Presented by: Bob Kogler, Rampart LLC
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Transcript of Presented by: Bob Kogler, Rampart LLC
Presented by: Bob Kogler, Rampart LLC
Protecting Steel Edges
Learning Outcomes• At the end of this webinar, you will be
able to:– Recognize sharp edges, outside corners,
crevices and welds – Define the proper steps to be taken to
treat sharp edges, outside corners, crevices and welds in order to avoid reduced coating barrier protection
Introduction• This webinar will describe:
– The importance of edge protection to the overall corrosion protection of the structure
– The reasons coatings tend to often fail at edges
– the advantages and disadvantages of specific methods of obtaining sufficient coating thickness on steel edges and other irregular steel surfaces, where coatings tend to pull away during curing, leaving thin or non-existent coverage
What is an “edge”?• Corners (inside/outside)• Cutouts• Welds• Fastener heads• Anything with an angle approaching
90 degrees (or worse)
Why do we can particularly about edges?
• Sharp edges, outside corners, crevices and welds are often sites where coating failures and corrosion begin due to reduced coating barrier protection
Reduced coating thickness is a result of surface tension created during the curing of the wet coating causing the coating to shrink, pulling the coating film away from the edges - solventborne coatings
Typical Failure initiation points
Avoiding Edge Failure• Design out the edges and
irregularities
Avoiding Edge Failure• Fabricate out the edge problem
Avoiding Edge Failure• Surface prep to remove the failure
point
Avoiding Edge Failure• Coating selection to mitigate the
failure point
Each Takes Investment• Its all about tolerance for
risk– How harsh is the exposure
– locally at the edge?– How long does the coating
need to perform?– Will there be access for
inspection and maintenance?
– Consequences of a coating failure?
Steps for Avoiding Reduced Coating Barrier Protection• The following steps are explained in SSPC
PA Guide 11, Protecting Edges, Crevices, and Irregular Steel Surfaces by Stripe Coating– Step 1: Eliminate the irregularities by
grinding, mechanical sanding or filing– Step 2: Apply a thicker protective coating film
to problem areas (Stripe Coating)– Step 3: Apply a full coat of paint with edge
retention properties, allowing application of a penetrating and/or good wetting coating to problem areas
Step 1• Outside corners and sharp edges
should be: – Ground such that the edge is rounded to
a 1/16-1/8 inch radius (NSRP SP-3 Panel reports)
– Chamfered, which reduces a sharp 90 degree corner to two 135 degree angles
• The distance between the two 135 degree angles is approximately 1/16-1/8 inch
Step 1 (Continued)
Step 1 (Continued)• The increased performance resulting
from rounding or chamfering edges depends on:– The service environment– The generic type of coating– The radius or size of the chamfer– Proper coating application per SSPC-PA 1,
Shop, Field, and Maintenance Painting of Steel
Step 1 (Continued)• Note: Research has shown that
rounding or chamfering had no measurable effect if an ethyl silicate inorganic zinc-rich (IOZ) coating is applied. Additional information on this topic can be found in, Corbett, W. D. “The Same Old Grind...An Investigation of Zinc-Rich Primer Performance Over Steel Corners.” Modern Steel Construction, Vol. 40, No. 6: p. 43-49
Step 1 (Continued)• For best practice, edge grinding
should be done in the shop, BEFORE blast cleaning where the work is accessible
Step 2• A “Stripe Coat” is a coat of paint applied either before or after a full coat is applied to an entire surface. A “Stripe Coat” is typically applied to:
•Edges•Welds•Outside corners•Bolt heads and threads•Crevices
Step 2 (Continued)• The project specification should clearly
state stripe coating requirements: – The areas that are to be striped– How to apply the stripe coat (brush or spray)– In what order to apply the stripe coat (before or
after the full coat)– Which coats are to be striped– Whether tinting of the stripe coat or use of
another color of coating is required– Details on the drying/curing requirements
between application of the stripe and full coat
Step 2 (Continued)•Situations where stripe coating is usually warranted are:
•Immersion service (e.g., interiors of fuel or water storage tanks; ship hulls)•Areas with high corrosion rates (e.g., cooling towers and splash zones)•Areas where access is difficult (e.g., towers, some bridges)•Built up members (e.g., lattice bars and boxes)
Step 2 (Continued)
Examples of Where Strip Coating Is Warranted
Step 2 (Continued)• Situations where stripe coating may
not be cost effective are: (RISK?)– Non-critical components (e.g., interior
bulkheads in habitable space on a ship)– Mild exposure (e.g., SSPC Environmental
zones 1A and 1B)– Inside corners (can be adequately
covered using proper spray technique)
Step 2 (Continued)• Application of the stripe coat can be performed
by brush or spray. The table below shows the advantages and disadvantages of the 2 methods
• Brush – control and working coating into complex details; labor intensive
• Spray – faster, less labor, good for edge retentive coatings and zinc-rich; may bridge small defects, risk of high builds
Step 2 (Continued)
• When applying a stripe coat:– The brush strokes should run parallel to, not
across, edges and crevices– Apply constant pressure of the brush during
application– Bolt heads and nuts should be striped in a
circular motion– Extend the stripe coating at least 1 inch from
edges and other irregular surfaces– Use round or oval brushes
Step 2 (Continued)• Spraying the stripe coat can reduce the amount of time spent in brush application, but the painter has less control over the precise boundaries of the area being coated
• The applicator should spray the coating along the flat surface, not directly at the edge itself, to prevent the atomization pressure from pushing the coating away from the edge
Step 2 (Continued)• It is good practice for the stripe coat to be
a different color from the adjoining full coats or substrate– Enables painters and inspectors to
visually verify there are no misses, skips or thin spots
Step 2 (Continued)• -When to Stripe- Before or After????
Step 2 (Continued)• Welds and crevices are best protected when
striped with a coating with good wetting properties
• High build coatings are best for striping edges
• Consult coating manufacturer to determine the appropriate coating to be used
• The coating selected should be designed for the service environment
Step 3• An alternative method for protection
of edges that may avoid the need for grinding and chamfering is the use of a coating that has edge retention properties
• Typically high solids products that provide improved film thickness retention at the apex of an edge
Step 3 (Continued)• A method for measuring the edge retention
properties of a coating is published in MIL-PRF-23236C
• Compares the film thickness of 3 specimens cut from a sample of coating applied to a non-chamfered 90 degree angle
• The ratio of the film thickness at the apex vs. the film thickness on the flat area is calculated and expressed as the percentage of edge retention of the coating
Step 3 (Continued)
Step 3 (Continued)• According to MIL-PRF-23236C:
– Any specimen having less than 50% edge retention fails the test
– An average value of 70% edge retention for 3 test specimens measuring using an optical microscope is required to qualify a coating
POLYASPARTIC URETHANEEDGE RETENTION
System:
Zinc Primer
Polyaspartic Urethane
System:
Zinc Primer
Polyaspartic Urethane
Edge Retention > 70%Edge Retention > 70%
Summary•Edges and complex geometries are the key to success or failure in a typical coating job•SSPC Guide 11 is a provides a nice roadmap to Good Painting Practice for addressing edges•By following the processes described in Guide 11 you can provide extra corrosion protection measures on edges, outside corners, crevices, bolt heads, welds and other irregular steel surfaces
Summary (con’t)• Avoiding edge failure in a PRACTICAL
and ACHIEVABLE manner requires a specification that is clear and targets added effort and material (cost) toward the details that are most likely to fail first
• Recent success has been achieved in mitigating risk of edge failure through the use of new, high solids, rapid cure coating systems IN CONJUNCTION WITH implementation of improved practices
The industry continues to look for value based solutions
Optimizing QA