Method Statement for Self healing Structural Steel Coating System

using ZEROKORR coating System

Content
1. INTRODUCTION
2. PURPOSE
3. SAFETY MEASURES
4. REFERENCE DOCUMENTS
5. EQUIPMENTS USE FOR REPAIR
6. MATERIALS
7. TYPICAL APPLICATIONS
8. SURFACE PREPARATION
9. APPLICATION PROCEDURE
10. TECHNICAL DATA
11. DISCLAIMER
12. SITE PHOTOGRAPHS
1. INTRODUCTION

This Method Statement sets out to describe the methodology of ZEROKORR SYSTEM
which is a self healing coating system that provides not only protection against moisture
and chloride ion penetration but also heals the pinholes and scratches itself which
prevents the steel to get expose to surface. This coating 4 coat system which reduces
the rate of diffusion of CO2 and impedes the impact of UV radiations and weathering
exposure.

2. PURPOSE

ZEROKORR SYSTEM acts as the first line of defense when the steel structure is under
constant exposure to elements in the environment. This solvent based four coat
system- ZEROKORR PRIMER, ZEROKORR INTERPRIMER, ZEROKORR TOP
COAT, ZEROKORR FINISH COAT creates well-adhered film over the surface of the
steel substrate which heals chemically the pinholes or scratches occurred due to silts
or metals in wind abrades the coating on surface. This inturn, helps in delaying the
initiation period of corrosion significantly and enhance service life of structure. In
addition to the above merits, the coating restrains chemical intrusions like chlorides,
CO2, moisture, water, UV radiations, etc. This coating supersedes all performance
parameters over traditional steel painting system.

3. SAFETY MEASURES:

a) Ensure implementation of all safety measures and procedures specific to the

nature and type of execution work being carried out at site.
b) To ensure that all safety precautions and measures as specified in the
technical datasheet (TDS) and material safety datasheet (MSDS) are fully
complied with.
c) Store & mix the material away from smokes, sparking, fumes, excessive heat,
direct sunlight, etc.
d) Wear protective gloves, goggles and nose mask while handling and using
ZEROKORR SYSTEM. In case of splashes on the skin and contact with eyes
wash thoroughly with plenty of water. In case of ingestion and inhalation
remove the personnel to fresh air. In all above cases seek medical advice.
e) The disposal of excess or spilled material is carried out in accordance with
local regulation.
f) All workers shall be made aware of the activities being carried out, safe work
procedures and emergency response plan.
 g) Working area will be barricaded locally, signboards etc. will be arranged to
prevent entry of the other unauthorized workers.
h) The task methodology shall be explained to all the key personnel and
workmen involved in that activity and standing instructions will be given.
i) Safety induction will be done for all workers before carrying out the job.
j) Ensure to use job specific PPE at worksite.
k) Work area shall be cleaned from the debris.
l) All emergencies or serious injuries / illness person(s) will be transferred to the
nearest hospital.

4. REFERENCE DOCUMENTS
 Material Datasheet of ZEROKORR SYSTEM
 Product Literature of ZEROKORR SYSTEM
 Material safety datasheet of ZEROKORR SYSTEM
 Material test certificate of ZEROKORR SYSTEM

5. EQUIPMENT USED FOR REPAIR.

Tools & Equipment Purpose/Use
Putty Knife Used for applying putty to cover dents, undulation, cracks, knots
Scrapping Knife Used for removing old paints and hard materials from surface and not
to use on oily or greasy surface directly
Chisel Knife Used for cutting hard old thick paint
Moulding Knife or Used for scraping or rubbing on peculiarly shaped/contours
Contour Knife
like statue, ornamental carving, curved portions etc
Pallet Knife Used for mixing the paint in drums.
Round Brush Used for painting very large areas quickly for preparatory application.
Curve Brush Used for painting curved surfaces of irregular design
Concrete Chipper For chipping loose concrete
Dust Brush Used for removing dust, dirt before painting
Angle Grinders Low RPM rotating grinders with cup cone brushes/grinder plates
Emery sheets available a) Used for removing unwanted materials
in four types: Sand b) Used for creating surface roughness
paper, Cloth emery,
Water proof emery,
Abrasive stones.
Elcometer Used for measuring dry film thickness (DFT) of paint in
microns and this works on electromagnetic principle
Masking tape Used for covering areas which are not to be painted
Spray Gun Used for painting the surfaces by mode of spraying
Drilling Machine with Mixing of paints
paddle arrangement

6. Materials
 ZEROKORR SYSTEM (PRIMER, INTERPRIMER, TOP, FINISH),
Compatible Thinner

7. TYPICAL APPLICATIONS
All Structural Steels, Steel chimneys, conveyors, Steel bridges, Trusses, workshops,
pipelines, all structural steel members, etc.

8. Surface Preparation
The main purpose of surface preparation is to provide strong adhesion between coating
and the substrate. It also facilitates in increasing the surface area covered under the
coating by roughening the surface. It is a well-known fact that the success of any
protective coating work relies heavily upon proper surface preparation. So, due thrust
and emphasis shall be given on this aspect.
 It is expected that before undergoing ZEROKORR SYSTEM coating, the steel
surface is structurally sound. If the structure is not sound (thikness of steel
surface, cracks, unevenness in the surface, etc), contact structural consultant
before going for steel coating.
 The steel substrate to be coated shall be blast cleaned using copper slag blasting
to achieve SA 2 ½ grade to achieve near white metal. If blasting is not feasible,
application of Etching Primer is recommended.
 Surface should be clean, free from oil, grease and dry before application of
coating.
 Substrate temperature should be between 150C to 400C.

9. Application Procedure
1. After thorough surface preparation, application of structural steel protective
coating ZEROKORR shall be initiated.
2. Mix Base and Hardener of ZEROKORR PRIMER in prescribed proportion by
volume thoroughly (1:1 by volume) and allow it to remain in a container for ten
minutes. Mix the material with a rotary hammer drill machine having a mixing
paddle arrangement in order to achieve the desired consistency of the paint.
Apply this mix by brush/spray within its pot life. Allow it to air cure for minimum 24
hours. Ensure the next coat is applied within 72 hours of application of
ZEROKORR PRIMER.
3. After a time interval of 24 to 72 hours, Mix the Base and Hardener of ZEROKORR
INTERPRIMER in prescribed proportion by volume thoroughly (1:1 by volume)
and allow it to remain in a container for ten minutes same as ZEROKORR
 PRIMER. Apply this mix by brush/spray within its pot life. Allow it to air cure for
minimum 6 hours. Ensure the next coat is applied within 72 hours of application
of ZEROKORR INTER PRIMER.
4. Follow the same procedure for ZEROKORR TOP COAT.
5. After a time interval of 6 to 48 hours, Mix the Base and Hardener of ZEROKORR
FINISH in prescribed proportion by volume thoroughly (1:1 by volume) and allow
it to remain in a container for ten minutes. Mix ZEROKORR TOP COAT by
volume with rotary hammer drill machine having a mixing paddle arrangement in
order to achieve desired consistency of the paint. Apply this mix by brush/spray
within its pot life. Allow it to air cure for 7 days. This coat can be ignored if the
structure is not exposed to sunlight.
6. There shall not be any dust deposition in between undercoats. Wipe the surface
with clean cloth in case there is dust deposition.
7. Addition of compatible thinner (epoxy/NC thinner) upto 10-15% for spray
application is permissible for achieving desirable consistency. Also use same
thinner for cleaning machine/brush/equipments.
8. For spraying a model typically such as Graco make Electro Hydraulic Airless Paint
Sprayer Model: DUTYMAX EH 200 DI / Wagonar can be used. For pump ratio,
tip size & tip pressure refer to the equipment manufacturer’s specification.
9. Do not apply the coating during rain, fog or mist or when the temperature falls
below 100C or above 500C and/or relative humidity exceeding 80%, in night hours
& before 8 am.

10. TECHNICAL DATA

IPN SYSTEM:
ZEROKORR
ZEROKORR FINISH COAT
ZEROKORR ZEROKORR TOP
INTERPRIMER (Only for UV
PRIMER COAT
COAT exposed
surfaces)
Appearanc Dark/Brown/Red Yellowish Grey shade Grey shade
e
Mix Curing Curing Curing Curing
Base Base Base Base
Proportion Agent Agent Agent Agent
(By Volume) 1 1 1 1 1 1 1 1

6-7 sqm/ltr/coat 5-6 sqm/ltr/oat 4-6 sqm/ltr/coat 7-8 sqm/ltr/coat

Coverage
40-50 per coat 50-60 per coat 95-105 per coat 30-40 per coat
D.F.T.
60 minutes for 2 60 minutes for 2
60 minutes for 2 lt.mix60 minutes for 2 [Link]
Pot Life [Link] [Link]

Curing
24 hrs. in air 24 hrs. in air 24 hrs. in air -
Time
 1 year in tightly 1 year in tightly 1 year in tightly 1 year in tightly
Shelf Life
sealed containers sealed containers sealed containers sealed containers
Packing 40 lt 40 lt 40 lt 40 lt
Cleaning Xylene base Thinner

*Being engineered self healing coating, it is available in selective shades prescribed in

standard shade card.
Note: Coverage mentioned in the technical data is tentative and may vary widely based upon
extent of surface preparation, surface profile, application expertise, ambient temperature etc.

11. Disclaimer:
This information given in good faith and to best of our knowledge is based on results gained
from experience and long-term testing. Whereas Krishna Conchem Products Pvt. Ltd.
(KCPPL) endeavors to ensure that any advice, recommendation specification or information
it may give is accurate and correct, it cannot accept any liability arising from the use of
products since the conditions of use are beyond its control whether or not in accordance with
any advice specifications, recommendation or information given by it.

12. SITE PHOTOGRAPHS

Surface blasting

Application of Primer
Application of Interprimer

Application of Top coat