ENVIRONMENTAL MANAGEMENT SYSTEM STANDARD OPERATING PROCEDURE QSRM 1. Title Standard operating procedure for “Spray painting” ‘To define the operational procedure to be performed during spray 2. Purpose painting for the vehicles This procedure describes the processes for managing health and safety risks associated with painting activities conducted at the SRM 3. Scope Institute of Science and Technology. This procedure addresses the requirements of the Safe Work Australia Code of Practice “Spray Painting and Powder Coating 4. Responsibility | General Manager Transport, Painting i charge 5. Role of a Repair Painter A Painter prepares body surfaces on motor vehicles, and assists in applies paint and other coatings. The individual also assists the Paint Specialist to carry out specialised painting jobs in workshops, which have specialised paint shop set-up within the body shop. An individual on this job should primarily have good memory to recall the Paints and allied material and its storage location for easy retrieval when asked by the senior Painter. The individual must have a strong eye to see even the minute scratches on different vehicle structure and surface. A technical bend of mind is desirable to understand the technical aspects of the vehicle relating to the auto spray-painting, assist in mixing variation of colours and sanding, filling and shaping, 5.1. Job duties of a Repair Painter in automobile workshop + Auto body painters remove rust and other debris from surfaces to be painted, fill cavities and dents in vehicles to create an even surface, mask or tape off details and components to avoid contamination and select the proper colors and substances for the project. + Maintain a working knowledge of current industry best practices in automotive repair. EMS-SOP-SP-Version 01 Page 1 of 20ENVIRONMENTAL MANAGEMENT SYSTEM @ S RM STANDARD OPERATING PROCEDURE Geamn inna + Conduct extensive diagnostic procedures to determine the sources of customers” problems and provide accurate repair recommendations. + Conduct necessary repairs * Maintain legible and accurate paperwork for both the customer and for our records + Clean and maintain the work environment to ensure equipment longevity and workplace safety. 5.2. Personal Requirements for a Repair Painter Following are the personal requirements for this job: + able to operate welding equipment + be physically healthy + have correct eye vision + have the capacity to work independently + work as a team member + should be able to pay attention to detail + have normal hearing + have no skin sensitivities + Should pay attention to safety. 6. Procedure 6.1. Vehicle Surface Preparation ‘When an accidental vehicle is brought to a work shop for repairs, the affected panels are either repaired by denting and painting or replaced and painted. It is the job of a body repair technician to assess the damage and repair the panel to bring it to its original shape. However, as a painter you will still need to prepare the surface before painting it. Surface preparation includes all the processes involved to restore a damaged or replaced panel So as to prepare the base for the top coat of paint. The following are the purposes of surface preparation: + Protection of the base metal. Protection from blisters and rust. * Better adhesion. Better adhesion between the various layers. EMS-SOP-SP-Version 01 Page 2 of 20ENVIRONMENTAL MANAGEMENT SYSTEM ©) S RM STANDARD OPERATING PROCEDURE. SS? Sees * Shape Restoration. Small dents or scratches are filled to restore panels to original shape. + Surface Sealant. To stop the absorption of the top coating paint material. 6.2, Surface Preparation Materials ‘The 3 main types of surface preparation materials are, + Primer + Putty or Body Fillers + Surfacer ‘These materials have different properties and uses and are usually used based on the condition of the panel as well the type of the base metal. 6.2.1. Primer Primers are used in a very thin layers over the base metal and usually do not need to be sanded. The following are the uses of primer: + Rust prevention + Adhesion between the base metal and the other layers, There are primarily four types of primers available + Wash Primer: Also known as Etching or self-etching primer, wash primer has an acid hardener added to it which etches the surface to make better adhesion. Due to this quality it can be applied directly to bare metal and makes for better rust prevention. There are one component options available however the two component wash primer has better rust prevention and adhesion properties. + Lacquer Primer: This type of primer is easier to apply and dry a lot faster, However, rust prevention and adhesion of the two component primer is superior to this type of primer. + Urethane Primer: Urethane primer is a two component grey surfacer designed for overall jobs. It fills well, sands easily and provides excellent colour holdout for all top coats. Epoxy Primer EMS-SOP-SP-Version 01 Page 3 of 20ENVIRONMENTAL MANAGEMENT SYSTEM ©) S RM STANDARD OPERATING PROCEDURE NF Sree Epoxy primer refers to sealer that is a non-porous finish. It is primarily recommended as the first base coat over bare steel. These base coats or epoxy primers can be used over fiberglass, plastic or the black iron phosphate coating, This primer can also be used on cracks and dents, Its bonding capacity is excellent and produces a good surface finish. Epoxy primers not only offer excellent adhesion to metals, but also serve as a proper base for extra undercoat products and top coats (paint) 6.2.2. Putty or Body filler Putty is a paste type undercoat material which is used to fill gaps and depressions and provide a smooth surface. Depending on the depth of the dent and the material there are a few different types of body fillers or putty available. Usually a spatula is used to apply a thick coat of body filler and then sanded to get a smooth surface. + Polyester Putty: Polyester putty is two component type putty. This type of putty is usually applied in thick coats and can be sanded off easily however it may leave a rough surface. + Epoxy Putty: Similar to the polyester putty, epoxy putty is a two component type putty which is stored separately until use, Due to its excellent rust resistance and adhesion to different base materials, epoxy putty is usually used for repair of resin parts. The curing, shaping and sanding performance of epoxy putty is not as good as polyester putty. + Lacquer Putty Lacquer putty is a one component type putty usually used after the surfacer to fill small seratches, pin holes and small dents. 6.2.3. Surfacer: Surfacers are applied over the primer, putty and other undercoats. It is a kind of 2nd coat paint which has the following qualities + Filling of light dents and paper scratches. + Stopping top coat absorption. + Adhesion between undercoat and top coat, Make sure to read the manufacturer's manual when using with the previous mentioned primers. EMS-SOP-SP-Version 01 Page 4 of 20ENVIRONMENTAL MANAGEMENT SYSTEM STANDARD OPERATING PROCEDURE + Lacquer Surfacer : This is a one component surfacer used for its ease of use and quick drying qualities. However, compared to other surfacers the adhesion and coating performance of Tacquer surfacers is not comparable 6.3. Repair Painter * Urethane Surfacer: Urethane surfacer is a two component type surfacer which has great coating performance however takes longer to dry at room temperature. Due to this problem itis usually force dried which is believed to hinder the coating performance. + Thermosetting Amino Alkaloid Surfacer: This is a one component type surfacer used for bake finish repainting as a primer, The baking is usually done at 900 C to 1200 C but the finish and coating performance of this is as good as of a new vehicle 6.4, Substrate Treatment 1. Identifying Paint: It is very important to identify the existing paint on the panel to be repaired. It is crucial to know the type of paint on the panel to avoid any major issues that may be caused otherwise. For eg. if the panel to be repaired has had an lacquer paint job in its history then the thinner from the surfacer or the top coat can seep through the old paint causing shrinking in the paint. A.common way to determine the type of paint is to rub the surface of the repaired panel with a rag dipped in lacquer thinner. A baked or urethane type paint job does not rub off however if itis a lacquer paint you will see the paint come on the rag. 2. Assessing the Extent of Damage: Before any repair work can be started, it is important to evaluate the damage and choose the suitable repair method. This can be achieved by the following 3 methods. ) Visual Inspection: Most of the damage to a vehicle is visible to the naked eye. The reflection on the panel surface is a great indicator of the deformation, It is important that the technician ‘moves around and inspects the panel by aligning his/her eyesight with the work area. The technician should also check the rest of the parts to compare or align the panel on which the repair has to be done. It is important that the inspection is done at this stage as once the repair work starts it becomes very difficult to evaluate the damage accurately. EMS-SOP-SP-Version 01 Page 5 of 20ENVIRONMENTAL MANAGEMENT SYSTEM © S RM STANDARD OPERATING PROCEDURE Sereereoeamncee ) Inspection by touch: Another way to identify the damaged area is by feeling the damaged area by hand. Move your hand on and around the damaged panel to feel for irregularities. This is an ideal method to locate small dents in a panel. Move your hand around the damaged area and original panel in a horizontal motion to identify the dents. ©) Inspection with a ruler: Place a ruler on the pane without damage and measure the clearance between the panel and the ruler at different points. Now place the same ruler on the damaged panel and check for difference in measurements from the measurements from the original panel. This method gives a more accurate quantitative result than the other two methods. Before the repair work can begin, the technician should make sure that that there is clear access to the panel to be worked on from both sides. Sometimes this involves removing some mechanical parts or seals and coatings. For example, when repairing a car door the technician will have to remove the locks, glass and window machinery. Tools mentioned earlier are used to remove these parts as most of the parts are fixed with nuts and bolts. It is also important to secure the unharmed panels of the vehicle by covering them, especially the edges with masking or protective material like masking tapes. These masking tapes are available in various materials and should be chosen based on the protection needed. ther skills Although the correction of mechanical difficulties caused by the collision involves and techniques than are practiced by the body technician, he/she must make sure that the body and the mechanics work perfectly together after the repair 3. Repairing Dents: Usually it is the repair technician job to remove the dents before the vehicle comes for paint. However, sometimes there might be very small bumps in the panel protruding, out of the surface of the original shape which should be hammered in, just below the original shape. A pick hammer or impact punch is used for this. 4, Removing the Paint: When an area of a vehicle is damaged it usually impacts the paint as well as the bare metal. It is always recommended to remove the ori inal paint before starting work to avoid peeling of the paint later. 5. Featheredging: The edge of the paint film is usually thick. Featheredging is the process of smoothing out the edges by sanding the edges to give it a gentle slope. Unable to do so may ‘cause a clear line visible after the top coat application. EMS-SOP-SP-Version 01 Page 6 of 20ENVIRONMENTAL MANAGEMENT SYSTEM STANDARD OPERATING PROCEDURE. SRM 6. Cleaning and Degreasing: An air duster gun should be used first to remove or blow off any sanded particles or dust that may be stuck on to the panel, The next step is to use a degreasing solvent to moisten the surface and remove any oil residue that may present itself with a dry rag. Ifany residue is left on the surface it may cause blisters or peel offs in the future. 7. Applying Primer: Primer is applied to the bare metal surface to ensure rust prevention and better adhesion, In most places a two component primer is used for automotive repairs however ‘one component primers ate also available. It is important to note that some primers may not provide the desired adhesion with the chosen primer so make sure to read the manufacturer's specifications and directions before use. + Mask the area neighbouring the area where the bare metal is exposed. + Follow the manufacturer's directions when mixing the hardener and thinner to the primer + The coat should be 0.1-0.2 mm, + Let the coat air dry for atleast 10 mins. + After the spraying remove the masking. + Make sure to wear safety glasses, respirator and solvent resistant gloves when applying the primer 6.5. Body 1. Checking the coverage of the body filler: To determine the amount of putty/body filler to be mixed it is important to again assess the extent of damage but this time without using your hands as they may leave some oil traces. 2, Polyester Putty/ body filler mixing: Often, the ingredients of the putty that is solvent, resin and pigments get separated in the can, So, prior to removing the putty from the can use an agitating rod to mix the entire ingredients of the can. Same goes for the hardener tube. Squeeze the tube before opening to mix the contents evenly. ‘The next step is to remove the putty on to the mixing plate and mix it with hardener in the ral recommended by the manufacturer. Make sure to mix the putty by scooping and folding the mixture till there is a uniform colour 3. Applying Body Filler EMS-SOP-SP-Version 01 Page 7 of 20ENVIRONMENTAL MANAGEMENT SYSTEM © ) STANDARD OPERATING PROCEDURE NO Sierra ms ix + First step is to select the right spatula for the job at hand, The following image shows an effective way to hold a spatula. The idea is to have proper control on the putty spreading. Make sure you do not apply large quantities of body filler at a time. Depending on the location and shape apply thi coats of the body filler. Scrape the body filler on the work surface enough to make sure that it enters every scratches and dents for proper adhesion. Increase the amount of body filler from the third stroke keeping the spatula a about 350 to 450 angle. Make sure to apply thin layer of body filler on the edges. 4, Drying the Body Filler: The reaction between the components of the body filler creates heat which starts the curing process. It usually takes about 25-30 minutes for the drying process after which the surface is ready for sanding, However, some ambient factors like high humidity or cold can slow down the process in which cases infrared lamps or heat guns can be used, 5. Sanding the Body Fillet: After the curing process, the unnecessary high spots have to be sanded down using a sander or a hand block. An orbital or dual action sander can be used for sanding. + Attach a #80 Grit sandpaper on to the sander and move the sander in all the di- rections to cover the complete area, + Repeat the process by attaching a #120 grit sandpaper on to a hand block. In this step, make the work surface is close to the original/desired shape. + Finally, use a #200 grit sandpaper with a hand block. At this stage you will have to sand outside the putty application area. This is done to make sure that the peripheral area of the repaired area is equalized with the rest of the panel. 6, Removing the Paper Scratches: This can be done by using about a #120 grit sandpaper on a hand block. Sand down the entire area removing all the paper scratches that might have been made by the #200 grit sandpaper. Make sure the periphery is featheredged. EMS-SOP-SP-Version 01 Page 8 of 20ENVIRONMENTAL MANAGEMENT SYSTEM STANDARD OPERATING PROCEDURE, 6.6. Surfacer Application 1. Scuffing: If surfacer or paint is applied to a surface without first preparing the surface, there is a possibility that proper adhesion may not be achieved causing the different layers to be separated if vibration ot body force is applied. In this process small marks or scratches are formed on the surface with a sandpaper. This is done to expose the active surface and in- crease the surface area of contact to enhance adhesion, Featheredging is also a part of this, process A dual action sander can be used with a #300 grit sandpaper to prepare the surface for the surfacer application. Sand surfaces around the putty applied area till the gloss of the paint is completely gone. Avoid sanding over the influence lines or edges of the panel being repaired. 2. Cleaning and Degreasing: Similar to the process in the previous steps a degreasing solvent should be used to ensure a residue free surface. You should take special care to remove any particles that might be stuck in pin holes or the surface by blowing compressed air through the air gun 3. Masking: To save the unwanted parts of the vehicle from getting over-sprayed masking is, done. Ensure the complete scuffed area is also accessible when masking, 4. Surfacer Mixing: Get the surfacer ready to get sprayed by mix- ing the components and thinner as per the manufacturer's recommendation. It is important to get the right consistency to ensure a smooth finish. 5. Surfacer Application (a) Mix the surfacer and thinner evenly using an agitating rod. Pour the mixture through a strainer into the paint cup of the air spray gun. (b) Spray a light layer of the surfacer onto the surface till the complete putty area looks wet. (c) Wait until the shine on the surface dulls down a little, this happens as the solvent evapo- rates. EMS-SOP-SP-Version 01 Page 9 of 20ENVIRONMENTAL MANAGEMENT SYSTEM ©) S RM STANDARD OPERATING PROCEDURE. NO semcgronsintnsies (d) Follow step (b) to apply atleast 2-3 more layers of the surfacer If there are any very minor deformations in the body filler more surfacer can be applied to that part but make sure it doesn’t drip. 6. Drying the Surfacer: Make sure that when a surfacer is force dried using an infrared lamp it should be done according to the manufacturer's recommendation only. 7. Applying the touch up putty Inspect the surface for any pinholes or sanding scratches. Apply the touch up putty to cover any such deformations found using a spatula. 8. Drying the Touch up Putty: Let the touch up putty dry fully or force dry it following the manufacturer's recommendation, 9. Sanding the Surfacer: The surfacer can be dry sanded or wet sanded. Choose a sanding technique based on the pros and cons discussed in the previous unit. ‘A #400 to #600 grit sandpaper is usually used at this stage. 10, Scuffing for the Top Coat: It is very important to scuff the surface before applying the top coat. 11. Applying Surfacer to a new Panel: If a panel is replaced it means that it may not require any body filler treatment, The process of painting a new panel usually starts with the application of a surfacer. 6.7. Masking Masking is a protective method in which adhesive tapes and papers are used to cover the parts which do not require finishing, During surfacer and top coat application, the neighbouring areas are protected using this method from overspray. As the name suggests, overspray is when the paint is sprayed beyond the part that needs to be repainted, This is done to make sure that the edges of the panel are properly painted. For example when a rear door of a car is to be painted the following image shows the overspray range. The overspray range is usually not too far from the panel but this may differ depending on the air pressure and spray gun handling. Masking is done to protect from this overspray. This is EMS-SOP-SP-Version 01 Page 10 of 20ENVIRONMENTAL MANAGEMENT SYSTEM ( S RM STANDARD OPERATING PROCEDURE done using masking tapes and masking papers which have been shown in the previous units. In this unit we will learn about the various applications of masking, 6.8. Masking Methods 1. Masking for Surfacer Application: The masking for surfacer application is kept simple as it does not require as high pressure as when top coating, Reverse masking is used for this process. Reverse masking is the process when the masking paper is applied inside out so that along with the border a light mist of paint is also formed. 2. Masking for Block painting: Block painting is done when repainting @ panel like a door or a fender where the panel needs to be separately masked out. As shown in the figure the door is left out and everything clse within the overspray range has been covered. If there are gaps or holes in the panel, spray mist may stick on to those surfaces, so it is important to mask these areas. In case the gaps are too narrow masking can be done on the inside as shown in the adjacent figure 3. Masking for Spot Repainting: Repainting for a quarter panel can be a little different as there are no clear borders. For such spot repainting shading is used to properly match the paint. Make sure to reverse mask these areas where shading needs to be done. When spot repainting an edge of the fender, only the front end needs to be masked as only a small area has to be painted. 6.9. Masking Precautions Cleaning and Degreasing: Before bringing the car into the work area make sure to get the car washed and cleaned. Areas that are excessively dirty need to thoroughly cleaned and places where the masking tape is to be applied should be cleaned with a degreasing solvent. This way mishaps like air blowing, tape peeling or overspray can be prevented, + Masking Range: The masking range can change based on the repainting method used as well as the method of operating the air spray gun. It is important to identify the minimum range when masking. + Masking of Non-detachable parts: Most of the parts and trims can be removed when repainting any panel, However, some parts are non-detachable or sometimes not worth taking apart. In such cases the masking should be done carefully leaving a gap as thick as the paint layer. If this gap is not left out, the paint will create a bridge between the new painted surface EMS-SOP-SP-Version 01 Page 11 of 20ENVIRONMENTAL MANAGEMENT SYSTEM STANDARD OPERATING PROCEDURE. and the masking tape and moreover removing the tape once the paint job is done will i gt difficult. If the gap is too big then the part will not be masked properly. + Masking on Rounded surfaces: When masking rounded surfaces keep in mind to leave the masking tape loose around the rounded edges as a tight fitting tape may lift or shrink, exposing the surface that needs to be masked, + Double Masking: The masking tape and paper are made of paper and are susceptible to tearing when over exposed to liquids. Keeping this in mind you should apply a double layer of masking, on such parts where there is a chance of accumulation of paint when being painted. + De-masking: Usually the masking materials are removed after the polishing is done however in some cases the masking around the edges should be removed while the paint is still wet as when the paint is dried out it turns brittle and removing the tape at this stage can spoil the paint job. Remove the tape by peeling it out in one direction, Make sure not to pull the masking material erratically. 6.10. Vehicle painting Painting is the process in which a liquid (paint) is applied on to an object and then dried or cured in order to make a solid coat of the paint on the object. The two main purposes of painting, are 1. Safety: Steel and plastics can be damaged due to erosion and in their original form may not be able to provide the desired strength either, Painting not only makes these materials safe from damage from external factors but also makes them usable for longer. 2. Aesthetic Effect: Paint adds colour and gloss to the vehicle and enhances the aesthetic effect of the vehicle making it more attractive. Colour is also added to vehicles for identification of some vehicles such as red to a fire truck and black and yellow to taxies. However now there are a lot more oj mns to enhance the aesthetic effect of a vehicle but paint would still be the more cost effective and impactful method of them all 6.11. Top Coating Preparation Before applying the top coat, preparations need to be done to ensure a time effective and quality result ‘The important preparations can be depicted in the following chart. EMS-SOP-SP-Version 01 Page 12 of 20ENVIRONMENTAL MANAGEMENT SYSTEM STANDARD OPERATING PROCEDURE. 1, Cleaning the Spray Booth: Before bringing the vehicle into the spray booth it is important to make sure that the spray booth is free from dust and other impurities. Use a duster gun to clean the booth and to avoid the dust from flying around in the air, wet the floor with water to avoid seeds in the paint at a later stage 2. Air blow the Vehicle: Use the compressed air from the duster gun to make sure the surface and surroundings are free from any dust particles or moisture. Also make sure that areas with gaps such as trunk lids, fenders or hoods are cleaned properly and all the dust has been blown out of these gaps. 3. Air Blow the Painter’s uniform: It is also important that the painter's clothes are free of any dust or debris after the previous processes. Use a duster gun to clean the clothes as well. 4. Degreasing: Use a shop rag dipped in a degreasing agent to wipe the surface to free it from any grease or contamination. Use a dry rag to wipe down the surface after the degreasing agent as well to free the surface from any oil residue that may have been left. 5. Tack Cloth: As iscussed in the previous section a tack cloth is used to wipe the dust off the surface, To use the tack cloth properly, do not press it hard on the surface as it may cause blisters, 6. Mixing the Hardener: The steps before this step were for the preparation of the vehicle and the surroundings. From this step, we have to prepare the top coat paint for application. To make sure that the hardener added is in the right ratio always read the manufacturer's directions, Carefully measure and mix the hardener as failing to do so may result in peeling, cracking, staining or water spots to occur in the final coat. The measurement may be done by weight or volume, use a weighing scale and measurement containers or scales respectively to successfully get the right balance. 7. Mixing the Thinner: The paint in its original form is very thick and cannot be sprayed through a spray gun. Add thinner to get the appropriate viscosity so that the paint flow and coverage can be optimum. Make sure to read the manufacturer's recommendation when choosing the thinner for dilution. 8. Pouring the Paint mix into the Spray Gun EMS-SOP-SP-Version 01 Page 13 of 20SRM ENVIRONMENTAL MANAGEMENT SYSTEM STANDARD OPERATING PROCEDURE. + Mix the paint, hardener and thinner mixture carefully and evenly using an agitating rod by stirring it + Pour this mixture into the paint cup of the air spray gun through a paint strainer. Make sure the cup is filled to about 3/4th of its capacity only to avoid the leakage from the breather hole. + Close and tighten the lid of the paint cup carefully to avoid any spills. 6.12. Top Coating Process ‘The process followed till this step is same for any type of paint that may be used to repaint the vehicle. Different paints as discussed in the Automotive paints unit may need different coats of materials to be applied on the surface for the desired finish. The most common paint that you will be using in the industry will be a 2K paint where the colour paint is followed by a few coats of a transparent paint called a clear coat which provides the gloss, finish and colour protection. In this section we will discuss the process of applying a coat of material on to the surface using an air spray gun. The process is similar for application of any coat on to the vehicle's surface. It is important that the layers to be applied are in the right order and composition and make sure you read the manufacturer's directions for confirmation. 1. Mist Coat Spraying + The amount of applied paint should be just enough to coat the surface with a small amount of gloss. + Cheek the surface for beads. If beads are found, increase the air pressure and spray a dry coat oon the surface to fan off them. + Recommended air pressure for this step is about 3 kg/m? or 42.3 psi KPa. + Recommended spray gun distance from the panel is about 200 mm or 7.8 inches. 2. Flash Time: Flash time is the time taken for the solvent within the paint to evaporate. Itis necessary to wait for the recommended flash time before applying the next coat for a durable and effective finish to the painted surface 3. Coat Spraying EMS-SOP-SP-Version 01 Page 14 of 20ENVIRONMENTAL MANAGEMENT SYSTEM Q) S RM STANDARD OPERATING PROCEDURE. SS Sis + Keep applying paint till a clear gloss is visible and the substrate is totally hidden. * Inspect the surface to make sure that the substrate is completely concealed. If not, wait for the flash time and repeat the first step till the substrate is completely covered. + Recommended air pressure for this step is about 3 kg/cm2 or 42.3 psi KPa. + Recommended spray gun distance from the panel is about 150 mm or 5.91 inches. 4, Finishing + The paint should be sprayed till the coat has a uniform texture and gloss. + Use the fluorescent light in the paint booth to inspect the texture and gloss. + Recommended air pressure for this step is about 3 kg/em2 or 42.3 psi KPa. + Recommended spray gun distance from the panel is about 150 mm or 5.91 inches. 5. Setting Time: Setting time is an air drying process during which the solvent within the paint is allowed to naturally evaporate before it is dried using heat. 6. Drying: After waiting for 10 to 20 minutes for the setting time, dry the surface for about 50 minutes at 600 C. This process is done when using a paint booth however sometimes depending on the job at hand you may not be using a paint booth in which case the surface can be air dried as well, Following are some examples of the general drying times. Resulting Surface Time Dust Free 0.5 hours Tack Free 3 hours Dry to handle 12 hours Hard Dry 20 hours: 6.13. Spray Gun Operation 1. Holding the Spray Gun: When holding the spray gun make sure your holding arm, hand and elbow are all relaxed. The image shows a typical method of holding the spray gun. 2. Spray Gun Distance: Spray gun distance is the distance between the spray gun and the surface being painted. If the gun is held too close to the surface, the applied coat will be very EMS-SOP-SP-Version 01 Page 15 of 20ENVIRONMENTAL MANAGEMENT SYSTEM RM STANDARD OPERATING PROCEDURE Peaiesinnce thick and there are chances of imperfections. On the other hand, if the distance is too far the coat will run thin and the resulting coat will be irregular and rough. 3. Spray Angle: Spray gun angle is the angle between the surface and the spray gun flow. It is important to keep the gun perpendicular to the surface 4. Stroke Speed: Stroke speed is the speed of moving the spray gun when painting. Ifthe stroke speed is low, the result will be a thick and improper coat and if the stroke speed is high, the resulting coat will be thin and rough. An irregular stroke speed will always result in an uneven coat. 5. Pattern Overlap: When paint is discharged from a spray gun a spray patter is formed which is thinner on the edges in comparison to the middle, To get a uniform coat it is important that the spray pattem is of a uniform thickness. Overlapping is done to achieve this uniform coat. % to 2/3 is considered ideal overlapping width in automotive painting, 6.14, Polishing Method 1. Checking the Paint Texture: Before beginning the polishing process, check the surface for irregularities. Compare the repainted surface to the original surface to determine the difference. If the repainted surface is too coarse and seems very different, it is always recommended to repaint the panel. However, with experience you will be able to accurately assess the difference more accurately and choose the appropriate combination of buffing equipment and materials 2. Wet Sanding with Sandpaper: If seeds or runs are found then use sandpaper to nub them out and smooth out the surface to match the original surface. #1500 to #2000 grit sandpapers are used in this process. To avoid clogging of the sandpaper you may use soap water, 3. Buffing Compound: Once the surface is dry, buff the surface to get the desired gloss and finish, Use an appropriate buffer and buffing compound. 6.15. Polishing Procedure ‘The polishing process is one of the most crucial part of the whole painting process as it shows the final results of all the work done during the entire repair process. Unable to carry out the process properly can result in the whole painting process going to waste. EMS-SOP-SP-Version 01 Page 16 of 20ENVIRONMENTAL MANAGEMENT SYSTEM STANDARD OPERATING PROCEDURE Once you have checked the paint texture for any irregularities, the first step would be to wet sand the surface to remove any nuns or scratches. 6.16. Wet Sani g Procedure 1, Wash and clean the area, Make sure the surface is free from any debris or film before starting the wet sanding, Use a regular car soap and sponge for cleaning the surface. Make sure to rinse thoroughly using a hose. + Avoid using car soap or shampoo with any kind of polishing or waxing material. + There is no need to wait for drying once surface washing is done. 2. Soak the piece of sandpapers in soapy water. Soak the sandpaper by placing the sandpaper along the edges of a bucket so that half of them are in the water. Leave the sandpaper in the water for about 5 minutes. + The sandpaper should be completely saturated with the soapy water. + Half of the sandpaper is soaked so that the dry part of the sandpaper can be used to attach with the sanding tool. 3. Attach the soaked sandpaper on to the sanding tool Wrap the sandpaper around the tool. Avoid sanding with by hand as the gaps between the fingers can make an uneven sanding which would result in an inconsistent finish. Use a tool like a pad or a squeegee for soaking. 4, Sand gently in circular motions, Use soaked sandpaper to start sanding of the surface in small circular motions. Apply very light amount of pressure. Increase the little pressure, if coat is not clear. Don’t apply too much pressure as it may cause seratches on the paint itself. 5. Move the sandpaper in multiple directions. To achieve an even sanding, the sandpaper should be moved in multiple directions. Keep switching the circular motions and sand the entire area evenly at different angles. + Itis difficult to identify an uneven surface while working however it might become visible in the final product + Make sure to apply even pressure even when changing directions. EMS.SOP-SP-Version 01 Page 17 of 20ENVIRONMENTAL MANAGEMENT SYSTEM. STANDARD OPERATING PROCEDURE. + When sanding, the colour may slightly bleed into the water however darker leaking might shows that sanding is too hard, 6, Add water if necessary. Make sure the sandpaper is saturated with soap water throughout the entire process of wet sanding. Keep dipping the sandpaper in the soapy water often and also pour some of the soapy water on the sanding surface. + A dry sandpaper will cause the paint to burn, + Ifthe paint is burnt, whole piece might need to be repainted completely. + The sandpaper should be replaced or swapped if they are worn out or become too soggy for use. 7. Be wary of the edges of your tools. Always keep the sanding tool flat on the vehicle surface avoiding the accidental use of the edges. 8. Follow up with wet sanding of the surface with finer grit sandpapers. Once the entire surface is sanded with a 1200 grit sandpaper, repeat the process with finer grit sandpaper preferably a 2000 or a 3000 grit sandpaper to make sure there are no shallow scratches or abrasions left on the surface by the previous processes. 9. Clean and dry the sanded area, Once the previous steps are completed, use a hose to rinse off the surface. Make sure the surface is free of any soap or debris before applying the polish on the surface. The surface needs to be completely dry so that it can buffed properly. Park the vehicle in the shade as direct sunlight may cause the paint to fade or damage it 10. Dampen the pad before using it on the polishing wheel. Wet the pad of the polishing wheel with clean water. Squeeze out the excess water as it needs to be damp. Make sure the pad is damp throughout the process as a dry pad may damage the paint. 11. Apply the rubbing compound on one body panel at a time. Apply the rubbing compound on the damp pad or directly on to the surface of the vehicle. The polishing wheel or polisher should be pressed against the paint of the vehicle and gently moved along the painted surface. 12, Maintain steady pressure and move the polisher back and forth. Make sure that the polisher -mains parallel to the body panel of vehicle. Always maintain a steady and even pressure on the polisher as it moves back and forth along the surface of the panel being polished EMS-SOP-SP-Version 01 Page 18 of 20ENVIRONMENTAL MANAGEMENT SYSTEM STANDARD OPERATING PROCEDURE 13. Move on to the next panel when a bright finish of the paint is visible. As the polisher wheel moves on the surface, the rubbing compound swirls and smears and then slowly disappears, leaving behind a shining surface. Now move on to the next panel when the shiny paint is seen. 14, Rinse the pad as required. Constant use of the pad causes polishing compound to stick and build up on the pad. You should take breaks from polishing to clean the pad. Rinse the compound off the pad with water and make sure to wring the pad so that it remains damp and clean. 15. Carefully buff around the intricate trim pieces. The edge of the pad moves the fastest and due to its position usually comes in contact with the rubbing compound the least. This makes it a big risk of burning the clear coat of the paint. So it needs extra care when buffing around the trim pieces that comes in contact with the polisher. 16. Wash and rinse the car again. Once all the panels of the vehicle have been polished, clean the pad properly and keep it aside. Make sure the polisher is unplugged and safely placed back. Spray the entire car with a water hose and wash it to ensure there is no rubbing compound left on the vehicle. Thoroughly rinse the vehicle once the washing is done. 17. Let the car dry. The painted surface needs to be completely dry before wax can be applied. The car can be air dried or a microfiber towel can be used to expedite the process. Hard water may cause spots being formed when air dried so use a towel to stop the spots from being formed, 18, Apply a coat of wax. Wax is applied on the surface of the vehicle to protect the new paint ‘as well as give it a bright and shiny finish. Apply the wax on to the application pad and then apply it to the vehicle in a circular motion. Make sure to cover the entire surface of the vehicle with the wax coat as the sun might damage the new paint otherwise. 19. Use a microfiber towel to polish the wax off. Check if the wax is completely dried off. Check it by touching it with your finger, if the wax wipes off under the finger then it is ready to be buffed. Use a microfiber towel to buff off the wax leaving behind a glossy shine ‘I. Automotive skills development council, Participant Handbook, 6.References | ASC/Q1407, Version 1.0 NSQF Level 3, National Skill Development and Corporation, Government of India. EMS-SOP-SP-Version 01 Page 19 of 20ENVIRONMENTAL MANAGEMENT SYSTEM STANDARD OPERATING PROCEDURE .) SRM Effective Date (from) Description Version 03.03.2023 SOP for Spray painting o1 sor SHOR, a Prepared by Verified by Dr. A. Bhargavi Haripriya Dr. S. Gopinath Assistant Professor EMS-SOP-SP-Version 01 Assistant Professor Approved by Dr. T. Rajasekaran GM Transport Page 20 of 20