Painting
Today LEARNERS , Tomorrow LEADERS
Prepared by
K.Sivakumar
CORROSION
WHAT IS CORROSION
CORROSION IS DESTRUCTION OR
DETERIORATION OF A MATERIAL
USUALLY A METAL,BECAUSE OF ITS
REACTION WITH ENVIRONMENT TO
WHICH IT IS EXPOSED
CORROSION IS ALSO CALLED
AN ELECTROCHEMICAL
PROCESS AS IT INVOLVES
FLOW OF ELECTRONS
THROUGH A CONDUCTIVE
PATH
CONTROLOF CORROSION
CORROSION CAN BE
CONTROLLED IF A BARRIER
LAYER IS CREATED OVER
THE METALLIC SURFACE
ACTIVEMETALS
THE METAL WHICH ABSORBS MORE
ENERGY CORRODE EASILY AND
FAST.
THEY ARE CALLED ACTIVE
METALS
Passive Metals
METALS LIKE
GOLD,SILVER,COPPER ABSORB
LESS ENERGY. THEY DO NOT
UNDERGO CORROSION EASILY
THEY ARE CALLED PASSIVE OR
NOBLE METALS
COMMON
METALS
ENERGY
REQUIRED
MOST
ACTIVITY
MOST
Least
Least
Magnesium
Zinc
Aluminum
Mild Steel
Cast Iron
Copper
Stainless
Steel
Silver
Gold
Platinum
ACME
For any corrosion to take place following four
elements are required to be present
1.Anode
2.Cathode
3.Metallic path
4.Electrolyte
If any of the members in ACME is missing
corrosion will not take place.
CLASSES OF
CORROSION
Two broad classes of corrosion
General corrosion
Localized corrosion
LOCALIZED CORROSION
General corrosion is uniform corrosion of metals
and results in uniform loss of material
Localized corrosion
Localized corrosion happens at discrete areas.
Adjacent area of corrosion attack will be free from
corrosion.
Difficult to inspect and CAUSE huge losses.
Localized corrosion is grouped into two classes.
PITTING
PITTING CORROSION
IF ANODE AND CATHODE REMAIN IN SAME AREA
FOR SOMETIME , CORROSION WILL BE
LOCALIZED LEADING TO PITTING CORROSION .
PITS ARE FORMED CAN ACCELERATE
CORROSION INCREASING THE RATE OF ATTACK
AND CAN PERFORATE THE SURFACE.
IF IT GOES UNNOTICED IT WILL FAIL LEADING TO
CATASTROPHIC LOSSES.
PITTINGS
CREVICE CORROSION
CREVICE CORROSION HAPPEN
1)WHEN METAL SURFACE IS SHIELDED
FROM FULL EXPOSURE FROM
ATMOSPHERE BECAUSE OF CLOSE
PROXIMITY OF ANOTHER
MATERIALFORMING A NARROW GAP
BETWEEN THEM
2)DIFFERENCE IN CONCENTRATION OF
OXYGEN or electrolyte between inside and
outside of the metal.
RATE OF CORROSION
Factors influencing rate of
corrosion
Oxygen
Temperature
Chemical salts
Humidity
Pollutants and Acidic gases
EFFECTS
Effects of corrosion
One fourth of steel produced is
wasted due to corrosion
Corrosion leads to catastrophic
failure of equipment /plant
Great threat to human life
Corrosion in food industry cannot be
tolerated as it cause health hazards
CORROSION CONTROL
Some of the approaches to control
corrosion
Selection of materials to suit the
environment
Design of Equipment
Good fabrication / construction of material
proper heat treatment welding etc.,
Modification of environment
Creation of barrier layer by protective
coatings.
. Proper Storage.
SURFACE PREPARATION
It plays vital role as it governs the
service life of a painting system
80% premature coating failures are
caused by improper surface preparation.
Important factors of surface preparation
of any surface
Shall be clean
Shall be rough
TYPES OF SURFACE
PREPARATION
A ) Non Abrasive cleaning
Solvent cleaning
Hand tool cleaning
Power tool cleaning
Flame cleaning
Pickling
B)Abrasive Blast Cleaning
Compressed air drives abrasives
through a nozzle to surface which is to
be blast cleaned.
Abrasives used are sand, steel grit, steel
shot, mineral slags, agricultural
products, dry ice, plastic beads, etc.
This can be done manually or machine
operated.
SURFACE PREPARATION STANDARDS - COMPARISION CHART
SURFACE
PREPARATIONS
STANDARDS
NACE
SSPC
ISO 8501-1
NON ABRASIVE
BLAST CLEANING
--
SOLVENT
CLEANING
--
SSPC SP 1
HAND TOOL
CLEANING
--
SSPC SP 2
St 2 Or St 3
POWER TOOL
CLEANING
--
SSPC SP 3
St 2 Or St 3
POWER TOOL
CLEANING TO
BASE METAL
--
SSPC SP 11
PICKLING
--
SSPC SP 8
SSPC SP 12
WATER CLEANING NACE 5
STANDARDS
SURFACE PREPARATION STANDARDS COMPARISION CHART
ABRASIVE BLAST
CLEANING
NACE
SSPC
ISO 8501-1
WHITE METAL
NACE NO 1
SSPC SP 5
SA 3
NEAR WHITE
METAL
NACE NO 2 SSPC SP 10
COMMERCIAL
NACE NO 3
SSPC SP 6
SA 2
BRUSH OFF
NACE NO 4
SSPC SP 7
SA 1
SA 2
STANDARDS
SURFACE PREPARATION STANDARDS COMPARISION CHART
CLEANING
NACE
SSPC
WHITE METAL
NACE
SSPC SP 5
NO 1
NEAR WHITE
METAL
NACE
NO 2
COMMERCIAL
NACE
SSPC SP 6
NO 3
SSPC SP
10
IS0
PERCENTAG PERCENTAG
E OF
E OF RUST
CLEANING ALLOWED
PERCENTAG
E OF
STAINS
ALLOWED
100%
100%
5%
100%
33%
DUTIES OF AN INSPECTOR
DUTIES OF AN INSPECTOR GOING FOR A SURFACE
PREPARATION CHECK.
Go thro the specification & documents
Note down the requirements like profile required, abrasive
suggested, level of cleaning, allowed RH%
TC for abrasive used
Calibration of instruments
Do blotter test or review the blotter test result as per
requirement
Ensure the fabrication clearance
BLOTTER TEST
What is blotter test?
Blotter test is conducted to verify the
cleanliness of compressed air
How to conduct blotter test
Expose a sheet of white paper (with
support) at a distance of one meter
for one minute to the air flow from the
compressed air supply
Result: There should be NO visible oil
stains, traces of water on the white paper.
RELATIVE HUMIDITY
WHAT IS RELATIVE HUMIDITY? (RH)
Relative Humidity is the ratio of moisture in the air
to the maximum moisture air can hold.
RH =
100
Moisture in the air
-------------------------------------------
Maximum moisture air can hold.
Painting should not be done when RH is more than
85%
RELATIVE HUMIDITY
Why RH to be checked
If RH is high ,moisture can condense on the coating that
affects the subsequent coats
If the RH is too low it slows the curing process
Why temperature of the substrate (steel temperature) to be
checked
1)solvent evaporates too fast resulting in dry spray
2)Pot life (maximum time paint can be kept idle after
mixing) will be reduced
3)Decreases the viscosity of the paint
Dry Bulb
Wet
Bulb
MEASURING RH
How to use sling psychometer/whirl hygrometer
Ensure the socks in wet bulb is wet (or) fill water in the
container
Whirl the instrument in the wind direction for 15 to 20
times
Note the wet bulb temperature
Repeat the above two steps
If the temperature stabilizes note down the same as WBT
Then note down the DBT
Using the chart find the RH/DPT
Measuring surface profile
What are we measuring?
Maximum peak-to-valley depth
Peak density
Surface texture generated by
abrasive impingement or some
power tools
Why is it important?
Anchors the coating system in place
Insufficient profile depth could result in poor coating
adhesion
Too much profile depth could cause pinpoint rusting
Research indicates increased peak density improves
coating adhesion and performance
Surface profile must be compatible with the entire
coating system
DIGITAL PROFILE CHECKING GAUGE
DIGITAL PROFILE CHECKING GAUGE II
Note: This Gauge is used to check the profile of the
Blasted Surface. Not to be used for Checking
Painting coating Thickness.
Ensure completeness of blasting
Do complete visual inspection
Ensure the cleaning level using
comparator
Measure the profile
Measure the RH%
Measure the steel temperature
Ensure the availability of primer paint
NOTE: Surface preparation inspection shall be given
priority since painting to be done within 4 hours
from blasting completion.
DIGITAL PSYCHROMETER
DEW POINT
TEMPERATURE(DPT)
What is dew point temperature (DPT)?
The temperature at which moisture condenses .
Why DPT to be checked?
To find the difference between DPT and Steel
temperature
Steel temperature should be at least 3 c
above the DPT.
Surface Thermometer
It is an instrument used to
measure the temperature of the
surface which is to be painted
TYPES
Magnetic type thermometer
Digital type thermometer
NON CONTACT INFRA RED
SURFACE TEMPERATURE
GAUGE
MAGNETIC TYPE SURFACE
TEMPERATURE GAUGE
MAGNETIC THERMOMETER
How to use Magnetic surface
thermometer
Keep it on steel surface and allow
it to stabilize for Two minutes.
Then Note down the reading
(Note: DO NOT lift up while taking the
reading)
BEFORE PAINTING
What to be ensured before painting and after
surface preparation?
Check the paint drum for
specification
shelf life
Any damage
Ensure the paint is mixed (if multiple pack
system)
as per manufactured data sheet
Ensure POT life
Ensure mechanical agitator are used ( Not to
be agitated by wooden log or steel rod)
