METHOD STATEMENT FOR THE

SURFACE PREPARATION AND

PROTECTIVE COATING
DOC. NO. Zealcon-MS-SPPC-001

METH
OD STATEMENT FOR THE
SURFACE PREPARTION AND PROTECTIVE
COATING

Document Issue Purpose

: For Approval

: For Review

: For Construction

28.07.2016

Issued for Review

SDH

REV

DATE

REASON FOR
ISSUE

Prepared
by

Reviewed
by

Approved
by

Approved by
Company /
FL SMIDTH

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METHOD STATEMENT FOR THE

SURFACE PREPARATION AND
PROTECTIVE COATING
DOC. NO. Zealcon-MS-SPPC-001

CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

Purpose
References
Definitions
Responsibilities
Pre-blast Preparations
Ambient Conditions
Equipments
Abrasives
Cleanliness degree
Precautions
Mechanical Cleaning
Cleaning of surface between coats
Painting
Painting Applications
Application Equipment
Re coating interval
Handling of coated items
Dry Film Thickness
Repairing of coating
Quality Control
Blast Cleaning and Painting Inspection Report

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METHOD STATEMENT FOR THE

SURFACE PREPARATION AND
PROTECTIVE COATING
DOC. NO. Zealcon-MS-SPPC-001

1.

PURPOSE
This Method Statement provides the guidelines for Blast Cleaning and Painting of
Fabricated structural steel materials & Mechanical equipment for D G Cement Project at
Workshop as well as at Site.

2.

REFERENCE

3.

4.

DEFINITIONS
COMPANY

D G Cement

CONTRACTOR

ZEAL Construction Engineering

CONSULTANT

FL Smidth

ITP

Inspection & Test Plan

QC

Quality Control

MS

Method Statements

RESPONSIBLITIES

5.

General Workshop Instructions 520530-8.0

EN ISO 8503-2:2012 Preparation of steel substrates before application of paints and
related products
Steel Structure Painting Council (SSPC)
ASTM D3335 Test Method for Low Concentrations of Lead, Cadmium and Cobalt in
Paint by Atomic Absorption Spectroscopy
AOAC 974.02, Lead in Paint, Atomic Absorption Spectophometric Method or
equivalent shall be used.
Design Drawings and Standards
Project application datasheets

Project Manager shall be responsible to provide recourses for execution of the

activity.
Painting supervisor and Painting QC Inspector shall be the responsible persons for
blast cleaning & Painting activities in accordance with General Workshop Instruction
520530-8.0 and this Method Statement.

PRE-BLASTING PREPARATIONS
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METHOD STATEMENT FOR THE

SURFACE PREPARATION AND
PROTECTIVE COATING
DOC. NO. Zealcon-MS-SPPC-001

6.

Before shipment for blast cleaning of fabricated items, shall be checked for free from
spatters, flux or other foreign matter.

All sharp edges, fillets, corners and weld seams shall be rounded or smoothed by
grinding, min. R= 2mm.

Any major surface defects, particularly surface laminations or scars likely to be

detrimental to the paint shall be removed by suitable dressing. All welds shall be
inspected and repaired if required prior to blast cleaning. Undercut and rough
geometry is not accepted.

All oil and grease traces shall be removed by solvent cleaning prior to starting blast
cleaning operations.

AMBIENT CONDITION
Blast cleaning shall not proceed on surfaces that are moist or may become moist before
the application of primer. Blasting shall not be permitted when metal surfaces are less
than 3 deg above the dew point or when the relative humidity of the air is greater than
85%.

7.

BLASTING EQUIPMENTS
The compressed air used for blasting shall be free of water and oil. Adequate coolers
and separators/traps shall be fitted and these shall be kept emptied. The discharge
pressure shall be measured at the nozzle with a hypodermic pressure gauge of 7 kg/cm
(100 PSI) and not less than 5.5 Kg/cm (80Psi).

8.

ABRASIVES
Abrasive for use on carbon steel and low alloy steel shall be in accordance with
General Workshop 520530-8.0
Abrasive used on stainless steel shall be free for chloride, zinc and iron
contaminants.
Company approval shall be required prior to use of abrasive.

9.

CLEANLINESS DEGREE

Blasting to Sa2 according to EN ISO 8501-1:2007 (Preparation of steel substrates

before application of paints and related products - Visual assessment of surface
cleanliness - Part 1\: Rust grades and preparation grades of uncoated steel
substrates and of steel substrates after overall removal of previous coatings) is
required. All dust must be completely removed before painting.
The roughness of the blasted surfaces shall conform to the demands made by the
paint manufacturer and at least grade fine to medium G according to EN ISO
8503-2:2012 (Preparation of steel substrates before application of paints and
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METHOD STATEMENT FOR THE

SURFACE PREPARATION AND
PROTECTIVE COATING
DOC. NO. Zealcon-MS-SPPC-001

related products - Surface roughness characteristics of blast-cleaned steel

substrates - Part 2: Method for the grading of surface profile of abrasive blastcleaned steel - Comparator procedure) or Rugotest No. 3 BN 9a if no other
requirements are specified by the paint manufacturer or in the paint programmes .
For programme V the roughness of the blasted surfaces shall conform to "medium
G" or according to the paint manufacturer's requirements in the painting
specification

10. PRECAUTIONS

Blasting shall be stopped sufficiently early to allow application of the primer on the
blast surfaces before sunset and before any oxidation develops. No visible oxidation
is acceptable on blast cleaned surface prior to painting.

A 25mm wide strip minimum around the blast cleaned surface shall not be painted
with primer unless adjacent surfaces are already painted or it is the last part of the
surface to be prepared.

The left strip of 25mm width shall also be blast cleaned next day to achieve the
required degree of surface preparation.

During blasting if any surface defects like laminations, cold-laps ect. detected, shall
be repaired and that surfaces shall be re-blasted.

The surfaces which cannot be blast cleaned due to un-access or blast cleaning is
impracticable may be cleaned mechanically subject to Company approval.

11. MECHANICAL CLEANING

Mechanical cleaning comprises power and hand tool cleaning method. Such surface
preparation methods shall be restricted to those areas where standard cleaning is
prohibited or impossible due to access or dust sensitive equipment presence and shall
be performed only with the acceptance of manufacturer approval procedure and
equipment used shall be recorded.
12. CLEANING OF SURFACE BETWEEN TWO COATS
Oil, Grease, dirt, dust or any other contaminants shall be removed completely prior to
the application of any succeeding coat of paint system.
13. PAINTING
13.1

Storage conditions

All material shall be stored under cover, preferably a warehouse. Outdoor

storage, for instance next to application site is acceptable only for quantities
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METHOD STATEMENT FOR THE

SURFACE PREPARATION AND
PROTECTIVE COATING
DOC. NO. Zealcon-MS-SPPC-001
to be used on a particular day and providing weather protection and provision
for cover are made.

If stored in an enclosed area, adequate ventilation must be provided for

precautions against fire and health hazards shall be taken, in keeping with
local regulations and normal safety practices.

All paint materials shall be stored in tightly sealed condition, and never stored
unprotected outdoors or exposed to direct sunlight. Recommended storage
temperature: 5 to 40 c.

Paint material cans shall only be opened immediately before use. Paints
which have gelled or in which sediments have formed during storage shall be
discarded. Paint materials shall be issued from storage on a first in first out
base.

Products which have reached their expiry date shall not be used unless
checked and approved by paint manufacturer.

13.2

Mixing & Thinning

Contents of paint shall be completely mixed and dispersed to obtain a

homogeneous blend. Only power mixer shall be used. Under no
circumstances shall hand mixing be allowed.

In case of Two Pack products, both components shall first be mixed

separately then together to ensure complete dispersion and mixing.

During application, the coating shall be agitated sufficiently often with a power
mixer to maintain pigments and extenders in suspension.

Continuous agitation during application shall be provided for:

a) Inorganic Zinc rich primer
b) Zinc rich epoxy primers
c) M.I.O pigmented coatings.

Powered agitators, either clamped on the rim of the paint containers of built in
agitator in the case of conventional spray equipment shall be used.

Paint which have been mixed in the original container shall not be transferred
before the settled pigment has been blended again into the binder may be
momentarily removed if required to ease mixing.

Paint shall never be mixed or maintained in suspension by means of air

bubbles.

If a skin has formed in a can, it must be removed, if the shin is thicker than 1
mm, the product will be discarded.
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METHOD STATEMENT FOR THE

SURFACE PREPARATION AND
PROTECTIVE COATING
DOC. NO. Zealcon-MS-SPPC-001

All pigmented coatings shall be filtered after mixing unless the painting
equipment used is fitted with adequate filters.

Only thinners recommended by the paint manufacturer shall be used.

Under particular conditions, thinning may however be necessary, this shall be

supervised by the manufacturers representative

14. PAINTING APPLICATIONS

14.1

Paint system
The type, number of coats and thickness of paint shall be as indicated in General
Workshop Instructions 520530-8.0 Para 5.5.6, 5.7 and 5.5.8

The primer and subsequent coats of each painting system shall be of the
same make.

The manufacturers instructions, including safety precautions, form part of the

present document and shall prevail over all other instructions in case of
conflict.

The dry film thickness shall not be less 90% of the specified thickness

14.2

Ambient Conditions

Coating application shall not be performed when weather conditions are not
as per the Manufacturers recommendations, and particularly;
a) In dusty or windy weather, or dust laden air.
b) In areas where injurious particles are in suspension.
c) If the surface temperature is less than 3c above the dew point of the
ambient air.
d) If the relative humidity is in excess of 85% (95% for inorganic ethyl zinc
silicate primer application.)

14.3

Generally when adverse conditions are expected soon, outdoor painting shall
be stopped. If it is raining either during or immediately after paint application,
proper steps such as re-painting shall be taken. (Except for ethyl zinc silicate
primer).

Paint application shall not be carried out if ambient temperature reaches or

exceeds 55c.
Precautions

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METHOD STATEMENT FOR THE

SURFACE PREPARATION AND
PROTECTIVE COATING
DOC. NO. Zealcon-MS-SPPC-001

Blast cleaned surface shall be given a coat of primer as soon as possible and
not later than 4 hours after surface preparation completion. If oxidation
appears during application of painting, that affected portion shall be re-blasted
as per specification.

As for as possible each coat of paint shall be applied without break. Any part
of the surface that was missed or insufficiently painted shall be repainted. The
next coat shall not be applied before the preceding coat is dry.

After each coat is sufficiently dry or polymerized and before the next coat
applied, surface cleanness shall be checked. Fresh water rinsing/ washing of
painted area shall be performed between each coat until satisfactory
cleanness is obtained.

Multi-coat systems shall have contrasting colors for each particular coat in
order to ensure proper coverage.

Surfaces of equipment and components in contact with structures (skid

bottoms, equipment base plates and the like) shall be painted.

Supports for items to be painted shall be designed so as to minimize contact

points.
Wet paint shall be protected from dust and other foreign matter that could result
in inclusions.
15. APPLICATION EQUIPMENT
The application method shall be governed by the manufacturers recommendation for
the particular coating being applied. Spray equipment shall be in compliance with
manufacturers recommendation, i.e.; nozzles, spray tips, spray angles, air/ fluid
pressure, etc. Roller application of the first primer coat is strictly prohibited.
16. RE-COATING INTERVALS

Each coat shall be allowed to dry or cure for a time specified by the manufacturer
before the application of any succeeding coat.

If the specified period between coats has been exceeded, sweeping with abrasive
or the corrective actions as recommended by the manufacturer shall be carried out.

All products that have been exposed to weathering for any length of time shall be
carefully checked for chalking or surface contamination and cleaned by appropriate
means to obtain a sound, contamination free surface for subsequent coat
application.

17. HANDLING OF COATED ITEMS

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METHOD STATEMENT FOR THE

SURFACE PREPARATION AND
PROTECTIVE COATING
DOC. NO. Zealcon-MS-SPPC-001

No handling shall be performed before the coating system is completely cured.

When handled, special precautions shall be taken to avoid to damaging the coating
system.

Where paint has been damaged in handling, repair shall be carried out according to
mentioned in section Repair of coating.
Before shipment and packing, Inspection shall be offered to CONSULTENT
/COMPANY.
Finished painted piping, steel structure shall be lifted, lowered or suspended by
using rubber or canvas belt with removable pin and clevis on one end to permit
removal of belt without damage to the paint.

18. DRY FILM THICKNESS

The tolerance limits for dry film thickness for each coat and the total coating systems
shall be strictly followed. It shall be observed that excessive film thickness may be
determined due to solvent retention and improper curing.
19. REPAIRING OF COATING

Repairs shall be performed as soon as possible and in accordance with the relevant
standards of surface preparation and specified coating system mentioned in General
Workshop Instruction 520530-8.0 Para. 5.5

All damaged and loosely adhering paint shall be removed and the surface cleaned to
the original specified standards. Edges of the surrounding intact paint shall be
feathered approximately 50 mm in from the damage area. Original paint system shall
be rebuilt as per specification.

Painting after erection welding should be performed immediately after the welding
work is finished in order to minimize the cleaning work before painting.

20. QUALITY CONTROL

During blast cleaning & painting the following instruments shall be available with QC
Inspector for inspection.
1. Wet Film Thickness Gauge.
2. Dry Film Thickness Gauge.
3. Humidity Gauge.
21. BLEST CLEANING & PAINTING INSPECTION REPORT
Check List for blast cleaning
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METHOD STATEMENT FOR THE

SURFACE PREPARATION AND
PROTECTIVE COATING
DOC. NO. Zealcon-MS-SPPC-001
Surface Preparation & Protective Coating Report

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