Pre-treatment

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Performance of a paint system

Good pre-treatment of the substrate

is a requirement to obtain good performance of the paint system

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Work to be carried out in the cleaning shop

Remove prior to pre-treatment:

Salt and soil: Oil - grease:

Clean water Solvent with emulsifying agent or alkaline cleaner

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Water quality: Potential sources and risks

Potential sources
Salts

Potential paint failures Osmotic blistering

Dust after drying Loss of adhesion

Contaminations
Particles

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The mechanism behind Osmotic blistering

Fresh water will try to dilute the salt water Migration through a semi-permeable membrane The pressure will increase

Fresh water and salt water separated by a membrane

Steel structure contaminated with salt. Paint applied without proper cleaning
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Different types of salt have different affinity to water / humidity

Laboratory test. Different types of salt are applied to the steel plates Several month of exposure At similar levels: Chlorides more severe than Sulphates

CD 4932 no. 99 Sodium Chloride

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Iron Sulphate

No salt

Equipment contaminating the surface

Oil contamination from grinder

Reasons may be: Oil leaking out of equipment Equipment has been stored with oil Lack of oil trap. (Air from compressor contains oil) Must be removed prior to surface preparation

CD 4932 no. 22

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Flaking of Tar Epoxy

Tar Epoxy system Flaking down to shop

primer Flaking due to poor pre -treatment Remains of oil found underneath the paint

CD 4934 no. 57

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Welding smoke is water soluble and can only be removed by water

Welding smoke
Area washed with water

Solvents will not remove the welding smoke completely If not removed, osmotic blistering may occur.

CD 0589 no. 11

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Blisters close to weld, probably due to welding smoke remaining on the the steel
Welding smoke is resoluble in water and will
create osmotic blistering Galvanic difference between steel plate and weld may aggravate the attack

CD 4934 no. 79

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Pre-treatment. Recommended equipment

Portable blast-cleaning unit Vacuum blasting equipment Air-powered grinding equipment
(Available with and without vacuum unit) Air-powered wire-brush Needle gun (Available with and without vacuum unit) Air-powered chisel Scraper with interchangeable hard metal shears

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Pre-treatment

Evaluation of methods
Blast cleaning Power grinding Power wire-brushing Manual wire- brushing. Needle hammer Power chiselling Manual scraping
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Ideal Not as good as blast cleaning, but best alternative. Great risk of unwanted polishing. Not recommended. Very poor. Usable, but risk of unwanted rough surface, Good in combination with other methods Usable in combination with other methods.

Reciprocating impact tools

Needle scalars or guns Chipping guns (chisels)

Scabblers. Small hand-held and walk-behind models. To break up heavy rust, mill scale and coatings.
Example: Rustibus

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Equipment. Hand and power tool cleaning

Mechanical rotating wire brush Needle gun Hand Wire brush

CD 4932 no. 39

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Pre-treatment of a tank. Disc sanding of substrate

Part of a tank Nice St 2 standard, almost St 3

CD 0589 no. 99

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Hand wire brushed surfaces

Surfaces treated approximately to the given standards according to ISO 8501
St 2 St 3

CD 4932 no. 41

CD 4932 no. 42

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Mechanical cleaning may give unfavourable surfaces Needle-hammer makes a rough surface and deep indentations Rotating wire brushes and disc-sanders may give a polished surface

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Pre-treatment

Illustration of various blasting methods

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Dry blasting Benefits and limitations

Advantages Disadvantages

Surface remains dry Good anchor pattern for paint No pre-rusting profile

Does not remove salt Does not remove oil Creates dust

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Introduction to blast-cleaning

Gives a good surface profile Several blasting standards can be achieved Does not remove salts from the substrate
Pre-treatment: Blast-cleaning1

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Surface preparation

Metallic or non-metallic abrasives.

Blast cleaning with Metallic or Non-metallic abrasives to specified:

Cleanliness acc. to ISO 8501 - 1 or 2 Roughness acc. to ISO 8503

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Abrasives There are two main groups

1. Metallic abrasives

Chilled iron grit (angular) High-carbon cast steel grit and shot (angular or round) Low-cast cast steel snot (round) Cut steel wire (cylindrical)

2. Mineral and slag abrasives

Natural abrasives: Garnet, Olivine, Staurolite Slags: Copper refinery Nickel refinery
Coal furnace Iron furnace Fused aluminium oxide

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Metallic / mineral abrasives Re-use

Metallic abrasives and Carborundum (Al.oxide) can be recycled and are usually used more than once. For stationary plants Mineral and slag abrasives are generally used only once. For open blast-cleaning

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Shape of abrasives

Three main types of abrasives

Grit (Angular) Shot (round) Wire cut (cylindrical)

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Recommendations regarding blast cleaning

Loose paint and rust to be removed prior to blast-cleaning

Use correct ratio between air and abrasive

Always use good quality abrasive

Correct air-pressure 7 kg/cm (100 psi) at the nozzle

4 - 4,5 kg/cm is a waste of time

Remove dust and spent abrasive residue with vacuum cleaner

or eventually dry, oil-free compressed air

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Blast cleaning

Factors influencing the production rate

Productivity is directly proportional to:

Pressure at Nozzle Capacity of the air compressor Pressure at Nozzle 7 kg/cm = 100% productivity

Pressure at Nozzle 5,6 kg/cm = 66% productivity Pressure at Nozzle 4,2 kg/cm = 50% productivity

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Blast - cleaning

Measure the air pressure at the nozzle

Pressure gauge

Nozzle

Nozzleholder Air

Rubber hose
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Blast cleaning

Loss of pressure
Air pressure, bar
10 8 6 4
7 bar : Recommended < 4 bar : Waste of time

50
3/4" 1"

100

150
1"

200
1 1/4"

250

Hose length, m

Hose diameter

1 1/4" 3/4"

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Surfaces blast - cleaned to various standards

Plate was originally partly rusty and partly painted. Blast-cleaned approximately to the given standards

Sa 1

Sa 2

Sa 2

CD 4932 no. 61 CD 4932 no. 62 CD 4932 no. 63

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Water jetting

Water-jetting is an alternative to blast cleaning. Water-jetting has: - Environmental - Technical - Practical .benefits and drawbacks

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An introduction to Ultra High Pressure Water Jetting (UHPWJ)

High water pressures (up to 2500 bar) Manual equipment: Heavy work Different types of nozzles can be included in one rotating nozzle unit Removes water soluble salts
Pre-treatment: Wj_equipment1

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Water Cleaning is classified according to the pressure (NACE / SSPC) Pressure, bar Below 340 340 - 680 680 - 1700 Above 1700 NB
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Classification LPWC HPWC HPWJ UHPWJ

- Pressure at nozzle !

Why Water-jetting ?

The Environment is affected (to some degree) by all types of surface preparation. Water jetting has many technical and environmental advantages, but also some drawbacks.

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Formation of blisters as a function of salt concentration on substrate (1 of 2)

Salt: 0 mg/ m Film: 150 microns Salt: 60 mg/ m Film: 150 microns

CD-1183 no.89

CD-1183 no.90

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Formation of blisters as a function of salt concentration on substrate (2 of 2)

Salt: 100 mg/ m Film: 150 microns

Salt: 200 mg/m Film: 150 microns

CD-1183 no.91

CD-1183 no.92

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