BS 5493 Protective Coating PDF

E S 1 BS*SLI73 7 7 m lb2Llbb7 O l b 0 5 3 0 B m
BS 5493 :1977
UDC 624.014.2 :691.71 : 620.197.6
Code of practice for

Protective coatingof iron and I
steel structures against corrosion

(Formerly CP 2008)
Code de bonne pratique pour I'enduisage des

constructions-enfer et en acier
pour la protection contre la corrosion
Richtlinie für Beschichtung von Eisen-und Stahlbauten zum

Schutz gegen Korrosion
British Standards Institution

COPYRIGHT British Standards Institute on ERC Specs and Standards
Licensed by Information Handling Services
BSI B S * 5 q 7 3 77 Lb24bb7 Olb053L T m
BS 5493 : 1977
Contents
Page Page
Foreword 2 12.1.6 Handling, stacking and repair 41
Code drafting committee coverBack 12.2 Zinc-rich paints 41
12.3 Drying-oil-type paints 41
Sectionone.General 12.4 One-pack chemical-resistant paints 41
1. Scope 3 12.5 Two-pack chemical-resistant paints 41
2. References 3 12.6 Bituminous coatings 41
3. Use of the code 3 12.6.1 General 41
3.1 General 3 12.6.2 Coal tar pitches and bitumens 41
3.2 Use by the experienced specifier 3 12.6.3 Asphaltic coatings 42
3.3 Use by the non-technical specifier 3 12.6.4 Application of coal tar pitches and
3.4 Specification requirements 3 asphalts 42
12.6.5 Overcoating 42
Sectiontwo.Factorsinfluencing the choice of ' 13. Characteristics of some other protective systems 42
protective systems 13.1 Powdercoatings 42
4. General 4 13.2 Grease paints 42
4.1 Recognition of the problem 4 13.3 Wrapping tapes and sleeves 42
4.2 Questions related to design, use and site 13.3.1 Petroleum-jelly tapes 42
requirements 4 13.3.2 Synthetic resin or.plastic tapes 42
4.3 Questions relating to coating systems 5 13.3.3 Coal tar and bitumen tapes 43
5. Environment 6 13.3.4 Two-pack taping 43
5.1 Classification of types 6 13.3.5 Wlastic sleeves 43
5.2 Identification of relevant types 6 13.4 Prbtection of steel by cement and allied
6. Life required of coating 6 products 43
6.1 Definition 6 13.5 Cathodic protection 43
6.2 Categories 6 14. Surfacepreparation 43
6.2.1 Life to first maintenance 6 14.1 General 43
6.2.2 Life between subsequent maintenances 6 14.2 Degreasing 43
6.3 Assessment of life requirement 6 14.3 Removal of scale and rust 43
7. Design of the structure 6 14.3.1 Blast-cleaning 43
8. Fabrication 8 14.3.2 Acid-ljicklilig 47
8.1 General 8 14.3.3 Flame-cleaning 47
8.2 Faying surfaces of friction-grip joints 8 14.3.4 Manualcleaning 47
8.3 Fasteners 8 14.4 Attention to detail 47
8.4 Procedure for welds 8
9. Facilities for application of coatings 8 Section three. Specifications and technical
10. Classification and charac,teristicsof protective requirements
coatings 9 15. Introduction 48
10.1 Classification 9 15.1 The scope of this section 48
10.2 Characteristic advantages of metal and 15.2 The need for specifications 48
paint coatings 39 15.3 The prime function of a'Specification 48
10.3 Other coatings 39 15.4 Responsibilities in preparing a
10.4 Application facilities :39 Specification 48
10.5 Effects of delays during application 39 15.5 The communicative value of a
10.6 Costs 39 Specification 48
II. Characteristics of metallic coatings 39 15.6 Schedules 49
11.1 Zinc coatings (other than zinc-rich paints) 39 15.7 Details 49
11.1.1 General 39 15.8 Definition and allocation of
1 1 .I .2 Galvanizing 39 responsibilities 49
1 1 .I .3 Sherardizing 40 16. Surfacepreparation 50
1 1 .I .4 Electroplating 40 16.1 Degreasing 50
1 1.2 Sprayed-metal coatings 40 16.2 Removal of rust and scale 50
11.2.1 General 40 16.2.1 Blast-cleaning 50
1 1.2.2 Sprayed-metal-plus-sealer systems 40 16.2.2 Acid-pickling 50
1 1.3 Metal-plus-paintsystems 40 16.2.3 Flame-cleaning 50
1 1.3.1 General 40 16.2.4 Manualcleaning 51
11.3.2 Zinc coatings plus paint 40 17. Coating system 51
12. Characteristics of paint systems (including 18. Stripe coats 51
metallic zinc-rich paints) 40 19. Control of thickness of paint coating 51
12.1 General 40 20. Control of thickness of metal coating 52
12.1 .I Binders 40 20.1 Galvanizing 52
12.1.2 Pigments 41 20.2 Sprayed metal 52
12.1.3 High-build coatings 41
12.1.4 Compatibility 41
12.1.5 Solvents 41

BS 5493 : 1977
Page Page
21. 32.3 Defects resulting from inferior
21.1 Availability 52 preparation,
materials or workmanship 60
21.2 Control of materials 52 32.4 degradation
Early of coatings 60
e 21.2.1 32.5
remedial
Other measures 60
52 21.2.2 Testing 33. Specifications for maintenance
coatings 60
21.3 Preparation for use 52 Factors33.1 for consideration
60
22. Application of protective coatings 52 33.2 Compatibility of maintenance with
22.1 52 original system 60
52 22.2 Painting 33.3 Location of different treatments 60
22.2.1 Brush-painting 52 33.4 Coating schedule 60
22.2.2 Spray-painting 60 53 34. -Final check
methods Other 22.2.3 53
Surface 22.2.4 finish 53 Section four. Inspection
22'2.5 Paint application procedure trials 53 35. Introduction 61
22.2.6 Other general requirements of a painting 36. Duties of the Inspector 61
Specification Levels53 37. 61of inspection
Galvanizing
22.3 and metal-spraying
53 38.61Inspection schedule
ng 22.4 39. Inspection and
record reports 61
sealantsand Mastics 22.5 54 40. Inspection
62 organization
23. Working conditions 54Measurement
41. film of thickness
62
23.1 available Methods 41.1 62
mperature 23.2 62 Procedures 41.2
23.3 Humidity 62 54 41.3 Calculations
23.4 External conditions 54
Sampling 42. 63 of materials
23.5 Contamination of prepared surfaces 6343. Inspection guide
wet and film 56
Shop 23.6 conditions 56 Section five. Maintenance
23.7 Lighting need 56 The 44. for maintenance
72
23.8 Hot conditions 56 45. Basic considerationsof maintenance
23.9safety
Health and 56 procedure
24.
Handling, transport, storageand erection 56 46.
Factors affecting decisions on maintenance 72
24.1 Selection of coating systems 56 46.1 Condition72 of coatings
Methods
24.2 of preventing damage
56 46.2 Variability of deterioration according
Storage
24.3 of coated
steelwork
57 to location 72
24.4 Responsibilitiesfor preventing damage 57 Factors
46.3 affecting deterioration 72
25. Treatments
72 for connections andGeneral
other special 46.3.1
areas 46.3.2 Effects
57 of design on rates of deterioration 72
General 25.1 requirements 57 46.3.3 Effects of environment on rates of
25.2 Bolts 57 deterioration 73
25.3Surfaces of connections joined by bolts 58 46.4 Type useand of structure 73
25.3.1 Non-friction-grip bolted connections 58 47. Factors affecting choice of procedure 73
25.3.2 Faying surfaces of structural 47.1 Environment 73
connections joined by high-strength Constraints
47.2 on site 73
friction-grip bolts 73 58 48. Organization
Welded 25.4 work 73 58 48.1 Labour
Clearance25.5 for
58coatings 48.2 Inspection 73
26. Manhole and joint cover plates, pipe couplings 48.3 Conduct of work on site 73
59 anditems
other small Choice
49. of maintenance method 73
surfaces
bearing
Machined
and27. Choice59 50. 74
of procedures
28. Steel in contact with other materials 59 Surface 51. preparation 74
74 28.1
59 Coating system General 51.1
28.2 Steel embedded in concrete 59 51.2 Factors appropriate t o use of different
28.3 Steel in contact with timber 59 methods on site 74
28.4 Steel in contact with other metals 59 51.2.1 Blast-cleaning with or without the
28.5 Steel in contact with or near rain-washed 74 addition of water
concrete 74 Flame-cleaning 51.2.2 59
28.6 Steel near to surfaces subject to treatment Powered 51.2.3 tools 75
(de-icing)
with road salts 59Hand-operated
51.2.4 tools 75
Surfaces
29.
inaccessible on completion 59 52. Application 75
30. Ancillary equipment Standards
59 53. of75
preparation
Use 31. 59 of desiccants Standards 54. of application 75
Remedial 32.75 work General 60 54.1
32.1 60 54.2 Brushing 75
32.2 Defects resulting from unsatisfactory 54.3 Roller-coating 75
application Spray
60 54.4 application 75
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B S I BS*5493 77 m 1 6 2 4 6 6 90 1 6 0 5 3 3 3 m
BS 5493 : 1977
Page Page
55. Recommendations for coatings 75 Tables
55.1
General 75 Environments
1. special
and situations 7
55.2 Previously painted steelwork 75 2. Principal
types of coating systems 9
55.3 Previously metal-coated steelwork with 3. Recommendations for protective coating
or without additional coating 75 systems forenvironments
specific
10
4. Typicalcoating systems and theircomponents24
Section six. Safety and health 5. Methods of blast-cleaning
45
56. Legislation 78 6. Classification of abrasivesused for cleaning steel 46
56.1 Health and Safety a t Work etc. Act 1974 78 7. Common types
mastics
of and
sealants
55
56.2 Factories Act 1961 78 64 8. Inspection guide
56.3 The Control of Pollution Act 1974 78 9. Treatment of previouslypainted
steelwork
76
57. Operational hazards 78 IO. Site treatment of previously metal-coated steelwork 77
57.1
General 78 11. The effect of atmospheric pollution on
57.2 Hazards to structure and surroundings 79 corrosion
57.3Risk of injury 79 12. Comparison of paint performance with the
57.3.1
Eyesight 79 corrosion
rate of bare steel 80
57.3.2Hearing 79 13. Suggested layout of a cost-calculation table
95
57.3.3 Respiratorysystem 79
58.Generalhygiene 79 Figures
1. Typical lives of zinc coatings in selected
Appendices environments 23
A. General principles of corrosion and i t s control 80 2. Corrosionpoints 83
B. Characteristics of paint binders 90 3. Crevices 84
C. Characteristics of paint pigments 92 4. Air circulation e.g. pipeline support 85
D. Sampling of paint 94 5.
Drainage 85
E. Choosing the most economical defence against 6. Protection of a stanchion a t ground level 86
corrosion 94 7. Corrosion a t gap in surrounding concrete 87
F. Methods for control of preparation (by blast- 8.Design for coating 88
cleaning) 96 9.Access for maintenance 88
G. Test for detecting soluble rust-producingsalts 1O. Shop coating costsrelative to thickness of steel 95
remaining on blast-cleanedsteel 96 11, Assessment of steel cleaning 96
H, Example of use of the code 97
J. Referencesand bihliography 1O0 Index 101
Foreword
This code of practice was originally published, under the assistance to users where coatings or materials do not
number CP 2008, in 1966; in accordance with BSI policy comply with the relevant British Standards. Although some
whereby codes of practice are now published in the general compositional requirementsof the coating materialsare
series of British Standards, this revision is published as included, these are not sufficiently detailed to provide
BS 5493. The code was originally drawn up to assist those more than a general indication of the characteristics of
responsible for the choice or application of measures to the coatings, and are not intended to be used as standards.
protect iron and steel from corrosion. The treatments suggested represent the minimum
Since that time developments have taken place in both the acceptable standard of good practice for important steel
methods and processes concernedwith the protection of structures, In some buildings and structures of less
steel from corrosion, and this new edition has been importance lower standards of protection may be
prepared to take account of these changes. acceptable but the reduction of initial costs will generally
The total content of the code has been reduced, the format result in higher maintenance costs. Where steelwork is
has been revised, and much of the explanatory matter that fully encased, e.g. in concrete, the standard of protection
appeared in the original code has been omitted but essential will generally be lower than that recommended here.
background information hasbeen included in the Protective processes are constantly being developed and
appendices. The section on cathodic protection has been improved, the recommendationsin the code cannot,
omitted entirely following the publication of CP 1021. therefore, be final and are not intended to discourage
Sections on specifications and inspectionhave been the use of other measures and materials where they can
included andthis reflects the importance attachedto these be shown to be equivalent to or better than those
matters as a means of achieving thefull potential of recommended here.
protective coatings in practice.
A new feature of this code is the inclusion of reference
numbers for complete protective systems and also for
their component parts. This should be of particular
2
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BSI BS85L193 77 W LbZ4bb9 03b0534 5

BS 5493 : 1977
Section one
British Standard Code of practice for

Protective coating of iron and
steel structures against corrosion
Sectionone.General of table 3) and on rare occasions this minimum reference
may suffice for a specification, but inmost cases it would
1. Scope leave a very wide choice of components and combinations
This code classifies recommended methods of protection to be selected. It would therefore usually be wiser to select
against corrosion of iron and steel structures exposed to more exactly (from the relevant part of table 4) the
environments commonly encountered. It describes the products to be used and t o ensure that they are agreed by
various methods in detail and gives guidance on how to all parties concerned(see note following table 4F, part 4).
specify a chosen protective system, how to ensure i t s Although the correct selection of a protective system and
correct application, and how it should be maintained. the correct specification of materials and methods are both
The code does not include specific recommendationsfor essential, they do not, by themselves, ensure the adequate,
ships, vehicles, offshore platforms, specialized chemical performance of the chosen system. The recommendations
equipment, or cladding materials;nor does it include given in sections four, five and six are equally important
detailed recommendationsfor plastics coatings or to the full realization of a successful corrosion protection
cement-mortar linings. scheme.
For steel of 5 mm thickness or less the recommendations 3.2 Use by the experienced specifier. A specifier who is
of DD 24 may be preferred. experienced in the technology of protection against
For some situations, weathering steel may be an alternative corrosion will need little guidance on how to find the
to ordinary structural steel with applied coatings. information required in the code. Nevertheless, thelist of
No detailed recommendationson the use of weathering questions given in clause 4 may be a useful guide.
steels are given in this code and when their use is con: Attention s
i drawn especially to section three because it is
templated. advice should be sought from the steel industry. very important that decisions and requirements in a
The titles of the other standards publications referred to (a) To distinguish between the problems that do and
in this code are listed on the inside back cover. do not have simple solutions.
Bibliographical references are listed in appendix J. (b) To consider factors (see clause 4) that will provide
evidence of the advantage of one type of system over
3. Use of the code
another for specific requirements.
3.1 General. The most frequent use of this code is likely
(c) To check that a protective system or specification
to be made when choosing and specifying a protective
offered by a supplier fulfils the requirementsof the code.
system for a new or proposed structure. For such a use
the basic procedures are as follows. (d) To select, in accordance with 3.1 (a) and (b) above,
a number of systems that meet the assessed environ-
(a) Identify the environment with the help of table 1.
mental conditions and the life requirements andthen
(b) Decide on the life requirement and select suitable to use clauses 1 O to 13 to narrow the choice before
systems (from the relevant part of table 3). seeking quotations.
(c) Compare these systems (with the assistance of the Attention is drawn to the step-by-step approachin
detailed information in table 4) and select the appendix H.
preferred system.
The non-technical specifiermay find inthe code some
(d) Define the system as completely as possible using unfamiliar terminology. Most of the technical termsused
table 4 and specify with the assistance of section three. are defined in BS 201 5.
These four fundamental procedures may be subdivided 3.4 Specification requirements. Attention is drawn
into more precise steps according to: particularly to clause 15 covering theneed to specify,
(1) the severity of the environment, i t s local fully and coherently, all the required operations. The lives
variations and any special Conditions; to firstmaintenance indicated in table 3 will be achieved
only by ensuring that the materials conform to the
(2) the size and nature of the structural contract; and
specification and that the application, handling and
(3) the experience and technical expertise of the user inspection procedures given in sections three and four
of the code (see 3.2 and 3.3). are followed. Nevertheless, the details given in this code
The code allocates key reference letters to the principal (or in any standard) are often insufficient t o set a quality
groups of protective systems (see tables 2 and 3). Some standard and whena specifier finds this to be the case he
users of the code may be tempted. to specify a protective should require the suppliersof coatings and other materials
system by quoting only the system reference (third column to provide appropriate performance data.
3
BSI B S * 5 4 7 3
BS 5493 : 1977
Section two
Section two. Factors influencing the choice of another, and between one proprietary material and
protective systems another within an individual system.
Costs may vary considerably even for the same coating
4. General system, and great careis necessary to ensure that
4.1 Recognition of the problem. The design of structures quotations for apparently identical products or services
is based largely on data and functional requirements which do in fact cover the same materials or application with
can be quantified. On the other hand the selectionof a the same degree of consistency and control. Appendix E
protective system involves qualitative judgement on the deals with the overall economicassessment of costs.
relative importanceof many factors that can vary wide!y Some of the critical conditions and circumstancesthat
according to the type of structure, i t s function, its general have to be taken into account before selectinga protective
location, its immediate environment, andany changes system are listed below in question form. Not every
(natural or otherwise) that may occur in its environment. question will be relevant for a particular application and
There are other factors affecting the selection (suchas the importance of each relevant question may vary.
required life to firstmaintenance, thickness of coatings, The order of relevant questions may have to be changed
etc,) which may appear to be quantitative, but should be because some answers might be modified in the light of
viewed with caution, because in practice, the degree of answers to later questions. The list should therefore be
variation may differ between one coating system and studied as a whole before the questions are considered
in detail.
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4.2 Questions related t o design, use and site requirements Sources of information
4.2.1 Function
(a) What is the main function of the structure?
Design remit
(b) What are the secondary functions of the structure?
4.2.2 Life
(a) For how long is it required to fulfilthis function? Design remit
(b) What is the life to firstmaintenance? (It may not be.possible to Design remit, clauses 6 and 7,table 3
decide this until further questions have been answered.)
4.2.3 Environment
(a) What is the general (atmospheric) environment a t the site of the Considerations of use and geography,
structure? clause 5, table 1
(b) What localized effectsexist or are to be expected Table 1
(e.g. fumes from chimneys)?
(c) What other factors may affect the structure Table 1
(e.g. surface temperature and abrasion)?
4.2.4 Appearance
(a) What is the structure required to look like (colour and finish)? Design remit
(b) Is the final coat to be applied on site? Depends on coating system selected,
24.1 and consideration of (a) above
4.2.5 Special properties
(a) What special properties are required of the coating Design remit, clauses 7 and 8
(e.g. coefficient of friction)?
4.2.6 Maintenance
(a) What access is there going to be for effective maintenance? Consider design remit and site, 47.2
(b) What is the possibility of effective maintenance? and A.3.6.6.
4.2.7 Health and safety
(a) Are any problems to be taken into account during initial treatment?
.(b) Are any problems to be taken into account during maintenance Section six. Consider design andsite
treatment?
4.2.8 Tolerance
Does the coating need to be tolerant of:
(a) indifferent surface preparation Clauses 9 and 17
(b) indifferent application techniques Discretion and experience
(c) departures from specification? Clause 17, discretion and experience
4
BS 5493 : 1977
Section two
4.3 Questions relating t o coating systems Source of information

4.3.1 Coating systems
(a) What coating systems are suitable? Clauses 10, 11, 12 and 24.1
(b) Are these systems readily available? Consult supliers, 21 .I
(c) Are the system elements mutually compatible? 12.1.4
(dl Can the coats be applied by:
brush
roller
airless spray 122.2
other? (describe)
4.3.2 Coating facilities
(a) Are the coating facilities readily available:
(1) for factory application
(2)for site application? 1 Clauses 9 and 10.4
(b) Do they cover all sizes and shapes of fabrication? Consult suppliers, 11.1.2
(c) Do they permit speedy application? Clause 22
(d) Do the facilities permit work to adequate standards? Experience
4.3.3 Compatibility with engineering and metallurgical features
(a) Is the design and jointing of the structure compatible with the Clauses 7 and 8
preferred coating technique?
(b) Does surface preparation (blasting, pickling) or application of 10.2,11.2.1 and 16.2.3
coating affect the mechanical properties of the steel in any way
that matters?
(c) Is the system compatible with cathodic protection? Consult specialist
4.3.4 Delays
What delays should be allowed between:
1
(a) fabrication and first protective coating;
(b) application of primer and undercoat;
(c) application of undercoat and finishing coat; 10.5 and 22.2.6,
consult specialist
(dl final shop coat and erection;
(e) erection and final treatment?
4.3.5 Transport, storage, and handling
How well does the coating withstand:
(a) excessive or careless handling;
(b) abrasion and impact;
(c) earlystacking;
(d) exposure to sea water during transit?
4.3.6 Experience
(a) What is known of the consistent performance of the coating?
1 Clauses 12.1.6 and 24
Case histories
4.3.7 Export
(a) What special precautions shouldbe taken when the steelwork is Full consideration of environment
exported? during transport, storage, and use
4.3.8 Maintenance
(a) Is the deterioration of the coating rapid and serious if maintenance Section five
is delayed?
4.3.9 costs
(a) What are the approximate costs of:
(1) the basic system;
(2) any additional items; Cost analysis of previous contracts;
(3) transport; appendix E; consult suppliers
(4) access? and contractors
(b) What are the approximate costs of maintenance? Cost analysis of previous maintenance;
appendix E; consult suppliers
and contractors
The manner in which this list of questions can assist in choosing a protective system is demonstrated in appendix H.
5
BSI BSX5493 77
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BS 5493 : 1977
Section two
5. Environment Section five of the code gives details of conditions of

coating which indicatethat maintenance is due.
5.1 Classification of types. Table 1 gives details of the most
common types of environment (exterior atmospheres, 6.2 Categories
including the problems of sheltered conditions, building 6.2.1 Life to firstmaintenance. The following ranges of
interiors, sea water, fresh water, soil) and of special life are used in table 3.
situations requiring additional or priority treatment
Very long typically 20 years or more
(high temperatures, refrigerated surfaces, fungal and
Long typically 1O to 20 years
bacterial growth, chemicals, abrasion or impact, local
Medium typically 5 to 10 years
mining and encasement in concrete).
Short typically less than 5 years
The definitions of environment and recommendations for
I t should br?noted however, that there may be wide
coatings are primarily related to conditions in the United
variability in the environment and in the application of
Kingdom. However, much oversea construction is supplied
the coating system which may shorten or lengthen the
by and controlled from the United Kingdom.
expected maintenance-free life. However, when
It should be noted therefore, that subtropical and maintenance is due after 20 years or more on 'very long
especially tropical environments can be much more life' systems in the more unfavourable combinations of
corrosive than those in Britain, because of the much circumstances, the coating may have deteriorated to such
higher and wider range of temperature, rainfall and an extent that it may be necessary to blast-clean and
humidity. The surface temperature of a stryture can, recoat the steelwork (see clause 55). On structures with
after heavy rain, quickly reach 70 O C or 80 C, and a design life of more than 50 years it is advisable to
humidities a t or close to 1O0 % can persist for long periods. inspect the coatings earlierthan the date scheduled for
The salinities of both fresh and salt waters can be much maintenance. It can then be decided if maintenance work
higher because of the high evaporation ratesof ground should be put in hand earlier than the scheduled datein
water; and high water temperature promotes rapid growth order to preserve the integrity of the coatingthat was
of corrosive bacteria, It should also be borne in mind that applied initially.
when coated or uncoated goods are shipped from a
Mechanical damage to coatings during handling, transport
temperate climate into or through a tropical climate,
and erection is not considered in table 3 but is discussed
the environmentalconditions during transport may be
in clause 24 and table 8 (section four).
much more aggressive than those in which the coatings
are intended to serve. For all these reasons, specialist 6.2.2 Life between subsequent maintenances.After galvan-
advice should be sought when considering protective ized or metal-sprayed structureshave been painted,
schemes in such environments. subsequent maintenance will be of the paint scheme.
Well maintained painted structuresmay have longer lives
5.2 Identification of relevant t y p e s . When selecting a between maintenance operations as the total intact paint
protective system, identification of the environment film becomes thicker.
should be allowed for by answering the following
6.3 Assessment of life requirement. I t may be necessary to
questions. assess the life ofeach part of a structure separately
(a) What is the nature of the general environment? (see 5.2(d) and (e) and 15.6). For each assessment
(b) Will theaenvironment change markedly after (whether or not more than one is required) the following
completion of the structure or in the foreseeable future? points should be taken into account.
(c) Is there local pollution, e.g. sulphur dioxide, (a) Required life of structure.
which could make the environment more corrosive , (b) Decorative aspects; the decorative life of a coating
than is a t first apparent? is not usually as long as the protective life.
(d) Should the worst environment be allowed for when (c) Irreversible deterioration if scheduled maintenance
determining protective systems or should the project is delayed.
be divided into different parts from an environmental (d) Difficulty or ease of access for maintenance
standpoint? (see clause 7).
(e) What special situations apply, e.g. watersplash and (e) Technical and engineering problems in maintenance.
residual pools, vulnerability of posts to traffic near
ground level or floor levels? (f) Minimum acceptable period between maintenances.
(9) Total maintenance costs, including shut-down of
plant, closure of roads, access costs, etc.
6. Life required of coating
6.1 Definition. Most structures are designed for a specific 7. Design of the structure
functional life. In the rare cases where access for repair or The design of the structure may influence the choiceof
maintenance of the coatings is impossible, the initial protective system. It may be appropriate and economic to
protective coating will be required to have the same life modify the design (see BS 4479) to suit the preferred
as the structure. More usually, however, thelife requireprotective system. The following points should be borne
ment of the initial protective coating is based on the time in mind when designing.
which can elapse before major or general maintenance of
(a) Easy access for protection and maintenance should
the coating becomes necessqry. That time is known as the
be provided and, wherever possible, pockets and recesses
'life to first maintenance' and its values, related to types
in which water and dirt may collect should be avoided.
of environment and coating systems, are given in table 3,
Corrosive chemicals, including de-icing salts, should be
which also indicates whichsystems have special
directed away from structural components, e.g. by
maintenance requirements.
drainage tubes.
6
BS 5493 : 1977
Section two
Table 1. Environments and special situations

Environment Special sifuations requiring priority consideration*
Category Description 3elevant Category Description Relevant

,art of part of
:able 3 table 3
Exterior Rain washed surfaces Mines Typically

mines.
coal Part 12
exposed Warm humid conditions.
Non-polluted Most rural and suburban areas with 'art 1 Water present (pH 2.5 to I l ) and
inland low sulphur dioxide, acid, alkali and sometimes saline
salt pollution.
MOTE. Some apparently non-industrial Encasement Alkaline concrete away from Part 14
areas may be polluted from distant in concrete
atmosphere, but carbonation occurs
sources, according t o prevailing wind
and topography close to surface and in cracks
Polluted Airborne sulphur dioxide, or other 'art 2 Part 15
Refrigerated Surfaces
near to refrigeration
inland pollution from industrial or domestic surfaces
systems subject to ice formation
sources and condensation
Non-polluted As non-polluted inlandwith salt 'art 4
coastal defectable. Typically nearer to coast High- The
temperature
aspect is usually
of Part 11
than a distance which may be as temperaturegreaterimportancethanthegeneral
little as 0.25 km or as much as 3 km, surfaces
atmosphere.
Thermal
shock
may
according to prevailing wind and need to be considered
topography (but with frequent salt
spray, treat as sea water splash zone) Chemicals
Polluted As polluted inlandwith salt 'art 3 Acids
and
Specific
corrosion
hazards from Part 16
coastal detectable. Typically nearer to coast alkalis both
liquid vapour
and
than a distance which may be as little Neither
Usually
solvents
and
petroleum
as 0.25 km or as much as 3 km, acidic nor products with dissolution effect
according to prevailing wind and alkaline many
onorganic
coatings
topography (but withfrequent visual Road Salts containing chlorides used to Part 17
salt spray, treat as sea water splash (de-icing) suppress ice formation,
zone) salts particularly
highways
on
Exterior As above except not washed by rain, Part 5 Abrasion Additional consideration in some Part 18
sheltered badly ventilated,and normally and impact applications
subject to condensation, e.g. under-
sides of bridges Fungi
and Additional consideration in some Part 19
appfications
bacteria
Interior Inside buildingswhich may or may
not be heated
Normally Allows for some condensation and Part 6
dry for exterior conditions during
erection, e.g. warehouses
Frequently Substantial condensation,
damp and we1 e.g. swimming baths Part 7
Non-saline Potable and non-potable water. Part 8

water Applicable to river installations,
sewage-treatment tanks, water tanks,
and domestic water systems
Sea water Sea and other salinewaters and

estuary water'
Immersed Permanent immersion,e.g. submerged Pa r t 10
structures, offshore drilling rigs
Splash zone Wind and water areaof floatingand Part 9
tidal structures, e.g. wharfs, piers,
sea walls or frequent salt spray
soil Earth, sand, rock, etc. Mainly buried Part 13

structures, e.g. pipelines and
exteriors of tunnels and underground
storage tanks
*Some environmentsare so highly corrosive that special high duty coatings not detailed in this code may be required.
7
E S 1 BS*5493
BS 5493 : 1977
Section two
(b) Certain areas may, after erection, be inaccessible 8.3 Fasteners. Fasteners which are exposed after assembly,
for maintenance andso may require a coating system such as steel pipe- and cable-hangers, are zinc- or
designed to last for the total life of the structure. aluminium-coated, or blast-cleaned andprimed before
(c) Some structural sections may be more suited to welding-on (if notblast-cleaned with the structure).
some coating systems than others; e.g. hollow sections Fixing nuts and bolts may be galvanized (see BS 7291,
can be more easily wrapped than structural shapes. sherardized (see BS 4921), or electroplated (see BS 3382
and table 4). An adequate thickness of zinc should be
(d) The method or size of fabrication may preclude specified, and when the zinc coatingon fasteners
or limit some coating systems. (applied by galvanizing, electroplating or sherardizing)
(e) The absence of sharp edges facilitates the even is too thin forthe life requirement, further coatings
application of paints which might recede from arrises. should be applied on surfaces exposed after assembly
(f) If materials are chosen which may give serious as follows.
bimetallic corrosion problems additional measures (a) Zincdust paints: to total thickness suggested by
are necessary. (See PD 6484.) The effect of contact with figure 1 for appropriate environment and life to first
other building materials should be considered (see maintenance,
clause 28).
(b) Other coatings: to thickness that will offer
(9) Electrical continuity in some exposed steel protection equivalent to that given to the main structure.
structures can be important. I f continuity is not
8.4 Procedure for welds. As-rolled steel may be blast-
otherwise provided, coppertapes may have to be
cleaned and protected with blast-primers beforefabrication
bonded to the steel parts to bridge the discontinuity
and welding (see table 4A). This prevents the serious
(eng. lightning conductors) but this creates a risk of
development of rust, which would be difficult toremove
bimetallic corrosion. Metal coatings retain electrical
after fabrication. The use of steel that has rusted heavily
continuity and most paint coatings provide electrical
during storage is best avoided for the same reason.
resistance.
When welding metal-coated or zinc-dust-painted steel,
it is sound practice first toremove the coating near the
weld area, or mask-off the weld area before coating.
8. Fabrication
Most painted steel can be cut and welded satisfactorily
8.1 General. Full protection applied in the shop provided that the coating thicknessis less than 25 Pm,
immediately after fabrication normally results in a longer but welds that are likely to be heavily stressed should
life of the protective system. However, damage during be examined by the engineer for porosity.
transportation and erection may subsequently necessitate After welding, scale and heat-damaged coatingsshould be
widespread repair or touch-up of coatings, so specifiers removed by local blast-cleaning and the areas renovated
may prefer to leave a final coat or coats of a multi-coat by re-applyingthe original coating (if possible). Galvanized
system for application on site. This may, however, or metal-sprayed surfaces may be made good by:
delay site work, e.g. removal of scaffolding. When the final
cost of paint is applied on site the specifier should choose (a) metal-spraying on site;
a system that is tolerant of delay (with possible contamin- (b) application of zinc-rich paints to reinstate the
ation) a t this stage. The specification shouldstate clearly original dry-film thickness; or
who is to be responsible for quality control a t each stage (c) application of low-melting-pointzinc alloys heated
in the fabrication and processing. by torch to a pasty conditiont.
8.2 Fayitig surfaces of friction-grip joints." The faying To avoid theneed for early maintenance of s i t e welds on
surfaces of friction-grip bolted joints (see BS 3294 and painted structures they shouldbe blast-cleaned before
BS 4604) require special attention. I f left bare, all points protection.
where moisture could gain access should be effectively
sealed, The alternative is to protect the faying surfaces, 9. Facilities for application of coatings
but inthis case the effect of the protective schemes on
Surface preparation (see clause 14) is normally done by
the slip factor has to be closely investigated, and their
the contractor applying the coating. I f blast-cleaningis
behaviour under static, dynamic and sustained loading
not available and it is necessary to use a surface-preparation
should be considered. If adequate t e s t results are not
method that is inferior to blast-cleaning, it is advisable to
available they should be obtained. Consideration should
choose a paint which is compatible with that surface
also be given to possible losses of pre-tension arisingfrom
preparation; the advantages of some chemical resistant
the behaviour of protective coatings on fasteners and in
paints are lost if they are applied over inadequately
friction-grip joints. Sprayed aluminium or zinc, hot-dip
prepared surfaces.
galvanizing, paints of the zinc silicate type, or special
paints with abrasive additions may be considered. When programming the work, factors to be considered
Most organic-based protective coatings, including include the following.
strippable coatings, oils, and waxes, would greatly reduce (a) The sequence of operations (e.g. blast-cleaning
the slip factor below theacceptable values for properly before fabrication is normally cheaper than blast-
prepared steel. cleaning after fabrication).
*The term 'faying surfaces of a friction-grip joint' means surfaces which, when in contact with one another, transmit a load across the
interface by friction.
tThese contain fluxes which should be removed.
8
BSI B S * 5 4 7 3 77 Lb24667 O I b 0 5 4 0 O m
es 5493 : 1977
Section two
(b) The application time (e.g. length of a drying or U to denote undercoat(s1; and
curing time for coating). F to denote finishing or top coat.
(c) Methods of application (e.g. airless spray, air spray, Numbers followiqg the alphabetical reference indicate
or brush). (See clause 22.) more specific alternativeswithin the general type.
(d) The possible advantage or disadvantage of applying For example:
the final coat(s) on site (see clauses 8.1, 12 and 24). SB3 denotes a complete system (S) of zinc coating (B),
Some coatings (e.g. galvanizing") cannot be applied being the third (3) alternative of the four systems listed
on site. in table 46.
*Galvanizing facilities are listed in the Galvanizers Directory, FF4A denotes a drying-oil-type (F) finishing coat
issued by the Galvanizers Association, 34 Berkeley Square, (second F), in the fourth (4) group of alternatives listed
London, W1X 6AJ.
in the last part of table 4F, and sub-group A for white
and tints. It is not itself a system.
IO. Classification and characteristics of
protective coatings The further alphabetical suffix that appears after some of
the numbers indicatesstill further-sub-classification,as in
10.1 Classification. The first stage of classification
the example FF4A above. Use of the designation FF4
separates all protective coatings into 'metallic' and
would imply any or all of the referenced products in the
'non-metallic'. (Metallic zinc-rich coating materials are
relevant product section.
treated as paints in this code (see 12.11.) The next stage
of classification groups the principal types of coatings in For some of the applications there are several systems that
the manner shown in table 2. Each group is given a key offer acceptable protection, so choice has to be guided by
reference letter (from the sequence B to M) which will be other characteristics. These include availabitity, convenience
used for identification throughout the code, especially in of application, ease of inspection and control, ease of
tables 3 and 4. The letter A is not used in table 2 but is maintenance, and economy in use for the specific structures
used as the key reference letter for blast primers in and'situations involved. The following general consider-
tables 3 and 4. ations are supplemented by more specific information in
tabres 3 and 4 and clauses 11 and 12.
Throughout the remainder of the code, the key reference
letter is prefixed by the letter S when a complete Metallic coatings are usually supplied under technical names
protection system is the subject of the reference. which are generally related to the techniques of application,
such as galvanizing, sprayed-metal (frequently known as
To identify the componentswithin a system the key
metal spray), etc. On the other hand, non-metallic '
reference letter is amplified by one of the following

coatings are usually suppliedas proprietary products.
suffix letters:
The products within each sub-classification group may
P to denote first treatment or primer (AP to denote have slightly different compositions and properties
blast primer);
Table 2. Principal types of coating systems (see 10.1)

Key Characteristic Reference Clause
reference constituents to table 4 reference
letter
~ ~ _ _
B Zinc coating (except sprayed- Zinc and/or zinc-iron alloy 4B 11.1

metal): bare or painted
C Sprayed-metal: bare, sealed Zinc or aluminium metal 4c 11.2
or painted
D Organic zinc-rich Zinc and organic binder 4D 12.2
E lnorganic zinc-rich Zinc and silicate binder 4E 12.2
F Drying-oil type Drying oil, urethane oil, alkyd, modified alkyd, 4F 12.3
phenolic varnish, or epoxy ester plus pigment
G Silicone alkyd Silicone-modified alkyd plus pigment 4G 12.3
H One-pack chemical-resistant Chlorinated rubber or vinyl copolymer resin 4H 12.4
plus pigment
J One-pack chemical-resistant Epoxy ester or alkyd primer with chlorinated- 4J, 4F 12.4,
and type F.primer rubber finisht 12.3
K Two-pack chemical-resistant Epoxy or polyurethane resin (including 4K 12.5
modification with coal tar) plus pigment
L Two-pack chemical-resistant Epoxy resin overcoatedwith chlorinated 4L 12.5
overcoated with type H travel rubber plus pigment
coat and finish
M Bitumens Coal tar or mineral bitumen with or 4M 12.6
without pigment, coal tar enamel
tMoisture-curing polyurethanes and high-moleculat eiaht - linear eDoxv ..

. . :esins (see aDDendix B). which are both one-oack chemical-
resistant materials, are not included in the productsections o f table 4 because of limited experience in their use. Where these materials
are considered the specifier should, as with all newer materials, refer to suppliers for recommended systems and conditions of use.
9
BS 5493 : 1977
Section two
Table 3. Recommendations for protective coating systems for specific environments

Introduction
The following lists of systems, classified by environment I t is impossible to achievean exactly uniform thickness
and typical time to first maintenance, indicate the options of any type of coating. The term 'nominal thickness' is
open to the specifier. The recommended treatments listed used in the heading to the fourth column of this table
for longer lives will always protect for shorter-period andelsewhere throughout the code to indicate an aim
requirements and are frequently economical also for these in such a manner that the permissible variation from that
shorter lives. Therecommendationsindicate minimum aimcanbe usefully specified.Themanner of specifying
requirements to ensure protection; thus combinations of thepermissible variation is described in clause 19.
metallic zinc or aluminium with paint are limited to sealed,
sprayed-metal or metal with relatively thin paint coatings,
although it is recognized that, for decorative purposes,
additional paint coatings will often be specified.
Table 3.Part 1, Exterior exposed non-polluted inland atmosphere
Typical time General description System Total nominal Notes

to first reference thickness (see the end
maintenance (table 41 (Fm) of this table)
(years)
Very long Galvanize SB1 (85 min.)

(20 or more) Unsealed sprayed aluminium SC2A 150
Unsealed sprayed zinc SC22 150
Sealed sprayed aluminium SC5A 1O0
Sealed sprayed zinc SC6Z 150
Long Galvanize plus paint SB8 (85 min. + 30 min.)

(1o to 20) Unsealed sprayed aluminium SC1A 1O0
Unsealed sprayed zinc SC1z 1O0
Sealed sprayed zinc sc5z 1O0
Sprayed aluminium plus paint SCSA 100 + (30to 100)
Sprayed zinc plus paint SC92 100+ (30to 100)
Organic zinc-rich SD3 1O0
Inorganic zinc-rich SE2 1O0
Silicone alkyd over two-pack chemical-resistant SG 1 245
One-pack chemical-resistant SH6 270
One-pack chemical-resistant over
two-pack chemical-resistant S L3 295
Medium Organic zinc-rich SD2 75

(5 to10) Drying-oil type SF7 165 to 190
Short Drying-oil type SF2 120 to 150

(less than 5) Dryingoil type SF5 85 to 105
NOTE. Treatments listed for the longer lives will always protect for shorter-period requirements and are frequently economical also for
these shorter lives.
. . 10
B S I BS*5493 7 7 Lb2Ybb7
OLb0542 Y W
BS 5493 : 1977
Section two
Table 3, Part 2. Exterior exposed polluted inland

Typical time General description System. Total nominal Notes
maintenance (table 4) (Pm) of this table)
(years)
Very long Galvanize (silicon in steel) SB3 21o

Sealed sprayed aluminium SC6A 150
Sealed sprayed zinc SCGZ 150
Long Galvanize SB2 140

(1o to 20) Galvanize plus paint SB9 (85 min. +'60 min.)
Unsealed sprayed aluminium SC1A 1O0
Unsealed sprayed zinc sc2z 150
Sealed sprayedaluminium SC5A 1O0
Sealed sprayed zinc sc5z 1O0
Sprayed aluminium plus paint SC1 OA 100+ (60to100)
Sprayed zinc plus paint SC1oz IO0 + (60to 100)
Organic zinc-rich SD5 150
Inorganic zinc-rich SE3 150
Silicone alkyd over two-pack chemical-resistant SG2 345
Two-pack chemical-resistant SK3 270
One-pack chemical-resistant
over two-pack chemical-resistant SL6 335
~~~ ~~
Medium Galvanize SB 1 (85 min.)

(5 to10) Galvanize plus paint SB8 (85 min. + 30 min.)
Inorganic zinc-rich S E2 1O0
Drying-oil type SF8 190 to 230
Short Drying-oí1type SF3 170 to 190

(less than 5) Drying-oil type SF6 130 to 150
NOTE. Treatments listed for the longer lives will always protect forshorter-period requirements and are frequently economical also for
Il
BsI BS*5493 77 m 3b24bb70360543 b m
BS 5493 : 1977
Section two
Table 3. Part 3. Exterior exaosed aolluted coastal atmosahere
me Typical
to first
General description Notes nominal
System
reference
Total
thickness (see the end
a
maintenance 4) of this table) (um) (table
Very long Galvanize (silicon in steel) SB3 21o

Sealed sprayed aluminium SC6A 150
Sealed sprayed zinc sc7z 250
I I I I
I I i
Long Galvanize SB2 140
(IOto 20) Galvanize plus paint SB9 (85 min. t 60 min)
Unsealed sprayed aluminium SC2A 150
Sealed sprayed zinc SC62 150
Sprayed aluminium plus paint SC1 OA 100 -!-(60 to100)
Sprayed zinc plus paint SC1oz 100+ (60 to 100)
Silicone alkyd over
I two-pack chemical-resistant I SG2 I345 I
Twopack chemical-resistant over zincsilicate SE4 275
I over two-pack chemical-resistant S L6 335
Medium Galvanize SB1 (85 min.) a, b, c, d

(5 to10) Galvanize plus paint SB8 (85 min. t 30 min.) h, i,
Sealed sprayed zinc SC52 1O0
I Inorganic zinc-rich I SE2 I100 I
I I I
Short
(less than 5)
I
Drying-oil type
Dryingoil type
I I
170 to 190
130 to 150
I
o
I One-pack chemical-resistant I SH2 I220
12
BSI B S * 5 4 9 3 7 7 m. Lb24bb7 03b0544 B m
BS 5493 : 1977
Section two
Table 3. Part 4. Exterior exposed non-polluted coastal atmosphere

maintenance . (table 4) (Pm) of this table)
(years)
Very long Galvanize SB2 140 a, b, c, d

(20 or more) Unsealed sprayed aluminium SC2A 150 d, f
Unsealed sprayed zinc SC32 250 a, c, d, f
Sealed sprayed aluminium SC6A 150 d, e, f
Sealed sprayed zinc SC62 150 d, e, f
Long Galvanize SB 1 (85 min.) a, b,c, d

(10 to 20) Galvanize plus paint SB9 (85 min. + 60 min.) h, i
Sealed sprayed aluminium SC5A 1O0 d, e, f
Sealed sprayed zinc SC52 1O0 dl e, f
Sprayed aluminium plus paint SC9A 100 + (30 to 100) e, i
Sprayed zinc pluspaint sc9z 100 i-(30 to100) e, i
Organic zinc-rich SD3 1O0 9
Inorganic zinc-rich SE2 1O0 9
Silicone alkyd over two-pack chemical-resistant SG 1 245
over two-pack chemical-resistant S L3 295
Medium Unsealed sprayed zinc SC1z 1O0 a, c, d, f

(5 to10) Organic zinc-rich SD2 75 9
Inorganic zinc-rich 75 SEI 9
Short Organic zinc-rich SDI 50 9

(less than 5) Dryingoil type SF2 120 t o 150 i
Dryingoil type SF5 85 to 105
One-pack chemical-resistant SH 1 160 i
I Table 3. Part 5. Exterior sheltered atmosphere
For galvanizing,
sprayed-metal (preferably sealed), usually to be recommended (see note (i)).
and zinc-rich coatingstherecommendationsare the same paint systems should at leastas good as for the
as for the relevant fully exposed condition, but when relevant fully exposed conditions with preference
'dead' pockets of air occur, the thickness of bare or for the more water-resistant systems, e.g. system types
sealed metallic zinc coatings shouldbe increased by H, J, K, L, and, where fully protected from sunlight, M.
about 25 %.Combinations of metal and paint are not
13
BS 5493 : 1977
Section two
Table 3. Part 6. Interior (of buildings) normally dry
Typical time General description System rotal nominal Notes

to first reference :hickness (see the end
maintenance (table 4) :$m) of this table)
(years)
Very long Galvanize SB1 :85 min.)

(20 or more) Unsealed sprayed aluminium SC1 A 1 O0
Unsealed sprayed zinc SC1z 1 O0
"
Long Galvanize plus paint SB8 :85 min. t 30 min.)

(10 t o 20) Sprayed aluminium plus paint SC9A 100 + (30to 100)
Sprayed zinc plus paint SCSZ 100 + (30to 100)
Inorganic zinc-rich SE 1 75
Drying-oil type or coal tar epoxy SF7 + SKE I165 to 190) + 250
Organic zinc-rich SD 1 50 9
Drying-oil type SF2 120 to 150 1
Short Drying-oil type SF 1 1 O0

(less than 5) Drying-oil type SF4 70
NOTE 1, Treatments listedfor the longer lives will always protect for shorter-period requirementsand are frequently economical also
for these shorter lives.
NOTE 2. The above recommendations take into account situationswhere the steelwork, althoughfully enclosed inside a building, may
be subject to conditions of external exposure during construction, e.g. where the erectionof cladding is unduly delayed. Furthermore,
these recommendations indicate typical lives to first maintenance under suchconditions, and provided that signs of corrosion are not
apparent during the delay period no further serious corrosion is likely to occur that could result in a shortening of the typical life to first
maintenance.
When it can be assured that there will be no delay between coating the steelwork and i t s enclosure within the building, and when the
design is such as to ensure dry conditions without local or general condensation or ingress of water, then the abovementioned
recommendations are likely to be conservative andthe time to first maintenance can be extended.
Under dry conditions, the loss of steel by corrosion i s slight, so provided that the steelwork insidea building remains dry and no
breakdown of the coatingi s likely to occur prior to enclosure of the steelworkwithin the building, the coating requirement may be
determined by experience of the conditions and by the natureof the construction.
Under these conditions, the above treatments would generally resultin times to first maintenance being longer than those quoted.
See also clause 8,
14
BSI B S * 5 q 7 3 7 7 m Lb24bb7 01605qb L
BS 5493 : 1977
Section two
Table 3. Part 7. Interior of building, frequently damp or wet

I
(years)
~
Very long Galvanized SB1 (85 min.)

(20 or morel Unsealed sprayedaluminium
Unsealed sprayed zinc
aluminium
Sealed sprayed zinc
SC1A
SC22
;;i
SC5A Sealed sprayed
SC52
Long Galvanize plus paint SB8 (85 min. + 30 min.)

( I O to 20) Unsealed sprayed aluminium SC2A 1O0
Sprayed aluminium plus paint SC9A 100 + (30 to100)
Sprayed zinc pluspaint SC92 100 + (30 to 100)
Two-pack chemical-resistantover zinc silicate SE6 27 5
Coal tar epoxy SK6 250

Coal tar epoxy S K6 250
I I I I
I
Short One-pack chemical-resistant SH2 220 j
(less than 5) One-pack chemical-resistantover
drying-oil type primer SJ 1 170 i
Two-pack chemical-resistant SKI 170 to 180
15
BS 5493 : 1977
Section two
Table 3. Part 8. Non-saline water (for potable water see note (n))

to first reference thickness (see the and
maintenance (table 4) (Fm) of this table)
(years)
Very long Galvanize SB2 140 b, c, d, m

(20 or more) Sealed sprayed aluminium SC6A 150 e, 1, m
Sealed sprayed zinc SCGZ 150 e, 1, m
Long Galvanize SB 1 (85 min.) m

(1 o to 20) Galvanize plus bitumen (BS 3416) SB9 (85 min. + 40) See table 4M
Sealed sprayed aluminium SC5A 1O0 e, I I m
Sealed sprayed zinc SC6Z 150 e, 1, m
Sprayed aluminium plus paint SCSA 100 + (30 to 100) e, 1, m
Sprayed zinc plus paint SCSZ 100 + (30 to 100) e, 1, m
One-pack chemical-resistant over two-pack
chemical-resistant over zinc silicate SE6 275
Two-pack chemical-resistant S K4 320
Hot-applied bitumen BS 41 47 Various See table 4M
Coal tars BS 41 64 Various See table 4M

Two-pack chemical-res.istant S K2 240
Bitumen BS 341 6 Various See table 4M
16
BSI BSm51-173 77 M 1b2qbb9 O L b 0 5 Y B 5 M
BS 5493 : 1977
Section two
Table 3. Part 9. Sea water splash zone, or frequent salt spray

(years)
Very long Sealed sprayed aluminium SC6A 150

(20 or more) Sealed sprayed zinc SC72 250
Long Galvanize plus coal tar epoxy SB1 + SK6 (85 min. + 150) i
( I O to 20) Galvanize (silicon in steel) SB3 210 a, b, c, d
Galvanize plus paint SB9 (85 min. + 60 min.) i
Sealed sprayed zinc SC62 150 4 %f I
Sprayed aluminium plus paint SC1 OA 100+ (60to 100) e, i
Sprayed zinc plus paint SC1oz 100+ (60 to 100) e, i
One-pack chemical-resistant overtwo-pack
chemical-resistant over zinc silicate SE7 47 5
Galvanize SB2 140

Sealed sprayed zinc sc5z 150
over two-pack chemical-resistant over zinc silicate SE6 275
Short Galvanize SB 1
(less than 5) Unsealed sprayed zinc SC1z
Two-pack chemical-resistant SK2
over two-pack chemical-resistant SL2
NOTE. Treatments listed for the longer lives will always protect for shortenperiodrequirements and are frequently economical also for

17
BS 5493 : 1977
Section two
Table 3. Part IO. Sea water, immersed

maintenance (table 4) (vm) of this table)
(years)
Very long Sealed sprayed aluminium SC6A 150 dl e, f

(20 or more) Sealed sprayed zinc sc7z 250 dl e, f
Long Galvanize plus coal tar epoxy SB1 i- SKE (85 min. t 150)
(IO to 20) Galvanize (silicon in steel) SB3 21o
Sealed sprayed zinc SCGZ 150
I Sprayed aluminium plus paint SC1 OA
SC 1oz
100 t (60 to100)
100 + (60 to 100)
Sprayed zinc plus paint
One-pack chemical-resistant overtwo-pack
chemical-resistant over zinc silicate SE7 475
Medium Galvanize SB2 140

(5to I O ) Unsealed sprayed zinc SC22 150
Sealed sprayed aluminium SC5A 1 O0
Sealed sprayed zinc SC52 1O0
One-pack chemical-resistantover two-pack
chemical-resistant over zincsilicate SE6 275
Short Galvanize SB 1 (85 min.)

(less than 5) Unsealed sprayed zinc SC1z 1O0
NOTE 1. Note (k), at the end of table 3, refers to anti-fouling paints.
NOTE 2. Treatments listed for the longer lives will always protect for shorter-period requirements and are frequently economical also for
18
BSI BSm5493 77 3b24bb7 Olb0550 3 m
BS 5493 : 1977
Section two
Table 3. Part 11. High temperature surfaces
The coatings that protect structural steel against corrosion Arc-sprayed alumihium should preferably be specified
may also need to be heat-resistant. Resistance to heat is where there may be cyclical temperature fluctuations.
influenced mainly by the nature of the temperature cycle, The sprayed a[uminium may also be silicone-sealed
the maximum service temperature and its duration. (SCGAH) and, for temperatures typically about 250 OC,
Furthermore, the behaviour of the coatingwill vary silicone-sealed sprayedaluminium SC6AH can have a very
considerably accordingto whether or not the surface long life (20 or more years).
remains dry (even when cold). When warm, the presence The zinc silicate systems are also recommended;
of hot gases will have specific effects: system SEI, for example, may, in some circumstances,
Only general recommendations can be given and specialist last for up to1O years before maintenanceis needed.
advice should always be sought. The zinc silicate/aluminium silicone treatment SE8 is to be
For temperatures up to200 O C , sealed sprayed aluminium preferred for the more severe conditions and in favourable
(SCGA) or sealed sprayed zinc (SCGZ) may be considered circumstances may have long life to firstmaintenance.
for long or even very long life to first maintenance, For temperatures up t o 900 "C aluminium (175 prn
depending on the circumstances. A special silicone alkyd nominal thickness) appliedby electric arc under controlled
over a zinc silicate primer system (SGI type but thinner) conditions may be considered for some uses; the current
may be considered for medium lives. The paint coating edition of BS 2569 : Part 2, gives some alternatives.
should be less than 100 pm forradiators, etc. Colours are For components to be used a t service temperatures up to
usually satisfactorybut for higher temperatures the 1000 'C the current edition of BS 2569 : Part 2, specifies
aluminium version is recommended (see table 4F. part 4, a nickel-chromium alloy; with sulphurous gases present
product section F5). Where silicones cannot be tolerated, the nickel-chromium is followed by aluminium and in
a silicone-free aluminium paint may be specified; advice each case there is a subsequent heat treatment.
should be sought from paint suppliers. The maintenance
period is related to the operating temperature. Certain The life to firstmaintenance of coatings recommended
for temperatures up to550 OC, up to 900 OC, and up to
drying-oil types of coating (e.g. SF1 or SF41 will give
short-term protection but selection of the paint requires 1000 "C will depend on the exact combination of
specialist advice. conditions in service but willusually be less than 1 O years,
although the sprayed aluminium coating may last longer
For temperatures up toabout 550 OC aluminium if maximum temperature and other conditions are not
(175 pm nominal thickness) is suitable as sprayed, too severe.
Table 3. Fart 12. Mines
Specialist advice shouldbe sought because conditions Zinc coatings (but notaluminium coatings or paint in
differ considerably in different mines. coal mines) shouldbe considered provided that the water
Advice should also be sought from H.M. Inspector of >
has pH 5. For sprayed zinc or aluminium a sealed
Mines and Quarries regardingthe special restrictions coating is preferred. Data on the coatings and likely
which apply t o materials taken down into mines performance, given in parts 8, 9 and 10 of this table, can
(e.g. low-flash-point paints) and theprocesses which be used for guidance but the time spans to first
may be used in mines (e.g. blast-cleaning). maintenance may vary widely according to local conditions.
Table 3. Part 13. S o i l
Many specialist coatings exist,e.g. wrapping tapes, preferred protective scheme of the part of the structure
bituminous coatings (BS 3416, BS 4147, BS 4164 as above ground) may vary accordingto the nature of the
appropriate), powder coatings andpolythene sleeves, soil, and specialist advice is required. Clinker and ashes
often in conjunction with cathodic protection. The contain soluble sulphates and unburnt coke, which
choice is greatly influenced by the nature of the shorten coating life. In inorganic moderately reducing
structure, ¡.e. pipe, pile, or column. soils and highly reducing organic soils,zinc coatings
Suitable coal tar epoxy systems are SK8 for 10 to 20 years, usually have paint or plastic finishes, sprayedzinc is
SK7 for 5 to 10years and SK6 for 2 to 5 years. preferably sealed. Aluminium coatings are not
recommended for direct contact with.alkaline clays.
The suitability of metallic coatings and other paint
systems (which may be desired because they form the

19
E S 1 B S * S 4 9 3 77 M Lb24669 O L b 0 5 5 L 5 M
BS 5493 : 1977
Section two
Table 3. Part 14. Encasement in concrete (see note I f ) )
Steel requires no protection when fully encased in alkaline (see 13.4 and A.3.5.3). Where the coated steel enters the
(uncarbonated) concrete. Protection by sprayed zinc, concrete, a bituminous coating may subsequently be
by galvanizing, or by zinc-rich coatings to BS 4652, type 3, applied usefully a t any interface where water may tend
is beneficial in the zone which may become carbonated to remain (see figure 6).
Table 3. Part 15. Refrigerated surfaces (down to -30 "C)

~~
The low temperature reduces the corrosion rates but Typical coating systems include zinc silicate SEI or
facilitates condensation conditions. 'Where water is present two-pack zinc epoxy SD2 for 5 to 1O years; one-pack
an effective barrier layer is requiredonthe steel. chemical-resistant paint systems SH4 for 5 to 1O years
Sealed or unsealedsprayed-metalcoatingsandbareand SH3 for less than 5 years;and two-packchemical-
galvanizing are generally suitable (e.g. SBI, SC1A, SC1 2, resistant systems SK2 for 5 to 1O years and SKI for
SCSA, SC52 of table 4). less than 5 years.temperatures
For below -30 "C specialist
advice should be sought.
Table 3. Part 16. Chemicals

~~~~
For storage or transport of chemicals specialist advice Metallic zinc is generally suitablefor chemicals when the
should be sought. The effect of the coating on the pH-value is in the range 5 to 12; metallic aluminium is ,
chemical should be considered as well as the protection generally suitable when the pH-value is in the range
of the steel. 4 to 9. Only specially formulated two-pack chemical-
When subject to splashes of acid or alkaline chemicals, resistant paints andsilicates are suitable for solvents
painting recommendations are similar to those given in and petroleum products. In splash conditions coal tar
part 7 of this table, except that oil-type paints epoxy (SK7 for 10 to 20 years, SK6 for 5 to 10 years,
(systems F and G) should not be used and zinc silicates. SK5 for less than 5 years) or zinc silicate (SE2 for
are not recommended for acid conditions. 10 to 20 years) may be suitable.
Table 3. Part 17. Road (de-icing) salts
Highway authorities recognize that special protection is 79 to 88). Onthe other hand, no provision is made for
required for bridge steelwork such as parapets and railings the special protection of the undersides of bridges against
exposed to de-icing salts. For example,galvanizingplusroad salts. When,occasionally, de-icing salt can attack
paint is advised in the Department of Transport'sNotessuch steelwork it is usually the result of accidental
for Guidance onthe Specification for RoadandBridgeblockage of a drain or failure of a deck joint.
Works, published by HMSO London, 1976 (seepages
Table 3. Part 18. Abrasion and impact

~~
Galvanized steel is recommended for resistance t o For the longest life of paints,anabrasive should be
abrasion,roughhandling, or impact. Thethickness of incorporated in the finish, e.g. in SK4 two-pack chemical-
coatingshould be determined by the surroundingresistant, Zinc silicate systems, SEIfor less than 5 years
environment and the degree of wearexpected.SprayedorSE3or SE4 for 5 to 10 yearsmayalsoberecommended.
metal (sealed or unsealed) also has good resistance and
the coating polishes byfriction.
Table 3. Part 19. Fungi and bacteria

~~
As for the appropriate environment (see parts 1 to 10

of this table) with suitable fungicidal or bactericidal
additives to the undercoat and finish of paint systems.
20
BSI B S * 5 4 9 3 37 m 1624669 0360552 7 m
-Table 3. Part 20. Notes to table 3. (i) Maintenance ofpainted metal coatings. The 'life to first
maintenance' given in the first column of the table is calculated
(a) Life of zinc coatings. The life of metallic zinc coatings in typical to allow substantial retention of the metal coating and is suitable
atmospheres and sea water is shown in figure 1. Life in the atmo- for maintenance work designed to retain a metal-plus-paintprotec-
sphere decreases with increase in sulphur dioxide pollution. tive coating. The apparent anomaly in some parts of the table
(b) Thickness of galvanizing. BS 729 specifies the standard (that metal coatings are recommended 'for very long' life to first
galvanized coating at theequivalent of 85 prn minimum for steel maintenance, whilst the same thickness of metal coating plus
5 mm thick or more. Thinner steel, automatically galvanized tubes paint is recommended for 'long' life only) arises from the normal
and centrifugal work (usually threaded work and fittings) have practice of maintaining metal-plus-paint coatings before significant
thinner coatings. Galvanized coatings thinner than 85 pm minimum degradation of paint or loss of metal has occurred. (It should be
are not included in table 3, but where it is desired to use such thin- noted that an area of degraded paint can hasten the corrosion of
ner coatings their lives can be ascertained by reference t o figure 1. metal by acting as a poultice, particularly on a surface not subjected
Thicker galvanized coatings (see 11.1.2) are not specified in BS 729 to washing by rain.) Where it is desired to retain a reasonably
-but thegeneral provisions of that standardapply; the galvanizer intact layer of paint as the basis for maintenance after the
should be consulted before specifying. recommended life to first maintenance, the initial paint coating
(c) Build-up or repair of zinc coatings. Inadequate thickness e.g. should be thicker (typically more than 75 Pm). The extra thickness
on small components, may be made-up by applying zinc-dusf paint should be in finishing paints rather than in primers or undercoats.
to give the total thickness of zinc for the life requirement. (i) Painting ofsurfaces which have notbeen blastcleaned. It is
Discontinuities and damaged areas may be made good by zinc- recognized that blast-cleaning is not always possible, but schemes
spraying, special zinc-alloy solder-sticks or zinc-rich paint. based on lower standards of preparation require maintenance mate
(dl Maintenance intervals for metalcoatings which are to be painted. frequently than do comparable paint coatings over blastcleaned
When bare galvanized surfaces or sealed sprayed-metal surfaces are surfaces.
maintained by the use of paint, the future maintenance intervals (k) Anti-foulingpaints. Special formulations of paints are available
will be those of the metal-plus-paint system, which is often less to prevent formation of marine deposits on structures. Most anti-
than that for the bare metal coating but longer than for a similar fouling paints need to be re-applied every year or two. Zinc and
paint system applied directly t o steel. Unsealed sprayed-metal aluminium should not normally be overcoated with copper or
coatings are usually designed to protect the structure forits required mercury compounds.
life. Maintenance operations for such coatings are usually more ( I ) Sealers for metal coatings forpotable water. Vinyl or epoxy
elaborate than for sealed coatings. The systems recommended in co-polymer sealers (see table 4C, part 2) are usually used.
table 3 in the 'very long' life category will in general meet the life
requirements when maintenance is effected after 2 0 years. Where (m) Zinc and aluminium coatings in non-saline water. The
there is scope for maintenance of very-long-life coatings before the maintenance-free lives given for zinc are for cold scale-forming
20-year period has elapsed, it may be advantageous to undertake waters. The maintenance period in nonscale-forming waters will
such maintenance, especially if the structure is required to last be one category less (Langelier's index is used to calculate:
indefinitely. In the more unfavourable combinations of whether the water is scale-forming). Choice of aluminium or zinc
circumstances in one category it may be necessary to blast-clean and <
is often on the basis of pH- value, aluminium for pH 5 or 6 ;
recoat the steel (see table 101. zinc for pH >5 or 6.Since the composition of these waters may
vary greatly, previous experience or expert advice should be sought.
(e) Sealed and painted metalcoatings. The appearance and life of For hot water, specialist advice should be sought.
sprayed-metal coatings is improved by sealing (see 11.2.2). There
is no requirement for a measurable overlay of sealer but sealers (n) Structures forpotable water.
should be applied until absorption is complete. Sealing is particularly (1) General, Coatings used for all structures, including pipes,
desirable when it is desired to retain the sprayed coating when the fittings, tanks and tank covers in contact with potable
surface is eventually t o be maintained, and such maintenance water, must be non-toxic and must not impart any taste or
requires only the renewal of the sealer. Painting of sprayed-metal odour, colour or turbidity to the water, and must not foster .
coatings is seldom the preferred treatment except when colour, microbial growth.The National Water Council maintains a list
an inert barrier or abrasion resistance is required. of approved coatings.
( f ) Contact of metal coatings with concrete. The alkalinity of (2) Tanks. Small tanks should be galvanized and, if further
concrete makes it unsuitable for direct contactwith &minium protection is necessary, high-build bitumen paint should be
and an inert barrier layer should be present. Such a layer is not applied in sufficient coats to give a dry-film thickness of
needed with zinc coatings which react sufficiently with concrete 500 prn.
to form only a useful mechanical bond. In the atmosphere an Tanks too large for galvanizing may be protected as follows.
I interface of either aluminium or zinc with concrete, soil, etc. (i) Prepare the steel surface by blast-cleaning or manual
benefits from application of an inert layer. cleaning and apply high-build bitumen paint to give 500 prn
(9) Sealed zinc-rich coatings. The appearance of a zinc-rich coating dry-film thickness. Alternatively, a hot-applied bitumen
is improved by the application of a suitable sealer coat. Guidance coating may be used, although some coatings of this type
on type of top coatto be used should be obtained from the supplier can supportmicrobial growth.
of the zinc-rich c6ating. (i¡) Blastclean and apply an approved high-build chlorinated
(h) Painted galvanized coatings. rubber or cold-cured epoxy resin coating that complies
(1) For the less aggressive environments (or for shorterlives than with the potable water requirements above to give a dry-
indicated) a single coat of paint (30 prn or more), over film thickness of 250 pm.
pretreatment if specified, is sufficient. (3) Tank covers. The undersides of tank covers should also
(2) For more aggressive and wet environments two coats of receive a protective coating.
paint (60 pm or more) areused to minimize through-pores. (0)Table 3, Parts 7,8,9 and 10. Electrochemical attack can
occur in a wet environment if parts of a structure coated with
zinc or aluminium are in contact with bare steel or more
cathodic metals such as copper. In immersion conditions such as
sea-water the anodic zinc or aluminium can be rapidly destroyed.
This action can be avoided by electrically insulating the differing
parts from each other.

BSI B S * 5 4 9 3 - 7 7 W 3624bh7 0'1b0553 9 W
BS'5493 : 1977
Section two
Galvanized coating , specifiedminimumweight, g/m2
Specified minimum thickness, um

Figure 1. Typical lives of zinc coating in selected environments
23
BSI B S * 5 4 9 3 77 m 3 6 2 4 b b 9 0 3 6 0 5 5 4 O m
BS 5493 : 2977
Section two
Table 4. Typical coating systems and their components* (see 12.1.4 regarding
compatibility)
This table is presented in twelve principal sections, identified as tables 4A,48 etc., to 4M
according to the group key reference letters (see table 2). These main sections are, where
applicable, further divided into sub-parts accordingto the following list.'
Product sectionAP Blast primers

Table 4B
Table 4C
Group B systems
I Zinc coatings other than sprayed-metal
Part 1 Group C systems Sprayed-metal coatings

' I Part 2 Product section CP Pretreatments and sealers for sprayed-metal coatings
Table 4D
Part 1 Group D systems Organic zinc-rich systems
Part 2 Product section DF Organic zinc-rich paints
Table 4E
Part 1 Group E systems Inorganic zinc-rich paints
Part 2 Product section EF Zinc silicate paints
Table 4F
Part 1 Group F systems Drying-oil-type paints
Part 2 Product section FP Drying-oil-type primers
Part 3 Product section FU Drying-oil-type undercoats
Part 4 Product section F F Drying-oil-type finishes
Table 4G Group G systems Silicone alkyd paint over two-pack chemical-resistant
primer and undercoat
Table 4H
Part 1 Group H systems One-pack chemical-resistant paints
Part 2 Product section HP One-pack chemical-resistant primers
Part 3 Product section HU One-pack chemical-resistant undercoats
Part 4 Product sectionH F One-pack chemical-resistant finishes
Table 4J Group J system Drying-oil-type primer with one-pack

chemical-resistant undercoat andfinish
Table 4K
Part 1 Group K systems Two-pack chemical-resistant paints
Part 2 Product section KP Two-pack chemical-resistant primers
Part 3 Product section KU Two-pack chemical-resistant undercoats
Part 4 Product section KF Two-pack chemical-resistant finishes
Table 4L Group L systems Two-pack primer and undercoat, overcoated with

one-pack chemical-resistantfinish
Table 4M Product section M F Bitumen and coal tar products
*Notes to table 4 are on a pull-out folder followingtable 4M. The folder should be extended whilst using any
part of table 4 so that all notes are immediately visible when required.
24
BSI B S * S 4 9 3 77 W LbS4bb9 0360555 2
BS 5493 : 1977
Section two
Table 4A: Product section AP. Blast primers (note (C)")

For airless spray, productsAP2A to AP4A may have 2 % less (volume) solids
Reference Binder Main pigment rlolume blain pigment Dry-film Additional information
iolids in total thickness; (see note (c)* for
:nominal X) aigrnent (ym per coat) application method)
!weight % min.) (advised)
AP1A Two-pack epoxy Zinc phosphate 25 40 20
AP1 B Zinc dust 30 35 20 See BS 4652

Essential to avoid settlement
of pigment
AP2A Two-pack polyvinyl Zinc 10 85 15 Also has uses other than

butyral tetroxychromate as a blast primer
(see tables 4C and4D)
AP3A Two-pack polyvinyl Zinc 10 B5 15 Suspect with cathodic

butyral/phenolic tetroxychromate protection if there is any
discontinuity in covering
system. See also AP2A
AP4A One-pack polyvinyl Zinc phosphate 22 40 20 Slightly inferior to AP3A

butyrallphenolic
AP4B. Zinc chromate 22 20 20 Slightly inferior to AP3A
*Notes to this table are on a pull-out folder following

table 4M. The folder should be extended whilst using any part of table 4 so that all
nqtes are immediately visiblewhen required.
Table 4B. Group B systems. Zinc coatings other than sprayed

For continuously galvanized sheet (BS2989) or electroplated sheet (BS3083) see DD 24.
Reference
number
Surface Coating T Remarks
preparation
Zinc coating
coating
T -T;Nominal
Number of coats
system
Pre- Paint thickness,
treatment (ym)
SB 1 See BS 729 Galvanize 85 min. Factory-appliedafter fabrication or semi-

fabrication. This thicknessis applicable to
steel 5 mm (ormore) thick (see 11.I 2 )
SB2 Grit-blast Galvanize 140 See 11.1.2. Consult galvanizer before

andlor pickle specifying
SB3 Pickle Galvanize 210 See 11.1.2. Consult galvanizer before

(silicon in steel specifying
SB4 See BS 729 Galvanize and 43 Centrifuged after galvanizing. Mainly small
centrifuge parts, particularly threaded work. Consult
galvanizer if greater thickness desired
SB5 See BS 4921 Sherardize 15 Factory-applied. Mainlysmall parts,

particularly threaded work. SB5 is BS 4921 class 2 and SB6
SB6 See BS 4921 Sherardize 30 i s BS 4921 class 1
SB7 See BS 1706 Zinc plate 25 BS 1706 class ZN10. Factory-applied, Small parts.
or BS 3382 ZN10 Threaded parts platedto BS 3382 : Part 2 have 4 pm to
9 pm; are not recommended for general use: they would
be satisfactory only in dry interiors
~ ~ ~~ ~~ ~~ ~~
SB8 See BS 729 Galvanize 1 85 min. See note (e) and 11.3 for advice on painting zinc coatings.
(85 pm min.) + 30 min. Pretreatment not necessary for some paints
SB9 See BS 729 Galvanize 2 85 min See note (e) and 11.3 for advice on painting zinc coatings.
(85pm min.)
-
+ 60 min. Pretreatment not necessary for some paints
Note 1. SB1, SB4, SB5, SB6 and SB7 usually have average thickness upto 50 % higher than the minimum.
Note 2. Paint systems for galvanized steel. Galvanized steel should be degreased prior to applying paints.When galvanizing or zinc plating
is supplemented by painting with some specially selected primers,in particular productsFP1D, FP1 E, FPZC, KPIC, KPl-D, no pretreatment
other than degreasing is necessary. Before applying most other paints it is necessary to degrease and apply one of the pretreatments
listed in the table 4C, part 2. Finishes for use over these pretreatments includethose listed in table 4K, part 4and table4H. part 4or
(for immersed conditions only)table 4M. Most drying-oil-type paints other than the primers listed above are unsuitable for use over zinc
coatings because of possible developmentof adhesion failure (see 11.3).
-. .
25
BS 5493 : 1977
Section two
I Table 4C. Part 1. Group C systems. Sprayed-metalcoatings

Applied to components in factory or t o complete structures on site
Referenc Surface Coating Remarks

number preparation
Metal type Number of coats Nominal
system
thickness*
note (dl)
SClA See BS 2569 Aluminium 1O0 See note (a)t.

SC1z Zinc 1O0
SCPA Aluminium 150 Also for use up to 550 O C
(see note (bll
sc2z Zinc 150 See note (a)
SC3A Aluminium 250 See note (b)
SC32 Zinc 250 See note (a)
SC42 Zinc 350 See note (a)
~~
SC5A See BS 2569 Aluminium 1 - 1O0 Pretreatment optional

sc5z Zinc 1 - 1O0 Choice of sealed versus unsealed:
SC6A Aluminium 1 - 150 see 11.2.2. Choice of sealer:
SC6Z Zinc 1 - 150 see table 4, part 2. Seal until
SC7A Aluminium 1 - 250 absorption complete.
sc7z Zinc 1 - 250 Note: polyurethanesealer should
SC82 Zinc 1 - 400 be compatible with metallic zinc,
i i I1 i i
SC6AH See BS 2569 For use up to 550 OC.
SC9A See BS 2569 Alumlnium See 11.3.1 100 t (30 to 100) See note (b).
sc9z See BS 2569 ~~;rhium See 11.3.1 100 + (30 to 1001 Inert paintcoatings preferred:
SC1 OA See BS 2569 Aluminium
2 - See 11.3.1 1O0 tto(60 100) dry film thickness
See BS 2569 Zinc 2 - See
-
11.3.1 100 +100)
175
(60to <100pm (see 11.3)
*Nominal thickness for metals given as in BS 2569. Minimum local thicknesses are also given in BS 2569. Zinc coatingsthinner than 100 Pm
and sealed or painted may be specified for short and medium livesin some environments but are not incorporated in table 3.
tNotes to this table are on a pull-out folder followingtable 4M. The folder should be extendedwhilst using any part oftable 4 so that all
notes are immediately visiblewhen required.
26
BS 5493 : 1977
Section two
Table 4C.
Part 2. Product
section
CP.
Pretreatments
and sealers for sprayed-metal
coatings I
Reference Binder Main pigment Volume Main Additionai
solids pigment information (see
(nominal in total note (c)* for
%) pigment application method)
(weight %
min.)
Two-pack polyvinyl Zinc materials,

Pretreatment ¡.e. first
before
treatment
butyral tetroxychromate sealing. For
spray,
airless minimum percentage
volume solids may be8 %
Two-pack polyvinyl Zinc
butyral/phenolic tetroxychromate
CP3A Blend of vinyl Clear 10 - Products CP3 and CP4 recoatable a t all time intervals.
chloridelacetate Vinyls for atmospheric or immersed conditions;
CP3B copolymers with Aluminium 15 95 phenolic or epoxyfor chemical resistance except
or without extremely alkaline conditions; polyurethane for
CP3C non-saponifiable Coloured 15 - severe atmospheric conditions. Pigments used should
plasticizers preferably be fine powder, non-flaking;
chemical-resistant,with high UV-light resistance
CP4A Two-pack Clear 10 - and low water-absorption
phenolic
CP4B Aluminium
CP4C Coloured
Clear
Aluminium ~ 115 I 95 I
ITwo-pack epoxy Coloured I 15 I- l
Two.pack Clear
polyurethane
Aluminium
CP6C Coloured
Aluminium I15 I 95 I For service

up to 550 OC (see BS 2569: Part 2)
*Notes to this table are on a pull-out-folder followingtable 4M. Thefolder should be extended whilst using any part of table 4 so that all
Table 4D. Part 1. Group D systems. Organic zinc-rich systems
Reference
Surface preparation Coating system Nominal system
(Swedish Standard") thickness, pm
SDI Sa2% Product reference DF see below 50

SD2 Sa2% 75
SD3 Sa2% 1O0
SD5t Sa2% 150
*See 14.3.1.5.
tDesignation SD4 is not used.
Note. No products other than epoxyzinc-rich have been included in this table, BS 4652 covers other media.
Table 4D. Part 2. Product section DF. Organic zinc-rich paints
Reference Binder Main Volume Main Dry-film Additional information

pigment solids
(nominal
%)
DF Two-pack Zinc 35 Quality covered by BS 4652, type 3. Maximum of

epoxy dust 75 pm recommended by sprayfor each layer.
An initial prefabricationprimer may be only 25 Nm
27
BSI BSm5Y93 7 7 Lb2Llbb9 OLb0558 8 m
BS 5493 : 1977
Section two
Table 4E. Part 1. Group E systems, Inorganic zinc-rich systems

~~~
Reference
Surface coating
Nominal thicknesses, Nominal
preparation Pm system
thickness,
Undercoat
Finish
Primer Pm
EPI, EP2 KUI, KU2 KFI, KFZ
(see table 4K) (see table 4K)
SEI Sa2% 75 75
SE2 Sa2% 1O0 1O0
SE3 Sa2% 150 150
S E4 Sa2% 75 1O0 1O0 275
SE5 Sa2%200 75 1O0 375
HFI, HF2
(see table 4H)
Sa2%
475 Sa2% 200 200
Sa2% 75
1 CI: lIO
Table 4E. Part 2. Product section EP. Zinc silicate paints
(see table 4C)
25 1O0
Reference Binder Main Volume Main Dry-film

Additional
information
pigment solids pigment thickness (see note (C)* for application
method)
(nominal in total (Pm per coat)
%) pigment (minimum
(weight % advised)
min.)
EPlA Al ka1i Zinc dust 40 80 75

Normal spray or pressure pot. Not normally
silicate recommended for airless spray (consult
manufacturer). High-build
EP2A Organic Zinc dust 40 80 50
silicate
~~~ ~
'Notes to this table are on a pull-out folder following
I Table 4F. Part 1. Group F systems. Drying-sil-type paints
Reference Surface coating

Nominal thicknesses, Nominal
thickness,
Primer Undercoat Finish Pm
FPI to FP5 FUI to FU4 FFI to FF4
SF1 35st2 35 35 105

SF2 st2 70 25 to 40 25 to 40 120 to 150
SF3 st2 5070 80to 50 to 80 170 to 230
SF4 Sa2% 35 - 35 70
SF5 Sa2% 2535 to 35 25 to 35 85 to 105
SF6 Sa2% 70 . 35 to 40 25 to 40 130to 150 '
SF7 Sa2% O! 70 to 80 25 to 40 165 to 190

SF8 Sa2% 70 70 t o 80 50 to 80 190 to 230
28
BSI B S * 5 Y 9 3 77 m L b 2 4 b b 9 OLb0559 T m
BS 5493 : 1977
Section two
Table 4F. Part 2. Product section FP. Drying-oil-type primers
Reference Binder Dry-film Additional

information
thickness (see note ( C ) * for
(Pm per coat)application method)
(minimum
advised)
FPlA I Blendofrawand Brush application
1 process drying recommended (see note (c)*)

oils Slow drying
Redlead
Fp,B
FPlE I 40
I
FP2A I Drying oil
modified with
phenolic or
I
phenolic-
modified resin 30 Brush application
recommended (see note (c))
Alkyd or
modified alkyd
Fp3c
I Drying.oil epoxy
40 Quick drying red lead.
Brush application
ester (one-pack
(one-pack
polyurethane)
*Notes to this table are on a pull-out folder following table 4M. The folder should be extendedwhilst using any part of table 4 so that the
notes are immediately visible when required.
29
BSI B S m 5 4 9 3 7 7 m 1 6 2 4 b b 9 0160560 6 M
BS 5493 : 1977
Section two
I Table 4F. Part 3. Productsection FU. Drying-oil-type undercoats

~ ~ ~~~
Reference Binder Main pigment Volume Main Dry-film Additional information
-Ï
solids pigment thickness (see note (c)* for application
(nominal %I in total (Pm per coat) method)
pigment (minimum
(weight % advised)
min.)
4
Drying oil Titanium dioxide 35 Note (f)
modified with (white and tints)
phenolic or and coloured pigments
phenolic-modified (full colours).
resin Suitab1.y extended
r
Micaceous iron I 50 ao 40 Note (9)
oxidet
ao 75 High-build in excess of
75 pm per coat may present
through-dryingproblems.
Note (9)
I
FU1D
I
Aluminium
45
95 Non-leafing aluminium pigment
recommended
FUSA Alkyd or Titanium dioxide 45 - 35 Note (f)

modified alkyd (white and tints)
and coloured pigments
(full colours).
Suitably extended
+
~
FU26 Micaceous iron oxide 50 ao 40 Note (9)
I FUSC ao 75
FU2C is high-build
airless spray
FUSD Aluminium 95 25 As for FU1D

-
FU3A Chlorinated Titanium dioxide 35 Note (h)
rubber modified (white and tints)
with alkyd in the and coloured pigments
ratio 2 (min.) to (full colours).
1 (CR to alkyd) Suitably extended
~
FU36 Micaceous iron oxide ao 35

~
FU4A Drying.oil Titanium dioxide 45 35 Note (f)
1!
epoxy ester (white and tints)
(one-packepoxy) and coloured pigments
(full colours).
Suitablv extended
FU46 Micaceous iron oxide ao 40 Note (9)

~
FU4C is high-build
FU4C ao 75 airless spray
FU4D I Aluminium 95 25 As for FU D1

table 4M. The folder should be extended whilst using any Partof table 4 SO that all
tUsually known as MIO
30
BSI B S * 5 4 7 3 7 7 a Lb2Llbb9 O l b 0 5 b L 8
BS 5493 : 1977
Section two
Table 4F. Part 4. Product section FF. Drying-oil-type finishes
1 1 :i
Reference 3inder Main pigment Volume Main Dry-film Additional information
solids pigment thickness (see note (c)* forapplication
(nominal %) in total (Pm per coat) method)
pigment (minimum
[weight % advised)
min.)
FFlA Drying ail Fade-resistantcoloured - 35 Mixture of suitable pigments

nodified with pigments and may be required, depending on
Jhenolic or carbon black shade and opacity specified
Jhenolic-modified
FFI B resin Micaceous iron oxide BO 40 High-build ofFFlC over
75 Pm per coat has through-
FFlC BO 75 drying problems (note (9))
F F2 Drying
Aluminium
oil 45 95 25 Non-leafing aluminium pigment
nodified with recommended to improve shelf
jhenolic or life or finish. Forvery high
Dhenolic-modified lustre and if leafing aluminium
resin pigment is used, two-pack may
be permissible
FF3A
FF3B
FF3C
Alkyd or
modified alkyd
Rutile titanium
dioxide: white
and tints
Fade-resistant coloured
pigments and
Micaceous iron oxide

I 90
80
35
35
40
For reduced gloss, suitable
matting agents or extender
pigments may be added
As for F F I A and note (9)
Note (9)
FF3D 80 75 As for FFlC
FF3E Aluminium 95 25 As for FF2
F F4A Drying-oil Rutile titanium 45 90 35 As for FF3A

epoxy ester dioxide: white
"
FF4B Fade-resistant coloured 45 35 As for FFIA and note (g)

pigments and carbon
black
FF4C Micaceous iron oxide 50 80 40 Note (9). FF4D is for high

build airless spray
FF4D 45 80 75
FF4E Aluminium 45 95 35 As for FF2
FF5A Silicone alkyd Rutile titanium 45 90 35 Reduced gloss levels

(at least 30 % dioxide: white not recommended
silicone) and tints
FF5B Fade-resistant coloured 45 35 As FFIA. Reduced gloss levels

pigments and not recommended
carbon black
FF5C Aluminium 45 95 i 25 As for FF2
table 4M. The folder should be extendedwhilst using any part of table 4 so that all
NOTE. Tables 4F (parts 1 to 4) especially, and other sections o f table 4 to a less extent, show groups of systems in each of which the
alternative combinationsof products offer about equal performance. A specification will, therefore, normally need to detail the requirements
more closely e.g., under SF7 a choice could be made as follows:
Surface preparation. Blast-cleanto Sa2% and apply blast primer (AP2A or AP3A) (10 pm to 15 Pm).
Primer FP2A. Zinc phosphatelmodifiedphenolic, two coats 70 pn.
Undercoat FUIC. MlO/modified phenolic, high-build 80 Pm.
Finish FFIB. MlO/modified phenolic 40 Pm.
31
BSI B S * 5 4 9 3 77 m 3624667 0360562 T m
BS 5493 : 1977
Section two
Table 4G. Group G systems. Silicone alkyd paint over two-pack primer and undercoat
Nominal
system
thickness,
Primer Pm
I
245
345
Table 4H. Part 1. Group H systems. One-pack chemical-resistant paints
Reference
Surface
T
coating
Nominal
preparation Fm
Primer
thicknesses,
Undercoat Finish
Nominal
system
thickness,
Pm
HPI, HP2 HU 1, HU2 HFI, HF2
SH 1 st2 35 1O0 25 to 30 160

SH2 st2 70 1O0 50 to 60 220
SH3 Sa2% 35 60 50 to 60 150
SH4 Saz% 70 1O0 25 to 30 200
SH5 Sa2% 70 1O0 50 to 60 220
SH6 Sa2% 70 1O0 1O0 270
SH7 Sa2% 1O0 1O0 1O0 300
Table 4H. Part 2. Product section HP. One-pack chemical-resistant primer
Referencs Binder pigment

Main
Volume Additional information
solidstotal in thickness (see note (c)* for application
(nominal %) per
pigment
(Pm coat) method)
advised)
I
HPIA Blend of Zinc phosphate 35 40 Recoatable
35 a t all time
chlorinated intervals. Tendsto stick
HP16 rubbers and Zinc
40 chromate 35 35 if early
stacked
non-saponifiable
HPIC plasticizers dust Zinc 40 95 40 Solvent addedjust before use.
(BS 4652 Type 1 Pigment tends to settle
during application. Recoatable
at all time intervals
HP1D 40 dust Zinc 95 40 Pigment tends to settle and

(BS 4652 Type 2) harden in container. Should be
homogenized prior to
application. Recoatable at
all time intervals
~~ ~
HP1E Metallic
45lead 50 35 Should be homogenized before
application. 6rush.application
recommended (see note (c)).
Recoatable a t all time intervals
HP2A Blend of vinyl 35

Zinc phosphate 35 40 Similar to Type HP1 above,
:hloride/acetate but better surface
HP26 :opolymers Zinc chromate 35 40 35 preparatioc is required for
(maleic modified) good adhesion. Recoatable
HP2C Nith or without Zinc dust 40 40 95 a t all time intervals
Ion-saponifiable HP2C is BS.4652 Type 1
HP2D
40 dasticizers 95 Zinc dust 40 HP2D is BS 4652 Type 2
*Notes to this table are on a puli-out folder following

32
BSI BS*5973 7 7 W LbZLtbb'7 OLb0563 L W
BS 5493 : 1977
Section two
Table 4H. Part 3. Product section HU. One-pack chemical-resistant undercoats
pigment
I
Reference Binder Main
solids totalin
information
thickness
Additional
(see note
for(c)*
I Blend of
1:I 1 1 1
HUIA Titanium dioxide Note (f).
chlorinated (white and tints) and HUIB is high-build
rubbers and chemical resistant
non-saponifiable coloured pigments
plasticizers (full colours).
HUIC
Suitably extended
Micaceous iron 40
I
80
;l
30 Note (9).
oxide HUID is high-build
H U ID 35 80 1."
O0
I l I
I
HU2A Blend vinyl
of Titanium dioxide Note (f).
'
chloridelacetate (white and tints) and HU26 is high-build
'"'6 chemical resistant
copolymers
with or without coloured pigments
non-saponifiable (full colours).
plasticizers Suitably extended .
HU2C Micaceous iron 40 80 30 Note (9).

oxide HUPD is high-build
HU2D 35 80 1O0
table 4M. The folder should be extendedwhilst using anypart of table 4

*Notes to this table are on a pull-out folder following SO that all
Table 4H. Part 4. Product section HF. One-pack chemical-resistant finishes
II
Reference Binder Main pigment Volume
solids
(nominal %I
Main pigment
in total
pigment
(weight % min.)
Dry film ,
thickness
(Pm per coat)
(minimum
Additional information
(see note (c)*for
application method)
advised)
3utile titanium 35 90 25 HF16 i s for high-build

chlorinated %oxide: white airless spray
rubbers and and tints 30
1 90 O0
non-saponifiable
-
plasticizers Fade-resistant 35 - 25 H F l D is for high-build
chemical-resistant airless spray
HFlD coloured pigments
and carbon black I3O l- I loo
HFIE Micaceous iron 40 80 30 Note (gl. HF1 Fis for high-

oxide build airless spray
HFIF 35 80 1O0
90 HFPA 35
Blend oftitanium
vinyl Rutile 25 HF2B i s for high-build
chloride/acetate dioxide: airless spray
HF2B copolymers
1 90 white
30and tints o0
with or without
HF2C 35
non-saponifiable Fade-resistant - 25 HF2D is for high-build
plasticizers chemical-resistant airless spray
HF2D pigments
coloured 30 - 1O0
and carbon black
EL
Micaceous iron 40 80 30 HF2F is for high-build
oxide airless spray
35 80 1O0
Aluminium 35 95 25 HF2H is for high-build

airless spray
95 30 100 -
HF2H
*Notes to this table are on a pull-out folder followingtable 4M. Thefolder should be extended whilst using any part of table 4 so that ell
33
BS 5493 : 1977
Section two
Table 4J. Group J system. Drying-oil-type primer.with one-pack chemical-

resistant undercoat and finish
preparation system
Finish
Undercoat thickness,
FP3, FP4
35 170
Table 4K. Part 1. Group K systems. Two-pack chemical-resistant paint
Nominal coating thicknesses, Nominal

thickness,
Undercoat
Finish
Primer Pm
KP 1 KUI, KU2 KFI, KFZ
SKI Sa2% 35 1O0 35 - 45 170 - 180

SK2 Sa2% 70 1O0 70 240
SK3 Sa2% 70 1O0 1O0 270
S K4 Sa2% 70 150 1O0 320
KF3:
coal tar
epoxy
Sk5 Sa2% 150 150

S K6 Sa2% 250 250
SK7 Sa2% 350 350
SK8 Sa2% 450 450
Table 4K. Part 2. Product section KP. Two-pack chemical-resistant primers
Reference
Binder Dry-film Additional information
solids totalin thickness (see note (c)* for
(pm per coat) application method)
(weight % min.) (minimum
advised)
1 I
~ ~~
KPIA Two-pack
epoxy Zinc
phosphate 35 35
Zinc dust
95 35 35
Zinc dustlzinc oxide 35 50 35
I 45
I 50 35 Brush application
*Notes to this table are on a pull-out folder following table 4M. The folder shouldbe extended whilst using any part of table 4 so that all.
notes are immediately visible when required.
34
BS 5493 : 1977
Section two
Table 4K. Part 3. Product section KU. Two-pack chemical-resistant undercoats
i
I
Reference Binder Main pigment Volume Additional information
solids in tatal thickness (see note (c)* for
(nominal %l
advised)
I
Titanium dioxide 40 Note (f). For airless
spray
(white and tints) or 40 % min. volume solids
chemical-resistant
coloured pigments - spray High-build airless
(full colours). (Note (f) I
K
y
Suitably extended I I
Micaceous iron Note (9). For airless spray
oxide KUIC advised dry-film
thickness 50 Pm. KU1D is
for high-buildairless spray
polyurethane
(white and tints) or
-1 40 ~~ -1 -Note (f), KU2B is for
chemical-resistant
coloured pigments
(full colours).
Suitablv extended
Micaceous iron Note (9). KUPD is for

oxide high-build airless spray
-
*Notes to this table are on a pull-out folder followingtable 4M.The fo!der should be extended whilst using any part of table 4 so that all

35
BS 5493 : 1977
Section two
Table 4K. Part 4. Product section KF. Two-pack chemical-resistant finishes

Reference Binder Main pigment Volume Main pigment Additional
information
Dry-film
solids in total thickness (see for
note
(c)*
(nominal %) pigment (pm per coat) application method)
(welght % min.) (minimum
advised)
KFIA rwo-pack epoxy Rutile titanium 45 90 For 40 reduced

gloss minimtfm
lsee note (i)) dioxide: white additions of suitable
KFlB and tints 40 90 1O0 matting agents or extender
pigments may bepermitted.
KFIB is for high-build
airless spray
KFIC Fade-resistant 45 - 40 KFID

As KFIA. is for
chemical-resistant high-build airless spray
KFID
~~
coloured pigments
and carbon black
~
40
I- l loo
I -
KFIE Micaceous iron Note (9). For airless spray
oxida of K F I E, 50 pm dry-film
KFIF thickness advised, K F I F for
KFIG Aluminium Not recommended where

chemical resistance is
KFPA Two-pack Rutile titanium As for K F I A . KFPB is for

polyurethane dioxide: white high-buildairless spray
KFPB :see note (i)) and tints
KFPC Fade-resistant As for KFIA. KFPD is for

chemical-resistent high-build airless spray
KFPD coloured pigments
end carbon bleck
KFPE Two-pack Micaceous iron As for KFIE. KFPF is for

polyurethane oxide high-build airless spray
KFPF (see note (i))
~~
KF3A Two-pack epoxy Silicate extender The two pigmentations

or modified enable the materialto be
KF3B epoxy coal ter supplied in two colours,
_ _ _ ~ black and chocolate, to
KFBC Micaceous iron identify succeeding coating.
oxide KF3B and KF3D are for
KF3D
*Notes to this table are on a puil-out folder followingtable 4M. The folder should be extended whilst using any part of table 4 so that ail
Table 4L. Group L systems. Two-pack primer and undercoat

overcoated with one-pack chemical-resistant finish (or travel
coat* (tie coat)) and site finish
r ~~
Reference Surface
preparation
I
Nominalcoating thicknesses, pm T Nominal
system
Primer Undercoat Finish thickness,
KPI KUI, KU2 HFI, HF2 Pm
(see table 4Kl (see table 4K) (see table 4H)
SL1 Sa2% 35 1O0 50 185

SL2 Sa2% 35 1O0 1O0 235
SL3 Sa2% 70 125 1O0 295
S L4 Sa2% 70 175 1O0 345
S L5 Sa2% 140 200 1O0 440
S L6 Sa2% 50 150 coat Travel 335
(FU31
35
Finish
(HF11
I 1O0
*The travel coat shouldbe applied before the epoxy coating is completely cured
(usually within 2 to 7 days, depending on shop conditions).
.36
BSI B S * 5 q 7 3 77 m Lb2qbb7 03b05b7 9
BS 5493 : 19
Section t
Table 4M. Product section MF. Bitumen and coal tar products
These products and their fields of use are described in the British Standards listedin the table. Except when usedas an
isolating coat over galvanizing(at a thickness of approximately 60 Pm) heavy coatings(at least 300 Pm) are advised.
Specificationand descriPtion Additional information
BS 1070
BS 3416
BS 4147 I Type A
Type B
Type I
Type I I
Class A grade (a) primers

Class A grade (b) primers
Class B synthetic primers
Class C grade (a) primers
Class C grade (11)primers
Normally dry 8 hours. Called black paint (tar-based)
Normally dry 4 hours. Called black paint (tar-based)
Normally dry 24 hours. Black bitumen coating: general use
Normally dry 24 hours.
Black bitumen coating: suitablefor drinking water containers
Cold-applied bitumen-based. S/P 50-íO0O C ; F/P 23 O C min.
Cold-applied bitumen-based. S/P 100-125'C; F/P 23 "C min.
Cold-applied chlorinated-rubber-based. F/P 23
O C ; F/P 200 O C
Hot-applied bitumen-based. S/P 80-100
OC min.
Hot-applied bitumen-based. S/P 100-120O C ; F/P 200 OC min.

Type 1 grade (a) coating Hot-applied unfilled biturnen. S/P 80-100O C ; F/P 200 'C
L
Type 1 grade (b) coating Hot-applied unfilled bitumen.S/P 100-120OC; F/P 200 OC min.
... Type 1 grade (c) coating Hot-applied unfilled bitumen.S/P 120-140O C ; F/P 200 OC min.
, . Type 1 grade (d) coating Hot-applied unfilled bitumen 40O C F/P 200 O C min.
For hot dipping and as a primer
Type 2 grade (a) coating Hof-applied bitumen/asphalt/inert non-fibrousfiller (23-35 X).
S/P 100-120OC; F/P 200 O C min.
Type 2 grade (b) coating Hot-applied bitumen/asphalt/inert non-fibrousfiller (25-35 %).
S/P 115-130'C; F/P 200 O C min.
Type 2 grade (c) coating filler (45-55 %).
Hot-applied bitumen/asphalt/inert non-fibrous
S/P 120-150O C ; F/P 200 O C min.
Type 3 grade (a) coating Hot-applied bitumen/asphalt/inert fibrous/inert
non-fibrous filler (20.40 %). F/P 200 O C min,
Type 3 grade (b) coating Hot-applied bitumen/asphalt/inert fibrous/inert
non-fibrousfiller (40-60 X).F/P 200 O C min.
. .
BS 4164 Type A coal tar primer Coal-tar-based primer for Types I I and IV coatings
Type B synthetic primer Chlorinated-rubber-based primerfor Types I I and IV coatings
Type 1 refined coal tar For dipping. Viscosity Grade38
Type 1 refined coal tar For dipping. Viscosity Grade 25
Type 2 filled coal tarpitch Softening grade 70. Service temperature 0-35
OC
Softening grade 85. Service temperature0-50 "C

Type II I modified coal tar For dipping. Softeningpoint 30-45 "C
Type IV filled modified coal tar Grade 95/25 maximum application temperature 250
OC
Grade 105/15 maximum application temperature 250

OC
. -
OC
"C
OC
Note. SIP i s the softening point, FIP is the flash point.

L 37
Table 4N. Notes to tables 4A to 4M
(a) Zinc coatings. The desirable thickness of bare zinc for
atmospheric orsea water use is indicated ln figure 1. Where
necessary zinc-dust paint may be applied to small partsafter
erection to bring the total zinc thicknessto the required ievel.
For sprayed-zinc coatings ES 2569 specifies theminimum
thickness as 76 % of the nominal thickness. For galvanized
coatings (see ES 729) only minimum thlckness is sptcified.
Zinc coatings may be safely used upto a t least ZOO C;
beyond that temperature specialist advice should be obtained
on the types of zinc coating to be used.
(b) Aluminium coatings. There is rarely any gain in applying
coatings thicker than 150 Fm.
(c) Application method. Paints and sealers are mostfre-
quently applied by airless spraybut brushing is recommended
for inhibitive primers. For airless-spray application the
percentage volumeof solids is usually slightly lower and the
recommendeddry-film thlckness is slightly higher; details
are given in the notesfor each section. Where no figures are
given the samecomposition may be usedfor brush, normal
spray or airless spray.
(d) Sealers for sprayed-metal coatings. Sealers should be
applied immediately after spraying, preferably by brush.
Pretreatment primer, productC P l or CPZ, should
preferably be appliedto sprayed coatings before sealing.
Seal with products CP3, CP4, CP5 or CP6 until absorption
Is complete,
( e ) British Rail 'T wash'. 9.0 % phosphoric acid s.g. 1.70;
16.6 %ethyl cellusolve, 16.5 76 methylated spirit, 57%
water, 1 % copper carbonate(all percentages are by weight)
A blue solution which turns the bright zinc surfaces black
when properly applied. (If such discolorationdoes not
occur, it is a sign that the pretreatmenthas not been effec-
tive.) Proprietary materials are availablefor the manufacture
of the 'T wash'.
(f) The weightof the principal pigment presentis dependent
on the shade andopacity specified. The extender should
be chemically resistant.
(91 Where special colour is not required MIO (micaceous iron
oxide) pigmentenhances protection.
(h) Used mainly in conjunction with chlorinated rubber
systems as:
. . . . . (1) a key between the primer and the chlorinated
. . . rubber top coating;
(2) as a 'travel coat' to avoid excessive damage during
transit.
Not recommendedwith cathodic protection,
(i) Two-packepoxy andpolyurethane; adhesion when
refurbishing
(1) Not more than 3 days after applying the two-pack
epoxy or polyurethane finish. applya further coatingof
suitable finish (product referenceHFl, HF2 or FF1 to
FF4). Refurbish every 10 years.
(2) Alternatively a t time of refurbishing use controlled
wet blastingwith entrained abrasiveto roughen surface.
Dry thoroughly. Noteneed for initial design to provide
for easy access for blasting.
_ .
.."._
_.
.,.,=-
-.. ....
- ..:

BSI B S * 5 q 9 3 7 7 W Lb2qbb7 03bOSb9 2 m
ßS 5493 : 1977
Section two
10.2 Characteristic advantages of metal and paint coatings. 11. Characteristics of metallic coatings
The general advantages of metallic coatings that should be
Zinc coatings (other than zinc-rich paints)
initially considered when choosinga protective system are
as follows. 11.1.1 General. Four methods for applying metallic coatings
are in general use.
(a) Predictable life,
(b) Single application system. (a) Hot-dip galvanizing: for structures, fittings and
(c) No drying time is needed. claddings.
(dl Protection of damaged areas by cathodic (b) Sherardizing: mainly for fittings, fasteners and
protection. small items.
(e) Good abrasion resistance. (c) Electroplating: mainly for fittings, fasteners and
small items.
Hot-dip coatings have the following additional advantages.
(dl Metal-spraying: for structures and fittings (including
(f) Good adhesion because of metallurgical bond to
fasteners when done after fabrication).
substrate.
(9) Coating thickness is unaffected by contours. The desirable weightor thickness of bare zinc for use in
(h) Major faults are easily visible. different environments can be derived from figure 1. The
metal corrodes a t a predictable and uniform rate, which
Sprayed-metal coatings have the following additional
increases as sulphur dioxide pollution ofthe environment
advantages over hot-dip coatings.
increases.
(i) They can be applied on site.
(i) Structures of any size can be coated. Areas of discontinuity or insufficient thickness of a metallic
(k) Thickness of coating can be built up as desired. zinc coating, howevercaused, may be rectified a t any stage
by the application of sprayed zinc, special zinc-alloy solder-
Thegeneraladvantages of paint coatings that should be sticksor zinc-rich paints,
(d consideredwhenchoosing a proteotive system are.
11.1.2 Gdvanizing. Cleaned steel is immersed in a bath
(a) Ease of application in shop or on site.
(b) Wide availability of painting facilities. of molten zinc; a partial alloying action results in a
(c) No effect on the mechanical properties of the steel metallurgically bonded coating. As SoOn as the steel is
substrate. cool (after withdrawal from the bath) it may be stacked
(d) Easy repair of damage to coatings. and transported or it can be primed for overcoating.
(e) Wide range of colours available for aesthetic purposes,The size of structural assembly that can be galvanized is
Zinc-dust-containing coatingshave of the application limited by the size of the largest bath in each galvanizer's
works*. The largest sizes that can be galvanized in the
advantages of paints and (in the dry-film form) some of
the advantages of other zinc coatings, but, in common United Kingdom are (at the time of preparation of this I
with sophisticated paint systems, they are critically code) :
dependent upon good surface preparation. (a) sections up to 27.4 m long;
10.3 Other coatings. The coatings listed in clause 13 have (b) assemblies 16.8 m x 3.6 m x 1.5 m;
only specific applications,to which their special individual (c) assemblies 5.2 m x 3.6 m x 1.8 m.
properties are well suited.
code
does
The not refer to the galvanizing of steel thinner
10.4 Application facilities. Mostfabricators haveregular than mm* Thinner components have thinner galvanized
facilities for applying paint in works or on site. Facilities coatings (see BS 729); ceatings on continuously galvanized
for spraying metal are not so common, and facilities for sheet are specified in BS 2989 (with further reference
galvanizing are comparatively rare (about a hundred plants in DD 24). The coating weight specifiedfor sheet is the
a exist in the United Kingdom). Such fact_smay affect the

choice of a protective system(seeclauses 4 and 9).
10.5 Effects of delays during application. For many
total weight on both sides of the metal; for components
the rate of coating on one side only is specified.
For sections not less than 5 mm thick reference shouldbe
protective systems the timing ofoperations is critically made t o BS 729, where a minimum specified weightof zinc,
important, particularly when the work has to be done 610 g/m2 , is equivalent to a thickness of 86 pm (shown
under adverse atmospheric conditions, In some situations as '85 pm minimum' in the tables) on each face. The
it is important to allow sufficient time for coatings to cure thickness of coating varies with the thickness of steel,
or for residual solventto evaporate, but more often failure surface preparation and conditions of immersion. It may
to achieve the expected performance is caused by unfore- be increased to 140 pm (1000 g/m2) if either the steel is
seen delays between operations. I f delays are likely, because grit-blasted before coating or the steel contains silicon
of uncertain weather, hold-up in buildin'g operations, or (typically more than 0.3 %l. The coating thickness maybe
other factors, a system tolerant of changes in periods increased to 210 pm (1500 g/m2)by using silicon (typically
between coats shouldbe selected or provision should be more than 0.3 %) or silicon-killed steels and cons?rltation
madefor appropriate remedial treatment if necessary. For with the steel supplier and garvanizer is essential if these
example a zinc-rich primer that has been exposed for thick coatings are. required. Brown staining may occur
several months before should be washeddown early in the life of steel containing silicon. This is a surface
thoroughly t o remove soluble zincsalts and in similar phenomenon and does not affect the protective value of
circumstances the surface of a paint based on epoxy resin the coating,
should beabraded orlightly blast-cleaned t o ensureBecause the recommendations in table 3 for galvanizingare
adhesion of the next coat.
based on products made of steel more than 5 mm thick,
10.6 Costs. Cost is a major factor in determining the the minimum thickness recommended is 85 pm, ¡.e. the
rl) choice of a protective system. Quotationsshould besought
from several for each system that meets allother
minimum permitted for such products in BS 729. Some
galvanized steel (see above) will have thinner coatings. BY
requirements. Appendix E gives guidance on the principles reference to figure 1, the different lives of such thinner
involved in assessing real costs.
1 *Listed in a directory issued by the Galvanizers Association, 34 Berkeley Square, London W1 X 6AJ.

39
BSI B S * 5 4 7 3 7 7 Lh24bb7 OLb0.570 7 W
BS 5493 : 1977
Section two
galvanized coatings can be estimated and the appropriate (c) the required decorative finish can be obtained only
life requirement to first maintenance may be assessed. by paint; or
11.1.3 Sherardizing. This process is used mainly for small (d) when additional abrasion resistance is required.
parts and fasteners,,particularly for threaded work where Generally one or two coats of paint may be sufficient
only small change of dimension is acceptable. After suit- except in abnormally aggressive environments. Sealed
able surface preparation, the items are tumbled in hot zinc sprayed metal is usually preferable to painted sprayed
dust. The thickness of the coatingvaries with the process- metal.
ing conditions; two grades (15 pm and 30 Pm) are specified
Appropriate paints usually have a longer life on metal
in BS 4921, and the lives of those thicknesses are compared
coatings than on bare steel, and rusting and pitting of the
in figure 1.
steel is reduced or prevented.
11.1.4 Hectroplating, Zinc-plating of small parts by the
11.3.2 Zinc coatings plus paint. The paints used should
electrolytic deposition of zinc from zinc-salt solutionsis
be compatible with the sprayed or galvanized surfaces.
done only by specialist firms.
Most paints, 0the.rthan those containing drying oils, are
It is rarely economic to electroplate thicker than 25 pm. suitable for application to zinc-coated steel that has been
Cadmium plating is an alternative used for special purposes. pretreated as described below. Some paints may be applied
BS 1706 specifies coating techniquesfor threaded parts. without pretreatment (see note 2 under table 4B for some
11.2 Sprayed-metal coatings that have been successfully used over a long period of
time; more recent developments are not included), Zinc-
11.2.1 General. The metals commonly used for spraying coated steel is a suitable base for paint but the first
structural steel are zinc and aluminium. treatment may be different from that of uncoated steel.
The technique of spraying metal is applicable to structures Acceptable treatments include thefollowing.
and fittings either in the shop or on site. An atomized (a) Pretreatment primersthat have been specially
stream of molten metal is projected from a special gun (fed
formulated for the treatment of zinc-coated steel
by either wire or powder) on to a surface prepared in accor-
before painting (see table 4C, part 2).
dance with BS 2569. There is no size limit (cf, galvanizing,
see 11.1.2) and the process is especially economical when (b) Many proprietary chemical conversion processes
the area/weight ratio is low. (chromate, phosphate or oxide types) are available for
spray, brush or dip application in the shop before
All grades of steel can be sprayed. The steel surface remains shop-painting of galvanized steel in controlled process
cool and there is no distortion, nor is there any effect on
plants. Manual application can lead to misuse, and
the metallurgical propertiesof the steel.
some procedures are not suitable for structural steel.
Coating thicknesses less than 100 pm are not usually
(c) A non-proprietary material, known as British
specified unless the sprayed metal is to be sealed or painted
Rail 'T Wash'; comprises 9.0 % by weight of phosphoric
immediately.
acid ( d = 1.70), 16.5 %ethyl cellusolve; 16.5%
For most atmospheric environments, there is no advantage methylated spirit; 57 % water; 1 % copper carbonate.
in spraying aluminium to a thickness greater than 150 Pm This is designed for use on galvanized surfaces andis a
(nominal). blue solution which turns the zinc surfaces black when
11.2.2 Sprayed-metal-plus-sealersystems. A sealer (table properly applied. If a surface does not turnblack
4C, part 2) which fills the metal pores and smooths the the pretreatment has not been effective.
sprayed surface, improves the appearance and life of a
sprayed-metal coating. it also simplifies maintenance,
which then requires only the renewal of the sealer. 12. Characteristics of paint systems (including
Sealers should be applied immediately after spraying the
metallic zinc-rich paints).
metal coating. Pretreatment primer CP1 or CP2 may be 12.1 General. Paint systems usually consist of primer,
applied beforesealing. Sealing itself is done with types undercoat(s) and finish coat. Each component normally
CP3, CP4, CP5 or CP6 until absorption is complete. contains pigment (solid particles) suspended in a solution
(There is no requirementfor a measurable overlay of of binder (resinsolution). Choice of pigment and ratio
sealer.) Type CP7 is used for sealing when surface of pigment to binder depends on the function of the paint;
temperatures up to 550 OC are envisaged. e.g. more binder will be used in a penetrating primer for
Metal-sprayingand sealing are normally done by specialist sprayed metal and more pigment in a high-build undercoat.
contractors* who are equipped to apply the full protective 12.1.1 Binderst. The binder more clearly defines the
system in shop or on site, essential characteristics of the coating (see appendix B),
11.3 Metal-plus-paintsystems Drying-oil-type paints dry in the presence of atmospheric
oxygen; the action is catalytically promoted by metallic
-11.3.1 General. Metal-coatedsteel is painted only when:
soaps. One-pack chemical-resistant coatings usually dry by
(a) the environment is very acid or very alkaline (¡.e. evaporation of solvent but the moisture-cured
when pH-value is outside the range 5 to 12 for zinc or polyurethanes are also in this group. Two-pack chemical-
4 to 9 for aluminium); or resistant coatings form by chemical reaction; the two
(b) the metal is subject to direct attack by specific components have to be mixed just before use.
chemicals (see table 3); or
'Listed in a directory issued by the Association of Metal Sprayers, Heathcote House, 136 Hagley Road, EdgbaSton,
Birmingham.Bl6 9PN.
tFor the correct use of the terms 'binder', 'vehicle' and 'medium' see BS 2015.
40
BSI BSX5q93
BS 5493 : 1977
Section two
12,1.2 Pigments. The pigments may inhibit corrosion, 12.4 One-pack chkmical-resistant paints. One-pack chemical-
reinforce the dry film, provide colour, and/or absorb or resistant paints, H, dry under any well ventilated conditions
reflect ultra-violet radiation, thus improving the durability but, where coatings are built up thickly, retained solvent
and stability of the coating (see appendix C). may keep films soft and prone to damage for days or even
weeks, Recoating is easy, unless the surface has become
12.1.3 High-buildcoatings, High-build formulations
heavily contaminated,because the films remain soluble
permit much greater film thicknesses per coat. They are
in suitable hydrocarbon solvents. Where the highest
usually applied by airless spray but can be applied by
chemical resistance is not required a system, J, of anti-
roller or brush.
corrosive, drying-oil-type primer, carefully selected for
12.1.4 Compatibility. All paints within a system should compatibility with a type-H chemical-resistantfinishing
have compatibility between coats andwith the metal system, allows some relaxation of the steel.preparation
substrate (¡.e. there shouldbe adequate adhesion t o the standards.
substrate and between coats overthe operating temperature
12.5 Two-pack chemical-resistant paints. Two-pack
range and there should be no under-softeningto cause
chemical-resistant paints, K, are resistant t o acids, alkalis,
lifting, wrinkling or bleeding-through of stains). For this
oils and solvents, but should not be used unless the highest
and other reasons it is generally advisable to obtain all
quality of surface preparation and application can be
the components of a paint system from the same source; assured. Cured films are hard and solvent-resistantso that
otherwise, assurance of such compatibility should be
intercoat adhesion may be doubtful, particularly where
obtained. I f cathodic protection is applied to the structure,
surface contamination may occur. Coal tar epoxy and
the paint system should be compatible with it (see 13.5 and
urethanehar coatings are rather cheaper and may be
CP 1021). easier to apply, but are restricted to darker coloursand
12.1.5 Solvents, Solvent modification of paint composi- have lower solvent resistance.
tion is frequently necessary to allow for the characteristics
Hot-applied, solvent-free epoxies have a particular use-
I of different methods of application. fulness for tank linings whereflammable solvents could
12.1.6 Handling, stacking and repair. Two-pack chemical- be a hazard.
resistant paints withstand reasonable handling and can be
Where the greater part of a two-pack chemical-resistant
readily stacked whenfully cured, but most other paints
system is to be applied in the shop and where travel or
are relatively easily removed down to primer. One-pack
erection damage may have t o be touched-up on site it may
chemical-resistant paintstend to stick on stacking, but
be advantageous to choose the system, L, incorporating a
drying-oil-containing paints can be stacked, with care,
chlorinated-rubber travel coat, which will readily accept
Touching-up on site is easy for most paintsbut initial
a further chlorinated-rubber coat after erection.
abrasion may be needed to provide adequate adhesion of
touching-up treatments over two-pack chemical-resistant 12.6 Bituminous coatings
paints. 12.6.1 General. Bituminous coatingsare low-cost coatings
12.2 Zinc-rich paints”. Metallic zinc-rich paints may be whose protective properties depend on film thickness.
organic (Type 3 as specified in BS 4652 : 1971) or inorganic. There is a wide range of materials based on either mineral
bitumen or coal tar fractions applied as unheated solutions,
With 90 % or more of zinc-dust (which may contain up to
hot solutions, or hot melts; bituminous emulsions are little
4 % zinc oxide) in the dry film the coating will afford
used for the protection of steel. Specially developed
cathodic protection but will be slightly permeable. The
materials, based on powdered coal dispersed in pitch, are
formation of zinc salts will gradually render the coating
widely used for the protection of underground pipes.
impermeable and it will then be a barrier coating. I f
damage t o the coating exposes the steel the zinc will again Blast-cleaning before coating gives the best performance
become cathodically sacrificial to prevent rustspreading. but is not essential for many uses.
Suitable sealer coats improve the appearance of zinc-rich Bituminous coatings have good resistance to dilute acids
paint coatings, The advice of the coating supplier shouldbe and alkalis, salt solutions and water, but are not resistant
sought regarding thetype of sealer to be used, especially to vegetable oils, hydrocarbons and other solvents. They
if the surface is exposed between applications. The various may become brittle in cold weather and soften in hot
uses of zinc-rich paints, as shop-primer, fabrication-primer weather. Bitumen-coatedarticles should not be stacked,
or main coating, are indicated in tables 3 and 4. Members The relevant British Standards are shown in table 4M,
and assemblies coated with zinc-rich paints may be handled which also lists the available types.
or stacked as soon as the coating is dry, but exposure of Bitumen solutions and emulsions are readily applied by
freshly applied zincsilicate paints to moisture within a brush or spray and are often used as priming coats for the
stack can result in deleterious changes. heavy-duty materials which can be applied hot or cold
12.3 Drying-oil-type paints. Drying-o,il-type paints, at the works or on site. The specifier should consider
F, cover a wide range of materials, ranging from largely inhibitive oleo-resin-based primersfor heavy-duty
obsolescent simple oil paints, which were slow-drying but bitumen provided that sufficient drying time (several
tolerant of less than perfect surface preparation, to phenolic weeks) can be allowed to pass before overcoating.
varnishes and epoxy ester paints, which dry well even a t 12.6.2 Coal tarpitches and bitumens. CoaCtar pitches
low temperatures. Recoating usually presents no problem have high resistance to moisture and good adhesion to
but chemical resistance is poor to moderate and weather steel, so they are very suitable for structures that are
resistance is moderate to good. immersed in water (especially foul water) or buried in the
Silicone alkyds, G, are more expensive than other drying- ground. The appropriate water supplyauthority should
oil-type paints, but keep cleaner and retain colour and gloss be consulted before coal-tar-based materialis used in
better than most other coatings. conjunction with potable water. Coal tar pitch is less
readily softened by hydrocarbon oils.
*Commonly called zinc-rich coatings.
41
BS 5493 : 1977
Section two
Prolonged exposureto weather and sunlight causes surface tough coatings. Polyesterand polyurethane powders give
chalking because of oxidation and loss of plasticizing com- better resistance to weather. Selected polyurethane and
ponents, so coal-tar pitches and bitumens should never nylon powders are particularly useful where impact and
be specified for such conditions (unless they are overcoated abrasion resistance is important, as on certain types of
with asphaltic material in solution or emulsion form), nor fastener. Unless anticorrosive pretreatmentsor solvent-
should they be used in very hot conditions (such as may borne primersare first used, powder coatings often have
arise in a pipeline downstream of a compressor). indifferent adhesion so that protection may fail rapidly
once the coating has been broken.
The coatings may be reinforced with glass fibre or asbestos
wrapping, especially for the protection of pipelines. Wrapp- 13.2 Grease paints. Coatings based on greaseshave two
ings made from vegetable fibres such as cotton or hessian uses:
'are liable to microbiological attack. (a) as permanent non-curingcoatings for application to
12.6.3 Asphaltic coatings. Asphaltic coatings have much the inside of box sections, and
better resistance than coal tar pitches to sunlight, weather (b) as temporary protectives (see BS 11 33 : 1966, section
and exposure to the direct heat of the sun. Resistance to
six, 1966) for components in store or for machined
breakdown under sunlightcan be improved with flake surfaces before assembly.
aluminium. Asphaltic coatings are recommended for buried
Thick grease films form effective barriers to moisture but
or submerged conditions and they are best used with
inhibitors are added to increase the effectiveness. Grease-
inhibitive primers.
based coatings should be used in conjunction with tapes
12.6.4 Application of coal tar pitches andasphalts. The or other wrappings on componentsthat are to be stacked
materials are heated as needed in boilers near the application or are liable to rough handling.
site. For vertical surfaces the material is daubed on with a
stiff brush, covering small rectangular areaswith short
13.3 Wrapping tapes and sleeves. Wrapping with adhesive
tape protects ferrous metals, particularly pipelines, joints,
strokes and overlapping to form a continuous coating.
In weld areas the brush strokes shouldbe in the direction valves, and other fittings by excluding the environment
from the substrate. For further protection against accidental
of the weld; a second coat should then be applied in the
damage and to promote adhesion of the wrapping tape it is
opposite direction. For horizontal su'rfaces the material
can be poured on and then trowelled-out and if unevenness good practice to clean thoroughly from the substrate any
rust products and to prime with an inhibitive primer before
occurs where a smooth surface is required, it may be
taping.
permissible to play a blow-lamp on to the surface and
finish by trowelling, Considerable skill is required in all Buried pipelines are often supplied wrapped a t works with
these operations (see BS 534). bitumen or coal tar reinforced by glass fibre and only the
joints require wrappinga t site.
12.6.5 Overcoating. In general, only bituminous material
should be used for overcoating bituminous materials. It When applying wrapping tape an overlap of a t least half
is, however, possible to overcoat with some emulsion paints the width of the tape is recommended and for coating
or cement pajnts and these may be desirable to reduce pipes of up to 300 mm diameter it is good practice to
surface heating under sunlight. use a tape of width matching approximately the diameter
of the pipe. Application by hand is satisfactory for small
13. Characteristics of some other protective jobs but for large installations, such as long pipelines,
systems fully automatic or semi-automatic methodsare used. The
skills lie in obtaining a consistent tensionthroughout the
13.1 Powder coatings. Coatings formed from pigmented operation, uniform bonding and the avoidance of air
resins, applied as dry powders and fused by heat, have been pockets.
developed for protection of lightweight steel components.
Three types of wrapping are commonly available.
Some types of powder coatings alsofind applications on
pipes and hollow sections, e.g. lighting columns, where 13.3.1 Petroleum-jelly tapes. These consist of fabric of
simple shapes facilitate coating and heat curing. They are natural or synthetic fibre or glass cloth impregnated with a
unlikely to be economical for use on heavy sections because mixture of petroleum jelly and neutral mineral filler. They
of the high temperatures requiredfor fusing or curing. should be used in conjunction with a petroleum-jelly
Powder coatings areof twomain types: primer. The coating is permanently plastic; it is suitable
for application to irregular profiles and should be smoothed
(a) thermoplastic powders, based on e.g. polyethylene, by hand, taking care to avbid any air pockets. When used
polypropylene, vinyl copolymers, or nylon-Il, which fuse to above ground, these tapes should be protected by a
form films without any chemical change; bituminous-tapeoverwrap in situations where they may
(b) thermosetting powders, based on e.g. epoxy, polyester, be subject to damage by abrasion. They are also suitable
acrylic or polyurethane resins, which cure to chemically as insulation t o avoid bimetallic contacts.
cross-linked films after being fused by heating. 13.3.2 Synthetic resin orplastic tapes. The most readily
Theremoplastic powders are frequently applied by a available synthetic tapes are polyvinyl chloride (PVC)
fluidized-bed technique in components that have been and polyethylene tapes. These polymer strips, usually
Rreheated so that the powder will stick readily. Coatings 125 Fm to 250 Pm thick with a fabric core, are coated on
can be built up to a thickness of 200 Fm to 300 pm in one side with a compact-adhesive, normally of synthetic
one operation and are highly protective where a complete rubber base. They are usually available in a range of colours
wrap-round can be achieved. if pipe identification is required.
Thermosetting powders are usually appliedby electrostatic Synthetic resin or plastic tapes are suitable as insulation
spraying to a film thickness usually between50 Fm and to avoid bimetallic contacts, particularly in d3mp or dirty
100 Fm, Epoxy powders are easily applied and form conditions.
. .
42
BSI BS*K5493 7 7 m Lb24bb9 O360573 4
BS 5493 : 1977
Section two
Best protection is obtained if the steel is first cleaned and 14. Surface preparation
coated with a conventional rust inhibitive primer. For
exterior exposure black polyethylene tape is preferred to
14.1 General. The surface preparation of the steelwork has
a major influence in determining the protective value of the
polyvinyl chloride because its surface degrades much less
on exposure to sunlight and weather. coating system.
13.3.3 Coal tar and bitumen tapes. These tapes are used For metallic coatings it is generally an integral part of the
mainly for buried pipelines, They have a high resistance process and is included in the relevant British Standards.
t o moisture and good adhesion t o steel. The fabric rein- Paints may be applied to surfaces in a variety of ways
forcement is usually made from glass fibre. The steel should and the type and standard of surface preparation should
first be cleaned and givena coating of coal tar or bitumen be specified as part of the protective coating treatment
primer. According to the temperature expected in service (see section three).
so can the low properties of the tape be varied.. For some The choice between blast-cleaning, acid-pickling, flame-
high temperatures and especiallyfor high-duty require- cleaning, and manual cleaning* is partly determined by the
ments, the grade of coal tar or bitumen used is such that nature of the coatings to be applied. It should be appreciated,
it is necessary to heat the tape to soften it sufficiently for however, that coatings applied to a properly prepared (ems.
good application and bonding, and to heat the overlap blast-cleaned) surfacewill always last longer than similar
when applied, to obtain the best seal. coatings applied to flame-cleaned or manually cleaned
surfaces. It should be borne in mind that some short-life
13.3.4 Two-pack taping. In this method of high-duty pro-
coatings do not warrant the high cost of the standards of
tection a woven tape is impregnated, after wrapping, with a
blast-cleaningwhich are required for long-life coatings.
two-pack solventless composition, normally a polyester or
two-pack epoxy. The technique usedis similar to that used 14.2 Degreasing. Grease and dirt are best removed by
in the preparation of glass fibre moulding, exceptthat the emulsion cleaners followed by thorough rinsing with
resin-impregnated glass cloth is intended to adhere t o the water, or by steam-cleaning, or by controlled high-
metal substrate. This method is used especially for shaft- pressure water jets.
ing exposed to marine conditions and for surfaces which Where it is necessary to use turpentine or similar solvents
may be subject to cavitation corrosion. to remove oil or grease, the use of detergent or emulsion
The surface to be protected should first be thoroughly cleaner should follow and the operation should be
cleaned to bright metal, then primed with a two-pack completed by thorough rinsing with clean fresh water.
epoxy (or similar). It should then be wrapped with glass Degreasing by washing in solvent is not recommended
cloth insheet or tape form and the cloth impregnated (except in automatic degreasing plants) because this
with a two-pack polyester or two-pack epoxy composition. invariably leads t o the spreading of a thin film ofgrease
It is good practice to apply a thin coating of the impreg- over the surface which can impair the coatings, It is equally
nating resin before applying the reinforcing substrate; important to avoid this spreading of grease when steam jets
then several layers are built up and the final surface is are used; the soil should be physically removed by scraping
trowelled smooth. The coating will then set to a hard before cleaning.
glass-like tough protective coating which is impermeable CP 3012 covers the cleaning of metal surfaces.
to water.
13.3.5 Plastic sleeves. Polythene and similar plastics may 14.3 Removal of scale and rust. The chemical structure
of rust is described in A.1.4, and the important point to
be used as protective sleeves on pipes and are sometimes
be noted is the presence of iron salts, such as sulphates
shrunk on to the metal. For spun iron pipes and castings
the application of a non-adherent but snug-fitting poly- and chlorides. These will cause early failure of paint
thene sleeve gives good protection. The sleeving is applied coatings applied over them.
a t the time of laying the pipe and joints are taped with 'Mill-scale' is the term used for the surface oxides produced
adhesive strip. during hot rolling of steel. It breaks and flakes when the
13.4 Protection of steel by cement and allied products. steel is flexed and paint applied over it may fail prematurely.
Cement-mortar linings are widely used for the internal The extent of such failures is unpredictable but they
protection of water mains. Special formulations and frequently occur within a few weeks of painting, particularly
coating proceduresare used. They have limited impact in aggressive environments.
resistance but may be repaired on site by fresh No protective coating can give long-life protection unless
applications. Conversely, steel structures (and steel both the scale and rust are removed.
reinforcement) may be in contact with, or embedded in, Information is given in 74.3.1 to 14.3.4 on the commonly
concrete. Codes of practice CP 1 1 O and CP 1 14 to CP 1 17, used methods of preparing steel surfaces for the application
relating to concrete and steel/concrete structures, contain of coatings.
relevant information. 14.3.1 Blast-cleaning. Abrasive particles are directed at
Exposed steel may be covered with gypsum plaster and high velocity against the metal surface. They may be
magnesium oxychloride cements, but it should first have carried by compressed air or high-pressure water,or thrown
been coated with a suitable bitumen coating that is resistant by centrifugal force from an impeller wheel. For some
to water penetration while the plaster or cement is curing. open blasting, high-pressure waterwithout abrasives may
13.5 Cathodic protection. The degree of protection be used. The various methods are listed in tabre 5.
afforded by a cathodic system may be enhanced by paint
coatings, but notall paint systems are compatible with
cathodic protection systems and specialist adviceshould
be sought.
*The term 'manual cleaning', as used in the code, encompasses all methods of cleaning other than blastcleaning, acid-pickling, and flame-
cleaning.

43
BSI B S * 5 4 7 3 7 7 m L62Ybb7 0160574 6 m
BS 5493 : 1977
Section two
14.3.1.IChoice of method of blast-cleaning. The choice places, e.g. by welding. Such areas should be cleaned and
will be determined mainly by the following factors. re-primed as soon as possible.
(a) Shape and size of steelwork. Centrifugal methods Where steel is cleaned after fabrication it may still be
are economic for plates and simple sections; they can necessary to apply a blast-primer, but often the first coat
also be used for large prefabricated sections, e.g. bridge of the full protective system can be applied,
sections, but only in specially designed plants. 'Misses' 14.3.1.3 Abrasives. Common abrasives for cleaning steel-
discovered by inspection can be cleaned with open- work are classified in table 6, with notes on their advant-
blast techniques. For large throughput of shaped items, ages and disadvantages. For size grades of shot and grit,
e.g. pipes, both open and vacuum-blasting techniques reference should be made to BS 2451. It is essential to
can be used in continuous and automatic plants. avoid the use of contaminated abrasives, as the following
(b) Effect of the stage at which it is carried out. For three types of contamination may occur.
blast-cleaningon site, open or vacuum-blasting methods (a) Dry dust and detritus from the surface and the
have to be used as on large fabricated sections, it may srnafier fines from the breakdown of abrasives. They
be impracticable to use centrifugal methods. can be removed by automatic and recirculatory
(c) Throughput, Centrifugal plants areeconomic for plants. Without such a cleaning process, abrasives
a high throughput, but even with a low throughput the should not be re-used.
method may still be preferable to large-scale open (b) Water, either on the surface, in the compressed
cleaning. air, or from conditions of very.high humidity, forms
(d) Environmental conditions. Despite its relatively agglomerates of dust and abrasive particles, inhibiting
high costs, vacuum-blasting may be necessaryt o avoid automatic cleaning processes.
contamination of the immediate area with abrasive. (c) Oil and grease on the surface or from the equip-
It should be ensured that the blast-cleaningprocess does ment preciude there-use of abrasives. Such oil and
not affect adjacent materials. grease should be removed before blast-cleaning.
(e) Types of surface deposit to be removed. Wet- The choice of abrasive will be determined mainly by
blasting methods, with abrasives, are particularly suitable economic considerations,but cast iron grit is recommended,
for removing entrapped salts in rustand for abrading particularly for surfaces to be metal-coated.
hand-painted surfaces, e.g. two-pack epoxies, before 14.3.1.4 Removal of surface dust after blast-cleaning. All
'recoating". dust, residues and debris should be removed from the
14.3.1.2 Stages for carrying out blast-cleaning. Steel may steel surface before the protective coating is applied. Dust
be blast-cleaned either before or after fabrication. Sometimes reduces adhesionof paint coatings and encouragesattack
it may be necessary both before and after. upon the steel by absorbing moisture.
Where steel is cleaned before fabrication it should be Unless the dust can be automatically removed with
protected with a suitable blast-primerto avoid rusting vacuum hand-operated or centrifugal machines, separate
before fabrication is completed. During fabrication, the vacuum cleaners should be used.
blast-primer will inevitably be destroyed or damaged in
*BSRA Report NS319. Removal of marine fouling and exhausted anti-fouling composition from ships' hulls by 'soft-blasting' (1971).
44
BSI B S * 5 4 7 3 7 7 m Lb24bbS O L b O 5 7 5 B m
RS 5493 : 1977
Section two
Table 5. Methods of blast-cleaning

Methods I Advantages . I Disadvantages
Dry methods using compressed
air or centrifugal force
Automatic plants based on High production rates, lowest costs, High capitalcost, high maintenance cost, lackof
centrifugal throwing of the no moisture problems, can be coupled flexibility, ¡.e. not suitable for recessed areas etc.
abrasive to automatic application of primer,
dust problems contained
Open blasting Simple to operate, very flexible and High cost of compressed air,low efficiency, liable to
based on propelling the abrasive mobile in use in both indoorcabinets moisture entrainmentfrom the compressed air,
with compressed air or special rooms or on site, low manually operated anda variable profile can result,
capital and maintenance costs operator requires protective clothing,serious dust
problems
Vacuum-blasting No dust problems, no special Can be very slow and therefore expensive on
based on propelling the abrasive protective clothing foroperators, awkward profiles and girder sections. Whereflat-plate
with compressed air and fairly low capital costs or gun-head automation is possible it may be
immediately recycling by suction considered, but liable to moisture entrainmentfrom
from the blast-cleaned surface the compressedair
Wet methods
(hydroblasting)
Open blasting Simple to operate, very flexible and Slow if firmly held contaminantsare to be removed,
based on projecting water mobile in use, suitable for removing dangerous a t very high pressure if proper precautions
a t very high pressure soluble contaminants,a t very high are not taken, limitation of dryingsurface before
pressure can.remove mill-scale, no painting unless approved water-basedor water miscible
dry dust hazards primers are used, requires availability of water and
drainage, operators require protective clothing
Open blasting Simple to operate, very flexible Dangerous a t very high pressure if proper precaution$are
based on projecting water and mobile in use, suitable for not taken, limitation of dryingsurface before painting
a t high pressure and entraining removing all firmly held unless approved water-basedor water-miscible primers
abrasive into the water stream contaminants as well as soluble are used, particulate dust hazard remains, requires
contaminants availability ofwater and drainage, operators require
protective clothing
Open blasting
based on injecting lowpressure As above High cost of compressed air, low efficiency, limitation
water into a compressed air of dryingsutface beforepainting unless approvedwater-
stream which is carrying based or water-miscible primersare used, dust hazard
an abrasive reduced, operators requireprotective clothing
Open blasting Similar to the above according to whether abrasive is

using steam-cleaning or is not entrained

45
BS 5493 : 1977
Section two
Table 6. Classification of abrasives used for cleaning steel

Abrasive Hardness Normal usage Advantages Disadvantages
Chilled iron-grit 60 to 80 RC Captive blasting Relatively cheap, cleans very Breaks down fairly quickly. In centrifugal
and open blasting quickly, will chip under wheel plants, special protection is
with recovery repeated impact with work required to reduce wear on moving
systems surface, presentingfresh parts
cutting edges
Chilled iron-shot 60 to80 RC Captive blasting Relatively cheap, very hard, As chilled.iron-grit. Because of
only should break downto grit ricochet effect is not suitable for open
in use blasting or in open cabinets
High-duty 55 to 64 RC Captive blasting Breaks down less quickly than More expensive than chilled iron,
chilled Iron-grit and open blasting chilled iron rendered sphericalin use, poorer and
or iron-shot with recovery slower rate of cleaning thanchilled iron
Heat-treated 30 to 40 RC AS high-duty AShigh-duty As high-duty

chilled iron-grit
or iron-shot
~~ ~
Steel grit 60 to 67 RC Captive blasting Does not break down so quickly More expensivethan chilled iron,
47 to 53 RC mainly as chilled iron, causes less rendered sphericalin use and is less
wear in centrifugal wheel plant efficient, supplied in various
hardnesses but a t best is not so hard
as chilled iron-grit and therefore
cleans more slowly
Steel shot 41 to49 RC Captive blasting As for steel grit As for steel grit, tends to hammer-in
only rather than loosenscale, ricochet
effect makes it unsuitable for open
blasting
Cut steel wire 41 to 52 RC Captive blasting As for steel shot and grit, High cost, rendered spherical in use and
only wears down as fairly even slower cleaning thanchilled iron
sizes
Aluminous oxide Not common in the Extremely hard Expensive, hardnessof dust is a danger
(corundum) United Kingdom to machinery unless used in sealed
captive blastplant
Copper slag Open blasting Cheap, no silicosis hazards Initial particles rathercoarse, breaks
only down to dusf very quickly, angular
particles tendto embed in workpiece
Iron slag Open blasting As for copper slag As for copper slag
only
Sand Open blasting CheaD In United Kingdom, Factory

Inspector's approval is required, danger
of silicosis
46
B S I BSmS493 77 m Lb2Vbb7 0360577 L m
BS 5493 : 1977
Section two
14.3.1.5 Standards of blast-cleaning. Three qualities of paint should be applied immediately. This method is not
blast-cleaningare given in BS 4232, I s t , 2nd and 3rd generally used outside the pipe industry, but large plates
quality. (The equivalent qualitiesin the Swedish Standard for storage tanks have been pickled in this way.
SIS 05 59 O0 are Sa3, Sa2%, and Sa2 respectively.) Generally, pickling is done by specialist firms.
I s t quality requires no residue l e f t on the steel, 14.3.3 Flame-cleaning. I n flame-cleaninga high
2nd quality requires a t least 95 % of the surface temperature oxyacetylene flameis passed over the surface
completely cleaned; to be cleaned. The effect of the heat is to remove scale
3rd quality requires a t least 80 % of the surface cleaned. and rust, partly by differential expansion and partly by
BS 4232 should be studied for complete requirements. evolution of steam from moisture in the rust. After flame-
(For methods of measuring cleanlinesssee appendices cleaning thesurface is wire brushed before painting.
F and G.) The method may be useful for maintenance work,
14.3.1.6 Surface profile. Blast-cleaning produces a particularly in damp weather. The first coating shouldbe
roughened surface and theprofile size is important. In applied while the surface is still warm and dry. The
BS 4232 a maximum amplitude, ¡.e. difference of level flame-cleaningof high-strength friction-grip-bolted
between a peak and the adjacent trough, of 0.1 mm is joints and the adjoining areas should be totally
recommended, but formost protective coatings smaller prohibited.
amplitudes are advisable. Generally it is advantageous to The method does not remove all rust and scale and is in
have as small an amplitude as can be economically no way a substitute for blast-cleaning.
achieved. This helps the avoidance of 'rust spotting' which
can occur with rough surfaces, where the coating does 14.3.4 Manual cleaning
not completely cover the peaks. 14.3.4.1 General. Tools such as wire brushes, hand-
The profile size is largely governed by the type and size scrapers, vibratory-needle guns and chipping hammers are
of abrasives and by the method of blasting. Fine available. They may or may not be power operated and
abrasives clean more quickly and more thoroughly than are often used for maintenance work or for the preparation
coarse abrasives, except where it is necessary to crack of steelwork to be exposed in non-aggressive conditions,
very heavy mill-scale. In modern automatic plants for such as:
plates and sections, the scale can be cracked by steam- (a) easily accessible steelwork in rural areas;
cleaning and heating before blast-cleaning. (b) steelwork inside buildings where conditions are
Profiles needed for sprayed-metal coatings are specified non-corrosive;
in BS 2569 and tend t o be of greater amplitude than (c) steelwork to be encased in brickwork, concrete, etc.;
those specified for paint coatings.
(dl internal surfaces of enclosed spaces that are to be
Generally for paint the size of the abrasive particles painted,
should not exceed G 17 (see BS 2451).
They should not be used for the preparation of steel
Automatic plants give the most consistentprofiles. For where high quality long-life systems are to be used.
manual operation, angles near the vertical give lower pro-
Powered tools incorrectly handled may produce marked
files, particularly when large abrasives are used.
surface roughness which could make it difficult toprotect
Instrumental methods of controlling preparation for adequately by paint.
painting are described in appendix F.
It is difficult toachieve a satisfactory standard for any
14.3.1.7 Surface quality of steel. Blast-cleaning is most length of time by manual cleaning.
effective on steel that has not been allowed to rust.
14.3.4.2 Standards of manual cleaning. Swedish Standard
Where steel has been allowed to rust badly, longer times SIS 05 59 00: 1967 laysdown two standards of manual
for blast-cleaningmay be required. Sometimes I s t cleaning, St2 and St3, and these arecorrelated to four
quality standards cannot be economically achieved. It initial steel rust grades A, B, C and D.
is therefore advisable to blast-clean steel as soon as is
practicable after rolling. In practice it is difficult toreproduce these standards
because of the difficulty of sustaining good operator
Steelwork should be sound and free from such performance.
segregation cracks, laminations or surface flaws as might
preclude its satisfactory protection against corrosion, 14.4 Attention t o detail. Apart from surface preparation
both initially and in service. Surface laminations, shelling, of the main bulk of the steelwork, attention should be
cracks, crevices, inclusions and surface flaws should be paid to the details, particularly the following.
removed by chipping and/or grinding before painting or (a) Sharp edges that may have a deleterious effect on
metal-coating. Burrsand sharp edges should be removed coatings should be removed.
before painting. When excessive grinding has been neces- (b) Burrs caused by removal of temporary lugs, etc.
sary the dressed areas should be re-prepared to the should be ground flat.
necessary quality, including filling or welding as required. (c) Welds should be dressed and weld spatter removed
14.3.2 Acid-pickling. Mill-scale and rust can be removed by grinding.
by acid-pickling. A particular type of pickling, known (d) Nuts and bolts should be properly treated.
as the 'Duplex' or 'Footner' process has a final treatment
(e) Fasteners, such as pipe-hangers, should be treated
in hot2 % phosphoric acid solution. This leaves a thin
before beingfixed t o the main structure.
phosphate coating ona warm steel surface, to which the

47
BSI BS*5473 7 7 l b 2 4 b b 9 0360578 3
B5 5493: 1977
Section three
Section three. Specifications and technical materials, surface preparation, application, storage,
requirements. handling, erection,and inspection a t all stages.)
(b) To serve as a basis for accurate pricing and tendering.
15. Introduction
(c) To be a complete reference document for suppliers
15.1 The scope of this section. The term 'specification' of materials, contractors, subcontractors andall other
as used generally in this code connotes 'the means of parties to a contract.
communicating requirements regarding thequality of
materials and standards of workmanship necessary to (d) To provide a basis from which disputes, controversies,
provide good protection to ferrous construction and arbitrations can be resolved,
materials and components against deterioration by 15.4 Responsibilitiesin preparing a Specification. The
corrosion'. But when used with an initial capital, Specification is usually prepared by the purchaser or by his
thus: 'Specification', it refers to the physical document, representative (who is usually the Consulting Engineer
so named, which is part of a set of Contract or Architect). In certain circumstances, however, it may
Documents. be prepared by others; e.g. a contractor or supplier who
A protective system is sometimes specified by defining is submitting an offer for the supply of work, materials,
the required performanceof the coatings, but whatever or service, or a corrosion consultant employed by any
the reason for preparing a Specification in that way, a t party to the contract for the specificpurpose of preparing
some later stage a specification of materials and workman- the Specification.
ship will have to be prepared to establish clearly what is Whoever does this work has several special responsibilities;
required, This section of the code is therefore devoted they are to ensure that:
largely to the preparation of clauses for the latter type of (a) The materials specified will be available when
specification. wanted (see 21.1).
A statement of technical requirementsand the writing (b) The details of the requirements are given as
of specification clauses on how to fulfil them may completely as is dictated by the complexity of the
appear to warrant separate treatment but the statement work to be done, regardless of the amount of the
has much in common with the specification clauses used work or the value of the contract.
to communicate such information, and in this section,
(c) The standards to be achieved a t every stage are
therefore, considerations of specifications and technical
in fact achievable.
requirements have been combined.
(d) The methods of operation specified for every stage
Model and typical clauses have not been provided since
of the work from the purchase of the materials to the
the main object has been to include technical information
final acceptance of the completed structure,are in
and advice on how to prepare clauses to cover a wide
fact possible and practicable. (For example, a
variety of materials and techniques.
Specification that requires manual cleaningfor surface
15.2 The need for specifications. The potential life of a preparation, in the belief that weathered steel will be
protective system is unlikely to be realized unless: provided, becomes impracticable if only steel with
(a) the correct choice of system is made (see section 2); semi-adherent mill-scalei s available. The Specification
(b) the materials used in the system can be supplied should allow for such possibilities.)
when required and with the properties attributed to 15.5 The communicative value of a Specification. The
them when makingthe choice; above-mentioned responsibilitiesin the preparation of a
(c) the materials are applied in conditions and with Specification are all of a technical nature and the details
standards of workmanship described elsewhere in this of how they should be fulfilled are given later in this
code as good practice; section.
(d) the handling, transport and storage (over which There are, however, other responsibilities whichare of
the main contractor has minimal control) of all materials equal importance. It should be remembered that Specifi-
and coated components results in no damage to the cations are the authoritative means of communication
integrity of the materials or coatingsthat cannot be between engineers, designers and their representatives
completely restored; on the one hand and manufacturers and contractors on
(e) the erection procedures cause no damage to the the other. This is true of all contract specifications. A
coatings that cannot be completely restored; protective coating specification, however, will have an
unusually wide readership. In order that the supply and
(f) such restoration of damaged areas results in a
application of a protective coating system be successfully
protection a t least as good as that of the undamaged
accomplished, all members of the team involved should
areas.
have access to the same information. It follows that all,
There are many variable factors (both natural and other- or a t least the relevant parts,of the information
wise) which can influence the fulfilment of all these contained in the Specification should be circulated to
conditions for success, and it follows that no two everyone concerned, including foremen, chargehands and
projects can be exactly similar. This is one reason why operators of preparation and application equipment;
a 'Specification' should always be included in a s e t possibly also to shippers, storemen and transport drivers.
of contract documents. Everyone of these is expected to understand what is
15.3 The prime functions of a Specification. Whether required of him, so the wording of each part of the
it concerns new structures or maintenance work, the document shouldbe clear, concise and absolutely
prime functions of a Specification for protective proof against misinterpretation by the person(s1 whose
treatment are as follows. duties and responsibilities are defined in that part. The
(a) To state the means by which the required life of assumption should never be made that anyone
the protection system is to be.achieved. ('Means' includes
48
BS 5493: 1977
Section three
expected to comply with an instruction in the Specifi- The schedule should, where necessary, define those areas
cation will correctly infer the intended meaning of that that are not tobe treated in a special manner.
instruction if the wording of it can have any possible The following features of a structural complex are those
other meaning, however remote and unlikely. Nor frequently requiring special treatment (especially where
should it ever be assumed (or intended) that an paint coatings are specified).
ambiguity is clarified by its context.
(a) Meeting faces of connections.
15.6 Schedules. A structural complex can rarely be
(b) Contact surfaces with concrete.
protected against corrosion by a single protective
system applicable t o all parts of the structures. It i s (c) Machines or bearing surfaces.
more likely that economies can be achieved by using (d) Areas associated with plated and galvanized
different protective systems for various parts of the components.
structure. The prime function ofthe Specification is (e) Coverplates.
then to state which system is required for each component (f) Welds and areas adjacent t o welds.
or group of components in the structural complex. This It is essential that the identification marking of such areas
is best done by the use of one or more 'schedules', which be understood by all parties and the Specification should
should contain all the relevant items in the following define how such identification marking is to be made.
list of basic information.
15.7 Details. Following the schedule, the Specification
should set out, in logical sequence, all the instructions
Basic items Requirement
deemed necessary to ensure that the potential lives of
Component or part of Can be identified by reference the various coating systems are realized. No detail should
project t o drawings be omitted i f such omission can adversely affect the
Sections of members References in schedules achievement of thataim.
Special requirements Areas such as connection Clauses 16 to 33 of this section are intended as a guide
surfaces requiring special from which the technical details required can be
treatment selected.
Coating system May be covered by a reference 15.8 Definition and allocation of responsibilities. A
to a standard or to this code protective coating scheme, perhaps more than any other
Surface preparation Reference to appropriate single aspect of a major construction project, requires
standard the cooperation of many officers and operators of
different trades and professions and of many suppliers
Metal coating Spray or galvanize to the and subcontractors with independent managements.
appropriate British Standard Such cooperation will be most effective if each
Coating thickness Special requirements responsible party knows, as early as possible, the exact
(if applicable) limit ofresponsibility within the overall organization of
Sealing for sprayed- Material and number of coats the project. Thus any difference of opinion 'or
metal coatings (if applicable) controversy that may arise within a contract regarding
materials and workmanship, or any departure from
Priming coat Type or product name and
the Specification may be resolved without delaying the
number. Colour (if applicable)
progress of the work and without resort to arbitration.
Stripe coat Type and product name and
It may not be possible to write all such details into a
number. Colour (if applicable)
Specification that is being prepared beforeall other technical
Undercoat Type and product name and details are finalized, but the desirability of such an inclusion
number (if applicable) should be borne in mind throughout all the stages of design,
Finish Any special finish requirements choice of coating system, choice of materials and planning
Film thickness Total or individual as required of the methods of surface preparation and coating
application. Methods of transport, handling, storage and
Inspection Levels to be observed
erection are equally important phases of the total work
which will affect the interrelation and hence the definition
Such a schedule may be included as an integral part of the of responsibilities.
Specification, or as a separate document, accordingto
The following is an example of the sort of complexity
whether it requires to be related t o working drawings or
that can make the division of responsibility both
fabrication drawings. I f the schedule is a separate contract
difficult and important.
document,-the Specification should be worded so that
the schedule has the same mandatory authority as the A coating system may be such that all stages can be
Specification. completed a t the fabricator's works or by a specialist
firm ofcoating contractors. Onthe other hand it may
When preparing such schedules it should be remembered
be convenient, or economic, or necessary that surface
that fabrication works and coating shops are often
preparation and possibly part of the coating be done by
geographically separated, so fabrication drawings may not
the fabricator and part or all of the coating by the
be available to the coating operators. I n such cases a com-
prehensive 'coating schedule', with diagrams if necessary,
should be supplied to the coating operator, preferably as
an integral part of the Specification.
49
BSI B S x 5 4 9 3 7 7 W - L b 2 4 b b 9 OLb0580 I W
BS 5493: 1977
Section three
coating contractor, In such cases the division of (e) Reference plates prepared for inspection purposes
responsibility is clear cut, but the issues are not always should be of a similar grade of material to that of the
so simple. general surfaces and they should be prepared in a
For reasons dealt with in detail in other sections of this similar manner. The surfacesof the reference plates
code, it may be convenient, desirable or necessary for can be preserved by using silica gel or by lacquering.
one or more stages of the coating system to be applied on Replica films, usually of a melamine or non-ferrous
site before or after erection, and possibly by a different metal, can be obtained but they are usually treated as
contractor. Decisions on the apportioning of work inspection aids rather than preserved samples prepared
between works andsite; and between contractor and to an established standard.
contractor, should be made a t some appropriate stage in (f) The blast primer should be applied before the
the design. It may happen that circumstances arise surface has deteriorated below an acceptable level.
after the award of the contract which require the Maximum periods between surface preparationand
arrangements to be changed. application of blast primers shouldbe specified.
The important fact is that divisions of responsibility for 16.2.1.3 Blast-cleaningfor metal-spraying. BS 2569
the performance requiredof the coating have been specifies a performance requirement for metal-spraying
introduced. The Specification should allow for this, and and blast-cleaning, therefore blast-cleaningis not usually
after the initial definition of responsibilities shouldstate specified separately.
how and/or by whom the responsibilities shouldbe
16.2.1.4 Blast-cleaning for galvanizing. Any special
re-allocated in the event of changes in the planned
blast-cleaning requirements,including sample plates,
procedures. should be specified if the blast-cleaning forms part of
Clauses 16 to33 give advice on how each phase of the the preparation of surfaces for thicker zinc coatings.
protective treatment operations shouldbe specified. 16.2.2 Acid-pickling
16.2.2.1 Standards of pickling. Pickling for galvanizing
16. Surfacepreparation and plating is part of each individual process and is not
16.1 Degreasing. Suitable degreasingprocedures should normally specified separately (but see CP 3012 : 1972,
be specified for all surface preparation (see 14.2). clauses 2.5 and 2.6). There are no British or other
16.2 Removal of rust and scale. The detailed instructions Standards for acid-pickling.andthe method varies from
will be determined by the choice of cleaning method works to works. The Footner process (see 14.3.2) has
(see 14.3). Points t o be considered for each method are been used for many years as a broad description of one
satisfactory method of preparing steel for painting. Cold
given in 16.2.1 to 16.2.4.
pickling processes are also now being used, but should
16.2.1 Blast-cleaning, Specification clauses for blast- not be specified without the relevant controls.
cleaning may vary according to whether a paint or metal
16.2.2.2 Removal of rust and scale. This may be simply
coating is to be applied.
specified as complete removal by pickling of mill-scale
16.2.1.1 Salt contamination of blast-cleanedsurfaces. In and rust.
additionto defining the surface cleanliness of blast-
16.2.2.3 Cleanliness of the surface, The Specification
cleaned surfaces, it may also be necessary to specify the should call for washing to remove all excess acid and
minimum permissible contamination of the surfaces by
salts, leaving no foreign deposits on thesteel.
deposits of hygroscopic salts. These will be reveajed by
testing (see appendix G), and the inclusion of clauses i.n 16.2.2.4 Overpickling: This can result in the pitting of
the Specification to cover washing with water or wet steel or in heavy deposits of phosphate, according to the
blast-cleaning may be necessary. process. The need to avoid overpickling should be covered
by an appropriate clause in the Specification.
It should be ensured that any salt solutions resulting fro'm
the washing of surfaces can be drained or flushed away so 16.2.3 Flamecleaning. Flame-cleaning is not usually
that there can be no further precipitation of salts by the specified for new work, but is commonly used to prepare
drying-out of the surfaces of the cleaned steel (or of surfaces for maintenance painting (see 14.3.4 and
any other surfaces nearby). 50.2.2).
16.2.1.2 Blast-cleaning forpainting, The required The following precautionary actions should be specified.
standard of cleaning can be defined by reference to the (a) Avoid overheating, because it causes distortion
appropriate quality in BS 4232. The Specification may of members or modification of steel properties.
also include information on the following. (b) Ensure that rate of flame movement is sufficiently
(a) Method of blast-cleaning. slow to avoid deposition of moisture.
(b) Abrasives and any restrictions on type and size. (c) Wire-brush thesurfaces immediately after appli-
(c) Profile, e.g. the maximum amplitude of the surface cation of the flame, then use dry air-blow or vacuum
roughness suitable for the protective system. I t is also equipment to remove detritus.
advantageous to specify the instrument to be used for (d) Select correct mixture ratio of gases to give best
measuring surface roughness. results.
(d) Standard of cleanliness. Reference should be made (e) Apply priming paint to surfaces that are still warm
to BS 4232 or Swedish Standard SIS 05 59 OO. Where but not hot from the flame-cleaningprocess. This
appropriate the method of measuring cleanliness (e.g. requirement may be considered to be of sufficient
'Surclean') may be specified. In certain instances, it importance to require reheating and further cleaning
may be preferable to specify final cleaning using of surfaces that haGe cooled. It may, however, be
vacuum equipment to reduce dust nuisance in the desirable to limitthe surface temperature to a
coating area. maximum of 40 OC before paint is applied.
50
E S 1 BS*S493 77 M LbZ4bb9 OLbO5BL 3 M
BS 5493:1977
Section three
'16.2.4Manualcleaning. (See 14.3.4.) Descriptive undercoat can be used to give increased film thicknesses,
specifications for cleaning with hand-heldtools are diffi- and stripe coats of finishing paint can be used to improve
cult toprepare. Reference can be made to Swedish abrasion resistance. Stripe coats are normally applied first
Standard SIS 05 59 O0 for pictorial representation when in order that they will be covered by the full coat, thus
appropriate. Otherfactors that should be considered ensuring that there will be a double film thickness on
during the preparation of specifications for manual the most vulnerableareas.
cleaning are as follows.
(a) Possible use, or limitations regarding the use, of 19. Control of thickness of paint coating
various typesof power tools. The two methods of specifying the film thickness are
(b) Use of bronze tools to reduce risk of sparking in based on:
areas subject to risk of explosion. (a) control of wet-film thickness;
(c) Methods of removing dust and detritus. (b) measurement of dry-film thickness.
(dl Limitations on use of hand-held tools to prevent Dry-film thickness is the final requirement but the measure-
surface damage such as indentations, cuts, peaks or ment of wet-filmthickness is often convenient as a quality
burrs. control procedure. It is essential to obtain, a t an early stage,
a good relation between the wet- and dry-film thicknesses
17. Coatingsystem for the coating system to be used. Using wet-film-thickness
The coating system should be clearly specified. Where measurement, it is possible to detect departures from
British Standards exist, as for metal coatings, the relevant specification requirements and to correct them during the
standard should be quoted and so should system references application process. This reduces the necessity for dealing
in accordance with table 2 where appropriate; alternatively with substandard dried or cured coatings.
the product references given in this code (see section two) It is not usual to specify wet-film thicknesses and their
may be quoted, together with the proprietary name of relation with the thickness of dry filmcan be established
the product where appropriate. when preparing test panels. Dry-film-thickness gauges
Where a system reference in accordance with table 2 is not measure only the total filmthickness present when the
used, each part of the system should be specified separately reading is made. Wet-film-thickness measurements indicate
as indicated in section two, e.g. a paint system should be only the thickness of each individual coat.
separated into blast primer, main primer, undercoat(s), The type of gauge that is to be used for the measurement of
and finishing coat. film thickness should be specified.
To assist application and inspection, a difference in the Variation of filmthickness is inevitable and although a
shades of colour of successive coats may be specified. minimum thickness can be specified, it is 0fte.n preferable
When choosing the shades, the need for obliteration by t o specify a nominal thickness. Where a relevant British
the finishing coat should be taken into account. Standard exists (e.g. BS 2569) it should be quoted. In
The Specification should include detailsof the remedial other cases it should be specified that over any square
action to be taken when part of the coating system is metre of a scheduled area (see 15.6)the average of the
damaged during transport, handling, storage, or erection readings taken should equal or exceed the nominal
(see clauses 24,251.The details given should ensurethat thickness and in no case should any readingbe less than
the remedial action specified is capable of restoring, to 75 % of the nominal thickness. In the Specification.for
thedamaged coating, the same potential life as that of the particular project, a specifier may feel justified in
the undamaged areas, using a different percentage but it is essential to use figures
that are based on practical requirements for the systems
The use of alternative materialsor systems may be
being used and surfaces being coated. The use of
permitted by clauses in the Specification (to assist the
unrealistic figures can result in extra costs and these
contractor in the preparation of a competitive tender
will notbe justified by the results obtained.
or for any other reason). The needto substitute
alternatives may also drise, for a variety of reasons, during It is not usual to specify destructive testing to measure
the execution of the contract. Should the use of alter- film thickness. It can, however, be used in cases of dispute
natives be permitted, either as a part of a tender su.b- and mostConditions of Contract make provision for this,
mission or during the execution of the contract, it i s Specifications can place more emphasison wet-film
important to ensure that all possible combinations of thickness for quality control when solventless coatings,
alternatives are compatible one with another and with especially those with high-build properties, are used.
all other aspects of the overall contract. The responsibility
Having defined the quality control method by use of the
for the correct performance of alternative systems and
systems employing alternative materials shouldbe film thickness, it is not usual also t o define the rate of
clearly established. paint application in ¡/m2 (litres per square metre). It may
be, however, that when the coating of test areas is specified,
18. Stripecoats manufacturers' figures for coverage can be checked during
the tests and the records will provide-useful data for
Extra coats of paint may be specified for areas where the inspection purposes.
shape and/or plane of application result in thinlyapplied
coatings, e.g. at the edges. Such areas are often also subject
to severe abrasion. To compensate for these effects, stripe
coats of paint can be applied; stripe coats of primer and/or
51
BSI B S * 5 4 7 3 7 7 m Lb24bb9OLb05B2 5 m
BS 5493: 1977
Section three
It is important to consider roughness, profile and preparing materials for use.

cleanliness of the proposed steel surfaces when (a) Correct materials, including batch numbers,
preparing specificationsfor liquid-applied anti- colour, etc., should be supplied.
corrosion coatings on steelwork.Changes in profile (b) .Allthe paint components of a coating system
can result in variations in the readings of a magnetic should preferably be obtained from the same
film-thickness gauge a t different points of the same manufacturer. However, if this is not possible, it is
coating. essential to ensure compatibility between products
(see 12.1.4).
20. Control of thickness of metal coating (c) Proper mixing should be carried out in accordance
20.1 Galvanizing.Wherenecessary, information on coating with specified instructions, e.g. the manufacturer's
thickness to supplement the information given in BS 729 data sheets.
or other appropriate British Standards, should be included (d) No thinners or other additions should be allowed,
in the Specification. except as recommended by the manufacturer in agree-
20.2 Sprayed metal. The thickness requirements and also ment with the Engineer. Any relaxation that will be
the permissible tolerances, where applicable, should be permitted, e.g. the thinning of a brushing grade to
included in the Specification. give it a consistency suitablefor spraying, should be
clearly indicated in the Specification.
(e) Arrangements should be made for keeping paint
21. Materials (other than thixotropic materials) stirred to maintain
21.1 Availability. It is advisable to check with the manu- the correct consistency during application.
facturers and/or suppliers,to ensure that sufficient supplies (f) Problems arising from either very hot or very cold
of the specified materials are or will be available to meet conditions a t time of application, should be referred to
the programme, I f alternative materials are subsequently the paint manufacturer.
permitted, owing to a change of programme or other (9) Materials taken from store should attain the
requirements, they should be as suitable as those previously temperature recommended for use before being applied.
chosen and compatible with one another, whatever com-
bination is eventually used.
22. Application of protective coatings
21.2 Control of materials
22.1 General. There are two basic methods of specifying
21.2.1 Storage. The Specification should define storage how protective coatings should be applied:
conditions for materials. When geographical locations
and meteorological conditions of storage are likely to be (a) to use a performance-type specification, ¡.e. to
in any way abnormal, the manufacturer of the materials stipulate the coating material and thickness required,
specified should be informed so that any special leaving theapplicator to use the most suitable and
recommendations for storage can be made. These and economic method; or
any other recommendations made bythe manufacturer, (b) to use a complete method specification, ¡.e. to
should be included in the Specification, togetherwith specify in fulldetail the type of equipment and method
details of maximum and minimum temperatures, suit- of application.
able buildings, shelf life, etc. Instructions should be Some specifications can be very concise where references
given regarding batch numberingand its relation to can be made to a British Standard.that fully defines the
date of receipt so that a sequence of storage can be process and quality required. It is important however,
organized to ensure that materials are issuedfrom the when detailing work to be done on site to consider any
store in the same order as that in which they were possible limitations imposed on the process by adjacent
received. operations.
21.2.2 Testing. I t is not usual to t e s t materials in the 22.2 Painting. The type of paint chosen frequently
condition in which they are delivered to the applicator decides the method of application.
(¡.e. to take samples from freshly opened containers). The
Specification may however require samples to be Brush, spray and roller are the methods commonly used
provided and retained in original unopened containers to apply paints to structural steelwork, although other
methods (e.g. dipping) may be used.
for subsequent testing should the coatingsfail to
perform in a satisfactory manner. 22.2.1 Rrush-painring. The advantage of brushing is that
it can apply shear forces within the paint where they are
Adulteration of paint can occur between the opening of
most required and so affect the consistency of the paint
a new can and the application to the surfaces. Detection
that it will spread into crevices and other irregularities.
of excess thinners in paint usually requires samples to
It has a disadvantage that it is labour intensive and slow
be taken from spray-equipment containers,kettles or
for large areas.
other receptacles. The Specification should state what
are the contractor's responsibilitiesfor providing samples Brush application has also the following advantages.
and also what tests are necessary should he be required (a) It is useful for small areas where a high proportion
to arrange for them with an approved testing establish- of masking would be required if spray application were
dent. used for general surfaces.
21.3 Preparation for use. The Specification should (b) It is an alternative t o spraying where toxic or
stipulate that the following precautions be taken when other health hazards preclude that method.
(c) It is less likely than spraying to result in contamin-
ation of surrounding areas by paint.
52
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BS 5493: 1977
Section three
The best results are obtained when specifications requirethe 22.2.4 Surface finish. Where the main requirement is
first coat of inhibitive primers to be brush-appliedand this the maximum unifbrmity of paint coatings, the normal
will apply to stripe coats where they are used. It is also criteria of a specification are creanliness and the
often found to be convenient to brush-apply stripe coats amplitude of profile variations. Where aesthetic or
of intermediate and finishing coats, even where other other considerations demand a smooth finish it may be
methods are used for applying full coats. (It is essential necessary to include in the Specification further clauses
to ensure that the grade(s) of paint supplied suit both regarding the smoothing of surfaces and/or filling
methods of application if there is any possibility that between coats, Where sucha finish i s required there
they might both be used.) is usually a limit tothe choice of application method
An extra brush-applied undercoat and/orfinishing coat and the Specification should definethat limit.
can be specified to ensure a good coating thickness a t the 22.2.5 Paint-application-proceduretrials. On large projects
edges of members. This technique providesextra benefit paint-application-proceduretrials are recommended. The
when undercoats andfinishing coats are spray-applied. same labour and equipment proposed for the main work
Good quality animal bristle or nylon bristle should be should be used and details should be included in the
used for brush-painting. (See BS 6150 and BS 3900 : Specification.
Part A5 respectively for notes for guidance on paint 22.2.6 Other general requirementsof a painting Specifi-
application and large-scale brushing tests.) cation. In addition to the foregoing specific instructions,
22.2.2 Spraypainting. In spray-painting, the liquid paint the Specification should include thefollowing require-
is atomized and projected on to the surface. One of the ments.
two following methods may be used. (a) Each painter employed should be skilled and
(a) Conventional air spraying, in which atomization experienced in the method he is using and the
is induced with compressed air and a low-pressure supervisor should be skilled in each method under
stream of paint droplets is issued from the nozzle. his control.
(b) Airless spraying, in which a stream of paint is (b) No paint should be applied to any surface until
projected a t very high pressure through a small that surface has been prepared and cleaned to receive the
nozzle and the sudden release of pressure, as the jet paint in accordance with the Specification.
issues, atomizes the paint.
(c) No further paint coat should be applied until the
Paint may also be applied by electrostatic spray but this previous paint coat has dried or cured sufficiently t o
method is not generally used for structural steelwork. receive it. With some coating materials, it is advisable
Conventional airspray enables paint tobe applied rapidly also t o place a limit on the maximum period between
but waste is high comparedwith brush-application. Air- coats to avoid intercoat contamination and to eliminate
less spray has an even higher speed of application and any other possible cause of intercoat adhesion failure.
wastes less paint than air spray; it is generally the most (d) Where, for any reason, the Specification has
economical method of application for structural steel- omitted relevant details, and where such details are
work. given in manufacturers' data sheets, the relevant
To achieve good results spray equipment should be properly manufacturers' instructions should be observed as if
handled by trained operators, The higher ratesof paint they had been included in the Specification.
deposition obtained when using airless-spray equipment 22.3 Galvanizing and metal-spraying. The application
means that more skill is required by the operator t o obtain of zinc and aluminium by these methods is covered by
uniform coatings. various British Standards (see clause 11) which safeguard
The application of paint by spray equipment may be the quality of the finished product,
restricted by factors which include the following. The Specification should indicate areas not tobe coated
(a) Overspray may not be tolerated. with metal, For example, the interior of a box girder may
(b) Some types of paint create a toxic hazard when be left untreated when the outside is metal-sprayed. In
sprayed, addition the fabricator may decide to leave some weld
(c) Some areas of structures may not be suitable for fusion faces uncoated. Such faces can be masked with
spray-painting. tape and the permanent protection can then be
(d) Specified paints may not be available in a quality subsequently applied.
suitable for spraying. The shape of a steel fabrication may prevent access to
(e) High winds can make spraying difficult. some surfaces for metal-spraying, or it may be too large
22.2.3 Othermethods. Roller application is useful for for galvanizing. Large flat units such as joist sections
large flat areas. are well suited to metal-spraying but forsmall sections,
as in lattice construction, galvanizing would be more
For dip-painting, surface preparation is followed by
economical.
complete immersionin paint. This is the favoured
method of coating surfaces when access to internal 22.4 Wrapping. The following important aspects of
surfaces is difficult for normal application equipment. wrapping processes should be covered by the
It is used largely for applying protective coatings to Specification,
pipes. (a) The percentage side lap of parallel wrapping strips.
Some materials used for the provision of very thick (b) The overlap a t end joints and a t other joints in
coatings have a very high viscosity and can be applied the wrapping.
only by daubing or trowelling. It is useful to consult
(c) The method of application of the wrapping or
the manufacturers' literature when preparing tape so that it adheres closely to the surface without
specification clauses for the application of these sagging or air pockets.
materials.
53
BSI B S a 5 4 9 3 7 7
5S 5493: 1977
Section three
(d) Smoothing of the contour of any protuberances Some materials and application processes are not so
by the application of a suitable mastic before wrapping. sensitive to inclement conditions and some relaxation
(e) Avoidance of folds. The material should be slit may be permitted in the Specification. These require-
along the line of a fold,and pressed flat withany ments may affect system selection wherework is carried
necessary additional applications to complete the out in difficultenvironments.
sealing of the surface. 23.2 Temperature. The temperatures of the environment
(f) Smoothing of petrolatum-impregnated*materials and of the surface to be coated can affect the following
to.a satisfactory finish on completion of the characteristics of paint before, during and after
wrapping. application.
(a) Solvent retention.
22.5 Mastics and sealants. The terms 'mastics' and (b) Viscosity of liquidcoatings and consequently
'sealants', as used in this code, cover a wide range of the brushing and spraying properties.
materials normally used for various methods of ( c ) Thickness and appearance of dry films.
waterproofing joints and surfaces. They usually have a (dl Drying time.
viscosity that makes them unsuitablefor the normal (e) Pot-life, curing time and overcoating periods
brush, spray or other types of application used with of two-pack materials.
liquid coatings.
The Specification should insist on compliancewith the
The more common typesof mastics and sealants, manufacturers' recommendations regarding temperature
together with some of their more important limitations.
properties, are listed in table 7.
Where it is necessary to raise ambient temperaturewithin
It is not practicable to list all the possible applications for an enclosure or to heat a surface, only indirect heating or
each type of mastic or sealant and it normally follows electrically heated blowers shouldbe specified. For most
that the material with the properties most suitedto the coating processes, the Specification should prohibit the
performance requirementof the particular application use of heaters that exhaust combustion products into
is used. Some of the more important factors to be con- the working environment. (Exception may be made where
sidered are listed below. flame-cleaningis specified for surface preparation.) A
Durability, which depends on environment. temperature change within the normal range has little
Permeability. effect on metal-coatingapplication unless it affects the
Elasticity or plasticity. dew-point of the environment; theSpecification
Creep, requirements can therefore be less stringent.
Application method: pour, trowel or gun. 23.3 Humidity. The Specification should stipulate that
cost, coatings are not applied to surfaces where the relative
Most of these materials are obtained as proprietary articles humidity of the atmosphere is such that:
and the Specification requirements to obtain successful (a) condensation is present on the surface; or
applications will therefore be based largely on
(b) it will affect the application and/or drying of the
manufacturers' information. However, the Specification
coating.
may include clauses to cover the following more
important aspects of good application. The Specification should further stipulate that:
Surface preparation. (c) when a rising relative humidity reaches a value
Priming of surfaces if necessary before application of such that it produces either of the conditions given in
mastic sealant. (a) and (b) above, the application of coatings may
. Correct method of application to proper thickness. not be started, or, if already started, shall be suspended;
Precautions to be adopted during application. and
Special drying or curing requirements. (d) during the time that the relative humidity remains
a t or exceeds that value the work may not be started
23. Working conditions or resumed.
23.1 General. The conditions under which protective When selecting limiting values of relative humidity, the
coatings are applied have an important influence on the thermal inertia of large sections should be Considered
quality and life of the complete system. It is easier to control relative to condensation. A contact thermometer should
conditions in an enclosed shop than on an exposed site, be used to determine if the surface temperatures are above
and for some coating systems application in a shop is or below thedaw-point. It is advisable to ensure that the
essential and should be specified. steel temperature is maintained a t not less than 3 OC
When a Specification defines the limits of environmental above the dew-point.
conditions in which coating work can proceed, it should When heating is being used to control the relative humidity
take into account the application properties of the of the environment in enclosed working spaces, it is usual
materials being used and should suggest practical methods to specify that heaters which exhaust combustion gases
for improving the immediate environment of the into the working environment should not be used (see
application and drying and curing processes. Generally 23.2).
wide controls (such as specifying that no operation may 23.4 External conditions. In order that the Specification
be undertaken when the temperature is below 4 OC or the is not unduly restrictive, clauses may be included that will
relative humidity higher than 80 %) may lead to unnecces- permit preliminary preparation to be done in the open
sary interruptions of work. under conditions that would not be suitable for final
*Petrolatum is petroleum jelly used for impregnation.
54
B S I BS*5Ll73 77 m Lb2Llbb7 c1160585 O W
as 5493:1977
Section three
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BS 5493: 1977
Section three
preparation. Preliminary surface preparation may include quality of the cleaning oncompletion. Badly cleaned
removal of oil and grease, initial blasting, chipping, wire- areas resulting from inadequate lighting can be given
brushing, etc. further cleaning.
Surface preparation immediately prior to application of 23.8 Hot conditions. The Specification should state
protective coatings, however,.should not he carried out the conditions that will prevail when coating hot surfaces
under conditions of rain, fog, mist, sleet or snow, nor or applying coatings in hotenvironments where such
where temperature and relative humidity are such as to conditions are not withinthe control of the contractor,
cause dew to form on surfaces to be treated. These The system included in the coating schedules should be
restrictions also apply to most priming and coating suitable for application to these surfaces and/or in
operations. It is also necessary to protect the coatings these conditions.
where the drying or curing process is not sufficiently 23.9 Health and safety. Contractors carrying out
advanced to withstand any imminent deposition of coating work are required to comply with all relevant
moisture or wind-borne dirt and dust. regulations (see section six).
The Specification should usually include clauses that Clauses should be included to require precautionsto be
require work to be suspended whensea spray, dust, or taken to avoid risk to health and safety where there are
other pollutants are contaminating the surface. It hazards additional to those covered by the statutory
should also require such surfaces to be further cleaned regulations and others, There may be special requirements
and prepared beforeadditional coatings are applied. relative to the owner's premises or other areas where the
23.5 Contamination of prepared surfaces and wet film. work is carried out.
Where surface preparation, coatingwork, or other
processes likely to cause contamination are proceeding
simultaneously, theSpecification should require 24. Handling, transport, storage and erection
precautions to be taken to ensure that prepared surfaces 24.1 Selection of coating systems. One of the factors
or surfaces with a wet coating arè not contaminated. taken into account when selecting a coating system for a
23.6 Shop conditions. When the Specification stipulates particular item is its resistance to mechanical damage during
that all coatings are to be applied in an enclosed shop, service, When works-coated steelwork is involved, the risk
the entire programme of fabrication surface preparation of damage to coatings during handling, transport, storage
and coating application should be planned in detail and erection is greatly increased and the coating's
a t an early stage in the design procedure. resistance to mechanical damage assumes prime importance.
Cleaning operations that produce dust anddetritus, In addition to the risks of mechanical damage, coatings
particularly nozzle blasting, should be geographically applied a t works may also be subjected to many different
separated from coating operations, It has been found in adverse environments during transport and storage of
some large fabrication works that the necessary steelwork before erection. Marine and othercontaminating
conditions for protective coating operations cannotbe environments of various types, high humidity, and pro-
maintained without the erection of special structures longed exposure for a variety of reasons may have to be
inside the factory t o separate the two processes. allowed for. In some cases covers and other forms of
Where separate accommodation i s provided for different protection may be provided prior to erection but in most
parts of the preparation and coating processes, it is cases, the coating system shall take these requirements into
essential to arrange that prepared or partially coated account in addition to fulfillingi t s role when in normal
surfaces are not allowed to deteriorate or to become service.
contaminated in any manner, especially as a result of Mechanical damage to coatings is of less consequence when
being takenoutdoors and/or moved through contami- only part of the system has been app1ied;because the
nated environments, making-goodof damage to a full coating system is more
It may be advisable to check that the contractor can fulfil difficult and costly, and may even be impossible where
the specified requirements of cleanliness, temperature patch-paintingof a final coat is not permitted, However,
and humidity before startingthe work. the adoption of a policy of partial coating a t works and
completion of the system a t a later stage may lead to
23.7 Lighting. Adequate lighting of surfaces is essential. problems of intercoat contamination, and the resistance
This may be provided as a general service for all trades of the coatingto the effectsof adverse environments during
and contractors, or it may be the responsibility of the transport and storage is reduced.
coating contractor, in which case some reference should
24.2 Methods of preventing damage. Care in the selection
be made in the Specification to illumination for work and
inspection. One method of ensuring adequate illumination of coating systems will help to minimize damage to
is to define the numberof lumens falling on the surface; coatings before erection. Features which can be
500 lumens has been found to be a satisfactory figure incorporated in the design of the fabrication and other
measures which can be adopted to reduce further the
for most operations. However, this may not be high
effects of mechanical damage are as follows.
enough for dark colours or for applications where
insufficient colour contrast between successive coats (a) The design should include lifting lugs or brackets
is available, e.g. grey metallic zinc priming of blast- where practicable.
cleaned surfaces. (b) The provision of a special lifting harness, nylon
It is difficult toprovide adequate lighting for blast- slings, rubber protected chains and chocks, etc.
cleaning operations, However, this is not so critical if (c) An adequate dryinghuring period for each coat
adequate lighting is provided for inspecting the and for the complete system before handling.
56
~~
B S I BSm5473 7 7 m Lb24bb7OLb0587 4 m BS 5493: 1977

Section three
(d) Methods of loading that will reduce site handling Alternatively the coating of connection surfaces may be
to the minimum. delayed until after erection.
O (e) Order and timing of loading to reduce site storage Other surfaces of connections that may require special
to the minimum. treatment are the meeting faces of structural connections
(f) Special supports, packings and lashings on the made with high-strength friction-grip bolts.
vehicles and trucks, and stacking in holds and on 25.2 Bolts. Some of the treatments that may be specified
decks, to avoid chafing. are as follows.
(9) Special wrapping of coated pipes and packagingof (a) Black bolts in steelwork that has been manually cleaned
smaller items. after weathering may be prepared and coated in the same
24.3 Storage of coated steelwork. The degradation of manner as the general surfaces.
coatings on stored steelworkcan be minimized (especially (b) Where black bolts are to be used for connections and
in poor environments) by the adoption of the following all surfaces are to be prepared by blast-cleaningafter bolting-
precautions. up is completed, the exposed surfaces of the bolts, nuts
(a) Separators. Coatedsurfaces should preferably not and washers should be cleaned a t the same time as the
be in contact. Wrapping, packaging or crates used to general surfaces. This also applies if high-strength
reduce damage whilst items are in transit may perform friction-grip bolts are used in similar circumstances.
this function. For large items, timber packings should (c) Where general surfaces of steelwork are prepared by
be specified. blast-cleaning beforebolting-up and it i s not practicable
(b) Stacking. Components should be stacked in such subsequently to utilize the same preparation method for
a manner that there can be no ponding where cover is not the connector surfaces, fhen pickling of the bolts may be
e provided. It may be necessary to limitthe number of layers

in a stack. The bottom layer should be laid on packings
raised above the ground and the rain splash zone. Timber,
specified to remove scale and to assist in manual preparation
of the exposed surfaces for coating,
BS 4604 states that high-strength friction-grip bolts are
usually of a softwood variety, provides a good surface on normally supplied with a light coating of oil. This coating
which coated steelwork may be stored with minimum will be removed by weathering and/or swabbing with
damage to the coatings. Timber packing may be set on solvents. Pickling of these bolts for plating or other coating
top of concrete or other more rigid supports. The area of process should not be specified without full consultation
the timber in contact with the members should be with the manufacturer and the Engineer (see also 8.2).
sufficiently large to avoid damage to the coatings, taking (d) Electroplating with zinc or cadmium should be specified
into account the dead weight of the steelwork stacked in accordance with the requirements of BS 3382 : Parts 1
on the packing. The number of positions of the packing and 2. The thickness of the coating shouldensure that
should ensure that steelwork is not distorted. Packings the protection offered is similar to thatprovided for the
should be reasonably clean and free from any con- general surfaces. It is usual to specify additional paint
I taminating agents which may adversely affect coatings. coatings where plated bolts, with protective coating
24.4 Responsibilitiesfor preventing damage.The equivalent to that used on the general surfaces, are not
responsibilities for care of the coatings shouldbe given available,
careful consideration, since the benefits of careful Where the components are subsequently to be protected
coating work and handling whilst the items are a t the with a full paint system, then the plating should be
works can be lost by rough treatment during transport specified 'without passivation' and any corrosion products
to, or storage on, the site. The possible variationsin the visible after assembly should be removed before priming
methods of transport and handling whilst steelwork is with one of the special types suitable(see section two).
being moved and erected and alsoin storage environments,
Where the componentsare not tobe painted, then the
and other considerations are limitless. It is not possible
plating thickness should be 25 Fm min. and passivation
to give firm recommendations and the requirements for
should be specified, the colour to be agreed by the
each project should be considered individually-. It is
Engineer.
essential, however, that the responsibilities a t the design
and erection stage are clearly defined and that decisions Cadmium-plated connections shouldbe identified; on
on coating systems, design requirements, methods of no account should they be flame-cut or welded, because of
transport and handling, equipmentused and other special toxic fumes, which can be lethal.
measures, are taken with a clear understandingof all Where zinc plating is specified for high-strength friction-
requirements. grip bolts, etc,, see (h) below.
(e) Sherardizing shouldbe specified in accordance with
25. Treatments for connections and other special the requirements of BS 4921 : 1973, class I (30 Pm min.)
areas Primers of suitable types shouldbe applied as soon as
possible after assembly. Phosphate passivation may be
25.1 General requirements. The treatment specified for
specified for improved performanceand satisfactory
the surfaces of bolts, nuts and other parts of connections
adhesion of paint coats,
should ensure that such surfaces have a standard of
protection against corrosion a t least equal to that provided (f) Mechanical plating, when available, may be specified
for the general surfaces. for the higher-strength steel bolts to give the minimum
thickness for galvanizing followed by centfifuging (see (9)
/i
The coatings on some surfacesof connections and
below). The process does not require pickling of the steel
6 connectors are more liable to mechanical damage during
erection and
assembly than those on general surfaces.
Specification of different coating systems may help to
and this should be stated.
Corrosion products should be removed before painting
reduce the greater risk or the effects of such damage. and the primers shouldbe of a suitable type,
, ,/-
57
BS 5493:
Section three
(9) Bolts may be specified as being galvanized according to masking should be specified to ensure minimum
the requirements of BS 729. It is normally further specified contamination by adhesives. The method of preparing
that they are centrifuged to ensure free running threads. surfaces after stripping the masking should also be
The minimum coating thickness specifiedis 43 Fm, but specified.
thicker coatings can be obtained where required. Where Where paint over sprayed metal or galvanizing is the
general-grade high-strengthfriction-grip bolts are required, specified protective system, masking may be used to
a galvanized finish may be specified subject to the prevent paint being appliedto the faying surfaces of
recommendations of (c) above. connections. Roughening of galvanized surfaces to
Passivation of coating should be omitted from the improve theslip coefficient should be carried out
specification requirements where the surfacesof galvanized before masking is applied.
connectors are to be painted. Edge sealing of the faying surfaces can be specified to
(h) Where zinc coating is preferred for high-strength prevent corrosion where steelworkis located in poor
friction-grip bolts, screwed rods, etc., then one of the environments. The specificationclauses should ensure
following should be specified for the associated nuts, that the edges on both faying surfaces are painted for a
to prevent galling. distance of 15 mm inside the perimeterof the connection.
(1) Allowance should bemade in the manufacture of In similar environments, where load-indicatingwashers
these items to ensure sufficient clearance on screw or bolts with load-indicatingheads requiring feeler gauges
threads to maintain a minimum coating thickness. for measuring shanktension are used, it is advantageous to
(2) Tapping to remove zinc, and threading the nuts specify that crevices should be sealed by applying high-build
on to the bolts a t works to reduce corrosion in storage. paint or mastic compatible with the coating system. This
(3) Electroplating the nuts with cadmium instead of sealing should be carried out after the final tightening of
zinc to a thickness equivalentto that on the bolts. all bolts.
25.4 Welded work. Where steelwork i s prepared and
(i)Spraying of bolt heads and shanks may be justified
primed before fabrication, the following procedures should
in some circumstances.
be specified.
(j) All fixings should be stored in such a manner as to
(a) The whole surface should be coated where weld-
ensure that they do not become corroded or contaminated.
through primers are used.
Exposed parts of fixings should, after assembly, be
degreased before surfaces are prepared or coatings applied. (b) Where primers are not to be applied in the weld
Access to coat the surfacesof connections can be difficult area, masking or removal of the coating bygrinding
and it is often necessary to specify that paint shall be should be specified. A strip approximately 50 mm
applied by brush. wide is normally sufficient but this may vary according
to the depth of weld and/or for other reasons.
25.3 Surfaces of connections joined by bolts
(c) Where welding is required subsequent to the
25.3.1 Non-friction-grip bolied connections. Where the
application of a multiple-coat system, the Specification
surfaces of fabricated components are prepared and coated
should require each coat to be stepped back about
before erection, the surfaces of the joints are usually
30 mm to allow for preparation of the weld surfaces
coated a t the same time. The joint surfaces of steelwork
and for making-good aftercompletion of the weld.
erected with a mill finish are usually specified to be coated
with priming paint, especially where thejoints are sub- Where subsequent welding of metal-sprayed steelworki s
sequently exposed to external conditions. As a further required, it is preferable for the weld area to be masked
protection against the ingress of water into the joint, a with a strip about 25 mm wide before metal-spraying.
further coat may be specified with joint surfaces being Sprayed metal is not easily removed by grinding.
brought together while the paint is wet. This requirement Weld surfaces on mill-finished steelwork should be specified
may also be specified for steelwork prepared and treated to be prepared in a similar manner to that for the general
with a blast primer where the remainder of the system surfaces, with special attention to the removal of scale and
is applied after erection. weld spatter by grinding or chipping. This also applies to
Brackets, clips, cable-hangers andsimilar items to be weld areas on steel surfaces treated with prefabrication
bolted to blast-cleaned steel with a blast primer should primp.
(if they are not factory-finished) be cleaned and primed Alkaline deposits l e f t on the surface by some welding
in a similar manner before being fixed. processes are removed when the surfaces are prepared
25.3.2 Faying surfacesof structural connections joined by blast-cleaning, wet-blasting,pickling and/or
by high-strength friction-grip bolts. It is important that galvanizing. Other methodsof surface preparation do
the friction characteristics of such faying surfaces be not remove these deposits and the Specification should
preserved. Paint coatings may affect them adversely. provide for washing the weld areas with clean water to
Therefore, where general surfaces are protected by paint ensure that deposits are removed before proceedingwith
coatings it is usual to specify that the faying surfaces are the preparation of general surfaces for coatings.
masked, or in some other way shielded from the painting 25.5 Clearance for coatings. Most of the British
process. Standards relating to metal coatings make some provisions
If the faying surfaces are blast-cleaned a t the same time regarding clearances for coatings on the threadsof screwed
as the general surfaces of the steelwork, it may be connectors. Specifications for coatings and design of
advantageous to specify masking andthat it should be fabrications should take such allowances into account.
retained as a temporary protection, being removed only Similar provisions for coatings other than metal should
immediately before assembly. In such cases the type of be made as necessary.
58
BSI B S * 5 4 7 3 7 7 m l b i 4 b b 7 OLbO587 B m
BS 5493: 1977
Section three
e 26. Manhole and joint coverplates, pipe couplings

and other
items
small
In addition to theprecautions for packagingandstorage,
(b) Layer of material of low permeability between
surfaces (e.g. adhesive PVC tapes).
(c) Use of masticsandsealants.
there are other specialmeasures that should be specified (d) Coating both surfaces on both sides of joint, especi-
for itemssuch as manhole and joint coverplates, pipe ally where corrosion cellscan formin crevices.
couplings and other small items. Where possible,
(el Use of plastics washers and sleeves for bolts.
galvanized or sprayed-metal coatings should be applied.
Since
cover
plates for high-strength friction-grip 28.5 Steel in contact with or near rain-washedconcrete.
bolted joints are often reversible, the treatment should not Aluminium coating on steel in COntact with wet CO~crete
only be the Same as for the main faying surfaces, but is subject to alkali attack and should be sealed or painted
also be specified for both sides of the plates, including or both.
edge treatment and sealing. 28.6 Steel near to surfaces subject to treatment with
road (de-icing) salts. Zinc and aluminium coatings should
be sealed or painted or both, as appropriate, where they
27. Machined and bearing surfaces
may be subjected to concentration of chlorides such as
Machinedandbearingsurfaces should be protected with may arise when rain (or thaw) follows the application of
suitable adhesive tapeor other temporary protection. road de-icing salt.
Satisfactory storage should also be arranged until erection
or assembly. 29. Surfaces
inaccessible on completion
28. Steel in contact with other materials The use of the term 'inaccessible surfaces' usually means
that the maintenance of coatings on such surfaces is not
28.1 Coating system. The system selected for coating steel possible. It usually follows that they are not visible and
surfaces in contact with other materials should not be appearance is therefore not important. However, excessive
adversely affected by these materials. corrosion of steel in such locations can result in extensive
28.2 Steel embedded in concrete. Concrete cover of replacement and although the use of good coatings can
adequate thickness offers sufficient protection in most delay the onset of corrosion, a better solution is often
environments. Coatings can affect the bond between steel obtained by eliminating such features in the design stage.
and concrete, so masking of the contact surfaces whilst This applies especially where fabricated steelwork is
coating the exposed areas of partially embedded steel may located in poor environments and/oris required to have
be specified. a long service life.
It is usual, especially in adverse environments, to specify Inaccessible surfaces maybe acceptable for fabrications
that coatings to such items shall extend to a minimum .with short lives and/or those located in good environments. .
distance of 75 mm into the concrete (or to the full depth The parts of structures where such conditions exist can
where this is less than 75 mm). I f corrosion occurs a t the usually be classified as surfaces that are inaccessible after
interface of the steel and concrete it will form corrosion fabrication is completed, and in these cases it follows that
products which will, in time, cause spalling of the concrete. the types of coatings used on plates or sections before
Good detailing is essential and may entail the use of brackets they are assembled may dictate the fabrication process.
with non-ferrous bolts and isolating layers or other similar For example, welding may not be practicable without
measures. The use of galvanizing or other suitable coatings damaging coatingsto which there is no access after
with additional protection to the built-in parts is usually completion of fabrication. In a different classification are
warranted for components that are located in a poor surfaces that are accessible after fabrication but become
environment and/or are required to have a long service inaccessible after erection because of cladding or other
0 life. similar reasons. These surfaces are usually more easily
dealt with, in thattransport or erection damage can be
28.3 Steel in contact with timber. Measures that may be
specified include the following. made good and additional protection in the form of
tape or further coatings can be applied where necessary
(a) Damp-proof layer between surfaces (e.g. bituminous
before thesurfaces are concealed.
paint, membrane or other compound with low
permeability and sufficient durability). This is important
with timber impregnated by the useof water-borne 30. Ancillary equipment
salts. be It may that ancillary equipment to be installed in the
(b) Thegalvanizing of steel surfaces gives a suitable structure is not included in the general structure
protection to steel in contact with timber, except where specification or contract. It is essential to consider the
the timber has been impregnated by the use of a water- specifications for the coatings of all such components in
borne salt preservative process. In the latter case corrosion relation to the main coating Specification, to ensure that
of the zinc will occur. all coatings in the completed structure or fabrication
(c) Use of plastics
washers
gaskets.
and
are compatible.
28.4 Steel in contact with other metals. Some of the
more common measures specified to minimize the effects 31. Use of desiccants
of electrolYtic action, introducing a layer of material Electric dehumidifiers andsuitable quantities of silica gel
a t the interface, are as follows. be
may specified as a means of preventing
corrosion.
(a) Coating both surfaces; a corrosion-inhibiting primer For such treatments to be successful:
may be used on the steel surface with a barrier coating (a) all components should be effectively sealed; and
on the surface of the other metal. (b) regular inspection and servicing shouldbe instituted.
59
BS 5493: 1977
Section three
32. Remedial work (b) The specification for maintenance painting may be
32.1 General, Remedial work is usually required for one very similar (apart from preparation and priming) to
or more of the following reasons. the original painting specification where the initial
(a) Inadequatepreparation. coatings were mainly applied after erection,
(b) Unsatisfactory application of the coating, e.g. low (c) When the execution of maintenance work is delayed
film thickness. it frequently happens that rust develops on some
(c) Degradation of the coating a t a greater rate than areas, and clauses are required in the Specification to
expected. cover the preparation and priming of such areas in
(dl Physicaldamage. addition to those for preparing surfaces of the
32.2 Defects resulting from unsatisfactory application. existing intact films.
Where protective coatings are found to be defective on (dl Accessibility for maintenance operations may be
completion owing to surface defects resulting from a problem.
inclement weather during the drying or curing period, (e) Changes in the environment may have occurred
it may be sufficient to specify rubbing down, followed by since the initial coating system was selected.
the application of further coating materials. With some of
(f) There may be restrictions on operations because
the materials used for coating work, a similar remedy may
of fire risks, possible contamination, etc.
be specified to correct low film thickness. This can apRly
only where there are no problems resulting from bad - (9) The weather may have an unduly disruptive effect
preparation, surface contamination or intercoat adhesion on the application of the selected maintenance system,
failure. in which case alternatives may have to be considered.
32.3 Defects resultingfrom inferior preparation, materials, 33.2 Compatibility of maintenance with original system.
or workmanship. The Specification shouldallow for Where the Engineer considers that the original treatment
complete removal of coating systems which, on completion, was successful, the first contract documents may be
are found to be defective as a result of inferior preparation helpful in the writing of a maintenance specification.
or quality of materials and/or standardof workmanship If these are available, the original Specification can be
in the priming or undercoating. Recoating may be used again with, where necessary, modifications for
permitted on a patch basis, or complete retreatment of all surface preparation.
member surfaces may be required. Irrespective of the areas 33.3 Location of different treatments. When different
involved the Specification should require complete treatments are to be applied to different areas the
removal and preparation, followed by the full coating operations to be carried out on each surface should be
system. clearly specified. This may be done by means of drawings
or schedules. If the work i s marked-up onsite, the
32.4 Early degradation of coatings. Where there is early
degradation of coatings by blistering, peeling, flaking, materials used for marking shouldnot interfere with the
efficacy of the treatments.
cracking or lack of adhesion, the Specification should
require the same remedial measures as detailed in 32.3. Where extra or stripe coats are to be applied, a contrasting
32.5 Other remedial measures. In all other cases, such as colour should be provided and the areas concerned should
change of colour, remedial measures in accordance be specially indicated.
with 32.2 may be specified. 33.4 Coating schedule. A Schedule of Systems, as for new
work, should be prepared, taking into account any special
programme requirements.
33. Specifications for maintenance coatings
33.1 Factors for consideration. Maintenance procedures 34. Finalcheck
are considered in section five. The specificationswill be
The Specification, when complete, may be a very complex
similar to those prepared for new work, but the following
document. Before it is issued or included in a set of
additional factors should be considered when preparing
contract documents, the final draft should be subjected
specifications for maintenance coatings.
to a detailed examinationto ensure that all instructions
(a) The method of surface preparation may be limited are clear and unambiguous, and especially that no
to flamedeaning or manual cleaning. mutually conflicting, contradictory or impossible
requirements are included.
60
Section four. Inspection (b) The requirements of the coating, ¡.e. its end use.
dh 35. Introduction
(c) The cost of inspection relative to the value of the
contract, particularly if several work locations are
The potential durability of a coating system can be involved.
realized only if it is applied to a suitably prepared surface, (d) Quality of supervision to be expected of the coating
in the correct manner and undercorrect conditions. These applicator.
three requirements are discussed in detail in section three. Three levels of inspection are recognized. They are
However, painting and metal coating differ from many defined as follows.
other industrial processes in that they are susceptible (1) Full, All operations observed by an Inspector and
to operator abuse or adverse environmental influences passed as complying with the Specification before the
throughout all stages of the work. Furthermore, it is next stage is started. (For larger projects, this may
generally difficult todeduce from examination of the require a team of inspectors.)
completed work what has occurred. Consequently,
the coating may fail prematurely, but more often (2)Intermittent. Part of all operations observed by an
the effect is a reduction in long-term durability. Inspector and passed as complying with the Specifica-
tion before the next stage is started.
Painting work should be inspected a t every stage and
it is important to include any surface preparation, (3)Occasional. All operations observed initially by an
priming or painting before deliveryto site. It is preferable Inspector for setting standards of workmanship.
to use an inspection team independentof those engaged Ad hoc visits by an inspector thereafter.
on the application work. The levels of inspection required should be specified in the
Inspection is not a substitute for adequate supervision inspection schedule.
and proper specification. I t s primary purpose i s to check
that the coating specification is being properly followed, 38. Inspectionschedule
and where, for any reason, this is not so, the inspection The inspection schedule is a document that specifies the
should lead to the instigation of immediate remedial type and scope of inspection required. It serves t o promote
action. The Specification should state the type and smooth running of the work by informing all concerned
degree of inspection that is to be carried out so that the of the stages a t which inspection will be carried out.
contractor is fully aware of i t s implications before the Furthermore where the Engineer is commissioning a
tendering stage. specialist organization it provides him with detailed
Some specialist inspection organizationsprovide a wider information on the service offered.
service than inspection as used in the strict sense here. The schedule i s a specification for inspection and should
For example, they provide consultancyservices which include a t least the following information.
could be involved in pre-site meetings, drawing-up of the (a) Part of the project to be inspected.
Specifications, etc.; this i s discussed in clause 40.
(b) Stage a t which inspection will be made, with
reference to the work stages in table 8, where
36. Duties of the Inspector appropriate.
The Inspector's duties will be determined by the nature of
(c) Standards (from coating specification).
the inspection, e.g. the type and level required and whether
it is to be carried out by the contractor or the Engineer. (d) Instruments or methods to be used.
Some or all of the following instructions will be included. (e) Method of reporting.
(a) Ensure that all appropriate clauses of the
Specification and manufacturers' recommendationsare 39. Inspection record and reports
complied with and that any deficiencies are immediately The compilation of clear and adequate records of
brought to the notice of the Client paying for the inspection work is an important part of the Inspector's
inspection, The Inspector has no power to suspend work duties. Apart from providing the necessary information on
(or to take any comparable action) unless that power progress, etc., they should subsequently proveto be a
has been delegated. valuable guide to the reasons for failure or success of a
(b) Maintain records of work done and supply progress particular coating system. It is important that the
reports. Inspector shouldkeep a daily log book and that i t s
information should be transferred to a more permanent
(c) Check that all the areas in the coating schedule
record for circulation to all interested parties andfor
have been completed.
eventual retention by the Client.
(d) Provide records of the work for maintenance
Reporting of inspection work may be on the basis of a
purposes.
single structural item, e.g. bridge beams, tanks, etc., or ona
: 37, Levels of inspection

The level of inspection, which should be adequate for the
particular job, will be determined by a number of factors,
time basis, e,g. weekly. l h e latter method i s commonly
used for complex structuresand reduces paperwork but
can lead t o difficulties in the subsequent identification of
the history of particular areas.
including the following. Typical report forms have not been included in this code
~
(a) Type of protection treatment, ¡.e. the tolerance of because of the variety of requirements and methods of
~ the material toused.
be (For example,
galvanizing presentation, but inmost cases a t least the following
requires a level of inspection lower than that for sprayed information is required.
metal, which in turn is less than that normally required
(a) Appropriate information regarding the contractor
for painting.) and the works inspection organization.
61
BS 5493 : 1977
Section four
(b) Identification of areas coded. 41.2 Procedures. When using wet-film gauges the following
(c) Relative dates when work was carried out. procedure should be included.
(d) Condition of surfaces before preparation. (a) Several measurements should bemade before the
paint has set or has lost an appreciable proportion of
(e) Condition after preparation.
the solvent.
(f) Information on systems being applied.
(b) Information on the wet-film thickness necessary to
(9) Equipment and techniques used. give a specified dry-film thickness should be obtained
(h) Working conditions. from the paint manufacturer but can be checked using
(i) Weather or ambient conditions. a dry-filmthickness gauge.
(c) The painted surface should be reasonably smooth.
(j) Type of quality control checks carried out, and
The readings may be disturbed by surface roughness
results. but close-pitched irregularities,such as result from
(k) Type of instruments used. blast-cleaning, do not invalidate the use of the wet-
(I) Handling or stacking procedures after painting. film gauge, if the object is to measure the thickness of
(m) Compliance or otherwisewith specification. coating above the peaks.
When using dry-film gauges the following procedure should
40. Inspectionorganization be included.
Inspection may be carried out by firms specializing in (a) Check that the instrument correctly records the
this field. Where required to do so they may offer thickness of a standard shim placed ona bare steel
additional services, including the following. surface of the same quality (so far as practicable) in the
(a) Pre-contractsite meetings with all interested parties. same surface condition as the steelwork on which the
measurements are to be made. The thickness of the
(b) Advice on design difficulties that may affect a shim selected should be approximately equal to the
proper implementation of the Specification. expected thickness of the protective coating. I f the
(c) Pre-contract inspection,¡.e., an inspection of the type of instrument does not permit the adjustment of
applicator's works to ensure that the premises and the zero reading, the reading obtained with the standard
equipment are adequate, shim should be recorded; if there is a discrepancy,
(d) Where necessary, advice on improvements in the actual measurements should be adjusted accordingly.
equipment, handling, etc. (b) Repeat the calibration a t least once an hour if
(e) Preparation of the Specification. working on the same surface, and before measuring
(f) Liaison with coating manufacturers. film thicknesses on the insides of angles, however
formed, and a t points nearer than 15 mm from an edge.
(9) Advice on health and safety hazards.
(c) Take care that the magnet or instrument case is
The Engineer will decide where he requires theseadditional
normal to the test surface.
services, which on major projects may be essential if he
has no suitably experienced staff of his own. (d) Watch carefully for evidence o f indentation of the
paint film during measurement; pull-off magnetic
Specialistorganizationsshouldemploy fully trained, .
gauges show some advantage in this respect. I f indent-
full time inspection staff. Trust has to be placed in the
ation occurs, it is often sufficient to interpose a thin
inspection team carrying out the work and this entitles
standard shim, making thenecessary correction to the
the Engineer to expect the team to be composed of
observations.
personnel of suitable experience. At present there is no
easy way of determining this other than by reputation. (e) Note that thick paint coatings may contract after
initial measurement owing to loss of remaining solvent.
41. Measurement of film thickness 41.3 Calculations. Mean applied wet- and dry-film
41 .I Methods available. Measurement of the thickness of thicknesses can be calculated from the paint consumption
paint or metal coating is an essential part of the inspector's on a t e s t area and a knowledge of paint properties, from
duties, the following formulae, using available data.
BS 3900 : Part C5 describes the determination of paint film t (wet) - 1O00 B
"
thickness by a number of methods. Some are destructive A

and are used mainly in cases of investigation or dispute. 10BxC
For field determination, one or more of the following (b) t (dry) =
A
~
methods is usually adopted.

(a) Dry-film-thickness gauges using the magnetic flux
or eddy current principle.
(b) Wet-film-thickness gauges of the wheel or comb type. (d) t (dry) =
1000 B
- A
1"
( yo; ):
(c) Calculation from the quantities of paint used. where
The first of these can also be used for metal coatings. t (wet) is the wet-film thickness (in Fm)
All the gauges and procedures for their use are described t (dry) is the dry-film thickness (in Pm)
fully and detailed in BS 3900 : Part C5, but the following A is the surface area coated (in m2)
additional points should be noted. B is the volume of paint consumed (in litres)
62
BSI E S 8 5 9 7 3 7 7 e Lb24bb9 OLb0573 T
BS 5493 : 1977
Section four
C is the solids content of paint(% by volume) 43. Inspectionguide

D is the density of wet paint (in kg/l)*
The inspection guide (see table 8 ) shows many of the types
E is the solids content of paint (% by weight)
of defect that may be found duringor after the various
F is the density of dry paint (in kg/l)*
protective coating operations.
-
G is the volatile content of paint, ¡.e. 100 E
(% by weight) It is not intended to be a comprehensive list but is a guide
H is the density of volatiles (in kg/l, as liquid)" to the more common defects. It should be borne in mind
that new techniques, processes and materials may produce
I f paint consumption is measured by weight, B in the above
new potential defects as well as advantages.
formulae should be replaced by W (7weight in kg of paint
consumed). The suggested action in the guide may be only one of a
number of ways of dealing with a problem. The aim
Alternatively the paintmanufacturer's conversionfactor
should be not only to remedy defects already evident but
from coverage (m2/0 toaverage dry-film thickness (Pm)
to prevent their recurrence.
can be employed when available.
It is emphasized that theinspection guide should be used
Measured film thicknesses will tend, on average, to be in conjunction with the Specification and the inspection
lower than calculatedvalues because of paint losses in schedule. Where defects arise from processes not covered
application. The loss factor depends on the method of in these documents, agreement between the parties
application (see appendix E, note 4). concerned is necessary before remedial action is taken,
In the absence of data specific to a given paint, Under the various 'work stages' in table 8 are'listed
approximate dry-film thicknessescanbe obtained by the suggestions for inspection instruments and equipment,
use offormula(b) and the nominal volume solids
values In addition the should have available for
given in the product sections of table 4.
general inspection work items such as liquid-sample
containers, specimen bags, torch, mirror, magnifying
42. Sampling of materials glass, sharp knife, marking chalks and all the appropriate
It maybeadvisable to take andkeeprepresentativestandards, material data sheets, specif¡cations,etc.
samples of materialssuch as abrasives, paints (see which are appropriate to thework in hand.
appendix D),etc., for use in case of dispute, and where
appropriate, the samples may be sent to a specialist
laboratory for examination and evaluation.
*This is not an SI unit, but it is more convenient,

(1 kg/l = 1000 kg/rn3).
63
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BS 5493 : 1977
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71
ES 5493 : 1977
Section five
Section five. Maintenance (9) Site conditions may render it difficult or impossible
to make a simple repair which would otherwise be
44. The need for maintenance sufficient. .
All structures, no matfer how good the protective system, Any or all of these aspects may have to be taken into
eventually need maintenance treatment. The effect of account when compiling a maintenance schedule.
deterioration, however, is variable, for it depends upon
both the degree of deterioration (which is rarely uniform) 46. Factors affecting decisions on maintenance
and its position on the structure. 46.1 Condition of coatings (see table IO.) On blast-
The need for maintenance of a protective system can cleaned surfaces, initial breakdown may take the form of
become apparent in one of three ways, arranged below pinpoint rusting a t peaks in the steel surface that have not
in descending order of the cost of rectification of the been adequately covered with paint. The presence of
observed deteriorations. mill-scaleon the surface will cause lifting ofthe paint.
(a) Mechanical failure of the structure. Repainting should always be carried out before the
(b) Visible failure of the coatings, as noticed finishing coats have ceased to protect the priming coat
'in passing' or during a casual (¡.e. non-scheduled) properly, or before they have deteriorated to such an
inspection, extent that they no longer provide a suitable base for the
new paint. It is unnecessary to remove the bulk of the old
(c) Discovery of incipient or advanced failure of the paint and this procedure, in time, leads to the build-up of
coatings by properly planned inspections a t regular a thick paint film all over the structure. Provided that
intervals and comparison of observations with reliable breakdown is not permitted to proceed beyond the
records of previous inspections. chalking stage, only minimal surface preparation is
There is therefore an obvious advantage in conducting necessary.
properly planned inspections and keeping reliable records, Galvanized coatings may be maintained a t any time,
both of which should form important parts of a compre- depending on protective, decorative and economic
hensive Maintenance Schedulefor any structural complex, requirements, but maintenance is more effective if it is
however small. done while a substantial part of the coating is still
Corrosion-inducedfailure of a structure i s nearly always serviceable. Galvanized-plus-paintcoatings may be
caused by severe corrosion a t a few especially vulnerable maintained while the paint layer is still basically sound,
points, Maintenance procedures should therefore be or a t a later stage (see table 3, note (i))provided that the
directed primarily a t these points, see appendix A. zinc coating is still sound and will accept a new paint
If deterioration is neglected for so long that it results system.
in mechanical failure, the remedial measures necessary Sprayed-metal coatings should alwaysbe resealed or
are beyond thescope of this code. repainted as soon as any appreciable attack on the metal
Secondary aims of maintenance are as follows. coating itself is manifested by the presence of white
corrosion product in patches and nodules. At this stage,
(a) Preservation of the who!e structure from
surface preparation i s minimal. A check should be made
deterioration and the need for repair, so that it
to see that the paint itself was not the cause of the white
performs i t s required function safely, efficiently,
product.
and economically throughout its designed life.
46.2 Variability of deterioration according t o location.
(b) Preservation of i t s appearance as specified by
Ideally, recoating shouldbecome necessary a t exactly the
legislation or by the user's requirements.
same time over all parts of the structure, but in practice
the coatingson some parts of a structure deteriorate more
45. Basic considerations of maintenance procedure rapidly than those elsewhere. Whether or not this is
If recommendations for maintenance painting are to be important depends upon the positions of the defects.
comprehensive they will also, necessarily, be complex for There will usually be a choice between repainting of the
the following reasons. entire structure and patch painting.
(a) Structures of all ages and types must be catered for. 46.3 Factors affecting deterioration
(b) There is a wide range of environmental conditions. 46.3.1 General. It is important, when considering the
advisability of renewing coatings, to evaluate the
(c) The functions of existing structures may change
consequences of notdoing the work. It is not sufficient
and existing maintenance procedures, formerly
successful, may need to be changed. to consider only the extent of the deterioration. The rate
of deterioration may have changed since the structure was
(d) The required functional life of the structure and originally designed and erected. It is important to know
the required life of its aesthetic appearance may be how it has changed or how it may further change. This
different, and the methods and materialsfor preserving involves a study of records of previous maintenance
them may not be compatible. coatings, (if any) and those of inspections between
(e) Accessibility may limit the frequency with which previous coatings (if any) and since the last coating.
inspections of the structure's integrity can be made. It i s also important to know the causes of the deterior-
(f) Rehabilitation of a deteriorated (or damaged) ation, and this involves a study of the design of the
Burface coating may be insufficient by itself t o restore structure and the changes in the environment.
the integrity of a protective system. Other work may be 46.3.2 Effectso f design on rates o f deterioration. In the
necessary if the full designed life of a renewal coating erected structure there may be locations (unforeseen in
is to be achieved. the original design) where the relative orientation of
72
BSI B S * 5 4 7 3 77 W Lb24bb7 O l b 0 6 0 3 7 m '
BS 5493 : 1977
Section five
surfaces is conducive to corrosion. Modifications should temperature belowwhich paint should not be applied;
be made so as to eliminate such conditions, especially this is generally 3 OC, 4 OC, or 5 OC, chosen so as to ensure
those described in (11, (2) and (3)below. For example: that there is no moisture or ice on the surface.
(a) intermittent welds may need to be sealed; On sites overseas the local meteorological data, especially
(b) drainage may need to be introduced, or improved, for rainfall and humidity, will provide guidance as to the
where water can otherwise lie onhorizontal surfaces or best timesfor painting.
flow over steelwork; I f painting has to be done when the general atmospheric
(c) accessibility for painting may need improvement. conditions are unsuitable, these conditions should be
improved locally'by providing shelters or screens and if
Badly corroded stress-carrying members need the necessary, artificial heat, with good ventilation. (Portable
attention of a structural engineer. dehumidification equipment is also available.)
Although a smooth surface is advantageous for protection, It should always be borne in mind that workdone in
the use of fillers may disguise a loss of section and thus unsatisfactory conditions will not produce such a
lead to a false sense of security.
satisfactory result as that done under correct conditions
In the particular case of bare steel it should be noted that and is likely to lead to early and sometimescostly failure.
plain steel surfaces exposed to freely circulating air,
47.2 Constraints on site. Activities (other than painting)
even when devoid of paint, corrode a t a slow rate of 25 Fm on or near the site may place severe restrictions on the
to 125 Fm per year in all but the most aggressive environ-
times a t which painting can proceed. In some cases
ments. Metal deteriorates a t a much faster rate when:
conflicting activities can be temporarily suspended by
(1) it is badly ventilated so that condensation remains advance arrangement, as in the case of many rail and road
for long periods; structures, but in other cases it may not be possible to
(2) it traps water; or carry out surface coating work except during periods
(3) it is subject to constant seepage of water, generally when other activities are normally stopped, for example,
where corrosion sores have already developed in old during close-down periods or annual holidays.
structures. .. There may also be the problem of physical access to the
structure concerned. Limitations of both the approach to,
46.3.3 Effects of environment on rates of deteriora.tion.
and the space around, the structure will affect decisions
The general environment may vary from year to year,
on the equipment and methodsused.
but departures from the well known average are rarely
of long duration.
48. Organization
The local environment, however, may be continually
48.1 Labour. The surface preparation for, and the
changing. The general improvement in recent years,
application of, modern protective coatings are highly
resulting from anti-pollution legislation, may be more
skilled jobs and the operatives mustbe properly trained;
than offset by theexistence of, or future construction of,
the use of unskilled labour can cost more than it saves.
sources of local .pollution. For example, a heavily used
For large concerns owning extensive steel structures,
motorway may blanket some area with combustion
there are two ways of maintaining their protective
products or unburnt diesel oil, or a factory using processes
coatings. They can train their own permanent staff,
which produce exceptional contaminantscould create bad
or l e t the work out to contract. The choice between
local conditions, even in rural areas.
these policies is influenced by the nature and volume
46.4 Type and use of structure. The type of structure and of the work.
the use made of it both have a bearing on the performance
d) of the protective coatingsandshould be taken into account.
48.2 Inspection. Whether work i s carried out by direct
labour or by contract, there shouldbe adequate
For example, some parts of a structure may be affected
inspection, to ensure that critical parts of the work have
by spillage and others by abrasion.
been prepared to the necessary standard before being
overcoated.
47. Factors affecting choice of procedure
A structuralengineer should decide what is critical for
47.1 Environment. Steam, exhaust gases, fumes and grit
the work concerned. See section four for guidance,
may all be present in industrial environments, and all are
prejudicial to good painting. Moreover, access may be 48.3 Conduct of work on site. Sites should be kept tidy
difficult, or possible for only a limited time(as in the case and care should be taken to avoid contamination of any
. of marine
structures). other activity taking place on or near the site. Control
The seasons have little effect on the timing ofindoor should be exercised over dust and fumesor other emissions
which may affect the environment, and appropriate
paintings of existing structures, but when the structure
disposal of waste products arising from the painting work
is exposed, inclement weather seriously interferes with
should be properly organized.
protective coating operations. For outdoor structures
the work should be programmed, so far as possible,
for periods when favourable weather can be expected.
49. Choice of maintenance method
The decision whetherto patch-paint or recoat completely
Generally it is undesirable to paint when the steel
i s largely an economic one. It will be influenced by the
temperature is less than 3 OC above the dew-point but
accessibility of the structure. If much scaffolding is needed,
*
judgement may be exercised to raise or lower this figure
so that the cost of access is a high proportion of the total
according to whether the temperature difference is
cost, it may be economical to re-coat the whole structure
increasing or decreasing. It is not always practicableto
while on site. This is certainly so when an excessive
calculate dewpoints, especially on the smallerjobs.
amount of patch-painting of small areas, say upwards of
In such cases it is common practice to specify a
10 %, would be involved.
73
BSI B S m 5 4 7 3 7 7 W L624667 0360604 O M
BS 5493 : 1977
Section five
If maintenance is undertaken a t the right time, it should special tools should be devised to ensure adequate cleaning
not be necessary to strip all the old coating before and painting. If the work is to be carried out by contractors,
repainting the structure. The ideal condition, in which a clause in the Specification should demand the design
none of the old paint needs more than thorough washing of such tools and require their approval by the Engineer.
down, is rare, Some parts of the structure will need Coatings on old structures frequently have numerous
repainting before the main body of the paint has neared lengthy cracks and fissures. When recoating it will save
the end of its life. Where the majority is in good condition time and produce a better result to caulk them after
and only a small proportion is poor to very poor, it may be applying the primary coat.
better to repair the defective areas by patch-paintingand
It is recommended that for structures with large areas
to leave the rest alone until later.
requirirlg treatment a reference area of structure is
prepared. The area chosen should be as typical as
50. Choice of procedures
possible of the structure and will generally include areas
For the work to be effective, surface preparation shouldbe of sound paint as well as corrosion sores, so as to permit
carried out to a satisfactory standard for the material to be demonstration of the treatment of the boundaries of
applied. Whilst some methods achieve this easily, it is more corroded areas, as well as the complete removal of rust
difficult withothers and thereare site limitations. and loose scale. The area should not be less than 1 m2
The methods available are not equal in effectiveness or and should be cleaned to the correct standard, When the
cost. The advantages and disadvantages are described work is to be carried out by contract, agreement should
I in 51.2. This is true also of application, the different be reached that the standard is a practicable one for the
methods available have advantages and disadvantagesin structure in question. Immediately the cleaning has been
different conditions, as described in clause 53. completed, two coats of clear varnish shouldbe applied
Some general notes for guidance are given as follows. over one-third of the area. The remaining area should then
(a) All removable parts impeding access to the work be repainted with the priming paint to be used on the
should be removed before work commences. structure. The additional coatings specifiedfor the structure
should then be applied as painting proceeds, all coats being
(b) Manual methods may be the only suitable ones in a t the specifiedfilm thickness. Each successive coat should
certain circumstances, but will result in an inferior
leave a width of 1O0 mm of the preceding coat exposed,
surface as compared with other methods, such as blast- then the appearance of each successive coat will provide a
cleaning. visual guide to the standard of painting to be provided.
(c) Washing down before repainting is always desirable, On completion, and after obtaining the approval of the
especially in marine environments, because it may Engineer, the different parts of the reference panel should
remove chlorides from the surface, but it is unlikely be overcoated with appropriate coats to completethe c
to remove sulphates. Consideration should be given to system.

problems of drying after washing. 51.2 Factors appropriate to use of different methods on
(d) Some modern paints become very hard when fully site
cured and special preparation, such as light blasting or
51.2.1 Blast-cleaning with or without the addition of
the use of emery, may be required to obtain good water. Several methods are available.
undercoat adhesion.
(a) Open blast. There may be problems with abrasives
(e) Thick films such as those obtained with pitches or and debris on some sites. Before using this method the
bitumens often develop deep cracks. These materials effect of such debris on persons, property, water
can be overpainted but the cracking cannotbe
courses, electric cables, etc. should be determined.
eliminated without complete removal of the film. The size of equipment may also be a problem.
(f) The maintenance system chosen dependsto some. (b) Recirculating blast overcomes most of the objec-
extent on the original process and the standard of tions to open-ended blastingbut is much slower and
surface preparation which can be achieved. Some there may be difficulties with some irregular shapes.
two-pack materialsare not always suitable for Size of equipment may be a problem on some sites.
maintenance and trials and compatibility tests should
be carried out before using them. (c) Hydroblasting with or without the addition of grit
overcomes some of the objections to dry blasting but
(9) The standard of protection required varies with hasan additional problem of drainage. It is not
atmospheric pollution and for different parts of the acceptable near electrical equipment. Size of equipment
structure, ¡.e. areas subject to condensation and and the need for a suitable water supply may be a
restricted air movement requirebetter protection than problem and care is necessary to protect the operator
fully exposed steelwork. and those nearby, particularly when using a high-pressure
(h) Sometimes the film becomes embrittled and loses jet.
its adhesion. In these cases complete stripping is No one method may be sufficient by itself and all methods
essential. may need to be supplemented by the use of hand-held
tools, such as lump and chipping hammers, wire and
51. Surfacepreparation dusting brushes.
51.1 General. Particular attention should be paid to the 51.2.2 Flamecleaning. Reasonably portable equipment
cleaning out of crevices andother places where dust and can be used in some locations where blast-cleaningis not
dirt have collected. Debris tends to build up a t ground practicable. Care is needed to ensure that surface temp-
level. Crevices frequently occur that are so positioned or eratures are not allowed to become excessive. In the case
dimensioned that standard scrapers, brushes, and other of structural steelwork of substantial sections an upper
tools will be ineffective. In such cases it is essential that limit of 200 "C surface temperature is considered
74
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BS 5493 : 1977
Section five
advisable by some authorities. Thinner sections may have by a suitable solventor emulsion cleaner which will not
to be cleaned a t a lower temperature. Steps should be attack the paintwork. This should be applied by swabbing
0 taken to ascertainwhattemperature is suitable in particular
cases. As a general guide, sections thinner than 0.5 mm
to avoid spreading the oil or grease to adjacent surfaces.
should not be flame-cleaned. Care should be taken to 54. Standards of application

consider the effect of heat transference to other parts of 54.1 General. In all methods the aim is t o produce a
the structure, and particularly to any materials in contact uniform coating of the film thickness specified, free from
with the other side of the steel. The existence of pipes pinholes, missed areas, runs, sags or curtains, and wrinkling
and cables should be noted. or other blemishes which may impair durability.
Flame-cleaning shouldnot be used near high-strength 54.2 Brushing. The film produced by brushing should be
friction-grip bolts or cold-worked high-tensile steels. free from brush marks, consistent with good practice for
It should also not be used to remove thick coatings of tar the type of paint used.
or bitumen; and it is not an economical procedure for 54.3 Roller-coating. Roller-coatingshould be conducted
stripping old intact paint. As a rough guide, i t s use should
so as to give a uniform full wet coating, the inaccessible
be considered only when the breakdown onthe old paint
areas being coated by brush to the specified film thickness.
has reached grade Re 6 (roughly 20 % of rust by area)
of the European scale* or beyond. It is important to take 54.4 Spray application. Spray application should give a
into account that flame-cleaningwill destroy the protective full wet coating with a minimum of spray pattern
coating on both sides of the plate. It should be noted that (orange-peel effect)..Each successive pass should overlap
flame-cleaningdoes not provide a suitable surface for many the previous pass to give a uniformly even film. This applies
sophisticated coatings such as zinc silicate, epoxide and equally to air spray and airless spray.
polyurethane two-pack coatings, etc.
55. Recommendations for coatings
@! 51.2.3 Powered tools. Therearevery few site limitations
55.1 General. A variety of systems may have been applied
other than those of space and access for compressors a t
some sites. to oldsteelwork and it is impracticable to set out detailed
guidance for each case. The following notes, however,
51.2.4 Hand-operatedtools. There are no site limitations,
provide a step-by-stepapproach.
but it is difficult to ensure an adequate standard of
cleaning for more than very limited areas. (a) If the existing material and the system are known,
obtainable, and have proved satisfactory, it is advisable
52. Application to use that part of the system which is applicable.
(b) The initial filmthickness (at least) of the original
See clause 22.
system should be restored. An additional stripe coat
53. Standards of preparation may be desirable a t places that have proved particularly
vulnerable, such as expansion-joint edges, bolts, rivets
The surfaces requiring preparation can range from severely and welds.
corroded steel to firmly adherent paintwork.
(c) If for any reason, the existing material cannot be
The different methods available for removing corrosion do used, specialist advice should be obtained. If this i s not
not produce thesame standard of finish. The commonly available then consideration may be given to the
specified, and desirable, requirement t o remove all rust materials listed in (1) and (2) below, provided that they
and corrosion cannot be achieved except by blast-cleaning.
satisfy a t e s t of compatibility with existing materials
But while some materials requirea blast-cleaned surface
and that there are no special requirements such as
for adequate adhesion, others can be applied satisfactorily
particular resistance to abrasion or chemicals.
to surfaces prepared by other methods provided that
they result in an adequate standard. The cost and (1 ) Surfaces not subject to condensation.
practicability of achieving such a standard varies, and if it External: conventional micaceous iron oxide or
can be obtained with difficulty over a small area it cannot chlorinated rubber paint.
generally be realized a t all over large areas. Internal: conventional micaceous iron oxide or
alkyd paint.
Where blast-cleaning is adopted, the aim should be to clean
the surface to a standard equal to SA2% of Swedish (2) Surfaces subject to condensation.
Standard SIS 05 59 O0 or BS 4232, 2nd quality, or a External: gelled bitumen or chlorinated rubber paint.
higher standard calledfor by the paint manufacturer. Internal: chlorinated rubber paint
Where other methods are used it will not be possible to (d) Primers that can be overcoated the same day should
clean the surface properly, but theaim should be to be used, so that minimum protection can be built upas
remove as much rust as possible. The difficulty of providing quickly as possible.
an adequate written description of an acceptable surface (e) The thickness of existing paintwork should be
applicable t o the varying conditions found in practice has checked with an inspection gauge. Exposure .of the
led some authorities to trythe use of visual aids. For large previous coat is no guide to thickness.
or important work the standard should be agreed on site
55.2 Previously painted steelwork. For previously painted
and recorded, preferably by the use of a reference area.
steelwork, the preparations and treatmentslisted in table 9
In the case of special materials the standard should be
are recommended.
that called for by the manufacturer.
55.3 Previously metal-coated steelworkwith or without
In the case of paintwork, all dust and loose and poorly
additional coating. Where previous coatings were galvanizing,
adherent material should be removed by brushing and
sprayed zinc or sprayed aluminium, the preparations and
scraping, all grease, oil or other stains should be removed
treatments listed in table 10 are recommended.
*See footnote 't' below table 9.
75
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BS 5493 : 1977
Section five
Table 9. Treatment of previously painted surfaces
Surface conditions Surface preparation Treatment (see note 7)

(see also 55.1 notes (a) to (e))
1, Paint film intact, slight chalking or Leave alone or wash down only if (a) (a) No coating required
checking of topcoat only, no
significant colour change Bristle brush and dust down i f (b) (see (b) Recoating requiredby legislation or by
note 5) appearance requirements. Apply one or two
finishing coats as required
2. Paint film firmly adherent, considerable Wire brush (see note 5) to remove all loose Intermediate and finishing coats as
chalking, cracking downto primer or material and dust down necessary
undercoat only, no rusting
3. Erosion or blistering or loss of adhesion Scrape and wire brush (see note 5) to (a) Prime any derusted patches.Build UP
a t or above substrateand/or light remove rust and loose material film thickness with appropriate intermediate
rusting (not worse than Re 3 (see and finishing coats overall
note 4 ) for thinfilms)
(b) Patch prime and undercoat derusted
Thin film (see note 1 ) patches, Build up filmthickness with
intermediate coat(s)as necessary. Apply
Thick film (see note 2) finishing coat overall
4. Thick film with rusted area less than (a) Rusted patches; remove rust by best Patch prime bare metal
one quarter (see notes 3 and 8) means available. See clause 53
Apply intermediate coat (see note 5) and
(b) Paint conditions 1,2and 3 as finishing coat(s) (see note 6)to required
described above thickness
(c) Sound paint: nil if patching is adequate
(d) Sound paint: wire brush i f finish coat

i s required (see note 5)
~ ~~
5. Thick film with rusted patches greater Remova all coating and rustby best means Build up new systemof primar, intermediate
than one quarterof area (see note 3) available. See clause 53 coat(s) and finishing coat(s)
Thin film rusting worse than Re 7

(sea note 4)
NOTE l. A thin filmis defined as one less than 150 pm thick.

NOTE 2.A thick film is defined as one greater than 150 pm thick.
NOTE 3. Area is defined as any surface of the structure whichis reasonably identifiable for treatment purposes. The condition of all parts
of a structure will not necessarily bethe same. In deciding the required treatment
it is necessary to consider thecondition of areas as large as
practicable for treatment purposes and deal with each on i t s merits.
NOTE 4. Re 3 is taken from 'Echelie Européenne de degrésd'enrouillement pour peintureantirouille' obtainable from the Paintmakers
Association, Alembic House, 93 Albert Embankment, London, SEI 7TY.
NOTE 5. For certain hard finishes special treatment
may be tlecassary to abrade the surface.
NOTE 6,It is a matter of judgement whetherto patch paint isolated patchesof rust only or to patch paint rustedareas and overcoat the
whole. In the latter case It is sometimes desirable, if time permits, to apply additional intermediatecoats to bring the patches to a similar
thickness to the surroundingareas, before overcoating the whole surface.
NOTE 7. When selecting a material for use in overcoating it is necessen/, unless there is definite knowledge of the materials being
overcoated, to testthecompatibility of the proposed materialwith existing materials.
NOTE 8. See also BS 61 50 and BS 3900.
76
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BS 5493 : 1977
Section five
Table 1O. Site treatment of previously metal-coated steelwork

Initial
condition
Present
condition
Surface
preparation
Replacement
of mefal
T Paint treatmentover
where required Sprayed metal Galvanizing
Bare Areas of corrosion If metal is to be Spray metal to Not normallynecessary.

metal andlor some rusting replaced, blast-clean appropriate If overcoating i s
coating of substrate* specification, required, see table 3
see table 3 and 11.3
If metal not to be Not applicable Build-up cleaned areas Build-up cleaned areas
replaced, dean with suitable painf with suitable paint
corroded areas by system and, preferably, system and, preferably,
best means available apply chemical-resistant apply chemical-resistant
finish overall finish overall
Areas with some If decoration required Not applicable Apply sealing coat and Apply suitable surface
white corrosion wash to remove salts, chemical-resistant pretreatment followed
products using stiff brush if finish for maximum by, preferably,
necessary. Remove life chemical-resistantfinish
loose material with
non-metallic brush
If decoration not
required, no action Not applicable
is necessary
Areas in sound If decoration is Not applicable Apply suitable paint Apply suitable surface
condition required, wash to which should be pretreatment; follow by
remove salts, using a chemical-resistantfor suitable paint which
non-metallic brush maximum life should be chemical-
resistant
If decoration not
is necessary
Sealed or Areas of corrosion If metal is to be Spray metal to See table 3 and 11.3, See table 3 and 11.3,
painted or some rusting replaced, blast-clean appropriate consider one or two consider one or two
metal of substrate specification, coats overall, preferably coats overall, preferably
coating see table'3 chemical-resistant chemical-resistant
If metal not tobe Not applicable Build-up cleaned areas Build-up cleaned areas
replaced, remove with suitable paint. with suitable paint.
corrosion product by Apply one or twocoats Apply one or two coats
best method available overall, preferably overall, preferably
chemical-resistant chemical-resistant
Areas with some Remove loose material Not applicable Apply furthercoats Apply furthercoats
degradation of with non-metallic brush of paintor sealer, of paint or sealer,
paint, dissipation preferably chemical- preferably chemical-
of sealer, oc loss resistant resistant
of adhesion of
either
Areas in sound If decoration is Not applicable As above As above

condition required, dust-down
If decoration is not
is necessarv
*It should be confirmed that the apparent rustingemanates from the substrate.
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BS 5493 : 1977
Section six
Section six. Safety and health The Construction (Notes of Accidents) Order 1964
IMPORTANT NOTE. This section of the code give.s 6 . 1 . 888).
recommendations for dealing with typical aspects of The Construction (Notice of Operations and Works)
safety and health which arise in the work of coating Order 1964 (S.I. 2211, regarding notice to be given to
iron and steel structures. It does not give complete the Health and Safety Executive.
coverage of all such aspects, because that is far beyond The Protection of the Eyes Regulations 1974 (S.I. 1681),
the scope of this code. It is the duty of users of the code, which apply to all surface preparation (except sand.
in so far as they are responsible for safety and health, papering) and spray painting.
to ensure that all statutory requirements are met.
Blasting (castings and other articles) Special Regulations
1949 (S.I. 2228), which apply to blasting in factories.
56. Legislation
Highly Flammable Liquids and Liquefied Petroleum
A number of Acts of Parliament contain,provisions relevant
to surface coating work and these have to be taken into Gases Regulations 1972 (SI. 917).
account when planning such work. The Acts shouldbe 56.3 The Control of Pollution Act 1974. This Act covers
studied directly for detail and coverage, together with any environmental pollution such as noise and the disposal of
other legislation relevant to particular situations. Some of toxic wastes.
the principal legislation is listed below with a brief
summary of the contents. 57. Operational hazards
56.1 Health and Safety at Work etc. Act 1974. This Act 57.1 General. Some of the operations involved in the
imposes a general duty on the employerto provide a safe surface protection of a structure give rise to conditions
place and method of working wherever the work is done. that are potentially hazardous to the structure itself
and/or surrounding property, whilst others pose hazards
56.2 Factories Act 1961, The provisions of the Factories to the health and safety of the operatives.
Act 1961 and the Regulations and Orders made under the
Factories Act remain in force but are now subject to the Especially prevalent among these hazardous conditions
enforcement procedures of the Health and Safety a t Work are the fumes and vapours which rise naturally by
etc. Act 1974. The relevant provisionswithin the Factories evaporation of solvents i n some paints and strippers;
Act itself include thefollowing. and the pollutants which are induced by operations,
I Section 129 'Use of lead paint in connection with
such as:
(a) fumes from lead-based paints when flame-cutting
buildings', sub-clauses (21, (3) (a), (b), and (dl, (41, (51,
and (61, which deal with the use of lead paint and with or flame-cleaning;
notification to the Health and Safety Executive of lead (b) dust from lead-based paints when rubbed-downdry;
poisoning. (c) dust or fumes from some modern hard-settingpainr-;
Section 130 'Power to take samples of paint, etc.'. (dl fumes from heating cadmium-coated components.
Section 131 'Prohibition of employment of women and Caution shouldalways be exercised in any operation which
young persons in painting buildings with lead paint'. generates dust or fumes.
Section 132 'Prohibitions supplementary to sections 129 The potential hazards of fumes are enormously increased
to 131. in confined spaces where dust and fumes can accumulate
Relevant Orders and Regulations under the Factories Act and where there is little or no ventilation, for example,
include thefollowing. inside a tank or small room or between girders under a
The Lead Paint Regulations 1927, S.R.& O. 827, which bridge deck. It should be remembered that similar
detail the precautions to be taken when using lead conditions can also occur in the open air if the air is still
paint for painting buildings; and the Lead Paint and/or there is a ventilation trap. Such conditions usually
(Prescribed Leaflet) Order 1964, (S.I. 559) a copy of necessitate the use of respirators supplying clean air
which should be given to each operative. and/or forced ventilation. Persons working in such
conditions should be within sight of others outsidethe
The Factories (Cleanliness of Walls and Ceilings) Order danger area. In these cases the advice of the Factory
1960 (S.I. 17941, which states the time limits for, Inspectorate shouldbe sought.
and the methods of, cleaning and painting factory
interiors. Many of the operations involvedin surface preparation give
rise to high levels of noise. The actual noise levels produced
The Construction (General Provisions) Regulations 1961 can be obtained only by measurement. The following
(SI. 1580), which deal with the appointment of examples of the general order of noise have been recorded.
safety supervisors, ventilation, work adjacent to water,
and the safe transport of materials.
The Construction (Working Places) Regulations 1966 dBA at 1 m*
(S.I. 94), which deal with scaffolding, slung scaffolding, Manual chipping 102 - 104
bosun's chairs, etc. Mechanical chipping 102 - 106
The Construction (Health and Welfare) Regulations 1966 Flame-cleaning . 7 8 - 92
(SI. 95), which deal with first aid, washing, toilet and Hydroblasting 105 approx.
messing facilities. Gritblasting 102 - 104
The Construction (Lifting Operations) Regulations 1961
(S.I. 15811.
*It should be noted that these figures are sound pressure levels not sound power levels, which would be 8 dBA to 10 dBA higher. Site
measurements are normally of sound pressure; sound power is then calculated. BS 5228 is set out the other way round as an aid to prediction.
. . . i . .
78
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BS 5493 : 1977
Section six
57.2 Hazards to structure and surroundings. Any operation a corresponding noise level, ear protection should be
I) is hazardous if it involvesnakedflameorthe production of provided (useful information is also given in BS 5228).
sparks in a restricted area. In such a case, flammable 57.3.3 Respiratory system. Some of -the operations of
vapours (arising naturally byevaporation of solvents or surface preparation and paint application give rise to dust,
induced artificially by operations) can accumulate and fumes or vapours which necessitate the provision of good
create a risk of fire, which becomes a risk of explosion ventilation and respiratory protection for operatives and
if the working space is confined or poorly ventilated. those nearby. In these circumstances it is important that
The risk of damage to the structure and surroundings in the protection is right for the particular conditions
these conditions is apparent and paralleledby the risk of involved. Some fumes, notably from cellulosic materials,
injury to people nearby. Therefore such hazards should not only affectthe respiratory system directly but can
be identified and suitable precautions taken. have further unpleasant-effectson the gastric system.
57.3 Risk of injury Advice should be sought from the Factory Inspectorate.
57.3.1 Eyesight. Many of the operations involved in
surface preparation produce particleswhich can damage 58. General hygiene
the eyes directly, and dust and some types of fumes, The various materials encounteredin dealing with old paint
which can also cause eye afflictions. Eye protection is and applying the new paint include some that are
essential for operatives doing such work and for those potentially harmful, and it is therefore necessary to
nearby. maintain a high level of personal hygiene. In particular,
57.3.2 Hearing. Many of the operations involved in surface hands should be washed before eating, overalls worn for
preparation give rise to a high level of noise. For each work should be removed before eating or going home and
different level of noise there is a corresponding period of should be laundered a t frequent intervals, and all possible
6. exposure which, if exceeded could result in damage to the
hearing of operatives and others nearby.Information
steps should be taken to avoid paint getting on to the skin,
Some materials will requ.ire additional precautions and
regarding noise levels and corresponding maximum advice on these should be sought from the manufacturer.
exposure times is given in the Department of Employment's When operatives are working in such conditions (for
booklet 'Code of Practice for reducing the Exposure of example, inside a box girder) that access to toiletfacilities
Employed Persons to Noise'. Whenever there is a possibility is not quick and easy, consideration shouldbe given to
of the exposure time exceeding the maximumquoted for the provision of toilet facilities nearer to the work site.
79
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BS 5493 : 1977
Appendix A
Appendix A (b) Humidity, In pure air, the critical level of relative

humidity is about 70 % but, in fact, corrosion occurs a t
General principles of corrosion and its control much lower humidities when deliquescent particles
settle on the steel. For example, the relative humidity
A.l Corrosion
should be reduced to 30 % t o prevent corrosion in
A.l .ICorrosion is a naturalphenomenon. Like most ships' holds.
metals, iron has a natural tendency to revert to i t s oxides
by combining gradually with oxygen and moisture, Table 11. The effect of atmospheric pollution on
forming rust. corrosion (1)*
The high economic cost of corrosion is accounted for
Three sites in Great Britain Three sites in Nigeriat
mainly by the outlay on preventive measures rather than
mild steel (Cu 0.3 %) ingot iron (Cu 0.03 %I
by the destruction of metal.
A.1.2 Mechanism. Most corrosion processes are electro- Relative sulphur Rate of Relative chloride Rate of
chemical, Corrosion cells are set up on the metal surface pollution (Sog), corrosion, pollution (NaCl), corrosion,
mg/dm2/day pm/year mg/dm2/day pmlyear
through heterogeneities in the metal itself or in i t s
environment. Common causes are, according to location, O. 5 57 O. 8 56
as follows, 1.9 82 3.1 380
(a) In or on the metal. Residual mill-scaleor foreign
matter, e.g. dust.
3.6 110 I 11.1 I 950
A.1.5.2 Effect of the environment. General classification,
(b) In the corrosive medium. Differences in the such as 'rural', 'industrial' and 'marine', can be useful guides
concentration of saline matter and oxygenas well as to the probable conditions a t a site, especially if records
variations in physical properties such as flow velocity are available from a nearby meteorological observatory,
and temperature. But for practical purposes, it is the 'microclimate'
(c) Contact between dissimilar metals, e.g. steel and immediately surroundingthe structure concerned that
copper alloys. matters. The general effects of rainfall, sunshine and
A.1.3 Microbiological corrosion.Corrosion can also occur atmospheric humidity are locally modified by the
in soils and waters as a result of microbiological activity. orientation of the steel surface, by i t s degree of exposure,
Micro-organisms such as sulphate-reducing bacteriautilize and by the circulation of air over it. The diurnal variation
hydrogen, which would otherwise accumulate and in the difference between steel and air temperatures is also
eventually stifle attack; other organisms promote the important, because this determines whether or not
supply of oxygen needed for corrosion cells; yet others can condensation occurs. The thicknessof section can
destroy protective coatings or consume corrosion significantly affect the difference between steel and air
inhibitors, such as nitrites added to cooling.waters. temperatures.
A.1.4 Rust. The initial corrosion product of iron is The classification of environments in respect of aggressive-
ferrous hydroxide, Fe(OHI2. This reacts with water and ness may differ according to whether it is based on the
oxygen to formhigher oxides and hydroxides,notably corrosion of bare steel or on the breakdown of a given
hydrated ferric oxide Fe203. H2O and magnetite Fe30 4 . protective coating. For example, although the corrosion
Most rusts have stratified structures and, moreover, they are rate in tests carried out a t Sheffield was about four times
generally impure. Most rustsare contaminated with solid that a t Calshot, the durability of a paint scheme was
particles and/or water-solublesalts. virtually the same (see table 12). This was because the
heavy atmospheric pollution a t Sheffield (largely due to
Sometimes rust stimulates the corrosionof steel by smoke when the tests were made some years ago) caused
retaining moisture on thesurface, but more often it tends
rapid corrosion but also retarded actinic breakdown of
to retard the attack.The composition of the metal affects
paint.
both the composition and properties of the rust layer and,
consequently, affects theextent of corrosion over a long
Table 12. Comparison of paint performance with
period. the corrosion rate of bare steel (2)
Rust formed in a sulphur-polluted or chloride atmosphere i s
especially dangerous because it contains corrosion-promot- Test site I Sheffield I Calshot
ing salts. These are concentrated in pits on the steel surface
Type of environment
and are very difficult to remove. The usual manual methods
of cleaning are ineffective in this case, because they leave Rate of corrosion of mild steel
salt traces in the pits which promote further corrosion, over 5 years, pm/year
leading to blistering and often to rapid failure of paint Life to failure of a 4-coat
over corroded steel. painting scheme, years
A.1.5 Corrosion in air
A.1.5.3 Rate of corrosion in air. Under normal conditions,
A.1.5.1 Controlling factors. Serious corrosion will occur the rate of corrosion of an unprotected mild steel surface
only if the air is polluted and sufficiently humid. which i s freely exposed outside in the United Kingdom is
(a) Pollution. Inland, the severity of corrosion is between about 25 Fmper year in rural districts and about
roughly proportional to the sulphur pollution of the 125 Fm per year in industrial districts. Overseas, the rate
air and, in marine atmospheres, to the quantity of varies from nil toabout 1O00 Fm per year, the highest rates
chlorides (sea salts) present (see table 111. occurring in certain marine environments (see table 11).
'Numbers in parentheses in this appendix refer to the bibliography in appendix J.
tThe most corrosive of these three sites w a s at the high water mark on a surf beach; the least corrosive only 370 m inshore. A t 60 km inland
the rate of corrosion had fallen to 5 pmlyear.
80
BS 5493 : 1977
Appendix A
A.1.6 Corrosion in soil are almost purewater, to the concentrated brine of the
0 A.1.6.1 Controlling factors. Soilcharacteristics are the
main criteria controlling the corrosion of buried iron and
Dead Sea. Estuarine waters are less saline than sea water
but are often polluted.
steel. Serious attack is more probable in disturbed soil, Statements in the literature on the effect of chloride
as when a pipe is laid in a trench, than in undisturbed soil concentration on the rateof corrosion are often
as when a pile is driven into solid ground. Troublescan erroneous since oxygen concentration is the main factor.
occur when steel piling with mill-scale is driven into the In salt-spray tests there is little change in the corrosion
ground since part of the scale may be removed giving rise rate over the range 0.05 %to 10 %of sodium chloride (7).
to a corrosion cell. The nature of dissolved solids and the amount of free
The oxygen content of the soil and the drainage are most and combined carbon dioxide in solution are important.
important. There is a distinction between aerobic soils, Some waters deposit calcium carbonateon corroding
which are well aerated, and anaerobic soils, which contain steel a t ordinary temperatures or when they are heated;
no free oxygen, but some soils alternate between these others can be made to do so by-chemicaltreatment.
conditions because of seasonal fluctuations in the water If, as usually happens, the calcium carbonate film has a
table. favourable crystal structure, it will stifle further attack.
In aerobicsoils, such as sand or chalk, air has reasonably Calcareous deposits of some protective value can also
free access to the buried metal and water can drain away form on iron and steel immersed in sea water, especially
readily so a layer of rust can form on the bare metal and when cathodic protection i s applied.
this may retard or stifle further attack. (c) Temperature. The effect of temperature on the
Despite theabsence of atmospheric oxygen, heavy corrosiveness of water varies with the operating
corrosion can occur in anaerobic soils through micro- conditions but ingeneral, rusting proceeds more rapidly
@. biological processes. The most important of these is the as the temperaturerises. In quiescent solutions the
corrosion rate of iron increases by a factor of 3 to 4 on
metabolism of 'sulphate-reducing' bacteria which utilize
hydrogen which would otherwise accumulateon the metal raising the temperature from ambient to about 75 OC,
surface and prevent further attack (3).The necessary and thereafter the rate decreases.
conditions occur in heavy clay, some waterlogged soils, A.1.7.2 Effect of flow.Water movement often accelerates
harbour mud and other media such as sludge in oiltanks. corrosion by promoting the supply of oxygen t o the metal
The pH-valueof the soil is a significant factor and, surface; high water speeds may also prevent adhesion of
in general, acid soils are aggressive and highly alkaline ones protective corrosion products. Under adverse conditions
are inert. The electrical resistance of.the soil is similarly increase of flow rates can increase corrosion rates by a
significant with the likelihood of severe corrosion factor of 100 (8).
decreasing as the resistance rises. In turbulent water, damage due to corrosion is often
A.1.6.2 Stray-current corrosion. Potential differences, aggravated by erosion and bycavitation. The latter can
such as may occur along a pipeline, can cause electric lead t o the rapid destruction of dynamic components
currents to enter the structure, travel along it and leave it. such as ships' propellers.
The (positive) current reduces or represses corrosion where A.1.7.3 Other factors. The internal corrosion of steel
it enters but aggravates corrosion where it leaves. water pipes may produce tuberclesof rust, which restrict
Such conditions can occur when a pipeline or armoured oxygen supply locally and cause corrosion by differential
cable runs through dissimilar soils, under varyingsoil aeration (see A.1.2 (b)). Anaerobic conditions favourable
cover, near to streams and ditches, or under a road. to the. growth of sulphate-reducing bacteriaare established
Corrosive currents can also originatefrom nearby d.c. beneath these incrustations, steel then becomes severely
traction systems or cathodically protected structures. pitted, and castiron suffers graphitic corrosion (see A.2.2.2).
A.1.6.3 Rate of corrosion in soil. It is not possible to Sulphate-reducing bacteriacan also cause corrosion in
generalize on corrosion in soils. Rates of 8 pm to 35pm polluted rivers and harbours andin storage tanks containing,
per year were observed in tests over 15 years in Great e.g. crude oil.
Britain (4). Moreover, tests carried out in America A.1.7.4 ßate of corrosion in water. The range of 75 ym
showed that corrosion generally slows down with time (5). to 125 pm per year is representative of the general wastage
For many structures, however, suchas pipelines, the rate of mild steel in still sea water. Corrosion rates are greater
of pitting is the important factor, and it can be very rapid. in splash zones or under high flow rates, e.g. 500 Fm per
In the most aggressive British soils, pits up to4 mm deep year. Fresh water is rather less corrosive.
have been found inpipe specimens after 15 years and an-- The rate of pitting is often much greater than general
even higher rate of pitting (2.6mm in 5 years) occurred in corrosion and it can be severe, especially if mill-scale is
an embankment made up fromashes. left on the steel.
A.1.7 Corrosioninwater A.1.8 Corrosion rates of zipc and aluminium. In view of
A.1.7.1 Controlling factors. The corrosion rate is governed their use as protective coatings for steel, the corrosion
primarily by the oxygen content, the chemical composition rates of zinc and aluminium are also of interest.
and the temperature of the water(6). (a) In the open air in Great Britain, zinc corrodes a€ a
(a) Oxygen content. Most natural waters are sufficiently rate which ranges from about 1 pm to 15 ym per year
well aerated to ensure continuing corrosion. Rusting in according to the environment (3). The same rates
many industrial waters, e.g. cooling waters, is often generally apply to zinc coatings (see figure I), but they
associated with their high oxygen content. do not show to advantage in sheltered, humid and
Q (b) Chemical composition. Natural waters vary greatly sulphur-polluted conditions. The 'white rusting' of
galvanized steel that occurs during shipment or storage
in composition. They range from certain lakes, which
81
BSI ES*!ì473
BS 5493 : 1977
Appendix A
is caused by sulphur orchloride pollution in a closed protective oxide film, which reforms spontaneously if it is
and humid environment. damaged but anything that interferes with this film
(b) Sprayed-alunliniumcoatings give excellent jeopardizes the corrosion resistance. Since chlorides tend
protection to steel in air: coatings 80 Pm thick have to break it down, even Cr-Ni-Mo stainless steels may
been found to have lives of 20 years or more in become slightly rust-spotted in marine environments.
industrial and marine environments(3). Their perform- The passivity of the film is also impaired if supply of
ance on a surf beach was outstanding (9). They are not oxygen to it is cut off by dust settling on the surface.
I widely used in soil although they have long life totally
immersed in sea water (IO).
Consequently, the performance of stainless steels in all
types of atmosphere is greatly improved by regular
cleaning, say a t monthly intervals.
A.2 Control of corrosion
For the same reason, stainless steels are liable to pit
A,2.1 Basic methods. There are four main methods for severely in soil, in wet timbers or in water. For example,
preventing or controlling corrosion. a sheet 2 mm thick became holed within 6 months when
(a) Treating the environment. immersed in the sea, where barnacles had settled and
(b) Insulating the steel from the environment by means cut off the oxygen supply.
of a protective coating. Some stainless steels become vulnerable to stress corrosion
(c) Cathodic protection. cracking in sea water after certain methods of heat
(d) Attention to design (see A.3). treatment, Where such a set of conditions can be foreseen
the advice of a metallurgist should be sought during design.
A.2.2 Relative corrosion resistance of different types of
A.2.3 Protection against atmospheric corrosion. Rusting in
iron and steel. In some cases, the danger or severity of
corrosion can be reduced by the choice of a more resistant atmospheric environments is best prevented by means of
protective coatings, as has been fully discussed in the code.
metal. The characteristics of the main typesof ferrous
metals in this respect are summarized below. Dehumidification of the air (12) is an alternative or a
useful adjunct in some cases (see A.3.2.2).
A.2.2.1 Structural steel. Structural steels manufactured
by different processes corrode a t substantially thesame Cathodic protection is impracticable, because of the
rate. The minor variations in their carbon content, analysis absence of an electrolyte.
and microstructure have little effect. A.2.4 Protection against soil corrosion. The degree of
The mill-scale on hot rolled steel is a potential source of protection should match the corrosivenessof the soil.
corrosion and is injurious to the performance of protective The most effective system is cathodic protection (CP 1021
coatings; it should be removed. plus a protective coating. Bitumen sheathing, about 6 mm
A.2.2.2 Cast iron. The casting skin formed on cast iron in thick, or a thick coal .tar pitch/epoxide coating should -
the mould is more adherent than mill-scaleand has some prove adequate in moderately corrosive soils.So should
protective properties. I f it is removed, unalloyed cast irons hot-dip galvanized coatings.
corrode a t substantially the same rate as descaled mild It may sometimes be useful to replace an aggressive soil
steels but there is an important difference in the effects of by a non-corrosive backfill, e.g. limestone or clean
corrosion on thetwo materials. washed sand.
Ordinary grey cast irons corrodein a peculiar way. A.2.5 Cathodic protection. Cathodic protection is a
They contain about 8 % o f elements other than iron, system in which an electric potential i s applied from an
mainly carbon in the form of graphite, phosphorus as external source to oppose the natural flow of electric
iron phosphide, and silicon. The graphite and iron current that gives rise to electrochemical corrosion.
phosphide are inert and remain in situ after the iron has This can be done by either the sacrificial anode method
corroded away. The silicon becomes oxidized to silica or or the impressed-current method, In the first case the steel
silicates, which help to bind the other constituents. is connected to a metal of lower potential, e.g. zinc, so that
Thus, the corrosion process leaves behind a non-metallic the zinc becomes the anode an-d corrodes, leavingthe steel
'graphitic corrosion residue', which largely retains the as the uncorroded cathode. In the second system the
appearance and shape of the original iron, although its current is applied from an external d.c. source. Again the
mechanical strength is negligible. steel becomes the cathode and usually graphite is used as
A.2.2.3 Low-alloy steel*, Low-alloy steels corrode more a permanent anode.
slowly than mild steel when freely exposed outdoors (1 11. Cathodic protection operates only in the presence of an
In time their corrosion rate falls to a low value and they electrolyte and is often used to protect steel immersed in
are designed to be used unprotected. These steels have been sea water and in corrosive soils. To reduce current require-
widely used in the bare condition in both rural and ments this method is generally used in conjunction with
industrial environments in North America and on a small protective coatings on the steel, Only a small current is
scale in the United Kingdom. then required to protect breaks in the coating.
A.2.2.4 Stainless steel, The resistance of stainless steels to Detailed recommendations on cathodicprotection are
atmospheric corrosion farsurpasses that of ordinary or given in CP 1021,but further advice should always be
low-alloy steels. The b e s t of them, e.g. the 18/10/3 obtained from a specialist.
Ci-Ni-Mo type, are virtually incorrodible in dust-free air.
They owe their immunity from corrosion to a thin
"Those intending to use low-alloy steel should consult the British Steel Corporation.
.. . .
82
B S I BSm5q93 77 L b 2 q b bOSl b O b L 3 L m
BS 5493 : 1977
Appendix A
Prone
corrosion
to Improved
Drainage hole(s)
Ensure preservation of
structural integrity. Avoid
discharge on to vulnerable
steelwork
( a ) Retention of dirt and water
Prone to corrosion
Dirt accumulates Tends to shed

and moisture dirt and water
penetrates to
faying surfaces A butt-welded
joint bemay
preferable to either
( b l Comparison of bolted and welded lap joints
(C I C;orrosion points on abox section
Ledges and corners where

moisture and dirt collect
I Improved
(welds ground
flush l
/fi/ Joints between inclined members
I d ) Corrosion pointsoninclined members
Figure 2. Corrosion points

83
BS 5493 : 1977
Appendix A
Prone to corrosion Im proved
Prone to corrosion Improved
L Y
Figure 3. Crevices
A.3 Designing for the prevention of corrosion A.3.3 Cavities and crevices
A.3.1 Introduction. The danger of corrosion canbe A.3.3.1 Filling. Cavities and crevices should be avoided
reduced and theefficiency of protection greatly increased or, if unavoidable, filled with weld metal or mastic
by careful attention to design. Experienced designers (see figure 3).
acquire a 'corrosion awareness' which enables them to Any large cavities that will become inaccessible when the
eliminate potential corrosion hazards. The main points structure has been completed shouldbe sealed with weld
that arise are considered below under thefollowing metal; where required,the seal should be tested by
headings. internal air pressure. Another method is to fill the cavities
(a) Entrapment of moisture and dirt. with concrete which is vibrated into position. Small spaces
(b) Contact with other materials. may be filled with mastic or rust-inhibitive paste or steel
packings coated with an inhi,bitive paint.
(c) Coating application.
A.3.3.2 Box sections. If box sections can be properly
(d) General factors. sealed and tested without structural damage their internal
The choice of suitable materials of construction and of surfaces should not need protection.
adequate protective measures is an important function of If hermetic sealing is impracticable, these surfaces will be
design. It has already been dealt with in the code. subjected to alternating condensation and evaporationof
A.3.2 Entrapment of moisture anddirt moisture. This arises from the fluctuating difference
A.3.2.1 Corrosion points. Corrosion is most likely a t between the internal and external temperatures which
points where rain, condensed moisture and dust collect. causes the enclosed space to breathe. In these circumstances
To avoid such corrosion points (see figure 2) the whole provision of drainage holes and painting of internal
surface should be as smooth as possible, without sharp surfaces may be necessary. Non-toxic primers and light-
edges, sharp corners, cavities or unnecessary protuberances. coloured finishing coats should be used as corrosion can
Welded tubular construction has an advantage in this remain undetected beneath a dark coating such as red iron
respect (13). oxide paint.
A.3.2.2 Joints, Joints should be arranged to give clean Protection can be prolonged by using desiccants to reduce
uninterrupted lines. Generally, welds are preferable to the internal humidity. Silica-gel, used a t the rate of
bolts or rivets, butt welds to lap joints, and continuous 250 g/m3 of void, is effective for 2 to 3 years inside a
welds to intermittent welds. If lap joints have to be used, reasonably well sealed structure, if the manholes are kept
appropriate welding orfilling may be needed. closed. The desiccant should be renewed a t intervals and it
should not be relied upon if its presence is likely to be
A.3.2.3 Fasteners. Care should be taken in the design of
forgotten.
fasteners and the choice of material for them (14).
A.3.2-4 Friction-grip bolts. The faying surfaces of A.3.3.3 Tubes. In general, the remarks made in A.3.3.2
friction-grip-bolted connections need special treatment apply to tubes and hollow sections. Internal protection is
as discussed in 8.2 and 25.3.2.

BSI €Ism5473 7 7 M l b 2 4 b b 9 O l b O b L 5 5 m
BS 5493 : 1977
Appendix A
seldom necessary but in doubtful cases a coating can be

0 appliedinside a t the time of manufacture.
(c) Applying a metallic coating to the steel, so as t o
reduce the potential difference between it and the
A.3.3.4 Enclosed steelwork. When steelwork is enclosed non-ferrous metal.
in brickwork, boarding,plaster,and other materials, it is of (d) Imposing overall cathodic protection.
prime importance that the surrounding space be kept dry,
A.3.5.2 Different types of steel. Contacts between mild
¡.e. below thecritical humidityfor corrosion (ske A.1.5.1 (b)).
steels and/or low-alloy steels will notaffect corrosion
I f this cannot be done, an effective protective coating
appreciably, if they are free from mill-scale. Trouble might
should be provided, particularly for steel surfaces in outer
arise, however, a t contacts between thesesteels and
walls and behind dry casings for false ceilings. In some
stainless steels.
buildings, these may be exposed t o process fumes.
The design should carefully avoid corrosion of steel
panelling on the cold side of air spaces, whether filled with
insulation or not. An air space should be left between the
steel and the insulation and arrangements made for warm
inside air to flow upthrough this.
. A.3.4 Circulation of air, drainage, and waterproofing
A.3.4,I Circulation of air, Free circulation of air around
and through the structure should be arranged (see figure 4);
this hastens the drying of surfaces after rain or dew.
Protective coatings breakdown exceptionally quickly on
sheltered surfaces, suchas the eaves of buildings, where
moisture lingers and such areaswould benefit from the
protection of special coatings.
A.3.4.2 Drainage. Arrangements should be made for and painting
shedding dripping water and condensation. Where
necessary, lengths of pipe should be attached to the Figure 4. Air circulation e.g. pipeline support
drain holes to carry the water clear so that it cannot be
blown back on to the structure (see figure 5a).
The design of storage tanks should permit complete
drainage (see figure 5b) or a sump should be provided from
which condensed water can be pumped. To avoid water
traps, the floor should be as smooth as possible, welded
joints should be ground flush and any stiffeners should be
fitted outside the plates.
Extra protection should be given to the most vulnerable
areas by coating the bottom and about 300 mm to
400 mm up the sides.
i
Water traps should be avoided where steel stanchions
enter the. ground or are embedded
(see figure 6 ) .
in a concrete base I zrq
i L 25 mm to 50 mm
~ A.3.4.3 Waterproofing. (15). Many structures,

especially 'Drip line well clear
bridges, are made of steel and reinforced concrete.
The prevention of corrosion and deterioration depends
on careful waterproofing and correct design of the 4 a) Schematic arrahgement at outside girder of a
concrete details to keep water away from the steel. concrete bridge deck
A.3.5 Contact with other materials
l A.3.5.1 Other metals. Electrochemical corrosion can
i appear a t contact surfaces between different metals."
Some metals, e.g. nickel and copper, aggravatethe
corrosion of steel while others, e.g. zinc, reduce it.
The danger of bimetallic corrosion is most serious for
immersed structuresbut should also be considered when
designing atmospheric or buried structures. The latent
corrosion cell can be made inert by one or more of the
following methods.
( b 1 Schematic arrangement for tanks
(a) Insulating the contact surfaces.
(b) Making thejoints watertight and usingan
Figure 5. Drainage
impermeable coating to keep out the electrolyte,
eq. rain water.
I *See PD 6484.

85
BSI B S m 5 4 9 3 77 m l b 2 4 b b 9 OLbOblb 7 M
BS 5493 : 1977
Appendix A
Prone to corrosion Improved

I
Rubber/ bitumen seal

\ !
i
Plan on Z-Z
Figure 6. Protection of a stanchion at ground level
A.3.5.3 Concrete. Portland cement concrete tends to A.3.5.4 Timber. Where steel is in contact with timber
inhibit the corrosion of embedded steel but it will not under corrosive conditions, thefaces of both materials
protect steel which is near the surface against corrosive should be coated with hot tar or with a bitumen bedding
attack. This subject is too complex to discuss in detail compound containing fillers, immediately before they
and is outside the scope of this code. In general, steel that are brought together. An insulating sheet of plastic,
is embedded in Portland cement concrete needs no e.g. polyethylene, may be used, especially if the timber
additional protection if the provisions of CP 110 are has been treated with preservative.
followed. Thesé include the following: Large washers of neoprene or similar material shouldbe
(a) Correct composition and compaction of the mix. fitted under nuts and bolt-heads to prevent water entering
(b) Adequate depth of cover of the reinforcement a; all the wood. The nuts and bolt-heads should be coated in
points. From 50 mm to 60 mm is recommended for the the same way as the bolts.
most severe conditions, e.g. exposure to sea water, Contact surfaces between zinc-coated or aluminium-
but 20 mm may be sufficient for indoor work. There is sprayed steel and wood need similar treatment,
evidence that these figures can be reduced by 25 % A.3.5.5 Other materials, Some other building materials,
if the steel is given a zinc coatingof 500 g/m2. e.g. gypsum plaster, are corrosive. Suitable insulation,
The depth of cover should also be related to the such as a waterproof membrane, should be provided
maximum size of concrete aggregate. where steel touches them and the penetration of water to
The concrete cover should be continuous. If gaps are the interface shouldbe prevented.
left in it, a corrosion cell may be set up (see figure 7). Problems can also arise through the evolution of
corrosive vapoursfrom plastics andother organic materials.
86
BSI BS*S473 7 7 m l b 2 4 b h 7 CllbObL7 7 W
BS 5493 : 1977
Appendix A
A steel tower with precast concretefeet had to be erected

on slopingground. A concrete collar was cast'in situ' to
protect the upper leg at ground level. Severe corrosion
occured at the gap that was left between the new and
theold concrete
. Corrosion point
A pipeline was allowed to rest on the trench bottom ( instead

of on a concrete bed) when the steel was encased in
concrete. Corrosion occurred along the unprotected part of
the pipe ( at the bottom 1
Figure 7. Corrosion at gap in surrounding concrete

87
BS 5493 : 1977
Appendix A
v
Avoid Prefer
T % i 2
Gap too small Gapaccess
enough
wide
for
(a) Ducting
Avoid Prefer
1
7r
Gap too small
1
I" Use T bar or weld in

spacer plate
( b 1 Back -to - back angles
Prefer
Sharp corners and Rounded corners
continuous welds and continuous
Figure 8. Design for coating
ubber/ bitumen seal
Access inadequate Access adequate
Figure 9. Access for maintenance
88
BS 5493 : 1977
Appendix A
14.3.6 Coating application A.3.7 General factors

A.3.6.1 General. The designer should strive to ensure that A.3.7.1 General design of the structure. The general
@ the protective coatingscanbe applied with ease and
efficiency, so as to achieve a continuous, uniform coating
design of the structure can affect €he performance of a
protective scheme.
everywhere. Consequently, details such as back-to-back (a) It is much easier t o protect large flat areas than
angles, recesses, deep corners and blind holes should be more complicated shapes. For example, truss types of
avoided (see figure 8 ) . bridge are more susceptibleto painting difficulties than
Sharp edges and corners cannot be coated evenly and beam and girdertypes and it is easier to protect tubular
coatings there are particularly vulnerable to damage; all construction than lattice work. Tubes may be better
edges and corners should therefore be radiused. Tubular than wires for guys and similar supports.
sections are better than I or H sections in this respect. (b) Sometimes, part or the whole of a structure can be
A.3.6.2 Galvanizing. Vent holes and drain holes should made detachable. It may then be economic to have
be provided in assemblies that are to be hot-dip them hot-dip galvanized andreturned for re-galvanizing
galvanized (see BS 4479). They serve to avoid internal when necessary.
pressures and airlocks during immersion, which may cause A.3.7.2 Load-bearing members. I f the design permits,
explosions. They also ensure that molten zinc is not the load-bearingmembers should be located where the
retained in pockets on withdrawal. corrosive conditions are least intense. For example,
A.3.6.3 Dip-painting. The details of steelwork that is to the members supporting the roof of a tank for corrosive
be dip-painted should resemble those for hot-dip chemicals should be external to the tank.
galvanized steel (see A.3.6.2). A.3.7.3 Services. The locations of service pipes, cables and
ducts attachedto the structure, or passing through box
o A.3.6.4 Metal-spraying. Sufficient access should be
provided to all surfaces that are to be metal-sprayed
(see BS 4479).
girders, should be agreed with all interested parties before
detail drawings are prepared,
A.3.6.5 Spray-painting. The paint-sprayinggun is more Lack of attention to such matters can lead t o the creation
flexible and wieldy than the metal-sprayingpistol, of corrosion points, which arise, forexample, where pockets
so the details recommendedfor metal-spraying are formed by not keeping conduits clear of the steelwork
(see BS 4479) should be adequate for spray-painting. or where steam and other exhausts from pipes are allowed
A.3.6.6 Access. The design should ensure easy access to to impinge on it. The time needed for maintenance is
all parts of the structure and thereby make it possible to uneconomically prolonged if service equipment has to be
inspect and renew theprotective scheme without moved before the work can begin.
difficulty. Thus, any falsework, screens or hoardings that 4.3.7.4 Fayhgsurfaces. Coatings on faying or flexing
would impair access to the corrected structure should be surfaces are particularly vulnerable to damage. For example,
easily removable. the failure of outdoor pipelines is most frequently due
Lack of forethought, may result in areas that can be to the abrasion of the coating through the expansion and
painted in the shop becoming inaccessible later (see contraction of bearing surfaces. One possible remedy is
figure 9). to provide graphite pipeslides.
Where the expense is justified, the design might include
A.3.7.5 Cathodic protection. Where cathodic protection
(see CP 10211 is to be applied, the design should ensure
special fittings for the attachment of painting gantries
good electrical continuity throughout and, if necessary,
or powered platforms and of awnings to shield maintenance
insulation from neighbouring structures. Permanent and
work from bad weather. These should be robust and
a
readily accessible insulated t e s t leads should be fitted a t
placed where they canbe maintained without risk of
representative points for checking the efficiency of the
' accident.
insulation.
89
BS 5493 : 1977 BSI B S * 5 4 7 3 7 7 LbZ4bb7 OLb0620 7 m
Appendix B
Appendix B
Characteristics of paint binders

B.1 Binders for dryingoil-type protective systems
Description Characteristics
Blend of raw and processed drying oils Very slow drying; good surface wetting where steel cannot be
well cleaned
Drying oil modified with phenolic or phenolic- Good water resistance; suitablefor primers and undercoatsbut
modified resin yellows in light-coloured finishes
Alkyd or modified alkyd Good all-round properties;4 h to 8 h overcoating in good conditions

depending on oil content (oil length). Prone to blistering in damp
conditions
The modification may be:

(a) blending with raw or processed Dries faster than blended oils alone, but slightly less tolerant
drying oil of poor surface cleaning
(b) copolymerizing with styrene or Faster-dryingalkyd but less tolerant of poor surface cleaning.
vinyl toluene Vinyl copolymers are sensitive to solvents and recoating times
are critical
(c) combining with an isocyanate to Basis of one-pack polyurethanes. Componentsare usually selected
form a urethane alkyd to provide additional hardness to the finish
Alkyd modified with chlorinated rubber Faster-drying alkyd with improved water resistance. Fair chemical
resistance when ratio of chlorinated rubber to alkyd is 2: 1 or more
Solution blends in suitable solvents. Full chemical resistance and suitability for use with cathodic
Chosen alkyd should be fully compatible protection is doubtful while saponifiable component is present
with the chlorinated rubber.
Dryingoil epoxy ester Faster drying than modified drying oil,with good water resistance,
(one-pack epoxy) but yellows in light-coloured finishes
Urethane oil Dryingoil film is hardened and toughened. Used for primers
required to withstand rough handling
drying oils suitably modified with isocyanates
Silicone alkyds When silicone resin content exceeds 30 %, alkyd is durable and
retfins gloss. Especially recommended for finishing coats exposed
to intense sunlight
B.2 Binders for one-pack chemical-resistant protectivesystems

Blend of chlorinated rubbers and Very low water permeability. Quick drying. Can be overpainted
non-saponifiable plasticizers. with no adhesion problems, even after prolonged aging
NOTE. For blends with alkyds see B.l
'alkyd modified with chlorinated rubber'.
Blend of vinyl chloride/acetate copolymers Similar to preceding binder but much less tolerant of poor surface
with or without non-saponifiable plasticizers cleaning and has a higher water-vapour permeability. More durable
NOTE. Primers with copolymer should be maleic in finishing coats exposed to intense sunlight. Low-build a t normal
modified to assist adhesion. viscosity
90
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BS 5493 : 1977
Appendix B
B.3 Binders for two-pack chemical-resistant protective systems

(For correct use of the terms 'binder', 'vehicle', 'medium', see BS 2015.)
Two-pack epoxy The epoxy resin is available a t different viscosities (low viscosity for
high build). The curing agent is either an amine or an amide.
mixture of an epoxy resin and The reaction on mixing is temperature dependent and resultsin a
suitable curing agent highly chemically resistant binder. Amines, especiallyaliphatic
amines, can be toxic until reacted and shouldbe used with great
care. The choice of curing agent also dependson required
performance. Paint manufacturer's advice shouldbe sought in
every case
Curing agents
aromatic amines Good water resistance andlowtemperature cure
aliphatic amine adducts Good speed of cure and solvent resistance,but tend to give poor
intercoat adhesion
aromatic amine adducts Good intercoat adhesion and resistanceto aqueous chemicals
polyamides Slower curing rate and good pot life, best when blended with
coal tar
Coal tar epoxy Cdal tar i s a diluent and cheapening additive which detracts little
from general properties and gives slightly better water resistance.
mixture of an epoxy resin with a suitable It is not satisfactory for solvent resistance and gives poor low-
coal tar fraction temperature flexibility, Recoating periods are critical and this
leads to intercoat adhesion problems and a tendency to bleed
into subsequent coats
Two-pack polyurethane The polyester can vary from brittle toflexible; blends are made
to suit finish requirements
mixture of suitable polyesterresins
with polyisocyanate curing agent,
aliphatic polyisocyanate Superior colour retention and UV-resistance; recommendedfor

finishing coat
aromatic polyisocyanate Suitable for primers, undercoats and finishes. Not used where
it i s important to avoid yellowing
NOTE. Two-pack polyurethanes have better weathering resistance and low-
temperature cure than two-pack epoxies but are more difficult to formulate
for high-build products and, during curing, are more sensitive t o moisture.
B.4 Binders for specific uses in protective systems

Description :haracteristics
Polyvinyl butyral resins
(a) For two-pack pretreatment primer Nhen mixed, the phosphoric acid reactswith resin and the metal
(see product sections of table 4) ;urFace to give a chemical bond. May be modified with phenolic
.esin for improved water resistance
(b) For single-pack 'blast primer' Wodified with phenolic resin

(see product sections of table 4)
Silicone resin In the skeletonof the binder, silicon replaces the more usual
:arbon. This adds heat resistance to i f s value as a binder
(e.g. aluminium silicones for steel chimney stacks)
Alkali silicates, (see product sections Aqueous binder reactingwith zinc-dust pigment; dries to a hard
of table 4) adherent cement-like structure with good abrasion resistance
Organic silicates, (see product sections Alkyl ester hydrolyzing and reactingwith zinc-dust pigment;
of table 4) dries to a hard adherentcement-like structure with good abrasion
resistance. More tolerant than alkali silicates to variations in
atmospheric moisture
91
BS 5493 : 1977
Appendix C
Appendix C
Characteristics of paint pigments

C.1 Pigments used mainly for primers
Red lead Suitable where oil content of binder is high

(also redhead white/lead) (¡.e. slow drying)
Zinc chromate Available with different degrees of solubility. Solubility can

inhibit corrosion but may also cause blistering. Paint manufacturer
should be consulted beforeuse
Zinc tetroxychromate Used in pretreatment primer with polyvinyl butyral resin binder
(see table A)
Zinc phosphate Good general-purpose pigment for primers. I t s light colour is an

advantage if producing light tints; early rusting caused by thin
films or overexposure can be seen
Metallic lead Satisfactory performancefor bridge protection and in paints for

direct application to galvanized steel. Reactive in certain
environments
More suitable than red lead for oil-free binders
Iron oxide Inert pigment of high staining power; yellow, red and black forms
are suitable as a cheap additive. Use of red form in primers may
mask initial breakdown by rusting
Zinc dust Gives some cathodic protection to steel when used as a sufficiently
high percentage of the total film to ensure electrical conductivity
through the dry paint film to the steel. See BS 4652
Calcium plumbate Used in paints for direct application to galvanized steel.

See 8s 3698
C.2 Laminar pigments used mainly for undercoats and finishes

Micaceous iron oxide (MIO)
Mica
Aluminium All these are used in protective coatings because the flakes lie
(a) leafing, coated with stearic acid parallel to the surface and overlap, forming a moisture barrier
(b) non-leafing and improving tensile strength. MIO and aluminium protect
the binder from UV-degradation. Leafingaluminium has high
Graphite lustre. Aluminium and graphite are used for high temperature
paints. Aluminium is not recommended for chemical resistance
Stainless Steel
Glass flake
C.3 White pigments for undercoats and finishes

Description I Characteristics
Titanium dioxide (rutile) The principal white colouring pigment is rutile titanium dioxide,
The anatase grade chalks on exposure to UV-light but is suitable
Titanium dioxide (anatase) for undercoats. A proportion of zinc oxide may be used for i t s
antifungal and biocidal properties. A proportion of antimony
Zinc oxide oxide is used where special fire-retardant properties are required
Antimony oxide
92
B s I BS*5473 7 7 lbZ14bb9 0 1 6 0 6 2 3 m
BS 5493 : 1977
Appendix C
C.4 Coloured pigments for undercoats and finishes

DescriDtion I Characteristics
Iron oxides Light-resistant cheap pigmknts available in shades of red,
yellow and black
Carbon blacks Very high staining power and, as relatively small additions,
give high-opacity black finishes. As tinters they are the basis
of grey finishes
Light-resistant organic or inorganic pigments Pigments should be selected which are known to be adequately
resistant to light when used with the binder specified
Light-resistant organic or inorganic pigments The pigment aswell as the binder should have the specified
with good chemical resistance chemical resistance
C.5 Extender pigments for undercoats and finishes

Extenders, as used in anticorrosive protective compositions are inorganic compounds of limited opacity and low refractive
index, they may occur in nature or can be made synthetically. The choiceof extender depends on the property requiredof
the protective coating.
Description :haracteristics
Oxides, mainly silicas Vaturally occurring as quartz (sand) and diatomaceous silicas such
1s kieselguhr. Synthetic silicas usually have a very fine particle size
and are very transparent in binders. Sand is useful for abrasion
resistance (deck and floor paints). Kieselguhr and synthetic silicas
Ire useful in reducing gloss of finishes (e.g. to achieve matt finishes)
Carbonates
calcium carbonate (chalks, limestone whiting) Ealcium and barium carbonates are also availablein synthetic
Form. The carbonates are cheap extenders with good all-round
calcium magnesium carbonate, (dolomite) xoperties but arenot suitable for acid-resistant finishes and
jhould be avoided where the environmentis considered severe
barium carbonate (witherite)
Silicates
aluminium silicatesjchina clay, mica, Cheap extender, useful for anti-settling properties
bentonite) Good for producing agel structure in formulations
calcium silicates (wollastonite, synthetic) Alkaline in nature and stabilizes emulsion or water-based paints
magnesium silicates (talc, asbestjne) Assists suspension and controls settlementin primers and undercoats
calcium-magnesium-iron silicates The fibrous nature prevents crackingof bituminous and like
(asbestos) products
Sulphates
barium sulphate (barytes (synthetic form), Insolubility makesit an outstanding extender in high-performance
blanc fixe) formulations
calcium sulphate (gypsum (synthetic form), Because of its water sensitivity, should be used with considerable
precipitated calcium sulphate) caution
93
BSI B S * S 4 7 3 7 7 m L b 2 q b b 9 OLbOb24 b m
BS 5493 : 1977
Appendix D
Appendix E
Appendix D . percentage on sub-contractedwork) and extra administra-
tive costs where appropriate and where not included in
Sampling of paint step 1.
Paint is more difficult to test than most materials used by Step 3. (Not relevant to private individuals.) Deduct tax
the engineer, because the performance of a paint film allowances. Typically, for limited liability companies in
depends on where and how it is applied. Chemical analysis the United Kingdom these comprise initial grants for
is no guarantee of quality but gives circumstantial evidence certain projects in development areas plus first-year
of conformity with a specification, of probability of allowances, adjusted for corporation tax.
contamination of material used or of incorrect mixing. Step 4. Estimate the time that will elapse before the
Physical tests of properties such as viscosity, density product or structure is available for use. Write down the
or non-volatile content are often easier to make and may cost in interest of any such delay assuming the capital sums
be equally informative. involved could have been otherwise employed during the
For these purposes comparison of a sample taken a t the extra time required (compared with the product or system
point of use with an agreed sample, either suppliedwith most speedily available).
the manufacturer's tender or taken from the delivered Step 5. Estimate maintenance costs (after making an
material, is required. Where a dispute is likely to arise, appropriate allowance for tax relief) during the life of the
three identical samples should be taken, one for the structure, including access costs such as scaffolding.
inspector, one for the painting contractor (or main In general, the future maintenance costs have to be
contractor) and one for the manufacturer. It is best to estimated, making allowancefor inflation and then
take reference samples from all batches of material discounted to present values (see maintenance terms in
delivered even if no immediate tests are to be made. the equation below).
Whilst the agreed sample should be taken after carefully Step 6. Estimate cost of disruption during maintenance
mixing the material under examination and using (or initially). As with maintenance costs, these have to be
established sampling methods, point-of-usesamples estimated, making allowancefor inflation, and then
should be taken straight from the painter's kettle or discounted to present values.
spray pot.
The maintenance costs plus the initial cost are frequently
Process samples of the 'as applied' system, when properly assessed as the Net Present Value (N), which represents
identified, can be invaluable if a dispute over performance the sum of money that has fo be set aside now to cover both
ensues. initial and maintenance costs over the total life required.
MI M2
Appendix E
N=F f ~ +- + etc.
(I + r)'l ( I +r)'z
where
Choosing the most economical defence against F is first cost of the protective system;
corrosion MI is the cost of maintenance in the year P I ;
The choice of the most economical defence against M2 is the cost of maintenance in the year P z ;
corrosion cannot be precise, because neither the timing r is the interest (or 'discount') rate;
nor the cost of future maintenance can be predicted NOTE. 12 % rate is written 0.12, etc. r can also be the
accurately and ratesof taxation change from time to expected rate of return on capital employed in the business.
time. Nevertheless, an overall economic appraisal should P , denotes the number of years to first maintenance;
be made, for it may help to influence a decision when Pz denotes the number of years to second maintenance,
there is uncertainty regarding the choice of protective etc.
system or products that require a protective system. Maintenance costs are steadily rising and so have to be
Each product or protective system has its own pattern of adjusted a t present-day values ( M ) to allow for inflation
capital and running costs. Choosing the optimum alternative a t an annual rate r l : ( r , is expressed like r ) .
requires care because some of the factors involvedcan be M , = M ( I + r l ) ' ! etc.
measured precisely whilst others can not, and the costs
arise a t different times.
A quick comparison of systems can be made by comparing
present first costs plus maintenance costs a t present values
In the simplest case, where the rate of inflation of
in each case. (Access anddisruption costs should, be taken
maintenance costs is the same as the interest (or 'discount')
into account a t this stage.) The comparison can then be
rate available on money (¡.e. where there is no time-value
elaborated by the following procedure.
of money), then r , = r and the formula i s simplified to:
Step 1. Set out the alternatives, ensuring that they have
N = F + the sum of all maintenance costs a t present-day
the same basis of comparison. Write down theextra
rates
capital cost (if any) arising from the need to make the
= the aggregate of all initial and maintenance costs
product from more expensive materials, to protect the
a t present-day rates
prqduct or structure, or to increase the thickness of steel
to allow for wastage by corrosion. This capital cost may Other costs can be treated as for the maintenance costs or
be a direct quotation or may be calculated (see note (c) for the first cost as appropriate. Table 13 illustrates a model
below) but make sure that quotations or calculations are cost-calculation table.
on the same basis. The following points should be borne in mind when
Step 2. Add extra transport costs (e.9. when work goes making the necessary calculations.
to specialist processing plant instead of direct to customer (a) For many protective schemes the initial cost in the
or to site), extra mark-up (the main contractor may add a factory is roughly proportional to total thickness,
94
BSI B S * 5 Y 9 3 7 7 lbZYbb9 OLbOb25 8 m
BS 5493 : 1977
Appendix E
but life to firstmaintenance i s not necessarily propor- than material costs, painting will become slightly more
tional to thickness; e.g. relatively thin metal coatings in expensive relative t o metal coatings and viceversa.
certain environments often have the longest lives to (9) Sprayed-metal, paint, powder, and tape coatingsare
first maintenance. usually costed by thearea covered, which should be
(b) Calculation of protection costs from fundamentals known reasonably accurately. Galvanizingis costed by
has been dealt with in industry-oriented handbooks, the weight of steel coated, ¡.e. by the thickness of steel.
e.g. 'Galvanizing for profit', Galvanizers Association, Costs also vary by product. The qualitative relation for
London, UK. In principle, first costs include: structural steel is shown in figure IO.
materials (h) The most economicalsystem for one job is not
labour necessarily the most economicalfor another, e.g.
overheads (including inspection, access equipment galvanized steel may be best for a bolted job but not
and tools for painting). where much site welding is necessary.
These are usually of the same order of magnitude, (i) First costs include access costs, e.g. scaffolding.
with materials being most costly for metal coatings and Surfaces treated before erection do not require
labour mostcostly for paint coatings. scaffolding.
(c) Surface preparation for painting is often analysed
separately, for i t s cost frequently amounts t o about Surface area pertonne, m'/ tonne
one-third of the total cost. Acceptance of poor surface 50 25 15 10
preparation may save 20 % or less of the total capital
I I I
I
cost, but is likely to reduce the life expectancy of a
coating by more than half, so adding more than 1O0 %
to the total lifecost. Incorrect choice of blasting
equipment (e.g. size of nozzle, grade of abrasive, etc.)
will increase the cost of surface preparation and may
even double it.
(d) In calculating paint quantities, the theoretical
dry-film requirement should be increased by up to
50 % to allow for locally thick coatings, wastage,.
repairs and losses (typically 30 %for air spray,
15 % for airless spray, 1 O % for electrostatic spray,
5 % for roller or brush application) etc. Manufacturers
should be asked to quote the percentage of solids by
volume in their paints to facilitate calculations.
(e) Labour costs for the application of paint increase
in an approximate ratio in the following order:
airless spray : normal air spray : roller : brush
1 : 2 : 3 : 4 Thickness of steel, mm
(f) JComparativecosts, unlike actual costs, change little *Except that with paint, the final coatis on site.
with time. When labour costs are rising more rapidly Figure 10. Shop coating costs relative to thickness of steel
Table 13. Suggested layout of a cost-calculation table

Competing systems
(conforming to systems under same environment and same time to
first maintenance in table 3)
First system
Second
system
Extra capital cost (step 1)

Add extra transport costs (step 2)
Add extra fabricator's mark-up (step 2)
-
Total gross extra capital cost
Deduct total taxed allowances (step 3)
Total gross extra capital cost, net of

tax allowances, etc.
Delay factor (step 4)
Maintenance costs (step 5)
Disruption factor (step 6)
Total cost of system, over and above costscommon to all

systems, and expressed in present-value terms
95
BSI B S a 5 4 9 3 77
BS 5493 : 1977
Appendix F
Appendix G
Appendix F Appendix G
Methods for control of preparation (by blast- Test for detecting soluble rust-producingsalts
cleaning) remaining on blast-cleaned steel
Grades of blast-cleatingare selected by the specifier in When blast-cleaning heavily rusted and rust-pitted steel
relation to the conditions of use and the protective system a surface appearance suggesting a standard of cleanness
chosen. Specifications for blast-cleaning includepictorial equivalent to white metal or Swedish Standard Sa2% or
standards (Swedish Standard SIS 05 59 00) or sketches Sa3 can be obtained, which, after an hour or two and
(BS 42321, but these can be used for site control only if sometimes after standing.overnight,develops rust-spotting
the lighting is good and the inspectors are highly a t points correspondingto the rust-pitting, In such circum-
experienced. Steel coupons blast-cleanedto an agreed stances it is a serious mistake to apply protective coatings
standard are better but should be carefully stored and until the cause of the rust-spotting has been eliminated.
handled to prevent deterioration. The cause is the presence of rust-producingsoluble salts
For convenience and to reduce disputes it is best to use of iron which are practically colourless and are located
instruments whichenable figures to be recorded. A light a t the lowest point of the rust pits. In the presence of
reflectometer, e.g. the Surclean Model 153*,can be used moisture they hydrolyseto iron oxides and acids;
to assess effectiveness of removal of mill-scale, freedom the acids dissolve more iron to form more iron salts thus
from rust, and general approach to 'white metal' producing, in time, large volumes of rust which will break
condition. This instrument measures the amount of blue the adhesion bond of protective coatings if applied before
light reflected from the surface compared with that from the salts are removed.
a standard grey tile. Repeatedly blasting the same area of Using potassiumferricyanide test papers any remaining
Steel causes an increase in reflection until a steady value soluble iron-salt contaminants can be detected as follows,
ßma, is reached corresponding to white metal (dependent (a) Spray a fine mist of water droplets on to a small
on the abrasive and the steel) as shown in figure 11. area of the blast-cleaned surface usinga hand spray
The acceptance level should be fixed as a percentage of (a scent-spray type of bottle if satisfactory).
R,,, for BS 4232, 2nd quality; the average of all readings
(b) Allow the water droplets to evaporate and a t the
on the work should be a t least 90 % of Rmaxand not more
moment when they have disappeared but the surface is
than one reading in ten should be below 80 % of ßma,.
just perceptibly wet apply a small piece of test paper
When using this control method the value of R,, and the
and press with the thumb for 2 to 5 seconds.
acceptance levels should be agreed by the Inspector, the
contractor and other interested partiesa t the start of If soluble salts remain, these will be drawn by capillary
the work. action into the test paper and will react with the
potassium ferricyanide to give a characteristic Prussian
blue complex as blue dots on the paper corresponding
to the contaminated pits on the blast-cleaned steel.
Time of blasting
Figure 11. Assessment of steel cleaning
*Supplied by Elcometer Instruments Ltd., Manchester.
96
BSI B S * 5 4 7 3 7 7 m L b 2 4 b b 4 OIbOb27. I BS 5493 : 1977
Appendix H
Appendix H
Example of use of the code (see clause 3)

The following example is intended to demonstrate, for the inexperienced specifier,the step-by-step approachto selection
af a coating system for a particular fabrication, taking all appropriate facfors into account,
The protective system to be selected and specified is required for a girder linking a sea-water pontoon to a fixed pointon
land a t a site in the United Kingdom,
It is assumed that the girder has been conceived as a welded box-girder with lightening holes and pin joints a t the ends.
The pin joints, which are considered to be purpose-made units to be attached to the ends of the girder bysite bolts,
are not included in the example.
iource of information or
The selection andspecification of a coating system ocation in the code
Step 1 Acquire an appreciation of what is included in the code and where it i s located rable of contents
ind index
Step 2 Consider if any modification of the design i s desirable i n the light of the advice in 15.3 and A.3
the code
In the example it is seen that a box section with lightening holes will not only trap
water but will be difficult to maintain internally, so it is decided to redesign the
girder as a welded plate girderwith lightening holes in the web. This reduces water
c trapping and makes all surfaces readily accessible.

Special attention is paid to the ends to ensure that any water resting on the
bottom flange can run offas the pontoon rises and falls.
Step 3 Ascertain and list the basic facts concerning the structure by answering the
questions i n 4.2
In the example, the facts (and assumptions) are tabulated as follows.
4.2.1 Function.
(a) Structure is required to link pontoon to shore. lesign remit
(b) Nil.
4.2.2 Life.
(a) 50 years. Design remit
(b) Reconsider iater.
4.2.3 Environment. >lause 5
(a) Coastal.
(b) Structure is a few feet above salt water and i s likely to be covered with
spray from time to time.
(c) At high tide, in storm conditions the under side may be hit by water-borne Design remit
flotsam, but there is unlikely to be mechanical damage arising from usage or
contamination by de-icing salts.
4.2.4Appearance.
(a) The owning authority requires the colour to be green overall. Design remit
(b) Yes.
4.2.5Special properties.
(a) Norequirement.
4.2.6 Maintenance
(a) Because of pontoon use, access for maintenance will be possibie only in Design remit
November and December.
(b) It is clear that maintenance will be difficult, Practical experience
4.2.7 Health and safety.
(a) No special points requiring attention are apparent a t this stage.
(b) The existence of offices adjacent to the shore connection suggests that Section six and
limits may be placed on permissible noise and/or dust createdduring practical experience
maintenance work.
4.2.8Tolerance.
(a) A high standard is essential a t this site, requiring works application of initial Clause 9-
coatings.
(b) As (a) above. However, site applied coats may need to be tolerant of a lower Suppliers
standard.
Step 4 Examine table 1. Select the description nearest t o 4.2.3 above. Turn t o the Table 1
Ilh corresponding part of table 3
In the example, the nearest description is ‘sea water: splash zone .. .
frequent Table 3, part 9
salt spray’.
97
COPYRIGHT British . Standards
. Institute on ERC Specs and Standards
BSI B S * 5 4 9 3 7 7 m 3 6 2 4 6 6 9 0160628 3
BS 5493 : 1977
Appendix H
Ìource of information or
The selection andspecification of a coating system ocation in the code
Step 5 Decide on a life requirement, taking into account the answers to questions 4.2.2, :lause 6
4.2.4,4.2.6
It is clear that a durable protective system is required. However, the decorative
coating may be expected to require attention a t shorter intervalsthan would
normally apply with a durable protective system. It is decided, therefore,
to select a 'long life' system to reduce the frequency of maintenance and 6.2.1
(incidentally) reduce the likelihood of potentially noisy surface preparation 6.2.2
being neededfor corroded areas. At the same time a greater frequency of 6.3(b)
maintenance for the decorative coatingis considered acceptable.
Step 6 Consider the 'long life' systems listed in table 3,part 9; eliminate any that are rable 3, part 9.
thought to be unsuitable. Make preliminary estimates of the approximate cost Appendix E
per square metre and inquire into the suitability (for the actual conditions) of
the remaining systems, so far as time permits
It is clear that some of the systems listed (SB1 + SK5; SB3; SB9; SC3Z; SC6Z;
SCIOA; SCIOZ; SE7; SK8; SL5) will require the decorativefinish as an addition;
yet there are no immediately obvious reasons for eliminating any of those
systems a t this stage. Therefore:
(a) if time permits, make inquiries (preferably of the manufacturers)
about all of these systems; or
(b) if there is not sufficient time, confine the inquiries to those systems
that include a finish that gives or seems to give the required appearance.
Step 7 On the basis of the conclusions reached in step 6 and any experience or
justified preference, select a limited number of systems for detailed examination
In fact, time is short (step 6(b) applies) so the selection of systems for detailed Table 3, part 9
study is limited to SB9; SC1 OA; SC1 OZ; SE7; SL5.
Step 8 Make a detailed study of the characteristics of the selected systems, asking the
questions listed in 4.3
In this example, this study could have been made as part of step 6 because the 4.3
time limitation discussed in step 7 was then already known.
A check list in the following form may be found useful. It tabulates the answer
for each of the five systems against each question.
4.3.1 Coating systems.
OA (a)
SC1 SB9 SC 1 oz SE7 SL5 Table 3, part 9
Yes (b) Yes Supplier/experience
Yes (c) Yes Supplier/experience
(d) Application method to suit material. No apparent limitation.
4.3.2 Coating facilities
SC1 OA SC1 SB9 oz SE7 SL5
(a) Yes(1) Depends
Yes Yes
on Yes Supplier/experience
size and shape
of structural
member
Yes Yes (2) Yes Supplier/experience
Yes Yes large
(b) Very
members
may be a
problem
Yes (c) Yes
Yes (d) Yes
4.3.3 Compatibility
SC1 OA SC1 SB9 oz SE7 SL5 Clauses 7 and 8
es Yes (a) Yes Yes Yes
with
(b) Not normal No No No No
structural steels; check
if special steels may
be used in the
fabrication
(c) N.A. (not applicable)
98
BS 5493 : 1977
Appendix H
Source of information or
The selection andspecification of a coating system location inthe code
4.3.4 Delays.
SB9 SC1 OA SC1oz SE7 SL5
(a) N.A. N.A. N.A. N.A.
(b) N.A. N.A. N.A. N.A.
(c) N.A. N.A. N.A. There may be problems
of intercoat adhesion.
be mayThereN.A. (d)
N.A. N.A. problems
of intercoat adhesion.
(e) The final coat should be applied as soon as possible after erection in view
of possible salt contamination. Ensure adequate pretreatment before applying
paint coat.
4.3.5 Transport, storage, handling (works-appliedcoats only).
\
SB9 SC1 OA SC1oz SE7 SL5 Experience
(a) Quite good Good Good Fair Fair applied to
(b) Quite good Good Good Fair Fair >
manufacturer's
(c) Good Good Good Doubtful Doubtful data
(dl N.A. N.A. N.A. N.A. N.A. >
NOTE. These are qualitative, not absolute, terms.
4.3.6 Experience.
Assumed reported equal for all systems.
4.3.7 Export.
Not applicable.
4.3.8 Maintenance.
Yes, if steel is exposed. Deterioration of finishing coat only is not serious.
4.3.9 costs.
(a) ((2)
I)
(44
(3)
I It is not practical to quote costs in a hypothetical exercise.
So far as can be seen these will be the same for all the systems
(b) considered.
Step 9 Make final selection

In the example, all five systems examined are of about equal merit. Assuming that
there is no large disparity in the Net Present Value of the corrosion protection,
it is decided to reduce the choice to the two sprayed-metal systems, since these
seem to have some slight advantage.
Step 10 Review the design in the light of the information now assembled
No further basic modification of the design seems necessary. However, detailing
should ensure adequate access for surface preparation and application of coatings,
with provision for slinging.
Step 1 1 Draft the Specification for inclusion in the tender documents

It may be advantageous t o permit the contractor to include alternative prices in
his tender for different systems where the performanceis equal.
The specifications for these items are based on the recommendations included Section 3
in this code. The clauses for fabrication, handling, transport, storage and
erection of steelwork cover all necessary precautions.
Full details of the protective system are given, including references to Section 2
British Standards; and clausescovering quality of other materials, standards
of workmanship and limitations on application environments are included. Section 3
Step 12 Draft the inspection requirements Section 4

Since undetected or unrepaired damage to the coating system can have serious 4.3.8
consequences it is considered necessary to specify 'full' level inspection for Clause 37
both works- and site-applied coats.
Furthermore, it is required that all inspection reports and other relevant Clause 39
information be kept available for future reference in connection with
maintenance.
Step 13 Final check Clause 34

-
99
BS 5493 : 1977
B S I BS*5473 77 Lb24667 0360630 3 m
Appendix J
Appendix J (13)Godfrey, G.B. The design and protection of tubular

structures. Symposium on the Protection of Structural
References and bibliography Steelwork. London: Zinc Development Association,
J.1. References cited in appendix A 1962.
(1) Hudson, J.C., and Stanners, J.F. The effect of climate (14)White, P.E. The selection and use of corrosion
and atmospheric polution on corrosion.Journal of resistant fasteners: for building construction.
Applied Chemistry, vol. 53, 1953, Symposium on Developments in Methods of
pp. 86-95.
Prevention andControl of Corrosion in Building.
(2)Sixth Report of the Corrosion Committee. Special November 1966,British Iron and Steel Federation.
Report No. 66. London: Iron and Steel Institute,
1959. (1 5) Waterproofing concrete bridgedecks. Paris: O.E.C.D.,
1972,obtainable from H.M.S.O.
(3) Booth, G.H. Microbiological corrosion. London: Mills
and Boon, 1971. 5.2 Bibliography
(4)Hudson, J.C., and Watkins, K.O. Tests on the DeparLment of Industry. Corrosion prevention directory.
corrosion of buried cast-ironand mild-steel pipes. London: H.M.S.O., 1975.
BlSRA Open Report MG/B/3/68. British Iron and
Steel Research Association, 1968. Shreir, L.L. (ed.). Corrosion (2vols). London: Newnes-
Butterworths, 2nd edition, 1976.
(5)Romanoff, M. Underground corrosion. National
Bureau of Standards Circular 579,Washington, D.C.: Evans, U.R. The corrosion and oxidation of metals.
U.S. Government Printing Office, 1957. London: Arnold, 1960.
(6)Corrosion of iron and steel by industrial waters and Evans, U.R. first supplementary volume. London: Arnold,
its prevention. Special Report No. 41. London: 1968.
The Iron and Steel Institute, 1949. Evans, U.R. second supplementary volume. London:
(7) Bishop, R.R. Costly car rot can be slowed. Arnold, 1976.
London: New Scientist, vol. 62, 1974,
pp. 380-3. Barton, K. (translated by J.R. Duncan). Protection against
atmospheric corrosion. London: Wiley, 1976.
(8)Butler, G., et al. The influence of movement and
temperature on the corrosionof mild steel. Journalof American Society for Testing and Materials. Metal corrosion
Applied Chemistry, vol. IO, 1960,pp. 80-93; vol. 15, in the atmosphere. Philadelphia, Special Technical
1965,PP. 325-8. Publication No. 435,A.S.T.M., 1968 (obtainable from
(9)Stanners, J.F. Metal coatings on steel a t Lighthouse University Microfilms, High Wycombe, England.)
Beach, Lagos, British Corrosion Journal, vol. 6, 1971, Chatfield, H.W. (ed.). The science of surface coatings.
pp. 197-9. London: Ernest Benn, 1962.
(IO)Scott, D.J. Aluminium sprayed coatings: their use Fancutt, F., et al. Protective painting of structural steel,
for the protection of aluminium alloys and steel. 2nd edition. London: Chapman Hall, 1968.
Transactionsof the Institute ofMetal Finishing. Morgan, M.A. Cathodic protection. London: Leonard Hill,
London, vol. 49, 1971,pp. 1 1 1-22 and 173-5, 1959.
(1 1) Chandler, K.A., and Kilcullen, M.B. Corrosion-resist- Slunder, C.J., and Boyd, W.K. Zinc: i t s corrosion
ant low-alloy steels: a review with particular reference resistance. London: Zinc Development Association, 1971.
to atmospheric conditions in the United Kingdom., Zinc Development Association. Galvanizing Guide.
British Corrosion Journal, vol. 5, 1970, No. 1, London: Zinc Development Association (re-issueda t
PP. 24-32.
frequent intervals).
(1 2)Gates, P.H. Corrosion prevented by humidity
control. Conferenceon heavy-duty coatings, 1972.
Institution of Corrosion Technology.
1O0
BS 5493 : 1977
í ndex
In this index references are not topage numbers but toclause, table, figure and appendix numbers. The method of
alphabetization used is word-byword. The use of boldtype denotes that the reference is wholly concerned with the
su-bjectsto which they refer.
Abrasion 12.1.6;Table1;Table3, part 18, note (e) Application methods (continued)
Abrasion resistance 10.2; 11.3.1; 13.1; 24.1;Table 3, high-buildcoatings 12.1.3
note ( e ) hot-dip galvanizing 11.1.2;22.3;A.3.6.2
Abrasive additives (to paint) 8.2; Table 3, part 18 immersion(dip-painting) 22.2.3
Abrasives see Blast-cleaning intervals between coats 10.5;22.2.6
Access29;A.3.6.6 manual,disadvantages11.3.2
classification 29 mastic22.5
design of 7; Tables 4A to 4M, note (i) painting
gantries A.3.6.6 brush
22.2.1
impossibilityof 6.1 defectsTable 8
insufficient 22.3;29;46.3.2 dipping 22.2.3
maintenance6.1;6.3;33.1;46.3.2;47.2;A.3.6.6 roller 22.2.3
platforms A.3.6.6 spray
22.2.2
safety 23.9;56;A.3.6.6 proceduretrials22.2.5
Acetate copolymerssee Binders and vehicles; Modifiers roller 12.1.3;22.2.3
Acid-pickling 14.3.2;16.2.2 sealanf22.5
bolts 25.2 specification 22
Duplex process14.3.2;16.2.2.1 spraying 11.2; 13.1; 22.2.2; A.3.6.5; Tables 4A to 4M,
Footner process14.3.2;16.2.2.1 note (c)
overpickling see Defects trials 22.2.5
potentialdefects Table8C trowelling 12.6.4;22.2.3
standards 16.2.2.1 wrapping 13.3;22.4
Acidity 11.3.1;Table 1 zinc 11.1;22.3
Actinicbreakdown A.1.5.2 Arbitration 15.3
Additives see also Coatings; Modifiers Arc-sprayed aluminiumsee Coatings, metallic
bactericidal Table 3, part 19 AromaticcompoundsAppendix B
flakealuminium 12.6.3 Asbestine Appendix C
inhibitors 13.2 Asbestos reinforcement 12.6.2; Appendix C
Adhesion 12.1.4 Ash, corrosivity Table 3, part 13
chemical-resistantpaints12.5 Asphalt see Coatings, bitumenltar
(to) epoxy resin10.5 Atmosphere see Environment
failure 22.2.6;32.2;32.4 Atmospheric cotrosivity see Corrosion
hot-dip galvanizingTable 48 (note)
paint on zinc 11 -3.2
refurbishing Table 4N BS 534cited 12.6.4
substrate10.2;13.1;Table 4B BS 729 cited 8.3; 11.I .2; 20.1; 25.2 (9); Table 3, note (b);
weather effects 12.6.2 Table 48 And notes
(to) tinc-rich primer 10.5 BS 1070 cited Table 4M
Adjacent materials, effectssee Contact surfaces BS 1133cited 13.2
Adulteration of paint see Defects ES 1706 cited Table 4B
Aerobic soils see Soil properties BS 2015 cited 3.3; 12.1 .I
Aesthetics 11.3.1;22.2.4;see also Colours; Life BS 2451 cited 14.3.1.3;14.3.1.6
Agricultural areas, non-toxic paints see Coating systems, toxicity BS 2523 cited Table 4F. part 2
Air conditioningsee Humidity control; Working conditions BS 2569: Part 2 cited 11.2.1; 14.3.1.6; 16.2.1.3; 19; Table 3,
Air pollution 23.4;23.6;A.1.5; Table 1 part 11; Table 4C and notes
Air spraying see Application methods BS 2989 cited 11.I .2; Table 48
AliphaticcompoundsAppendix B BS 3083 cited Table 48
Alkalinity 11.3.1; Table 1;Table 3, note (f); Table 4C, part 2; BS 3294cífed 8.2
see also Welds and welding BS 3382 cited 8.3; 25.2; Table 48
Alkyd see Binders and vehicles BS 3416 cited f a b l e 3, part 13; Table 4M
Alternative materialssee Specification BS 3900 cited 22.2.1;41.1
Aluminium coatings see Coatings, metallic BS 4147 cited Table 3, part 13; Table 4M
Aluminium paintsee Coatings, paint BS 4164 cited Table 3, part 13; Table 4M
Aluminium silicateAppendix C ES 4232 cited 14.3.1.5;14.3.1.6;16.2.1.2; Appendix F
Ambiguity see Specification BS 4479 cited 7;A.3.6.5
Amines see Appendix B BS 4604 cited 8.2; 25.2
Anaerobic soil see Soil properties BS 4652 cited 12.2; Table 3, part 14; Tables 4D. 4H
Ancillaryequipment 30 BS 4921 cited 8.3;11.1.3;25.2 (e); Table 48
Anti-fouling paint see Coatings, paint, types BS 5228cited 57.1
Antimony oxidesee Pigments BS Code of Practice CP 11O cited 13.4; A.3.5.3
Appearance see Aesthetics BS Codes of Practice CP 114, CP 115.CP 116, CP 117 cited 13.4
Application facilities 9;10.2;10.4;11.2.2 BSCodes of Practice CP 1021 cited 12.1.4;A.2.4:A.2.5;
Application methods A.3.7.5
airless spraying 12.1.3; 22.2.2; Tables 4A. 4E, 4K note (c) BS Code of Practice CP 3012 cited 14.2; 16.2.2.1
aluminium 11.2.1;22.3 Backfill see Soil replacement
arc-sprayingTable 3, part 11 Bacteria, sulphate-reducingsee Corrosion theory
asphalt12.6.4 Bacterialgrowth 5.1; Table 1; Table 3, patt 19
bitumen 12.6.4 Bactericidal additivessee Additives
brush 12.1.3;22.2.1;Tables4H.4K note(c) Barium carbonate (and sulphate) Appendix C
coal tar pitch 12.6.4 Barytes Appendix C
daubing 12.6.4;22.2.3 Bearingsurfaces27
design considerations A.3.5.1 BentoniteAppendix C
effect on substrate 10.2; 11.2.1 ; 16.2.3;51.2.2 BibliographyAppendix J
electroplating see Coatings, metallic Bimetallic corrosion 7;13.3.2;A.1.2;A.3.5.1,A.3.5.2
electrostatic spray13.1;22.2.2 copper A.3.5.1
fluidized-bedtechnique 13.1
101
BS 5493 : 1977
Bi-metallic corrosion (continued) Calcium plumbatesee Pigments

nickel A.3.5.1 Calcium silicate Appendix C
stainless steel A.3.5.2 CalciumsulphateAppendix C
zinc
A.3.5.1 CarbonationTable 1
Binders and vehicles 12.1.1; Table 4; Appendix B Cast iron, corrosion resistanceA.2.2.2
acetate copolymers Tables 4C. 4H; Appendix B Castingskin A.2.2.2
alkyd Tables2,3,4F; Appendix B Cathodic protection 10.2;12.2;13.5;A.2.4;A.2.5;A.3.5.1;
amides Appendix B A.3.7.5
amines (aliphatic and aromatic) Appendix B compatibility with paint 12.1.4
bitumen 12.6;Table 4M Cavitationcorrosion13.3.4
characteristicsAppendix B Cavity filling A.3.3.1
chlorinated rubber Tables4F,4H; Appendix B Cavityinsulation A.3.3.4
coal tar 12.6;Tables 2,4K, 4M Cavity-walleffects A.3.3.4
coal tar epoxy Appendix B Cement coating 12.6.5; 13.4; see also Contact surfaces
drying oil 11.3.2;12.1;12.3;Tables2,3, 48 (note), 4F Cement-mortarlinings 1; 13.4
epoxide 51.2.2;Tables2,4C.4F. 4K Centrifuging (galvanized fasteners) 25.2 (9); Table 46
epoxy ester 12.3; Tables 2, 4F. 4J, 4K Chalking 12.6.2; see also Defects
phenolic modification Table4F Chemical conversion 1I.3.2
phenolic resin 12.3; Table 2; Table 4C, part 2; Table 4F; Chemical plant 7
Appendix B Chemical resistance see Coatings, paint, types
polyamidesAppendix B Chemicals 7; 11.3.1; see also individual substances
polyisocyanatesAppendix B de-icing salts 7; Table 1;Table 3, part 17
polyurethane 51.2.2; Tables 2,4C, 4F, 4K, 4L; Appendix B storageand transport Table3, part 16.
polyvinyl butyral Tables4A,4C;AppendicesB, C Chemistry of corrosion Appendix A
polyvinyl chloride see vinyl chloride below Chimneys, effect on local environment 4.2.3
saponification 12.1 .I Chipping hammers see Manual cleaning
silicates Tables2,4E;Appendix B Chlorides (sea salts) 14.3; A.l; A.2.2.4; see also Corrosion
silicone alkyd 12.3; Table 2; Table 3, parts 1 to 4,11; theory
Tables 4F. 4G; Appendix B Choice of protective system see Coating systems, choice
silicone resin Table 4C; Appendix B Chlorinated rubbersee Binders and vehicles; Coatings, paint,
urethane alkyd Appendix B types
urethane oil Table 2; Table 4F, part 2 Chrome-nickel-molybdenum steel see Stainless steel
vinyl chloride Tables4C.4H; Appendix B Cissingsee Defects
vinyl resinTables2,4A,4C Cladding 1
Bitumen see Coatings, bitumedtar Classification
Black paint Table4M coating systemsTables2, 4
Blast-cleaning 9; 14.1; 14.3.1; 16.2.1; Table 5; Appendices F, G ; environments Tables1, 3
see also Surface preparation Clearance for coatings see Thread allowance
abrasives14.3.1.3;14.3.1.6;Table 6 Climate 5.1;A.1.5; see also Environment
choice
14.3.1.3 humidity 5.1;A.1.5.1 (b)
contamination 14.3.1.3 microclimate A.1.5.2;A.3.3.4
centrifugal 14.3.1;Table 5 rainfall 5.1
choice of method 14.3.1.1 temperature 5.1
dustremoval 14.3.1.4 Clinker, corrosivity Table 3, part 13
environment 14.3.1.1 CoalminesTable 1
hydroblasting see wet-blastingbelow Coal tar see Coatings, bitumenltar
maintenance ,Table 3, note (i) Coal tar epoxy 12.5; Appendix B
methods14.3.1;Table 5 Coal tar wrapping tape13.3.3
open blasting 51.2.1;Table 5 Coating systems 10 to 14; see also Coatings etc.
potential defects 43; Table 8;Appendix G alkyd 12.3;Tables2,4G
priming 14.3.1.2;Table 4A applicationfacilities 9;10.4
profile 14.3.1.6;19; see also Surface preparation application methods see Application methods
quality see standards below availability 21.1
recirculating 51.2.1 bitumenltar see Coatings, bitumenltar
safety
51.2.1 chemical-resistant Tables 2, 3, 4H, 4J, 4K, 4 L
specification 16.2.1 choice 3 to 14; 15.2; Appendix H
standards 14.3.1.5; 16.2.1.2; Table 3, note (j); Appendices F, G classification 10.1;Tables2,3, 4
vacuum-blasting14.3.1;Table 5 colours see Colours
working conditions23 compatibility 12.1.4;Table4C. part 1
wet-blasting 14.3.1; 16.2.1.1; 51.2.1; Tables 4A to 4M. control of thickness see Film thickness
note (i);Table 5 drying-oil 12.3;Tables2,4F
Blast primers see Primers finishesTables3, 4
Blistering 32.4; Table 9; A.1.4; see also Defects heat-resistant Table 3, part 11
Bolts see Connections; Fasteners inorganic zinc-rich 12.2;Tables 2,4E
Bond, electrical 7 keyreferenceletters 10.1
Bond, metallurgical 10.2; 1 1.I .2 life see Life
Boxsections13.2;22.3;A.3.3.2; Appendix H maintenance see Maintenance
Brickworklsteel interfacesee Contact surfaces metallic see Coatings, metallic
BridgesTable 1 miscellaneoussee Coatings (excluding bitumenltar,
British Rail T-wash see Primers metallic, paint)
Brittleness 12.6.1 multiple 5.2;15.6
Bronze toolssee Manual cleaning organic zinc-rich 12.2;Tables 2.4D
Brush(es), bristle 22.2.1;Table 9 other than bitumenltar, metallic, paint see Coatings
Brush(es1, wire Table 9; seealso Manual cleaning (excluding bitumenltar, metallic, paint)
Brush-paintingsee Application methods paint see Coatings, paint
Buriedstructures 12.6.2 primers see Primers
rates of deterioration 46.3
sealers see Sealers
Cadmium (electro-) plating see Coatings, metallic selection see choice above
CalciumcarbonateAppendix C silicone alkyd 12.3;Tables2,4G
102
W
BS 5493 : 1977
Coating systems (continued) Coatings, metallic (continued)

solventless 19 zinc (continued)
specification 17; see also Specification (hot-dip) galvanizing (continued)
thickness see Film thickness; Coatings, metallic, thickness coatingweight 11.1.2
toxicity Table3, note (n) designconsiderationsA.3.6.2
undercoatsTables 3, 4 painted . 11.3; Tables 3,4
viscosity 22.2.3 silicon steel
11.1.2
water-resistant Table 3, part 5 thickness of zinc 11.I .2; Table 3, note (b); Table 4
Coatingweight(galvanizing) 11.1.2 insulation from timber A.3.5.4
Coatings, bitumenltar 12.6; Table 2; Table 3, part 8; Table 4M painted 11.3;Tables3,4B, 4C
asphalt12.6.2; 12.6.3; 12.6.4;Table4M paints see Coatings, paint, types
bitumen 12.6; Table 2; Table 3, part 8; Table 4M plating 11.1.4;25.2 (dl; Table-48
black paint Table 4M sherardizing 11.1.3;25.2;Table 48
buried structures 12.6.2;A.2.4 sprayed10;11.2;Tables 2,3,4C
emulsions12.6.1;Table 4M sprayed and painted 11.3; Tables 2,3,4B, 4C
hot-applied 12.6.1; Table 3, part 8;Table 4M sprayed and sealed 11.2.2; Tables 2,3,4C
coal,powdered12.6.1 thickness 10.2;11.1.2; 11.2.1; 20; Table 3, note (b)
coal tar enamelTable 2 and (c); Tables 4A to 4M, note (a)
coal tar epoxy 12.5; Table 3, parts 6 to 10, 13, 16 whiterust A.1.8
coal tar pitch 12.6.2; Table 3, part 8 ; Table 4M zinc-iron alloy Tables 2, 48
coal tar pitch epoxide see coal tar epoxy (above); Coatings, paint, characteristics and properties 12
see also Coatings, paint, chemical-resistant abrasiveadditives8.2
emulsions 12.6.1 adhesion see Adhesion
finishing paints Tables 4K. 4M advantages9; 10.2
overcoating 12.6.5 binderlpigmentratio 12.1
reinforcement 13.3 chemical-resistantsee Coatings, paint, types
urethaneltar 12.5 colour see Colours
Coatings (excluding bitumenltar, metallic, paint) 10.3; 13 compatibility see Compatibility
cementlconcrete 12.6.5; 13.4 consistency21.3; Table 8
cement-mortarlinings 1;13.4 curingtime 23.2
grease paints 13.2 decorative11.3.l;see also Aesthetics
gypsumplaster13.4 defectsTable 8
magnesium oxy-chloride cement13.4 dryingtime 23.2
mastics see Mastics film thickness Tables 3,4; see also Film thickness
petroleum jelly tapes 13.3.1 mixing 21.3; Table 8
polyethylenesleeves 13.3.5;Table3, part 13 nominal thickness (definition) Table 3, introduction
polyvinylchloride 28.4 over-ageTable 8
powder 13.1; Table 3, part 13; see also Pigmented resins over-metalliccoatings 11.3
sleeves13.3;28.4; Table 3, part 13 pot-life 23.2
strippable 8.2 reinforcement 12.6.2
viscosity 22.5 shelf-life 21.2.1
wrapping tapes 7;12.6.2; 13.2; 13.3; 22.4; 24.2; 24.3; storage21.2.1; Table 8
28.4; Table 3, part 13 testing 21.2.2
Coatings, metallic 10.2; 11; Tables 2,3, 48, 4C; see also thickness see Film thickness
Coating systems thixotropy 21.3
advantages 10.2 toxicity 22.2.2;Table3, note (n)
aluminium 11.2;Tables2,3,4B,4C variations 19
arc-sprayedTable3, part 11 viscosity 22.2.3; 23.2; Appendix D; see also consistency
application 11.2;22.3 above
corrosionrate A.1.8 wet-film thickness see Film thickness
insulation(fromtimber) A.3.5.4 Coatings, paint, typesand constituents
sprayed 10.2; 11.2; Tables2,3;Table4C alkali silicate Table4E
sprayed and sealed 11.2.2; 11.3.1 ;Tables 2, 3, 4C alkyd see Binders and vehicles
sprayed and painted 1 1.3; Tables 2, 3, 4C aluminium paint Table 3, part 11
thickness 11.2.1;20;Table4C. note (b) anti-fouling Table 3, part IO, note (k)
cadmium (electro-) plating 11.1.4; 25.2 binders see Binders and vehicles
toxic fumes25.2 blast-primers see Primers
corrosionrate A.1.8 cement 12.6.5
defectsTable 8 chemical-resistant 9; 12.1.1; 12.1.6; 12.4; 12.5; Tables 2, 3,
electroplating see cadmium (electro-) platingabove 4H. 4J. 4K. 4L; see also individual types
galvanizingsee zinc below chlorinated rubber 12.5; Tables 2,4F, 4H, 4J, 4L. 4N (h);
hot-dip galvanizingsee zinc below see also Binders and vehicles
nickel-chrome Table 3, part 11 drying-oil see Binders and vehicles
painted 11.3; Table 3, note (h); Tables 4B. 4C drying time 23.2
sealed see Sealers emulsion 12.6.5
sherardizing see zinc below epoxide resin Tables 4C, 4D. 4F, 4K. 4L; see also chemical
sprayed-metal 10.2; 11.2; 22.3; Table 3; Table 4C; resistant above
see also aluminiumabove and zinc below epoxy ester 12.3; Table 4F. part 2
effect onsubstrate11.2.1 finishes Tables 2,3, 4
thickness 20;Tables 3,4B, 4C heat-resistant Table 3, part 11
nominal thicknesssee Nominal thickness high-build 12.1.3; 19; Tables 4E, 4F, 4H. 4K
zinc 10.2; 11.1; Tables2, 3, 4B,4C high-duty 13.3.3;13.3.4;Table 1
application 22.3 hot-appliedsee Coatings, bitumenltar
bolts 25.2 metallic see aluminium above, paint, zinc-richbelow
corrosionrateFigure 1;A.1.8 micaceous iron oxide see Pigments
designconsiderationsA.3.6.2 modifierssee Modifiers; Pigments
electroplating 11.1.4; 25.2 (d) oil 12.3
(hot-dip) galvanizing 9; 1O; 11.1 2; 22.3; Tables 2, 3, 413 organic zinc-richsee zinc-rich below
bath sizes 11.1.2 overcoating period 23.2; see also Delays
brown staining 11 .I .2 phenolic resinsee Binders and vehicles
phenolicvarnish 12.3

103
BSI B S X 5 4 7 3 7 7 I
BS 5493 : 1977
Coatings, paint, types and constituents (continued) Controversy15.3;15.8;seealsoDisputes

pigments see Pigments Conversion11.3.2
polyurethane 12.1.1;Tables2,4C;Table4F. part 2; Copper alloys and components Table 3, note (k); see also
Tables 4K, 4 L Corrosion theory
prefabrication primerssee Primers Corrosion awarenessA.3.1
pretreatment primerssee Primers Corrosion productssee Corrosion theory
primerssee Primers Corrosion rates of ferrous metals
red lead see Pigments in airA.1.5.3
resin See individual types (alkyd, oleo, epoxide, phenolic, in soil A.1.6.3
silicone, vinyl) in water A.1.7.4; A.1.8
sealers see Sealers Corrosion rates of non-ferrous metals
silicatesTable4E aluminium A.1.8
silicone alkyd see Binders and vehicles zinc
A.1.8
solventless 19 Corrosion resistances (relative)
thinners 21.3 asphalt12.6.3
detection of excess21.2.2;Table 8 bitumen 12.6.1 ; 12.6.2
t i e coat see travel coatbelow cast iron A.2.2.2
travel coat 12.5; Table 2; Table 4L, note (h) coaltar pitch 12.6.2
undercoatsTables 2, 3,4 lowalloy steel A.2.2.3
urethane oil Table4F, part 2 mild steel A.2.2.1
vehicles see Binders and vehicles stainless steel A.2.2.4
vinyl resinTable 2 CorrosiontheoryAppendix A
zinc-dust 10.2;Tables3, 4 Costs10.6; Appendix E
zinc-iron alloy 1 1 .I
.I;Table 48 assessment10.6;A.1.1
zinc phosphatesee Pigments blast-cleaning 9
zinc-rich 12.2 labourAppendix E
inorganic 12.2;Tables 2,3,4E maintenance 6.3
organic12.2;Tables2,3,4D shopcoatings Figure 11
sealed12.2;Table 3 note (9) variation 4.1
silicate-bound Table4E Coverplates26
zinc silicate 12.2 Crackingsee Defects
zinc tetroxychromatesee Pigments Curing time 23.2
Cold surfaces see Surface temperatures Curtainingsee Defects
Colours see also Aesthetics
aesthetic requirements 10.2; Table 3, note (e)
change 32.5 DD24 cited 11.1.2
distinctive 17; 23.7; 33.3; Table 4K, part 4; Table 8 Damage to coatings 12.2; 13.2; 13.3; 15.2; 17; 24; 32;
hot surfacesTable3, part 11 Tables 4H, 8L
incorrect Table 8 prevention 24
Compatibility 9; 11.3.2;12.1.4;12.4;13.5;15.4 (dl; 17; responsibility 24.4
21.1; 23.8; Table 4C, part 1 Datasheets, manufacturers' 22.5
Concretereinforcement A.3.4.3;A.3.5.3 'Dead' air Table 3, part 5
Concretestaining A.3.5.3 Decorative paint see Coatings, paint, characteristics
Concrete/steel interfacesee Contact surfaces Defects32;Table 8
Condensation 23.3; 23.4; A.1.5.2; A.3.2.1; A.3.3.2; A.3.3.4; adulteration of paint 21.2.2;Table 8G
Tables 1,8 bleeding-through 12.1.4
Connectors see Fasteners blistering 32.4
Connections25;seealsoFasteners burrs 14.3.1.7;16.2.4;Table 8A
bearingsurfaces27 chalking 12.6.2
bolts 25.2 colours incorrect Table 8G
coverplates26 cracking 32.4
choice of type A.3.2.2 crevices
14.3.1.7
faying surfaces see Faying surfaces curtainingTable 8J
friction-grip-bolted joints see Friction-grip-bolted joints 'dry spray'Table8J
high-strengthfriction-grip bolts 14.3.3;25.2;25.3.2 excess thinners 21.2.2;Table 8G
machinedsurfaces27 flaking 32.4
stripe coatssee Stripe coats grinning through Tables8J, 8K
strippablecoatings8.2 inclusions
14.3.1.7
surfaces25.3;A.3.2.4 indentations 16.2.4
Consistency see Coatings,paint, characteristics laminations 14.3.1.7;Tables 8A, 8B
Contact surfaces 28 lifting 12.1.4;14.3.1.7;Table 8K
steel/brickwork A.3.3.4 mill-scale residue Tables 8B, 8E
steel/concrete 13.4; 28.2; Tablo 3, part 14 and note ( e ) ; orange-peel effect Table 8K
A.3.5 overheating16.2.3;Table8D
steel/gypsumA.3.3.4;A.3.5.4 overpickling 16.2.2.4;Table8C
steel/other metals 28.4;28.5;A.3.5 peaks16.2.4
steellplaster A.3.3.4;A.3.5.4 peeling 32.4
steel/steel 25.3;27:A.3.2.4;A.3.7.4 pinholing Table8K
faying surfaces, definition 8.2 pitting 16.2.2.4;Tables 8A, 8C
steel/timber 28.3;A.3.3.4;A.3.5.4 residuesTables 8A to 8D
Contamination rust-spotting 14.3.1.6
blast-cleanedsurfaces16.2.1.1;23.5;23.6 saggingTables8J, 8K .
fasteners 25.2 saponification Table8J
grease Table 8 shelling Tables8A.8B
impregnatedtimber 28.3 thinners, excess see excess thinners above
intercoat 8.1;12.5;23.5;24.1;32.2 weld spatter and other welding faults Table 8A
oil Table 8 wrinkling 12.1.4;Table 8K
salt 16.2.1.1 Definitions
timber 28.3 faying surfaces8.2
water 12.6.2 life 6.1
Control of thickness see Film thickness manualcleaning14.1
.1.
104
BSI B S X 5 4 7 3 7 7 m l b 2 q b b 9 OlbOb35 O W BS 5493 : 1977
Degreasingsee Surface preparation Fabrication 8; see also Fasteners; Friction-grip-boltedjoints;

Dehumidification 31;A.2.3;seealsoDesiccants Welds and welding
De-icing-salt effects 28.6; Table 1; Table 3, part 17 defectsTable 8
Delay immediatecoating 8.1
effects 6.3; 10.5; 14.3.1.7; 44; 46.3.1; Tables 88, 8C, 8D, Facilities for application of coatings see Application facilities
8H, 8J Fasteners8.3;25.2
inter-process 10.5; 22.2.6; Table 4N (i);Tables 88, 8C, bolts 25.2
8D, 8H, 8J cadmium-plated 11.1.4;25.2
maintenance6.3;33.1 coating clearances25.5
site coating 8.1;10.5 electroplated 8.3; 11.I .4; 25.2
tolerance 8.1 friction-grip boltssee Friction-grip bolts
Descalingsee Surface preparation galvanized 8.3
Desiccants31;A.3.3.2 sherardized8.3;11.1.3;25.2
Design of structure 7;A.3 spun-galvanized 25.2
Detection of excess thinners see Defects storage25.2
Detergents see Surface preparation thread allowance (for metal coating) 25.5
Dew-pointsee Humidity zinc-coated 25.2
Dispute 15.3;19; Appendix D zinc-dust-painted 8.3
Drainage7;46.3.2;A.3.4.2 Faying surfaces 8.2; see also Contact surfaces; Friction
Drawings coefficients; Friction-grip bolts; Connections
fabrication 15.6 definition 8.2
working 15.6 frictioncoefficient 8.2
Dry-film thicknesssee Film thickness slip coefficient 8.2
Drying oil 12.1.1; see also Binders and vehicles; Coatings, Ferric/ferrouscompounds A.1.4
paint, types Fibre glass reinforcements 12.6.2;13.3
Drying oil epoxy ester Appendix B Film thickness 19; 20; 41; Tables 3,4; see also Coatings,
Duplex process see Acid-pickling metallic, thickness
I advisedTable 4
calculation 41.3
Economics see Costs control 19; 20
Edgesealing25.3.2 dry-film thickness 19; 23.2; 41; Table 4
Electrical continuity (bonding) 7 gauge calibration 41
Electrical resistance of soils see Soil properties advisedTable 4
Electroplating 8.3; 11.1.4; 25.2; Table 48; see also Coatings, dry/wet conversion factor 41
metallic high-build 12.1.3
Emulsion cleanerssee Surface preparation holiday detectionsee Inspection
Encasement in concrete see Contact surfaces measurement19; 41
Enclosed steelwork A.3.3.4; see also Contact surfaces nominal 19;Table 3, introduction
Environment 5: 47.1; Tables 1, 3,8; see also Working conditions stripecoat 18
acidic see pH-value variation
19
alkaline see pH-value wet-film thickness19;41
application 23;33.1;Table 8 Finishessee Coating systems; Coatings,paint, types
atmospheric, generalsee Climate Flake aluminium 12.6.3
atmospheric, local 46.3.3;Table 1 Flaking 32.4
changes33.1 Flame-cleaningsee Surface preparation
chemical Table 1; Table 3, partç 16,17 Fluidized-bed techniquesee Application methods
classification 5.1;Table1; Appendix H Footner process see Acid-pickling
climate see Climate Fresh watersee Non-saline wafer
coastal Table 1;Table 3, parts 3,4, 9, 1O Frictioncoefficients 8.2
humidity see Climate; Humidity Friction-grip-bolted joints 8.2; 25.2; 25.3; A.3.2.4
identification 5.2 loss of pre-tension 8.2
inland Table 1; Table 3, parts 1, 2 effect of coatings 8.2
interior 5.1; Table 1; Table 3, parts 6,7 flame-cleaning 14.3.3;51.2.2
local effects 46.3.3; Table 1 Fungal growth Table 1; Table 3, part 19
marine see coastal above
microclimate A.1.5.2;A.3.3.4
minesTable1;Table3, part 12 Galvanizingsee Coatings, metallic
non-saline Table 1; Table 3, part 8, notes (I),(m), (n) Glass-fibrereinforcement 12.6.2;13.3
pollution Table 1, Table 3, parts 2,3; see also Contamination Graphiticcorrosion residueA.2.2.2
saline see coastal above Grease see Degreasing
soil Table 1; Table 3, part 13 Grit-blastingsee Blast-cleaning
splashzoneTable 1 Gypsum AppendixC
storage24.1;24.3;Table 8 Gypsumlsteelinterface13.4;A.3.3.4;A.3.5.4
subtropical 5.1
surface preparation 23
temperature 5.1;A.1.5.2 Hand-cleaningsee Manual cleaning
transport 5.1;24.1 Hand tools see Manual cleaningtools
tropical 5.1 Handling of coated steelwork 24; see also Damage; Handling,
Epoxide resin Appendix B; see also Coatings, paints, types; transport, storage, and erection
Binders and vehicles Handling, transport, storage, and erection 12.1.6; 15.2; 15.8;
Epoxy co-polymer sealers for metallic coatings Table 3, 17: 24: Table 8L;see also separate headings
note ( e ) ;Table 4C. part 2 Health see Safety; Workingconditions
Epoxy ester see Coatings, paint, types; Modifiers Heat-curing 13.1
Erection 17; 24 Heat resistantpaint see Coating systems; Coatings, paint, types
EstuarinewaterTable 1 High-build paints see Coatings, paint, types
Ethyl cellusolve Tables 4A to 4M. note ( e ) High-duty coatingssee Coatings, paint, types
Example of use of the code Appendix H High-strength friction-grip boltssee Friction-grip bolts
Excess thinners see Thinners High temperature surfaces 11.2.2; 12.6.2; 13.3.3; Table 3,
Exclusions from code 1 part 11
Export, special conditions see Transport of coated steelwork Holiday detection see Inspection
Extender see Pigments Hollow sections 7; 13.1; see also Box.sections
105
-
BS 5493 : 1977
Hot-applled coatingssee Coatings, bitumenltar Maintenance (continued)

Hot-dip galvanizingsee Coatings, metallic, zinc environment 47.1
Hot surfaces see High temperature surfaces fire risk 33.1
Humidity 23.3 flamedeaning 14.3.3
climate 5.1;A.1.5.1 inspection48.2
dew-point 23.3;47.1 intervalsTable 3, note (d)
control 23.3;23.6;Table8;A.1.5.1 labour (skills) 48.1
localclimate 23.4;A.1.5.1 metalcoatings46.1;'55.3;Table 10
microclimate 23.6;A.3.3.4 organization48
working conditions 23.3;23.4;23.6 paint coatings 46.1; 55.2; Table 9
HydrogenaccumulationA.1.6.1 patch-painting49;Table 9
procedure trials 51 .I
rates of deterioration 46.3
Identification marking15.6 schedules33.4; 44
Immersed structures 12.6.2: 12.6.3; Table 1; see a/so site welds8.4
Corrosion rates specification 33
Impact 12.1.6;13.1;13.4; Table 1; Table 3, part 18; Table 8 standards of application 54
Inaccessibility see Access surface preparation 6.2.3; 33.1; 51; 53; Table 9
Inhibitors see Additives variability of deterioration 46.2
Inorganic zinc-rich paint see Coatings, paint, types vulnerable points 44
Inspection 35 to 43 Maleic acid see Modifiers
cleanliness
16.2.1.2 Manholecover-plates26
desiccants 31 Manualcleaning14.1; 14.3.4;16.2.4
guide43 bronze tools 16.2.4
inspectors see Inspectors defectsTable8
instruments 41;43;Table8; Appendix F definition 14.1, footnote*
levelsof37 joints 25.2
organization 40 limitations 16.2.4
recordsandreports 39 remedialwork33.1
schedule 38 standards14.3.4.2;16.2.4
Inspectors tools 14.3.4;51.1;51.2.3;51.2.4
duties 36 MarinestructuresTable 1
equipment 41.2; 43 Marking 15.6
powers 36 Masking 25.3.2
qualification 40 Mastics22.5;25.3.2;Table 7
training 40 Materials
Insulation 13.3.2; A.3.5.4 adulteration 21.2.2
Isocyanate Appendix B alternative17;21 .I
availability15.2;15.4;21.1
compatibility see Compatibility
Joints see Connections control 21.2
Joint covet-plates26 storage 21.2.1; Table 8
testing 21.2.2
identification marking15.6
Kieselguhr(extender)AppendixC
preparation for use21.3
Key reference letters 10.1; Tables 2,3, 4
sampling21.2.2;42;Appendix D
testing 21.2.2
Lead see Pigments Mechanical plating 25.2 (f)
Life 6;Table3; Figure 1 Matting agent see Modifiers
assessment ofrequirement6.3 Melamine 16.2.1.2
betweenmaintenances6.2.2;6.3 Mercury compounds Table 3, note (k)
categories
6.2 Metal-spray see Coatings, metallic; Application methods
decorative 6.3 Metallic coatings see Coatings, metallic
definition 6.1 Metallic paints see Coatings, paint, types
(to) first maintenance 3.4; 6.1; 6.2; 11.1.2; Table 3; Metallic soaps see Saponification
Figure 1 Method-type specification see Specification
lifelenvironment classificationTable3 Micaceous iron oxide see Coatings, paint, types
Lifting see Defects Microbiologicalcorrosion12.6.2;AppendixA
Light reflectometer see 'Surclean' Microbial growth Table 3, note (n)
Light-gaugestructures 1 Mild steel, corrosionresistanceA.2.2.1
Lightning conductors 7 Mill-scale see Defects; Surface preparation
Load-bearingmembersA.3.7.2 Mines Table 1:Table3, part 12
Low-alloy steel A.2.2.3 Mixing ofpaints see Coatings, paint, characteristics
corrosionresistanceA.2.2.3 Modifiers see also Additives; Binders; Pigments
acetate copolymers Table 4C
chlorinated rubberAppendix B
Machined(andbearing)surfaces27 drying oil Appendix B
Made-up groundsee Soil replacement epoxy ester Table 4F; Appendix B
MagnesiumsilicateAppendixC isocyanatesAppendix B
Magnetite
A.1.4 maleic acid Table 4H, part 2; Appendix B
Maintenance 44 to 55; see also Inspection; Remedial work matting agent Table 4F, part 4
access see Access phenollc resin Tables.4A, 4C; Appendix B
choice of method and procedure 47; 49; 50 plasticizer 12.6.2; Tables 4C. 4H; Appendix B
choice of coating system 55 silicates Table 3, part 11;Table 4K. part 4
coatingschedule33.4; 44 silicones Table 3, part 11; Table 4C; Table 4F. part 4;
compatibility 33.2 Table 4G; Appendix B
complexity 45 solvents12.1.5;12.4;12.5
condition of coatings 46.1; Table 9 styreneAppendix B
definition of areas33.3 thinners see Thinners
delay6.3;33.1 vinyl tolueneAppendix B
106
BS 5493 : 1977
Nickel-chrome Table3, part 11 Pigments (continued)

Noiselevels57.1; 57.3.2 paint Appendix C
Nominal thicknesssee a/so Tables 3, 4 precipitation Table 4H, part 2
definition Table3, introduction red lead Table 4F, part 2; Appendix C
variation from 19 silicas and silicates Appendix C
Non-leafingaluminium pigment see Pigments stainless steel Appendix C
Non-saline water Table 3, part 8, notes (m), (n) sulphates Appendix C
talc Appendix C
titanium dioxide
Offshore platforms1 anatase Appendix C
Oil paints see Coatings, paint, types rutile Table 4F, parts 3,4; Table 4H, parts 3,4;
Oil coating 25.2 (c) Table 4K, parts 3,4; Appendix C
Oleo-resinsee Primers white lead Table 4F, patt 2; Appendix C
Orange-peel effect see Defects witherite Appendix C
Organic zinc-rich paints see Coatings, paint, types wollastoniteAppendix C
Overcoatingafterdelay 10.5 zinc chromate Table 4A; Table 4F. part 2; Table 4H, part 2;
Overcoating bituminous materials, 12.6.5 Appendix C
Overheating
16.2.3 zinc dust 12.2; Table 4A; Table 4H, part 2; Table 4K, part 2;
Overpickling see Defects Appendix C
zinc oxide 12.2; Table 4K. part 2; Appendix C
zinc phosphate Table 4A; Table 4F, part 2; Table 4H, part 2;
Paint see Coatings, paint, characteristics and properties; Table 4K. part 2; Appendix C
Coatings, paint, typesand constituents zinc tetroxychromate Table 4A; Table 4G, part 2;
Paint samplingsee Materials Appendix C
*
Paint vehiclessee Binders and vehicles Pinholing see Defects
Painting see Application methods Pipecouplings26
Passivation Pipesand pipelines 12.6.1;12.6.2;13.1;13.3
fasteners25.2 rate of corrosion in soil A.1.6.3
stainless steel A.2.2.4 stray-currentcorrosion A.1.6.2
Patch-painting 49 Pitch see Coatings, bitumenltar
Peelingsee Defects Pitting see Defects
Performancedata3.4 Plasterlsteel interfacesee Contact surfaces
Performance-type specificationsee Specification Plasticsleeves 13.3.5
Petrolatum wrapping tape 13.3.1; 22.4 Plasticizer see Binders and vehicles;Modifiers
Petroleum-jelly wrapping tape 13.3.1; 22.4 Plastics
Phenolic resinsee Binders and vehicles; Coatings,paint, types; coatings 1
Modifiers wrapping tapessee Coatings (excluding bitumenltar,
Phosphatedeposit14.3.2;16.2.2.4;Table8C metallic, paint)
Phosphate treatment see Primers Pollution see Air pollution; Contamination
Phosphoric acid 14.3.2; Tables 4A to 4M. note ( e ) PolyamidesAppendix B
pH-value 11.3.1; Table 1; Table 3, part 16; A.1.6.1 Polyethylene (polythene) 13.3.2; B.3.5; Table 3, part 13
Pickling see Acid-pickling Polyurethane see Binders and vehicles
PiersTable 1 Polyvinyl butyralsee Binders and vehicles
Pigmented resinsfor powder coatings Polyvinyl chloride(PVC) 13.3.2; see also Binders and vehicles
thermoplastic (nylon11, polyethylene, polypropylene, Pot-life 23.2
vinyl co-polymers) 13.1 Potable water 12.6.2; Table 3, notes (I),(m), (n);see also Tanks
thermosetting (acrylic, epoxy, polyester, polyurethane) 13.1 Potassium ferricyanide t e s t Appendix G
Pigments 12.1.2; Appendix C Poultice action Table 3, note (i)
aluminium Table 4C; Table 4F. parts 3, 4; Table 4K, part 4; Powder coatingssee Coatings (excluding bitumenltar, metallic,
Appendix C paint)
non-leafing Table 4C. part 2; Table 4F. parts 3, 4 Power tools see Surface preparation
antimony oxide (fire retardent) Appendix C Pretreatment
asbestos Appendix C passivationsee Passivation
barium compounds (barytes, blance fixe, witherite) priming see Primers; Priming
Appendix C surface preparation see Surface preparation
benoniteAppendix C Primers Tables 2, 3, 4
calcium plumbate Table 4F, part 2; Appendix C blast 14.3.1.2;Tables 2, 3,4A
carbonates Appendix C British Rail T-wash 11.3.2; Tables 4A to 4M. note (e)
carbon black Table 4F. part 4; Table 4H, part 4; calciumplumbate Table4F
Table 4K. part 4; Appendix C chemical-resistantTable4F
chalkAppendix C chemicalconversion11.3.2
chinaclayAppendix C copper carbonate 11.3.2; Tables 4A to 4M, note (e)
diatomaceous silicas see kieselguhr below ethyl cellusolve 11.3.2; Tables 4A to 4M. note (e)
dolomite Appendix C oleo-resin 12.6.1
extenders Appendix C phenolic resin Tables4A.4C
fade-resistant Table 4F, part 4: Table 4H, part 4; phosphoric acid 11.3.2; Tables 4A to 4M, note (e)
Table 4K. part 4 polyvinyl butyral Tables4A.4C
fire-retardantsee antimony oxideabove prefabrication Table 4D. part 2
glass flakeAppendix C pretreatment 11.2.2; 11.3.2; Tables 4B,4C, notes Id), (e)
graphiteAppendix C T-wash 11.3.2; Tables 4A to 4M. note (e)
gypsum Appendix C zinc chromate Table 4A
iron oxideAppendix C zinc phosphate Table 4A
kieselguhrAppendix C
leafingAppendix C
zinc silicate Table 3, parts 7 to 11, 16, 18; Table 4E
PrimingdefectsTable 8
1
light-resistantAppendix C Profile see Surface preparation
magnesiumcompounds Appendix C Protective coatingssee Coating systems; Coatings
metallic lead Table 4H. part 2; Table 4K, part 2; Appendix C
micaAppendix C
U micaceous iron oxide Table 4F. parts 3,4; Table 4H.

parts 3,4; Table 4K. parts 3, 4; Appendix C
non-leafing aluminium Table 4F, parts 3,4; Appendix C
Quality control
film thickness 19
metalcoatingthickness 20
107
BS 5493 : 1977 BSI BSm5493 7 7 m
Quality control (continued) Solvent-freeepoxies12.5

responsibility 8.1 Solvents see Modifiers
Quality standards3.4;12.4;12.5;14.3.1.5;53 Specification15 to 34
alternative materials 17; 21.I
ambiguity 3.2; 3.4; 15.5; 34; Table 4F, part 4, note
Radiators Table 3, part 11 application methods 22; see also Application methods
Red lead see Pigments circulation 15.5
Rain-washed surfaces 28.5; Table 1; Table 3, notes clarity 3.2;3.4;15.5
Referenceplates16.2.1.2;16.2.1.4;51 coating schedule15.6;17;33.4
References Appendix J coating system17
Refrigerated surfacessee Surface temperatures communicativevalue3.2;3.4;15.5
Refurbishing Table 4N conformitywith 3.4;4.2.8
Reheating see Surface preparation connections 25
Reinforcement of coatings 13.3.4;13.6 Contrac!Document15.1
Remedial work 32; Table 8; see also Maintenance electrcplating 25.2
applicationfaults 11.1.1;32.2 erection damage see Damage to coatings
degradation 32.4 film thickness see Film thickness
materialfaults32.3 functions 15.3
preparationfaults32.3 hmdling, transport, storage, and erection see Damage to
Resin ses Binders and vehicles; Coatings; Modifiers; Pigments coatings
for powder coatings; Primers labour (skills) 22.2.6
Responsibilities, allocation and definition 8.1;15.4;15.8 maintenance 33
Rubbing-downsee Specification materials control see Materials
Rust formation (theory) Appendix A materials preparationsee Materials
Rust removalsee Surface preparation method-type 22.1
Rust-spotting Appendix G;see also Defects need for 15.2
Rust staining of concrete A.3.5.3 painting 22.2
performance-type 15.1;22.1
preparation of materials for use see Maintenance
Safety and health 56 to 58 qualitycontrol19
eye protection 57.3.1 remedial work see Remedial work
fumes57.1 responsibilities 15.4;15.8;8.1
hygiene 58 rubbing-down 32.2
legislation 56 sampling21.2.2
noiseeffects57.1;57.3.2 schedules15.6
operational hazards specialareas15.6;25
health 57.3 special tools 50.1
structures
57.2 standards15.4;17
surroundings 57.2 supervision22.2.6
respiratory system57.3.3 surface finish 22.2.4
Sagging see Defects surface preparation see Surface preparation
Saline concentration 5.1; see also Corrosion theory technical details 16 to 33
Salt contamination 16.2.1.1;Table 1 testing of materials 21.2.2
Samplingsee Materials weldedareas25.4
Saponification 12.1.1;Table 8J workingconditions 23
Scale see Surface preparation, mill-scale Splash zone Table 1; see also Environment
Screw threads, clearance for coatings 25.2; 25.5 Spray-painting see Application methods
Sealants22.5;Table 7 Sprayed-metalsee Coatings, metallic
Sealers 11.2.2; 12.2; Table 3, note (1); Tables 4C. notes (c), (dl Stacking (storage) 12.1.6; 12.2; 12.6.1 ; 24.3
Sea walls Table 1 Stainless steel
Sea water Table 1; see also Salt contamination corrosion resistanceA.2.2.4
Selection of systemsee Coating systems passivationA.2.2.4
Service pipes and ducts, location A.3.7.3 stress-corrosion cracking' A.2.2.4
Sewage-treatmenttanksTable 1 Standards of quality see Quality standards
Shelf life 21.2.1 Standards of workmanship see Workmanship, quality
ShelteredsurfacesA.1.5.3;A.3.4.1 Steel in contact with other materialssee Contact surfaces
Sherardizingsee Coatings, metallic, zinc Storage see also Damage to coatings
Ships 1 coatedsteelwork13.2;15.8;17;24.3
Shop conditionssee Working conditions coating materials 21.2.1; Table 8
Silica gel see Desiccants fasteners
25.2
Silicates Tables 4E, 4K; Appendix B;see also Primers, zinc paint Table 8
silicate Stores procedure
Silicon in steelTable3, parts 2, 3 coatedmaterials24.3
Silicones see Binders and vehicles;Modifiers coatingmaterials21.2.1
Site conditionssee Environment; Working conditions Stray-current corrosionsee Pipes and pipelines
Sleeves 13.3;28.4;Table3, part 13 Stress-corrosion cracking, stainless steel in sea water A.2.2.4
Soap see Saponification Stripe coats18;22.1;55.1
Soil aggressiòn Table 1; Table 3, part 13; A.2.4; see ako Soil Strippablecoatings 8.2
properties Structural design see Design of structure
Soil properties A.1.6; see also Buried structures StyreneAppendix B
acidity A.1.6.1 Submerged structuressee Corrosion rates; Immersed structures
aerobic
A.1.6.1 Sulphate-reducing bacteriasee Microbiological corrosion
alkalinity A.1.6.1;Table3, part 13 Sulphur A.1.4;A.1.5
anaerobicA.1.6.1 Sulphur dioxide 5.2;Table 1
ash Table3, part 13 Supervisionsee Inspection
clinker Table3, part 13 'Surclean' method of measuring cleanliness 16.2,1.2; Table 8;
electrical resistanceA.1.6.1 Appendix F
sulphatesTable3, part 13 Surface preparation 9;14; 16; 22.2.6; Table 4
Soil replacementA.2.4 acid-picklingsee Acid-pickling
Soluble salts, detection Appendix G blast-cleaningsee Elast-cleaning
Specialtreatmentsschedule 15.6 burrs
14.4
108

Surface preparation (continued) Ultra-violet variationand effects 12.1.2; 12.6.2; 12.6.3; Table 4C
chlorides14.3 UndercoatTables 2, 3,4
choice ofmethod 14.1 Underground structuressee Buried structures; Soil properties
connection surfaces25.3 Urethane alkyd Appendix B
control Appendix F Urethane oil see Binders and vehicles
degreasing14.2;16.1 Use of the code 3
descaling14.3 by example Appendix 11
detergents 14.2 by experienced specifier 3.2
Duplex process see Acid-pickling bynon-technicalspecifier 3.3
edges 14.4
emulsioncleaners14.2
fasteners
25.2 Vacuum cleaning 14.3; 16.2.3; Table 5
facilities available 9 Vehicles (paint) see Binders and vehicles
faying surfaces25.3.2 Vehicles (transport)1
flame-cleaning14.1;14.3.3;16.2.3;33.1;51.2.2 Ventilation
Footner process see Acid-pickling Vibratory-needle gun14.3.4.1
friction-grip-bolted joints 14.3.3;25.3.2 Vinyl chloridesee Binders and vehicles
grit-blastingsee Blastcleaning Vinyl resin see Binders and vehicles
hand-tools 51.2.4; see also Manual cleaning Vinyl sealers for metallic coatings Table 3, note ( I ) ; Table 4,
jetting part 2
steam 14.2; 14.3.1.6 Vinyl tolueneAppendix B
water 14.2 viscosity
maintenance 51 mastic 22.5
manual cleaningsee Manual cleaning paint see Coatings, paint, characteristics
mill-scale 14.3;16.2;Table 8 sealant
22.5
pickling see Acid-pickling
power tools 16.2.4;51.2.3
profile 14.3.1.6; 19 . . . - Water resistancesee Coating systems
referenceplates16.2.1.2;16.2.1.4; Appendix F' Water tanks Table 1; Table 3, note h )
reheating 16.2.3 Waxes see Coatings (excluding bitumenltar, metallic, paint)
rust and scale removal 14.3;16.2;A.1.4; Appendix G Weathering steel 1
scraping14.2 Weld spattersee Welds and welding
solvents14.2 Welded tubular construction
special tools 51.1 advantages A.3.2.1
specification 16 box girders see Box girders
standards 14.1; 14.2; 14.3.1; 14.3.4.2; 16.2; 53; Table 4; Weldsand welding 8.4;25.4
Appendix G alkaline deposits25.4
sulphates
14.3 connections 25.4
steam-cleaning 14.3.1.6 discontinuities 45.3.2; Table 8
'Surclean'16.2.1.2;Table8; Appendix F fusion faces22.3
tolerance 12.3;12.4 heat-damagedcoatings8.4
turpentine 14.2 porosity 8.4
welds see Welds and welding priming 25.4
wire-brushing 16.2.3 procedure 8.4;25.4
Surface temperatures spatter 14.4;25.4; Table 8A
cold Table 1 tubularconstruction A3.2.1
hot 11-2.2; 12.6.2; 13.3.3; 23.8; Table 1; Table 3, part 11 undercutTable 8 A
Swedish Standard SIS 05 59 O0 cited 2; 14.3.1.5; 14.3.4.2; Wet-film thicknesssee Film thickness
16.2.1.2; Table 4; Appendices F, G Wet grit-blastingsee Blast-cleaning
Systems see Coating systems WharfsTable 1
White rustsee Coatings, metallic, zinc
Wire brush(es)(ing)see Manual cleaning, tools; Surface
Tanks, water Table 1; Table 3, note (n) preparation
Tapes, wrapping see Coatings (excluding bitumenltar,metallic, Witherite Appendix C
paint) Working conditions 23
Tar see Coatings, bitumenltar air pollution 23.6; Table 8
Temperature variation see Climate; Surface temperatures; cleanliness23.6; 58
Working cönditions confined spaces57.1
Test plate 16.2.1.2;16.2.1.4 defectscaused by Table 8
Testing of materialssee Materials, testing dew-point see humidity below
Thermal inertia 23.3 external 23.4
Thickness of coatingssee Film thickness health 23.9; 56 to 58
Thin steel sections 1; 11.1.2 heating 23.2;23.3
Thinners21.3 humidity 23.3;23.4
detection of excess 21-2.2; Table 8 lighting 23.7
Thixotropy 21.3 . safety23.9; 56 to 58
Thread allowance (for metallic coating) 25.2;25.5 sensitivity 23.1
Timberlsteel interfacesee Contact surfaces shop
23.6
Time to first maintenance Table 3; see also Life temperature 21.3;23.2;23.8
Time to overcoating 12.6.1; seealso Delays weather 23.4
Tolerance Workmanship, quality 8.1;22.2.6
coatings 8; 9; 20 Wrapping see Coatings (excluding bitumenhar, metallic, paint)
surface preparation 9;12.3; 12.4
Toxicity see Coating systems; Coatings, paint, characteristics
Transport of coated steelwork 15.8; 17; 24; see a/so Damage Zinc-alloy solder 11.1
to coatings Zinc chromatesee Pigments; Primers
Travel coat Table 2; Table 4L, note (h) Zinc coatingssee Coatings, metallic
Tie coatsee Travel coat Zinc-dust paintssee Coatings, paint, types
Tubes A.3.3.3; A.3.7.1; see also Box sections; Welds and welding Zinc-iron alloy Tables2, 4B
T-wash see Primers Zincoxide 12.2
Two-packwrapping tapes13.3.4 Zinc phosphatesee Pigments; Primers
1o9
BSI BSa51.1’73 77 L b 2 4 b b 7O L b O b 4 O 4 m
BS 5493 : 1977
Zinc silicate see Primers

Zinc-rich paints 12.2; Tables 2, 3, 4
inorganic 12.2; Tables 2, 3, 4E
organic 12.2; Tables 2 , 3 , 4 D
sealed Table 3, note (9)
silicate-bound Table4E
2inc.tetroxychromate sec Pigments
110
Standards publications referred to
@ I BS 534Specification for steelpipesandspecials for waterand sewage
BS 729 Hot-dip galvanized coatings on iron and steel articles
BS 1070 Black paint (tar-based)
BS 11 33 Packaging Code
Section 6 Temporary protection of metal surfaces against corrosion (during transport and storage)
BS 1706 Electroplated coatings of cadmiumand zinc on iron and steel
BS 2015 Glossary of paint terms
BS 2451 Chilled iron shot and grit
BS 2523 Lead-based priming paints
BS 2569 Sprayed metal coatings
Part 1 Protection of iron and steel by aluminium and zinc against atmospheric corrosion
Part 2 Protection of iron and’steel against corrosion and axidation a t elevated temperatures
I BS 2989 Specification for continuously hot-dip zinc coated andiron-zinc alloycoated steel: wide strip, sheet plate and slit wide strip
BS 3083 Specification for hot-dip zinc coated corrugated steel sheets for general purposes
BS 3294 The use of high strength friction grip bolts in structuralsteel work
BS 3382 Electroplated coatings on threaded components
Part 1 Cadmium on steel components
Part 2 Zinc onsteel components
BS 3416 Black bitumen coating solutionsfor cold application
BS 3698 Calcium plumbate priming paints
BS 3900 Methods of t e s t for paints
Part A4 Notes for guidance on paint application
Part A5 Large scale brushing test
PartC5 Determination of film thickness
I
BS 4147 Specification for bitumen based hot applied coating materialfor protecting ironand steel including suitable primers where
required
.m BS 4164 Specification for coal tar based hot applied coating materialsfor protecting ironand steel, including suitable primers where
required
BS 4232 Surface finish ot blast-cleanedsteel for painting
BS 4479 Recommendations for the design of metal articlesthat are to be coated
BS 4604 The use of high strengthfriction grip bolts in structural steelwork. Metric series
BS 4652 Metallic zinc-rich priming paint (organic media)
BS 4921 Sherardized coatings on iron and steel articles
BS 5228 Code of practice for noise control on construction and demolition sites
BS 6150 Code of practice for painting of buildings
I CP 110Structural use ofconcrete
CP 114 Structural use of reinforced concrete in buildings
CP 115 Structural use of prestressedconcrete in buildings
CP 116 Structural use of precastconcrete
CP 117 Composite construction in structural steel and concrete
CP 1021Cathodic protection
CP 201O Pipelines
Part 2 Design and construction of steel pipelines in land
Part 3 Design and construction of iron pipelines in land
CP8012 Cleaning and preparation of metal surfaces
DD 24 Recommendations for methods of protection against corrosion on light section steel used in building
I I PD 6484Commentary on
corrosionat bimetallic contacts
and its alleviation

BSI B S * 5 4 7 3 7 7
BS 5493 : 1977
This British Standard, having been prepared underthe direction'of grade designations. Enquiries shouldbe addressed to the
the Codes of Practice Committee for Civil Engineering was Publications Manager, British Standards Institution, Linford Wood,
published under theauthority of the Executive Board on Milton Keynes MK14 6LE. The number for telephone enquiries is
0908 320033 and for telex 825777.
31 October 1977.
@British Standards Institution, 1977 Contract requirements
A British Standard does not purport to include all the necessary
First published, as CP 2008, October 1966 provisions of a contract. Users of British Standards are responsible
First revision October 1977 for their correct application.
ISBN: O 580 09565 7 Revision of British Standaads
British Standards Institution British Standards are revised, when necessary, by the issue either
Incorporated by Royal Charter, BSI is the independent national of amendments or of revised editions. It is important that users of
body for the preparation of British Standards. It is the UK member British Standards should ascertainthat they are in possession of
of the International Organizationfor Standardizationand UK the latest amendments or editions. Information on all BSI
sponsor of the British National Committee of the International publications is in the 6SI Catalogue, supplemented each month by
Electrotechnical Commission. BSI News which is available to subscribing membersof the
Copyright Institution and gives details of new publications, revisions,
Users of British Standards are reminded that copyright subsists in amendments andwithdrawn standards. Any person who, when
all BSI publications. No partof this publication may be reproduced making use of a British Standard, encounters an inaccuracyor
in any form without the prior permission in writingof BSI. This ambiguity, is requested to notify BSI without delay in order that
the matter may be investigated and appropriate action taken.
does not preclude the freeuse, in the course of implementing the
standard, of necessary details suchas symbols andsize, type or The following BSI references relate to the work on this standard:
CommitteereferenceBDB/7 Draftfor comment75/12246 DC I
I Code Drafting Committee
Prevention of corrosion
Chairman Mr K A Chandler Engineering Equipment Users Association Mr L S Evans
Association of Metal Sprayers Mr J C Bailey Institute of British Foundrymen Dr R V Riley
Mr E J Cunningham Institute of Metal Finishing Dr M Clarke
Mr E A Gerhold Institution of Civil Engineers Mr W F Leeming
Mr R E Mansford Institution of Corrosion Technology Mr D A Bayliss
British Cast Iron Research Association Mr D R Whitchurch Institution of Electrical Engineers Mr H .Gosden
British Constructional Steelwork Mr F I Lees Institution of'Gas Engineers Dr J T Harrison
Association Mr F H Needham Institution of Municipal Engineers Mr K C Horton
British Gas Corporation Dr J T Harrison Mr T Irving
British Iron and Steel Research Association Mr K A Chandler Institution of Structural Engineers Mr A G Senior
British Railways Board Mr D F Goodman Institution of Water Engineers& Scientists Mr K J Reynolds
Mr F D Timmins Ministry of Defence Mr D A Chapman
British Steel Corporation Mr A K Allan Mr J Garland
Mr G A Orton Mr G Scholes
Co-opted Mr C A Pequignot National Coal Board Dr I Evans
Mr D Pye National Federationof Painting and Mr S J Benge-Abbott
Mr A G Walker Decorating Contractors
Construction Industry Research and Mr P Pullar-Strecker Paint Research Association Mr A W Bullett
Information Association Paintmakers Associationof Great Mr A E Claxton
Council of lronfoundry Association Mr D R Whitchurch Britain Ltd. Mr A T S Rudram
Department of the Environment- Mr P Whiteley Royal Institute of British Architects Mr D A S Goodman
Building Research Establishment, Royal Institution of Chartered Surveyors Mr F J Cave
Building Research Station White Lead Manufacturers Association Mr M R P e t t i t t
Department of the Environment (PSA) Mr R H Cutts Zinc Development Association Mr F C Porter
Department of the Environment (Highways) Mr P Elliott Chairman of ISE/28. Mr N S Making
Mr T A Rochester
Department of the Environment- Dr R R Bishop
Transport and Road Research Laboratory
Electricity Supply in England andWales Mr I P Gillson
Mr A Meredith
Amendments issued since publication
Amd. No. Date of issue Text affected
4443 January 1984 Indicated by a line in the margin
-
British Standards Institution 2 Park Street London W1A 2BS . Telephone 01-629 9000 Telex 266933 .
8505-IO-3k-JWD BDBl7


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What factors influence the choice of protective coating system?

What factors influence the choice of protective coating system?

What are the different types of protective coatings discussed in the document?

What are the different types of protective coatings discussed in the document?

E S 1 BS*SLI73 7 7 m lb2Llbb7 O l b 0 5 3 0 B m

Code of practice for

steel structures against corrosion

Code de bonne pratique pour I'enduisage des

Richtlinie für Beschichtung von Eisen-und Stahlbauten zum

British Standards Institution

COPYRIGHT British Standards Institute on ERC Specs and Standards

BSI BS85L193 77 W LbZ4bb9 03b0534 5

British Standard Code of practice for

4.3 Questions relating t o coating systems Source of information

5. Environment Section five of the code gives details of conditions of

Table 1. Environments and special situations

Category Description 3elevant Category Description Relevant

Exterior Rain washed surfaces Mines Typically

Non-saline Potable and non-potable water. Part 8

Sea water Sea and other salinewaters and

soil Earth, sand, rock, etc. Mainly buried Part 13

reference letter is amplified by one of the following

Table 2. Principal types of coating systems (see 10.1)

B Zinc coating (except sprayed- Zinc and/or zinc-iron alloy 4B 11.1

tMoisture-curing polyurethanes and high-moleculat eiaht - linear eDoxv ..

Table 3. Recommendations for protective coating systems for specific environments

Table 3.Part 1, Exterior exposed non-polluted inland atmosphere

Typical time General description System Total nominal Notes

Very long Galvanize SB1 (85 min.)

Long Galvanize plus paint SB8 (85 min. + 30 min.)

Medium Organic zinc-rich SD2 75

Short Drying-oil type SF2 120 to 150

Table 3, Part 2. Exterior exposed polluted inland

Very long Galvanize (silicon in steel) SB3 21o

Long Galvanize SB2 140

Medium Galvanize SB 1 (85 min.)

Short Drying-oí1type SF3 170 to 190

Table 3. Part 3. Exterior exaosed aolluted coastal atmosahere

Very long Galvanize (silicon in steel) SB3 21o

Medium Galvanize SB1 (85 min.) a, b, c, d

Table 3. Part 4. Exterior exposed non-polluted coastal atmosphere

Typical time General description System Total nominal Notes

Very long Galvanize SB2 140 a, b, c, d

Long Galvanize SB 1 (85 min.) a, b,c, d

Medium Unsealed sprayed zinc SC1z 1O0 a, c, d, f

Short Organic zinc-rich SDI 50 9

I Table 3. Part 5. Exterior sheltered atmosphere

Table 3. Part 6. Interior (of buildings) normally dry

Typical time General description System rotal nominal Notes

Very long Galvanize SB1 :85 min.)

Long Galvanize plus paint SB8 :85 min. t 30 min.)

Short Drying-oil type SF 1 1 O0

Table 3. Part 7. Interior of building, frequently damp or wet

Typical time General description System Total nominal Notes

Very long Galvanized SB1 (85 min.)

Long Galvanize plus paint SB8 (85 min. + 30 min.)

Organic zinc-rich SD3 1O0

Typical time General description System Total nominal Notes

Very long Galvanize SB2 140 b, c, d, m