Transcript
Jotun TSS Academy Jotun TSS Academy
1 Day Paint School
Welcome to Jotun 1 Day Paint School PT. Wijaya Karya, 26 June 2017
By : Mochamad Rizal Efe ndi Technical Training - TSS Performance Coatings PT. Jotun Indonesia Jotun Paint School
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Jotun TSS Academy
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1 Day Paint School 1. Introduction of Jotun
2. 3. 4. 5. 6. 7. 8.
Why and what do we paint? Paint technology Corrosion Surface pre-treatment Application Health and Safety Green step
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Jotun HQ Norway
The Global Company • • • •
Established since 1926 Head office in Sandefjord, Norway Turnover 2,1 bill USD (2015) More then 9800 employees
• 71 companies in 45 countries, Facilities in 19 countries, represented in morewith then36 90Production countries in the world • Regional Lab and R&D in UEA,Norway,USA,China,S.Korea,and Malaysia Jotun Paint School
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Facts and figures • Among the 20 largest paint companies in the world • 36 production facilities in 19 countries • 71 companies in 45 countries • Represented in more than 90 countries around the world • More than 9.400 employees worldwide • Head office in Sandefjord, Norway
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PT. Jotun Indonesia • • • • • • • • •
Sales in Indonesia since 1985, First factory in Indonesia 1996, Expansion production factory in MM2100 Bekasi 2005 Expansion Jotun Distribution Center in 2015 No 1 in Marine segment No 1 in Protective segment No 1 in Powder Coating Segment Top 3 in Decorative segment Branch Offices in Surabaya, Pekanbaru, Balikpapan,
Makasar and Batam • Medan, Computerized tinting machines ( Multicolor) in more than 700 shops
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PT. Jotun Indonesia
• Our current production capacity is up to 40million liters (mix Solvent and Water base) per year • We had build new warehouse, called Jotun Distribution Center with capacity up to 10.000 pallets • Multi Color Tinting Machine capacity of 1200 cans/day (mix Solvent and Water Base)
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Jotun TSS Academy 6 Branches :
Jotun Paint School
• Medan • Pekanbaru • Batam
1 Day Paint School • Palembang • Surabaya • Balikpapan
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• Makassar
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More then 700 Jotun Multicolor Centre and 50 Multi Color Industry in Indonesia (Dealers) Jotun Paint School
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Decorativep aints
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Marinecoatings
Protectivec oatings
Use
Application
Brands/ Products
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Powderc oatings
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Jotun Customers
Red HPI Box Customers Customers
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Customers already signed up for HPS • Jotun’s Hull Performance Solutions was launched early 2011 • Numerous sophisticated customers have applied or contracted one or more vessels with HPS
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Protective Coatings
HP I
Mining
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Energy
HeavyIndustry
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Infrastructure
Offshore
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Worldwide Project References
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Cruiseship FREEDOM OF THE SEA
Jotun Global Marine references Jotun Paint School
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SSP PIRANEMA (Photo Sevan Marine)
HORDALAND BRIDGE, Norway
Jotun Global P rotective references Jotun Paint School
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DELTA PROJECT, NEDHERLAND
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TIANJIN PORT, CHINA
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WEST TOWER, GUANGZHOU, CHINA
DUBAI METRO, U.A.E.
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BURJ KHALIFA, DUBAI, U.A.E.
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UNION PROPERTIES TOWER, DUBAI, U.A.E.
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Jotun Decorative global references Jotun Paint School
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BAHRAIN WORLD TRADE CENTRE, BAHRAIN
ATLANTIS THE PALM, DUBAI, U.A.E.
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Petronas – Twin Tower Kuala Lumpur.
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Burj Dubai
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THE EIFFEL TOWER
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Indonesia Project References
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BOGASARI
OIL TANKER, HUMPUSS
Indonesian Marine references Jotun Paint School
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Conoco Phillips, Natuna Sea
FSO Arco Ardjuna PHE ONWJ
BP TANGG UH LNG
Indonesian Protective Project References
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PLTU PLTGU Muara Karang Expansion 600MW
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Tanjung Jati B 3&4 2x 660 MW
PLTU Lontar 3x315 MW
And many more in acceleration program 10.000 MW phase 1 and 2 and up coming 35.000 MW
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PLTGU Tanjung Priok 1x 740 MW
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PLTU Paiton III 1x850 MW
PLTU Rembang 2x316 MW
And many more in acceleration program 10.000 MW phase 1 and 2 and up coming 35.000 MW
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Regatta
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Sea World
Grand Indonesia
Indonesian Decorative references Jotun Paint School
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Juanda Airport, Surabaya
Jotun Single Source Solution Jotun Paint School
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Training and Tools • Jotun Paint School • Coating Academy • JAMP (Jotun Assets Management Program)
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A Wide Pool of Qualified Coating Advisors
PT. Jotun Indonesia currently supported by 60 Coating Advisor for Performance Coating Segment certified as Inspector by NACE, SSPC and FROSIO
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1 Day Paint School 1. 2. 3. 4. 5. 6. 7. 8.
Introduction Why and whof atJotun do we p aint Paint technology Corrosion and Cathodic Protection Surface preparation Application Health and Safety Green step
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Mengapa Cat Dip erlukan? Ada dua alasan utama untuk mengecat : Untuk melindungi properti dan untuk alasan kosmetik Hal ini secara finansial sangat penting untuk melindungi struktur terhadap korosi. Sebuah sistem cat yang baik akan menjadi metode biaya-efektif untuk melindungi struktur: Umur struktur diperpanjang, biaya pemeliharaan berkurang dan resiko kecelakaan yang mempengaruhi orang-orang dan lingkungan berkurang.
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Why do we paint? Safety and economy: The industry wishes to preserve their investments to avoid accidents. If it was cheaper to let constructions corrode, and simply build new ones when the safety limit was passed, we would have seen many more rusty plants, ships and platforms
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What are differences between below terms? Coating Any layer that covering /shielding construction from environment
Painting Liquid , applied in liquid condition, cured as solid coating
Lining Thick or very thick coating, used in submerged condition
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What kind of coating could protect this construction
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1 Day Paint School 1. of do Jotun 2. Introduction Why and what we paint 3 . Co r r o s io n
4. 5. 6. 7. 8.
Paint technology Surface preparation Application Health and Safety Green step
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Definition of corrosion
Corrosion is a chemical reaction between a metal and its surrounding environment
under the formation of corrosion products
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Pengertian Korosi
Logam (Metal)
Korosi (Corrosion)
Karat (Rust)
• Karat/Rust hanya bisa dihilangkan dengan cara mekanik, dengan dibakar, digerinda, di-wire brush atau dengan blasting • Coating atau cat hanya mencegah proses korosi tidak terjadi
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Parameters influencing the corrosion speed • • • •
Humidity Temperature Concentration of salts Amount of air pollution, including acid rain, soot and dust particles
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Corrosion Protection by coatings • Barrier effect – Creates a barrier that stops the ionic current (i.e. corrosion current) Example: epoxy-coatings
• Inhibitive/passivizing effect – The coating passivizes the steel surface Example: coatings mixed with anti corrosive pigments (lead, chromates or phosphates)
• Cathodic effect – The coating itself acts as an anode (galvanic effect) Example: zinc rich coatings
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Barrier effect Most paints protect the steel by forming a barrier to the surrounding environment • A barrier will increase the resistance in the galvanic circle • A thick barrier will give better protection than a thin
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Jotun Barrier Effect with Glass Flake Technology Thickness 1500
Baltoflake Marathon 1000GF
Chemflake for internal tank with excellent chemical resistant
600 500 400 300
Marathon Jotamastic 90 GF
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A thick barrier will give better protection than a thin
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Inhibitor effect In inhibitive coatings, moisture may penetrate to reach the inhibitive primer where the reactive are activated, which in turnpigments passivizes the metal substrate at the coating/metal interface Example of Inhibitive pigments: • Red Lead (not used) • Lead/zinc chromate (not used) • Zinc phosphate Product with inhibitive pigments are not suited for immersed substrates Jotun Paint School
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Cathodic effect • Some paints offer the same cathodic protection effect as sacrificial anodes • A zinc-rich primer reacts to protect the steel substrate when the topcoat is damaged • The CP type of paints is not an inert paint film as the barrier coatings • The paints contain active, metallic pigments • The reactcreates with moisture and pigments the steel and a calcareous deposit on bare spots of the steel substrate Jotun Paint School
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Zinc Rich Paints
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(Cathodic Protection)
Zinc Epoxy (Organic Zinc)
Zinc Et hil Silicate (In Organic Zinc)
• Chemically curing • Good adhesion & mechanical strength • May be recoated with most types of paint, except Alkyd • Dry heat resistant up to 120ºC • Film thickness: 25 – 125 m • Not acid- and alkaline resistant (Resistant between pH 5-9)
• Very good solvent resistance • Very high heat resistance (max 400ºC) • Very high mechanical strength • Max. DFT: 100 m At higher DFT tendency of mud-cracking or checking Jotun Zinc Ethil Silicate Product
Jotun Zinc Epoxy Product
Resist 78 , Resist 86,
Barrier 77, Barrier 80, Barrier 90
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1 Day Paint School 1. of do Jotun 2. Introduction Why and what we paint 3. Corrosion 4. Paint tec hnology
5. 6. 7. 8.
Surface preparation Application Health and Safety Green step
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Composition of paints Paints
Binder Natural Resin Drying oil Coal Tar Nitrocellulose Synthetic Resin Alkyd CR Epoxy Polyester Polyurethane Silicate Vinyl Jotun Paint School
Pigments
Solvents
Additives
Colouring
Hydro carbons
Wetting agent
Extender
Ketones
Anti-settling
Inhibitive pigm.
Esters
Dryer
Cathodically protective
Ethers
Anti-skinner
Alcohols
Plasticiser
Biocides
Water 61
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The properties of a paint will be decided by the binder • Three generic type of binders are applied to test panels: Alkyd, epoxy and polyurethane • Exposed to sunlight, water chemicals • Different properties are demonstrated. • Important to select the correct purposetype of paint for the
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Solid Content
( illustration only )
Solvents, 20% Additives, 8%
Solvents, 50%
Pigments, 24% Additives, 5% Pigments, 15%
Binder, 48%
Binder, 30% Solid content: 50%
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Solid content: 80%
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Drying / Curing Mechanism • The properties of a paint film is closely related to how the binder dries or cures • The three most common drying / curing mechanisms are: 1. Solvent evaporation (physically drying) 2. Reaction with oxygen in the air (oxidation) 3. Chemical reaction between resin and hardener
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Drying / Curing Mechanism Physically drying
Oxidative drying
Chemically curing
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• Alkyd
• Epoxy (solvent and water borne) • Zinc epoxy • Epoxy Mastic • Polyurethane • 2-pack Acrylic • Zinc Silicate • Polysiloxane • Polyester
Chlorinated rubber Vinyl Acrylic Silicone Bitumen Tar Antifoulings
• Vinylester
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Jotun Product Jotun Physically drying • •
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Jotun Chemically curing
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Chemically curing binder? Harus Memperhatikan hal penting berikut : 1. Pastikan umur pakai (Self Life) cat masih bagus. 2. Pastikan Comp A bertemu Comp B yang tepat 3. Pastikan mixing ra tio Comp A : Comp B 4. Gunakan mechanical agitator (mixer) 5. Applikasikan sebelum masa reaksi (pot life) habis 6. Diamkan selama waktu induction time
Untuk bereaksi awal 7. Lakukan pengecatan ulang sesuai waktu recoating intervals
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Chemically curing ?
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1 Day Paint School 1. 2. 3. 4.
Introduction of do Jotun Why and what we paint Paint technology Corrosion
5. Surface preparation
6. Application 7. Health and Safety 8. Green step
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Penyebab Utama Kegagalan Pengecatan Penyebab utama kerusakan cat/coating adalah : • Persiapan permukaan yang kurang bagus • Aplikasi pengecatan yang kurang baik Meskipun menggunakan cat/coating dengan kualitas tinggi, tetapi jika persiapan permukaan dan cara aplikasinya salah maka performa cat tersebut tidak akan bagus. Jotun Paint School
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Persiapan permukaan terdiri dari :
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(Surface Steel Preparation)
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1. Removing Sharp Edges
Cross section of painted steel with a sharp edge
• Paint applied with spray • edge Forms inferior coating thickness around the Sharp edge, low DFT Steel Paint
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1. Removing Sharp Edges
Cross section of painted steel with well rounded edge
• Paint applied by spray • Forms even thickness around the edge
Paint
Steel
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1. Removing Sharp Edges
Pre-surface condition • Visual inspection should be conducted on all steel items prior to surface preparation • This will determine the level of pre-preparation requirements such as grinding, filling etc.
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1. Removing Sharp Edges
Steel preparation prior to cleaning: Laminations, undercuts, welding seams
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1. Removing Sharp Edges
Steel preparation: Edges and weld spatters
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1. Removing Sharp Edges
Bad welding and non-removal of spatters
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1. Removing Sharp Edges
Early corrosion on sharp edge and spot welds
• Paint has newly been applied • Exposed to wind and weather for approximately 2 weeks
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1. Removing Sharp Edges
Rough welding seam at internal water tank
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1. Removing Sharp Edges
Paint unable to cover intermittent area
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2. Removing Dirt, Oil and Grease
Cleaning with detergent
• Apply the cleaner from below and upwards • Work systematically on all surfaces • Let the cleaner react, normally 1-5 minutes • Wash off from below and upwards • Final rinse from above and down Jotun Paint School
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2. Removing Dirt, Oil and Grease
Washing with detergent, rinse with fresh water
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3. Washing with fresh water
Osmotic blistering Osmotic blistering occurs when paint has been applied on a surface contaminated with water soluble salts
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3. Washing with fresh water
Formation of blisters as a function of salt concentration on substrate (1 of 2) Salt: 60 mg/ m Film: 150 microns
Salt: 0 mg/ m Film: 150 microns
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3. Washing with fresh water
Formation of blisters as a function of salt concentration on substrate (1 of 2)
Salt: 100 mg/ m Film: 150 microns
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Salt: 200 mg/m Film: 150 microns
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3. Washing with fresh water
Welding smoke is water soluble and can only be removed by water
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3. Washing with fresh water
Blisters close to weld • Welding is water soluble and will create osmotic blisteringsmoke if not removed • Galvanic difference between steel plate and weld may aggravate the attack
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4. Surface Treatment
Steel Preparation Standards
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4. Surface Treatment
ISO 8501-1
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4. Surface Treatment
Wire Brush • Wire brushing is relatively easy to use for maintenance on previously coated surfaces • Wire brushing will not, however, feather edge existing coatings • Wire brushing will not remove mill scale
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4. Surface Treatment
Hand wire brushed surfaces
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4. Surface Treatment
Disc sanding and grinding Disking and grinding is a similar process to mechanical wire-brush There is a danger of polishing the surface or gouging the steel or substrate Suitable for feathering of edges to intact paint after spot repair
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4. Surface Treatment
Polished erection and welds
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4. Surface Treatment
Abrasive blast cleaning • • • •
Gives a good surface profile Surface stays dry High production rate Several blasting standards can be achieved
• Does not remove oil, grease and salts from the substrate • Creates dust
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4. Surface Treatment
Abrasive blast cleaning Abrasive is projected under high pressures onto the surface which removes: – Old coatings, surface ready for new coatings to be applied – Mill scale and rust
Surface profile is created
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4. Surface Treatment
Blasting standard ISO 8501-1
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4. Surface Treatment
Blasting test area
• It may be difficult to evaluate a surface according to a standard • Test areas are often put up on the site to make sure that the actual standard specified is followed • Agreement before the work starts will help to avoid later disagreements
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Types of abrasives Abrasives used in the abrasive blast cleaning process The main groups are metallic, non-metallic and specialist products
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Abrasives and blasting profile
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Abrasives and blasting profile Abrasive blast cleaning increases the surface area of the steel The profile will differ depending on type of abrasive: shot, grit and also size The surface profile can determine the adhesion value of a coating and is a very important aspect to coatings and corrosion protection Profile comparison ISO 8503-1 Jotun Paint School
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Abrasive spot blasting
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Spot blasting • Blast-cleaning destroys the edges of the intact paint film around the damage • This results in poor adhesion • Damaged paint edges must be feathered prior to application of the new paint
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Kerusakan akibat spot blasting • Edges has not been feathered prior to application of the paint • The edges are weak points in the paint film • Corrosion attack initiates on such areas
CD 4934 no. 80
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1 Day Paint School 1. 2. 3. 4. 5.
Introduction of do Jotun Why and what we paint Paint technology Corrosion Surface preparation
6. Application
7. Health and Safety 8. Green step
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Application • • • • •
Good work practice Brush Roller Stripe-coating Airless spray
Cleanliness and good housekeeping before, during and after application are one of the most important factors to have a good result Jotun Paint School
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Important to open the tin correctly ! • Remove all loose particles from the lid • Loosen the lid • Lift the lid away from the tin in such a manner that the contaminants do not fall into the paint
Application: Open_dirtytin1
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Chemically curing binder? Harus Memperhatikan hal penting berikut : 1. Pastikan umur pakai (Self Life) cat masih bagus. 2. Pastikan Comp A bertemu Comp B yang tepat 3. Pastikan mixing ra tio Comp A : Comp B 4. Gunakan mechanical agitator (mixer) 5. Applikasikan sebelum masa reaksi (pot life) habis 6. Diamkan selama waktu induction time
Untuk bereaksi awal 7. Lakukan pengecatan ulang sesuai waktu recoating intervals
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Chemically curing ?
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Tools for mixing of paints • Always use mechanical agitator to ensure proper mixing of both one and two pack products • Proper mixing will not be achieved by a stick • A wooden stick may also contain dirt and loose parts that may contaminate the paint and clog the spray equipment
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Mixing two component paint • Component B is poured into the component A (base) • Component B may have a high viscosity. Make sure to use all of it • Ensure correct mixing ratio • Use mechanical agitator
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Consequence of inferior mixing: • To the right: Correct mixing and mixing ratio. • To the left: Insufficient mixing and / or incorrect mixing ratio.
Cd-4930-60
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What factors influence the drying / curing process ?
• • • • • •
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Relative humidity, % Ventilation Temperature Film thickness Number of coats Evaporation speed of solvents
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Parameter kondisi cuaca yang baik untuk coating ?
• Relative humidity di bawah 85% • Suhu permukaan konstruksi 10˚C -40˚C • Suhu permukaan konstruksi minimum 3˚C diatas Dew Points
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Application by brush • The brush pushes the coating into the substrate assisting with wetting adhesionand the subsequent • Certain coatings such as epoxy mastics are specifically formulated for this type of application • Always check the product data sheets etc. for details on application
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Application by brush Brush vs Airless Spray Application • Brush application may often achieve in the range of 50 microns dry film thickness • Airless spray can apply coatings at extremely high dry film thickness • Brush much slower than airless spray
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Application by roller • Type of roller to use must be selected on what to paint and the type of paint to use
• Not recommended to use roller on the 1st coat
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Application by roller Roller Application vs Spray Application • The use of rollers to apply a coating will result in a thinner dry film compared to spray application • The dry film thickness with roller application will be much lower than airless spray application. High solids and high performance coatings are normally spray applied • Additional coats may have to be applied to meet the desired dry film thickness while applying coatings by roller application
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Stripe coating Stripe coating is defined as an additional coating applied to selected areas of a substrate or surface The extent of stripe coating that may be required on a structural steel member with lots of edges etc.
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Stripe coating • A paint brush is an excellent tool for stripe coating • Wet the substrate properly • Works the paint well into the substrate • Welds, edges and notches must be stripe coated
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Stripe coating • Many holidays • The paint must be worked properly into the rough substrate using several strokes with the paint brush
CdCd-4934 -49344934-97 -97
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Stripe coating Stripe coating between first and second full coat: – – – – –
Weld seams Edges Bulbs Angels Notches etc.
Note the contrasting colours Excellent work
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Application by Airless spray • Airless spray painting is particularly suitable for anticorrosive and high coatings applied to performance large structures such as ships, bridges, tanks etc. • This illustration demonstrates a coating applicator applying a high build coating to structural steelwork • Airless spray is by far the most popular form of coating application for heavy duty industries
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Application by Airless spray • This animation demonstrates the use of an airless spray gun • The paint, coloured in red, is forced through the gun at high pressure and through the tip where it is atomized and pushed onto the surface • Although the process is called airless, the process requires compressed air to work the equipment • Electric type airless spray equipment are also available
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Airless spray equipment • PUMP - The pump pressurizes the paint • POWER - A power source is required • HOSE - High pressure hoses. • CONTAINER - Holds the material • GUN - Atomizes and directs the paint onto the surface It is important that only genuine parts are used for the equipment. Never purchase cheap replacements or spares
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Airless spray Jotacote UHB
Jotamastic 90GF
Jotamastic 90
Hardtop AX
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Airless spray
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2”
2”
10” or 25,4 cm Jotun Paint School
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Rules when spraying
distance between spray gun and • Correct substrate: (30-60 cm)
• Correct angel (90°) • Overlapping (50% or cross application)
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Airless spray • Keep the spray gun at a correct distance from the object • A correct distance ensures a good, homogenous paint film • Too great a distance gives poor float and an uneven surface • Trying to reach areas far away will give an uneven film thickness • Shadows are created behind welds • Waving with the gun results in an unacceptable spray pattern
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Application of a Tank
• Pre-treatment Sa 2 ½ • Paint system: Glass flake reinforced polyester • Good application technique
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Application technique combination of tools • Some areas are difficult to reach with a spray gun • Start with the paint brush • Then, use the back roller • Finally, apply the remaining areas with the spray gun
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1 Day Paint School 1. 2. 3. 4. 5. 6.
Introduction of do Jotun Why and what we paint Paint technology Corrosion and Cathodic Protection Surface preparation Application
7. Health and Safety
8. Green step
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Many risks are involved when working with paints Safety
– Explosion and Fire
Health
– Manufacturing and Surface treatment Environment
– Emission to air (VOC) – Emission to water (Maintenance) – Emission to soil (Waste handling)
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HSE Information – SDS 1. Identification of the company
9. Physical and chemical
2. Composition and ingredients 3. Hazard identification
properties 10. Stability and reactivity 11. Toxicological information 12. Ecological information 13. Disposal considerations 14. Transport information 15. Regulatory information 16. Other information
4. First aid measures 5. Fire fighting measures 6. Accidental release measures 7. Handling and storage 8. Exposure control and personal
protection
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Personal Protective Equipment (PPE) General PPE list: • Safety Helmet • Safety Harness (if working in height) • Safety shoes or boots • Protective overalls • Visible jacket • Gloves • Safety glasses or goggles • Ear protectors • Respirator
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Physical risk – High pressure Surface treatment involves equipment with high pressures • Blast cleaning • - Mixture of air and particles • Airless spray application • - Paint
Never point any high pressure unit at another person or at yourself! - This includes pur e air (> 5 bar)! Jotun Paint School
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Inhalation of Solvents The most dangerous hazard
• Solvents will be transported by the blood stream to internal organs of the body • Amount absorbed depends on: Type of solvent, period of exposure, concentration and work load • Will cause damage to: Brain, nervous system, respiratory system, liver, kidneys and reproductive systems
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Chemical risk – Skin contact Chemicals can be absorbed through both intact skin and damaged skin Typical health effects: – Irritation • Reddening, stinging sensation etc.
– Corrosion • Tissue damage; eyes, skin, respiratory system
– Sensitisation • Reddening, blisters etc.
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Flammability - Solvents Solvents are heavier than air: • A fire may start in lower areas or compartments • Hot work may ignite the solvents • A fire or an explosion may be initiated • Ignorant personnel below can be affected
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Precautions When Painting in Confined Spaces. • • • • • • • •
Ensure good ventilation Exhaust points for fumes / solvents must be close to the bottom Start application from the bottom and up Always use non-sparking tools Use only approved light and electrical equipment Use fresh air masks Safety lines Sufficient rest periods
Never smoke or use naked flames !
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Explosion Typical explosion range fo r pa int solvents: 1 vol.% (10.000 ppm) - 8 vol.% (80.000 ppm)
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General precautions Good housekeeping is very important for avoiding accidents!
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1 Day Paint School 1. 2. 3. 4. 5. 6. 7. 8.
Introduction of do Jotun Why and what we paint Paint technology Paint production Corrosion Surface preparation Application Health and Safety
9. Green step
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Green step
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Green Step • VOC emission
• Hazardous materiel
These substances can give chronic health effects and contribute to high levels of ozone and smog at ground level, and they are therefore regulated in many countries
Hazardous raw materials are to be replaced by less hazardous alternatives. New raw materials must not reduce products' overall safety, health and environmental properties
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Green Step • Reducing energy consumption
• Reducing carbon footprint
First and foremost, Jotun's consumption of energy is linked to our facilities, including production and warehouse
The carbon footprint is a measure of the impact our activities have on the environment, and in particular climate change
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Green step • Reducing waste
Our key objectives are Reduce, Reuse and Recycle, to be applied in all our operations, including waste from offices as well as production waste. Reducing and disposing of chemical waste is a major focus area
For more colourful world, we all need to be a littleagreener Jotun Paint School
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