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CONTENTS

1. Scope............................................................................................................................... 3

2. Reference Documents................................................................................................. 3

3. General........................................................................................................................... 3

4. Surface Preparation.................................................................................................... 4

5. Painting........................................................................................................................... 5

6. Inspection and Testing............................................................................................... 8

7. Paint Storage ………………………………………………………………………………………… 9

8. Safety Precautions ………………………………………………………………………………… 9

9. Paint repair procedure ………………………………………………………………………… 10

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1. Scope:
This document covers all the requirements of Non-marine Painting Procedure for the
MHS Equipment for 25000 MT Grain Storage Silo for AALL Projects, as per the approved
Manufacturing Quality Plan.

2. Reference documents:
 Client's Approved Manufacturing Quality plan
 Approved drawings
 Paint Manufacturer's Specification & datasheets

3. General Introduction :
The procedure for applying liquid epoxy paint involves several key steps, from surface
preparation to the curing process. Below is a detailed step-by-step guide to applying
liquid epoxy paint to ensure optimal results.

Materials and Tools Needed

o Liquid Epoxy Paint (base and hardener
components) Make : Berger
Product: EPOXY FINISH
(Polyamide cured top coat based on Epoxy resin and special pigment)

o Thinner (if required for thinning the

paint) Make : Berger
o Product: Epoxy Thinner

o Epoxy Primer
Make: Berger
Product: EPOXY PRIMER
(Polyamide & polyamine cured Epoxy primer)

o Clean Cloths/Rags

o Paintbrushes, Spray Equipment (spray gun, airless spray system)

o Protective Gear (gloves, mask, goggles, overalls suits)

o Surface Preparation Tools (abrasive blast equipment, sandpaper, wire brushes, etc.)
o Mixing Containers (for mixing paint components)
o Measuring Equipment (for correct mixing ratios)

o Dry Film Thickness Gauge (Micro test or Elecometer)

o Ventilation System or Spray Booth (for safety when spraying)

o Instrument for measuring surface roughness : Third Party Testing Agency

o Instrument for humidity and temperature measurement : Digital Hygrometer and thermometer
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4. Surface Preparation
Proper surface preparation is crucial for the paint to adhere well and achieve long-
lasting durability.

4.1 Fabrications (not tooling) shall be prepared for paint to ISO 8501-3 P2 with dressed edges as a
minimum,
unless otherwise stated in the project specifications or ITP.

4.2 All surfaces to be painted shall be thoroughly degreased by solvent cleaning to remove oil,
grease, dirt etc.
and surface rinsed with clean water.

4.3 Surface profile shall be in accordance with that shown on the paint system document.

4.4 Surfaces to be painted shall be prepared by hand cleaning and mechanical cleaning to ISO 8501-1
to the level detailed on the

Paint data sheet or other mechanical means as required.

4.5 Surface preparation shall not be carried out in an environment where: -

4.5.1 Metal surface temperature is less than 3°C above surrounding air dew point
4.5.2 Relative Humidity is in excess of 85%
4.5.3 Air temperature is below 5°C
4.5.4 Surface is likely to become damp after preparation and prior to painting
4.5.5 Any of the above conditions are likely to occur prior to painting
4.5.6 Any defects discovered during the surface preparation, primer or any process shall be rectified
with agreement ensuring
coating quality is not compromised.

4.6 All the surfaces that are cleaned, with exception of lap joints and areas left blank for
welding at site, shall be coated with primer coat within a period of 4 hours after
cleaning. Under no circumstances shall cleaned surfaces be left unprotected overnight.

Method of Classification Procedure and Degree of Reference

cleaning Steel Surface Finish Standards
Degreasing Thorough removal of oil, grease
and other contaminants from
metal surface. Total area to be
cleaned and no residue in any
form is allowable.
Blast Cleaning Sand Blasting Thorough blast cleaning. Almost Min. Sa2.5
all the mill scale, rust and foreign Grade of SIS-
(All large size matter shall be removed. Finally 05-5900-1967
component/structure surface should be cleaned and
will be done sand dried ensuring no moisture
blasting) content is present on the surface.
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Tool based cleaning Power / Hand Thorough scraping, wire St.2 or St.3 of
Tool / wire brushing and grinding. Swedish
(All accessories and brushing Treatment should remove loose specifications
small and delicate mill scale, rust and foreign
components will be matter. Finally surface is cleaned
covered under hand with brush and/or compressed
tool based cleaning. ) air.

4.7 Surface preparation measurement: The visual assessment of the surface profile will
be done as per IS 8501-1. The surface preparation roughness will be
measured using a surface roughness meter/ tester as per SA 2.5 standards.
Surface profile shall be 50 - 60 microns
Annexure for cleaning classification
Copper slag Blasting Toll based cleaning
Body of pre-cleaner Hand rails
Cyclone Control gate
ducting of dust collection Motor mounting stools
supporting structure cyclone Two way diverter
Bag filter body Aeration blower
Bag filter structure Sweep auger
Bag filter platform

5 Painting
5.7 General:

Painting shall not be carried out in an environment where: -

5.7.1 Metal surface temperature is less than 3°C above the surrounding air dew-point.
5.7.2 Relative humidity is in excess of 85%.
5.7.3 Air or metal surface temperature is below 5°C.
5.7.4 Any of the above conditions are likely to occur before the paint is dry.
5.7.5 Paints shall be applied in accordance with the Paint manufacturer’s recommendations.

5.8 Priming:

It is a two pack high performance polyamide & polyamine cured epoxy primer
containing special anticorrosive pigment. it has excel ent adhesion to steel and suitably
treated light alloys. It cures to a tough and high rust preventive coat with excellent
chemical and water resistant properties.

5.1.1 Primer: (Name: Epoxy Primer, polyamide & polyamine cured epoxy primer,
Berger)
SL . No. Description Specification
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1. Method of application Spray

2. Recommended film thickness 30-35 µm per coat
3. Covering capacity 13-15 sq m per litre
4. Mixing Ratio Hardener 4:1 (by Volume)

5. Drying Time Surface dry : Within 1/2 hour

(AS PER THE BERGER PAINT MANUFACTURER'S Hard dry : Within 8 hour
SPECIFICATIONS AND DEPENDING ON THE Full Cure : Within 7 days
TEMPERATURE AND HUMIDITY)
6. Interval before over coating Minimum : 1/2 hour
Maximum : 7 days
7. Pot Life @ 30˚C 6-8 Hours
8. Storage life Up to 12 months as long as the material is
stored in a steel container under standard
warehousing storage condition
9. Dry Heat Resistance Up to 100˚C (Intermittent)

5.3. Mixing the Epoxy Paint (Name: Epoxy Finish, polyamide cured top coat,
Make: Berger
5.3.1 Measure the Components:

o Epoxy paint typically comes in two parts: the base (resin) and hardener (curing
agent).

o Carefully measure both components in the ratio specified by the manufacturer

(commonly 3:1 or 4:1 base to hardener by volume).

5.3.2 Mix Thoroughly:

o Pour the base and hardener into a clean, dry mixing container.

o Use a mechanical stirrer or a mixing stick to properly mix the components

thoroughly. Ensure that the mixture is uniform and without streaks.

5.3.3 Thinning (if necessary):

o If the paint is too thick for your application method (e.g., spraying), add the
recommended thinner. Follow the manufacturer’s guidance for the correct
thinner intake and dilution percentage depending upon the mode of application.

5.3.4 Pot Life:

o Be aware of the pot life (working time) of the mixed epoxy paint. It’s the amount
of time the paint remains usable after mixing, typically between 30 minutes to 2
hours. Do not use the paint after it begins to harden in the container.

5.4. Application of Epoxy Paint:

The method of application depends on the tools available and the specific requirements
of the machinery surface. Paint coating shall be applied by spray unless stated
otherwise or where spray is not suitable.
5.4.1 Set Up the Spray Equipment:
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o If using an air spray gun or airless spray, adjust the pressure according to the
paint's specifications and the surface being painted.

5.4.2 Apply in Thin Coats:

o Hold the spray gun about 6 to 9 inches from the surface and apply thin, even
coats, moving in a back-and-forth motion with 50 % overlapping.

5.4.3 Avoid Over-Spraying:

o Keep a consistent speed and distance to avoid paint built-up, which could lead to
run down or sagging.
5.4.4 Multiple Coats:

o In wet on wet coating, second coat can be applied after 5 - 10 minutes of flash off
time, as per the Berger Paint Manufacturer's specifications.

o In Specific case when temperature is less than 5 degrees and relative humidity is
more than 85%, second coat should be applied after 6-8 hours. This is also as per
Berger Paint Manufacturer Specifications.

5.5 Drying and Curing

5.5.1 Initial Drying (Touch Dry Time):

o Allow the paint to dry to the touch, which can typically take between 30
minutes to 2 hours, depending on the temperature and humidity.

5.5.2 Curing Time:

o Epoxy coatings generally require a full curing time of 7 days at room

temperature to reach maximum hardness and durability. Follow the
manufacturer's guidelines for specific curing times.

o Ensure proper ventilation if curing in a confined space

Activity Metal Surface Specification of paint No. of Dry Film Surface Hard
Temperature material coats Thickness Drying Drying
(µm) Time time
Primer Combination of 1 30-35 1/2 Hour 8 Hour
Coat Polyamide &
5˚C<T< 50˚C polyamine cured
(Relative epoxy primer
Final Coat Humidity < 85%) Polyamide cured 2 30-35 2 Hour 8 Hour
epoxy Paint
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Note: Final DFT Thickness Recommendation -

Minimum Thickness - 100 Microns
Maximum Thickness - 120 Microns
+20% DFT Microns allowed at corner, edge areas

6 Inspection and testing

6.7 Inspection:
o After the paint has dried and cured, inspect the surface for uniformity, coverage,
and defects.
o If necessary, touch up any missed spots or poorly covered areas with additional
paint.

6.8 Testing:

Testing of the applied paint coatings is critical to ensure the paint’s performance,
durability, and adherence to specific quality standards. Testing shall be performed as
per the methods listed below-

6.2.1. Adhesion Test : Cross-hatch / X-cut (ASTM D3359)

Before applying any tests to the painted surface, ensure that the machine or part to be
painted is properly cleaned and prepared. The surface should be free from
contaminants such as oil, dust, rust, or dirt. Common preparation techniques include:
o Apply the epoxy paint to the test surface and allow it to cure for 24 hours.
o Use a razor blade to make a grid pattern (crosshatch) on the painted surface.
o Use an adhesive tape to remove the squares and observe how much of the paint
is removed.
o The adhesion is rated on a scale from 0 (worst) to 5 (best), where 5 is no
removal and 0 is complete failure.

6.2.2 Thickness Measurement

The DFT is a critical parameter in assessing the performance of protective coatings, as it

affects the coating's durability, corrosion resistance, and overall protective properties.

 Method: Dry Film Thickness (DFT) Measurement (ASTM D4138)

 Specimen Preparation: The coated sample must be prepared by ensuring that

the coating is completely dry and cured before testing.

 Measurement Points: The DFT measurement should be performed at multiple

points on the coated surface to ensure accurate and representative results. The
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number of measurement points may vary depending on the size of the coated
area. Final paint coating thickness to be 100-120 microns measured by DFT test.

6.2.3 Impact Measurement test

It measures the ability of a coating (such as paint, lacquer, or other surface coatings) to
withstand mechanical impact without cracking, peeling, or delaminating.

 Method : ASTM D2794

 Test Equipment: The test uses a device known as an impact tester, which
applies a specified force to the coated surface via a falling weight or other
controlled mechanisms.
 Impact Test: The specimen is subjected to an impact using a specified weight
dropped from a controlled height, producing a deformation of the coating. The
impact force can vary depending on the height from which the weight is
dropped or the size and shape of the impactor.
 Evaluation: After the impact, the coated sample is examined for damage, such
as cracking, chipping, or loss of adhesion. The test may also involve checking the
coating's deformation or any other signs of physical failure.

Note: 1) As it is a Non-marine class paint, Salt Deposition test is not required, as per the
Berger paint manufacturer specifications.

2) Pull off test is not possible due to the unavailability of testing laboratory /
equipment for this in Faridabad.

7 Paint Storage:
7.7 : All paint shall be stored in accordance with requirements laid down by the
paint manufacturer. Outdoor storage for instance next to application site is
acceptable for quantities to be used on the particular day, provided provision for
weather protection and cover are made. The storage area shall be well ventilated
and protected from spark, flame, direct exposure to sun or excessive heat,
preferably located in an isolated room or in a separate building. Recommended
storage temperature 5˚C to 25˚C.
7.8 : All paint container shall be clearly labelled to show at the time of use paint
identification and instruction in legible form. The container shall be opened only at
the time of use. Paint which have livered, gelled or deteriorated during the storage
shall not be used. Paint for which shelf life specified by the manufacturer has
expired, shall not be used.

7.9 : All paint material shall be stored in tightly sealed condition and never
stored in unprotected outdoor or exposed to direct sunlight. Paints in which hard
settling have formed shall be discarded. Paint material shall be issued on a first in
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first out basis.

8 Safety Precautions:
8.7 : Following safety measures and precaution need to be taken into consideration during
surface preparations and painting process.
8.7.1 : Proper earthling shall be provided for all the electrical equipment’s.
8.7.2 : Any spillage of the volatile material shall be wiped off immediately.
8.7.3 : Necessary safety tool such as PPE, first aid kid should be available at the work place.
8.8 : Safety Norm:

8.8.1 : During removal of oil, grease, rust & scales from the surface appropriate apron, gloves,
respiratory and safety glasses shall be used by the operator.
8.8.2 : During Painting
8.8.2.1 Task performer should wear hand gloves and aprons during painting
procedure to prevent skin irritation, inflammation, rashes or pustules on hand,
arms or body.
8.8.2.2 Work place and storage room should be adequately ventilated.
8.8.2.3 Before starting work clean hands with soap and use good barrier cream.
8.8.2.4 Splashing on the skin must be washed off immediately.
8.8.2.5 After work hand, face and arms must cleaned thoroughly with soap & water
and dried with clean cloth.

9 Paint repair procedure:

9.1. Repair of damaged primer or paint:

9.1.1: Spot Repair: Where paint or primer is damaged due to the handling and transport or later
erection /welding, the repair of the damaged coating shall be done as per the procedure
mentioned below:
9.1.2. Surface Preparation: Remove the coating from damaged area by mechanical scraping and
emery paper conforming to the surface Min. Sa2.5 Grade of SIS-05-5900-1967 or St.2 or St.3 of
Swedish specifications to expose white metal. Blast clean surface if possible. One primer coat and
two paint coats shall be applied on the damaged spot after surface preparation.

9.2. Galvanizing material repair procedure

To repair damaged galvanized steel:
9.2.1: Clean the area thoroughly. Remove any rust, dirt, or other debris using a wire brush or
sandpaper.
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9.2.2: Apply a galvanizing repair paint or zinc-rich (60% to 70%) primer to the cleaned area. This
will help protect the steel from further corrosion. Follow the product instructions carefully for best
results.
9.2.3: If the damage is more extensive, you may need to apply a cold galvanizing compound. This is a
liquid zinc coating that can be brushed or sprayed onto the affected area.
9.2.4: For deeper pits or holes, you may need to use a filler material designed for galvanized steel
before applying the repair paint or compound. This helps restore the surface.
9.2.5: Allow the repair product to fully dry and cure according to the manufacturer's
recommendations before exposing the area to moisture or wear.

The key is to thoroughly clean the damaged area and apply a product specifically formulated to
protect galvanized steel from further corrosion. Taking these steps can help extend the lifespan of
the galvanized steel surface
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