Process Industry Practices Coatings: PIP CTSE1000 Application of External Coatings

REAFFIRMATION WITH EDITORIAL REVISION
December 2012
Process Industry Practices

Coatings
PIP CTSE1000
Application of External Coatings
PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES
In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these technical
requirements into a single set of Practices, administrative, application, and engineering
costs to both the purchaser and the manufacturer should be reduced. While this Practice
is expected to incorporate the majority of requirements of most users, individual
applications may involve requirements that will be appended to and take precedence
over this Practice. Determinations concerning fitness for purpose and particular matters
or application of the Practice to particular project or engineering situations should not
be made solely on information contained in these materials. The use of trade names
from time to time should not be viewed as an expression of preference but rather
recognized as normal usage in the trade. Other brands having the same specifications
are equally correct and may be substituted for those named. All Practices or guidelines
are intended to be consistent with applicable laws and regulations including OSHA
requirements. To the extent these Practices or guidelines should conflict with OSHA or
other applicable laws or regulations, such laws or regulations must be followed.
Consult an appropriate professional before applying or acting on any material
contained in or suggested by the Practice.
This Practice is subject to revision at any time.
© Process Industry Practices (PIP), Construction Industry Institute, The University of

Texas at Austin, 3925 West Braker Lane (R4500), Austin, Texas 78759. PIP member
companies and subscribers may copy this Practice for their internal use. Changes or
modifications of any kind are not permitted within any PIP Practice without the express
written authorization of PIP. Authorized Users may attach addenda or overlays to clearly
indicate modifications or exceptions to specific sections of PIP Practices. Authorized
Users may provide their clients, suppliers and contractors with copies of the Practice
solely for Authorized Users’ purposes. These purposes include but are not limited to the
procurement process (e.g., as attachments to requests for quotation/ purchase orders or
requests for proposals/contracts) and preparation and issue of design engineering
deliverables for use on a specific project by Authorized User’s client. PIP’s copyright
notices must be clearly indicated and unequivocally incorporated in documents where an
Authorized User desires to provide any third party with copies of the Practice.
PRINTING HISTORY
April 1999 Issued July 2005 Technical Correction June 2007 Editorial Revision
February 2005 Complete Revision February 2006 Editorial Revision December 2012 Reaffirmation with Editorial Revision
Not printed with State funds

December 2012
Process Industry Practices

Coatings
PIP CTSE1000
Application of External Coatings
Table of Contents
CTSE1000-D102 - External Coating
1. Introduction .................................3 Systems, Coating System No. 2, Inorganic
1.1 Purpose ..............................................3 Zinc/Epoxy Polyamide IZ/EC
1.2 Scope .................................................3 CTSE1000-D103 - External Coating
Systems, Coating System No. 3, Epoxy
2. References ..................................3 Polyamide (3 Coats) EC/EC/EC
2.1 Industry Codes and Standards ..........3 CTSE1000-D104 – External Coating
2.2 Other References ...............................4 Systems, Coating System No. 4, Epoxy
Phenolic EP
3. Definitions ...................................4 CTSE1000-D105 – External Coating
4. Requirements ..............................5 Phenolic (3 Coats) EP/EP/EP
4.1 General...............................................5 CTSE1000-D106 – External Coating
4.2 Procedures .........................................5 Systems, Coating System No. 6, Epoxy
4.3 Surface Preparation ...........................7 Polyamide/Urethane EC/UR
4.4 Application ..........................................8
4.5 Inspection .........................................12 CTSE1000-D107 – External Coating
4.6 Shipping, Handling, and Storage .....15 Systems, Coating System No. 7, Coal Tar
Epoxy (2 Coats) TE/TE
Data Forms CTSE1000-D108 – External Coating
Systems, Coating System No. 8, Inorganic
CTSE1000-D1 – Documentation Zinc/Water-Borne Acrylic IZ/WA
Requirements Sheet CTSE1000-D109 – External Coating
The following data forms shall be part of this Systems, Coating System No. 9, Alkyd (3
Practice only if indicated on the purchaser’s Coats) OA/OA/OA
completed Documentation Requirements Sheet. CTSE1000-D110 – External Coating
Systems, Coating System No. 10,
CTSE1000-D2 – Color Selection Sheet Inorganic Zinc/Silicone Acrylic (2 Coats)
CTSE1000-D101 - External Coating IZ/SA/SA
Systems, Coating System No. 1, Inorganic
Zinc IZ
Process Industry Practices Page 1 of 15

December 2012
CTSE1000-D111 – External Coating CTSE1000-D127 – External Coating

Systems, Coating System No. 11, Silicone Systems, Coating System No. 27, Thermal
for Stainless Steel (2 Coats) SS/SS Spray Aluminum/Silicone Sealer -
CTSE1000-D112 – External Coating Aluminum TSA/SSA
Systems, Coating System No. 12, Heat- CTSE1000-D128 – User-Defined Coating
Cured Silicone (2 Coats) HS/HS Systems
CTSE1000-D113 – External Coating CTSE1000-D129 – External Coating
Systems, Coating System No. 13, Epoxy Systems, Coating System No. 28, Epoxy
Mastic for Manufacturer’s Standard EM Novolac EN
CTSE1000-D114 – External Coating CTSE1000-F – Daily Inspection Report
Inorganic Zinc/Heat-Cured Silicone (2
Coats) IZ/HS/HS
CTSE1000-D115 – External Coating
Inorganic Zinc/Epoxy Mastic/Urethane
IZ/EM/UR
Systems, Coating System No. 16, Low
Temperature Curing Epoxy (2 Coats)
EL/EL
Polysiloxane (2 Coats) PX/PX
Mastic (2 Coats)/Urethane EM/EM/UR
Novolac (2 Coats) EN/EN
Phenolic (2 Coats) EP/EP
Systems, Coating System No. 21, Organic
Zinc/Urethane OZ/UR
Mastic/Water-Borne Acrylic EM/WA
Mastic/Epoxy Polyamide EM/EC
Mastic/Urethane EM/UR
Systems, Coating System No. 25, High
Build Epoxy (2 Coats)/Urethane
EH/EH/UR
Systems, Coating System No. 26, Coal
Tar Epoxy (1 Coat) TE

PIP CTSE1000 REAFFIRMATION WITH EDITORIAL REVISION
Application of External Coatings December 2012
1. Introduction
1.1 Purpose
This Practice provides requirements for the application of industrial external coatings.
1.2 Scope
This Practice describes the general requirements for surface preparation, application, and
inspection of protective coatings.
2. References
Applicable parts of the following Practice, industry codes and standards, and references shall be
considered an integral part of this Practice. The edition in effect on the date of contract award
shall be used, except as otherwise noted. Short titles will be used herein where appropriate.
2.1 Industry Codes and Standards

• American Society for Testing and Materials (ASTM)
– ASTM D3359 – Standard Test Methods for Measuring Adhesion by Tape Test
– ASTM D4285 – Standard Test Methods for Indicating Oil or Water in Compressed Air
– ASTM D4417 – Standard Test Methods for Field Measurement of Surface Profile
of Blast Cleaned Steel
– ASTM D4541 – Standard Test Methods for Pull-Off Strength of Coatings Using
Portable Adhesion Testers
– ASTM E337 – Standard Test Method for Measuring Humidity with a Psychrometer
(the Measurement of Wet- and Dry-Bulb Temperatures)
• Society of Protective Coatings (SSPC)
– SSPC-AB 1 – Mineral and Slag Abrasives
– SSPC-PA 1 – Shop, Field, and Maintenance Painting
– SSPC-PA 2 – Measurement of Dry Paint Thickness with Magnetic Gages
– SSPC-PA Guide 3 – Guide to Safety in Paint Application
– SSPC-SP 1 – Solvent Cleaning
– SSPC-SP 2 – Hand Tool Cleaning
– SSPC-SP 3 – Power Tool Cleaning
– SSPC-SP 7/NACE No. 4 – Brush-Off Blast Cleaning
– SSPC-SP 11 – Power Tool Cleaning to Bare Metal
– SSPC-VIS 1-89 – Visual Standard for Abrasive Blast Cleaned Steel (Standard
Reference Photographs)
• INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)
– ISO 2178: Non-magnetic coatings on magnetic substrates - Measurement of
coating thickness - Magnetic method

– ISO 2360: Non-conductive coatings on non-magnetic electrically conductive basis

materials - Measurement of coating thickness - Amplitude-sensitive eddy current method
– ISO 2409: Paints and varnishes - Cross-cut test
– ISO 4624: Paints and varnishes Pull-off test for adhesion
– ISO 4677-2: Atmospheres for conditioning and testing - Determination of relative
humidity - Part 2: Whirling psychrometer method
– ISO 8501-1: Preparation of Steel Substrates before Application of Paints and
Related Products - Visual Assessment of Surface Cleanliness - Part 1: Rust Grades
and Preparation Grades of Uncoated Steel Substrates and of Steel Substrates after
Overall Removal of Previous Coatings
– ISO 8503-5: Preparation of Steel Substrates before Application of Paints and
Related Products - Surface Roughness Characteristics of Blast-Cleaned Steel
Substrates - Part 5: Replica tape method for the determination of the surface profile
– ISO 8504-2: Preparation of steel substrates before application of paints and
related products - Surface preparation methods - Part 2: Abrasive blast-cleaning
– ISO 8504-3: Preparation of steel substrates before application of paints and related
products - Surface preparation methods - Part 3: Hand- and power-tool cleaning
– ISO 8573: Compressed air
– ISO 11126: Preparation of Steel Substrates before Application of Paints and
Related Products - Surface Preparation Methods (10 Parts)
– ISO 12944-4: Paints and Varnishes - Corrosion Protection of Steel Structures by
Protective Paint Systems - Part 4: Types of Surface and Surface Preparation
– ISO 12944-7: Paints and Varnishes - Corrosion Protection of Steel Structures by
Protective Paint Systems - Part 7: Execution and Supervision of Paintwork
2.2 Other References
• National Institute of Occupational Safety and Health (NIOSH)

– NIOSH Publication No. 92-102 – NIOSH Alert: Request for Assistance in
Preventing Silicosis and Deaths from Sandblasting
3. Definitions
CS: Carbon and low-alloy steel
DFT: Dry film thickness
SS: Austenitic stainless steel
nonferrous: Copper, aluminum
owner: Party who owns the facility wherein the coating system will be used
purchaser: Party who awards the contract to the supplier. The purchaser may be the owner or the
owner’s authorized agent.
supplier: Party responsible for furnishing and/or installing the coating system

4. Requirements
4.1 General
4.1.1 Project Scope
4.1.1.1 Documents required to define the scope of work are listed on purchaser’s
data sheet CTSE1000-D1.
4.1.1.2 If selected on purchaser’s documentation requirements sheet
PIP CTSE1000-D1, data sheets CTSE1000-D101 through CTSE1000-D127
shall be used to define specific requirements for each coating system.
4.1.1.3 Surface preparation, application, and materials shall be in accordance
with the purchaser’s external coating system data sheets.
4.1.1.4 Coating materials used in the same system shall be supplied by the same
manufacturer, unless otherwise approved by the purchaser.
4.1.1.5 Finish color requirements shall be in accordance with purchaser’s data
sheet CTSE1000-D2.
4.1.2 Conflicts, Exceptions, Deviations, and Substitutions
4.1.2.1 All conflicts between the referenced documents and this Practice shall be
submitted in writing to purchaser for clarification and resolution before
proceeding with the coating application.
4.1.2.2 All exceptions, deviations, and substitutions to the requirements specified
herein and in referenced documents shall be approved by the purchaser.
4.1.3 Regulations and Material Safety Data Sheets (MSDS)
4.1.3.1 Protective coating applications shall comply with all applicable federal,
state, and local codes and regulations on surface preparation, coating
application, storage, handling, safety, and environmental requirements,
including the recommendations of SSPC-PA Guide 3.
4.1.3.2 The latest issue of the coating manufacturer’s product data sheets,
application instructions, and MSDS shall be available at the painting site
and complied with during painting operations.
4.2 Procedures
4.2.1 Surfaces not to be Coated
4.2.1.1 Unless specified otherwise, the following surfaces shall not be coated:
a. Interior surfaces of piping and equipment
b. Nonferrous metals
c. Galvanized or metallized surfaces
d. Insulation jacketing
e. Nonmetallic materials such as wood, tile, brick, concrete, and
thermoplastics
f. Cast iron products such as manhole covers and grating

4.2.1.2 The following surfaces shall not be coated and shall be protected from
surface preparation and painting activity in the area:
a. Valve stems, flange faces, and other machined contact surfaces
b. Internal surfaces of valves
c. Electrical contact points
d. Nameplates and identification tags
e. Glass surfaces of gage glasses and sight glasses
f. Resilient seal materials
g. Gasket contact surfaces
h. Equipment identification
i. Inspection point identification markers
4.2.2 Precautions for Stainless Steel and Nonferrous Metals
4.2.2.1 All SS and nonferrous metals shall be protected from blasting, overspray,
and coatings intended for CS, especially coatings containing zinc.
4.2.2.2 Abrasives for use on SS shall be in accordance with SSPC-AB 1 or
ISO 11126, natural abrasives (except silica sand) as well as coal furnace
slag and fused aluminum oxide and shall be free of metals.
4.2.2.3 If hand or power tool cleaning is required on SS and nonferrous metals,
only SS wire brushes that have not been previously used on CS surfaces
shall be used.
4.2.2.4 Coatings and solvents for use on SS and nonferrous metals shall be free
of substances such as chlorides, sulfur, halogens, or metallic pigments
that can harmfully affect SS or nonferrous metals.
4.2.2.5 For items having dual materials of construction, coatings containing zinc
shall not overlap onto SS or nonferrous metals, including the SS to CS
weld. Examples of such applications include:
a. CS saddles and skirts on SS equipment
b. SS piping within CS skirts
c. SS nozzles, flanges, and piping on clad equipment
d. Miscellaneous CS clips and brackets on SS equipment
e. SS components in CS piping systems
f. CS trunnions on SS piping and equipment
g. CS flange rings on SS lap joint flanges
4.2.2.6 CS lap joint flanges shall be coated before assembly.
4.2.2.7 Color-coding and fabrication markings applied directly onto SS and
nonferrous metals shall be applied with low-chloride markers.

4.3 Surface Preparation

4.3.1 Preparation for Blasting
4.3.1.1 All welds shall be relatively smooth, without sharp edges, and free of
weld slag and weld spatter before blasting. Purchaser shall be notified of
such defects for corrective action before proceeding with work.
4.3.1.2 Unless approved in writing by purchaser, neither welding nor grinding,
including cosmetic grinding, shall be permitted on the pressure-resisting
components and welds of pressure vessels and piping after hydrostatic
testing.
4.3.1.3 Before blasting, all visible deposits of oil and grease shall be removed
using the methods defined in SSPC-SP 1 or ISO 12944-4.
4.3.1.4 High-pressure water jetting or steam cleaning may be used to remove oil,
grease, and other surface contaminants.
4.3.1.5 Presence of oil shall be checked either by rubbing a clean white cloth on
the steel surface or by sprinkling water on the steel surface.
Comment: If oil or grease is present, the water will not spread out
but will form beads.
4.3.2 Abrasive Blasting
4.3.2.1 Abrasive blast cleaning shall be performed with a clean, sharp grade of
abrasive.
4.3.2.2 Grain size shall be suitable for producing the specified anchor profile.
4.3.2.3 All abrasives shall be free of dust, dirt, and other foreign matter and shall
be kept dry at all times.
4.3.2.4 Silica or other abrasive substances containing more than 1 percent
crystalline silica shall not be used as an abrasive blasting material. Refer
to NIOSH Publication No. 92-102.
4.3.2.5 Only designed ventilation and containment shall be used to protect
personnel.
4.3.2.6 If automatic blasting equipment is used, the abrasive mix shall be
maintained so that a consistently sharp profile is produced.
4.3.2.7 Air supply compressors shall be equipped with adequately sized and
properly maintained oil and water separators.
4.3.2.8 Air compressors shall be capable of maintaining 690 kPa (100 psig)
minimum at the nozzle.
4.3.2.9 Air compressors shall be equipped with either dryers or aftercoolers to
remove entrained moisture from the compressed air.
4.3.2.10 Abrasive blast cleaning shall not be performed if the ambient or substrate
temperature is less than 3°C (5°F) above the dew point temperature.

4.3.2.11 Dew point temperature shall be determined by sling psychrometer in

accordance with ASTM E337 or ISO 4677-2, at the location where work
is being performed.
4.3.2.12 Substrate temperature shall be determined with a surface thermometer.
4.3.2.13 Blast-cleaned surfaces that show evidence of rust bloom or that have
been left uncoated overnight shall be recleaned to the specified degree of
cleanliness before coating.
4.3.2.14 All visible burrs, laminations, slivers, and scabs shall be removed or
repaired after blasting.
4.3.2.15 After blasting and immediately before spraying, dust and loose residues
shall be removed by brushing, blowing off with clean dry air, or vacuum
cleaning.
4.3.2.16 Inhibitive washes intended to prevent rusting after blasting shall not be
permitted.
4.3.2.17 Alternative forms of surface preparation shall not be used without written
approval from the purchaser.
4.3.3 Degree of Cleanliness and Anchor Profile
4.3.3.1 Degree of cleanliness and anchor profile shall be as required for the
specified coating system.
4.3.3.2 All blast-cleaned surfaces shall be inspected for proper cleaning before
painting. SSPC-VIS 1 or ISO 8501-1 shall be used as a visual standard
for confirming the degree of surface cleanliness.
4.3.3.3 Anchor profile shall be verified in accordance with ASTM D4417,
Method C. Anchor profile may also be verified in accordance with
ISO 8503, when approved by purchaser.
4.3.4 Hand or Power Tool Cleaning
If specified, hand tool or power tool cleaning shall be in accordance with
SSPC-SP 11. SSPC-SP 2 or ISO St 2, SSPC-SP 3 or ISO St 3 may be used if
SSPC-SP11 is not practical, when approved by purchaser.
4.4 Application
4.4.1 General
4.4.1.1 Application shall be in accordance with SSPC-PA 1 or ISO 12944-7, the
coating manufacturer’s published application instructions, MSDS, and
the requirements specified herein.
4.4.1.2 All application equipment shall be provided as recommended by the
coating manufacturer, shall be clean and in good condition, and shall be
suitable for applying the coating as specified.
4.4.2 Temperature, Humidity, and Weather Conditions
4.4.2.1 Paint shall not be applied while any of the following conditions are
present or expected before the paint dries:

a. Temperature: Ambient, substrate, or coating material temperatures are

above 49°C (120°F), below 10°C (50°F), or outside the range
recommended by the coating manufacturer.
b. Humidity: The ambient or substrate temperature is less than 3°C (5°F)
above the dew point or outside the range recommended by the coating
manufacturer. Dew point temperature shall be determined by sling
psychrometer in accordance with ASTM E337, ISO 4677-2, or
equivalent electronic device at the location where work is being
performed.
c. Wind: During strong or gusty wind conditions, particularly for spray
application.
d. Weather: During rain, snow, or fog or on damp surfaces or surfaces
that may have frost.
4.4.3 Materials
4.4.3.1 Coating materials shall be in accordance with purchaser’s external
coating system data sheets.
4.4.3.2 All solvents used for thinning shall be in accordance with the coating
manufacturer’s recommendations.
4.4.3.3 Coating materials shall be furnished in the coating manufacturer’s
unopened containers, clearly marked, and kept covered, clean, and
protected.
4.4.3.4 All materials shall be handled and stored in accordance with the coating
manufacturer’s latest published instructions and SSPC-PA 1
(ISO 12944-7).
4.4.3.5 Equipment fabricators shall indicate on their drawings the coating
manufacturer and coating product numbers used.
4.4.4 Mixing and Thinning
4.4.4.1 Materials shall be mixed and thinned in accordance with the coating
manufacturer’s written instructions.
4.4.4.2 All mixing shall be done in clean containers that are free from grease,
paints, and other contaminants. Containers shall be kept covered to
prevent contamination by dust, dirt, or rain.
4.4.4.3 Mixing of partial kits shall not be permitted.
4.4.4.4 Inorganic zinc primers and all pigmented coatings shall be strained
before application in accordance with the coating manufacturer’s written
instructions.
4.4.4.5 Thinning shall not exceed the maximum allowable volatile organic
compound (VOC) level for the coating involved.
4.4.5 Shelf and Pot Life
4.4.5.1 Materials that have exceeded the coating manufacturer’s recommended
shelf life shall not be used.

4.4.5.2 Coating manufacturer’s recommended pot life shall not be exceeded. If

this limit is reached, the spray pot shall be emptied and cleaned, and new
material shall be mixed.
4.4.6 Priming
4.4.6.1 Primers shall be applied before flash rusting or other contamination
occurs.
4.4.6.2 Previously coated surfaces shall be protected from contamination and
overspray.
4.4.6.3 Primer shall have a uniform thickness over welds, edges, and corners and
shall be free of mud cracking.
4.4.6.4 Primer shall not be applied within 100 mm (4 inches) of unblasted
surfaces or 50 mm (2 inches) from the edges to be field welded.
4.4.6.5 Inorganic zinc primer shall be applied using an agitated pot.
4.4.7 Topcoating
4.4.7.1 Each coat of paint shall be of a contrasting color to indicate the extent of
coverage.
4.4.7.2 Each coat of multiple-coat systems shall be allowed to cure sufficiently
in accordance with the coating manufacturer’s directions before
topcoating.
4.4.7.3 Minimum drying time between coats shall be in compliance with the
coating manufacturer’s instructions.
4.4.7.4 If the maximum recoat time has been exceeded, previously applied
coatings shall be roughened before topcoating or treated in accordance
with the coating manufacturer’s directions.
4.4.7.5 Before topcoating over an inorganic zinc primer, the cure of the primer
shall be verified.
4.4.7.6 Inorganic zinc primers shall have all overspray removed with a stiff
bristle brush or wire screen and shall be clean and thoroughly cured
before topcoating.
4.4.7.7 If spray applying over inorganic zinc primers, a mist coat shall be used to
avoid bubbling. The mist coat may be a thinned coat or applied by a
quick pass of the spray gun before applying the full coat, but sufficient
time shall be allowed for solvent evaporation.
4.4.8 Film Thickness
4.4.8.1 Wet film thickness shall be checked during the application of each coat
to assure the specified dry film thickness (DFT) is met.
Comment: Wet film thickness measurements are not suitable for some
materials such as inorganic zinc primers, flake filled epoxies, etc.
4.4.8.2 The DFT of each coat on CS shall be checked in accordance with the
procedures defined by SSPC-PA 2 using a magnetic gage that has been
properly calibrated.

4.4.8.3 Coating thickness on nonmagnetic substrates shall be checked using a

Type 2 gage suitable for use on nonferrous substrates.
4.4.8.4 Coating thickness may also be measured using ISO 2178 for non-
magnetic coatings on magnetic substrates or ISO 2360 for coatings on
non-magnetic substrates. However, sampling procedures shall follow
SSPCPA 2.
4.4.8.4 Measurements shall be taken after removal of dry spray and overspray.
4.4.8.5 All gages shall be adjusted to compensate for the substrate effect before
application of any coating.
4.4.9 Defects
4.4.9.1 Each coat of paint shall be of a uniform film, free of defects
(e.g., pinholes, voids, bubbles, skips, runs, sags, blisters, wrinkles, and
mud cracking), and of a uniform thickness and appearance.
4.4.9.2 Care shall be exercised to prevent overspray, spillage, or application of
coatings to surfaces for which they are not intended. Dry spray and
overspray shall be removed.
4.4.9.3 DFT of each coat shall not be outside the specified range.
4.4.10 Touch-Up
4.4.10.1 Before application of any coat, all defects and damage to the previous
coat(s) shall be repaired. Damage to finished work shall be thoroughly
cleaned and recoated.
4.4.10.2 Damaged areas shall be spot-blast cleaned, power tool cleaned, or hand
tool cleaned as necessary to restore any exposed steel to an original
degree of cleanliness. All loose, cracked, and damaged coating shall be
removed and the adjacent sound coating feathered back approximately
50 mm (2 inches) to form a uniform and smooth surface. Feathering shall
be done by hand or power sanding with a grit wheel or sandpaper. The
prepared surface shall be free of loose, burnt, or blistered coating.
4.4.10.3 Unless specified otherwise, the coating used for repair shall be the same
as the original and shall have the same DFT.
4.4.11 Job Stencil
4.4.11.1 After the coating system has been applied in the shop or field, if
specified by the purchaser, a job stencil shall be applied in a prominent
location to identify the coating system used.
4.4.11.2 Stencil shall be of 25 mm (1 inch) high letters of a color contrasting with
the finished paint.
4.4.11.3 Stencil shall provide the following information:
a. Top line shall be used for the PIP External Coatings Systems
Document Number.
b. Second line shall be used for SSPC surface preparation.

c. Next line(s) shall be used for each coat of paint, followed by the date
of application (month and year).
d. Last line shall be the name of the shop or field coating contractor.
4.4.11.4 If there are a large number of structural shapes, a job stencil shall be
applied to about 10 percent of the pieces.
4.4.11.5 Small pieces such as lap flanges, hangers, etc. shall not be stenciled.
4.5 Inspection
4.5.1 General
4.5.1.1 All inspections and tests shall be performed that are necessary to ensure
that surface preparation and coating application comply with the
requirements of this Practice.
4.5.1.2 Purchaser’s inspector(s) shall be given adequate notice before the start of
surface preparation and coating application to witness the work.
4.5.1.3 Purchaser’s inspector(s) shall have the option to witness or repeat any of
these functions as necessary.
4.5.1.4 All materials, equipment, and work shall be available to purchaser’s
inspector(s) at all times.
4.5.1.5 Purchaser’s inspector(s) shall have access to the work site during the
progress of the work and the right to conduct any inspection or testing
deemed necessary to ensure that the coatings are properly applied.
4.5.1.6 All instruments used in inspection activities (e.g., thermometer,
pyrometers, hygrometers, thickness gauges, profile gauges, and holiday
detectors) shall be furnished in proper working order and calibrated
before use.
4.5.1.7 Dew point, relative humidity, and surface temperature shall be
determined before surface preparation. Readings are required at 4-hour
intervals or at other time intervals approved by the purchaser.
4.5.1.8 Alternatively, continuous monitoring of dew point and relative humidity
may be performed using systems established or accepted by the purchaser.
4.5.1.9 Substrate temperature shall be 3°C (5°F) minimum above the dew point.
4.5.1.10 Work shall not proceed if the ambient temperature or relative humidity is
not in accordance with Section 4.4.2.
4.5.1.11 Air supply for blast cleaning, pneumatic tools, and spray equipment shall
be tested for oil and water contamination in accordance with ASTM
D4285 or applicable parts of ISO 8573, and as follows:
a. All lines shall be tested separately.
b. Testing shall be performed at the beginning and end of each work
shift and at not less than 4-hour intervals.

4.5.1.12 If contamination is discovered:

a. All necessary corrective actions shall be made and the air supply
retested.
b. Surfaces determined to have been blasted with contaminated air shall
be cleaned with solvent and reblasted with clean air and abrasive.
c. Coatings determined to have been applied using contaminated air
shall be removed and reapplied using clean air.
4.5.1.13 Recirculated shot and grit used for abrasive cleaning shall be tested for
the presence of oil by immersing in water and checking for oil flotation.
Tests shall be made at the start of blasting, at 4-hour intervals thereafter,
and at the end of blasting.
4.5.1.14 If oil contamination in the abrasive is evident:
a. Contaminated abrasive shall be replaced with clean abrasive and
retested before proceeding.
b. All steel blasted since the last satisfactory test shall be reblasted.
4.5.1.15 Abrasive-cleaned surfaces shall be inspected for proper surface
cleanliness and anchor profile using SSPC or ISO 8501-1 visual
comparators.
4.5.1.16 Surface preparation anchor profile shall be verified using either coarse or
extra-coarse replica tape (as required by profile depth) and a spring-
loaded micrometer in accordance with ASTM D4417, Method C. Anchor
profile may also be verified in accordance with ISO 8503-5, when
approved by purchaser.
4.5.1.17 SSPC-VIS 1 or ISO 8501-1 visual standards shall be used for confirming
the degree of surface cleanliness if adequacy of cleaning is in question.
4.5.1.18 If coating adhesion or intercoat adhesion are of suspect quality, the
adhesion shall be checked periodically.
4.5.1.19 Adhesion may be assessed by means of portable pull-off adhesion tester
in accordance with ASTM D4541 or ISO 4624 or one of the appropriate
tape tests in accordance with ASTM D3359 or ISO 2409.
4.5.1.20 Adhesion test method shall be approved by the purchaser.
4.5.1.21 Acceptable adhesion classifications or pull-off strengths shall be in
accordance with coating material manufacturer’s recommendations and
approved by the purchaser.
4.5.1.22 Completed paint job shall pass inspection by the purchaser’s inspector(s).
4.5.1.23 Any work found not to be in accordance with the requirements specified
herein shall be corrected.
4.5.2 Inspection Checklist
4.5.2.1 Prepainting Inspection
1. Verify that coating, thinning, and blasting materials are as specified.

2. Verify that storage conditions for all materials are adequate and
properly maintained.
3. Verify that surfaces not to be coated are masked off or otherwise
protected before surface preparation and coating application of
adjacent surfaces.
4.5.2.2 Presurface Preparation
1. Verify that oil and grease are removed before surface preparation.
2. Verify that welds and sharp edges have been suitably prepared.
4.5.2.3 Surface Preparation
1. Verify that the air supply is clean and free of oil and moisture.
2. Verify the cleanliness and dryness of abrasives.
3. Verify the adequacy of cleaning and blasting equipment, hoses, etc.
4. Verify that ambient, substrate, and dew point temperatures are
appropriate for proper surface preparation.
5. Verify that visible burrs, slivers, scabs, and weld spatter have been
removed after blasting.
6. Verify the degree of surface cleanliness and that contaminants have
been removed.
7. Verify, using appropriate instruments, that the anchor profile is as
specified.
4.5.2.4 Coating Application
1. Verify that materials are as specified, that materials are properly
labeled, and that the shelf life has not been exceeded.
2. Verify that mixing, thinning, and induction times are in accordance
with the coating manufacturer’s instructions.
3. Verify that the proper application equipment is being utilized.
4. Verify that the air supply is clean and free of oil and moisture.
5. Verify that the ambient, substrate, and dewpoint temperatures are
appropriate.
6. Verify that the applicator is checking wet film thickness during
application.
7. Verify that coating manufacturer’s requirements regarding recoat
time are observed.
8. Verify that the previous coat is sufficiently cured before application
of topcoats.
9. Visually inspect each coat for defects and uniform appearance.
10. Verify, by following the procedures of SSPC-PA 2, that the DFT is
within the specified range after each coat.

4.5.2.5 Final Acceptance

1. Visually inspect the coated surface for defects and uniform
appearance.
2. Verify, by following the procedures of SSPC-PA 2, that the total
DFT is within the specified range.
3. Verify that all identified repairs have been properly made.
4. Verify that the coating system is cured.
4.5.3 Records
4.5.3.1 A Daily Inspection Report, PIP CTSE1000-F, for documenting that specified
requirements have been met shall be completed for each work shift.
4.5.3.2 Supplier’s forms may be used with prior approval by purchaser.
4.5.3.3 A log shall be maintained of all reports, inspections, and tests (including
date, time, and results of instrument calibrations).
4.6 Shipping, Handling, and Storage

4.6.1 Coated items shall not be handled or moved until all coatings have been properly
dried or cured in accordance with the coating manufacturer’s instructions.
4.6.2 Coated items shall be handled with equipment such as wide belt slings, web
belts, and wide padded skids selected to prevent damage to the coating.
4.6.3 Handling equipment likely to cause damage to the coating shall not be used.
Items such as chains, cables, hooks, tongs, metal bars, and narrow skids shall not
be permitted to come in contact with the coating.
4.6.4 Dragging or skidding coated pipe shall not be permitted.
4.6.5 Coated items shall be loaded, padded, and secured for transport in a manner such
that the coating will not be damaged in transit.
4.6.6 Coated items shall be separated so that the items do not bear against each other.
4.6.7 Coated items shall be stacked off the ground using suitable means (e.g., parallel
height ridges of rock-free sand, wooden timbers placed under the uncoated pipe
ends, etc.) to avoid damage to the coating.

ASSOC. PIP: DOCUMENTATION
CTSE1000 REQUIREMENTS PIP CTSE1000-D1
PAGE 1 OF 4
APPLICATION OF EXTERNAL COATINGS DECEMBER 2012
NO. DATE REVISION DESCRIPTION BY CHECKED APPROVED
PROJECT NO. PROJECT DOCUMENT NO.

FACILITY NAME
LOCATION
PIP DOC NUMBER/ TITLE REV DATE NOTES

PROJ DOC NUMBER
CTSE1000 YES NO APPLICATION OF EXTERNAL COATINGS
CTSE1000-D1 YES NO DOCUMENTATION REQUIREMENTS
CTSE1000-D2 YES NO COLOR SELECTION SHEET
CTSE1000-F YES NO DAILY INSPECTION REPORT
CTSE1000-D101 YES NO COATING SYSTEM NO. 1

Inorganic Zinc
IZ
Inorganic Zinc/Epoxy Polyamide
IZ/EC
Epoxy Polyamide (3 Coats)
EC/EC/EC
Epoxy Phenolic
EP
Epoxy Phenolic (3 Coats)
EP/EP/EP
Epoxy Polyamide/Urethane
EC/UR
Coal Tar Epoxy (2 Coats)
TE/TE
Inorganic Zinc/Water-Borne Acrylic
IZ/WA
Alkyd (3 Coats)
OA/OA/OA
Inorganic Zinc/Silicone Acrylic (2 Coats)
IZ/SA/SA
PAGE 2 OF 4

FACILITY NAME
LOCATION

PROJ DOC NUMBER
Silicone For Stainless Steel (2 Coats)
SS/SS
Heat-Cured Silicone (2 Coats)
HS/HS
Epoxy Mastic For Manufacturer’s Standard
EM
Inorganic Zinc/Heat-Cured Silicone (2 Coats)
IZ/HS/HS
Inorganic Zinc/Epoxy Mastic/Urethane
IZ/EM/UR
Low Temperature Curing Epoxy (2 Coats)
EL/EL
Polysiloxane (2 Coats)
PX/PX
Epoxy Mastic (2 Coats)/Urethane
EM/EM/UR
Epoxy Novolac (2 Coats)
EN/EN
Epoxy Phenolic (2 Coats)
EP/EP
Organic Zinc/Urethane
OZ/UR
Epoxy Mastic/Water-Borne Acrylic
EM/WA
Epoxy Mastic/Epoxy Polyamide
EM/EC
Epoxy Mastic/Urethane (2 Coats)
EM/UR/UR
PAGE 3 OF 4

FACILITY NAME
LOCATION

PROJ DOC NUMBER
High Build Epoxy (2 Coats)/Urethane
EH/EH/UR
Coal Tar Epoxy (1 Coat)
TE
Thermal Spray Aluminum / Silicone Sealer -
Aluminum
TSA/SSA
CTSE1000-D128 YES NO
PAGE 4 OF 4

FACILITY NAME
LOCATION

PROJ DOC NUMBER

Epoxy Novolac
EN
YES NO
YES NO
YES NO
YES NO
YES NO
YES NO
YES NO
NOTES:
ASSOC. PIP:
CTSE1000 COLOR SELECTION SHEET PIP CTSE1000-D2
PAGE 1 OF 1

FACILITY NAME
LOCATION
ITEM COLOR REFERENCE
NOTES:
ASSOC. PIP:
CTSE1000 EXTERNAL COATING SYSTEMS PIP CTSE1000-D101
COATING SYSTEM NO. 1

PAGE 1 OF 2
Inorganic Zinc DECEMBER 2012
IZ

FACILITY NAME
LOCATION
DESCRIPTION:
Inorganic zinc coating.
SURFACES:
Carbon steel. Do not apply to stainless steel or nickel alloy surfaces.
SURFACE PREPARATION:
Abrasive blast to SSPC SP-10 (Sa 2.5) with a nominal profile of 50 µm (2 mils).
REFERENCES
The latest edition (or edition indicated) of the following industry standards and references shall be considered an integral part
of this External Coating System.
International Organization for Standardization (ISO)
ISO 8504-2 Preparation of Steel Substrates Before Application of Paints and Related Products - Surface Preparation
Methods - Part 2: Abrasive Blast-Cleaning-second edition
The Society for Protective Coatings (SSPC)
SSPC-SP 10/NACE No. 2, Near-White Blast Cleaning
SYSTEM
Coat Type Application Minimum Maximum Shop (S)/
No. Code Generic Type Method DFT, µm (mils) DFT, µm (mils) Field (F)
1. IZ Inorganic Zinc S 65 (2.5) 100 (4.0)
2.
3.
Total: 65 (2.5) 100 (4.0)
*Application Method: S=Spray; B=Brush; R=Roller
Notes:
Unless otherwise specified, refer to the coating manufacturer’s data sheets for information on the recommended application
temperature range, wet film thickness, approximate coverage in square feet/gallon, pot life, and drying times to touch, handle,
and cure for each coating product.
Mixing and Thinning: Mix according to manufacturer’s instructions and SSPC PA-1.
Application: Apply according to manufacturer’s instructions and PIP CTSE1000.
Job Stencil Required: Yes No

ASSOC. PIP:

PAGE 2 OF 2
Inorganic Zinc DECEMBER 2012
IZ
FACILITY NAME
LOCATION
Repair:
Manufacturer Coat 1 Coat 2 Coat 3

(Inorganic Zinc) (None) (None)
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Inorganic Zinc/Epoxy Polyamide DECEMBER 2012
IZ/EC

FACILITY NAME
LOCATION
DESCRIPTION:
Inorganic zinc primer (IZ) with a high build polyamide catalyzed epoxy finish (EC).
SURFACES:
REFERENCES
SYSTEM
2. EC Epoxy Polyamide S, B, R 75 (3.0) 125 (5.0)
3.
Total: 140 (5.5) 225 (9.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Inorganic Zinc/Epoxy Polyamide DECEMBER 2012
IZ/EC
FACILITY NAME
LOCATION
Repair:

Inorganic Zinc Epoxy Polyamide (None)
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Epoxy Polyamide (3 Coats) DECEMBER 2012
EC/EC/EC

FACILITY NAME
LOCATION
DESCRIPTION:
A polyamide catalyzed epoxy system consisting of a catalyzed epoxy primer (EC) and two coats of catalyzed epoxy finish
(EC).
SURFACES:
Abrasive blast to SSPC SP-6 (Sa 2) with a nominal profile of 50 µm (2 mils).
REFERENCES
SSPC-SP 6/NACE No. 3, Commercial Blast Cleaning
SYSTEM
1. EC Epoxy Polyamide Primer S, B, R 40 (1.5) 75 (3.0)
Total: 140 (5.5) 225 (9.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Epoxy Polyamide (3 Coats) DECEMBER 2012
EC/EC/EC
FACILITY NAME
LOCATION
Repair:

Epoxy Polyamide Primer Epoxy Polyamide Epoxy Polyamide
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Epoxy Phenolic DECEMBER 2012
EP

FACILITY NAME
LOCATION
DESCRIPTION:
Catalyzed epoxy-phenolic system.
SURFACES:
Stainless steel or aluminum pipe, equipment, and vessels, usually under insulation. Suitable for stainless steel or high nickel
alloys if temperature limits not exceeded.
Abrasive blast to SSPC SP-7 (Sa 1) with a nominal profile of 25 µm (1 mil).
REFERENCES
SSPC-SP 7/NACE No. 4, Brush-off Blast Cleaning
SYSTEM
1. EP Epoxy Phenolic Spray 150 (6.0) 200 (8.0)
2.
3.
Total: 150 (6.0) 200 (8.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Epoxy Phenolic DECEMBER 2012
EP
FACILITY NAME
LOCATION
Repair:

Epoxy Phenolic (None) (None)
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Epoxy Phenolic (3 Coats) DECEMBER 2012
EP/EP/EP

FACILITY NAME
LOCATION
DESCRIPTION:
Three-coat catalyzed epoxy-phenolic system.
SURFACES:
Carbon steel, usually under insulation. May be used for mixed carbon steel/stainless steel/nickel alloys installations when
economical.
REFERENCES
SYSTEM
1. EP Epoxy Phenolic Primer S, B, R 75 (3.0) 100 (4.0)
2. EP Epoxy Phenolic S, B, R 65 (2.5) 100 (4.0)
Total: 200 (8.0) 300 (12.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
EP/EP/EP
FACILITY NAME
LOCATION
Repair:

Epoxy Phenolic Primer Epoxy Phenolic Epoxy Phenolic
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Epoxy Polyamide/Urethane DECEMBER 2012
EC/UR

FACILITY NAME
LOCATION
DESCRIPTION:
Catalyzed epoxy primer (EC) with a two-package aliphatic urethane (UR) finish.
SURFACES:
Carbon steel. Other materials or substances may be painted with this system.
REFERENCES
SYSTEM
2. UR Aliphatic Urethane S, B, R 50 (2.0) 75 (3.0)
3.
Total: 115 (4.5) 175 (7.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
EC/UR
FACILITY NAME
LOCATION
Repair:

Epoxy Polyamide Aliphatic Urethane (None)
Notes:
ASSOC. PIP:

PAGE 1 OF 2
EC/UR

FACILITY NAME
LOCATION
DESCRIPTION:
Catalyzed epoxy primer (EC) with a two-package aliphatic urethane (UR) finish.
SURFACES:
Carbon steel. Other materials or substances may be painted with this system.
REFERENCES
SYSTEM
3.
Total: 115 (4.5) 175 (7.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
EC/UR
FACILITY NAME
LOCATION
Repair:

Epoxy Polyamide Aliphatic Urethane (None)
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Coal Tar Epoxy (2 Coats) DECEMBER 2012
TE/TE

FACILITY NAME
LOCATION
DESCRIPTION:
Two-coat catalyzed coal tar epoxy (TE) paint system.
SURFACES:
Carbon steel, usually under insulation or for wet exposures.
Abrasive blast to SSPC SP-6 (Sa 2) with a nominal profile of 50 to 75 µm (2 to 3 mils).
REFERENCES
SYSTEM
1. TE Coal Tar Epoxy S, B, R 175 (7.0) 250 (10.0)
3.
Total: 350 (14.0) 500 (20.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Coal Tar Epoxy (2 Coats) DECEMBER 2012
TE/TE
FACILITY NAME
LOCATION
Repair:

Coal Tar Epoxy Coal Tar Epoxy (None)
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Inorganic Zinc/Water-Borne Acrylic DECEMBER 2012
IZ/WA

FACILITY NAME
LOCATION
DESCRIPTION:
Inorganic zinc primer (IZ) with a water-borne acrylic finish (WA).
SURFACES:
REFERENCES
SYSTEM
2. WA Water-Borne Acrylic S, B, R 50 (2.0) 100 (4.0)
3.
Total: 115 (4.5) 200 (8.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Inorganic Zinc/Water-Borne Acrylic DECEMBER 2012
IZ/WA
FACILITY NAME
LOCATION
Repair:

Inorganic Zinc Water-Borne Acrylic (None)
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Alkyd (3 Coats) DECEMBER 2012
OA/OA/OA

FACILITY NAME
LOCATION
DESCRIPTION:
Three-coat alkyd paint (OA) system.
SURFACES:
Carbon steel. Other substrates may be coated.
Abrasive blast to SSPC SP-6 (Sa 2) with a nominal profile of 50 µm (2 mils). Alternative methods of surface preparation may
be used.
REFERENCES
SYSTEM
1. OA Alkyd S, B, R 25 (1.0) 50 (2.0)
2. OA Alkyd S, B, R 40 (1.5) 50 (2.0)
3. OA Alkyd S, B, R 40 (1.5) 50 (2.0)
Total: 100 (4.0) 150 (6.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Alkyd (3 Coats) DECEMBER 2012
OA/OA/OA
FACILITY NAME
LOCATION
Repair:

Alkyd Alkyd Alkyd
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Inorganic Zinc/Silicone Acrylic (2 Coats) DECEMBER 2012
IZ/SA/SA

FACILITY NAME
LOCATION
DESCRIPTION:
Inorganic zinc (IZ) primer with a two-coat silicone acrylic finish.
SURFACES:
REFERENCES
SYSTEM
2. SA Silicone Acrylic S 10 (0.5) 25 (1.0)
3. SA Silicone Acrylic S 25 (1.0) 50 (2.0)
Total: 100 (4.0) 175 (7.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Inorganic Zinc/Silicone Acrylic (2 Coats) DECEMBER 2012
IZ/SA/SA
FACILITY NAME
LOCATION
Repair:

Inorganic Zinc Silicone Acrylic Silicone Acrylic
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Silicone for Stainless Steel (2 Coats) DECEMBER 2012
SS/SS

FACILITY NAME
LOCATION
DESCRIPTION:
Two-coat air-dry silicone system (SS/SS).
SURFACES:
Stainless steel for the prevention of stress corrosion cracking.
REFERENCES
SSPC-SP 7/NACE No. 4, Brush-Off Blast Cleaning
SYSTEM
1. SS Silicone S 40 (1.5) 50 (2.0)
2. SS Silicone S 40 (1.5) 50 (2.0)
3.
Total: 75 (3.0) 100 (4.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Silicone for Stainless Steel (2 Coats) DECEMBER 2012
SS/SS
FACILITY NAME
LOCATION
Repair:

Silicone Silicone (None)
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Heat-Cured Silicone (2 Coats) DECEMBER 2012
HS/HS

FACILITY NAME
LOCATION
DESCRIPTION:
Two-coat heat-cured silicone coating (HS) system.
SURFACES:
Carbon steel. Other substrates may be coated.
Abrasive blast to SSPC SP-10 (Sa 2.5) with a nominal profile of 25 µm (1 mil).
REFERENCES
SYSTEM
1. HS Heat-Cured Silicone S 25 (1.0) 50 (2.0)
2. HS Heat-Cured Silicone S 25 (1.0) 50 (2.0)
3.
Total: 50 (2.0) 100 (4.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Heat-Cured Silicone (2 Coats) DECEMBER 2012
HS/HS
FACILITY NAME
LOCATION
Repair:

Heat-Cured Silicone Heat-Cured Silicone (None)
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Epoxy Mastic for Manufacturer’s Standard DECEMBER 2012
EM

FACILITY NAME
LOCATION
DESCRIPTION:
One-coat high-build self-priming epoxy mastic.
SURFACES:
Manufacturer’s Standard finished items where abrasive blast cleaning for top-coating is not practical.
Prepare the surface per SSPC SP-2 or -3 (St 2 or St 3). Check compatibility by top-coating a small area; proceed if no lifting of
the existing Manufacturer’s Standard finish is observed.
REFERENCES
Methods - Part 3: Hand- and Power-Tool Cleaning First Edition
SSPC-SP 2, Hand Tool Cleaning
SSPC-SP3, Power Tool Cleaning
SYSTEM
1. - Manufacturer’s Standard - - -
2. EM Epoxy Mastic S, B, R 100 (4.0) 150 (6.0)
3.
Total: 100 (4.0) 150 (6.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Epoxy Mastic for Manufacturer’s Standard DECEMBER 2012
EM
FACILITY NAME
LOCATION
Repair:

Manufacturer’s Standard Epoxy Mastic (None)
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Inorganic Zinc/Heat-Cured Silicone (2 Coats) DECEMBER 2012
IZ/HS/HS

FACILITY NAME
LOCATION
DESCRIPTION:
Two-coat silicone paint system (HS) applied over inorganic zinc primer (IZ).
SURFACES:
Carbon Steel. Do not apply to stainless steel or nickel alloy surfaces.
REFERENCES
SYSTEM
2. HS Heat Cured Silicone S 10 (0.5) 25 (1.0)
3. HS Heat Cured Silicone S 25 (1.0) 40 (1.5)
Total: 100 (4.0) 165 (6.5)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Inorganic Zinc/Heat-Cured Silicone (2 Coats) DECEMBER 2012
IZ/HS/HS
FACILITY NAME
LOCATION
Repair:

Inorganic Zinc Heat Cured Silicone Heat Cured Silicone
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Inorganic Zinc/Epoxy Mastic/Urethane DECEMBER 2012
IZ/EM/UR

FACILITY NAME
LOCATION
DESCRIPTION:
Inorganic zinc primer (IZ) with epoxy mastic intermediate (EM) and two-package aliphatic urethane finish (UR).
SURFACES:
Carbon Steel. Do not apply to stainless steel or nickel alloys.
REFERENCES
SYSTEM
Total: 215 (8.5) 325 (13.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Inorganic Zinc/Epoxy Mastic/Urethane DECEMBER 2012
IZ/EM/UR
FACILITY NAME
LOCATION
Repair:

Inorganic Zinc Epoxy Mastic Aliphatic Urethane
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Low Temperature Curing Epoxy (2 Coats) DECEMBER 2012
EL/EL

FACILITY NAME
LOCATION
DESCRIPTION:
Two-coat catalyzed low temperature curing epoxy system. One coat primer (EL) and one coat finish (EL).
SURFACES:
Carbon steel, usually under insulation. Special system for ambient application temperatures of 30°F (-1°C) to 50°F (10°C).
This system may be used for mixed carbon steel/stainless steel/nickel alloys installations when practical.
REFERENCES
SYSTEM
1. EL Low Temperature Cure Epoxy S, B, R 75 (3.0) 125 (5.0)
2. EL Low Temperature Cure Epoxy S, B, R 125 (5.0) 175 (7.0)
3.
Total: 200 (8.0) 300 (12.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Low Temperature Curing Epoxy (2 Coats) DECEMBER 2012
EL/EL
FACILITY NAME
LOCATION
Repair:

Low Temperature Cure Low Temperature Cure (None)
Epoxy Epoxy
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Polysiloxane (2 Coats) DECEMBER 2012
PX/PX

FACILITY NAME
LOCATION
DESCRIPTION:
Two-coat polysiloxane coating system for high temperature service.
SURFACES:
Carbon steel and/or stainless steel.
Abrasive blast to SSPC SP-10 (Sa 2.5) with a nominal profile of 50 to 75 µm (2 to 3 mils).
REFERENCES
SYSTEM
1. PX Polysiloxane Spray 100 (4.0) 150 (6.0)
2. PX Polysiloxane Spray 100 (4.0) 150 (6.0)
3.
Total: 200 (8.0) 300 (12.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Polysiloxane (2 Coats) DECEMBER 2012
PX/PX
FACILITY NAME
LOCATION
Repair:

Polysiloxane Polysiloxane (None)
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Epoxy Mastic (2 Coats)/Urethane DECEMBER 2012
EM/EM/UR

FACILITY NAME
LOCATION
DESCRIPTION:
Epoxy mastic (EM) with a two-package aliphatic urethane (UR) finish.
SURFACES:
Carbon Steel.
REFERENCES
SYSTEM
Total: 250 (10.0) 375 (13.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Epoxy Mastic (2 Coats)/Urethane DECEMBER 2012
EM/EM/UR
FACILITY NAME
LOCATION
Repair:

Epoxy Mastic Epoxy Mastic Aliphatic Urethane
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Epoxy Novalac (2 Coats) DECEMBER 2012
EN/EN

FACILITY NAME
LOCATION
DESCRIPTION:
Two-coat catalyzed epoxy novolac system.
SURFACES:
Carbon steel, usually under insulation. This system may be used for mixed carbon steel/stainless steel/nickel alloys
installations when practical.
REFERENCES
SYSTEM
1. EN Epoxy Novolac S, B, R 100 (4.0) 150 (6.0)
3.
Total: 200 (8.0) 300 (12.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Epoxy Novalac (2 Coats) DECEMBER 2012
EN/EN
FACILITY NAME
LOCATION
Repair:

Epoxy Novolac Epoxy Novolac (None)
Notes:
ASSOC. PIP:

PAGE 1 OF 2
EP/EP

FACILITY NAME
LOCATION
DESCRIPTION:
Two-coat catalyzed epoxy phenolic system.
SURFACES:
Carbon steel, usually under insulation. May be used for mixed carbon steel/stainless steel/nickel alloys installations when
economical.
REFERENCES
SYSTEM
3.
Total: 200 (8.0) 300 (12.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
EP/EP
FACILITY NAME
LOCATION
Repair:

Epoxy Phenolic Epoxy Phenolic (None)
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Organic Zinc/Urethane DECEMBER 2012
OZ/UR

FACILITY NAME
LOCATION
DESCRIPTION:
Organic zinc-rich epoxy primer with aliphatic polyurethane finish.
SURFACES:
Carbon steel. Do not apply to stainless steel or other non-ferrous alloys.
REFERENCES
SYSTEM
1. OZ Organic Zinc S, B, R 50 (2.0) 100 (4.0)
3.
Total: 90 (3.5) 165 (6.5)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Organic Zinc/Urethane DECEMBER 2012
OZ/UR
FACILITY NAME
LOCATION
Repair:

Organic Zinc Urethane (None)
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Epoxy Mastic/Water-Borne Acrylic DECEMBER 2012
EM/WA

FACILITY NAME
LOCATION
DESCRIPTION:
Epoxy mastic primer (EM) with water-borne acrylic finish (WA).
SURFACES:
Manufacturer’s Standard items where abrasive blast cleaning for top-coating is not practical.
REFERENCES
SSPC-SP 3, Power Tool Cleaning
SYSTEM
3. WA Water-Borne Acrylic S, B, R 50 (2.0) 75 (3.0)
Total: 150 (6.0) 225 (9.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Epoxy Mastic/Water-Borne Acrylic DECEMBER 2012
EM/WA
FACILITY NAME
LOCATION
Repair:

Manufacturer’s Standard Epoxy Mastic Waterborne Acrylic
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Epoxy Mastic/Epoxy Polyamide DECEMBER 2012
EM/EC

FACILITY NAME
LOCATION
DESCRIPTION:
Epoxy mastic (EM) with epoxy (EC).
SURFACES:
Manufacturer’s Standard finished items where abrasive blast cleaning for top-coating is not practical.
REFERENCES
SSPC-SP3, Power Tool Cleaning
SYSTEM
Total: 200 (8.0) 300 (12.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Epoxy Mastic/Epoxy Polyamide DECEMBER 2012
EM/EC
FACILITY NAME
LOCATION
Repair:

Manufacturer’s Standard Epoxy Mastic Epoxy Polyamide
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Epoxy Mastic/Urethane DECEMBER 2012
EM/UR

FACILITY NAME
LOCATION
DESCRIPTION:
Epoxy mastic primer (EM) with an aliphatic urethane finish (UR)
SURFACES: Carbon steel. Can be used on stainless steel or nonferrous alloys, usually for color coding. Can be applied over
manufacturer’s standard finish items where abrasive blast cleaning for top coating is not practical. This system is also suitable
for galvanized surfaces.
SURFACE PREPARATION: For bare metal, abrasive blast to SSPC SP-6 (Sa 2) with a nominal profile of 50 to 75 µm (2 to
3 mils).To coat a manufacturer’s standard paint, prepare the surface in accordance with SSPC SP-2 or -3 (St 2 or St 3). For
galvanized surfaces, prepare in accordance with SSPC SP-7 (Sa 1), suitably weathered, or in accordance with manufacturer’s
recommendation.
REFERENCES
SSPC-SP 3, Power Tool Cleaning
SSPC-SP 7/NACE No. 4, Brush-Off Blast Cleaning
SYSTEM
2. UR Aliphatic Urethane Finish S, B, R 50 (2.0) 75 (3.0)
3.
Total: 150 (6.0) 225 (9.0)
Notes:
ASSOC. PIP:

PAGE 2 OF 2
Epoxy Mastic/Urethane DECEMBER 2012
EM/UR
FACILITY NAME
LOCATION
Repair:

Epoxy Mastic Urethane (None)
Notes:
ASSOC. PIP:

PAGE 1 OF 2
High Build Epoxy (2 Coats)/Urethane DECEMBER 2012
EH/EH/UR

FACILITY NAME
LOCATION
DESCRIPTION:
High-build epoxy (EH) with a two-package aliphatic urethane (UR) finish.
SURFACES:
Carbon Steel.
REFERENCES
SYSTEM
1. EH High Build Epoxy S, B, R 250 (10.0) 375 (15.0)
2. EH High Build Epoxy S, B, R 250 (10.0) 375 (15.0)
Total: 650 (22.0) 825 (33.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
High Build Epoxy (2 Coats)/Urethane DECEMBER 2012
EH/EH/UR
FACILITY NAME
LOCATION
Repair:

High Build Epoxy High Build Epoxy Aliphatic Urethane
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Coal Tar Epoxy DECEMBER 2012
(1 Coat) TE

FACILITY NAME
LOCATION
DESCRIPTION:
One-coat catalyzed coal tar epoxy (TE) paint system.
SURFACES:
Carbon steel or stainless steel, usually under insulation or for wet exposures.
REFERENCES
SYSTEM
2.
3.
Total: 200 (8.0) 250 (10.0)
Notes:

ASSOC. PIP:

PAGE 2 OF 2
Coal Tar Epoxy DECEMBER 2012
(1 Coat) TE
FACILITY NAME
LOCATION
Repair:

Coal Tar Epoxy (None) (None)
Notes:
ASSOC. PIP:

Thermal Spray Aluminum / Silicone Sealer - PAGE 1 OF 2
Aluminum DECEMBER 2012
TSA/SSA

FACILITY NAME
LOCATION
DESCRIPTION:
Thermal sprayed aluminum with silicone aluminum sealer
SURFACES:
Abrasive blast in accordance with SSPC SP-5 (Sa 3) with a minimum profile of 65 µm (2.5 mils).
SYSTEM
1. TSA Thermal Spray Aluminum TS 200 (8.0) 300 (12.0)
2. SSA Silicone Sealer - Aluminum S See Below See Below
3.
Total: 200 (8.0) 300 (12.0)
*Application Method: TS=Thermal Spray; S=Spray; B=Brush; R=Roller
APPLICATION REQUIREMENTS:
References
ANSI/AWS C2.18, Guide for the Protection of Steel with Thermal Sprayed Coatings of Aluminum and Zinc and Their Alloys
and Composites
AWS C2.23M/C2.23:2003, Specification for the Application of Thermal Spray Coatings of Aluminum, Zinc, and Their Alloys
and Composites for Corrosion Protection of Steel
SSPC-SP 5/NACE No. 1, White Metal Blast Cleaning
Application
Thermal spray coating (TSC) shall be applied in accordance with AWS C2.23M/C2.23 requirements, including mandatory
Annex I.
TSC shall be sealed with silicone aluminum, sufficiently thinned to completely penetrate into the body of the TSC and seal the
interconnecting surface porosity.
Tensile Bond
Companion tensile test specimen coupons shall be prepared and thermal spray coated using the production application
procedures. Coupons shall be minimum 6 mm (0.25 in.) thick, unless TSC supplier demonstrates thinner coupons will not
distort when TSC is applied. Tensile-bond measurement required every 50 m² (500 ft²). Bond-strength measurement shall be
made without application of sealer. If measured bond-strength is less than 6.89 MPa (1000 psi), the production TSC shall be
removed and reapplied.
Documentation
TSC supplier shall submit its application procedure proposed for the contract work.
Job reference standard (JRS) shall be prepared by the TSC supplier, for use as a comparator to evaluate suitability of the
application process.
TSC supplier shall prepare a job control record (JCR) to record production and QC information. JCR shall record, at a
minimum, the information delineated in AWS C2.23M/C.23, Annex B.
Repair
Repairs shall be in accordance with maintenance repair procedures outlined in ANSI/AWS C2.18.
ASSOC. PIP:

PAGE 2 OF 2
Thermal Spray Aluminum DECEMBER 2012
TSA
FACILITY NAME
LOCATION

MATERIALS
Thermal Spray Wire
Thermal spray wire shall be 99% Al, conforming to AWS C2.25/C2.25M, C2.25 Classification W-Al-1100 (UNS No. A91100).
Sealer
Silicone Sealer - Aluminum (manufacturer) (tradenemae/product number)
Top Coat
Not Required N.A. N.A.
Notes:
ASSOC. PIP:
PAGE 1 OF 3
USER-DEFINED COATING SYSTEM DECEMBER 2012

FACILITY NAME
LOCATION
COATING SYSTEM NO.:

GENERIC MATERIALS:
DESCRIPTION:
SURFACES:
REFERENCES
SYSTEM
1. ( ) ( )
2. ( ) ( )
3. ( ) ( )
Total: ( ) ( )
Notes:
ASSOC. PIP:
PAGE 2 OF 3

FACILITY NAME
LOCATION
COATING SYSTEM NO.:

GENERIC MATERIALS:

Repair:

( ) ( ) ( )
ASSOC. PIP:
PAGE 3 OF 3

FACILITY NAME
LOCATION
COATING SYSTEM NO.:

GENERIC MATERIALS:
Notes:
ASSOC. PIP:

PAGE 1 OF 2
Epoxy Novolac DECEMBER 2012
EN

FACILITY NAME
LOCATION
DESCRIPTION:
Catalyzed epoxy novolac system.
SURFACES:
Stainless steel, usually under insulation.
REFERENCES
SSPC-SP 7/NACE No. 4, Brush-off Blast Cleaning
SYSTEM
2.
3.
Total: 100 (4.0) 150 (6.0)
Notes:

ASSOC. PIP:

Epoxy Novolac PAGE 2 OF 2
DECEMBER 2012
EN
FACILITY NAME
LOCATION
Repair:

Epoxy Novolac (None) (None)
Notes:
ASSOC. PIP:
CTSE1000 DAILY INSPECTION REPORT CTSE1000-F
PAGE 1 OF 1
Facility Name/Location:
Item Name: Purchaser/Location:
Item Tag No.: Job No:
Service: Purchaser Order No.:
Unit: Supplier/Location:
P&ID No.: Supplier Order/Serial Nos.: /
Instructions:
This form shall be completed for each work shift to verify compliance with PIP CTSE1000.
Record unsatisfactory work, conditions causing unsatisfactory work, and corrective action.
Attach copies of all replica tape readings taken.
Attach additional sheets, notes of meetings, or reports as necessary for backup.
Submit a copy of all forms and back-up documents to the purchaser’s inspector(s).
Report Date: / /
Start of Start of Midpoint of End of
Condition Blasting painting painting painting
Time
Ambient Temperature °C °F
Relative Humidity (%)
Dew Temperature °C °F
Substrate Temperature °C °F
Weather Conditions
Surface Preparation:
Condition of Surface Before Blasting:
Method of Removing Contamination Before Blasting:
Method of Blasting: Abrasive Type: Grade:
Degree of Cleanliness Obtained:
Anchor Profile: µm mils Method of Measuring Anchor Profile:
Application Information:
Method of Spraying:
DFT Gage Type and Model: Date Calibrated:
DFT DFT
Thinner Specified Obtained
Lining Lining No./Type µm µm Actual Overcoat
Linings Applied Batch No. Color Used mils mils Interval (hrs)
Coat 1
Coat 2
Coat 3
Comments:
Supplier’s Signature:
Inspector’s Signature:

Process Industry Practices Coatings: PIP CTSE1000 Application of External Coatings

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REAFFIRMATION WITH EDITORIAL REVISION

Process Industry Practices

This Practice is subject to revision at any time.

© Process Industry Practices (PIP), Construction Industry Institute, The University of

Not printed with State funds

Process Industry Practices

Process Industry Practices Page 1 of 15

CTSE1000-D111 – External Coating CTSE1000-D127 – External Coating

Process Industry Practices Page 2 of 15

2.1 Industry Codes and Standards

Process Industry Practices Page 3 of 15

– ISO 2360: Non-conductive coatings on non-magnetic electrically conductive basis

• National Institute of Occupational Safety and Health (NIOSH)

Process Industry Practices Page 4 of 15

Process Industry Practices Page 5 of 15

Process Industry Practices Page 6 of 15

4.3 Surface Preparation

Process Industry Practices Page 7 of 15

4.3.2.11 Dew point temperature shall be determined by sling psychrometer in

Process Industry Practices Page 8 of 15

a. Temperature: Ambient, substrate, or coating material temperatures are

Process Industry Practices Page 9 of 15

4.4.5.2 Coating manufacturer’s recommended pot life shall not be exceeded. If

Process Industry Practices Page 10 of 15

4.4.8.3 Coating thickness on nonmagnetic substrates shall be checked using a

Process Industry Practices Page 11 of 15

Process Industry Practices Page 12 of 15

4.5.1.12 If contamination is discovered:

Process Industry Practices Page 13 of 15

Process Industry Practices Page 14 of 15

4.5.2.5 Final Acceptance

4.6 Shipping, Handling, and Storage

Process Industry Practices Page 15 of 15

NO. DATE REVISION DESCRIPTION BY CHECKED APPROVED

PROJECT NO. PROJECT DOCUMENT NO.

PIP DOC NUMBER/ TITLE REV DATE NOTES

CTSE1000-D1 YES NO DOCUMENTATION REQUIREMENTS

CTSE1000-D2 YES NO COLOR SELECTION SHEET

CTSE1000-F YES NO DAILY INSPECTION REPORT

CTSE1000-D101 YES NO COATING SYSTEM NO. 1

PROJECT NO. PROJECT DOCUMENT NO.

PIP DOC NUMBER/ TITLE REV DATE NOTES

PROJECT NO. PROJECT DOCUMENT NO.

PIP DOC NUMBER/ TITLE REV DATE NOTES

PROJECT NO. PROJECT DOCUMENT NO.

PIP DOC NUMBER/ TITLE REV DATE NOTES

CTSE1000-D129 YES NO COATING SYSTEM NO. 28

NO. DATE REVISION DESCRIPTION BY CHECKED APPROVED

PROJECT NO. PROJECT DOCUMENT NO.

ITEM COLOR REFERENCE

COATING SYSTEM NO. 1

PROJECT NO. PROJECT DOCUMENT NO.

Application: Apply according to manufacturer’s instructions and PIP CTSE1000.

Job Stencil Required: Yes No

COATING SYSTEM NO. 1