PRODUCING COATING SPECIFICATIONS THAT WORK

by

R A Francis
Aurecon, South Melbourne, Victoria, Australia

God said to Noah: make yourself an ark . . . and coat it with pitch inside and out.
Genesis 6:14
Noah’s ark may be the earliest example of the selection and written specification of a quality coating and
there is no doubt that the resultant coating performed the task required of it. Indeed, until relatively recently,
we were still seeing coating specifications for structural steel along the lines of ‘wire brush the surface and
apply two coats of good quality paint’, little advancement over that used by Noah. However, conditions are
rather different 6000 years on. We require coatings to withstand environments other than heavy rainfall and
wear and tear by animals. We require coatings to last longer than 40 days and 40 nights. Unlike Noah, we
have environmental and health and safety regulations to obey and coating contractors and paint company
representatives to deal with. Perhaps most importantly, the Almighty generally is not called upon to select
coatings and write the specification, so mistakes can be made.

A good coating specification is essential if steel structures are to continue to function as designed. This
paper describes some of the factors that the specifier must consider when selecting coatings to protect
steelwork, and some typical specification clauses. It follows the content of AS/NZS 2312 [1], and that
document should be an essential reference for anyone selecting and specifying coatings for steel in our part
of the world.

1 FACTORS INFLUENCING COATING SELECTION

The most important characteristic of a coating system for protecting a steel structure against corrosion
would normally be the ability to provide protection to the substrate for as long as possible, that is, maximum
durability. However, there are many other factors that must be considered and some of these are described
below.

(a) Environment

The environment is perhaps the single most important factor affecting durability of a coating system. A
coating which lasts a few months in a severe marine environment may last decades in a mild environment.
In addition, acidic environments can be corrosive to zinc coating systems which have excellent durability in
neutral environments. The important environmental factors influencing corrosion in atmospheric
environments were discussed in an earlier paper [2]. Recently, a new standard [3] has provided more
details on determining local corrosivity in Australia, including provision of corrosion maps of major centres.
This standard uses the ISO corrosivity categories which are becoming widely used around the world for
selecting methods of corrosion control for structures and other items exposed to the atmosphere. The
corrosion categories are summarised in Table 1.

STEEL CONSTRUCTION VOLUME 45 NUMBER 1 – DECEMBER 2011 11

 Table 1: Corrosivity categories according to AS 4312 and AS/NZS 2312

AS 4312 AS/NZS 2312 Steel corrosion rate Typical environment

Corrosivity
category category (µm/yr)
C1 A very low <1.3 dry indoors
C2 B low 1.3–25 arid/urban inland
C3 C medium 25–50 coastal or mild industrial
C4 D high 50–80 sea-shore (calm)
C5M E-M very high – marine 80–200 sea-shore (surf)
C5I E-I very high – industrial 80–200 severe industrial
T F – – inland tropical

(b) Colour and gloss

Many of the most corrosion resistant coatings, such as metal spray, galvanizing and inorganic zincs are
only available in matt grey. Even when considering coatings applied to minimise the effects of corrosion,
there are many situations where colour or gloss or both are required and such coatings are not appropriate.
Some reasons for requiring colour, even for nominally protective coatings, include:

 Colour is often necessary for logos and identification

 Colour can brighten dark areas and hide ugly areas
 Colour is required for safety, heat reflection, visibility, etc
 Colour and gloss may enhance public image, provide visual impact, etc.

(c) Shop or site application

Many structures are fabricated and coated in a shop, taken to site and erected. In such cases, coatings
would normally be applied in a shop, with only some touch up required on site. Such an approach will
normally provide optimum durability because of the following advantages:

 Coating is carried out under controlled conditions meaning less contamination from smoke, dust, etc
 Areas which become inaccessible can be coated
 Inspection is easier and more thorough
 There will not be problems working around other trades, so fewer ‘extras’
 Coating should not be affected by bad weather.

Some coatings, such as galvanizing, are only applied in a shop. The main concerns with shop-applied
coatings are that the item must be small enough to be able to be transported and there will always be a
problem with site touch up. The range of coatings that can be site-applied is less than for those designed for
shop application.

(d) Surface preparation and coating application methods

Most of the best quality primers must be applied to a blast cleaned surface. If blast cleaning is not permitted
for environmental or other reasons, then only a limited range of products is available. Similarly, many
modern high performance coatings must be applied by spray. At best, brush or roller can only be used for
small areas with such coatings. If spraying is not permitted for environmental or OH&S regulations,
concerns with overspray or other reasons, then selection will be from a limited number of coating products.

Section 7 of AS/NZS 2312:2002 covers these and other issues in more detail. The specifier must review
these before selecting coatings.

2 CONTENT OF A COATING SPECIFICATION

Before selecting coatings and looking at some individual clauses in a specification, it is necessary to
present an overview of the content of a typical coating specification. The following are sections which would
normally be present in a typical protective paint specification. There may be other more general sections,
such as a list of contractor submittals, requirements for a kick-off meeting, transport arrangements for shop-
applied coatings and warranty and guarantee requirements.

12 STEEL CONSTRUCTION VOLUME 45 NUMBER 1 – DECEMBER 2011

1. Scope. This provides a concise but accurate description of the items that will be coated. It should also
contain items that will not be coated, such as flange faces, friction grip surfaces, etc. The section may also
contain some general clauses.

2. References. This section will provide a list of standards and other documents referred to in the
specification. It is normally produced after the document is completed.

3. Definitions and abbreviations. This section contains important definitions and abbreviations that may
need clarifying or defining for those outside the coatings industry.

4. Surface preparation. This provides detailed requirements regarding surface preparation requirements
for the selected coating system.

5. Coating materials. This lists the coatings used in the selected coating system.

6. Coating application. This provides details of how the coatings should be applied.

7. Inspection requirements. This lists the tests required for surface preparation and coating application
and the required records.

3 COATING SYSTEMS FOR STRUCTURAL STEEL

There is an almost infinite number of combinations of primer, intermediate and top coats, along with
variations in thickness, pigment types and application properties. Therefore, selecting an optimum coating
system is not easy. AS/NZS 2312 has about 70 metallic and paint coating systems for atmospheric
exposure, along with 48 additional systems for other environments. A full discussion of all these, let alone
the many other systems which may be suggested by suppliers, users or other standards, is clearly not
possible. The following sections describe some commonly recommended atmospheric coating systems, and
the factors that must be considered if they are selected.

There are many other coating systems in addition to those described below. Some covered in AS/NZS 2312
include:

 Metal or thermal spray zinc or aluminium systems. These are selected for very severe environments
where long life is required and the high cost can be justified.
 Very thick coatings, such as ultra high build epoxy, polyester or vinyl ester. These are generally used
for very severe environments such as splash zones or severe chemical exposure. They would not
normally be specified for atmospheric environments.
 Continuously galvanized or electro-galvanized products that have significantly thinner zinc coatings
than that achieved with hot dip galvanizing, and proportionally lower durability. They would normally
only be used for mild environments.
 Chlorinated rubber coatings have good durability and are easy to maintain, but their high solvent
content means they have very limited availability.

The durability of the systems as given in [1] is provided in the discussion. This is the life to first major
maintenance, noting that normally some minor touch up will be required before this time. Rather than
discussing durability in all environments as given in [1], the life to first maintenance is given only for the
‘C4: High’ corrosivity (AS/NZS 2312 Category D) environment. This environment is found from
approximately 0.1 to 1 kilometre inland from a surf beach, such as most sites along the east coast of
Australia from the Victorian border to Fraser Island. This includes major centres such as Sydney,
Wollongong, Newcastle and the Gold Coast. Such corrosivity is also found on sheltered bays, such as
Melbourne or Brisbane right on the coast. Sites further inland will have proportionally greater durability and
sites more corrosive will have reduced durability compared to the figures given.

4 HOT DIP GALVANIZING

Zinc metal is perhaps the most important weapon in the fight against corrosion. It corrodes at a much lower
rate than steel, often one-twentieth or less, so an intact coating of reasonable thickness will provide good

STEEL CONSTRUCTION VOLUME 45 NUMBER 1 – DECEMBER 2011 13

durability to steelwork except in the most aggressive environments. More importantly, if the coating is
damaged exposing steel, the zinc will corrode in preference to the steel, protecting it by cathodic protection.
As a result, zinc coatings last a long time and when they do break down, they do not blister or undercut,
reducing the need for maintenance.

The single most important coating for protecting steel against corrosion is probably hot dip galvanizing
(HDG). This process, coating the steel by dipping in a bath of molten zinc after thorough cleaning, has been
successfully protecting steel for over 100 years. It has many advantages over paint coatings. It can provide
complete protection to complex shapes, it has excellent adhesion and is highly abrasion resistant. Unlike
most paints, edges have good thick coating coverage and no cure time is required. It is process rather than
operator controlled, and inspection and quality assurance requirements are normally much simpler.
However, it is only a factory-applied process and there is a limit to the size of an item which can be
galvanized. The heat of the molten zinc can cause distortion of complex shapes, and vent and drain holes
may be required. Along with other zinc coatings, they are only available in grey colour and are not suitable
in acidic environments. The rough finish is unlikely to be acceptable in architectural applications, and touch
up and repair will always be visible and usually of reduced durability.

A big advantage to the specifier with HDG is the ease of specification. A comprehensive Australian standard
[4] is available and a simple sentence on a drawing along the lines of

‘Hot dip galvanize the item to AS/NZS 4680’

is often sufficient. This standard covers surface preparation, galvanizing and inspection, and these do not
have to be separately specified. However, note that the quality of the finish permitted in AS/NZS 4680 is
pretty ordinary (for example, bare spots up to 40 square centimetres area are permitted) and architectural
finishes will require details of the required finish.

The durability of HDG in various corrosivity zones is given in Table 5.2 of AS/NZS 2312:2002, summarised
for the C4 environment in Table 2. The HDG industry usually designates coating thickness in terms of
grams per square metre rather than microns (100 grams per square metre is 14 microns). The galvanizer
has little control over zinc thickness. Specifiers cannot request a zinc coating thickness. Thickness depends
mainly on steel section thickness (the thicker the section, the longer it takes to heat up resulting in a thicker
coating). The other important variable is the silicon content of the steel. A silicon content of around 0.2%
gives a bright, but thin coating while silicon contents less than or greater than this give a dull grey, thicker
coating. Different batches of the same grade of steel can vary in silicon content giving different appearance
and, more importantly, different zinc thicknesses. If a thicker than normal galvanized coating is required, the
specifier should communicate requirements to the galvanizer. Longer residence times and abrasive blast
cleaning, at additional cost, may be required if the section thickness and silicon content are not adequate.

Table 2: Hot dip galvanizing systems

Average coating Article thickness AS/NZS 2312 C4

System
thickness (µm) (mm) durability (years)
HDG390 55 1.5 to 3 5 – 15
HDG500 70 3 to 6 10 – 25
HDG600 85 >6 15 – 25
HDG900 125 >6, high Si, etc 25+

AS/NZS 2312 lists a number painted HDG systems, so called duplex systems, showing very good durability.
Painting the galvanizing provides colour as well as additional durability. While there have been many
successful examples of painted galvanizing performing well, there have also been many examples where
the paint has severely disbonded from the galvanizing after only a few years. Surface treatments needed to
achieve long-term adhesion appear somewhat arbitrary and painting galvanizing is not worth the risk.
Galvanizing alone provides very good durability, but if colour is required paint systems should be specified.

14 STEEL CONSTRUCTION VOLUME 45 NUMBER 1 – DECEMBER 2011

5 INORGANIC ZINC SILICATE SYSTEMS
Inorganic zinc silicate (IZS) is one of the best liquid coatings that can be used to protect steelwork. A
relatively thin coating of the order of 70 to 100 microns can provide better protection in severe environments
than many organic coating systems two or three times as thick. Like galvanizing, it is hard and tough and
provides cathodic protection if damaged. Unlike galvanizing, it can be used on items of any size and applied
on site as well as in a shop. It is the only paint coating that can be used for friction grip joints. It can only be
applied to properly blast cleaned steel and application and curing can be challenging. Although it is often
considered as a competitor, IZS should be considered as a complementary coating system to
galvanizing [5]. Inorganic zinc is different from other paint coatings in that, despite initially producing a
porous film, it continues to harden and cure over time, and it becomes denser and more protective.

There are two main types of inorganic zincs, water-borne and solvent-borne. The water-borne is harder and
faster drying, but must be applied under dry, windy conditions. The solvent-borne must have a certain
minimum humidity to cure, but is a little more forgiving in application. The water-borne is considered to have
slightly better durability, but selection should really be on prevailing environmental conditions. Generally,
water-borne would be selected for application under dry conditions, the solvent-borne under more humid
conditions. AS/NZS 2312 has three IZS systems: IZS1 is a solvent-borne system applied to 75 microns,
IZS2 and IZS3 are water-borne. AS 4848.1 [6] covers surface preparation and application of a solvent-borne
system to a minimum thickness of 100 microns, slightly higher than IZS1 so with durability probably closer
to IZS2. These systems are listed in Table 3, although the durability of the solvent-borne system is rather
conservative. As with hot dip galvanizing, application of a single coat of solvent-borne inorganic zinc can be
specified by a single sentence such as:

‘Apply a single coat of solvent-borne inorganic zinc according to AS 4848.1’

Again, this covers surface preparation and inspection so these do not have to be separately specified.
Although the standard requires the product to meet the requirements of AS 3750.15 Type 4 which covers
properties such as minimum zinc content, acceptable proprietary products would normally be listed. Some
coating suppliers provide cheaper, low zinc products which are acceptable for interior and mild
environments, but should be avoided in marine environments.

Table 3: Inorganic zinc silicate coating systems

Surface Coating AS/NZS 2312 C4

System
preparation durability (years)
IZS1 Sa2½ 75 µm solvent-borne IZS 5 – 10
IZS2 Sa2½ 75 µm water-borne IZS 15 – 25
IZS3 Sa2½ 125 µm water-borne IZS 25+
AS 4848.1 Sa2½ 100 µm solvent-borne IZS –

6 COLOUR (POLYURETHANE) COATING SYSTEMS

Where colour is required, the most widely specified systems include a top coat of polyurethane, designated
PUR in AS/NZS 2312. Polyurethane provides excellent gloss, colour and durability. Mid coats are based on
epoxies which also have excellent durability, adhesion and toughness, but chalk, so normally require
topcoating. Primers can be zinc-rich, either epoxy zinc or inorganic zinc, or zinc-free epoxy. There are a
number of possible systems, depending on environment, required durability, whether it is maintenance or
new work and whether there are restrictions on blasting or spraying. For most new work, PUR4 consisting of
75 microns of zinc-rich primer, 125 microns of epoxy mid coat and 50 microns polyurethane top coat, is a
widely-specified system, ideal for most environments. Variations to this system are shown in Figure 1,
indicating the sort of decisions that the specifier must make.

STEEL CONSTRUCTION VOLUME 45 NUMBER 1 – DECEMBER 2011 15

 PUR2a* PUR1
PUR2
Sa2½ St2
Sa2½
75 Zinc primer 125 Epoxy mastic
75 Epoxy primer
50 PU 50 PU
50 PU
Maintain
No zinc Can’t blast
Lower cost Lower cost, Two coat Two coat
Two coat No zinc

PUR7 PUR4 PUR6

Sa2½ Maintain
Can’t
Sa2½ Can’t blast, St 2
75 Zinc primer 75 Zinc primer 75 Epoxy mastic
spray Can’t spray
75 HB epoxy 125 HB epoxy No zinc 75 HB epoxy
75 HB PU
50 PU 75 HB PU

No zinc
Higher cost & durability

PUR3
Sa2½
75 Epoxy primer PUR5
125 HB epoxy Sa2½
50 PU 75 Zinc primer
200 HB epoxy
50 PU

Notes: (1) PU = polyurethane

(2) HB = High build
(3) Numbers indicate nominal thickness in microns
(4) * PUR2a is not listed in AS/NZS 2312

Figure 1: Relationship between polyurethane topcoat systems in AS/NZS 2312

Looking at the stages in the various systems:

 Surface preparation and priming: For most new work, the surface would be blast cleaned to
AS 1627.4 [7] Class Sa2½ with a zinc-rich primer. Either inorganic zinc or epoxy zinc could be
specified, but recent findings indicate that, in a multi-coat system, there is little difference between
performance of epoxy zincs and inorganic zincs. As epoxies are easier to apply and top coat, and do
not have curing limitations of inorganic zincs, they would normally be recommended. If use of zinc is
restricted, such as in some refineries or if the environment is acidic, a zinc-free epoxy primer would
be specified, again to 75 microns. Such primers may contain zinc phosphate inhibitive pigment or no
corrosion resistant pigments. If blast cleaning cannot be carried out, hand or power tool cleaning to
ISO 8501-1 [8] St2 is specified. Epoxy mastic is normally applied to a minimum dry film thickness of
125 microns if applied by spray, 75 microns if brush application is required (primers should not be
applied by roller). Epoxy mastic would also be the primer specified for spot repair, even if spot
preparation can be carried out by blast cleaning, as it is likely to be compatible with existing
weathered coatings.

 Mid or intermediate coats: A mid coat is normally applied to build up thickness and ensure good
coverage. Three coats will always provide better protection than two as there is better coverage of
critical areas such as edges and corners. A mid coat of 125 microns of standard epoxy is normally
sufficient, although this can be increased to 200 microns for very severe environments. If spraying
cannot be used, the mid coat would be specified to 75 microns. A mid coat is not required in less
severe environments, for shorter life or to reduce costs.

16 STEEL CONSTRUCTION VOLUME 45 NUMBER 1 – DECEMBER 2011

 Top coats: A thin top coat of polyurethane is applied to provide colour and gloss retention as epoxies
exposed to atmospheric environments tend to chalk. The top coat is normally specified as 50 microns,
but for some colours a second coat is required for opacity. Where spraying is not possible, high build
polyurethanes which can be applied up to 75 microns by brush or roller are preferred.

Table 4 lists the polyurethane systems and gives relative durability of each. Generally, for best durability,
blasting rather than hand or power tool cleaning should be used and three coat systems are better than two
coat systems. Although not indicated by the durability figures, zinc-rich primers provide far better protection
to edges and damaged areas and should be specified wherever possible in atmospheric applications.

Table 4: Polyurethane topcoat systems

Ref No. Surface First coat Second coat Third coat Total C4
prepara- thickness Durability
ation (µm) (years)
PUR5 Sa2½ 75 µm zinc primer 200 µm high build epoxy 50 µm polyurethane 325 15 – 25
Excellent durability, colour and gloss. Requires blasting and spray application.
PUR4 Sa2½ 75 µm zinc primer 125 µm high build epoxy 50 µm polyurethane 250 10 – 15
Very good durability, colour and gloss. Requires blasting and spray application.
PUR3 Sa2½ 75 µm epoxy primer 125 µm high build epoxy 50 µm polyurethane 250 10 – 15
Non zinc primer for acidic conditions, or restrictions on zinc. Requires blasting and spray application.
PUR7 Sa2½ 75 µm zinc primer 75 µm HB epoxy 75 µm HB polyurethane 225 5 – 10
Similar to PUR4 but for brush/ roller application. For new work or where full removal of existing coating is
required.
PUR6 St2 75 µm spot epoxy 75 µm HB epoxy 75 µm HB polyurethane 225 2–5
mastic
For repair of above systems. Brush or roller application. Mid coat could be epoxy mastic.
PUR2a* Sa2½ 75 µm zinc primer 50 µm polyurethane 125 –
Lower durability version of PUR4. *Not listed in AS/NZS 2312
PUR2 Sa2½ 75 µm epoxy primer 50 µm polyurethane 125 5 – 10
Lower durability version of PUR3.
PUR1 St2 125 µm epoxy mastic 50 µm polyurethane 175 2–5
For repair of above systems, no blasting but spraying allowed.

7 ALTERNATIVE COLOUR COATING SYSTEMS

Polyurethane top coat systems are widely specified and used, and have shown excellent performance over
many years. One problem with polyurethane is that, during application, free isocyanate in the curing agent
is a hazardous material, and painters must be careful to minimise exposure. There is no free isocyanate in
cured product and such coatings have no known hazard once the coating is cured. The industry is well
aware of the OH&S issues and with proper ventilation and the correct use of personal protective equipment,
such coatings can be safely applied. However, health concerns have led to a desire for safer coatings.

Catalysed or two-pack acrylics were introduced in the 1980s as an alternative isocyanate-free coating and
became popular in Australia. However, their long term performance has been disappointing, showing
reduced durability and greater chalking than the polyurethane equivalents. Furthermore, they are difficult to
apply with problems such as very fast drying (although slow curing) and issues with intercoat adhesion.
Most of the polyurethane systems described above have catalysed acrylic equivalents in AS/NZS 2312 (the
ACC systems) but there is little reason to consider them.

The latest top coat technology is the polysiloxane coating, which appears to have even better durability and
gloss retention than polyurethanes. However, as a new coating, they do not have the long-term experience
of the polyurethanes and are more expensive. AS/NZS 2312 only lists one polysiloxane system, noting its
reduced durability because of limited practical experience. It is a two coat system with a polysiloxane top
coat of 125 microns over 75 microns of zinc rich primer. However, coating suppliers now recommend that
this product simply replace polyurethane as a 50 or 75 micron coating in a system such as PUR4 or PUR5.

STEEL CONSTRUCTION VOLUME 45 NUMBER 1 – DECEMBER 2011 17

Accelerated testing suggests such systems should give better durability and gloss retention than the
polyurethane equivalents.

AS/NZS 2312 also lists single pack alkyd (ALK) and water-borne acrylic latex (ACL) systems. These are
easy to apply, relatively cheap and come in a wide range of colours. However, their durability is
considerably reduced compared with the above systems, and they are rarely specified for structural
steelwork except in mild environments. A single coat of alkyd primer (ALK1) may be all that is required for
internal steel beams which are never exposed to the weather. One system which does have good durability
is a single coat of acrylic latex over 75 microns of water-based inorganic zinc silicate over a blast cleaned
surface (ACL2). ACL2 does require 2 coats, but one is usually sufficient unless colour has poor opacity.
Note this system has lower durability than 75 microns of water-based inorganic zinc by itself (IZS2). The top
coat is purely for decorative purposes and actually inhibits the long term protection that can be achieved by
uncoated inorganic zincs. This is a water-based system so can meet the low Volatile Organic Compound
(VOC) requirements of ‘Green Star’ buildings without compromising durability. However, it can be difficult to
apply and requires low humidity and windy conditions for proper curing.

Although epoxies chalk and discolour with exposure to UV, they can be used without a top coat, or indeed
as a top coat where colour and gloss retention are not critical. They have ease of application, ease of
maintenance and good economy as well as good durability. High build epoxies applied up to 200 microns or
more over 75 microns of zinc-rich (EHB4) or zinc-free primer (EHB3) over blast cleaned steel can provide
an economic coating system with good durability. The ultimate epoxy atmospheric systems use micaceous
iron oxide (MIO) pigment in the top or intermediate coat or both. This flaky pigment adds to moisture
resistance, provides additional protection against UV light and gives a lustrous metallic finish, at additional
cost. EHB6 is a two-coat MIO epoxy systems with very good durability. It should be stressed that, even
where gloss, appearance and colour retention are not critical requirements, polyurethane systems are often
specified as they hold less dirt, are easier to clean and do not lose thickness from chalking.

The AS/NZS 2312 systems covered in this section are summarised in Table 5.

Table 5: Other Recommended AS/NZS 2312 Colour Paint Systems

Ref No. Surface First coat Second coat Third coat Total C4
prepar- thickness Durability
ation (µm) (years)
ALK1 St2 40 µm alkyd primer 40 NR
Simple system for use in a non corrosive environment.
ALC2 Sa2½ 75 µm WB IZS primer 40 µm acrylic latex 40 µm acrylic latex 155 5 – 10
Water based system with reasonable durability. Requires blasting and spraying.
EHB3 Sa2½ 75 µm epoxy primer or 200 µm high build epoxy 275 10 – 15
EHB4 zinc primer
High durability, two coat system where appearance not critical. Requires blasting and spraying.
EHB6 Sa2½ 75 µm zinc primer 125 µm epoxy MIO 125 µm epoxy MIO 325 10 – 25
Very high durability system where a MIO finish is acceptable. Requires blasting and spraying.

Notes: (1) NR = Not recommended

(2) WB IZS = Water-borne inorganic zinc silicate.

8 SURFACE PREPARATION
Selection of the optimum coating system is crucial, but the specification must make the surface preparation
requirements clear, especially when blast cleaning is required. A typical specification clause for blast
cleaning is along the lines of:

‘The surface shall be blast cleaned with steel grit or garnet to AS 1627 Part 4 Class Sa2½ with an
angular profile between 40 microns and 75 microns, as measured by replica tape (Method A in
AS/NZS 3894 Part 5).’

18 STEEL CONSTRUCTION VOLUME 45 NUMBER 1 – DECEMBER 2011

Such a clause covers two main requirements: the visual cleanliness and the surface profile (or anchor
pattern). Issues of concern to the specifier include:

 Blast cleaning for atmospheric work is normally specified to Class Sa2½, sometimes called “near
white”. This is almost completely clean but a few stains of adherent contamination are allowed. These
do not interfere with coating adhesion or durability. A completely clean surface (Class Sa3 or white
metal) is normally only required for critical applications such as tank or pipeline linings, underground
or underwater structures or similar environments. A lesser standard of cleaning, Class Sa2 leaves
quite a bit of contamination and may be suitable for mild environments and less exacting coatings.
The manufacturer’s data sheet will give cleanliness requirements, but Class Sa2½ should be
specified, even if Sa2 is permitted. However, never specify a lesser standard than permitted by the
manufacturer. ISO 8501-1 also contains descriptions of the classes of blast and is sometimes used in
specifications.

 The clause limits abrasives to steel grit or garnet. Steel grit is only used in shops where it is cleaned
and recycled. Garnet can be used in the field as well as in shops. There are a number of other
abrasives available, but some, such as some slag, have environmental and OH&S issues as they may
contain heavy metals. Sand as an abrasive was banned in Australia many years ago as it can cause
silicosis, but is still used in many other countries. Garnet and steel grit are both effective, low dust
abrasives and will provide a clean, rough surface with minimal environmental impact.

 Surface profile is a measure of the height of the peaks to the valleys of the blasted surface. A profile
range, very roughly related to coating thickness is required for most heavy duty coatings. The profile
must be jagged or angular for optimum adhesion, and rounded profile produced by shot is not
normally acceptable. If not given in the data sheet, Table 6 shows typical profiles for atmospheric
coating systems. There are a number of methods for measuring profile, but replica tape is most
accurate and the only method that provides a hard copy for QA purposes. Profile is not related to
cleanliness, but is not specified for lesser cleanliness grades such as hand or power tool cleaned
surfaces.

Table 6: Typical profile requirements for different primer coating types

Nominal DFT Recommended

Primer coating type
(microns) profile (microns)
Epoxy (zinc) primer 75 to 100 30 – 50
Inorganic Zinc 75 to 125 30 – 50
High Build Epoxy 150 to 250 50 – 75

Limits on non visible contamination, such as salts, are sometimes specified. However, this is normally only
required for maintenance work in severe environments where salt contamination has been a problem. It is
not normally required for new work. There are conflicts in the industry over acceptable levels, methods of
test and the effect of subsequent coatings. Section 4.2.6 of [1] provides a summary of some of the issues.

Clauses on removal of oil, grease and related contamination, removal of fabrication defects, removal of dust
after blasting and the time limit between blasting and priming will also require specification.

9 APPLICATION, INSPECTION AND QUALITY ASSURANCE

The best coating system is wasted if it is not properly applied. Most of the high durability coating systems
described above must be carefully applied by skilled applicators to properly prepared surfaces. In some
ways, surface preparation and application are more critical than the coatings used. A full discussion of items
requiring specification is outside the scope of this paper, but three important aspects will be reviewed.

‘Storage, handling, mixing, thinning and application of all materials shall be in accordance with the
manufacturer’s recommendations. All coatings shall be used prior to expiration of shelf life, and
catalysed coatings shall be used prior to expiration of pot life.’

STEEL CONSTRUCTION VOLUME 45 NUMBER 1 – DECEMBER 2011 19

A clause such as this means that you do not have to specify all these requirements. The manufacturer’s
technical data sheet (TDS) then becomes part of the specification. You may wish to override some TDS
requirements, for example you may require that the paint is sprayed for good finish, whereas the data sheet
may allow any method of application. Data sheets rarely specify the requirement for stripe coats on edges,
welds and other critical regions. They may not include all temperature and humidity restrictions that are
desirable. However, a clause such as this is normally a mandatory part of any coating specification.

‘Preference shall be given to contractors who are registered with the Painting Contractor’s
Certification Program (PCCP).’

Good quality coating contractors are essential for any coating work, but making sure such contractors are
selected is not easy. Good contractors will have trained workers, well-maintained equipment, good QA
processes and satisfied customers, among many other qualities. Checking on these is not easy. The
Painting Contractor Certification Program (PCCP) [9] is a scheme that accredits contractors who can
demonstrate that they can meet certain minimum performance requirements. There are five classes of
certification. Classes 1 to 4 cover application of coatings of increasing complexity in a shop or on site. Class
5 covers removal of hazardous material such as lead paint, and such certification is normally mandatory for
such work.

‘No surface preparation or coating application shall take place if the relative humidity is greater than
85%, the surface temperature less than three degrees above the dew point or under other
unfavourable weather conditions, unless the work is well protected from such conditions. In addition,
the coating shall not be applied if the ambient temperature is below 10° C or surface temperature
above 45° C.’

Temperature, humidity and dew point must be monitored and controlled during surface preparation and
coating application. A freshly blasted surface may rust if exposed to high humidity or dew point conditions.
A freshly painted surface will more often than not be damaged by the same conditions. In addition, most
paints will dry too slowly or too quickly if applied at temperatures which are too low or too high. Restrictions
such as these would normally be included in most specifications. The manufacturer’s data sheet should give
this information and Table 8.1 in [1] provides useful information.

10 CONCLUSIONS
Structural steel will usually require a protective coating system if it is to provide years of good service. This
paper has provided:

 Some of the factors that must be considered when selecting a protective coating system
 Some recommended coating systems from AS/NZS 2312
 Some typical clauses from a protective coating specification.

Following such advice should enable steel structures to remain corrosion-free for many years.

11 REFERENCES
[1] Standards Australia/Standards New Zealand, AS/NZS 2312:2002, ‘Guide to the protection of
structural steel against atmospheric corrosion by the use of protective coatings’.

[2] Francis, R.A. 1996, ‘An update on the corrosion process and protection of structural steelwork’, Steel
Construction, vol. 30, no. 3, pp. 2-11.

[3] Standards Australia, AS 4312—2008, ‘Atmospheric corrosivity zones in Australia’.

[4] Standards Australia/Standards New Zealand, AS/NZS 4680:2006, ‘Hot-dip galvanized (zinc) coatings
on fabricated ferrous articles’.

[5] Francis, R.A. 1998, ‘Inorganic zinc or galvanizing: Choosing the ideal corrosion protection for
structural steel’, Steel Construction, vol. 32, no. 3, pp. 2-10.

20 STEEL CONSTRUCTION VOLUME 45 NUMBER 1 – DECEMBER 2011

[6] Standards Australia, AS 4848.1—2006, ‘Application specifications for coating systems, Part 1: Single
coat inorganic (ethyl) zinc silicate—Solvent-borne’.

[7] Standards Australia, AS 1627.4—2005, ‘Metal finishing—Preparation and pretreatment of surfaces—

Abrasive blast cleaning of steel’.

[8] International Standards Organization, ISO 8501-1:2007, ‘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’.

[9] http://www.apas.gov.au/pccp/

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