Technical Guide

Guide to Protective Coatings,

Inspection, and Maintenance Second Edition

U.S. Department of the Interior Bureau of Reclamation Technical Service Center Denver, Colorado April 2012

Mission Statements

The U.S. Department of the Interior protects Americas natural

resources and heritage, honors our cultures and tribal communities,

and supplies the energy to power our future.

The mission of the Bureau of Reclamation is to manage, develop,

and protect water and related resources in an environmentally and

economically sound manner in the interest of the American public.

Technical Guide

Guide to Protective Coatings,

Inspection, and Maintenance

U.S. Department of the Interior Bureau of Reclamation Technical Service Center Materials Engineering and Research Laboratory Denver, Colorado April 2012

BUREAU OF RECLAMATION Technical Service Center, Denver Colorado Materials Engineering and Research Laboratory, 86-68180

Technical Guide

Guide to Protective Coatings, Inspection, and Maintenance

bot-ro,k,-,3) Prepared: David S. Tordonato, Ph.D. Date Materials Engineer, Materials Engineering and Research Lab, 86-68180

e-tY 9,9k Prepared: Allen D. Skaja, Ph.D Date Chemist, Materials Engineering and Research Lab, 86-68180

Checke ob i Jo Merten, Ph.D. Date Title, p, 86-68180

9hflot_ Date Peer Review: William Kepler, Ph.D., P.E.

Manager, Materials Engineering and Research Lab, 86-68180

REVISIONS

Date Description Pre

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Tech

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Acronyms and Abbreviations

ASTM American Society for Testing and Materials

CFR Code of Federal Regulations

CSI Construction Specification Institute

DBE dibasic ester

DFT dry film thickness

EPA United States Environmental Protection Agency

FRC foul-release coating

ft/s feet per second

HVLP high-volume, low-pressure

MERL Reclamations Materials Engineering and Research Laboratory mg/L milligrams per liter

ml milliliter(s)

MSDS Material Safety Data Sheet

NACE National Association of Corrosion Engineers

NMP Nmethyl-pryrrolidone

OSHA Occupational Safety and Health Administration

PCB polychlorinated biphenyls

PDMS poly(dimethyl siloxane)

psi pounds per square inch

Reclamation Bureau of Reclamation

RSN required submittal number

SSPC Steel Structures Painting Council

TSC Technical Service Center

UV ultraviolet

VOC volatile organic compound

WFT wet film thickness

Symbols

F degrees Fahrenheit

g/m3

micrograms per square meter

s/cm microsiemens per centimeter

g/L micrograms per liter

Contents

Page

Preface.................................................................................................................... ix

Chapter I: Introduction and Background ......................................................... 1 Standards ................................................................................................................. 1 Coating References ................................................................................................. 1 Terminology ............................................................................................................ 2 Corrosion................................................................................................................. 2 Service Exposure .................................................................................................... 4

Chapter II: Materials .......................................................................................... 5 Components of Coatings ......................................................................................... 5

Solvent ........................................................................................................... 6 Resin .............................................................................................................. 7 Pigment .......................................................................................................... 8

Coating Types ......................................................................................................... 9 Generic Coatings ............................................................................................ 9

Chapter III: Specifications ................................................................................ 13 Construction Specification Institute ...................................................................... 13 Reclamation Coating Specifications ..................................................................... 14 Coating Tabulations and Categories ..................................................................... 15

Coating Tabulations ..................................................................................... 16 Coating Categories ....................................................................................... 16

Manufacturers Product Data and Application Sheets .......................................... 17 Addendums and Modifications ............................................................................. 18

Chapter IV: Inspectors Role ............................................................................ 19 Primary Responsibilities ....................................................................................... 19 Daily Responsibilities ........................................................................................... 19 Material Approval ................................................................................................. 21 Documentation ...................................................................................................... 22 Instruments, Gauges, and Tools ............................................................................ 22

Conflicts ....................................................................................................... 22 Substrate Inspection .............................................................................................. 23 Coating Inspection Checklist Sheet ...................................................................... 23 Precoating Conference .......................................................................................... 23

Chapter V: Material Storage, Containers, and Shelf Life ............................. 25 Storage .................................................................................................................. 25 Containers ............................................................................................................. 26 Shelf Life .............................................................................................................. 26

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Chapter VI: Surface Preparation ..................................................................... 27 Surface Contaminants ........................................................................................... 27

Types of Surface Contaminants ................................................................... 27 Compressed Air Contaminants .................................................................... 28 Flash Rusting ............................................................................................... 29

Presurface Treatment ............................................................................................ 30 Abrasive Blast Material ........................................................................................ 30

Nonmetallic Abrasives ................................................................................. 31 Naturally Occurring ............................................................................ 31 Byproduct ............................................................................................ 31 Manufactured ...................................................................................... 32

Sampling and Testing .................................................................................. 32 Sampling ............................................................................................. 32 Testing................................................................................................. 32

Nozzle Blast Pressure ........................................................................................... 33 Surface Preparation Methods ................................................................................ 33

SSPC-SP1: Solvent Cleaning ...................................................................... 34 SSPC-SP2: Hand Tool Cleaning ................................................................. 34 SSPC-SP3: Power Tool Cleaning ............................................................... 34 SSPC-SP15: Commercial Grade Power Tool Cleaning.............................. 34 NACE 4/SSPC-SP7: Brushoff Blast Cleaning ........................................... 35 NACE 8/SSPC-SP14: Industrial Blast Cleaning ........................................ 35 SSPC-SP8: Pickling .................................................................................... 35 NACE 3/SSPC-SP6: Commercial Blast Cleaning ...................................... 35 NACE