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Surface preparation is the essential first stage treatment of a steel substrate before the
application of any coating.
The surface preparation process not only cleans the steel, but also introduces a suitable profile
to receive the protective coating.
i. A - Steel surface largely covered with adhering mill scale, but little if any rust
ii. B - Steel surface which has begun to rust and from which mill scale has begun to flake
iii. C - Steel surface on which the mill scale has rusted away or from which it can be scraped,
but with slight pitting under normal vision
iv. D - Steel surface on which the mill scale has rusted away and on which general pitting is
visible under normal vision
Various methods and grades of cleanliness are presented in ISO 8501-1[1]. This standard
essentially refers to the surface appearance of the steel after hand cleaning, power tool
cleaning, abrasive blast cleaning or flame cleaning and gives descriptions with pictorial
references of the grades of cleanliness.
02.Hand and power tool cleaning
Surface cleaning by hand tools such as scrapers and wire brushes is relatively ineffective in
removing mill scale or adherent rust. Power tools offer a slight improvement over manual
methods and these methods can be approximately 30% to 50% effective but are not usually
utilised for new steelwork fabrications. Where it is not possible to clean by abrasive blasting,
hand and power tool methods may be the only acceptable alternative methods.
The surface preparation by hand and power tools is covered by BS EN ISO 8504-3[2], and
the standard grades of cleanliness in accordance with ISO 8501-1[1] are:
04.Flame cleaning
This method uses an oxy/gas flame that is passed over the steel surface.
The sudden heating causes rust scales to flake off as a result of differential expansion
between the scales and the steel surface.
All loose rust can then be removed by scraping and wire brushing followed by dust
removal.
Flame cleaning is not an economic method and may damage coatings on the reverse side
of the surface being treated.
Also the technique is not very effective in removing all rust from steel, so it is rarely
used.
05.Acid pickling
This process involves immersing the steel in a bath of suitable inhibited acids that
dissolve or remove the millscale and rust but do not appreciably attack the exposed steel
surface.
The cleaning can be 100% effective.
Acid picking is normally only used for structural steel intended for hot-dip galvanizing.
06.Removal of soluble iron corrosion products
Depending upon the condition of the steelwork prior to blast cleaning, there may be
surface contaminants present other than mill scale and rust.
Initial steel surface conditions of Grades A to C are unlikely to be affected, however
Grade D condition (steelwork that is pitted) could contain contaminants within the pits
that may not be removed by the dry blast cleaning process.
The testing for soluble iron corrosion products is not usually required for new steelwork
but is sometimes carried out on steelwork which has been stored in an external
environment for long periods of time and on existing structures undergoing maintenance
treatments.
A low pressure system exists in which water is injected into the air stream which then
shrouds the air/abrasive mixture and prevents dust escaping during the blasting operation.
The air/water pressure at the nozzle is relatively low; up to 7.0kgF/cm2 (100lbF/in2).
Because of the low water to air ratio of the system, fine particulates of abrasive can
remain on the steel surface and need to be removed by water washing.
This method can produce a high visual standard of cleaning and is effective in removing
a high proportion of soluble salts.
Some wet abrasive processes use inhibitors in the water to prevent rusting of the cleaned surface.
It is important to establish whether any remaining traces of such inhibitors will be compatible
with the paint coating to be applied subsequently. Generally, where inhibitors are not used, any
surface rusting after wet abrasive blasting is usually removed by final light dry blast cleaning.
ii. Ultra-high pressure water jetting
Ultra-high pressure water jetting over 1,700
bar (25,000psi) is gaining in popularity,
partly because of its ability to remove high
percentages of soluble salts from the steel
surface.
It has the advantage of not generating spent
abrasive and not incurring the cost of
abrasive disposal.
Also, at the higher pressures, lower volumes
of water are used, and this makes disposal Ultra high water pressure
costs lower than with traditional water blasting
blasting methods.
Ultra-high pressure water jetting leaves a warm surface from which traces of residual
water quickly dry, but does not generate sufficient heat to cause thermal stress in the steel
surface.
The removal of a high proportion of soluble salts from the steel surface is seen to be the
major advantage of ultra-high pressure water jetting.
Rust and coatings are sheared and lifted from the surface relatively easily compared with
other blasting methods.
Soluble salts are removed more effectively because the steel profile generally remains
unchanged.
Injecting small amounts of abrasive into the water stream can induce a rougher surface
profile but can also increase operating costs.
The surface preparation by Ultra-high pressure water jetting is covered by ISO 8501-4[3].
Ultra-high pressure water jetting is an extremely versatile and effective method of removing
paint and metal coatings, soluble salts and other contaminants from steel surfaces. It is
environmentally friendly and, although at present it is costly compared with traditional blast
cleaning methods, it is considered to be an emerging technology which will, in the near future,
rival and possibly replace traditional open abrasive blast cleaning methods.
The surface treatment specification should describe the surface roughness required,
usually as an indication of the average amplitude achieved by the blast cleaning process.
Several methods have been developed to measure or assess the distance between the
peaks and troughs of blast cleaned surfaces.
These have included comparator panels, special dial gauges, replica tapes and traversing
stylus equipment.
Usually, comparators or replica tapes are used, and the relevant standards are BS EN ISO
8503-1[4] and BS EN ISO 8503-5[5] respectively.
BS EN ISO 8501-3:2006[7] describes preparation grades of welds, cut edges and other
areas, on steel surfaces with imperfections to make the steel surfaces suitable for the
application of coatings.
Three preparation grades are described, with illustrated examples of relevant
imperfections, as:
The selected preparation grade is correlated with the environment corrosivity category
(C1 to C5 as described in BS EN ISO 12944 Part 2[8]) as appropriate for the structure.
Sawn and flame-cut ends and edges need treatment to ensure that the coating adheres and
is of sufficient thickness.
02.Welded connections
At welded connections, the key factors in ensuring the effectiveness of the coating system
are the effectiveness of the protection before final coating.
The areas local to welds are usually masked, to prevent them being coated.
The masking stays in place until the joint is welded; this is not an ideal form of protection
if there is prolonged exposure before welding.
After welding, it is essential that the joint surfaces, including the weld itself, are prepared
to the specified standard of cleanliness and profile. Because of the contamination that
occurs from the welding flux, particular attention needs to be paid to cleaning off all
residues.
The surfaces of welds themselves should not need any grinding if they comply with the
requirements of BS EN 1011: Part 2[10] for smoothness and blending into the parent
metal. However, rough profiles, badly formed start-stops, sharp undercut and other
defects such as adherent weld spatter should be removed by careful grinding.
Particular attention needs to be paid to the blast cleaned profile because weld metal is
harder and site blast cleaning is more difficult than shop blasting.
03.Bolted connections
Preloaded bolted connections merit particular consideration, both of the surfaces that will
remain exposed and of those that will not (e.g. the faying surfaces).
The friction surfaces are usually either unpainted or metal sprayed without sealer. Hence,
they need to be protected (usually by masking tape) until the parts are finally bolted
together.
Attention should be paid to the removal of any adhesive used on the protective films for
the faying surfaces, and to the removal of any lubricants used on the threads of bolts.
Care should also be taken to avoid contamination of surfaces during bolting up. For
example, older air-power wrenches tend to produce a fine oily or misty exhaust which
may settle on the surface.
06.Cleanliness at site
Just as surface cleanliness before first coating is fundamental to performance of the
system, so is the cleanliness of painted surfaces prior to the application of subsequent
coats.
On site, thorough cleaning shortly before painting is always necessary to remove
contamination accumulated over time and from construction activities including dust,
grout leaks from concreting, and the products of blast cleaning, bolting and welding.