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APPLICATION GUIDELINES |
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NOTE:
For reference purposes only. For additional or more detailed information
contact POR-15, Inc. or an Authorized Industrial Partner directly.
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Introduction
These guidelines cover the external and internal surface
preparation and the coating of equipment or vehicles. These applications
include, but are not limited to, structural steel and production equipment,
coastal, offshore facilities, manufacturing and processing plants. Some
the general items to be coated are steel structures and supports, piping,
tanks, vessels, pumps and compressors. |
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| Material Handling |
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Most POR-15
products are moisture cured and therefore react with humidity.
Because of this, it is extremely important to limit the
time the container is open and only pour out what material
is needed. |
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All POR-15 products
should and must be stored in a covered shelter. Care should
be taken to ensure that unused containers remain sealed
and partial containers are properly resealed. |
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Ideal temperature
range for storage: 50-75F / 10C-24C. |
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Use only POR-15
solvent for thinning. Substitutions nearly always compromise
application and performance properties and will void any
product warranty because other solvents typically contain
water and impact curing mechanisms. |
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For roller or
brush applications, Use a natural fiber brush or a natural
or synthetic fiber roller cover with a 1/4 or3/8 inch nap.
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Use POR-15 Solvent
for clean-up. |
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| Surface Preparation Standards |
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* View product data
sheets to determine appropriate surface preparation methods
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Modified SSPC-SP-1 |
A two-step preparation system
using Marine Clean™ degreaser (step 1) and Metal Ready™
zinc phosphate (step 2) solution. This modification was
developed due to the limited capabilities of
SSPC I solvent cleaning and the
difficulties associated with certain surfaces with blast
or tool cleaning. |
SSPC-SP-2:
HAND TOOL CLEANING |
Surface
preparation before and after Hand-Too Cleaning entails following
SSPC-1. Remove all loose mill scale, loose rust and other
detrimental foreign matter with non-power hand tools. Under
SSPC-SP-2 it is not intended that adherent mill scale, rust,
and paint be removed by this process. Mill scale, rust,
and paint are considered adherent if they cannot be removed
by lifting with a dull putty knife. |
SSPC-SP-3:
POWER TOOL CLEANING |
Surface preparation before
and after Power-Tool Cleaning entails following SSPC-SP-1.
Remove all loose mill scale, loose rust and other detrimental
foreign matter with power assisted hand tools. |
SSPC-SP-5,
NACE 1:
WHITE METAL BLAST CLEANING |
A white metal blast clean surface
is free of all visible oil, grease, dirt, dust, mill scale,
rust, oxides, corrosion products, paint, and other foreign
matter. SSPC-SP-5 will result in the highest performance
of a paint system since all surface contamination is completely
removed. |
SSPC-SP-6, NACE
3:
COMMERCIAL BLAST CLEANING |
Same as SSPC-SP-5 with the
exception that satins from the removed rust and other surface
contaminants are not completely removed. In addition, the
surface will not necessarily be uniform in colour as it
would under SSPC-SP-5. |
SSPC-SP-7, NACE
4:
BRUSH-OFF BLAST |
A brush-off
blast cleaned surface, shall be free of all visible oil,
grease, dirt, rust, loose mill scale, loose rust, and loose
paint. Tightly adherent surface matter (including rust,
mil scale, and paint) may remain. Note: Not typically performed
on surfaces subject to severe conditions. |
SSPC-SP-10, NACE
2:
NEAR-WHITE BLAST |
Same as SSPC-SP-6 with the
exception that any staining which remains should be minimal
and occur uniformly over the surface; not concentrated in
spots or areas. |
SSPC-SP-11:
POWER TOOL CLEANING TO
BARE METAL |
This standard
is suitable where a roughened clean, bare metal surface
is required, but where abrasive blasting is not feasible
or permissible. It differs from SSPC-SP-3, Power-Tool Cleaning,
in that SSPC-SP-3 requires only the removal of loosely adherent
materials, and does not require producing or retaining a
surface profile. |
SSPC-SP-12, NACE
5:
WATERJETTING |
Waterjetting is used to
achieve a defined degree of cleaning of surfaces prior to
the application of a protective coating or lining system.
This standard is primarily for applications in which the
substrate is carbon steel. However, waterjetting can be
used on nonferrous substrates such as bronze, and aluminum. |
SSPC-SP-13, NACE
6:
CONCRETE SURFACE PREPARATION |
Concrete
must be at least free of contaminants, loosely adhering
concrete, and dust, and should provide a sound, uniform
surface suitable for the application of protective coating
or lining systems. |
SSPC-SP-14, NACE
8:
INDUSTRIAL BLAST CLEANING |
An industrial blast cleaned
surface shall be free of all visible oil, grease, dust,
and dirt, traces of mill scale, rust, and coating. Traces
of the above are permitted if they cannot be lifted with
a dull putty knife. Shadows, streaks, and discolorations
caused by stains of rusts, stains of mill scale, and stains
of previously applied coating may be present on the remainder
of the surface. |
SSPC-SP-15:
COMMERCIAL POWER TOOL
CLEANING |
This standard
is suitable where a roughened, clean, bare metal surface
is required, but where abrasive blasting is not feasible
or permissible. The surface shall be free of all visible
oil, grease, dirt, rust, coating, oxides, mill scale, corrosion
products, and other foreign matter. It differs from SSPC
11 because rust, paint, and scale may remain on the surface. |
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| General Information |
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1. |
Above-grade
equipment generally requires protective coatings for atmospheric
corrosion control and/or aesthetics. |
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2. |
Internal protective
coatings are frequently required in vessels and tanks to
minimize attack from aggressive environments such as acids,
caustics and produced fluids containing chlorides, carbon
dioxide and/or hydrogen sulfide. |
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3. |
Experience has
shown that many of the premature coating failures are due
to improper surface preparation coating system selection
or coating application. Therefore, in addition to utilizing
proven coating systems and products, using experienced coating
application contractors is essential to the success of a
coating job. |
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4. |
POR-15, Inc.
requires coating applications contractors to perform inspection
duties and provide documentation on the following conditions
on a daily basis: weather conditions, blast profile, applied
wet film thickness of the coating and the total dry film
thickness of the project. In addition to contractor-supplied
inspection, some projects warrant having a POR-15, Inc.
representative (or third-party inspector) on location to
oversee the coating contractor’s performance. See application
checklist for additional information. |
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Typically, major
projects warrant an experienced, qualified, technical advisor
from POR-15, Inc. or an Authorized Industrial Partner on
location to provide technical support during the first week
or two of coating operations. Follow-up visits and inspection
are frequently required. |
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6. |
Essentially
all coating projects, regardless of size, warrant pre-job
coating meetings with representatives from POR-15, Inc.,
an Authorized Industrial Partner and coating application
contractors in attendance. Such meetings are effective in
reducing miscommunication and job delays. |
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POR-15, Inc.
specifications specify coating systems that have proven
to be cost-effective in most situations. However, special
conditions such as aggressive process environments or short-life
projects may require coating system modifications in order
to achieve specific project objectives. Also, the coating
systems listed in these guidelines are only recommendations.
Contact POR-15, Inc. or an Authorized Industrial Partner
for more specific recommendations. |
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| Surface Preparation |
Pre-Cleaning
of Surfaces
Prior to any surface preparation, all oil, grease, drilling
fluids, salt, and other contaminants shall be removed (Modified
SSPC-SP1) by washing with Marine Clean™ as specified. High
pressure washing or scrubbing with bristle brushes, as appropriate,
shall be used for initial washing. Then, a final thorough
rinse with fresh water shall be employed. |
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Blasting Abrasives |
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Near-White blast cleaning (SSPC-SP10)
shall be performed using medium or all purpose abrasive
similar to Clemtex Black Grit #3, StanBlast Medium or 16/40
abrasive. Sweep or brush off blasting (SSPC-SP7) shall be
performed with fine abrasive similar to Clemtex Black Grit
#6, StanBlast Fine or 30/60 mesh abrasive. NOTE: Blast media
shall not contain metallic components that can become embedded
in the substrate during the blasting process. |
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All abrasives shall be selected
so that they provide the required anchor profile. Deck coating
and tank linings may require deeper anchor profile. Reclaimed
abrasives should be angular (not rounded), free of oil,
grease, iron oxide, etc. A minimum of 10% of the abrasive
by volume should be replaced daily to ensure that contamination
is kept to a minimum and the abrasive remains effective. |
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Abrasive blast equipment shall
be capable of delivering a minimum of 95-100 psi simultaneously
to every nozzle in use on the job. |
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Before any abrasive blasting,
all clamps from stainless steel tubing, piping, conduits,
etc. must be removed by the paint crew. Also, stainless
steel instrument tubing and piping should be covered to
prevent contamination before abrasive blasting begins. |
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Deeply Pitted Surfaces |
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Before a POR-15®
base coat is applied, deeply pitted surfaces, will
require at least rinsing with Marine Clean™ and
fresh water and in some cases require re-blasting
after the surface is dry to remove contaminating
residue, which typically causes the blasted surfaces
to rust. Pitted surfaces are then to be filled with
POR-Patch™ or Epoxy Putty as directed. |
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All deep pits and
holes shall be prepared and coated as follows: |
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Modified SSPC-SP1 or abrasive
blast to white metal finish. |
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Fill with POR-Patch™ or Epoxy
Putty, followed by POR-15®. In addition, PowerMesh may be
used to provide additional structural reinforcement or where
holes are too large to fill properly. |
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Complete specified paint system. |
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Grit Blasting Splash Zone |
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Splash zone areas
or any surface wet by seawater shall be prepared
for painting in the following manner: |
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Rough abrasive blast the surface
to remove loose scale and heavy corrosion products. |
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Wash all surfaces, with 1500-psi
minimum water pressure with Marine Clean™, that have been
rough blasted with clean, fresh water for removal of salts
deposited on the surface. |
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After the fresh water wash,
the surface shall be blown-down with compressed air to remove
the excess water. A check for salt should also be conducted
to ensure that the surface is clean enough for final abrasive
blasting. Near White Metal Blast should follow, as soon
as possible, after the wash, to avoid further contamination
from seawater. |
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Prevention of Damage from Abrasive Blasting |
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Peripheral
Equipment |
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The coating contractor shall assure that all
gauges, sight glasses, instruments,
instrument tubing, instrument tags, vessel
name plates, navigation aids and other items
of equipment are protected from damage
during abrasive blasting. Appropriate
masking and protective shielding shall be
employed. |
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Rotating
Equipment |
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Rotating equipment shall be protected from
damage by selection of appropriate surface
preparation procedures and abrasives.
Appropriate shielding, masking, use of
filter media, and other protective measures
shall be employed by the coating contractor
to protect such equipment. |
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When surface preparation is required around
and/or on compressors, turbines, engines,
pumps, or any other sensitive equipment to
abrasive blasting, do not use abrasive
blasting. Use one of the following methods
of surface preparation: |
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Ultra High Pressure water
jetting, 25,000 psi and above |
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High pressure water blast,
10,000 to 25,000 psi. |
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Power Tool Cleaning (SP3 or
SP11) and/or Hand Tool Cleaning
(SP2) |
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Over Blast |
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During all blasting operations, the coating
contractor shall exercise caution and employ
masks, shields, etc. to assure that coated
surfaces adjacent to the blast area are
protected from over blast damage by stray or
rebounding blast particles. |
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Corrections |
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All areas outside the scope of work affected
by over blast shall be sweep blasted and
coated as specified by POR-15, Inc. at no
additional cost to POR-15, Inc. |
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Additional
Considerations |
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Surface
Contaminants |
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All oil, grease,
soil, dust or foreign matter deposited on the
surface, after the surface preparation has been
completed, shall be removed prior to painting.
In the event that rusting occurs, after
completion of the surface preparation, the
surface shall be again prepared in accordance
with the specified method. |
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Handling
of Coating Material |
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All materials
shall be mixed in accordance with the
appropriate data sheet. Only POR-Solvent shall
be used and there shall be no substitution of
thinners, converters, or other materials. |
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The induction
time after mixing prior to application of
multi-component coatings, recommended by POR-15,
Inc., shall be followed. |
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Handling
of Coating Equipment |
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Spray equipment
and hoses shall be thoroughly cleaned to prevent
contamination of the coating material, which is
being applied, from any residues from previously
applied materials. |
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Coating
Restrictions |
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The coating
contractor should follow written recommendations
for special surface temperature, relative
humidity, and dew point requirements. |
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Surfaces shall
not be recoated until the preceding coat has
properly cured as specified. In general, the
surface may be considered to be ready for
recoating when the next coat can be applied
without the development of paint film
irregularities such as lifting or loss of
adhesion to the undercoat. The minimum drying or
curing time specified by POR-15, Inc shall be
the minimum acceptable period. |
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The Splash Zone
Areas of offshore platforms (waterline up to 4
ft) shall be blasted and the full coat system
shall be applied on the same day. The coating
contractor shall schedule blasting so as to
avoid blasting more area than can be coated with
POR-15® and top coated in one day. |
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All other areas
shall be base coated with POR-15® the same day
that surface preparation has been completed. The
coating contractor shall schedule blasting so as
to avoid blasting more area than can be coated
with POR-15® in one day. |
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In the event
that work cannot be resumed for a period of time
and the unfinished system is contaminated, it
will be necessary to use a Marine Clean™ and
fresh water wash, with 1500psi minimum water
pressure, and abrasive blasting if rust has come
though the existing coating. All oil spillage
and grease, which may have accumulated on the
surface, must be detergent washed per Modified
SSPC-SP1 before blasting and painting operations
are resumed. |
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Coatings must
not be force cured under conditions, which will
cause checking, wrinkling, blistering, formation
of pores, or detrimentally affect its condition
or appearance. |
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Newly painted
surfaces shall be protected to the fullest
practical extent from rain, condensation, or
contamination, until the coating has dried. |
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All coats shall
be applied at the specific range of DFT or WFT,
which are specified by POR-15, Inc. In the event
the required thickness is not achieved,
additional coats shall be applied until the
required thickness is obtained. Application
shall be such that the film thickness will not
affect appearance or service life of the
coating. |
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Work shall be
carried out in such a manner that there shall
not be any unpainted areas left behind, or
spraying over unprepared surfaces as the work
progresses. Examples are: |
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No painting
should be done on beams unless both
flanges and the web portions are
completely prepared for painting. This
means top, bottom, and sides. |
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Tubular
pieces shall be prepared for painting
completely around the circumferences. |
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Surface
temperature, ambient temperature, and dew point
at the time of application shall be within the
limits specified by POR-15, Inc. |
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All coatings
shall be applied in a uniform and continuous
film, free of holidays, skips, runs, sags and
other defects. |
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Splash Zone Coating |
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If
the full coating system is not applied during
the same day, it will be necessary to: |
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Rinse all coated surfaces with
Marine Clean™ and fresh water |
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Spot
or overall re-blast and/or overall
sweep if rusting is detected (Paint
Inspector’s discretion), |
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Apply the full paint system. |
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All oil spillage,
grease, or other contaminants which may have
accumulated on the surface, shall be detergent
washed per modified SSPC-SP1 before abrasive
blasting and painting operations are resumed. |
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Alternate Application Procedures
Brush
application of spot primer is acceptable
provided proper thickness is achieved. Roller
application of a coating is permissible if
specified coverage rates are followed and if the
manufacturer's data sheet allows roller
application. Non-skids coatings containing
holidays shall be removed and reapplied. |
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Special Coating Procedures |
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All
flange edges, welds, nuts, bolts, edge of
I-beams, and all other irregular surfaces with
small radius features shall be coated with
POR-15® using a brush. |
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All
threaded surfaces shall be brushed with POR-15®
prior to application of sprayed coats. All
thread compounds or Teflon tape shall be
removed. All thread protectors shall be
reinstalled after topcoat has cured. |
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Feathered edges of existing coatings lifted by
freshly applied coatings shall be sanded flush
and sealed with a brushed coat of POR-15®.
Following proper cure of the brushed coat,
application of the specified intermediate or
finish coat may proceed. |
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Spot Painting |
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Special care must be taken to avoid pinhole
failures caused by loose, frayed edges of the
sound coating at the outer edges of the blasted
area. Before painting begins, feather edging of
the loose, frayed coating must be done with
great care by hand sanding or with knife-edge.
Any old paint that curls or lifts, after
application of the spot paint, shall be removed
and the area repainted. |
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