BGAS PREPARATION

BY: ARDI PRIYANTO

I. CORROSION

• Corrosion: Corrosion can be generally defined as degradation of a metal by

chemical or electro-chemical means.

• In a corrosion circuit the current is always direct current (DC).

• It is conventionally thought that a current passes from positive + to negative -, ie from
anode to cathode.
• In fact electrons are flowing in exactly the opposite direction,
I. CORROSION

• Anode: An anode is a positively charged area, Anode Always corrode

• In this state the atom is now an ion, (An ion is a charged particle
and can be positive or negative, a single atom or a group of atoms,
known as a molecule.)

• Cathode: A cathode is a negatively charged area where there are more electrons
than needed in its passive state.

• These are electrons released from the anode

I. CORROSION

• Electrolyte: An electrolyte is a substance, which will conduct a current and be

broken down by it, (dissociate into ions). Ie: Water, Soil, Concrete

• As the electrons pass into the electrolyte it is dissociated into positive and negative
ions, as shown by the formula: -2H2O2H+ + 2OH-.

• The corrosion triangle, E: Electrolyte

A: Anode C: Cathode
I. CORROSION

• The positive iron ions, Fe++, receive the returning hydroxyl ions and ionically bond
together to form iron hydroxide, which is hydrous iron oxide, rust and is shown by the
formula: Fe++ + 2OH Fe (OH)2 It is now apparent that corrosion only occurs at the
anode, never at the cathode, hence the term cathodic protection.
I. CORROSION

• In common with all chemical reactions certain factors can increase the reaction rate.

• 1. Temperature

• 2. Hygroscopic salts  Blister

• 3. Aerobic conditions, (presence of oxygen): Shown by :-2H2O + O2 + 4e  4OH-

• 4. Presence of some types of bacteria on the metal surface (SRB) Anaerobic Condition

• 5. Acids and alkalis.

• 6. Bi-metallic contact. Also known as bi-metallic corrosion

 Graphite + 0.25 v

I. CORROSION Titanium 0.0 v

Silver - 0.1 v
Nickel 200 - 0.15 v

• Bi-metalic Corrosion Lead - 0.2 v

Admiralty brass - 0.3 v
Copper - 0.35 v
Tin - 0.35 v
Mill scale - 0.4 v
Low alloy steel - 0.7 v
Aluminium alloys - 0.9 v
Mild steel - 0.7 v
Zinc - 1.0 v
Magnesium - 1.6 v
I. CORROSION

• Mill scale is formed during the rolling operation of steel sections. The oxides of iron form
very quickly at temperatures in excess of 580°C.

• The first oxide formed is FeO (Wustite), iron oxide (Magnetite), the next is Fe3O4
(Haematite)

• The thickness of mill scale varies from 25-100 μm

I. CORROSION - WEATHER CONDITIONS

 % Relative humidity (max 89%).

 Air temperature (dry bulb temperature).

 Steel temperature (>30C above dew point).

 Calculated dew point temperature.

 Manufacturers recommended minimum application temperature (approx50C typically).

Considerations
II. SURFACE PREPARATION

• Therefore two factors need to be considered when inspecting a surface preparation.

• 1 Degree of cleanliness.

• 2 Surface profile (degree of roughness).

II. SURFACE PREPARATION

• Surfaces can be prepared for paint application in several different ways; each one varies in
cost, efficiency, ease and suitability.
A. Dry abrasive blast cleaning.
B. Water blasting.

C. Hand and power tool cleaning.

D. Flame Cleaning
E. Pickling

F. Vapour Degreasing
G. Weathering
II. SURFACE PREPARATION

• A. DRY ABRASSIVE CLEANING.

• Dry abrasive blast cleaning involves compressing air and forcing it along a hose
• and out of a small aperture called a nozzle. A pressure of 100psi results in the
• air exiting the nozzle at approximately 450mph
II. SURFACE PREPARATION
II. SURFACE PREPARATION

• Sand
• It is not permitted to use sand. SI 1657 states that any mineral used as an abrasive must
release less than 1% free silica on impact. (Silica causes pneumonicosis or silicosis.)
COSHH regulations do not allow the use of sand containing silica for dry blasting. Sand
itself is perfectly safe, but shattering on impact releases silica which can be inhaled.
• COSHH (The Control of Substances Hazardous to Health)
II. SURFACE PREPARATION

• A. Copper slag
• Although the name implies metallic content the amount of copper in the
structure is extremely minute
II. SURFACE PREPARATION

• B. Garnet
• A natural mineral classed as being of diamond type hardness, can be either
expendable or recyclable. If the situation justifies, cleansing units are available
to extract contamination so that the material can be reused, usually up to
three times.
II. SURFACE PREPARATION

• C. Metallic Grit
• In this context, steel and iron are both metallic.

• Metallic abrasives are recyclable because the particles reduce in size slowly
II. SURFACE PREPARATION

• D. Metallic Shot
• Shot is spherical and doesn’t shatter (otherwise it would form grit). When
supplied the particles are virtually uniform in size and shape, (not a working
mix) but like the grit they wear down slowly in size.
II. SURFACE PREPARATION

• E. Metallic shot and grit mixed

• A typical mix ratio of shot to grit as used in a pipe coating mill would be 70-80% shot to
20-30% grit.
 II. SURFACE PREPARATION

• 1. Adhesion and profile

• A commonly used definition of adhesion is the force required to separate two surfaces in
touch.
• Two theories of adhesion are:
A. Molecular interference
• Because the surface is rough and uneven the paint wets and locks into theprofile. Analogy –
velcro. Physical.
B. Molecular attraction
• Negatively charged particles attracted to positive areas and vice versa. Analogy - magnet
(sometimes called ionic bonding). Chemical
 II. SURFACE PREPARATION

• II. Profile
• Surface profile, anchor pattern, key, peak to trough height and amplitude are all
expression meaning the cross section of a blasted area, as measured from the top of the
peaks to the bottom of the troughs. The surface profile requirements are given on the
specification for the job, eg for BGAS 30-75microns

• Other Name of Surface profile: Anchor Pattern, Key, Peak to trough height, Amplitude
 II. SURFACE PREPARATION

• II. Profile measurement

• This can be done in two ways. (Qualitative and Quantitative)
1. Measuring using gauges with and without replica tape. (Needle gauge and Micrometer
gauge with replica tape)  Quantitative (Nilai dan satuan)/ digit and unit
2. Assessing using surface comparators.  Qualitative (OK or not OK)
 II. SURFACE PREPARATION

• II. Profile measurement

1. MEASURING GAUGE (QUANTITATIVE) UNIT IN MICRO METER

Needle gauge
Dial Micrometer with Replica Tape
 II. SURFACE PREPARATION

• II. Profile measurement

• MEASURING GAUGE (QUANTITATIVE) UNIT IN MICRO METER
• A. Needle Gauge must be calibrated using flat surface/glass (THIS CAN NOT BE USED
IN CURVE SURFACE (PIPE)
• Dial Micrometer with Replica Tape:
• - Zero the dial  Remove backing paper from replica tape  using pen/pencil rub all
over area mylar  Remove replica tape  check mylar with dial micrometer  the
profile is The result of dial Gauge minus Mylar Thickness (usually 50 micron)
 II. SURFACE PREPARATION

• II. Profile measurement

• 2. SURFACE COMPARATOR (QUALITATIVE)
• The comparators are not for assessing cleanliness
• The grading used is (Fine Medium and Coarse)
• Any profile below the lower limit for fine grading is referred to as finer than fine. Any
profile above the upper limit for coarse grading is referred to as coarser than coarse.
 II. SURFACE PREPARATION

• RUST GRADE MATERIAL

• Preparation of steel substrate before application of paints and related products
• Rust grades. BS 7079 Pt. A, ISO 8501, SS 05 59 00
• A. Rust grade A: Steel surface largely covered with adherent mill scale with little if any rust.

RUST GRADE “A”

 II. SURFACE PREPARATION

• RUST GRADE MATERIAL

• B. Rust grade B: Steel surface, which has begun to rust and from which the mill scale has
begun to flake.

RUST GRADE “B”

 II. SURFACE PREPARATION

• RUST GRADE MATERIAL

• C. Rust grade C: Steel surface on which the mill scale has rusted away or from which it can be
scraped, but with slight pitting visible under normal vision..

RUST GRADE “C”

 II. SURFACE PREPARATION

• RUST GRADE MATERIAL

• D. Rust grade D: Steel surface on which the mill scale has rusted away and on which general
pitting is visible under normal vision..

RUST GRADE “D”

 II. SURFACE PREPARATION

• Abrasive blasting grades.

• 1. Sa 1 Light blast cleaning: When viewed without magnification, the surface
shall be free from visible oil grease and dirt and from poorly adhering mill scale,
rust, paint coatings and foreign matter.

• 2. Sa 2: Thorough blast cleaning. When viewed without magnification, the

surface shall be free from visible oil grease and dirt and most of the millscale, rust,
paint coatings and foreign matter. Any residual contamination shall be firmly
adhering.
 II. SURFACE PREPARATION

• Abrasive blasting grades.

• 3. Sa 21/2: Very thorough blast cleaning. When viewed without magnification,
the surface shall be free from visible oil grease and dirt and from mill scale, rust,
paint coatings and foreign matter. Any remaining traces of contamination shall
show only as slight stains in the form of spots or stripes.

• 4. Sa 3: Blast cleaning to visually clean steel. When viewed without

magnification the surface shall be free from visible oil grease and dirt and shall be
free from mill scale, rust, paint coatings and foreign matter. It shall have a uniform
metallic colour
 II. SURFACE PREPARATION

• Blasting Grade A: SA 2.5 and SA-3

• From the above definitions it can be seen that Sa 1 and Sa 2 are not achievable on rust
• grade-A

A-SA-3 A-SA-2.5
 II. SURFACE PREPARATION

• Blasting Grade B: SA 1, SA-2, SA-2.5 and SA-3

B-SA-1 B-SA-2 B-SA-2.5 B-SA-3

 II. SURFACE PREPARATION

• Blasting Grade C: SA 1, SA-2, SA-2.5 and SA-3

C-SA-1 C-SA-2 C-SA-3

C-SA-2.5
 II. SURFACE PREPARATION

• Blasting Grade D: SA 1, SA-2, SA-2.5 and SA-3

D-SA-1 D-SA-2 D-SA-2.51 D-SA-3

 II. SURFACE PREPARATION

• B. Water blasting
• Surface preparation methods using water are more environmentally friendly than open
blasting and also, from the safety aspect, spark free. They are ideal for removal of soluble salts,
sulphates and chlorides, (the hygroscopics) although complete removal needs high pressure
ranges. Wet blasting methods are also ideal for removing layers of toxic materials, eg red lead,
calcium plumbate and zinc chromate primers.
• 1. High pressure water blasting up to 30,000psi (water jetting)
• 2. High pressure water plus abrasive injection (20,000psi and uses abrasives)
• 3. Low pressure water plus abrasive injection (Uses normal blasting pressures of 100psi)
 II. SURFACE PREPARATION

• C. Hand and power tool cleaning. 7079 Pt A, ISO 8501, SS 05 59 00

• Any hand operated or power tools, including needle guns, wire brushes, emery cloth and
grinders can be used to achieve these standards
• One major disadvantage of this method is the lack of surface profile. Wire brushing will not
produce a profile and in most cases will actually reduce an existing profile, sometimes
resulting in burnishing, which is polishing, and a smooth shiny area does not provide good
adhesion
 II. SURFACE PREPARATION

• Hand and power tool cleaning Surface grade

• St2: Thorough hand and power tool cleaning. When viewed without magnification the surface
shall be free from visible oil, grease and dirt and from poorly adhering millscale rust, paint
coating and foreign matter.
• St3:Very thorough hand and power tool cleaning. As for St2 but the surface shall be treated
much more thoroughly to give a metallic sheen arising from the metallic substrate.
 II. SURFACE PREPARATION

• because mill scale is harder than the brush bristles, (phosphor bronze / beryllium bronze).
There is no standard for rust grade A!
• Hand and power tool cleaning B St 2 and St 3.

B- ST-2 B- ST-3
 II. SURFACE PREPARATION

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

C- ST-2 C- ST-3
 II. SURFACE PREPARATION

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

C- ST-2 C- ST-3
 II. SURFACE PREPARATION

• D. Flame cleaning
• Three factors contribute to how flame cleaning works:
1. Expansion: All materials have different co-efficient of expansion, Mill scale is chemically
bonded to the steel and applied heat causes the materials to expand at different rates, thus
breaking the chemical bond.
2. Dehydration: Water in the corrosion products and in the fissures
3. Heat penetration: The heat is conducted efficiently into the substrate aiding the drying of
the steel and removal of penetrated oil or grease.
 II. SURFACE PREPARATION

• E. PICKLING
• Pickling is acid bath followed by washing
• Footner’s Duplex system. Pickling followed by passivation
• Sulphuric is the most common acid used for economic and safety reasons.
• Footners duplex system involves the pickling process followed by a passivation process using
phosphoric or chromic acid along with a small percentage of iron filings, which produces iron
chromate or iron phosphate salts, which are not soluble..
 II. SURFACE PREPARATION

• F. Vapour degreasing
• Fumes from a solvent bath condense on a component suspended over the bath and dissolve
any oil or grease which then drips back into the bath.
• G. Weathering
• Weathering relies on co-efficient of expansion properties as mentioned in flame cleaning.
When left in a stockyard, open to temperature changes, day and night the mill scale sheds.
This can now leave the steel open to atmospheric corrosion, which produces such as
sulphate salts.
 III. SURFACE CONTAMINANTS AND TESTS

• Some tests are Qualitative and some are Quantitative. A qualitative test is one, which give a
result as accept/reject, pass/fail, go/no go, whereas a quantitative test is one, which gives a
result in known units eg milligrams/m2. (Quantitative shall have digit and unit)
 III. SURFACE CONTAMINANTS AND TESTS

• 1. Hygroscopic salts : potassium ferricyanide, (now called potassium hexacyanoferrate)

Qualitative
• If there are any dissolved salts they react with the potassium ferricyanide to
• form potassium ferrocyanide, The ferrocyanide is Prussian blue
 III. SURFACE CONTAMINANTS AND TESTS

• 2. Soluble chlorides: silver nitrate test Qualitative

• The test for detecting chloride salts is known as the silver nitrate test. As with the previous
test a solution of silver nitrate, 2% with distilled water is made and the Whatman papers cut
into strips. The strips are then soaked in the solution and pressed onto the area under test
for about 20 seconds, then washed in distilled water. The reaction between silver nitrate and
any chloride salts present produces silver chloride, which remains on the strip after washing.
If the strip is then dipped into photographic developer the chlorides show up as black/brown
 III. SURFACE CONTAMINANTS AND TESTS

• 3. MerkoquantQuantitative
• A salts/distilled water solution is made and by swabbing an area of 150mm x 150mm, using
approximately 22.5ml. Merkoquant strips, which consist of a small disposable plastic strip and
a chemically impregnated cotton pad, are then dipped into the solution and the resulting
colour change is compared to a master chart on the container
 III. SURFACE CONTAMINANTS AND TESTS

• 3. MerkoquantQuantitative
 III. SURFACE CONTAMINANTS AND TESTS

• 4. Bresle sample patch Quantitative

• A test with a reported accuracy of approximately 95%. An adhesive patch with a rubber
diaphragm is firmly affixed to the substrate and distilled water is injected by hypodermic
needle through the side of the patch. The distilled water is extracted and injected several
times to produce a solution of any salts present. By measuring the electrical conductivity
change in the solution, the level of salt contamination can be determined.
 III. SURFACE CONTAMINANTS AND TESTS

• 4. Bresle sample patch Quantitative

 III. SURFACE CONTAMINANTS AND TESTS

• 5. Copper Sulphate Solution (to detect mill scale) Qualitative

• This test only for Blast Cleaning SA 3 grade.
• Spray chemical and check if any black spot mean still have mill scale
• This test is usually for preparation TSA (Thermal Spray Aluminium)
 III. SURFACE CONTAMINANTS AND TESTS

• 6. Test to detect the presence of oil or grease Qualitative

• Using Solution (Non Aliphatic) Using Xylene
• Other than ultra violet light, oil and grease can be detected by dropping solvent onto the
suspect area and absorbing the solution on Whatman or blotting paper. The solvent will
evaporate and oil or grease will give a darker appearance (fluorescence yellow/green)
 III. SURFACE CONTAMINANTS AND TESTS

• 7. Test to detect the presence of moisture on a substrate (Talcum/Chalk)Qualitative

• Presence of moisture, even in the teeniest amount, can affect the choice of paints and if work
can be done or otherwise.
• A very simple test for the presence of moisture is to sprinkle with talc or powdered chalk
and then lightly blow away. The powder will stick to areas where moisture is.
 III. SURFACE CONTAMINANTS AND TESTS

• 8. Test to detect the presence of dust on a substrate (Sellotape) Qualitative

• A piece of self-adhesive tape is stuck onto the surface and snatched off, the dust/finings sticks
to the tape. By then sticking the tape onto white paper the dust can easily be seen
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• Paint has been classified in many ways eg by principle involved:

• 1. Barrier: The material forms a thick impermeable layer of a high electrical resistance eg
urethane
• 2. Passivation: Causing a chemical reaction between the paint constituents and the substrate
eg rust inhibitive primers.
• 3. Cathodic protection: Employs the bi-metallic principles by using a less noble metal as
pigmentation eg zinc in zinc rich primers
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• There are 3 main groups of paint::

• 1. Paints containing solvents
• 2. Solvent free multi-pack, (MCL’s)
• 3. Powder paints
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• All have the same basic constituents:

• 1. Binder
• 2. Solvent
• 3. Pigment or other additive
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• A. Binder (Vehicle/Non-Volatile/Film Former)

• 1. Ease of application (flow properties or viscosity).
• 2 Adhesion to the substrate for the expected life of coating.
• 3 Resistance to abrasion.
• 4 Resistance to chemical attack according to environment.
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• A. Binder (Vehicle/Non-Volatile/Film Former)

• 5 Cohesive strength, its ability to hold together as a film.
• 6 Dialectric strength.
• 7 Ability to resist the passage of water.
• 8 Ability to change from a liquid as applied, into a solid to provide the above properties and
others, for the expected life of the coating
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• A. Type of Binder (Vehicle/Non-Volatile/Film Former)  BGAS

• 1. Acrylics.
• 2. Alkyds.
• 3. Epoxies. (second coat)
• 4. Ethyl and methyl silicates.
• 5. Polyurethane (Top Coat) Resin To anything
• 6. silicones
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• A. Type of Binder (Vehicle/Non-Volatile/Film Former)  NON-BGAS

1. Cellulose resins.

2. Chlorinated rubber.
3. Emulsions.
4. Natural oils and resins.

5. Phenolic resins.
6. Styrene and vinyl
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• Binder -Solvent Combinations:

A. WATER
• Vinyls, acrylics, epoxies, alkyds, bitumens, polyurethanes, acrylatedrubbers. (Weak)
B. WHITE SPIRIT
• Natural oils, natural resins, alkyds, phenolics. (strong)
C. XYLENE (Stronger)
• Chlorinated rubber.
D. ACETONE (Strogest)
• Epoxy.
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• Binder -Solvent Compability:

• Compatibility for over-coating.
• Correct solvent group for binder.
• Flashpoint and toxicity considerations.
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

Solvent strength in Common names Binders

descending order
Water Emulsions PVC/PVA
Vinyls
Acrylics – other materials eg
epoxy
Bitumins, polyurethanes,
Alkyds, acrylated rubbers
Aliphatic White spirit Natural oils
hydrocarbons Turpentine Natural resins
Turpentine substitute Alkyds
Solvent naphthas Phenolics
Hexanes upwards
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

Solvent strength in Common names Binders

descending order
Aromatic Xylene Chlorinated rubber
hydrocarbons Toluene
Benzene

Ketones Acetone Epoxy

Methyl ethyl ketone
Methyl ISO butyl
ketone
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• Resin
• Natural resins are from the main plant, tree 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
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• Solvent
• A solvent free binder, or a binder using a very weak solvent, will cause very few problems
when over coating another product. Usually in this situation the problem would be limited to
different expansion and contraction ratios. Providing a key by abrading can mostly rectify or
at least minimise this. However, a very strong chemically curing binder like epoxy, needs a
strong solvent and can cause problems over coating other materials, even when they are fully
cured.
• Strong solvents for strong binders. Weaker solvents for weaker binders (i.e Epoxy)
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• Polymer
• 1. Linier Polymer
• As the name implies the atoms or molecules which form the polymer, join on at the end of
the structure and in so doing saturate the structure. This type of polymer is also referred to
as a solution polymer
• A linear polymer is a non-convertible or reversible material and also thermoplastic. From the
binder types the linear polymers are acrylics, vinyls, chlorinated rubber, asphalt and coal tars
and cellulosic resins.
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• Polymer
• 2. Branched polymer:
• Oxidation drying, non-reversible. Natural oils and resins , become very brittle with age.
• 3. Crosslinked polymer:
• Chemically curing, very strong, multi-directional polymerisation, examples: epoxies, urethanes
and polyurethanes
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• Oils
• Natural oils are produced from the seeds of a plant: Natural oils (vegetable oils) are produced
from seeds of a plant, well known examples being linseed, castor, olive, coconut, soya and tung
oil.
• 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
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• Oils
• A. Drying Oils
• Three sets of double bonds along a carbon backbone, react readily in ambient conditions.
(unsaturated oils).
• B. Semi-drying Oils
• One or two sets of double bonds, not as reactive as drying oils. Need a catalyst (heat) to start
polymerisation.
• C. 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.
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• Oils
• Oils and resins are mixed to give a binder with modified properties:
• 1. LONG OIL PAINT more than 60% Oil to Resin.
• Elastic and slower drying, mainly used in domestic applications (decorative materials).
• 2. MEDIUM OIL PAINT between 45% and 60% Oil to Resin.
• 3. SHORT OIL PAINT less than 45% Oil to Resin.
• Faster drying, suitable for steelwork. More brittle, with shorter over-coating time
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• Pigment
• They are derived from many sources, animal, vegetable, mineral and synthetically produced
and can be in a wide variety of particle sizes and shapes. Pigments used in paints must remain
as solid particles within the vehicle (the binder plus the solvent if a solvent is used) and not
dissolve.
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• Pigment
• Pigments can be subdivided into groups according to the main function they perform in paint:
1. Anti-corrosive: rust inhibitive properties.
2. Metallic Pigment: work sacrificially.
3. Opaque pigment: inert, provide opacity and colour. (hiding Power)
4. Extenders: add bulk, reduce cost.
5. Laminar: provide impermeability
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• Pigment
1. Anti-corrosive: rust inhibitive properties.
PRIMER COLOUR
Red lead (basic) (natural oils and resins) RED toxic
Calcium plumbate White Toxic
Coal Tar Black Toxic
Zinc Chromate Yellow Toxic
Zinc phosphate Purple/Grey most common
Barium Metaborate
Zinc Phosphosilicate
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• Pigment
2. Metallic Pigment: work sacrificially.
Also used to protect the substrate by cathodic protection. Material must be below steel in the
galvanic list.
Two most commonly used are :
A ZINC (better for galvanic protection).
B. ALUMINIUM (excellent ultra-violet reflective properties) solar protection.
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• 3. Opaque Pigment.
Inert particles which have excellent light scattering properties in order to give covering
(opacity) and colour.

Carbon Black
Cobalt Blue
Chrome Greens/Yellows/Oranges
Iron Browns/ Reds/ Yellows
Calcium Reds/ Yellows
Titanium Dioxide White
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• Pigment
4. Extender pigments.
Low priced, readily available materials, also known as fillers. They add bulk, improve intercoat
adhesion, increase cohesive strength, and give extra thickness to paint film at low cost

Clays White Kaolin, China clay

Chalk White Calcium carbonate
Talcum White Magnesium silicate
Slate Flour Dark Grey Aluminium Silicate
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

5. Laminar pigments.
Plate-like pigments which provide impermeability. In theory, they have a leafing effect,
overlapping as the coating dries.
Common laminar pigments:
1. Graphite.
2.Glass flake.
3. Aluminium flake (ultra-violet reflective).
4. Micaceous Iron Oxide (Mio) (ultra-violet reflective)
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

5. Laminar pigments.
Attributes of Mio:
UV A and B reflection, retards permeation (rembes), durability, provides adhesion to next layer.
 IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

PVC
The pigment to binder ratio is a very important factor in the design and manufacture of paint
and is known as the pigment volume concentration. There is an ideal pigment binder ratio,
which varies from paint to paint, pigment to pigment and this is known as critical pigment
volume concentration (CPVC).
IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• Below CPVC: Too much binder to solids ratio, good gloss properties, but poor opacity
and with a tendency to blister (low cohesive strength).
IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• Near CPVC: A film with lower gloss properties but greater cohesive strength and just
enough resin to encapsulate each particle, giving good resistance to water permeation.
• Above CPVC: The CPVC is exceeded and all particles are not wetted, the film would be
porous, low in cohesive strength and adhesion
IV. PAINT CONSTITUENTS AND BASIC TECHNOLOGY

• Other Additives
a) Anti-settling agents: Aids to shelf life.
b) Plasticizers: Reduce brittleness, aid application, improves flexibility.
c) Driers: Allow even through drying of oxidizing films.
d) Anti-skinning agents: Retard the formation of surface skins
V. SOLUTIONS AND DISPERSIONS

• SOLVENT: Will dissolve another material.

• SOLUTE: Is dissolved in the solvent
• SOLUTION: The resultant liquid produced by dissolving a solute in a solvent.
• Contoh Gula di dalam air, gula=Solute, air=solvent, air gula yg terlarut Namanya solution
V. 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
VI DRYING AND CURING OF PAINT FILMS

• A. Solvent evaporation
• No chemical reaction. (single Pack)
• Polymers are preformed and saturated.
• Linear polymers closed at the ends by hydrogen and have no double bonds.
• Also called reversible or non-convertible
• Contoh Chlorinated Rubber (vinyl Acrylic, Cellulose)
VI. DRYING AND CURING OF PAINT FILMS

• B. Oxidation
• Uses atmospheric oxygen.
• Oxygen chemically combines with unsaturated double bonds.
• Process can be accelerated by addition of driers.
• Also called convertible or non-reversible.
• Contoh Alkyd’s, Phenolic, Oil Based Paint
VI. DRYING AND CURING OF PAINT FILMS

• C. 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!
• 1. Convertible or non-reversible.
• 2. Chemically cross-linking polymers
• Contoh (Epoxies, Polyurethanes)
VI. DRYING AND CURING OF PAINT FILMS

• 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.
VII. PAINT SYSTEM

• A paint system is one or more layers of paint, which will give corrosion protection by one of,
or a combination of corrosion protection methods.
• 1. Primer (1st Coat): anti corrosive to protect the steel. (Coarse Pigment particle)
• 2. Mio (2nd Coat): protects primer, provides impermeability. (Mio: Micaceous Iron Oxide)
• 3. Mid coat or build coat: protects underlying coating, builds thickness, and provides good
adhesion for subsequent layer
• 4. Finish coat: aesthetic , correct colour, provide a smooth surface to allow cleaning and
shedding of water.
VII. PAINT SYSTEM

• A. PRIMER
• Rust inhibitive pigments passivate the substrate.
• - Mordant or wash primers (t-wash), acid reaction with the substrate produces inhibitive
salts. No measurable thickness sudah jarang di gunakan, biasanya utk paint material yg
di galvanizing Toxic
• - Etchant primers, (polyvinyl butyral) similar Reaction but leaves a measurable thickness
of 15-25 um.
VII. PAINT SYSTEM

• A. PRIMER
• Rust inhibitive pigments passivate the substrate.
• - Mordant or wash primers (t-wash), acid reaction with the substrate produces inhibitive salts.
No measurable thickness sudah jarang di gunakan, biasanya utk paint material yg di
galvanizing Toxic
• - Etchant primers, (polyvinyl butyral) similar Reaction but leaves a measurable thickness of 15-
25 um.  untuk SS ATAU AL
• LIHAT HALAMAN 31 PA 10 Non Ferrous Surface(A2-41), Table SPA6a-SPA6b-SPA6c,
• (A2-25) table SPA1e
VII. PAINT SYSTEM

• B. MID COAT/ BUILD UP COAT

• Extender particles increase surface area to provide adhesion for any subsequent layer
VII. PAINT SYSTEM

• C. FINISH COAT
• Mainly aesthetic, but have other properties.
• Gloss finish, to assist in shedding water.
• Solar reflective (white) biasanya utk Chemical Plant, heat absorbent (black).
VII. PAINT SYSTEM

• Other
• - Moisture tolerant:-moisture has no appreciable ill effect
• - Moisture curing polyurethane:-uses water vapour from the atmosphere to cure, damp
or moist, but not wet. Damp: no signs of water, but temperature is below dew point. Low
RH is a problem (min 35%)
• Moisture sensitive: Will not Tolerance with Moisture or High Humidity at All and All give
of Carbon Dioxide as part of curing process
VII. PAINT SYSTEM

• Damp: No sign of water but the Temperature is close to dew point

• Moist: No standing water but an Un-noticeable film of water
• Wet: Droplet or standing water are present
VII. PAINT SYSTEM

• Powder Coatings
• Thermoplastic or thermosetting.
• Most commonly thermosetting, needs heat.
• Convertible coatings chemically cured. Usually electrostatically applied.
VII. PAINT SYSTEM

• Sacrificial systems

• The zinc acts as a barrier, and corrodes in its own right until there is coating damage and
both metals are exposed to electrolyte. Zinc oxides are formed, and repairs the damage.
VIII. PAINT MANUFACTURE

1. Ball Mill
Steel balls rotate in cylinder, grind mill base to required particle size (5000 -40000 lts).
2. Attritor Mill
Upright static cylinder, the steel balls are moved by motorised paddles.
3. High speed disperser
A 2500 rpm blender, produces mill base.
VIII. PAINT MANUFACTURE

4. Kady Mill (another type is silverson mill) .

For the manufacture of emulsions and waterborne paints.
5. Sand Mill (pearl mill or bead mill).
Mill base injected at bottom, forced through sand, refined, removed at top. Water cooled
6. Colloid Mill
(High speed stone mill) Vertical or horizontal
VIII. PAINT MANUFACTURE

7. Triple Roll Mill

Used to produce mastics, fillers and putties. 3 rolls travel at different speeds, paste sticks to
faster of rolls.
8. Single Roll Mill
Used to produce small batches of expensive materials (gilts, silvers etc.)
IX. TESTING OF PAINTS FOR PROPERTIES AND
PERFORMANCE

BS 3900 Methods of test for paint.

BGC PS PA9 Table 2 : RESULTS REQUIRED BY BGAS.
Tests subdivided into:
A. Tests on wet materials.
B. Tests on dry materials.
IX. PAINT TESTING

1. Determination of volatile/non-volatile
Procedure:
a. Clean glass plate and rod is weighed.
b. Add 2g of paint, and weigh again.
c. Place into hot air oven (or hot plate).
d. Stir paint to evaporate solvent (volatile).
IX. PAINT TESTING

1. Determination of volatile/non-volatile Organic Compounds (VOC)

Procedure:
i. Clean glass plate and rod is weighed.
ii. Add 2g of paint, and weigh again.
iii. Place into hot air oven (or hot plate).  Below Flash Point of Paint
iv. Stir paint to evaporate solvent (volatile)
IX. PAINT TESTING

2. FLASH POINT
Test carried out in accordance with BS 3900 part A9 using abel cup.
Defined as: the temperature at which vapour from a solvent will ignite in the presence of
an external source of ignition.
High flashpoint is safer than a low flashpoint.
IX. PAINT TESTING
IX. PAINT TESTING

3. The density (Specific Gravity) Cup Defined as being weight per unit of volume, density is
calculated by weighing a known volume of material and using the formula

Pyknometer, SG cup, weight per litre, weight per gallon.

 IX. PAINT TESTING

• DENSITY = Weight / Volume

• Density itu harus ada digit and unit (g/cc)
• Specific gravity / Relative Density : only Digit without unit
• Cara: Campurkan Part A dan Part B tanpa solvent utk yg double pack,
• Timbang SG Cup kosong (100cc), Masukkan Cat yg sdh dicampur ke dalam SG cup dan tutup cup sampai
cat keluar melalui lubang kecil diatas tutup, kemudian timbang lagi.
• Setelah di timbang kurangi dengan berat cup kosong sebelum diisi cat nilai tersebut adalah nilai berat
(weight).
• Untuk mencari density : Weight di kurangi dg Volume cup (100cc) ..
• Latihat soal Page: 10-5
IX. PAINT TESTING

• 4. Hegman grind gauge , For fineness of grind, degree of dispersion

IX. PAINT TESTING

• The Hegman grind gauge, also called a fineness of grind gauge, is used to measure the
degree of dispersion of paint
IX. PAINT TESTING

• 5.Viscosity: (kekentalan)
• Defined as: A fluid’s resistance to flow
• A. Rotational viscometer with rotothinner measures dynamic viscosity. Units = poises
• 1 poise = The force required to maintain unit velocity between 2 surfaces separated by
1cm of fluid.
IX. PAINT TESTING

• 5.Viscosity:
Rotothinner Viscometer
IX. PAINT TESTING

• 5.Viscosity:
• B.Viscosity Krebs Stormer Viscometer
• Kinematic Viscosity
IX. PAINT TESTING

• 5.Viscosity:
• B.Viscosity Krebs Stormer Viscometer
IX. PAINT TESTING

• 5.Viscosity:
• C. Flow Viscosity
• There are various types of flow cups eg Zahn and Frikmar, used for hot fluids,
• Ford, ISO and DIN used for ambient temperature materials
IX. PAINT TESTING

• 5.Viscosity:
• C. Flow Viscosity (Ford Flow Cup No.4) Ford flow cup showing the 4mm hole
IX. PAINT TESTING

• 6. Film Thicknesses:
• A. WFT measurement: Eccentric Wheel.
• Must be used circumferentially on curved surfaces.
IX. PAINT TESTING

• 6. Film Thicknesses:
• B. WFT measurement: Comb Gauges.
• Must be used longitudinally on curved surfaces
IX. PAINT TESTING

• 6. Film Thicknesses:
• B. WFT measurement: Comb Gauges.
IX. PAINT TESTING

• 7. Film Thicknesses:
• C. DFT (Destructive Test Gauges): The PIG (painting Inspection Gauge)
• Turn PIG 90deg. Light comes on -view graticule scale through eyepiece. Tables in
instruction book give conversion factors for each blade, from graticule units into microns
IX. PAINT TESTING

• 7. Film Thicknesses:
• C. DFT (Destructive Test Gauges): The PIG (painting Inspection Gauge)
IX. PAINT TESTING

• 7. Film Thicknesses:
• C. DFT (Destructive Test Gauges): The Saberg test drill Usually using on Brittle paint
IX. PAINT TESTING

• 7. Film Thicknesses:
• D. DFT (Non Destructive Test Gauges): DFT Measurements, Magnetic
• 1. Banana Gauge
IX. PAINT TESTING

• 7. Film Thicknesses:
• Banana gauge measures non-ferromagnetic coatings over ferromagnetic substrates.
• Modern gauges of this type often quote ±5 % accuracy.
• Can Not used for MIO is ferromagnetic coating
IX. PAINT TESTING

• 7. Film Thicknesses:
• D. DFT (Non Destructive Test Gauges): DFT Measurements, Magnetic
• 2. magnetic, horseshoe gauge (used on TSA=Thermal Spray Aluminium).
IX. PAINT TESTING

• 2. magnetic, horseshoe gauge (used on TSA=Thermal Spray Aluminium).

• The magnetic horseshoe gauge is a very old type of gauge still favoured for measuring hot
surfaces such as metal spray. Accuracy often quoted as better than ±10% and as for all
magnetic gauges, it is suitable for use in hazardous areas.
IX. PAINT TESTING

• 7. Film Thicknesses:
• D. DFT (Non Destructive Test Gauges): DFT Measurements, Magnetic
• 3. The Tinsley pencil, Sometimes called a foreman's gauge is suitable for spot checks and is
not very accurate, even on modern gauges of this type ±15 %
IX. PAINT TESTING

• 7. Film Thicknesses:
• E. DFT (Non Destructive Test Gauges), Electronic Gauges
IX. PAINT TESTING

• 7. Film Thicknesses:
• E. DFT (Non Destructive Test Gauges), Electronic Gauges
• The electronic gauges work mainly on two principles: electromagnetic induction and
eddy current.
• Modern electronic gauges are sometimes supplied with probes suitable for both
situations and the gauges automatically change function according to the fitted probe.
• Accuracy ±½%.
IX. PAINT TESTING

• 7. Film Thicknesses:
IX. PAINT TESTING

• 7. Film Thicknesses:
IX. PAINT TESTING

• 8. Tests For Mechanical Properties On Paint:

• A. Abrasion resistance
• Sample plates are weighed, and placed beneath abrasive discs for a number of cycles, then
weighed again to determine abrasion resistance.
IX. PAINT TESTING

• 8. Tests For Mechanical Properties On Paint:

• B. Impact Test: Tubular impact tester.
• 1kg weight dropped 1 meter onto the paint surface of a test panel. Assessed for damage,
direct or indirect.
IX. PAINT TESTING

• 8. Tests For Mechanical Properties On Paint:

• C. Flexibility test: conical mandrel, Test plate bent over 3mm to 37mm diameter mandrel
IX. PAINT TESTING

• D. Accelerated Testing, Weatherometers

• 1. Humidity cabinets: For testing tropical conditions. Humidity is very high at 95% and
elevated temperatures up to 55°C.
• 2. Salt spray cabinets: For checking paint ability to withstand salt laden environments.
• 3. Water soak tests: Allowing painted panels to be submerged to test for water
absorption, by weighing before and after submersion.
IX. PAINT TESTING

• D. Accelerated Testing, Weatherometers

• 4. Temperature cycling: hotter and colder than normal operating temperatures.
• 5. Prohesion testing: (Protective adhesion) 3% salt water spray @ 350c, (60 min on : 60
min off) no undercut, blisters etc. Beyond 3mm boundary, after test duration of 1000
hours.
IX. PAINT TESTING

• E. Drying and Curing

• 4. Ballotini test
• Ballotini, tiny spheres of glass, or sometimes sand is trickled onto a newly painted block
graduated in hour of traverse, eg 24 hours for the block to traverse full length under the
funnel.
• 5. BK drying recorders
• The BK gives more information than the Ballotini, which purely indicates drying time. The
BK defines also the stages of drying
IX. PAINT TESTING

• F. Other test of Paint

• 1. Mechanical thumb test
• This is a test for even through drying of paint. It simulates pressing a thumbonto a surface
and applying a twisting motion
IX. PAINT TESTING

• F. Other test of Paint

• 2. Wolff-Wilborn Pencil Scratch Test
IX. PAINT TESTING

• F. Other test of Paint

• 3. Opacity: The opposite of transparency, a test to determine the ability to hide (cover)
the substrate.
• A. Use Of The Pfund Cryptometer
• -.View through the glass prism.
• -. Record the point where the background can no longer be seen.
• -. This is the opacity thickness.
IX. PAINT TESTING

• 3. Opacity: The opposite of transparency, a test to determine the ability to hide (cover)
• A. Use Of The Pfund Cryptometer
IX. PAINT TESTING

• 2. Opacity: The opposite of transparency, a test to determine the ability to hide (cover)
the substrate.
• B. Hiding Pow\er Charts and Adjustable Applicator
IX. PAINT TESTING

• F. Other test of Paint

• 4. Gloss: Measured with a glossmeter (reflectometer)
IX. PAINT TESTING

• G. ADHESION TEST
• 1. Primer to Substrate Failure

• 2. Cohesive Failure: Fail within layer,

• kegagalan didalam satu layer (Primer, second atau top Coat)
IX. PAINT TESTING

• G. ADHESION TEST
• 3. Adhesive Failure: Between Layer, Kegagalan diantara layer (antara primer dg second,
atau second ke top coat)

• 4. Adhesive Failure
• Kegagalam pada lem atau perekat
IX. PAINT TESTING

• G. ADHESION TEST
• 1.V Cut test: A craft knife is all that is required to perform this test. Cut through the
paint, to the steel substrate, with two cuts forming an inclusive angle of approximately
30°, with leg length of approximately 15 mm.
IX. PAINT TESTING

• G. ADHESION TEST
• 2. CROSS HATCH TEST: CUT 6 LINES VERTICAL AND 6 LINES HORIZONTAL,
CREATING 25 x 2mm SQUARES.
• APPLY AN AGREED TAPE PULL OFF AND COMPARE % AREA OF DETACHMENT AS
PER BS 3900 Pt E6.
IX. PAINT TESTING

• G. ADHESION TEST
• 3. Tests The Dolly Test: Hand Operated Type(with scale of failure force on view)
IX. PAINT TESTING

• G. ADHESION TEST
• 3. Tests The Dolly Test:
• HATE: Hydraulic Adhesion Test Equipment
X. CATHODIC PROTECTION:

 Sacrificial anodes systems.

Impressed current systems.
A. Sacrificial Anode System: This system sometimes called, galvanic anode system, works
on the principle of bimetallic corrosion, the natural potential between metals.
B. Impressed Current: The impressed current system is used to protect long lengths of
pipeline from one installation, a distance of approximately 10 miles. The current needed
to run the system comes from the national grid and is connected through a
transformer rectifier (TR)
X. CATHODIC PROTECTION:
X. CATHODIC PROTECTION:

Sacrificial Anode System

X. CATHODIC PROTECTION:

Monitoring Potentials
XI. CATHODIC DISBONDMENTTEST

For FBE: Fusion Bonded Epoxy

XI. CATHODIC DISBONDMENTTEST

Part of the electrical circuit of the corrosion reaction is the evolvement of hydrogen gas
from the cathode. Hydrogen is a very powerful gas and can cause cracking in steel, (HICC).
If hydrogen gas can penetrate underneath a coating it can easily disbond it. This is known as
cathodic or hydrogen disbondment.
Where disbondment has occurred the coating will chip off as the cuts are being made. The
distance from the edge of the hole to the extent of the disbondment is measured and
should not exceed the stated requirements. For example, FBE maximum 5mm after 28 days
XII. HOLIDAY/PINHOLE DETECTION

Holidays and pinholes in a paint film are defects which allow ingress of an electrolyte and
therefore are detrimental to an anti-corrosion system and need repair.
For coatings of thicknesses above 500 μm it would be necessary to use a high voltage
holiday detector, but for coatings of less than 500 μm it is normal to use a wet sponge
pinhole detector.
The negative terminal is connected to bare steel on the structure to be tested.
The positive terminal is connected to a hand stick with a sponge on the end.
The operating power is provided by two, 1½v batteries in the control box
XII. HOLIDAY/PINHOLE DETECTION

Low Voltage wet sponge: for Thickness paint below 300 micron Range 9 to 90v. (Some have
only 2 settings)
Low Voltage wet sponge intermediate for thickness paint 300 to 500 micron
67.5v. Or 90 Volt Sponge is wetted in water with a drop of detergent
XII. HOLIDAY/PINHOLE DETECTION

High Voltage pin hole detector, For paint thick paint above 500 micron typical high voltage
set for pinhole detection. Operates up to 15kv too high for normal paint systems (BGAS
req 5 Volt per micron)
XII. HOLIDAY/PINHOLE DETECTION

Test springs now not allowed on BGAS projects

XIII. PAINT APPLICATION

Paint technology is advancing rapidly and specialized equipment and materials are being
introduced into the industry on a regular bases. However, conventional paint application
methods still apply. The three main basic methods are:
A. Brush.
B. Air Spray/Conventional Spray.
C. Airless Spray.
D. Electrostatic Spray (FBE)
E. Wire and Pistol (TSA)
XIII. PAINT APPLICATION

A. Brush.
Application by Brush:
1. Environmentally friendly
2. Less Waste than roller
3. Good in Area poor access
4. Slow Application – Un-even DFT
5. Small Area only – Gives good Coverage
(Stripe coat al/ edges, welds, corners, attachment etc. by brush)
XIII. PAINT APPLICATION

B. Air Spray/Conventional Spray.

XIII. PAINT APPLICATION

C. Airless Spray.
XIII. PAINT APPLICATION

C. Airless Spray.
XIII. PAINT APPLICATION

C. Airless Spray.
Reversible Tip: Easy for Cleaning
XIII. PAINT APPLICATION

D. Electrostatic Spray Biasanya digunakan pada applikasi FBE

XIII. PAINT APPLICATION

D. Electrostatic Spray Biasanya digunakan pada applikasi FBE

XIII. PAINT APPLICATION

E. Wire and Pistol (TSA)-Thermal Spray Aluminum

Hot duty surfaces (> 340 0C) (BGC/PS/PA10 PAGE 29 Table SPA 3c)
Requires the highest grade of cleanliness: Profile 75um/Grade sa3 (check for mill scale)
1 Thermally sprayed aluminium.
2 Inorganic zinc silicate.
3 Polysiloxane Inorganic coating.
XIII. PAINT APPLICATION

E. Wire and Pistol (TSA)-Thermal Spray Aluminum

 The preferred system, giving longest life.
 Wire and pistol type (most common).
 High purity wire.
 Butane/propane and oxygen fuel gas.
 Propelled by compressed air onto substrate.
 Thickness approx100 -125 um
For high temperature service silicone sealer must be applied
XIII. PAINT APPLICATION

2 Inorganic zinc silicate.

IZS: Inorganic Zinc Silicate
Alternative to TSA.
Apply as per manufacturers recommendation.
Apply silicone sealer.
Apply heat to cure sealant (turn the system on).
XIII. PAINT APPLICATION

3 Polysiloxane Inorganic coating.

 Alternative to TSA and IZS.
 Will withstand temperatures up to 11000c.
 Apply as per manufacturers recommendation.
 This is not sealed.
XIV. PAINT FAULT

A. Osmotic Blister: Blisters can contain gas, liquid or crystals

Lack of surface preparation/ salt contamination (Salt Water)
Action: Remove Paint, Wash by fresh water kemudian Salt Contamination test, remove all
the paint by dry abrasive
XIV. PAINT FAULT

B. Cracking
1. Mud Cracking
2. Crazing/Hair Cracking
3. Crocodiling / Alligatoring
XIV. PAINT FAULT

B. Cracking
1. Mud Cracking: Over Thickness
Action: Remove All Paint and apply paint with control thickness
2. Crazing/Hair Cracking: differential of expansion,
Action: Spot Blas on Crack area Re Apply paint
XIV. PAINT FAULT

B. Cracking
3. Crocodiling / Alligatoring: Over Service life
Action; Remove paint and Re-paint
XIV. PAINT FAULT

C. Cratering
Caused by escaping solvent or gases
High viscosity paint will not flow to fill the depressions. Resulting in small bowls and craters
Sand down Check DFT and build up.
Prevent: Check Temperature Steel (too High Temp) and check viscosity
 XIV. PAINT FAULT

D. Sagging, Runs, Tears.

Penyebab:
- Low Viscosity or High viscosity
Action Sagging: using same thinner swap with brush
Then sweep blast.
Action Tear: scrapper remove paint, Sandown then Re-paint
Prevent: Control viscosity and Application technic (thicknesss)
 XIV. PAINT FAULT

E. Flaking
As material ages, it gets brittle, cracks and starts to detach.
Oxidising paints are especially vulnerable.
Action: Remove (Re-blast) and repaint
 XIV. PAINT FAULT

F. Holiday:
Defined as : A void, a miss, or an uncoated area
Sandown and apply same paint
If IOZ re-blast spray Zinc Rich epoxy
 XIV. PAINT FAULT

G. Wrinkling – Lifting
Strong Binder and Strong Solvent apply on weak Binder weak solvent.
Action: Re-blast all paint and use or change paint system correct
 XIV. PAINT FAULT

H. Algae and Mould Growth

Remedy: treat with biocidal agent for 24 hours,
then clean with detergent/stiff bristle brush/water washing
 XIV. PAINT FAULT

I. Orange peel
Similar appearance to the skin of a citrus fruit.
Caused by paint viscosity problems or by applicator technique
Pressure paint high than Air pressure
Action: Sandown and re-paint
 XIV. PAINT FAULT

J. Ropiness/ Brush Mark

Caused by brushing when film is almost dry,
or when paint viscosity is too high
remedy: sandown apply paint use good viscosity and use good paint brush
 XIV. PAINT FAULT

K. Wrinkling and Rivelling

Strong Binder and Strong Solvent apply on weak Binder weak solvent.
Action: Re-blast all paint and use or change paint system correct
 XIV. PAINT FAULT

L. Delamination
Wrong application Method,
Pigment particle not settle down uniformly, permukaan di bawahnya
Masih muncul
Remedy: Spot Blast and spray not using paint brush
 XIV. PAINT FAULT

M. Rash or Spot Rusting

Cause: rogue peaks, or possibly by contamination of the paint film by foreign matter, such as grit
or dirt etc.
Remedy: Sandown and Re-apply paint
 XIV. PAINT FAULT

N. Blooming – Blushing
Antifouling and topcoat exposed to High Humidity
 XIV. PAINT FAULT

O. Chalking
Degradation of the binder due to disruptive factors in the environment
Extreme case of epoxy chalking, due to gradation by exposure to sunlight
(minimum and maximum to recoat)
Remedy: Re blast Re paint
 XIV. PAINT FAULT

P. Bleeding Through – yellow vinyl coat

Strong Binder and Strong Solvent apply on weak Binder weak solvent.
Action: Re-blast all paint and use or change paint system correct
 XIV. PAINT FAULT

Q. Inter-Coat Delamination
Too long Recoat: Re blast and repaint
Condensation: scrap check moisture and re blast and re paint.
 XIV. PAINT FAULT

R. PinHole and Solvent popping

 XV. COLOUR

Primary Colour: Red,Yellow Blue

Hue: Refers to the basic colour (red, green, yellow, blue etc.)
Brightness : The darkness or lightness of the colour.
Saturation: How vivid the colour appears (also known as chroma, intensity, weight).
 XV. COLOUR

A. Hue
From 00 (neutral) to 24 even numbers only.
B. Brightness
From A (max white) to E (max black).
C. Saturation
01 to 56 Higher number = stronger colour. Lower number= greyer the colour
XV. COLOUR
XV. COLOUR