SSPC-TU 6

May 1, 1999
Editorial Revisions November 1, 2004

SSPC: The Society for Protective Coatings

TECHNOLOGY UPDATE NO. 6
Chemical Stripping of Organic Coatings From Steel Structures

1. Scope to produce bubbles of hydrogen at the interface between the

stripper and the substrate, rendering the stripper ineffective.
This document defines chemical strippers and discusses For these applications, the aluminum-containing coatings must
their use for removing existing conventional organic coatings first be removed using one of the bond breakers, typically an
from steel structures. Chemical stripping is recognized as one NMP based product.
of a number of technologies available for the removal of existing
coatings prior to repainting. 3.2 STRIPPER SELECTION: Chemical stripper selection
is based upon a number of variables, all of which can be as-
2. Description and Use sessed by performing patch tests on the existing paint system.
Typical variables include thickness of the existing coating,
Chemical stripping involves application of a chemical to ambient temperature and humidity, presence of aluminum
existing paint, allowing it to dwell for a period of time to attack paint, and time restrictions on the potential job site such as
the organic binder, removing bulk paint/stripper residues, traffic control restrictions. Since these variables do exist, it is
and properly cleaning the steel substrate prior to repainting. highly recommended that a representative from the stripper
Section 3 below describes methods used to identify which type manufacturer, or his agent, be present to assist in conducting
of stripper will work most effectively, and typical application patch tests. Changes to application parameters (such as amount
and removal options. Section 3 also presents containment and applied and dwell time) can affect the results of a patch test.
disposal options for stripper wastes. A trained manufacturerʼs representative can assist in proper
assessment of patch test results. To account for existing paint
3. Discussion thickness variations on a candidate structure, patch tests should
be conducted in more than one location and each should cover
3.1 GENERIC STRIPPER TYPES AND USES: The at least one square foot of surface.
chemical composition of strippers falls into two distinct generic The stripper types described in Section 3.1 generally work
categories. The first group is generally a blend of low molecular best at ambient temperatures above 10 °C (50 °F) and at high
weight solvents known as “bond breakers.” The stripper solvents relative humidity. When using the bond breaker strippers, ap-
break existing paint bonds and “wrinkle” the paint so that it can plication thicknesses and dwell times will vary. However, products
be removed from the surface. Where old paint exists in multiple with solvents of low molecular weight and thus greater volatility
coats, bond breakers may require multiple applications for com- have far shorter dwell times than the less volatile NMP/DBE
plete removal. Bond breakers may contain toluene, methylene products. Also, the latter products are generally lower in vola-
chloride, or methyl ethyl ketone, which can remove paint faster, tile organic compound (VOC) solvent content. As mentioned
but may result in worker exposure to potentially hazardous in Section 3.1, the bond breakers frequently require multiple
chemicals and therefore require special worker protection to applications to remove existing paint systems completely.
maintain exposure below permissible exposure limits (PELs). The caustics will typically remove up to 500 micrometers
Bond breaking strippers may also be comprised of compounds (20 mils) of existing oil (e.g., alkyd) paint systems using a strip-
such as N-methyl-pyrrolidone (NMP) or dibasic ester (DBE). per wet film thickness of 1600 micrometers (63 mils). Cover-
These strippers work more slowly but are generally less toxic age rates at 1575 micrometers (62 mils) application thickness
and may require less stringent worker protection. The bond average between 0.5-0.6 m2/L (20-25 sq. ft/gal) for caustic
breakers are generally selected for use in removing all coat- strippers. Coverage rates will decrease in direct proportion as
ings except oil-based, inorganic, or metallic coatings. The application thickness increases. Dwell time for alkyd coatings
second category of chemical strippers is the caustics. These will vary between 4 and 24 hours, depending on their oil length.
strippers contain one or more common caustic chemicals, such Variations of the existing paint thickness as well as weather
as sodium, calcium, and magnesium hydroxide. Rather than conditions can greatly impact dwell times. Properly supervised
attacking bonds between coating layers or between coating patch testing can accomplish assessment of all the variables
and substrate, caustics soften the entire paint system. Their and will provide definitive information regarding performance of
use is generally restricted to oil based paint systems, typical of stripper type and cost for each application. It is recommended
those found on structures such as bridges and tank exteriors. that service environment conditions during patch test and strip-
These older structures more commonly contain lead-based per application be fully documented.
primers, on which caustics have proven to be quite effective. An
exception to the use of caustics on oil based paint exists where 3.3 CONTAINMENT: Containment guidelines for chemi-
aluminum flake pigment is present. Caustics cause aluminum cal stripping involve the following considerations: containment
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SSPC-TU 6
May 1, 1999
Editorial Revisions November 1, 2004

during stripper application; during stripper removal; during where the caustic causes accumulation of oil at the steel/coat-
surface preparation for painting; and during painting. Each ing interface, resulting in loss of stripper adhesion on vertical
of these considerations will vary based on geometry of the surfaces. The dried splatter coating will prevent this premature
structure (tanks, bridges, pipelines) as well as on which meth- release and allow the stripper to complete its stripping cycle.
ods are used for application and removal of the stripper. In The need for a splatter coating is typically discovered during
general, the containment structure should be in accordance the patch test cycle.
with SSPC-Guide 6 (Class 1C, 2C or 3C), and it should be Production rates for strippers can vary greatly and should
constructed so as to prevent stripper residues from impacting be determined based on patch tests and other variables listed
the immediate environment. Typically, plastic sheeting, at least above, but typically should be directly related to how much area
150 micrometers (6 mils) thick, is resistant to the chemical strip- can be cleaned following the dwell cycle. For example, if the
pers described above, and works adequately for most applica- dwell cycle is overnight, application will generally take place in
tions, if it can withstand any anticipated wind load. For some the previous afternoon. The area sprayed should be restricted
structures such as around the circumference of ground storage to that which can be properly cleaned prior to the next spray
tanks, additional materials such as plywood may be employed cycle. For tanks, using a three man crew, production rates are
to serve as a base for retaining solid stripper residues so they typically between 300 to 400 m2 per day (3,000 to 4,000 sq.
can be more easily transferred into waste containers. In addi- ft. per day) for a complete application/removal cycle, whereas
tion, it is advisable to provide some means of containing any for bridges and other structural steel of complex geometry,
rinse liquids generated during stripper removal. Containment these rates will drop to between 100 to 200 m2 per day (1,000
structures may or may not require forced air ventilation based to 2,000 sq. ft. per day).
on which type of stripper is used, the method of removing the
stripper, potential exposures during pre-painting and painting 3.6 STRIPPER REMOVAL: Chemical stripper residues
operations, and project locale. can be removed using a number of methods which include
both hand and mechanical tools and rinsing or wiping. Choice
3.4 WORKER HEALTH AND SAFETY: Specific require- of removal methods should be based on structure geometry,
ments for worker health and safety can be found by referring production rate desired, and collection of waste residues. When
to the product specification sheets and material safety data removing residues where bond breaker strippers have been
sheets supplied by the chemical stripper manufacturer. Typi- used, rinsing is usually not required, but the surface may require
cally, caustic strippers are water based and therefore do not a wipe prior to a second stripper application or subsequent
release significant airborne contaminants. However, since they surface preparation for painting. This step, if required, will be
are corrosives, they can cause skin burns. Materials that are identified during patch testing.
chemically impervious must be used to protect eyes and skin. Most older structures with lead paint will be chemically
Solvent based strippers also require chemically resistant skin stripped using a caustic product. This process requires hand
protection, and protection against airborne solvent vapors scraping the bulk residues using broad knives, followed by rins-
may be required. Depending upon the method of removal (see ing to remove any remaining lead primer residues. The rinsing
Section 3.6), airborne concentrations of toxic metals may be step can be accomplished with wet sponges for smaller areas
encountered when removing coatings containing lead or other but for larger jobs, rinsing should be done with a system which
toxic metals. produces a minimal amount of water. Typically, any airless
Specific respiratory and personal protective equipment paint pump using a 0.5 mm (0.02 in) tip, will generate a rinse
requirements should be in accordance with all applicable stream of less than 1.25 L/min (0.33 gal/min) at 3.4 MPa (500
OSHA standards. psi). This will suffice to remove any excess stripper residues
with minimal water waste. Pressure washers are not recom-
3.5 STRIPPER APPLICATION: Procedures for applying mended as they generate more pressure and water and their
chemical strippers vary based on geometry of the structure to waste streams are more difficult to contain. Other mechanized
be stripped, type of stripper used, and productivity desired. In removal processes which can enhance productivity while
general, strippers are spray applied using conventional paint minimizing waste include ice blasting, carbon dioxide (CO2)
pumps. Caustic strippers require pumps which are chemically blasting, and vacuum rinsing.
resistant and can accommodate thicker materials. The caustics During stripper removal, care must be taken to direct all
should be air sprayed but the bond breakers can be applied with wastes, including rinse liquids, to the containment area. Certain
airless pumps. Chemical strippers may also be applied using structures may lend themselves to separation of liquids and
trowels or brushes although these tools will generally not allow solids. Where applications produce excessive liquids during
for the thickness control which can be achieved by spraying. the removal cycle, stripper residues can be filtered to facilitate
Some caustic applications may require using a splatter easier disposal (see Section 3.7 below).
coat prior to full application of the stripper. The splatter coat Following removal of caustic chemical stripper residues,
is a light, non-continuous application of the stripper which is steel surfaces will typically exhibit some degree of alkalinity.
allowed to dry prior to spraying the full stripper coating. The This alkalinity may require reduction prior to painting, based
splatter coating is typically required on older alkyd paint systems, on the chemistry of the coating to be applied. Surface pH can
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 SSPC-TU 6
May 1, 1999
Editorial Revisions November 1, 2004

be reduced, if required, with either a light application of dilute re-coat the steel, and additional processing such as abrasive
acetic acid or with a water rinse. These options should be dis- blasting, or power tool cleaning, combined with application of
cussed with the paint manufacturer so that surface condition a surface-tolerant prime coat, may be required.
prior to painting can be agreed upon. In addition to proper pH,
additional inspection criteria should include visual inspection of 4. Disclaimer
the total work area to determine that all visible stripper residues
have been removed. 4.1 This technology update is for information purposes
only. It is neither a standard nor a recommended practice. While
3.7 STRIPPER WASTE DISPOSAL: Waste products from every precaution is taken to ensure that all information furnished
chemical stripping projects can exhibit a number of different in SSPC technology updates is as accurate, complete, and
characteristics depending on which stripper product is used, useful as possible, SSPC cannot assume responsibility nor
and how much lead or other hazardous materials exist in the incur any obligation resulting from the use of any materials,
old paint system. Typically, where caustic strippers are used on coatings, or methods specified herein, or of the technology
old oil paint systems (which can contain lead levels up to and update itself.
above fifty percent by weight), the resulting waste stream will
likely test above the toxic chemical leachate procedure (TCLP) 4.2 This technology update does not attempt to address
limit for lead and may be above corrosivity (pH) limits. In these problems concerning safety associated with its use. The user
cases, typical handling involves reduction of pH and stabiliza- of this specification, as well as the user of all products or prac-
tion of the lead prior to disposal. Refer to SSPC-Guide 7 for tices described herein, is responsible for instituting appropriate
further information on the testing, handling, storage treatment health and safety practices and for ensuring compliance with
and disposal of the resulting waste streams. all governmental regulations.
On-site treatment of hazardous waste may require special
approval. Contact local regulatory agencies prior to performing 5. References
on-site stabilization. Wastes generated when using the bond
breaker solvents may require different treatment protocol de- Carroll, Courtney. “Chemical Stripping: A Viable Alterna-
pending on which solvents are present. Treatment for these tive,” Achieving Quality in Coating Work, Proceedings from
wastes may require incineration of the organic residues prior to the SSPC 92 Seminars (SSPC 92-13). (Pittsburgh: SSPC,
stabilization of lead. Liquid waste must be tested for leachable 1992), pp. 212-215.
lead and corrosivity, and if above regulatory limits, will require “Chemical Stripping Removes Lead Paint from Water Tower,”
treatment and filtration. JPCL Vol. 13, No. 3 (March 1996), pp. 43-44.
Following filtration, some wastes might be able to be taken “Chemicals Safely Remove Lead Paint from Tanks” Aboveg-
to a local publicly owned treatment works (POTW) facility for round Tank Update, CEEM Publications, (December 1991).
disposal, depending upon the POTWʼs influent standards. All “Lead Paint Removed from Water Tank Using Chemical Strip-
federal and local disposal guidelines should be assessed prior per,” JPCL, Vol. 8 No. 10, (October 1991), pp. 41-44.
to disposal. Mickelsen, R. Leroy and Walter M. Haag. “Removing Lead-
Based Paint from Steel Structures with Chemical Stripping,”
3.8 ADDITIONAL FACTORS AFFECTING THE USE OF JPCL, Vol. 14, No. 7 (July 1997), pp. 22-29.
CHEMICAL STRIPPERS: The biggest advantage gained from “Minnesota DOT Tests Chemical Stripper,” JPCL, Vol. 12
using chemical strippers is that the process does not generate No. 2, (February 1995), pp. 58-59.
dust. This may be significant when the coating being removed Rodkey, James L. “Lead Paint Removal at Reasonable Cost
contains lead or other hazardous materials. Containment re- by Chemical Stripping,” Industrial Lead Paint Removal: Com-
quirements are generally low to moderate and are designed to pliance and Worker Safety, Proceedings of the Fifth Annual
prevent the strippers and stripper waste products from impacting Conference on Lead Paint Removal (SSPC 92-04). (Pittsburgh:
the surrounding environment. SSPC, 1992), pp. 21-36.
Coating removal is very effective for flat surfaces and be- Trimber, Kenneth A., Industrial Lead Paint Removal Hand-
comes less effective as the structure geometry becomes more book, Second Edition. (Pittsburgh: KTA-Tator, Inc., 1993).
complex. Production rates for chemical stripping vary based on
production crew size and geometry of the structure.
Suitability of the chemically stripped steel surface for
subsequent painting ranges from poor to excellent depending
on the quality of the original surface preparation and the ex-
tent of degradation which may have occurred during service.
Chemical stripping does not create a surface profile on steel
substrates nor will it remove adherent rust and mill scale, or
existing thermal spray metallic coatings. The condition of the
original surface can influence the choice of coating used to
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