PROCEDURE FOR SURFACE PREPARATION

AND PAINTING

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 REVISION CONTROL SHEET

Sl. Rev. Date of Details of No. of Reviewed Concurred Accepted

No No. Revision Revision Pages by by by
C&I
1 0 28.04.05 Initial Issue 46 and CE (FE) CE (C&I)
QA

CONTENTS
Sl. Page
Description
No. No.
1 Cover Sheet 3
2 Revision Control Sheet 4
3 Contents 5
4 Title 6

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 5 Scope 6
6 Purpose 6
7 Applicability 6
8 Reference 6
9 Responsibility 7
10 Pre-requisite 7
11 Procedure 7
12 Acceptance Criteria 18
13 Flow chart for Acceptance/ Rejection 19
14 Checklist 20
15 Precaution 20
16 Preservation 21
17 Job Hazard Analysis 22
18 Records 23
19 Distribution List 23
20 Annexure I (More about Shot Blasting) 24
21 Annexure II (Common Defects in Painting) 25
22 Annexure III (Theoretical Spreading Rate & 26
Loss Calculation)
23 Annexure IV (Health & Safety) 30
24 Annexure V (Approved make of Paints) 33
25 Annexure VI (Data sheet of Zinc Anode 304) 34
26 Annexure VII (Data sheet of Protectomastic) 36
27 Annexure VIII (Data sheet of HP Zinc 38
phosphate Primer)
28 Annexure IX (Data sheet of Torpedo Synthetic 40
Enamel)
29 Annexure X (Data sheet of Lumeros HR Al.) 42
30 Annexure XI (Data sheet of HR Silicone Al.) 44
31 Annexure XII (Report) 46

4.0 TITLE:

TICB/IEP – 14: PROCEDURE FOR SURFACE

PREPARATION AND PAINTING.

5.0 SCOPE:

This procedure covers surface preparation and paint application as

protective coatings on all the structural steel items either locally
fabricated or supplied as finished product, but their paints have started
peeling off or rusting have started appearing on the surface over the

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 passage of time but before handing over to NPCIL, as part of final touch
up coat to improve aesthetic look at the hand over, under Kaiga 3 & 4
Field Instrumentation Package works.

6.0 PURPOSE:

The purpose of this procedure is to provide guidelines for surface

preparation and painting of structural steel items at site, to protect the
steel surfaces from rusting and corrosion due to atmospheric condition.
To ensure a good adhesion between the paint film and steel surface it
is necessary that the surfaces be properly pre-treated and cleaned.

7.0 APPLICABILITY:

This procedure is applicable for all structural steel items either

fabricated at site or supplied as finished product, but requires re-
painting.

8.0 REFERENCE:

 IS 1477 (part I & II)

 ASME Section V
 Tender document for FIELD INSTRUMENT PACKAGE OF KAIGA 3
& 4.
 ‘PROJECT ERECTION QUALITY MANUAL’ of TICB / kaiga.
 Standard Practices for Shot Blasting and Painting in NPCIL.
 Paint Manufacturer’s instruction for surface preparation and
painting, and data sheets of different kind of paints.
 PP – M – 123P: Painting Specification.

9.0 RESPONSIBILITY:

The responsibility of implementation of this procedure lies with the

CONSTRUCTION MANAGER of M/s. TECNIMONT ICB, Camp: Kaiga
project 3 & 4.

10.0 PRE-REQUISTES:

 Structures fabricated as per procedure No. TICB / IEP - 03 and

cleared for surface preparation and painting.
 Shot blasting machine equipped with Moisture Separator,
Calibrated PG, GC 40 – 60 CHILLED IRON shot, Wire mesh, Air
Compressor, Running pressure wire brush, Power Buffer etc.

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  Hand / Power cleaning tools like wire brushes, scrapers, chipping
hammers, chisels, grinders, disc sanders and wire brushes.
 Paints as approved by NPCIL, airless spray gun and brush.
 Safety appliance for shot blasting operator and worker as per the
approved Safety Manual of M/s. TICB.
 Suitable material for covering and protecting the nearby equipments
while applying finish paint or touch up paint at site.
 Qualified manpower for shot blasting and painting as per procedure
No. TICB/MANPOWER: PROCEDURE FOR QUALIFICATION OF
MANPOWER. [Note: Each shot blaster shall shot blast both sides of
single test piece of 300 X 300 sq. mm (approx). The person is deemed
to be qualified for shot blasting if the blasted test pieces pass visual
and copper sulphate solution tests].

11.0PROCEDURE FOR SURFACE PREPARATION AND PAINTING:

11.1. SURFACE PREPARATION:

Proper surface preparation is essential for the success of any protective

coating system. If contaminants like oil, grease, dirt and chemicals are
not removed from the surfaces, they will prevent the adhesion of the
first coat. Rust left on the surface will loosen the coating whereas
millscale, if not completely removed, will accelerate corrosion. The most
expensive and technologically advanced coating system will fail if the
surface is not prepared properly.

Surface preparation shall be done by Iron Shot Abrasive Blast Cleaning

method to a minimum of Sa 2½ (near white metal) as per Swedish
Standard SIS 05-5900:1967 after removal of grease, oil and other
contaminants preferably by using solvents.
If blasting is not possible mainly for small supports with very low
surface area power tools like grinders, disc sanders and wire brushes
along with manual tools like scrapers, chipping hammers or chisels,
brushing shall be used to remove loose rust and scale to Sa2, Swedish
Standard SIS 05-5900:1967. All surfaces shall be thoroughly wiped
clean before application of paints.

The various steps involved in surface preparation of structural steel

fabricated at site is as given below:

STEP I: DEGREASING

This is primarily done to remove oil, grease and other contaminants by

the use of solvents and is done as the first step in surface preparation
of steel in case the steel surface is contaminated with oil or grease. The
sequence for degreasing is as below,

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 1. The contaminated section of the steel surface is wiped with rags
soaked in solvents.

2. After oil, grease and other contaminates are removed the surface
is wiped dry to remove any traces of solvents present. Chemical
degreasing shall be done in case of presence of oil.

3. Further surface cleaning shall be done only after the steel surface
is completely dry.

STEP II:

SHOT BLASTING OR HAND & POWER TOOL CLEANING.

A. IRON SHOT ABRASIVE BLAST CLEANING:

Iron shot abrasive cleaning effectively removes millscale, rust and old
coatings. The substrate should be degreased and all weld spatters
removed prior to blasting. This is because contaminants like grease or
oil are not completely removed by shot blasting and they tend to impair
the adhesion of the paint film.

Here iron shot are injected into a rapidly moving air stream and
propelled at high velocity through a nozzle against the surface to be
cleaned. The sequence of operation is as given below,

1. Ensure that the fabricated structures are completely free from oil
and grease and that all the welding joints have been completed.
2. All threaded parts shall be protected such that no damage occurs
during shot blasting.
3. Arrange all the items to be shot blasted in such as manner that the
blasting operations can be carried out without interruption.
4. After the equipments are connected fill the abrasives and pressurize
the hopper to the required pressure.
5. Start blasting operation and continue till the required cleaning is
achieved.

The profile of the substrate after blasting will depend on the following:

a) The grade of abrasive used.

b) The air pressure employed.
c) The technique of blasting.

Too low a profile may not provide a sufficient key for a coating while too
high a profile may result in uneven coverage with high sharp peaks
which may lead to the failure of a coating in the long run. By using Iron
shot abrasive (S390), roughness profile of around 35 – 40 microns shall

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 be maintained and so the same shall be adopted for big structures like
panels, racks etc.

B. HAND & POWER TOOL CLEANING:

This method of cleaning is adopted when the surface area for cleaning
is very small, mainly in case of supports for Light channels etc.

1. With the help of wire brushes, scrapers, chipping hammers and

chisels the loosely adhering rust, millscale or other contaminants
shall be removed.
2. Further cleaning is done using grinders, fitted with buffing
wheels, disc sanders etc. to obtain the required standard of
cleaning.

11.2. PAINT APPLICATION:

Proper application of protective coating is an important criterion in

giving the paint system its required life. Given below are the methods
of painting to be adopted at Kaiga 3 & 4 along with the advantages and
disadvantages of each.

I. AIRLESS SPRAY:

This is by far the most versatile method because it enables application

at variable thicknesses. The equipment utilizes an electric or air driven
motor and a high-pressure fluid pump to compress the coating to
extreme pressures. The paint is then made to pass through a special
tip, which atomises it and controls the application properties.

The main advantages of this method are:

a) High build coating can be applied without thinning.

b) Very fast rate of application.

As already indicated, the special tips used in the spray gun and the
pressure control enables one to monitor application of very low to very
high viscosity products. Similarly, different slot angles produce spray
fans of different widths. The selection of a particular fan width is
dependent on the shape and size of the structure to be painted. The
choice of fan width is also related to orifice size. For the same orifice
size the paint applied per unit area will be less, wider the spray fan.
The general indication of orifice sizes is given below to help in choosing
the proper orifice size for a paint.

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 WET FILM THICKNESS ORIFICE SIZE (MM)
Upto 50 microns 0.02 – 0.03
100 – 200 microns 0.03 – 0.04
> 200 microns 0.04 – 0.07
Mastics 0.10 – 0.15

There are several designs of tips available, the choice of which depends
upon the finish required, the ease of application and ease of cleaning
blockages from tips.

II. CONVENTIONAL SPRAY:

This is a widely accepted method of paint application where liquid paint

is atomized by an air stream. A correct combination of air pressure, air
volume and fluid flow has to be selected to achieve full atomization and
a paint film free of defects. One may also face problems like sagging,
pin-holing and poor paint flow if the control parameters are not
monitored properly.

The major disadvantage of conventional spray is that high build coating

cannot be applied by this method, as most paints have to be thinned to
a suitable viscosity for satisfactory atomization.

III. BRUSH APPLICATION:

This method is used frequently for decorative painting; in protective

coatings this is in vogue in painting complex areas where the use of
spray methods would increase the loss factor. However, a word of
caution about brush application. It is difficult to achieve a high build
by brush application in one coat. The process is relatively slow and may
result in a poor finish for thixotropic or high viscosity topcoats.

IV. MATURATION TIME:

Maturation time is a very important criterion for two pack products

where curing takes place through chemical reaction when the
components are mixed before application. The mixed paint is normally
matured for 30 – 40 minutes to initiate the reaction process that
ensures thickness build up and proper drying of the paint film.

Maturation time is, however, to be adjusted depending on pot life and

ambient temperature. Products having a short pot life should be
allowed less maturation time. Similarly, at high ambient temperature
conditions a lower maturation time will provide the adequate effect
during film formation.

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 11.3. TYPE OF PAINT:

The structural fabricated material after surface preparation shall be

painted within 4 hours as per the painting requirements based on the
area of installation. The different types of paints to be used are EPOXY,
ALUMINIUM and ENAMEL.

Painting activity shall be a continuous process irrespective of holidays

and other non working days. During application of paint the
temperature shall be between 10 0 C and 50 0 C and humidity less than
90 %. Painting shall not be carried out during rain or in case of
presence of fog or mist.

Recom-
Type of Colour of
mended Make Primer Putty Overcoat
Paint overcoat
options
Berger Vellum &
Zinc Anode-304
M/s. Micronised Protectomastic Silver
(Inorganic zinc
Option I Berger Silica powder + (high build Epoxy) gray(shade
Silicate)
Paints Protectomastic Thinner T14NPC No.365 of IS-
Epoxy Thinner 870
or 844 5)
M/s. CDC Carbozinc 11
Carboline – 890
Option II Carboline SG (Inorganic - do - - do -
(epoxy)
Madras zinc Silicate)
Duco High
Build Primer
Surfacer (12-
Duco Duco putty (13- Duco Paint (03-
Option I 9017) with Aircraft gray
Paints 9002) 104)
Thinner (60-6)
Synthetic if required in
Enamel ratio of 2:3
Micronised
Bison HB Zinc Silica powder + Torpedo Synthetic
Berger
Option II Phosphate Torpedo Enamel paint - do -
Paints
Thinner 800 synthetic Thinner 800
enamel
Lumeros HR-47 or
Heat
Zinc Anode – HR Silicone
Resistant
Option I Berger 304 Thinner Aluminium with
Aluminum
870 thinner/ cleaner –
Paint
853, if required

11.4. APPLICATION OF EPOXY PAINTS:

Epoxy painting is to be done for all the fabricated items that are to be
installed in radioactive areas.

TYPICAL PAINTING SPECIFICATION USING BERGER EPOXY PAINT*

SURFACE Ist COAT 2nd COAT 3rd COAT 4th COAT

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 Mix silica powder
Zinc
Berger (micronised) with Berger
Steel Anode
Protectomastic Protectomastic & apply Protectomastic
304
with putty knife

* this may change with paint of different brands.

1st COAT (ZINC ANODE 304)

 Zinc anode 304 shall be applied as first coat, this is a two pack self-
curing solvent consisting of Ethyl silicate (part A) and Metallic zinc
(part B). Before application the two parts is to be mixed in the ratio
of 35:65 by weight.
 Weigh out the components in the recommended proportion.
 Stir part A thoroughly to obtain uniform consistency.
 Slowly add part B (Zinc dust) to part A while stirring constantly and
continue stirring until the powder is thoroughly dispersed.
 Strain the mixture through a 80 mesh sieve.
 Allow the mixture to mature for 15 – 20 minutes before application
and keep stirring from time to time during application.
 The pot life of this paint is 4 – 6 hrs hence should be used within
that period.
 Painting shall be done using airless spray (Spray gun with pump
ratio of 30:1, Tip size 0.38 mm to 0.43 mm and Tip pressure of 110
–160 Kg/cm2) without thinning.
 In case of application of paint by conventional spraying, add upto
5% thinner 870 depending on conditions. Any standard equipment
can be used at an atomizing pressure of 3.5 – 4.4 Kg/cm2.
 For application with brush, the required consistency shall be
obtained by using Thinner 870 upto 5 – 10%.
 The drying time is 30 minutes for Touch dry, 3 – 4 hrs for Handling
and overnight for hard drying. The curing period is 6 – 7 days.
 For overcoating the paint must be fully cured and free from residual
solvents. The painted surface shall be left for a minimum of
overnight period before application of overcoat with no maximum
limit. While overcoating, a mist coat shall first be applied to avoid
bubbling, which appears due to air entrapment.
 All equipment shall be cleaned with Thinner 870 after use.

2nd COAT (BERGER PROTECTOMASTIC)

 Berger Protectomastic (Vellum shade No.365 of IS 5) shall be used

as 2nd coat of paint. This is a two pack, cured with Polyamidoamine,
with composition of modified epoxy with special catalyst suitably
pigmented. Before application both the parts (base & catalyst) shall
be mixed in the ratio of 1:1 by volume.

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  Stir the base thoroughly and mix one part of base and one part of
catalyst by volume to uniformity.
 Add 5 – 10 % Thinner 844 / 808 immediately before application.
 While using airless spray gun add 5 – 10 % Thinner 844 /808. Use
spray gun having pump ratio of 30:1 – 41:1, Tip size 0.30 mm –0.90
mm and a Tip pressure of 110 –210 Kg/cm2. However pump ratio
23:1 can also be used with increased input pressure subject to
standardization at site.
 Conventional spraying can be done using standard equipments. For
obtaining required consistency thinner 844/808 may be used.
 For application with brush use short bristle brush for working the
material into irregularities.
 The pot life of 10 % thinned paint is 90 minutes dependant on
ambient temperature.
 Drying time is 3 hours for touch dry, overnight for handling and 18
hours for hard drying. The curing period of this paint is 7 days.
 Overcoating of protectomastic is to be done within the stipulated
period to achieve optimum intercoat adhesion. Overcoating shall be
done after a minimum of overnight period.
 All equipments shall be cleaned using Thinner 844 / 808 after use.

3rd COAT (PUTTY)

 Wherever dents and unevenness in the surface is observed, a coat

of putty shall be applied to obtain a uniform and even surface.
 Mix silica powder (micronised) with protectomastic to produce a
liquid paste and apply wherever necessary with a putty knife.
 After 8 – 10 hrs of drying apply sand paper and smoothen the
surface.
 Clean and dry the surface.

4th COAT (BERGER PROTECTOMASTIC)

 Berger Protectomastic (Silver gray shade) shall be used as 4th coat

of paint.
 For other instruction follow the steps as given while applying 2nd
coat of paint.

The total composite thickness of the epoxy paint shall between 265 to
325 microns. Touch-up painting if necessary shall be done after
installation of the fabricated items at site.

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 The above painting procedure given is for BERGER EPOXY PAINT. In
case of other NPCIL approved paints as listed above against clause No.
11.3, the application procedure shall have the approval of NPCIL.

11.5. APPLICATION OF SYNTHETIC ENAMEL PAINT:

Synthetic Enamel painting shall be done for the items installed in non-
radioactive areas.

TYPICAL PAINTING SPECIFICATION FOR BERGER SYNTHETIC

ENAMEL PAINT.

SURFACE Ist COAT 2nd COAT 3rd COAT 4th COAT

Primer Berger Bison Putty (if required) +
Berger Torpedo Berger Torpedo
HB Zinc Phosphate Bison HB Zinc
Synthetic Enamel Synthetic Enamel
Primer (to be applied Phosphate Primer
Steel Paint (to be Paint (to be applied
immediately within 4 (to be applied 12
applied 10 hrs 12 hrs after 3rd
hours of surface hrs (min.) after 1st
after 2nd coat) coat)
preparation) coat)

1st COAT (BERGER BISON HB ZINC PHOSPHATE PRIMER)

 The first coat shall be applied with Berger Bison HP primer.

 This is a single pack primer with a composition of modified alkyl
medium pigmented with zinc phosphate.
 The primer shall be stirred thoroughly before and during use. This
can be applied using spray gun or by using brush.
 For thinning of the paint, Berger Thinner 800 shall be used if
required.
 For airless spraying add upto 5% thinner and use equipment with
pump ratio of 30:1, Tip size of 0.43 mm – 0.53 mm and Tip pressure
of 120 – 150 Kg/cm2.
 Conventional spraying can be done using any standard equipment
while controlling the consistency of the paint using thinner 800.
 For brush application preferably use without thinning.
 The drying time is 1- 2 hrs for touch dry, 6 – 8 hrs for handling and
overnight for hard drying.
 The surface shall be dried for a minimum period of 12 hrs before
overcoating.

2nd COAT (PUTTY + Berger Bison HB Zinc phosphate Primer)

 Wherever dents and unevenness in the surface is observed, a coat

of putty shall be applied to obtain a uniform and even surface.

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  After 8 – 10 hrs of drying apply sand paper and smoothen the
surface.
 Clean and dry the surface.
 Apply Zinc phosphate primer following steps as mentioned above.

3rd COAT (BERGER TORPEDO SYTHETIC ENAMEL PAINT)

 Berger Torpedo Synthetic Enamel (Aircraft gray shade No. 631 of IS

5) shall be used as 3rd coat; this is single pack synthetic enamel with
a composition of Alkyd resin medium suitably pigmented.
 This paint has to be thoroughly mixed prior to use and also during
application. It can be applied by using airless spray gun or by
brushing.
 The viscosity of the paint shall be controlled using Berger thinner
800.
 While using airless spray gun, add 5 % Thinner 800 and use a gun
with a pump ration of 30:1, Tip size of 0.28 mm – 0.38 mm and Tip
pressure of 110 – 160 Kg/cm2.
 Conventional spraying can be done using any standard equipments.
 For application using brush use preferably without using thinner.
 Drying time is 4 hours for surface dry and 12 hours for hard dry.
 The surface shall be allowed to dry for a minimum period of 12 hrs
before overcoating.

4th COAT (BERGER TORPEDO SYTHETIC ENAMEL PAINT)

 For the 4th coat also Berger Torpedo Synthetic Enamel shall be used.
For detail of application refer to the steps as given for application of
3rd coat of paint.

The total composite thickness of enamel paint shall between 120 – 170
microns. The painting equipments shall be cleaned using Thinner 800.
The above procedure is as given for using Berger Torpedo Synthetic
Enamel paint. In case of other paints are used then the procedure for the
same shall have the approval of NPCIL.

11.6. APPLICATION OF ALUMINUM PAINT:

Aluminum paint shall be used for applying over the surfaces of light
channel exposed during cutting & fabrication and on structures as
indicated in the fabrication drawings. Manufacturer’s instruction shall
be referred to for any special application procedure. The paint applied
shall be allowed to cure as per the instruction of the manufacturer.

TYPICAL PAINTING SPECIFICATION*

SURFACE Ist COAT 2nd COAT 3rd COAT

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 Zinc Anode HR Silicone Aluminium or HR Silicone Aluminium
Steel
304 Lumeros HR/47 or Lumeros HR/47
* this may change with paint of different brands.

1st COAT (ZINC ANODE 304)

 This coat of Zinc anode 304 shall be applied as per the instruction
given for application of 1st coat of paint under clause 11.4.

2nd COAT (Lumeros HR47 Aluminium Paints)

 Lumeros HR47 is a single pack, consisting of silicone resin and

aluminium.
 This shall be used as 2nd coat of application and the paint is to be
stirred before and occasionally during use.
 For brush application the paint shall be applied to the required
thickness without using thinner.
 For application by conventional spray the consistency of the paint
shall be adjusted using thinner 853 upto a maximum of 5%.
 The drying time is 3-4 hours for touch dry.
 The paint shall be allowed to dry for a overnight period before
application of the next coat of paint.

3rd COAT (Lumeros HR47 Aluminium Paints)

 The 3rd coat of paint shall be applied after a minimum of an

overnight period and as per the instruction given for application 2nd
coat of paint.

The overall paint thickness shall be between 120 – 130 microns. The
painting equipments shall be cleaned using thinner 853.

12.0ACCEPTANCE CRITERIA:

12.1. SURFACE CLEANING:

FOR SURFACE CLEANED BY SHOT BLASTING:

i) The standard of cleaning of the surface cleaned by shot blasting shall

be Sa2½ (near white metal) of Swedish Standard SIS 05 – 5900:1967.
Proper cleaning of recognizable by its near white or silver gray surface
and evenness of the colour all along of the surface.

ii) The shot blasted surface shall be tested with saturated solution of
copper sulphate (CuSO4 - 2H2O). The solution with copper sulphate &
water in equal volumetric proportion shall be prepared and kept in a
bottle with rubber dropper. A drop of the solution shall be applied on
the shot blasted surface and this test spot should show bright reddish
uniform copper colour immediately after application. If any foreign

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 particle, sand or iron oxide is present on surface, the solution will
retain its colour or may turn black. After this testing is complete the
surface area of test, shall be reblasted to dislodge the solution. Shot-
blasting being the most thorough system of cleaning the blasted
surface gives a uniform light gray appearance.

iii) Areas that appear shadowed solely because of difference in the blast-
cleaning pattern on the steel structure shall be deemed as clear
surface.

iv) Surface cleaned to the extent of 90 % (min.) shall be treated as surface

fully clean.

FOR SURFACE CLEANED BY HAND / POWER TOOLS:

The standard of cleaning of the surface cleaned by shot blasting shall be

Sa2 (Commercial Blast) of Swedish Standard SIS 05 – 5900:1967.

FOR PAINTING:

The painted surface shall be visually checked for uniformity of coating

and for defects such as bubbles, blisters, poor adhesion, sags, brush
marks, patching, cissing, etc. The required thickness for paint in
radioactive areas (Epoxy painting) is around 190 microns, non-
radioactive areas it should around 150 microns.

13.0FLOW CHART FOR ACCEPTANCE / REJECTION OF MATERIAL

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 Release of Fabricated Items for
Surface preparation and painting

Verify Records to Confirm Above

Remove oil & Grease

using solvents

Carry out Surface cleaning/

Shot Blasting

Reject Inspect Accept

Identify type of Enamel

Epoxy
paint to be used
Apply coat of
1st Apply 1st coat of
Zinc Anode 304 Bison HB primer
Wait for Overnight Aluminum Paint
Wait for Overnight
period period
Follow Manufacturer’s
Apply 2nd coat of Instruction for applying
Protectomastic
Rectify
Wait for Overnight
period
Reject Inspect

Yes Verify if A
Apply Putty application of putty Yes Verify if
is necessary
Apply Putty application of putty
Rectify Dry for 12 hrs. is necessary
No
Rectify Dry for 12 hrs.
Smoothen & No
clean
Smoothen &
clean
Apply 4 th coat of
Reject Inspect
Protectomastic
Not Ok Apply 3rd coat of
Ok Reject Inspect Torpedo synthetic
Wait for Overnight
Rectify
period Not Ok enamel
Ok
Wait for Overnight
period
Inspect for defect & Apply 4th coat of
Reject
thickness of paint Torpedo synthetic
enamel

Wait for Overnight

Rectify
period

Inspect for defect &

Reject
thickness of paint

Accept

Store till
Intended use

14.0CHECKLIST:

For SURFACE PREPARATION:

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  Check before surface preparation if the material has been cleared
as per procedure no. TICB/IEP – 03: PROCEDURE FOR
STRUCTURAL FABRICATION AND FILLET WELDING.
 The edges should be rounded of before shot blasting.
 Check for exposed threaded parts these are to be covered before
shot blasting.
 The cleaned surface shall be checked using CuSO4-2H2O.

For PAINTING:

 The first coat of paint shall be applied within 4 hrs of surface

cleaning.
 Check for environmental conditions and dryness of the surface to
be painted. Painting shall not be carried out in humid conditions
and late in the evenings to avoid setting of dew on to the surface.
 Check for the expiry date of the paint before use.
 It must be kept in mind that only specified thinner as per the
manufacturer recommendation is to be used.
 While application of the subsequent coat of paint checks shall be
made for overcoating period as per the instruction of the
manufacturer.

Refer to the format for checklist as enclosed vide annexure I and also
refer QAP No. TICB / QAP: 14; QAP FOR SURFACE PREPARATION
AND SHOT BLASTING.

15.0PRECAUTION:

 For the various general safety aspects refer to site SAFETY

MANUAL of TICB.
 The shot blaster must make use of the PPE’s.
 The compressor should be checked for healthiness and certified
for operational safety and provided with necessary safety relief
system.
 The hopper should be pressure tested to at least 1.5 times the
normal working pressure. This should be periodically retested.
 Hopper should be provided with suitable isolation valves. The
pressure gauge should be tested and periodically recalibrated.
 Periodic checking for tightness of hose clamps.
 Periodic checking of healthiness of hose and checking for any
chocking in the grit flow path.
 Paint storage area shall be separately identified and declared as a
No-Smoking zone.
 Painting operation should be carried out in a well-ventilated place
and free from dust.
 The edges of the supports that need to be welded at site should be
kept free to enable proper welding to EP’s.

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  The handling of the painted items should be handled carefully so
that no scratches occur to the items painted.
 Use off the mixed paint within the stipulated pot life period.
 Do not apply when the temperature falls below 100C or above 500C
and when relative humidity rises above 90 %. Don’t apply paint
during rain, fog or mist.
 Brush and spray equipment shall be cleaned with suitable thinner.
 Mix quantity, which can be used off within the utilization period.
 Overcoating of the paints shall be done within the stipulated period
for achieving optimum intercoat adhesion.
 Store paint in well ventilated covered area.
 Arrange forced ventilation if painting is carried out in confined
areas.
 In case of accidental contact of paint with skin, wash thoroughly
with plenty of water and soap.
 Keep away flames, sparks from paints storage areas and paint
application areas.

16.0PRESERVATION:

If the painted items are not to be immediately installed at site they

should be stacked properly so that no damages occur to the painting.
The area they are stored should be sufficiently dust free, covered and
no logging of water should occur.

After these are installed at site these will be periodically inspected for
any wear and tear and also for any damages caused by other activities
around the installation. After inspection and discrepancy noticed
should be corrected after creating proper records.

Further to this refer to procedure No. TICB/ IEP – 21: PROCEDURE

FOR PRESERVATION OF C & I ITEMS.

17.0JOB HAZARD ANALYSIS:

Sl. HAZARDS
ACTIVITY PRECAUTIONS
No TYPE RESULTS
1 Cleaning Of Steel Flammable Fire due to flammable 1.Maintain good house keeping.
surface using solvents. 2.Keep fire-fighting equipment
solvents or handy.
mechanical 3.Provide good ventilation.
means. Inhalation Vapours could irritate the 1.Use of nose mask.
mucous membrane. In high 2.Good ventilation.
concentration could acts as an
anesthetic.
Skin Contact Long and frequent skin 1.Use rubber hand gloves.
contact could leading to 2.Wash contact area with plenty
dermatitis of water.

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 Eye contact Vapours cause irritation. 1.Good ventilation.
Environme- Soil Pollution Proper disposal of cloth/cotton
ntal. that is used for cleaning.
Physical Bodily injury during cleaning. 1.Use hand gloves.
2.Proper handling of material.
2 Starting of Physical 1.Striking of hose to the 1.Check the tightness of clamps.
Compressor. persons near by due to high 2.The pressure should be
pressure. increased gradually.
3.Verify the condition of
compressor and refer the
fitness certification.
4.Ensure the good condition of
hose.
3 Charging of Physical – Over pressurization due to 1.Check proper functioning of
Hopper with girt (Pressure failure of safety relief valves or the safety /isolation valve.
and air hazards). chocking of hose/pressure 2.Ensure the hose is free of
pressurization. gauges. defects & use hose of
requisite working pressure.
3.Ensure good working
condition of pressure gauges.
4 Blasting Inhalation Dust inhalation. Use of facemask, nose mask.
operation. Eye contact Dust irritation to eye. Use of safety goggle.
Environme- Air pollution by dust and Barricade the area of operation.
ntal grit/shot.
Physical Busting of hose due to choking Before starting work check the
of nozzle. condition of nozzle.
5 Painting by Flammable Paints may catch fire due to 1.Maintain good house keeping.
brush/Spray. external source. 2.Keep fire-fighting equipment
handy.
3.Provide good ventilation
4.In painting areas no hot work
shall be carried out.
Inhalation Vapours could irritate the Good ventilation.
mucous membrane.
Skin Contact Long and frequent skin contact Use rubber hand gloves.
could leading to dermatitis
Eye Contact Irritation Use Safety goggle.
Environmenta Land pollution due to spillage 1.Avoid the spillage.
l of paints and improper 2.Proper disposal of paint
disposal of paint containers. containers, brushes, waste
rags, etc.
Physical Obstruction hazard due to Proper routing of spray hoses.
spray hose.
Chemical Fire 1.Maintain good house keeping.
2.Keep fire-fighting equipment
handy.
6 Painting at Physical Falling of men and material 1.Proper access to be provided.
heights. from height. 2.Use of safety belt.
3.Ensure workers are having
height pass.
 The area of the shot blasting shall be identified separately.
 The work spot shall be enclosed to minimize the dust pollution.
General
7  Good housekeeping to be maintained by removing girt.
precautions
 Entry into shot blasting & painting area shall be restricted.
 During painting at site the nearby equipments shall be covered.

Also refer to Annexure – IV: HEALTH AND SAFETY

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18.0RECORDS:

Records in the format as enclosed in Annexure VI shall be prepared

and signed.

19.0DISTRIBUTION:

Sl. COPY ISSUED ISSUED

AUTHORIZED FUNCTIONARIES
No. No. AS ON
Chief Engineer (C&I), NPCIL/Kaiga 3
1 Controlled
&4
Chief Engineer (FE), NPCIL/Kaiga 3 Controlled
2
&4
Additional Chief Engineer (C&I Controlled
3
Process), NPCIL/Kaiga 3 & 4
4 QA Engineer, NPCIL/Kaiga 3 & 4 Controlled
5 Construction Manager, TICB/Kaiga Controlled
6 QA/QC Engineer, TICB/Kaiga Controlled
7 Erection – in - charge, TICB/Kaiga Controlled
8 Training Officer, TICB/Kaiga Controlled

ANNEXURE - I

MORE ABOUT SHOT BLASTING

This done to clean the surface before painting and is achieved by propelling
abrasive (shot) from a blasting machine using compressed air at a delivery pressure
of 6 to 7 Kg/cm2. The abrasives are stored in a pressure storage container in form
of a hopper. The air pressure is maintained on the surface of the abrasive so that
it flows from the bottom of the hopper through a valve in the mixing chamber where
the compressed air carries it to the nozzle. Cleaning takes place as a result of the
airflow along with abrasive to the surface being blasted. By varying the air
pressure, the rate of flow of abrasive can be controlled. Every time the hopper gets
empty the compressor valve is shut off and the hopper recharged after unscrewing
the top. During the shot blasting operation the following points are to be taken into
consideration:

 The size of the nozzle.

 The distance of the nozzle from the work piece.
 The angle of the nozzle to the work piece.
 The size & length of the air hose.

In case of deposits of oil, grease etc on the materials to be shot blasted then these
shall be cleaned with approved solvents before starting of the blasting operation.

SIZE OF THE NOZZLE:

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 The nozzle size is usually specified as the internal diameter of the throat. The nozzle
size shall be selected considering the amount or the type of the work to be done,
the volume of compressed air available and at what pressure. Generally the nozzle
length is about six times the nozzle size and shall be in the range of 150 – 200 mm.

DISTANCE OF THE NOZZLE FROM THE SURFACE:

The nozzle shall be held at the correct distance from the area being blasted. The
closer the nozzle is held to the surface, the greater the impact of the particle and
more concentrated the blast stream. As the nozzle is moved away from the surface
the blast pattern widens and a greater area is covered. By trial & error the optimum
distance shall be arrived at for a particular job.

ANGLE OF THE NOZZLE:

The angle of the nozzle to the work is also important. If the nozzle is held
perpendicular to the surface, the operation becomes inefficient because of
rebounding abrasives slows down the abrasive emerging from the nozzle. It is best
if the nozzle is held at an angle of approximately 300 to the vertical in order to
undercut the material to be removed.

Annexure - II

COMMON DEFECTS

Sl. COMMON
CAUSES PREVENTION & REMEDY
No. DEFECTS
1. Improper thinning and application.
Low 2. Highly absorbent surface. 1. Follow recommended instruction on
1
Coverage 3. Rough texture of surface. application procedures and thinning.
4. Direct application over putty.
1. Caused by trapped moisture or gases 1. Smooth sand the surface and then
2 Blistering
in paint films. repaint it.
1. Applying paint over oily, greasy or
very smooth surface.
Remedy:
Poor 2. Applying over loose particles like
3 1. Employ proper surface preparation.
Adhesion dust or rust.
2. Surface should be repainted.
3. By not sanding previous coat of paint
or applying over partially dried coat.
1. Apply finish coat using recommended
thinner.
Sags and 1. By application of excessive thick coat.
4 Remedy
runs 2. By using wrong thinner.
1. Sand surface to smooth the sagged
areas and repaint.
1. Use proper brushes and thin paint to
desired proportion.
1. Applying paint using poor quality
Remedy
Brush brushes.
5 1. Sand surface to a smooth finish and
Marks 2. Highly viscous paint.
apply paint (after thinning to desired
3. Careless application.
proportion).
2. Use good quality brushes.
1. Application of finish coat over spot
puttied surfaces. 1. Always apply thin coat of putty as
6 Patchiness
2. Incomplete drying of putty. advised by paint manufacturer.
3. Application of thick coat of putty.

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 2. Sandwich coats of putty with paint
coats in case of Epoxy paints and
with primer in case of enamel paints.
Remedy:
1. Scrap the surface and repaint
adopting the right surface
preparation.
1. Clean surface prior to sanding and
remove all sanding dust.
1. Small impurities in paint, visible in
7 Cissing Remedy:
center of hole.
1. Remove paint completely from the
affected areas and repaint.

Annexure - III

THEORETICAL SPREADING RATE AND APPLICATION LOSSES

It is extremely complicated to estimate accurately the quantity of paint

required for a particular job since the theoretical spreading rate does not
take into account the various “ losses” involved during application.

Experienced contractors, having knowledge of application conditions, are

best able to produce more or less accurate estimates. These notes are
intended to supplement this experience by highlighting the major areas of
“losses”. Usually two types of losses are considered: “ Apparent Losses”
where the paint – though on the surface – does not contribute to the required
thickness, and “Actual Losses” where the paint is lost or wasted.

APPARENT LOSS

 Effect of blast profile: On a blasted surface the film thickness over the
peaks is less than the thickness over the troughs. However, it is the
thickness over the peaks which is most important in relation to
performance of the paint coating; and hence it can be considered that
the paint which does not contribute to this thickness is “lost in the steel
profile”. The extent of paint “loss” is proportional to the surface
roughness produced by blasting or, in other words, the dimension and
type of abrasive used.

Typical “losses” is dry paint film thickness for given blast profiles are
suggested below:

SURFACE BLAST PROFILE DFT LOSS

Steel blasted using round
0-50 microns 10 microns
shot and shop primed

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 Fine open blasting 50-100 microns 35 microns

Coarse open blasting 100-150 microns 60 microns

150-300 microns
Old pitted steel – reblasted 125 microns
(or more)

 Paint distribution: This is loss of paint resulting from over-application

when an attempt is made to achieve the minimum specified paint
thickness with reasonable certainty.

The extra paint consumed over and above that calculated from the
theoretical spreading rate is dependent on the method of application as
well as on the type of structure being painted. A simple structure with a
high proportion of flat surfaces should not incur heavy loses, but for
complex structures losses will be high.

TYPE OF
APPLICATION LOSS (%)
STRUCTURE
Brush + Roller Simple structures 5%
Brush + Roller Complex structures 10%
Spray Simple structures 20%
60% for single coat
Spray Complex structures 40% for two coats
30% for three coats

When an open complex structure is sprayed, no, realistic estimate can

be made of paint distribution loss. In case the specification calls for a
minimum thickness at all measured points, the distribution losses would
be higher than those indicated above.

Actual Losses

These include the paint loss during application and wastage:

 Application: The paint which drips from a brush or roller during transfer
from the container to the surface being painted can be termed as
application loss. With care, this can be discounted as a significant
contribution to overall “loss”.

When application is done by spraying, losses are inevitable and their

extent is dependent largely on the shape of structure being painted
together with atmospheric conditions.

The following spray losses are common:

Well ventilated but confined space 5%

Outdoors in almost static air 5-10%
Outdoors in windy conditions Over 20% (this figure can be

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 abnormally high if painting is in
unsuitable windy conditions)

 Paint wastage: Some wastage is inevitable; paint is spilt, a certain

amount remains in discarded containers; and in case of two pack
materials, mixed paint may be left beyond its pot life.

The following losses are common:

Single pack materials Not more than 5%

Two pack materials 5-6%

Calculation of practical spreading rate:

Having given the theoretical spreading rate and the preceding loss factors,
it is possible to calculate the practical spreading rate, as is illustrated by
the following example:

Example:

Two coats of two-pack paint are to be applied by spray in a confined space

to a blasted surface to yield a DFT of 100 microns per coat. The theoretical
spreading rate is 6.0 Sq. Mtr./Ltr. What is the practical spreading rate?

First Coat

Required DFT 100.00 microns

Loss due to surface roughness 10.00 microns
Loss due to distribution 40%, i.e. 100 X 0.4 40.00 microns
150.00 microns
Loss due to application 5%, i.e. 150 X 0.05 7.50 microns
157.50 microns
Loss due to wastage 10%, i.e. 157.5 X 0.1 15.75 microns
173.25 microns

Extra Paint used (173.25 – 100) = 73.25 X 100 = 73.3%

100
Second Coat

Required DFT 100.00 microns

Loss due to surface roughness Nil
Loss due to distribution 40%, i.e. 100 X 0.4 40.00 microns
140.00 microns
Loss due to application 5%, i.e. 140 X 0.05 7.00 microns
147.00 microns
Loss due to wastage 10%, i.e. 147 X 0.1 14.70 microns
161.70 microns

Extra paint used (161.7 – 100) = 61.7 X 100 = 61.7%

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 100
Total loss for two coats = 73.3+ 61.7 = 67.5%
2

In other words, for the two-coat system, 67.5% more paint is required than
would be calculated from the theoretical spreading rate.

Loss factors: In the above example the theoretical spreading rate is 6 Sq.
Mtr./Ltr. In practice 1.68 Ltr. of paint can be expected to cover 6 Sq. Mtr.

Therefore, the practical spreading rate is 6/1.68 = 3.6 Sq. Mtr. / Ltr.

The loss factor is usually expressed as the difference between the theoretical
and practical spreading rates expressed as a percentage of the theoretical
spreading rate. In the above example the loss factor is (6 –
3.6)/6 = 40%.

Calculation of Volume Solids

The volume solid of a paint can be calculated as follows:

% volume solid = DFT (microns) X Theoretical coverage (Sq. Mtr. /Ltr.)

100

The volume solids of a paint is an indicator of the mileage it will give at a

specified thickness.

Thinner Consumption

This is another important parameter and has to be closely monitored to

obtain the desired performance from the paint film. In each Data Sheet a
special section is devoted to thinner consumption which should be strictly
adhered to. However, it should be noted that the mentioned quantity is only
for adding to the paint. We have always quoted the consumption for and
optimum environment and this depends on prevailing temperature.
Application methods, nature of surface and weather conditions.

Adding a small percentage of extra thinner does not necessarily impair the
film properties, but excess thinning increases the quantity of liquid paint
without contributing to the solid content. the volume solid, after thinning,
should be calculated and the resultant coverage worked out to achieve the
recommended film thickness.

Volume solid percentage after thinning = Volume solid % X 100

% thinner added +100

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 Annexure - IV
HEALTH AND SAFETY

The majority of paints, coatings and thinners do not present special hazards
in storage or use provided that good standards of industrial hygiene are
maintained. However, it must be remembered that these materials can
introduce two potential hazards – health and fire.

Health

Protection paints, coatings and thinners are mixtures of various chemicals,

some of which are potentially hazardous if their use is not strictly controlled
in accordance with good standards of industrial hygiene and safe working
practice.

The following is a guide to the potential hazards and recommended safe

practices.

Ingestion

The ingestion of paint should be avoided. Food and drink should not be
brought into, stored, prepared or consumed in areas where paints are
stored, handled or used. Smoking in such areas should be prohibited.

In the event that paints, thinners etc., are accidentally swallowed, do NOT
induce vomiting. Seek immediate medical advice.

Inhalation

The inhalation of paints, dust or fumes should be avoided by the use of local
ventilation or extraction. Where fumes or dust are unavoidable, suitable
approved respirators or face masks should be worn.

Remember that solvent vapours are heavier than air and will tend to
accumulate at the bottom of tanks or in confined spaces. Never enter areas
where this could have happened without wearing suitable breathing
apparatus. If dizziness, drunkenness or headaches are experienced, these
could be caused by solvent vapour – move immediately into fresh air and do
not return until the area has been declared safe. Where necessary, gas tests
should be carried out in confined areas or areas that are difficult to ventilate
effectively. If anyone should be overcome by fumes, carefully remove him to
fresh air-allow to recover gradually and seek immediate medical assistance.
In areas where the ventilation is poor, an airfed mask hood is essential. If
any doubt exists, wear an airfed mask hood.
Skin Contact

Normally harmless chemicals can cause irritation by repeated or prolonged

contact with the skin and, in extreme cases, there is a risk of dermatitis. All
personnel who handle and use paints should wear appropriate protective

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clothing (as a minimum; gloves, eye protection and overalls). Splashes of
paint on the skin should be treated promptly by copious washing with clean
water or an approved cleansing agent. (Solvents should not be used for
personal cleaning.)

Eye Protection

It is recommended that operators should wear suitable eye protectors when

there is a risk of paint splashing into their eyes.

Splashes of paint into the eyes should be treated promptly by copious

washing with fresh water for at least 10 minutes. It is a sensible precaution
to seek immediate medical advice.

Personal Hygiene

All personnel involved in the handling and use of paints should be

encouraged to observe the highest standards of personal hygiene. Suitable
protective clothing should be supplied and maintained and adequate
facilities for washing provided. In the event of clothing becoming soiled with
paint, it should be changed and the affected area thoroughly washed with
soap and water. Personnel should be encouraged to wash especially before
eating food.

Fire and Explosion Risk

With the exceptions of solvent – free and water – thinned materials, all
paints contain organic solvents which are flammable to a greater or lesser
degree.

User of paint and related products should make themselves aware of their
statutory duties with regard to national regulations, and seek advice from
Government Agencies, if in doubt.

The main points to observe are:

 Storage and usage should be in separated areas, constructed to the

appropriate standard of fire resistance. The quantity of material stored in
the actual working areas should be as small as is practicable.

 Adequate ventilation and extraction should be provided and maintained.

 Adequate fire prevention and fire fighting equipment should be provided

and maintained. Do not attempt to fight fire with water – this will cause
the fire to spread.

 Fight fire with dry chemical, foam or carbon dioxide extinguisher.

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 All possible sources of ignition should be strictly controlled e.g., electrical
equipment, metal to metal sparks. Smoking should be prohibited in areas
where paint materials are used, stored or handled.

 In the event of a fire the possibility that poisonous fumes may be emitted
must always be recognized- if in doubt, use breathing apparatus.

Spillages

Spillages of paint should be cleaned up as soon as they occur. The use of

rags and sawdust should be discouraged and inert absorbent material used.
Ventilate the area to remove fumes.

Annexure - V

LIST OF NPCIL APPROVED PAINTS

Sl. No. NAME MANUFACTURER

1 CARBOLINE 890 CDC CARBOLINE

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 2 EMITE HF EPOXY GARWARE PAINTS

3 0.3 – 104 DUCO PAINTS

4 PROTECTOMASTIC BERGER PAINTS

ZINC ANODE 304 (PRIMER

5 BERGER PAINTS
FOR EPOXY)
TORPEDO SYNTHETIC
6 BERGER PAINTS
ENAMEL PAINT
BISON HB ZINC PHOSPHATE
7 BERGER PAINTS
(PRIMER FOR ENAMEL PAINT)

8 LUMEROUS HR 47 BERGER PAINTS

9 HR SILICONE ALUMINIUM BERGER PAINTS

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 ANNEXURE - VI

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 ANNEXURE - VII

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 ANNEXURE - VIII

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 ANNEXURE – IX

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 ANNEXURE - X

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 ANNEXURE - XI

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 Annexure - XII
FORMAT No. 018/NPCIL/TICB/Kaiga/IEP - 18

REPORT FOR SHOT BLASTING AND PAINTING

USI No. : REPORT No. :

UNIT : DATE :
APPLICABLE DRAWING’S :
ITEM DESCRIPTION / TAG No. :
TYPE OF PAINT :
No. OF COAT :

Surface Preparation One Checked By

Delicate
coat
SL parts / TICB NPCIL Final TICB NPCIL
primer Overall
NO threads Paint
Erec QA C&I QA applied Finishing Erec QA C&I QA
protected Thickness
within
Remark Sign Remark Sign Remark Sign Remark Sign Remark Sign Remark Sign Remark Sign Remark Sign
4hrs

(T. Chellapandian) (B G S Rajan) (A K PRASAD, ACE(C&I-P) (N R Gopinath, SO/F)

TICB (EREC) TICB (QA) NPCIL (C & I) NPCIL (QA)

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