AS 1627.

0 1997

Australian Standard

Metal finishing Preparation and

pretreatment of surfaces

Part 0: Method selection guide

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 This Australian Standard was prepared by Committee MT/9, Metal Finishing. It
was approved on behalf of the Council of Standards Australia on 1 September 1997
and published on 5 December 1997.

The following interests are represented on Committee MT/9:

Australasian Institute of Metal Finishing
Australian Chamber of Commerce and Industry
Department of Defence (Australia)
Institute of Metals and Materials Australasia
Metal Trades Industry Association of Australia
Royal Australian Chemical Institute
Society of Automotive Engineers Australasia
Telstra Corporation
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Review of Australian Standards. To keep abreast of progress in industry, Australi an Standards are
subject to periodic review and are kept up to date by the issue of amendments or new editions as
necessary. It is important therefore that Standards users ensure that they are in possession of the latest
editi on, and any amendments thereto.
Full detail s of all Australian Standards and related publications will be found in the Standards Australi a
Catalogue of Publi cations; this information is supplemented each month by the magazine The
Australian Standard, which subscribing members receive, and which gives details of new publications,
new editions and amendments, and of withdrawn Standards.
Suggestions for improvements to Australian Standards, addressed to the head office of Standards
Australia, are welcomed. Noti fication of any inaccuracy or ambiguity found in an Australian Standard
should be made wit hout delay in order that the matter may be investigated and appropriate action taken.

This Standard was issued in draft form for comment as DR 96514.

 AS 1627.0 1997

Australian Standard

Metal finishingPreparation and

pretreatment of surfaces

Part 0: Method selection guide

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Originated as AS 1627.0 1977.

Second edition 1997.

PUBLISHED BY STANDARDS AUSTRALIA

(STANDARDS ASSOCIATION OF AUSTRALIA)
1 THE CRESCENT, HOMEBUSH, NSW 2140
ISBN 0 7337 1464 1
 AS 1627.0 1997 2

PREFACE

This Standard was prepared by the Joint Standards Australia/Standards New Zealand
Committee MT/9, Metal Finishing, to supersede AS 1627.0 1977, Metal finishing
Preparation and pretreatment of surfaces, Method 0: Method selection guide for
preparation and pretreatment of steel surfaces.
This Standard is the result of a consensus among Australian and New Zealand
representatives on the Joint Committee to produce it as an Australian Standard.
This Standard is the first part of a series of Standards titled Metal finishing Preparation
and pretreatment of surfaces, and the objective of this revision is to upgrade the guidance
given on the selection and application of the appropriate methods of surface preparation
of metallic materials prior to the application of a protective coating. Other parts in the
series are as follows:
AS
1627.1 Part 1:Cleaning using liquid solvents and alkaline solutions
1627.2 Part 2:Power tool cleaning
1627.3 Part 3:Flame descaling
1627.4 Part 4:Abrasive blast cleaning
1627.5 Part 5:Pickling, descaling and oxide removal
1627.6 Part 6:Chemical conversion treatment of metals
1627.7 Part 7:Hand tool cleaning of metal surfaces
1627.9 Part 9:Pictorial surface preparation standards for painting steel surfaces
(ISO 8501-1:1988)
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1627.10 Part 10: Cleaning and preparation of metal surfaces using acid solutions (non-
immersion)
The Standard covering wash primer pretreatment of metal surfaces (formerly AS 1627.8
which has been withdrawn) is AS 3884 1991, Etch primers (single pack and two-pack)
for pretreating metal surfaces.
In this edition, the appendix which gave examples of surface preparation specifications
has been deleted. Advice on the preparation of coating specifications is given in
AS/NZS 23121994, Guide to the protection of iron and steel against exterior
atmospheric corrosion.

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Care should be taken to ensure that materi al used is fr om the current editi on of the Standard and that it is updated whenever the
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The use of materi al in pri nt form or in computer soft ware programs to be used commercially, with or wit hout payment, or in
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 3 AS 1627.0 1997

CONTENTS
Page

1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 REFERENCED DOCUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 THE PURPOSE OF SURFACE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . 5
4 SCOPE OF STANDARDS IN THE AS 1627 SERIES . . . . . . . . . . . . . . . . . . . 9
5 SPECIFYING SURFACE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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 AS 1627.0 1997 4

STANDARDS AUSTRALIA

Australian Standard
Metal finishingPreparation and pretreatment of surfaces

Part 0: Method selection guide

1 SCOPE This Standard gives guidance on the selection of the appropriate methods for
the preparation and pretreatment of metal surfaces prior to the application of a protective
coating. The methods and the related Australian Standards are as follows:
(a) Solvent and alkaline cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AS 1627.1
(b) Power tool cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AS 1627.2
(c) Flame descaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AS 1627.3
(d) Abrasive blast cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AS 1627.4
(e) Pickling and descaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AS 1627.5
(f) Chemical conversion treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AS 1627.6
(g) Hand tool cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AS 1627.7
(h) Treatment with acid solutions (non-immersion) . . . . . . . . . . . . . . . . . AS 1627.10
The Standard also makes reference to AS 1627.9, which gives pictorial guidance on
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surface finishes of steel after various treatments.

The AS 1627 series of Standards apply primarily to surfaces intended to be painted,
powder coated, metal sprayed or hot dipped in molten metal. For requirements for surface
preparation prior to the application of electroplated coatings refer to ASTM B 183,
ASTM B 242, ASTM B 252, ASTM B 253 and ASTM B 254.
NOTE: Before any of these surface preparation methods are applied to a metal surface, it is
important that, where necessary, prior dressing be carried out to remove any gross defects
present on the surface (see Clause 3.2).

2 REFERENCED DOCUMENTS The following documents are referred to in this

Standard:
AS
1627 Metal finishing Preparation and pretreatment of surfaces
1627.1 Part 1: Cleaning using liquid solvents and alkaline solutions
1627.2 Part 2: Power tool cleaning
1627.3 Part 3: Flame descaling
1627.4 Part 4: Abrasive blast cleaning
1627.5 Part 5: Pickling, descaling and oxide removal
1627.6 Part 6: Chemical conversion treatment of metals
1627.7 Part 7: Hand tool cleaning of metal surfaces
1627.9 Part 9: Pictorial surface preparation standards for painting steel surfaces
(ISO 8501-1:1988)
1627.10 Part 10: Cleaning and preparation of metal surfaces using acid solutions
(non-immersion)
3894 Site testing of protective coatings
3894.1 Method 1: Non-conductive coatings Continuity testing High voltage
(brush) method

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 5 AS 1627.0 1997

AS/NZS
2312 Guide to the protection of iron and steel against exterior atmospheric corrosion
ASTM
B 183 Practice for preparation of low-carbon steel for electroplating
B 242 Practice for preparation of high-carbon steel for electroplating
B 252 Guide for preparation of zinc alloy die castings for electroplating and
conversion coatings
B 253 Guide for preparation of aluminium alloys for electroplating
B 254 Practice for preparation of and electroplating on stainless steel
D 610 Test method for evaluating degree of rusting on painted steel surfaces
ISO
8501 Preparation of steel substrates before application of paints and related products
Visual assessment of surface cleanliness
8501-1 Part 1: Rust grades and preparation grades of uncoated steel substrates and of
steel substrates after overall removal of previous coatings
Supplement to Part 1: Representative photographic examples of the change of
appearance imparted to steel when blast-cleaned with different abrasives
8501-2 Part 2: Preparation grades of previously coated steel substrates after localized
removal of previous coatings.
SSPC
SSPC-VIS 1-89 Visual standard for abrasive blast cleaned steel
SSPC-VIS 3 Visual standard for power- and hand-tool cleaned steel

3 THE PURPOSE OF SURFACE PREPARATION

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3.1 General The life of a coating is dependent to a considerable extent on the surface
preparation of the substrate metal. The primary purpose of any method of surface
preparation is to produce a surface that is clean and free of any material which may cause
premature failure of the coating. Oil and grease are detrimental to the adhesion of all
coatings and should be removed as completely as is practicable.
The surface preparation for painting should satisfactorily remove any deleterious matter to
enable the priming paint to wet the surface sufficiently to develop adequate adhesion.
Contaminants that promote corrosion, such as chloride salts, sulfate salts, certain metallic
ions, perspiration and moisture, should be completely removed.
Whilst rust and rust scale are particularly detrimental to the performance of any coating,
mill scale is erratic in its effect on the performance of paints. Tightly adhered or intact
mill scale can often be tolerated under paint for mild atmospheric exposure; however, mill
scale should always be removed prior to painting for exposure in severe industrial, marine
or immersion environments, or where primers of low wetting properties are to be used.
3.2 Initial surface condition The amount of work, time and money required to achieve
any degree of surface preparation will depend upon the initial condition of the surface to
be cleaned.
Before commencing any surface finishing process, all gross surface defects including
laminations, deep pitting, saw and guillotine cuts, burrs present on both sides of drilled
holes or cut shapes, sharp edges, undercut areas and gouge marks should be ground flush
or radiused. All welds should have spatter, slag and remnants of welding wire removed
and should be ground to a smooth radius, with no porosity, holes, dags, hooks or
protrusions visible. Oxycut surfaces should be adequately dressed.
If such defects are not removed or ground smooth, it cannot be expected that surface
preparation treatments such as pickling or abrasive blast cleaning will rectify the surface,
as in many cases these treatments will only brighten the surface of the defects, leaving
them more visible. If a prepared surface is to be painted and the paint film is required to

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 AS 1627.0 1997 6

be tested for pinholes, holidays, cracks and other discontinuities by the high voltage
(brush) method, the presence of any defects referred to in this Clause will interfere with
the test (see AS 3894.1).
In many cases, it is necessary to take into consideration the amount of rust, old coatings,
contamination and pitting present on the surface. Although there are a large number of
initial conditions, they can be divided, for convenience, into eight main surface condition
grades, and arranged in two groups as follows:
(a) New constructions :
(i) Grade A Steel surface covered completely with adherent mill scale with
little, if any, rust.
(ii) Grade B Steel surface which has begun to rust, and from which the mill
scale has begun to flake.
(iii) Grade C Steel surface from which most of the mill scale has rusted away or
from which it can be scraped, but with little pitting visible to the naked eye.
(iv) Grade D Steel surface where the mill scale has rusted away and where
pitting is visible to the naked eye.
NOTE: These descriptions are those given in AS 1627.9 (see Clause 4.9).
(b) Painted constructions :
(i) Grade E Paint top-coat almost intact; some primer may show; rust covers
less than 0.1% of the surface.
(ii) Grade F Paint top-coat somewhat weathered; the primer may be visible and
slight staining or blistering may be present. After stains are wiped off, less
than 1% of area shows rust, blistering, loose mill scale, or loose paint film.
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(iii) Grade G Paint severely weathered, blistered or stained; up to 10% of the

surface is covered with rust, rust blisters, hard scale or loose paint film; very
little pitting visible to the naked eye.
(iv) Grade H Large portion of surface is covered with rust, pits, rust nodules
and non-adherent paint; pitting is visible.
The four grades in Group (b) represent the equivalent surfaces of painted steel
encountered in maintenance painting of existing structures. The maximum amount of rust
present in Grades E, F, G and H increases in geometric progression; each rust percentage
being 10 times that of the preceding grade, i.e. 0.1%, 1%, 10% and 100% respectively as
upper limits.
When estimating rust percentages, schematic diagrams of the type shown in Figure 1 can
serve as practical aids. The illustration shows squares with the black circular dots
representing various area percentages. This diagram is not intended to reproduce the
appearance of actual rust patterns but merely to act as a guide in judging the percentage
of a surface covered by rust (after removal of stains) or rust blisters.
NOTE: The pictorial representations illustrated in Figure 1 are similar to those given in
ASTM D 610.
3.3 Considerations for the selection of a surface preparation process In general,
factors such as severity of environment, the need for maximum life without maintenance,
and the selection of a sophisticated coating, require the best possible surface preparation.
In order to achieve maximum value for the expenditure planned, all factors require
consideration. The use of specialized coating types over poor surface preparation is rarely
successful.
In general, coatings required for highly corrosive environments require a higher standard
of substrate surface preparation than is needed for coatings that are to be used in a mild
environment.

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 7 AS 1627.0 1997
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FIGURE 1 SCHEMATIC DIAGRAMMATIC EXAMPLES FOR

ESTIMATING RUST PERCENTAGES

Higher standards of surface preparation generally lead to a longer life for any given
protective system in any given environment. However, the benefits, if any, of longer life
should always be evaluated against the additional cost of the surface preparation, which
can be high. As an example, a coating over a wire-brushed surface containing mill scale
and rust would fail prematurely if subjected to the severe exposure conditions that would
occur at a jetty structure. The additional cost of blast cleaning would be recovered in a
short time because of the resultant increased service life. However, if the steel is to be
used in an enclosed, ventilated building, the additional life to be gained from better
surface preparation may well be beyond the estimated life of the building, and no value
would be obtained from the additional cost of a high standard of surface preparation.
Table 1 gives examples of suitable preparation methods and compatible priming coats for
steel surfaces subject to a range of industrial and atmospheric environments.
NOTE: Recommendations for surface preparation treatments for a wide range of paint and metal
coating systems, and recommendations for the preparation of paint coating specifications, are
given in AS/NZS 2312.

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 AS 1627.0 1997 8

TABLE 1
COMPATIBILITY OF SURFACE PREPARATION WITH FIRST COATS
Compatible priming coats (see Notes 1 and 2)
Typical exposure environment Surface preparation method Inorganic Organic Epoxy High-build Epoxy mastic Chlorinated Alkyd
zinc zinc primer epoxy (see Note 3) rubber primer
Chemical fumes and splash Abrasive blast AS 1627.4 Class 21/ 2 or 3 S S S S S S NR
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Watersalt and fresh (See Note 4) Abrasive blast AS 1627.4 Class 2 / 2 or 3

1
S S S S S NR NR
Water immersion and splash Abrasive blast AS 1627.4 Class 2 NR NR NR NR S NR NR
Abrasive blast AS 1627.4 Class 2 / 2 or 3
1
S S S S S S NR
Abrasive blast AS 1627.4 Class 2
Severe marine, marine, industrial
Power tool clean AS 1627.2 Class 2 NR NR NR NR S NR NR
Pickle AS 1627.5
Abrasive blast AS 1627.4 Class 21/ 2 or 3 S S S S S S S
Tropical Abrasive blast AS 1627.4 Class 2 NR NR S NR S NR S
Power tool clean AS 1627.2 Class 1 or 2 NR NR NR NR S NR S
Abrasive blast AS 1627.4 Class 21/ 2 S S S S S S S
Abrasive blast AS 1627.4 Class 2 NR NR S S S NR S
Moderate
Power tool clean AS 1627.2 Class 1 or 2
Pickle AS 1627.5 NR NR S S S NR S

Abrasive blast AS 1627.4 Class 2 NR S S S S S S

Pickle AS 1627.5 NR NR S S S S S
Mild
Power tool clean AS 1627.2 Class 1
NR NR S S S NR S
Hand tool clean AS 1627.7 Class 1
NOTES:
1 S = suitable, NR = not recommended.
2 These priming coats are examples of many options available. Not all of these coats may be suitable for a given environment. Full details of coating systems and advice on
alternative materials should be obtained from coating manufacturers or consultants before their use.
3 Also known as surface tolerant epoxy mastic (Paint Reference No. 32 see AS/NZS 2312). Some aluminium-pigmented products may be unsuitable for surfaces subjected
to chemical fumes and splash. The coating manufacturer should be consulted on suitability for service.
4 For fresh water service, the higher grade of surface preparation (Class 3) is normally recommended. Coatings for use with potable water require the approval of the
purchaser.

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 9 AS 1627.0 1997

4 SCOPE OF STANDARDS IN THE AS 1627 SERIES

4.1 General Clauses 4.2 to 4.10 summarize the contents of all parts of the AS 1627
series of Standards (see Clause 1) and advise on the selection of precleaning and surface
preparation processes.
4.2 Part 1: Cleaning using liquid solvents and alkaline solutions This Standard
describes procedures for cleaning metal surfaces of loosely adhering matter, oil, grease,
wax, dirt and perspiration, by treatment with liquid solvents and alkaline solutions. These
procedures are not suitable for the removal of rust, rust scale or mill scale but may be
used to degrease surfaces prior to the use of other mechanical methods such as power tool
cleaning or abrasive blasting.
The Standard categorizes processes as follows:
(a) Alkaline processes Alkaline processes are suitable for the removal of dirt, light
deposits of oil and water-wettable or water-soluble contaminants. The following
techniques are suitable for the application of alkaline solutions:
(i) Hand rubbing or scrubbing.
(ii) Mechanical agitation.
(iii) Boiling.
(iv) Power spraying.
(v) Electrolytic cleaning.
(vi) Ultrasonic agitation.
(b) Solvent processes Solvent processes are used for the removal of oil, grease, wax,
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dirt, perspiration and other solvent-soluble contaminants. They include liquid

solvent cleaning and solvent vapour cleaning (vapour degreasing).
(c) Emulsion processes Oils and high flash-point hydrocarbons can dissolve most
greases, particularly at high temperatures. The addition of emulsifiers, soaps and
wetting agents to hydrocarbon solutions enhances their penetrating power and
permits the removal of such contaminants and associated soil, by power flushing.
(d) High-pressure cleaning processes The impingement of a high pressure stream of
hot or cold water admixed with a suitable alkaline detergent, combines mechanical
displacement with alkaline cleaning. Tables in the Standard give guidance on the
applicability of typical cleaning processes and advice on the methods of application
of these processes.
4.3 Part 2: Power-tool cleaning This Standard sets out procedures and equipment
recommended for the removal of visible rust, mill scale, corrosion products and loose or
flaky paint, by the use of power driven tools. It covers equipment including power impact
tools, power grinders, power sanders and power wire brushes.
Power-tool cleaning is usually employed where the nature of the work does not demand
the removal of all mill scale, rust and other corrosion products from steel and is
particularly suitable where, for reasons of size and location of structures, limitations exist
on the use of other methods of surface preparation.
Prior to the application of power-tool cleaning, oil, grease and any salts are first removed
using processes specified in AS 1627.1. It is advisable to remove heavy rust scale by
hammering or scraping prior to using power tools.
The Standard classifies the degree of surface preparation into classes which relate to those
specified in AS 1627.9. It gives advice on the use of various power-tool methods
applicable to both ferrous and non-ferrous metals.

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 AS 1627.0 1997 10

Care is necessary when using power tools. Excessive roughening of the surface should be
avoided, because ridges and burrs with sharp edges may not be protected by a proper
thickness of paint film. Excessive wire brushing may create a smooth burnished surface to
which paint will not adhere. Excessive use of needle guns may burr over the edges of
corrosion pits, entrapping the corrosion products; subsequently, early failure of the paint
system is most likely.
Power-tool cleaning is more effective than hand tool cleaning and provides a better
foundation for paint.
4.4 Part 3: Flame descaling This Standard sets out procedures for flame cleaning and
descaling of steel surfaces to remove loose rust and paint. It includes flame cleaning
methods for new, unpainted and previously painted steel surfaces.
Descriptions are given of the cleaning head and gases as well as the method of use. Flame
cleaning is a method of surface preparation that is suitable for use in shops or locations
where it is impossible to blast clean, but where a method of surface preparation
marginally better than hand or power-tool cleaning is desired.
At best, flame cleaning of steel produces results somewhere between that of power wire
brushing and Class 2 blast cleaning. Flame cleaning removes only part of the mill scale.
To be fully effective, the flame traverse should be followed by very thorough wire
brushing, removal of loose debris, and priming while the steel is still warm. Tests on
flame-cleaned steel, which has been allowed to cool and stand prior to priming, have
shown it to give results little or no better than power wire-brushed steel.
Very thin steel sections should not be flame cleaned because they may buckle with the
heat.
4.5 Part 4: Abrasive blast cleaning This Standard sets out methods and procedures
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for the abrasive blast cleaning of metal surfaces and defines the various levels of
preparation of such surfaces.
Abrasive blast cleaning is the most effective process for preparing a surface prior to
painting and is usually used where long-term protection is required. Anchor patterns are
produced by abrasive particles propelled with high force onto the steel surface in either
the wet or dry condition. Such processes use a wide variety of blasting media, either
applied by a closed recirculating system or by open blasting.
All surfaces should be cleaned free of oil and grease before abrasive blast cleaning.
The choice of the blasting medium is important and needs to be considered in conjunction
with the protective system. The Standard gives examples of metallic and non-metallic
blast-cleaning abrasives.
Angular abrasives predominantly cut the surface, whereas rounded abrasives shot-peen the
surface. The use of rounded abrasives for some coating systems may not be satisfactory
because they result in a lesser degree of keying for the coating.
Relatively soft abrasives are preferred for the abrasive blast cleaning of zinc or aluminium
coatings.
A pictorial representation of four different rust grades on steel is given in AS 1627.9. The
nature of these rust grades is as follows:
(a) Grade A A grade A steel surface is covered completely with adherent mill scale
and little, if any, rust.
(b) Grade B A grade B steel surface has begun to rust and the mill scale has begun to
flake.
(c) Grade C A grade C steel surface has the mill scale either rusted away or is
removable by scraping; little pitting is visible to the naked eye.
(d) Grade D A grade D steel surface has the mill scale rusted away and has
considerable pitting visible to the naked eye.

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These four grades may be blast cleaned to any one of the following four classes, as
follows:
(i) Class 1 Class 1 is light blast cleaning, which removes loose mill scale, rust and
foreign matter.
(ii) Class 2 Class 2 is medium blast cleaning (sometimes called commercial or
thorough blast cleaning), which substantially removes mill scale, rust and foreign
matter particles such that grey metal is visible.
(iii) Class 21/2 Class 21/2 is near white blast cleaning, which removes mill scale, rust
and foreign particles to the extent that only traces remain in the form of spots or
stripes, and the cleaned surface shows varying shades of grey.
(iv) Class 3 Class 3 is white metal blast cleaning, by which visible mill scale, rust
and foreign particles are entirely removed and the cleaned surface has a uniform
metallic colour, but may show varying shades of grey when viewed from different
angles.
It is important to ensure that the profile height of the blasted surface is within the range
to suit the protective system to be applied, as it significantly affects both the adhesive
characteristics of the painting system and the dry film thickness required.
Wet abrasive blast cleaning is recommended for the effective removal of soluble salts, as
traces of these salts may remain on the surface even after dry blast cleaning to Class 3
standard.
Blast cleaning is essential as a pretreatment for sprayed metal coatings.
Caution must be exercised when blast cleaning thin sections, since damage by warping or
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excessive peening of the surface may occur.

Blast-cleaned surfaces are very reactive and begin to rust in a very short time, especially
after wet blasting. If a corrosion inhibitor is required for water used in the wet blasting
process, it should be selected after consultation with the paint manufacturer.
Blast-cleaned surfaces should be coated as soon as possible after treatment, before any
contamination has taken place.
NOTES:
1 Open-air abrasive blasting may not be permitted in some built-up areas. References should
be made to appropriate regulatory authorities.
2 Where extensive grinding has followed abrasive blast cleaning, it is necessary to reblast
these dressed areas to remove all rust.
The Standard gives information to assist in the choice of a blast cleaning method and on
the effect of abrasive size on surface roughness.
4.6 Part 5: Pickling, descaling and oxide removal This Standard gives details of
pickling and descaling procedures for ferrous metals and cleaning and oxide removal
procedures for non-ferrous metals and alloys.
Pickling is used for the complete removal of scale, metallic oxides or other contaminants
from metal surfaces, prior to the application of a suitable protective coating. It is used as
an alternative to mechanical methods such as abrasive blast cleaning.
The surface produced by pickling is generally smooth and contains a film of re-oxidized
iron or iron phosphate (where phosphoric acid is used). This surface may not be suitable
for the application of some coatings, e.g. inorganic zinc and high-build epoxy coatings, or
for metal spray coatings. The use of corrosion inhibitors in rinse solutions, to prevent
early rusting of a pickled surface, may also cause incompatibility with subsequent
coatings. Coating manufacturers or suppliers should be consulted before the application of
coating systems to pickled surfaces is carried out.

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 AS 1627.0 1997 12

The two most common acids used for pickling are sulfuric acid and hydrochloric acid.
With increasing enforcement of anti-pollution regulations, the popularity of the cheaper
sulfuric acid is declining, as hydrochloric acid is more easily recovered in acid
regeneration plants and hence is favoured for continuous pickling installations.
Hydrochloric acid is also more practicable for batch pickling, because the high heat of
reaction reduces the amount of external heating necessary. It also dissolves scale faster
than sulfuric acid. Acid fuming, often cited as a major deterrent to hydrochloric acid
pickling, can be effectively controlled by adhering to correct operating procedures. Other
acids, such as phosphoric, nitric, hydrofluoric, citric and sulfamic, are used for special
purposes. An inhibitor should always be used with any acid to prevent excessive attack on
the base metal during pickling. Special finishing precautions, including fresh water
rinsing, are necessary to remove residues of unreacted acid. Final rinses containing dilute
phosphoric or chromic acid are often used to temporarily passivate the pickled surface.
Pickled steel, like blast-cleaned steel, should be painted as soon as possible after cleaning
and drying.
In the design of fabricated steel, special consideration should be given to the elimination
of pockets or crevices, which can trap acid during pickling. Attention is drawn to an
appendix in which the dangers of pickling high tensile steels are pointed out.
Where production is sufficiently high to keep the equipment in use, pickling results in
low-cost shop preparation. Pickling is impractical for field use.
Pickling of large fabricated members or large structural beams is limited by the size of
tanks available.
4.7 Part 6: Chemical conversion treatment of metals This Standard specifies
requirements and procedures for the chemical conversion treatment of metals prior to the
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application of a suitable organic protective coating and includes the following processes:
(a) Phosphate conversion of ferrous and non-ferrous metals Phosphate conversion
coatings are produced by treatment with solutions containing the appropriate
dihydrogen orthophosphates. These coatings are applied principally to ferrous
materials, aluminium, zinc and cadmium. The coating mass per unit area and the
apparent density are dependent on
(i) the base material and its surface condition;
(ii) the previous mechanical and chemical treatment of the base material; and
(iii) the processing conditions for phosphating.
All phosphate conversion coatings are porous to some degree, but can be
substantially sealed by appropriate after-treatment. They consist essentially of metal
phosphates with fine to large interlocking crystals chemically bonded to the steel
surface. This interlocking crystal arrangement provides the key for good paint
adhesion. The Standard specifies five classes of phosphate coating for ferrous
metals, as follows:
(A) Class A1 Heavyweight.
(B) Class A2 Heavyweight (rapid processing).
(C) Class B Mediumweight.
(D) Class C Lightweight.
(E) Class D Extra lightweight.
The process can only be carried out in the manufacturers plant and is usually used
on items supplied in a fully finished condition. Phosphate-coated work should be
inhibited and painted within 24 h of treatment.

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Phosphate conversion coatings are not suitable for use under every type of paint.
The paint manufacturer should be consulted to ensure that treated surfaces are
compatible with the proposed protective system.
(b) Chromate conversion of aluminium and aluminium alloys Chromate conversion
coatings are applied to aluminium and aluminium alloys to retard corrosion, as a
base for organic films including paints, plastics and adhesives, and as a protective
coating having a low electrical contact impedance.
4.8 Part 7: Hand tool cleaning of metal surfaces This Standard describes procedures
and equipment for the preparation of metal surfaces by the use of hand tools. Preparation
is carried out in three stages, as follows:
(a) Preliminary cleaning and descaling including chipping and scraping.
(b) Hand-tool cleaning.
(c) Final cleaning for the removal of loose material and dust.
Hand-tool cleaning involves the use of wire brushes, hand sanding, hand scraping,
chipping or hammering, either singly or in combination. This type of cleaning is suitable
for the removal of loosely adherent rust, mill scale and degraded paint coatings.
Hand-tool cleaning can be an acceptable method of surface preparation for mild interior
and exterior atmospheric exposures, and for many maintenance situations where paints
with good wetting properties are used. Hand-tool cleaning is the least effective method of
surface preparation for durability of paint coatings and should only be considered where
the more effective methods are not warranted or cannot be used. It is a labour intensive
method, which is slow and physically arduous.
It will not remove all residues of rust or other corrosion products, nor will it remove
firmly adherent mill scale. Oil, grease and similar foreign matter, and soluble fluxes and
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fume deposits from welding should be removed before hand-tool cleaning is carried out.
All hand tools should be used in such a way as to prevent sharp cuts, burrs or sharp edges
forming on the surface. If such defects occur, they will need to be removed by hand
sanding or with tungsten carbide-tipped scrapers. Excessive wire brushing should be
avoided as it may burnish a steel surface to an extent that it prevents good paint adhesion.
4.9 Part 9: Pictorial surface preparation standards for painting steel surfaces
(ISO 8501-1) This ISO Standard has been endorsed without amendment. Using colour
photographs, the Standard describes four grades of rust for steel surfaces, and a number of
preparation grades achievable when preparing a surface by either blast cleaning, hand and
power-tool cleaning, or flame cleaning methods.
The Standard also sets out a procedure for carrying out a visual assessment of steel
substrates.
The standard colour photographs are pictorial representations of the cleanliness of four
rust grades of hot-rolled structural steel surfaces (A, B, C and D).
The photographs include two degrees of thoroughness of hand and power tool-cleaning for
three rust grades, four degrees of blast cleaning and one degree of flame cleaning for each
of the four rust grades.
These visual standards are used to specify the required degree of surface pretreatment.
The user is cautioned, however, that these or any other visual standards should be
considered a supplement to, and not a substitute for, surface preparation specifications.
NOTE: Other Standards with pictorial representations include the Supplement to ISO 8501-1,
and ISO 8501-2.
In addition, the Steel Structures Painting Council (SSPC) has published the following two
related Standards:
(a) SSPC-VIS 1-89, Visual standard for abrasive blast cleaned steel.
(b) SSPC-VIS 3, Visual standard for power- and hand-tool cleaned steel.
These Standards are available from KTA-Tator Australia, 136 Lord Street, Richmond,
Vic. 3121.

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4.10 Part 10: Cleaning and preparation of metal surfaces using acid solutions (non-
immersion) This Standard sets out methods for the removal of light oxides and soil
from metal surfaces by brushing or swabbing with acid solutions, prior to chemical
conversion or the application of paint. The methods apply where immersion and abrasion
methods are impracticable.
They apply particularly to aluminium and zinc and their alloys, but may also find
application with copper, iron and steel. The Standard gives specific procedures for the
cleaning and oxide removal from:
(a) Aluminium and aluminium alloys.
(b) Zinc and zinc alloys.
(c) Copper.
(d) Iron and steel.
These procedures are not suitable for direct application to heavy oxide and soil deposits,
the removal of which may require prior degreasing using solvent or alkaline solutions or
mechanical cleaning.
All solutions should be applied and removed as directed by the manufacturer, under
favourable atmospheric conditions.
The quality of wash water requires monitoring to ensure that cleaned surfaces are not left
contaminated after washing to remove acid residues.
A check to ensure that no smut (see AS 1627.5) is present after acid treatment is an
important part of the cleaning process. The presence of any smut will cause problems with
adhesion.
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5 SPECIFYING SURFACE PREPARATION A specification defining the method of

surface preparation should include the following information:
(a) Method to be used.
(b) Degree of cleaning required.
(c) Surface profile height required (blast cleaning only) and method of measurement.
(d) Type of abrasive to be used (blast cleaning only).
(e) Type and concentration of inhibitor (wet blasting and pickling).
(f) Treatments required for welds and steel defects.
(g) Requirements for the prior removal of grease and oil.
(h) Reference to the appropriate Part of AS 1627.
(i) Maximum delay allowed before coating application.
(j) Special requirements for particular site and weather conditions.
The surface preparation specification should be followed by the painting specification and
care should be taken to ensure compatibility between the prepared surface and the paint
system.

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