MAINTENANCE GUIDE OF THE

ANTICORROSION COATING IN PORT

MACHINERY EQUIPMENTS

Foreword

As to port machinery equipments, the function of anticorrosion

coating is not simply beautiful visually，but also which will protect steel

structures out of natural corrosion. The anticorrosion capability of the

exterior coating has very important effect on assuring the most durability

of port machinery equipments.

ZPMC provide the certified painted production, which is designed

according to the durability and considering the natural corrosion of

coating in the correlative environment conditions provided by buyers.

Reasonable application and coating system can actually assure the

coating of steel structures to possess suitable anticorrosion function and

life. While some undefined factors will dramatically restrict the durability

of anticorrosion coating, such as without repairing coating damages and

cleaning the grease of coating surface in time etc. If exterior hidden

disasters can not be eliminated in time, which will accelerate wearing

down the coating and shorten anticorrosion life. Therefore, users should

strictly execute the maintenance work in the process of using the Port

machinery equipment, assuring the best anticorrosion capability of

coating.

1. General principles

1.1 Scope

This guide is applied to daily maintenance of anticorrosion coating

in the process of using the Port machinery equipments.

2. Standard comparison of coating rust

Rust is corrosion from substrate to surface, as follows is European

scale of degree of rusting for anticorrosive paints standard comparison:

The below table shows rust areas percent according to rust grades:

grades Rust areas percent

Re1 0.05%

Re2 0.5%

Re3 1%

Re4 3%
 Re5 8%

Re6 15~20%

Re7 40~50%

Note: when somewhere rust grade is more than Re4 or the single rust area

is bigger than 0.25 square meters, the owners need to remove the rust and

repair the coating. When the most scale of rust areas of Port machinery

equipment is Re4, owners should remove rust and repair for the whole

machine.

3. Inspection period and content of daily maintenance

3.1 Inspection period

3.1.1 Inspection of coating in warranty period

After delivering the Port machinery equipment, owners should

generally inspect the coating surface of Port machinery equipment every

year.

3.1.2 Inspection of coating after warranty period

In order to assure the continuing effective anticorrosion coating

capability, in the first half of the year of equipment coating warranty

period expiration, owners should invite experts to evaluate anticorrosion

effect for coating of the whole machine, and take corresponding

measurements to assure anticorrosion effect according to evaluation

results. We advise owners to inspect the whole machine surface condition

once half a year after the warranty period.

3.2 Inspection content and measurement

Inspection content is generally inspecting coating surface of the

whole machine, including inspection of surface cleanliness (grease and

other contamination), surface salt deposit, surface water, local surface

coating damage and some coating appearance etc, owners should take

protective measurements for the different defects.

3.2.1 Inspect and deal with the contamination of coating surface

3.2.1.1 If the Port machinery equipment is contaminated by grease, dust

and other contamination, the accumulation will directly damage the

coating. If there are black or yellow adhesive objects, whose source

should be inspected, then measurements should be taken to prevent

contamination from increasing to continue, and surface contamination

should be cleaned out by using cleanliness agent.

Note: The long-term accumulation and cover of grease contamination

will easily cause the whole coating damage.

3.2.1.2 If there is much dust or corrosive salts covered the surface of steel

structure, the owner should remove them by high-pressure water, the

pressure is not less than 2000psi.

3.2.2 Inspections and treatments of salt deposit of coating surface

Salt deposit of coating surface can accelerate the loss of coating,

so please immediately clean it out by water when you find a layer of

white powder deposit.

3.2.3 Inspections and treatments of the waterlogging on coating surface

During the operating, some drain holes may be jamed up, so that

results in some places waterlogging occurs. The waterlogging of coating

surface can accelerate corrosion, so the anti-corrosion life of coating will

be shortened. Please inspect the state of the waterlogging on coating

surface regularly, and dredge it in time.

3.2.4 Inspections and treatments of local damage of coating

It is inevitable to collide or abrade during the operating, which

makes the coating damaged. These coating damages must be repaired

according to the repair standard regardless of whether the collision and

abrasion damage the substrate of steel structure. During inspections,

once found the coating is damaged, please pay attention to the coating

damaged by blunt object. The coating scratches are not obvious, but the

local peeling and loose phenomena may have happened. Therefore, these

damages should be timely removed during repairing to avoid substrate

corrosion. Coating damaged places must be repaired in time to avoid

expanding the rust zone because of exposed for a long time.

3.2.5 Inspections of paint powdering

It’s a normal phenomenon that there is slight powdering and gloss

loss of the finish paint after the equipment is used for a time. The direct

sunlight for a long time transforms the coating into powders or particles,

it is a natural phenomena of coating attenuation.

3.2.6 Inspections of paint color fading

It will be fading after the coating suffers from the erode-corrosion of

ocean climate, the consistent exposure and the high heat and humidity of

beach sunlight for a long time. So it is normal that port machinery

equipment is operating after a long time.

3.2.7 Inspections of the coating of galvanized steel surface

Galvanized steel has a good anti-corrosion performance. Zinc

coating plays a nice role on protecting steel through sacrificing anode,

because the potential of zinc is lower than steel. For the whole beauty,

some galvanized parts such as handrails are also painted. But the adhesive

force of the coating on the galvanized parts is less than the steel, so it may

be peeled off after a long time. There is no need to be repainted when the

red rust on the zinc coating. Because which indicates that substrates have

not be eroded.

3.2.8 Inspections of the coating on stainless steel

Stainless steel is a material of corrosion resistance, so it is not rusted

in general. But some easy-rusted contaminants such as iron scraping

attached to the surface of stainless steel would make the stainless steel

surface rust. The owner can remove the rusts by power tools or sandpaper

to get fresh surface exposed when the stainless steel surface is rusted.

4. Paint for maintenance

4.1 Choice of Paint brand

 If the owner need purchase new paint to repair and maintain the

coating of port machinery equipment, please choose the paint brand

which same as original paint system as soon as possible. For convenience,

purchasers also can choose heavy anti-corrosion protection paints of

some famous paint brands nearby such as Hempel, Sigma, IP, Jotun,

ZPMC and so on.

4.1 Choice of coating

Coatings with convenient for application, high solid volume, fast curing

or thicker film thickness is recommended for primer and intermediate

coat. Inorganic rich zinc primer is not suitable for repairing, but epoxy

rich zinc primer or high solid volume with surface tolerant coatings is

proposed. The color and style of chosen top coat should accord with

original top coat.

5. Coating system inspection and maintenance requirements

5.1 Coating system inspection requirements

5.1.1 Users should arrange schedule for mechanical inspection and

maintenance according to work amount.

5.1.2 Coating system inspection and maintenance are carried out at a

rainless, dry and optimum temperature.

5.2 Coating system maintenance requirements

5.2.1 Substrate treatment

5.2.1.1 Surface contaminant such grease, oil should be removed prior to

follow-up surface treatment.

5.2.1.2 Use power tool or hand tool to clean loose coatings and corrosion

to minimum ST3 or SSPC-SP3. All surface to be renovated should be dry,

and free from contamination harmful to coating system such as grease,

dust etc.

5.2.2 Painting application condition control

5.2.2.1 Painting shall be applied when weather is fine.

5.2.2.2 Carefully read the coating products specification before painting

to understand environment control requirement of painting.

5.2.2.3 Ordinary condition control for painting as bellow: the temperature

is no less than 5℃ the relative humidity is no more than 85%, the surface

temperature of steel is more than 3℃ above the dew point. ( particular

demands on coating specification).

5.2.2.4 Painting can’t be applied in rainy, foggy or high temperature days

(steel temperature no less than 45℃).

5.2.3 Painting requirements

5.2.3.1 Carefully read coating products specification before painting to

mix each compounds correctly. Note the pot life and forbid to use

coatings exceeding the pot life.

5.2.3.2 Painting operations shall be performed in a proper application

method according to the recommended instructions from coat producer

integrated with practice situation. Brush and roller are recommended for
the renovation of coating system.

5.2.3.3 The account of mixed coating should keep to principle of

maximize the utilization to avoid waste and environmental pollution.

5.2.3.4 Spay is not recommended when wind speed is greater than 7 m/s.

5.2.4 Inspection and control of dry film thickness.

5.2.4.1 Need to recoat several times as dry film thick is too thin one coat

when brush or roller.

5.2.4.2 The renovation should be according to the actual situation of area

requiring renovation (from primer to top coat if primer is damaged, for

example), and make sure every renovated coat should satisfy the required

film thickness.

5.2.4.3 Make sure that the total film thick of renovated coating system no

less than 220～250 μm.

5.2.5 Appearance control requirement

5.2.5.1 Film faults must be ground feature to slope shape with 30° to

make sure a fine smoothness of renovated film.

5.2.5.2 Grind the surface of intermediate and top coat by sandpaper (no

more than 100 meshes are recommended) is not proposed to avoid marks.

5.3 If possible, waterborne or low VOC coatings are prefered to reduce

environment pollution.

6. Safety precautions

6.1 Climb equipment shall be prepared before maintenance work is

 carried out.

6.2 Scaffolds should be erected when climb equipment is absent and

relative safety protection is followed.

6.3 Operator should give applicator necessary safety education and

training is recommended.

6.4 Learn Material Safety Data Sheet (MSDS) of coating before

painting.

6.5 Protective measures such as safety belt、helmet and safety glasses etc

must be taken for applicators.

6.6 No open flames and no cross operation in painting operation area.

6.7 Warning sign should be erected before coating dry totally.

6.8 Assistant materials should be recycled and uniform disposal.

6.9 Uniform disposal of abandoned coating and thinner, no littering and

dumpling.