and practical experience have shown that application of the first coat with a roller is not to be recommended.

This is particularly true on surfaces where the pretreatment has not been ideal or where moisture or other impurities having collected on the surface. Areas generally not suitable to be coated with a roller are: Complicated structures, porous or uneven surfaces, corners, sharp edges, along areas with many bolt heads or rivet heads. A paint roller may be used with good results for subsequent coats. Application by Spraying A paint brush is not a very practical choice when painting large areas. Here paint spraying equipment is a more effective alternative. The most important advantages of spray-application are: It gives a very high production rate and is suitable for large jobs. All coats, including the first, may be applied by airless spraying. Airless spraying, when used correctly, offers the advantages of giving a higher film thickness per coat. A much more even film thickness is obtained.

Paint Technology

The major disadvantages of spray- application are: It requires a lot of training / practice to apply an even film to a predetermined thickness, with no defects and a smooth surface. Airless Spray High-pressure spraying is used for application of most types of coating used to protect ships, offshore structures and industrial plants. Paint application using airless spraying must be carried out correctly in order to obtain satisfactory results. It is very important that the spray-gun is kept in constant motion. The spray-gun must be held at the correct distance from the substrate, i.e. about 30-60 cm (12-24 inches). The gun should be held perpendicular to the substrate Each stroke should overlap the previous stroke by 50% or cross application. Difficult areas such as profiles, corners, edges, etc. are sprayed first. The other surfaces are subsequently sprayed. The wet film thickness should be controlled continuously during spraying. Always remember to choose the correct nozzle for the job. It is not suitable for application in narrow gaps or areas with difficult access (Like rat holes, behind corners etc.) Location and surrounding environment may be affected.

Environmental Protection

Figure 6.26: Stroke and Triggering with at Spray Application

Start Stroke Pull Trigger Release Trigger

End Stroke

Correct distance between spray gun and substrate: (30-60 cm) Correct angel (90) a n ge Overlapping (50% or cross application)

Figure 6.27: Rules for Spray Painting

22

(ii) Checks to he carried out during Application The painter only has one instrument available for checking the film thickness during application, wet Film auge (comb or wheel). It is important to use the cam regularly, This ensures good checking during the entire application process so that the correct film thickness is achieved over the entire structure. The atmospheric conditions should always be checked during application of paint, and the correct ventilation ensured, especially in tanks. These conditions must be monitored throughout the application process and whilst the paint is drying / curing.
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Substrate
Wet Film Comb Dry Film Destructive Measurement

Figure 6.28: Dry Film Non-Destructive Measurement

(iii) Mixing and Thinning Do not add unnecessary quantities of thinner to the paint as this causes slower drying and you will have to apply the paint in greater wet-film thicknesses to achieve the same dry film. Use of the correct (specified) thinners is important as adding the wrong thinner can cause poor results in terms of corrosion protection.

Figure 6.29: Mixing of Paint

When applying two-component paints, the mixing process itself is also important. Use mechanical agitators and not stirrers. Good agitation or mixing of the two

Environmental Protection

components and the correct mixing ratio are important. Follow the instructions on the technical data sheet for the product. Plural component spray (two-component spray) are also available for applying special two-component paints, where the components are mixed in the correct ratio in the unit itself.

Figure 6.30: Pre-Blasting Preparation and Application of the Paint have been Carried out well

6.7 PAINT FAILURES

As you have already studied that paint supplied in containers is a semi-finished product. The finished product only exists once the paint has been applied to the structure in a complete paint system. This is where we see how good the protection is. The most important and most common paint failures occur as a result of poor or insufficient steelwork, preparation or application. Some of these faults are revealed during or shortly after application but some only appear after a certain period in service. The most common failures are: (i) (iii) (v) Insufficient film thickness Dry spraying Wrinkling/lifting (ii) Sags/runs (iv) Pinholes, popping (vi) Blistering (viii) Cracking (x) Chalking

(vii) Rust penetration (ix) Flaking (i)

Insufficient film thickness is often the result of non-s ystematic application and inadequate checks with a wet film gauge. Sags/runs occur when the paint is applied too thickly or too much thinner has been added to the paint. This is probably because the specification has, not been followed. Occasionally, faults are also found in the paint. The inspector must note the production number in the daily log. Sags/runs should be repaired immediately with a brush.

(ii)

24

Paint Technology

Figure 6.31: Sags/Runs

Dry spraying is normally a result of poor application or difficult weather conditions. The most common application fault is too great a distance between the spray gun and the structure. High temperature combined with low relative humidity will also contribute to dry spraying as the solvents evaporate en route from the gun to the object. Strong wind or strong ventilation also contributes to an increased risk of dry spraying.

Figure 6.32: Dry Spraying

(iv) Pinholes often occur on porous substrates, for example zinc silicate. On these substrates, it is important to apply a thin layer of paint, normally called-a tie coat or by using the mist coat - full coat technique. Pinholes are also found if there is too strong ventilation during application.

Figure 6.33: Pinholes

25

Environmental Protection

.W

Figure 6.34: Pinholes Magnified

(v) Blistering is normally an adhesion-related problem and is due to poor cleaning before application of the paint. The most common cause of blistering is the application of the paint to a substrate contaminated with salt (osmotic blistering). After blisters have formed, they burst and the underlying unprotected material begins to rust if rust formation has not already started. Osmotic blistering occurs on exposure under water or in areas with heavy condensation. In particular, the salts sodium chloride and ferric chloride, and welding smoke, cause blistering, Other causes of blistering can be dust or grit on the surface (reduces adhesion), voids between the steel and the paint or trapped air in the paint film.

Figure 6.35: Blistering

Figure 6.36: Blistering

(vi) Rusting occurs after a blister in the paint film bursts. The failure will occur most quickly where the paint film is too thin. Particularly susceptible areas are sharp edges, rough welds and places which are difficult to access for application. If rusting occurs after a very short time without prior blistering, there will be an opening through to bare steel, i.e. a pinhole. 26

.If

Paint Technology

Figure 6.38: Rusting

(vii) Cracking occurs after a certain ageing of the coating. The causes can be: The top coat is harder than the coats underneath Excessively thick system combined with temperature variations Excessively fast curing of two-component systems Excessively thick zinc silicate gives "mud cracking".

Figure 6.39: Thick Old Alkyd Paint has been finder Stress

Figure 6.40: Too Thick Paint Film (Cracking)

There are various degrees of cracking. Cracks can either form in the top coat only or throughout. The time before the fault occurs can vary. Mud cracking occurs, immediately after application but cracking occurs only after a certain time.
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(viii) Flaking is normally the result of a poorly cleaned substrate (oil, grease) or the paint being applied onto condensation or surfaces with amine sweating. Paint will frequently flake off from areas with blistering or cracking and occurs where adhesion is poorest.

Figure 6.41: Flaking

(ix)

Chalking is an ageing problem. The binder is degraded by UV radiation from the sun and the pigments appear as dust on the surface. The paint's ability to resist chalking will vary according to the binder used. Epoxy will chalk in sunlight after just a few months whereas polyurethane will retain its gloss for many years.

Figure 6.42: Chalking

(xi)

Wrinkling/Lifting WRINKLING Appearance Small wrinkles through or partly through the paint film Caused by Skin drying of the paint film, which is usually applied too thick

28

Paint Technology

Figure 6.43: Wrinkled Surface LIFTING

Appearance
.

Caused by

Small wrinkles through the paint film

Softening and raising or swelling of a previous coat by the application raising swelling by of an additional coat Not Normallywhen overcoating A lkyd Lifting often caused because the solvents in the new coat is too strong Lifting for the previous coat

Figure 6.44: Paint Lifting Defect

6.8 SAFETY, HEALTH AND ENVIRONMENT (SHE)

In recent years. awareness o f SHE-related matters has increased. This is reflected in legislation and by companies and individuals becoming involved in such matters. We have decided to focus on health problems in connection with the surface treatment of structures.

Figure 6.45: Safety First

29

General Guidelines During the preparation and use of paint, it is important to be aware of the risks associated with the activity. In brief. Follow current legislation from local and national authorities. Read the safety data sheets for all products. Know the risks and how to protect yourself. Obtain the necessary training in the use of the products and equipment to be used. Use the necessary protective equipment to protect the respiratory system, eyes, skin and hearing. Ensure correct storage and handling of products and associated thinners before, during and after the work. The products should be collected in a specially allocated area. (i) Safety Safety aspects are particularly important in connection with the use of solvent-based paints. Solvents are flamrnable and i n the right environment and under unfavourable conditions can cause both fire and explosion. Be aware that solvents are heavier than air and will sink down to areas which lie below the painting work.

Figure 6.46: Protective Equipment

In general, the following aspects should be checked in connection with painting work. Plan the work and co-ordinate this with other activities in the area. Inspect the area where the work is to be performed. Shut off the area affected. Check the equipment to be used, including safety and protective equipment Closed rooms must be declared gas-free before work begins. gas-free

Take extra safety precautions when painting in tanks and confined area Adequate ventilation, explosion-proof working lights and equipment, assistant with a line and adequate breaks in fresh air.