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Reliance

Procedure for Surface Preparation


and
Painting of Structural Steel

EPCMD-2-QM00-JEP-ME-019

00

29.03.2011

Issued for
implementation

PPP / PKD

PKS / EMK / KSS

SNS

Rev

Date

Description

Prepared
by

Checked by

Approved
by

Reliance
Contents
1. Purpose 3
2. Scope ..3
3. References

..3

4. Abbreviations and Terms .3


5. Responsibilities ..4
6. Methodology ..4

EPCMD-2-QM00-JEP-ME-019 00
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Reliance
1.

Purpose
External painting for Steel that is exposed to atmosphere is required to protect from
oxidation / corrosion by chemical / Electro chemical reactions respectively. Integrity of
these coatings / paintings depends on the grade of surface preparation and method of
paint application. Therefore all structural steel material that is exposed to atmosphere
is required to be coated either before or after fabrication at shop. All fabricated
structures coated at shop shall be identified with sequential numbering system to have
proper correlation with the reports generated. This procedure is developed to meet the
specification requirement and to take care of problems faced during construction.
Some of the problems encountered in Surface cleaning, Painting of steel during
construction are as follows.
Salt contamination Test conducted at once and found that deposited salt on the job
surface was more than the acceptable limit.
At some locations on the pipe way, external painting was carried out with out
proper cleaning of the deposited salts on the job surface (i.e. after blasting)
resulted in localized places rusts and blisters formations.
% RH, DBT, WBT & Dew point temperature was not recorded. It was observed that
some places rusting started through primer, though intermediate coat & Finish
Coats are intact.
At many places conducted adhesion test and observed that adhesion was not proper
between prime coat and Metal surface, resulted in paint is pealing off.
At some places excess DFT was observed, which are in the range of 300 400
microns.
To avoid recurrence of all these problems this procedure is developed to provide step
by step guidelines to carryout in-process and final Inspection of Grit blasting and
Painting of Structural Steel items at shop and field.

2.

Scope
The procedure covers the identification of structural steel material / plates and
inspection stages, testing requirements during surface preparation and paint
application. The procedure is applicable to all personnel whom so ever involved in the
activities of sand / grit blasting and painting of structural steel items.

3.

REFERENCE
ISO 8501 Surface Preparation standards for painting Steel surfaces.
ASTM D 3359-95a Standard Test methods for measuring Adhesion by Tape Test.

4.

Abbreviations & Terms


HOD

- Head of the Department

EPCMD-2-QM00-JEP-ME-019 00
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Reliance

5.

QMD

- Quality Management Department

DCC

- Document Control Center

MDR

- Material discrepancy Report.

NCR

- Non-Conformance Report.

DFT

- Dry film thickness

WFT

- Wet film thickness

RH

- Relative Humidity

Responsibilities
Construction Managers/Engineer in Charge are responsible for implementing this
procedure in their area.
HOD QMD is responsible for maintaining this procedure.
DCC is the custodian of this document

6.

Methodology
The following procedure shall be followed during in-process and final inspection of steel
surface preparation by Grit / any other approved blasting material and painting.
6.1

Structural steel material received for Grit / abrasive blasting and painting shall
be visually inspected and ensured that job is free of physical damages; job
surface is free of Grease, oil, dirt etc.

6.2

In case of any fabricated structure / item, the identification (mark number /


drawing number etc) markings given at fabrication shop shall be protected by
providing a mask on the identification.

6.2.1 Structural steel items prior to surface cleaning and painting i.e. before
fabrication shall be identified with numbering system. Marking on the items may
be carried out by punching /marking with paints and it shall be protected during
blasting/painting by suitable means.
6.2.2 All other Structural material before blast cleaning shall be numbered as
described in clause no 6.2.1.
6.2.3 For easy identification of the hard punched location on the job i.e. after blasting
and painting, these markings shall be encircled with (bright colour) contrast
paint.
6.3

Ensure proper environmental conditions / atmospheric conditions before


releasing the job for surface blasting. The % of RH & Dew point temperature
shall be measured once in every 4 hrs of working period and record.

EPCMD-2-QM00-JEP-ME-019 00
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6.4

Whenever atmospheric conditions are not with in the specified limits (that
is>85% of RH or as specified in relevant specification whichever is stringent),
blasting shall not be started or process shall be stopped.

6.5

Blasting material (Grit / abrasive) shall be inspected and record the batch
number, size and verify the manufacturers test certificates (as applicable).

6.6

In case blasting material received is not meeting the specified requirement, it


shall be rejected and kept in quarantine area with proper identification.

6.7

Blasting shall be carried out under acceptable atmospheric conditions, with


correct grit / abrasive particle size. Blasting equipment parameters that is
Pressure, availability of moisture filter, nozzle sizes etc. shall be set as
recommended by the manufacturer.

6.8

The blasted surface shall be cleaned with dry air and measure the surface profile
with profile gauge or press-O-film and record the values. Also measure the salt
contamination once in a shift on the blasted job surface at random, the salt
contamination limit and the surface profile obtained shall be with in the specified
limit.

6.9

Measure and record the thickness of the rusted / pitted structural steel
members if observed any after surface cleaning as per relevant Work
Instructions.

6.10

Carry out the visual inspection on the blasted surface for any physical defects
like, laps / surface laminations, Residual Blast Product Contamination etc. If
observed rectify the defects before application of paint and clean the surface to
the specified limit. Also check and ensure that surface salt contamination of the
cleaned surface is with in acceptable limit.

6.11

In case the thickness of the Rusted / Pitted structural steel members / plates
are not meeting the specification requirement or any material discrepancy
observed after surface cleaning a Material discrepancy report EPCMD- 2-QM00FMT-GE-024 / Non Conformance Report EPCMD-2-QM00-FMT-GE-014 shall be
prepared (as the case may be). Keep the discrepant material in quarantine area
with proper identification.

6.12

Received paint material shall be inspected for formation of lumps etc., record
the batch number, shelf life or expiry date. Expired date of paints shall not be
used unless revalidated by the authorized personnel, in case further these paint
are not useable, record the details of that paint in form EPCMD-2-QM00-FMTME-137 and keep at quarantine area with proper identification.

6.13

Expired shelf life paints shall be stored with proper identification at quarantine
area.

6.14

Before applying the prime coat, check up the job surface temperature,
Atmospheric conditions and time gap between surface blasting and application
of paint. Time gap shall not be more than 4 hrs.

6.15

Properly mix / stir the primer and apply to the blasted surface by acceptable
method. Measure wet film thickness at random during prime coat and record the
value (WFT).

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6.16

After curing do visual inspection, measure DFT and record the values. Repairs if
any shall be recorded and repairs are to be attended with approved paint repair
procedure.

6.17

Adhesion test shall be carried out as per ASTM D 3359-95a (Standard Test
methods for measuring Adhesion by Tape Test) once in every shift and ensure
the integrity of the paint. In case adhesion test fails, further it shall be
conducted on 10% of other items / materials processed in the same shift,
further if any one of these samples fails, then entire lot of that shift has to be
tested individually. The material on which adhesion test failed shall be reblasted and painted.

6.18

Before application of 2nd coat, ensure the dryness of the job surface. Clean the
surface; apply the second coat with approved method within specified intervals
mentioned in the Data sheet.

6.19

Carry out visual inspection after final curing, measure DFT, carryout Adhesion
Test. Repairs if any are to be attended.

6.20

Similarly carryout painting and inspection as above for subsequent coating (as
applicable).

6.22

Release note shall be prepared for coating accepted material before releasing
from Shop.

6.23

Record of various activities shall be maintained and to be retained / handed over


as specified in the contract.

6.24

It should be ensured that the handling & transportation is done with care so that
the paintings are not damaged due to abrasion with slings.

6.25

It should be ensured that no blasted surface left unpainted overnight.

6.26

During application of painting, continuous stirring by electrical stirrer is required


to maintain homogeneous mixture.

6.27

When steel grits are used as blasting medium, it shall be of recommended


shapes, density in line with applicable specification or mixture of various shapes
as per pre-established norms.

6.28

In order to maintain salt contamination within acceptable limits, recycling


periods of grits needs to be established upfront.

EPCMD-2-QM00-JEP-ME-019 00
Confidential Reliance. All rights reserved

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