1protective Coatings Application Unit 5

Protective Coatings Application
UNIT: 5.1.1
RELATIVE HUMIDITY AND DEW POINT
Protective Coatings Application: UNIT - 5
Objective:
To understand and how to measure relative humidity and dew point, and their effect on coating
application and cure.
Relative humidity and dew point have an effect on surface preparation and coating application.
Relative humidity and dew point have an effect on coating overcoating, cure and long term
performance.
Protective coatings personnel should know the implications of relative humidity and dew point.
Relative Humidity
Relative humidity can be classified as:
'The amount of moisture in the air compared to the maximum amount possible'.
Relative humidity is expressed as a percentage, 1-100%.
Relative humidity varies between different environments.
Some countries have a low relative humidity while others have a constant high relative humidity.
Copyright 2010 Fitz-Coatings Ltd

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Dew Point
Dew point can be described as 'The temperature at which condensation will occur'
This illustration is of a fizzy drink taken from the cold fridge into a warm environment - condensation
occurred and is visible on the tin.
If this process occurred during paint application then coating failure is a high possibility.
Examples of where condensation is a risk include the end of a sunny hot day when the temperature
drops.
Relative Humidity and Dew Point
The paint specification and or the suppliers product data sheets will specify the criteria for relative
humidity and dew point.
Generally a maximum relative humidity is specified at 85-90%.
The steel temperature should be 3 degrees centigrade (5 degrees fahrenheit) above the dew point.
Always read the specification before the products are mixed and used to ensure you are aware of
the criteria on relative humidity and dew point.

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Relative Humidity
Some coatings are sensitive to moisture and humidity while other coatings require moisture to cure.
An example of the latter includes moisture-cured urethanes and inorganic zinc silicates as
demonstrated in this photograph being used as a shop primer.
Always check the coating supplier data sheets for details on the minimum or maximum allowable
relative humidity during application or curing.
A high relative humidity, even after coating application, may have an effect on the cure of a coating.
Amine Bloom on a Coating
This is an illustration of amine bloom on an amine cured epoxy coating.
This bloom was caused by high humidity and moisture during the curing process.
Coating failure is a high risk if you overcoat the surface bloom.
This bloom may be removed, however always seek advice from the coating supplier.

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Checking the Relative Humidity
A whirling hygrometer is an instrument used for checking the relative humidity.
The instruments are very reliable and have been around for a number of years.
The relative humidity and dew point checks can be conducted by the inspector, supervisor or the
applicator if training is conducted correctly.
Electronic version of the equipment are also available.
Assessing the Relative Humidity
Painting Inspectors generally determine the relative humidity and dew point, however the supervisor
or coating applicator is well capable of conducting these checks.
Training can be conducted on:
• How to use a whirling hygrometer.

• How to use the calculation tables etc.
• How to maintain the hygrometer.
• How to document the readings and determine if the preparation or painting can proceed.

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Use of a Whirling Hygrometer
The video used on the website demonstrates the use of a whirling hygrometer by a qualified painting
inspector.
Any trained personnel can use a whirling hygrometer.
There are particular ways to use the whirling hygrometer such as the number of revolutions per
minute etc.
Ensure the readings are not taken in one particular location as you can get micro climates especially
on large structures.
Relative Humidity Equipment
Specialist equipment is available which will automatically calculates the relative humidity and dew
point.
The gauge (dew meter) must be calibrated regularly.
Check the instrument for damage and level of power in the batteries.
This type of equipment may not be allowed in all environments due to the use of the batteries.

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Relative Humidity and Dew Point
Once the wet and dry bulbs have been reviewed and recorded, charts or discs will then be used to
calculate the relative humidity.
With a little practice this process is relatively simple.
The electronic versions are capable of giving all this information without any doing any calculations
Hygrometric Tables
The easiest way to calculate the relative humidity and dew point when using a whirling hygrometer is
with the hygrometric table as illustrated.
You simply record the wet and dry bulbs on the whirling hygrometer and compare these recording
on the table and you will get a relative humidity reading.
Various tables are available for calculating relative humidity and dew point.

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Steel Temperature Gauge
To calculate the dew point you also need to establish the steel temperature.
The steel temperature can be assessed by a digital thermometer or a magnetic steel temperature
gauge as shown.
The digital thermometer may not be allowed in all environments due to the use of batteries.
The disadvantage to the magnetic steel temperature gauge is the time taken while the gauge
stabilises on the surface.
Steel Temperature Gauges
Simple animation comparing the two types of thermometers used to assess the steel temperature.
The animation used on the website illustrates the use of a digital type and magnetic steel
temperature gauge.
The digital gauge is popular as it will give instant readings while the magnetic gauge may take 10-15
minutes.
Whirling Hygrometer Thermometers

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Until recently all whirling hygrometer thermometers held mercury.
Due to Health and Safety concerns other materials such as dyed spirits are used.
Always check the thermometer for damage before using the instrument.
Spare thermometers should be available and stored correctly.
Maintenance of Instruments
Regular maintenance should be conducted on the whirling hygrometer such as cleaning or replacing
the wicks, and ensuring you use clean distilled water.
Check the instrument before every use for wear and tear.
Always store the instrument after use.
Environments
Some environments such as offshore platforms have constant high humidity.
Controls may be required during surface preparation and application of coatings.
Specialist equipment is available for controlling the relative humidity during coating operations.

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Plan the works around the most suitable months and working hours.
Be aware of the different work locations and 'micro climates,. It is possible to have different
environmental conditions in close proximity due to sunlight, heated pipes, steam etc.
Summary
This training unit has reviewed the requirements for relative humidity and dew point specifically
related to protective coatings.
We reviewed the use of a whirling hygrometer and steel temperature gauge along with the electric
dew meter.
We also discussed the calculation charts etc.

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UNIT: 5.1.2
STEEL TEMPERATURE

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Objective:
To understand how to measure and assess steel temperatures and the effect on paint
application
Steel temperature is related to the overall environmental conditions.
Steel temperature is generally specified within the paint specification.
Too high or low steel temperature can effect coating application, drying, cure and performance.
Painting Specifications
Most painting specifications and suppliers product data sheets generally recommend the steel
temperature is a minimum 3 degrees centigrade (5 degrees fahrenheit) above dew point.
The three degrees centigrade is a safety margin as two and a half degrees may be fine if the steel
temperature is rising such as first thing in the morning however if it is late afternoon and the air is
getting cooler the safety margin is more critical.
Dew Point
If coatings are applied when the steel temperature is close to the dew point there is a danger of
condensation and possible coating failure.

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Never take a risk as coating failures are common for such basic ignorance.
Check the dew point before the paint is mixed and applied.
Some coatings are moisture sensitive and the dew point is even more critical with these coatings.
Magnetic Thermometer
The magnetic thermometer is a simple process.
Check for damage before use then:
• Fix thermometer to surface.
• Leave for approx 10-15 minutes.
• Check and record the temperatures.
• Remember where the gauge is placed!
Store the gauge away at the end of every use.
Magnetic Steel Temperature Gauge
The video simply demonstrates how the magnetic steel temperature gauge is used.
The gauge is placed on the substrate and left for approx 10-15 minutes until you achieve a constant
temperature.
Providing the substrate is magnetic the gauge will stick to the surface and there is no need for
batteries which may not be allowed on certain locations.

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Digital Thermometer
Digital thermometers are easy to use.
Prior to use ensure you check for wear, tear, damage and calibration, then:
• Engage probe.
• Press the probe onto surface.
• Hold for 20-30 seconds.
• Record the surface temperature.
• Do not drag probe over surface.
Electronic Steel Temperature Gauge
This is a video of an electronic steel temperature gauge being used on a steel substrate.
The electronic steel temperature gauge will give instant temperature readings compared to the
magnetic steel temperature gauge.
The equipment can be sensitive so never drag the probe over the surface.
As batteries are required in this gauge, they may not be permitted on all work locations.
Steel Temperature Gauges
Simple animation of steel temperature gauges.
The animation used on the website demonstrates the use of a digital and magnetic steel
temperature gauge.
The digital will give instant readings while the magnetic may take 10-15 minutes.
The magnetic gauge is intrinsically safe and robust.

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Steel Temperature Gauge in Operation
The video used on the website demonstrates the use of digital thermometer being used in a painting
environment.
Digital thermometers:
• Simple to operate and use.

• Check calibration ( certificate may be required ).
• Check for wear and tear and damage.
• Do not drag the probe over the surface.
Steelwork
It is important to understand steel can warm and cool when exposed to general environmental
conditions.
During the day the steel will warm up and may retain heat (hotter than air temperature) and cool in
the evening.
Depending on the location of steel and thickness etc the steel temperature may vary on a single
structure.
Conduct a number of steel temperature checks.

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Coating Failure
Applying coatings at too high or too low a steel temperature can lead to coating failures and defects.
Always follow the coating supplier recommendations for guidance on the relative humidity and dew
point criteria.
The criteria for the relative humidity and dew point should be on the product data sheets.
Record all findings for future evidence.
Service Conditions
Coatings should be selected to suit environment and steel temperature.
Some coatings can withstand temperatures above 400

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Summary
This training unit reviewed the requirements on steel temperature specifically for the protective
coatings industry.
The steel temperature is linked with the relative humidity and dew point as the steel temperature
must always be above the dew point.
Coating specification require the steel temperature to be 3oC (37oF) above the dew point.
Both magnetic and electronic gauges or instruments are available to assess the steel temperature.

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UNIT: 5.2.1
BRUSH APPLICATION

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Objective:
To understand how, where and when a brush can be used in the industrial coating industry. To
understand the advantages and disadvantages of brush application
The protective coatings applicator will almost certainly use a brush during coating operations.
The most simple of application tools.
Various types and sizes available.
Used with most coatings for full coatings, stripe coatings etc.
Limited application thickness.
Brush
Paint application by brush is a widely used in various industries.
The process is a simple method of getting paints from a tin or try and applying the coating to a
substrate.
The process has literally been used for hundreds of years.
The coatings have changed dramatically and the types of brushes have changed over the years, but
the overall process remains unchanged.
We will review brush application of coatings in this unit.

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Paint Brushes
A typical brush illustrating handle, ferrule and bristling material.
These brushes are available in various sizes, usually 25 to 150 mm (1 to 6 inches) wide.
Bigger paint brushes are available, however these are impractical to use.
The industry norm for a typical painters brush is 50-75 mm (2-3 inches).
The bristles on the paint brush are used to temporarily hold the paint between the paint container
and the surface to be coated.
Bristles are available in two types of materials:
• Synthetic-nylon, polyester etc
• Animal hairs
The animal hair tends to be used for high quality and decorative work with the synthetic hair being
used for industrial work.

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Paint Brushes
Advantages of Brush Application:
• Works paint into the surface and substrate.
• Minimal equipment costs.
• Relatively easy to use.
• Easy to clean and store.
• Displaces dust and moisture from the surface.
• Good for stripe coating such as edges, welds etc.
• Good for touch-up to painted surfaces.
• No requirement for compressed air, power etc.
Disadvantages of Brush Application:

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• Slow and labour intensive.

• Generally applies thin film thickness. Additional coats may be necessary to build up the
specified thickness.
• Sometimes the finish is not as good as spray application.
Brush Application for additional protection:
Brush application to welds and edges is good painting practice. This process is known as stripe
coating.
Ensure you have correct grade of material for stripe coating.
Plan work activites with stripe coating in mind as you still may have to observe the overcoating times
etc.
Stripe coats are sometimes a different shade to assist with the process.
Brush Application
The video used on the website demonstrates the use of a brush being used for paint application.
The video used on the website also details the application of a stripe coat to welds, bolts and
awkward locations prior to the application of an overall coat by spray method.
If the whole structure was brush painted you would realise how slow and uneconomical the process
can be.
Stripe Coating
This is a simple animation of stripe coating.
The animation used on the website demonstrates the locations where stripe coating should be
applied prior to the overall coating.
If a spray gun cannot coat an area then stripe coating should be conducted.

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Vulnerable locations where paint falls away ie welds and edges should be stripe coated.
Always refer to the paint specfication or guides such as SSPC PA Guide 11 Protecting Edges,
Crevices, and Irregular Steel Surfaces by Stripe Coating.
Paint Brushes
Types of Brushes.
Flat Brush:
• Usually 25-100 mm (1-4 inches) wide.
• Used in volume by general coating operatives.
• 75-100 mm (3-4 inches) most popular for flat surfaces.
• 150 mm (6 inches) are available, however have limited use.
Types of Brushes.
Dogs-Leg:

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• Has a number of names including 'dogs leg' and 'podger'.
• Good tool for inaccessible and hard to reach locations.
• Various lengths are available.

• Not suitable for large or flat locations.
Types of Brushes.
Finch:
Small brushes are used in certain areas:
• Used for small areas i.e. 'cutting in'

• Limited use although there may be circumstances where very fine application is
necessary such as cables and wires etc.
Use of a New Paint Brush
Prior to using a new brush, it is recommended to brush the bristles over your hand to remove any
loose bristles, or wash in detergent and water and allow to dry.

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Loose bristles may come out during the paint application and will have to be removed prior to the
next coat.
The quality of the brush has a big impact on the above.
Paint Brush
Use of a Paint Brush.
Loading the brush comes with practice.
• Dip brush half way into the paint.

• Remove excess paint by tapping the edge of the container.
• Never overload the brush.
• Try and keep tin or paint container close to the work-face.
Paint Brushes
The general role for paint application is a relatively simple process when using a brush:
• Apply the paint in smooth, even strokes.

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• Paint from top to bottom on a surface.
• Apply paint from an unpainted surface onto a painted surface.
• The coating should be spread over the surface holding the brush at an angle of
approximately 45 degrees to the work.
• Do not push down on the brush during application. Pushing hard will produce brush
marks.
The general role for paint application is simple:
• It is recommended to use cross strokes when smoothing the coating, however for the final
stroke try and use brush in one parallel direction.
• Do not brush against an edge. Brushing paint against an edge can result in thin coatings
in an already vulnerable area.
• Take note of the coating being used as some coatings have to be applied fairly quickly
once the coating is in contact with the surface, this is true with fast curing coatings or
rapid evaporating solvents.

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Edge Coating
Try and brush onto an edge as this will help with coating thickness on critical areas.
Do not brush against the edges as you will push or even pull the coatings away from this point.
Additional stripe coating may also be necessary and in many cases specified.
Brush Application - Paint Mixing
Do not mix up too much paint for brush application, especially two-part products.
It will become more difficult to apply two part coatings when the pot life time is being used up.
Older coatings are also difficult to apply by brush application.
Check that the product is brushing grade as spraying grade products will be difficult to apply.

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Brush Application - Pot Life
An illustration of a coated surface with a coating system which was close to exceeding its pot-life.
Poor flow and finish is generally the outcome when paint has exceeded the pot-life.
If thinners or solvents are used, ensure you abide by the manufacturer's product data sheet
recommendations.
Do not add thinners if the product has exceeded pot-life.
Brush Vs Airless Spray Application
This simple animation demonstrates the typical thickness variation you will find when comparing
brush application against airless spray application.
Brush application may only achieve 50-100 microns dry film thickness.
Airless spray can apply coatings at extremely high dry film thickness.
Airless spray will require the operator to be trained in the process.
Film Thickness-Brush Application
The video used on the website demonstrates the use of a brush to apply a coating to a weld seam
repair on a steel structure.
The overall coatings have been applied by airless spray in 3 coats.
Brush application may take up to 6 coats to achieve the same dry film thickness. it is also
considerably slower.
Over application by brush could lead to runs and sags and poor quality finish.

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Brush Application - Grade of Material
Ensure you get the the correct film thickness overall and you have correct grade of material.
It can be difficult to monitor the wet film thickness when applying a coating by brush application.
Poor application will give erratic dry film thickness and edges as demonstrated.
Additional coatings may be required for brush application.
Brush Application - Pitted Steel
A brush is ideal for poorly prepared or pitted surfaces, as the paint is pushed into the surface by the
brush.
The brush pushes the coating into the pits ensuring the paint wets the surface and achieves a good
adhesion.
This process may not be possible, by spray application.
More than one coat may be necessary when applying paint to a rusted or pitted surface.

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Pitted or Rough Substrate.
The animation used on the website simply demonstrates the use of a brush on a pitted surface.
The brush pushes the coating into the substrate assisting with wetting and the subsequent
adhesion.
Certain coatings such as epoxy mastics are specifically formulated for this type of application.
Always check the product data sheets for details on application etc.
Brush Application to a 'Dusty' surface.
Although it is not recommended to apply a coating to a dusty surface, brushing a coating compared
to spray application will help to push away any light dust debris which may settle even after surface
cleaning.
The ideal process is to dust clean and vacuum, if possible.
Spray application may trap this dust leading to adhesion problems.
Brush Application
Brush Maintenance:
If a brush is not cleaned correctly after use, residual paint and coatings will go hard and the brush
will be useless.
Always clean the paint brush after use.
Good paint brushes can last a long time if correctly maintained.
Little maintenance is required so ensure you look after the paint brush.

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Maintenance
Good paint brushes can last a log time if they are looked after.
Old coatings will contaminate new works leaving a bitty and uneven paint film that may have to be
removed.
Always look after the paint brush!
Summary
In this training unit we have reviewed the use of a paint brush to apply coatings.
We have reviewed the design of a paint brush, how to use the brush and advantages and
disadvantages of a paint paint brush.
We also discussed how to look and maintain the brush.

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UNIT: 5.2.2
ROLLER APPLICATION (INC.MITT, TROWEL ETC)

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Objective:
To understand how, where and when a roller can be used for the application of heavy duty
coatings. To understand the advantages and disadvantages of roller application.
The protective coatings applicator will use a roller in their duties.
Common form of coating application for large areas.
Rollers can be used with various coatings.
The process is simple to use.
The equipment is relatively inexpensive.
Roller Application
Paint is applied by roller in various industries.
A roller is an ideal application tool for applying coatings to flat locations.
Simple to use with no power required, the roller is used globally especially for commercial and
decorative products.
This training unit will review the use of paint rollers and give an overview of its uses to the protective
coatings applicator.

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Roller Application
By far the biggest use of rollers is in the decorative market.
Rollers are used by decorators (and house owners) word wide to apply emulsion type coatings to
walls and ceilings.
There are circumstances where the roller is used by the protective coatings applicator for solvent
containing products.
Protective Coatings
Not all coatings can be applied by the use of a roller. Many high performance coatings are
developed for spray application.
The roller will not achieve the specified film thickness and is not compatible with certain high
performance coatings, especially the products with a short pot life or heavily pigmented coatings.
Always check the paint specification or product data sheets.

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Roller Head and Cover
A typical industrial type roller illustrating handle and roller head or cover.
The roller head is usually 23mm to 50mm (1-2 inches) in diameter and varies in length, however an
average roller size is 230mm (9 inches).
The quality can vary tremendously between suppliers of the roller and associated equipment.
Ensure you purchase the equipment from reputable suppliers.
Roller Head
The roller head or cover slides over the roller mechanism and can be left there and cleaned in-situ
until a new roller head is required.
The roller head can last a long time provided they are not abused and stored correctly.
Paint trays are generally manufactured to match the size of the roller head.

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Radiator Head
Small 'radiator' rollers are also available and widely used. These are approximately 25mm (1'') in
diameter and 100mm (4'') long.
The life of these rollers tends to be limited and it is not always economical to clean.
The name comes from the fact that the decorator can get behind the small gap in between the wall
and the radiator in domestic houses.
Radiator rollers are commonly found in the protective coatings industry.
Paint Rollers
Various types of roller material are available and these include:
• Nylon.
• Lambs Wool.
• Mohair.

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• Plastic Foam.
There are also various pile length to suit the coating and substrate to be coated.
If possible, conduct trial with a number of roller types to find the best type of material to suit material
and finish.
Roller Fibre Length
The fibre length is called the NAP.
Use a thick NAP on pitted or uneven surfaces.
Use a thin NAP where appearance is important.
Whichever NAP is used, a textured finish to some degree is usually found with roller application.
Roller Application
Demonstration with the use of a small roller.
Larger rollers are available and more economical however the bigger rollers can be too big unless
you have a flat surface.
There is always a risk of spreading paint with a roller and you have to monitor the wet film thickness.
Can spread paint to a low film thickness. Not allowed on some contracts.

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Roller Application
Advantages of roller application:
• Roller application is faster than brush application.
• The roller head is available in various fabrics allowing the roller to be used with most paint
materials.
• Extension poles allow the painter to apply coatings to various heights without scaffold etc.
• The roller is very easy to use.
Disadvantages of roller application:
• Although faster than brush application, roller application is still more labour extensive
compared to spray application.
• Unless you have a completely flat surface an element of stripe coating will be required
especially to edges.

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• Roller application may not penetrate the paint coating into a rough or pitted surface.
• Roller application tends to spread paint on the surface, and an uneven coating is
possible.
• Roller application may tempt an applicator to spread out a coating to give a greater
spreading rate, but this practice will result in a low film thickness.
Roller Application Vs Spray Application
Dry film thickness:
The use of rollers to apply a coating will result in a thinner dry film compared to spray application.
The dry film thickness with roller application can be as low as 50 microns with certain coatings, while
airless spray can apply a much greater thickness. High solids and high performance coatings are
normally spray applied.
Additional coats may have to be applied to meet the desired dry film thickness while applying
coatings by roller application.
Roller Application
Roller application is faster and more economical than brush application, however 'cutting-in' will still
be required to awkward areas where the roller will not achieve a uniform coating.
Not all coatings can be applied by roller.
Ensure you check the painting specification and product data sheets.
The work location will have to be evaluated to establish if a roller can be used and what size and
type of roller material.

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Pre-Cleaning a Roller
Washing the roller in fresh water will prevent the roller fabric material coming loose and getting stuck
in the paint coating. It is therefore generally recommended to wash a roller before it's first use,
especially with decorative products.
Solvent cleaning may also be conducted, however be aware of the Health and Safety implications.
Certain rollers do not need pre-cleaned and can be used as delivered.
Check with the suppliers for recommendations on pre-cleaning etc.
With the exception of decorative use, most roller heads are, however disposed of after use.
Paint Roller
Use of a Roller Tray:
Try and load the roller with paint uniformly ensuring all the roller fabric is coated.
Push the roller back and forth on the tray until an even loading is achieved.
Do not overload roller or paint will drip from the fabric.

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Roller trays are available in aluminium and plastic.
Basic application:
• Place the roller on the surface to be coated.
• Spread the coating liquid on the roller and over the surface by forming a 'W' or 'V' about a
metre wide and apply pressure back and forth until an even coating is applied.
• Do not press too hard on a roller as this may cause foaming by entrapping air.
Roller Application
Although the roller is used for light industrial coatings such as topcoats, the main day to day use is
with decorative coatings.
Decorative coatings world wide are applied to the internal and external of buildings with the use of
the roller.
Decorative coatings have been formulated to ensure a good quality finish is achieved with the use of
traditional rollers.

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Power Roller
Paint can be fed directly to the roller by the use of special equipment.
This process called, a power fed roller, can speed up the application process and gives a more even
coating.
Check with the suppliers of the equipment as this process may only be available for water based
products or decorative products.
Paint Rollers
Use of Paint Rollers:
If rollers are not cleaned correctly after use, residue paint and coatings will set and the roller will be
useless.
Always clean the roller after use, otherwise dispose of the roller head.
Depending upon the type of coating and quality of the roller sometimes it is more economical to
dispose of the roller after every shift.
It may be virtually impossible to clean certain paints from rollers, especially with fast drying products.

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Roller Head Cleaning
If the roller is used for emulsion type coatings, the head may simply be cleaned by using clean water
immediately after application.
There are however some solvent based two part coatings that will not be cleaned with water after
use.
Check the product data sheets for exact details on roller head cleaning.
Mitt Glove
It is possible to apply certain coating with the use of a paint mitt.
If a painter is working at height etc the mitt can make things easier to apply coatings rather than
carry a brush or roller.
Can be useful for stains or varnishes to awkward structures such as wooden fences, rails etc.
The product is generally made from a high density polyester. There is a possibility that some of the
mitt material will get transferred onto the painted surface leaving a undesirable finish
It is recommended that a protective glove is used below in case the paint gets through the mitt.

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A test piece is recommended.
Trowel and Squeegee
Certain high solids coatings can be applied by trowel.
These coating are generally applied in millimeters of thickness to flat areas and typically concrete
surfaces.
The manufacturers application details must be closely observed with regards to mixing and
thickness etc.
A squeegee is often used to apply coatings to flat concrete floors as illustrated.
As with the trowel application, ensure you have the right kind of equipment and comply with the
product data sheets.
Summary
Within this training unit we have reviewed the use of paint application by the use of a roller.
Roller application is predominately used for emulsion type coatings and light commercial coatings,
however some protective coatings can be applied by the roller.

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We reviewed the use of a roller, the cleaning of a roller and general care and maintenance.
We also discussed the use of a paint mitt and trowel.

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UNIT: 5.2.3
AIRLESS SPRAY (INTRODUCTION)

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Objective:
To give the protective coating applicator an appreciation
of airless spray painting and its use for the application of industrial coatings.
One of the most common forms of coating application.
Must be conducted by trained operatives.
Ideal for factory and site application.
Capable of large volume application.Prior to conducting any spray painting the
protective coatings applicator must successfully complete the spray painting
training units.
Airless Spray Application
The protective coatings applicator will come into contact with airless spray painting either:
• As an airless spray painter on completion of training.
• As an assistant to airless spray painter by mixing paint, moving equipment, cleaning etc.
• Working on general protective coating applicator duties such as stripe coating, masking
etc.

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Airless Spray Painting
Airless spray painting is particularly suitable for anti-corrosive and high performance coatings
applied to large structures such as ships, bridges, tanks etc.
This illustration demonstrates a coating applicator applying a high build coating to structural
steelwork.
Airless spray is by far the most popular form of coating application for heavy duty industries.
Airless Spray Painting Equipment
This is an illustration of the full airless spray equipment.
Compressed air is delivered from the compressor to the airless spray unit.
The mixed paint is pumped through the airless spray and down the paint line, through the spray gun
and out of the tip where the paint is atomized and applied onto the prepared substrate.
Due to the volume of paint used the spray painter has to take additional PPE and RPE, typically full
spray mask compared to brush or roller applicator.

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Airless Spray Equipment
Due to the high pressures, volume of paint and aggressive nature of some paint ingredients such as
glass flake, the tips are made from very resilient metal such as tungsten and are changed regularly.
Check the suppliers instruction manual for advice on tip cleaning and changing requirements.
Only use genuine parts when changing the tip or conducting general maintenance.
Airless Spray Unit in Operation:
• Illustration of typical site airless spray unit.

• 65:1 ratio size. Bigger sizes available.
• The units are mobile.
• The units are robust.
• The units are powered by compressed air or electric.
Airless Spray Gun
The animation used on the website demonstrates the use of an airless spray gun.
The paint, coloured in red, is forced through the gun at high pressure and through the tip where it is

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atomised and pushed onto the surface.
Although the process is called airless, the process requires compressed air to work the equipment.
Electric type airless spray equipment are also available.
Airless Spray Equipment
Typical airless spray unit:
• Ideal for in shop applications.
• Only requires compressed air although electric powered units are available.
• Pressure ratio sizes are available from 5:1 to 68:1.
• Specialised units can have a higher pressure ratio.
Electric Airless Spray Equipment
This is an example of electric airless spray equipment.

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Once used for decorative coatings and light duty commercial coatings, electric airless now have the
capability of applying high performance coatings.
Obviously power is a requirement.
Airless Spray Application
The video used on the website demonstrates the use of airless spray equipment being used on a
steel structure.
The process is effective and efficient.
Airless spray is a widely used process for applying coatings, especially high build coatings.
Most large contracts use airless spray for application of coatings.
Airless Spray Motor Ratio
What Does Ratio Mean?
If a pump has a ratio of 10:1, it means that the surface area of the air motor piston is 10 x greater
than the paint piston surface area.
So, if you put 6.8 bar (100psi) air pressure onto the air motor, the resultant paint pressure will be 10
x greater i.e. 6.8 bar (100 psi) air x 10 = 68 bar (1000 psi) paint pressure
Airless Spray
Advantages of airless spray include:
• High capacity output.
• Low paint loss - if the equipment is used correctly.
• Negligible paint fog.

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• Excellent coverage in awkward places.
• High-viscous materials can be sprayed easily.
• Thick coats easily applied in single pass.
• Mobile unit. Only compressed air or electric power required.
• Robust.
Disadvantages of airless spray:
• Airless spray can produce a rough finish compared to other types of spray such as
conventional spray.
• There will be an initial cost of equipment and spare parts.

• Some form of power is required such as compressed air or electricity.
• A level of skill is necessary and training is required.
The one big advantage of airless spraying compared to other forms of coating application is the
speed that the coating can be applied, especially on flat locations.
The video used on the website demonstrates the application of a high performance, high solids
coating applied at over 400 microns (16 mil) in one application.
The personnel must be trained in this process.

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Airless Spray Application Equipment
Illustration of airless spray application of high performance coatings to steel structure.
High solids, up to 100%, can be easily applied in large volumes.
No other spray method can achieve the same output as airless spray.
Airless spray is a more effective method of spray application than the air spray type methods of
application, especially over large areas as illustrated.
Airless Spray
Safety First Pressurised Equipment - Beware!
Never :
• Put you hand or fingers in front of the gun.

• Point the gun at your body, or at anyone else.
• Tamper with spray equipment.
While there is paint in the equipment or in the paint line the equipment will be under pressure.

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Skin and Body Damage
Air or electric is used to work the equipment which pressurizes the paint in the equipment, paint line
and gun.
If you have your body to close to the tip, the pressurized paint can easily penetrate your skin and
lead to possible amputation.
Never tamper with airless spray equipment.
Airless Spray
Safety First.
Before Turning ON pump:
• Always follow the manufacturers recommendations on maximum pressures and operating

instructions.
• Always lock the gun trigger in OFF position and check all connections.
• Read the manufacturers instructions.
Ensure the operative is fully trained.

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Airless Spray
Safety!
Before removing any part of equipment including the gun and tip, ensure you:
• Shut off pump. Read the instructions.

• Discharge contents of gun.
• Lock the gun trigger in off position.
Ensure there is no pressure in the paint line or equipment.
If in doubt - Ask your Supervisor!
Airless Spray Painting
Learning how to hold the spray gun and apply even coats is only part of the spray painting training.
The training involves the equipment, maintenance, removing parts, cleaning, set-up and off course
using the equipment.

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Summary
Spray painting can be a dangerous task to untrained personnel.
Coatings are applied under high pressures and can easily penetrate human skin, and in some
instances this can lead to amputation.
Do not use airless spray equipment unless trained.
This training unit was an introduction to airless spray.
The protective coatings applicator may assist the qualified spray painter and therefore have an
understanding of the process.
We reviewed the principals of airless spray, types of equipment, advantages and disadvantages and
health and safety implications.

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UNIT: 5.2.4
AIR ASSISTED SPRAY (INTRODUCTION)

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Objective:
The objective of this training segment is to give the protective coating applicator an appreciation
of air assisted including conventional and HVLP spray painting and its use within the industrial
coatings.
Air assisted spray painting is a common method of coating application, especially factory
applied coatings.
Air is required to assist coating application.
Air assisted spray painting is restricted to selective coatings.
Air assisted spray painting generally applies thinner coats as opposed to airless spray.
Air Assisted Spray
The use of air assisted spray equipment was used exclusively in the motor vehicle refinishing where
it gained its initial popularity. Now it is used in most paint industries.
• High Pressure Low Volume Spray (HPLV) Conventional Spray - Low Pressure is used.
• Air assisted spraying is a completely different process from airless spray equipment.
• Considerable differences in pressures are used between the two processes.
• Air assisted is not generally used for high solids or high performance paints.
Air Assisted Spray Painting
The video used on the website demonstrates a high quality finish coating being applied by a air
assisted spray unit.
The sprayer is using a suction feed spray gun which holds very little paint and would be impractical
for large volume works.
The coating used are relatively low in volume solids and a thin coating is usually applied.

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Advantages of Air Assisted Spray (Conventional Air Spray)
• Conventional air spray has a fine atomisation and quality of finish.

• Good operator control.
• Low capital cost.
• very good for certain coatings.
• Easy to change coloured paints which use small volumes of paint.
Some products are specifically developed for application with conventional spray.
Always check the product data sheets for details on paint application recommendations.
HVLP Equipment
High volume low pressure equipment still uses air to transfer the coatings onto the substrate,
however the pressures are much lower than traditional air assisted or conventional spray equipment.
This equipment has an increased transfer efficiency as more paint is delivered to the surface being
coated.

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Air Assisted Spray Equipment
Three basic methods are used to feed the gun:
• Gravity Feed - bottom left.
• Pressure Feed - top centre.
• Suction Feed - bottom right.
The basic spray application process is the same with all feeds. The paint is sent to the cap of the
gun and mixed with compressed air where it is atomised and applied to a substrate.
Conventional Air Gun
A three dimensional 3D view of a conventional spray gun illustrating air cap, fluid needle, air and
paint inlet areas.
This type of gun has more parts that airless spray gun.
Conventional spray painting equipment is used for factory facilities such as automotive, furniture,
small parts and substrates where a quality finish is required.

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Suction-Feed Gun:
The gun is fitted with a cup which usually contains 1-2 litres of paint.
When the trigger is pulled, suction is developed at the top of the gun, drawing fluid at the cap and up
to the nozzle where it is sprayed.
This process is generally used for low volume work.
Suction-feed equipment is ideal for small volume work especially where a quality finish is required.
Conventional Spray Equipment
Simple animation of conventional spray equipment.
• Suction feed demonstration where the paint is sucked up into the gun.
• The paint, illustrated as red in colour, is held in the pot.
• The paint and air is mixed at the cap.
• The paint is atomised with the air during application.
Pressure Feed Gun

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The paint is applied under pressure from a pressure feed tank.
This pressure allows faster application and the use of more viscous materials than suction or gravity
spray methods.
Illustration of a small pressure tank, line and gun.
Larger pressure tanks are available to suit the type of contract.
Pressure Feed Gun and Pot
The animation used on the website demonstrates the use of a large pressure feed spray pot that is
used for spray painting large type structures.
The equipment is bigger than a suction feed process and can hold considerable more paint in the
pot.
Some units also have mixers built into the pot so heavy materials can be mixed on a continuous
basis.
Gravity-Feed Gun:
Paint materials is put into the pot which allows paint to be gravity fed into the gun.
A small pot is used, so this process is not generally used for large volume work.
This process can, with the right tip and paint holder, be useful for non-slip coatings to decks etc.
The process is similar to suction feed in respect of low volume work etc.
Personnel Protection - Masks
There are a large selection of of masks available to the spray operative and assistants.
Check the risk and COSHH assessments for the recommended mask to be used during coating
application.

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It is essential that the spray operatives understand the type of masks to be used and that the RPE is
available.
The equipment must be in good working order and maintained regularly.
Conventional Spray Application
• Video demonstrating a the application of a heavy duty industrial coatings to steel.

• The process is considerably slower than airless spray.
• The process does create overspray due to the mixture of coating and air as the paint is
atomised for application.
Note: The stripe coating to welds and edges.
Coating Application
Air assisted spray.
The protective coating applicator may assist the spray painter, however full training is necessary
before the protective coatings applicator or general operative can us the equipment.
Remember - Never tamper with equipment!
Air Assisted Airless
We have discussed conventional air spray and airless spray.
There is also an addition type of application equipment which is a combination of both.
Air assisted airless is used for certain products were a high quality finish is required.
As with other spray methods, full instructions with accompany the equipment with regards to health
and safety as well as maintenance and general use.

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Summary
This training unit reviewed the use of air assisted spray equipment.
We reviewed the different types of equipment used including suction feed, gravity feed and pressure
feed types.
We discussed the advantages of air assisted spray equipment compared to airless spray equipment.
We also discussed the safety requirements for the spray operator.

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UNIT: 5.3.1
WET FILM THICKNESS

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Objective:
To measure the wet film thickness of an applied coating. With a knowledge of the target dry film
thickness and the volume solids of the paint, the applicator can calculate the required wet film
thickness at which the paint must be applied.
The protective coatings applicator should be able to calculate the wet film thickness of most
applied coatings.
Most coatings have a different wet film thickness from the dry film thickness.
Film thickness at applied stage can not be calculated without knowing the required wet, and
ultimately, the dry film thickness.
The calculation and process is a simple method.
Wet Film Thickness
To establish the wet film thickness you must assess the volume solids of the coating.
You must also establish the specified dry film thickness.
The volume solids information will be found on the product data sheets.
The information on the required dry film thickness can be found on the suppliers application product
data sheets or within the painting specification.

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Paint Volume Solids
The volume solids are expressed as a percentage, usually between 10 to 100%.
Some suppliers recommend both the wet and dry film thickness in their literature.
Contract specifications may vary from the recommendations on the supplier's product data sheets.
Always check both documents.
Ensure you understand what the volume solids means as this is important in understanding both the
wet and dry film thickness.
Product Data Sheets
Product data sheets will be available for all coating materials and the applicator should have the
latest revision of the product data sheets at hand.
These data sheets will detail the volume solids of the coating and generally recommend the wet and
dry film thickness of the specific product.

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Volatile and Non-Volatile Contents
Paints contain volatile and non-volatile components.
Once applied, the volatile components i.e. solvents and diluents will evaporate.
The non-volatile component i.e. binder will remain on the surface.
You must understand the difference between non-volatile and volatile to understand how to
calculate the wet and dry film thickness.
Note: The above is theoretical only and does not consider practical wastage.
Paint Drying
This simple animation demonstrates the liquid paint application to a solid surface.
The solvents or volatile component of the paint evaporate leaving a solid film or the non-volatile
component of the paint.
The rate of evaporation will depend upon the type of solvents along with temperatures and air flow.
Volume Solids
This is a cross sectional view of a coating applied by spray equipment that has a volume solids of
50%.
50% of the coating evaporates and 50% remains on the surface.
The above is theoretical and does not account for general paint loss such as mixing, over spray,
rough and porous surfaces, poor application etc.

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Dry Film Thickness
You have to establish the dry film thickness before you calculate the wet film thickness.
The dry film thickness can be found in the painting specification or suppliers product data sheet.
Also check the thickness criteria ie minimal, average film thickness or a specific standard such as
the SSPC-PA 2.
If there is no dry film thickness specified in the contract use the product data sheets for information.
Wet Film Calculation
The common form of assessing the wet film thickness is with a wet film comb.
Other instruments such as wet film thickness wheels are also used although there use in protective
coating application is limited.
All applicators should understand how a wet film comb works.
All applicators should use a wet film comb during coating application.

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Wet Film Combs
Wet film combs are available in plastic disposable types and a reusable metal type comb.
If the comb is cleaned correctly it can last a long time.
Clean the wet film comb immediately after use before the paint dries between the teeth.
The plastic combs must be disposed of after every use as the paint and solvent can melt the comb.
Wet Film Comb in Operation
The animation used on the website demonstrates how a wet film comb is used on a newly applied
painted surface.
The wet comb must be used immediately after paint application. This is essential on a multi-coat
system where the new coating can soften the previous coat.
All applicators should have a wet comb in their possession and be capable of using a wet film comb
during coating application.
Wet Film Thickness
The Formula:

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Wet Film Thickness: (WFT) Dry Film Thickness: (DFT) Volume Solids (%): (VS)
WFT = 100 x DFT
Example 1:
In order to achieve a DFT of 90 microns (3.6 mil) using a paint with 60% Volume Solids we would
calculate:
WFT = 100 x DFT
Example 2:
In order to achieve a DFT of 120 microns (4.8 mil) using a paint with 75% Volume Solids we would
calculate:
WFT = 100 x DFT

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The Formula:
Of course, volume solids will change with the addition of the non-solid thinners or solvents.
We must then re-evaluate the volume solids before we calculate the wet film thickness.
It is not uncommon for the applicator to add thinners or solvents to a coating and do not consider the
change in volume solids.
Always seek advice about the use of solvents and thinners from the paint supplier.
Wet Film Thickness
The Formula for recalculating the volume solids after thinning the paint.
Volume of Paint: (VolP) Old Volume Solids(%): (oldVolS%) Volume of Thinners (%): (VolT) New
Volume Solids (%): (newVolS%)
newVolS% = VolP x oldVolS%
Example 3:
Say we add 0.5 litres of thinner to every 5 litres of paint with a volume solids of 60% calculate the
new Volume Solids:

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newVolS% = VolP x oldVolS%
Coating Application
The coatings applicator, specifically the spray painter should use wet film combs as a matter of
course.
By using a wet film comb on a continuous basis the coating will be applied at a consistent film
thickness and there should be less paint wastage and less re-work (applying additional thickness)
Film Deficiencies and Contaminants
The coating applicator should also be aware of film deficiencies and contaminants while monitoring
the coating application.
The correct type of application equipment should be used. The applied coating should go on as a
uniform film without sags, runs or other visual deficiencies. The coating should be free from brush
hair, roller fluff etc.
If the coating is bubbling or separating spot work immediately. The wrong (or too much) solvent may
be used or the wrong curing agent has been added.
Also stop work if you see cissing or fish eyes on the coating as these will show immediately if the
surface is contaminated.

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Summary
Within this training unit we have reviewed the wet film thickness of applied coatings.
We have reviewed the requirement to determine the volume solids of a coating from the product
data sheets and the formula to establish the wet film thickness.
We also discussed how the volume solids change when thinners or solvents are added.

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UNIT: 5.3.2
DRY FILM THICKNESS

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Objective:
To measure the dry film thickness of applied coatings by non-destructive testing methods.
Only method of dry film thickness that can be obtained without destroying the dried film.
There is a direct correlation between the wet film thickness and dry film thickness.
Tests are usually conducted by Supervisors, QC or Managers.
Dry film thickness assessment is a simple test method but procedures do differ.
Dry Film Thickness
With the exception of a few items such as inadequate surface preparation, one of the most common
occurrences of a coating system not achieving its predicted life is inadequate dry film thickness.
Many coating systems applied to steelwork have a design life of say 10,15,20 years etc and
providing the initial application and adhesion was correct then the coating should achieve the
predicted life, however the dry film thickness has to be correct.
We will review dry film thickness in this training unit.
The dry film thickness should be detailed within the painting or coating specification or suppliers
product data sheets.

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It is important to determine criteria for dry film thickness:
Examples include -
• Minimum
• Average - Nominal
• Maximum
Specific standards may also be specified.
SSPC-PA 2 PROCEDURE FOR DETERMINING CONFORMANCE TO DRY COATING

THICKNESS REQUIREMENTS
This document is widely specified as a method of determining the dry film thickness.
The standard was developed by SSPC, the Society for Protective Coatings.
The standard looks at;
Type 1 Gauges: Magnetic pull off DFT gauges
Type 2 Guages: Electronic DFT gauges
The standard have been updated over the years and is trying to align with other International
Standards.

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Dry Film Thickness Gauge
The most common types gauges consist of:
• Magnetic pull off (banana gauge)
This gauge has no batteries so can be used in all locations.
• Electro-Magnetic (digital or analogue)
Batteries are required in this gauge, however the gauge is very fast and efficient and very accurate.
Type 1 Magnetic Gauge
The video used on the website is a demonstration of a type 1 magnetic dry film thickness gauge.
The first part of the video demonstrates the calibration of the gauge and the second part the gauge
is being used on a steel structure.
This gauge has a few quick guidelines on use:
• The surface must be magnetic

• The coating must be hard enough to withstand the magnet pressing onto the surface
• The dry film thickness readings must not be taken within 25mm (1 inch) away from an
edge, weld etc.
• There should be no magnetic particles near the gauge or within the coating.
Magnetic Dry Film Thickness Gauge
This cross sectional animation is a magnetic dry film thickness gauge under calibration (verification)
which should be done on a regular basis throughout the shift.
The surface must be 'Magnetic' such as steel.

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To calibrate with a shim, simply push the dial forward until the magnet spring connects to the
surface and slowly bring the dial back until the magnet pops up and read the measurement on the
dial.
When using this gauge you have to ensure there are no magnetic particles on or in the coatings,
otherwise you will get inaccurate readings.
The substrate should not be vibrating also as the magnet may be pushed of the surface, again
giving inaccurate readings.
Dry Film Thickness Gauge
The animation used on the website is a demonstration of a dry film thickness gauge being used on a
coated steel substrate.
The process works on the basis of electromagnetic induction.
Use of the equipment is straightforward for trained operatives.
The specification must be reviewed before use to establish the test method to be used.
Various types and sizes of gauges are available.
Some gauges simply detail the dry film thickness per reading while others are very sophisticated.
The video used on the website demonstrates the simple use of a digital dry film thickness gauge on
a painted steel structure.
The dry film thickness gauge will give instant readings which are viewed on the screen of the
instrument.
Always check the dry film thickness criteria ie minimum, average, SSPC standard procedure etc and
the amount of readings required.
Dry Film Thickness
Surface Coating:
You have to ensure that the coating system is dry or cured sufficiently to conduct dry film thickness
otherwise the gauge will deform the coating giving a false reading.
A 'thumb' test is the best method of testing if the coating can be tested for dry film thickness.
Simple test method:
Push your thumb into the surface and if there is no deformation then the checks are ready.

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Dry Film Thickness
Soft Coating:
If the coating is not hard enough the probe will sink into the coating and give a false reading as
illustrated in The animation used on the website.
You could use a shim over the surface, if the coating is not too soft, and deduct the thickness of the
shim from the final thickness.
The best method is to ensure the coating is dry and hard enough to withstand a dry film thickness
test.
Some dry film thickness gauges are very sophisticated.
The dry film thickness can be downloaded to a computer which can calculate the minimum, nominal,
average etc.
Some suppliers have built in software to compare to the specific standards such as SSPC and
PSPC standards.
The dry film thickness gauges can calculate thousands of readings and these can be transferred to
the inspection reports.
Abrasive Blast Cleaning
Surface Profile:
The blast profile should be considered when taking dry film thickness.
The dry film thickness gauge will have to be verified on a similar substrate unless otherwise
specified.
The above is more important when checking thin coatings.
Some standards detail the verification of a dry film thickness gauge on the existing surface profile.

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Dry Film Thickness - Surface Profile
Illustration of a cross-sectional view of a surface profile and coating applied.
As the probe moves over the coating the readings may vary due to the variation in surface profile.
Check the paint specification for any surface profile corrections.
The paint specification may advise on the surface profile implications on calibration etc.
Dry Film Thickness
Calibration and verification of the Equipment
Some painting specification require verification on a smooth plate while others specify a blast
cleaned surface.
An example is ISO 19840 which specifies calibration on a smooth plate then adjust readings for
surface roughness.
Always check the painting specification prior to conducting the dry film thickness.
Although the term calibrate is used, the only party that can perform a calibration is the manufacturer
or an approved laboratory.
The user verifies the accuracy of the gauge prior to and after each period of use.

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Non-Electrical Dry Film Thickness Gauge
This is an illustration of a magnetic type banana pull off gauge non-electrical mechanically operated
gauge.
No batteries are required for this gauge to operate, so it can be used in all locations safely.
The gauge is for ferrous surfaces only.
The gauge is quite simple to use.
The gauge is categorized as as type 1 gauge in SSPC-PA 2
The gauge is considerably slower to use than an electrical digital dry film thickness gauge which can
take a number of readings vey quickly.
Magnetic Dry Film Thickness Gauge
The magnetic pull off gauge is used extensively in high risk areas such as oil and gas rigs and
petrochemical areas where electrical equipment may not be permitted.
Check the site rules and regulations. If in doubt ask somebody who is aware of the regulations.
A permit to work may be necessary for using this type of equipment.

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If in doubt, ask!
Digital Electro Magnetic Dry Film Thickness Gauge
This is an illustration of a digital electro magnetic gauge.
The process can be a simple measure and read or sophisticated calculations.
Capable of storing a great number of film thickness readings.
Various ranges are available from 0-1000 microns (40 mil) and some up to 20 millimetres (800 mil)
or even more.
The gauge is categorized as as type 2 gauge in SSPC-PA 2
Verification of the Dry Film Thickness Gauge
Calibration (verification) shims are supplied by the manufacturer of the gauge.
The different colours relate to the different thickness.
When you verify a gauge, use the shim with a thickness close to that you intend to measure.
Check that the shims or foil has a calibration certificate or can be traced to a known calibration

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system.
Also check the painting specification for specific calibration procedures.
Although the term calibrate is generally used the only party that can perform a calibration is the
manufacturer or an approved laboratory.
The user verifies the accuracy of the gauge prior to and after each period of use.
Refer to specific standards for the calibration procedure such as SSPC-PA2.
Dry Film Thickness Gauges
Equipment Maintenance:
The equipment can be sensitive to damage.
Try and look after the equipment
• Keep the equipment clean.
• Keep the equipment in a protective case when not in use.
• Change the batteries regularly.
• Maintain the equipment as per the manufacturer's instructions.

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Dry Film Thickness Gauges
General Guidelines:
• Read the manufacturers instruction manual.
• Look after the equipment.
• Do not drag the probe over the surface.
• Try to avoid taking readings within 12mm (1/2'') from edges, holes or similar locations on
the steelwork.
• Take dry film thickness readings as per specification or coating supplier

recommendations.
Check the Painting Specification
'Not too thick!'
Try and ensure coatings are applied to the recommendations of the coating supplier.

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Over thickness can create problems as well as under thickness, although these may not be seen
immediately.
Over thickness can cause stress etc in the coating and cause adhesion problems later.
Always seek advice on coating thickness.
Summary
Within this training unit we have reviewed the use of dry film thickness gauges used in the protective
coatings industry.
We reviewed some specific standards such as SSPC PA2 and the type 1 and type 2 type gauges.
We also reviewed some of practicalities with the use of both gauges.

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UNIT: 5.3.3
DRYING AND RECOATING (INC, CURE)

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Objective:
To understand the drying and recoating process of industrial coatings.
All coatings have some sort of a drying process.
The drying and recoating times are different.
The drying and recoating times will be defined on the product data sheets.
The drying and recoating periods are effected by temperature and environmental conditions.
Drying and Recoating
Paint Materials:
When paint is delivered to the user it should be ready for use and no thinners or solvents are
required for general application. There are generally two main grades of paint:
• Brushing grade (b)
• Spraying grade (s)
Ensure you order the correct grade of coating material for the job.
Quarantine any material if the wrong grade of paint is delivered.

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Drying Period
The coating drying period can be generally defined as:
• The solvent has evaporated from the coating.
• The curing by oxidation or chemical reaction is taking place.
Do not confuse the drying period with cure or overcoating period or time.
Note: There are different levels of drying.
Cure
You may see the term cure, cured, curing time etc on the product data sheets.
Cured is the description of a coating that has reached its maximum potential or resistance after the
initial drying and can be put into service.
This term is essential when using a tank lining for example and the coating must be cured before it
can go into service.
Do not get confused with drying and curing.

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Curing of a typical coating may be up to seven days at a specific temperature. Both the drying and
curing time will need to be extended at low temperatures.
Some coatings will stop curing at a specific low temperature ie 10 degrees centigrade (50 degrees
fahrenheit).
Drying and Recoating
Temperature and Drying Time:
There are various factors which effect drying of a coating.
Normally the higher the temperature the shorter the drying period.
This drying period will also be effected by the thickness of the coating.
The drying time and temperature correlation should be found on the product application data sheets.
Paint Drying
The animation used on the website demonstrates how paint dries after it is applied to a solid
substrate.
The solvents or volatile contents evaporate leaving a solid film or non-volatile contents of the paint
to dry and cure.
The speed of evaporation depends upon the type of coating and solvent also the temperature and
airflow.
Paint Drying - Air Movement
Animation demonstrating paint application and drying.
Air movement can have a big effect on paint drying and is usually recommended.
Once the coating has been applied, good airflow is essential.

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Warm airflow may also assist the drying, however do not force heat unless this is recommended and
approved by the supplier.
Dry Film Thickness on Paints
Factors which effect correct dry film thickness of a coating:
If the coating has not dried through it will be difficult to obtain the correct dry film thickness as the
probe will sink into the coating.
This is especially true with thicker coatings and coatings which dry solely by solvent evaporation.
As previously discussed the air flow issue is important.
Dry Film Thickness
The animation used on the website demonstrates the use of a dry film thickness probe being used
on a soft coating.
If the coating is not hard enough the probe will give inaccurate readings.
Use of a shim between the probe and coating may assist the process. The overall dry film thickness
minus the shim thickness will give the correct dry film thickness. This task should only be conducted
by qualified or experienced personnel who fully understand the process.
Application Data Sheets
Suppliers product data sheets should give guidance on:
• Hard dry.
• Overcoating time.
• Full cure.

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The above information will also be closely linked with the temperature ie hard dry after 6 hrs at 20
degrees Centigrade (68 degrees Fahrenheit) etc
If in doubt, contact the coating supplier for technical advice.
Heating
It is possible to apply additional heating to speed up the drying and reduce the over coating time for
the next coat.
You must be very careful with this process.
1. The heating must be consistent over the entire structure

2. Force heating may trap solvent as the outer skin of the paint may dry first so solvents can
not be removed
3. You could introduce stresses to a coating by increasing the heat and reducing the
overcoating time.
Always seek advice from the coating suppliers.
Overcoating Periods
The overcoating time is also very dependent upon temperature.
e.g.. An epoxy coating with an overcoating time of say 6 hours at 30

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Applicator or User
The user of a product must be aware of:
• The minimum overcoating time.
• The maximum overcoating time.
Ignorance to the above will lead to coating failure.
Overcoating to soon This could lead to solvent entrapment and blistering.
Overcoating to late This could lead to adhesion problems and flaking.
As always, check the supplier's data sheets before you start the works as pre-planning is essential.
Exceeded Overcoating Periods
The animation used on the website demonstrates the effects of exceeded overcoating periods.
The second coat will not adhere to the first leading to possible delamination and flaking from the
newly applied coating.
Check with the suppliers for maximum overcoating times and temperature criteria.

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Overcoating Periods
As previously discussed, overcoating a coating too soon can lead to solvent entrapment of the
previous coat along with other coating problems.
You may not see the potential problem straight away and these problems may not occur for many
weeks or months.
Thickness, ventilation and temperature effect overcoating periods.
Coating Blistering
The animation used on the website demonstrates the potential problem with overcoating a multi-coat
paint system to soon.
Solvents can become trapped in the first coat which will push the coating from the surface.
The blisters may take weeks or months to form as the solvent forms the blister.
The problem could be worse when the coating is immersed.
Forced Heating
The animation used on the website simply demonstrates how heat rises in confined locations such
as this tank area.
If a tank coating operation was ongoing and heat was forced into the bottom of a tank the heat may
cure the coating at the top of the tank faster than the lower sections.
This may have an effect on the minimum and maximum overcoating to different sections of the tank.
Be careful when heating confined areas and monitor the heating and temperatures on an ongoing
basis.
Plan your works accordingly.

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Exceeded Overcoating Periods
Overcoating too late can lead to adhesion problems between coats. If overcoating periods have
been exceeded you may have to:
• Abrade the surface.
• Flash blast the surface.
• Solvent rub or wipe the surface.(maybe impractical for large areas)
Always seek the supplier's advice on overcoating times of a coating as all coatings have different
characteristics.
Illustration of a delamination failure due to extended overcoating on a epoxy coating.
Always check the minimum and maximum overcoating times, which will be found on the product
data sheets.
Some coatings are more prone to maximum overcoating periods and the overcoating times are then
very critical and must be observed.

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Abrading the Surface
If the overcoating times have been exceeded it may be possible to abrade or flash blast the surface
to give a key for the subsequent coating.
This process is common practice with galvanized surfaces which can be 'flash blasted' prior to
coating.
You must conduct a test piece to ensure the right abrasives and pressures are being used.
Rubbing Down in Operation
The video used on the website demonstrates the operative abrading the surface ready for additional
coating application.
Solvent cleaning or washing down etc may be necessary after abrading to remove the debris.
The hand rubbing down technique may be suitable for small areas, however uneconomical with
large areas where flash abrasive blast cleaning may be the best option.
Solvent Wash/Rub
A solvent rub maybe required if the existing coating has exceeded the overcoating times.
The suppliers recommendations is essential for this process.
It is usually only practical on small areas.
The process may not give the same results as flash blasting or abrading the area.
If abrading the area, solvent washing or water washing maybe also required to remove dust and
debris.

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Summary
This training unit reviewed the drying, recoating periods and final cure of a coating.
We discussed how it is important that the coating applicator is aware of the differences between the
drying time and cure time and how film thickness and temperatures has an affect on this process.
We also discussed the potential problems with overcoating to early and to soon.

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UNIT: 5.3.4
STRIPE COATING

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Objective:
To understand why and when stripe coats should be applied in a protective coating system.
The protective coatings applicator will conduct stripe coating in their application role.
Stripe coating is always recommended on steel protection.
Stripe coating is generally applied by brush.
Stripe coating provides additional protection to vulnerable locations.
Stripe Coating
Stripe coating is defined as an additional coating applied to selected areas of a substrate or surface.
This photograph illustrates the extent of stripe coating that may be required on a structural steel
member with lots of edges etc.
The stripe coating can be very extensive, especially on older structures.
Most coating specifications includes a stripe coat in the coating system.
Areas which usually require a stripe coating include:

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• Welds.
• Edges.
• Corners.
• Awkward areas.
• Rivets.
• Nuts, Bolts etc.
Stripe coating is generally restricted to steel surfaces.
Application of Stripe Coat
Stripe coatings are usually applied by brush, however spray application can be conducted to some
locations. Ensure you check the paint specification for any instructions on the method of stripe
coating.
The brush is by far the most widely used method and can get into all areas without fear of misses.
The brush also wets the surface which may be difficult by spray methods.

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Reason for Stripe Coating
This photograph is an illustration of the thinning of an applied paint coating at a sharp edge.
The paint 'runs away' from shape edges.
Thickness is not normally specified for stripe coating although a good covering is required.
The use of contrasting colours is also generally recommended.
Edge Retention
Coatings have a natural tendency to flow away from edges resulting in low thickness and early
coating failure.
Solutions include:-
1. Elimination of the sharp edge by grinding, sanding or filing.

2. Applying a greater coating thickness by use of stripe coats.
3. A combination of the two.
4. The use of coatings specially formulated to provide good edge coverage as illustrated in
the photographs.

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SSPC Paint Application Guide No. 11 should be consulted for further details.
Areas for Stripe Coating
Potential low areas of coating thickness after spray application, e.g. edges, awkward areas.
The coating applicator will have to use their initiative for stripe coating.
The stripe coating should always be inspected by a supervisor or painting inspector.
This diagram illustrates where a coating will be low in film thickness without the use of a stripe coat.
Stripe Coating
The animation used on the website demonstrates the extent of stripe coating on a structural
member.
The stripe coating is usually applied prior to the overall coat, however sometimes this can be applied
after the final coat, if aesthetics are not an issue and the painting inspection allows this process.
Monitor the overcoating time on the stripe coat to ensure you are not overcoating to soon or late.
Stripe Coating to a Steel Structure
The video used on the website demonstrates the simple but essential procedure of stripe coating
prior to full coat application.
The stripe coating is applied to all the awkward areas as well as the welds and edges.
Sometimes stripe coating is required on all coats due to the configuration of the structure.

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Steel Fabrication
Stripe coating to welds, edges in a tank lining fabrication.
You only get one opportunity during the build phase of a contract.
Note the contrasting colour between existing coating and the stripe coating.
Inspect all stripe coating to ensure the area is coated and the stripe coat is cured.
Extent of Stripe Coating
Stripe coating to rivets on a steel structure.
Some structures have thousands of rivets, edges and awkward areas.
It is better to have additional stripe coating rather than have some misses!
The applicator must use common sense with stripe coating.
Experienced applicators and spray painters will be well aware of what areas need stripe coated.

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Brush Stripe Coating
The purpose of a stripe coating is to ensure that paint is applied to vulnerable locations and areas of
difficult application by a spray gun.
There are no requirements on the type of brush, however a 'dogs leg' has found to be very useful for
stripe coating as the brush is on an angle and can get access to tight areas without the applicator
continuously bending their wrists.
Also the dogs leg brush can give the applicator an additional 60 centimeters (24 inches) in length.
Stripe Coating
The video used on the website simply demonstrates a protective coatings applicator applying a
stripe coat to a tank lining prior to the overall coat.
The process can be relatively slow compared to spray painting, but is very important.
All welds must be coated and any areas where the spray painter will find difficult to achieve a solid
continuous film.
Summary
This training unit has reviewed the use of stripe coating.

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Stripe coating is an essential process for coating application and should be conducted on most
coatings.
We discussed the purpose of the stripe coats and where the stripe coating should be conducted.
We also discussed the types of brushes used etc.

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UNIT: 5.4.1
SURFACE CLEANING

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Objective:
To understand the cleaning requirements prior to paint application.
Paint coatings require clean surfaces to ensure the correct level of adhesion is achieved.
There are numerous types of surface contaminants which could have an adverse effect on
coating adhesion.
The protective coatings applicator will be require to recognise and remove surface contaminants
prior to coating application
The Coating Applicator
The coating applicator must be able to conduct any cleaning operations prior to coating.
The coating applicator should be able to recognise contamination that may cause coating adhesion
failure.
The coating applicator must understand the importance of surface cleaning.
It is therefore essential that training and qualifications are imposed in the coatings industry.
Surface Contamination

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Contamination such as grease or oils may not always be that visible, especially in locations with low
light level areas.
Thorough inspection must be conducted on the surface to be coated by the supervisor or inspector
prior to commencement of work.
The cleaning procedures should be agreed in advance of the works.
Contaminated Surface
The animation used on the website demonstrates the problems that will be encountered if surface
contamination is not removed prior to coating application.
The paint failure may not always be instant and adhesion failure may only occur at a later date.
Specialised degreasing agents may be used, however check for paint compatibility etc with the
coating supplier.
Pre-Surface Inspection
A pre-surface inspection must be conducted prior to any form of surface preparation as grease, oil
etc can easily be spread from other mechanical trades, overalls etc.
Sometimes the contamination is not always as clearly visible as the illustration.

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Coating Failure
Failure to remove contamination will certainly reduce the adhesion of a coating system.
Initially the coating may cure and look fine, however failure of the system is inevitable.
Contamination of a surface may happen prior to the first coat or during mid-coat.
Never apply a coating over contamination.
Contamination Problem
This photograph is an illustration of grease, oil or foreign matter on a surface which was left on the
surface prior to coating application.
The result is 'cissing' and is quite visible soon after application.
Additional surface preparation will be necessary to solve the problem, however in some
circumstances total removal of the coating may be necessary.

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Contamination of the Surface
Possible Remedies:
• Solvent clean - used for small areas only.
• Water wash - hot and cold water.
• Steam clean - heavily contaminated areas.

• De-grease using special cleaning agents.
Always conduct test piece on the surface first.
Seek advice from the coating supplier before conducting any surface cleaning.
Steam Cleaning
The animation used on the website demonstrates the use of steam cleaning on a contaminated
coated surface.
The stream is used at high pressures and very high temperatures. This process may damage
certain areas and surfaces.
Always conduct a test piece first.
Solvent Cleaning
Video of solvent cleaning.
Solvent cleaning is used as a pre-surface cleaning procedure prior to coating operations.
This process is and should be restricted use due to health hazards.
if an alternative exists and is compatible with the coating then this alternative should be used.

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Check COSHH and risk assessments prior to using solvents.
Example Problem:
Bitty or dried-in contamination on or in the coating system.
• A rough and poor surface film is visible.

• The appearance can look very unsightly.
• The contamination traps dirt and debris.
• The contamination leaves an uneven surface.
Surface Contamination - Bitty Surface
Example Remedy:
Scrape or lightly abrade the surface without gouging the surface. Flash blasting may be required
and more economical over a large area.
Ensure a trial area is completed and agreed.

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Re-apply an overall coat to the cleaned surface ensuring the coating are compatible.
This particular problem can be found on steel, plaster, wood etc
Surface Scraping
The animation used on the website demonstrates the use of a scraper to remove contaminated
surfaces such as dry spray and overspray.
Ensure you do not cut into the surface coatings with the scraper as this can cause other issues
especially with thin coatings.
There are specific scrapers developed for such tasks.
Paint Scraper
Certain paint scrapers exist that are designed that the protective coatings applicator can draw back
over the surface removing dry spray, over spray and surface contamination such as dirt etc with
damaging the coatings.
The tip of the scraper is folded over as illustrated.

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Example Problem:
This surface was previously spray painted:
• Overspray is visible.
• Dryspray is visible.
The above are generally caused by poor application techniques and can be avoided during coating
application.
Example Remedy:
Scrape or abrade the surface without damaging the coating. Special scrapers are available for this
process.
Do not attempt to apply more coatings to hide the problem.
Applying additional coats of paint over overspray or dryspray will lead to potential adhesion
problems as the newly applied coating will not be able to fully wet the existing coating.
Video of Abrading
The video used on the website demonstrates the rubbing down of a painted surface ready for
additional coats.
The abrading will leave a key for the subsequent coats.
Post cleaning created by the abrading will also be necessary.
The process can be a slow and expensive procedure over a large area.

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Check the surface for general airborne dust and contamination.
If possible dust down the surface followed by a fresh water wash and allowed to dry before coating.
If dust is inevitable, brush application of the coatings may be the best option, especially on the first
coat.
Summary
This training unit has reviewed surface cleaning.
We discussed the different types of surface contamination that can be typically found on a surface
and the different methods of removal of the contamination.
We also discussed how it is important that the protective coatings applicator is aware of the
implications of coating over a surface that is not fully cleaned.

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UNIT: 5.4.2
COATINGS DAMAGE AND REPAIR

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Objective:
To understand remedial paint application procedures for damaged coated surfaces. Coatings
may be damaged:
During handling and transportation.
During site erection.
By other trades.
By general wear and tear in service.The protective coatings applicator will almost certainly
repair damaged coatings/conduct coating maintenance.
In-Service Coatings
Damage and repair can be minimised on coatings:
• by education and training of personnel.
• by conducting regular inspection of the coatings.
• by conducting regular maintenance.
Coating repair can be very expensive and repairs and maintenance should be conducted before the
repairs become complete removal of a coating.

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New Coated Steelwork
Damage and repair to coatings can be minimised:
• by education and training of personnel.
• by using durable high performance coatings.
• by applying coatings correctly and allow cure before transportation and erection.
• By being careful with the coated product.
Coating Systems -
There are many factors which have an effect on damage of a coating.
These factors include:
• Cure and hardness of the coating.
• Thickness of the coating.

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• Durability of the coating.
• The generic type of the coating.
A good painting specification should consider damage during construction and general
maintenance.
Coating Performance and testing
Coating systems are tested by the supplier against mechanical damage.
Panels are however fully cured prior to testing which is not always the case to real life situations.
This illustration demonstrates the use of impact test to a coated panel.
Tests include dropping weights from specific heights and assessing the extent of coating damage.
Coating Damage and Repair
Protection:
• Special packing should be used during transport and erection.

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Topcoating:
• Topcoats should be applied and and allowed to cure in the factory or coating facility
before being transported to site.
• Topcoats can be applied on site which will minimise damage, but may not be practicable.
• There are risks of higher costs if the coating is applied on site due to access and
containment.
• There will always be a risk of primer or undercoat breakdown or getting contaminated if

topcoated at a later date.
Steelwork Site Works
The cost of the steel painting works could be reduced considerably with the correct planning and
management.
The coated steel should be cured (hard enough to withstand transport and general handling) before
going to site.
The steel should be stacked and stored correctly so it can be easily retrieved without damaging
other items of paint work.
Sometime the cost of site coating repairs are more that the full initial surface preparation and coating
activities.

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Good Repair Procedures
It is important to have good repair procedures available for a coating system.
This illustration is of a feather edged coating using an orbital grinder. This process allows for paint
overlap on the coatings to be applied without having an hard edge.
Hand preparation to repairs is often conducted and the correct repair procedure must be conducted
and inspected.
If the existing coating is very thick or brittle, this may be difficult to achieve.
Site Repair
An example of steel steelwork being constructed on a site.
The three coat system (grey/white/yellow) have been sanded back to give a good feather edge and
overall area.
The main weld will then receive spot blasting prior to coating application.
Considerable site masking may also be required.

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Poor Repair.
The edges of the existing coating have not been abraded and disking would be impossible due to
limited access.
The coating is already breaking down only a few weeks after application.
Pre-planning is essential for conducting repairs or general maintenance.
The right tools and trained personnel should be made available to achieve a good repair.
Poor Repair
Another example of a damaged coating.
No attempt has been made to feather edge around the damaged location or build up the coating
thickness.
The repair looks very unsightly.
The repair will break down and further repairs will need to be conducted.

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Spot Repairs
The animation used on the website demonstrates the use of a disking machine to conduct a spot
repair on an existing coating system.
The edges are correctly feather edged and the repair coats should overlap the existing coating by
50mm (2'').
You will need to inspect between coats to ensure the overlap is correct and the old coating is not
being lifted by the new coating.
Site Maintenance
This is an example of a site repair.
The feather edge is very good to the extent that it is difficult to see the overlap area.
This repair should last as long as a coating applied directly onto the surface without any overlap.
This process becomes more difficult as the existing coating film thickness increases.
Repair to Thick Existing Coating
This is an example of a coating repair to a existing thick coating.

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The thicker the existing coating the more difficult it is to get an esthetically pleasing repair unless the
new repair coating is the same thickness as the existing coating in the repair area.
As a coating overlap is recommended this process can not be conducted.
A trial area is always recommended.
Thick Coatings - brush repair
If the existing coating is quite thick (above say 300-400 microns) 12-16 mil, then the coating system
would have to built up with a number of brush coating to achieve the desired dry film thickness
before the top coating can be applied.
As the coating is built up the original spot repair would be increased slightly at every coat.
In this type of coating repair it is not common to increase the coating repair by over 100%.
Good and Bad Repair
Another example of a site coating repair.
The coating overlap is about right at 50mm (2''), however preparation was poor and surface
corrosion is already visible after one coat.

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You must ensure you overcoat the primer as soon as possible and achieve the correct dry film
thickness.
Always seek the suppliers advice on the correct product, grade and recommended dry film
thickness.
Summary
In this training unit we have reviewed coating damage and repair.
We reviewed some of the problem with damaged coating and how correct management will help to
minimize damage.
We also looked at how to correctly conduct coating repairs.
We also looked at poor quality paint repairs.

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UNIT: 5.4.3
MATERIALS AND EQUIPMENT HANDLING

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Objective:
To understand the basic handling procedure during paint operations.
The protective coatings applicator will handle various materials during their duties.
Materials could be heavy, awkward, flammable or toxic.
Plant and general application equipment may have to be delivered, moved and stored on a daily
basis.
You will not necessarily find handling instructions with equipment.
Material Handling
Within the construction and coatings industry there will be a lot of material handling.
Material handling may be conducted in the coatings factory or on the construction site.
Never attempt to handle steelwork without adequate training.
Check the specific task risk assessments and method statements.
If in doubt ask!

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Lifting Equipment
There may be occurrences when the coating operative is involved with moving plant or equipment
such as containers etc.
The operative should be trained in such tasks and follow the risk assessments specific to the task.
A lifting plan should be available reviewing the training, lifting equipment, the structure and type of
attachments.
It is important that the weight of the structure is known as this will determine the method of lifting.
Training Requirements
External training will be required for such items as fork truck and mobile units or cranes.
Check the training requirements and procedures etc prior to using such equipment.
Ensure all operatives are suitably qualified to use such equipment.
Check the method statements which should be developed for the tasks which will include the
training requirements etc.

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Telehandler
Telehandlers are often used to move surface preparation and coating equipment around sites.
The operator must be trained in the use of the telehandler or other similar type equipment.
Full method statements must be in place to use such equipment and a specific risk assessment
must be conducted.
Fork Truck Equipment
Cherry pickers are frequently used in the coatings industry, both on sites to remove equipment,
plant, paint etc around the site and in the maintenance shop for bring equipment to and from the
shop and on and off transport.
The operator should be fully qualified to use the equipment.
Lifting plans should be developed and used.
The equipment should be fully serviced and working correctly.

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Procedures and Instructions:
All workers must be trained in manual handling.
• Check the procedures for lifting and general movement of blast and spray equipment.
• Ensure the operative has conducted a manual handling course.
• Check for level ground, damage to lifting aids etc.
• Do not lift if you suffer back problems or similar ailments.

• If in doubt ask!
Moving Spray Equipment
Spray equipment is often moved around the paint shop and construction sites.
Ensure that the tyres are inflated and the handles are intact before moving paint application
equipment.
Move the hoses, paint lines etc. separately.
Try and work as a team with other personnel.

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Check the method statements and risk assessments specific for the task being performed.
Blast Equipment
All blasting equipment should have robust wheels and a handle.
The equipment is not however designed to be pushed/pulled on uneven surfaces.
Remove all connections and hoses and ensure there is no abrasive inside the blast unit.
If the equipment is to be moved via a fork truck or telehandler ensure;
• A handling plan is in place

• There should be two men plus driver on the task
• There should be two handling straps used to ensure the item does not swing when being
lifted
• Personnel are competent in the task and understand how the straps are connected etc
Slings and Lifting Aids
When moving equipment around ensure the lifting aids are in order, not damaged or worn.

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Most lifting slings are controlled by colour code (such as yellow) which will be indicated on the
control board.
Operators must be trained to conduct any form of lifting or rigging and the job specific risk
assessments must be in place before work commences.
Material Movement
The coating applicator must be aware of the safety arrangements, lighting etc. before moving paint
coating, chemicals, thinners etc.
Material requisition forms are sometimes used in this process.
Ensure all tins and containers are sealed before moving. Check the lids are in place and there are
no leaks.
Be aware of other trades while moving equipment around a site, especially hazardous materials
such as paint and thinners.
Dont leave hazardous materials un-supervised.
Materials and Equipment
Always Ensure:

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• COSHH and Risk assessments are available.
• Instruction from the Supervisor is made available.
• The correct material, include activator is collected together.
• The lids are secure and the tins have handles.
• The correct PPE and RPE is available and used i.e. gloves, overalls
Paints and Materials
Never :
• Carry paints or chemicals without secure lids.

• Lift too much at one time and try to carry the same weight in both hands or arms.
Take two trips instead of one if the material is too heavy.
Do not take risks.

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Material Handling
Use of wooden Pallets:
• Pallets are not overloaded.

• Items are placed in centre of the pallet.
• The pallet is not worn or damaged.
• The pallet is not painted or rotten.
Conduct regular inspection on used pallets.
If in doubt ask!
Scaffolding Stairs
Never carry heavy objects to the work face via scaffold stairs.
If you carry heavy objects via a scaffold staircase there is potential for;
1. General risk to operative due to heavy weight

2. Risk of losing balance as you climb/decrease the stairs

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3. Danger of losing footing and falling down the stairs or over the handrail
4. Danger or hurting other personnel.
The site should be able to deliver heavy objects via a crane, fixed lift etc.
Summary
Within this training unit we have reviewed materials and equipment handling.
We discussed the requirements for using lifting equipment and qualifications of personnel also the
correct method of moving and lifting blast cleaning and spray painting equipment etc around a site
or complex.

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UNIT: 5.5.1
SHOP PAINTING

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Objective:
To give the protective coatings applicator an understanding of the shop painting process and
the duties that may be expected from the protective coatings applicator.
Majority of items are prepared and coated in factory facilities.
The size, type and location of paint shops varies considerably.
Paint shops can be independent or part of a fabrication facility.
Temporary paint shops are available for specific contracts.
Shop Painting
The role of the protective coatings applicator should not change between working in a fixed paint
shop or on a site.
The sites may have individual rules for all operatives ie you may be working on a pipeline
construction site which is a temporary site or a petrochemical site which is a permanent site.
What they have in common is the requirement for protective coatings applicators either on project
work or maintenance.
The paint shop operative typically works on new items that head off for site construction.
The paint shop operative would be expected to be multi-tasked and conduct a number of coating
and associated activities.

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Health and Safety
The paint shop will usually have a site induction for new visitors.
The paint shop will also have specific rules for operatives and visitors which must be observed.
As a minimum all personnel should have hand, body, eye, ear and feet protection.
Paint shops are typically very noisy environments.
Warning signs must be clearly displayed.
Shop Painting
The shop paint general process consists of:
• Delivery of Items.
• Unloading, storage and identification.
• Pre-cleaning, preparation activities.

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• Surface Preparation.
• Coating Operations.
• Inspection, cure and testing.
• Marking, storage and loading.
Role of Industrial Operative - Paint Shop
• Applying coatings by brush, roller etc. inc. stripe coating.
• Pre-surface preparation such as removing grease, oil and surface contamination.
• Chipping, grinding steel defects such as sharp edges, weld spatter etc.
• Loading and unloading.
• General cleaning i.e. paint shop, general stores, paint store.
• Light maintenance.
• Paint mixing, tin crushing and correct disposal.
• Assisting blast cleaning and paint spraying operatives.
• Masking components.
• Snagging and final touch up.

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Shop Painting
Delivery of Items:
• Most items are delivered by road.
• A delivery note will accompany all delivered items. Check the note on delivery arrival.
• Conduct visual inspection. Look for damage, missing parts etc.
• Work to the company Quality Assurance system or client procedures and specification.
Unloading and Storage:
• Some items may go directly into paint shop while others will be stored.
• Specific training may be necessary for loading and unloading equipment.
• Check storage requirements for each specific job as special requirements may be
specified.

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Review the painting specification and agreed method statements in advance of work.
Paint Shop Layout
The paint shop layout is important and needs to be considered carefully to ensure it runs efficiently
and effectively.
The paint shop should be designed so the preparation activities are separated from the coating
activities.
Depending on size and dimensions the structures will enter the building at one end and exit the
opposite end.
The layout should be ensure there is no cross contamination between the preparation or different
coating systems.
The paint shop should have suitable background lighting throughout.
Paint and fume extraction should be installed within the paint shop and will need to meet any
environmental legislation.
The environmental conditions must be suitable for coating system and the correct, safe indirect
heating should be used.
The floor should be solid and free from holes, hazards etc. Protection maybe required from the
coating operation.
The sequence of the works has to be co-ordinated especially if multi-coat systems are used.
The spray equipment cleaning will be essential in a paint shop as different coatings, by different
suppliers will be encountered.

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Paint Shop Layout
Paint and fume extraction should be installed within the paint shop and will need to meet any
environmental legislation.
The environmental conditions must be suitable for coating system and the correct, safe indirect
heating should be used.
The floor should be solid and free from holes, hazards etc. Protection maybe required from the
coating operation.
The sequence of the works has to be co-ordinated especially if multi-coat systems are used.
The spray equipment cleaning will be essential in a paint shop as different coatings, by different
suppliers will be encountered.
The items are generally delivered to the paint shop by road transport and removed and stored, or
taken directly into the abrasive blast cleaning hall or booth. Recycled abrasive is usually used in the
blast chamber or wheelabrator.
The specification will dictate if any washing is conducted to the structure. This is usually conducted
externally to ensure no water or moisture enters the paint shop etc.
Ideally the paint shop will have overhead cranes otherwise fork truck or cranes will be used to move

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the structure around.
The structure will be inspected for any pre-preparation requirements such as grinding etc before
being moved inthe blast hall, chamber or wheeelabrator.
When the surface preparation has been conducted, the structure should be moved into the paint hall
or location.
The structure may be laid on trestles or frames for coating operations.
The structure should only be moved once the coating is hard enough. If the structure is moved
outside it has to be able to withstand the elements and any environment change in temperatures
etc.
Additional checking is always required for a coated structure coming into natural light. Touch up is
usually required on coated items.
Contact Points
The contact area on trestles or stools holding the component should be as small as possible.
Contact points should not be overlooked as these will require some form of touch up either in the
paint shop or on site.

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Angle bar is a good example of a minimal contact.
Note: Ensure that the trestles or stools are suitable for the weight of the components.
Check method statements etc.
Lighting
It is essential that a paint shop has good lighting.
Some paint shops also work day shift and night shift so the lighting should provide consistent
lighting 24 hours a day.
The lighting should meet any local legislation etc.
The lighting should be maintained regularly as poor lighting will lead to misses etc on both the
surface preparation and coating activities.
Task Lighting
Task lighting may also be required in a paint shop.
Some structures may be large or you may have to prepare and coat internal areas.

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These lights must be intrinsically safe to ensure they do not cause any explosion if they accidentally
damages etc.
Remove these lights back to the store at the end of the task.
Heating
Paint shops should have good heating.
Coatings applied in a paint shop will need to dry hard before they can be moved. Some coating
systems are multi-coat also, so adequate heating is essential to stop the paint shop blacking
through put.
Some form of equipment, such as elecrtic compressors can generate heat which can be
re-circulated within the paint shop also.
With most coating systems the ideal consistant temperature should be around 20oC (68oF).
Air flow can also be important especially when trying to remove solvents and fumes.
Shop Painting
Pre-cleaning and Preparation Activities:

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• Check clients painting specification:Method statements and procedures.

• Method statements and procedures.
• Method statements and procedures.
General: Surface contamination:
• Grease, oil etc.
Removal of surface contaminants.
The customers painting specification should specify removal method.
• Steel Defects:
Removal of weld spatter, sharp edges etc
The customers painting specification should specify removal method.
Some delivered items may be contaminated pre-delivery:
• Oil contaminated on the steel surface.
• Check the clients pre-cleaning requirements and the painting specification.
• Solvent wash and degrease may be required prior to surface preparation.
Note:
Check for COSHH and risk assessments when conducting any pre-cleaning procedures.

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Flame cut edges.
Example of flame cut edge on piece of pre-primed fabricated steel.
• Grinding or dressing will be necessary to remove this flame cut edge.
• Check client requirements and the general specification for the works and pre-preparation
requirements.
• Coatings will fail if applied to this type of steel finish even if blast cleaning is conducted as
a method of surface preparation.
Skip Welds, Sharp Edges and Weld Spatter.
The video used on the website demonstrates skip welds, sharp edges and weld spatter.
All the above must be rectified prior to surface preparation.
Visual inspection must be conducted on steel prior to surface preparation, usually by the paint
supervisor or painting inspector and marked up accordingly.
Shop Preparation and Painting

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Surface Preparation:
A typical blast chamber used to conduct surface preparation to structural steelwork.
• Purpose built items, specific to paint shop.
• Ideal conditions for surface preparation.
• Abrasive is generally recycled chilled iron as this is economical to use.
Shop Prepaparation and Painting
Surface Preparation:
• Manual blast cleaning is still conducted for shop painting, usually in a blast chamber.
• Automatic equipment can be found in large factories. Examples include plate abrasive
blast cleaning in fabrication facilities etc.
• Paint shop sizes vary from small paint shops who coat small sections of steel to
shipbuilding yards who prepare and coat large sections of steel.
Abrasive Blast Cleaning
Abrasive blast cleaning in a small paint shop blast chamber:
• The process is a manual abrasive blast cleaning.

• Work is conducted with a in-house abrasive blast chamber as illustrated.
• Steel abrasives are generally used.
• The process is economical compared to site abrasive blast cleaning.

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Abrasive Blast Units and Hoppers
The abrasive blast units are normally situated along side the abrasive blast cleaning chamber or
outside the paint shop.
The size of the blast chamber and hoppers will usually determine the best location.
Good access is essential for maintenance.
Recyclable Abrasives
The paint shop has the big advantage over site painting in that it is easier to re-cycle the abrasives.
Typically chilled iron grit abrasive is used in the blast chamber.
This abrasive can be re-cycled, cleaned and put back into the abrasive blast unit as illustrated.

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Centrifugal Blast Cleaning
Some large paint shops have the ability to have a centrifugal blast cleaning unit installed.
These blast cleaning units can be very economical and are ideal for flat plate. Other structural
members can be blast cleaned also, depending upon the size of the equipment and equipment
opening.
The centrifugal blast unit will require electricity and will generally have its own extraction unit.
Shop Painting
Coating Operations:
Prepared items are usually coated separately from the preparation area.
Check the specification for requirements of client ie:
• Ambient conditions.
• Methods of application.
• Coatings, thickness, colour etc

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• Details for cure and storage.
Coating Application:
Illustration of coating application of a sprayed coating to structural steelwork in a paint shop.
There should be minimal contact on the trestles otherwise there will be contact points to touch up
later.
Contact points should receive the same treatment as the remainder of the steelwork.
Always check the painting specification and specific method statements prior to commencement of
the works.
Airless Spray to Steelwork
The video used on the website demonstrates the use of airless spray to structural steelwork in a
factory facility.
Airless spray is ideal for shop and factory works.
Abrasive shop or blast primer is being applied in The video used on the website which is a thin fast
drying primer.
Contact points have to be coated at the same time or prior to the deterioration of prepared surface.

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Stripe Coatings
Brush stripe coating should be assessed and applied before the fully coating system as illustrated.
This area is virtually impossible to fully spray apply a coating on a continuous basis without
excessive film thickness.
Stripe coatings would have to be applied to this, and similar locations.
Apply stripe coats to areas were spray painting can not apply a full and even coat.
Shop Painting
Inspection, cure and testing:
• Inspection of work is usually conducted by a qualified painting inspector, supervisor,

manufacturer etc.
• The painting specification may detail the qualifications required by the painting inspector.
• The painting specification will detail all inspection and testing requirements such as
thickness, holiday detection etc.
• A quality inspection is usually developed which will detail the level of inspection and hold,

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witness and surveillance points.

• Also check quality assurance procedures etc.
Coating Cure:
Illustration of a component which was placed outside before the coating had time to harden or cure.
Check the coating cure time and do not subject the coating to adverse weather until the relevant
cure or hardness has been achieved. Some coating are susceptible to problems if curing is
conducted in cold or damp locations.
Detachment of the coating was the outcome on this coated structure.
Temperature will have a major bearing on coating cure and must be considered when applying
multicoat systems.
Wet Film Thickness
The protective coating applicator will still be responsible for conducting wet film thickness checks.
The applicator should know the wet and dry film thickness before applying the coating.
Wet combs should be made available to all applicators.

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Painting inspectors can also verify the wet film thickness providing they use the appropriate RPE
and PPE.
Dry Film Thickness
Illustration of dry film thickness testing of a cured coating using an electromagnetic thickness gauge.
The dry film thickness will be specified in the paint specification or manufacturers data sheets.
Always check the dry film thickness criteria ie minimal, average etc.
There may be a specific test requirement such as the SSPC or other Industry body.
Completed Works
Storage and Loading Requirements in the paint shop:
• Finished items generally should be stored ready for delivery.
• Check any specific storage requirements.
• Complete paperwork as contract requirements.

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• Get completed works signed off, if possible by the customer or inspector.
Paint Store
A paint shop may have a permanent paint store or utilize a container store similar to what is used on
sites.
Whichever paint store is used, the area must be suitably designed for paint storage with correct
lighting, fire extinguishers, signage etc.
Paint stores must always be clean and tidy.
House Keeping
It is very important that the paint shop is cleaned on a continuous basis.
Due to the single facilities there is a lot of activities and tasks ongoing at the same time.
House keeping should be a high priority and all coating operative should clean up after every task.
A five minute clean up is generally recommended also after every shift.
Poor housekeeping can give a perception of poor quality. There are also potential fire risks also

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with poor house keeping along with the potential trip hazards etc.
Paint Shop Layout
An inspection and test plan will have to be developed for each contract or project which will detail
the specification and product data sheets.
The standards used, environmental conditions, thickness of coating and overcoating times should
be detailed in the inspection test plans along with any remedial or touch up.
The inspection test plan will detail all the inspection criteria included in the surface treatment and
coating application.
The paint shop supervisor should be familiar with the inspection test plan, coating specification and
product data sheet.
Summary
In this training unit we have reviewed the surface preparation and coating activities in a paint shop.
We reviewed the requirements of a typical paint shop layout and fixed equipment such as heating,
lighting, extraction and blast chambers and blasting units such as centrifugal blast cleaning units.
We also reviewed the importance of good housekeeping in a paint shop.

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UNIT: 5.5.2
SITE PAINTING

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Objective:
To understand the implications of conducting site painting activities.
The protective coatings applicator will generally conduct some site painting in their duties.
Site painting has more Health, Safety and Environmental issues than shop painting.
Most industrial work-painting is conducted on site.
Every site can be completely different to the next site.
Shop Painting Vs Site Painting
We have previously discussed shop painting and how the surface preparation and coating activities
can be conducted under controlled conditions.
• Surface preparation can be conducted in a blast chamber or centrifugal blast cleaning

equipment
• Coating operations can be conducted in a paint shop with the use of controlled
de-humidification, heating, extraction etc all built in into the facilities. Overhead lifting is
also generally used also.
• The paint shop will generally only contain coating application personnel and not other
trades or members of the public.
Site painting may not have any facilities and other trades and public may be close by. The logistics
are completely different and generally more difficult.

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Site Painting Vs Shop Painting
Site painting imposes two distinctive differences from shop painting;
1. Health and Safety - The coating operative may not work permanent on a particular site
compared to a paint shop employee. There may be considerable differences on every
site and potentially new hazards on every site.
2. Environmental Conditions - The coating operative may have to work in a various
environmental condition from site to site. Some sites may be close to the coast or
offshore, others could be on heavily corrosive petrochemical site. Specific methods of
surface preparation and containment may be required for site coating operations. The
coating operative may also have to work from various forms of access.
Mobile Units
Many site coating operations have to be accessed by the contractor using mobile elevating working
platforms (MEWPS).
All coating operatives will have to be fully trained in the use of the equipment, including the banks
man or assistant.
The work will be considerably slower than working within a paint shop.

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There will be containment issues especially if blast cleaning, water jetting, spray painting etc is to be
conducted.
If coating operations (brush and roller) are used without containment then the task is subject to
environmental conditions which varies considerably.
Scaffold Access
Scaffold access may be supplied to the coating contractor by others or by the coating contractor.
The scaffold must be able to reach all the parts of the structure to be prepared and coated.
Plant and equipment may have to be placed close to the structure with blast hose, paint lines, air
lines etc strapped to the structure or access to reach the work face.
The scaffold will probably need design which will detail the maximum weight requirements which is
essential if you are abrasive blast cleaning from the scaffold etc.
Containment
Specialist containment may be required on some sites.
The containment will;

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• Contain blast media

• Contain dusts and debris
• Contain over spray
• All localized environmental control with the use of heating, de-humidification, lighting etc.
The containment may be done by scaffolders, specialist contractors or trained coating operatives.
Rope Access Coating Operatives
Many organizations use rope access operatives for conducting surface preparation and coating
activities.
As scaffold access can be very expensive rope access is being used on difficult access locations
such as offshore platforms etc.
Protective coatings applicators would have to be fully trained and independently accredited to
become rope access workers.
Site Painting Activities
Industrial painting activities is conducted on numerous sites and locations around the globe.

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• Petrochemical industries.
• Offshore installations.
• Shipyards and Fabrication facilities.
• Construction sites.
• Bridge and structure maintenance.
Generally any areas that uses steel will conduct some form of painting operations from time to time.
Site Painting
Site painting can have many hazards:
• Be aware of other trades and activities.
• Ensure all the work is programmed and co-ordinated correctly.
• Ensure COSHH and Risk assessments are produced before the work starts.
• Method statements are essential as this would detail the trade interface.

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Site Painting
Sites differ with different trades and different activities ongoing at any one time.
Multi-trade sites:
• Working with other trades such as welders, electricians, plumbers etc. Examples includes
petrochemical sites, ship yards and offshore construction facilities.
Single-trade site:
• Working with paint trades only such as bridge painting. No other activities interfering with
the painting.
Site Working
No two sites are the same.
Different sites will have different rules and different safety cultures.
The coatings operative will have to comply with the owners or operators site safety rules which may
include a specific health and safety induction.

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Drugs and alcohol testing is usually conducted on the first day and random testing thereafter.
Site Safety Induction
A number of site safety induction programs are generally available:
• Company induction.
• Site specific induction.
Site induction booklets are generally given out during the induction.
It is important that all personnel conduct the company induction and any specific site induction that
may be necessary.
First aid, PPE requirements, permit to work training may also be required with the induction etc.
Planning of Work Activities
Planning of work activities is essential for conducting surface preparation and coating activities.
Site painting may involve working with the owners personnel or other contractors who are on the site
on a temporary basis also.
Planning of the works should be reviewed by the owners to ensure it fits in with other site activities.
The planning will be done by the contractors management who can organize plant and labour to
suit.

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Health and Safety Documentation
Prior to commencement of works on any site, the relevant health and safety documentation must be
developed by the coating contractor and submitted to the site owner for review and approval.
Although sites vary the following is an example of health and safety documentation;
• Method statements
• Risk assessments
• COSHH assessments
• Details of plant and equipment
• Details of labour to be used
• Labour training records
• Emergency plans
• Certificates of conformity etc
Permit to Work
Many sites have a permit to work system in place. A permit to work system a safety management
system used to ensure all other trades are aware where you are working, items are isolated and a
safe process of working is in place.

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Examples could be painting in confined spaces or grinding (hot permit).
The protective coatings operative should be fully aware of the permit to work systems as they can
vary from site to site.
Site Working - Housekeeping
Good housekeeping on site is essential as all plant, stores etc are generally temporary.
Always clean up immediately, never leave unopened tins, paint spillages etc.
Keep walkways clear of ducting and hoses etc.
Check the site procedures for site cleaning.
Conduct toolbox talks with operatives and conduct regular housekeeping audits.
Site Cleanliness
Site cleanliness extends to paint lines, air lines, equipment etc
Every site will have different access and a different environment.
No two sites will be the same.

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Take time to get to know your environment.
Keep the site tidy and safe.
Storage
Storage and plant will be required for site works.
Paint stores and general stores will normally be required. Power and lighting will be required for the
stores.
Mobile generators may be required for the power and therefore fuel will have to be delivered or
stored on site also.
All storage units will have to comply with health and safety regulations and have suitable fire
extinguishers etc.
Large Plant
Depending upon the type of contract, there may be a large amount of plant such as;
• Compressors
• Heaters

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• Dust/Grit Recovery Units

• Lighting
• Blast Equipment
• Spray Equipment etc
All the above will require to be;
• Delivered safely
• Set out on site
• Maintained
• Security checked
Electrical Testing
All electric equipment must be tested.
The equipment that the protective coatings applicator may be involved with include;
• Grinders/Diskers
• Heaters
• Vacuum equipment
• Dust recovery equipment
• Generators
• Lighting etc
All electrical equipment should be checked by a qualified electrician and the tagged.

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Noise
The protective coatings operative will be exposed to noise pollution on many of the sites.
Noise can seriously damage your hearing so the operative must ensure that they wear ears
protection from noise at all times.
There should be site warning signs where ear protection is required.
As the ear defenders reduce the noise levels, the coatings applicator has to very aware of what is
going on around them at all times as they may not hear warnings from other personnel or object and
traffic movement.
Climatic Conditions
Climatic conditions will be more difficult to contain on a site than shop painting.
Some sites have very inclement conditions such as rain, wind etc which makes any surface
preparation or painting more difficult.
The works should be planned to suit the particular season, if possible.
Work internally during winter months and externally during the summer months.

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Hot Conditions
Some site works in the summer months may expose the coatings applicator to heat stress. This
may also happen in internal areas where heat is generated.
If the coating operative is exposed to heat the company must;
1. Provide adequate water, rest and shade

2. implement a work and rest schedule
3. Provide a climate controlled area for cool down
4. Train people on potential heat stress risks
5. Provide the correct clothing
Conversely if it is cold conditions that protective clothing will be required to keep the operative warm.
Inspection Test Plan
A specific inspection test plan should be developed for the site coating activities.
No two sites will be the same so the inspection test plan should consider the exact details of the
works.

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The inspection test plan should detail the level of inspection of the works and the surveillance,
witness or hold points.
A number of inspection test plans may be required if the site is large or if a different number of
coating systems are use.
Maintenance or New Construction
Site painting usually consists of maintenance or maintenance painting;
New Construction
New construction works generally consists of site weld preparation and coating, site repair and
damage or preparing fabrication primers and application of intermediate and top coats.
Cosmetic coats may also be applied to new construction works.
Works can be conducted from mobile elevated access platforms (MEWPS) or temporary scaffold.
Maintenance painting is common on numerous sites such as petrochemical, offshore, marine etc.
Various operators have their own maintenance painting programs in place and can can vary from
site to site.

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Maintenance painting has many challenges which must be planned correctly including;
• Types and methods of preparation

• Site working environment Including on-line and live operations etc
• Site contamination such as grease, oils and air borne pollutants etc
• Preparing and coating around attachments such as gauges, cables, signs, etc
Spray Spray Painting
Site spray painting is very different from spray painting in a paint shop.
The structures can be old so will have rivets and inaccessible areas or areas difficult to paint.
Access is often required for site painting such as scaffold etc.
Work at heights is common for site painting.
Many areas may require masking also on site painting or spraying.
Site Painting
Ambient Conditions:
It is not uncommon to find that a coating applicator can be within specification for one area on a site
and out of specification only a few yards away.
For this reason you have to monitor the environmental conditions throughout the structure.
Check the painting specification and monitor the environmental conditions in all areas of the work.

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Steel Structures
It is not uncommon to find that steel structures can take an extra few hours to reach ambient
temperatures compared to normal air temperatures.
The air temperature may be higher than the steel temperature as the steel may have cooled
overnight and will take time to warm up.
The steel thickness and location will also need to be considered.
Site Painting - Cutting in
Cutting-in is usually conducted prior to full coating operation on site works.
Cutting in may be required prior to the overall spray or roller coat application.
Procedures for site coating are considerably different than for shop working as you have to consider
all the obstacles around the painting zone.
Site Painting
Paint Overspray:
The coatings applicator must be aware of paint overspray while working on an open site.

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Overspray can come off the roller and brush as well as general spray equipment.
With spray equipment additional caution is necessary as overspray can travel for miles.
Always monitor wind conditions before and during paint application.
Coating Application by Spray Method
General Rules for spray application in open environments:
• Monitor wind conditions.

• Use the correct application equipment.
• Do not add thinners.
• Keep a 'stand-by' watching for overspray.
Sealant
Due to the configuration and design of structures there will be many areas where a sealant is used
in gaps and joints.
Where it is necessary to apply sealant prior to the top coat, a sealant compatible with the top coat,
and having good adhesion to the intermediate coat, should be used.
Surfaces to receive sealants should be prepared and protected to provide a clean, dry surface free
from contaminants.
Sealants should be applied by hand gun at a smooth even rate along the prepared joints/gaps such
that air entrapment is avoided.
The sealant, which is typically a polysulphide, should be smoothed out after application. Other types
of sealants are avaialble.
The size of the cartridge should be appropriate for the size of the joint/gap to be filled. Open
cartridges should be used the same day.

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Check the coating specification for the details on the type of sealant and any environmental
constraints.
Summary
In this training unit we have reviewed site painting.
We reviewed the differences in shop and site painting and the health and safety implications with
site painting.
We also reviewed construction and maintenance painting on sites and quality requirements for the
works.

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UNIT: 5.5.3
GENERAL MAINTENANCE - PLANT AND EQUIPMENT

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Objective:
To understand the requirement for general maintenance of plant and equipment in the coatings
industry
The protective coatings applicator will use a number of items of plant and equipment during their
duties.
Major maintenance is usually conducted by trained fitters or electricians.
Plant and equipment is used for preparation, coating application and associated activities such
as cleaning, grit removal etc.
Maintenance Management
All coating contractors should have a maintenance management system to ensure the equipment
used by the protective coatings applicator is;
• Effective and efficient

• Safe and not defective in any way
The contractor is responsible to ensure that the coating applicator is using safe equipment and not
exposed to poorly maintained equipment.

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Plant and Equipment - Maintenance
General maintenance is conducted on the following categories of plant and equipment:
• Spray paint equipment.
• Abrasive blast equipment including associated equipment such as dust and grit
extraction.
• Large plant used in the protective coatings industry.
• Small tools such as grinders and diskers.
• Miscellaneous items.
Spray Paint Equipment:
The type of spray equipment that is used in the coatings industry can be quite extensive.
• Airless Spray.
• Conventional or air assisted.

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• HVLP. - high volume low pressure.

• Electric airless spray types (illustrated).
• Tips, lines, paint units, packing etc.
Always use the supplier's instruction manual.
Instruction and Maintenance Manuals
Generally all equipment used in the protective coatings industry will have an instruction manual
and/or a maintenance manual.
These are available when you hire or purchase equipment or can generally be down loaded via the
suppliers web site.
There can be many parts to equipment which must be available for maintenance and spares.
Some basic spray guns have over 20 parts!
Personnel
Only trained and qualified personnel should be able to maintain equipment.
Some equipment has electrical equipment or high pressure parts etc.

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The company has the responsibility to maintain equipment with qualified personnel.
The protective coatings applicator should not attempt to fix or maintain equipment without adequate
training or supervision.
Plant Register
The contractor must maintain a plant register of all plant and equipment used either in the paint
facilities or on specific sites.
Equipment should be permanently marked or tagged for ease of identification.
Plant and equipment should not be transferred from one site to another without being re-registered.
The register will detail any maintenance dates or testing dates for insurance purposes etc.
Illustration of a typical airless spray unit.
Always ensure the equipment is not under pressure before removing the paint lines etc.
The manufacturer's instruction manual will detail all parts and part numbers.

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It is generally true to say there is more maintenance required when the spray unit is using or has
been using heavy duty coatings.
Airless Spray Gun
The animation used on the website demonstrates how a typical airless spray unit operates.
The paint, shown in red is forced through the gun at very high pressures and out the tip to produce
the fan.
No air is used in the process and the drop in pressure creates the spray fan.
The atomised paint is then applied to the surface.
Airless Spraying
Airless spray painting is an extremely popular method of applying coatings especially high
performance coatings which require high pressures.
The equipment must be maintained correctly before it goes to site or is used.
Inadequate maintenance will result in poor spray application, poor quality results, wastage of paints
and more importantly potentially unsafe to the operator.
Spray Tips
Tips are generally changed by the spray operator, however cleaning or cleaning maybe conducted
during general maintenance.
Dry paint is often found in the orifice and should be cleaned with soft wire, solvents and brushes etc.
Never poke sharp objects into the orifice as you will damage the tip and equipment.
The supplier's instruction manual will detail the cleaning of tips and associated equipment.

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Spray Tips
Spray tip are often overlooked and not cleaned or changed correctly.
Some coatings such as zinc rich primers, ceramic coatings and glass flake can wear a tip very
quickly.
As the tip is worn out the fan decreases and more paint is used.
• Check and clean spray tips regularly

• Have spare tips available
Tip Replacement
The spray tip is generally relatively easy to replace and will be detailed in the suppliers instruction
manual.
The trigger safety catch must be in place before removing any parts from a spray gun.
The equipment should not be under pressure also.
The supervisor should demonstrate the tip replacement to spray painting assistants.
Spray Equipment
This is a drawing of a typical airless spray unit detailing the main parts.
There are however many other parts within the equipment such as gaskets etc which require
continuous maintenance.
The protective coatings applicator should never tamper with spray equipment unless thoroughly
trained.
Airless spray pressurizes the paint to the extend that the release of this paint can instantly penetrate
the skin of a person. The material can then get into the blood stream with serious consequences.

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The coating applicator may use conventional spray units for certain tasks or coatings.
This process is not as popular as airless spray which has faster application rates.
Little maintenance is generally required to these units.
As with airless spray units, check with the manufacturers instruction manual for parts, spares etc.
Conventional Spray Gun
Simplified demonstration of a conventional spray gun.
The paint material, shown as red is held in the pot and sucked up into the nozzle and mixed with air.
The paint pot is relatively small and only holds small volumes of paint.
The mixed air and paint is then atomised and applied onto the surface.
Although there are more parts than an airless spray unit the maintenance is easy to conduct after a
little training.
Conventional Spray Application
The video used on the website demonstrates the use of a conventional spray type equipment
applying coatings to a steel structure.
Some specialised coatings have to be applied by air assisted equipment.
This process requires air to atomise the coating and is considerably slower than the airless spray
process.

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Air Assisted Spray (conventional spray equipment)
Air assisted equipment will also have instruction manuals which details the parts.
Little maintenance is generally required on this type of equipment, providing it it cleaned after every
use.
The equipment is not generally use for aggressive materials so there is less wear and tear on the
parts.
These are non pressurized units, however the air should be switched off when removing any parts.
Abrasive Blast Equipment:
Abrasive blast equipment generally requires less maintenance than paint spray equipment.
General wear is found on the equipment due to air pressure and movement of the abrasives.
Independent pressure testing is required on such equipment and is generally conducted annually or
bi-annually.
Always ensure equipment has been pressure tested.

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Abrasive Blast Equipment:
Abrasive blast equipment is available in a number of sizes to suit the contract or job requirement.
All the equipment will have the supplier's instructions or parts manual.
Never tamper with the equipment unless you have been fully trained and have the instruction
manual available.
A plant checklist should be developed for conducted regular maintenance.
Abrasive Blast Cleaning Equipment
This diagram illustrates the various parts on a abrasive blast unit.
Each part may have a different maintenance requirement and maintained or cleaned at different
times.
All the relevant parts will be found in the supplier's maintenance manual or general instructions.

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Abrasive Blast Cleaning Equipment
Another diagram of abrasive blast cleaning equipment.
This diagram illustrates some of the internal areas of the equipment.
An inspection cover will be placed on the side of the blast unit to allow access to the internal of the
blast unit.
Internal areas should be checked on a regular basis.
Abrasive Blast Unit
The abrasive blast units are categorized as pressure vessels and must be tested as such.
The abrasive blast units must have some form of traceability or identification to ensure that the
equipment is independently tested.
An abrasive blast unit that has not be tested should be taken out of service.
The equipment will not be insured also.
Abrasive Blast Hose

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Abrasive blast hose does not generally require any maintenance and is usually categorized as a
consumable.
It must be inspected for wear and tear before any use.
it is possible to cut out ruptures, however the rupture may be an indication of wear.
Not all abrasive blast hoses are the same quality.
Also ensure the abrasive blast hose is manufactured and to the correct pressures and this is clearly
displayed.
Abrasive Blast Units-Maintenance
Routine inspection of abrasive blast pots consists of stripping the attachments for work shop review
etc.
The abrasive blast unit should be inspected internally also to ensure there are no visual defects in
the steel such as wear on any particular 'hot spots,.
All the abrasive debris should be cleaned from inside the abrasive blast unit via the inspection hatch
cover found on the side of the unit.
There are a number of smaller its on an abrasive blast unit which require inspection;

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• Couplings - Check gasket and screws. Replace if damage or worn

• Nozzle - Replace if work or damaged
• Hoses - such as dead mans handle etc. Generally replaced when damaged or worn.
• Abrasive valve - Should be removed and inspected internally for wear and tear.
• Pop up valve - Check for wear and tear -Replace if worn or damaged.
• Oil/water filters - Inspect and replace if damaged.
Specialist Equipment
Access equipment and compressors are usually supplied by plant or rental organisations.
Minimal maintenance, as described within the equipment suppliers list, is usually conducted i.e.
water and oil change or checking levels.
Get to know the maintenance procedures for each type of equipment.
Compressors generally require inspection and maintenance after a certain amount of hours.
Large Abrasive Vacuum Units
Large abrasive vacuum units are used on certain contracts.

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• The units are usually powered by diesel or electric.

• The units are used for surface preparation techniques.
• The units must be maintained by a competent and qualified personnel.
Always read the instructions and maintenance manuals, especially for bespoke equipment.
Dust Box:
This type of equipment is used for dust removal during abrasive blast cleaning.
The size for this type of equipment can vary to suit the contract.
The equipment is made by specialised organisations who work in the coatings industry.
General maintenance for the protective coating applicator is cleaning or changing dust bags.
Surface Treatment Equipment
There are numerous types of large plant used in the surface preparation and coating application
industry.
Plant maintenance manuals and procedures should be available.

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Only trained or supervised operatives should conduct any form of maintenance.
Dust Collection Filters
There are various types of filters available for dust extraction units. Some filters are easy to change
while older units have shakers using dust bags etc.
The maintenance should be conducted during the main managed maintenance periods, generally
within a work shop.
Care must be taken when cleaning filters in case the dusts contain hazardous debris such a lead
coating dusts etc.
Specialist Equipment
A lot of large plant is hired and maintained by the plant company:
• Compressors - available in various sizes and types.

• Cranes -Usually hired and generally includes the driver.
• Lifting equipment - MEWPS.
• Fork truck- as illustrated.
• Specialised equipment such as generators etc.

- Page 189 -
The plant company will have their own plant maintenance procedures. The plant must be made
available when inspection or maintenance is required.
Maintenance of Equipment
Minimal maintenance is usually necessary on cherry pickers etc as most items are owned by plant
organisations.
If maintenance is conducted on owned plant, a qualified competent person should be used.
Manufacturer's instructions should detail minor maintenance and inspections to be conducted prior
to use.
Personnel must be trained and qualified to use such equipment.
General Maintenance
General maintenance can be conducted on small tools as per manufacturers instructions, which
usually consists of changing parts, lubrication and general repair. Examples include:
• Chipping gun.
• Mechanical wire-brush.

- Page 190 -
• Disk and grinder.
• Needle gun etc
Lifting Equipment
Maintenance of plant may require the movement of equipment from the transport, moving from the
site or moving around the stores etc.
Do not undertake any plant movement unless you review the risks and type of lifting equipment.
Some plant will have 'lifting lugs' which may need tested, other types of plant have no obvious
allocated places for lifting.
Check the maintenance manual (if available) and get the Supervisor to advise.
Always conduct a risk assessment into the task.
Maintenance Manuals
Remember!
• All types of equipment should have maintenance manuals.

- Page 191 -
• Only trained personnel should maintain plant and equipment.

• Poorly repaired equipment can be very dangerous.
• Certain types of plant and equipment can only be operated by trained and qualified
operators.
• If in doubt about anything ask!
Summary
This training unit has reviewed general maintenance for plant and equipment.
We reviewed the requirement for management of maintenance to plant and equipment and the role
of qualified personnel for certain items while other items can be maintained on sites by coating
operative providing training is conducted.
We also reviewed the potential risk with poor maintenance and the impacts on safety and quality.

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UNIT: 5.5.4
EQUIPMENT CLEANING

- Page 193 -
Objective:
To understand the requirement for cleaning plant and equipment following coating application
The protective coating applicator will conduct equipment cleaning as part of their duties during
paint application.
Cleaning equipment correctly will extend the life of the equipment.
Cleaning equipment will ensure minimal contamination on future use of the equipment.
General equipment consists of brush, roller and some spray equipment.
Brush and Roller
It is important that the applicator understands the implications of equipment cleaning.
A trained coating operative should be able to look after the tools that are used on a daily basis.
When using a brush, remove as much of the paint as possible back into the paint tin or pot before
cleaning.
The same process should be used for roller or mitt.

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Brush and Roller
If you have used a solvent based material, clean the brush or roller in the correct solvent or
equipment cleaner.
Check the product data sheets for advice on the type of solvents to be used for equipment cleaning.
Ensure you are still wearing the correct PPE and RPE such as goggles and gloves.
Do not remove the RPE and PPE for equipment cleaning as the task is still hazardous.
If an emulsion or water miscible coating has been used you can clean with detergent or water.
This process can only be done while the material is still in liquid state. It is not possible to dissolve
cured paint.
Run water over the brush or roller until all paint has been removed.
Check the procedures for correct disposal of the water etc.

- Page 195 -
Brush and Roller
Once the brush or roller is cleaned in water or solvent it is still a good idea to wash the item with a
light detergent.
This process is only generally applicable to the decorative industry products.
This process will not work with heavy duty or industrial coatings which are only soluble in solvents.
Failure to clean correctly will result in unusable equipment.
Bristles or roller hair will go hard.
Re-dissolving with strong solvents will damage equipment and leave bits within the roller or bristles.
Bits of dried coating will appear in the next application coating.

- Page 196 -
Brush and Roller
Do not leave brushes or rollers in the paint tin or container for long periods of time.
Leaving paint brushes or rollers in paint make cleaning a lot more difficult as well as reducing the life
of the equipment.
Always remove brushes and rollers from the paint tin or container and clean correctly before storing
away for further use.
Poorly Cleaned Paint Brush
A poorly cleaned paint brush could lead to contamination when used at a later date.
A bitty surface finish is produced as pieces of old paint etc are passed onto the next coating.
Excessive cleaning or cleaning with strong solvents etc can also loosen the hairs which can also be
placed within the next coating.

- Page 197 -
Two Part Coatings
There may certain coatings with very strong colours or quick during two part products that make the
cleaning of the roller uneconomical and they are disposed of at the end of the shift.
The roller apparatus can be cleaned and put away safely while the roller is safely disposed of.
Poorly Cleaned Roller
If the roller head is cleaned with solvents for re-sure the process must be conducted correctly with
the right solvent and allowed to dry before being used again, especially with a different generic
coating.
Roller heads can retain some of the cleaning solvents and this can effect the next coating.
Conduct a test piece first prior to overall use.

- Page 198 -
Paint Spray Equipment
The protective coatings applicator may assist the paint sprayer during coating application and
equipment cleaning.
Training on spray equipment will be necessary before the paint sprayers assistant can assist in
equipment cleaning.
Equipment manuals should be available to the operative and work should always be supervised.
Suppliers training may also be conducted on equipment cleaning and maintenance.
Paint Spray Equipment:
Always ensure the spray equipment is not under pressure before removing any of the parts.
Never leave paint in the spray equipment or in the paint lines.
Always read the equipment supplier's instruction manual on conducting maintenance, cleaning and
general inspection of the equipment.
If in doubt ask!

- Page 199 -
Paint Spray Equipment:
It is important that you use the correct type of equipment cleaner/solvent (sometimes called gun
cleaner).
Ensure all cleaning materials are disposed of correctly.
Check the method statements for the process and ensure a COSHH and risk assessment has been
conducted for the specific task.
Always wear the correct level of PPE and RPE for equipment cleaning as the process is still
hazardous.
Paint Flushing
When you have finished with the spray equipment, it is common to flush the equipment with solvents
or thinners to clean all the paint from the equipment and spray lines.
Allow the solvents or thinners to flush right through the equipment until you see a clear liquid.
Always remember to remove the tip for this process.
Air Assisted Spray Equipment

- Page 200 -
The process of cleaning air assisted spray equipment is relatively straight forward.
1. Remove as much paint as possible from the pot

2. Pour the correct solvent into the pot
3. Pull the trigger until the solvent comes through clean
4. Remove the air cap and fluid needle and place in the solvents
5. Never place the gun in solvent as this can dissolve the oils on the leather packings
6. solvent clean all the threaded connections on the gun
7. Dry all parts and reassemble the gun
8. Store correctly
Warning!
Cleaning brushes, rollers and spray equipment with solvents is still hazardous and full PPE and RPE
is required;
• Body protection
• Solvent resistant gloves
• Inhalation protection (masks)
• Eye protection
Only clean equipment in a well ventilated area and ensure a Risk Assessment is available and
understood.

- Page 201 -
Summary
In this training unit we have reviewed the cleaning of application equipment such as brush and roller
along with spray equipment.
We reviewed the cleaning process and the problems associated with poorly cleaned application
equipment.
We also discussed the requirement for PPE and RPE during the cleaning process.

- Page 202 -
UNIT: 5.5.5
MAINTENANCE PAINTING OPERATIONS

- Page 203 -
Objective
This training unit will review the elements of maintenance painting.
The unit specifically relates to external onshore steel structures.
Maintenance Painting
Maintenance painting is generally defined as partial or full removal of existing coatings and touching
up, fully overcoating existing coatings or recoating in order to maintain a structure.
There is no single method of maintenance painting and the process varies from client to client.
Options available include:
• Spot repair coating breakdown and touch up locally

• Spot repair coating breakdown touch up locally and fully overcoat
• Fully remove coating i.e. Isolated locations and fully coat i.e. Tank external on a site or
partial pipe rack.
The chosen process is usually based on the maintenance philosophy and budgets etc.

- Page 204 -
Maintenance painting can also be conducted during repairs or shut downs.
Examples:
1. A tank internal inspection is necessary so the tank is emptied and inspected. Minor touch
up may be considered if time permits.
2. Insulation on a valve has to be removed for bi-annual inspection. Preparation and coating
may be conducted on the valve prior to re-insulating.
The above examples may be classified as emergency repairs, however it is still maintenance and
does illustrate the complexity of conducting maintenance painting.
Maintenance painting can also be conducted during repairs or shut downs.
Examples:
1. A tank internal inspection is necessary so the tank is emptied and inspected. Minor touch
up may be considered if time permits.
2. Insulation on a valve has to be removed for bi-annual inspection. Preparation and coating
may be conducted on the valve prior to re-insulating.
The above examples may be classified as emergency repairs, however it is still maintenance and
does illustrate the complexity of conducting maintenance painting.

- Page 205 -
In an ideal world a structure is fully prepared and coated at new build to give a designed life i.e. 25
years.
The structure should be maintained locally before the coating breakdown is too large, say below 5%
of the surface area. Overall coatings may be applied also.
In a mildly corrosive environment minor maintenance may be conducted at say 7, 15 and 20 years
to achieve a 25 year life prior to full maintenance.
We are not, however in an ideal world and maintenance may be dictated by economics, insurance
company, profits, oil prices, access availability and client knowledge or ignorance.
No two sites will be the same.
Economics
Maintenance painting is more economical than total refurbishment which would consists of total
removal by abrasive blast cleaning, water jetting etc. and application of the coating system by spray
type methods.
Maintenance painting can be done on a localised basis and spot repairs can generally be conducted
while plant is in service.

- Page 206 -
Monitoring coating breakdown and conducting repairs before overall refurbishment could entail
annual costs, however the budgets over 5, 10 and 20 years will be considerably lower than ad-hoc
refurbishment.
Touch up repairs can be also conducted after hand preparation methods.
Whole Lift Cost
The whole life cost of the structure must be considered when conducting maintenance painting.
The process must be calculated over the design life i.e. 25 years.
Maintenance may be conducted, say every 5 years so and therefore 3 maintenance programmes
will be carried out.
The initial steel condition and type of coating system are important factors in maintenance painting.
Other considerations for calculating whole life costs include:
• The environment or service condition

• Labour, material and access costs
• Maintenance intervals
• Methods of surface preparation
• How long the coatings or repair will last

- Page 207 -
Coating Specifications
A specific maintenance painting specification should be developed.
The specifications should consider how the coating is repaired and re-painted.
Too many specifications are developed for new build and do not really consider the long term
maintenance.
A maintenance painting specification would be used to 'track' the coating systems used and ensure
compatibility of coating systems.
If existing coating systems are unknown then compatibility trials would be necessary. Coating
compatibility trials, including adhesion tests, should be supervised by an experienced and suitably
qualified Coating Inspector.
The coating supplier should be involved with any compatibility tests and produce technical reports
etc.
Adhesion
It is extremely importance to achieve good adhesion with the new coatings used in maintenance
painting, especially with overall coats.

- Page 208 -
Some existing coatings could be hard and have an impervious surface.
A number of options to ensure good adhesion is achieved include:
• Solvent clean (wipe)

• Abrade by abrasive paper or light abrasive blast cleaning
• Using specially developed tie-coat
Some specifications require that the maintenance coating is brush applied to ensure the coating
wets the surface which will assist in coating adhesion.
Coatings Survey
A coatings survey should precede a planned maintenance programme.
The coatings survey will ensure that spot repairs, touch up, overall coats etc. can be conducted on
the existing coating.
The survey will include:
• Location
• Substrate material
• Coating type (if known)
• Adhesion (specify adhesion test)
• Extent of coating breakdown
• Blistering
• Flaking and general adhesion failure
• Corrosion
• Chalking
• General Coating Defects
The extent of coating breakdown should be detailed as scattered or localised.

- Page 209 -
Coating Survey (cont)
The coating survey should detail any contamination such as grease, oil etc. that will require to be
removed prior to any form of surface preparation being conducted.
Removal of such contamination could be achieved by:
• Solvent cleaning
• Degreasing, alkali, emulsion, cleaning agents
• High pressure water jetting
• Steam cleaning
Removal of heavily contaminated surfaces may reveal unidentified coating breakdown or corrosion.
Scope of Maintenance
Although a maintenance painting specification may exist, a coating survey can be used to define the
scope of work for the painting contractor.
It is important that all parties are aware of the extent of the work so there will be less risk of potential
disputes between contractors and plant or equipment owner about the extent of repairs etc.

- Page 210 -
Because of the aforementioned any coating survey should be specific with regards to scattered or
localised coating breakdown.
Pre-Job Conference
A pre-job conference between all interested parties is essential for a successful coating project
where the specification is reviewed and to ensure that all members of the project team understand
the requirements.
Specifications for maintenance painting can vary from job to job depending on:
• Condition of surface to be repaired

• Extent of repairs
• Methods of surface preparation
• Plant shutdown
• Effect on plant personnel at the site
• Budget constraints
• Use of in-house or contract labour
• Accessibility
• Client requirements
A site visit may be beneficial to review points in the specification where interpretation and agreement
are required.

- Page 211 -
Surface Preparation
Surface preparation can be more difficult compared to a full refurbishment or new build project.
There is a possibility of widespread contaminants such as:
• Grease
• Oil
• Chemical salts
• Corrosion products etc.
These must be removed prior to conducting any form of surface preparation.
A trial removal process is always recommended.
There will be an element of pre-surface preparation required to existing coating which may be
established with the paint compatibility trials.
Apart from grease and oil etc there maybe soluble salts on the surface. Chalking may also be
present. The degree of chalking will depend upon the type of coatings previously used ie epoxy and

- Page 212 -
the amount of sunlight. Chalking is a white powder substance that must be removed, however it is
not always clearly visible especially on light coatings.
All forms of surface contaminants must be removed before applying new coatings.
Although some coatings are called "surface tolerant" it is essential to have a clean surface and
achieve good adhesion otherwise you will get premature coating failure.
Coating Systems
There is no single source maintenance coating system. Variables include the types and methods of
preparation, temperature, location, environmental conditions, existing coating system etc.
Coating suppliers have developed surface tolerant coatings that can be applied onto mechanically
prepared surfaces, old coatings etc.
Examples include;
- High build epoxy with or without aluminium to about 200 microns in one or two coats followed by
the application of a urethane acrylic or polyurethane.
- Specialist solvent free surface tolerant coatings that can also tolerate some moisture
- Moisture cured coating systems
If the surface can be abrasive blast cleaned zinc primers are an option, however this is not
recommended for spot repairs due to overlap issues

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Containment
Containment is usually a requirement when conducting surface preparation and coating activities.
The containment will stop used abrasive and dust escaping from the work place while allowing
controlled conditions around the work face.
The containment will also contain any overspray etc.
There are various types of containment from basic monoflex sheeting to heat shrink type which is
more robust.
Operation of Plant and Equipment
In many instances the plant and equipment will be in operation and live.
Any maintenance painting must be strictly conducted in accordance with the Health and Safety
rules. Permits to work may be required.
All personnel must be aware of the potential hazards with the particular environment.
Prior to conducting any form of surface preparation, removal or protection of sensitive items maybe
required against possible damage.
Masking certain items such as gauges and dial faces maybe a requirement. The scope of works or

- Page 214 -
specification should detail the requirements of equipment protection or removal.
Forms of Surface Preparation
There are various forms of surface preparation used for maintenance painting and the two most
commonly used are mechanical preparation and abrasive blast cleaning.
Mechanical tool Preparation - Wire brushing, discing, sanding and grinding are the most common
form of mechanical surface preparation.
The process of mechanical preparation can be labour intensive and slow but is capable of preparing
individual spots of coating breakdown back to bare steel.
The sanders and certain grinders are also used to feather edge the existing coatings.
The operator should ensure that the spot repairs do not polish the surface increasing any risk of
reduced adhesion for the coating system.
Mechanical Preparation
Mechanical preparation is often used as method of surface preparation. If the prepared area is
ground to to a very shiny surface they could be potential paint related adhesion problems.
The surface should not be polished as illustrated.

- Page 215 -
A slight roughening will help with the adhesion of the coating.
Feather Coating
It is important to the integrity of the full coating system that the existing coating is feathered at the
periphery of the repair areas.
This photograph demonstrates feathering of a coating system on a spot repair.
All the existing coating should be visible around the circumference of the spot repair.
There should be no lip or edges on the existing coating.
Spot repair coatings should overlap the existing coating by 50mm (2 inches)
Maintenance -Spot Repairs
When conducting spot repairs it is important to feather edge the existing coating to a firm edge.
Orbital sanders are ideal for this process as they are quick and efficient.
Hand sanding is also an option.
Don't use to rough of a sandpaper as you can damage the existing coating.
The coating overlap should be around 50 mm (2 inches)

- Page 216 -
Forms of Surface Preparation (cont)
Abrasive Blast Cleaning Abrasive blast cleaning may be used for spot repairs. The surface
preparation and surface profile will be better than that produced by mechanical tool preparation,
however there is a danger of damage to adjacent coatings.
The impact of the abrasive could crack the existing adjacent coating which may result in loss of
adhesion at a later date.
If abrasive blast cleaning is conducted for spot repairs the following is recommended:
• Use lower pressures

• Use the correct type of blast nozzle such as a straight bore type
• Select abrasive to suit the process
For thick coatings an additional mechanical or hand feathering process may be required.
Compatibility between Coats
Maintenance painting is often conducted on old and aged coatings.
Newly applied coatings can be incompatible with part or all of the existing coatings.

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If there is an incompatibility issue, curling could occur. Curling is a term used to describe the lifting
and softening of a coating due to a reaction with the repair coating.
The process may be visible instantly or take a number of days or weeks to develop.
A deformation of the coating occurs and removal is the only option.
Trial Location
A full preparation and coating trial is recommended when conducting maintenance painting.
All parties should be fully aware of the level of pre-cleaning, extent of surface preparation and
coating application required.
The trial would also identify any technical issues with the surface preparation or coating systems.
The trial should be marked up and used as a quality standard and reference area if a dispute arises
about the quality of workmanship.
Ambient Conditions
The surface preparation and coating activities must be conducted in accordance with the coating
manufactures recommendations.

- Page 218 -
As most of the work will probably be exposed to the elements and subject to change, the use of
surface or moisture tolerant fast drying coatings may be necessary.
It is not always practical to cover the location while conducting hand preparation and coating,
however if abrasive blast cleaning was to be adopted full containment would be necessary and the
environment could be controlled allowing the use of most maintenance products.
Inspection Activities
Coating inspection should be used when conducting any maintenance painting programmes.
The coating inspector may assist with the coatings survey and review the scope of work.
The coating inspector should be available for the pre-job conference between owner and painting
contractor.
• An inspection plan should detail the Inspection Activities including:

• Pre-inspection of the structure coated
• Surface preparation
• Coating Application
• Inspection and reporting

- Page 219 -
Summary
Within this training unit we have reviewed maintenance painting operations.
We reviewed the options for maintenance painting and the problems associated with contamination,
overcoating, compatibility problems etc.
We also discussed the methods of surface preparation and coating systems.

- Page 220 -

1protective Coatings Application Unit 5

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Protective Coatings Application

Relative humidity can be classified as:

Relative humidity is expressed as a percentage, 1-100%.

Relative humidity varies between different environments.

Copyright 2010 Fitz-Coatings Ltd

Relative Humidity and Dew Point

Generally a maximum relative humidity is specified at 85-90%.

Copyright 2010 Fitz-Coatings Ltd

Amine Bloom on a Coating

This is an illustration of amine bloom on an amine cured epoxy coating.

Coating failure is a high risk if you overcoat the surface bloom.

Copyright 2010 Fitz-Coatings Ltd

Checking the Relative Humidity

A whirling hygrometer is an instrument used for checking the relative humidity.

Electronic version of the equipment are also available.

Assessing the Relative Humidity

Training can be conducted on:

• How to use a whirling hygrometer.

Copyright 2010 Fitz-Coatings Ltd

Use of a Whirling Hygrometer

Any trained personnel can use a whirling hygrometer.

Relative Humidity Equipment

The gauge (dew meter) must be calibrated regularly.

Copyright 2010 Fitz-Coatings Ltd

Relative Humidity and Dew Point

With a little practice this process is relatively simple.

Copyright 2010 Fitz-Coatings Ltd

Steel Temperature Gauge

Steel Temperature Gauges

Whirling Hygrometer Thermometers

Copyright 2010 Fitz-Coatings Ltd

Until recently all whirling hygrometer thermometers held mercury.

Spare thermometers should be available and stored correctly.

Always store the instrument after use.

Some environments such as offshore platforms have constant high humidity.

Controls may be required during surface preparation and application of coatings.

Copyright 2010 Fitz-Coatings Ltd

We also discussed the calculation charts etc.

Copyright 2010 Fitz-Coatings Ltd

Protective Coatings Application

Copyright 2010 Fitz-Coatings Ltd

Copyright 2010 Fitz-Coatings Ltd

The magnetic thermometer is a simple process.

Check for damage before use then:

• Fix thermometer to surface.

• Leave for approx 10-15 minutes.

• Check and record the temperatures.

• Remember where the gauge is placed!

Store the gauge away at the end of every use.

Magnetic Steel Temperature Gauge

Copyright 2010 Fitz-Coatings Ltd

Digital thermometers are easy to use.

Electronic Steel Temperature Gauge

Steel Temperature Gauges

Simple animation of steel temperature gauges.

The magnetic gauge is intrinsically safe and robust.

Copyright 2010 Fitz-Coatings Ltd

Steel Temperature Gauge in Operation

• Simple to operate and use.

Conduct a number of steel temperature checks.

Copyright 2010 Fitz-Coatings Ltd

Record all findings for future evidence.

Coatings should be selected to suit environment and steel temperature.

Some coatings can withstand temperatures above 400