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    Guideline - Painting, Coating & Corrosion Protection - Dulux - Mild Steel - Surface Preparation

    Uploaded by

    zinha_al

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
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    of 2

    THE CRITICAL STEP

    In this Tech Note, our aim is to cover the most common type of
    surface preparation used in preparing structural steel for long-term
    corrosion protection.
    The purpose of surface preparation of steel prior to application of a
    protective coating system is two- fold:

     To remove contaminants on the steel that may cause initiation or


    continuation of the oxidation (rusting) process, and/or prevent adhesion of
    the first coat to the steel and
     To increase the profile and hence the surface area per square metre in
    order to maximise the adhesion between the steel and the primer.
    Contaminants can cause failure of the coating by preventing an Abrasive blast cleaning is the most effective and fast
    adequate bond from occurring, and also may contribute to the rusting way of removing millscale and other contaminants
    of the steel substrate.
    A lower than desirable surface profile compromises the ability of the
    coating to key into, and adhere to, the substrate resulting in lower
    bond strength.
    Furthermore, zinc rich primers rely on direct contact of the zinc metal
    with the steel, and the higher the surface profile, the greater the
    contact.
    SURFACE PREPARATION STANDARD AS1627
    The Australian Standard AS1627 series covers a number of surface
    Millscale is a common cause of premature rust and
    preparation processes. must be removed prior to painting
    The method preferred by Dulux Protective Coatings within the
    AS1627 series is the standard AS1627.4 - Abrasive Blast Cleaning.
    A Class 2½ “Near White Metal” blast cleanliness, to match visual
    standard Sa 2½ in AS1627.9, and to generate an angular surface
    profile of 30 to 60 microns will be suitable for all types of steelwork
    except perhaps steel for immersion. This method is far quicker and
    more cost-effective than hand or power tool cleaning, and provides
    maximum contact between the primer and the steel.
    This method is also by far the most effective way to remove
    millscale. (Refer to Tech Note 1.1.4 – Millscale)

    SHARP EDGES ON STEELWORK


    Sharp edges, laminations, burr marks and welds must all be
    attended to during surface preparation.
    Sharp edges cannot be painted over, as coatings will always pull
    away from the sharp edge and pond on either side. The result is that
    the edge will carry a far lower film build than is necessary for
    Sharp edges must be ground off prior to painting
    adequate corrosion protection, and will exhibit edge corrosion. To
    overcome this problem, sharp edges must be ground off to achieve a
    radius of at least 2 mm to ensure that the film build of the applied
    coating will be uniform on the rounded edge.
    Sharp edges are of particular concern on perforated steel or
    expanded sheet steel, as the sharp edges are so extensive that
    rounding them off is impractical. (See Tech Note 1.1.5 – Perforated
    Metal).
    SHOP PREPARATION
    1. Wash and degrease all surfaces to be coated in accordance with
    AS1627.1 with a free-rinsing, alkaline detergent, such as Gamlen CA
    No. 1 in strict accordance with the manufacturer’s written instructions
    and all safety warmings.
    2. Wash with fresh potable water and ensure that all soluble salts are
    removed in accordance with AS 3894.6 methods A&D.
    3. Grind all sharp edges with a power tool to a minimum radius of 2 mm.
    4. Power tool clean welds to AS1627.2 Class 2 to remove roughness.
    Remove filings, preferably by vacuum or compressed air.
    5. Abrasive blast clean all steel surfaces to be painted in accordance with
    AS1627.4 to visual standard AS1627.9 Class 2.5 (equivalent to Spot abrasive blast cleaning is a practical method of
    ISO8501-1, Sa 2.5: Very Thorough Blast-Cleaning). Use a non-metallic removing rust in situ.
    medium that will generate a surface profile of 35 to 65 microns (as
    tested to AS3894.5 Method A.)

    APPLICATION OF COATING
    1. Commence application within 4 hours of abrasive blasting or before
    surface is contaminated, otherwise repeat abrasive blasting step.
    2. Stripe coat welds, bolts, boltholes and all edges with primer before
    application of full primer coat nominated in the Coating System section
    of the specification.
    3. Prior to application, ensure that the surface is free of contaminants
    including oil, grease, dirt, dust, salt and any other deleterious materials
    that will interfere with coating performance.

    TREATMENT OF ON SITE WELDING


    1. Remove weld spatter.
    2. Power tool clean welds to AS1627.2 Class 2 to remove roughness.
    Remove filings, preferably by vacuum or compressed air.
    3. Prime welds immediately with the nominated primer before
    contamination can reoccur. Ensure that the primer overlaps the sound MBX® Bristle Blaster® is ideal in awkward or difficult
    adjacent coating by not less than 25mm or greater than 50mm. to access places.
    4. Apply intermediate and topcoats over the primed welds to match the
    surrounding coating system, overlapping the sound adjacent coating by
    not less than 25mm or greater than 50mm.

    ALTERNATIVE STANDARDS
    In addition to the Australian Standard AS1627.4, there are similar
    global standards. These are offered below for reference:

    Brush-Blast AS1627.4 Class 1 NACE 4 SSPC – SP 7 Sa1

    Commercial Blast AS1627.4 Class 2 NACE 3 SSPC –SP 6 Sa2

    Near White Blast AS1627.4 Class 2.5 NACE 2 SSPC – SP10 Sa 2 – ½

    White Blast AS1627.4 Class 3 NACE 1 SSPC- SP 5 Sa3


    Ultra high pressure water jet will not create a new
    For more information, please contact the Dulux Protective Coatings Technical profile, but will reveal the original profile of a blast
    Consultant in your state. cleaned surface.

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