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Chapter 9

Surface Preparation
Introduction

The objective of surface preparation is to create proper adhesion of a coating over the substrate.
Adhesion is the key to coating effectiveness, and it determines whether the coating is merely a thin
sheet of material lying on the substrate or whether it becomes an actual part of the substrate.

Adhesion becomes an even more critical condition for coatings applied in corrosive areas. Thus,
proper surface preparation is vital to the long life and effectiveness of a coating applied in corrosive
service.

One industry that has been especially concerned with proper adhesion is the automotive industry.

Properly applied coatings should have relatively uniform adhesion over the entire surface. Steel
surfaces are reactive with acids, chlorides, sulfides, and numerous other chemicals. Where these
materials have access to the surface, rapid corrosion results. On the other hand, with the proper
adhesion of coatings over the steel surface and with a smooth, dense, uniform surface, coatings can
prevent these reactive materials from coming in contact with the steel and therefore provide full
protection. Most coating materials are compatible with steel surfaces, which with proper surface
preparation such as abrasive blasting or acid pickling provide a good surface over which to apply
high-performance coatings.

The purpose of surface preparation is to ensure that the maximum bond strength will develop at the
interface between the substrate and the coating. The weakest area across the coating should be
within the adhesive or organic coating layer and not at the interface of the coating and the substrate.
Failure within the coating is referred to as cohesive failure; failure at the interface between the
substrate and the coating is referred to as adhesion failure.

If any failure is to be tolerated, the cohesive-type failure is preferable

The unmodified vinyl chloride acetate resin is a strong polymer. When applied
directly to a substrate, the cohesive strength of the polymer is stronger than its adhesion
to the substrate so that the separation from the substrate is at the interface between the
coating and the substrate. On the other hand, the vinyl chloride acetate resin to which a
small amount of maleic acid has been added and incorporated into the polymer, when
applied to a substrate, has excellent adhesion. In this case, the vinyl coating itself will
break before the bond between the coating and the substrate. This is the type of
adhesion that is essential for coatings used in corrosive areas.
From a surface preparation standpoint, the ideal type of coating failure is 100% cohesive.

Another type of adhesion failure occurs where the substrate itself fails rather than the coating. Such
failure is not uncommon on concrete. Epoxy coatings applied to concrete often will have a greater
tensile strength and cohesion than the concrete.
Types of Adhesion
The type of adhesive bond depends both on the substrate and the coating. The three types of
adhesive bonds are: (1) chemical, (2) polar, and (3) mechanical. The chemical bond, which is created
by a chemical reaction between the coating and the substrate, is undoubtedly the most effective
bond. One example of this type of bond is hot dip galvanizing, where the steel and the zinc metal
amalgamate or dissolve within themselves
Table 9.9: Surface Preparation Results Compiled from Tests Run by NACE Technical
Committee T-6H-15

Table 9.8: Surface Preparation Standards in Descending Order of Effectiveness


Table 9.10: NACE and SSPC Water Jetting Standards

Table 9.11: Summary of Techniques for the Preparation of Steel and Concrete
Surfaces Prior to Coating
Table 9.12: Minimum(A) Surface Preparation Requirements for Steel with Commonly
Used Types of Coating.

Table 9.13: Commonly Used Abrasives

Table 9.14: Comparative Maximum Heights of Profile Obtained with Various Abrasive
in Direct Pressure Blast Cleaning of Mild Steel Plats using 80 psig Air and 5/16 in
Diameter Nozzle.
Table 9.15: Ranking of Bonding Strengths Associated with Four Profile Heights on
White Metal Surfaces

Table 9.16: Ranking of Bonding Strength Associated with Different Abrasives on


White Metal Surfaces

Table 9.17: Relating Level of Cleanliness to Bonding Strength


Table 9.18: Comparative Cleaning Rates of Various Sized Abrasives in Direct Pressure
Blast Cleaning of Flat Plates Using 80 psig Air and 4/16 in Diameter Nozzle

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