Hanseatic Shipping Company
- on board library – (CBT 5)
Surface Preparation and Maintenance
Guideline and Recommendation for Deck Officer,
Bosun and Deck Rating
based on recommendations
of Hempel paints
Course Format
Course is made up of this power point
presentation accompanied by the short
questionnaire next to you!
Please ask an agency employee to assist
whenever required.
You can advance through the presentation by
hitting the “ENTER” key with your desired
speed!
You should be able to complete in 1 hour
Check on yourself
Please read the questionnaire and answer
the questions to your best knowledge
without consulting this presentation or an
instructor.
Be fair to yourself!
Complete it (not more than 8-10 minutes),
turn it around and continue here.
General recommendation to maintenance
Contents:
1. Maintenance – Why? When?
2. Planning
3. Surface Preparation
4. Paint Preparation
5. Application Environment
6. Paint Application
7. Safety
1. Maintenance Why? When?
WHY?
All coatings gradually deteriorate.
The degree may depend on:
Initial surface preparation
The type of coating
The area where it is used
Well planned maintenance will preserve both the
corrosion protection and the desired appearance.
1. Maintenance Why? When?
WHEN?
Early Late
Inspection Inspection
Regular inspection reveals early tell tale signs of
deterioration.
Repair is simple!
If done before major breakdown, costly refurbishment
can be eliminated.
Records
Records of work executed, condition
reports, paint specification sheets assist
future planning and paint locker
stock records help to have the
right materials available for the
ongoing program.
Initial Defects
Stage 1 Stage 2
Tell Tale Signs
Such a
surface easily
retains dirt.
Loss of gloss Chalking
Initial Defects
Thorough removal of
chalked layer (powder)
as well as other visible
contaminants before
recoating is absolutely
important.
Secondary Defect (A)
Blisters
Bubbles in the dry paint.
They may contain liquid and are
created by localized loss of
adhesion and lifting of the paint
film. Probable cause: paint
Applied over contamination!
Secondary Defect (B)
Cracking - splitting of the dry paint.
Possible causes:
• Too short recoat interval between
coats
• Hard coating applied over soft
coating
• Chemical attack - or
• Simply age of the coating system.
Secondary Defect (C)
Flaking - Peeling
Lifting of the dry paint from the
underlying surface.
Possibly caused by application to
moist or otherwise contaminated
surface.
Typical on board damage
Chemical attack (e.g. spillage of oils or solvents)
Coating will become
discolored,
wrinkled,
blistered,
cracked,
softened or
dissolved.
Typical on board damage
Hot surfaces (e.g. steam pipes)
Coating will become
discolored,
charred and/or
burnt away
Typical on board damage
Mechanical Damage (e.g. on hatch coamings or decks)
break down,
erosion or
removal of coating
through impact or wear from constant impact
Typical on board damage
Corrosion
Corrosion (rust) is the final stage of coating deterioration!
NO PROTECTION REMAINS
Remedy: Maintain the coating system in accordance to the
maintenance plan designed for your vessel!
2. Planning
Questions: How Much Repair Needed?
What is the Problem?
• Initial defects
• Secondary defects
The criteria for repair and maintenance should be defined
as part of the ships specific maintenance plan and
prevailing conditions!
Planning
Determine and mark out areas with:
•Loss of Gloss
•Dirty Areas
•Chalking
•Blisters
•Cracking
•Flaking
•Chemical Attack
•Heat
•Mechanical Damage
•Corrosion
Are above localised or scattered or occupying larger areas?
How should the defects be treated?
Contamination and/or initial defects
Thorough cleaning with fresh water
and/or suitable cleaners as provided by
reputed companies.
In the case of loss of gloss or chalking a
fresh finish coat may be applied.
How should the defects be treated?
Localised secondary defects
Thorough cleaning, then:
Remove defective coating from the
affected areas by power tool grinding
and touch up the spots to full coating
thickness of the surrounding area.
How should the defects be treated?
scattered secondary defects and larger areas
Same procedure as for initial defects
plus one full finish coat over the total
area.
Divide larger areas into workable
sizes to be finished one by one for
best results!
How should the defects be treated?
Corrosion
Thorough cleaning, then:
Total removal of all corrosion products
and remnants of old coating system.
Apply the specified system to full
thickness while observing the recoating
intervals between layers.
When should the defects be treated?
How many man hours are required for:
cleaning and surface preparation
application of system
allowance for recoating intervals
Can work be completed before the area has
to be taken into use again?
Are sufficient quantities of correct qualities
available on board to complete the task?
Planning continued
Do not start a job of a size which cannot be
efficiently done within a fair time with the
resources available.
Plan instead step by step in workable stages.
Provide protection for electrical or other
sensitive equipment to prevent
damage from cleaning fluids,
dust, grit, paint etc.
Planning continued
Adequate Lights is essential for safety and for proper
cleaning and painting. “Holidays”
(forgotten areas) and too thin areas
will be avoided.
Rule of the thumb: If you can read newspaper print – light is ok!
Surface Preparation
Salts
The final cleaning by fresh water
hosing is important for the removal
of salts (mostly from spray) which
will otherwise result in early
breakdown of the coatings applied
Surface Preparation
Manual tools
Apart from the use of chemicals and power tools very good
Results are still to be achieved from well know “hand” tools
like
•Scrapper
•Wire Brush
•Sandpaper
•Chipping Hammer
Always use this tools whilst wearing the appropriate PPE, i.e.
hard head, cloves, closed overall, chipping goggles, dust mask,
etc
Surface Preparation
Method - Abrasive Blasting
Open nozzle abrasive blast cleaning is the best method of surface
preparation. However, dusty and contaminating to adjacent areas.
Recommended use:
Abrasive quality: hard, non-contaminated. No soft sand!
Abrasive size distribution: 0.2 -1.1 mm for general work.
10-12 mm nozzle, not worn out: Distance 30 cm and blasting
angle 60° - 85° to surface.
Surface Preparation
Method – Power Tools
Pneumatic or electrical power tools should be used.
Compressed air must be free from oil and water.
Make sure not to polish the surface with worn out wire
brushes.
Surface Preparation
Method – Wet Blasting
Wet blasting is often used as it reduces dust contamination.
Handle as open nozzle abrasive blasting, but remove sludge
before it dries out. If possible, avoid using inhibitors.
Surface Preparation
Method – Vacuum Blasting
Vacuum abrasive blasting is far less dusty and less likely to
contaminate adjacent areas than open nozzle abrasive blasting.
However, the method has a low/slow production rate.
Recommended use:
Abrasive quality: hard non-contaminated. No soft sand!
Abrasive size distribution: 0.2 - 1.1 mm..
Surface Preparation
Method – Hydro blasting
High pressure water jetting (hydro blast) produces a high velocity
water jet by forcing pressurized (up to 30,000 psi) water through
a specially designed small orifice nozzle.
The method requires fresh water and specially trained operators,
plus special safety precautions for operators and surroundings, i.e.
area must be cleared for all other personnel. The method is very
fatiguing to the operator.
Surface Preparation
Method – chemical
cleaner and degreasers
Use any original fabricate from a reputed company in
concentrations as recommended by the supplier. Follow
strictly any safety advise to protect the user and the
environment.
Surface Preparation
Method – rust
converters / conditioners
In general they contain acid and will consequently leave soluble
salts on the surface which may cause for blistering or other
types of failure. Therefore do not use or use only followed by
washing down with plenty of fresh water. Follow strictly any
safety advise to protect the user and the environment.
Surface Preparation
Method – rust inhibitors
Mainly consisting of water soluble salts/oils. Again, they may
leave soluble salts/soaps. Therefore, wash with plenty of fresh
water afterwards - or even better, do not use them. If you do
use them, watch out for contamination of adjacent areas. If
possible, avoid using any acid or alkali containing materials
altogether. Follow strictly any safety advise to protect the user
and the environment.
Surface Preparation
Cleanliness - Standards
There are different aids available to achieve the desired results.
Standards are set in order to be achieved. Use the International
Standard ISO 8501-1:1988, as reference.
Other prominent standards you may refer are to:
• Steel Structures Painting Council - SSPC.
• British Standards Institution BS 7079
Find the standard you should achieve and compare the relevant
picture with the actual surface. Check also the text and
determine if it describes the actual surface.
For optimum surface preparation refer to ISO 8501-1:1988 Sa 2
½ for abrasive blasting and to St 3 for power tool cleaning.
Surface Preparation
Roughness and Dust Removal
The types of paint which are typically used for shipboard
maintenance are not critical in relation to roughness of the
surface. However, too high roughness could mean poor paint
coverage over roughness peaks and pinhead rusting.
Dust will nearly always be present to a certain extent, but too
much causes poor adhesion of the coatings.
Remove dust by:
a) Vacuum cleaner.
b) Clean bristle brush.
c) Blowing with dry, clean compressed air.
Surface Preparation
Tape Test
Wiping with a white clothes or bare hands might reveal
deficiencies but an easy and effective check to establish
whether dust has been removed sufficiently is:
Transparent, adhesive tape
Few minutes only and amounts of dust may remain.
4. Paint Preparation
Products / Safety
Before you start to handle or use any coating, learn all that
is worth and necessary knowing about the product and the
correct and safe use of it.
Paint Preparation
Storage / Housekeeping
Ensure that all the coatings are stored under correct conditions,
i.e. in a shaded store which is dry and ventilated and with a
suitable temperature. Establish a store/stock system where the
products are used on a “first in - first out” basis.
Paint Preparation
Many of the coatings are supplied as a BASE and a CURING AGENT
Mixing in a predetermined mixing ratio. The components must be mixed
in this ratio.
If the quantity needed is smaller than the
quantity supplied, the correct mixing ratio is
mentioned on the tin/drum. Use only the correct
ratio - not too much and not too little! It is
written on container or the accompanying
documentation. Take your time to study and to
understand it!
Wrong ratio = poor performance.
Paint Preparation
Stirring! Keep Stirring!
Use a mechanical stirrer, actuator if on board. After stirring,
the material should have a completely uniform color with no
lumps or sediments. Always stir for an extra 30 seconds. This is
not a simple job and crew involved should be aware of the
importance of a perfect stirring job as base for a good paint job.
Zinc primers have heavy pigments!
Therefore, keep stirring to avoid setting of the heavy part of the
material.
Paint Preparation
Thinning Use always and only the THINNER as specified in the data sheet!
Do not thin the paint unless absolutely necessary. When thinning,
add only the minimum volume necessary to obtain a good paint
flow and film formation. Before thinning always check that the
pressure of the spray pump is correct, the filter clean and the
spray nozzles not worn out. Two component paints must be mixed
before thinning takes place. Too much thinner causes paint
“running” and/or solvent “boiling”, i.e. holes in the paint film and
too low paint film thickness. Insufficient thinning can cause an
“orange peel” effect and, if spray applied, spray dust on the
surface. In hot climates extra thinner may be necessary.
Paint Preparation
Pot Life
Two-component paint must be used within a certain period of
time after mixing of the two parts. The pot-life depends on the
temperature - a high temperature shortens the pot-life. Check
the pot-life of the product on the data sheet. Thinning will
not prolong the pot-life. If the pot-life is exceeded, do not use
the paint. The chemical reaction has already changed its
properties. Discard it!
5. Application Environment
Air Temperature
Too low air temperature will delay the drying of the paint and
it may begin to slide and form “curtains”.
Too high air temperature will cause dry spray giving a powdery
surface and a porous film.
The best temperature for painting is 15-30°C/59-86°F.
Application Environment
Steel Temperature
Use a steel surface thermometer to check the temperature of
the surface itself. A high temperature of the steel surface will
result in a too rapid temperature setting of the paint and thereby
a porous coating. A low temperature of the steel surface will delay
the drying of the paint. If a cold item is brought into a warm
workshop, water (condensation) may form on the surface.
Therefore, wait until the steel piece is also warm before starting
to paint.
Application Environment
Relative Humidity / Dew Point
There may be water on the steel surface because of condensation.
This will prevent adhesion of the paint.
Use a psycho meter and a dew point calculator to calculate the
relative humidity and the dew point. Compare the dew point with
the temperature of the steel surface.
The temperature of the steel surface must be at least 3°C or 5°F
above the dew point shown on the calculator. The difference in
temperature between day/night and night/day often causes
condensation.
6. Paint Application
Manual Methods - Brush
A brush is a slow, but very good application tool, methods
especially for areas difficult to spray.
Use a good quality brush and use it for stripe coating on
welding seams, on all sharp edges and on areas difficult to spray
before applying full coats with e.g. airless spray. The brush-applied
coating will penetrate into rough surfaces (weld seams) and by
“laying” on the paint on critical areas such as sharp edges, a
better protection is achieved.
Paint Application
Manual Methods - Roller
Rollers are only suitable for applying a cosmetic coat on an
already well protected surface. If rollers must be used for
application of rust preventive primers and intermediate coats,
apply evenly without “stretching” the paint.
Several (2-4) coats may be necessary to substitute one coat
applied by spray.
Paint Application
Spraying Methods
Air spray provides a lower production, more spray dust
methods and only low thicknesses can be applied even
of high-build products. Therefore, air spray is generally
only recommended as a touch-up/repair tool for minor
areas.
Airless spray is the fastest and most efficient method of
application of coatings. Check the following when using airless
spray:
-That the spray pump has enough volume, output pressure
and capacity.
-That the nozzle size and fan width are correct for the paint type.
Check the product data sheet!
Paint Application
Special attention areas
Special attention must be paid to areas difficult to reach and coat.
These includes:
• all sharp edges
• welding seams
• corrugated areas
• behind bulb angles
• behind hand rails
• mouse holes
• underside of coamings
• etc. etc.
Stripe coating and extra coats on such spots are a must for
professional, long-lasting protection
Paint Application
Cleaning of tools
As the same application tools (spray pumps, guns, brushes etc.)
may be used for different types and colors of material, they
should always be kept clean. Clean tools give better results!
Clean the tools in the thinner or tool cleaner recommended
for the particular product. Do not use a tool cleaner as thinner!
Paint Application
Application technique
Experienced/trained paint applicators avoid these problems which
are difficult to fix and which can be costly. Use a systematic
method of spraying the paint from the correct distance
(approx. 30 cm/1 ft). Use a wet film comb during application in
order to determine that a correct and even wet film is obtained.
It is far easier to correct uneven film during application than later
on, as later corrections may be visible.
Apply the paint evenly!
Uneven movements during application will result in an uneven
paint film. This can result in: • paint running • paint sagging • porous coat
• undercoated areas/holidays !
Paint Application
Over coating intervals
!
If the coats are applied too quickly after each other, running,
sagging, solvent retention and insufficient curing may occur.
If they are applied after too long intervals, they may not
stick/adhere to each other.
Before starting to coat, i.e. when planning the job, check the
data sheets of all the products to be used. Find out about the
minimum and maximum recoat intervals and take them into
consideration for your job planning and job execution!
Paint Application
Correct drying and curing
When the coating job is finished do not just leave the site.
Maintain ventilation and/or heating to ensure that the coatings
dry and cure in the proper manner.
Paint Application
D.F.T. control
It is the final quality assurance check of the
total dry film thickness (d.f.t.) to measure that
The correct thickness has been applied.
A too low thickness means early rusting. Therefore additional
coats may be required if target thickness is not met initially.
A too high thickness means over consumption of material and
the possibility of the coatings not drying but remaining soft.
The best and most accurate instrument is the latest models of
digital instruments with memory. All instruments must be
adjusted properly before use.
Paint Application
Keep fences
Keep all fences and warning signs posted until the coatings
are completely dry and are safe for tolerate general traffic.
Paint Application
Temperature
Temperature has a great influence on the behavior of the
paint, both during application and drying/curing. In cold
weather, paint gets thicker and more difficult to spray.
It also dries and cures more slowly. It is always better to
heat the paint than to thin it down. Preferably, the
temperature of the paint should be 15-25°C /59-77°F during
application. In warm weather, paint gets thinner, but tends
to dry spray. Extra thinning may be necessary. The pot life
of two-component products is shorter. The temperature of
the steel should not be above 40°C/104°F during application.
7. Safety
Material safety
Material safety equals
1. A paint store which is clean, tidy and orderly.
2. Tins stored and stocked so that they do not turn over and leak.
3. Lids covering tins containing coatings or solvents.
4. Watch out for fumes and ventilate if necessary.
5. Product data sheets and materials safety data sheets are to
be kept accessible and available.
Safety
Equipment safety
Airless spray must always be earthed as static electricity can
develop within the system and be the cause of explosion.
All couplings must be of a close fit, especially on high pressure
equipment. Replace damaged hoses. During airless spraying the
paint is under an immense hydraulic pressure. Release of the
pressure through the spray gun or any leaks of the equipment
is dangerous, and a stream of paint may easily penetrate human
skin in which case immediate medical aid is required.
Safety
Personal safety
Minimize contact of paint with your skin. Cover as much as
possible with sensible working clothes. Wear gloves and eye
protection. Consider the use of a suitable barrier cream on
exposed skin. Use air fed hood/mask or respirator in confined
spaces. Ensure safe access and adequate lighting. Tidy up as
you proceed - good housekeeping contributes to safety.
Respect safety regulations.
Safety
Job site safety
On site safety can be enhanced by small measures, such as:
-non-skid/slip coatings on walking areas
-high visible coatings to mark danger zones
-tidy and clean surfaces in general
-immediate removal of spillage
Safety
Fire hazard
Never allow
Naked flames - matches - cigarettes
-in the same area where paint is being applied or stored.
Always
Thoroughly ventilate any area where
paint is spilled. Clean up immediately and dispose of the
cleaning material in a closed metal container.
And
If fire should occur, do not attempt to put it out with water –
use powder or carbon dioxide (CO2) fire extinguishers.
Thank You – Now Get Started!
Plan the job
Prepare the job
Execute all works
safely and efficiently
Always remember – an unprofessionally executed paint job
is wasting Money, Time, Material, Efforts and Work Force
