ATC 88

BGAS Painting Grade 2/3

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Wheelabrators (Centrifugal Blast

Units)

Abrasive Particle
Speed 220 Mph

Series Of Drums
Rotating At 2600
Rpm

100% Surface
Coverage

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1
 Wheelabrators or Centrifugal Blast
Units
 Operate at approx. 2600 RPM.
 Totally enclosed (good operator safety).
 Automatic chain driven roller feed.
feed
 Varying number of operating wheels.
 Gravity fed abrasive (re-usable).
 Airwash cleansing system for abrasives.
 Preferred abrasive is metallic shot.

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Automatic Blasting Machines

Wheelabrators

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 Centrifugal Blasting Chamber

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Dry Abrasive Blasting Equipment

 COMPRESSORS pressure rating in psi capacity in cfm.

 BACK PRESSURE AT NOZZLE hypodermic needle
gauge.
 VAPOUR TRAPS, knock-out pots (removal of oil and
water from air stream).
 PRESSURISED BLAST POTS of suitable capacity.
 CARBON IMPREGNATED HOSES, to reduce static shock.
 NOZZLES, Venturi (450 mph) and Straight bore (200
mph).
 SAFETY TO IGE SR 21 (Institute of Gas Engineers :
Safety Regulations).

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3
 Typical Set-up of a Dry
Abrasive Blasting Operation

Pressurised
blast pot
Compressor
Carbon
Vapour traps
impregnated
(knock out pots)
reinforced hose

p
Whiplash
prevention
cables
External bayonet
type couplings
Blasting nozzle

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Internal view of VENTURI NOZZLE increases speed of

abrasive from 200 mph to 450 mph.

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Typical portable site
blasting
bl i machines.
hi

Reccova valve, fitted to

other end of air lines to
dead man handle.

Exhaust beware!

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Blasting Safety

Carbon impregnated hose.

Hose must have external,
Bayonet type couplings,
with whiplash restraints.

Air Filter
(breathing air not
supplied directly
from compressor).

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5
 Blasting Safety

Carbon impregnated hose

whiplash cables air-fed
helmet protective visor
leather apron dead man’s
handle gauntlets.

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6
 Bayonet Type (Chicago) Couplings

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Dead Man’s Handle

Blasting nozzle Air Connection

trigger which
must be under
Fail Safe Trigger
the direct
control of the
operator.

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7
 Measuring Blast Pressure at the
Nozzle

Hypodermic needle gauge

Method
Alert the operator.
Shut off abrasive.
Insert the needle
through the hose, with
th needle
the dl ttowards
d th
the
nozzle, at an angle of
approximately 45
degrees.

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Wet Blasting: Methods

 High pressure pure water blasting

<30,000psi.
 High pressure water plus abrasive injection.
injection
 Low pressure water plus abrasive injection.
 Steam cleaning.
 Air blasting with water injection.

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 Ultra High Pressure Water Jetting,
>30,000 PSI

UHP Water Jetting Low Pressure

(above 30
30,000
000 psi) water cleaning

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Wet Blasting

Abrasive blasting with water injected in to the

abrasive stream at the blasting nozzle

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9
 Steam Cleaning
High Pressure Water
Jetting – up to
30 000 psii
30,000

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Hand and Power Tool Cleaning, (BS

7079 Pt A)
Hand and power wire brushes, chipping
hammers, needle guns, emery cloth.

St 2 Thorough hand and power tool cleaning.

St 3 Very thorough hand and power tool

cleaning.

Note: because millscale is harder than the brush

bristles, (phosphor bronze / beryllium bronze).
There is no standard for rust grade A!

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10
 Jason’s Hammer and a Needle Gun

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Surface Preparation

Hand and power tool cleaning B St 2 and St 3.

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11
 Surface Preparation

Hand and power tool cleaning C St 2 and St 3.

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Surface Preparation

Hand and power tool cleaning D St 2 and St 3.

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12
 Flame Cleaning

1 EXPANSION, co-efficient of expansion.

2 DEHYDRATION,, moisture is evaporated.
p
3 HEAT PENETRATION, heat conducted into substrate.

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 Pickling is acid bath followed by washing.

 Footner’s Duplex system.
 Pickling followed by passivation
passivation.
 Passivation is treatment in phosphoric or
chromic acid, which passivates the steel by
forming a layer of rust- inhibitive salts which
also aid adhesion and provide resistance to
cathodic disbondment.

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13
 Footner’s Duplex System

 Remove oil and grease and check using UVA

lamp (contamination shows up yellow/green).
 Immerse in 5 10% sulphuric acid
5-10% acid, 5-25
5 25 mins
@ 65-700C.
 Rinse in clean water.
 Immerse in 2% Phosphoric/chromic acid, with
0.5% iron filings, 1-2 mins @ 800C.
 Rinse in clean water.
 Check ph level between 4.5 and 7.0.

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Surface Preparation, Chemical

Cleaning

PH indicator papers,
used to measure
acidity or alkalinity of
the substrate after
final wash.
For BGAS the pH
should be between
4.5 and 7.

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14
 Surface Contaminants and Tests
(Section 3)

Hygroscopic salts : potassium ferricyanide, (now called

potassium hexacyanoferrate)

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Surface Contaminants and Tests

(Section 3)
 Soluble chlorides: silver nitrate test.
 Mill scale: copper sulphate (only for Sa 3
grade).
grade)
 Oil or grease: solvent (not aliphatic) or U/V
LAMP.
 Moisture: talcum or chalk.
 Dust: sellotape.

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15
 Copyright © TWI Ltd

Quantitative Tests for Hygroscopic

Salts

Merkoquant test Bresle sample patch

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16
 Salts Detection, Bresle Sample Patch
Kit

Copyright © TWI Ltd

Paint Technology (Section 4)

 There are 3 main groups of paint:

 Paints containing solvents.
 Solvent free multi-pack, (MCL’s)
 Powder paints.

All have the same basic constituents:

 Bi d (film
Binder (fil fformer, non-volatile,
l til vehicle).
hi l )

 Solvent.
 Pigments and other additives.

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17
 Binder properties

Ease of application to:

 Give adhesion to the substrate.
 Provide resistance to abrasion.
 Provide chemical resistance.
 Provide cohesive strength.
 Provide dialectric strength.
 Resist the passage of water.
 Change from a liquid into a solid.
 Hold the pigments in suspension.

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Binders used in Other binders (non BGAS)

National Grid (BGAS)
specifications
 Acrylics.
 Cellulose resins.
 Alkyds.
 Chlorinated rubber.
 Epoxies.
 Emulsions.
 Ethyl and methyl
 Natural oils and resins.
silicates.
a
 Phenolic resins.
 Polyurethane
 Styrene and vinyl.
 silicones

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18
 Oils

Natural oils are produced from the seeds of a plant.

Examples:
Linseed, soya, olive, coconut, tung, castor.

These oils must combine with oxygen, therefore must

be unsaturated.
A saturated oil already has enough oxygen bonds,
and will not solidify and form a film.

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Resins

Natural resins are from the main plant, tree

trunk).
trunk) Resins are naturally brittle and fast
drying, therefore need modification. This is
done by addition of oils.
Natural resins are Copals and Dammars and
Coumarones, Amber and Laq. Other resins
such as frankincense and myrrh are more
valued for their perfume qualities.

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19
 Oils

Drying Oils
Three sets of double bonds along a carbon backbone,
react readily in ambient conditions.
conditions (unsaturated oils)
oils).
Semi-drying Oils
One or two sets of double bonds, not as reactive as
drying oils. Need a catalyst (heat) to start
polymerisation.
Non-drying Oils (saturated oils)
Cannot be used as binders, will not polymerise, no
activity points. They are used as plasticisers, to give
flexibility and ease application. Modifies the film
properties.

Copyright © TWI Ltd

Oil Paints

LONG OIL PAINT more than 60% Oil to Resin.

y g, mainly
Elastic and slower drying, y used in domestic
applications (decorative materials).

MEDIUM OIL PAINT between 45% and 60% Oil to

Resin.
SHORT OIL PAINT less than 45% Oil to Resin.
Faster
F t drying,
d i suitable
it bl ffor steelwork.
t l k MMore b
brittle,
ittl
with shorter over-coating time.

A mixture of oil and resin = oleoresinous.

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 Binder - Solvent Combinations

WATER
y , acrylics,
Vinyls, y , epoxies,
p , alkyds,
y , bitumens,,
polyurethanes, acrylated rubbers.
WHITE SPIRIT
Natural oils, natural resins, alkyds, phenolics.

XYLENE
Chlorinated rubber.

ACETONE
Epoxy.

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Binder - Solvent Compatability

 Compatibility for over-coating.

 Correct solvent group for binder.
 Flashpoint and toxicity considerations.

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21
 Solvents

Strong solvents for strong binders.

Weaker solvents for weaker binders.

The stronger solvents have a low number of

carbon atoms in the chemical formula.

The higher the number of carbon atoms, the

higher the boiling point of the solvent,

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Solvents

Solvent strength: its ability to dissolve the binder.

Evaporation rate: controls polymerisation and

drying.

Flash point: safety factor of the solvent.

Toxicity: safety levels of exposure.

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 Polymers

A string or structure of repeated units

Linear Polymer
Pre formed
formed, reversible
reversible, very sensitive to some HC
solvents, thermoplastic. Also called solution polymer.
Branched polymer
Oxidation drying, non-reversible. Natural oils and
resins , become very brittle with age.
Crosslinked polymer
Chemically curing, very strong, multi-directional
polymerisation, examples: epoxies, urethanes and
polyurethanes.

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Polymers are 3
dimensional in
Linear the dry paint film
film.

Branched

Cross
Linked

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23
 Pigments

Animal, vegetable, mineral, or synthetic.

Particle
P ti l size
i varies
i ffrom 1/
10 th micron
i tto average size
i
of 1 micron.

Contribute to cohesive strength, abrasion resistance,

durability, opacity and in some instances,
impermeability, and resistance to u/v rays.

Pigments must not dissolve in the vehicle.

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Pigments

Anti-corrosive: rust inhibitive properties.

Metallic: work sacrificially.

Opaque: inert, provide opacity and colour.

Extenders: add bulk, reduce cost.

L
Laminar:
i provide
id impermeability.
i bili

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 Anti-corrosive (Rust Inhibitive)
Pigments
Primer Colour
Red lead (basic)
(natural
( t l oils
il and
d resins)
i ) Toxic
T i Red
R d
Calcium plumbate Toxic
White
Coal Tar Toxic Black
Zinc Chromate Toxic Yellow

Zinc phosphate most common Purple/Grey

Barium Metaborate.
Zinc Phosphosilicate.

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Metallic Pigments

Also used to protect the substrate by cathodic

protection.

Material must be below steel in the galvanic list.

Two most commonly used are :

 ZINC ((better for g

galvanic p
protection).
)
 ALUMINIUM (excellent ultra-violet reflective
properties).

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 Opaque Pigments

Inert particles which have excellent light

scattering properties in order to give covering
((opacity)
p y) and colour.

 CARBON Black
 COBALT Blue
 CHROMIUM Greens/Yellows/Oranges
 IRON Browns/Reds/Yellows
 CALCIUM Reds/Yellows
 TITANIUM DIOXIDE White

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Extender Pigments

Low priced, readily available materials, also known as

fillers. They add bulk, improve intercoat adhesion,
g , and give
increase cohesive strength, g extra thickness
to paint film at low cost.

 CLAYS Kaolin , China Clay (White)

 CHALK Calcium Carbonate (White)
 TALCUM Magnesium Silicate (White)
 SLATE FLOUR Aluminium Silicate (Dark Grey)

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 Laminar pigments

Plate-like pigments which provide impermeability.

In theory, they have a leafing effect, overlapping as
the coating dries.
Common laminar pigments:
 Graphite.
 Glass flake.
 Aluminium flake (ultra-violet reflective).
 Micaceous Iron Oxide (Mio) (ultra-violet reflective).
Attributes of Mio:
UV A and B reflection, retards permeation,
durability, provides adhesion to next layer.

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Laminar Pigments

Standard Pigment Mio Theoretical

Delaminated Mio

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 Critical Pigment Volume
Concentration (CPVC)

Below CPVC Near CPVC Above CPVC

opacity high gloss,

Poor opacity, gloss blistering
Good opacity, cohesive strength, gloss, impermeability,
Porous, low cohesive strength, poor adhesion
Pigment/binder ratio can vary from paint to paint.

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Other Additives

Anti-settling agents:
 Aids to shelf life.
Plasticisers:
 Reduce brittleness, aid application, improves
flexibility.
Driers:
 Allow even through drying of oxidising films.
Anti-skinning agents:
 Retard the formation of surface skins.

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28
 Solutions and Dispersions
(Section 5)

SOLVENT: Will dissolve another material.

SOLUTE: Is dissolved in the solvent

SOLUTION: The resultant liquid produced by

dissolving a solute in a solvent.

EXAMPLE:

Solvent + solute = solution

Would be sugar + water = sweet water

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Solutions and Dispersions

Dispersion: a solid or a liquid within another liquid,

where there is no solubility.

There are two types of dispersion

1 Suspension: fine particulate solids dispersed
within a liquid, no solubility.
Example: Sand + Water

2 Emulsion: a liquid dispersed within another liquid

where there is no solubility.
Example: Oil + Water

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29
 Drying and curing of Paint Films
(Section 6)

Solvent evaporation

 No chemical reaction.
 Polymers are preformed and saturated.
 Linear polymers closed at the ends by hydrogen
and have no double bonds.
l called
 Also ll d reversible
bl or non-convertible.
bl

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Drying and Curing of Paint Films

Oxidation

 Uses atmospheric oxygen.

 Oxygen chemically combines with unsaturated
double bonds.
 Process can be accelerated by addition of driers.
 Also called convertible or non
non-reversible
reversible.

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30
 Drying and Curing of Paint Films

Chemical curing
Must be mixed in the correct ratio (2 pack).
Pot life (period after opening and mixing where the
paint remains in a usable condition).
Induction period (stand time, to allow for wetting of
particles and crosslinking to begin).

These must be observed and controlled!

 Convertible or non-reversible.
 Chemically cross-linking polymers.

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Curing Agents Used in 2-pack

Epoxies
AMIDES: Fully cured in 7 days at 20°C.

AMINES: Fully cured in 3 days at 20°C.

ISOCYANATES: Suitable for use where low

temperatures are unavoidable, fully cured in 16
hours at 20°c.
In 1984, at the union carbide plant in bhopal, india,
water was accidentally released into a methyl
isocyanate storage tank, resulting in 7000 fatalities.
Very toxic, CO2 is produced when applied in damp
conditions. Great care needed during use and
removal!
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31
 Drying and Curing of Paint Films:
Coalescence

High boiling point solvents

penetrate the spheres and
Solvent Evaporation fuse the binder globules,
creating a solid film

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