Safety

Provided that the necessary precautions are taken, surface preparation and
application of marine paints shouldn’t be dangerous. Always protect yourself
and minimize the risk of accidents.

Personal protection

Wear suitable protective clothing during surface preparation, as well as during

application. This should include a dust mask or respirator, goggles for eye
protection, a hard hat and earplugs if necessary.

Before you start any form of mechanical or power tool cleaning, you should
check that there are no inflammable liquids or gasses nearby. This is
particularly important in confined spaces. Also, make sure that there is
adequate ventilation and airflow to remove dust and solvent fumes from ANC
E
TEN ION C
HAR
T

MAIN IFICAT
the area. SPE
C

For safety reasons, we strongly discourage against smoking during paint

application, or while working with inflammable liquids. This also applies to the
paint locker where materials are stored.

Preparation for the job

Before you begin, make sure you read and understand the following:

• Product Datasheet (PDS)

• Safety Data Sheet (SDS)
• Additional information on the paint drum labels

Working in confined spaces

When painting in enclosed spaces, such as ballast tanks or cargo holds, make
sure that there is sufficient ventilation. This is both for safety reasons and also
to ensure a correct curing of the coating. For more information on ventilation,
please read our online Information Sheets on ‘working in confined spaces
(1433)’ and on ‘ventilation practice (1434)’.

Storage conditions

Your storage room should be a dry and clean area where the paints will not be
exposed to fire hazards. Paints should be put in order, so that they cannot be
mixed up. We recommend storing hardeners next to their corresponding base
(which also makes stock control easier). If new paints are added, these should be
put in the back and the older paints in the front (‘first in, first out’). This reduces
waste by ensuring you use the paints with the nearest expiry dates first. Details
on the shelf life can be found online in our PDS.

1 PPG SIGMACARE® PLUS Guide to maintenance at sea

Planning
To ensure the painting process goes smoothly, you should take the following
into account when planning your schedule:

• Sailing route
N
TIO
• Condition of the vessel PLA
NO
F AC

• Check current paint systems

• Availability of paints (order if not available)
• Weather conditions

Evaluate the substrate condition

Work systematically and divide large surfaces into smaller areas in order to get
a more detailed evaluation. Check the substrate for local or scattered corrosion
(especially corners, edges, welding seams) and possible paint defects.

Check which coatings are required for different areas

Make sure you know exactly which paints you have to use in order to protect
the part of the vessel you are about to paint. Check either the Maintenance
Specification Chart or the paint history, which will give you the names of the
paints that make up the coating system. Also, you will find a few details such
as color, dry-film thickness1, wet-film thickness2, the type of thinner/cleaning
solvent to use, and the PDS number of the paint.

Make a clear plan for the job

Estimate the size of all the areas you need to paint in square meters (square
feet), including any edges of surrounding areas. If there are several small
areas close together, it may be better to clean, prime and topcoat the entire
area in order to achieve a better finish.

Check the Maintenance Manual, or the PDS, to find the theoretical3, or

practical spreading rate4 per liter (per gallon), and the recommended dry-film
thickness for the paint you are using.

To estimate the total time needed for the job, the following operations have to
be considered:

• Surface preparation
• Preparation of the paint and the application equipment
• Application of the paint
• Cleaning of tools and equipment

Remember that surface preparation is the most time-consuming part of the

coating process, so we so advise mixing the paint after this has completed.

1 Depth of cured coating film, usually expressed in microns (micrometers) or mils.

2 
The thickness of a wet-coating film immediately after application, before evaporation of any volatile material from the film.
3 Spreading rate of a coating to a completely flat surface, assuming no losses in handling.
4 Spreading rate of a coating, calculated at the recommended dry-film thickness and assuming a normal application loss.

2 PPG SIGMACARE® PLUS Guide to maintenance at sea

Planning
Normally, flash rust5 will occur overnight on a surface cleaned down to bare
steel, and even more quickly in humid weather conditions. Therefore, don’t
clean more than you can paint in one day, or no more than the weather
permits.

If you are using a two-component paint, which requires a base and a hardener
to be mixed together, the paint’s pot life6 will determine the time available for
application. This can be found in the PDS under the heading ‘instructions for
use’. Don’t mix more paint than you can use within the pot life – remember that
pot life can vary dramatically depending on temperature.

Atmospheric conditions

Weather exposure is an important factor during the paint application.

Parameters such as dew point, air temperature and humidity should be in
accordance with limits stated in the PDS.

Check the availability of paints and equipment

Check whether all required coatings are available in the paint locker or can be
obtained from the nearest stock point. Be sure to keep a record of the paints
kept onboard and to correct the amounts after use of any of the cans.

Calculate and collect sufficient paint from the stores

To determine how much paint you need, check the ‘Paint Amounts Matrix’ in
Appendix B. Should you still need any information on the amount of volume
solids7 of a paint, or a spray loss factor8, please refer to the PDS.

Check the combination of the base and hardener

When using a two-component paint, find the mixing ratio9 in the PDS. Mix the
two-component coating properly before application; we recommend using a
power stirrer.

5 Rusting that occurs on metal within minutes to a few hours after surface cleaning is done. The speed with which flash
rusting occurs may be indicative of salt contamination on the surface, high humidity, or both.
6 Time during which a coating material can be successfully applied to a substrate after the initial opening of the can,
or after the hardener is added to initiate the curing reaction. Pot life often varies with temperature and humidity.
7 Solid ingredients as a percentage of total ingredients. This number can be used to calculate the amount of wet-film
thickness that needs to be applied to produce the desired dry-film thickness of a coating. For instance, a coating with
50% volume solids will require twice as much wet-film thickness as is desired in the dry-film thickness, because
half the volume of the material will volatilize.
8 The percentage of paint that will be lost during a spray application. Please do note that an application by brush or roller
will also involve losses, although significantly smaller.
9 The volume ratio of the base and hardener of a two-component paint: specified by the manufacturer for complete curing
into the desired film.

3 PPG SIGMACARE® PLUS Guide to maintenance at sea

Surface preparation
Once the surface to be treated has been identified, a suitable surface
preparation method should be used in order to achieve the required surface
condition prior to the application of the coating. There are several different
methods of surface preparation that can be used onboard, and selection
should be based on their suitability and practicality for the particular project
under consideration.

The most practical, commonly used and cost-effective method for

maintenance at sea is mechanical cleaning (power or hand tool cleaning) in
combination with high-pressure fresh water washing (HPFWW) at a minimum
of 200 bar. For more information on surface preparation methods, please
refer to Appendix A.

As mentioned earlier, the effective performance of the coating system

depends mainly on correct preparation of the substrate. Therefore, in order to
achieve an optimal result, the recommended steps described in this chapter
should be followed.

Contaminants

There are many surface contaminants that can adversely affect the
performance of the coating system. These include:

• Rust
• Mill scale
• Soluble salts
• Oil/grease
• Dirt dust
• Water
• Rust inhibitors and cleaning chemicals
• Old, loose coating

A poor performance of the coating is often due to poor pre-treatment of

the substrate. Overcoating a substrate that isn’t clean invariably leads to
premature failure.

Heavy scale

The removal of heavy scale is very important to achieve a satisfactory

performance of the coating system. To detect its presence, strike the
surface with a sharp object (such as a chipping hammer). This will chip off
the heavy rust scale and/or loose paint. You can remove all rust by power tool
preparation with rotating steel brushes or carborundum discs or, to achieve
higher standards, by vacuum blasting. For difficult areas, such as corners
and bolt heads, a needle gun may be used, which provides a suitable profile
for adhesion of the paint. Small amounts of loose rust can be removed by
hand with a wire brush, but be aware that a wire brush may polish rather than
remove corrosion.

4 PPG SIGMACARE® PLUS Guide to maintenance at sea

Surface preparation
Dust and debris

Remove all remnants of cleaning materials, such as dust and loose particles
with a brush or compressed air blowing. Ensure that the adjacent areas are
clean and that the existing coating system is intact.

Oil and grease

Oil and grease, if present, should be removed by using a suitable water-

soluble detergent, followed by washing with fresh water to remove the
emulsified residues. Any presence of oil or grease on the surface will
adversely affect the adhesion of the applied coating system and may
result in premature failure.

Salts/dirt/loose paint

In order to remove the water-soluble salts from sea salt deposits and corrosion,
dirt, loose paint and other contamination from the surface, high-pressure fresh
water washing (HPFW washing) should be used as a cleaning method.

Before starting, the cleaning agent should be mixed with fresh water. Never use
seawater to remove salts and dirt. We recommend high-pressure washing with
fresh water at a minimum of 200 bar (3000 p.s.i.).

5 PPG SIGMACARE® PLUS Guide to maintenance at sea

Coating preparation
Atmospheric conditions

Weather exposure is an important factor during the paint application and

will also affect the surface itself. Make sure that the atmospheric conditions
(temperature, dew point, humidity, etc.) are within the limits stated in the PDS.

Read the labels

Make sure you read the labels on the drum. The labels provide details of the
coating system, which are essential for preparing and applying the paint as
well as for safety reasons.

Clean the lid

PART-2
PART-1
Clean the lid of the drum in order to ensure that no dirt or water on the lid can
get mixed with the contents of the can.

Splitting the paint into smaller cans

We recommend using the smallest paint cans possible for your application.
After all, smaller cans are easier to mix, easier to carry and easier to
dispose of.

Mixing the base and hardener

When using two-component paints, it’s extremely important to mix the base and
hardener in the ratio as stated in the PDS. For more information on mixing the
base and hardener, please refer to ‘Appendix D: Mixing two-component paints’.

Thinning according to the PDS

In general, thinners can be divided into paint-mixing thinners and cleaning

thinners. Paint-mixing thinners are used to reduce the viscosity of the paint
and to clean equipment. However, cleaning thinners, which are specifically
used to clean spray equipment, lines and nozzles, must not be used to thin
down paint. Recommended paint thinners are shown in the PDS. When
adding thinners to paint it’s important to stir well as this will evenly distribute
the thinners throughout the paint. Always remember that thinner should only
be added to two-component paints after the base and hardener have been
mixed in the right proportions.

Cleaning the application tools and equipment

Paint thinners or cleaning thinners can be used to wash most equipment,

such as brushes and rollers. Spray equipment and nozzles usually require
large quantities of cleaning thinner; therefore, so we recommend using the
most economical cleaning thinner for these. During short breaks, or overnight,
ensure your brushes and rollers are kept in good condition, soaked in the
recommended thinner. Water should be used for alkyd paints.

6 PPG SIGMACARE® PLUS Guide to maintenance at sea

Coating preparation
Check wet-film thickness

In this Maintenance Manual, you’ll find the specified dry-film thicknesses of

50
100
150
200
250
300
350
400
450
500
550
WE T

600
the coatings used onboard. Paints with 50% volume solids mean that the dry- FIL M GA UG E 50 - 12 00
MI CR ON S
film thickness is 50% of the wet-film thickness.

1200
To determine the desired wet-film thickness, you should check both the

1150
1100
1050
1000
950
900
850
800
750
700
650
recommended dry-film thickness and the volume solids of the coating.
To measure wet-film thickness, use the wet-film gauge. For the percentage
volume solids of a coating, please refer to the PDS.

Check overcoating interval

Since the overcoating interval of a coating is considerably influenced by

temperature, carefully read the overcoating information in the PDS.

7 PPG SIGMACARE® PLUS Guide to maintenance at sea

Coating application
Choose the right equipment

Most maintenance at sea jobs involve painting small areas, so a brush or a

roller is normally used. When larger areas are involved, airless spray may be
the right tool. Brushes are used for stripe coating, edges and difficult areas.
Rollers are best for the application of paints when airless spray equipment
isn’t available or suitable.

Whichever application method you are using, always bring clean rags. Coating
application should be carried out in accordance with the PDS and in such a
way that the coating film is applied with a uniform thickness and without any
coating defects (e.g. ‘holidays’, pinholes, sags, etc.)

The most common application methods are the following:

• Brush application
• Paint roller application
• Spray application, which could be:
- Air spray (low pressure): normally described as pneumatic or conventional
- Airless spray (high pressure): normally described as hydraulic or airless

Brush application

Paintbrushes are commonly used to apply our marine coatings onboard ships
and vessels. Using the right brush and technique is essential for achieving
even coverage.

The best brushes for application direct to steel are flat, round or oval and long
handled brushes. The type you’ll need depends on the size and type of area
being painted.

Flat brushes are ideal for coating large surfaces. While round and oval
brushes are suited to spot repairs on small pipes and bolts, and for applying
the first coat of primer. Long handled brushes are great for painting hard
to reach areas and are generally used as a supplement to airless spray
application.

After use, clean brushes immediately with the correct thinner.

8 PPG SIGMACARE® PLUS Guide to maintenance at sea

Coating application
Paint roller application

The paint roller is a fast working tool for onboard maintenance. Using the
right technique will help you to achieve uniform coverage at the specified
film thickness.

Apply the coating to the surface with slow and even movements. Up, down
and across. Dip the roller often to keep it well filled with paint. Avoid excessive
rolling as this will increase the risk of not achieving the specified film
thickness.

Typical materials for paint rollers are:

• Lamb’s wool: long-piled and therefore preferred for rough and

uneven surfaces
• Mohair: short-piled and therefore well suited for smooth surfaces.
Special lacquer rollers are available for areas where a high finish is required
• Nylon and Dynel: hardwearing, synthetic alternatives to lamb’s wool
and mohair
• Foam roller: a cheap but unstable material, unsuited for application on steel
and metal

Advantages of roller application:

• Easy to move around, and is independent of power supply or

compressed air
• Cleaner than spray application
• Faster than brush application
• Well suited for painting of large, even surfaces

Spray application

Airless spray application is, without doubt, the most common application
method used in shipyards and other places where large steel constructions
are being protected against corrosion.

For each type of airless spray equipment, you should follow the supplier’s
instructions for storing, cleaning and dismounting.

Before use, ensure that filters are clean and the pressure, pump capacity,
hose length and nozzle size are correct.

Finally, when using airless spray equipment, remember, never point the gun
at people.

9 PPG SIGMACARE® PLUS Guide to maintenance at sea

Housekeeping
Take good care of all equipment used, either for surface preparation or for
paint application. After use, thoroughly clean spray equipment, brushes and
rollers with the cleaning thinner as mentioned in the PDS.

Cleaning of the paint locker

It’s very important to keep the paint locker clean at all times.
Avoid contamination of paint by dust, dirt, etc.

Taking care of partly used drums

Two-component paints cannot be stored for reuse once they’ve been mixed.
However one component paints can safely be stored and used again within
their shelf life10. Check the PDS for advice.

To store leftover paint properly, you should close the tin lid firmly. If the lid
isn’t completely sealed, solvents and drying agents may evaporate over time.
Turn small tins upside down for a few minutes, then store them the right
way up. This will allow a small amount of paint to cover the lid and make an
airtight seal.

Waste treatment

All waste, including solvents and paint remains, should be disposed of

onshore in chemical waste disposal facilities.

Check all coating areas for correct curing

Before applying the second coat, always check that the first coat has cured
sufficiently. Check the PDS for guidance.

Periodic assessment

Regular review of all accessible areas (periodic assessment) during service

will save a lot of trouble. Any damage to the paint system will be more easily
treated when discovered at an early stage.

Maintaining stock levels

One of the most essential aspects of maintenance at sea is to plan all

necessary maintenance well in advance. Therefore, always check the paint
locker to see whether the paints required are available. When ordering, please
refer to the order list for the correct name, color and ordering codes of the
products required and place orders via your head office.

Finally, when filling up the paint store, make sure you put the oldest paints in
front of the new paints. To help operatives use the oldest products first, follow
the ‘first in, first out’ principle.

10 The amount of time a paint or coating remains in usable condition during storage.

10 PPG SIGMACARE® PLUS Guide to maintenance at sea

Appendices

11 PPG SIGMACARE® PLUS Guide to maintenance at sea

Appendix A:
Overview of surface pre-treatment methods

Purpose: To obtain a sound substrate for the coating caused by dust pollution and by the disposal of spent
system to be applied on, and to ensure optimal abrasives are eliminated.
performance.
The most commonly used forms of hydro jetting are:
Disc grinding
• High-pressure water jetting operating with pressures
Disc grinding is the best and most efficient power tool from 700-1700 bar
and can remove rust, mill scale, loose paint, sharp edges • Ultra high-pressure water jetting operating with
and steel defects, depending on the standard used. pressures above 1700 bar

Power tooling High-pressure washing

Ensure that you carry out hand-power tool cleaning We recommend high-pressure washing with a pressure
thoroughly. When viewed without magnification, the of 150 to 300 bar. In some cases, high-pressure water
surface should be free from visible oil, grease and dirt, cleaning up to 750 bar is used for the removal of loose
and from poorly adhering mill scale, rust, paint coatings paints, salts and rust. If abrasive material such as grit
and foreign matter. or sand is added to the water when wet blasting, slurry
blasting will be achieved.
Needle gun
Degreasing
A needle gun can be used for removing loose paint, rust
and mill scale. As the needle gun leaves the surface Clean with thinners and clean rags. Make sure you have
uneven, you should also grind the area afterwards. lots of clean rags to hand and change them regularly.
This will ensure that oil and grease are removed and
This can be a slow process, and is generally only used not just distributed over the surface. Finally, wash the
if other methods aren’t available, but is the only reliable surface with clean fresh water.
method for mechanical removal of heavy corrosion on
bolts and corners. When cleaning with a water-soluble oil and grease
remover, the cleaner should be used in accordance
Wire brushing with the manufacturer’s recommendations. To remove
contamination, the surface should be washed with fresh
Wire brushing is used for the removal of loose paint and water, preferably high-pressure washing at around 150
rust, especially on areas with difficult access or if no bar. This will remove water-soluble salts, emulsified
other effective methods are available. Wire brushing by residues and dust all at once.
hand or power tool is suitable only for the removal of light
rust and loose paint. Heavy rust scale will be polished but How to check degreasing
will not be removed. Wire brushing is normally a better
solution for rough surfaces compared to grinding. For If the grease has been removed successfully, the water
deep pitting the manual steel brush is more efficient shouldn’t make any droplets on the surface. It should
compared to the machine-driven wire brush. only wet the surface, or run off in puddles.

Chipping or scraping Dust cleaning

The purpose of chipping and scraping is to remove Dust can be removed by brushing, clean compressed air
any heavy rust and loose paint. Chipping or scraping or by vacuum cleaning. In tanks or other confined spaces,
shouldn’t be the only surface preparation method you vacuum cleaning is recommended, as other methods will
use; it should always be followed by grinding or another only move the dust from one place to another.
more efficient cleaning method.
How to check dust cleaning?
Hydro jetting
To check that surface is free of dust, press a piece
Hydro jetting is a surface cleaning technique, which of transparent adhesive tape to the surface. Remove
relies entirely on the energy of water striking a surface the tape and place it on a piece of white paper. The
to achieve its cleaning effect. Abrasives aren’t used surface is dust-free if there is no dust and/or any other
in hydro jetting systems. Consequently, the problems contamination visible.

12 PPG SIGMACARE® PLUS Guide to maintenance at sea

Appendix B:
Paint amounts matrix

Find the amount of LITERS you need

Area in square meters

Type of DFT
Product name
application (microns)
1 10 50 100 200 300 400 500 750 1,000

PPG SIGMA AQUACOVER 25 Brush/Roller 75 0.18 1.8 9 18 36 54 72 89 134 179

PPG SIGMA AQUACOVER 45 Brush/Roller 50 0.15 1.5 8 15 31 46 62 77 116 154

Brush/Roller 75 0.23 2.3 12 23 46 69 93 116 174 232

PPG SIGMACOVER 280 Brush/Roller 75 0.14 1.4 7 14 28 41 55 69 104 138

PPG SIGMACOVER 435 Brush/Roller 75 0.13 1.3 6 13 25 38 50 63 94 125

Brush/Roller 125 0.21 2.1 10 21 42 63 83 104 156 208

PPG SIGMACOVER 456 Brush/Roller 75 0.12 1.2 6 12 24 36 48 61 91 121

Brush/Roller 125 0.20 2.0 10 20 40 61 81 101 151 202

PPG SIGMACOVER 630 Brush/Roller 125 0.16 1.6 8 16 32 47 63 79 119 158

Brush/Roller 150 0.19 1.9 9 19 38 57 76 95 142 190

PPG SIGMACOVER 350 Brush/Roller 125 0.18 1.8 9 18 36 55 73 91 137 182

Brush/Roller 150 0.22 2.2 11 22 44 66 88 109 164 219

PPG SIGMADUR 550 Brush/Roller 50 0.10 1.0 5 10 19 29 38 48 72 95

PPG SIGMAGUARD 795 Brush/Roller 150 0.21 2.1 11 21 42 63 84 105 158 210

PPG SIGMAGUARD 603 Brush/Roller 150 0.16 1.6 8 16 32 47 63 79 118 158

PPG SIGMAPRIME 200 Brush/Roller 75 0.14 1.4 7 14 28 41 55 69 104 138

PPG SIGMARINE 28 Brush/Roller 75 0.14 1.4 7 14 29 43 57 72 107 143

Brush/Roller 100 0.19 1.9 10 19 38 57 76 95 143 191

PPG SIGMARINE 48 Brush/Roller 35 0.08 0.8 4 8 16 25 33 41 61 82

Brush/Roller 70 0.16 1.6 8 16 33 49 65 82 123 163

PPG SIGMARINE 49 Brush/Roller 35 0.07 0.7 4 7 15 22 29 37 55 74

PPG VIKOTE 46 Brush/Roller 100 0.24 2.4 12 24 48 72 95 119 179 239

PPG VIKOTE 56 Brush/Roller 35 0.11 1.1 5 11 21 32 42 53 79 105

Please note that all figures are indicative only

13 PPG SIGMACARE® PLUS Guide to maintenance at sea

Appendix B:
Paint amounts matrix

Find the amount of LITERS you need

Area in square meters

Type of DFT
Product name
application (microns)
1 10 50 100 200 300 400 500 750 1,000

PPG SIGMA AQUACOVER 25 Airless spray 75 0.24 2.4 12 24 48 72 95 119 179 239

PPG SIGMA AQUACOVER 45 Airless spray 50 0.21 2.1 10 21 41 62 82 103 154 206

Airless spray 75 0.31 3.1 15 31 62 93 124 154 232 309

PPG SIGMACOVER 280 Airless spray 75 0.18 1.8 9 18 37 55 74 92 138 184

PPG SIGMACOVER 435 Airless spray 75 0.17 1.7 8 17 33 50 67 83 125 167

Airless spray 125 0.28 2.8 14 28 56 83 111 139 208 278

PPG SIGMACOVER 456 Airless spray 75 0.16 1.6 8 16 32 48 65 81 121 162

Airless spray 125 0.27 2.7 13 27 54 81 108 135 202 269

PPG SIGMACOVER 630 Airless spray 125 0.21 2.1 11 21 42 63 84 105 158 211

Airless spray 150 0.25 2.5 13 25 51 76 101 127 190 253

PPG SIGMACOVER 350 Airless spray 125 0.24 2.4 12 24 49 73 97 122 182 243

Airless spray 150 0.29 2.9 15 29 58 88 117 146 219 292

PPG SIGMADUR 550 Airless spray 50 0.13 1.3 6 13 25 38 51 64 95 127

PPG SIGMAGUARD 795 Airless spray 150 0.28 2.8 14 28 56 84 112 140 210 280

PPG SIGMAGUARD 603 Airless spray 150 0.21 2.1 11 21 42 63 84 105 158 210

PPG SIGMAPRIME 200 Airless spray 75 0.18 1.8 9 18 37 55 74 92 138 184

PPG SIGMARINE 28 Airless spray 75 0.19 1.9 10 19 38 57 76 95 143 191

Airless spray 100 0.25 2.5 13 25 51 76 102 127 191 255

PPG SIGMARINE 48 Airless spray 35 0.11 1.1 5 11 22 33 44 54 82 109

Airless spray 70 0.22 2.2 11 22 44 65 87 109 163 218

PPG SIGMARINE 49 Airless spray 35 0.10 1.0 5 10 20 29 39 49 74 98

PPG VIKOTE 46 Airless spray 100 0.32 3.2 16 32 64 95 127 159 239 318

PPG VIKOTE 56 Airless spray 35 0.14 1.4 7 14 28 42 56 70 105 140

Please note that all figures are indicative only

14 PPG SIGMACARE® PLUS Guide to maintenance at sea

Appendix B:
Paint amounts matrix

Find the amount of US GALLONS you need

Area in square feet

Type of DFT
Product name
application (mills)
10 100 500 1,000 2,000 3,000 4,000 5,000 8,000 10,000

PPG SIGMA AQUACOVER 25 Brush/Roller 3 0.04 0.4 2.2 4.4 9 13 18 22 35 44

PPG SIGMA AQUACOVER 45 Brush/Roller 2 0.04 0.4 1.9 3.8 8 11 15 19 30 38

Brush/Roller 3 0.06 0.6 2.8 5.7 11 17 23 28 45 57

PPG SIGMACOVER 280 Brush/Roller 3 0.03 0.3 1.7 3.4 7 10 14 17 27 34

PPG SIGMACOVER 435 Brush/Roller 3 0.03 0.3 1.5 3.1 6 9 12 15 25 31

Brush/Roller 5 0.05 0.5 2.6 5.1 10 15 20 26 41 51

PPG SIGMACOVER 456 Brush/Roller 3 0.03 0.3 1.5 3.0 6 9 12 15 24 30

Brush/Roller 5 0.05 0.5 2.5 5.0 10 15 20 25 40 50

PPG SIGMACOVER 630 Brush/Roller 5 0.04 0.4 1.9 3.9 8 12 16 19 31 39

Brush/Roller 6 0.05 0.5 2.3 4.7 9 14 19 23 37 47

PPG SIGMACOVER 350 Brush/Roller 5 0.04 0.4 2.2 4.5 9 13 18 22 36 45

Brush/Roller 6 0.05 0.5 2.7 5.4 11 16 21 27 43 54

PPG SIGMADUR 550 Brush/Roller 2 0.02 0.2 1.2 2.3 5 7 9 12 19 23

PPG SIGMAGUARD 795 Brush/Roller 6 0.05 0.5 2.6 5.2 10 15 21 26 41 52

PPG SIGMAGUARD 603 Brush/Roller 6 0.04 0.4 1.9 3.9 8 12 15 19 31 39

PPG SIGMAPRIME 200 Brush/Roller 3 0.03 0.3 1.7 3.4 7 10 14 17 27 34

PPG SIGMARINE 28 Brush/Roller 3 0.04 0.4 1.8 3.5 7 11 14 18 28 35

Brush/Roller 4 0.05 0.5 2.3 4.7 9 14 19 23 37 47

PPG SIGMARINE 48 Brush/Roller 1.4 0.02 0.2 1.0 2.0 4 6 8 10 16 20

Brush/Roller 2.8 0.04 0.4 2.0 4.0 8 12 16 20 32 40

PPG SIGMARINE 49 Brush/Roller 1.4 0.02 0.2 0.9 1.8 4 5 7 9 14 18

PPG VIKOTE 46 Brush/Roller 4 0.06 0.6 2.9 5.9 12 18 23 29 47 59

PPG VIKOTE 56 Brush/Roller 1.4 0.03 0.3 1.3 2.6 5 8 10 13 21 26

Please note that all figures are indicative only

15 PPG SIGMACARE® PLUS Guide to maintenance at sea

Appendix B:
Paint amounts matrix

Find the amount of US GALLONS you need

Area in square feet

Type of DFT
Product name
application (mills)
10 100 500 1,000 2,000 3,000 4,000 5,000 8,000 10,000

PPG SIGMA AQUACOVER 25 Airless spray 3 0.06 0.6 2.9 5.9 12 18 23 29 47 59

PPG SIGMA AQUACOVER 45 Airless spray 2 0.05 0.5 2.5 5.1 10 15 20 25 40 51

Airless spray 3 0.08 0.8 3.8 7.6 15 23 30 38 61 76

PPG SIGMACOVER 280 Airless spray 3 0.05 0.5 2.3 4.5 9 14 18 23 36 45

PPG SIGMACOVER 435 Airless spray 3 0.04 0.4 2.0 4.1 8 12 16 20 33 41

Airless spray 5 0.07 0.7 3.4 6.8 14 20 27 34 55 68

PPG SIGMACOVER 456 Airless spray 3 0.04 0.4 2.0 4.0 8 12 16 20 32 40

Airless spray 5 0.07 0.7 3.3 6.6 13 20 26 33 53 66

PPG SIGMACOVER 630 Airless spray 5 0.05 0.5 2.6 5.2 10 16 21 26 41 52

Airless spray 6 0.06 0.6 3.1 6.2 12 19 25 31 50 62

PPG SIGMACOVER 350 Airless spray 5 0.06 0.6 3.0 6.0 12 18 24 30 48 60

Airless spray 6 0.07 0.7 3.6 7.2 14 21 29 36 57 72

PPG SIGMADUR 550 Airless spray 2 0.03 0.3 1.6 3.1 6 9 12 16 25 31

PPG SIGMAGUARD 795 Airless spray 6 0.07 0.7 3.4 6.9 14 21 27 34 55 69

PPG SIGMAGUARD 603 Airless spray 6 0.05 0.5 2.6 5.2 10 15 21 26 41 52

PPG SIGMAPRIME 200 Airless spray 3 0.05 0.5 2.3 4.5 9 14 18 23 36 45

PPG SIGMARINE 28 Airless spray 3 0.05 0.5 2.3 4.7 9 14 19 23 37 47

Airless spray 4 0.06 0.6 3.1 6.2 12 19 25 31 50 62

PPG SIGMARINE 48 Airless spray 1.4 0.03 0.3 1.3 2.7 5 8 11 13 21 27

Airless spray 2.8 0.05 0.5 2.7 5.3 11 16 21 27 43 53

PPG SIGMARINE 49 Airless spray 1.4 0.02 0.2 1.2 2.4 5 7 10 12 19 24

PPG VIKOTE 46 Airless spray 4 0.08 0.8 3.9 7.8 16 23 31 39 62 78

PPG VIKOTE 56 Airless spray 1.4 0.03 0.3 1.7 3.4 7 10 14 17 27 34

Please note that all figures are indicative only

16 PPG SIGMACARE® PLUS Guide to maintenance at sea

Appendix C:
Glossary of notes

1
Dry-film thickness (DFT) 7
Volume solids

Depth of cured coating film, usually expressed in Solid ingredients as a percentage of total ingredients.
microns (micrometers) or mils. This number can be used to calculate the amount of
wet-film thickness that needs to be applied to produce
the desired dry-film thickness of a coating. For instance,
2
Wet-film thickness (WFT) a coating with 50% volume solids (V/S) will require twice
as much wet-film thickness as is desired in the dry-film
The thickness of a wet-coating film immediately after thickness, because half the volume of the material will
application, and before evaporation of any volatile volatilize.
material from the film.

8
Spray loss factor
3
Theoretical spreading rate
The percentage of paint that will be lost during a spray
Spreading rate of a coating to a completely flat surface, application. Please note that an application by brush or
assuming no losses in handling. roller will also involve losses, although significantly smaller.

4
Practical spreading rate 9
Mixing ratio

Spreading rate of a coating, calculated at the The volume ratio of the base and hardener of a two-
recommended dry-film thickness and assuming a component paint: specified by the manufacturer for
normal application loss. complete curing into the desired film.

5
Flash rust 10
Shelf life

Rusting that occurs on metal within minutes to a few The amount of time a paint, or coating, remains in usable
hours after surface cleaning is done. The speed with condition during storage.
which flash rusting occurs may be indicative of salt
contamination on the surface, high humidity, or both.

6
Pot life

Time during which a coating material can be

successfully applied to a substrate after the initial
opening of the can, or after the hardener is added to
initiate the curing reaction. Pot life often varies with
temperature and humidity.

17 PPG SIGMACARE® PLUS Guide to maintenance at sea

Appendix D:
Mixing two-component paints

Mixing ratio of two-component products

If you require a smaller amount of paint than the standard supplied set you can make a measurement-mixing stick for
accurate measuring of the two components.

You should always use a flat wooden stick or iron bar, as paint cannot be mixed effectively using a round stick.

In the PDS of a two-component product, you can find the mixing ratio by volume – base to hardener (don’t take the
mixing ratio by weight). On the stick you can mark the amount of base and hardener with a ruler (see figure below).
If you use a wooden stick you can make a notch with a knife to mark the measurements.

For example: PPG SIGMAPRIME

Ratio by volume: base to hardener = 80:20

If the mixing ratio is 78:22 every 10 cm (approx. 4 inches) of can height should
consist of 7.8 cm (approx. 3 inches) of base material and 2.2 cm (approx. 0.8 inches)
of hardener. Mark a measuring stick to the correct proportions.

Put the stick in an empty, clean tin and fill this with base material to the first mark 22%
(make sure the base material is premixed).

Then fill the second part with hardener. 78%

Mix the two components together and add thinner if necessary.

18 PPG SIGMACARE® PLUS Guide to maintenance at sea