Surface Preparation - Ferrous Metals - Wattyl Web Customer Service

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SURFACE PREPARATION<strong>Ferrous</strong> MetalI-10Flash RustFlash rust is inevitable when steel is cleaned with water without the use of an inhibitor. This leads toproblems when trying to evaluate the degree of cleanliness of a hydrojetted steel surface as the formationof flash rust means that the substrate condition is constantly changing. Experience has shown that thesteel cleanliness should not be judged when the substrate is wet.The performance of a system applied to a hydrojetted surface is partly governed by the degree of flashrusting. The flash rusting can be divided into three categories:Light (L):Medium (M):Heavy (H):Present as tightly adhering and appears as a surface staining that will partially discolourthe original metallic surface and will not be heavy enough to easily mark objects brushedagainst it.Present as a layer which obscures the original metallic surface and will be heavy enoughto mark objects brushed against it.Present as powdery rust that obscures the metallic surface and easily marks objectsbrushed against it.For more details and definitions, please consult SSPC-VIS 4 / NACE VIS 7.However it is very difficult to quantify the amount of flash rust as it is constantly changing. Proceduralchanges can be made to reduce the flash rust formation and keep the interval between a dry substrateand coating application as short as possible. As good working practice the following should also beadopted:• Reduce the time between completely wet and completely dry.• Keep the interval between a dry substrate and coating application as short as possible. Somecoatings do have some tolerance to damp surfaces and can be applied under certain conditions.• Accept only firmly adherent flash rust.• Never mechanically wire brush to remove flash rust – this will result in polished surfaces andrehydojetting may be required.Factors affecting the speed of flash rusting:• Soluble salts on the substrate.• Drying time of steel / humidity / temperature.Appearance of SteelHydrojetted steel has a different appearance than dry blasting, even before flash rusting.Generally surfaces look dull and pitted steel can have a mottled appearance. This is caused when thecorrosion products are washed out of the pits leaving a bright steel surface and the surrounding areas areleft dull grey, brown to black in colour (ferric oxide). Which is the reverse of a dry abrasive blastedsurface where the failure to remove corrosion products from the pits gives a dark pit whilst thesurrounding steel is a bright sliver colour.Damp/Dry SubstratePrior to recoating the substrate should be dry – use water sensitive paper as per FTS Guidelines. Forcertain coatings a damp substrate is acceptable.Version 2, January 2010 6 of 8
SURFACE PREPARATION<strong>Ferrous</strong> MetalI-10EXISTING SYSTEMSAt 14 – 21 MPa (2,000 – 3,000 psi) existing paint can be removed, however, at 7 – 10 MPa (1,000 – 1,500psi) only loosely adherent paint can be removed. If an existing system is left on the steel surface thenthere is a risk of island formation. Water can creep under the apparently ‘tightly adherent coating’ whichis subsequently overcoated, leading to failure. Secondly, an existing paint film may be sufficiently thickthat when overcoated there is an edge effect, where a freshly applied paint film moves away from a sharpedge and less paint is applied to the edge. This can be avoided by:• High pressure removal of all existing coating.• Feather all existing edges back to firm edge (i.e. discing).• Stripe coat also edges of existing system.Ballast TanksWith ballast tanks there are still a number of practical problems, which make it difficult to achieve auniformly acceptable standard of surface preparation. These problems are:• Complex form (i.e. stiffeners etc).• Poor visibility – constant water vapour (mist) present in the tank.• Constant high humidity leading to - high levels of flash rust, and- difficulty in achieving dry substrate prior to recoating.Special attention should be paid to these items.PREPARATION ON UNDERWATER SURFACESFouling, loose paint and other contaminants should be removed by High Pressure Water Cleaning. Anyfouling and/or loose paint remaining after High Pressure Water Cleaning is to be removed by scraping orsweep blasting. The removal of an oil or grease belt can be achieved by scraping heavy deposits from thesurface, and High Pressure Water Cleaning in combination with the use of suitable detergents. This shouldbe followed by a thorough fresh water wash and drying prior to blasting and/or repainting. It may benecessary to blast clean such areas after this operation when oil has penetrated the underlying paintsystems.Rusty spots should be pre-treated by blast cleaning and touched up with an anticorrosive system withinthe requirements given in the relevant specifications. If water (abrasive) blast cleaning is applied, asuitable primer should be used, followed by the system as described in the specification.CAST IRONDry Abrasive BlastAbrasive blast using a non-metallic grit, to achieve a surface similar to AS 1627.4, Sa 2½. Clean thesurface to remove all preparation residue.Wet Abrasive BlastWet abrasive blast using a non-metallic grit to achieve a surface similar to AS 1627.4, Sa 2½. Flash rustingwill occur almost immediately. High pressure water wash using clean, fresh water to remove all blastingresidue.Version 2, January 2010 7 of 8
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Surface Preparation - Ferrous Metals - Wattyl Web Customer Service

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