Good Pqinting Prqctices

Point Applicotion
Choice of Applicotion Melhod

The importance of the correct application of a coating system cannot be overstressed; if it is applied under the
specified film thickness then premature corrosion may occur . On the other hand if it is applied too thickly, then
other problems such as slow curing or cracking etc can occur. The method of application is also an important

factor as it can affect the final appearance and performance of the paint system. Other factors to be
considered when deciding on the method of application.
a. The Shape of The Structure

A complicated structure (such as lattice work) may be unsuitable for spray application because of extremely
high loss factors involved and another method of application, such as roller, may be more suitable.
Small diameter pipes are more likely to be brush applied whereas the coating of the internal surface of
a large diameter pipes is more suitable for spray application.
b. The Location of The Structure
The possibility of overspray onto adjacent structures or vehicles parked close to a building or structure may
prohibit the use of spraying. Also the location of an area to be coated may be such that it is uneconomical or
physically impossible to apply paint by spray in that area.

c. Manufacturer's Recommendations
Certain produce are formulated for spray application only and too fast drying for brush or roller application;
other products must be spray applied to achieve the specified film thickness in one coat.

The above mentioned factors are just examples of some of the considerations that should be taken into
account when choosing a method of paint application.

Methods of Applicolion

There are four common methods of applying coatings to steel and other surfaces

Airless Spray

But not one of them is the "best" method for all coatings

Brush Applicolion
Brush application is not an outdated method of paint application as is sometimes thought and indeed is still the
basic method by which most decorative and maintenance coatings are applied. lt is relatively slow method but
can be the most suitable for applying paint to small complex structures and also "hard{o-access" areas. lt is
also a useful method of applying a "stripe" coat to areas such as bolts, rivets, edges, corners etc prior to the

to ensure the correct film thickness is achieved in these areas. The

brushing action can ensure good wetting and flooding of surfaces where high quality surface preparation is not
provided. This helps to improve the adhesion of the coatings of these surfaces. There are various types of
brushes: the flat wall type, brush which may be up to 6 inches (lScm) in width with bristles up to 6 inches

application of the spray-coat, so as

(1Scm) in length; the oval brushes which are often used in the marine and industral areas for the application
of coatings to irregular surfaces, such as rivets, raillings etc.
When applying a coating by brush the following tips may be useful to ensure an even application
Brush should not be dipped further than 1-1 1/2 inches (2.5-3.Scm) into the paint so as to prevent dripping or
the running of the paint onto the handle. Wipe the excess paint from the brush by gently tapping the bristles
against the side of the can.
The coating should then be spread over the substrate, holding the brush at angle of about 45'. Light strokes
should be used to evenly spread the coating on the surface followed by light parallel strokes over the surface
of the coating to smooth the surface and eliminate brush marks or other irregularities in the surface. Always
brush the final strokes from the last brush load into the previous brush load, overlapping the wet-edge so as

to prevent uneven film thickness at the overlap areas.

Fast drying products require a slightly different technique where the brush should be dipped and filled and
applied to the surface as quickly as possible. Apply the coating using a few rapid strokes. Do not go back to
the coating and try to "brush it out" as it will result in uneven film thickness caused by pilling up the coating and

also unsightly brush marks. Apply the next brush stroke in the

same manner as quickly as possible

remembering to brush the lapped area from the latest wet edge into the previous brush load. lf applying a fast
drying product to an edge or surface irregularity, always brush out over the edge regularly so as to ensure the
correct film thickness is achieved in this area.

Roller Applicotion
Roller application is generally used for large flat areas such as walls, steel sheeting, etc. lt is a faster method
of application than brush but not as fast as spray application. The universal use of this method is limited by two
factors:
a. the geometry of the structure and
b. certain coating which are, by their nature, unsuitable for roller application

Roller application achieves a much better finish if the surface is smooth. lf the surface is badly pitted, rusted
or uneven, brush or spray application would be more suitable. Roller application does not thoroughly wet the

surface and also often does not achives the recommended film thickness. However, it is useful method of
application of coating with lower losses than spray application.
Dsclomer:Theabovenformatonsgiventothebestofourknowledgebasedonlaboratortestngandpractilexperen

However,astheproductisoftenusedundercondtons

beyond our control, we nnot guarantee anything but the quality of the product tself We reserued the right to change the gven informaton wthout prior not

The paint roller consists of a roller (usually foam, nylon or animal hair) and a handle to which it is attached. The
roller is usually about2 inches (Scm) in diameter 9 inches (23cm)long. Smaller rollers exist for small objects.
The length of the pile on the roller varies lrom

inch (6mm)To 1 112 (40mm)depending on the material used

surfaces whereas the shorther pile is used on the smoother

114

for the pile. A long pile is used for rough

surfaces.

Rollers can have very long handles or poles which make their use in shipyards particularly common as they
are used regularly for touch up work where expensive scaffolding need not be employed.

Convenlionol Sproy
Spray application of coating is the faster method of applying a paint. Conventional air spraying is commonly
used in application of coatings to cars, industrial products, and small areas of repair where a high quality of
final appearance is essential. Essentially the paint is atomised to form a mist by the passage of a low pressure
air stream and liquid paint through a small tip. The air then applies a pressure to the force the liquid paint
through the orifice of the gun and propel itto the surface to which it is being applied.

Typically the air pressure involved is 40-100 psi. By controlling the viscosity of the paint, the volume and
pressure of the air supply and the tip size, a paint can be successfully applied to the surface. A high viscosity
coating is better applied using a pressure feed system with a heavy duty gun whereares an automotive coating

would use a completely different set of equipment e.g. a suction gun.

There are two method of bring in the coating to the spray gun, either pressure feed or suction

A suction feed gun is usually fitted with a "cop" or "containe/'which contains the coating to be applied. (This
liquid have already, if necessary, been thinned to the correct viscosity for spray application). When the trigger
of the gun is operated, suction developed at the tip of the gun draw paint from the cup to the nozzle where it
is sprayed. lt cannot be used successfully for the application of high viscosity coatings.

ln a pressure feed gun, the coating is forced into the gun under pressure. The coating is stored in a pressure
pot. This pot is connected to the gun by a fluid and an air hose and to an air supply by a large diameter hose
(3-4 inch) (75-100mm). The coating is forced under pressure through the fluid hose to the gun and air supplied
directly to the gun force the coatings of high viscosity and is faster than the suction feed method.
With all type of spraying (including airless), it is essential to have a water and oil separator to ensure that the
air supplied from the compressor is clean. lf this is not provided, the result is usually premature coating
breakdown because of contamination of the coating as it is applied.
The paint roller consists of a roller (usually foam, nylon or animal hair) and a handle to which it is attached. The

roller is usually about 2 inches (Scm) in diameter and 9 inches (23cm) long. Smaller rollers exist for small
objects. The length of the pile on the roller varies lrom 114 inch (6mm).

Disclomer : The above nformaton

gven to lhe best of our knowledge based on laborator testing and practl experen However, as lhe product is otten used under conditions

beyond our ntrol, we nnot guarantee anything but the quality of the product itself We reserved the rght to change the given information wthout pror notce

Airless Sproy

This method of application is usually favoured for high build coating on large areas. lt has considerable
advantages over conventional spray, brush and roller methods of application in speed of work and the ability
to achieve specified film thickness in one application. Hydraulic pressure alone is used to apply coatings by
airless spray , in a controlled spray pattern. The coating is atomised by forcing it at high pressure (2000-4000
psitypically)through an accurately designed small office (known as tip) at different pressure and orifice size,
to form a "fan" of paint droplets. A combination of high velocity and rapid expansion of the coatings on passing
through the orifice into the atmosphere causes them to break up (atomise) without the additional assistance of

atomising air.
The pressure is supplied by either an electric or air activated pump. The air activated pump, which is the most
commom on-site equipment, can transmit to the coating material pressures of 20-75 times the pressure of the
air supplied to the pump by compressor. (Typically hydraulic cylinder ratios are 30:'1 , 45:1 and 60:1 ). Some
pumps are fitted directly to a wall and are supplied by 200 litre drums, other fit over the top of a 5 litre or
20 litre drums and have wheels which make them portable on site.
Special high pressure paint lines are necessary for the material to be sprayed.
Airless spray application can be controlled by the pressure, tip size and angle and the viscosity of the material
being applied. The recommended practice in every instance is to ensure that the most suitable spray tip and
pressure are selected and tried, and to establish, prior to painting, whether any addition of solvent would be
necessary. The tip size is very important as combined with the pressure they determine to flow rate of the
paint. Serious consideration should also be given to the spray angle ensuring that the optimum fan width is
provided in relation to the shape and size of the structure being coated. lt is important to ensure that all the
equipment is kept very clean so as to ensure the minimum of delay because of tip blockages etc. Reversible
tips are available to clean tips quickly but good housekeeping is the best way to ensure trouble-free
application. Some useful procedures that should be followed are:
a. Always use clean tips and clean these with solvent if application is to be stopped for more than 15 minutes.
Always ensure that the tip size recommended on the product data sheet is being used.

b. Stir paints with air-driven mixers and not with pieces of wood as splinters cause blockages and also can
damage the pump.

c. Use a filter on the paint intake line, in the pump and in the gun (unless specifically instructed by the data
sheet to leave the filter out).
d. Keep the paint containers covered, even if the paint container is under the pump, so as to prevent dust and
grit etc getting into the paint.
e. At the completion work of each day, ensure that the pump, paint lines and gun are thoroughly cleaned with

the recommended cleaning solvent.

f. Spray Technique: The spray fan should be kept at right angles to the surface and the gun should be triggered
at the end of each pass. The ideal distance for holding an airless spray gun from the surface being coated is
12-15 inches (30-40cm) as this will ensure a full wet coat is applied. Distance in excess of 20 inches (50cm)
encourage pinholding, dry spray and overspray to occur.
Ensure that the safety trigger device is in working order and only released during spraying operations. Airless

spray application requires a high degree of care because of the pressures involved. When spraying it is
advisable to avoid placing hands or fingers in front of the gun as the coating can be forced into the flesh
and bloodstream.
Dscloimer : The above nformation is gven to the best of our knowledge based on laborator testng and practil experence However, as the product is ofen used under conditons

beyondourcontrol,wennotguaranteeanythngbutthequalityoftheproducttself

Wereservedtherghttochangelhegiveninformationwthoutprornotce

Properly controlled airless spray is probably the most economical method of spray application. The equipment
is relatively expensive but the savings on major applications often offset the high initial coat. The use of airless
spray has several advantages over conventional spray application.

i.

Airless Spray is a faster method of application.

ii.

Overspray is reduced to a minimum resulting in a healthier, cleaner and safer working environment.
iii. Much more viscous paint can be applied.
iv. Solvent entrapment is reduced as much of the solvent in the paint is lost when the paint leaves the gun.

v.

Providing that adequate pressure is available, more than one gun can be used with spray pump.
vi. lmproved surface wetting characteristics (especially when fast drying paints are being applied).
Discloimer:Theaboveinformalonsgiventothebestofourknowledgebasedonlaboratortestngandpractlexperen

beyondourcontrol,wennotguaranteeanythngbutthequalityoftheproductitself

Ihis

dofo sheet supersedes oll previous

issues.

Howevet,astheproductsoftenusedunderconditons

Wereseryedtherighttochangethegvennformationwthoutprornotice

(LZG /17 /04/131

KCC Points Sdn. Bhd.

l'2t961 fl

Good Pointing Proclices

lmportonce of Surfqce Preporotion

The cleaning and surface preparation of a substrate should not be considered as a seperate matter but as an
integral part of the coating system. The objective of surface preparation is to clean the substrate, creating a
surface profile to which a coating can properly adhere subsequently. Thus, a proper and correct surface
preparation recommendation is essential to enhance the durability and effectiveness of a coating system.

There are two main objectives to surface preparation: firstly, to remove the loose material such as mill scale,
dirt, oxide films, grease, etc. from a substrate so that the coating can adhere to the surface, and secondly, to
increase the surface area of the substrate by increasing the roughness and anchor pattern of the surface. lf a
coating is applied to a contaminated surface that has not been cleaned then the adhesion of the coating
system to the surface can only be as good as the adhesion of the contamination to the surface or the adhesion
of the coating to the contamination.

l.

Mosonry, Concrele ond Plqster:

New concrete should be allowed to cure for at least 4 weeks before any painting commences. The surface
must be clean, sound and dry. New plaster concrete normally has a loosely adherent layer of laitance on its
surface which should be removed by acid etching, power tool cleaning or sweep blasting. From oils, curing
compounds and releasing agents also need to be removed thoroughly as these will affect the adhesion of the
coating to the substrate. The most effective method of obtaining a satisfactory surface for painting is to blast
clean carefully using a non-metallic aggregate.

Acid etching is carried out using dilute hydrochloric acid (10-15% concentration) however, on reinforced
concrete, the use of an organic acid (eg. Muriatic) is preferred. The acid reacts with the calcium compounds
in the cement and can usually be seen to bubble. The reaction product, calcium chloride, must then be washed

away thoroughly by means of a fresh wash rinsing.

For old concrete, depending on the situation, mechanical cleaning using scarifying equipments may be
necessary to be employed to remove old coatings or unsound surface layers of concrete. This method is
mostly used for "repair" areas where mortars are used to reprofile the surface.

2. Wood, Plywood ond Woll Boord

Moisture content in wood materials should not be more than 15% before painting. Knots and pitches should
be scraped off or if still soft, shall be removed by solvent and be sealed with recommended sealant. Sand
papering to obtain smooth surface if required would be necessary.

3. Previously Pointed Surfoces:

The old and composition of an existing surface coating on a substrate can have considerable bearing on how
a freshly applied system will perform. Before coating, a thorough examination of the substrate is advisable and
the surface should be checked for cleanliness, chalking adhesion and / or other defects. lf the existing surface
coating system is intact and sound, then these surfaces can generally be cleaned with a degreasing solution
and freshwater, and allowed to dry prior to painting. However, where there are areas of coating breakdown,

spot repair or complete repair may be needed and one of the previously described methods should be
employed. lf in doubt, contact your local KCC representative for advice.

4. Non-Ferous Metqls
There are a number of non-ferrous metals used in construction industry which require painting for either
aesthetic or protective reasons; Copper, Zinc,Bronze, Aluminium, Galvanized steel etc.
Aluminium for instance is an important structural non-ferrous metal that are found in the construction, aviation
and shipping industries. Adequate surface preparation is essential for these metals so as to ensure proper
adhesion of the paint system. Surface cleanliness is usually confined to the complete removal of oil, dirt and
grease by degreasing prior to priming with a specially formulated coating.

Golvonized Melol
Many paint systems fail when applied to galvanized steel, mostly because of the absence of a proper etching
wash primer or insufficient surface preparation. All galvanized steelwork must be thoroughly degreased
with an emulsifier degreaser.

or

The acidic copper solution reacts with the galvanized steel and turns it black; where oil / grease is still present
on the surface, the acidic solution cannot react with the Zinc and thus remains brightly metallic in color. Thus
the affected areas that have not been properly degreased can be identified and clean again. The mordant
solution also etches the surface.
A "Wash Primer" should then be applied after a freshwater wash to remove the residual mordant solution. For
aged galvanized substrates the surface should be thoroughly washed to remove any soluble salts on the
surface followed by thorough degreasing of the surfaces. With both new and aged galvanizing, a light abrasion
using silica bonded paper will enhance the adhesion of the subsequent coating system applied.

Aluminium, Copper, Bross ond Bronze

The surface should be thoroughly degreased and lightly abraded using silica bonded sandpaper or light sweep
blasting at reduced pressures prior to the application of paint. A suitable primer would be an etching primer or
wash primer.

5. Ferrous Melols
Metal corrosion, virtually synonymous in the paint industry with rusting, is simply the tendency of a ferrous
metal to return to its natural state as an ore. lt is largely due to electrolytic reaction which takes place in the
presence of moisture and air. The application of a protective coating on the ferrous metals will provide a layer
of surface coating film to retard rusting by the exclusion of water and air from the metal surface.

The exclusion of water and air by a paint film is more theoretical than factual, for all organic paint films are
permeable to moisture in some degree (an organic paint film is a chemical composition of carbon compounds
of living organisms). Film breakdown due to corrosion under the film; may take place quickly if the surface is
not properly treated and is not provided with a corrosion inhibitor.
Phosphating a metal surfaces with iron or zinc phosphate is of great value in providing adhesion for an organic
film as well as in providing a corrosion inhibitor to lengthen the life of film. Some finishing materials prevent rust
and corrosion; some are practically neutral; others actually promote the action. An effective metal protective
coating, therefore, requires a dense material and rust-inhibitive pigments. Unlike wood surfaces, polished
steel surface lacks the profiles required for favorable paint adhesion.

Another condition exists in the finishing of metal products. The slightest abrasion of the finished surface will
cause the metal to rust. This rusting will spread under the paint film, causing premature breakdown of the
surface coating. Paint adherence to metal, therefore, must and can be improved by (1) roughening the surface
mechanically or chemically (2) depositing a film improves the bond between paint and metal. Various cleaners
or methods are used to prepare a metal surface.

Alkali cleaners of a 5-10% caustic solution are commonly used to clean the surface. Thorough rinsing is almost
importance because any alkali residues left on the surface will affect the paint adheston.
Acid cleaners are frequently used to remove rust and scale. A B-10% aqueous solution of sulfuric acid or commercial hydrochloric acid is very effective in removing rust from a metal surface. Due to the safety and hazards
involved in this type of acid cleaning, it is wise to consult an expert before proceeding.
A 5% aqueous solution phosphoric acid not only removes a considerable amount of surface contamination but
also forms a very thin crystalline structure which improves paint adhesion.
Emulsion cleaners in which soaps and detergents are mixed with water are very effective means in removing
oil & grease. Thorough rinsing is necessary. Abrasive blast cleaning produces a chemically clean and rough
surface which is most ideal for painting. As newly blasted surface may rusts very quickly, painting must be
followed immediately.
Wiping with thinner or solvent is quite effective as a metal cleaner, especially on small surfaces
Mechanical cleaning with a wire brush or abrasive paper is quite effective in removing rust or loose mill scale

The proper surface preparation method would be selected accordingly to the paint system to be applied and
available facilities. Unless othenvise specified in the painting system, abrasive blast cleaning to SA 2.5 of
SIS 055900 or equivalent is always the most economical and effective surface preparation.

Surfoce Roughness (Anchor Potlern)

ln connection with surface preparation, roughness is defined as the irregularities in surface texture, which are
caused by abrasive blast cleaning. Most paint system need an anchor pattern characterized by a surface
roughness to obtain maximum adhesion.
The anchor pattern must be clearly specified seperately in specifications for surface preparation. During actual
field work, the anchor pattern can be easily and conveniently assessed by visual or tactile comparison, using
sta nda rd ized comparators.

Abrosives
The abrasive used in blasting shall be graded steel grit, flint, silica sand, or similar, and shall be such that it will
produce a surface roughness complying to the specification and requirement as per the respective primer
coating. The abrasive shall be dry, clean and free from soluble contaminants.

Cleoning
After blasting, remove all accumulated grit, sand, dust etc., by vacuum cleaning or by clean dry compressed
air, leaving the surface always clean, dry and free from mill scale, rust and other foreign matter.

Surfoce Preporolion Slondords

Listed below is a summary of the most commonly used standards.
Surface Preparation Specifications (SSPC-S P0)
Surface Preparation Standards for Painting Steel Surfaces. (SlS 055900)
Surface Finish of Blast Cleaned Steel for Painting. (854232)
Surface Preparation Specifications for Abrasive Blast Cleaning. (NACE)

SSPC-SP1

Solvent Cleaning

Removal of loose rust, loose

mill scale contaminants with
solvent, alkali emulsion or
steam.

SSPC-SP2

Hand Tool Cleaning

Removal of loose rust, loose

mill scale and loose paint to
degree specified by power tool

chipping, descaling, sanding,

wire brushing and grinding.

srs 055900

B, C, D-St2

Removal of loose rust, loose

mill scale and loose paint to
degree specified by power tool

chipping, descaling, sanding,

wire brushing and grinding.
SSPC-SP3
sls 055900

Power Tool Cleaning

B, C, D-Sr3

Removal of loose rust, loose

mill scale and loose paint to
degree specified by power tool

chipping, descaling, sanding,

wire brushing and grinding.

srs055900

"White Metal" Cleaning

A, B, C, D, -Sa3 First

854232

Quality No.1

SSPC-SP5

Removal of all visible rust mill

scale, paint and foreign matter

by blast cleaning by

using

sand, grit, shot or gamet. (For

NACE

very corrosive

atmosphere

where high coat of cleaning is

warranted.
SSPC-SP6

sts055900
B54232
NACE

"Commercial" Cleaning
B, C, D, -Sa2
Two-third of each
element of Third Quality

surface area is free of

all No.3

Blast cleaning until at least

visible residues. (For rather
severer conditions of exposure.)

SSPC-SP6

"Brush-Off' Cleaning

Blast cleaning of all except

sts055900

B, C, D, -SA1

tightly adhered residues of mill

NACE

No.4

scale, rust and

SSPC-SP8

Pickling

Complete removal of rust and

coatings,
exposing numerous evenly
distributed flecks of underlying
metal.

mill scale by acid pickling,

duplex pickling or electrolytic
pickling.
SSPC-SP1O

s1s055900
NACE

"Near White

Blast cleaning nearly to white

metal cleanliness, until at least

Metal
blast cleaning second
quality No.2

Ihis doto sheet supersedes oll previous issues.

95% of each element of surface

area is free af all visible
residues. (For high humidity,
chemical atmosphere, marine,
or other corrosive environment.)

(LZG

/02/0s/13)

KCC Points Sdn. Bhd.ft

(121967