Pre-blasting preparation

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Most coating failures result from poor or inadequate:

Steel preparation Cleaning Surface preparation Application Access Ventilation Coating selection Inspection and control Premature exposure (Exposed too soon)

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Investigation by a Guarantee Insurance company has shown:

95 % of all coating failures result from Poor surface preparation Poor application
85 % of all failures appear within 1-2 years This fits in well with our own experience

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Pre-blasting preparation involves the following activities

Rounding or smoothing of: Sharp edges Corners Welds Grinding of: Laminations Flame cut edges Weld spatter Notches minimum diameter: 30 mm Inspected and approved before cleaning
See ISO 8501 Visual assessment of surface cleanliness
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Steel preparation

Edges and weld spatters

Sharp edge
Gas cut edge
A A. Remove by grinder or disc sander. B. Rolled steel sections normally have round edges. Therefore can be left untreated. A. Remove visible spatter before gritblasting with grinder or chipping hammer. B. For spatter not readily removed, remove using grinder/disc.

Weld spatter
B

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Pre-blasting preparation

Rounding sharp edges

Coating applied to a square-cut section Sharp edge Coating
Reduced coating thickness at sharp edges due to tension created during drying / curing

Steel

Rounded edge Even coating thickness

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Cross section of painted steel with a sharp edge

Paint applied with spray Forms inferior coating thickness around the edge Paint

Cd-4932-21 Steel

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Cross section of painted steel construction with well rounded edge

Paint applied by spray Forms even thickness around the edge Paint

Cd-4932-20
Steel

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Grinding of sharp edges, welds etc. Disc sander and disc grinder
Sander for removing mill scale, paint and rust

Grinder for heavy grinding, such as edges and weld beads

Cd-4932-03

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Steel support prior to pre-blasting preparation

Sharp edges Rust grade: A to B according to ISO 8501

Cd-4930-46

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Edge rounded with disc grinder

A well rounded edge will ensure a sufficient paint film over the entire construction

Cd-4932-12

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Steel support after blast-cleaning to Sa 2

The sharp edges have been rounded prior to blast-cleaning: Good !

Cd-4930-48

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Weld with pinhole. Visible through the paint system

Will lead to initiation of corrosion Remedial actions: Remove the paint, re-weld and grind. Apply paint

Cd-4930-42
NOTE: Such defects may be difficult to find during inspection
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Early corrosion on sharp edge and spot welds

Paint has newly been applied Exposed to wind and weather for approximately 2 weeks

Cd-4930-78

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Insufficient pre-blasting preparation

Notch Power tooling has been carried out Sharp edge not grinded

Cd-4932-16

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Severe corrosion due to a combination of several effects

Sharp edges Rough welds (not grinded) Missing stripe coating

Cd-4930-71

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Severe corrosion due to a combination of several effects

Sharp edges Rough welds (not grinded) Missing stripe coating

Cd-4930-72

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Small weld spatters

Even only one small weld spatter may be sufficient to initiate corrosion which with time may lead to severe problems

NOTE: Small failures like this are difficult to find

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Cd-4930-45

Remaining weld beads after removal of supports welded on to the structure

Prior to pre-treatment these must be grinded away to form an acceptable substrate for the paint system

Cd-4932-04

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Pre-blasting preparation

Laminations, undercuts, welding seams

Lamination
Remove using grinder

Undercut
Undercuts exceeding classification ruling should be repaired by welding and grinding.

Manual weld bead

Sharp profile peaks to be smoothed using grinder

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Unacceptable weld. Too rough and full of pinholes / pores

Weld spatters close to weld Rewelding and grinding must be carried out prior to reblasting and painting

Cd-4930-39

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Paint on a very poor weld. Pinholes and holidays visible after second stripe coating

Neither rewelding nor grinding have been carried out prior to application Remedial Actions: Reblasting, rewelding, grinding and blast -cleaning: COSTLY

Cd-4930-41

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Paint applied on a very poor weld. Pinholes and holidays visible after application

Neither rewelding nor grinding have been carried out prior to application Remedial Actions: Reblasting, rewelding, grinding and blast -cleaning: COSTLY

Cd-4930-40

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Spot welding leads to crevices which are susceptible to corrosion

Not recommended solution for exposure to severe / aggressive environments

Cd-4930-36

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Spot welds after painting

Paint is unable to fill gap between the parts welded together These area may be susceptible to corrosion Not recommended for exposure to severe / aggressive environments

Cd-4930-37

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Sharp edge an spot welds. Early corrosion attack

Construction newly painted Exposed to humid atmosphere Corrosion initiates after a short period of time on weak areas: Sharp edges, crevices and spot welds

Cd-4930-38

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Pre-blasting preparation Grinding a small construction

Mark areas where

grinding are required Remove weld spatters Grind the welds Grind the notches Important to carry out the grinding to improve the life time of the paint system
Pre-treatment: Grind_spatters1

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