Surface Preparation &

Painting Procedure

XXXX YYYY
SDN BHD

Quality Management System

Standard Procedure

Document Title
Document No XXXX /PMT/SP-004
Revision No 00
Effective Date 1 December 2016
Reviewed by General Manager
Approved by Managing Director

MASTER CONTROLLED COPY

UNCONTROLLED COPY
 XXXX YYYY
Standard
Document No : XXXX
SDN BHD Procedure /PMT/SP-004
Page No : 2 of 29
Quality Revision No. : 00
Management Effective Date : 1 Dec 2016
System
Title: Surface Preparation & Painting Procedure

This document is the exclusive property of XXXX Engineering & Construction Sdn Bhd (XXXX ) and
upon request, may distribute on a confidential basis. Further distribution, copying, reproduction in
whatever form is to be done only with the express permission of XXXX . This document must be returned
to XXXX at the request of XXXX and no copies in whatever form of any part of this document is to be
retained without the permission of XXXX . XXXX will seek recourse should this notice be violated.

Revision History
Rev. No. Page Description Prepared by
No.
0 All New Issue Syaiful Rasyidi
Table of contents
1. PURPOSE................................................................................................................................ 5
2. SCOPE..................................................................................................................................... 5
3. TECHNICAL DEFINITIONS and ABBREVIATIONS..................................................................5
4. REFERENCE DOCUMENTS.................................................................................................... 6
5. GENERAL................................................................................................................................. 9
5.1. Equipment................................................................................................................................. 9
5.2. Handling of Blasting & Painting material.................................................................................10
6. SURFACE PREPARATION..................................................................................................... 11
6.1. General................................................................................................................................... 11
6.2. Pre-Cleaning of Surfaces and Solvent Cleaning.....................................................................11
6.3. Surface Preparation by Blast Cleaning...................................................................................11
6.3.1. Blasting Abrasives.......................................................................................................... 13
6.3.2. Techniques and Constraints...........................................................................................13
6.4. Surface Preparation by Hand and Power Tool Cleaning.........................................................14
7. PAINT APPLICATION.............................................................................................................. 15
7.1. Pre Application Procedures..................................................................................................... 15
7.1.1. General.......................................................................................................................... 15
7.1.2. Mixing and Thinning....................................................................................................... 16
7.1.3. Other Miscellaneous Requirements...............................................................................16
7.2. Application Methods................................................................................................................ 17
7.3.1. General.......................................................................................................................... 17
7.3.2. Spray Application........................................................................................................... 17
7.3.3. Brush Application........................................................................................................... 18
7.3.4. Roller Application........................................................................................................... 18
7.4. Repair of Defects.................................................................................................................... 19
7.4.1. General.......................................................................................................................... 19
7.4.2. Inadequate Coating Thickness.......................................................................................19
7.4.3. Coating Damage not exposing steel surface substrate..................................................19
7.4.4. Coating Damage exposing steel surface substrate........................................................19
7.4.5. Repair of Zinc Silicate primer.........................................................................................19
7.4.6. Repair of Fully Cured Epoxy coatings............................................................................19
8. INSPECTION.......................................................................................................................... 20
8.1. Inspection Equipment............................................................................................................. 20
8.1.1. Surface Comparator....................................................................................................... 20
8.1.2. Surface Profile............................................................................................................... 20
8.1.3. Wet Film Thickness Gauge............................................................................................20
 8.1.4. Dry Film Thickness Gauge............................................................................................. 21
8.1.5. Relative Humidity........................................................................................................... 21
8.1.6. Temperature Gauge....................................................................................................... 21
8.1.7. Hypodermic Needle Gauge............................................................................................ 21
8.1.8. Pinhole / Holiday Detector.............................................................................................. 21
8.2. Quality Control (QC)............................................................................................................... 22
8.2.1. Flow chart for inspection of Blasting and Painting Activities...........................................22
8.2.2. Testing/Inspection.......................................................................................................... 23
9. DOCUMENTATION................................................................................................................. 25
10. MANDATORY REQUIREMENT.............................................................................................. 25
10.1. Surface preparation, Painting and Repair Procedure..............................................................25
11. SAFETY.................................................................................................................................. 25
APPENDICES...................................................................................................................................... 27
i. APPENDIX 1: Salt Contamination Report.................................................................................1
ii. APPENDIX 2: Dust Level Report..............................................................................................2
iii. APPENDIX 3: Surface Cleanliness Report...............................................................................3
iv. APPENDIX 4: Checking of paint Report...................................................................................4
v. APPENDIX 5: Paint Application Report.....................................................................................5
vi. APPENDIX 6: Painting Thickness Report.................................................................................6

1. PURPOSE

This procedure serves as guideline for any Blasting and Painting job awarded to XXXX YYYY
Sdn Bhd.

2. SCOPE

This procedure defines the minimum technical requirements of Blasting & Painting for Steel
Structures, Piping, Vessel, Tank and etc which is required coatings in order to meet Project
specification, Coating Manufacturer recommendations, Reference code and standards in any
Blasting and Painting job awarded to XXXX YYYY Sdn Bhd.

3. TECHNICAL DEFINITIONS and ABBREVIATIONS

The following abbreviations and definitions shall be used in this

specification.
Abrasive blast The impingement of a high-kinetic-energy stream of
cleaning blast cleaning abrasives onto the surface to be prepared

Anchor pattern Contour of a blast-cleaned surface on a plane

perpendicular to the surface.

Application Application, drying and/or curing of a coating layer.

Dew Point The temperature of a given air/water-vapour mixture at

which under atmospheric pressure, condensation starts.

DFT Dry Film Thickness; the thickness of the dried or cured

paint or coating film.

WFT Wet Film Thickness; the thickness of the uncured or wet

paint or coating film

HSE Health, Safety and Environment.

Pot life The time interval, after mixing of paint or coating

materials, during which the mixture can be applied
without difficulty or loss of final coating quality.

Thinner Volatile liquid added to lower the viscosity of the paint to

ease application.

MSDS Material Safety Data Sheet

 4. REFERENCE DOCUMENTS

ISO 9001 : 2008 : Quality management systems Requirements

ISO 8501-1 : 2007 : Preparation of steel substrates before application of paints and related
products -- Visual assessment of surface cleanliness -- Part 1: Rust grades and preparation
grades of uncoated steel substrates and of steel substrates after overall removal of previous
coatings

ISO 8501-2 : 1994 : Preparation of steel substrates before application of paints and related
products -- Visual assessment of surface cleanliness -- Part 2: Preparation grades of previously
coated steel substrates after localized removal of previous coatings

ISO 8501-3 : 2006 : Preparation of steel substrates before application of paints and related
products -- Visual assessment of surface cleanliness -- Part 3: Preparation grades of welds,
edges and other areas with surface imperfections

ISO 8501-4 : 2006 : Preparation of steel substrates before application of paints and related
products -- Visual assessment of surface cleanliness -- Part 4: Initial surface conditions,
preparation grades and flash rust grades in connection with high-pressure water jetting

ISO 8502-3 : 1992 : Preparation of steel substrates before application of paints and related
products -- Tests for the assessment of surface cleanliness -- Part 3: Assessment of dust on steel
surfaces prepared for painting (pressure-sensitive tape method)

ISO 8502-4 : 1993 : Preparation of steel substrates before application of paints and related
products -- Tests for the assessment of surface cleanliness -- Part 4: Guidance on the estimation
of the probability of condensation prior to paint application

ISO 8502-6 : 2006 : Preparation of steel substrates before application of paints and related
products -- Tests for the assessment of surface cleanliness -- Part 6: Extraction of soluble
contaminants for analysis -- The Brestle method

ISO 8502-9 : 1998 : Preparation of steel substrates before application of paints and related
products -- Tests for the assessment of surface cleanliness -- Part 9: Field method for the
conductometric determination of water-soluble salts

ISO 8503-1 : 2012 : Preparation of steel substrates before application of paints and related
products -- Surface roughness characteristics of blast-cleaned steel substrates -- Part 1:
Specifications and definitions for ISO surface profile comparators for the assessment of abrasive
blast-cleaned surfaces

ISO 8503-2 : 2012 : Preparation of steel substrates before application of paints and related
products -- Surface roughness characteristics of blast-cleaned steel substrates -- Part 2: Method
for the grading of surface profile of abrasive blast-cleaned steel -- Comparator procedure

ISO 8503-5 : 2003 : Preparation of steel substrates before application of paints and related
products -- Surface roughness characteristics of blast-cleaned steel substrates -- Part 5: Replica
tape method for the determination of the surface profile
 ISO 11125-3 : 1993 : Preparation of steel substrates before application of paints and related
products -- Test methods for metallic blast-cleaning abrasives -- Part 3: Determination of hardness

ISO 11125-2 : 1993 : Preparation of steel substrates before application of paints and related
products -- Test methods for metallic blast-cleaning abrasives -- Part 2: Determination of particle
size distribution

ISO 11127-2 : 2011 : Preparation of steel substrates before application of paints and related
products -- Test methods for non-metallic blast-cleaning abrasives -- Part 2: Determination of
particle size distribution

ISO 2808 : 2007 : Paints and varnishes -- Determination of film thickness

ISO 19840 : 2012 : Paints and varnishes -- Corrosion protection of steel structures by protective
paint systems -- Measurement of, and acceptance criteria for, the thickness of dry films on rough
surfaces

ISO 16276-1 : 2007 : Corrosion protection of steel structures by protective paint systems --
Assessment of, and acceptance criteria for, the adhesion/cohesion (fracture strength) of a coating
-- Part 1: Pull-off testing

ISO 16276-2 : 2007 : Corrosion protection of steel structures by protective paint systems --
Assessment of, and acceptance criteria for, the adhesion/cohesion (fracture strength) of a coating
-- Part 2: Cross-cut testing and X-cut testing

ISO 4628-1 : 2003 : Paints and varnishes -- Evaluation of degradation of coatings -- Designation
of quantity and size of defects, and of intensity of uniform changes in appearance -- Part 1:
General introduction and designation system

ISO 4628-2 : 2003 : Paints and varnishes -- Evaluation of degradation of coatings -- Designation
of quantity and size of defects, and of intensity of uniform changes in appearance -- Part 2:
Assessment of degree of blistering

ISO 4628-3 : 2003 : Paints and varnishes -- Evaluation of degradation of coatings -- Designation
of quantity and size of defects, and of intensity of uniform changes in appearance -- Part 3:
Assessment of degree of rusting

ISO 4628-5 : 2003 : Paints and varnishes -- Evaluation of degradation of coatings -- Designation
of quantity and size of defects, and of intensity of uniform changes in appearance -- Part 5:
Assessment of degree of flaking

ISO 4628-6 : 2011 : Paints and varnishes -- Evaluation of degradation of coatings -- Designation
of quantity and size of defects, and of intensity of uniform changes in appearance -- Part 6:
Assessment of degree of chalking by tape method

ISO 4624 : 2002 : Paints and varnishes -- Pull-off test for adhesion

ISO 2409 : 2013 : Paints and varnishes -- Cross-cut test

 ISO 12944-7 : 1998 : Paints and varnishes --Corrosion protection of steel structures by protective
paint systems -- Part 7: Execution and supervision of paint work

ASTM D 4541 : Standard test method for pull-off strength of coatings using portable adhesion
testers
ASTM D 4752 : Standard test method for measuring MEK resistance of ethyl silicate (inorganic)
zinc-rich primers by solvent rub.
ASTM E 337 : Standard method for measuring humidity with a whirling hygrometer (the
measurement of wet- and dry-bulb temperatures).
NACE No. 1 : Surface preparation standard white metal blast cleaning.
NACE No. 2 : Surface preparation standard near-white metal blast cleaning.
NACE No. 4 : Brush-off blast cleaning
NACE No. 5 : Surface preparation and cleaning of metals by water-jetting prior to recoating.
NACE 6G198 : Wet abrasive blast cleaning
NACE RP0188 : Discontinuity (holiday) testing of new protective coatings on conductive
substrate.
SSPC-PA 2 : Measurement of dry coating thickness with magnetic gauges.
SSPC-SP 1 : Solvent cleaning.
SSPC-SP 3 : Power tool cleaning.
SSPC-SP 5 : White metal blast cleaning.
SSPC-SP 7 : Brush-off blast cleaning.
SSPC-SP 10 : Near white blast cleaning.
SSPC-SP 11 Power tool cleaning to bare metal.
SSPC-SP 12 : Surface preparation and cleaning of metals by water-jetting prior to recoating.
SSPC-SP TR 2 : Wet abrasives blast cleaning.
SIS 05-59-00 : Swedish standard : Pictorial surface preparation standard for painting steel
surfaces.
PTS 30.48.00.31 : Protective Coatings and Linings, September 2012
PTS 30.10.02.11 : Metallic Materials Selected Standard, December 2010
PTS 30.48.40.31 : Thermal Spray Coatings Of Aluminum And 85/15 Zinc/Aluminum Alloy,
December 2010
PTS 39.01.10.11 : Selection of Materials For Life Cycle Performance (EP) Materials Selection
Process, December 2010.
PTS 39.01.10.12 : Selection of Materials For Life Cycle Performance (EP) Upstream
Equipment, December 2010.
PTS 30.10.02.13 : Non-metallic Materials Selection And Application, October 2009
5. GENERAL

5.1. Equipment

5.1.1.The compressed air supply for Blast Cleaning equipment shall be free of water and oil.
Adequate separators and traps shall be provided and these shall be kept emptied
regularly of water and oil. Accumulations of oil and moisture shall be removed from the
air receiver by regular purging. Air compressors shall not be allowed to deliver air at a
temperature in excess of 110 C. The grit shall normally be discharged with a pressure
of 7 bar measured at the nozzle using a hypodermic pressure gauge and shall not under
any circumstances fall below 5.6 bar for normal cleaning operations.

5.1.2.The coating spraying equipment to be used shall meet the recommendations and
instructions set forth by the paint manufacturer for each specific coating system. Airless
Spray is normally the choice of application method but if conventional air spray is used,
an adequate moisture trap shall be placed between the air supply and the pressure pot
feed to the gun. The trap shall continuously bleed off any water or oil from the air supply.

5.1.3.Blasting Equipment:

a) Auto Blast Machine

b) Blasting Pots (600 lbs, 150 lbs, 50 lbs)
c) Air Compressor (825cfm, 600cfm, 375cfm)
d) Air After Cooler / Air Dryer
e) Air Distributor Manifold
f) Air Filters / Moisture Separator
g) Air Tool (For Power Brushing)
h) Pencil Blast Unit
i) Dead Man Handle
j) Air and Blasting Hoses
k) Blasting Helmet / Hood and Full Body Kit

5.1.4.Painting Equipment
a) Airless Spray Pump / Spray gun
b) Conventional Spray Pot / Spray gun
c) Pneumatic paint agitator
d) Moisture Separator / Air filter
e) Spray paint hose/ Air hose
f) Paint brush / Roller

5.2. Handling of Blasting & Painting material

 5.2.1.All paint and consumables shall be received in the Manufacturers original containers
and marked with the description of the content. Storage shall be done in dry, clean
and well ventilated areas.

5.2.2.Paint Type, Brand Name, Date of Manufacture, Batch Number and other information
shall be documented for trace ability.

5.2.3.The paint shall be thoroughly stirred with appropriate mechanical agitator prior
application. No hand / manual mixing are allowed. All paint mixing shall be carried out
to Manufacturers recommendation in clean containers and free of oil, grease and
other contaminants.

5.2.4.Inter Mixing of different brand or type of paint shall not be permitted.

5.2.5.Paint material that has gelled or otherwise deteriorated during storage or with expired
shelf life shall not be used.

5.2.6.Thinning of paint material, when necessary for proper application shall be

carried out under supervision of Competent Supervisor or Paint Manufacturers
Representative and follow strictly as per Product Technical Data Sheet. Only
approved thinner shall be used and measured accordingly.

5.2.7.Blasting abrasives shall be placed on wood block or other stocking method at

minimum of one foot above ground level.

5.2.8.All blasting abrasives shall be dry and free from contaminants. Abrasive blasting shall
not be done in open area close to the painting application and wet painted surface.

5.2.9.All stainless steel and duplex must be handle with caution. All lifting purpose must be
handled using lifting belt. Forklift fork must be cover by soft material to avoid damage
onto stainless steel or duplex stainless steel surface.

5.2.10. The shelf life and pot life of the Glass Flake paint shall be in accordance to
the Product Technical Data Sheet.

5.2.11. All paints materials shall be stored in accordance with coating manufacturers
latest published instruction. The coating material shall be handled and stored in
accordance with the manufacturers latest published instructions and shall be
protected from damage, moisture, direct sunlight and subject to material requirement.

5.2.12. Only complete kits shall be mixed in accordance with coating manufacturers
latest published instruction.

5.2.13. Protection of equipment from paint spray, dust abrasive blast shall be taken
into consideration and preventative measures.

6. SURFACE PREPARATION
 6.1. General
For optimum paint performance, surfaces to be painted or coated shall be completely dry
and free from burrs, weld spatter, flux, rust, loose scale, dirt, dust, grease, oil and other
foreign matter deleterious and harmful to paint. After preparation of substrate surface,
any grit or dust shall be removed and a layer of primer applied before any corrosion or
recontamination occurs, normally within four (4) hours after blasting. Surface preparation
shall be subjected to inspection before the primer coat is applied to ensure all traces of
dust and foreign matter have been removed by brushing, blowing with dry clean
compressed air or vacuum cleaning.

6.2. Pre-Cleaning of Surfaces and Solvent Cleaning

This cleaning process is mandatory before further cleaning or surface preparation. Prior
to the actual cleaning operation, surface contaminants such as oil, grease, hydrocarbon
etc. shall be removed preferably by degreasing with suitable degreaser or solvent
cleaning according to SSPC-SP1. The degreased surface shall be further washed or
rinsed down with fresh water to remove all traces of the degreaser chemicals.

The surface shall be allowed to dry thoroughly before proceeding with any further
coating work. This process also applies to all metal surfaces to be coated that do not
require blast cleaning or power tool cleaning.

Excessive rust scale shall be removed by impact cleaning tools or high pressure water
jetting. All edges shall be ground to a minimum radius of 2 mm. Flame cut areas shall be
ground flush.

6.3. Surface Preparation by Blast Cleaning

Blast cleaning shall be carried out through ISO 8504-2:1992 to the required visual
standard in accordance with ISO 8501-1:1988 or equivalents. All surfaces, where
accessible shall be prepared by abrasive blast cleaning to a minimum of SA 2.5 ISO
8501-1(SSPC-SP10).

Table 6.1 Nearest Equivalent of the Main Surface Preparation Specifications

ISO NAC
Surface Preparation
SSPC Description
8501-1 E
Removal of oil, grease, dirt, soil and
Solvent Cleaning
other contamination by cleaning with
SP1 NA NA solvent, vapour, alkali emulsion or
steam.

Hand Tool Cleaning Removal of loose rust, loose mill

scale and loose paint by hand
SP2 ST 2 NA
chipping, scraping, sanding and wire
brushing.
 Removal of loose rust, loose mill
Power Tool Cleaning
scale and loose paint by power tool
SP3 ST 3 NA chipping, de-scaling, sanding, wire
brushing and grinding.

A white metal blast cleaned surface,

when viewed without magnification,
White Metal Blast Cleaning shall be free of all visible oil, grease,
SP5 Sa 3 1 dust, dirt, mill scale, rust, coating,
oxides, corrosion products and other
foreign matter.

A near white metal blast cleaned

surface, when viewed without
magnification, shall be free of all
visible oil, grease, dust, dirt, mill
scale, rust, coating, oxides, corrosion
Near White Metal Blast
product, and other foreign matter.
Cleaning
SP10 Sa 2 2 Random staining shall be limited to
no more than 5% of each unit area of
surface and may consist of light
shadows, slight streaks, or minor
discolorations caused by stains of
rust, stains of mill scale, or stain of
previously applied coating.
A commercial blast cleaned surface,
when viewed without magnification,
shall be free of all visible oil, grease,
dust, dirt, mill scale, rust, coating,
oxides, corrosion products and other
Commercial Blast Cleaning foreign matter.
SP6 Sa 2 3 Random staining shall be limited no
more than 33% of each unit area of
surface and may consist of light
shadows, slight streaks or minor
discolorations caused by stains of
rust, stains of mill scale, or stains of
previously applied coating.
A brush-off cleaned surface, when
viewed without magnification, shall
be free of all visible oil, grease, dirt,
dust, loose mill scale, loose rust and
loose coating. Tightly adherent mill
scale, rust and coating may remain
Brush-Off Blast Cleaning
SP7 Sa1 4 on the surface.
Mill scale, rust and coating are
considered tightly adherent if they
cannot be removed by lifting with a
dull putty knife after abrasive blast
cleaning has been performed
Power Tool Cleaning To Removal of all visible rust, mill scale,
Bare Metal paint and foreign matter using power
SP11 NA NA
tools and producing a minimum
profile of 25 microns.

6.3.1. Blasting Abrasives

6.3.1.1. Blasting abrasives for use in blast cleaning carbon steel and low alloy steel are specified in
ISO 8504-2. All non-metallic blast cleaning abrasives shall meet the requirement of ISO 11126
and be tested in accordance with test methods specified in ISO 11127 Part 1-7. The
conductivity of abrasives to be used on carbon and stainless steels shall be less than 150
S/cm. Suitable blasting abrasives are as follows:

a) Mixed Steel Grit and Steel Shot (Auto Blast Machine)

b) Garnet 30-60 (Manual Blast)

6.3.1.2. All blasting abrasives shall be tested and qualified in accordance with the procedures
described in SSPC-AB1 Abrasive Specification No.1; Mineral and Slag Abrasives.

6.3.1.3. Abrasives that are classified as Scheduled Waste under the Environmental Quality Act (EQA)
1974 shall not be used. Sand or other materials producing silica dust shall not be used. The
abrasives shall be free from oil, grease, moisture, salt, dust etc. Re-used abrasives shall be
clean, sharp and free from contaminants and re-qualified to SSPC-AB 1 requirements.

6.3.2. Techniques and Constraints

6.3.2.1. Blast cleaning shall not be carried out when the temperature of the surfaces to be coated is
less than 3 Celsius above the dew point or when the relative humidity of the air is greater
than 85 %.

6.3.2.2. Abrasive blasting shall not be done in open areas close to painting operations or wet coated
surfaces to prevent dust and grit contamination. Normally grit blasting shall be permitted only
during daylight hours except that rough grit blasting will be allowed during the night provided
that the surface is subsequently blasted to the specified standard under good light conditions.
The illumination of the surface during final blasting shall be at least 500 Lux and all
environmental restrictions are observed.

6.3.2.3. The blast profile and angular anchor pattern shall be that recommended by the paint
manufacturer to suit the minimum requirements of their respective primers. The acceptable
peak-to-valley height range shall be between 50 ~ 75 microns except for area to be coated
with Epoxy Glass Flake which is 50-100 microns. The profile shall be checked at frequent
intervals

6.3.2.4. All welded areas and appurtenances shall be given special attention for removal of welding
flux in crevices. Welding spatters, slivers, laminations and underlying mill scale not removed
during fabrication and exposed before and during blast cleaning operations shall be removed
by the best mechanical means and the edges smoothed or rendered flush. Where rectification
 is necessary on abrasive blast cleaned surfaces, the dressed areas shall be re-blasted to
remove all rust, slag and grit and to provide an adequate anchor pattern.

6.3.2.5. Blasting shall continue a minimum of 25 mm into any adjacent coated areas and the edges
shall be feathered. After dry blast cleaning, no acid washes, cleaning solutions, solvents or
other chemical treatment shall be used on metal surfaces. This restriction includes inhibitive
washes to prevent rusting. Any blast-cleaned steelworks on which rust develops shall be re-
blasted prior to being painted.

6.3.2.6. All blasted surfaces shall be coated before any blooming or oxidation of the steel occurred. If
any surface has been left more than 4 hours between blasting and painting or blooming or
oxidation occurs on the blasted surface, the surface shall be re-blast.

6.3.2.7. The salt contamination on the steel surfaces after blasting shall be less than 30 mg/m2 prior
to painting application. Water Jetting shall be carry out if the salt contamination level not meet
as per requirement.

6.4. Surface Preparation by Hand and Power Tool Cleaning

6.4.1.The most technically effective surface preparation method is blast cleaning.
Manual preparation shall only be used when blast cleaning is either not feasible or
not strictly required eg. galvanize steel and stainless steel.

6.4.2.Manual cleaning shall be performed using hand wire brushes or mechanically

operated tools (grinders, chippers, wire brushes) in accordance with ISO 8504-3.
Where welds occur within these areas or when these areas cannot accommodate
a power disc, power impact tools shall be applied (vibratory and rotary hammers,
needle guns, chisels) followed by brush cleaning.

6.4.3.If the surface being prepared lies adjacent to a coated surface which is not to be
refurbished, the power tool cleaning shall overlap the coated surface by at least 25
mm. The minimum requirement for successful coating application is St 3 ISO
8501-1 (SSPC-SP3) at the time of coating. Care shall be taken to ensure that the
substrate surface does not become polished during power tool cleaning.

7. PAINT APPLICATION

7.1. Pre Application Procedures

7.1.1. General

7.1.1.1. Any surfaces to be coated shall be dry and rendered dust free prior to application of primer
coat. This can be accomplished by blowing off the surface with clean dry air or using an
industrial vacuum cleaner together with a clean dry stiff brush. The particle quantity and
particle size do not exceed rating 2 of ISO 8502-3.
7.1.1.2. The blasted surfaces shall be examined for traces of smudge, oil, grease or other
contamination and also tested for the presence of soluble salts. If present they shall be
removed by solvent washing or for salts by water washing or steam cleaning and the areas
re-blasted.
7.1.1.3. Release Note to be issued for items that are ready to be coated. All paint and coating
application shall be carried out in accordance with the provisions of the Client Specifications
7.1.1.4. Adequate masking protection work shall be provided to prevent paint from being applied to
areas where it is not required Machine, equipment etc.
7.1.1.5. All paint and coating materials received at work site must be in their original unopened and
undamaged containers.
7.1.1.6. The Paint Manufacturers Recommendation with regard to mixing, thinning, application
methods, drying time, curing time, over coating time, storage, shelf and pot life of paint shall
be strictly adhered to.
7.1.1.7. The first coat of paint shall be applied as soon as possible before any blooming or oxidation of
the steel occurs during the same day light hours.
7.1.1.8. No paint shall be applied on edges prepared for field weld. A minimum of 50 mm shall be left
uncoated, these areas must be covered with masking tape prior to painting.
7.1.1.9. Stripe Coating shall be applied manually with paint brush to areas of limited access such as
corners, edges and welded joints prior to spray application.
7.1.1.10. If condensation, rain rust or other contamination settle on the surface which is not touch
dry, then the paint shall be removed, cleaned and repaint in accordance to coating repair
procedure.
7.1.1.11. All coated surface shall have a continued film of uniform thickness and free from pores. Any
this spots or areas missed in application shall be re-coated.
7.1.1.12. Each coat shall be in proper state of cure or dryness prior application of the succeeding coat.
Manufacturers recommendation of over coating time shall be adhered to.
7.1.1.13. Paint pot life shall be in accordance with Paint Manufacturers recommendation. When
expired, the spray pot shall be emptied and paint material shall be discarded in accordance of
HSE Procedures.
7.1.1.14. Handling of coated material should be done with padded slings, soft lifting gear, sand
bags or other suitable materials that shall be used to prevent damage to painted items
during loading unloading and transportation. Any damaged shall be repaired accordingly.

7.1.2.Mixing and Thinning

7.1.2.1. All coating materials shall be thoroughly stirred in a pressure pot with a power mixer for a time
sufficient to thoroughly remix the pigments and vehicles. Sufficient agitation to maintain good
mixing shall be applied until the product is used. Coatings containing heavy or metallic
pigments that have a tendency to settle shall be kept in continuous suspension in the
pressure pot by a mechanical agitator or stirrer
7.1.2.2. If during mixing / stirring air is entrapped in the product, sufficient time should be allowed for
air bubbles to escape, before application is started. This is to reduce the risk of pin-holing of
the coating layer to be produced. Thinner shall not be added to primer or paints unless
 necessary for proper application according to the paint manufacturers recommendation. The
type of thinner used must comply with same.
7.1.2.3. If the coating material requires the addition of a catalyst, the pot life under application
conditions shall be clearly stated on the label. The pot life shall not be exceeded. When the
pot life limit is reached, the spray pot shall be emptied, the material discarded, the equipment
cleaned and new material catalyzed.
7.1.2.4. Hydrostatic and other testing of welds shall be completed prior to painting weld lanes, ends of
pipe and related components that will require subsequent welding at site shall be masked off
after blast cleaning and left uncoated for a distance of 50 mm from all areas requiring welding.

7.1.3. Other Miscellaneous Requirements

7.1.3.1. For multi-coat system, a mist coat shall be applied over inorganic zinc primer to avoid surface
defects. Necessary care shall be exercised to ensure a smooth and uniform coating is applied
over inorganic zinc primer.
7.1.3.2. Extra coats of paint shall be applied on areas where shape and/or plane of application results
in thinly applied coatings; example at edges, weld behind angles, corners etc and areas not
fully accessible by spray in order to obtain the specified coverage and thickness. A stripe coat
of paint shall be brush applied before applying the subsequent coat.

7.2. Application Methods

7.3.1. General

7.3.1.1. Unless otherwise recommended by the paint manufacturer and accepted by the Client, paints
shall NOT be applied when:

Incomplete surface preparation or oil, grease and dust still present on substrate
to be painted.
The surface temperature is less than 3C above Dew point.
The air or surface temperature is below 5C as it would adversely affect curing
of Paint.
The relative humidity of air is greater than 85% except for inorganic zinc silicate
up to 90%.
The metal substrate temperature is higher than that recommended by the paint
manufacturer for application
 There is a likelihood of an adverse change in weather conditions within two
hours after application that would result in a drastic drop in air temperature
below those as specified above.
There is a deposition of moisture in the form of rain, condensation etc. upon the
surface.
The available light is less than 500 Lux

7.3.1.2. Coatings shall be uniformly applied without runs, sags, solvent blisters, dry spray or other
blemishes. All blemishes and other irregularities shall be repaired or completely removed and
recoated. Special attention shall be paid to crevices, corners, edges, weld lines, bolt heads,
nuts and small brackets to apply the specified minimum dry film thickness by brush
application if spray will not completely cover all surfaces.
7.3.1.3. Edges of existing coating shall be feathered towards the substrate prior to over-coating
Primers should not be over-coated with the second coat paint until the specified minimum
over-coating time is achieved
7.3.1.4. Inter-coat contamination shall be minimized by maintaining proper cleanliness and by
applying the intermediate and finish coats within the over-coating time recommended by the
paint manufacturer. If contaminants are present, they shall be removed before applying
succeeding coats. Contrasting color shall be used for each coat of paint.

7.3.2. Spray Application

7.3.2.1. Paints shall be applied by Air Spray (Conventional) or Airless Spray Hose and containers,
lines and pots shall be thoroughly cleaned before addition of new materials. The spray gun
shall be held no closer than 200 mm (between 450 mm to 600 mm) from the surface to be
coated at right angles to the surface. Uniform parallel passes should be made with the spray
gun. Each spray pass shall overlap the previous pass by 50%. Large surfaces should always
receive passes in two directions at right angles to each other.
7.3.2.2. Each coat is to be applied uniformly and completely over the entire surface. All runs and sags
shall be brushed out immediately or the paint removed and the surface re-sprayed. Before
spraying each coat, all areas such as corners, edges, welds, small brackets, bolts, nuts and
interstices shall be pre-coated, usually by brush to ensure that these areas have at least the
minimum specified film thickness.

7.3.3. Brush Application

7.3.3.1. Brush application may be used under the following circumstances:

When spraying for any reasons cannot properly coat areas

When spray application is deemed to be difficult, adverse to the required
quality finish, uneconomical or may affect other plant, equipment property,
personnel etc. due to location of work accessibility
For the application of self-etching primers
For touch-up or repair to localized damaged paint areas or areas of
incorrectly applied paint
For application of initial stripe coat of paint to corners, edges, crevices, holes,
welds or other irregular surfaces

7.3.3.2. Paint brushes used shall be of a style and quality that will permit proper and appropriate
application of paint. Good quality hog bristle is preferred and nylon or other synthetic bristle
 types are prohibited. Round or oval brushes are considered most suitable for rivets, bolts,
irregular surfaces etc. Wide flat brushes are suitable for large flat areas but not to exceed
width of 120 mm. Brushes shall be kept in good condition at all times and discarded if
damaged or excessively worn. The brushing shall be done so that a smooth coat, as uniform
in thickness as possible is obtained. There should be no deep or detrimental brush marks.
7.3.3.3. Paint shall be worked into all crevices and corners. Runs and sags shall be brushed out.
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 coating.

7.3.4. Roller Application

Roller application shall be discouraged and shall be subject to the specific approval of
customer. If allowed, it will only be used on relatively large surface areas provide the first
primer coat of paint is applied by brush and its use in accordance to Paint
Manufacturers instructions. Rollers shall be manufactured from good quality carpet pile
or lambs wool.

7.4. Repair of Defects

7.4.1. General

7.4.1.1. A specific paint system or scheme for the repair and/or touch-up painting of each generic type
shall be submitted for approval from customer before application of any further coat of
material, all damages to previous coats shall be repaired. All loose paint shall be removed to
a firm edge. All surface irregularities and contaminants shall be removed. Hard glossy
surfaces may require abrading to obtained suitable surface for painting.
7.4.1.2. If the surface being prepared lies adjacent to a sound coated surface which is not to be
repaired, the surface preparation shall overlap the coated surface by at least 25 mm.

7.4.2.Inadequate Coating Thickness

Areas with inadequate coating thickness shall be thoroughly cleaned and if necessary
abraded and additional compatible coats applied shall blend in with the final coating on
adjoining areas.

7.4.3. Coating Damage not exposing steel surface substrate

The damaged area shall first be washed down to remove all contamination, followed by
rinsing with clean fresh potable water and left to dry. The coating around the damaged
area shall be feathered or chamfered by sanding down to ensure continuity of the patch
 coating. The full coating system shall then be re-applied strictly in accordance with
specification.

7.4.4. Coating Damage exposing steel surface substrate

The damaged area shall be re-cleaned as originally specified for that item and the full
coating system re-applied in accordance with paint technical data sheet. The re-cleaning
shall carry over on to the secure surrounding coating for not less than 25mm all round
and the edges shall be feathered or chamfered by sanding down to ensure continuity of
the patch coating.

7.4.5.Repair of Zinc Silicate primer

Damaged surfaces of zinc primer shall be cleaned to remove all loose materials and
blast cleaned with a portable vacuum blast cleaning unit. The surfaces shall be coated
with one coat of the primer which is the same as the damaged primer. If blast cleaning is
not possible, power tool cleaning may be used subject to customer agreement.

7.4.6. Repair of Fully Cured Epoxy coatings

In case of repairing damage to fully cured epoxy coatings, the coating work shall only be
carried out after the surface of the fully cured epoxy to be coated has been suitably
abraded to provide an adequate tooth for the coating to be applied. The repair coating
shall be compatible with the existing coating.

8. INSPECTION
The following inspection shall be checked and recorded.

a) Chloride Content of Abrasives Material (Per Batch)

b) Ambient Temperature and Relative Humidity.

c) Surface Preparation i.e. Anchor Pattern and Cleanliness.

d) Dust Level Test.

e) Salt Contamination Test

f) Wet Film Thickness (WFT) for each application.

g) Dry Film Thickness (DFT) for each application.

h) Visual Inspection for each application.

i) Pinhole / Holiday Test (After Final Coating)

j) Pull Off Test, Cross Cut Test (Whenever Required)

 All inspection equipment shall be maintained and calibrated. QA/QC Inspector shall be
responsible for the proper maintenance, calibration and functioning of inspection equipment

8.1. Inspection Equipment

8.1.1. Surface Comparator

Elcometer 127- Keane Tator surface comparator as a reference to check blasted surface
and allow the estimation of surface roughness of either grit and shot blasted surfaces.

8.1.2. Surface Profile

The surface shall be checked at frequent intervals and shall be measured in the first
instance using a needle surface profile gauge such as the Elcometer Model 123 and
122/124 on the blasted surface as per user manual of the equipment. Before any
measurement been made using a needle surface profile gauge, it shall be checked for
zero reading by using a glass surface.

8.1.3. Wet Film Thickness Gauge

A Wet Film Thickness gauge (Comb-type) such as Elcometer Model 112 or similar
approved shall be used. Measurement shall be made at frequent intervals during
or within 5 10 minutes of actual application, but in any case before the coating
has set or lost it appreciable proportion of solvent.

8.1.4. Dry Film Thickness Gauge

Portable Magnetic Type DFT Gauge such as Elcometer Model 211, 345 and 456 or
similar approved shall be used.

8.1.5. Relative Humidity

The Elcometer 116 Whirling Hygrometer employs the wet and dry bulb principle to
determine the relative humidity of the atmosphere. Reading shall be taken at regular
intervals.

8.1.6. Temperature Gauge

The Elcometer Model 113 Magnetic Steel Thermometer indicates the substrate surface
temperature.
8.1.7. Hypodermic Needle Gauge

The air pressure shall be determine by injecting the needle into the blasting hose
pointed towards the nozzle and nearest possible to the blasting nozzle. Always store the
gauge in its dry, dust free condition.

8.1.8. Pinhole / Holiday Detector

Pinhole and discontinuities shall be checked by low pulse direct current detector type.
For film thickness under approximately 500 microns and below, a wet sponge low-
 voltage type model Elcometer 270 to be used. For film thickness above 500 microns
holiday detector type model Elcometer 236 to be used. Pin hole or holiday testing shall
be carried out in accordance with ASTM D5162.

8.2. Quality Control (QC)

8.2.1. Flow chart for inspection of Blasting and Painting Activities

8.2.1.1. Before blasting

8.2.1.2. After blasting

8.2.1.3. Before painting

8.2.1.4. After painting

8.2.2. Testing/Inspection

The following tests shall be carried out during paint trial and during the work and shall be
reported in a format agreed with COMPANY Representative.

8.2.2.1. Visual Inspection

Individual coat and completed coatings shall be visually inspected for appearance. Coats
and coatings shall be smooth and free from dry spray, pinholes, blisters, craters and
excessive sagging.

8.2.2.2. Profile Height

The profile height shall be spot checked by means of a surface profile gauge (e.g.
Elcometer 123)

8.2.2.3. Steel Temperature, Relative Humidity and Dew Point

 Steel temperature, relative humidity and dew point shall be measured by means of a
temperature gauge, hygrometer and dew point calculator (e.g. Elcometer 113, 116 and
114). Reading shall be taken at regular intervals depending on changes in climatic
conditions.

8.2.2.4. Film Thickness

During coating, the wet film thickness shall be spot checked. Specified total
minimum DFT shall be spot checked by means of a magnetic type thickness gauge (e.g.
Elcometer 456) The gauge scale shall be 0-1200 microns range.

Film thickness shall also be measured on individual coats. The specified average film
thickness shall not vary by more than plus or minus 20% in accordance with SSPC PA 2.

8.2.2.5. Calibration

Profile height and film thickness gauge shall be calibrated at least twice daily in
accordance with the manufacturer recommendations. Reference panels for profile height
and reference foils for film thickness shall be representative of the actual work.

8.2.2.6. Finished Paintwork

The finished paintwork shall have the correct shade, degree of gloss and evenness and
be free from tackiness after drying/curing. The painted surface shall be free from
defects that may prove deleterious to the coating quality.

8.2.2.7. Pinhole / Holiday

Holiday detection use High Voltage Spark Equipment accordance ASTM D5162 (5V per
microns or not exceed 25KV) shall be carried out on Splash Zone Areas and Internal
Coating Lining with dry film thickness 500 microns and above. For coating systems that
are below 500 microns dry film thickness, the Low Voltage Wet Sponge technique should
be used and set high as practicable within 67.5 Volt to 90 Volt.

9. DOCUMENTATION
 Inspection results for surface preparation and coating shall be recorded in Painting Inspection
Report as per Appendices.

10. MANDATORY REQUIREMENT

10.1. Surface preparation, Painting and Repair Procedure

10.1.1. Paint Manufacturer Representative and QC Inspector shall be present during

blasting and painting operations. Warranty of paint product & application shall be
specified and agreed as per contract.
10.1.2. A dead man handle for blasting nozzles shall be used in all cases.
10.1.3. Each layer of paint shall be allowed to dry for a period of time within the limits
prescribed by the paint manufacturer before the next layer is applied.
10.1.4. Subsequent layers of a paint system shall have a difference in tint or colours.
10.1.5. During application and drying, adequate ventilation shall be provided in the
enclosed area.
10.1.6. Transport and construction of painted structures shall be carried out after
sufficient drying time.
10.1.7. Waste management shall be referred to HSE procedure.
10.1.8. Only professional skilled blasters and painters shall be employed. Blasters
and painters working on every painting job shall be certified in accordance with a
scheme approved by the Principal. If not certified, the skill of all blasting and
painting personnel shall be verified before commencing any painting or coating
work.
11. SAFETY
11.1.When required, adequate certified safe scaffolding shall be provided to access the
surface which have to be cleaned and painted. This is to ensure the safety of the
operating personal.
11.2.Appropriate protection work including safety signboard shall be provided to protect other
areas of the work and other personnel from any nuisance or contamination caused by
the blast cleaning and coating operations.
11.3.Safety precaution shall be clearly described on the material safety datasheet (MSDS) of
paint and coating materials. All operating personnel shall strictly follow the instruction on
the MSDS and the Personal Protective Equipment (PPE) required.
11.4.Equipment used shall be safe to operate i.e. the airless spray units shall have catches
attached to spray gun and blasting nozzle triggered by demand with Dead-Man Handle
Devise.
11.5.In the event the dead man trigger being disabled by blaster during blasting operation, the
blasting personnel qualification shall automatically be revoked and the personnel shall
be removed from the project indefinitely.
11.6.All blasters shall be equipped with air-fed blasting hood and leather gloves. Painter shall
be equipped with respirator mask complete with replaceable filter cartridge and
 cotton glove or leather glove. Painter shall also be equipped with air-fed painter hood
when doing painting work (spray painting) in confined space.
11.7.The safety officer / promoter of blasting / painting discipline shall be responsible for the
safety of operation. He/She is to ensure all personnel are equipped with standard PPE,
safe access (scaffolding), check equipment regularly, and coordinate with other
Discipline safety officer/promoter and conduct daily briefing during toolbox meeting.
11.8.The intended blasting area on open ground shall be sufficiently barricade by installing
windbreaker. This is to minimize grit dust affecting surrounding area.
 APPENDICES
i. APPENDIX 1: Salt Contamination Report
ii. APPENDIX 2: Dust Level Report
iii. APPENDIX 3: Surface Cleanliness Report
iv. APPENDIX 4: Checking of paint Report
v. APPENDIX 5: Paint Application Report
vi. APPENDIX 6: Painting Thickness Report