Code Painting Steel Plant

INTERPLANT STANDARD - STEEL INDUSTRY
CODE OF PRACTICE FOR PAINTING IN

STEEL PLANT
IPSS
0.
IPSS:1-07-064-03
Corresponding Indian Standard does not exist
FOREWORD
0.1
This Inter Plant Standard has been prepared by the Standards Committee on Paints &
Portable Maintenance Equipment, IPSS 1:7, with the active participation of the
representatives of all the steel plants and established manufacturers and painter
specializing in painting of steel surfaces, and was adopted in January 2003.
0.2
Inter Plant Standardization for steel industry primarily aims at achieving rationalisation
and unification of parts, sub-assemblies, items & consumables used in steel plant
equipment and accessories, and provides guidance in indenting stores for existing
equipment (or while placing orders for additional requirements) by individual steel plants.
For exercising effective control on the inventories, it is advisable to select a fewer number
of sizes (or types) of products mentioned in this document, in the form of Company
Standard of individual steel plants; it is not desirable to make deviation in technical
requirements.
0.3
It has been observed that nearly seventy percent of steel structurals are damaged due to
corrosion. Corrosion results in loss of assets, higher maintenance cost and additional risk
to human lives. For corrosion mapping the steel plant has been categorised into different
zones depending on intensity of corrosion. Much emphasis has been given on surface
preparation which is considered as the essence of painting. The provisions of Swedish
codes have been adopted for surface preparation which is the world wide practice. The
primers, intermediates and finish coats of a wide range of paints have been specified to
help the executing agencies in identifying the required coating systems, speed sheets
have been provided as a ready reference to select an appropriate painting scheme for a
specified area.
1.
SCOPE
1.1
This Inter Plant Standard contains the Painting Schedule covering the materials, tools,
facilities and quality requirements for surface preparation and painting of various
structures and equipments in existing and new units. The term painting referred hereafter
will cover rust preventive, corrosion preventive, fungs / insect preventive, decorative,
organic/inorganic, metalic coating and surface protection for the following :
a)
Structural steel work including building frames, technological structures and claddings
for these, surfaces of floor plates, walkways etc., steel doors, window, rolling shutters, etc.
in existing and new units.
Various types of static and rotary equipment including electric motors, crane structures,
panels and control desks.
b)
c)
d)
e)
f)
Steel tanks, vessels, bins, bunkers, stacks, etc.

Pipe lines and ducts with bridges, trestles, hangers etc, to support them.
RCC and PCC structures including building frames, bins, bunker bridges etc.
All kinds of masonry works.
ENVIRONMENT:
For the purpose of painting the plant has been divided in five broad categories according to the
level of corrosive environment prevailing in such areas :
i)
Normal (negligible corrosion) (N) less than 1 mil/year
ii)
Nominal corrosive area (NC)
1 mil/year
iii)
Moderately corrosive area (MC) 1 to 3 mils/year
iv)
Severely corrosive area (SC)
more than 5 mils/year
v)
Hot, Hot and corrosive area (HC) 5 mils/hr.
(1 mil = 1/1000 of an inch)
2.
SURFACE PREPARATION
Significance of surface preparation corrosion is an electrochemical phonemon. Therefore, most

of the primers are designed to behave electrochemically at the surface such as by providing a
passive layer at the surface & cathodic protection. Any obstruction in the form of rust, grease, or
old paints will affect the electrochemical link of pigments at the surface. Therefore, performance
of painting system depends greatly on the surface cleaning.
2.1
VARIOUS FACTORS AFFECTING THE SURFACE
2.1.1
EFFECT OF MILL SCALE : Generally the steel plates for structural steel work or
industrial use are manufactured by hot rolling during which the surface is oxidised rapidly
and forms a layer of iron oxide which is called mill scale. The thickness of mill scale
varies from 0.2 to 2.5 mils of an inch). Mill scale has a laminated structure and consists of
three layers of iron oxide in different forms. The first layer next to the substrate is Ferrous
oxide (FeO). The middle layer is Ferrous Ferric Oxide (Fe3O4) and the final exposed layer
is Ferric oxide (Fe2O3). An uniform and perfectly intact mill scale would provide an
effective defensive barrier against corrosion. From the commercial point of view, it is not a
practical proposition, because to achieve the desired result of painting over undamaged
mill scale, it shall be done at the rolling mill before the steel has the left the rolls.
2.1.2
EFFECT OF RUST : Besides mill scale, a steel substrate also get rusted due to `natural
corrosion by electrochemical cell formation. Rust is highly detrimental because iron gives
rise to four times its volume of rust. Rust is essentially the conversion of metal iron into a
hydrated form of its oxide, Fe2O3. 6H 2O. If a substrate is not free from mill scale or rust,
accelerated rusting of base metal can occur through electrolytic action between the mill
scale or rust and steel. The mill scale, or rust is cathodic to steel. The potential difference
between mill scale or rust and steel is about 0.3V. This electrochemical action would
corrode the steel further. It is also liable to spill and carry away the paint film. Hence before
application, the substrate shall be free from mill scale or rust.
2.1.3
EFFECT OF GREASE OIL, DUST ETC. : Before application of paints, the surface shall
be free from any grease, oil, dust or loose particles. Poor adhesion results when paint is
applied to a substrate containing the above. If the coating has poor adhesion to the
surface, it will permit oxygen and moisture penetrating through the film and will initiate
corrosion. Oil or grease present on the surface can also retard drying of paints.
Immediately before painting, all loose materials shall be cleaned from the surface by
dusting, brushing or washing down. Surface containing oil or grease shall be cleaned with
solvent or by means of steam jet.
2.1.4
EFFECT OF MOISTURE : Whatever my be the protective value of the paint when it is

applied on a surface containing condensed moisture, serious corrosion may occur under
the paint film. The corrosion in this case is by electro-chemical process which is
represented below by a simplified overall reaction :
4Fe + 6H 2O + 6O2 = 2Fe2O3. 6H 2O (RUST)
Therefore before painting, the surface shall be dry.
2.1.5
EFFECT OF ACID OR ALKALI : Acids or alkali remaining on the surface will accelerate
corrosion reaction underneath. This generally happens when a surface is improperly
treated with acid pickling or alkali cleaning or when the atmosphere is acidic or alkaline.
2.1.6
EFFECT OF WELDING : If the welding is not carried out correctly, it can cause corrosion
of the surface. The runs of welding are rough, making it difficult to ensure adequate and
complete cover by paints. Oxidation caused by the welding process is detrimental to the
performance of the paint film applied to the welded plate. The runs of welding shall be
carefully removed from the surface by mechanical or abrasive cleaning or by any other
suitable method.
2.2
2.2.1
SURFACE PREPARATION METHODS

BLAST CLEANING : Blast cleaning is the ideal surface preparation method to achieve
an ideal surface for painting. All the other forms of surface preparation have their
limitations. In blast cleaning, an abrasive is directed at high velocity against the surface.
The abrasives are generally iron or steel shots / grits or coarse sand. There are three
recognised specifications for blast cleaning standards and all give three equivalent
grades.
BLAST GRADE SPECIFICATIONS :
a)
b)
c)
British
standard
BS First Quality
Second
4232:1967
Quality
Steel structures painting White metal Near
white
council (USA) (SPCC (SP-5-63)
(SP-10-63)
Spec.)
Swedish
standard* Sa-3
Sa-2
organization (SIS-05-59001985
* Swedish standards are universally accepted.
Third Quality
Commercial
(SP-6-63)
Sa-2
BLASTING GRADE RECOMMENDATION GUIDES

Swedish
standard
Sa-3
Corrosive
Environment
Extremely
aggresive
Fairly corrosive
Application
When long term protection is desired because

of difficult access to surface.
Sa-2
When long term protection is desired for
chemically resistant systems such as
polyurethane, epoxy and ohlororubber resin
paints.
Sa-2
Mildly corrosive
For steel to be painted with an ordinary
synthetic conventional system
The Swedish standard contains photographs of the various standards of three different
degrees of blasted steel and is preferred for reference purpose by most individuals. While
the Swedish standard is pictorial, the other two are descriptive, attempting to define the
areas of residual scale etc. allowable for each grade. The Swedish standards, which are
the most universally accepted, illustrate steel in four conditions before blasting has been
carried out, as this will obviously affect the visual appearance of the surface after the
required preparation. These are :
a)
A completely mill scale covered uncorroded surface.
b)
A surface which has begun to rust with mill scale present.
c)
A surface which is fully corroded but not visibly pitted.
d)
A surface which is severely corroded with obvious pitting.
The grades of cleaning by blasting are prefixed by the reference Sa, thus Sa-3 is steel
blasted to white metal with all rust, mill scale etc. being removed fully. This is quite difficult
to achieve practically and is normally specified for certain speciality coatings. Sa-2 ,
second quality or near white is the more usually accepted standard and would be
considered as a suitable base to realise the full expected service of most coating systems.
Anything less than this shall be a compromise. Brush off or sweep blasting is frequently
used as a more rapid and probably cheaper method of removing firmly adhering and
broken coating systems.
SURFACE PROFILE : Blast cleaning produces a roughened surface and the evenness of
this profile is important. Most specifications call for peak to trough amplitudes of 100
microns maximum.
Abrasive
Sand
Very fine
Fine
Medium
Max. Abrasive particle size

(mesh)
Max. Height of
Profile (mills)
80
40
18
1.5
1.9
2.5
Coarse
Crushed Iron Grit
G-50
G-40
G-25
G-16
Iron Shot
S-230
S-330
S-390
2.2.2
12
3.0
25
18
16
12
3.3
3.6
4.0
8.0
18
16
14
3.0
3.3
3.6
MANUAL CLEANING : Swedish standard SIS-05-5900:1985 lays down standard such

as St-2 and St-3 and these are co-related to four initial rust grades A to D. In practice,
standardization is difficult as results are related to operative performance. The traditional
method of removal of mill scale on plates was to allow the plating to weather. This process
loosens the mill scale which was then removed by scraping and wire brushing. This is an
uncertain process as some mill scale is inevitably left on the surface. It is impossible to
remove all rust or mill scale by this process. Although largly superceded by blast cleaning,
this method is still used for :
a)
Maintenance painting
b)
Easily accessible steel work in rural / mild corrosive areas.
c)
Steel work where conditions are non-corrosive
d)
Steel work which is to be encased in brick work, concrete etc.
e)
Internal surface of enclosed spaces that require painting.
The degree of cleanliness achieved is largely dependent upon the amount of weathering
to which the steel has been subjected and the efforts of the operatives who have difficult in
maintaining a constant satisfactory standard. There is only one recognised standard for
manual cleaning operation and that is the Swedish standard SIS-05-5900:1985.
While this standard refers to the plates/structures that have been weathered for relatively
short periods, and does not therefore show a great deal of pitting. It gives a fair indication
of the type of surface preparation that can be achieved. Two standards are recognised St2
and St3.
St-1 : A lower standard St-1 was recognised in the 1960 edition. Of late this standard has
been deleted. These are described as follows :
It is assumed that prior to treatment, the steel surface has been cleaned of dirt and
grease and that the heavier layers of rust have been removed by chipping.
St-2 : Thorough scraping, emery cutting and wire brushing etc to be done manually. The
treatment shall remove loose mill scales, rust and foreign matters. Finally, the surface is
cleaned with a vacuum cleaner, clean dry compressed air or clean brush. It shall then
have a faint metallic sheen. The appearance shall correspond to the prints designed for
St-2.
St-3 : Very thorough scrapping, chipping, emery cutting and wire brushing etc. Surface
preparation same as for St-2 but much more thoroughly. After removal of dust, the surface
shall have a pronounced metallic sheen and correspond to the prints designed for St-3. All
inspectors shall study the photographs in the Swedish standard as they give a far better
idea of the standards than any written description.
2.2.3
MECHANICAL CLEANING : Surface is cleaned by using pneumatic or electrical tools

like power disc. sander, power driven wire brush, chippers and rotatory descalers etc. it is
a better method than manual cleaning.
2.2.4
FLAME CLEANING : Oxy-acetylene flame is generally used to remove old paint and rust.
Since the coefficient of expansion for steel and rust is different, on heating rust etc flakes
off. This process is not in practice due to the chances of fire hazards and is expensive too.
But this process is better than manual and mechanical cleaning but cannot be preferred to
blast cleaning.
2.2.5
CHEMICAL CLEANING : Old paint can be removed by suitable paint cleaning solvent.
2.3
SURFACE PREPARATION FOR CONCRETE / MASONRY SURFACE
2.3.1
NEW CONCRETE SURFACE : The new concrete/masonry surfaces are very absorbent
in nature, hence before painting proper curing of the surface shall be done. In case of
smooth concrete surface light sand blasting would be ideal to provide key to paint.
Alternately, acid etching with 10% hydrochloric acid can also be carried out. After acid
etching surface shall be washed thoroughly with fresh water and surface shall be allowed
to dry thoroughly, before application of paint. No anti-corrosive primer is generally
necessary for concrete / masonry surface but a tack/tie coat of clean lacquer or thinned
finish coat shall be applied before the final painting.
2.3.2
OLD CONCRETRE MASONRY SURFACE : Various surface contaminants like grease,

oil, scales etc. shall be removed by using 10% Caustic solution. Thereafter, surface
preparation procedure can be same as in case of new concrete / masonry surface.
3.
3.1
PAINTING GUIDELINES
APPLICATION OF PAINT The following precautions are suggested during paint
application :
Do not apply paint when temperature falls below 10 degree centigrade.

Do not apply paint when humidity is above 80% or during fog, rain or mist.
All the primers and finishes are to be supplied in brushing consistency. Thinner
shall be added only if viscosity increases during the application due to higher
ambient temperature. Normally, addition of thinner is restricted upto 5-10% by
volume in case of brush application. In case of spray application only
recommended thinner shall be used to bring the paints to spraying consistency.
Blast cleaned surfaces shall be coated with primer within maximum 3-4 hours. If
relative humidity is over 75%, this shall be reduced to 1-2 hours for better
performance.
All the two packed primers and paints shall be used up within the pot life
3.2
mentioned in data sheets.
Application of paints are recommended at ambient temperature. The substrate

shall also be at ambient temperature.
VOLUME SOLIDS At a given dry film thickness, volume solid will govern the covering
capacity of a paint. This is the volume of non-volatile matters which will form the paint film
after application. The volume solid is related to theoritical covering capacity as per the
following formula:
% volume solid = T.C.C x D.F.T / 10
T.C.C = Theoretical covering capacity ( in sqm)
D.F.T = Dry film thickness (in microns)
3.2.1
THEORETICAL COVERING CAPACITY The theoretical covering capacity at a given

dry film thickness can be calculated from volume solids as per following formula :
T.C.C. = % volume solid x 10 / D.F.T (in microns)
3.2.2
PRACTICAL COVERING CAPACITY The practical covering capacity depends on the

losses which occurs during the paint application. Hence, theoretical covering capacity can
not be achieved during the field application. These losses are due to the surface
conditions, surface profile, shape of substrate, application procedure, poor skill of painters
and weather conditions. Though there is no formula for calculating these losses but on the
basis of actual observation a guideline is available.
3.3
LOSS FACTOR As stated above, the following table indicates the estimated
percentage losses. The losses may vary by + 10 depending on the various circumstances
such as nature of pitting, type of profile, wind direction and its intensity etc.
3.3.1
GUIDELINE FOR LOSSES DURING APPLICATION OF PAINT :

BARE METAL/1ST COAT
Type of surface
application
method
Airless
PLATES
spray
Air spray
Brush
Airless
ANGLE/
spray
FLAT
Air spray
Brush
TUBULAR
Airless
FRAME
spray
WORK
Brush
4.
COATED METAL /2ND

COAT
NEW
OLD
After the
After the
shop primer
primer
30
35
NEW
Blast cleaned
Sa 2.5
35
OLD
Derusted
St 3/Sa 2.5
40
40
30
45
50
40
55
35
25
45
45
40
55
50
35
75
60
40
75
50
25
75
60
30
75
30
35
20
30
METHODS OF APPLICATION
Proper application of protective coatings is an important criterion in giving the paint system
its required life. Given below are the four main application procedures along with the
advantages and disadvantages of each.
4.1
BRUSH APPLICATION
Used frequently for decorative paints, and also in complex areas where the use of spray
methods would increase the loss factor. However, a word of caution about brush
application, it is difficult to achieve a high built by brush application in one coat. The
process is relatively slow and may result in a poor finish for thixotropic or high viscosity top
coats.
4.2
ROLLER APPLICATION
A popular method of decorative paints, it is sometimes also used for protective coatings.
Though faster than brush application, it is not easy to control the paint film thickness by
this method. Rollers of different lengths are available to suit varying surface roughness.
They are not recommended for application of primers since it is difficult to ensure complete
wetting of the surface especially when pitted.
4.3
CONVENTIONAL SPRAY
A widely accepted method of paint application where liquid paint is atomised by an air
stream. A correct combination of air pressure air volume and fluid flow has to be selected
to achieve full atomisation and a paint film free of defect. One may also face problems like
sagging, pin-holing and poor paint flow if the control parameters are not monitored
properly.
The major disadvantage of conventional spray is that high build coatings can not be
applied by this method, as most paints have to be thinned to a suitable viscosity for
satisfactory atomisation.
4.4
AIRLESS SPRAY
This is by far the fastest and most versatile method because it enables application at
variable thicknesses. The equipment utilises on electric or air driven motor and a high
pressure fluid pump to compress the coating to extreme pressures. The paint is then made
to pass through a special tip which atomises it and controls the application properties.
The main advantanges of this method are :
a)
High build coatings can be applied without thinning.
b)
Very fast rate of application.
As already indicated, the special tips used in the spray gun and the pressure control
enables one to monitor application of very low to very high viscosity products. Similarly,
different slot angles produce spray fans of different widths. The selection of a particular fan
width is dependent on the shape and size of the structure to be painted. The choice of fan
width is also related to orifice size. For the same orifice size the paint applied per unit area
will be less, wider the spray fan. The general indication of orifice sizes is given below to
help in choosing the proper orifice size for a paint.
Wet Film Thickness

Upto 50 microns
100-200 microns
> 200 microns
Mastics
Orifice Size (mm)

0.02-0.03
0.03-0.04
0.04-0.07
0.10-0.15
There are several designs of tips available, the choice of which depends upon the finish
required, the case of application and ease of cleaning blockages from tips.
5.
PAINT MATERIAL
The paint systems specified herein and listed in Table 1 to 5 for different exposure
conditions shall be the minimum acceptable quality of surface protection against the
respective environment provided the paint materials are manufactured from quality
products under stringent quality control. For any proprietory paint formulation, the
performance of which has been tested in actual site conditions or under simulated
conditions in test laboratory, the manufacturers recommendations in all respects shall be
adhered to.
The vehicle or the resin medium of the specified paint system for the respective paint
product shall be chosen from the following and a compatible combination thereof as
specified in Table 1 to 5 in order to provide a long lasting anti-corrosive protection of the
surfaces.
5.1
5.1.1
PRIMER PAINTS (P) - Primer paints shall be applied only on dry and clean surface.
PRIMER PAINT P1 (Phenolic Alkyd based) - A single pack air drying phenolic modified
alkyd composition with zinc phosphate as a primer paint conforming generally to IS 2074.
Air drying time
About one hour (touch dry)

Overnight (hard dry)
40 microns (min)
Dry film thickness

(DFT)/Coat
Temperature resistance
5.1.2
Upto 100oC dry heat
PRIMER PAINT P2 (Chlororubber based)

A single pack air drying high build chlorinated rubber based zinc phosphate primer.
Percent chlororubber
Air drying time
Dry film thickness
(DFT)/Coat
20 to 22% (chlorine above 65% in

chlororubber)
About 15 minutes (touch dry)
50 microns (min)
Upto 65oC dry heat
5.1.3
PRIMER PAINT P3 (PVC Copolymer alkyd based)

Polyvinyl chloride (PVC)
Alkyd zinc phosphateredoxide based

primer
Ratio : PVC copolymer + alkyd resin (1:1)
Pigments
Zinc phosphate & fillers
Air drying time
24 hours
Dry film thickness
80 microns
(DFT)/Coat
Upto 80oC dry heat
5.1.4
PRIMER PAINT P4 (Epoxy based)

A two pack air drying Epoxy polyamide resin based redoxide zinc phosphate primer.
Epoxy content (% wt)
Air drying time
Dry film thickness
(DFT)/Coat
5.1.5
15 18
About 30 minutes (touch dry)
30 microns (min)
Upto 120oC dry heat
PRIMER PAINT P5 (Epoxy based)

A two pack air drying Epoxy polyamide with zinc dust of at least 92% zinc dust on the dry
film.
Epoxy content (% wt)
Air drying time
Dry film thickness
(DFT)/Coat
5.1.6
08 to 10
Less than 10 minutes (touch dry)
Less than 2 hours (hard dry)
40 microns (min)
Upto 300oC dry heat
ETCH PRIMER P6 (Poly-vinyl Butyral resin based)

A two pack air drying Epoxy polyvinyl butyral resin based wash primer with inhibitive
pigments.
Air drying time
Dry film thickness
(DFT)/Coat
5 to 7 minutes (touch dry)

2 hours (hard dry)
8 microns
Upto 65oC dry heat
Applicable for
5.1.7
Galvanised iron, aluminium, light alloys

etc., on which the adhesion of
conventional paints are poor.
PRIMER PAINTP7 (Ethyl zinc silicate, EZS based)

A two pack heavy duty zinc dust rich silicate primer which protects the surface with just a
single coat.
Total solids ( 3 wt)
Density (gms/cc)
Air drying time
Dry film thickness
(DFT)/Coat
5.1.8
84 + 2
3.07 + 0.05
To top coat 16 hours
60 microns
Upto 450oC dry heat
PRIMER PAINTP8 (High built coal tar Epoxy)

A two pack cold cured H.B. epoxy coal tar coating no primer is required.
Mixing ratio
Air drying time
Dry film thickness
(DFT)/Coat
5.1.9
Sl.
NO
1.
2.
3.
4.
5.
6.
7.
8.
9.
Base : Hardener (4:1 by vol)

Hard dy 48 hours full cure 7 days
100 microns
Upto 450oC dry heat
PRIMER PAINTP9 (DINBOND M3M-AD)

PRODUCT DETAILS
TYPE
COMPOSITION
TEMPERATURE
RESISTANCE
A single pack one component self priming protective

coating.
Modified Vinyl Polymer binder.
Upto 130oC Higher serviceability offer in customized

versions.
POT LIFE
Unlimited.
AIR DRYING TIME
Touch dry = 20 - 30 mins
Hard dry
= 1 1 hr.
DRY
FILM 30- 35 microns approx.
THICKNESS
PER
COAT
COLOUR
Clear transparent.
FINISH
Smooth, clear
COMPATIBLE WITH a) Primer
- Yes
b) Finish paint - Yes, except chlorinated rubber paints.
10.
11.
Sl.
NO
12.
THINNER/
CLEANER
SCOPE
DINBOND TH-2 in minor proportion only.

For protection of steel structures hot rolled & cold rolled
including G.I. & concrete/masonry exposed to strong
mineral acid vapour attach, thermal oxidation, saline
conditions, rain humidity etc and middly alkaline
conditions. Excellent protection against sulfurous fumes
sand/shot blasting not required of the substrate.
PRODUCT DETAILS
USES
AND a) Concrete surfaces
METHODOLOGY
1) New Yes, Glass filled systems for acidspillage
2) Old Yes, as in (1) including floors subjected to
movement of persons & equipment.
b)
c)
d)
e)
f)
Structural steel
1) New structural steel Yes
2 ) Old/prerusted steel having primer paint & on
finish coat Yes, except chlorinated rubber
synthetic enamels (alkyd baded)
G.I. Sheets Yes
Mild/Nominal corrosive area Yes
Severe corrosive area Yes
Whether applied in hot corrosive area Yes.
5.1.10 PRIMER PAINTP10 (POLY OXIDE)

S.
NO
1)
2)
3)
4)
5)
6)
7)
8)
PRODUCT DETAILS
TYPE
COMPOSITION
TEMPERATURE
RESISTANCE

coating.
Modified Vinyl Polymer binder.
Upto 130oC Higher serviceability offer in customized

versions.
POT LIFE
Unlimited.
AIR DRYING TIME
Touch dry = 20 - 30 mins
Hard dry
= 1 1 hr.
DRY
FILM 35 microns approx.
THICKNESS
PER
COAT
COLOUR
Grey, Black, Yellow, Green, Red, Oxide Red, P.C. Red
& other sheet.
FINISH
Matt.
9)
COMPATIBLE WITH
a) Primer
- Yes
b) Finish paint
- Yes, except chlorinated rubber
paints.
10)
THINNER/
CLEANER
Sl.
NO
11)
12)
PRODUCT DETAILS
SCOPE
For protection of steel structures hot rolled & cold rolled

including G.I. & concrete/masonry exposed to strong
mineral acid vapour attach, thermal oxidation, saline
conditions, rain humidity etc and middly alkaline
conditions. Excellent protection against sulfurous fumes
sand/shot blasting not required of the substrate.
USES
METHODOLOGY
3) New Yes, Glass filled systems for acidspillage
4) Old Yes, as in (1) including floors subjected to
movement of persons & equipment.
b) Structural steel
1) New structural steel Yes
2 ) Old/prerusted steel having primer paint & on
finish coat Yes, except chlorinated rubber
synthetic enamels (alkyd baded)
c) G.I. Sheets Yes
d) Mild/Nominal corrosive area Yes
e) Severe corrosive area Suggested as top coat with
high inlet loading.
f) Whether applied in hot corrosive area Yes, as in
(e).
5.1.11 PRIMER PAINTPC1 (High built coal tar Epoxy)

A two pack, polyamide cured, non-shrinking, epoxy resin sealant.
Mixing ratio
DFT/Coat
Air drying time
Over coating interval
Colour
Finish
Base : Catalyst = 1:1 (by volume)

Sufficient only to penetrate and seal the
surface 30-35 microns.
Touch dry = 30-60 minutes
Hard dry 16 hours
2 hours (min.)
Clear
Glossy
93
Overcoat
5.2
High built enamel or coal tar epoxy.
INTERMEDIATE PAINTS (I)

These paints are formulated with micaceous iron oxide (NIO) and shall be applied over
prime coat as an intermediate layer to provide weather proof seal of prime coat.
5.2.1
INTERMEDIATE PAINTS (I1) (Phenolic alkyd based)

A single pack high built phenolic based paint with MIO.
Air drying time
DFT/Coat
Compatible with
5.2.2
4 to 6 hours (Touch dry)

2 days (Hard dry )
75 microns (min).
Upto 100oC dry heat
Primer P1.
INTERMEDIATE PAINTS (I2) (Chlororubber based)

A single pack air drying high built chloro based paint with MIO.
Air drying time
DFT/Coat
Compatible with
5.2.3
Upto 65oC dry heat

Primer P2, P3 & P4.
INTERMEDIATE PAINTS (I3) (PVC alkyd based)

PVC Copolymer
Pigments
DFT/Coat
Compatible with
5.2.4
15 minutes (Touch dry)

24 hours (Hard dry )
70 microns (min).
Resin 1:1
Micaceous iron oxide (MIO)
80 microns
Upto 80oC dry heat
Primer P2 & P3.
INTERMEDIATE PAINTS (I4)

A two pack air drying high build epoxy resin based paint with MIO.
Air drying time
DFT/Coat

7 days (full cure )
100 microns.
Upto 180oC dry heat
Compatible with
5.3
Primer P4 & P5.
FINISH (TOP COAT) PAINTS (F)

Finish paint coats shall be applied over prime coats and intermediate coats after cleaning
& touch up of primed surface.
5.3.1
FINISH PAINT F1
A single pack air drying high gloss phenolic alkyd modified synthetic enamel paint
suitably pigmented.
Air drying time
DFT/Coat
5.3.2

24 hours (hard dry)
25 microns (min).
Compatible with
Upto 100oC dry heat

Primer P1, Intermediate I1
Colour
Generally all shades
FINISH PAINT F2
A single pack air drying polyurethane enamel of high gloss and hard finish suitably
pigmented.
Air drying time
DFT/Coat
5.3.3
2 to 2 2 hours (Touch dry)

6 hours (hard dry)
30 microns (min).
Compatible with
Upto 100oC dry heat

Primer P1 & P8, Intermediate I1
Colour
FINISH PAINT F3
A two pack air drying bituminous aluminium paint.
Air drying time
DFT/Coat
5.3.4

21 hours (hard dry)
25 microns (min).
Compatible with
Upto 100oC dry heat

Primer P1 Intermediate I1
Colour
Bright metallic
FINISH PAINT F4
A ready mixed oil-alkyd based synthetic enamel paint of high gloss and hard wearing
properties.
Air drying time
Coverage
Compatible with
Colour
5.3.5
6 to 8 hours
14 to 16 sq m/litre.
Upto 60oC
P8
FINISH PAINT F5
A single pack air drying plasticised chlororubber paint suitably pigmented.
Air drying time
DFT/Coat
5.3.6
30 minutes (Touch dry)

24 hours (hard dry)
35 microns (min).
Compatible with
Upto 65oC dry heat

Primer P2 & P1, Intermediate I2 & I3
Colour
Nearly all shades except few
FINISH PAINT F6
A PVC copolymer alkyd based enamel.
Density
Total solids (1 wt)
DFT/Coat
Compatible with
5.3.7
1.17 + 0.05
55 + 2
40 microns
P2 & P3
FINISH PAINT F7
A two pack air drying epoxy polyamide enamel suitably pigmented.
Air drying time
DFT/Coat
5.3.8

7 days (full cure)
40 microns (min).
Compatible with
Upto 130oC dry heat

Primer P4 & P5, Intermediate I4
Colour
FINISH PAINT F8
A single pack synthetic rubber based aluminium paint.
Air drying time

DFT/Coat
Compatible with
Colour
5.3.9
2 hours (Touch dry)

24 hours (hard dry)
25 microns
Upto 200oC dry heat
No Primer paint except primer P5 is
applicable in case of non-ferrous substrate
Smooth aluminium
FINISH PAINT F9
A single pack heat resistant silicon resin based paint with leafing aluminium / graphite
powders.
Air drying time
DFT/Coat
Compatible with
Colour

24 hours (hard dry)
20 microns (min).
Upto 400oC dry heat
No Primer paint except P7 is applicable,
shall be applied on cleaned blast steel
surface
Smooth aluminium
5.3.10 FINISH PAINT F10

A heavy duty single pack air drying anti-corrosive black bituminous paint.
Air drying time
DFT/Coat
Compatible with
Colour

72 hours (hard dry)
100 microns
Upto 80oC dry heat
Primer P1
Black

A heavy duty two pack (85:15 w/w) or single pack air heat cured aluminium paint based on
silicon resin.
Air drying time
DFT/Coat
Compatible with
4 hours (Touch dry)

18 hours (hard dry)
24 hours (recoating time)
15 to 20 microns.
600oC (max)
No Primer
Colour
Lustrous aluminium

Type Reinforced, Bituminous for medium based paint.
Air drying time
DFT/Coat
Compatible with
Colour
2 hours (surface dry)

25 microns.
No Primer
Black

Type single pack, air drying bituminous medium pigmented with graphite powder and
other inert fillers.
Air drying time
DFT/Coat
Compatible with
2 hours (Touch dry)

24 hours (hard dry)
Heat cured at 100 oC for 6 hours after 24
hours of application.
30 microns.
100 oC - 540oC
No Primer

Type single pack, air drying unpigmented bituminous varnish.
Air drying time
DFT/Coat
Compatible with
4 hours (Touch dry)

16 hours (hard dry)
16 hours overnight (recoating time)
30 microns.
230 oC
No Primer

Type two pack, cold cured solventless epoxy resin, coal tar and other adhesive and
pigments.
Air drying time
DFT/Coat
10 hours (Touch dry)

48 hours (hard dry)
150-200 microns.
230 oC
Compatible with
Etch Primer for G.I./Aluminium sheets
5.3.16 FINISH PAINTF-16 (DINBOND M3M)

SL.
NO.
1.
PRODUCT DETAILS
TYPE

coating.
Modified Vinyl Polymer binder with inert additives
customized according to chemical environment.
2.
COMPOSITION
3.
TEMPERATURE
RESISTANCE
POT LIFE
AIR DRYING TIME
4.
5.
6.
7.
8.
9.
Unlimited.
Touch dry = 20 mins
Hard dry
= 1 1 hrs.
FILM 40 microns approx.
PER
DRY
THICKNESS
COAT
COLOUR
FINISH
COMPATIBLE WITH
Sl. NO
10.
THINNER/
CLEANER
11.
SCOPE
Upto 150oC.
Clear.
Clear.
a) Primer
- None, except base coat of Dinbond
M3M AD or Poly Oxide
b) Finish paint - No.
PRODUCT DETAILS
For protection of steel structures, concrete/masonry
exposed to strong acidic/alkaline conditions together
with abrasive conditions.
12.
USES
METHODOLOGY
1) New Yes,
2) Old Yes, especially recommended including
floors subjected to movement of persons &
equipment.
b) Structural steel
1)
New structural steel Yes, with a basecoat of
Dinbond M3M-AD
2) Old/prerusted steel having primer paint & on finish
coat over it No.
c)
d)
e)
f)
G.I. Sheets No
Mild/Nominal corrosive area Yes
Severe corrosive area Yes.
Whether applied in hot corrosive area Yes.
5.3.17 FINISH COAT FC1

Anticorrosive polymer coating system based on epoxy / pnenolic based (interpenitrating
polymer network developed by CBRI, Roorkee).
Base
Mix proportion
Curing
Coverage
Colour
Compatible with
Epoxy / phenolic
Base : curing agent = 1:1
48 hours at 25oC
5-6 sq m/litre on smooth concrete surface
Red/Yellow/Brown
Epoxy sealant PC1
5.3.18 FINISH COAT FC2

Catalyzed high build epoxy resin, two pack.
Air drying time
Curing
DFT/Coat
Compatible with
Colour
2 3 hours (Touch dry)

24 hours (hard dry)
7 days (min)
100-150 microns.
120oC
No Primer / PC1
White / Grey
Paint manufacturers test report or technical data sheet pertaining to the paint selected shall be
obtained. The data sheet shall indicate among other things the relevant standards, if any,
composition in weight percent of pigments, vehicles, additives, drying time, viscosity, spreading
rate, flash point, method of application, quality of surface preparation required, corrosion
resistance properties and colour shades available.
6.
MIXING AND THINNING AND STORAGE OF PAINT

All ingredients in a paint container shall be thoroughly mixed to breakup lumps and
disperse pigments before use and during application, to maintain homogeneity. Mixing
shall be mechanical except when the container size is 20 litres or less; mixing by air
bubbling is not permitted. All pigmented paints shall be strained after mixing to remove
skins and other undersirable matters.
Dry pigments, pastes, tinting and colours shall be mixed and/or made into paint so that all
dry powders get wetted by vehicles, and lumps and particles are uniformly dispersed.
Additives that are received separately, such as, curing agents, catalysts, hardners etc
shall be added to the paint as per manufacturers instructions. These shall be promptly
used within the pot life specified by the manufacturers and unused paint thereafter
discarded.
Thinners shall not be used unless essential for proper application of the paint. Where
thinners are used, they shall be added during the mixing process and the type and
quantity of thinner shall be in accordance with the instructions of the paint manufacturer.
6.1
STORAGE OF PAINT
All paints shall be stored strictly in accordance with requirements laid down by the paint
manufacturer. The storage area shall be well ventilated and protected from sparks, flame,
direct exposure to sun or excessive heat, preferably located in an isolated room or in a
separate building.
All paint containers shall be clearly labelled to show at the time of use the paint
identification, date of manufacture, batch number, order number and special instructions in
legible form. The containers shall be opened only at the time of use. Paints which have
gelled or otherwise deteriorated during storage shall not be used. Paints for which the
shelf life specified by the manufacturer has expired, shall not be used without inspection
and approval by the Purchaser.
7.
PAINT APPLICATION
General
Paint shall be applied in accordance with manufacturers recommendations and as
supplemented by this specification.
Paint shall generally be applied by brushing, except that spraying may be used for finish
coats only when brushing may damage the prime coats. Roller coat or any other method of
paint application shall not be used unless specifically authorised. Spraying shall not be
adopted on red lead or zinc rich paints. Daubers may be used only when no other method
is practicable for proper application in difficult accessible areas.

Paint shall generally not be applied when the ambient temperature is 10oC and below, for
paints which dry by chemical reaction. The temperature requirements specified by the
manufacturer shall be met with. Also, paint shall not be applied in rain, wind, fog or at
relative humidity of 80%; and above or when the surface temperature is below dew point,
resulting in condensation of moisture. Any wet paint exposed to damaging weather
conditions shall be inspected after drying and the damaged area repainted after removal
of the paint.
Each coat of paint shall be continuous, free of pores and of even film thickness without
thin spots. The film thickness shall not be so high as to affect detrimentally either the
appearance or the service of the paint.
Each coat of paint shall be allowed to dry sufficiently before application of the next coat to
avoid damage such as lifting or loss of adhesion. Undercoats having glossy surface shall
be roughened by mild sand papering to improve adhesion of subsequent coat. Successive
coats of same colour shall be tinted, whenever practicable, to produce contrast and help
identify the progress of work.
The application of paint by brush or spray are covered below :

7.1
BRUSH APPLICATION
Proper brushes shall be selected for a specific work piece. Round or oval brushes to
IS:487 are better suited for irregular surfaces whereas flat brushes to IS:384 are
convenient for large flat areas. The width of flat brushes shall not generally exceed
125mm. Paint shall be applied in short strokes depositing uniform amount of paint in each
stroke followed by brushing the paint into all surface irregularities, orifices and corners and
finally smoothing or levelling the paint film with long ad light strokes at about right angles
to the first short strokes. All runs and sags shall be brushed out. The brush marks shall not
be left in the applied paint as far as practicable.
7.2
SPRAY APPLICATION
The spraying equipment shall be compatible with the paint material and provided with
necessary gauges and controls. The equipment shall be cleaned of dirt, dried paint,
foreign matter and solvent before use.
The paint shall be applied by holding the gun perpendicular to the surface, at a suitable
distance and move in a pattern so as to ensure deposition of an uniform wet layer of paint.
All runs and sags shall be brushed out immediately; areas not accessible to spray shall be
painted by brush or dauber.
7.3
SHOP PAINTING
All fabricated steel structures shall have a minimum of two primer coats prior to despatch
to site. The paint shall be applied immediately after surface preparation to the specified
quality preferably within two hours.
Surface in contact during shop assembly shall not be painted. Surfaces in contact after
field erection shall receive three shop coats of specified primer unless the paint will
interfere with assembly. Surface which will be inaccessible after assembly shall also
receive two shop coats of specified primer. Surfaces which cannot be painted but require
protection shall be given a coat of rust inhibitive grease to IS:958 of 2000 or solvent
deposited compound to IS 1153:2000 or 1674:1990 or an international equivalent.
Surfaces to be in contact with concrete shall not be painted. Surfaces to be in contact with
wood, brick or masonry shall be given one shop coat of the specified primer.
The shop coats shall be continuous over all edges including ends meant for joining at site
by welding, except where the paint is harmful to welding operator or is detrimental to the
finished welds. In such cases, no paint shall be applied within 50mm of the welding edge
and the unprotected surface shall be given a coat of corrosion inhibitive compound. The
unpainted area shall be exposed prior to welding, the welded joint cleaned and deslagged
and immediately covered by paint same as that has been used for the remaining surface.
Small machinery, motors, electrical equipment and instruments etc shall receive the full
specified coats of paint in the shop.
Large machine, large motors, cranes, gear cases, conveyors etc shall be shop painted
completely as per the relevant paint system taking into account the exposure conditions.
7.4
SITE / FIELD PAINTING

After the erection/assembly of fabricated structures at the plant site, damaged and
defective shop coats shall be touched up with the same type of paint as used for shop
coat. The work shall include removal of damaged paint work, surface preparation of the
damaged area (due to damage of shop coat or due to site fabrication) to St-3 quality and
painting thereof to cover up all field connections, welds, rivets and all damaged or
defective paint and rusted areas. The fabricated steel structures shall then be painted with
finish coats as specified.
If necessary, equipment and large machinery having full painting shall be given one finish
coat compatible with shop coats after necessary cleaning and touch up.
The first coat of paint at site shall be applied before weathering of the shop coat becomes
excessive, preferably within three months of the shop coat. The finish coat of paint shall be
applied after all concrete work has been completed and all cement and concrete spatters
and drippings removed and damaged surfaces touched up before application of the finish
coat.
If in the opinion of the purchaser, the damage to shop coat is extensive, then instead of
spot touch up one overall coat of primer for each shop coat shall be applied after cleaning.
Surfaces which have not been shop coated but require to be painted shall be given the
necessary surface preparation and prime coat before application of intermediate and finish
coats and before any damage occurs to the surface from weather or other exposure.
Steel structures which are fabricated at site shall be painted with prime and finish coats
after necessary surface preparation as specified after fabrication and erection at site.
All cracks and crevices shall be filled with compatible paint or putty. All fields welds and
all areas within 50 mm of welds shall be cleaned before painting, using surface
preparation method as specified to attain the specified surface quality grade; in any event
all welds shall either be blast cleaned or thoroughly power wire brushed or chemically
scrubbed or solvent cleaned depending on the nature of the weld deposits.
During application of paint at site care shall be taken to protect any damage to buildings,
floors, structures, electrical equipment including motors, valve stems, glass, moving parts,
bearings, coupling shafts, lubrication points and other sensitive parts. Any paint falling on
or applied to such surfaces shall be removed.
7.5
MAINTENANCE PAINTING
In all maintenance painting, the aim is to repaint before the old paint has deteriorated to a
stage where it has to be entirely removed. This is done by periodically applying a single
new coat of paint over the cleaned old paint substrate. The ordinary length of such a
period for a iron and steel complex set up in tropical industrial environment is around three
to four years depending on the paint system initially adopted.
In maintenance painting it is ordinarily intended that sound, adherent old paint be removed
unless it is excessively thick or brittle or is incompatible with the new paint. It is essential,
however that the removal of deteriorated paint be carried back around edges of the spot or
area until an area of completely intact and adherent paint film, with no rust or blisters
underneath is attained. Edges of tightly adherent paint remaining around the area to be
recoated must be feathered, so that the repainted surface can have smooth appearance.
The remaining old paint shall have sufficient adhesion so that it cannot be lifted as a layer
by inserting the blade of a dull putty knife under it. For defective areas of old paint
substrate, spot clean to provide new anchoring profile and apply adequate number of
coats of compatible primer over those areas to build them up to a satisfactory level. Then
an overall finish coat is applied or two finish coats as it becomes necessary.
8.
SAFETY MEASURE - For safety point of view the persons along with the supervisors
who have to do painting, cleaning, short blasting etc as a normal practice prevailing in the
plant must take safety induction from safety engineering department before starting the
job. The supervisors must follow the safety induction instructions such as use of safety
belt, helmet, goggles, apron, fuller mask etc while doing the job.
ENVIRONMENT
Categorization of various plant units according to the corrosive environments as defined on
page no. 2
Sl
No
1.
Safety
corrosive
area
(area
code
SC)
Department
Unit/Areas
PCM & Desulphuri- Common salt platforms.

sation
2.
Lime Dolomite Brick

Plant
Limekiln area all the bldgs., equipments,

pipelines and allied structures.
3.
Slag
Plant
4.
Coke Ovens
All structures, equipments, pipelines and allied

structures in the vicinity of quenching towers on
guide car side.
5.
Coal Chemical
Sulphur storage shed, sulphuric acid plant,

ammonium sulphate plant - all buildings,
equipments, pipelines and allied structures in
and around the above bldgs in site C.
6.
Rolling Mills
Acid
handling
plants,
- all structures,
equipments, pipelines and allied structures.
7.
Power Plant
Water treatment plants, - all bldgs., equipments,

pipelines and allied structures.
Granulation Granulating and storage bays - all buildings,

equipments, pipelines and allied structures.
ENVIRONMENT
page no. 2
Sl
Department
Unit/Areas
No
1.
Blast furnace
Metal and slag side platforms, splash guards,
cast-house columns and girders, stoves &
Hot, Hot
platforms, stacks etc.
& corrosive
2.
Steel melting shop
LD converters, mixers, continuous caster and
area
adjoining structures, dedusting chimney.
(area
code
H, HC)
3.
Coke Ovens
Guide cars, quenching cars, ram cars, charging

cars, wharf battery and under ground heating
systems.
4.
Blooming & slabbing Soaking pit chimneys, soaking pit, structurals

mills
with cover cars.
5.
Power Plant
Chimneys for ID fans, dedusting chimney.
6.
Hot strip Mill
Reheating furnace, equipments subjected to

high temperature.
7.
Cold rolling mill
Furnaces of annealing & galvanising lines and

equipments subjected to high temperature.
ENVIRONMENT
page no. 2
Sl
Department
Unit/Areas
No
1.
Blast furnace
Furnace platform, all pipelines with supporting
structures, skip pit and skip car, cast house roof,
Modemain roof and platform.
rately
2.
BF auxiliary unit
Gas cleaning plant all equipments &
corrobuildings, BF high lines, ladle repair shop, Pug
sive
Mill.
area
3.
PCM
& All structures and equipments except common
Desulphurisation
salt platform in PCM.
(area
4.
Coke ovens
Conveyor galleries, deck plates, idler stand,
code
trestles, grab cranes, screening house, service
MC)
bunker roofs, pipelines and allied structures,
slot bunkers roof.
5.
Sintering plant
Line plant building equipments, pipelines and
allied structures.
6.
Rolling mills
Mill stand area, Reheating furnace area.
7.
Power plant
Back pressure turnbine area, underground steel
structures and equipments in underground of
plot bunkers, boiler house roof, cooling towers
(RCC & steel strl. And equipments), RCC
chimneys for boiler and water treatment plant.
8.
Gas pipelines and The entire gas pipelines and supports.
supports
ENVIRONMENT
page no. 2
Sl
No
1.
Nominal
corrosive
area
(area
code
NC)
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Department
Unit/Areas
Blast furnace
Pump house, workshop area, ladle repair shop

and other structures not covered under any
other four catagories.
Steel melting shop
General
structures
and equipments and
pipelines with support except LD and mixer
area.
SMS Auxiliary area
Scrap yard, ingot yard, stripper bays.
LDBP
Equipments, pipelines & area not covered
under SC.
Slag granulation plant Area not covered under SC.
Coke ovens
Other structures and equipments not covered
under any other category.
Coal
chemical Buildings, equipments, pipelines and bldgs.
Department.
structures.
Sintering plant
Other structures not covered under MC.
Hot Mills
Other structures, equipments, etc not covered
CRM
Other buildings, equipments, etc not covered
under SC.
Water Management Bldg.,
equipments, pipelines and allied
Department.
structures in DWS and TPH.
Power plant
Other bldgs., equipments pipelines and allied
structures not covered under any other category.
ENVIRONMENT
page no. 2
Sl
Department
Unit/Areas
No
1.
Coal
chemical Other structures, equipments etc. not covered
Department.
Nor-mal 2.
Plate mill
Other structures, equipments, pipelines and
(Neglible
allied structures not covered under MC.
corro3.
Hot rolling mill
Other structures, equipments, pipelines and
sive
allied structures not covered under MC.
area)
4.
Cold rolling mill
Other areas, buildings, equipments, pipelines
and allied structures not covered under SC.
(area
5.
Repair shops
Structures and equipments not covered under
code
any other category.
N)
6.
Foundries
All buildings, equipments, pipelines and allied
7.
Pipeline supports
Buildings, equipments, pipelines and allied
8.
Roll shop
9.
10.
Bridges & culverts

Loco repair shops
11.
12.
All RCC & steel structures.
All RCC & steel structures.

structures.
Loco light shop & All buildings, equipments, pipelines and allied
wagon maint. Shop
structures.
Mechanical shop
structures.
ENVIRONMENT
page no. 2
Sl
Department
Unit/Areas
No
13.
Special plate plant
structures.
Nor-mal
(Neglible 14.
Repair shops
corrostructures.
sive
area)
15.
Oil reclamation plant
structures.
(area
code
16.
Cable tunnels
RCC structures.
N)
17.
Central stores
PS-1 (RCC), PS-II (steel), Refractory stores

(steel).
18.
Pipeline supports
Other than covered under MC.
19.
FM (M) Workshop, All structures.

Fabrication
shop,
CCR
work shop,
Structural shop.
COLOUR CODE
S
T
R
U
C
T
U
R
E
S
ITEMS PAINTED
COLOUR
Building frames
Crane girders
Crane stops
Gutters
Aircraft grey
Azure blue
Post office red
Black bitumen
aluminium
Signal red
Lemon yellow
Lemon yellow
Lemon yellow
Fire escape, platforms & ladders etc

General hand railing, Top runners
Rung ladders
All members blocking passage for
movement
Trestles, towers & pipe bridges
652
631
632
355
Fire fighting equipment
Light grey
Dark admiralty
Base: Lemon
yellow
Strip: Black
(100mm wide)
Aluminium
Base: Light grey
Strip: same shade
as for pipling
around the tank at
half the tank height
Signal red
11 KV AC Machine
3.3 KV AC Machine
400 V AC Machine
400 V DC Machine
250 V DC Machine
230 V AC Equipment
110 V AC Equipment
All indoor control and switchgear panels
All outdoor transformers, switchgear,
panels, etc.
Instrumentation panels
Telecommunication panels
Light grey
Post office red
Brilliant green
Azure blue
Oriental blue
Light orange
Canary yellow
Grey
Dark admiralty
grey
Opaline green
Smoke grey
631
538
221
104
174
557
309
697
632
General indoor equipment

General outdoor equipment
Crane bridges, trolleys, hooks etc & other
mobile equipment
Furnaces
Tanks
ELE-CTRICAL
EQUI-PMENT
537
355
355
355
Dark admiralty
grey
Aircraft grey
Aluminium
Conveyor gallery structures

Steel chimney
EQUIPMENT
AND
MACHINERY
COLOUR NO. OF
IS: 5-1994
693
104
538
-
693
-
631
537
275
692
PIPE WORK:
Colours shall be as given below. The base colour shall be applied throughout entire
length except on surface of materials such as asbestos, aluminium, brass, bronze,

galvanised steel, stainless steel and other corrosion resistant alloys and rubber/synthetic
polymers. In such cases identification colour bands of at least 500 mm width shall be
provided near each branch, valve and at distance not exceeding 10M either as local
colour coatings or coloured adhesive tape of suitable material or label attached to the pipe
work. Additional identification bands superimposed over the base colour shall be
provided near each branch, valve and at distance not exceeding 10M, the bands shall be
at least 25mm wide except in case of double bands where the first band shall be about
100mm wide. Direction of flow shall be clearly marked on the pipe lines at intervals not
exceeding 10M and at all branches and change of direction.
Contd. 42
ITEMS PAINTED
Raw or river water (untreated)
Cooling water
Boiler feed water
Condensate
Drinking water
Industrial water
Hydraulic power water
Compressed air
Instrument air
vacuum
COLOUR
Base : Sea green
Band : White
Base : Sea green
Band : French blue
Base : Sea green
Base : Sea green
Band : Light brown
Base : Sea green
First Band : French blue
Second band : Signal
red
Base : Sea green
Band : Light orange
Base : Sea green
Band : Black
Base : Sky blue
Base : Sky blue
Band : Light brown
Base : Sky blue
Band : Black
COLOUR NO.
OF IS: 5-1994
217
217
166
217
217
410
217
166
537
217
557
217
101
101
410
101
-
Steam : (below 3.5 kg/sq cm)
(between 3.5 kg/sq cm & 20 kg/sq cm)
(21 40 kg/sq cm)
(above 40 kg / sq cm)
Drainage
Lubricating oil
Hydraulic oil
Transformer oil
Fuel oil
ITEMS PAINTED
Coke oven/coal gas/other fuel gases
Base : Silver grey if

Bitulac or Al-jacket
Band : Brilliant green
Base : Silver grey if
Bitulac or Al-jacket
Band : French blue
Base : Al-jacket
Band : Dark violet
Base : Al-jacket
Band : Signal red
628
Base : Black
Base : Light brown
Band : Light grey
Base : Light brown
Band : Dark violet
Base : Light brown
Band : Light orange
Base : Light brown
Band : Signal red
410
631
410
796
410
557
410
537
COLOUR
Base : Canary yellow

Band : Signal red
Freon (chlorofluore derivative of methane Base : Canary yellow
and ethane)
Band : Light yellow
Argon
Band : French blue
Acetylene
Band : Dark violet
L.P.gas
First Band : Signal red
Second Band: Traffic
green
Nitrogen
Oxygen
Band : White
Regenerated acid (dilute) (1)
Base : Dark violet
Band : Light brown
Hydrochloric acid (conc) (1)
Base : Dark violet
First Band : Light brown
Second band : Light
brown
221
628
166
796
537
COLOUR NO.
OF IS: 5-1994
309
537
309
631
309
166
309
796
309
537
267
309
309
796
410
796
410
410
Spent liquor
Wash liquor
Dilute acidic liquors
Hydrofluoric acid (conc) (1)

Acidic slurries (1)
Alkalis
Non-acidic slurries
Fire fighting system
ITEMS PAINTED
Rain water down pipes
Duct work
Lighting conduits
Instrument conduits
Power conduits
Base : Dark violet

First Band : Light Grey
Second band : Light
brown
796
631
Base : Dark violet

Band : Light grey
Base : Dark violet
First Band : Light grey
Second band : Brilliant
green
Base : Dark violet
Band : Silver grey
Base : Dark violet
Band : White
Base : Dark violet
Band : Deep buff
Base : Sea green
Band : White
Base :Signal red
796
631
796
631
COLOUR
Base : Sea green
Band : Sky Blue
Base : Aluminium
Base : Black
Band : Yellow
Base : Black
Band : Red
Base : Black
410
221
796
628
796
796
360
217
537
COLOUR NO.
OF IS: 5-1994
217
101
309
537
-
NOTE: (1) For these services, hazard marking as per Fig. 4C of IS:2379 shall also be provided.
NOTES:
1.
The tables give an overall guideline for the structures/equipments etc. however, type
and frequency etc. may be altered depending on specific location and equipment as per
the consultant and owner.
2.
All columns, rooflegs, trestles and pipe line supports up to +1m shall be painted with
bituminous coating in nominal corrosive and normal areas.
3.
All machined items of spare parts lying in open yard shall be given one coat of
strippable paint (25 30 ) by spray.
4.
All foundations of new structures to be painted with two coats of bituminous black.
5.
All repainting and maintenance painting is subjected to joint inspection report.
6.
Necessary written clearances from authorised persons shall be obtained before starting
the painting work at hazardous areas like gas lines, electrical connections high tension
wires, acid lines, crane gantries, running equipments etc and at heights.
7.
The name plates of the equipments like gear box, motors, panels, resistance boxes and
controllers etc shall not be painted and shall be masked before applying the primer. Bolts
& Nuts shall not be painted and shall be coated with strippable lacquer or similar paint.
8.
The electrical conducting parts like power rails, power collectors, cross bars, slip rings,
magnet drum, protective device and other parts like grease fittings, dualine valves, rope
drum grooves etc. and parts specifically advised shall not be painted.
9.
Paint shall generally be applied by brushing except when brushing may damage the
primer coat.
10.
Paint shall not be applied in rain, wind, fog, or at relative humidity of 80% and above or
when the surface temperature is below 10 degree or rises above 50 degree.
11.
Each coat of paint shall be continuous, free of pores and of even film thickness.
12.
Each coat of paint shall be allowed to dry sufficiently before application of the next coat.
Undercoats having glossy surface shall be roughened by mild sand papering to improve
adhesion of subsequent coat.
13.
Surface to be in contact with concrete shall not be painted. Surface to be in contact with
wood, brick or other masonry shall be given one coat of specified primer.
14.
The prime coat shall be applied as soon as possible after the surface preparation is
complete.
15.
Safety measures as stipulated in manufacturers specification are to be followed.
GENERAL INSPECTION BEFORE & DURING PAINTING

1.
Inspection of general appearance of finished works shall be as per IS 1477(part

1):2000.
2.
DFT test shall be carried out with the help of Elcometer or equivalent standard
thickness gauge. The thickness gauge is to be checked and tested as per standardised
test bits supplied with the instruments before using.
3.
Testing of paints shall be carried out as per IS 101 (Part 3/ sec 1):2001.
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Code Painting Steel Plant

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INTERPLANT STANDARD - STEEL INDUSTRY

CODE OF PRACTICE FOR PAINTING IN

Corresponding Indian Standard does not exist

Steel tanks, vessels, bins, bunkers, stacks, etc.

Significance of surface preparation corrosion is an electrochemical phonemon. Therefore, most

VARIOUS FACTORS AFFECTING THE SURFACE

EFFECT OF MOISTURE : Whatever my be the protective value of the paint when it is

SURFACE PREPARATION METHODS

BLASTING GRADE RECOMMENDATION GUIDES

When long term protection is desired because

A completely mill scale covered uncorroded surface.

A surface which has begun to rust with mill scale present.

A surface which is fully corroded but not visibly pitted.

A surface which is severely corroded with obvious pitting.

Max. Abrasive particle size

MANUAL CLEANING : Swedish standard SIS-05-5900:1985 lays down standard such

MECHANICAL CLEANING : Surface is cleaned by using pneumatic or electrical tools

SURFACE PREPARATION FOR CONCRETE / MASONRY SURFACE

OLD CONCRETRE MASONRY SURFACE : Various surface contaminants like grease,

Do not apply paint when temperature falls below 10 degree centigrade.

mentioned in data sheets.

Application of paints are recommended at ambient temperature. The substrate

THEORETICAL COVERING CAPACITY The theoretical covering capacity at a given

PRACTICAL COVERING CAPACITY The practical covering capacity depends on the

GUIDELINE FOR LOSSES DURING APPLICATION OF PAINT :

COATED METAL /2ND

Wet Film Thickness

Orifice Size (mm)

About one hour (touch dry)

Dry film thickness

Upto 100oC dry heat

PRIMER PAINT P2 (Chlororubber based)

20 to 22% (chlorine above 65% in

PRIMER PAINT P3 (PVC Copolymer alkyd based)

Alkyd zinc phosphateredoxide based

PRIMER PAINT P4 (Epoxy based)

PRIMER PAINT P5 (Epoxy based)

ETCH PRIMER P6 (Poly-vinyl Butyral resin based)

5 to 7 minutes (touch dry)

Galvanised iron, aluminium, light alloys

PRIMER PAINTP7 (Ethyl zinc silicate, EZS based)

PRIMER PAINTP8 (High built coal tar Epoxy)

Base : Hardener (4:1 by vol)

PRIMER PAINTP9 (DINBOND M3M-AD)

A single pack one component self priming protective

Upto 130oC Higher serviceability offer in customized

DINBOND TH-2 in minor proportion only.

5.1.10 PRIMER PAINTP10 (POLY OXIDE)

A single pack one component self priming protective

Upto 130oC Higher serviceability offer in customized

DINBOND TH-2 in minor proportion only.

For protection of steel structures hot rolled & cold rolled

5.1.11 PRIMER PAINTPC1 (High built coal tar Epoxy)

Base : Catalyst = 1:1 (by volume)

High built enamel or coal tar epoxy.

INTERMEDIATE PAINTS (I)

INTERMEDIATE PAINTS (I1) (Phenolic alkyd based)

4 to 6 hours (Touch dry)

INTERMEDIATE PAINTS (I2) (Chlororubber based)