Selecting the most ideal painting system for structural steel fabrications and galvanised steel fabrication is a daunting task in front of the maintenance managers and the chief engineers. It becomes more critical situation when the steel fabrications and the machinery or equipments have to be installed in the most stringent working atmospheres such as coastal areas, highly humid area, nearly salty and saline atmosphere, areas with steam, water vapor, and chemical fumes, places with high operating temperature. For getting the optimum and the best results from a painting system, in terms of long equipment life, highest anti corrosion and the aesthetics, discussing the various aspects of anti corrosion paints products as frequently asked questions:

For which types of steel fabrications and the industries sector, is this painting process recommended?
We recommend this for painting and re-painting of MS & GI structures , fabrications, PEBs, metal buildings, off-shore platforms construction, all rusted and non-rusted steel fabrications, solar power plants, HVAC plants, ready mix plants factory trusses, support structures, tank farms, chimneys, steam, water, chemicals and petro-solvents pipe-lines, columns, I-beams, bridges, dams, transmission towers, telecom signal towers, EOT cranes, formworks and scaffoldings a/c ducts etc.

Which products shall be selected? What basic chemical anti-rust properties such products must have?
The product selected must be safe for workmen, low fuming, non-toxic and readily available. These products must have minimum 12 months of shelf- life and the metal cleaners shall be water based (non flammable). We are sure our premium grade anti corrosion products will be useful. All these products must offer excellent corrosion protection to mild steel fabrications from atmospheric rusting, oxidation and surface chipping corrosion. These chemicals and the paint coatings must have excellent adhesion to the metal or substrate as per recommended indian standard specs.

What is the process sequence to be followed?
The exact sequence to be followed is:
Pre-cleaning
Complete removal of oil and grease, surface rust must be ensured. This can be carried by chemical cleaning, solvent cleaning, sand blasting, sand papering, grinding, mechanical cleaning or any other means. Corrosion, rusting, oxidation, shot blasting or sand blasting or grit blasting are the best methods for surface cleaning.

Total removal of residual water, cleaning of even traces of acidic cleaners, all foreign matters, dust, and dirt from the cleaned surface must be ensured. These traces of impurities can cause hydrogen embrittlement in the microscopic pores of the metallic surface. These impurities promote sub-surface corrosion, after some duration. Trapped hydrogen will try to escape to atmosphere and will rupture the finished paint however; it may be thick and strong. The opened–up areas of paint coating or film on steel now provide nucleus for further rusting.

De-rusting
The chemical de-rusting is easily accomplished by use of rustogel 1406 offered by innovative for all corroded mild steel fabrications and structural steel. These cleaners are based on phosphoric acid, solvent, wetting agents and foaming agents. Being in gel format, the chemical is quite useful for de-rusting; cleaning and maintenance of all heavy steel fabrications in vertical and horizontal positions.

Painting
Innovative Coating Industries recommended products are:
Zinkote 20 GP
Manufactured using 99 per cent pure zinc dust rich paint for highest corrosion resistance, coverage 2 m2 zinc contents in dft – 88-92 per cent – zinc deposit coating – 20-25 offers highest anti corrosion properties over a long period. Confirmation – ASTM A780.

Zinkote 20 Premium
Manufactured using 99 per cent pure zinc flakes rich paint for highest corrosion resistance. Coverage: 2 m2 zinc contents in dft: 88-92 per cent: zinc deposit per spray coating: 20-25 microns. Maximum two coats recommended. Confirms to – ASTM A780.

Is zinc rich paint (for cold galvanising) available in ready to use aerosol spray format for on-site use?
Zinc rich paint is also offered as zinc metal spray (light grey finish) and zinc bright spray (silver bright finish) in 500 ml self spray aerosol spray cans.

What are the advantages of using aerosol sprays?
Zinc metal spray (light grey finish) and zinc bright spray (silver bright finish) offered in 500 Ml self spray aerosol spray cans are most convenient to use. In case of onsite use, it offers very uniform zinc coating film; the aerosol cans are extremely user-friendly and are used at work sites quite often and are quite handy light weight for using at greater heights.

Authored By_

Pradeep Vaidya, CEO, Innovative Coating Industries
MIDC, Pune
Thane: B-7 / 701, Vedant Comples Vartak Nagar Naka: Thane (West) 400606
Mob: 09820181738
Email – puvpromtech@gmail.com
Sonia Vaidya Tech Mktg Executive: Thane
Tel: 022 25883265, Mob – 9819813015
Email – soniavaidya30@gmail.com