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CORROSION, SURFACE
PREPARATION – BLASTING &
PAINTING
 AGENDA
 WHAT IS CORROSION?
 FACTORS TO INCREASE CORROSION RATE
 MOTTO FOR PAINT APPLICATION
 SURFACE PREPARATION METHOD
 SURFACE PREPARATION INSPECTION
 RUST GRADE
 TYPES OF ABRASIVE
 QUALITY TESTING
 BLASTING & PAINTING SPECIFIED CONDITION
 PAINT SYSTEMS
 FILM THICKNESS
 DFT / WFT CALCULATION
 PAINTING DEFECTS
 PAINT PRODUCT DATA SHEET (PDS)
 PAINT REPAIR PROCEDURE
 QUESTIONS IF ANY?

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 WHAT IS CORROSION
 CORROSION : Degradation of material due to chemical or electro-chemical reaction. (Always occurred outside of the surface)
 ERROSION : Always occurred Inside of the surface

ELECTROLYTE 2H20 → 2H+ + 2OH-

ODE
A N
@ H)2
IO
N
e (O
S F
RRO - = ST
CO O H / RU
2 XI D E
++
+ DR
O
Fe H Y
N
IRO

ANODE Fe → Fe++ + 2e- CATHODE

(2H+ + 2e- = H2
Fig.01 Corrosion Triangle MOSTURE)

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 FACTORS TO INCREASE CORROSION RATE
1. TEMPERATURE : Hotter steel will be corroded faster.
2. HYGROSCOPIC SALTS : Sulphates (In industrial & agricultural area) & Chlorides (In marine area)
3. AEROBIC CONDITIONS : High moisturize area
4. ACIDS & ALKALINE SOLUTIONS
5. BACTERIAS
6. BI-METALLIC CONTACT : When two different materials comes in contact, High Nobel metal becomes cathode and less Nobel
metal become anode.
 Nobility of materials are mentioned in Galvanic List

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 MOTTO FOR PAINT APPLICATION

1. SAFETY OF HUMANS

2. LONG LIFE

3. AESTHETIC LOOK

4. COLOR CODING

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 SURFACE PREPARATION METHOD

There are two method for surface preparation which is defined as per BS 7079 & ISO 8501.

A) Degree of Roughness (Surface Profile)

B) Degree of Cleanliness

a) DRY ABRASIVE BLAST CLEANING

b) WATER BLASTING
c) HAND AND POWER TOOL CLEANING
d) FLAME CLEANING
e) PICKLING
f) VAPOUR DEGREASING

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 SURFACE PREPARATION INSPECTION

Degree of Roughness (Surface Profile) : By

a) Dial Micrometer With replica tape (For any position)
b) Needle gauge (For flat position)
c) Comparator blocks

 SURFACE PROFILE : Known as anchor

pattern / Peak to through height

 Normally It is
40 – 70 Microns

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 SURFACE PREPARATION INSPECTION

Degree of Cleanliness to be assess by the Abrasive blasting grades.

INSPECTION BY NAKED
BS 7079 Pt-A / EYE / MAGNIFICATION
SSPC NACE
ISO 8501-1 GLASS or
ISO GRADE PHOTOGRAPHS

Blast cleaning to visually clean steel Free from Mill scale,

Sa 3 White metal SP5 Grade 1 Uniform with metallic color

Very thorough blast cleaning Very minor mill scale allowed,

Sa 2 ½ Near White metal SP10 Grade 2 Light spots or strips allowed.

Thorough blast cleaning Shall be free from oil, grease,

Sa 2 Commercial finish SA6 Grade 3 dirt & most of the mill scale

Light blast cleaning Shall be free from visible oil,

Sa 1 Light blast and brush of SP7 Grade 4 grease & dirt

Shall be free from visible oil,

st2 Hand tool cleaning SP2 -- grease & dirt

Shall be free from visible oil,

st3 Power tool cleaning SP3 -- grease & dirt

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 RUST GRADE

As per the BS 7079, Rust grades are defined below,

1. RUST GRADE A : Surface is covered with adherent mill scale with little if any rust.

2. RUST GRADE B : Mill scale begun to flake & surface begun to rust

3. RUST GRADE C : Entire surface is corroded, Slight pitting is visible

4. RUST GRADE D : Heavily pitted

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 TYPES OF ABRASIVE

Abrasives are listed below which are used in industrial blasting.

1) Sand : Silica causes silicosis cancer. It is not permitted to use Sand as per govrnment Rule.

2) Copper Slag : Typically use 1 time only.

3) Garnet : Can be reused.

4) Metallic grit : Can be reused.

5) Metallic shot : Can be reused.

6) Mixture of shot & grit : Typical ratio of mix grit & shot is (70-80% Shot + 20-30% Grit)

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 QUALITY TESTING
AFTER SURFACE DURING & BEFORE
BEFORE SURFACE DURING SURFACE AFTER FINAL PAINT
PREPARATION / BEFORE SUB - PAINT
PREPARATION PREPARATION APPLICATION
PRIMER APPLICATION APPLICATION

VISUAL INSPECTION NON ENVIRONMENT SURFACE CLEANLINESS (Sa 2 ½ or

ENVIRONMENT CONDITIONS PAINT VISUAL EXAMINATION
BLASTED ITEM CONDITIONS as required)

SALT TEST (Typically less than 20

WELDING CLEARANCE 1. HUMIDITY 1. HUMIDITY DFT
mg/m2)

2. AIR or METAL SURFACE PROFILE (Typically 40-70 2. AIR or METAL

DIMENSIONAL CLEARANCE HOLIDAY TESTING
TEMPERATURE microns) TEMPERATURE

ABRASIVE DRYNESS 3. DEW POINT DUST LEVEL 3. DEW POINT ADHESION TEST

PAINT MIXING RATIO OVERCOATING PERIOD HARD DRY TIME

APPLICABLE PAINT BATCHES WFT / DFT TOUCH DRY TIME

POT LIFE PAINT MIXING RATIO

FULLY CURE TIME
INDUCTION PERIOD APPLICABLE PAINT BATCHES

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 BLASTING & PAINTING SPECIFIED CONDITIONS

PAINT IS NOT PERMISSIBLE TO APPLY IF,

1. DURING RAIN, SMOKE & HIGH WIND CONDITION

2. METAL OR AIR TEMPERATURE BELOW 5° C

3. RELATIVE HUMDITY IS MORE THAN 85 %

4. DIFFERENCE BETWEEN DEW POINT & AIR OR METAL TEMPERATURE IS BELOW 3° C (DEW POINT 3° C ≤ AIR or METAL TEMP.)

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 PAINT SYSTEM

1. PRIMER COAT :

 Principle :

1. Passivation (Bonding with metal),

2. Cathodic Protection (Bi-metallic contact)

2. MID COAT / INTERMEDIATE : Work as a film former for high DFT

3. FINAL COAT

 Principle :

1. Barrier (Moisture , Sunlight & Electric resistance)

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 FILM THICKNESS

1. WET FILM THICKNESS (WFT)

INSPECTED BY :

A. ECCENTIRC WHEEL (FOR CIRCULAR POSITION)

B. COMB GAUGE (FOR FLAT POSITION ONLY)

2. DRY FILM THICNESS (DFT)

INSPECTED BY :

A. DFT GAUGE

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 DFT / WFT CALCULATIONS

WFT CALCULATIONS : DFT CALCULATIONS : PAINT CALCULATION:

WFT = (V / A) X 1000, (V / A) X 1000 = (DFT / VS%) X

DFT = (WFT / 100) X VS%,
Where; V : Paint in Litre
100
Where; VS% : Paint Volume of Solid %
A : Surface area in Square meter
Where; V : Paint in Litre

A : Surface area in Square meter

VS% : Paint Volume of Solid %

Note : Spread rate & loss factor to be

consider as per the paint manufacturer

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 PAINT DEFECTS
PAINT DEFECT APPEARANCE CAUSES REMEDIES

SAGGING In this defect paint drips 1. Use proper methods to

downwards on the surface keep a check on the
due to application of too paint’s viscosity.
thick or wet layer of paint.
2. Keep a check on desired
High humidity or low temperature and
temperature can also lead to humidity.
this.

WRINKLING Applying too much paint or 1. Ensure that the under

drying during high coat is dry before
temperatures or painting on applying another layer.
a topcoat before the
undercoat is dry can cause 2. Also ensure that the new
this defect to happen. paint is compatible with
the previous one.

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 PAINT DEFECTS
PAINT DEFECT APPEARANCE CAUSES REMEDIES

BLISTERS Blistering is caused due to 1. Remove any unstable

the trapping of air, moisture paint films and allow the
or solvent between the wall to dry thoroughly.
surface and the paint film. Then repaint with a
recommended paint.

CHALKING Chalking occurs when 1. Remove any unstable

ultraviolet rays cause the paint films, allow the wall
paint binder to disintegrate. to dry thoroughly and
It can happen when interior repaint with a
paints are used for exterior recommended paint.
surfaces. 2. Make sure the paint is not
adulterated with foreign
materials.

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 PAINT DEFECTS
PAINT DEFECT APPEARANCE CAUSES REMEDIES

CRACKING This can occur on recoat or if 1. Use proper solvents after

coating is applied to solvent consulting with experts,
sensitive substrates. to prevent cracking.

CISSING / Small round depressions in 1. Use clean tools and water

CRATERING the surface of the coating are or solvents for painting the
known as craters. These can members.
appear due to the use of 2. Proper spray booth air
contaminated painting tools filtration and the
or embedded contaminants contaminant elimination.
on the substrate or coating. 3. The addition of surface
wetting agents.

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 PAINT DEFECTS
PAINT DEFECT APPEARANCE CAUSES REMEDIES

LOSS OF GLOSS Loss of gloss may be caused 1. Proper humidity control.

due to poor surface
preparation, presence of oil 2. Use appropriate thinner
or due to over thinning of on clean surfaces
paint.

FLAKING Flaking-off of paint film is due 1. Ensure that the surface is

to improper application of dry and clean.
paint.
Dust are not cleaned
properly before application
of paint

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 PAINT PRODUCT DATA SHEET

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 PAINT REPAIR PROCEDURE

Prior to the application of any re-coat, damaged paints shall be removed, prepare the surface and reapply the applicable paints.

1. TOP COAT DAMAGED – BASE COAT UNDAMAGED

a) Damaged coating shall be removed with a hand file / emery paper or a fine grinder.

b) The damaged area shall be wiped with a suitable solvent to remove debris.

c) 25 mm periphery area of the damaged area to be chamfered and prepared smooth surface profile.

d) Apply new topcoat as specified.

2. BASE COAT DAMAGED

a) The surface of exposed metal shall be power tool cleaning as per SSPC SP3 or spot blasting to SSPC SP5 and apply primer,

Mid coat & Final coat as specified.

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 ANY QUESTION?

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THANK YOU

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