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Standard Operating Procedure Confidential

TITLE: Standard operating procedure for DATE: 20-03-2021


Surface preparation and TSZC/ TSAC coating
with application of Primer and Paint. PAGE 1 of 5

CORROSION PROTECTION ENGINEERS INDIA


STANDARD OPERATING PROCEDURE

PURPOSE:

To remove rust scale, loose mill scale, loose rust, and loose coatings,
leaving tightly bonded mill scale, rust, and previous coatings. This is an
ideal method for removing oxides and/or loose and peeling coatings from
galvanized metal.

PREPARATION

For new steel, all surface imperfections such as sharp edges, weld splatter,
weld folding and slag shall have been removed from surfaces. All edges
shall have a radius of curvature of no less than 2.0mm.

ABRASIVE BLASTING
1. Grit blasting is the only method of preparing surfaces for metal
spraying. It removes rust, mill scale and other surface contaminants
and produces a suitably roughened surface profile. Clean, dry,
compressed air shall be used for blasting. Moisture separators, oil
separators, traps or other equipment may be necessary to achieve this
requirement.

2. A high standard of surface preparation is required to develop the


optimum thermo-mechanical bond required for metal sprayed
coatings. Steel surfaces to be arc sprayed with zinc or aluminium or to
be flame sprayed with zinc should be abrasive blast cleaned to at
least Class 2.5 to produce a sharp angular profile of at least 50µm.
Standard Operating Procedure Confidential

TITLE: Standard operating procedure for DATE: 20-03-2021


Surface preparation and TSZC/ TSAC coating
with application of Primer and Paint. PAGE 2 of 5

3. Steel surfaces to be flame sprayed with aluminium or aluminium


alloys should be abrasive blast cleaned to Class 3 to produce a sharp
angular profile of at least 75µm. Profile depth should be measured
using a surface profile gauge or replica tape. Coating thicknesses in
excess of 300µm may require an increase in surface profile.

4. Metal sprayed coatings should not be applied if any discoloration of


the cleaned surface has occurred, or when the temperature of the
substrate is below the dew point. Any visible rust that forms on the
surface of the steel after blast cleaning shall be removed by re-blasting
the rusted areas to meet the requirements of the specification before
metal spraying.

SPRAYING

1. The first metal spray coat should be applied within 4 hours after the
last cleaning and before any discoloration of the prepared surface
occurs.

2. Spray angle should be near to right angles to the substrate as possible,


with a spray range or standoff between 100 - 200mm.

3. The sprayed metal coating should overlap on each pass. Two or more
coats of this layer should be sprayed alternatively in vertical
and horizontal passes to ensure uniform coverage to the minimum
specified coating thickness.
Standard Operating Procedure Confidential

TITLE: Standard operating procedure for DATE: 20-03-2021


Surface preparation and TSZC/ TSAC coating
with application of Primer and Paint. PAGE 3 of 5

SEALING

1. Due to the thermal spray process, the coating typically has around
10% porosity.

2. The purpose of sealing is to fill this porosity and delay oxidization of


the coating. Sealing extends the life of the coating as well as
providing a smooth finish and giving color if desired.

3. Ensure the coating is free of moisture before application and all


solvents have evaporated before subsequent coats to avoid solvent
entrapment.

PAINT SYSTEMS

1. Metal sprayed anti corrosion coatings are normally put into service
without any finishing, however sealers and paint systems can be
applied to suit particular environmental conditions or if aesthetics
require.

2. When steel protected only by paint is damaged or weathered, it can


corrode in the unprotected area and additionally proceed to corrode
the steel under the paint, a phenomenon called “scribe creep”.

3. The corrosion products of iron are many times higher than zinc,
resulting in progressive failure or paint peeling away from the
damaged or weathered site. By contrast, when the steel is protected by
TSZ that is then painted, any damage to the paint, even if it goes
through the TSZ, does not result in significant steel attack.
Standard Operating Procedure Confidential

TITLE: Standard operating procedure for DATE: 20-03-2021


Surface preparation and TSZC/ TSAC coating
with application of Primer and Paint. PAGE 4 of 5

4. The TSZ coating galvanically protects the steel until it is consumed,


minimizing scribe creep failure of the paint and also greatly reducing
the severity of steel corrosion. 150 - 200 micron TSZ alone can
provide up to 25+ years to first maintenance in most environments.

5. Should the steelwork require a paint system for aesthetic reasons, it is


not always necessary to retain the same 150-200 micron of the TSZ as
it is there to galvanically protect the steel with the paint acting as a
barrier.

6. An example specified widely overseas: 100 micron TSZ, 50 micron


epoxy sealer, 100 micron epoxy build coat, and 50 to 100 micron
polyurethane.

7. TSZ applied by arc spray equipment achieving high production rates,


poor machine settings, rough finishes or higher coating thicknesses
may produce a coarse surface profile of the finished coating.

8. This may be an issue in some cases when TSZ is to be part of a duplex


system. A specification of a low build paint system or areas of low
paint build during application may cause ‘peaks’ in the TSZ to
activate, causing white zinc oxide and blistering the barrier
coating. The coatings recommend a profile height of less than 50
microns for TSZ before paint system is applied.
Standard Operating Procedure Confidential

TITLE: Standard operating procedure for DATE: 20-03-2021


Surface preparation and TSZC/ TSAC coating
with application of Primer and Paint. PAGE 5 of 5

9. TSZ coatings have a porosity of approx 10%, depending on the


specification or desired finish a low viscosity material with good
wetting properties such as vinyl, acrylic, or thinned epoxy are used.
Higher volume solids are preferable to reduce the number of sealing
coats required. Be sure all solvents have evaporated before subsequent
coats to avoid solvent entrapment.
10.Always discuss with your paint representative for the correct
sealers/topcoats, application, drying times and coating thicknesses for
paint application over TSZ coatings.

R.D.G. Shekar Bhagyalakshmi.S


Managing Partner Marketing Executive
9686111973 9686111978

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