IPS-M-TP-205
MATERIAL AND EQUIPMENT STANDARD
FOR
ZINC-RICH EPOXY PAINT (ORGANIC ZINC-RICH)
AS
PRIMER, INTERMEDIATE
AND
TOP COAT (FINISH)
ORIGINAL EDITION
AUG. 1993
This standard specification is reviewed and
updated by the relevant technical committee on
May 1999(1) and July 2012(2). The approved
modifications are included in the present issue
of IPS.
This Standard is the property of Iranian Ministry of Petroleum. All rights are reserved to the owner.
Neither whole nor any part of this document may be disclosed to any third party, reproduced, stored in
any retrieval system or transmitted in any form or by any means without the prior written consent of the
Iranian Ministry of Petroleum.
Aug. 1993 IPS-M-TP-205
FOREWORD
The Iranian Petroleum Standards (IPS) reflect the views of the Iranian Ministry of Petroleum and are
intended for use in the oil and gas production facilities, oil refineries, chemical and petrochemical
plants, gas handling and processing installations and other such facilities.
IPS are based on internationally acceptable standards and include selections from the items
stipulated in the referenced standards. They are also supplemented by additional requirements
and/or modifications based on the experience acquired by the Iranian Petroleum Industry and the
local market availability. The options which are not specified in the text of the standards are
itemized in data sheet/s, so that, the user can select his appropriate preferences therein.
The IPS standards are therefore expected to be sufficiently flexible so that the users can adapt
these standards to their requirements. However, they may not cover every requirement of each
project. For such cases, an addendum to IPS Standard shall be prepared by the user which
elaborates the particular requirements of the user. This addendum together with the relevant IPS
shall form the job specification for the specific project or work.
The IPS is reviewed and up-dated approximately every five years. Each standards are subject to
amendment or withdrawal, if required, thus the latest edition of IPS shall be applicable
The users of IPS are therefore requested to send their views and comments, including any
addendum prepared for particular cases to the following address. These comments and
recommendations will be reviewed by the relevant technical committee and in case of approval will
be incorporated in the next revision of the standard.
Standards and Research department
No.17, Street14, North kheradmand
Karimkhan Avenue, Tehran, Iran .
Postal Code- 1585886851
Tel: 88810459-60 & 66153055
Fax: 88810462
Email: Standards@ nioc.ir
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Aug. 1993 IPS-M-TP-205
GENERAL DEFINITIONS
Throughout this Standard the following definitions shall apply.
COMPANY :
Refers to one of the related and/or affiliated companies of the Iranian Ministry of Petroleum such as
National Iranian Oil Company, National Iranian Gas Company, National Petrochemical Company
and National Iranian Oil Refinery And Distribution Company.
PURCHASER :
Means the “Company" where this standard is a part of direct purchaser order by the “Company”,
and the “Contractor” where this Standard is a part of contract document.
VENDOR AND SUPPLIER:
Refers to firm or person who will supply and/or fabricate the equipment or material.
CONTRACTOR:
Refers to the persons, firm or company whose tender has been accepted by the company.
EXECUTOR :
Executor is the party which carries out all or part of construction and/or commissioning for the
project.
INSPECTOR :
The Inspector referred to in this Standard is a person/persons or a body appointed in writing by the
company for the inspection of fabrication and installation work.
SHALL:
Is used where a provision is mandatory.
SHOULD:
Is used where a provision is advisory only.
WILL:
Is normally used in connection with the action by the “Company” rather than by a contractor,
supplier or vendor.
MAY:
Is used where a provision is completely discretionary.
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Aug. 1993 IPS-M-TP-205
CONTENTS : PAGE No.
1. SCOPE ............................................................................................................................................ 4
2. REFERENCES ................................................................................................................................ 4
3. UNITS .............................................................................................................................................. 5
4. COMPOSITION ............................................................................................................................... 5
5. ANALYSIS ...................................................................................................................................... 7
6. PROPERTIES ................................................................................................................................. 8
7. STORAGE LIFE AND PACKAGING .............................................................................................. 9
8. INSPECTION................................................................................................................................. 10
9. LABELING .................................................................................................................................... 10
10. DIRECTIONS FOR USE ............................................................................................................ 11
11. DIRECTIONS FOR SAFETY ...................................................................................................... 11
12. MATERIAL QUALITY ASSURANCE ......................................................................................... 11
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Aug. 1993 IPS-M-TP-205
1. SCOPE
This is Standard specification which is mainly generated from SSPC-20 covers the minimum
requirements for the composition, analysis, properties, storage life and packaging, inspection and
labeling of zinc rich epoxy paint ( organic zinc-rich) to be used as primer, intermediate and top coat.
Note 1:
This standard specification is reviewed and updated by the relevant technical committee on
May 1999. The approved modifications by T.C. were sent to IPS users as amendment No. 1
by circular No. 84 on May 1999. These modifications are included in the present issue of IPS.
Note 2:
This standard specification is reviewed and updated by the relevant technical committee on
July 2012. The approved modifications by T.C. were sent to IPS users as amendment No. 2
by circular No. 349 on July 2012. These modifications are included in the present issue of
IPS.
2. REFERENCES
Throughout this Standard the following dated and undated standards/codes are referred to. These
referenced documents shall, to the extent specified herein, form a part of this standard. For dated
references, the edition cited applies. The applicability of changes in dated references that occur
after the cited date shall be mutually agreed upon by the Company and the Vendor. For undated
references, the latest edition of the referenced documents (including any supplements and
amendments) applies.
SSPC (STEEL STRUCTURES PAINTING COUNCIL) VOL. 2
SSPC 20 "Zinc-Rich Primer (Type I, “Inorganic” and Type II, “Organic”)"
SSPC-PA Guide 3 "A Guide to Safety in Paint Application"
SSPC SP 5 “White Metal Blast Cleaning”
SSPC-PA 1 “Shop, Field and Maintenance Painting”
SSPC Guide 12 “Guide to Zinc-rich Painting System”
ASTM (AMERICAN SOCIETY FOR TESTING AND MATERIALS)
(Specification for Ingredients)
D520 "Standard Specification for Zinc Dust Pigment "
(Test Methods for Properties)
A36 "Standard Specification for Carbon Structural Steel"
B117 "Standard Practice for Operating Salt Spray (Fog ) Apparatus"
D56 "Standard Test Method for Flash Point by Tag Closed Cup Tester"
D521 "Chemical Analysis of Zinc Dust (Metallic Zinc Powder)"
D562 “Standard Test Method for Consistency of Paints Measuring Krebs
Unit (KU) Viscosity Using a Stormer –Type Viscometer”
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Aug. 1993 IPS-M-TP-205
D1308 "Effect of Household Chemicals on Clear and Pigmented Organic
Finishes"
D1475 "Standard Test Method for Density of Liquid Coatings, Inks and
Related Products"
D1544 "Color of Transparent liquids (Gardner Color Scale)"
D1652 “Epoxy Content of Epoxy Resins”
D2369 "Standard Test Method for Volatile Content of Coating"
D2371 "Standard Test Method for Pigment Content of Solvent –
Reducible Paints"
D3359 "Measuring Adhesion by Tape Test"
D3925 “Practice for Sampling Liquid Paints and Related Pigmented
Coating
UFS (US FEDERAL STANDARDS)
(Standard Specification)
PPP-P-1892 "Paint, Varnish, Lacquer And Related Materials, Packaging And
Marketing Of"
(Federal Test Method Standard No. 141)
Method 4331 "Spraying Properties"
Method 4541 "Working Properties and Appearance of Dried Film"
ANSI (AMERICAN NATIONAL STANDARDS INSTITUTE)
ANSI Z400.1/Z129.1 "Hazard Evaluation and safety data sheet and precautionary
labeling preparation"
BSI (BRITISH STANDARD INSTITUTION)
BS381C "Colors for Identification on Coding and Special Purposes"
IPS (IRANIAN PETROLEUM STANDARDS)
IPS-E-GN-100 “Engineering Standard for Units”
IPS-E-TP-100 "Engineering Standard for Paints"
3. UNITS
This Standard is based on International System of Units (SI), as per IPS-E-GN-100 except where
otherwise specified.
4. COMPOSITION
4.1 Ingredients and Proportions
Ingredients and proportions of paint shall be as specified in Table 1 and Sections 4.2 through 4.6.
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Aug. 1993 IPS-M-TP-205
4.2 Percentage
The paint consists of 70% by weight of nonvolatile film forming solids (pigments and binder).
4.3 The zinc rich described in this specification consists of zinc dust, an organic vehicle, and
selected additives as required.
4.4 Pigmentation
The major pigment component in paint is zinc dust of either types described in Table 2.
Other pigment components may include curing aids, tinting colors, suspension and pot life control
agents, but should constitute only a minor part of the total pigment portion so as not to detract from
the ability of this paint to protect galvanically.
4.5 Vehicle
Organic vehicle consists of catalyzed epoxy. The epoxy resin shall be a di-epoxide condensation
product of biphenol A and epichlorohydrin with terminal epoxide group with the requirements of
Table 3.
4.6 Curing Agent Component
The curing agent consist of a liquid type polyamide resin and volatile solvent.
The undiluted polyamide resin shall meet the requirements of Table 4.
TABLE 1 - COMPOSITION OF PAINT
COMPOSITION INGREDIENT
INGREDIENTS Wt. % STANDARDS
PIGMENT ( 83 ±2 Wt. %) 58 ASTM D520
VEHICLE ( 17 ±2 Wt. %) 12 ---
SOLVENT 30 ---
SELECTED ADDITIVES AS REQUIRED ---
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Aug. 1993 IPS-M-TP-205
TABLE 2 - COMPOSITION OF ZINC DUST PIGMENT
Type I Type II Type III
Total zinc, calculated as Zn, min, % 97.5 98.0 99.0
Metallic zinc, min, % 94.0 94.0 96.0
Material other than metallic zinc, ZnO,
and admixed CaO, where applicable
max % 0.75 ... ...
Calcium, calculated as CaO, max, % 0.7 0.7 ...
Lead, calculated as Pb, max, % ... 0.01 0.002
Iron, calculated as Fe, max, % ... 0.02 0.002
Cadmium, calculated as Cd, max, % ... 0.01 0.001
Chlorine, calculated as Cl, max, % ... 0.01 ...
Sulfur, calculated as SO2, max, % ... 0.01 ...
Moisture and other volatile matter, max, %
0.10 0.10 0.10
Oily or fatty matter, or both, max, % ... 0.05 ...
Zinc oxide (ZnO), max, % 6.0 remainder remainder
Coarse particles, max, %:
Total residue retained on a 150-μm
(No. 100) sieve
none 0.1 0.1
Total residue retained on a 75-μm
(No. 200) sieve
... 0.8 0.8
Total residue retained on a 45-μm
(No. 325) sieve
4.0 3.0 3.0
Type I General Grade.
Type II High Purity Grade.
TABLE 3 - EPOXY RESIN ANALYSIS
REQUIREMENTS ASTM
CHARACTERISTICS Min. Max. METHOD
EPOXIDE EQUIVALENT 450 550 D1652
COLOR, GARDNER (40% IN BUTYL --- 4 D1544
CARBITOL)
TABLE 4 - CURING AGENT ANALYSIS
REQUIREMENTS ASTM
CHARACTERISTICS Min. Max. METHOD
1
AMINE VALUE 230 250 ---
COLOR GARDNER --- 8 D1544
SPECIFIC GRAVITY 0.96 0.98 D1475
VISCOSITY, AT 75° C POISES, 31 37 ---
1) perchloric acid titration
5. ANALYSIS
5.1 The paint shall conform to the composition (analysis) requirements of Table 5.
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Aug. 1993 IPS-M-TP-205
TABLE 5 - ANALYSIS
MINIMUM STANDARDS
1
CHARACTERISTICS REQUIREMENTS ASTM
TOTAL SOLIDS, % BY WEIGHT OF PAINT 70 D2369
PIGMENT, % BY WEIGHT OF TOTAL SOLIDS 83 D2371
2
TOTAL ZINC DUST , % BY WEIGHT OF PIGMENT 93 D521
2
TOTAL ZINC DUST , % BY WEIGHT OF SOLIDS 77 ---
1) The minimum composition requirements of zinc-rich paint is controversial. It is
recognized that zinc rich primer containing extenders, although having less total zinc dust
than specified, may be able to pass all other requirements of this specification. However,
these compositional requirements are necessary, as certain non-zinc containing coating
may be able to pass all other requirements of this specification.
2) Zinc dust shall meet requirements for composition of pigment (ASTM 520).
6. PROPERTIES
6.1 The paint shall meet the qualitative requirements of Sections 6.2 through 6.9.
6.2 Pot Life
The pot life of the zinc-rich paint, when mixed and ready for application in accordance with
manufacturer’s instructions, shall be a minimum of four hours at 21°C and 50% relative humidity.
Although physical properties (viscosity, etc.) may not change, loss of pot life is indicated by lack of
adhesion when tested in accordance with Section 6.6.
6.3 Working Properties
The mixed paint shall spray easily, and show no streaking, running, sagging, or other objectionable
features when tested in accordance with US Federal Standard No. 141, Methods 4331, and 4541.
6.4 Test Panel Preparation
Steel test panels ( ASTM-A 36 hot rolled steel or equivalent) measuring 10 cm × 15 cm × 1.5 mm,
or greater, shall be blast cleaned to Sa3 (white metal) with a nominal anchor profile from 40-90
microns and coated with the zinc-rich paint. The panels shall be blast cleaned and coated on both
sides and all edges. The paint shall be spray applied and hardened in accordance with
manufacturer’s recommendations. The dry film thickness shall be 60-90 microns unless otherwise
designated. Prior to any exposure testing, all panels shall be aged for 14 days at 24-26°C and 45-
55% relative humidity.
6.5 Mudcracking
The paint when applied in accordance with Section 6.4 to a 125-150 microns dry film thickness,
shall show no mudcracking when viewed under 10X magnifications.
6.6 Adhesion
The paint when applied and hardened in accordance with Section 6.4, shall adhere to the steel
substrate when subjected to the "Cross-Cut/Tape Test" (ASTM-D3359, Method B).
There shall be no separation of the paint film, or delamination of an entire square. Spalling loss of
adhesion around the perimeter due to cutting of each square is acceptable.
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Aug. 1993 IPS-M-TP-205
Adhesion rating should be no less than 4B grading when evaluated according to the procedure of
ASTM-D 3359,Method B.
6.7 Salt Fog Resistance
The paint when applied and hardened in accordance with Section 6.4 and scribed as described
below, shall pass, 1,000 hours minimum exposure to salt fog (ASTM-B 117) without any blistering
or rusting of the coated portion, with no under cutting from the scribe (Slight rusting in the scribe
mark will be permissible and resulting staining should be ignored).
Strips 6 mm wide along the edges of the panel may be ignored. Testing shall be done in triplicate.
The scribe mark shall be centrally positioned in the lower half of the panel and shall consist of an
"X" comprising the diagonals of a 5 × 5 cm square. To insure proper positioning, cleanliness and
depth of scribe mark, a template and scriber or cutting tool having a cutting edge at least 0.8 mm
wide shall be used. The operator shall bear down hard and go over each arm of the cut twice to
insure a clean scribe of sufficient depth to remove any zinc particles from the scribe and to expose
clean steel.
6.8 Additional Resistance Tests
Because of the diversity of potential service environments, this specification may require the zinc-
rich paint be further exposed and qualified by at least one additional test relating to the intended
exposure. For example, if the intended service is a petroleum tanker cargo hold which is ballasted
with sea water, appropriate test requirements other than those already specified might be:
- Salt Water Immersion (1,000 hours) ASTM-D 1308.
- Oil Immersion (1,000 hours) ASTM-D 1308 or a cycling combination of both.
Comparative testing of all candidate zinc-rich paints will be more meaningful than individual testing
of each primer.
Standard test which may be useful for further qualification are available from a number of
organizations, including ASTM, US Government Federal Specifications (TT-P, mil-P, etc.), US
Federal Test Method Standards (141), and Canadian Government Specifications Board.
However, it should be emphasized that a well designed non standard test may often provide more
meaningful information for a given service condition than one or more standard tests.
6.9 Flash Point
The minimum flash point, as determined by the Tag closed cup (ASTM D56) should be 10°C.
Specific applications, such as the interior of tanks, holds, and other confined spaces normally
require a minimum flash point of 38°C.
6.10 Color
This paint can be used as top coat only where the finished color is not specific.
7. STORAGE LIFE AND PACKAGING
7.1 Storage Life
The vehicle of the paint shall show no thickening, curdling, gelling, gassing, or hard caking after
being stored for 12 months from the date of delivery in a tightly covered unopened container.
7.2 Packaging
The pigment portion of multicomponent zinc-rich paints shall be packaged separately to be mixed
with the liquid portion shortly before use. Each container of liquid shall be packaged and labeled in
accordance with the requirements of Federal Specification PPP-P-1892 and shall include directions
showing correct proportions of liquid to pigment along with necessary mixing instructions.
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Aug. 1993 IPS-M-TP-205
8. INSPECTION
8.1 All materials supplied under this specification shall be subject to timely inspection by the
purchaser or his authorized representative. The purchaser shall have the right to reject any
material(s) supplied which is (are) found to be defective under this specification. In case of dispute,
the arbitration or settlement procedure established in the procurement documents shall be followed.
8.2 Samples of any or all ingredients used in the manufacture of this paint may be requested by the
purchaser and shall be supplied upon request, along with the supplier’s name and identification for
the materials.
8.3 Unless otherwise specified, the methods of sampling and testing should be in accordance with
US Federal Test Method Standard No. 141, applicable method of the American Society for Testing
and Materials (ASTM 3925).
9. LABELING
9.1 Refer to ANSI Standard Z400.1/Z129.1 "Hazard Evaluation and safety data sheet and
precautionary labeling preparation".
9.2 Marking of Container
Each container shall be legibly marked with the following information:
Name: Zinc Rich Epoxy Paint (Organic Zinc-Rich) as Primer, Intermediate and Top coat
(Finish)
Specification: IPS-M-TP-205
MESC No.: ........................................................................................
No. of Components: ........................................................................
Maximum temperature resistance: ................................................
Type of Spray: .................................................................................
Kind and size of spray nozzle tip: .................................................
Cleaning material: ...........................................................................
Flash point °C: ................................................................................
Pot life (hours): ...............................................................................
Drying time for over coating: ........................................................
Kind of thinner: ..............................................................................
With reference to BS381C No. (to be specified by specifier)
Lot Number: ....................................................................................
Stock Number: ................................................................................
Date of Manufacture: ......................................................................
Storage temperature: .....................................................................
Shelf life: .........................................................................................
Quantity of Paint in Container: .....................................................
Information and Warnings (if needed): ........................................
Manufacturer’s Name and Address: .............................................
Design Guide: For guidance on the usage of this paint for various application/environment
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Aug. 1993 IPS-M-TP-205
and temperature ranges reference shall be made to IPS-E-TP-100
10. DIRECTIONS FOR USE
The manufacturer shall supply complete instructions covering uses, surface preparation, mixing,
thinning, application method, application conditions, pot life, wet and dry film thicknesses,
temperature and humidity limitations, drying times, etc. with each container of paint.
11. DIRECTIONS FOR SAFETY
The following directions for safety shall be supplied with each container of paint:
- Paints are hazardous because of their flammability and potential toxicity. Proper safety
precautions shall be observed to protect against these recognized hazards. Safe handling
practices are required and should include, but not be limited to, the provisions of SSPC-PA
Guide 3,"A Guide to Safety in Paint Application" and to the followings:
- Keep paints away from heat, sparks, and open flame during storage, mixing, and
application. Provide sufficient ventilation to maintain vapor concentration at less than 25%
of the lower explosive limit.
- Avoid prolonged or repeated breathing of vapors or spray mists, and prevent contact of the
paint with the eyes or skin.
- Clean hands thoroughly after handling paints and before eating or smoking.
- Provide sufficient ventilation to insure that vapor concentrations do not exceed the
published permissible exposure limits. When necessary, supply appropriate personal
protective equipment and enforce its use.
This paint may not comply with some air pollution regulations because of its hydrocarbon solvent
content.
Ingredients in this paint, if so formulated, and which may pose a hazard include lead and chromate-
containing pigments and hydrocarbon solvents. Applicable regulations governing safe handling
practices shall apply to the use of this paint.
12. MATERIAL QUALITY ASSURANCE
12.1 In order to determine the acceptability of a lot or batch of a qualified product, the paint shall
meet the requirements of sections 12.1 through 12.4.
12.2 Viscosity of the mixed paint shall be determined in accordance with ASTM D 562. Variance
shall be within ±5 Krebs Units or equivalent units of another viscometer of the viscosity of the
previously qualified paint.
For viscosities lower than 55 K.U., a 4 Ford Cup shall be used in accordance with ASTM D 1200.
Variations shall be within ±5 seconds of the viscosity of the previously qualified paint.
12.3 Weight per gallon of the mixed paint shall be determined in accordance with ASTM D 1475.
Variance shall be within ±0.4 pounds (180 g) of the nominal weight per gallon of the previously
qualified paint.
12.4 Solids percent by weight of the mixed paint shall be determined in accordance with ASTM D
2369. The percent solids by weight shall be no less than that specified in Table 5. Variance shall be
within ±2% of the nominal percent solids by weight of the previously qualified paint.
12.5 Other tests may be used to determine the acceptability of a lot or batch of a qualified product
at the discretion of the user.
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