PAINTING

FOUNDAMENTAL

Paolo
Perantoni
 What is «corrosion»???

• Corrosion is deterioration of a material, usually a

metal, because of a reaction with its
ambient.Protective coatings are used to form artificial
protective layer over iron /steel surface prolonging its
life.

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Corrosion cell

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 Corrosion cell

• Anod: part of metal that

corrodes (dissolves in
the electrolyte)
• Cathode: less active CATHODIC
PROTECTION
area of electrode –ie
metal surface- where
the electrons are
consumed
• Electrolyte: liquid that
conducts electricity
• Metallic pathway: joins
anod with cathode

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 Corrosion control

 Design
 Inhibitors
 Material Selection
 Cathodic protection (sacrifical anods/impressed current)
 Protective coating
 Alteration of enviroment (dehumidification equipment)

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 Corrosion cell

 When a steel structure corrodes, all four elements of

corrosion cell are present
 Steel conducts electricity creating its own metallic
pathway between anodic and cathodic parts of its
surface (different electrical potential between
different area because of disomogenity of the steel)
 Water; acts as an (poor) electrolyte but combining
with chemicals in atmosphere (ie sodium chloride in
marine enviroment) becomes more efficient as
concentration of dissolved chemicals increases.

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 Surface
preparation

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The real life of anticorrosion painting applied on a metallic
surface depends in wide measure on the way it has been
prepared

TYPES OF FAILURES

Paint detachment Metallic detachment

Steel Steel

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 Sandblasting / Gritblasting
Projection on the metallic layer of abrasive with high kinetic energy by means of
air compressed to remove the darter of calamine, oxide and other
contaminations.

ASTM D4285 – Test method for indicating Oil or Water in Compressed

Air

The surface preparation by means of gritblasting could not be

performed if:

1) Relative Humidity upper to 85%

2) The application of the primer could not start during the next 4 hours
(this limit time could be increased in case of different environmental
conditions.)
For example: if relative Humidity low 50% the time can be increased up to
8 hours

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 Abrasives

Particles of material projected on the metallic surface with a speed of about 90-
100 m/s

Metallic Abrasives: Shotblasting

Gritblasting
Non metallic Abrasives: Corundum – Baking soda – Garnet - Sand
Aluminium oxide – Cuprum oxide

Hydroblasting

Jet of water with high pressure

impact with a small quantity of
abrasive (overhaul operations)

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Example of not correct
surface preparation

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 Don't have gaps, fissures and welding lenghts…

Probables initiation Adequate Best

of crevice corrosion
Continuous Welding

Probables initiation Best

of crevice corrosion

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 Weldings Quality..

Irregularity Slag Best

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 Elimination of prominences, corners and
asperity…

Sharp edge Sharp Sharp

chamfer rounded
Paint
Steel
1 mm R = > 2 mm

NEVER ALWAYS OFF-SHORE

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Surface preparation
controls

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 Cleaning

Elimination of all extraneous materials like grease, varied dirts, oil, traces of
damp, total elimination of calamine, blight and old painting

Grade of preparation with ISO 8501-1

A Sa 2 ½ - Very accurate Gritblasting or "to metal almost white"

At visual inspection the surface must

result free from observable traces of
oil, grease and dirt, from calamine,
blight, paintings and extraneous
substances. Any trace of
contamination only appear like read
stains in form of points or strip.

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 Cleaning

A Sa 3 - Gritblasting up to visual complete cleanliness or "to white

metal”

At visual inspection the surface

must result free from observable
traces of oil, grease and dirt,
from calamine, rust, paintings
and extraneous substances. It
must present a uniform metallic
color

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 Roughness

Depending on

1) Abrasive for sand/grit blasting

2) Painting products

Rz – Average peak:
distance among the 5 more elevated peaks
and the respective 5 deeper dales

Ra – Arithmetical average Value:

About 1/7 of Rz Value

Testex Tape
ISO 8502-3 Assessment of dust on steel
surfaces prepared for painting (pressure-
sensitive tape
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method)
 Control of Soluble Salt

Not always Mandatory if the supplier operates in seaside

required zones
ISO 8502-6

Soluble salt gauge

Electrical Conducibility
Laboratory instrument

Kit for Chlore Test

Field test equipment

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Painting

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 Application Method

System Method

Brush - Roll
Process before of Touch up – Stripe coat

Airless Atomization of the painting without air

High capacity, better rapidity of work,
small overspray, capability of apply
paintings without solvent

Spray with air Spray Gun - Works of touch finishing

(conventional) Small surface
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Accessibility to the surface to paint or overhaul

h = 1000 mm - Maximum accessible distance from the operator

a = 300 mm – Minimum admissible distance
(h) over 1000 mm – (a) min. 800 mm

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Safety

Masks
Gloves
Filter
Aspirators
Dust collectors
Materials
inflammable
Extinguishers
Respect Law

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 Painting products Storehouse

• Respect of the indication of the technical data sheets of the

paintings

• Areation

Conditions always from avoid: FREEZING - OVERHEATING

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Painting Controls

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 Inorganic Zinc control

ASTM D 4752 – Measuring MEK Resistance of Ethyl Silicate

Inorganic Zinc

Verify the resistance of the inorganic zinc to the

solvents by tests with methyl ethyl ketone –
(MEK)
Is mandatory before the application of over
painting Method

50 doubles passes of
MEK
Result
No type of release of zinc on the cotton or white
clouts
Rating 5 – ASTM D4752
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Environmental control before, during and after
painting
Surface Temperature – Air Temperature – Relative Humidity
Dew Point calculation

When ALWAYS

Both in outdoor or in box

painting
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 Chart for Dew Point calculation
Condensed water transition temperature

Air Temperature

Example
T° enviromental of 15°C
Relative Humidity of 65%

Relative
Dew point
Humidity

Surface Temperature
Always calculate 3°C
more than the Dew Point

8+3 (min.)= 11°C

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 Wet film Thickness
Operation to perform on each individual layer of painting

Wet film Gauge

In operation of the deliberate
thickness, the relative tooth will soak
itself of paint

Calculation

Wet film thickness (W.F.T)

Dry film thickness (D.F.T) X 100

Solid by volume (S.B.V)%

Data always available and to take from the data

sheets of paint

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 Final standard
controls

Visual aspect

Absence of: Sags, holes, wants, bubbling Limited

areas with “orange peel”

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 Thickness measurements

Always to perform on each individual layer with digital

instruments calibrated as indicated from the builder on
calibrated "sheets" set

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 Measure method according to SSPC-PA 2

Conditions
Area of 10 m2 Items until 30 m2
Diam. 4cm
1 measurement area each 10m2
Items until 100 m2
3 measurements area
Items over 100 m2
3 measurements area + 1 measurement
Point of measure area each 100m2 additional

Areas to measure According to

Readings

Geometry of the article

Areas of difficult accessibility
3 readings minimum for point of measure Representative average
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 Acceptability

ITN 07791
Thickness of measure point: average of at least three readings of thickness

Result
Dry film thickness in 10 m2 : average of 5 point of measure

Nominal tolerance dry film thickness: -10% +40%

Example

Nominal D.F.T of 325 µm

Minimum admitted 293 µm - Maximum admitted 455 µm

And in additional: Each single reading should not be less to 80% of minimum admitted value

Example

Nominal D.F.T of 325 µm

Minimum admitted 293 µm - Nothing of 15 readings must be less to 234µm

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 NOT standard Controls
Destructive controls

To perform only in case of not conformity

Always on panels (200x200x5mm) painted in the same conditions

ASTM D3359 X cut Test Acceptability

ASTM D4541 Pull-Off Test ITN 07791

ASTM D4138 P.I.G. Test

NACE RP0188 Holyday Test

WHEN? AT THE FINAL POLYMERIZATION OF THE PAINTING SYSTEM

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 Adhesion tests

ASTM D3359 X-Cut Test

By means of cutter to execute a X with angle among 30° and 45° until to the metal base

Test depending by the operators

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 ASTM D4541 - Pull-Off Test

Manual, Hydraulic or Pneumatic method

Level of adhesion measured in Mpa - Pull off of the painting system by means of a "dolly“ glued on it

Incontestable Data

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 Destructive Thickness Measurements

P.I.G. Test – Paint Inspection Gauge

Incontestable method for the thickness measurement

Reference: each individual layer of painting

Top coat

Primer

45° 26°~ 5°~

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 Porosity Control

Search of Pinholes in a painting system

Special Customer request

Nuovo Pignone Cycles

Control until 500 µm Control until 7,5 mm
WET sponge High voltage

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 CONCLUSION

The painting process failures happen above all for:

Don't respect of the environmental conditions during the

surface preparation and the application of the painting
product
Dirty and greasiness on the surface before painting
Blending of painting product not correct – Improper
thinners
Not respect of recoating Time
Handling and delivery with wet paint
Insufficient practice of the suppliers to the same process
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Supplier qualification

ITN07791

PQR SURF-TR-003

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