STEEL KONNECT (INDIA) PVT. LTD.

SKIPL /QC/P - 06
PROCEDURE MANUAL PAGE : 1 of 7
PROCEDURE FOR SURFACE PREPARATION REVISION : 01
& PAINTING DATE : 03.08.2014

1. PURPOSE
The purpose of this document is to follow proper methodology to carry out the activities in sequence
for surface preparation & painting at SKIPL fabrication yard & also touch – up / repair painting on
damaged portion

2. SCOPE

This Specification covers the surface preparation and coating application requirements for structural
steel fabricated products.

3. REFERANCE DOCUMENTS

The following EN, ASTM, National Association of Corrosion Engineers (NACE) standards, and
Steel Structures Painting Council Surface Preparation (SSPCSP) written Specifications, latest
editions are part of this Specification. SA 2½. "Near White Cleaning"

ASTM D714 Standard Test Method for evaluating degree of blistering of paints.
ASTM D4212 Standard Test Method for viscosity by Dip type viscosity cups.
ASTM D4214 Standard Test Method for evaluating degree of chalking.
ASTM D4285 Standard Test Method for indicating oil or water in compressed air.
ASTM D4414 Standard practice for measurement of wet film thickness.
ASTM D4417 Standard Test Method field measurement of surface profile of blast
cleaned steel
ASTM D4541 Standard Test Method for pull-off strength of coating using portable
adhesion testers.
ASTM D5162 Standard practice for discontinuity (holiday0 testing of non conductive
protective coating on metallic substrates.
ASTM E337 Standard test method for measuring humidity with a Pyrometer (the
measurement of Wet & Dry bulb Temp.
ISO 8501-1 Rust grades & preparation grades of uncoated steel substrates & of
steel substrates after overall removal of previous coating.
ISO 8502-3 Test for the assessment of surface cleanness.

4. GENERAL

4.1 Manufacturer's Data Sheets

Directions on manufacturer's data sheets shall be followed for application and mixing. The
Contractor shall have copies of data sheets available at the site where the coating work is being
performed. Inspection requirements are defined in Company’s specification.

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 STEEL KONNECT (INDIA) PVT. LTD. SKIPL /QC/P - 06
PROCEDURE MANUAL PAGE : 2 of 7
PROCEDURE FOR SURFACE PREPARATION REVISION : 01
& PAINTING DATE : 03.08.2014

Engineer QC Head QA&C Management Representative

4.2 Mixing of Coatings of Different Manufacturers Color.

All coats of a multicoated system shall use materials from a single manufacturer color

5.0 COATING APPLICATION

5.1 General Application Requirements

Surfaces to be coated shall be clean, dust-free, and dry before application of any coating and shall
meet applicable abrasive blasting surface preparation requirements before priming.
The specified coating system primer shall be applied within 4 hours from the time that surfaces are
cleaned and before rusting, discoloration, or surface contamination occurs. Coatings shall be applied
under the environmental conditions shown in the coating manufacturer’s data sheets.
Ambient conditions may have an effect on the abrasive blasting process as well as on the blast
cleaned surface before painting. Ambient conditions include:
• Air temperature (and substrate temperature)
• Relative humidity
• Dew point temperature
• Environmental exposure
Air Temperature
It is unwise to abrasive blast if the steel surface is much colder than the surrounding air. Moisture
may condense on the blasted surface causing the surface to flash rust. The substrate temperature may
be checked using steel surface thermometer.
Relative Humidity
When blast cleaning, high humidity (moisture) can result in the rapid deterioration of the cleaned
surface. Final dry abrasive blasting should not be performed in wet or damp conditions (i.e., when
raining or when the relative humidity is very high—generally greater than 90%).

Relative humidity (RH) is defined as the amount of moisture (water vapour) in air, compared with
the maximum possible in the air (i.e., saturation level). If RH reaches 100%, then the air will not
support any more water vapour and a surplus would appear as condensation.
For that reason, most coating specifications require that coating not be carried out if RH exceeds a
certain limit, usually 85 or 90%. In addition, if air is saturated with water vapour, the evaporation of
solvents is inhibited, causing problems with coating film formation.

No coating shall be applied:

• On wet surfaces,
• When the relative humidity exceeds the manufacturers written recommendations, or 85%, which
ever is less.
• When the surface temperature is less than 5°F above the dew point,
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PROCEDURE FOR SURFACE PREPARATION REVISION : 01
& PAINTING DATE : 03.08.2014

• When the ambient or surface temperatures are below the manufacturers recommended temperature
for application and curing, coating materials shall be furnished in the manufacturer's
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Engineer QC Head QA&C Management Representative

unopened containers, clearly identifiable, and shall be kept covered, clean and protected. Materials
older than manufacturer’s recommended shelf life shall not be used.
All components shall be thoroughly mixed as per recommendations noted in the manufacturer’s data
sheets. All mixing shall be done in clean containers, free from traces of grease, other paints or
contaminants. Containers shall be kept covered to prevent contamination by dust, dirt or stain. Paint
shall be mechanically mixed in full batches. Partial mixes are not acceptable.
The coating manufacturer's recommended pot life shall not be exceeded. When this limit is reached,
the spray pot shall be emptied and cleaned, and new material mixed.
Care shall be exercised to prevent overspray, spillage or application of coatings to surfaces for which
they are not intended. Skips, sags, and drips are to be repaired.
The number of coats to be applied shall never be fewer than the number of coats required by this
Specification and the Technical Requirements and shall have individual coat dry film thicknesses not
less than the minimum thickness specified. Wet film thicknesses are to be verified at the start of
work (until the painter is familiar with the paint and work) with a wet film thickness gauge.
Thickness requirements shall be met with each coat and total thickness shall not be "made-up" in any
one coat.
All coating film thicknesses shall be free of defects such as runs, sags, pinholes, voids and bubbles.
All coatings shall be allowed to dry for at least the minimum time recommended by the paint
manufacturer, considering temperature and humidity, before applying succeeding coats.

Maximum overcoat time shall be limited to manufacturer’s recommendations.

5.2 Spray Application.

Contractor's applicators shall be skilled in the proper application technique for each coating. Proper
equipment, per the coating manufacturer's data sheets, shall be used.
Applicators or equipment failing to meet this requirement, to the Company's or the coating
manufacturer's satisfaction shall be removed from coating application.
Spray guns, lines, and pressure pots shall be cleaned prior to adding new material. The air caps,
nozzles and needles shall be those recommended by the coating manufacturer for the material being
sprayed.
Moisture traps or separators shall be installed between the air supply and the pressure Pot. The drain
valve must be kept open slightly to permit continuous draining of any condensate during operations.
Operating pressures shall comply with the recommendation of the coating manufacturer.
All pressure pots shall be equipped with pressure regulators and gauges.
Paint shall be applied in a uniform layer, with 50% overlapping of the previous pass.
During application, the spray gun shall be held perpendicular to the surface being painted.
 STEEL KONNECT (INDIA) PVT. LTD. SKIPL /QC/P - 06
PROCEDURE MANUAL PAGE : 4 of 7
PROCEDURE FOR SURFACE PREPARATION REVISION : 01
& PAINTING DATE : 03.08.2014

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Engineer QC Head QA&C Management Representative

INSPECTION
The Contractor shall perform all inspection necessary to ensure that surface preparation and coating
application complies with the requirements of this specification.

5.3 Compressed air

The cleanliness of compressed air shall be checked, as necessary, by blasting without sand or paint
onto a white cloth for 20 seconds. If oil or water appears on the cloth, all traps and separators shall
be blown down until subsequent 20-second cloth tests show no further oil or water.

5.4 The Company may request test. Abrasive Material

Abrasive material shall be tested as necessary to ensure it is free of contamination and will not
promote corrosion of the metal surface. The inspection procedure and acceptance criteria shall be as
follows:
• Place abrasive material (a teaspoon full) into a small vial of distilled water, shake vigorously, and
allow settling for one minute.
• The top of the water shall not contain a layer of grease/oil or fine particulates.
• The water shall not be discoloured.
• The pH of the water shall not be less than 5 as measured with pH indicating paper.
• The water shall be free of a white precipitate (an indication of chloride salts) when a drop of 5%
silver nitrate is added to the water.
• Test results shall be documented.

5.5 Environmental Conditions

The following shall be checked and recorded at the beginning of each day's operation and several
times during the application process:
• Ambient temperature
• Relative humidity
• Dew point
• Moisture-free surface
• Temperature of the surface to be coated
These recordings shall be compared with criteria stated, If any criteria is exceeded, coating shall not
be applied.
 STEEL KONNECT (INDIA) PVT. LTD. SKIPL /QC/P - 06
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PROCEDURE FOR SURFACE PREPARATION REVISION : 01
& PAINTING DATE : 03.08.2014

5.6 Surface Preparation (including Touch-Up Preparation)

Immediately prior to priming, blasted surfaces shall be inspected by the following methods to verify
that the specified surface preparation has been achieved:
• The anchor pattern shall be verified using Testex Inc. "Press-O-Film" tape coating Application or
Profile measuring instrument.

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Engineer QC Head QA&C Management Representative

Dry film thicknesses shall be measured using an Elcometer. The dry film thickness gauge shall be
calibrated to the Company's satisfaction at the beginning of coating work and thereafter, regularly
and whenever the Company requests recalibration. Calibration shall be made by comparison with the
dry film thickness measured on known standards such as a micrometer-measured paint film or
National Bureau of Standards Calibration coating Inspection Record for each coat as work proceeds
as well as for the total thickness of each finished coating system.
All areas found to contain runs; overspray, pinholes, sags and/or other signs of improper application
shall be repaired in accordance with the manufacturer's recommendations.

6.0 STEEL SURFACE TREATMENT

1. Welded areas shall be checked to verify any defects that may affect the protection quality of
coating paint.
2. Sharp edges shall be grinded to be round, smooth. Other imperfect weld or slag shall be treated by
grinding machine or sand paper.
3. Non continuous welding line shall be filled again by welding.

7.0 SURFACE PREPARATION

1. Thoroughly remove oil and grease out of the surface using solvent or other proper methods.
2. Thoroughly remove all "evidence" of salt and contaminants.
3. Sand blast to achieve standard SA 2.5 (surface is free from oil, grease and other contaminants)
4. Remove all the remaining during blasting by brush, pressed air or vacuum cleaner. Avoid re-
contamination caused by clothes or hand touching.
5. Sand blasting shall be taken from one area to another, so that cleaned areas must be rust
preventive and painted immediately before getting rust again. Surface ready for painting must be
completely clean. No oxidized or contaminated is visible.
6. Surface temperature is at least 3 degrees above the dew point to avoid water condensing. (Dew
point is depended on surface temperature and humidity)
7. Areas that cannot reach with blasting nozzle or less important can be mechanically treated with
grinding machine
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PROCEDURE FOR SURFACE PREPARATION REVISION : 01
& PAINTING DATE : 03.08.2014

8.0 INSPECTION & EVALUATION FOR STEEL SURFACE PREPARATION

8.1. Oil and grease check

Oil and grease check shall be carried out a 2-3 locations per square meter and in 40-50% out of
prepared area, as following:
Drip some drops of gasoline onto checked area. Wait for 10-15 seconds then adsorb the remaining
gasoline with a piece of filter paper. Drip some other drops of gasoline onto another piece of filter
paper. Wait and check the two dry stains on paper by naked eyes. If two colors look the same the
surface is accepted as free from oil and grease.

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Engineer QC Head QA&C Management Representative

8.2. Dust check

Dust check shall be carried out on whole prepared surface. Use a magnifier with 6 times
magnification to survey. No visible dust is okay.

8.3. Cleanness check

Dust check shall be naked eyes or a magnifier according to cleanness levels. It also can be checked
by comparing to standard images in ISO 801-1:1998
Another method of checking: Before surface preparation, take a sample that meets the cleanness of
requirements. Cover the sample with transparent coating. Use the sample as standard for control.
Fast check: Cleanness check can be quickly conducted by wiping the surface with white dry clean
cotton. If the cotton becomes dirty, the surface is not clean. If the cotton becomes wet, the surface is
either still wet or not free from oil.

9.0 Rectification of Low DFT and Poor Blasting

1.) Surface Preparation shall be done manual by using Emery Paper / Wiremesh Grinder where
ever Require.

2.) Where ever less DFT Observed Final Paint shall be applied directly to achieve Require DFT as
per following method.

 Where Low DFT observed in area less then 0.25 M² paint shall be applied Manual by Brush /
Roller and above 0.25M² area spray gun shall be use.

Final DFT will be check after as per supplier Paint Data sheet time.

After fulfill of Requirement Re-offer to TPI / Client for Inspection.

 STEEL KONNECT (INDIA) PVT. LTD. SKIPL /QC/P - 06
PROCEDURE MANUAL PAGE : 7 of 7
PROCEDURE FOR SURFACE PREPARATION REVISION : 01
& PAINTING DATE : 03.08.2014

Prepared By Reviewed By Approved By

Engineer QC Head QA&C Management Representative