM D5162-08, ASTM D4748-08
NACE RP0274-04, NACE SP0490-2007, NACE SP0188-2006, ANSI/AWWA C214-07,
ANSI/AWWA C213-07,ISO 2746:1998
Lining and Special Coating
Lining
Antifouling
Intumescent
Cementitious
Powder Coating
Electrostatic Spray
Reinforced Plastic
Coating Concrete
Surface Preparation
Moisture content
Pinholess
Mat Reinforce
Non Liquid Coating
Galvanizing
Spray Metalizing/Thermal Spray
Main Coating Standard
ASTM
SSPC
ISO
NACE
NORSOK
Coating Inspector Certification
INTERNATIONAL
NACE (National Association Corrosion Engineer)
Level 1, Level 2, Level 3-Peer Review
Frosio
Level 1, Level 2, Level 3
LOCAL
Ascoatindo
Inspector Muda, Madya, Utama.
Health and Safety
Potensial Hazard
Volatile content ; Thinner, hazard material.
Paint application ; high pressure hazard, hazard material.
Working at height ; >2 m
Confined space ; Oxygen level, Explossive gas, Toxic gas.
Slip, Trip, Fall

Risk Assessment
Thank You
Question and Answer